RIEJU Tango 250 Chassis Workshop Manual
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RIEJU Tango 250 Chassis Workshop Manual

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TANGO 2
TANGO 250
50
C h a s s i s w o r k s h o p m a n u a l

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Summary of Contents for RIEJU Tango 250

  • Page 1 TANGO 2 TANGO 250 C h a s s i s w o r k s h o p m a n u a l...

  • Page 2: Table Of Contents

    Contents INTRODUCTION UPDATES FOR THE MANUALS SYMBOLS USED IN THE MANUAL ABBREVIATIONS USED IN THE MANUAL GENERAL WORK RULES RECOMMENDATIONS LEARNING ABOUT THE MOTORCYCLE MAINTENANCE OPERATIONS TECHNICAL CHARACTERISTICS AND SPECIFICATIONS TIGHTENING TORQUES UNPACKING “AESTHETIC APPEARANCE” CHECK IDENTIFICATION DETAILS IDENTIFYING THE MAIN ELEMENTS CONTROLS AND INSTRUMENTS KEYS STEERING LOCK...
  • Page 3 Contents REMOVAL 1. SEAT 2. SIDE COVERS 3. FRONT SIDE COVERS 4. REAR COWLING 5. SILENCER 6. EXHAUST 7. “AIS” SYSTEM (secondary air valve) 8. BATTERY 9. REAR TURN INDICATORS 10. REAR LIGHT 11. AIR FILTER 12. REGULATOR 13. TURN INDICATORS CONTROL UNIT 14.
  • Page 4 Contents REMOVAL 35. STEERING 36. FRONT FOOTRESTS 37. REAR FOOTRESTS 38. REAR BRAKE PEDAL 39. CHAIN PROTECTOR 40. TRANSMISSION CHAIN 41. REAR BRAKE CYLINDER 42. KICK-START LEVER 43. SWINGING ARM ELECTRICAL SYSTEM 1. PRECAUTIONS 2. GENERAL WIRING 3. BATTERY 4. LIGHTING SYSTEM 5.
  • Page 5 Introduction Introduction...

  • Page 6: Updates For The Manuals

    N.B.: Rieju, S.A. reserves the right to make modifications at any time without any prior no- tification.

  • Page 7: Symbols Used In The Manual

    Introduction SYMBOLS USED IN THE MANUAL ATTENTION! Practical advice and information that refers to the safety of the motorcyclist (user of the machine) and the features that maintain the condition and integrity of the machine itself. ATTENTION! Descriptions that relate to work that is dangerous for the te- chnical maintenance staff, repair staff, other workshop staff or for those from outside, for the environment, for the machine and for the equipment.

  • Page 8: Abbreviations Used In The Manual

    Introduction ABBREVIATIONS USED IN THE MANUAL Figure T Tq Tightening torque Page Part Section Diag Diagram Table Bolt N.B.: The illustrations frequently show securing or adjustment bolts or screws, indicated by the letter B. The number following this letter indicates the quantity of identical bolts (B) or screws to be found on the unit or component being described and its corresponding illustration.

  • Page 9: General Work Rules

    Introduction GENERAL WORK RULES • The tips, recommendations and warnings that follow are aimed at ensuring that work is carried out in a rational way and with maximum operational safety, thereby eliminating significantly the chances of accidents, injury and damages of any nature and downtimes. They should therefore be scrupulously observed.

  • Page 10: Recommendations

    Introduction RECOMMENDATIONS • Before beginning any work on the motorcycle, wait for each and every one of the machine’s components to cool down completely. • If the operations envisage the use of two mechanics, they need to agree in advance on the tasks to be performed and synergies.
  • Page 11 Introduction Never use naked flames under any circumstances. Never leave open and unsuitable containers containing petrol where others are passing, close to heat sources, etc. Never use petrol as a cleaner to clean down the machine or to wash the workshop floor. Clean the various components with detergent with a low flammability rating.
  • Page 12 Familiarising yourself with the Familiarising yourself with the motorcycle motorcycle...

  • Page 13: Maintenance Operations

    Familiarising yourself with the motorcycle ERVICE ERVICE EVERY AINTENANCE OPERATIONS 1.000 3.000 5.000 · · · Check the braking system · Change Change Check the transmission oil level · · · Check chain tension and wear · · Check suspensions ·...
  • Page 14 Familiarising yourself with the motorcycle Transmission oil Type CASTROL SAE 20W-50 API, “SH” or higher Quantity 1 litre Air filter Wet-type foam rubber cartridge Type Fuel Lead-free petrol Type 7,5 L. Fuel tank capacity Carburettor Type DellOrto VHST-28 ECS Spark plug D8EA / NGK DENSO Type 0,6 - 0,7 mm.
  • Page 15 Familiarising yourself with the motorcycle Suspension PAIOLI telescopic forks Front 0.37 mm bars 340 cc CASTROL SAE I5W per bar Hydraulic shock absorber Rear Brake disks Brake disks 260 mm. Ø Front 200 mm. Ø Rear Mixed/road tyres Front 100/80-17” 55P Rear 130/70-17”...

