MH Verkstadshandbok

SERVICE MANUAL
REF. OF PUBLICATION:
0634111000004
USE THIS SERVICE MANUAL WITH THE RELATED MANUALS INDICATED IN

THE FOREWORD TO THIS MANUAL
1A EDITION
2007-10
RYZ
IMPORTANT
Read this manual and follow the instructions carefully. Especially important information is indicated with the words WARNING,
CAUTION and N.B., which have quite precise meanings.
Pay special attention to the instructions that follow these titles.
WARNING:
Contains a potential danger that may cause injury or even
death.
CAUTION:
Contains a potential danger that may damage the machine.
N.B.:
Contains special information to aid maintenance or clarify
some point in the instructions.
WARNING:
This service manual has been prepared for authorised G.H.E.
ENGINEHISPA NIA, S.L. dealers, and should only be used
by qualied Technical Service department mechanics. Mechanics without experience or without the proper tools and equipment cannot carry out the service work described in this manual properly.
A bad repair may cause injury to the mechanic, and the machine may not be in a condition to ensure the safety of rider and
passengers.
RYZ
FOREWORD
This manual describes the procedures for the diagnosis, maintenance, adjustments, basic service work, changing of
parts and the dismantling and assembling of the main parts.
Model applicable: RYZ 50 CROSS (C) and RYZ 50 SUPERMOTARD (SM) with the following VIN numbers and later ones:
VTVDV0C00XXXXXXXX ~
VTVDV0CE2XXXXXXXX ~
VTVDV1CE2XXXXXXXX ~
This text is classied into sections, each of which has a section number, as can be seen in the Contents on the following page, and
on the rst page of every individual section there is a contents list for that section.
Keep this manual to hand so that it can be consulted quickly when carrying out service work.
The specied points must be carefully observed to ensure that the machine functions perfectly in accordance with the specication.
When changing parts or carrying out service work that involves dismantling, it is recommended to use genuine G.H.E. ENGINEHISPANIA, S.L. spare parts, tools and service materials, as specied in the corresponding descriptions.
All the information, gures and specications in this manual are based on the latest approved product information available at the
time of publication.
The main model used for the description throughout this manual is the model with basic specications. Therefore the gures may
appear slightly different from the model in the workshop. G.H.E.
ENGINEHISPANIA, S.L. reserves the right to make changes without prior warning.
RELATED MANUALS
TITLE OF THE MANUAL
MANUAL NO.
APPLICABILITY
RYZ50 SPARE PARTS CATALOGUE
0634111000001
Manual with all the spare parts for the RYZ50 model.
G.H.E. ENGINEHISPANIA, S.L.

DEPARTAMENTO DE SERVICIO
COPYRIGHT G.H.E. ENGINEHISPANIA, S.L. 2006
RYZ
NOTES:
RYZ
CONTENTS OF SECTION
SECTION
GENERAL INFORMATION
SPECIFICATIONS
MAINTENANCE
CHASSIS
ENGINE
ELECTRICAL SYSTEM
TROUBLESHOOTING
RYZ
NOTES:
RYZ
GENERAL INFORMATION 1-1
SECTION 1
GENERAL INFORMATION
CONTENTS
USING THIS MANUAL ................................................................................................................................................................... 1-2
IDENTIFICATION ........................................................................................................................................................................... 1-3
Machine identication .......................................................................................................................................................... 1-3
Engine identication ............................................................................................................................................................ 1-3
RYZ
1-1 GENERAL INFORMATION
USING THIS MANUAL

1) At the beginning of this manual there is a GENERAL CONTENTS LIST, enabling the SECTION containing the information needed for the service to be found quickly. In addition,
each section has its own contents list on its rst page with a
description of its main points.
2) In each section of this manual the page numbers start from the
beginning. The numbers appear at the top of the page together
with the name of the section.
3) This manual includes units of measurement in the international
system (SI).
4) The use of the SPECIAL TOOLS and of the TIGHTNESS TORQUE SPECIFICATIONS are indicated in bold type, as in the
following example:
2) Immobilise the clutch dog with the special tool.

Special tool (C)
3) Tighten the nut.
Tightness torque:
7.5 daNm (75 Nm)
4) Fold back the clutch nut tab washer.
5) Fit the clutch control lever with its spring and its washer.
RYZ
GENERAL INFORMATION 1-1
IDENTIFICATION
IDENTIFICATION OF THE MACHINE
1) The machine is marked with a plate (1), situated on the righthand side of the chassis. This plate has the VIN (VEHICLE
IDENTIFICATION NUMBER) engraved on it.
2) The VIN (VEHICLE IDENTIFICATION NUMBER) is engraved
on the right-hand chassis beam (2).
ENGINE IDENTIFICATION
The Engine Identication Number (1) is marked on the engine, on
the left-hand side of the machine.
RYZ
NOTES:
RYZ
SPECIFICATIONS 2-2
SECCION 2
SPECIFICATIONS
CONTENTS
GENERAL SPECIFICATIONS ........................................................................................................................................................ 2-2
ENGINE SPECIFICATIONS ............................................................................................................................................................ 2-2
CHASSIS SPECIFICATIONS ........................................................................................................................................................... 2-4
TIGHTENING TORQUES ................................................................................................................................................................ 2-5
RYZ
2-2 SPECIFICATIONS
GENERAL SPECIFICATIONS
SPECIFICATION
ELEMENT
RYZ TL
RYZ SM
RYZ UB
Model code
DIMENSIONS
Total length
RYZ TL: 2.095 mm

RYZ SM y UB: 1.980 mm
Total width
820 mm
Height without rear-view mirror
RYZ TL: 1.210 mm

RYZ SM: 1.170 mm
RYZ UB: 1.150 mm
Distance between axles
820 mm
WEIGHT
Weight empty
RYZ TL: 97 kg
RYZ SM: 98 kg
RYZ UB: 101 kg
Weight running
RYZ TL: 97 kg
RYZ SM: 98 kg
RYZ UB: 101 kg
Maximum permittable weight
255 kg
Top speed
45 km/h
ENGINE SPECIFICATIONS
ELEMENT
SPECIFICATION
ENGINE
Engine type
AM6.(EU.2)-liquid cooled 2-stroke
Make
Minarelli 50 cc
Cubic capacity
49,7 cm
Stroke x diameter
40,3 x 39 mm
Maximum power
1,4 Kw a 5.000 rev/min
Maximum torque
2.89 Nm a 4.000 rev/min
Volumetric compression ratio
12.0 0.1 : 1
FUEL
Recommended fuel
Only 95 octane lead-free petrol
Total capacity of fuel tank
6 litres 0.5
(including reserve)
RYZ
SPECIFICATIONS 2-2
ELEMENT
ESPECIFICACIN
LUBRICATION
Type
Separate lubrication by a variable rate piston pump, synchronised

with the throttle and driven by geared take-off from the crankshaft.
The oil is injected directly into the carburettor.
Recommended oil
Semi-synthetic Motul 510 2St special

anti-smoke two-stroke oil
Oil tank capacity
1.1 Litres
COOLING
Type
Circulation of water coolant by a pump driven by geared take-off

from the crankshaft.
Cooling circuit capacity
0,7 Litres
IGNITION
Type
CDI
Spark plug
NGK BR 9ES
CARBURETTOR
Make / Type
DELLORTO / PHBN 16
Idle rate
93050 rev/min
Initial position of air screw
1.5 turns
Needle
A8 3rd notch
Main jet
84
Idle jet
34
TRANSMISSION
Type
By sprocket and crown gear, with the gearbox and rear wheel
joined by a 126 link roller chain.
(12.7 pitch)
Primary transmission
20x71
Secondary transmission
11x52
Gearbox
6 speed
Gearbox capacity
0.75 litres Motul TRANSOIL (SAE 10W30)
Clutch
Multi-disk with oil bath and cable control
Magneto
Ducati 85 W
Starter motor
Ducati
RYZ
2-2 SPECIFICATIONS
CHASSIS SPECIFICATIONS
ELEMENT
SPECIFICATION
WHEELS
Front wheel
Front tyre
Front pressure
Rear wheel
Rear tyre
Rear pressure
RYZ TL: 1,85X21

RYZ SM: 2,5X17
RYZ UB: 1,85X16
RYZ TL: 90/90X21
RYZ SM: 100/80X17
RYZ UB: 90/90X16
RYZ TL: 1,9 1 bar
RYZ SM: 2.0 1bar
RYZ UB: 2.3 1 bar
RYZ TL: 2,5X18
RYZ SM: 3,5X17
RYZ UB: 2,5X16
RYZ TL: 120/80X18
RYZ SM: 130/70X17
RYZ UB: 120/80X16
RYZ TL: 2.1 1 bar
RYZ SM: 2.3 1 bar
RYZ UB: 2.7 1 bar
FRONT BRAKES
Type
Disk with hydraulic calliper
brake pistons
25 mm (2)
Disk
Disk thickness
RYZ TL: 200 mm; RYZ TOP TL: 220 mm

RYZ SM: 200 mm; RYZ TOP SM: 220 mm
RYZ UB: 220 mm; RYZ TOP UB: 220 mm
4 mm
main piston (cylinder)
12 mm
REAR BARKES
Type
Disk with hydraulic calliper
brake pistons
32 mm (2)
Disk
Disk thickness
RYZ TL: 240 mm; RYZ TOP TL: 260 mm

