RIEJU Toreo 50 Instruction manual

Engine workshop manual

Index
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INTRODUCTION
NOTES FOR EASY CONSULTATION 6
GENERAL WORK PROCEDURES 7
RECOMMENDATIONS 8
SPARK PLUGS 10
ENGINE RIEJU
EQUIPMENT KIT 14
LUBRICANTS 14
ENGINE DISASSEMBLY 15
MAINTENANCE 22
ENGINE ASSEMBLY 26
ENGINE SERVICINGAND COMMISSIONING SCHEDULE 33
PARTS AND THEIR TORQUE WRENCH SETTINGS 34
EXPLODED VIEW OF THE ENGINE AM6 EURO2 35


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Introduction
Introduction

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• All checks, maintenance, repairs or replacements, etc. on the vehicles manufactured by Ma-
laguti are to be performed by skilled and expert technical personnel with specific experience in sta-
te-of-the-art technology and full knowledge of the quickest and most rational procedures, technical
characteristics, setting values and tightening torques, which may only be properly and exhaustively
provided by the manufacturer.
• This set of WORKSHOP MANUALS concerning two-stroke engines provides technicians of
the sector (Authorised Service Centres, etc.), the essential information for operating in accordance
with the latest good working practices and work safety regulations.
• These publications provide all necessary information for routine procedures on all the RIEJU-
motor vehicles equipped with two-stroke engines currently in production at the date of issue. The
information provided deals with the motor vehicle ENGINES. Some basic technical information has
been intentionally omitted as it is considered to be common knowledge.
• Additional information is available in the SPARE PARTS CATALOGUES of each model.
• It is important that before referring to the specific engine manual, the information given in this
general section be carefully read as it provides all the essential hints and guidelines for best consulting
the various topics and main technical subjects.
Note:
These manuals provide the necessary information and instructions for routine maintenance
and servicing.This information has been given to us by the engine manufacturers.We therefore
decline all responsibility for any error, omission or misrepresentation. RIEJU reserves the right
to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact the RIEJU, S.A. Service Division.
1.1 MANUAL UPDATES
• The updates will be sent by us ( in a reasonable time). Every Cd-Rom you will receive, will super-
sede the one already in your hands.
• The table of contents will be duly updated in the event that new pages are inserted, which ren-
der the consultation of the manual difficult.
• IMPORTANT! The Workshop Manuals are to be considered as essential tools to be properly
kept up-to-date so as to maintain their “ validity” over time.

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EDITING SYMBOLS
CAUTION! Recommendations and precautions regarding rider safety and
motor vehicle integrity.
WARNING!
Situations entailing the risk of personal injury to maintenance or repair mecha-
nics, other workshop personnel or third parties, or damage to environment,
vehicle or equipment.
FIRE HAZARD
Indicates operations which may constitute a fire hazard.
RISK OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
TOXIC
Indicates a possibility of intoxication or inflammation of the upper respiratory
tract.
MECHANICAL MAINTENANCE
Operations to be performed only by an expert mechanic.
ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical / electronic technician.
NO!
Operations to be absolutely avoided.
ENGINE SERVICE MANUAL
Indicates information which may be obtained by referring to said manual.
SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring to said catalogue.
TOXIC
TOXIC
TOXIC

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Note:
The letter Tr in the illustrations refers to retaining or adjusting screws.The
number following this letter refers to the number of the same type of screw
in the unit or component described and illustrated. Letters not followed by
a number indicate a single screw . In case of different screws being referred
to in the illustration, the letterTr is followed by a number and a small letter
, for instance: (Tr4a).
Unless otherwise specified, units and components are reassembled by pro-
ceeding in the reverse order of removal.
OPERATIONAL SYMBOLS
L) Loctite
O) Oil lubrication
G) Greasing
O
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Pr Tr
P
Ap
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Es
T
Tr
Figure
Tightening torque
Page
Paragraph
Section
Diagram
Table
Screw

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1.3 GENERAL WORK PROCEDURES
• The advice, recommendations and warnings given hereafter are aimed at ensuring
maximum work safety as well as at considerably reducing the risk of accidents, personal
injury, equipment damage and idle times. They should therefore be strictly adhered to.
ADVICE:
• Only use quality tools and equipment.
• Only use equipment conforming to EU Directives for lifting the vehicle.
• During operations, always keep tools and equipment at hand, possibly laying them out
according to the sequence in which they are to be used. Absolutely avoid putting them on
the vehicle itself, out-of-sight or in poorly accessible places.
• Always keep the work area clean and tidy.
•When tightening screws or nuts, start with the larger diameter or inner fasteners, and
tighten them in progressive “pulls” in accordance to a “criss-cross” pattern.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
• Adjustable wrenches (F-1) should only be used in case of emergency, i.e. when a properly
sized wrench is not available. They should preferably not be used as the movable jaw tends
to open thus risking damaging or not properly tightening the bolt to the correct torque. In
any case, when using an adjustable wrench, take care to proceed as shown in Figure 1.
• Except for occasional customers, always make out and deliver to the customer a work
sheet specifying the operations performed, with notes as to any future checks eventually
required.
F-1

