RIEJU Motor AM6 Workshop Manual Download Page 2

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Index

Engine

INTRODUCTION

NOTES FOR EASY CONSULTATION

GENERAL WORK PROCEDURES

ENGINE SERVICINGAND COMMISSIONING SCHEDULE

PARTS AND THEIR TORQUE WRENCH SETTINGS

EXPLODED VIEW OF THE ENGINE AM6 EURO2

Summary of Contents for Motor AM6

Page 1: ...E n g i n e w o r k s h o p m a n u a l ...

Page 2: ...RK 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 ...

Page 3: ......

Page 4: ...3 ENGLISH Introduction Introduction ...

Page 5: ...ommon 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 informatio...

Page 6: ... 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 MA...

Page 7: ... 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 L G F Pr Tr P Ap S Es T Tr Figure Tighteni...

Page 8: ...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 a...

Page 9: ...d 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 ...

Page 10: ...lean 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 ...

Page 11: ... 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 he...

Page 12: ...ny 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 remova...

Page 13: ......

Page 14: ...13 ENGLISH Engine RIEJU Engine RIEJU ...

Page 15: ... 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 GENERAL PURPOSE LUBRICANTS GENERAL PURPOSE LUBRICANTS ...

Page 16: ...n 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...

Page 17: ...r 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 th...

Page 18: ...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 ...

Page 19: ...l 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...

Page 20: ...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 ne...

Page 21: ...nents TOGETHER output shaft secondary shaft and remaining fork and raise F 26 paying attention to the shim washer un der the secondary shaft 28 REMOVE the equaliser countershaft pull the connecting rod from the crankcase on clutch side if necessary tap gently with a plastic or rubber mallet paying attention not to damage the thread N B as far as the clutch crankcase side is concerned the crankshaf...

Page 22: ...p in its seat and replace the O ring f Plug the oil delivery pipe 2 into the new pump g Plug the oil supply pipe 1 into the pump h Take the purge screw and gasket off the pump 5 and let the oil containing air bubbles leak out Wait until only oil is leaking out Purging can thus be considered accomplished You can now refit the screw in place I Reconnect the control cable 3 to the pump lever making s...

Page 23: ...isas sembly and this could adversely affect engine operation Always use the special plugs to ensure correct assembly of the oil seals A Secondary gear shaft oil seal Secondary gear shaft oil seal assembly plug B Connecting rod oil seal Connecting rod oil seal assembly plug clutch side Connecting rod oil seal assembly plug flywheel side C Clutch lever oil seal Clutch lever oil seal assembly plug D ...

Page 24: ...ting rod is perpendicular 3 MAKE SURE the transmission is in perfect working order and fit the shim washers in the right positions If you have replaced components make sure that they are put in the same positions as the parts removed and that the end float does not exceed 0 1 mm To obtain this condition measure the distance of the shim washers on the crankcase and com ponents and fill any gaps wit...

Page 25: ... the lubricated piston pin the surface of which must be in perfect condition Make sure that the piston pin can be fitted by manual pressure and that it does not yield under its own weight 8 CHECK the piston rings for faults of any type and make sure that the clearance between the two ends is within the values shown in the chart The checks must be carried out using a feeler gauge The piston ring mu...

Page 26: ...tification letters on the cylinder and piston The cylinder identification letter can be found on the flat surface of the oiler 10 WATER PUMP a Place the clutch crankcase right hand side on a flat surface b Fit the oil seal in the right direction as shown F 35 c Fit the impeller gasket dowels and water pump cover F 34 F 34 ENGINE TYPE MIN MAX PLAY AM6 50 WATER COLLED CAST IRON CYLINDER 0 049 0 062 ...

Page 27: ...them falling out 2 PREPARE the transmission assembly primary secondary keeping all components to gether F 36 Put a 0 6 mm shim washer under the 1st speed gear and position the fork in the 3rd and 4th primary gear F 36 LOWER the assembly thus formed into its seats F 37 Raise the 5th speed gear on the secondary shaft and insert the fork F 38 Fit the other fork 6th speed gear into its seat F 39 F 37 ...

Page 28: ... the fork guide pins into the desmodronic shaft F 41 Fit the fork guide rod into its seat F 42 Turn the desmodronic shaft until it reaches the position shown in the figure F 43 N B these operations must be effected without forcing with a hammer or other tools F 41 F 40 F 43 F 42 ...

Page 29: ...ankcase on flywheel side using the tool 1 F 46 keep the connecting rod at the T D C whilst tightening the screw until the connecting rod touches the bearings 7 FIT the dowel bolts 1 2 F 47 apply gasket paste on the mating sides of the crankcases F 47 and oil all shafts Place the crankcase flywheel side over the other crankcase and tap gently all over with a wooden leather or plastic mallet until t...

Page 30: ...needs to be replaced it is recommended to replace the pair since this will ensure smoother and quieter operation 13 FIT the crankshaft clutch side in the following order 1 The overturned oil seal 1 F 50 using the special plug 2 F 50 2 The O ring 1 F 51 3 The spacer 2 F 51 with the bevelled side facing the crankshaft Push in place until it stops Now fit the key 1 F 52 the countershaft drive gear 2 ...

Page 31: ...ing components on the output shaft in the order given clutch rod grea se beforehand ball and disc pusher 16 FIT the clutch disc assembly in the order shown in F 54 the iron discs 1 2 3 F 54 should be fitted with the notch highlighted by the arrows at 120 the one from the other starting from the notch facing upwards on the first disc Fit the last clutch disc making sure it is timed with the boss F ...

Page 32: ...he hole for fixing the spring is the same as before disassembly 90 F 57 20 FIT the starter assembly whilst hooking the spring to the hub on the cover 21 FIT the dowel bolts and a new gasket on the crankcase the clutch cover if necessary this operation can be made easier by turning the impeller of the water pump Secure in place with screws Cs 1 0 1 2 kg m If you have disassembled it refit the oil p...

Page 33: ...r the centre cylinder O ring in the stud bolts the O ring on the cylinder head the head clean beforehand Tig hten the nuts evenly and diametrically Cs 1 4 1 6 kg m check the position and tightness of the O ring on the cylinder head 24 FIT the reed valve F 60 followed by the exhaust manifold tightening the four screws evenly and diametrically Cs 0 9 1 1 kg m 25 REFIT the flywheel cover a new gasket...

Page 34: ...equipment Petrol ducts Oil ducts Front and rear brake liquid ducts Coolant duct Fuel heating duct Tire pressure Tire condition pressure and wear Level of front and rear brake liquid Level of coolant Level of battery electrolyte Screw tightness Battery charge level Replace Air filter filtering element Front and rear brake pads Gearbox oil Chain pinion gear wheel Clutch discs Spark plug Check and or...

Page 35: ... clutch Selector Magneto flywheel Magneto flywheel Spark plug Nut Pipe fitting Temperature probe Hex nut T C B screw T C C E screw T C C E screw T C C E screw T C B screw T C C E screw T C C E screw T C C E screw Stud bolt T C B screw T C C E screw Hex screw Neutral indicator light Hex screw T C C E screw T C C E screw Nut Hex screw T C C E screw Hex nut Clutch adj screw Hex nut Screw Hex nut 14 x...

Page 36: ...Engine Rieju 35 Engine ENGLISH ESPAÑOL 2 8 EXPLODEDVIEW OFTHE ENGINE AM6 EURO2 ...

Page 37: ...RIEJU S A c Borrassà 41 E 17600 FIGUERES GIRONA SPAIN Telf 34 972500850 Fax 34 972506950 www riejumoto com e mail rieju riejumoto com ...

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