RYZ SM: 260 mm; RYZ TOP SM: 280 mm
RYZ UB: 260 mm; RYZ TOP UB: 280 mm
4 mm
main piston (cylinder)
12 mm
FRONT SUSPENSION
Type of suspension
Telescopic forks
Type of front forks
Hydraulic uid shock absorber
Forks capacity
0.3 litres per tube
Travel
230 mm
RYZ
SPECIFICATIONS 2-2
ELEMENT
SPECIFICATION
REAR SUSPENSION
Type of suspension
Variable exibility swinging arm, combined with a 44 mm central

single hydraulic shock absorber
Travel of central single hydraulic shock absorber
44 mm
STEERING
Type
Steering column mounted on ball bearings
RYZ
2-2 SPECIFICATIONS
TIGHTENING TORQUES
ELEMENT
TIGHTENING TORQUE
BODY
Side covers
0,1 daNm (1 Nm)
Front mudguard
0,1 daNm (1 Nm)
Rear mudguard
0,8/0,1 daNm (8/1 Nm)
Skirting
0,8/0,1 daNm (8/1 Nm)
CHASSIS
Front wheel shaft
4,5 daNm (45 Nm)
Rear wheel shaft
1,2 daNm (12 Nm)
Rear wheel shaft nut
6,5 daNm (65 Nm)
Suspension arm nut
6,5 daNm (65 Nm)
Chassis engine mounting
2,8 daNm (28 Nm)
Shock absorber top mounting
4,3 daNm (43 Nm)
Shock absorber top mounting
4,3 daNm (43 Nm)
Forks T-sections
1,5 daNm (15 Nm)
Front brake calliper
2,5 daNm (25 Nm)
Rear brake calliper
2,5 daNm (25 Nm)
Front brake disk
1 daNm (10 Nm)
Rear brake disk
1 daNm (10 Nm)
Support on chassis
1,9 daNm (19 Nm)
Steering lock
0,6 daNm (6 Nm)
ESTNDAR
5.mm diameter nut and bolt
0,5 daNm (5 Nm)
6 mm diameter nut and bolt
1 daNm (10 Nm)
2,2 daNm (22 Nm)
3,5 daNm (35 Nm)
5,5 daNm (55 Nm)
RYZ
MAINTENANCE AND COMMISSIONING 3-1
SECTION 3
MAINTENANCE AND COMMISSIONING

CONTENTS
INTRODUCTION............................................................................................................................................................................... 3-2
MAINTENANCE PLAN ................................................................................................................................................................. 3-2
Checking ............................................................................................................................................................................... 3-2
Renewing .............................................................................................................................................................................. 3-2
Checking and decarbonising ................................................................................................................................................. 3-3
Checking and greasing ......................................................................................................................................................... 3-3
Checking and adjusting ......................................................................................................................................................... 3-3
Cleaning and adjusting .......................................................................................................................................................... 3-3
COMMISSIONING............................................................................................................................................................................. 3-4
Battery preparation (except maintenance-free batteries) ...................................................................................................... 3-4
Checking levels ..................................................................................................................................................................... 3-4
Commissioning the fuel and oil circuits ................................................................................................................................ 3-4
Checks before delivery to customer ..................................................................................................................................... 3-5
TIGHTENING TORQUE SPECIFICATIONS ................................................................................................................................... 3-6
SERVICE MATERIALS REQUIRED ............................................................................................................................................... 3-6
RYZ
3-2 MAINTENANCE AND COMMISSIONING
INTRODUCTION
This section includes all the information needed to perform the recommended maintenance and commissioning operations. Observing these procedures will ensure the machine functions more reliably and has a longer useful life, while reducing the need for costly
repair work.
All maintenance technicians must be familiar with the whole of this section.
MAINTENANCE PLAN
Reinforced maintenance is designed for machines used in severe conditions: driver temperament, short journeys with a cold engine,
dusty regions or environments with a temperature higher than 30C.
3
CHECKING
MAINTENANCE OPERATIONS
500 KM
OR 3 MONTHS
REINFORCED MAINTENANCE
EVERY 3,000 KM
EVERY 6,000 KM
Every 1.500 km
Every 3.000 km
Adjusting idle speed
Throttle cable and oil pump
Front and rear brake cable
Functioning of the electrical equipment
Fuel circuit
Oil circuit
Front and rear brake uid piping
Coolant circuit
Carburettor heating circuit
Tyre pressures
X
X
Condition, pressure and wear of tyres

Front and rear brake uid level
Coolant level
Battery electrolyte level
Tightening nuts and bolts
EVERY 3.000 KM
EVERY 6.000 KM
Every 1.500 km
Every 3.000 km
Intake lter element
Front and rear brake pads (where appropriate)
Charging the battery
RENEWING
500 KM
OR 3 MONTHS
Gearbox oil
Chain sprocket- crown gear (where appropriate)
Clutch disks (where appropriate)
X
X
X
X
RYZ
CHECKING AND DECARBONISING

500 KM
OR MONTHS
EVERY 3.000 KM
EVERY 6.000 KM
Every 1.500 km
Every 3.000 km
Piston (1)
Every 10.000 km
Cylinder head (1)
Every 10.000 km
Exhaust port (1)
Every 10.000 km
(1) The need to decarbonise can be estimated by checking the quantity of carbonisation present in the cylinder exhaust outlet.
CHECKING AND GREASING

500 KM
OR MONTHS
EVERY 3.000 KM
EVERY 6.000 KM
Every 1.500 km
Every 3.000 km
500 KM
OR MONTHS
EVERY 3.000 KM
EVERY 6.000 KM
Every 1.500 km
Every 3.000 km
Chain tension and condition
CHECKING AND ADJUSTING

Clutch cable
Oil pump control
Spark plug
Tension of the wheel spokes
EVERY 3.000 KM
EVERY 6.000 KM
Every 1.500 km
Every 3.000 km
CHECKING AND ADJUSTING

Carburettor
500 KM
OR MONTHS
RYZ
COMMISSIONING
BATTERY PREPARATION (EXCEPT MAINTENANCE-FREE BATTERIES)
1) Remove the battery
2) Remove the six ller plugs and the air vent plug.
3) Replenish with electrolyte up to the

UPPER LEVEL mark.
Electrolyte:
(35% sulphuric acid = 1.28 g/cm)
4) Allow the battery to stand for approximately half an hour.
5) Top up if necessary.
6) Charge the battery for at least 2 hours at an intensity of 400 mA
(0.4 A).
7) Ret the battery and connect the vapour vent pipe.
8) Connect the red cable to the positive battery terminal and the black
cable to the negative battery terminal.
WARNING:
A continuacin, eventualmente se deber restablecer el
nivel de la batera despus de una carga completa, utilizando exclusivamente agua destilada.
CHECKING LEVELS
1) Check the gearbox oil level.
2) Check the coolant level.
3) Check the brake uid level.
COMMISSIONING THE FUEL AND OIL

CIRCUITS
1) Put 1 litre of unleaded petrol in the fuel tank. This should be 95 or
98 octane mixed with 3% Motul 510 semi-synthetic 2-stroke oil.
2) Put Motul 510 semi-synthetic 2-stroke oil in the oil tank.
Engine oil:
Motul 510 semi-synthetic 2-stroke oil
3) Start up the engine and disconnect the special tube entering

the carburettor to check that the oil is owing drop by drop (the
speed of the drops increases with the engine revs).
4) Complete the lling of the fuel tank with unleaded 95 or 98
octane petrol without oil mixture.
RYZ
CHECKS BEFORE DELIVERY TO CUSTOMER

1) Check the tightness of the wheel nuts.
Front wheel tightness torque:
4.5 daNm (5 Nm)
Rear wheel tightness torque:
6.5 daNm (75 Nm)
2) Check the tightness of all nuts and bolts.

3) Check the adjustment and effectiveness of the brakes.
4) Check the ination pressure of the tyres when cold.
Front tyre ination pressure:
RYZ SM: 2 bars (200 kPa)
RYZ C: 1.5 bars (150 kPa)
Rear tyre ination pressure:
RYZ SM: 2.3 bars (230 kPa)
RYZ C: 1.7 bars (170 kPa)
5) Check the functioning of the lights, the turn indicators, the horn
and the brake light.
6) Check the functioning of the different indicator lights.
7) Carry out a road test.
RYZ
TIGHTENING TORQUE SPECIFICATIONS

SECURING DEVICES
daNm
Nm
Front wheel shaft bolt
4,5
45
Rear wheel shaft nut
6,5
65
SERVICING MATERIALS REQUIRED
3
MATERIALS
RECOMMENDED MH PRODUCT
USE
Engine oil
Filling the engine oil tank
Electrolyte
35% sulphuric acid = 1.28 g/cm
Topping up the battery during maintenance
RYZ
CHASSIS 4-1
SECTION 4
CHASSIS
CONTENTS
SERVICING THE MACHINE .......................................................................................................................................................... 4-2
FRONT WHEEL .............................................................................................................................................................................. 4-2
Removal .............................................................................................................................................................................. 4-2
Assembly ............................................................................................................................................................................. 4-2
Operations that can be performed with the front wheel removed ....................................................................................... 4-2
FRONT BRAKES ........................................................................................................................................................................... 4-3
Dismantling the front brake calliper and brake pads .......................................................................................................... 4-3
FORKS ........................................................................................................................................................................................... 4-3
Removal .............................................................................................................................................................................. 4-4
Dismantling the fork tubes ................................................................................................................................................... 4-4
Sealing rings ....................................................................................................................................................................... 4-5
Removal .............................................................................................................................................................................. 4-5
Assembly ............................................................................................................................................................................. 4-6
REAR WHEELS ............................................................................................................................................................................ 4-7
Dismantling the rear brake calliper and brake pads ........................................................................................................... 4-7
Operations that can be performed with the rear wheel removed ........................................................................................ 4-8
TRANSMISSION CHAIN ............................................................................................................................................................... 4-8
Adjusting the chain tension ................................................................................................................................................. 4-8
SEAT ............................................................................................................................................................................................... 4-9
Removal .............................................................................................................................................................................. 4-9
FUEL TANK .................................................................................................................................................................................. 4-9
Removing the fuel tank or fuel tap ...................................................................................................................................... 4-9
SHOCK ABSORBER .....................................................................................................................................................................4-10
Removal ............................................................................................................................................................................. 4-10
AIR FILTER ................................................................................................................................................................................... 4-10
Removing the air lter sponge ............................................................................................................................................ 4-10
Removing the air lter box .................................................................................................................................................. 4-11
EXHAUST ...................................................................................................................................................................................... 4-11
Removal .............................................................................................................................................................................. 4-11
CARBURETTOR ............................................................................................................................................................................ 4-12
Removal .............................................................................................................................................................................. 4-12
Adjustment ........................................................................................................................................................................... 4-13
Dismantling the valves ........................................................................................................................................................ 4-13
CHASSIS ....................................................................................................................................................................................... 4-13
Removal .............................................................................................................................................................................. 4-13
Removing the frame ........................................................................................................................................................... 4-14
Assembly ............................................................................................................................................................................. 4-15
TIGHTENING TORQUE SPECIFICATIONS ..................................................................................................................................4-15
SERVICING MATERIALS REQUIRED ..........................................................................................................................................4-15
SPECIAL TOOLS .......................................................................................................................................................................... 4-15
RYZ
4-2 CHASSIS
SERVICING THE MACHINE

FRONT WHEEL
CAUTION:
Place the machine on a at surface.
Stand the machine on a suitable support, in such a way
that the front wheel is off the ground.
Do not activate the brake lever during the removal and
retting process.
REMOVAL
1) Unscrew the speedometer cable.

