Mh Verkstadshandbok

8/12/2019 Mh Verkstadshandbok

1/92

REF. OF PUBLICATION:

0634111000004

1AEDITION2007-10

USE THIS SERVICE MANUAL WITH THE RELATED MANUALS INDICATED IN

THE FOREWORD TO THIS MANUAL

w w w . m o t o r h i s p a n i a . e s

SERVICE MANUAL


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IMPORTANTRead this manual and follow the instructions carefully. Especia-lly important information is indicated with the words WARNING,CAUTION and N.B., which have quite precise meanings.

Pay special attention to the instructions that follow these titles.

WARNING:

Contains a potential danger that may cause injury or even

death.

CAUTION:

Contains a potential danger that may damage the machine.

N.B.:

Contains special information to aid maintenance or clarify

some point in the instructions.

WARNING:

This service manual has been prepared for authorised G.H.E.

ENGINEHISPA NIA, S.L. dealers, and should only be used

by qualified Technical Service department mechanics. Mecha-

nics without experience or without the proper tools and equi-pment cannot carry out the service work described in this ma-

nual properly.

A bad repair may cause injury to the mechanic, and the machi-

ne may not be in a condition to ensure the safety of rider and

passengers.


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FOREWORD

This manual describes the procedures for the diagnosis, maintenance, adjustments, basic service work, changing of

parts and the dismantling and assembling of the main parts.

Model applicable: RYZ 50 CROSS (C) and RYZ 50 SUPERMOTARD (SM) with the following VIN numbers and later ones:

VTVDV0C00XXXXXXXX ~

VTVDV0CE2XXXXXXXX ~VTVDV1CE2XXXXXXXX ~

This text is classified into sections, each of which has a section number, as can be seen in the Contents on the following page, and

on the first page of every individual section there is a contents list for that section.

Keep this manual to hand so that it can be consulted quickly when carrying out service work.

The specified points must be carefully observed to ensure that the machine functions perfectly in accordance with the specification.

When changing parts or carrying out service work that involves dismantling, it is recommended to use genuine G.H.E. ENGINEHIS-

PANIA, S.L. spare parts, tools and service materials, as specified in the corresponding descriptions.

All the information, figures and specifications in this manual are based on the latest approved product information available at the

time of publication.

The main model used for the description throughout this manual is the model with basic specifications. Therefore the figures may

appear slightly different from the model in the workshop. G.H.E.

ENGINEHISPANIA, S.L.reserves the right to make changes without prior warning.

RELATED MANUALS

TITLE OF THE MANUAL

RYZ50 SPARE PARTS CATALOGUE

MANUAL NO.

0634111000001

APPLICABILITY

Manual with all the spare parts for the RYZ50 model.

G.H.E. ENGINEHISPANIA, S.L.

DEPARTAMENTO DE SERVICIO

COPYRIGHT G.H.E. ENGINEHISPANIA, S.L. 2006


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NOTES:


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SECTION 1

GENERAL INFORMATION

CONTENTS

USING THIS MANUAL................................................................................................................................................................... 1-2IDENTIFICATION ........................................................................................................................................................................... 1-3 Machine identification .......................................................................................................................................................... 1-3 Engine identification ............................................................................................................................................................ 1-3

GENERAL INFORMATION 1-1


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1-1 GENERAL INFORMATION

USING THIS MANUAL

At the beginning of this manual there is a GENERAL CON-

TENTS LIST, enabling the SECTION containing the informa-

tion needed for the service to be found quickly. In addition,

each section has its own contents list on its first page with a

description of its main points.

In each section of this manual the page numbers start from the

beginning. The numbers appear at the top of the page together

with the name of the section.

This manual includes units of measurement in the international

system (SI).

The use of the SPECIAL TOOLS and of the TIGHTNESS TOR-

QUE SPECIFICATIONS are indicated in bold type, as in the

following example:

Immobilise the clutch dog with the special tool.

Special tool (C)

Tighten the nut.

Tightness torque:

7.5 daNm (75 Nm)

Fold back the clutch nut tab washer.

Fit the clutch control lever with its spring and its washer.

1)

2)

3)

4)

2)

3)

4)

5)


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GENERAL INFORMATION 1-1

IDENTIFICATION

IDENTIFICATION OF THE MACHINE

The machine is marked with a plate (1), situated on the right-

hand side of the chassis. This plate has the VIN (VEHICLE

IDENTIFICATION NUMBER) engraved on it.

The VIN (VEHICLE IDENTIFICATION NUMBER) is engraved

on the right-hand chassis beam (2).

ENGINE IDENTIFICATION

The Engine Identification Number (1) is marked on the engine, on

the left-hand side of the machine.

1)

2)

1


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SECCION 2

SPECIFICATIONS

CONTENTS

GENERAL SPECIFICATIONS ........................................................................................................................................................ 2-2ENGINE SPECIFICATIONS ............................................................................................................................................................ 2-2CHASSIS SPECIFICATIONS ........................................................................................................................................................... 2-4TIGHTENING TORQUES ................................................................................................................................................................ 2-5

SPECIFICATIONS 2-2

2


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2-2 SPECIFICATIONS

2

GENERAL SPECIFICATIONS

ELEMENT

Model code

DIMENSIONS

Total length

Total width

Height without rear-view mirror

Distance between axles

WEIGHT

Weight empty

Weight running

Maximum permittable weight

Top speed

SPECIFICATION

RYZ TLRYZ SM

RYZ UB

RYZ TL: 2.095 mm

RYZ SM y UB: 1.980 mm

820 mm

RYZ TL: 1.210 mm

RYZ SM: 1.170 mm

RYZ UB: 1.150 mm

820 mm

RYZ TL: 97 kg

RYZ SM: 98 kg

RYZ UB: 101 kg

RYZ TL: 97 kg

RYZ SM: 98 kg

RYZ UB: 101 kg

255 kg

45 km/h

ENGINE SPECIFICATIONS

ELEMENT

ENGINE

Engine type

Make

Cubic capacity

Stroke x diameter

Maximum power

Maximum torque

Volumetric compression ratio

FUEL

Recommended fuel

Total capacity of fuel tank

(including reserve)

SPECIFICATION

AM6.(EU.2)-liquid cooled 2-stroke

Minarelli 50 cc

49,7 cm

40,3 x 39 mm

1,4 Kw a 5.000 rev/min

2.89 Nm a 4.000 rev/min

12.0 0.1 : 1

Only 95 octane lead-free petrol

6 litres 0.5


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ELEMENT

LUBRICATION

Type

Recommended oil

Oil tank capacity

COOLING

Type

Cooling circuit capacity

IGNITION

Type

Spark plug

CARBURETTOR

Make / Type

Idle rate

Initial position of air screwNeedle

Main jet

Idle jet

TRANSMISSION

Type

Primary transmission

Secondary transmission

Gearbox

Gearbox capacity

Clutch

Magneto

Starter motor

ESPECIFICACIN

Separate lubrication by a variable rate piston pump, synchronised

with the throttle and driven by geared take-off from the crankshaft.

The oil is injected directly into the carburettor.

Semi-synthetic Motul 510 2St special

anti-smoke two-stroke oil

1.1 Litres

Circulation of water coolant by a pump driven by geared take-offfrom the crankshaft.

0,7 Litres

CDI

NGK BR 9ES

DELLORTO / PHBN 16

93050 rev/min

1.5 turnsA8 3rd notch

84

34

By sprocket and crown gear, with the gearbox and rear wheel

joined by a 126 link roller chain.

