RIEJU 125 CBD AC Service Manual
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RIEJU 125 CBD AC Service Manual

RIEJU 125 CBD AC Service Manual

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ENGINE 125 CBD AC
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Summary of Contents for RIEJU 125 CBD AC

  • Page 1 ENGINE 125 CBD AC s r i...

  • Page 2: Table Of Contents

    Index Engine 1.INTRODUCTION 1.1 ENQUIRY NOTES 1.2 UPDATING GUIDE 1.3 WRITING SIMBOLOGY 1.4 OPERATIVE SIMBOLOGY 1.5 WORK GENERAL RULES 1.6 RECOMMENDATIONS 1.7 SPARK PLUGS 1.8 SPARK PLUG MAINTENANCE 1.9 SPARK PLUG REPLACEMENT 1.10 MOTOR REMOVAL 1.11 MOTOR DISASSEMBLY 2.GENERAL SPECIFICATIONS 2.1 TORQUE GENERAL SPECIFICATIONS 2.2 LUBRICATION DIAGRAM 2.3 VALVES SET ADJUSTMENT...
  • Page 3 Index Engine 3.6 DISASSEMBLY OF THE START SYSTEM SHAFT WITH PEDAL 3.7 CHANGE SHAFT 3.8 CHASSIS 3.9 ROCKER ARM, TRANSMISSION AND CHANGE SELECTOR 3.10 CRANKSHAFT 3.11 ROCKERS, CAMSHAFT AND VALVES 3.12 CYLINDER HEAD CHECK AND REPAIR 3.13 VALVE SEATINGS 3.14 VALVES AND VALVE SPRINGS 3.15 CAMSHAFT CHECKING 3.16 ROCKERS AND THEIR SHAFTS CHECKING 3.17 CAMSHAFT CHECKING...
  • Page 4 Index Engine 3.36 CRANKSHAFT AND ROCKER ARM SHAFT 3.37 CHANGE SELECTOR 3.38 TRANSMISSION, FORKS AND CHANGE SELECTOR INSTALLATION 3.39 TRANSMISSION 3.40 CHASSIS 3.41 CHASSSIS (RIGHT SIDE) 3.42 CHANGE SHAFT AND START SYSTEM WITH PEDAL 3.43 CHANGE SELECTOR SEGMENT AND CHANGE SHAFT 3.44 START SYSTEM WITH PEDAL INSTALLATION 3.45 CLUTCH, HOOD AND OIL PUMP 3.46 OIL PUMP INSTALLATION...
  • Page 5 Introduction...

  • Page 6: Introduction

    The aim of these guides, is about the standard technical interventions in the whole range of engi- ne (two-stroke engine) for RIEJU motor vehicles in the production phase at the spreading time of these manuals. This information refers to the “ENGINES” of the motor vehicles. Some information has been deliberately omitted, since (according to us) it is an essential part of the basic technical knowledge.

  • Page 7: Writing Simbology

    Introduction Engine 1.3 WRITING SIMBOLOGY ATTENTION! Some caution advice and information as regards to the safety of the motorcyclist (vehicle user) and the safeguard of the whole vehicle. ATTENTION! Descriptions relating to some dangerous interventions for the maintenance engineer, the repair technician, the workshop staff or strangers, for the atmosphere, for the vehicle and for the equipments.

  • Page 8: Operative Simbology

    Introduction Engine Figure Pr Tr Torque Page Sub-section Section Diagram Table Bolt Remark: Illustrations frequently shown fixing or regulator screws, specified with the letter Tr. The number besides this letter indicates the quantity of identical Tr existing in the group or object component of the description and its corresponding illustration. The letter without number, indicates quantity 1.

  • Page 9: Work General Rules

    Introduction Engine 1.5 WORK GENERAL RULES • The following advice, recommendations, and warnings, guarantee rational interventions in the maximum operative safety, ruling out considerably the probabilities of accidents, all kind of damage and time-out. Therefore, we advise you to observe them scrupulously.

  • Page 10: Recommendations

    Introduction Engine 1.6 RECOMMENDATIONS • Before beginning any intervention in the motor vehicle, wait till all and each one of the components of the same vehicle are completely cool down. • If the operations need two technicians work, it is necessary that they previously come to an agreement on tasks and synergies.
  • Page 11 Introduction Engine Never use, under no circumstances, free flames. Never leave open and not suitable containers with fuel, blocking the pass, near to heat sources, etc. Never use fuel like a cleansing detergent for the motor vehicle or for the workshop floor. The components must be cleaned with a low grade of inflammability detergent.