2) Unlock the two bolts on the wheel shaft clamp (1) (2) at the
front of the fork arm.
3) Remove the wheel shaft, the washer and the spacer.
4) Remove the wheel.
CAUTION:
Do not activate the brake lever, or as an alternative precaution place a wedge between the brake pads.
ASSEMBLY
1) Ret in the reverse order to removal, bearing the following points in mind:
Grease the wheel shaft, together with the speedometer takeoff, before retting the wheel.
Position the speedometer take-off in such a way that it does
not interfere with the cable (3).
Wheel shaft tightness torque:
4.5 daNm (5 Nm)
Wheel shaft clamp tightness torque:
1.2 daNm (12 Nm)
OPERATIONS THAT CAN BE PERFORMED WITH

THE FRONT WHEEL REMOVED
Changing the tyre or the inner tube.
N.B.:
Identify the roll direction of the tyre before removing it,
and refit in the same direction (Supermotard only).
RYZ
CHASSIS 4-3
Changing the brake disk.

N.B.:
In retting, respect the order of assembly: mark the outer
side and t the six self-locking bolts.
Changing the wheel bearings.
Changing the speedometer take-off.
FRONT BRAKE
N.B.:
The brake pads are identical; on dismantling without renewing, identify the tting direction and ret in the same
direction.
WARNING:
As a result of removing the wheel, the calliper or the
brake pads, and before performing a road test, check the
good functioning of the brake by applying the brake lever
various times.
DISMANTLING THE FRONT BRAKE CALLIPER

AND BRAKE PADS
1) Remove the two bolts (1) from the calliper on the fork arm.
2) Remove the pins (2).
3) Remove the brake pads (3) and the anti-vibration plates (4).
FORKS
CAUTION:
that the front wheel is off the ground.
Do not activate the brake lever during the dismantling
and retting process.
RYZ
4-4 CHASSIS
REMOVAL
1)
2)
3)
4)
5)
6)
7)
8)
9)
Remove the headlight housing assembly.

Remove the front mudguard.
Disconnect the headlight and the turn indicators.
Remove the two bolts from the brake calliper, and remove it
without disconnecting it.
Unscrew the speedometer cable from the speedometer takeoff.
Remove the guides from the exible hydraulic uid pipe and
the speedometer cable.
Remove the handlebars.
Remove the steering locknut (1).
Remove the two bolts (2) from the top T section.
10) Remove the forks top T section (3) with the instrument panel
and contact key switch.
11) Remove the front wheel.
12) Remove the steering bolt (4) with its washer (5).
13) Extract the forks bottom T section (6) and the two steering column arms (7) (the forks are tted a little tightly onto the steering arm bearings).
14) Remove the washer (8) on the bottom T section.
DISMANTLING THE FORK ARMS

N.B.:
If the arms are being dismantled to change the seals, loosen in order the securing bolts on the top T section and
the fork tube plugs.
1)
2)
3)
4)
5)

Disconnect the headlight and the turn indicators.
Remove the brake calliper without disconnecting it.
Unscrew the speedometer cable from its drive.
Remove the guides from the exible hydraulic uid pipe and
the speedometer cable.
6) Remove the front wheel.
7) Remove the six bolts (1) on the top and bottom T sections.
8) Remove the fork arms.
RYZ
CHASSIS 4-5
SEALING RINGS
REMOVAL
1) Remove the forks. See Dismantling the forks in this section.
2) Remove the fork tube plug (1).
3) Remove the spacer (2) and the spring (3).
4) Upturn the fork tube to empty the hydraulic uid into a container.
N.B.:
Slide the tube in and out of the fork arm several times to
empty out the uid.
5) Remove bolt (4) and its seal (5).

6) Withdraw the fork tube from the fork arm with the piston, the
end of compression cone and its washer.
7) Remove the dust guard (6), the circlip (7) and the seal (8) from
the forks arm.
RYZ
4-6 CHASSIS
ASSEMBLY
WARNING:
Check the condition of the fork tube: there should not be
any signs of corrosion or impacts, and should be perfectly straight and clean.
1) Fit a new seal (1), lightly lubricated, using a seal pusher.

2) Ret the seal circlip (2).
3) Insert the fork tube into the fork arm with the end of compression cone (3) and its washer (4), taking care not to bend over
the seal lip.
4) Fit a new seal and tighten the drain screw.
Drain screw tightness torque:
2.3 daNm (23 Nm)
5) Fit a new dust guard, lightly lubricated.

6) Pour in 0.3 litres of SAE 15 (Esso Univis N46) type hydraulic
uid into the fork tube.
Hydraulic uid for forks:
SAE 15 (Esso Univis N 6) type
7) Ret the spring (5) with the tighter coils upwards.

8) Ret the spacer (6).
9) Ret the fork tube plug (7).
Tube tightness torque:
2 daNm (20 Nm)
RYZ
CHASSIS 4-7
REAR WHEEL
CAUTION:
that the rear wheel is off the ground.
Do not activate the brake pedal during the dismantling
and retting process.
N.B.:
If the brake calliper is being renewed, the circuit will have
to be bled.
DISMANTLING THE REAR BRAKE CALLIPER AND

BRAKE PADS
1) Dismantle the rear wheel shaft, the chain tensioners (1)
and the spacers (2).
2) Remove the wheel without unhooking the chain.
N.B.:
The wheel needs to be removed to allow the brake calliper
to be extracted from its housing in the suspension arm.
3) Remove the pins (3).

4) Remove the brake pads.
N.B.:
The brake pads are identical; on removing without renewing, identify the tting direction and ret in the same
direction.
CAUTION:
As a result of removing the wheel, the calliper or the
brake pads, and before performing a road test, check the
good functioning of the brake by applying the brake pedal
various times.
RYZ
4-8 CHASSIS
OPERATIONS THAT CAN BE PERFORMED WITH

THE REAR WHEEL REMOVED
Changing the tyre, the inner tube or valve.
N.B.:
Identify the roll direction of the tyre before removing it,
and ret in the same direction (Supermotard only)
Changing the brake disk.
N.B.:
Ensure the correct tting direction for the disk, with the
marked part outwards. Fit the six self-locking bolts.
Changing the wheel bearings.
Changing the crown gear.
N.B.:
Fit the six normal self-locking bolts. If the crown gear is
to be reused, its turn direction must be noted before removing.
TRANSMISSION CHAIN
CAUTION:
The machine must be on its support, with the gearbox in
neutral.
ADJUSTING THE CHAIN TENSION

1) Unscrew the nuts (1) from the wheel shaft and the locknuts (2)
on the tensioner bolts.
2) Turn both tensioning bolts (3) the same amount to achieve a
movement of 25 mm in the chain.
Chain movement: 25 mm
3) Check the correct alignment of the chain between the gearbox
output sprocket and the rear crown wheel.
4) Retighten the nuts on the wheel shaft and the locknuts on the
tensioner bolts.
RYZ
CHASSIS 4-9
5) Check the chain tension.

CAUTION:
A chain that is too tight causes rapid wear of the gearbox
output shaft, the rear wheel bearings, the chain and the
sprockets.
SEAT
REMOVAL
1) Remove the plug (1) on the inside of the rear skirting.
2) Remove the seat nut through the hole in the rear skirting, and
pull the seat (2) backwards to separate it from the chassis.
3) Remove the seat.
FUEL TANK
REMOVING THE FUEL TANK OR FUEL TAP
1) Remove the seat see Removing the seat in this section.
2) Remove the bolts (1) from the radiator fairings.
3) Remove the bolts (2) from the fuel tank.
4) Lift up the tank to disconnect the fuel level indicator connector

(2), the fuel supply pipe (3) and the fuel tap vacuum outlet (4).
5) Remove the tank.
RYZ
4-10 CHASSIS
SHOCK ABSORBER
REMOVAL
CAUTION:
Stand the machine on blocks under the chassis to ensure
that the rear wheel is off the ground.

2) Remove the nut, the washer and the bottom securing shaft
3) from the shock absorber (1).
Remove the nut, the washer and the top securing shaft from
the shock absorber (2).
4) Remove the shock absorber from the right-hand side of the

machine by pulling it downwards.
AIR FILTER
REMOVING THE AIR FILTER SPONGE
1) Remove the left-hand side cover.
2) Remove the air lter cover (four screws) and its seal.
CAUTION:
The grilles are of a different size. Be sure to reposition
them correctly on retting.
3) Remove the sponge (1) and the two grilles (2).
RYZ
CHASSIS 4-11
REMOVING THE AIR FILTER BOX

2) Remove the side fairings.
3) Remove the shock absorber see Removing the shock absorber in this section.
4) Remove the two bottom securing bolts (1) on the skirting.
5) Remove the air intake connector (2) from the air lter box.
6) Remove the three securing bolts (3) from the air lter box.
7) Loosen the clamp on the hose from the air lter to the carburettor.
8) Remove the air lter box from the left-hand side of the machine.
4
EXHAUST
REMOVAL
N.B.:
The rear silencer can be removed on its own.
1) Remove the left-hand side fairing.

