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