RIEJU MR 300 User manual

MR 300 – 250 - 200
Owner’s manual

2
Owner’s manual
RIEJU
MR 300 – 250 -200
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, sub-agencies RIEJU and advanced owner. It is assumed
that users of this publication for the maintenance and adjustment 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.
Note: 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.
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.

Índice
General information 6
Introduction 7
Legal notices 7
Notices and warnings 7
Preliminary warnings 8
Location of components 9
Identification 12
Steering lock 12
Specifications 13
Electric diagram 15
Table of tightening torques 18
General 18
Engine 19
Multifunction gauge 22
Homologation 23
Operating instructions 24
Starting procedure 25
Breaking-in 25
Daily inspection before riding 26
Cleaning 30
Storage 30
OBD Operation 31
Maintenance 33
Maintenance table 34
Maintenance 36
1. Clutch 36
2. Clutch discs 36
3. Throttle cable 36
4. Spark plug 36
5. Air filter 37
Removing the filter 37
Cleaning the filter 38
6. Carburettor 38
7. Transmission oil 39
8. Piston and ring 40
9. Cylinder head, cylinder and exhaust valve 40
10. Exhaust system 40
11. Muffler fibre 41
12. Connecting rod and bearings 41
13. Kick-starter and gear shift pedal 41
14. Rubber gasket exhaust/silencer 41
15. Motor bearings 41
16. Coolant 41
17. Radiator tube and connections 44
18. Brakes adjustment 44
19. Brakes wear 45
20. Brake fluid 47
21. Brake fluid level 47
22. Brake pump piston and dust cover (front and rear) 48
23. Calliper piston and dust cover (all callipers) 48
24. Brake hoses 48
25. y 26. Spokes and wheels 48
4

Índice
27. Chain guide 48
28. Chain guide wear 48
29. Chain guide shoe 49
30. Front Suspension 49
31. Front suspension oil 50
32. Bolts, nuts and fasteners 50
33. Petrol tube 50
34. Fuel system 51
35. Steering head adjustment 51
36. General lubrication 52
37. Steering bearing 52
38. Wheel bearing 52
39. Swingarm and linkage 52
40. Rear suspension 52
41. Chain 54
42. Tires 55
43. Battery charge 56
Settings 57
Introduction 58
Carburator setting 58
Opening of the throttle valve and influences 58
Idle jet and mixing screw 58
Carburettor needle 59
Main jet 59
Reference carburetion (competition only) 59
Correction factors 60
Secondary transmission ratio 61
Suspension setting 61
Available settings 61
Suspension Settings 62
Rear Shock Absorber (Kyb) 63
Static SAG 63
Correction according to type of terrain 63
Adjusting Your Motorcycle 64
Adjustment of the pre-loading of the centrifugal spring 66
Troubleshooting 67
Warranty manual 73

General information

General information
Introduction
RIEJU thanks you for your trust.
By choosing the new RIEJU MR you have just joined the great RIEJU team, and as a
user of the number one brand of off-road bikes, you deserve the distinguished care that
we would like to offer you, both after purchasing your RIEJU and in the explanations
that we set out in this manual.
Your RIEJU MR is a bike designed for high-level competition, it is the fruit of many
years of competition and experience in demanding disciplines. The many successes
achieved by the great riders of our RIEJU bikes has provided the basic data to be able
to create these high-end motorcycles. Exclusive RIEJU motorcycles that have three
key factors: Reliability, high performance and good stability.
Congratulations because your choice has undoubtedly been the right one. With your
skills in handling your RIEJU and with the proper preparation and the corresponding
reviews, vital for your RIEJU to be highly reliable, you can enjoy the most comfortable
and fulfilling motorcycling.
Thank you for your trust and welcome to RIEJU.
Legal notices
In the interest of technical development RIEJU reserves the right to modify the
construction, equipment and accessories of the motorcycle without prior notice.
Measurements, weight and power data are understood to include the respective
tolerances. Depending on the volume of equipment and accessories of your RIEJU, as
well as in the approved versions in accordance with the different laws of each State,
there may be variations with respect to the descriptions and illustrations. Therefore, the
photographs contained in this manual may not correspond to the model purchased. For
this reason no liability shall be derived for error, printing error or omission.
Notices and warnings
Please read this manual thoroughly, paying particular attention to the following
warnings:
DANGER
Notices about a danger that leads to serious injury or even death.
WARNING
Notices regarding danger that could result in personal injury and/or damage to the
vehicle.
7