2) Unhook the two springs (1) from the exhaust pipe at the cylinder point.
3) Remove the securing bolt (2) on the exible support to the
chassis.
RYZ
4-12 CHASSIS
4) Remove the bottom securing bolt (3) on the rear silencer.

5) Unscrew the top securing bolt (4) on the rear silencer.
6) Separate the silencer from the exhaust pipe.
7) Remove the exhaust pipe.
CARBURETTOR
REMOVAL
2) Remove the fuel tank see Removing the fuel tank in this
section.
3) Disconnect the carburettor heating pipes (1).
CAUTION:
Plug the pipes to prevent coolant from spilling.
4)
5)
6)
7)
Remove the throttle cable (2).

Remove the bolt from the starter motor connector (3).
Remove the oil pipe (1).
Loosen the clamp on the inlet connection (5) with a 3 mm male
safety spanner.
Special tool 3 mm safety spanner
Ref. 25 0020001 8
8) Loosen the clamp on the air lter connection (6).

9) Free the carburettor from the inlet connection.
10) Remove the carburettor.
RYZ
CHASSIS 4-13
ADJUSTMENT
Idle: screw (7).
Mixture: screw (8).
DISMANTLING THE VALVES

1) Remove the carburettor see Removing the carburettor in
this section.
2) Remove the four bolts on the inlet connector, two of them (1)
using the 4mm male safety spanner.
Special tool 4 mm safety spanner
Ref. 25 0020001
3) Remove the connector and the inlet valve.
CHASSIS
REMOVAL
N.B.:
This method is only valid when changing the chassis. In
the event of a chassis change as a result of an accident, it
will be necessary to complete the repair method or change
the damaged elements.

2) Remove the fuel tank see Removing the fuel tank in this
section.
3) Remove the side covers.
4) Disconnect and remove the battery.
5) Disconnect the rear wiring and the rear brake light switch.
6) Remove the exhaust assembly.
7) Remove the rear brake uid reservoir and the master cylinder
without disconnecting it.
8) Loosen the clamp on the air lter hose.
9) Remove the top securing bolt on the shock absorber.
10) Remove the two rear chassis securing bolts on the main chassis.
11) Remove the rear chassis assembly.
12) Remove the chain.
RYZ
4-14 CHASSIS
13) Disconnect:
a) The neutral switch.
b) The yellow magneto output cable.
c) The starter connector.
d) The temperature sensor.
e) The ignition unit.
f) The earth cables on the ignition module.
g) The supply pipe on the oil pump.
h) The petrol and choke valves.
i) The oil pump cable.
j) The clutch cable.
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
Remove the bottom securing bolt on the radiator.

Loosen the top rear engine securing bolt.
Remove the bottom rear securing bolt.
Remove the three bolts on the two engine supports under the
engine.
Loosen the two side securing bolts on the front engine support
(without removing the nuts).
Loosen and remove the two front engine support securing bolts on the chassis front box section.
Push the support forwards.
Remove the engine assembly and radiator.
Remove the oil tank.
24) Disconnect:
a) the front headlight.
b) the instrument panel connection.
c) the steering lock connection.
d) the control unit connection.
e) the starter switch connection.
f) the brake light switch.
g) the throttle, starter, clutch and speedometer cables.
25) Remove the master cylinder from the front brake without disconnecting it.
26) Remove the handlebars.
27) Remove the top forks T section.
28) Remove the forks assembly and front wheel.
29) Remove the suspension arm assembly, the shock absorber,
brake calliper, brake cylinder and rear wheel.
30) Remove the chassis.
REMOVING THE FRAME

Remove:
a) the controls and cables.
b) the prop stand.
c) the rear brake pedal.
d) the main wiring.
e) the electrical components.
f) the steering bearings.
g) the locknuts.
RYZ
CHASSIS 4-15
ASSEMBLY
Carry out the assembly of the new chassis proceeding in the
reverse order.
N.B.:
Before assembling the new chassis, ensure that the VIN
number is engraved and the chassis plate afxed.

SECURING DEVICES
daNm
Nm
Front wheel shaft bolt
4,5
45
Front wheel shaft tightness torque:
1,2
12
Fork tube drain bolt
2,3
23
Fork tube plug
2,0
20

MATERIALS
Air lter oil
Forks hydraulic uid
USE
Motul Air Filter Oil
Adhesive oil for the air lter sponge
SAE 15 (Esso Univis N N46) type
Filling the front fork tubes
SPECIAL TOOLS
254002000198
Safety spanner (3 mm)
254002000199
Safety spanner (4 mm)
RYZ
NOTES:
RYZ
ENGINE 5-1
SECTION 5
ENGINE
CONTENTS
OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE WITHOUT REMOVING IT .................................................... 5-3
Removing the cylinder head ............................................................................................................................................... 5-3
Dismantling the cylinder-piston assembly ........................................................................................................................... 5-3
ENGINE ASSEMBLY ...................................................................................................................................................................... 5-4
Removal .............................................................................................................................................................................. 5-4
Installation............................................................................................................................................................................ 5-5
DISMANTLING THE ENGINE ........................................................................................................................................................ 5-6
Mounting the engine on its support ..................................................................................................................................... 5-6
Removing the magneto ....................................................................................................................................................... 5-6
Removing the armature ....................................................................................................................................................... 5-7
Removing the starter motor (where tted) ........................................................................................................................... 5-7
Removing the gearbox output sprocket ............................................................................................................................... 5-7
Removing the clutch cover .................................................................................................................................................. 5-8
Removing the clutch ............................................................................................................................................................ 5-8
Removing the crankshaft-connecting rod gears and balance shaft ..................................................................................... 5-10
Removing the connector and the inlet valve......................................................................................................................... 5-10
Removing the cylinder head/cylinder assembly .................................................................................................................. 5-11
Removing the piston ............................................................................................................................................................ 5-11
Removing the thermostat valve............................................................................................................................................ 5-11
Removing the temperature sensor ...................................................................................................................................... 5-11
Separating the engine crankcases ...................................................................................................................................... 5-12
Dismantling the gearbox and the selecting system ............................................................................................................. 5-13
Removing a primary or secondary drive shaft gear ............................................................................................................. 5-14
Removing the balance shaft ................................................................................................................................................ 5-15
Removing the crankshaft-connecting rod ............................................................................................................................ 5-15
Checking the crankshaft-connecting rod ............................................................................................................................. 5-15
FITTING SPECIFIC ELEMENTS IN THE ENGINE ........................................................................................................................ 5-17
Fitting the crankshaft-connecting rod bearings ................................................................................................................... 5-17
Fitting the output seal .......................................................................................................................................................... 5-18
Fitting the selector shaft output seal..................................................................................................................................... 5-18
Fitting the clutch lever output seal ....................................................................................................................................... 5-18
Fitting the balance shaft ...................................................................................................................................................... 5-18
Fitting the crankshaft-connecting rod .................................................................................................................................. 5-18
Fitting the gearbox ............................................................................................................................................................... 5-19
Fitting the left-hand half-crankcase ..................................................................................................................................... 5-20
Checking the piston ............................................................................................................................................................. 5-21
Checking the piston rings .................................................................................................................................................... 5-21
Feting the piston ................................................................................................................................................................ 5-22
Fitting the cylinder .............................................................................................................................................................. 5-22
Fitting the cylinder head ...................................................................................................................................................... 5-23
Fitting the right-hand seal .................................................................................................................................................... 5-23
Fitting the crankshaft-connecting rod gears and the balance shaft ..................................................................................... 5-24
Fitting the clutch .................................................................................................................................................................. 5-24
Adjusting the clutch control lever ......................................................................................................................................... 5-26
Fitting the kick-start system (where tted) and the clutch cover .......................................................................................... 5-26
Fitting the magneto .............................................................................................................................................................. 5-26
VARIOUS OPERATIONS ............................................................................................................................................................... 5-27
Removing the water pump .................................................................................................................................................. 5-27
Fitting the water pump ........................................................................................................................................................ 5-27
Dismantling the oil pump and its drive gears ....................................................................................................................... 5-28
Fitting the oil pump ............................................................................................................................................................. 5-28
RYZ
5-2 ENGINE
TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................................................5-29

SERVICING MATERIALS REQUIRED ...........................................................................................................................................5-29
SPECIAL TOOLS ........................................................................................................................................................................... 5-30
RYZ
ENGINE 5-3
OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE

N.B.:
The following operations do not require the engine to be removed.
REMOVING THE CYLINDER HEAD

1) Remove the seat see Removing the seat in Section
4 CHASSIS.
2) Remove the fuel tank see Removing the fuel tank in Section
4 CHASSIS.
3) Drain the cooling circuit (drain screw on the water pump).
4)
5)
6)
7)
8)
Remove the radiator/cylinder head pipe (1).

Disconnect the carburettor heating pipes (2).
Disconnect the temperature sensor.
Remove the suppressor.
Remove the spark plug.
N.B.:
To remove the cylinder head, see corresponding chapter
in this section.
DISMANTLING THE CYLINDER-PISTON ASSEMBLY

4 CHASSIS.
4 CHASSIS.
3) Remove the exhaust see Removing the exhaust in Section
4 CHASSIS.
4) Drain the cooling circuit (drain screw on the water pump).
5) Remove the radiator/cylinder head pipe.
6) Disconnect the carburettor heating pipes.
7) Remove the securing bolts from the front support on the chassis cradle.
RYZ
5-4 ENGINE
8) Unscrew the side securing bolts on the engine support.

