RIEJU Nuuk Instruction manual

Rieju - Nuuk
Workshop Manual

Workshop Manual
RIEJU - NUUK
The descriptions and images in this publication are given for illustrative purposes only and are
not binding. While the basic characteristics as described and illustrated in this booklet remain
unchanged, Rieju S.A. reserves the right, at any time and without being required to update this
publication beforehand, to make any changes to components, parts or accessories, which it
considers necessary to improve the product or which are required for manufacturing or
construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of
each model should be checked at the official RIEJU sales network.
© Copyright 2014 - Rieju S.A. All rights reserved. Reproduction of this publication in whole or in
part is prohibited.
Rieju S.A. C/ Borrassà 41 E-17600 Figueres GIRONA-SPAIN
www.riejumoto.com

This manual for service stations was made by Rieju S.A. to be used by the
workshops of dealers and sub-agencies RIEJU. It is assumed that users of this
publication for the maintenance and repair of Rieju vehicles has a basic
knowledge of the principles of mechanics and technique procedures of vehicle
repair. Any significant changes to vehicle characteristics or specific repair
operations will be communicated by updates to this manual.
N.B. Provides key information to make the procedure easier to understand and
carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to
the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the
repairer.
Personal safety Failure to completely observe these instructions will result in
serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the
correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations
leads to the risk of serious damage to the vehicle and sometimes even the
invalidity of the guarantee.

Con
tents
4
Introduction 7
 Rules 8
 Safety rules 8
 Maintenance rules 9
 Components 10
o
Battery 10
o
Controller 11
o
Display 11
o
Drive unit 12
o
Charger 12
Diagnosis Software 13
 Software Installation Process 14
 Software appearance and description 15
 Connect the Bosch diagnostics tool 16
 Software don’t connect 17
o
Error: CAN fail 17
o
Error: VCU no detected 17
 Components information 18
Troubleshooting 19
 Motorbike don’t turn ON 20
Fail: We turn the key but the dashboard doesn’t turn ON, always is
black. Battery doesn’t charge.
20
Check switch-on-relay 20
Checks fuse 15A 21
Checks 12V battery 21
Fail: We turn the key but the dashboard doesn’t turn ON, always is
black. Battery charge.
23
Checks big dashboard connector 23
Fail: We turn the key but the dashboard doesn’t turn ON, always is
black. Battery don’t charge and is impossible connect with the
diagnose software
24
Check VCU C1 connector 24
 Power batteries don’t charge 25
Fail: Motorbike run correct, any error appears on the dashboard
but the power batteries don’t charge.
25
Check charger power connexions 25
Check charger CAN connexions 26
Check side stand 27
Check side stand switch 27
Fail: Motorbike run correct for a time but battery of 12V is
discharging, ERROR appears on the dashboard and the power
batteries don’t charge.
28

Contents
5
Check fuse 40A 58V 29
Fail: Motorbike runs correct, any error appears on the dashboard
but km rage is too small and bike doesn’t have full power.
29
Check batteries are correct plugged 29
Check CAN connector of batteries 30
Fail: Motorbike run correct but don’t charge, one ERROR appears
but we can connect with the diagnose software and motorbike
don’t charge.
31
Check VCU C2 connector 31
 Motorbike don’t run 32
Fail: We turn the key the dashboard is ON, but the motorbike
doesn’t run. Dashboard error light is ON. If we put the bike to
charge, charge led flashes but really the system doesn’t charge.
32
Check 40A 58V 32
Fail: We turn the key the dashboard is ON, but we can pass of the
START screen. Dashboard error light is ON. Motorbike doesn’t
charge.
33
Check CAN drive unit 34
Check DC/DC 48V connector 34
Check power wires of driver unit 36
Fail: We turn the key the dashboard is ON, but we can pass of the
START screen. Dashboard error light is OFF. Motorbike doesn’t
charge.
37
Check power wires of driver unit 37
Fail: We turn the key the dashboard is ON, but dashboard error
light is ON and motorbike doesn’t run. Motorbike doesn’t charge.
38
Check earth cables of the drive Unit 38
Fail: We turn the key the dashboard is ON, but we can pass of the
START screen. Dashboard error light is OFF. Motorbike doesn’t
charge. We can’t connect with diagnose software tool.
39
Checks fuse 7,5A 39
Fail: We turn the key the dashboard is ON, but we can pass of the
START screen. Dashboard error light is OFF. Motorbike charge.
We can connect with diagnose software tool but any Error
appears.
40
Checks small dashboard connector 40
Fail: Dashboard error light is ON, motorbike doesn’t run. Motorbike
charge.
41
Throttle check 41
Fail: We turn the key the dashboard is ON, but we can pass of the
START screen. Dashboard error light is OFF. Motorbike charge.
We can connect with diagnose software tool but any Error
appears.
42
Mode switch check 42
 Motorbike run and charge 43
Fail: Any Error on the motorbike function but main lights doesn’t
works.
43