General information
Preliminary warnings
DANGER
Three out of four fatal accidents are due to head injuries. The risk of brain injury is
three times greater if no helmet is used. Always wear an approved helmet, the
probability of remaining unscathed in the event of an accident is increased by 20%. It is
also recommended to use eye protection as well as gloves, boots and other protective
items that should be in perfect condition.
Never carry a passenger. Your RIEJU is not approved for this purpose, nor does it
have space on the seat, handlebars or footrests for the passenger. In addition, the
extra weight can impair handling.
Avoid modifying your RIEJU with non-original accessories and do not remove the
original elements, these changes could affect the stability and handling, making the
vehicle dangerous or illegal. The use of original spare parts and accessories or parts
approved by RIEJU is recommended. It is an essential condition for maintaining the
warranty.
Your RIEJU has been designed for off-road use, it has not been designed for long
journeys on the road or motorway. Such use may result in damage to the engine due
the high revolutions and the tires are not suitable for use on paved surfaces. It has not
been designed for urban use either. Long stops at traffic lights in the city could cause
engine overheating.
Keep your RIEJU in good condition. To avoid any problems, inspect your motorcycle
before every use, and perform all maintenance as recommended in this manual. After a
fall, check that the main elements have not been damaged. Riding a motorcycle in poor
condition can cause an accident with serious injuries and even death.
DANGER
The exhaust pipe and other elements reach high temperatures during use and take
time to cool down once the engine has been turned off. Avoid handling or touching
anything during this period. The use of shorts is not recommended, since it can cause
burns to the legs.
DANGER
Avoid wearing loose clothing that could get caught on parts of the vehicle or the
surroundings. Although total safety is impossible, the use of adequate equipment
reduces the possibility and/or severity of injuries.
8

General information
Location of components
Number
Name
Number
Name
1
Front reflectors.
11
Licence plate holder with rear light,
position, intermittent and rear
reflector.
2
Headlight position, long and
short beam.
12
Front brake disc
3
Front turn signals.
13
Front brake calliper
4
Rear-view mirrors.
14
Front fork
5
Overflow pipe.
15
Starter
6
Fuel tank.
16
Gear shift pedal
7
Fuel valve.
17
Secondary exhaust
8
Air filter.
18
Carburettor
9
Side stand.
19
Chain
10
Chain guard.
20
Chain guide
1
2
3
4
6
7
8
9
10
11
5
12
13
14
15
16
17
18
19
20
9

General information
Number
Name
Number
Name
21
Muffler
30
Suspension linkage
22
Rear brake fluid tank
31
Footpegs
23
Seat
32
Rear brake pedal
24
Rear shock absorber gas tank
33
Centrifugal regulation
25
Kick-starter
34
Crankcase guard
26
VIN chassis number
35
Exhaust
27
Radiator
36
Manufacturer’s identification plate
28
Rear brake disc
29
Rear brake calliper
28
29
30
31
32
33
34
35
36
21
22
23
24
25
26
27
10

General information
Location of components
Number
Name
Number
Name
1
Choke lever
7
Fuel tank cap
2
Clutch fluid reservoir
8
Steering lock
3
Multifunction gauge
9
Stop
4
Front brake fluid tank
10
Throttle
5
Clutch lever
11
Front brake lever
6
Turn signals, lights, horn and starter
Number
Name
Number
Name
1
Long and short-beam lights
4
Start
2
Horn
5
Stop
3
Turn signals
1
2
3
4
5
6
8
9
10
11
7
1
2
4
5
3
11