9) Remove the engine securing bolt (1) and push the support
forwards.
N.B.:
To remove the cylinder head, the cylinder and the piston,
see corresponding chapter in this section.
ENGINE ASSEMBLY
REMOVAL
4 CHASSIS.
4 CHASSIS.
3) Remove the left-hand side fairing.
4) Disconnect the battery.
5) Drain the cooling circuit (drain screw [1] on the water pump).
6) Remove the chain guard (two bolts).
7) Remove the chain.
8) Remove the exhaust see Removing the exhaust in Section
4 CHASSIS.
9) Disconnect the oil supply and the oil pump control cable.
10) Remove the clutch cable.
11) Disconnect the starter motor, the neutral switch, the magneto
output wiring (the yellow cable and high-tension coil supply cables), the suppressor and the temperature sensor.
12) Disconnect the carburettor heating pipes.
13) Separate the carburettor from the air lter box and inlet connectors.
14) Disconnect the coolant pipes on the water pump and cylinder
head.
RYZ
ENGINE 5-5
15) Loosen the three engine securing points (2), without removing
the top rear securing nut.
16) Loosen the two securing points (3) on the chassis strengtheners (4).
17) Remove the front support securing shaft.
18) Lower the two chassis strengtheners.
19) Loosen the two side securing bolts (5) on the front engine support (without removing the nuts).
20) Loosen and remove the two front engine support securing bolts (6) on the chassis front box section.
21) Push the support forwards.
22) Remove the rear bottom securing shaft.

23) Unhook the engine from the top rear chassis pins (7) to remove it.
N.B.:
With the engine removed, see Section 5 ENGINE for details of operations to be performed on the engine.
INSTALLATION
1) Fit the shaft, the washers and the nut (1) on the engine top
rear mounting.
RYZ
5-6 ENGINE
2) Hang the engine on the top rear securing shaft (2).

3) Insert the engine securing shaft into the front support (3) and
the two chassis strengtheners (4).
4) Insert the rear bottom securing shaft (5).
DISMANTLING THE ENGINE
MOUNTING THE ENGINE ON ITS SUPPORT

1) Mount the engine on the engine support mounting.
Special tool (A)
3) Immobilise the motor on the mounting with two rubber pegs.

3) Mount the assembly onto the engine support while held in a
workbench clamp.
Special tool (B)
REMOVING THE MAGNETO

1)
2)
3)
4)
Remove the magneto cover.

Remove the paper gasket.
Immobilise the rotor (1) with a front pivot spanner (2).
Remove the nut.
N.B.:
Depending on the model, the rotor acts as a crown gear
for the starter motor.
RYZ
ENGINE 5-7
5) Screw the magneto extractor onto the rotor.

Special tool:
Ref. 2533002000198
6) Immobilise the magneto extractor and turn the pushing bolt until the rotor comes free.
REMOVING THE ARMATURE

1) Remove the three securing bolts (1) from the
stator plate and armature assembly (2).
2) Remove the stator plate and armature assembly.
N.B.:
Tap the bolts with a mallet and punch to help to free the
assembly.
WARNING:
The three bolts should be renewed with every removal.
REMOVING THE STARTER MOTOR (WHERE FITTED)

1) Remove the three securing bolts (1) from the starter motor.
2) Remove the two rubber pegs that immobilise the motor on its
mounting.
3) Move the engine on the mounting guides to allow the starter
motor to be removed.
4) Ret the two rubber pegs.
REMOVING THE GEARBOX OUTPUT SPROCKET

1) Remove the rubber ring (1) with a pair of pliers.
2) Remove the sprocket (2).
3) Remove the second rubber ring.
RYZ
5-8 ENGINE
REMOVING THE CLUTCH COVER

1) Remove the kick-start lever securing bolt (where tted).
2) Apply the kick-start lever slightly and hold it in position.
3) Loosen the stop (1) on the starter shaft and release the kickstart lever to slacken the spring.
4) Remove the kick-start lever.
N.B.:
Prepare a container to hold the oil from the gearbox.
5) Remove the bolt (2) to drain the gearbox.
6) Remove the eight cover securing bolts.

7) Remove the cover.
8) Remove the two centring pivots and the paper gasket.
REMOVING THE CLUTCH

1) Remove the four bolts and springs (1) from the pressure plate (2).
2) Remove the pressure plate.
RYZ
ENGINE 5-9
3) Remove the assembly (3) consisting of four friction disks and

three smooth disks.
4) Remove the primary shaft: the pusher (4), the ball (5) and the
push rod (6).
5) Remove the clutch control lever (7) with its spring (8) and its
washer (9).
5
6) Fold back the clutch nut (10) tab washer (11).
7) Immobilise the clutch dog (12) with the clutch immobilisation
tool.
Special tool (C)
8) Remove the nut and the washer.
9) Remove the clutch dog (12), the grooved spacer (13), the hood
(14), the at washer (15) and the tapered washer (16).
RYZ
5-10 ENGINE
REMOVING THE CRANKSHAFT-CONNECTING

ROD GEARS AND BALANCE SHAFT
1) Immobilise the balance shaft with a bolt (a) inserted in the
threaded perforations.
2) Turn the gear (1) on the balance shaft so that the bolt rests
against a crankcase rib.
3) Remove the crankshaft-connecting rod nut (2).
4) Remove the balance shaft nut (3).
5) Remove the two gears (20 and 30 tooth) and the key.
(4) from the crankshaft-connecting rod.
6) Remove the 34 tooth gear and the key (5) from the balance
shaft.
REMOVING THE INLET CONNECTOR AND VALVE

1) Remove the four bolts on the inlet connector, two of them (1)
using the safety spanner.
Special tool:
Ref. 254002000199
2) Remove the connector and the inlet valve.
3) Check the perfect condition of the valve assembly blades and

support.
WARNING:
The position of the stop must be 7 mm from the valve stop.
RYZ
ENGINE 5-11
REMOVING THE CYLINDER HEAD/CYLINDER ASSEMBLY

1) Remove the spark plug.
2) In the order indicated, loosen the four securing nuts on the
cylinder head/cylinder assembly in two or three steps
3) Remove the four nuts and washers.
4) Remove the cylinder head and the two O-rings.
5) Remove the cylinder and the cylinder gasket.
REMOVING THE PISTON

1)
2)
3)
4)
Remove one of the two circlips (1) with a pair of circlip pliers (2).
Remove the gudgeon pin.
Remove the piston.
Remove the needle bearing assembly from the end of the connecting rod.
REMOVING THE THERMOSTAT VALVE

1) Remove the two bolts (1) from the thermostat valve (2).
2) Remove the thermostat valve.
WARNING:
In retting, take care to position the breather hole (a) at the
highest point.
REMOVING THE TEMPERATURE SENSOR
WARNING:
There is a metal gasket to ensure the temperature
sensor (1) remains watertight.
RYZ
5-12 ENGINE
SEPARATING THE ENGINE CRANKCASES

1) Remove the three securing bolts on the left-hand crankcase.
2) Fit the protective bush onto the crankshaft-connecting rod.

Special tool (D)
3) Fit the crankcase opening tool supplied with the plate onto the
left-hand crankcase.
Special tool (E)

Special tool (F)
4) Fit the assembly onto the crankcase with the four bolts. (1).
5) Remove the two rubber engine support mounting pegs.
6) Turn the tools central bolt until the crankcases separate.
N.B.:
On opening, tap the ends of the secondary and selection
shafts alternately with a plastic mallet to ensure that the
two crankcase separate in parallel.
7) Remove the left-hand crankcase.

N.B.:
Recover the friction washers that may be stuck to the lefthand crankcase with oil.
8) Remove the centring rods (2).
9) Remove the two rubber engine support mounting pegs.
RYZ
ENGINE 5-13
DISMANTLING THE GEARBOX AND THE

SELECTION SYSTEM
1) Position the selector drum to guide the Mecanindus pin against
the secondary drive shaft selector fork shaft. .
2) Remove the selection shaft (1) tted with its two friction washers.
3) Remove the secondary drive shaft selector forks shaft (2).

4) Remove the top selector fork (3) from the secondary drive
shaft.
5) Turn the selector drum (4) to lower the selector fork (5) on the
primary drive shaft in the bottom slot of the drum.
6) Remove the selector drum.
7) Remove the second selector fork (6) from the secondary drive
shaft.
RYZ
5-14 ENGINE
8) Remove together the secondary drive shaft assembly

and the primary drive shaft tted with its selector fork.
9) Remove the friction washer (7) from the secondary drive shaft,
in the event of it being stuck with oil onto the right-hand crankcase.
10) Remove the locking ball (8) and its push spring.
REMOVING A GEAR FROM A PRIMARY OR SECONDARY DRIVE SHAFT

1) Remove the rubber rings and the gears with pliers.
2) On retting, take note of the position and the direction of tting
for every part:
1. Primary drive shaft with 1st speed gear.
2. 3rd speed and 4th speed gear.
3. 5th speed gear.
4. 2nd speed gear.
5. 6th speed gear.
6. Rubber ring.
7. Secondary drive shaft.