  • Page 12: Spark Plugs

    Introduction Engine 1.7 SPARK PLUGS 1. Insulator 2. Body 3. Lining 4. Electrode 5. Earth electrode 6. Thread SPARK PLUGS CONTROL AT 1.000 Km • Do not to touch the spark plug if the motor is hot. • The coal tip and the insulator coloration (around the central electrode) provide with useful information about the thermic degree of the spark plug, the carburation, the lubrication and the overall condition of the engine.

  • Page 13: Spark Plug Maintenance

    1.9 SPARK PLUG REPLACEMENT AT 5000 Km • At the foreseen kilometres, replace always the spark plug with a new one, choosing one of those that the Company RIEJU, S.A. recommends. • When the discharged spark plug is being eliminated, inspect always its general look (as previously stated) to check the good state of the engine.

  • Page 14: General Specifications

    General specifications Engine 2.1 TORQUE GENERAL SPECIFICATIONS • The following table specifies the fixed torques with ISO standard thread. The torque specifications for components or special units are indicated in the chapters of this guide referring to ISO. To avoid strains, screw the units gradually and cross them in one or alternative goes, to obtain the specified torque..

  • Page 15: Lubrication Diagram

    General specifications Engine 2.2 LUBRICATION DIAGRAM Rocker Rocker (Exhaust) (Intake) Rocker shaft Pull (clutch) Camshaft Chassis (LS) Centrifugal filter Driving shaft Oil pump Drive shaft Oil in the sump Oil impeller Don’t damage the chassis surface, otherwise there will be oil leaks.
  • Page 16 General specifications Engine Camshaft Cylinder head Cylinder Chassis cowling (LS) Centrifugal filter Crankshaft Drive shaft Chassis (LS) Chassis (RS) Driving shaft Clutch Chassis cowling (RS) For a better performance, use always oil and “amalibe”.

  • Page 17: Valves Set Adjustment

    Checks and adjustments Engine 2.3 VALVES SET ADJUSTMENT Remark: The valves set should be adjust when the motor is cool down and at room tempe- rature. When adjusting or measuring the valves set, the piston should be in the top dead centre (TDC) at the compression moment.
  • Page 18 Checks and adjustments Engine Steps for measuring: • Rotate the crankshaft anticlockwise aligning the mark (a) of the rotor with the stationary point (b) of the chassis cover (1), with the piston in the top dead centre (TDC), and when the mark of the control gear is aligned with the mark of the cylinder head.
  • Page 19 Checks and adjustments Engine • Install the adjuster to impede it turns and tighten the locknut. Locknut: , Kgf.m ( N.m). • Measure the set of valves. • If the play is incorrect, repeat the aforementioned steps until the correct play is achieved.
  • Page 20 Checks and adjustments Engine 3) CHECK: • Electrodes (1). Damages/Wear => Replacement. • Insulator (2). Standard colour => Replacement. The standard colour is light brown. 4) CLEAN: • Spark plug. (Clean the spark plug with a spark plug cleansing or a wire brush). 5) MEASURE: •...

  • Page 21: Ignition Point Control

    Checks and adjustments Engine Remark: • Before installing the spark plug, clean the surface of its seating and its gasket. • In case you do not have a torque gauge, a good evaluation for the correct torque is to tighten (1) the spark plug by hand and then tighten from 1/4 to 1/2 turn to (2). •...

  • Page 22: Compression Pressure Adjustment

    Checks and adjustments Engine 3) CHECK: • Ignition Point. Steps for checking: • Get the engine started and let it warming up for some minutes. Leave it working in the specified rotation. Idling speed: 1.300 - 1.400 rpm • Check visually if the stationary point (a) is inside the band (b) in the magneto flywheel. Outside the band = >...
  • Page 23 Checks and adjustments Engine 4) REMOVE • Spark plug. Before removing the spark plug, blow on the area with compressed air to eliminate any piece of dirt, in order to avoid it falls inside the engine. 5) INSTALL: • Compressor gauge (1). 6) MEASURE: •...

  • Page 24: Checking Of The Motor Oil Level

    Checks and adjustments Engine Steps for measuring: • Get the engine started with the throttle totally opened, until the compression reading becomes stabilized. Before getting the engine up, connect the cable from the spark plug to earth to avoid sparks. 7) INSTALL: •...