  • Page 16: Tightening Torques

    Familiarising yourself with the motorcycle TABLE OF TIGHTENING TORQUES Element Kg*m Notes Front wheel bolt 38 - 52 3,8 - 5,2 Front wheel bolt lock 17 - 23 1,7 - 2,3 Rear wheel bolt 72 - 98 7,2 - 9,8 Front/rear brake calliper 24 - 36 2,4 - 3,6...

  • Page 17: Unpacking

    Familiarising yourself with the motorcycle UNPACKING Unpack the motorcycle following the directions present in the packaging itself, which must • then be disposed of in accordance with existing regulations. “AESTHETIC APPEARANCE” CHECK • Check visually that all components made of plastic material are fitted correctly and that the motorcycle does not have any visible scratches, marks, etc.
  • Page 18 Familiarising yourself with the motorcycle IDENTIFICATION OF MAIN ELEMENTS (left-hand side) 1. Headlight. 2. Right-hand controls. 3. Left-hand controls. 4. Seat. 5. Exhaust pipe. 6. Rear grab bar. 7. Prop stand. 8. Gear change pedal. 9. Fuel tank. IDENTIFICATION OF MAIN ELEMENTS (right-hand side) 10.

  • Page 19: Controls And Instruments

    Familiarising yourself with the motorcycle CONTROLS AND INSTRUMENTS 1. Rear-view mirror. 6. Front brake lever. 11. Turn indicators switch. 2. Clutch lever. 7. Throttle twist grip. 12. Horn button. 3. Instrument panel. 8. Starter button. 13. Left-hand handlebar grip. 4. Main switch. 9.

  • Page 20: Prop Stand

    Familiarising yourself with the motorcycle PROP STAND • Check that the prop stand is well secured and moves properly. The retention system, consisting of traction springs, should also be checked frequently. INSTRUMENT PANEL Turn indicators indicator light This indicator light flashes when the turn indicator switch is moved to the left or to the right.

  • Page 21: Tyres

    Familiarising yourself with the motorcycle TYRES Dimensions position dimensions FRONT 90/100 - 19 55P REAR 120/90 - 16 63P CHECKING THE PRESSURE Tyre pressures should be checked and adjusted with the tyres at ambient temperature. position 1,7 kg / cm FRONT REAR REAR...

  • Page 22: Transmission Oil

    Familiarising yourself with the motorcycle TRANSMISSION OIL Changing the oil 1. Stand the motorcycle on a flat surface. 2. Warm up the engine for several minutes. 3. Stop the engine. Place a container under the engine to hold the oil. 4.

  • Page 23: Brake Fluid

    Familiarising yourself with the motorcycle BRAKE FLUID Check When checking the fluid level, turn the han- dlebars to ensure that the top of the master cylinder is level. Check that the brake fluid level is above the minimum level mark on the rear brake fluid reservoir, and check that there is fluid for the front brake by looking through the inspection F-13...

  • Page 24: Adjusting The Transmission Chain Tension

    Familiarising yourself with the motorcycle ADJUSTING THE TRANSMISSION CHAIN TENSION The chain is adjusted by loosening the rear wheel shaft and screwing in or unscrewing the nuts and bolts adjacent to the shaft (A/ F-16), ensuring that there is the same distance on both sides of the shaft at all times.
  • Page 25 Removal Removal...

  • Page 26: Seat

    Removal 1. SEAT Insert the key into the lock (A/F-1) located on the rear right-hand side and turn it to the right to release the seat. Then lift the seat at the rear and pulling it backwards to withdraw it from the front anchor point (B/F-2).

  • Page 27: Rear Cowling

    Removal 4. REAR COWLING * Remove the seat. Unscrew the 2 bolts (A/F-6). The remove the 2 spacers (B/F-6) and withdraw from the front. 5. SILENCER Loosen the clamp (A/F-7) on the connection between the exhaust pipe and the silencer. Then unscrew the 2 bolts (B/F-8) securing the silencer to the chassis.