8. 1st speed gear.
9. 3rd speed gear.
10. 4th speed gear.
11. 6th speed gear.
12. 2nd speed gear.
13. 5th speed gear.
14. Rubber ring.
15. Friction washer.
RYZ
ENGINE 5-15
WARNING:
When renewing a gear, renew the corresponding gear on
the other drive shaft.
The rubber rings must be renewed after every dismantling.
REMOVING THE BALANCE SHAFT

1) Remove the balance shaft (1) using a plastic mallet if necessary.
5
REMOVING THE CRANKSHAFT-CONNECTING ROD
1) Remove the crankshaft-connecting rod (2) with its spacer (3)
and its O-ring (4) by lightly tapping its end with a plastic mallet,
if necessary.
N.B.:
The crankshaft-connecting rod is tted freely onto the right-hand crankcase bearing.
CHECKING THE CRANKSHAFT-CONNECTING ROD

1) Using a set of feeler gauges, check the side clearance of the
connecting rod big end.
2) The connecting rod big end side clearance must not exceed:
4/10 mm.
Maximum side clearance: 4/10 mm (0.4 mm).
RYZ
5-16 ENGINE
3) The eccentricity values measured at the ends of the crankshaft-connecting rod must not exceed 4/100 mm, and must be
measure at:
- 50 mm from the transmission side
- 50 mm from the magneto side
Maximum eccentricity: 4/100 mm (0.4 mm).
RYZ
ENGINE 5-17
FITTING SPECIFIC ELEMENTS IN THE ENGINE

FITTING THE CRANKSHAFT-CONNECTING ROD
BEARINGS
CAUTION:
The crankshaft-connecting rod bearings and seals must
be renewed after each opening of the engine crankcase.
N.B.:
On opening the crankcases, if the bearings remain fitted
to the crankshaft-connecting rod, use a bearing remover
(1).
N.B.:
If the bearing remains in the left-hand crankcase, the
crankcase must be heated up using a heat stripper to release it.
This operation should be performed quickly, to ensure that
the bearing is removed and refitted in the crankcase.
1) Turn one of the crankcases over onto its flat joint, heat it
up (to 80 to 90C) until the bearing falls out by itself.
2) Remove the seal.
3) While the crankcase is still hot and expanded, fit the new bearing fully into its housing.
4) Fit a new seal into the left-hand crankcase using the tool.
Special tool (G)
CAUTION:
The right-hand side seal must be tted after closing the
crankcases, tting the O-ring and the spacer, to prevent it
from turning over or damaging the seal rims.
RYZ
5-18 ENGINE
FITTING THE OUTPUT SEAL

1) Using the pusher tool, t the gearbox output seal.
Special tool (G)
FITTING THE SELECTOR SHAFT SEAL

1) Using the pusher tool, t the selector shaft seal.
Special tool (H)
FITTING THE CLUTCH LEVER SEAL

1) Using the pusher tool, t the clutch shaft seal.
Special tool (I)
FITTING THE BALANCE SHAFT

1) Fit the balance shaft (1) into the right-hand half of the crankcase, using a plastic mallet where necessary.

1) Fit the crankshaft-connecting rod (2) to the right-hand half of
the crankcase.
N.B.:
The crankshaft-connecting rod is tted freely onto the right-hand crankcase bearing.
RYZ
ENGINE 5-19
FITTING THE GEARBOX

1) Lightly grease and t the friction washer (1) onto the right-hand
crankcase secondary drive shaft needle bearing assembly.
2) Fit the push spring and t the locking ball (2) lightly greased into
its housing.
3) Fit together the secondary drive shaft assembly and the primary
drive shaft tted with its selector fork (3) into the right-hand half
of the crankcase.
4) Fit the curved fork (4) on the 5th speed gear onto the secondary
drive shaft.
5) Fitting the selector drum with its two washers.

6) Position the selector fork guide (3) in the intermediate slot of the
selector drum.
RYZ
5-20 ENGINE
7) Fit the selector fork (5) on the 6th speed gear.

8) Position the selector fork guide (4) in the lower slot of the selector drum.
9) Position the selector fork guide (5) in the upper slot of the selector drum.
10) Fit the selector forks shaft (6).

11) Position the selector drum in 4th speed; the Mecanindus pin is
aligned with the selector fork shaft.
12) Fit the selector shaft (7), tted with its two 5 friction washers.
FITTING THE LEFT-HAND HALF-CRANKCASE

1) Check that the friction washers are present on:
a) the secondary drive shaft (1).
b) the selector drum (2).
c) the selector shaft
2) Fit the centring rods (4).
3) Check that the right-hand crankcase joining surface is perfectly
clean.
4) Apply sealing paste to the right-hand crankcase joining surface.
5) Grease the ends of the shafts lightly.
6) Check that the left-hand crankcase joining surface is perfectly
clean.
7) Fit the left-hand half of the crankcase.
8) Screw the stud on the end of the crankshaft-connecting rod.
Special tool (J)
RYZ
ENGINE 5-21
9) Insert the support tool supplied with the plate on the stud
Special tool (E)
Special tool (F)
10) Centre the assembly on the crankcase with the four bolts. (5).
11) Fit the centring tool on the support tool.
Special tool (K)
12) Screw the stud nut down until the crankcases close completely
with the screw-plate (1).
13) Fit and tighten the thirteen securing bolts.

Securing tightness torque:
1,1 daNm (11 Nm)
N.B.:
Check that the crankshaft-connecting rod turns freely inside the crankcases.
14) Fit the gear lever without tightening it. Turn the primary drive
shaft manually and check that the gears turn smoothly.
15) Lubricate the crankshaft-connecting rod and the bearings lightly
with 2-stroke oil.
CHECKING THE PISTON

1) The pistol should not show signs of scratching or seizing.
2) The piston rings must move freely in their grooves.
CHECKING THE PISTON RINGS

1) Remove the piston rings carefully.
2) Fit one ring inside the cylinder bore parallel to the bore, and
with a feeler gauge, measure the ring gap clearance
Piston ring gap clearance: from 0.15 mm to 0.30 mm

Limit of use: 1 mm
RYZ
5-22 ENGINE
REFITTING THE PISTON

1) Fit the needle bearing assembly (1) in the connecting rod small
end, after lubricating it with 2-stroke oil.
2) Fit the piston on the connecting rod, with the front positioning
cams of the piston rings towards the intake side.
3) Fit the gudgeon pin.
4) Fit the circlips with a pair of circlip pliers.
CAUTION:
The circlips should be renewed with every removal.
CAUTION:
The circlip openings should face upwards or
downwards (2), but never sideways.
5
FITTING THE CYLINDER
1) Fit a new cylinder gasket (1) without oil or grease.
2) Ensure that the openings of the rings are facing
the piston positioning dogs.
3) Fit the cylinder (2) and insert it, while at the same time compressing the piston rings by hand.
4) Instert the cylinder into the piston compressing the piston rings
by hand.
RYZ
ENGINE 5-23
FITTING THE CYLINDER HEAD

1)
2)
3)
4)
Check that the O-ring housings are perfectly clean.

Fit new O-rings (1) on the cylinder head.
Fit the cylinder head onto the cylinder.
Tighten the 4 cylinder head securing nuts diagonally in 2 or 3
stages.
Cylinder head nuts tightness torque:

1.8 daNm (18 Nm)
5) Fit the spark plug.
Spark plug tightness torque:
2.5 daNm (25 Nm)
5
FITTING THE RIGHT HAND SEAL
1) Fit a new O-ring (1) and spacer (2) on the crankshaft-connecting rod.
2) Fit a new seal (3), with the lip facing outwards. Use the special
tool
Special tool (G)
RYZ
5-24 ENGINE

GEARS AND THE BALANCE SHAFT
1) Fit the key (1) into its housing on the crankshaft-connecting rod.
2) Fit the key (2) into its housing on the balance shaft.
3) Fit the crankshaft-connecting rod (3), with the marked tooth

facing outwards.
4) Fit the balance shaft gear (4), ensuring that the space between
the marked tooth with two points (a) coincides with the tooth
marked with one point (a) on the crankshaft-connecting rod
gear.
5) Fit the nut without tightening it.
6) Immobilise the balance shaft with a bolt (b) inserted in the
threaded perforations.
7) Turn the gear on the balance shaft so that the bolt rests against
a crankcase rib.
8) Tighten the nut (5) on the balance shaft.
Nut tightness torque:
6 daNm (60 Nm)
9) Fit the gear (6) with the spot-facing outwards and the nut (7).
10) Tighten the crankshaft-connecting rod gear.

7.5 daNm (75 Nm)
FITTING THE CLUTCH

1) Fit the primary drive shaft.
a) the tapered washer (1) with the dished side towards the
bearing.
b) the at washer (2).
c) the clutch bell housing (3). d) the ribbed spacer (4), e) the
clutch dog (5),
f) the nut tab washer (6) and the nut (7).
RYZ
ENGINE 5-25
2) Immobilise the clutch dog with the special tool.

Special tool (C)
3) Tighten the nut.
7.5 daNm (75 Nm)
4) Fold over the clutch nut tab washer.
5) Fit the clutch control lever with its spring and its washer.
6) Fit the pusher (8), the ball (9) and the push rod (10) onto the
primary drive shaft.
7) Fit the clutch disks beginning with a friction disk (11) and alternating smooth and friction disks (12).
8) While tting, ensure that the marks (a) on the smooth disks are
turned 120 one from the other.
9) Fit the pressure plate (13), ensuring that the arrow (b) on the
plate coincides with the round mark (c) on the clutch dog.
10) Fit the springs (14) on the pressure plate and the 4 bolts and
washers (5).
Bolts tightness torque:

0.5 daNm (5 Nm)
RYZ
5-26 ENGINE
ADJUSTING THE CLUTCH CONTROL LEVER

1) Loosen the pressure plate locknut (1).
2) Position the lever resting on the control rod.
3) Turn the central pressure plate bolt (2) to position the control
lever at 30 with respect to the sealing joint of the magneto
cover.
4) Tighten the locknut without altering the adjustment.
2.7 daNm (27 Nm)
FITTING THE KICK-START SYSTEM (WHERE FITTED) AND THE CLUTCH COVER
1) Fit the spring (1) onto the kick-start shaft.

2) Fit the kick-start attack gear (2), and the take-off ramp (a)in
alignment with the arm of the return spring (b).
3) Fit the kick-start shaft (3).
4) Fit the two centring rods and a new paper gasket.
5) Fit the clutch cover, turning the crankshaft-connecting rod manually if necessary, so that the water pump gear meshes with
the crankshaft-connecting rod gear.
6) Fit the eight cover securing bolts.

1.1 daNm (11 Nm)
7) Fit and apply the kick-start lever slightly and hold it in position.
8) Fit the starter shaft stop.

3 daNm (30 Nm)
9) Release the kick-start lever.
FITTING THE MAGNETO

1) Fit the armature assembly.
2) Fit and tighten the three securing bolts (1) on the armature assembly.
0.3 daNm (3 Nm)
RYZ
ENGINE 5-27
3) Fit the rotor (3) onto the crankshaft connecting rod, ensuring
that it is seated on the key.
4) Immobilise the rotor with a front pivot adjustable spanner (1).
5) Fit and tighten the rotor nut.
5.2 daNm (52 Nm)
6) Fit the gasket and the magneto cover.
0,4 daNm (4 Nm)
VARIOUS OPERATIONS
REMOVING THE WATER PUMP
1)
2)
3)
4)
5)
6)
Remove the eight clutch cover securing bolts.