(12.7 pitch)

20x71

11x52

6 speed

0.75 litres Motul TRANSOIL (SAE 10W30)

Multi-disk with oil bath and cable control

Ducati 85 W

Ducati

SPECIFICATIONS 2-2

2


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2-2 SPECIFICATIONS

2

CHASSIS SPECIFICATIONS

ELEMENT

WHEELSFront wheel

Front tyre

Front pressure

Rear wheel

Rear tyre

Rear pressure

FRONT BRAKES

Type

brake pistons

Disk

Disk thickness

main piston (cylinder)

REAR BARKES

Type

brake pistons

Disk

Disk thickness

main piston (cylinder)

FRONT SUSPENSION

Type of suspension

Type of front forks

Forks capacity

Travel

SPECIFICATION

RYZ TL: 1,85X21

RYZ SM: 2,5X17RYZ UB: 1,85X16

Disk with hydraulic calliper

RYZ TL: 90/90X21

RYZ SM: 100/80X17

RYZ UB: 90/90X16

RYZ TL: 1,9 1 bar

RYZ SM: 2.0 1bar

RYZ UB: 2.3 1 bar

RYZ TL: 2,5X18

RYZ SM: 3,5X17

RYZ UB: 2,5X16

RYZ TL: 120/80X18RYZ SM: 130/70X17RYZ UB: 120/80X16

RYZ TL: 2.1 1 bar

RYZ SM: 2.3 1 bar

RYZ UB: 2.7 1 bar

25 mm (2)

RYZ TL: 200 mm; RYZ TOP TL: 220 mm

RYZ SM: 200 mm; RYZ TOP SM: 220 mm

RYZ UB: 220 mm; RYZ TOP UB: 220 mm4 mm

12 mm

Disk with hydraulic calliper

32 mm (2)

RYZ TL: 240 mm; RYZ TOP TL: 260 mm

RYZ SM: 260 mm; RYZ TOP SM: 280 mm

RYZ UB: 260 mm; RYZ TOP UB: 280 mm

4 mm

12 mm

Telescopic forks

Hydraulic fluid shock absorber

0.3 litres per tube

230 mm


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ELEMENT

REAR SUSPENSION

Type of suspension

Travel of central single hydraulic shock absorber

STEERING

Type

SPECIFICATION

Variable flexibility swinging arm, combined with a 44 mm central

single hydraulic shock absorber

44 mm

Steering column mounted on ball bearings

SPECIFICATIONS 2-2

2


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2-2 SPECIFICATIONS

2

TIGHTENING TORQUES

ELEMENT

BODYSide covers

Front mudguard

Rear mudguard

Skirting

CHASSIS

Front wheel shaft

Rear wheel shaft

Rear wheel shaft nut

Suspension arm nut

Chassis engine mounting

Shock absorber top mounting

Shock absorber top mounting

Forks T-sections

Front brake calliper

Rear brake calliper

Front brake disk

Rear brake disk

Support on chassis

Steering lock

ESTNDAR

5.mm diameter nut and bolt

6 mm diameter nut and bolt




TIGHTENING TORQUE

0,1 daNm (1 Nm)

0,1 daNm (1 Nm)

0,8/0,1 daNm (8/1 Nm)

0,8/0,1 daNm (8/1 Nm)

4,5 daNm (45 Nm)

1,2 daNm (12 Nm)

6,5 daNm (65 Nm)

6,5 daNm (65 Nm)

2,8 daNm (28 Nm)

4,3 daNm (43 Nm)

4,3 daNm (43 Nm)

1,5 daNm (15 Nm)

2,5 daNm (25 Nm)

2,5 daNm (25 Nm)

1 daNm (10 Nm)

1 daNm (10 Nm)

1,9 daNm (19 Nm)

0,6 daNm (6 Nm)

0,5 daNm (5 Nm)

1 daNm (10 Nm)

2,2 daNm (22 Nm)

3,5 daNm (35 Nm)

5,5 daNm (55 Nm)


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SECTION 3

MAINTENANCE AND COMMISSIONING

CONTENTS

INTRODUCTION............................................................................................................................................................................... 3-2MAINTENANCE PLAN ................................................................................................................................................................. 3-2 Checking ............................................................................................................................................................................... 3-2 Renewing .............................................................................................................................................................................. 3-2

Checking and decarbonising ................................................................................................................................................. 3-3

Checking and greasing ......................................................................................................................................................... 3-3

Checking and adjusting ......................................................................................................................................................... 3-3

Cleaning and adjusting .......................................................................................................................................................... 3-3COMMISSIONING............................................................................................................................................................................. 3-4 Battery preparation (except maintenance-free batteries) ...................................................................................................... 3-4

Checking levels ..................................................................................................................................................................... 3-4

Commissioning the fuel and oil circuits ................................................................................................................................ 3-4

Checks before delivery to customer ..................................................................................................................................... 3-5

TIGHTENING TORQUE SPECIFICATIONS ................................................................................................................................... 3-6SERVICE MATERIALS REQUIRED ............................................................................................................................................... 3-6

MAINTENANCE AND COMMISSIONING 3-1

3
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3

INTRODUCTION

This section includes all the information needed to perform the recommended maintenance and commissioning operations. Obser-

ving these procedures will ensure the machine functions more reliably and has a longer useful life, while reducing the need for costly

repair work.

All maintenance technicians must be familiar with the whole of this section.

MAINTENANCE PLAN

Reinforced maintenance is designed for machines used in severe conditions: driver temperament, short journeys with a cold engine,dusty regions or environments with a temperature higher than 30C.

3-2 MAINTENANCE AND COMMISSIONING

CHECKING

MAINTENANCE OPERATIONS

REINFORCED MAINTENANCE

Adjusting idle speed

Throttle cable and oil pump

Front and rear brake cable

Functioning of the electrical equipment

Fuel circuit

Oil circuit

Front and rear brake fluid piping

Coolant circuit

Carburettor heating circuit

Tyre pressures

Condition, pressure and wear of tyres

Front and rear brake fluid level

Coolant level

Battery electrolyte level

Tightening nuts and bolts

Charging the battery

500 KMOR 3 MONTHS

Every 1.500 km

EVERY 3,000 KM EVERY 6,000 KM

Every 3.000 km

XX X

XX X

XX X

XX X

XX X

XX X

XX X

XX X

XX X

X

X X

XX X

XX X

XX X

XX X

X X

RENEWING



Intake filter element

Front and rear brake pads (where appropriate)

Gearbox oil

Chain sprocket- crown gear (where appropriate)

Clutch disks (where appropriate)

500 KMOR 3 MONTHS

Every 1.500 km

EVERY 3.000 KM EVERY 6.000 KM

Every 3.000 km

X X

X X

X X

X X

X


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3

CHECKING AND DECARBONISING


REINFORCED MAINTENANCEPiston (1)

Cylinder head (1)

Exhaust port (1)

500 KMOR MONTHS

Every 1.500 km


Every 3.000 km

Every 10.000 km

Every 10.000 km

Every 10.000 km

(1) The need to decarbonise can be estimated by checking the quantity of carbonisation present in the cylinder exhaust outlet.

CHECKING AND GREASING



Chain tension and condition

500 KMOR MONTHS

Every 1.500 km


Every 3.000 km

XXX

CHECKING AND ADJUSTING



Clutch cable

Oil pump control

Spark plug

Tension of the wheel spokes

500 KMOR MONTHS

Every 1.500 km


Every 3.000 km

X

X

X

X

X

X

X

X

CHECKING AND ADJUSTING



Carburettor

500 KMOR MONTHS

Every 1.500 km


Every 3.000 km

XX


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BATTERY PREPARATION (EXCEPT MAIN-TENANCE-FREE BATTERIES)

Remove the battery

Remove the six filler plugs and the air vent plug.

Replenish with electrolyte up to theUPPER LEVEL mark.

Electrolyte:(35% sulphuric acid = 1.28 g/cm)

Allow the battery to stand for approximately half an hour.

Top up if necessary.

Charge the battery for at least 2 hours at an intensity of 400 mA

(0.4 A).

Refit the battery and connect the vapour vent pipe.

Connect the red cable to the positive battery terminal and the black

cable to the negative battery terminal.

CHECKING LEVELS

Check the gearbox oil level.

Check the coolant level.

Check the brake fluid level.

COMMISSIONING THE FUEL AND OILCIRCUITS

Put 1 litre of unleaded petrol in the fuel tank. This should be 95 or

98 octane mixed with 3% Motul 510 semi-synthetic 2-stroke oil.

Put Motul 510 semi-synthetic 2-stroke oil in the oil tank.

Engine oil:Motul 510 semi-synthetic 2-stroke oil

Start up the engine and disconnect the special tube entering

the carburettor to check that the oil is flowing drop by drop (the

speed of the drops increases with the engine revs).

Complete the filling of the fuel tank with unleaded 95 or 98octane petrol without oil mixture.

