RIEJU RR-Spike 50 Workshop Manual

Rieju rr-spike 50

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Owner's manual (100 pages)

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January 30, 2025

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Summary of Contents for RIEJU RR-Spike 50

Page 1 E n g i n e w o r k s h o p m a n u a l...
Page 2: Table Of Contents
Index Engine INTRODUCTION NOTES FOR EASY CONSULTATION GENERAL WORK PROCEDURES RECOMMENDATIONS SPARK PLUGS ENGINE RIEJU EQUIPMENT KIT LUBRICANTS ENGINE DISASSEMBLY MAINTENANCE ENGINE ASSEMBLY ENGINE SERVICINGAND COMMISSIONING SCHEDULE PARTS AND THEIR TORQUE WRENCH SETTINGS EXPLODED VIEW OF THE ENGINE AM6 EURO2...
Page 4 Introduction Introduction...
Page 5 (Authorised Service Centres, etc.), the essential information for operating in accordance with the latest good working practices and work safety regulations. • These publications provide all necessary information for routine procedures on all the RIEJU- motor vehicles equipped with two-stroke engines currently in production at the date of issue. The information provided deals with the motor vehicle ENGINES.
Page 6 Introduction Engine EDITING SYMBOLS CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. WARNING! Situations entailing the risk of personal injury to maintenance or repair mecha- nics, other workshop personnel or third parties, or damage to environment, vehicle or equipment. FIRE HAZARD Indicates operations which may constitute a fire hazard.
Page 7 Introduction Engine Figure Pr Tr Tightening torque Page Paragraph Section Diagram Table Screw Note: The letter Tr in the illustrations refers to retaining or adjusting screws. The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated.
Page 8: General Work Procedures
Introduction Engine 1.3 GENERAL WORK PROCEDURES • The advice, recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times. They should therefore be strictly adhered to. ADVICE: •...
Page 9 Introduction Engine WARNINGS • Before carrying out any operation on the vehicle, wait for all parts to cool down. • For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand. •...
Page 10 Introduction Engine Never use open flames for any reason. Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash point solvents to clean the vehicle components.
Page 11: Spark Plugs
Introduction Engine 1.5 SPARK PLUGS 1. Insulator 2. Body 3. Gasket 4. Electrode 5. Earth electrode 6. Threads SPARK PLUG CHECK 1,000 km • Remove the spark plug while the engine is hot ( taking utmost care to avoid scalding!). •...
Page 12: Spark Plug Maintenance
SPARK PLUG REPLACEMENT 5000 km • Upon prescribed mileage being reached, always replace the spark plug. Use RIEJU, S.A. recommended spark plugs. • When replacing exhausted spark plugs, visually inspect spark plug condition as described above to ascertain whether or not the engine is running properly.
Page 14 Engine RIEJU Engine RIEJU...
Page 15: Lubricants
Engine Rieju Engine 2.1 EQUIPMENT KIT Code RIEJU 0/000.640.9999 2.2 LUBRICANTS LUBRICANTS TABLE LUBRICANTS FOR TWO-STROKE ENGINE 1) Synthetic mix oil 2) Gearbox oil SAE 10W30, type SE GENERAL PURPOSE LUBRICANTS GENERAL PURPOSE LUBRICANTS GENERAL PURPOSE LUBRICANTS 3) Grease for moving parts...
Page 16 Engine Rieju Engine 2.3 DISASSEMBLY OF THE ENGINE After removing the spark-plug and carburettor proceed as follows: 1) DRAIN the engine oil by removing the relevant drain bolt. 2) UNSCREW the coolant drainage screw (1/F-1); remove the water pump cover by undo- ing the two fixing screws (2/F-1).
Page 17 Engine Rieju Engine 6) REMOVE the sliding stop screw for starting from clutch side (1/F-5). 7) REMOVE the fixing screws of the plastic oil pump cap (1/F-6). Undo the screws securing the oil pump to the cover; then remove the pump.
Page 18 Engine Rieju Engine F-10 11) DISENGAGE the nut from its fixing tab (1/F-9); using the appropriate wrench (1/F-10), unscrew and remove the fixing nut (2/F-10) of the clutch boss. 12) REMOVE the following pieces in this order: clutch boss (1/F-11), spacer (2/F-11), clutch gear (3/F-11), shim washer (1/F-12), tapered washer (2/F-12), paying attention to the direc- tion in which they are assembled so as to reassemble them correctly afterwards.
Page 19 Engine Rieju Engine 15) UNSCREW the nut (2/F-14) with a 19 mm wrench, whilst holding the flywheel in place with the special wrench; then remove the following parts in this order: drive pinion, countershaft drive gear, key, spacer bushing and O-ring.
Page 20 Engine Rieju Engine 20) DISASSEMBLING the thermal section: a) unscrew the 4 cylinder head holding nuts and remove the relevant washers; remove the head, its O-ring, the cylinder, the cylinder gasket and the four O-ring on the stud bolts. F-18...