Remove the clutch cover.
Remove the eight water pump cover securing bolts (1).
Remove the cover.
Remove the two centring pivots and the paper gasket. (2).
On the inside of the clutch cover, remove:
a) the rubber ring (3).
b) the washer (4).
c) the 30 tooth nylon gear (5).
d) the driving cotter pin (6).
e) the washer (7).
f) the turbine with its shaft (8).
g) the seal (9).
7) Check the condition of the turbine shaft. If there is evidence of

wear, renew the turbine.
FITTING THE WATER PUMP

1) Fit a new lightly greased seal (9), using the special tool.
Special tool (L)
2) Proceed in the reverse order to dismantling.
CAUTION:
The rubber ring and the paper gasket must be renewed
every time the unit is dismantled.
RYZ
5-28 ENGINE
DISMANTLING THE OIL PUMP AND ITS DRIVE

GEARS
1)
2)
3)
4)
5)
Remove the eight clutch cover securing bolts.

Remove the clutch cover.
Remove the oil pump cover.
Remove the two oil pump securing bolts.
Remove the pump (1) with its O-ring.
6) On the inside of the clutch cover, remove:

a) the two rubber rings (2).
b) the gear (3).
c) the driving cotter pin (4).

d) the washer (5).
e) the pump shaft and its washer (6).
f) the gear with its two washers (7).
7) Check the condition of the oil pump shaft. If there is evidence of
wear, renew the shaft.
FITTING THE OIL PUMP

1) Lubricate the two shafts.
2) Proceed in the reverse order to dismantling.
CAUTION:
The rubber rings and the O-ring must be renewed every
time the unit is dismantled.
RYZ
ENGINE 5-29

PARTS SECURED
daNm
Nm
Cylinder head
1,8
18
Crankcases
1,1
11
Transmission cover
1,1
11
Water pump
1,1
11
Inlet connector
1,1
11
Crankshaft-connecting rod gear
7,5
75
Balance shaft gear
6,60
Clutch bell housing
7,5
75
Clutch pressure plate
0,5
Clutch stop locknut
2,7
27
Starter motor
1,1
11
Rotor
5,2
52
Stator
0,3
Magneto cover
0,4
Gearbox drain plug
1,18
18
Spark plug
2,5
25

MATERIALS
Engine oil
Gearbox oil
USE
Filling the engine oil tank
Motul TRANSOIL (SAE 10W30)
Filling the gearbox
RYZ
5-30 ENGINE
SPECIAL TOOLS
2533002000198
Magneto extractor
254002000199
Valve assembly male safety
key (4 mm)
A
Engine support adaptation
B
Engine support
C
Clutch immobilisation tool
D
Large model protection bush
E
Crankcase opening and
extraction tool
F
Crankcase opening plate
G
Primary transmission side
crankshaft seal pusher
H
Selector shaft seal pusher.
I
Clutch lever lip seal pusher
J
Pin (10. length125)
K
Centring device with ange
L
Water pump lip seal pusher
N.B.:
All these tools are included in the engine maintenance kit (reference: 253002000193).
RYZ
ELECTRICAL SYSTEM 6-1
SECTION 6
ELECTRICAL SYSTEM
CONTENTS
SERVICING THE MACHINE........................................................................................................................................................... 6-2
REMOVING THE BATTERY ........................................................................................................................................................... 6-2
REMOVING THE STARTER MOTOR RELAY ............................................................................................................................... 6-2
REMOVING THE VOLTAGE REGULATOR/TURN INDICATOR CONTROLLER ......................................................................... 6-2
REMOVING THE IGNITION CONTROLLER ................................................................................................................................. 6-3
REMOVING THE MAGNETO ROTOR AND ARMATURE ............................................................................................................. 6-3
REMOVING THE NEUTRAL POSITION SWITCH ......................................................................................................................... 6-3
REMOVING THE STARTER MOTOR ............................................................................................................................................ 6-3
REMOVING THE DIODES ............................................................................................................................................................. 6-4
DIGITAL INSTRUMENT PANEL (WHERE FITTED) ...................................................................................................................... 6-5
USE ................................................................................................................................................................................................. 6-5
Button functions.................................................................................................................................................................... 6-5
Succession of the functions ................................................................................................................................................. 6-5
FUNCTIONS OF THE MAIN MENU................................................................................................................................................ 6-6
Current speed....................................................................................................................................................................... 6-6
Trip (TD) .............................................................................................................................................................................. 6-6
Automatic chronometer (LAP) ............................................................................................................................................. 6-6
Average speed (AVE) ......................................................................................................................................................... 6-7
Totaliser (TOD) ................................................................................................................................................................... 6-8
Rev-counter (RPM) .............................................................................................................................................................. 6-8
Battery voltage alarm............................................................................................................................................................ 6-8
Sleep mode.......................................................................................................................................................................... 6-9
CONFIGURATION........................................................................................................................................................................... 6-9
Altering the wheel circumference ........................................................................................................................................ 6-10
Altering the unit of measurement ........................................................................................................................................ 6-10
Altering the pulses per wheel turn ....................................................................................................................................... 6-11
Altering the pulses for every engine revolution .................................................................................................................... 6-11
STARTING THE SYSTEM UP......................................................................................................................................................... 6-12
FIRST INSTRUMENT PANEL INSTALLATION ............................................................................................................................. 6-12
ELECTRICAL CHARACTERISTICS............................................................................................................................................... 6-13
Maximum functioning characteristics ................................................................................................................................... 6-13
Functioning operating characteristics................................................................................................................................... 6-13
Connector conguration....................................................................................................................................................... 6-13
RYZ
6-2 ELECTRICAL SYSTEM
SERVICING THE MACHINE

REMOVING THE BATTERY
1) Remove the seat see Removing the seat in Section 4
(CHASSIS)
2) Disconnect and remove the battery.
WARNING:
First disconnect the negative cable and then the positive
cable.
REMOVING THE STARTER MOTOR RELAY

4 (CHASSIS)
WARNING:
cable.
4 CHASSIS.
4) Disconnect and remove the starter motor relay (1).
REMOVING THE VOLTAGE REGULATOR/TURN INDICATOR CONTROLLER

4 (CHASSIS)
WARNING:
cable.
4 CHASSIS.
4) Remove the two securing bolts.
5) Disconnect and remove the regulator (2).
N.B.:
The same device has two functions: voltage regulator and
turn indicator controller.
RYZ
REMOVING THE IGNITION CONTROLLER

1) Remove the right-hand radiator fairing.
2) Disconnect and remove the ignition block (3).
N.B.:
The ignition block has two functions, an ignition box and a
high tension coil.
REMOVING THE MAGNETO ROTOR AND

ARMATURE
1) Remove the ve cover securing bolts.
2) Remove the rotor (1).
N.B.:
For other operations on the magneto, see Section 5 (ENGINE).
Depending on the model, the rotor also acts as a starter
crown gear.
6
REMOVING THE NEUTRAL POSITION
SWITCH
1) Remove the chain guard (two bolts).
2) Disconnect the switch cable (1).
3) Remove the switch (2).
WARNING:
Tilt the machine over to prevent the oil from spilling from
the box.
REMOVING THE STARTER MOTOR

1) Remove the left-hand cover securing (ve bolts).
2) Remove the three securing bolts from the starter motor.
(two inside and one outside).
3) Disconnect the supply cable (1) from the starter motor (2).
4) Remove the starter motor.
RYZ
REMOVING THE DIODES

4 (CHASSIS)
WARNING:
cable.
4 (CHASSIS).
N.B.:
To access the diodes, the taping needs to be cut and an incision made in the main wiring protection conduit. The diodes
are protected by a plastic coating.
6
The function of the diodes is the following:
Polarity anti-inversion diode (1).
Turn indicator circuit anti-reverse diodes (2).
RYZ
DIGITAL INSTRUMENT PANEL

(WHERE FITTED)
USE
BUTTON FUNCTIONS
1) The button can be used to:
2) Move from one function to another.
Set the trip meter, chronometer and average velocity display
3) to zero.
Alter the wheel circumference value, the unit of measurement
and the number of pulses per wheel turn or engine revolution.
It is always possible to pass from one function to another, regardless

of the status of the machine in movement or halted. The only thing
required is to press the button briey (1 second),and on releasing it,
the new screen appears with the new function.
Zeroing of the trip meter, as well as adjusting the chronometer and
average speed display can be carried out with the machine either
halted or in motion, in accordance with the procedures described in
the following paragraphs.
The CONFIGURATION menu can only be accessed with the machine halted, by positioning in TOD function and holding the button
down for 5 seconds.
Data will only be memorised by leaving the conguration menu by
means of the mode button.
ASSOCIATED
FUNCTIONS
KEY
BUTTON
SPEED
OFF
ON
ON
>0
The conguration
menu cannot be
accessed
ON
ON
All the button

functions are enabled
Button inactive
SUCCESSION OF THE FUNCTIONS

It is always possible to pass from one function to another, either with
the machine halted or in motion, by using the button and in the following sequence:
TD
LAP
AVE
TOD
RPM
See the functions in the procedures described in the following paragraphs.
RYZ
FUNCTIONS OF THE MAIN MENU

CURRENT SPEED
The information is always displayed in large electronic digits (see
gure), regardless of the function selected or the alarm active.
The information is displayed on screen every 0.5 seconds.
Representation of the current speed data:
1) Representation in kph (original conguration): in this case, the
km/h logo will be displayed.
2) Representation in Mph (See Altering the unit of measurement
in CONFIGURATION): in this case no logo will be displayed.
TRIP (TD)
This is an automatic onboard partial totaliser.