General information
Identification
Your RIEJU has an identification plate (1) which
details: manufacturer, chassis number,
approval number and level of noise emissions.
The chassis number is also stamped on the
right side of the steering column.
Steering lock
Your RIEJU has a steering lock. It is located on
the right side of the lower fork flange. To lock
the steering:
1.
Turn the handlebar all the way to the
left.
2. Insert
the key into the lock and turn it
anti-clockwise ⅛ back.
3. Press the key in.
4.
Turn the key clockwise to its initial
position and remove it. The closure
must be sunk so that the lock is
effective.
1
12

General information
ENGINE
Cycle
2-stroke
Number of cylinders
Mono-cylindrical
Refrigeration
Liquid cooled
Capacity
199,4 cc
249,3 cc
299,3 cc
Bore
62,5 mm
66,4 mm
72,0 mm
Stroke
65,0 mm
72,0 mm
72,0 mm
Carburettor
Dell’Orto PHBG 21 (Keihin PWKS 38 competition model)
Intake type
V-Force 4 Reed valve system
Lubrication system
Fuel mix
Starter system
Kick-starter/Electric starter on E-START models
Ignition system
Digital CDI -Euro 5
Pre-ignition set-up
Spark plug
DENSO W24ESR-U and NGK BR8EG
Distance between
electrodes
0,7/ 0,8 mm
TRANSMISSION
Primary reduction
3,31 (63/19)
Gearbox
6 speeds, cascade
Gear ratio
1ª
2,07 (14/29)
2ª
1,63 (16/26)
3ª
1,33 (18/24)
4ª
1,10 (20/22)
5ª
0,91 (23/21)
6ª
0,79 (24/19)
Secondary transmission
By chain
Secondary reduction
4,16 (12/50) MR 200
3,67 (13/49) MR 250 //
3,69 (13/48) MR 300
Competition models only
3,30 (13/42)
MR 200-250-300
Chain
110 Links // 5/8 "x 1/4" with seals (112 links) competition
model only
Type of clutch
Multi-disc oil bath with hydraulic drive
Clutch drive
Hydraulic
Lubrication
Medium
Oil
Capacity
900cc (new) ; 800cc (Replace)
DIMENSSIONS
Total height
1235 mm
Total length
2145 mm
Seat height
960 mm
Ground clearance
375 mm
Overall width
810 mm
Wheelbase
1480 mm
Dry weight
105 kg
Fuel tank capacity
10 l
13

General information
FRAME
Type
Central backbone frame in 25 CrMo 4 steel, aluminium alloy
subframe
Measurements of
tires and rims
Front
Excel 1.6 x 21 - 90/90 - 21
M/C 54R MICHELIN ENDURO MEDIUM F TT
Rear
Excel 2.15 x 18 - 140/80 – 18 (250cc/300cc) //
120/90 – 18 (200cc)
70R MICHELIN ENDURO MEDIUM R TT
Tire pressure
Front
1,0 bar
Rear
1,0 bar
Suspension
Front
KY B fork ø48 mm AOS System (Air Oil
Separated), closed cartridge, with spring and
compression and rebound
Rear
Progressive system with KY B single shock
absorber with adjustable high and low speed
compression and rebound
Suspension travel
Front
300mm (KYB)
Rear
131 mm (KYB)
Front fork oil volume
KYB
350 ml. (cantidad)
Brakes
Front
Disc, with Nissin 2-piston floating calliper
Rear
Disc, with Nissin 1-piston floating calliper
Brake discs
Front
NG wave Ø260 mm disc
Rear
NG wave Ø220 mm disc
FLUIDS
RECOMMENDED
Fuel
Lead free (minimum RON 98)
Recommended Fuel
Gasoline with a content of 10% ethanol
Oil mixture
(JASO FC ) LIQUI MOLY 2T
SYNTH OFFROAD
RACE
100% synthetic oil at 2% (50:1)
Semi-synthetic oil at 2% (50:1)
Mineral oil at 3% (32:1)
Coolant2
LIQUI MOLY
RAF12+
Antifreeze mixture at 30%
Brake fluid
LIQUI MOLY
DOT-4
DOT-4
Clutch fluid pump
MAGURA ROYAL
BLOOD
Mineral oil
Transmission oil
LIQUI MOLY
SYNTH 5W40
OFFROAD RACE
Synthetic motor oil API SJ; ACEA A3; JASO MA-2
Fork oil
KYB
KBY Fork oil 01M
CARBURATION
Competition
4
Type of carburettor
Keihin PWKS 36
Keihin PWKS 38
Keihin PWKS 38
Main jet
185
175
175
Idle jet
45
42
42
Needle
NOZI
N1EF
Needle position
3rd from above
Throttle valve
6
7
7
Air screw
1 and 1/2 turns from closed
(2) Cold countries should adjust the coolant to their temperature. (4) Exclusive use in closed circuit.
E5
E10
14