1)

2)

3)

4)

5)

6)

7)

8)

1)

2)3)

1)

2)

3)

4)

3

COMMISSIONING

WARNING:

A continuacin, eventualmente se deber restablecer elnivel de la batera despus de una carga completa, utili-

zando exclusivamente agua destilada.


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CHECKS BEFORE DELIVERY TO CUSTOMER

Check the tightness of the wheel nuts.

Front wheel tightness torque:4.5 daNm (5 Nm)

Rear wheel tightness torque:6.5 daNm (75 Nm)

Check the tightness of all nuts and bolts.

Check the adjustment and effectiveness of the brakes.

Check the inflation pressure of the tyres when cold.

Front tyre inflation pressure:RYZ SM: 2 bars (200 kPa)RYZ C: 1.5 bars (150 kPa)

Rear tyre inflation pressure:RYZ SM: 2.3 bars (230 kPa)RYZ C: 1.7 bars (170 kPa)

Check the functioning of the lights, the turn indicators, the horn

and the brake light.

Check the functioning of the different indicator lights.

Carry out a road test.

1)

2)

3)

4)

5)

6)

7)


3


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TIGHTENING TORQUE SPECIFICATIONS

SECURING DEVICES

Front wheel shaft bolt

Rear wheel shaft nut

daNm Nm

4565

3

4,56,5

SERVICING MATERIALS REQUIRED

MATERIALS

Engine oil

Electrolyte

RECOMMENDED MH PRODUCT USE

Filling the engine oil tank

Topping up the battery during maintenance

Motul 510 semi-synthetic 2-stroke oil

35% sulphuric acid = 1.28 g/cm


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SECTION 4

CHASSIS

CONTENTS

SERVICING THE MACHINE .......................................................................................................................................................... 4-2FRONT WHEEL .............................................................................................................................................................................. 4-2 Removal .............................................................................................................................................................................. 4-2 Assembly ............................................................................................................................................................................. 4-2

Operations that can be performed with the front wheel removed ....................................................................................... 4-2

FRONT BRAKES ........................................................................................................................................................................... 4-3 Dismantling the front brake calliper and brake pads .......................................................................................................... 4-3

FORKS ........................................................................................................................................................................................... 4-3 Removal .............................................................................................................................................................................. 4-4 Dismantling the fork tubes ................................................................................................................................................... 4-4

Sealing rings ....................................................................................................................................................................... 4-5

Removal .............................................................................................................................................................................. 4-5

Assembly ............................................................................................................................................................................. 4-6

REAR WHEELS ............................................................................................................................................................................ 4-7 Dismantling the rear brake calliper and brake pads ........................................................................................................... 4-7 Operations that can be performed with the rear wheel removed ........................................................................................ 4-8

TRANSMISSION CHAIN ............................................................................................................................................................... 4-8 Adjusting the chain tension ................................................................................................................................................. 4-8

SEAT ............................................................................................................................................................................................... 4-9 Removal .............................................................................................................................................................................. 4-9

FUEL TANK .................................................................................................................................................................................. 4-9

Removing the fuel tank or fuel tap ...................................................................................................................................... 4-9SHOCK ABSORBER ..................................................................................................................................................................... 4-10 Removal ............................................................................................................................................................................. 4-10

AIR FILTER ................................................................................................................................................................................... 4-10 Removing the air filter sponge ............................................................................................................................................ 4-10

Removing the air filter box .................................................................................................................................................. 4-11

EXHAUST ...................................................................................................................................................................................... 4-11 Removal .............................................................................................................................................................................. 4-11

CARBURETTOR ............................................................................................................................................................................ 4-12 Removal .............................................................................................................................................................................. 4-12

Adjustment ........................................................................................................................................................................... 4-13

Dismantling the valves ........................................................................................................................................................ 4-13

CHASSIS ....................................................................................................................................................................................... 4-13 Removal .............................................................................................................................................................................. 4-13

Removing the frame ........................................................................................................................................................... 4-14 Assembly ............................................................................................................................................................................. 4-15

TIGHTENING TORQUE SPECIFICATIONS .................................................................................................................................. 4-15SERVICING MATERIALS REQUIRED .......................................................................................................................................... 4-15SPECIAL TOOLS .......................................................................................................................................................................... 4-15

CHASSIS 4-1

4


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FRONT WHEEL

REMOVAL

Unscrew the speedometer cable.

Unlock the two bolts on the wheel shaft clamp (1) (2) at thefront of the fork arm.

Remove the wheel shaft, the washer and the spacer.

Remove the wheel.

ASSEMBLY

Refit in the reverse order to removal, bearing the following po-ints in mind:

Grease the wheel shaft, together with the speedometer take-off, before refitting the wheel.

Position the speedometer take-off in such a way that it does

not interfere with the cable (3).

Wheel shaft tightness torque:4.5 daNm (5 Nm)

Wheel shaft clamp tightness torque:1.2 daNm (12 Nm)

OPERATIONS THAT CAN BE PERFORMED WITHTHE FRONT WHEEL REMOVED

Changing the tyre or the inner tube.

N.B.:Identify the roll direction of the tyre before removing it,and refit in the same direction (Supermotard only).

1)

2)

3)

4)

1)

4-2 CHASSIS

SERVICING THE MACHINE

CAUTION:Place the machine on a flat surface. Stand the machine on a suitable support, in such a waythat the front wheel is off the ground. Do not activate the brake lever during the removal andrefitting process.

CAUTION:

Do not activate the brake lever, or as an alternative pre-caution place a wedge between the brake pads.

4


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Changing the brake disk.

N.B.:In refitting, respect the order of assembly: mark the outerside and fit the six self-locking bolts.

Changing the wheel bearings.

Changing the speedometer take-off.

FRONT BRAKE

N.B.:The brake pads are identical; on dismantling without re-newing, identify the fitting direction and refit in the samedirection.

DISMANTLING THE FRONT BRAKE CALLIPERAND BRAKE PADS

Remove the two bolts (1) from the calliper on the fork arm.

Remove the pins (2).

Remove the brake pads (3) and the anti-vibration plates (4).

FORKS

1)

2)

3)

WARNING:

As a result of removing the wheel, the calliper or thebrake pads, and before performing a road test, check thegood functioning of the brake by applying the brake levervarious times.

CHASSIS 4-3

4

CAUTION:

Place the machine on a flat surface. Stand the machine on a suitable support, in such a waythat the front wheel is off the ground. Do not activate the brake lever during the dismantlingand refitting process.


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REMOVAL

Remove the headlight housing assembly.

Remove the front mudguard.

Disconnect the headlight and the turn indicators.

Remove the two bolts from the brake calliper, and remove it

without disconnecting it.Unscrew the speedometer cable from the speedometer take-

off.

Remove the guides from the flexible hydraulic fluid pipe and

the speedometer cable.

Remove the handlebars.Remove the steering locknut (1).

Remove the two bolts (2) from the top T section.

Remove the forks top T section (3) with the instrument panel

and contact key switch.Remove the front wheel.

Remove the steering bolt (4) with its washer (5).

Extract the forks bottom T section (6) and the two steering co-

lumn arms (7) (the forks are fitted a little tightly onto the stee-

ring arm bearings).

Remove the washer (8) on the bottom T section.

DISMANTLING THE FORK ARMS

N.B.:If the arms are being dismantled to change the seals, loo-sen in order the securing bolts on the top T section andthe fork tube plugs.


Disconnect the headlight and the turn indicators.

Remove the brake calliper without disconnecting it.Unscrew the speedometer cable from its drive.

Remove the guides from the flexible hydraulic fluid pipe and

the speedometer cable.

Remove the front wheel.

Remove the six bolts (1) on the top and bottom T sections.Remove the fork arms.

1)

2)3)

4)

5)

6)

7)

8)

9)

10)

11)

12)

13)

14)

1)

2)

3)

4)

5)

6)

7)8)

4-4 CHASSIS

4


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CHASSIS 4-5

4

SEALING RINGS

REMOVAL

Remove the forks. See Dismantling the forks in this section.

Remove the fork tube plug (1).

Remove the spacer (2) and the spring (3).

Upturn the fork tube to empty the hydraulic fluid into a container.

N.B.:Slide the tube in and out of the fork arm several times toempty out the fluid.

Remove bolt (4) and its seal (5).

Withdraw the fork tube from the fork arm with the piston, theend of compression cone and its washer.