  • Page 25: Motor Oil Change

    Checks and adjustments Engine 6) Get the engine started and let it warming up for some minutes. 7) Pull the engine up. Remark: Wait some minutes till the oil goes down, before checking the oil level. 2.8 MOTOR OIL CHANGE 1) Get the engine started and let it warming up for some minutes.

  • Page 26: Oil Flow Checking

    Checks and adjustments Engine 5) SUPPLY: • Oil in the sump. Quantity of oil: 1,0 L 6) CHECK: • Level of motor oil. See section “CHECKING THE LEVEL OF MOTOR OIL” “OIL FLOW CHECKING”.

  • Page 27: Exhaust System Checking

    Checks and adjustments Engine 2.10 EXHAUST SYSTEM CHECKING 1) CHECK: • Screws (1) (exhaust pipe). Loose / damages = > Tighten / replace. • Gasket (exhaust pipe). Leak of exhaust fumes = > Tighten / replace. Screw: 0, Kgf.m ( N.m) 2) CHECK: •...
  • Page 28 Engine RIEJU...

  • Page 29: Motor Disassembly

    Engine disassembly Engine 3.1 MOTOR DISASSEMBLY CYLINDER HEAD, CYLINDER AND PISTON REMARK: With the assembled motor in the frame, the cylinder head, camshaft and cylinder can be checked, replace the following parts: • Seat • Side cowling • Fuel tank •...
  • Page 30 Engine disassembly Engine 4) ALIGN: • Magneto mark (a) (with the stationery point (b) of the chassis cowling). Remark: Rotate the crankshaft anticlockwise with a spanner. Steps for alignment with TDC: • Rotate the crankshaft anticlockwise aligning the mark (a) with the top dead centre (TDC) (b).
  • Page 31 Engine disassembly Engine 8) REMOVE: • Screws (cylinder head). • Cylinder head. Remark: • Loosen each one of the screws 1/4 turn and remove them when they are completely loose. • Loosen the screws, beginning with the smaller number. • The stamped numbers on the cylinder head indicated the torque sequence. 9) REMOVE: •...

  • Page 32: Magneto Flywhee

    Engine disassembly Engine Remark: • Before removing the clamp rings of the bolt, cover the cylinder with a clean cloth to avoid that something falls inside the engine. • Before removing the bolt, take the slot flanges out of the clamp rings and the orifi- ce rim.
  • Page 33 Engine disassembly Engine 2) REMOVE: • Magneto flywheel (1). • Cotter. Remark: • Remove the flywheel magneto with the rotor extractor (2). • Centre the rotor extractor of the magneto flywheel. Make sure that the play bet- ween the extractor and the flywheel is the same in all the points, after installing the securing screws.

  • Page 34: Clutch

    Engine disassembly Engine 4) REMOVE: • Guides of the timing chain (1). • Timing chain (2). 3.3 CLUTCH Remark: The clutch unit can be removed with the assembled motor in the frame. To be able to do it take the following parts out: •...
  • Page 35 Engine disassembly Engine 2) REMOVE: • Gasket (1). • Tangs guide (2). 3) EXTRAER: • Screws of the pressure plate (1). • Clutch springs (2). • Pressure plate (3). • Friction plates (4). • Separators (5) Remark: Loosen the screws of the pressure plate diagonally. 4) REMOVE: •...
  • Page 36 Engine disassembly Engine 5) LOOSE: • Nut (clutch drum) (1). Remark: • Smooth the rim of the clamp rings (2). • Loosen the nut (1) from the clutch drum while the drum is hold with the universal clutch support (3). 6) REMOVE: •...
  • Page 37 Engine disassembly Engine 7) LOOSE: • Nut (1). Remark: • Place a folded aluminium sheet between the teeth of the primary gear and those of the hood. • Take care not to damage the gear teeth. 8) REMOVE: • Nut. •...

  • Page 38: Chassis

    Engine disassembly Engine 3.8 CHASSIS 1) REMOVE: • Screws (chassis). • Battery cable supports. Remark: • Loosen the screws diagonally. • Loosen each one of the screws 1/4 turn and remove them when they are completely loose. 2) REMOVE: • Screw of the change selector ring. Use an Alien spanner of 4 mm.

  • Page 39: Rocker Arm, Transmission And Change Selector

    Engine disassembly Engine • Use the screwdriver only in the indicated points. • The chassis (LS) should remain downwards. • Separate the chassis after checking if the change selector ring and the clamp ring shaft have been removed. • Do not damage the contact surfaces of the chassis. 3) REMOVE: •...

