RIEJU MRX-SMX 50 Instruction manual

MRX-SMX 50
MRX-SMX 50
Chassis workshop manual

1
Chassis
EN
G
LI
S
H
Index
INTRODUCTION
MANUAL UPDATES
SYMBOLOGY USED IN THE MANUAL
ABBREVIATIONS USED IN THE MANUAL
GENERAL WORK RULES
RECOMMENDATIONS
GETTING TO KNOW THE MOTORBIKE
MAINTENANCE OPERATIONS
TECHNICAL SPECIFICATIONS
UNPACKING
APPARANCE
DATA FOR IDENTIFICATION
ANTI-TAMPERING LABEL
IDENTIFYING THE MAIN ELEMENTS
CONTROLS
KEYS
STEERING LOCK
SIDE STAND
INSTRUMENT PANEL
TYRES
CHECKING TYRE PRESSURES
FUEL TANK
COOLANT
REPLACING COOLANT
ENGINE OIL
TRANSMISSION OIL
BRAKE FLUID
ADJUSTING THE MINIMUM REV SETTING
ADJUSTING TRANSMISION CHAIN TENSION
6
7
8
9
10
15
15
18
18
18
18
19
20
20
20
20
21
22
22
22
23
23
24
24
25
25
26

ENGLISH
Chassis
2
Index
DISASSEMBLY
1. REAR VIEW MIRRORS
2. FRONT HEADLIGHT HOLDER
3. FRONT SIDE COVERS
4. SEAT
5. NUMBER PLATE HOLDER
6. REAR COVER
7. FRONT MUDGUARD
8. FUEL TANK
9. FUEL TANK PROTECTOR
10. HANDLEBARS
11. STEERING
12. CLUTCH LEVER
13. FRONT BRAKE CYLINDER
14. FRONT HEADLIGHT
15. FRONT INDICATOR LIGHTS
16. REAR LIGHT
17. REAR INDICATOR LIGHTS
18. INSTRUMENT PANEL
19. TURN INDICATOR REGULATOR
20. CONTACT RELAY
21. CONTROL UNIT (CDI)
22. BATTERY
23. OIL SENSOR
24. OIL TANK
25. AIR FILTER
26. FUEL TRANSMISSION/OIL MIXER
27. “AIS” SYSTEM
28. EXHAUST
29. SILENCER
30. RADIATOR
31. CARBURETTOR
32. GEAR CHANGE LEVER
33. REAR BRAKE LEVER
34. SIDE STAND
28
28
29
29
30
30
30
31
31
32
32
33
33
34
34
35
35
36
36
37
37
38
38
38
39
39
39
40
40
41
41
42
42
43

3
Chassis
EN
G
LI
S
H
Index
35. REAR BRAKE CYLINDER
36. REAR BRAKE CALLIPER
37. ENGINE
38. REAR WHEEL
39. CHAIN PROTECTOR
40. DRIVE CHAIN
41. SHOCK ABSORBER
42. SWING ARM
43. FRONT WHEEL
44. FRONT BRAKE CALLIPER
45. FRONT BRAKE DISK
46. SPEED SENSOR
47. FRONT FOOTRESTS
48. REAR FOOTRESTS BRACKETW
48. TIGHTENING TORQUES
43
43
44
45
45
45
46
46
47
47
47
48
48
48
49

ENGLISH
Introducción
Chassis
4
Introduction

5
EN
GLISH
Introduction
Introduction

ENGLISH
Introducción
Chassis
6
This workshop manual contains the main electromechanical checks, as well as the essential general
checks and the fitting of components supplied separately, designed to prepare the factory-new mo-
ped for delivery.
It is very important to adhere strictly to the instructions set out in the manual. Interventions carried
out superficially, or worse still, omitted entirely, may result in personal injury to the user, damage to
the machine, etc., or may simply result in disagreeable complaints.
N.B.: Rieju, S.A. reserves the right to make changes at any time, without prior notification.
For any enquiry, or for further complimentary information, please call the Rieju S.A. After-
sales Service.
MANUAL UPDATES
Updates will be sent within a reasonable period of time. Each new CD-Rom will update previous
information.
The contents list will be updated if the modifications and/or variations in the pages affect the ability
to consult the manual.
IMPORTANT! This series of workshop manuals should be considered as work instruments in the-
mselves and can only maintain their “value” over time if they are kept constantly up to date.

Introducción
7
Chassis
EN
G
LI
S
H
SYMBOLOGY USED IN THE MANUAL
CAUTION! Recommendations and precautions regarding rider safety and mo-
tor 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.
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

ENGLISH
Introducción
Chassis
8
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 follo-
wed by a number indicate a single screw . In case of different screws being
referred to in the illustration, the letter Tr 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.
F
Pr Tr
P
Ap
S
Es
T
Tr
Figure
Tightening torque
Page
Paragraph
Section
Diagram
Table
Screw
ABBREVIATIONS USED IN THE MANUAL

Introducción
9
Chassis
EN
G
LI
S
H
GENERAL WORK RULES
ADVICE:
F-1
•
•
•
•
•
•
•
•
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.
• 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.