Con
tents
6
Checks fuse 7,5A 43
Fail: Any Error on the motorbike function but main turn lights
doesn’t works.
43
Checks turn light box 43
Checks turn light switch 44
Pre-Delivery 45
 Aesthetic inspection 46
Appearance check 46
 Electrical system 47
 Levels check 47
Level check 47
 Road test 47
Test ride 47
 Static test 47
Static control after the test ride 47
 Functional inspection 47
Functional Checks 47

Introduction

Introduction
8
This manual try to solve the most common problems found on the drive train
from Bosch, currently installed in the models Rieju Nuuk.
When you turn on the bike (or switch on main lights) the dashboard performs a
total self diagnostic check. If during this process an error is detected, an
indicator in the Display will be switched on. If this error no longer exists, the light
will automatically shut off after a driving cycle (charge and discharge of the
battery).
 Rules
This section describes general safety rules for any maintenance operations
performed on the vehicle.
 Safety rules
Always make sure that your battery is fully functional. Should you have
any questions, please contact the vehicle manufacturer or vehicle dealer.
Read all safety information and instructions. If you do not observe the safety
information, fire and/or severe injuries can occur.
Do not open the battery. This poses the risk of a short-circuit. An opened
battery voids all warranty claims.
Protect the battery against heat (e.g. including prolonged exposure to
sunlight) and fire. Do not operate or store the battery near hot or combustible
objects. This poses the risk of an explosion.
Do not immerse the battery in water.
When it is not being used, please keep the battery away from paper clips,
coins, keys, nails, screws or other small metal objects that could create a
short-circuit between the contacts. A short-circuit between the battery
contacts can result in combustion or a fire. All warranty claims against Bosch for
short-circuit-related damage arising in such circumstances shall be deemed null
and void.
Do not place the charger and the battery near combustible material.
Charge batteries only when they are dry and at a location where fires cannot
occur. The battery and the charger become warm during charging. This poses a
risk of fire.

Introduction
9
If used improperly, liquid can emerge from the battery. Avoid contact with
it. If you inadvertently come into contact with this liquid, rinse the affected
skin areas with copious amounts of water and seek additionally medical
assistance. Escaping battery liquid can cause skin irritations or burns.
Batteries must not be subjected to any mechanical impact. This poses the
risk of damaging the battery.
In the event of damage or improper use of the battery, vapours can
emerge. Ensure an adequate supply of fresh air and seek medical assistance if
discomfort persists. The vapours can irritate the respiratory passages.
Charge the battery only with the original Bosch charger. If a charger other
than the original Bosch charger is used, the risk of a fire cannot be ruled out.
Use the battery only in conjunction with the original vehicle. Only this way
the battery will be protected against dangerous overloads.
Use only original Bosch batteries that are approved for your vehicle by
the manufacturer. The use of other batteries can result in injuries and poses
the risk of fire.
Read and observe the safety information and instructions in all operating
manuals for the vehicle system as well as the operating manual for the
vehicle.
Keep the battery away from children.
Do not charge a damaged battery and do not use it. Contact the vehicle
manufacturer or vehicle dealer.
 Maintenance rules
Use original RIEJU spare parts recommended by the Manufacturer. Non-
original or non-conforming spares may damage the vehicle.
Use only the appropriate tools designed for this vehicle.
After refitting, make sure that all the components have been installed correctly
and work properly.
Use only equipment with metric sizes for removal, service and reassembly
operations. Metric bolts, nuts and screws are not interchangeable with coupling