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1.4 WARNINGS
• Before carrying out any operation on the vehicle, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed
by each of them are clearly defined and coordinated beforehand.
• Make sure that each component has been properly fitted before proceeding with the next
one.
• Lubricate all parts (where applicable) before reinstalling them.
• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.
• The torque settings specified in the manuals refer to the “final torque”, which must be
attained progressively by steps.
• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled
down.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
• Work in a comfortable position and ensure that the vehicle is stable.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts because, in addition to
not providing a sufficient clamping force, they may also damage the screw head
or nut hexagon.
• Never tap the wrench with a hammer or other similar tools to loosen or tig-
hten screws and nuts (F-2).
• Never attempt to increase the lever arm by fitting a tube into the wrench (F-
3).
F-2 F-3

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Never use open flames for any reason.
Never leave open containers or containers not suitable for holding fuel in passageways,
close to heat
sources, etc
Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash
point solvents to clean the vehicle components.
Never suck from or blow into the fuel pipe.
When welding, make sure that there are no flammable liquids in the vicinity. Always re-
move the tank, even if completely empty, and disconnect the negative cable (-) from the
battery.
Never leave the engine running in closed or poorly ventilated areas.
Before any servicing, make sure that the motorbike is perfectly stable.
The front wheel should preferably be anchored to the equipment (A/F-4) integral with the
lifting board.
F-4

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1.5 SPARK PLUGS
1. Insulator
2. Body
3. Gasket
4. Electrode
5. Earth electrode
6. Threads
SPARK PLUG CHECK 1,000 km
• Remove the spark plug while the engine is hot ( taking utmost care to avoid
scalding!).
• The carbon deposits and the colour of the insulator ( around the central
electrode) provide good information as to the heat range of the spark plug
and to carburetion, lubrication and general condition of the engine.
• A light brown colour of the insulator indicates that engine working conditio-
ns are generally correct.
• Sooty black deposits, that are dry ( to the touch) and opaque, are a sign that
working temperature is too low, i.e. that the heat range of the spark plug is
too high, mixture too rich or ignition defective.
•A whitish colour of the insulator is indicative of too lean a mixture or of too
low a heat range of the spark plug (i.e. spark plug too “hot”).
• Check electrode gap (F-6) (even if the spark plug is new) by means of a
calibrated thickness gauge. If necessary, adjust by acting only on the earth
electrode.
F-5
F-6
Pr Tr - Nm
20 - 25

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SPARK PLUG MAINTENANCE
• Spark plug maintenance consists essentially of a periodical visual inspection. Remove the
spark plug and check for proper condition and gap.
• Clean the electrodes and the insulator thoroughly by means of a wire brush.
• Remove any residual dirt with a strong jet of compressed air.
• Lubricate spark plug thread with engine oil or graphitised grease, and install it by hand until
finger tight.
Tighten to the specified torque with a spark plug wrench (see F-6).
It is imperative that any spark plug exhibiting cracks on the insulator or corro-
ded electrodes be replaced.
SPARK PLUG REPLACEMENT 5000 km
• Upon prescribed mileage being reached, always replace the spark plug. Use RIEJU,
S.A. recommended spark plugs.
• When replacing exhausted spark plugs, visually inspect spark plug condition as described
above to ascertain whether or not the engine is running properly.
ENGINE REMOVAL
• For removal of the engine from the chassis, refer to the “Chassis” Workshop Manual,
which lists all the operations required.
ENGINE DISASSEMBLY
The manufacturer declines all responsibility for damage of any kind caused by
disassembly and reassembly of the engine and its parts if unsuitable tools are
used.
Use only ORIGINAL RIEJU SPARE PARTS.