Remove the dust guard (6), the circlip (7) and the seal (8) fromthe forks arm.

1)2)

3)

4)

5)

6)

7)


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ASSEMBLY

Fit a new seal (1), lightly lubricated, using a seal pusher.

Refit the seal circlip (2).

Insert the fork tube into the fork arm with the end of compres-

sion cone (3) and its washer (4), taking care not to bend over

the seal lip.

Fit a new seal and tighten the drain screw.

Drain screw tightness torque:2.3 daNm (23 Nm)

Fit a new dust guard, lightly lubricated.Pour in 0.3 litres of SAE 15 (Esso Univis N46) type hydraulic

fluid into the fork tube.

Hydraulic fluid for forks:SAE 15 (Esso Univis N 6) type

Refit the spring (5) with the tighter coils upwards.

Refit the spacer (6).

Refit the fork tube plug (7).

Tube tightness torque:2 daNm (20 Nm)

1)

2)

3)

4)

5)

6)

7)

8)

9)

4-6 CHASSIS

WARNING:

Check the condition of the fork tube: there should not beany signs of corrosion or impacts, and should be perfec-

tly straight and clean.

4


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CHASSIS 4-7

4

REAR WHEEL

N.B.:If the brake calliper is being renewed, the circuit will haveto be bled.

DISMANTLING THE REAR BRAKE CALLIPER ANDBRAKE PADS

Dismantle the rear wheel shaft, the chain tensioners (1)

and the spacers (2).

Remove the wheel without unhooking the chain.

N.B.:The wheel needs to be removed to allow the brake calliperto be extracted from its housing in the suspension arm.

Remove the pins (3).

Remove the brake pads.

N.B.:The brake pads are identical; on removing without re-newing, identify the fitting direction and refit in the samedirection.

1)

2)

3)

4)

CAUTION:

Place the machine on a flat surface.Stand the machine on a suitable support, in such a way

that the rear wheel is off the ground. Do not activate the brake pedal during the dismantlingand refitting process.

CAUTION:

As a result of removing the wheel, the calliper or thebrake pads, and before performing a road test, check thegood functioning of the brake by applying the brake pedalvarious times.


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OPERATIONS THAT CAN BE PERFORMED WITHTHE REAR WHEEL REMOVED

Changing the tyre, the inner tube or valve.

N.B.:

Identify the roll direction of the tyre before removing it,and refit in the same direction (Supermotard only)

Changing the brake disk.

N.B.:Ensure the correct fitting direction for the disk, with themarked part outwards. Fit the six self-locking bolts.

Changing the wheel bearings.

Changing the crown gear.

N.B.:Fit the six normal self-locking bolts. If the crown gear is

to be reused, its turn direction must be noted before re-moving.

TRANSMISSION CHAIN

ADJUSTING THE CHAIN TENSION

Unscrew the nuts (1) from the wheel shaft and the locknuts (2)on the tensioner bolts.

Turn both tensioning bolts (3) the same amount to achieve a

movement of 25 mm in the chain.

Chain movement: 25 mm

Check the correct alignment of the chain between the gearbox

output sprocket and the rear crown wheel.

Retighten the nuts on the wheel shaft and the locknuts on the

tensioner bolts.

1)

2)

3)

4)

4-8 CHASSIS

CAUTION:

The machine must be on its support, with the gearbox inneutral.

4


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CHASSIS 4-9

4

Check the chain tension.

SEAT

REMOVAL

Remove the plug (1) on the inside of the rear skirting.

Remove the seat nut through the hole in the rear skirting, andpull the seat (2) backwards to separate it from the chassis.

Remove the seat.

FUEL TANK

REMOVING THE FUEL TANK OR FUEL TAP

Remove the seat see Removing the seat in this section.

Remove the bolts (1) from the radiator fairings.

Remove the bolts (2) from the fuel tank.

Lift up the tank to disconnect the fuel level indicator connector(2), the fuel supply pipe (3) and the fuel tap vacuum outlet (4).Remove the tank.

5)

1)

2)

3)

1)

2)

3)

4)

5)

CAUTION:

A chain that is too tight causes rapid wear of the gearboxoutput shaft, the rear wheel bearings, the chain and the

sprockets.


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RYZ

SHOCK ABSORBER

REMOVAL


Remove the nut, the washer and the bottom securing shaft

from the shock absorber (1).

Remove the nut, the washer and the top securing shaft from

the shock absorber (2).

Remove the shock absorber from the right-hand side of the

machine by pulling it downwards.

AIR FILTER

REMOVING THE AIR FILTER SPONGE

Remove the left-hand side cover.

Remove the air filter cover (four screws) and its seal.

Remove the sponge (1) and the two grilles (2).

1)

2)

3)

4)

1)

2)

3)

4-10 CHASSIS

CAUTION:

Stand the machine on blocks under the chassis to ensurethat the rear wheel is off the ground.

CAUTION:

The grilles are of a different size. Be sure to reposition

them correctly on refitting.

4


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CHASSIS 4-11

4

REMOVING THE AIR FILTER BOX


Remove the side fairings.

Remove the shock absorber see Removing the shock ab-

sorber in this section.

Remove the two bottom securing bolts (1) on the skirting.Remove the air intake connector (2) from the air filter box.

Remove the three securing bolts (3) from the air filter box.

Loosen the clamp on the hose from the air filter to the carbu-

rettor.

Remove the air filter box from the left-hand side of the machi-

ne.

EXHAUST

REMOVAL

N.B.:The rear silencer can be removed on its own.

Remove the left-hand side fairing.

Unhook the two springs (1) from the exhaust pipe at the cylin-der point.Remove the securing bolt (2) on the flexible support to the

chassis.

1)2)

3)

4)5)

6)7)

8)

1)

2)

3)


34/92

RYZ

Remove the bottom securing bolt (3) on the rear silencer.

Unscrew the top securing bolt (4) on the rear silencer.

Separate the silencer from the exhaust pipe.

Remove the exhaust pipe.

CARBURETTOR

REMOVAL


Remove the fuel tank see Removing the fuel tank in this

section.

Disconnect the carburettor heating pipes (1).

Remove the throttle cable (2).

Remove the bolt from the starter motor connector (3).

Remove the oil pipe (1).

Loosen the clamp on the inlet connection (5) with a 3 mm malesafety spanner.

Special tool 3 mm safety spannerRef. 25 0020001 8

Loosen the clamp on the air filter connection (6).

Free the carburettor from the inlet connection.Remove the carburettor.

4)

5)

6)

7)

1)

2)

3)

4)

5)

6)

7)

8)

9)10)

4-12 CHASSIS

CAUTION:

Plug the pipes to prevent coolant from spilling.

4


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CHASSIS 4-13

4

ADJUSTMENT

Idle: screw (7).

Mixture: screw (8).

DISMANTLING THE VALVES

Remove the carburettor see Removing the carburettor in

this section.Remove the four bolts on the inlet connector, two of them (1)

using the 4mm male safety spanner.

Special tool 4 mm safety spannerRef. 25 0020001

Remove the connector and the inlet valve.

CHASSIS

REMOVAL

N.B.:This method is only valid when changing the chassis. Inthe event of a chassis change as a result of an accident, itwill be necessary to complete the repair method or changethe damaged elements.


Remove the fuel tank see Removing the fuel tank in this

section.Remove the side covers.Disconnect and remove the battery.

Disconnect the rear wiring and the rear brake light switch.

Remove the exhaust assembly.

Remove the rear brake fluid reservoir and the master cylinder

without disconnecting it.

Loosen the clamp on the air filter hose.Remove the top securing bolt on the shock absorber.

Remove the two rear chassis securing bolts on the main chassis.

Remove the rear chassis assembly.

Remove the chain.

1)

2)

3)

1)

2)

3)

4)

5)

6)

7)

8)

9)

10)

11)

12)


36/92

RYZ

Disconnect:a) The neutral switch.

b) The yellow magneto output cable.

c) The starter connector.

d) The temperature sensor.

e) The ignition unit.

f) The earth cables on the ignition module.g) The supply pipe on the oil pump.

h) The petrol and choke valves.

i) The oil pump cable.

j) The clutch cable.

Remove the bottom securing bolt on the radiator.Loosen the top rear engine securing bolt.

