RIEJU MRT 50 Instruction manual

MRT 50
MRT 50
Chassis workshop manual

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Contents
INTRODUCTION
AUPDATES FOR THE MANUALS
SYMBOLS USED
ABBREVIATIONS USED IN THE MANUAL
GENERAL WORK RULES
RECOMMENDATIONS
LEARNING ABOUT THE MOPED
MAINTENANCE OPERATIONS
TECHNICAL SPECIFICATIONS AND CHARACTERISTICS
UNPACKING
“AESTHETIC APPEARANCE” CHECK
DETAILS FOR IDENTIFICATION
SAFETY LABEL
IDENTIFYING THE MAIN ELEMENTS
CONTROLS
KEYS
STEERING LOCK
PROP STAND
INSTRUMENT PANEL
TYRES
CHECKING THE PRESSURE
FUEL TANK
COOLANT
RENEWING COOLANT
ENGINE OIL
TRANSMISSION OIL
BRAKE FLUID
ADJUSTING THE IDLING RATE
ADJUSTING THE TRANSMISSION CHAIN TENSION
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Contents
REMOVAL
1. SEAT
2. FRONT SIDE COVERS
3. REAR SIDE COVERS
4. REAR COWLING
5. CHAIN PROTECTOR
6. REAR MUDGUARD
7. REAR MUDGUARD
8. FILTER CANISTER
9. AIR FILTER
10. EXHAUST PIPE
11. SILENCER
12. “AIS” SYSTEM (Secondary air valve)
13. FUEL TANK
14. OIL TANK
15. OIL SENSOR
16. OIL FILTER
17. RADIATOR
18. PROP STAND
19. GEAR LEVER
20. KICK-START LEVER
21. REAR BRAKE PEDAL
22. SHOCK ABSORBER
23. FUEL TRANSMISSION/OIL MIXER
24. CARBURETTOR
25. ENGINE
26. FRONT HEADLIGHT
27. INSTRUMENT PANEL
28. FRONT TURN INDICATORS
29. REAR TURN INDICATORS
30. REAR LIGHT BULB
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31
32
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34
34
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Contents
Introduction
REMOVAL
31. TURN INDICATORS CONTROL UNIT
32. REGULATOR
33. E.C.U.
34. ODOMETER TAKE-OFF
35. HANDLEBARS
36. STEERING
37. FRONT WHEEL
38. FRONT BRAKE CYLINDER
39. FRONT BRAKE CALLIPER
40. FRONT BRAKE DISK
41. CLUTCH LEVER
42. REAR WHEEL
43. REAR BRAKE CALLIPER
44. REAR BRAKE DISK
45. REAR BRAKE CYLINDER
46. SWINGING ARM
47. TRANSMISSION CHAIN
48. FRONT FOOTRESTS
49. REAR FOOTRESTS
ELECTRICAL SYSTEM
1. PRECAUTIONS
2. GENERAL WIRING
3. TROUBLESHOOTING
4. IGNITION SYSTEM
5. LIGHTING SYSTEM
6. CHECKING THE INSTRUMENTS
7. SENSORS
8. PROGRAMMING MAE INSTRUMENT PANEL
9. PROGRAMMING KOSO INSTRUMENT PANEL
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48
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50
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Introduction
Introduction

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Introduction
Chassis
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This workshop manual contains the main electromechanical checks, as well as the general essential
checks and the fitting of components that are supplied unattached, in order to make delivery of the
moped newly arrived from the factory.
It is very important that the indications given in the manual are adhered to strictly. Work carried
out is a superficial way, or worse still, not carried out at all, may lead to personal injury to the user,
damage to the machine, etc., or simply be the source of disagreeable complaints.
N.B.: Rieju, S.A. reserves the right to make modifications at any time without any prior noti-
fication.
For any enquiry of for further information, please call the Rieju, S.A. Customer Service.
UPDATES FOR THE MANUALS
Any update will be sent within a reasonable period of time. Each new CD-Rom updates the informa-
tion in the previous one.
The list of contents will be updated if the modifications and/or variations in the pages do not ensure
the consulting of the manual.
IMPORTANT! The series of workshop manuals must be considered as an actual work instrument,
and the manuals can only maintain their “value” over time if they are kept constantly up to date.