Introduction
10
members using English measurements. Using unsuitable coupling members
and tools may damage the vehicle.
When carrying out maintenance operations on the vehicle that involve the
electrical system, make sure the electrical connections have been made
properly, particularly the ground and battery connections
Before do a maintenance o reparation operation you MUST WAIT 1 minute
after switch of the key. This is a time that the VCU needs to save all
registers after save this registers the power is switch off and you can
proceed without any risk
 Components
The scalable powertrain system consists of five components with the following
characteristics:
o Battery:
The specially developed lithium-ion battery offers not only high energy density,
but also high safety. Thanks to modularity, several battery packs can be
operated in parallel.
 Lithium-ion battery
 High energy density and long service life
 Robust, powerful (2.4 kWh, 48 V) and safe
 Modular construction allows expansion of capacity and range
BATTERY FEATURES
Size 364 mm × 260 mm × 100 mm
Weight 15 kg
Weight Energy content 2.4 kWh per battery pack
Nominal voltage 48 V
Nominal capacity 50 Ah per battery pack
Operating temperature −8 ... +58 °C (internal cell temperature)
−8 ... +40 °C (ambient)
Charging temperature +5 ... +44 °C (internal cell temperature)
Installation type Aluminium case, IP65 protection,
passive cooling

Introduction
11
o Controller:
The control unit is the brains of the powertrain system. It converts the driver's
request into intelligent commands for the system components and in this way
ensures the perfect response at all times.
 Powerful Bosch control unit
 Compact housing
 Easy integration of vehicle safety systems such as ABS and ESP®
(optional, additional Hardware required)
CONTROLLER FEATURES
Size 142 mm × 123 mm × 43 mm
Voltage 12 V
I/Os 6 analogue input, 8 external switches, 4
CAN interfaces
Communication protocol CAN bus
Diagnosis Analysis of system status via diagnosis
app or tester interface
Connectivity Connectivity box can be integrated via
CAN
o Display:
The high-quality display can be integrated into every vehicle quickly and easily.
All system information is displayed clearly. You can select from four different
driving modes: Go, Cruise, Boost, Crawl.
 Intuitive 4.4" liquid crystal display with LED status lights
 The ability to select the driving mode: Go, Cruise, Boost, Crawl
 Display of battery status & range.
DISPLAY FEATURES
Size 166 mm × 127 mm × 36 mm, 4.4 " LCD
Driving modes Go, Cruise, Boost, Crawl
Base information Speed, remaining range, total
kilometers, time, temperature, date
Driving data Trip distance, trip time, average speed,
average energy consumption
Battery information Battery level indicator (segment and %)
Status LED Lights, turn signal, system alerts,
charging status
Connectivity Bluetooth low energy
Information app Format of date and time, unit of total/trip
distance, trip time, average trip speed /
consumption, synchronization with
uDrive Connect app
Language versions DE, EN, IT, FR, ES, NL

Introduction
12
o Drive unit:
The powerful 48 V drive converts the energy of the battery into maximum
traction and recharges the battery when braking. This creates maximum driving
pleasure.
 Powerful 48 V Bosch drive (10.5 kW)
 Light (9 kg), compact and air-cooled
 Integrated inverter
DRIVE UNIT FEATURES
Size 169 mm × 148 mm
Weight 9 kg
Continuous performance 7.5 kW
Max. performance 10.5 kW
Max. recuperation 7 kW
Max. torque 55 Nm
Max. rotational speed 12,000 rpm
o Charger:
The compact, actively cooled charger ensures fast charging when connected to
common 230 V domestic power sockets. You can select from two different
charging modes: Standard and Quick.
 High charging power (1.2 kW) and integrated air cooling
 Compact design and two charging modes
 Charging possible from every 230 V domestic power socket
CHARGER FEATURES
Size 300 mm × 180 mm × 80 mm
Weight 3.5 kg
Power rating 33 A
Voltage Input 230 V AC, Output: 48 V DC
Charging current
(one battery)
Quick 20 A, Standard 10 A
Charging times
(standard mode)
50 % in ca. 2 h (one/two batteries)
100 % in ca. 4.5 h (one/two batteries)
Charging times
(quick mode)
50 % in ca. 1 h (one battery)
50 % in ca. 1.8 h (two batteries)
Installation type Built in or as home charger incl. status
LED, carrying handle and cable
management
Protection class IP66

Diagnosis Software

Diagnosis Software
14
 Software Installation Process
To ensure a trouble-free installation, please refer to following description of
installation process:
1. Search and open directory “Driver_Installation”.
2. Install the device driver by run as administrator
“Run_this_to_install_driver.bat” (this will fail if the directory path contains
whitespaces).
3. The target system is automatically detected and the correct drivers will
be installed. Upon successful completion, press any key.
4. To start the application, double-click the “Diagnosis Software” launcher.
Notice: In case of failure, please contact your support partner.