General information
15

General information
16

General information
17

General information
Table of tightening torques
Engine
Measure
Torque(Nm)
Nut
Engine axles
M10
60
Handlebar
Measure
Torque(Nm)
Screw
Lower handlebar flange
M10
40
Screw
Upper handlebar flange
M8
25
Screw
Vlutch
M6
10
Frame
Torque(Nm)
Screw
Crankcase guard
M6
10
Screw
Left-hand side protector
M6
10
Screw
Tie Rod cylinder Head
M8
20
Subframe
Torque(Nm)
Screw
Upper subframe
M8
25
Loctite® 243TM
Screw
Lower subframe
M8
25
Loctite® 243TM
Fork
Torque(Nm)
Screw
Fork protector - guided hose
M6 (pl)
8
Screw
Fork protector - foot
M6
8
Screw
Foot fork
M8
15
Screw
Front axle
M24
35
Screw
Front brake calliper
M8
25
Loctite® 243TM
Screw
Upper flange
M7
15
Screw
Lower flange
M7
12
Tank
Measure
Torque(Nm)
Screw
Tank-silentblock-chassis
M6
10
Rear shock absorver
Measure
Torque(Nm)
Screw
Upper shock absorber
M12
60
Loctite® 243TM
Screw
Lower shock absorber
M12
50
Link
Measure
Torque(Nm)
Nut
Tie-rod - chassis
M12
80
Loctite® 243TM
Nut
Tie-rod - Rocker arm
M12
80
Loctite® 243TM
Nut
Rocker arm - swinging arm
M12
80
Loctite® 243TM
Swing-arm
Measure
Torque(Nm)
Nut
Swinging arm nut
M14
80
Screw
Shoe chain - protector
M6
10
Screw
Lower shoe chain - chassis
M8
25
Loctite® 243TM
Screw
Chain guide
M6
10
Nut
Rear wheel axle nut
M20
100
Exhaust
Measure
Torque(Nm)
Screw
Muffler - upper
M6
12
Screw
Muffler - Lower
M6
12
Screw
Silentblock exhaust
M6
12
Plastic
Measure
Torque(Nm)
Screw
Front fender
M6
12
Screw
Rear fender
M6
12
Screw
Inf. side plates to radiator
M6
8
Screw
Tank and plates
M6 (pl)
6
Screw
Right-hand valve cover
M6
12
Screw
Electrical components box
M6 (pl)
6
18

General information
Stand
Measure
Torque (Nm)
Screw
Stand
M8
25
Loctite® 243TM
Rear brake
Measure
Torque (Nm)
Screw
Brake pedal
M8
20
Screw
Rear brake pump
M6
12
Loctite® 243TM
Electricity
Measure
Torque (Nm)
Screw
Battery
M5
2,5
Gear shift pedal
Measure
Torque (Nm)
Screw
Gear shift pedal
M6
12
Kick-starter
Measure
Torque (Nm)
Screw
Kick-starter
M6
12
Loctite® 243TM
Seat
Measure
Torque (Nm)
Screw
Seat
M6
10
Table of tightening torques
Nº
Part name
Measure
Torque (Nm)
1
Valve cover bolts
M5x15
8
2
Crankcase bolt
M6x25
12
3
Gear shift pedal bolt
M6x12
14
1
2
3
19

General information
Nº
Part name
Measure
Torque (Nm)
4
Kick-starter-to-axle bolt
M6x20
12
5
Kick-starter pedal bolt
M6x75
10
4
5
1
2
3
20