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SYMBOLS USED IN THE MANUAL
ATTENTION! Practical advice and information that refers to the safety of the
motorcyclist (user of the machine) and the features that maintain the condition
and integrity of the machine itself..
ATTENTION! Descriptions that relate to work that is dangerous for the te-
chnical maintenance staff, repair staff, other workshop staff or for those from
outside, for the environment, for the machine and for the equipment.
DANGER OF FIRE
Operations that could cause a fire.
DANGER OF EXPLOSION
Operations that could lead to an explosion.
TOXIC
Indicates the danger of poisoning or inflammation of the primary respiratory
tracts.
MEMBER OF TECHNICAL STAFF RESPONSIBLE FOR THE
MECHANICAL MAINTENANCE
Operations that assume competence in the field of mechanics/motorcycles.
MEMBER OF TECHNICAL STAFF RESPONSIBLE FOR
ELECTRICAL MAINTENANCE
Operations that assume competence in the field of electricity/electronics.
NO!
Operations that must be avoided.
WORKSHOP MANUAL
Information to be gleaned from this documentation.
SPARE PARTS CATALOGUE
Information to be gleaned from this documentation.
TOXIC
TOXIC
TOXIC

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Introduction
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N.B.:
The illustrations frequently show securing or adjustment bolts or screws, indicated
by the letter B. The number following this letter indicates the quantity of identical
bolts (B) or screws to be found on the unit or component being described and its
corresponding illustration. A letter without a number indicates that the quantity is
1. In the case of different bolts or screws shown in the same figure, the Bwill be
followed by the number and by a lower-case letter (e.g.: (B4a).
The refitting of units and components is normally done in this opposite way to dis-
mantling operations (except for a specific description).
F
T Tq
P
Ap
S
Diag
T
B
Figure
Tightening torque
Page
Part
Section
Diagram
Table
Bolt
ABBREVIATIONS USED INTHE MANUAL

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GENERAL WORK RULES
TIPS:
F-1
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Always use equipment of an optimum quality.
Use specially designed equipment, in accordance with European guidelines, to raise the
machine.
While carrying out work, keep tools within reach, as far as possible according to a
predetermined sequence, and in any event never on the machine or in areas that are
hidden or difficult to access.
Keep the work area clean and tidy.
When tightening nuts and bolts, begin either with those with the larger diameter or the
inner ones, proceeding to tighten them in successive steps in a criss-cross pattern.
The correct method is using a set gap spanner, with a pulling rather than a pushing
action.
Adjustable spanners (F. 1) should only be used in an emergency, e.g. when the correct
size of set spanner is not available. When force is applied to these, the mobile jaws tend
to open, with the risk of possible damage to the bolt head or nut, as well as obtaining an
unreliable tightening torque. In any event, they must be used as illustrated in Figure 1.
Except in special service cases, a work sheet should be prepared for the customer, setting
out all the work carried out and notes about any possible future checks.
• The tips, recommendations and warnings that follow are aimed at ensuring that work
is carried out in a rational way and with maximum operational safety, thereby eliminating
significantly the chances of accidents, injury and damages of any nature and downtimes.
They should therefore be scrupulously observed.

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Before beginning any work on the moped, wait for each and every one of the machine’s
components to cool down completely.
If the operations envisage the use of two mechanics, they need to agree in advance on the
tasks to be performed and synergies.
Always check that a component has been fitted correctly before proceeding to fit
another.
Lubricate the (envisaged) parts before refitting them.
Gaskets, sealing rings, rubber rings and keys must be renewed each time they are
removed.
The par values indicated in the manuals refer to the “final tightness”, and need to be
reached progressively, step-by-step.
Loosening and tightening operations on aluminium alloy parts (crankcase) must be
performed when the engine is cold.
Always use screwdrivers of the correct size for the screws on which they are to be used.
Never work in uncomfortable conditions or those of precarious stability of the
moped.
Never re-use a gasket or rubber ring.
Never tighten or loosen nuts and bolts with pliers, since, in addition to not
exercising enough locking force, this can damage the bolt head or the nut.
Never strike the spanner with a hammer (or other tool) to loosen or tighten
nuts and bolts (F-2).
Never increase the leverage by inserting a pipe over the spanner (F-3).
F-2 F-3
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RECOMMENDATIONS

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Never use naked flames under any circumstances.
Never leave open and unsuitable containers containing petrol where others are passing,
close to heat sources, etc.
Never use petrol as a cleaner to clean down the machine or to wash the workshop floor.
Clean the various components with detergent with a low flammability rating.
Never suck or blow into the petrol supply pipe.
Never carry our soldering or welding in the presence of petrol. Remove the fuel tank
even if it is completely empty, and disconnect the negative cable (-) from the battery.
Never leave the moped with the engine running in closed or poorly aired
spaces.
Before carrying out any work, make sure the moped is perfectly stable.
F-4