Diagnosis Software
15
 Software appearance and description
The application is tabbed into a “system” tab [1] and four “component” [2] tabs.
Via the connect and disconnect button [3] a connection to a Bosch 48V central
drive system can be established and terminated.
The “system view” [1] contains general information about the connected system,
allows editing of configuration values [11-14] and selection of system firmware
update containers [4]. Additionally the user is able by pressing the report button
[5] to generate a diagnostic report for the connected system. To trigger a
configuration/firmware update [6] and setting the application language [7]
(currently English only) the user may press the corresponding buttons. Clicking
on the “Info” button [8] will open up a window with information about application
version and support contacts. The status bar [9] informs the user about running
action status. Errors of failed actions will be indicated in red in the status result
area on the applications bottom [10].
The current vehicle identification number (VIN) will be shown [11].
The “Maximum number of batteries” setting [12] is editable in OEM mode only.
The “Maximum charging current” setting [13] can be changed in order to comply
with regional limitations in order not to overheat AC outlets.
The “Odometer” field [14] shows the total distance of the connected drive
system. Resetting or reducing the value will be refused by the target ECUs.
1
2
2
2
2
3
4
5
6
7
8
9
10
11
12
13
14

Diagnosis Software
16
 Connect the Bosch diagnostics tool
Diagnostics cable is placed on the front of the bike to acces it you must
dissasembly the front cover on the bike.
1. Take out the front cover (as show on the picture bellow).
2. Unplug connector protection.
3. Turn on ignition key.
4. Connect Bosch diagnosis tool to the bike and with the computer (use
harness supplement send by Bosch diagnostic tool)

Diagnosis Software
17
 Software don’t connect
o Error: CAN fail
When the CAN fails appear the following Error on the diagnosis software
Root causes:
a. Divers don’t install  Install drivers according “Software
Installation Process” instructions.
b. Software don’t connect with Controller  Check correct assembly
of cable supplement and status of it (all pins are OK).
c. Bosch tool is not connected or don’t works correctly.  Check
that the led tool has green colour and when we “click” on Connect
button the led flashing and change between colour green and red.
Notice: In case of don’t solve the issue, please contact your support partner.
o Error: VCU no detected
Turn ignition on and check that the emergency switch of the bike is in on
position
Notice: In case of don’t solve the issue, please contact your support partner.

Diagnosis Software
18
 Components information
Once the software is connected to the VCU the software will show the
components connect on the system, if one or more components don’t are
connected means a CAN issue, on this step the software don’t has the full
information of these components.
To have the full information of the different components (status of components,
errors, etc.) is necessary click on each tab of each component. If one tab is not
clicked we will not obtain the information of this component.
On each tab we found DTC Reset button when we push this button we erase
the historic errors of the component selected, this operation is necessary do on
each component with errors.
If we can’t erase the error mans that it continues active on the bike and is
necessary repair it on the bike.
1

Troubleshooting

Troubleshooting
20
 Motorbike don’t turn ON
Fail: We turn the key but the dashboard doesn’t turn ON, always is black.
Battery doesn’t charge.
Connect diagnosis software to the bike.
a. Any ERROR is show on the software.  Check switch-on-relay
b. Diagnosis software can’t connect with the VCU  Check fuse of 15A
and check 12V battery.
Check switch-on-relay:
If the relay is NOk when we turn the key to ON position front lights will ON.
To access to the switch on relay, remove the upper plastic cover removing 5
screws.
Take out the relay and apply a voltage of 12V to pins 86 and 85; make sure that
there is continuity between pins 30 and 87.
If the relay is not working, replace it.
If the relay is working, check harness continuity, check fuse of 15A and check
12V battery.