  • Page 40: Crankshaft

    Engine disassembly Engine 3) REMOVE: • Neuter switch. 3.10 CRANKSHAFT 1) REMOVE: • Crankshaft (1) with the rocker arm shaft. (2). Remark: • Remove the crankshaft with the crankshaft extractor (1). • Tighten the screws of the crankshaft extractor till the end, but make sure that the body of the tool is in parallel with the chassis.

  • Page 41: Rockers, Camshaft And Valves

    Engine disassembly Engine 3.11 ROCKERS, CAMSHAFT AND VALVES 1) LOOSEN: • Locknut of the valve adjusters. • Valve adjusters. 2) REMOVE: • Clamp plate (1). 3) REMOVE: • Camshaft (1). • Space washer (2). 4) REMOVE: • Rockers shafts. • Rockers (intake and exhaust). Remark: •...
  • Page 42 Engine disassembly Engine 5) CHECK: • Valve closing. Leaks in the valve seating = > Check the valve , valve seating and width of the val- ve seating. See section: “CHECK AND REPAIR – VALVE SEATING”. Steps for checking: • Fill up the intake chamber and then the exhaust chamber with petrol (1). •...

  • Page 43: Cylinder Head Check And Repair

    Engine disassembly Engine 7) REMOVE: • Clasp seating (1). • Spring (2). • Valve (3). • Constraint ring (4). • Spring seating (5). Remark: • Identify the position of each piece carefully, so that they can be reinstalled in their original positions. 3.12 CYLINDER HEAD CHECK AND REPAIR 1) ELIMINATE: •...
  • Page 44 Check and repairs Engine 2) CHECK: • Cylinder head. Scratches / damages = > Replace. 3) MEASURE: • Strain. Unspecified = > Rectify. Strain of the cylinder head: Below 0,0 mm Steps for measuring the strain and correction: • Place a rule (1) and a calibre of thickness (2) on the surface of the cylinder head as it is illustrated above.

  • Page 45: Valve Seatings

    Check and repairs Engine 3.13 VALVE SEATING 1) ELIMINATE: • Carbon sediment.. (in the face and in the valve seating). 2) CHECK: • Valve seating. Groove / Wear = > Polish the valve with emery. 3) MEASURE: • Width of the valve seating (a). Unspecified = >...
  • Page 46 Check and repairs Engine 4) POLISH WITH EMERY: • Front of the valve. • Valve seating. Remark: • After correcting the valve seating or replacing the valve and its guide, the seating and the front should be polished with emery. Steps for fixing the valves: •...

  • Page 47: Valves And Valve Springs

    Check and repairs Engine Remark: • Make sure that the front and the seating are completely free from the abrasive paste after each fixing of valves. • Apply blue ink of mechanics (Dykem) on the front of the valve (b). •...
  • Page 48 Check and repairs Engine 3) MEASURE: • Contact front of the spring. Wear / damages / scratches = > Replace. 4) MEASURE: • Internal Diameter of the valve guide. Unspecified = > Replace. Internal diameter of the valve guide: Inlet: - 5, Exhaust: - 5,...

  • Page 49: Camshaft Checking

    Check and repairs Engine 6) MEASURE: • Warping (valve rod). Unspecified = > Replace. Warping limit: 0,01 mm 3.15 CAMSHAFT CHECKING 1) CHECK: • Cam salient. Groove / scratches / blue coloration = > Replace. 2) MEASURE: • Cam measurements (a) and (b). Unspecified = >...

  • Page 50: Rockers And Their Shafts Checking

    Check and repairs Engine 3) CHECK: • Oil leak in the camshaft. Obstruction = > Compressed air blowing. 3.16 ROCKERS AND THEIR SHAFTS CHECKING 1) CHECK: • Cam contact surface (1). • Adjuster surface (2). Wear / grooves / scratches / blue coloration = > Replace. Steps for checking: •Check if the two contact areas of the rockers have signs of abnormal wear.

  • Page 51: Camshaft Checking

    Check and repairs Engine Internal diameter (rocker) : 1 000 ~ 1 ,01 mm • Measure the external diameter (b) of the rockers. Unspecified = > Replace. External diameter (rocker shaft): 3.17 CAMSHAFT CHECKING 1) CHECK: • Timing Chain. Rigidity / damages = > Replace the chain and the gear. 2) CHECK: •...