ENGLISH
Introducción
Chassis
10
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 perfor-
med 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
•
•
•
•
•
•
•
•
•
•
•
•
•
RECOMMENDATIONS

Introducción
11
Chassis
EN
G
LI
S
H
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

Getting to know the motorbike

13
EN
GLISH
Getting to know the motorbike
Getting to know the motorbike

Getting to know the motorbike

Rieju chassis
15
Chassis
EN
G
LI
S
H
SPECIFICATIONS AND TECHNICAL CHARACTERISTICS
1ST SERVICE
1.000 KMS.
2ND SERVICE
3.000 KMS.
MAINTENANCE OPERATIONS SER. EVERY
5.000 KMS.
Brake system checking
Transmission oil level checking
Chain tension and wear inspection
Suspension control
Controls and cables checking adjustment and grease
Wheel spoke tension and wheel off-centre inspection
Air filter cleaning and grease
Carburettor checking and adjustment
Spark plug checking and adjustment or change
Screws and chassis nut control – plastics
Electrical system checking
Segments wear control
Radiator water level control
Exhaust system checking
Oil pump operation checking
·
Change
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
2050 mm.
790 mm.
1170 mm.
920 mm.
1332 mm.
358 mm.
Weight
Dry 93 kg.
Engine
Type
Transmission
Make
Cylinder arrangement
Cylinder capacity
Bore x stroke
Starting system type
Lubrication system
Oil type
2-stroke
6 speeds
Minarelli
Monocylindrical, forward-inclined cylinder
49,7 c.c.
40,3 x 39 mm.
Kick-starter and electric starter
Wet sump
CASTROL TTS injection 2-stroke oil
·
Change
·
·
·
·
·
·
·
·
·
·
·
·
·
MRX SMX
1970 mm.
790 mm.
1170 mm.
920 mm.
1332 mm.
358 mm.

ENGLISH
Rieju chassis
Chassis
16
Transmission oil
Type
Quantity
CASTROL MTX SAE 10W 40
820 c.c.
Air filter
Wet type foam rubber cartridge
Fuel
Type
Tank capacity
95 Unleaded petrol
8,4 L.
Carburettor
Dellorto PHBN 16 HS
Spark plug
Type
Electrode gap
NGK BR 9 ES
0,6 - 0,7 mm.
Clutch type
Wet, multiple-disc
Primary transmission
Clutch crown wheel
Drive pinion
Transmission ratio
Z = 71
Z = 20
1: 3,55
Secondary transmission
Engine output pinion
Drag plate
Transmission ratio
Chain
Z = 11
Z = 52
1: 4,36
420 x 126 steps
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
GEARCHANGE

Rieju chassis
17
Chassis
EN
G
LI
S
H
Suspension
Front
Rear
MRX / SMX
MRX / SMX
Inverted hydraulic fork
Ø 35 mm
CASTROL OIL FORK 15W 20, 245 cc per bar
Hydraulic damper
Suspension
Front
Rear
MRX PRO / SMX PRO
PAIOLI Inverted hydraulic fork
Ø 38 mm
CASTROL OIL FORK 10W, 325 cc per bar
Gas filled damper and spring preload adjustment
Brakes
Front
Rear
MRX / SMX
Disc Ø 260 mm
Disc Ø 200 mm
Tyres
Front
Rear
MRX / MRX PRO
80/90 - 21, con cámara, 1’7 kg/cm2
110/80 - 18, con cámara, 1’8 kg/cm2
Brakes
Front
Rear
MRX PRO / SMX PRO
Wave type Disc Ø 260 mm
Wave type Disc Ø 200 mm
Tyres
Front
Rear
SMX / SMX PRO
100/80 - 17, con cámara, 1’8 kg/cm2
130/70 - 17, con cámara, 1’9 kg/cm2
Electric equipment
Ignition system
Generator
Ignition advance
Electronic 12V 95W
Ducati
20º 1,4 mm before the P.M.S.
Bulb voltage and wattage
Headlight
Taillight
Dashboard
Turn signal lights
Odometer lighting
12V 35/35W
12V 21/5W
12V 1,2W
12V 10W
12V 1,2W

ENGLISH
Rieju chassis
Chassis
18
UNPACKING
• Unpack the motorcycle following the indications appearing on the same packaging, after
that it should be thrown according to current regulations.
“AESTHETIC” CONTROL
• Control visually that all the components of plastic material are correctly assembled and
that the motorcycle does not show any scratch, mark, etc.
IDENTIFICATION DATA
Engine identification number
• The data for identifying the engine (A/F -1) are on the right sump.
Vehicle identification number
• The identification number of the motorcycle (B/F -2) is stamped on the steering pipe. This
identification number is used to identify the moped.
F-1 F-2
B
A
F-3
C
C
SAFETY TAG
It contains the identification data of the motor-
cycle according to the 97/24/CE guidelines.
It is absolutely essential to indicate the identi-
fication data of the motorcycle when ordering
spare parts.
This tag should not be substituted either mo-
dified.
It is located in the left side of the chassis close
to the steering pipe.

Rieju chassis
19
Chassis
EN
G
LI
S
H
IDENTIFICATION OF THE MAIN PARTS
(Left side)
1. Headlight
2. Oil mixing tank
3. Battery (SMX)
4. Gear pedal
IDENTIFICATION OF THE MAIN PARTS
(Right side)
5. Radiator
6. Tool box
7. Fuel tank cap
8. Rear brake pedal
9. Passenger footrest
10. Number plate light and
plate holder
1
2
4
3
10
7
5
8
9
6
F-4
F-5