Remove the bottom rear securing bolt.

Remove the three bolts on the two engine supports under the

engine.

Loosen the two side securing bolts on the front engine support

(without removing the nuts).Loosen and remove the two front engine support securing bol-

ts on the chassis front box section.Push the support forwards.

Remove the engine assembly and radiator.

Remove the oil tank.


Disconnect:

a) the front headlight.

b) the instrument panel connection.

c) the steering lock connection.

d) the control unit connection.e) the starter switch connection.

f) the brake light switch.

g) the throttle, starter, clutch and speedometer cables.

Remove the master cylinder from the front brake without dis-connecting it.

Remove the handlebars.

Remove the top forks T section.

Remove the forks assembly and front wheel.

Remove the suspension arm assembly, the shock absorber,

brake calliper, brake cylinder and rear wheel.Remove the chassis.

REMOVING THE FRAME

Remove:a) the controls and cables.

b) the prop stand.c) the rear brake pedal.

d) the main wiring.

e) the electrical components.

f) the steering bearings.

g) the locknuts.

13)

14)15)

16)

17)

18)

19)

20)

21)

22)

23)

24)

25)

26)

27)

28)

29)

30)

4-14 CHASSIS

4


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ASSEMBLY

Carry out the assembly of the new chassis proceeding in the

reverse order.

N.B.:

Before assembling the new chassis, ensure that the VINnumber is engraved and the chassis plate affixed.

CHASSIS 4-15


SECURING DEVICES

Front wheel shaft bolt

Front wheel shaft tightness torque:

Fork tube drain bolt

Fork tube plug

daNm Nm

45

12

4,5

1,2

232,3

202,0


MATERIALS

Air filter oil

Forks hydraulic fluid


Adhesive oil for the air filter sponge

Filling the front fork tubes

Motul Air Filter Oil

SAE 15 (Esso Univis N N46) type

SPECIAL TOOLS

254002000198

Safety spanner (3 mm)

254002000199

Safety spanner (4 mm)

4


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NOTES:


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SECTION 5

ENGINE

CONTENTS

OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE WITHOUT REMOVING IT .................................................... 5-3 Removing the cylinder head ............................................................................................................................................... 5-3

Dismantling the cylinder-piston assembly ........................................................................................................................... 5-3

ENGINE ASSEMBLY ...................................................................................................................................................................... 5-4 Removal .............................................................................................................................................................................. 5-4

Installation............................................................................................................................................................................ 5-5

DISMANTLING THE ENGINE ........................................................................................................................................................ 5-6

Mounting the engine on its support ..................................................................................................................................... 5-6 Removing the magneto ....................................................................................................................................................... 5-6

Removing the armature ....................................................................................................................................................... 5-7

Removing the starter motor (where fitted) ........................................................................................................................... 5-7

Removing the gearbox output sprocket ............................................................................................................................... 5-7

Removing the clutch cover .................................................................................................................................................. 5-8 Removing the clutch ............................................................................................................................................................ 5-8

Removing the crankshaft-connecting rod gears and balance shaft ..................................................................................... 5-10

Removing the connector and the inlet valve......................................................................................................................... 5-10

Removing the cylinder head/cylinder assembly .................................................................................................................. 5-11

Removing the piston ............................................................................................................................................................ 5-11

Removing the thermostat valve............................................................................................................................................ 5-11 Removing the temperature sensor ...................................................................................................................................... 5-11

Separating the engine crankcases ...................................................................................................................................... 5-12

Dismantling the gearbox and the selecting system ............................................................................................................. 5-13 Removing a primary or secondary drive shaft gear ............................................................................................................. 5-14

Removing the balance shaft ................................................................................................................................................ 5-15

Removing the crankshaft-connecting rod ............................................................................................................................ 5-15 Checking the crankshaft-connecting rod ............................................................................................................................. 5-15

FITTING SPECIFIC ELEMENTS IN THE ENGINE ........................................................................................................................ 5-17 Fitting the crankshaft-connecting rod bearings ................................................................................................................... 5-17

Fitting the output seal .......................................................................................................................................................... 5-18

Fitting the selector shaft output seal..................................................................................................................................... 5-18

Fitting the clutch lever output seal ....................................................................................................................................... 5-18 Fitting the balance shaft ...................................................................................................................................................... 5-18

Fitting the crankshaft-connecting rod .................................................................................................................................. 5-18

Fitting the gearbox ............................................................................................................................................................... 5-19

Fitting the left-hand half-crankcase ..................................................................................................................................... 5-20

Checking the piston ............................................................................................................................................................. 5-21

Checking the piston rings .................................................................................................................................................... 5-21 Fefiting the piston ................................................................................................................................................................ 5-22

Fitting the cylinder .............................................................................................................................................................. 5-22

Fitting the cylinder head ...................................................................................................................................................... 5-23

Fitting the right-hand seal .................................................................................................................................................... 5-23

Fitting the crankshaft-connecting rod gears and the balance shaft ..................................................................................... 5-24

Fitting the clutch .................................................................................................................................................................. 5-24 Adjusting the clutch control lever ......................................................................................................................................... 5-26

Fitting the kick-start system (where fitted) and the clutch cover .......................................................................................... 5-26

Fitting the magneto .............................................................................................................................................................. 5-26

VARIOUS OPERATIONS ............................................................................................................................................................... 5-27 Removing the water pump .................................................................................................................................................. 5-27

Fitting the water pump ........................................................................................................................................................ 5-27 Dismantling the oil pump and its drive gears ....................................................................................................................... 5-28

Fitting the oil pump ............................................................................................................................................................. 5-28

ENGINE 5-1

5


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TIGHTENING TORQUE SPECIFICATIONS ................................................................................................................................... 5-29SERVICING MATERIALS REQUIRED ........................................................................................................................................... 5-29SPECIAL TOOLS ........................................................................................................................................................................... 5-30

5-2 ENGINE

5


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N.B.:The following operations do not require the engine to be re-moved.

REMOVING THE CYLINDER HEAD

Remove the seat see Removing the seat in Section

4 CHASSIS.

Remove the fuel tank see Removing the fuel tank in Section

4 CHASSIS.Drain the cooling circuit (drain screw on the water pump).

Remove the radiator/cylinder head pipe (1).

Disconnect the carburettor heating pipes (2).

Disconnect the temperature sensor.Remove the suppressor.

Remove the spark plug.

N.B.:To remove the cylinder head, see corresponding chapterin this section.

DISMANTLING THE CYLINDER-PISTON ASSEMBLY

Remove the seat see Removing the seat in Section4 CHASSIS.


4 CHASSIS.

Remove the exhaust see Removing the exhaust in Section

4 CHASSIS.

Drain the cooling circuit (drain screw on the water pump).

Remove the radiator/cylinder head pipe.

Disconnect the carburettor heating pipes.

Remove the securing bolts from the front support on the chas-

sis cradle.

1)

2)

3)

4)

5)6)

7)

8)

1)

2)

3)

4)

5)

6)

7)

OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE

ENGINE 5-3

5


42/92

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Unscrew the side securing bolts on the engine support.

Remove the engine securing bolt (1) and push the support

forwards.

N.B.:To remove the cylinder head, the cylinder and the piston,see corresponding chapter in this section.

REMOVAL

Remove the seat see Removing the seat in Section

4 CHASSIS.


4 CHASSIS.

Remove the left-hand side fairing.

Disconnect the battery.Drain the cooling circuit (drain screw [1] on the water pump).

Remove the chain guard (two bolts).

Remove the chain.

Remove the exhaust see Removing the exhaust in Section

4 CHASSIS.

Disconnect the oil supply and the oil pump control cable.Remove the clutch cable.

Disconnect the starter motor, the neutral switch, the magneto

output wiring (the yellow cable and high-tension coil supply ca-

bles), the suppressor and the temperature sensor.

Disconnect the carburettor heating pipes.

Separate the carburettor from the air filter box and inlet con-nectors.

Disconnect the coolant pipes on the water pump and cylinder

head.

8)

9)

1)

2)

3)

4)5)

6)

7)

8)

9)10)

11)

12)

13)

14)

5-4 ENGINE

ENGINE ASSEMBLY5


43/92

RYZ

ENGINE 5-5

Loosen the three engine securing points (2), without removingthe top rear securing nut.