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Familiarising yourself with the
Familiarising yourself with the
moped
moped

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TECHNICAL SPECIFICATIONS AND CHARACTERISTICS
1st SERVICE
500 KM
2nd SERVICE
3.500 KM
MAINTENANCE OPERATIONS SERVICE
EVERY
3.000 KM
Check the braking system
Check the transmission oil level
Check chain tension and wear
Check suspensions
Check, adjust and grease levers and cables
Check wheel centring and spoke tensions
Clean and grease the air filter
Check and adjust the carburettor
Check and adjust the spark plug or renew
Check the tightness of the nuts and bolts on
the chassis and on plastic units
Check the electrical system
Check wear on piston rings
Check radiator coolant levels
Check the exhaust system
Check condition of the battery and its terminals
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Change
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Change
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Dimensions
Total length
Total width
Total height
Seat height
Distance between wheel shafts
Minimum distance to the ground
Dry weight
Engine
Type
Number of gears
Make
Model
Cylinder and arrangement
Cylinder capacity
Diameter x stroke
Starting system
Lubrication system
Type of oil
2 stroke
6 gears
Minarelli
AM 6 (EU 2)
1 forward-inclined
49.7 cc
40.3 x 39 mm
Kick-start lever
By pump
CASTROL TTS 2-stroke injection
MRT
2070 mm.
800 mm.
114 5 m m .
870 mm.
1380 mm.
288 mm.
MRT SM
MRT
85 kg.
MRT SM
85 kg.
2150 mm.
800 mm.
116 5 m m .
890 mm.
1405 mm.
310 mm.

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Transmission oil
Type
Quantity
CASTROL MTX SAE 10W 30
820 c.c.
Air filter
Wet-type foam cartridge
Fuel
Type
Fuel tank capacity
95 octane lead-free petrol
6,32 L.
Carburettor
Dellorto PHBN 16 HS
Spark plug
Type
Distance between electrodes
NGK BR 9 ES
0,6 - 0,7 mm.
Clutch
Multi-disk in oil bath
Primary transmission
Clutch crown wheel
Engagement gear
Transmission ratio
Z = 71
Z = 20
1: 3,55
Secondary transmission
Engine output sprocket
Rear wheel sprocket
Transmission ratio
Chain
Z = 11
Z = 52
1: 4,36
420 x 126 links
Speed
1ª
2ª
3ª
4ª
5ª
6ª
Primary shaft
Z = 12
Z = 16
Z = 19
Z = 22
Z = 24
Z = 25
Secondary shaft
Z = 36
Z = 33
Z = 29
Z = 27
Z = 25
Z = 24
Gear ratio
1: 3,00
1: 2,06
1: 1,53
1: 1,23
1: 1,04
1: 0,96
Output ratio
1: 10,65
1: 7,31
1: 5,43
1: 4,37
1: 3,69
1: 3,40
GEAR CHANGE

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Suspension:
Front
Rear
MRT 50 / MRT 50 SM
37 mm Ø bars
CASTROL 15 W 20 FORK OIL , 245 cc per
bar
Hydraulic shock absorber
Suspension:
Front
Rear
MRT 50 PRO / MRT 50 PRO SM
40 mm Ø inverted hydraulic forks
CASTROL 10 W FORK OIL , 325 cc per bar
Gas shock absorber with separate bottle
Brake disks
Front
Rear
MRT 50 / MRT 50 SM
220 mm Ø
180 mm Ø
Tyres
Front
Rear
MRT 50 / MRT 50 SM
80/90 - 21, with tube, 1’7 kg/cm2
110/80 - 18, with tube, 1’8 kg/cm2
Brake disks
Front
Rear
MRT 50 PRO / MRT 50 PRO SM
300 mm Ø Wave type double piston
260 mm Ø Wave type double piston
Tyres
Front
Rear
MRT 50 PRO / MRT 50 PRO SM
100/80 - 17, with tube, 1’8 kg/cm2
130/70 - 17, with tube, 1’9 kg/cm2
Electrical equipment
Ignition
Generator
Ignition advance
Electronic 12V 85W
Ducati
20º 1’4mm. before T.D.C
Voltage and wattage of bulbs
Headlight
Rear light
Instrument panel
Turn indicators
Odometer lighting
12V 35/35W
12V 21/5W
12V 1,2W
12V 10W
12V 1,2W