  • Page 28: Exhaust

    Removal 6. EXHAUST PIPE Loosen the clamp (A/F-9) on the connection between the exhaust pipe and the silencer. Remove the 2 nuts (B/F-10) securing the exhaust pipe to the engine at the front. ATTENTION: Before removing the exhaust pipe, make sure it has cooled down. F-10 7.

  • Page 29: Rear Turn Indicators

    Removal 9. REAR TURN INDICATORS Unscrew the 2 bolts (A/F-13) from the wheel arch protector and the rear nut (B/F-14). Disconnect the cables (C/F-15) from the general wiring. Then loosen the screw (D/F-16) securing the nut on the inside, and pull out the cable to remove the light.

  • Page 30: Rear Light

    Removal 10. REAR LIGHT * Remove the wheel arch protection cover (See 9. Rear turn indicators). Disconnect the terminal (A/F-17) from the wiring. Then loosen the two screws (B/F-18) securing the rear light cover. To extract it, pull the cable (C/F-19) to remove the light. ATTENTION: Before removing the lights, pay attention to the sequence of the termi- nals for later refitting (see wiring diagram).

  • Page 31: Air Filter

    Removal 11. AIR FILTER *Remove the seat and the right-hand side cover. Unscrew the 3 screws (A/F-20) from the filter cover. Then remove the filter (B/F-21). ATTENTION: When refitting, situate the fin (C/F-22) on the filter forwards as indicated in the image. ATTENTION: This type of filter is always kept wet with oil.

  • Page 32: Regulator

    Removal 12. REGULATOR *Remove the seat and the left-hand side cover. Disconnect the regulator from the wiring (A/F-23). Then unscrew the 2 nuts (B/F-22) to withdraw it. F-23 13. TURN INDICATORS CONTROL UNIT *Remove the seat and the left-hand side cover. Disconnect the turn indicators control unit (A/F-24) from the general wiring.

  • Page 33: Starter Relay

    Removal 15. STARTER RELAY * Remove the seat and the left-hand side cover. ATTENTION: Cover the relay terminals with a protector to prevent them from short- circuiting with the chassis. Disconnect the starter relay (A/F-26). Remove the starter relay from the bracket (B/F-27). A spare fuse (C/F-28) is housed at the back of the securing rubber.

  • Page 34: Filter Canister

    Removal 17. FILTER CANISTER * Remove the seat, the fuel tank and the silencer. To make the task easier, unscrew the 2 bolts (A/F-30) from the rear of the chassis and loosen the 2 front ones (B/F-30). Loosen the nozzle (C/F-31) from the carburettor and the breather pipe. Then unscrew the 4 bolts (D/F-32) from the top of the canister.

  • Page 35: Shock Absorber

    Removal 18. SHOCK ABSORBER *Remove the seat and the filter canister. To make the task easier, unscrew the 2 bolts (A/F-34) from the rear of the chassis and loo- sen the 2 front ones (B/F-34). Unscrew the 2 bolts (C/F-35) securing the shock absorber to the chassis and withdraw backwards.

  • Page 36: Fuel Tank

    Removal 19. FUEL TANK *Remove the seat. ATTENTION: Before removal, shut the fuel tap on the tank. Remove the fuel tap clamp (A/F-36). Unscrew the 3 screws (B/F-37) securing the tank to the chassis. Then remove the cap and separate the protector from the tank (C/F-38). Place a container under the tank and drain out the petrol by removing the clamp (D/F-39).

  • Page 37: Carburettor

    Removal 20. CARBURETTOR *Remove the seat and the fuel tank. Loosen the 2 clamps (A/F-40) securing the carburettor to the filter canister and to the engine. Disconnect the throttle cables (B/F-40). Dis- connect the choke cable (C/F-40). Then disconnect the suction hose and the remaining pipes.

  • Page 38: Engine

    Removal 23. ENGINE * Remove the front side covers, the carburettor and the exhaust pipe. To make the task easier, remove the rear brake pedal. Disconnect the SPARK PLUG, the CLUTCH CABLE, the ENGINE AIR INTAKE, the CARBURETTOR and the TRANSMISSION CHAIN. Gain access from the top to disconnect the 2 terminals from the engine (C/F-44).

  • Page 39: Front Turn Indicators

    Removal 24. FRONT TURN INDICATORS Disconnect the light from the general wiring (A/F-45). Then loosen the screw (B/F-46) securing the nut on the inside, and pull out the cable to remove the light. ATTENTION: Pay attention to the position of the cables, to ensure they are refitted correctly.