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Engine RIEJU
Engine RIEJU

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2.1 EQUIPMENT KIT
Code RIEJU 0/000.640.9999
2.2 LUBRICANTS
LUBRICANTS TABLE
LUBRICANTS FOR TWO-STROKE ENGINE
1) Synthetic mix oil
2) Gearbox oil SAE 10W30, type SE
GENERAL PURPOSE LUBRICANTS
3) Grease for moving parts
G
ENERAL P
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RP
OS
E L
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BRI
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SG
ENERAL P
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RP
OS
E L
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BRI
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ESPAÑOL
2.3 DISASSEMBLY OF THE ENGINE
After removing the spark-plug and carburettor proceed as follows:
1) DRAIN the engine oil by removing the relevant drain bolt.
2) UNSCREW the coolant drainage screw (1/F-1); remove the water pump cover by undo-
ing the two fixing screws (2/F-1). Pay attention to the dowel bolts (1/F-2).
3) UNDO the fixing screws of the flywheel cover (left hand side) and remove it.
Remove the starter motor (if fitted) by removing the two screws on the crankcase and the
screw on the support strap.
4) Take the carburettor out of its seat; remove the intake union and the relative clutch “brid-
ge”; remove the plate group (1/F-3).
5) REMOVE the sprocket (1/F- 4) by removing the snap ring (2/F-4); using ring pliers, remove
the sprocket by hand and remove the other snap ring underneath the sprocket.
F-1 F-2
F-3 F-4

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6) REMOVE the sliding stop screw for starting from clutch side (1/F-5).
7) REMOVE the fixing screws of the plastic oil pump cap (1/F-6). Undo the screws securing
the oil pump to the cover; then remove the pump.
8) REMOVE the cover/crankcase fixing screws (of which one M6x55 (2/F-6), that secure
the water pump cover and the relative clutch cover to the crankcase); now remove the
cover (3/F-6) and its gasket.
9) TAKE the starter assembly OUT of its seat (only for versions with starter pedals),
bearing in mind that the any shim washers must be put in the same position when the com-
ponent is reassembled.
CAUTION: when disassembling this group, carefully check the position of the
pieces so as to reassemble them correctly afterwards.
10) UNDO the screws compressing the clutch springs (1/F-7); then remove the clutch pla-
te (2/F-7) and the entire set of discs (3 /F-7); remove the disc pusher, the ball and the clutch
rod (1, 2, 3/F-8), which are housed in the centre hole of the change shaft.
F-6F-5
F-7 F-8

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11) D I S E N GAG E the nut from its fixing tab (1/F-9); using the appropriate wrench
(1/F-10), unscrew and remove the fixing nut (2/F-10) of the clutch boss.
12) REMOVE the following pieces in this order: clutch boss (1/F-11), spacer (2/F-11), clutch
gear (3/F-11), shim washer (1/F-12), tapered washer (2/F-12), paying attention to the direc-
tion in which they are assembled so as to reassemble them correctly afterwards.
13) USING the magneto flywheel locking wrench (1/F-13), lock the flywheel and slacken
the retaining nut of the gear on the countershaft with the wrench (1/F-14).
14) REMOVE the gear on the countershaft (1/F-14) and the key.
F-10F-9
F-11 F-12
F-13 F-14

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15) UNSCREW the nut (2/F-14) with a 19 mm wrench, whilst holding the flywheel in
place with the special wrench; then remove the following parts in this order: drive pinion,
countershaft drive gear, key, spacer bushing and O-ring.
16) BLOCKING the rotor of the magneto flywheel with the special locking wrench
(1/F-15), unscrew the rotor retaining nut with a 15 mm wrench.
17) REMOVE the rotor of the magneto flywheel by means of the appropriate puller
(1/F-16), which must be screwed into the threaded seat of the rotor; whilst holding the
latter in place with a wrench, turn the centre screw.
18) REMOVE the stator by undoing the screws that secure it to the plate (1/F-17).
19) TAKE the stator plate OUT of its seat by removing the 3 screws that secure it to the
crankcase (2/F-17), and remove the key (3/F-17).
F-16F-15
F-17

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20) DISASSEMBLING the thermal section:
a) unscrew the 4 cylinder head holding nuts and remove the relevant washers; remove the
head, its O-ring, the cylinder, the cylinder gasket and the four O-ring on the stud bolts.
CAUTION: before removing the circlips of the piston pin, put a clean cloth
into the opening on the crankcase, to prevent the circlips dropping into the
engine.
21) REMOVE the two circlips (F-18), remove the piston pin and, if you intend to use a 2-
diameter plug, knock gently taking care to hold the piston on the opposite side in order to
avoid damaging the connecting rod.
22) REMOVE the 13 screws joining the two crankcases (F-19) and take the clutch pin out
of its seat.
23) SEPARATE the 2 crankcases by gentling tapping the secondary shaft and shift shaft
with a wooden mallet.
IMPORTANT: if you need to take the crankshaft out of its seat, use the spe-
cial tool (1/F-20).
24) Once the crankcases have been separated, CHECK that the shim washers are on the
shafts and not on the crankcase that has just been removed (F-21).
F-19F-18
F-20 F-21
This manual suits for next models
2
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