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Front wheel bolt
Front wheel bolt lock
Rear wheel bolt
Front/rear brake calliper
Silencer
Exhaust pipe side coupling
Engine mounting bolt
Handlebar lever bolt
Shock absorber bolts
Forks bolt
Handlebar securing bolt
Top steering nut
Intermediate steering nut
Swinging arm bolt
Element Kg*mN*m Notes
38 - 52
17 - 23
72 - 98
24 - 36
6 - 10
6 - 10
20 - 26
2 - 4
38 - 52
51 - 69
18 - 24
18 - 24
25 - 34
60 - 75
3,8 - 5,2
1,7 - 2,3
7,2 - 9,8
2,4 - 3,6
0,6 - 1,0
0,6 - 1,0
2,0 - 2,6
0,2 - 0,4
3,8 - 5,2
5,1 - 6,9
1,8 - 2,4
1,8 - 2,4
2,5 - 3,4
9,0 - 7,5
TABLE OF TIGHTENING TORQUES
G
G
Grease
G
G
G

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UNPACKING
Unpack the moped following the directions present in the packaging itself, which must then
be disposed of in accordance with existing regulations.
“AESTHETIC APPEARANCE” CHECK
Check visually that all components made of plastic material are fitted correctly and that
the machine does not have any visible scratches, marks, etc.
DETAILS FOR IDENTIFICATION
Machine Identification Number
The machine’s identification number (A/F-2) can be found stamped on the steering column.
This identification number is used to identify the moped.
Engine identification number
The details for identifying the engine (B/F-1) can be seen on the left-hand crankcase.
F-2
F-1
A
B
SAFETY LABEL
This contains the machine’s identification de-
tails as laid out in Directive 97/24/CE. It is es-
sential indicate the machine’s identification de-
tails when requesting spare parts.
This label must not be replaced or altered.
It is located on the left-hand side of the chassis
close to the steering column.
•
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F-3

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IDENTIFICATION OF MAIN ELEMENTS
(left-hand side)
1. Headlight.
2. Right-hand controls.
3. Left-hand controls.
4. Seat.
5. Prop stand.
6. Gear change pedal.
7. Fuel tank.
IDENTIFICATION OF MAIN ELEMENTS
(right-hand side)
8. Fuel tank cap.
9. Forks.
10. Radiator.
11. Rear brake pedal.
12. Pillion passenger
foot-rests.
13. Exhaust pipe.
14. Number plate holder.
F-4
F-5
MRT SM
MRT SM
43
1
2
567
8
9
101112
13
14

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CONTROLS
Controls/instrumentos
1. Rear-view mirror
2. Horn button
3. Light switch
(dipped beam/main beam).
4. Main switch.
5. Instrument panel.
6. Front brake cylinder.
7. Throttle twist grip.
8. Front brake lever.
9. Turn indicator switch.
10. Manual choke lever.
11. Clutch lever.
12. Left-hand
handlebar grip.
4
KEYS
• The machine is supplied with two keys with a numerical code that allow:
- The ignition to be switched on
- The lights to be switched on
- The steering to be locked
STEERING LOCK
• Locking: With the handlebars turned fully to the left, push the key fully in and turn it
to the left.
• Unlocking: Turn the ignition key to the right.
PROP STAND
• Check that the prop stand is well secured and moves properly. The retention system,
consisting of traction springs, should also be checked frequently.
F-6
F-7
1 3 6 7
891011
12
2 5

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INSTRUMENT PANEL
F-8
1-
2-
2b-
3-
4-
5-
6-
Turn indicators indicator light
This indicator light flashes when the turn indicator switch is moved to the left or to
the right.
Oil level indicator light
This indicator light comes on when the oil level is low.
Oil temperature indicator light
This indicator light comes on when the oil temperature is too high.
Coolant temperature indicator light.e.
This indicator light comes on when the coolant temperature is too high. When the
indicator light comes on, stop the engine immediately.
Mode button.
See programming section.
“N” neutral indicator light
This indicator light comes on when the transmission is in the neutral position.
Main beam indicator light.
This indicator light comes on when the headlight is on main beam.
1
6
5
2
3
4
MAE
F-9
5
6
KOSO 1
2b