Loosen the two securing points (3) on the chassis strengthe-

ners (4).

Remove the front support securing shaft.

Lower the two chassis strengtheners.

Loosen the two side securing bolts (5) on the front engine su-

pport (without removing the nuts).Loosen and remove the two front engine support securing bol-

ts (6) on the chassis front box section.Push the support forwards.

Remove the rear bottom securing shaft.

Unhook the engine from the top rear chassis pins (7) to remove it.

N.B.:With the engine removed, see Section 5 ENGINE for de-tails of operations to be performed on the engine.

INSTALLATION

Fit the shaft, the washers and the nut (1) on the engine top

rear mounting.

15)

16)

17)

18)

19)

20)

21)

22)

23)

1)

5


44/92

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Hang the engine on the top rear securing shaft (2).

Insert the engine securing shaft into the front support (3) and

the two chassis strengtheners (4).

Insert the rear bottom securing shaft (5).

MOUNTING THE ENGINE ON ITS SUPPORT

Mount the engine on the engine support mounting.

Special tool (A)

Immobilise the motor on the mounting with two rubber pegs.

Mount the assembly onto the engine support while held in a

workbench clamp.

Special tool (B)

REMOVING THE MAGNETO

Remove the magneto cover.

Remove the paper gasket.

Immobilise the rotor (1) with a front pivot spanner (2).Remove the nut.

N.B.:Depending on the model, the rotor acts as a crown gearfor the starter motor.

2)

3)

4)

1)

3)

3)

1)

2)

3)4)

5-6 ENGINE

DISMANTLING THE ENGINE5


45/92

RYZ

ENGINE 5-7

Screw the magneto extractor onto the rotor.

Special tool:Ref. 2533002000198

Immobilise the magneto extractor and turn the pushing bolt un-

til the rotor comes free.

REMOVING THE ARMATURE

Remove the three securing bolts (1) from thestator plate and armature assembly (2).

Remove the stator plate and armature assembly.

N.B.:Tap the bolts with a mallet and punch to help to free theassembly.

REMOVING THE STARTER MOTOR (WHERE FITTED)

Remove the three securing bolts (1) from the starter motor.

Remove the two rubber pegs that immobilise the motor on its

mounting.Move the engine on the mounting guides to allow the starter

motor to be removed.

Refit the two rubber pegs.

REMOVING THE GEARBOX OUTPUT SPROCKET

Remove the rubber ring (1) with a pair of pliers.

Remove the sprocket (2).

Remove the second rubber ring.

5)

6)

1)

2)

1)

2)

3)

4)

1)

2)

3)

WARNING:

The three bolts should be renewed with every removal.

5


46/92

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REMOVING THE CLUTCH COVER

Remove the kick-start lever securing bolt (where fitted).

Apply the kick-start lever slightly and hold it in position.

Loosen the stop (1) on the starter shaft and release the kick-

start lever to slacken the spring.

Remove the kick-start lever.

N.B.:Prepare a container to hold the oil from the gearbox.

Remove the bolt (2) to drain the gearbox.

Remove the eight cover securing bolts.

Remove the cover.

Remove the two centring pivots and the paper gasket.

REMOVING THE CLUTCH

Remove the four bolts and springs (1) from the pressure plate (2).

Remove the pressure plate.

1)

2)

3)

4)

5)

6)

7)

8)

1)

2)

5-8 ENGINE

5


47/92

RYZ

ENGINE 5-9

Remove the assembly (3) consisting of four friction disks andthree smooth disks.

Remove the primary shaft: the pusher (4), the ball (5) and the

push rod (6).

Remove the clutch control lever (7) with its spring (8) and its

washer (9).

Fold back the clutch nut (10) tab washer (11).

Immobilise the clutch dog (12) with the clutch immobilisation

tool.

Special tool (C)

Remove the nut and the washer.

Remove the clutch dog (12), the grooved spacer (13), the hood

(14), the flat washer (15) and the tapered washer (16).

3)

4)

5)

6)

7)

8)

9)

5


48/92

RYZ

REMOVING THE CRANKSHAFT-CONNECTINGROD GEARS AND BALANCE SHAFT

Immobilise the balance shaft with a bolt (a) inserted in the

threaded perforations.

Turn the gear (1) on the balance shaft so that the bolt rests

against a crankcase rib.Remove the crankshaft-connecting rod nut (2).Remove the balance shaft nut (3).

Remove the two gears (20 and 30 tooth) and the key.

(4) from the crankshaft-connecting rod.

Remove the 34 tooth gear and the key (5) from the balance

shaft.

REMOVING THE INLET CONNECTOR AND VALVE

Remove the four bolts on the inlet connector, two of them (1)

using the safety spanner.

Special tool:Ref. 254002000199

Remove the connector and the inlet valve.

Check the perfect condition of the valve assembly blades andsupport.

1)

2)

3)

4)

5)

6)

1)

2)

3)

5-10 ENGINE

5

WARNING:The position of the stop must be 7 mm from the valve stop.


49/92

RYZ

ENGINE 5-11

REMOVING THE CYLINDER HEAD/CYLINDER ASSEMBLY

Remove the spark plug.

In the order indicated, loosen the four securing nuts on the

cylinder head/cylinder assembly in two or three steps

Remove the four nuts and washers.

Remove the cylinder head and the two O-rings.Remove the cylinder and the cylinder gasket.

REMOVING THE PISTON

Remove one of the two circlips (1) with a pair of circlip pliers (2).

Remove the gudgeon pin.

Remove the piston.Remove the needle bearing assembly from the end of the con-

necting rod.

REMOVING THE THERMOSTAT VALVE

Remove the two bolts (1) from the thermostat valve (2).

Remove the thermostat valve.

REMOVING THE TEMPERATURE SENSOR

1)2)

3)

4)5)

1)

2)

3)4)

1)

2)

5

WARNING:

There is a metal gasket to ensure the temperature

sensor (1) remains watertight.

WARNING:In refitting, take care to position the breather hole (a) at the

highest point.


50/92

RYZ

SEPARATING THE ENGINE CRANKCASES

Remove the three securing bolts on the left-hand crankcase.

Fit the protective bush onto the crankshaft-connecting rod.

Special tool (D)

Fit the crankcase opening tool supplied with the plate onto theleft-hand crankcase.

Special tool (E)Special tool (F)

Fit the assembly onto the crankcase with the four bolts. (1).

Remove the two rubber engine support mounting pegs.Turn the tools central bolt until the crankcases separate.

N.B.:On opening, tap the ends of the secondary and selectionshafts alternately with a plastic mallet to ensure that thetwo crankcase separate in parallel.

Remove the left-hand crankcase.

N.B.:

Recover the friction washers that may be stuck to the left-

hand crankcase with oil.

Remove the centring rods (2).

Remove the two rubber engine support mounting pegs.

1)

2)

3)

4)

5)6)

7)

8)

9)

5-12 ENGINE

5


51/92

RYZ

ENGINE 5-13

DISMANTLING THE GEARBOX AND THESELECTION SYSTEM

Position the selector drum to guide the Mecanindus pin against

the secondary drive shaft selector fork shaft. .

Remove the selection shaft (1) fitted with its two friction was-

hers.

Remove the secondary drive shaft selector forks shaft (2).

Remove the top selector fork (3) from the secondary driveshaft.

Turn the selector drum (4) to lower the selector fork (5) on the

primary drive shaft in the bottom slot of the drum.

Remove the selector drum.

Remove the second selector fork (6) from the secondary drive

shaft.

1)

2)

3)

4)

5)

6)

7)

5


52/92

RYZ

Remove together the secondary drive shaft assembly

and the primary drive shaft fitted with its selector fork.

Remove the friction washer (7) from the secondary drive shaft,

in the event of it being stuck with oil onto the right-hand crank-

case.

Remove the locking ball (8) and its push spring.

REMOVING A GEAR FROM A PRIMARY OR SECON-

DARY DRIVE SHAFT

Remove the rubber rings and the gears with pliers.

On refitting, take note of the position and the direction of fitting

for every part:

1. Primary drive shaft with 1st speed gear.

2. 3rd speed and 4th speed gear.

3. 5th speed gear.

4. 2nd speed gear.

5. 6th speed gear.

