MH RYZ 50 Cross C User manual

REF. OF PUBLICATION:
0634111000004
1AEDITION
2007-10
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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IMPORTANT
Read 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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CONTENTS OF SECTION SECTION
GENERAL INFORMATION
SPECIFICATIONS
MAINTENANCE
CHASSIS
ENGINE
ELECTRICAL SYSTEM
TROUBLESHOOTING
1
2
3
4
5
6
7

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NOTES:

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SECTION 1
GENERAL INFORMATION
CONTENTS
USING THIS MANUAL ...................................................................................................................................................................1-2
IDENTIFICATION ........................................................................................................................................................................... 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 daN•m (75 N•m)
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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NOTES:

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SECCION 2
SPECIFICATIONS
CONTENTS
GENERAL SPECIFICATIONS ........................................................................................................................................................ 2-2
ENGINE SPECIFICATIONS ............................................................................................................................................................ 2-2
CHASSIS SPECIFICATIONS ........................................................................................................................................................... 2-4
TIGHTENING 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 TL
RYZ 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 cm³
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 screw
Needle
Main jet
Idle jet
TRANSMISSION
Type
Primary transmission
Secondary transmission
Gearbox
Gearbox capacity
Clutch
Magneto
Starter motor
ESPECIFICACIÓN
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-off
from the crankshaft.
0,7 Litres
CDI
NGK BR 9ES
DELL’ORTO / PHBN 16
930±50 rev/min
1.5 turns
A8 – 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
WHEELS
Front wheel
Front tyre
Front pressure
Rear wheel
Rear tyre
Rear pressure
FRONT BRAKES
Type
Ø brake pistons
Disk Ø
Disk thickness
Ø main piston (cylinder)
REAR BARKES
Type
Ø brake pistons
Disk Ø
Disk thickness
Ø main piston (cylinder)
FRONT SUSPENSION
Type of suspension
Type of front forks
Forks capacity
Travel
SPECIFICATION
RYZ TL: 1,85”X21”
RYZ SM: 2,5”X17”
RYZ UB: 1,85”X16”
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: 2,5”X18”
RYZ SM: 3,5”X17”
RYZ UB: 2,5”X16”
RYZ TL: 120/80X18”
RYZ SM: 130/70X17”
RYZ 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 mm
4 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
BODY
Side 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
ESTÁNDAR
5.mm diameter nut and bolt
6 mm diameter nut and bolt
8 mm diameter nut and bolt
10 mm diameter nut and bolt
12 mm diameter nut and bolt
TIGHTENING TORQUE
0,1 daN·m (1 N·m)
0,1 daN·m (1 N·m)
0,8/0,1 daN·m (8/1 N·m)
0,8/0,1 daN·m (8/1 N·m)
4,5 daN·m (45 N·m)
1,2 daN·m (12 N·m)
6,5 daN·m (65 N·m)
6,5 daN·m (65 N·m)
2,8 daN·m (28 N·m)
4,3 daN·m (43 N·m)
4,3 daN·m (43 N·m)
1,5 daN·m (15 N·m)
2,5 daN·m (25 N·m)
2,5 daN·m (25 N·m)
1 daN·m (10 N·m)
1 daN·m (10 N·m)
1,9 daN·m (19 N·m)
0,6 daN·m (6 N·m)
0,5 daN·m (5 N·m)
1 daN·m (10 N·m)
2,2 daN·m (22 N·m)
3,5 daN·m (35 N·m)
5,5 daN·m (55 N·m)

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SECTION 3
MAINTENANCE AND COMMISSIONING
CONTENTS
INTRODUCTION............................................................................................................................................................................... 3-2
MAINTENANCE 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 .......................................................................................................................................................... 3-3
COMMISSIONING............................................................................................................................................................................. 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 ................................................................................................................................... 3-6
SERVICE 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 30ºC.
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 KM
OR 3 MONTHS
Every 1.500 km
EVERY 3,000 KM EVERY 6,000 KM
Every 3.000 km
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
XXX
X
XX
XXX
XXX
XXX
XXX
XX
RENEWING
MAINTENANCE OPERATIONS
REINFORCED MAINTENANCE
Intake filter element
Front and rear brake pads (where appropriate)
Gearbox oil
Chain – sprocket- crown gear (where appropriate)
Clutch disks (where appropriate)
500 KM
OR 3 MONTHS
Every 1.500 km
EVERY 3.000 KM EVERY 6.000 KM
Every 3.000 km
XX
XX
XX
XX
X

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MAINTENANCE AND COMMISSIONING 3-3
3
CHECKING AND DECARBONISING
MAINTENANCE OPERATIONS
REINFORCED MAINTENANCE
Piston (1)
Cylinder head (1)
Exhaust port (1)
500 KM
OR MONTHS
Every 1.500 km
EVERY 3.000 KM EVERY 6.000 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
MAINTENANCE OPERATIONS
REINFORCED MAINTENANCE
Chain tension and condition
500 KM
OR MONTHS
Every 1.500 km
EVERY 3.000 KM EVERY 6.000 KM
Every 3.000 km
XXX
CHECKING AND ADJUSTING
MAINTENANCE OPERATIONS
REINFORCED MAINTENANCE
Clutch cable
Oil pump control
Spark plug
Tension of the wheel spokes
500 KM
OR 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
CHECKING AND ADJUSTING
MAINTENANCE OPERATIONS
REINFORCED MAINTENANCE
Carburettor
500 KM
OR MONTHS
Every 1.500 km
EVERY 3.000 KM EVERY 6.000 KM
Every 3.000 km
XX

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3-4 MAINTENANCE AND COMMISSIONING
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 the
“UPPER 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 OIL
CIRCUITS
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 98
octane petrol without oil mixture.
1)
2)
3)
4)
5)
6)
7)
8)
1)
2)
3)
1)
2)
3)
4)
3
COMMISSIONING
WARNING:
A continuación, eventualmente se deberá restablecer el
nivel de la batería después de una carga completa, utili-
zando exclusivamente agua destilada.