  • Page 40: Instrument Panel

    Removal 26. INSTRUMENT PANEL Remove the headlight trim (A/F-49) to access the odometer connections. Disconnect the odometer (B/F-50). Then unscrew the 2 top screws (C/F-50) securing the screen to the bracket. F-49 F-50 27. FRONT BRAKE CYLINDER Disconnect the brake light micro-switch terminals (A/F-51). Unscrew the connector (B/F-52) securing the pipe to the cylinder.

  • Page 41: Clutch Lever

    Removal 28. CLUTCH LEVER Disconnect the clutch cable (A/F-53) and the choke cable (B/F-53). Then unscrew the 2 screws (C/F-54) and remove the lever. F-53 F-54 29. HANDLEBARS *Remove the controls on each end. Unscrew the 4 bolts (A/F-55) and remove the handlebars.

  • Page 42: Rear Brake Calliper

    Removal 31. REAR BRAKE CALLIPER Unscrew the connector using the bolt (A/F-57). Then unscrew the 2 bolts (B/F-57) securing the calliper to the calliper bracket. ATTENTION: The copper gaskets should be renewed and the circuit bled when refitting the calliper. F-57 ATTENTION: Brake fluid is corrosive.

  • Page 43: Front Wheel

    Removal 33. FRONT WHEEL Unscrew the nut (A/F-61). Loosen the wheel shaft securing bolt (B/F-62) located on the forks. Remove the wheel shaft (C/F-62). F-61 F-62 34. FRONT BRAKE DISK * Remove the front wheel. Unscrew the bolts (A/F-63) securing the disk. F-63 35.

  • Page 44: Front Footrests

    Removal 36. FRONT FOOTRESTS Unscrew the screw (A/F-65) securing the nut (B/F-65). ATTENTION: Make a note of the position of the spring so that it can be refitted correctly. F-65 37. REAR FOOTRESTS Unscrew the bolt (A/F-66) securing the nut (B/F-66).

  • Page 45: Chain Protector

    Removal 39. CHAIN PROTECTOR Unscrew the 2 screws (A/F-68) and remove the protector. F-68 40. TRANSMISSION CHAIN Remove the 2 bolts (A/F-69) securing the protector and remove it. Extract the clip (B/F- 70) securing the connector link and remove the chain. ATTENTION: When refitting, consult the Adjusting the transmission chain tension section.

  • Page 46: Rear Brake Cylinder

    Removal 41. REAR BRAKE CYLINDER Unscrew the 2 bolts (A/F-71). To remove the cylinder it is necessary to dis- connect the STOP switch (B/F-71) and unscrew Remove the clamp (C/F-71) from the brake fluid supply tube and drain into a container. ATTENTION: Brake fluid is corrosive.

  • Page 47: Electrical System

    Electrical system Electrical system...

  • Page 48: Precautions

    Electrical system 1. PRECAUTIONS There are a number of important precautions to be taken before beginning to inspect or repair the electrical system. • Special attention must be paid to the polarity of the battery. • Always check the condition of the battery on beginning any repair. •...

  • Page 49: Battery

    Electrical system 3. BATTERY CHECKING THE CONDITION OF THE BATTERY • The battery should be removed from the machine to carry out checks. • When removing it, first disconnect the negative terminal to avoid any possible short circuits. • The condition of hermetically-sealed batteries can be checked by measuring voltage across the terminals with a digital meter that can measure tenths of volts.

  • Page 50: Lighting System

    Lighting system 4. LIGHTING SYSTEM Adjusting the height of the front headlight beam horizontal main beam 5 metres With the rider seated on the machines, the headlight beam should be adjusted in such a way that the main beam is situated below the headlight horizontal. In case of having to change a bulb, avoid touching the inside of the headlight with the hands.
  • Page 51 Lighting system Checking right-hand light switch and start button. STAR BUTTON Check that there is a circuit between the connector cables. Start button ON button position – circuit between the cables Colour: W/BL and W/BL Checking the right controls: Light switch, turn indicator switch and horn button. TURN INDICATOR SWITCH HORN...
  • Page 52 Lighting system Checking the contact relay With relay terminals 85 and 86 connected to a battery, check the circuit between terminals 30 and 87. The meter should register 0 Ω On disconnecting the battery, it should register infinity. ∞ The meter should register (infinity) Checking the turn indicator relay 12V 10W bulbs...

  • Page 53: Sensors

    Checking the instruments SENSORS Neutral sensor To check this sensor, the circuit should be checked between the terminal and earth. With the gearbox in neutral, it should register 0 Ω ∞ On selecting a gear the meter should register (Infinity). Checking the diode 6.

  • Page 54: Wiring Diagram

    Electrical system 6. WIRING DIAGRAM...
  • Page 55 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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