Page 21 Engine Rieju Engine 25) PUT the neutral signal pin in the position shown in the photo (F-22), hence remove the shift shaft and its relevant lower shim washer (1/F-23). F-22 F-23 26) PULL OUT the fork guiding rod and remove the top fork (F-24); to take the fork out of its seat, remove the desmodronic shaft (F-25) and raise the gear on the secondary shaft carrying the forks.
Page 22 Engine Rieju Engine 30) IF the oil pump needs to be replaced, proceed as follows (F-27): F-27 a) Detach the oil pump supply pipe (1) and put a plug into it to prevent oil leaks. b) Detach the oil delivery pipe leading from the pump to the carburettor (2).
Page 23: Maintenance
Engine Rieju Engine 2.4 MAINTENANCE GENERAL WARNINGS Before reassembling the engine either totally or partially, thoroughly clean the parts by washing them with petrol, drying them with compressed air and making sure that they are sufficiently oiled and in perfect working order.
Page 24 Engine Rieju Engine PREVENTIVE CARE 1) WASH the two crankcases and the bearings with petrol and blow them with compres- sed air, checking that the bearings run freely and noiselessly. CAUTION: if it should be necessary to replace a bearing, the seat must be heated before installing the new bearing.
Page 25 Engine Rieju Engine 6) ENSURE that the clutch assembly is in working order. To do so, ensure that the iron discs are in good condition, that the notches on the cork discs are not too deformed and that their coating is not burnt. Check that the grooves on the clutch boss are not too deeply marked;...
Page 26 Engine Rieju Engine Repeat the measurements in several positions along the cylinder jacket, between the top face of the cylinder and the exhaust gap (F-34). Then check the diameter of the piston and compare it with that of the cylinder (F-33).
Page 27 Engine Rieju Engine 2.5 ENGINE REASSEMBLY 1) PLACE the clutch crankcase (right hand side) on a flat surface. Then, fit the spring and the gear selection poppet ball in their seats and apply grease to prevent them falling out. 2) PREPARE the transmission assembly (primary/secondary) keeping all components to- gether (F-36).
Page 28 Engine Rieju Engine 3) FIT the desmodronic shaft (F-40). Insert the fork guide pins into the desmodronic shaft (F-41). Fit the fork guide rod into its seat (F-42). Turn the desmodronic shaft until it reaches the position shown in the figure (F-43).
Page 29 Engine Rieju Engine 4) INSERT the shift shaft with the lower washers (0.6 mm thick) (1/F-44) and insert the return spring hooks in the relevant anchoring bridge (F-45) then check that: - By putting the desmodronic shaft in 3 speed, make sure the rollers of the cam are at an equal distance from the fork hooks.
Page 30 Engine Rieju Engine 10) FIT the key for the magneto flywheel; put the stator in its seat and fasten in place with the fixing screws (Cs 0.25 ÷ 0.3 kg*m). Fit the rotor and tighten the nut (Cs 4.3 ÷ 4.5 kg*m), using the usual wrench (F-48).
Page 31 Engine Rieju Engine F-53 F-52 14) PROCEED in reverse order. Refit the clutch assembly and remember to replace the nut fixing washer with a new one; fit the clutch boss fixing nut (Cs 5.5 ÷ 6.0 kg*m) and bend the tab.
Page 32 Engine Rieju Engine 17) FIT the springs and fixing screws and tighten (Cs 0.3 ÷ 0.5 kg*m). 18) Correct operating position of the clutch is obtained when the lever, in the position indicated by the arrow (F-55), is parallel to the cover resting surface.
Page 33 Engine Rieju Engine 22) Before assembly, CHECK the condition of the cage on the piston pin and its rollers. Fit the piston, making sure that the arrow marked on the top is facing towards the ex- haust side (F-59), and therefore towards the piston pin and its circlips.
Page 34: Engine Servicingand Commissioning Schedule
Engine Rieju Engine 2.6 ENGINE SERVICING AND COMMISSIONING SCHEDULE 1000 K VERY FTER AINTENANCE OPERATIONS 5000 MONTHS Check Adjustment of engine idling speed Gas and oil pump control Front and rear brake control Operation of the electrical equipment Petrol ducts...
Page 35: Parts And Their Torque Wrench Settings
Engine Rieju Engine 2.7 PARTS AND THEIR TORQUE WRENCH SETTINGS ORQUE SETTING CREWS ART POSITION ART NAME Kg*m Spark plug Spark plug 14 x 1.25 20÷25 2÷2,5 Cylinder head M7 x 1 14÷16 1,4÷1,6 Cylinder head Pipe fitting M8 x 1.25 24÷26...
Page 36: Exploded View Of The Engine Am6 Euro2
Engine Rieju Engine 2.8 EXPLODED VIEW OF THE ENGINE AM6 EURO2...
Page 37 RIEJU, S.A. c/.Borrassà, 41 E-17600 FIGUERES, GIRONA (SPAIN) Telf. +34 / 972500850 Fax +34 / 972506950 www.riejumoto.com / e-mail rieju@riejumoto.com...

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