6. Rubber ring.

7. Secondary drive shaft.

8. 1st speed gear.

9. 3rd speed gear.

10. 4th speed gear.

11. 6th speed gear.

12. 2nd speed gear.

13. 5th speed gear.

14. Rubber ring.

15. Friction washer.

8)

9)

10)

1)

2)

5-14 ENGINE

5


53/92

RYZ

ENGINE 5-15

REMOVING THE BALANCE SHAFT

Remove the balance shaft (1) using a plastic mallet if neces-

sary.

REMOVING THE CRANKSHAFT-CONNECTING ROD

Remove the crankshaft-connecting rod (2) with its spacer (3)

and its O-ring (4) by lightly tapping its end with a plastic mallet,

if necessary.

N.B.:

The crankshaft-connecting rod is fitted freely onto the rig-

ht-hand crankcase bearing.

CHECKING THE CRANKSHAFT-CONNECTING ROD

Using a set of feeler gauges, check the side clearance of the

connecting rod big end.

The connecting rod big end side clearance must not exceed:

4/10 mm.

Maximum side clearance: 4/10 mm (0.4 mm).

1)

1)

1)

2)

5

WARNING:

When renewing a gear, renew the corresponding gear onthe other drive shaft.The rubber rings must be renewed after every dismant-ling.


54/92

RYZ

The eccentricity values measured at the ends of the cranks-

haft-connecting rod must not exceed 4/100 mm, and must be

measure at:

- 50 mm from the transmission side

- 50 mm from the magneto side

Maximum eccentricity: 4/100 mm (0.4 mm).

5-16 ENGINE

5

3)


55/92

RYZ

FITTING THE CRANKSHAFT-CONNECTING RODBEARINGS

N.B.:On opening the crankcases, if the bearings remain fittedto the crankshaft-connecting rod, use a bearing remover(1).

N.B.:If the bearing remains in the left-hand crankcase, thecrankcase must be heated up using a heat stripper to re-lease it.This operation should be performed quickly, to ensure thatthe bearing is removed and refitted in the crankcase.

Turn one of the crankcases over onto its flat joint, heat it

up (to 80 to 90C) until the bearing falls out by itself.

Remove the seal.

While the crankcase is still hot and expanded, fit the new bea-

ring fully into its housing.Fit a new seal into the left-hand crankcase using the tool.

Special tool (G)

1)

2)3)

4)

FITTING SPECIFIC ELEMENTS IN THE ENGINE

ENGINE 5-17

5

CAUTION:

The crankshaft-connecting rod bearings and seals mustbe renewed after each opening of the engine crankcase.

CAUTION:

The right-hand side seal must be fitted after closing thecrankcases, fitting the O-ring and the spacer, to prevent it

from turning over or damaging the seal rims.


56/92

RYZ

FITTING THE OUTPUT SEAL

Using the pusher tool, fit the gearbox output seal.

Special tool (G)

FITTING THE SELECTOR SHAFT SEAL

Using the pusher tool, fit the selector shaft seal.

Special tool (H)

FITTING THE CLUTCH LEVER SEAL

Using the pusher tool, fit the clutch shaft seal.

Special tool (I)

FITTING THE BALANCE SHAFTFit the balance shaft (1) into the right-hand half of the crankca-

se, using a plastic mallet where necessary.

FITTING THE CRANKSHAFT-CONNECTING ROD

Fit the crankshaft-connecting rod (2) to the right-hand half of

the crankcase.

N.B.:The crankshaft-connecting rod is fitted freely onto the rig-

ht-hand crankcase bearing.

1)

1)

1)

1)

1)

5-18 ENGINE

5


57/92

RYZ

ENGINE 5-19

FITTING THE GEARBOX

Lightly grease and fit the friction washer (1) onto the right-hand

crankcase secondary drive shaft needle bearing assembly.

Fit the push spring and fit the locking ball (2) lightly greased into

its housing.

Fit together the secondary drive shaft assembly and the primary

drive shaft fitted with its selector fork (3) into the right-hand half

of the crankcase.

Fit the curved fork (4) on the 5th speed gear onto the secondary

drive shaft.

Fitting the selector drum with its two washers.

Position the selector fork guide (3) in the intermediate slot of the

selector drum.

1)

2)

3)

4)

5)

6)

5


58/92

RYZ

Fit the selector fork (5) on the 6th speed gear.Position the selector fork guide (4) in the lower slot of the se-

lector drum.

Position the selector fork guide (5) in the upper slot of the se-

lector drum.

Fit the selector forks shaft (6).

Position the selector drum in 4th speed; the Mecanindus pin isaligned with the selector fork shaft.

Fit the selector shaft (7), fitted with its two 5 friction washers.

FITTING THE LEFT-HAND HALF-CRANKCASE

Check that the friction washers are present on:

a) the secondary drive shaft (1).b) the selector drum (2).

c) the selector shaft

Fit the centring rods (4).

Check that the right-hand crankcase joining surface is perfectly

clean.

Apply sealing paste to the right-hand crankcase joining surface.

Grease the ends of the shafts lightly.

Check that the left-hand crankcase joining surface is perfectly

clean.

Fit the left-hand half of the crankcase.

Screw the stud on the end of the crankshaft-connecting rod.

Special tool (J)

7)

8)

9)

10)

11)

12)

1)

2)

3)

4)5)

6)

7)

8)

5-20 ENGINE

5


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ENGINE 5-21

Insert the support tool supplied with the plate on the stud

Special tool (E)

Special tool (F)

Centre the assembly on the crankcase with the four bolts. (5).Fit the centring tool on the support tool.

Special tool (K)

Screw the stud nut down until the crankcases close completely

with the screw-plate (1).

Fit and tighten the thirteen securing bolts.

Securing tightness torque:

1,1 daNm (11 Nm)

N.B.:

Check that the crankshaft-connecting rod turns freely insi-

de the crankcases.

Fit the gear lever without tightening it. Turn the primary drive

shaft manually and check that the gears turn smoothly.

Lubricate the crankshaft-connecting rod and the bearings lightly

with 2-stroke oil.

CHECKING THE PISTON

The pistol should not show signs of scratching or seizing.

The piston rings must move freely in their grooves.

CHECKING THE PISTON RINGS

Remove the piston rings carefully.

Fit one ring inside the cylinder bore parallel to the bore, andwith a feeler gauge, measure the ring gap clearance

Piston ring gap clearance: from 0.15 mm to 0.30 mm

Limit of use: 1 mm

9)

10)11)

12)

13)

14)

15)

1)2)

1)

2)

5


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REFITTING THE PISTON

Fit the needle bearing assembly (1) in the connecting rod small

end, after lubricating it with 2-stroke oil.

Fit the piston on the connecting rod, with the front positioning

cams of the piston rings towards the intake side.

Fit the gudgeon pin.Fit the circlips with a pair of circlip pliers.

FITTING THE CYLINDER

Fit a new cylinder gasket (1) without oil or grease.

Ensure that the openings of the rings are facing

the piston positioning dogs.Fit the cylinder (2) and insert it, while at the same time com-

pressing the piston rings by hand.

Instert the cylinder into the piston compressing the piston rings

by hand.

1)

2)

3)4)

1)

2)

3)

4)

5-22 ENGINE

5

CAUTION:

The circlips should be renewed with every removal.

CAUTION:

The circlip openings should face upwards ordownwards (2), but never sideways.


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ENGINE 5-23

FITTING THE CYLINDER HEAD

Check that the O-ring housings are perfectly clean.

Fit new O-rings (1) on the cylinder head.

Fit the cylinder head onto the cylinder.

Tighten the 4 cylinder head securing nuts diagonally in 2 or 3

stages.

Cylinder head nuts tightness torque:

1.8 daNm (18 Nm)

Fit the spark plug.

Spark plug tightness torque:

2.5 daNm (25 Nm)

FITTING THE RIGHT HAND SEAL

Fit a new O-ring (1) and spacer (2) on the crankshaft-connec-

ting rod.

Fit a new seal (3), with the lip facing outwards. Use the special

tool

Special tool (G)

1)2)

3)

4)

5)

1)

2)

5


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FITTING THE CRANKSHAFT-CONNECTING RODGEARS AND THE BALANCE SHAFT

Fit the key (1) into its housing on the crankshaft-connecting rod.