  • Page 52: Timing Chain Strut

    Check and repairs Engine 3.18 TIMING CHAIN STRUT 1) CHECK: • Ratchet brace operation. Irregular operation = > Replace. Steps for checking: • While the adjuster rod is lightly pressed by hand, use a screwdriver to turn totally the adjuster rod clockwise. •...
  • Page 53 Check and repairs Engine “c” Diameter of the cylinder 5 , 00 ~ 5 , “T” conical limit 0,05mm Ovalidad “R” 0,01mm “C” = maximum D “T” = (maximum D or D ) - (maximumD or D “R” = (maximum D or D or D ) - (maximum D...

  • Page 54: Rings Checking

    Check and repairs Engine 3.20 RINGS CHECKING 1) MEASURE: • Lateral play. Unspecified = > Replace the piston and its rings altogether. Remark: • Eliminate the carbon sediments from the grooves of the piston rings before mea- suring the lateral play. Lateral play (rings of the piston): Top ring - Limit 0 mm...

  • Page 55: Bolt Checking

    Check and repairs Engine 3.21 BOLT CHECKING 1) CHECK: • Bolt. Blue coloration / grooves = > Replace and immediately control the lubrication system. 2) MEASURE: • Play piston - bolt. Steps for measuring: • Measure the external diameter of the bolt (a). Unspecified = >...

  • Page 56: Crankshaft

    Check and repairs Engine 3.22 CRANKSHAFT 1) MEASURE: • Non-alignment crankshaft. Unspecified = > Replace the crankshaft and/or ball bearings. Remark: • Measure the non-alignment crankshaft Rotate the crankshaft unit slowly. Non-alignment limit: 2) MEASURE: • Lateral play of the connecting rod. Unspecified = >...

  • Page 57: Rocker Arm Checking

    Check and repairs Engine 4) CONTROL: • Oil leak in the crankshaft. Obstruction = > Compressed air blowing. 3.23 ROCKER ARM CHECKING 1) CHECK: • Teeth of the rocker arm drive gear (1). • Teeth of the rocker arm driven gear (2). Wear / damages = >...

  • Page 58: Clutch Hood Checking

    Check and repairs Engine 3.24 CLUTCH HOOD CHECKING 1) CHECK: • Teeth of the primary gear (1). • Teeth of the hood gear (2). Wear / damages = > Replace both gears. Excessive noise during the operation = > Replace both gears. 3.25 CLUTCH CHECKING 1) CHECK: •...
  • Page 59 Check and repairs Engine 3) CHECK: • Separators. Damages = > Replace the separators unit. 4) MEASURE: • Separators strain. Unspecified = > Replace the separators unit. Take the measurements on a plane table with the help of a thickness calibre (1). Strain limit (separators): Lower than 0,05 mm...

  • Page 60: Rod Operation Checking

    Check and repairs Engine 7) CHECK: • Nails (of the hood) (1). Rims / wear / damages => Eliminate the rims or replace the hood. • Grooves in the clutch drum (2). Rims / wear / damages = > Replace the clutch drum. Remarks: •...

  • Page 61: Forks And Change Selector Checking

    Check and repairs Engine 3.27 FORKS AND CHANGE SELECTOR CHECKING 1) CHECK: • Fork extension (1). • Extremities of the change forks (2). Scratches / warping / wear / damages => Replace. 2) CHECK: • Grooves in the change selector. Wear / damages / scratches = >...
  • Page 62 Check and repairs Engine 4) CHECK: • Movement of the change forks (in the guide bar). Irregular movement = > Replace the fork and the bar. Remark: • If the change fork and the transmission gear are damaged, replace the gears which are side by side of the unit.

  • Page 63: Oil Pump Checking

    Check and repairs Engine 3.29 OIL PUMP CHECKING 1) MEASURE: • Play among tips (TO). (between internal rotor (1) and external rotor (2). •Lateral play (B). (between external rotor (2) and the pump casing (3). Unspecified = > Replace the oil pump unit. •...

  • Page 64: Oil Leads Checking

    Check and repairs Engine 2) CHECK: • Rotary filter. Cracks / damages = > Replace. Contamination = > Clean. 3) CHECK: • Oil impeller. Cracks / damages = > Replace. Contamination = > Clean. 3.30 OIL LEAKS CHECKING (COVER OF THE CASSING IN THE RIGHT SIDE) 1) CHECK: •...

  • Page 65: Chassis

    Check and repairs Engine 3.31 CHASSIS Wash the chassis properly with kerosene. Clean the surfaces which bear the gaskets and the surfaces in contact with the chassis properly. 1) CHECK: • Chassis. Cracks / damages = > Replace. • Oil leaks. Obstruction = >...
  • Page 66 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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