Fit the key (2) into its housing on the balance shaft.

Fit the crankshaft-connecting rod (3), with the marked tooth

facing outwards.

Fit the balance shaft gear (4), ensuring that the space betweenthe marked tooth with two points (a) coincides with the tooth

marked with one point (a) on the crankshaft-connecting rodgear.

Fit the nut without tightening it.

Immobilise the balance shaft with a bolt (b) inserted in the

threaded perforations.Turn the gear on the balance shaft so that the bolt rests against

a crankcase rib.

Tighten the nut (5) on the balance shaft.

Nut tightness torque:6 daNm (60 Nm)

Fit the gear (6) with the spot-facing outwards and the nut (7).

Tighten the crankshaft-connecting rod gear.

Nut tightness torque:

7.5 daNm (75 Nm)

FITTING THE CLUTCH

Fit the primary drive shaft.

a) the tapered washer (1) with the dished side towards the

bearing.

b) the flat washer (2).

c) the clutch bell housing (3). d) the ribbed spacer (4), e) the

clutch dog (5),f) the nut tab washer (6) and the nut (7).

1)

2)

3)

4)

5)6)

7)

8)

9)

10)

1)

5-24 ENGINE

5


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ENGINE 5-25

Immobilise the clutch dog with the special tool.

Special tool (C)

Tighten the nut.

Nut tightness torque:7.5 daNm (75 Nm)

Fold over the clutch nut tab washer.

Fit the clutch control lever with its spring and its washer.

Fit the pusher (8), the ball (9) and the push rod (10) onto the

primary drive shaft.

Fit the clutch disks beginning with a friction disk (11) and alter-

nating smooth and friction disks (12).

While fitting, ensure that the marks (a) on the smooth disks are

turned 120 one from the other.

Fit the pressure plate (13), ensuring that the arrow (b) on the

plate coincides with the round mark (c) on the clutch dog.

Fit the springs (14) on the pressure plate and the 4 bolts and

washers (5).

Bolts tightness torque:

0.5 daNm (5 Nm)

2)

3)

4)

5)

6)

7)

8)

9)

10)

5


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ADJUSTING THE CLUTCH CONTROL LEVER

Loosen the pressure plate locknut (1).

Position the lever resting on the control rod.

Turn the central pressure plate bolt (2) to position the control

lever at 30 with respect to the sealing joint of the magneto

cover.Tighten the locknut without altering the adjustment.


2.7 daNm (27 Nm)

FITTING THE KICK-START SYSTEM (WHERE FIT-TED) AND THE CLUTCH COVER

Fit the spring (1) onto the kick-start shaft.

Fit the kick-start attack gear (2), and the take-off ramp (a)inalignment with the arm of the return spring (b).

Fit the kick-start shaft (3).

Fit the two centring rods and a new paper gasket.

Fit the clutch cover, turning the crankshaft-connecting rod ma-nually if necessary, so that the water pump gear meshes with

the crankshaft-connecting rod gear.

Fit the eight cover securing bolts.


1.1 daNm (11 Nm)

Fit and apply the kick-start lever slightly and hold it in position.

Fit the starter shaft stop.

Nut tightness torque:3 daNm (30 Nm)

Release the kick-start lever.

FITTING THE MAGNETO

Fit the armature assembly.

Fit and tighten the three securing bolts (1) on the armature as-

sembly.


0.3 daNm (3 Nm)

1)

2)

3)

4)

1)

2)

3)

4)

5)

6)

7)

8)

9)

1)

2)

5-26 ENGINE

5


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ENGINE 5-27

Fit the rotor (3) onto the crankshaft connecting rod, ensuring

that it is seated on the key.

Immobilise the rotor with a front pivot adjustable spanner (1).

Fit and tighten the rotor nut.


5.2 daNm (52 Nm)

Fit the gasket and the magneto cover.

Bolts tightness torque:0,4 daNm (4 Nm)

VARIOUS OPERATIONS

REMOVING THE WATER PUMP

Remove the eight clutch cover securing bolts.

Remove the clutch cover.

Remove the eight water pump cover securing bolts (1).

Remove the cover.

Remove the two centring pivots and the paper gasket. (2).

On the inside of the clutch cover, remove:

a) the rubber ring (3).

b) the washer (4).

c) the 30 tooth nylon gear (5).

d) the driving cotter pin (6).

e) the washer (7).

f) the turbine with its shaft (8).

g) the seal (9).

Check the condition of the turbine shaft. If there is evidence of

wear, renew the turbine.

FITTING THE WATER PUMPFit a new lightly greased seal (9), using the special tool.

Special tool (L)

Proceed in the reverse order to dismantling.

3)

4)

5)

6)

1)

2)

3)

4)

5)

6)

7)

1)

2)

5

CAUTION:

The rubber ring and the paper gasket must be renewed

every time the unit is dismantled.


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DISMANTLING THE OIL PUMP AND ITS DRIVEGEARS

Remove the eight clutch cover securing bolts.

Remove the clutch cover.

Remove the oil pump cover.

Remove the two oil pump securing bolts.Remove the pump (1) with its O-ring.

On the inside of the clutch cover, remove:

a) the two rubber rings (2).

b) the gear (3).

c) the driving cotter pin (4).

d) the washer (5).

e) the pump shaft and its washer (6).

f) the gear with its two washers (7).

Check the condition of the oil pump shaft. If there is evidence of

wear, renew the shaft.

FITTING THE OIL PUMP

Lubricate the two shafts.

Proceed in the reverse order to dismantling.

1)

2)

3)

4)5)

6)

7)

1)

2)

5-28 ENGINE

5

CAUTION:

The rubber rings and the O-ring must be renewed everytime the unit is dismantled.


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ENGINE 5-29

5


PARTS SECURED

Cylinder head

Crankcases

Transmission cover

Water pump

Inlet connector

Crankshaft-connecting rod gear

Balance shaft gear

Clutch bell housing

Clutch pressure plate

Clutch stop locknut

Starter motor

Rotor

Stator

Magneto cover

Gearbox drain plug

Spark plug

daNm Nm

18

11

1,8

1,1

111,1

111,1

111,1

757,5

6,606

757,5

50,5

272,7

111,1

525,2

30,3

40,4

181,18

252,5


MATERIALS

Engine oil

Gearbox oil


Filling the engine oil tank

Filling the gearbox

Motul 510 semi-synthetic 2-stroke oil

Motul TRANSOIL (SAE 10W30)


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RYZ

SPECIAL TOOLS

2533002000198

Magneto extractor

5-30 ENGINE

5

254002000199

Valve assembly male safety

key (4 mm)

AEngine support adaptation

B

Engine support

CClutch immobilisation tool

DLarge model protection bush

ECrankcase opening andextraction tool

FCrankcase opening plate

GPrimary transmission side

crankshaft seal pusher

H

Selector shaft seal pusher.

I

Clutch lever lip seal pusher

J

Pin (10. length125)

KCentring device with flange

LWater pump lip seal pusher

N.B.:

All these tools are included in the engine maintenance kit (reference: 253002000193).


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ELECTRICAL SYSTEM 6-1

SECTION 6

ELECTRICAL SYSTEM

CONTENTS

SERVICING THE MACHINE........................................................................................................................................................... 6-2REMOVING THE BATTERY ........................................................................................................................................................... 6-2REMOVING THE STARTER MOTOR RELAY ............................................................................................................................... 6-2REMOVING THE VOLTAGE REGULATOR/TURN INDICATOR CONTROLLER ......................................................................... 6-2REMOVING THE IGNITION CONTROLLER ................................................................................................................................. 6-3REMOVING THE MAGNETO ROTOR AND ARMATURE ............................................................................................................. 6-3REMOVING THE NEUTRAL POSITION SWITCH ......................................................................................................................... 6-3

REMOVING THE STARTER MOTOR ............................................................................................................................................ 6-3REMOVING THE DIODES ............................................................................................................................................................. 6-4DIGITAL INSTRUMENT PANEL (WHERE FITTED) ...................................................................................................................... 6-5USE ................................................................................................................................................................................................. 6-5 Button functions.................................................................................................................................................................... 6-5

Succession of the functions ................................................................................................................

Documents

Mh Verkstadshandbok