This function is always displayed in small digits accompanied by
TD.
The data displayed indicates the distance travelled by the machine
expressed either in km or in miles (depending on the measurement unit selected), with a resolution of 0.1 (km or miles).
It is an automatic meter which is activated autonomously by the
rst pulse coming from the speed sensor.
The data is not memorised permanently.
The meter associated with this parameter can be zeroed by holding the button down (in relation toTOD function) for approx. 3
seconds, until the value 000.0 appears. Zeroing this meter also
zeroes the lAP and AVE functions.
If the data exceeds the 999.9 gure, the system returns the TD,
LAP and Ave to zero and begins to count again.
CAUTION:
When there is no current present, the TD value will be
irremediably lost.
AUTOMATIC CHRONOMETER (LAP)

This is the chronometer related to the TD and AVE.
The information is displayed in small digits and accompanied with
LAP.
The data represents the real time of the distance covered by the
machine associated with the TD parameter (in the mm:ss format if
the hour=0, and in the hh:mm format if the hour>0).
It is an automatic meter:
1) It is activated autonomously by the rst pulse coming from the
speed sensor.
2) When LAP is operative, the digit separating the hours from minutes or minutes from seconds is displayed ashing, whereas
it is unashing when LAP is not operative.
RYZ
3) 3) It stops 3 seconds after the reception of the last pulse from the
speed sensor.
The data is not memorised permanently. The meter can be zeroed by
holding down the button (in relation to the LAP function) for approximately 3 seconds, until the 0.0 value appears.
Zeroing this meter, either with the machine halted or in motion, also
causes the zeroing of the TD and AVE functions.
If the data exceeds the 23-59 value, the system returns the TD, LAP
and Ave to zero and begins to count again.
CAUTION:
When there is no current present, the LAP value will be
irremediably lost.
AVERAGE SPEED (AVE)

The information is displayed in small electronic digits, accompanied by AVE, which indicates the function selected.
The data represents the average speed maintained by the machine (expressed in km/h or in Mph, depending on the unit of measurement selected), calculated as the proportion between the distance travelled (represented by TD) and the time needed to travel the
distance (represented by LAP); the average speed is calculated
every 0.1 km (or 0.1 miles depending on the unit of measurement
selected) travelled by the machine.
The data is not memorised permanently.
The counter associated with this function can be zeroed by holding
the button down (in relation to the AVE function) for approx.
3 seconds, until the 0.0 value appears.
Zeroing this meter, either with the machine halted or in motion,
also causes the zeroing of the TD and LAP functions.
The AVE meter is also zeroed when LAP reaches the 23:59:59
value, or when TD reaches the 999.9 value.
If the data to be displayed exceeds the 409 value, the character
---- will be displayed.
CAUTION:
When there is no current present, the LAP value will be
irremediably lost.
RYZ
TOTALISER (TOD)
The information is displayed in small electronic digits, accompanied by TOD, as can be seen in the gure.
The data is memorised permanently in a non-volatile memory (updated with every kilometre travelled).
If no data appears registered in the memory, the number 00000
will be displayed.
The information is always calculated in km. However, it can be
expressed either in km or in miles. The conversion is possible by
accessing the conguration menu.
In normal use instrumentation conditions, it is not possible to zero
this information.
REV-COUNTER (RPM)
The information is displayed in small digits and accompanied by
an indication along the graphical bar and the inscription RPM
next to this.
The data is displayed in revolutions per minute.
The value is updated every 0.5 seconds.
The resolution is a constant 100 rpm over the whole scale.
Scale background value: 12,000 rpm.
The number of pulses for each engine revolution can be selected
by accessing the conguration menu.
The graphical bar, updated every 0.5 seconds, is interpreted in
accordance with the following table:
Sec.
Rpmx100
Rpmx100
(turns/min) illuminated (turns/min)
Sec.
illuminated
Rpmx100
(turns/min)
Sec.
illuminated
From 36 to 41
From 80 to 85
14
Up to 14
From 42 to 47
From 86 to 91
15
From 15 to 17
From 48 to 53
From 92 to 93
16
From 18 to 20
From 54 to 61
10
From 94 to 95
17
From 21 to 23
From 62 to 67
11
From 96 to 97
18
From 24 to 29
From 68 to 73
12
Over 97
18 and above
- excessive
From 30 to 35
From 74 to 79
13
BATTERY VOLTAGE ALARM

When the voltage value is lower than or equal to 12.0v, the system
activates the alarm.
The indication consists of ashing the battery symbol and displaying the inscription MIN (regardless of the function being displayed).
This alarm does not affect the normal functioning of the instrument
panel.
The state of alarm ceases when the voltage returns to 12.5v.Thus,
the entire sequence is repeated every time the voltage is lower
than or equal to 12.0v, and is interrupted every time the voltage is
greater than 12.5v.
RYZ
SLEEP MODE
Every time the key switch is turned to the OFF position,
the following operations take place:
1) The screen and its lighting are switched off.
2) All the indicator lights that were on are turned off.
3) Entry into sleep phase, characterised by a low current consumption, in which the system interrupts every activity.
CONFIGURATION
The conguration menu can only be accessed with the machine
halted.
Holding the mode button down for approximately 5 seconds accesses the TOD function, and the conguration menu is displayed.
This menu allows the user to alter the following parameters:
1) the circumference of the wheel (minimum 1,000 mm, maximum 2,500 mm).
2) Unit of measurement (Km/h or Mph).
3) Number of pulses coming from the speed sensor for each turn
of the wheel (minimum 1, maximum 12).
4) Number of pulses for each engine revolution (minimum 1,
maximum 6).
To ensure that the alterations made in the conguration menu are

consolidated, the user needs to run through the entire sequence of
screens envisaged in this menu, making sure to exit the conguration menu (and re-establishing the standard operating mode). To
re-establish the standard operating mode, keep the mode button
held down in the last screen, regarding the number of pulses per
engine revolution (which is the last menu conguration screen),
until the apparatus returns to the standard operating mode.
If the conguration menu is exited by:

1) putting the machine in motion,
2) turning the ignition key,
3) or not holding the button down for 20 seconds, the alterations
made will not be registered and the system will return to the
preceding values.
CAUTION:
The system will only permanently save the changes made
when the conguration procedure is carried out correctly.
RYZ
ALTERING THE WHEEL CIRCUMFERENCE

Once inside the conguration menu, the rst parameter that can
be altered is the wheel circumference.
The screen displays the only information seen, which is the circumference of the wheel, whereas all the other segments are off.
The different gures that make up the wheel circumference value
can be altered, starting with the most signicant gure and moving
successively to the least signicant.
Depending on the detail selected (which will be displayed ashing),
a brief press of the button will cause the gure to rise by one unit,
while a longer press will enable changing to another gure.
The information regarding the wheel circumference selected is
stored in memory.
CAUTION:
Regulating interval: from 1,000 mm to 2,500 mm with
intervals of 1 mm.
Once the regulating menu has been accessed:
- if 20 seconds go past without the button being pressed, or
- if the machine is started up, or
- if the key switch is turned to the OFF position, the system will automatically return to standard operating mode,
and the changes made will be lost.
ALTERING THE UNIT OF MEASUREMENT

Once the wheel circumference regulating has been completed, it
is possible to alter the unit of measurement by pressing the button
for approximately 3 seconds.
Once the least signicant gure has been altered: at this point the
two inscriptions km/h and
Mph will appear on the screen, and at the outset the selected
value will ash.
The procedure for changing the unit is identical to that described
in the previous section.
The information regarding the unit of measurement is stored in
memory.
CAUTION:
intervals of 1 mm.
RYZ
ALTERING THE PULSES PER WHEEL TURN

Once the unit of measurement has been selected ( it appears ashing), press the mode button for 3 seconds. It will then be possible
to alter the number of pulses for the wheel.
This parameter expresses the number of pulses which the electronic sensor sends to the instrument panel for every turn of the
wheel.
This information is stored in memory.
CAUTION:
intervals of 1 mm.
ALTERING THE IMPULSES FOR EVERY ENGINE

REVOLUTION
Once the alteration made in the previous screen is completed, the
button must be held down for 3 seconds, and then it will be possible to alter the number of pulses for every engine revolution.
This parameter expresses the number of pulses for each revolution of the engines primary drive shaft that the machine is able to
send to the instrument panel.
This screen can be distinguished from the previous one by having
the logo RPM.
This information is stored in memory.
CAUTION:
intervals of 1 mm.
RYZ
STARTING THE SYSTEM

On switching on (key from OFF to ON), the system provides the
user with a series of data, which, in order to simplify things, are
shown on different screens in the form of pages:
1) First page: software version and date. This information only
appears during the rst instrument panel installation.
2) 2) Second page: glass check; all the glass segments remain lit
up for 3 seconds.
3) Third page: wheel circumference, measurement unit (only in
the case of km/h), number of pulses for each turn of the wheel
and number of pulses for each engine revolution (see gure).
4) At the same time as displaying the aforementioned screens,
the system also checks the indicator lights
and the glass backlighting: all the indicator lights come on and
then go off at the end of the screen check.
5) Once all of this has been completed, the system displays normal view.
6
FIRST INSTRUMENT PANEL INSTALLATION
The values that the instrument panel has registered by default
are:
1) Wheel circumference: 2,205 mm.
2) Unit of measurement: km/h for speed and km for distance.
3) Pulses per turn of the wheel: 1.
4) Pulses per engine revolution: 1.
To alter any of these parameters it is necessary to follow the
steps described in the CONFIGURATION part of this section.
N.B.:
During the rst instrument panel installation, the version
and date of the software incorporated always appear on the
screen.
RYZ
ELECTRICAL CHARACTERISTICS
MAXIMUM FUNCTIONING CHARACTERISTICS
CHARACTERISTICS
Min.
Max.
Unit
17
-20
+85
Maximum current internal
20
mA
Maximum input current
20
mA
Maximum output current
20
mA
Max. operating temperature

Storage temperature
CARACTERISTICAS OPERATIVAS DE FUNCIONAMIENTO

CHARACTERISTICS
Min.
Typ.
Max.
Unit
6,0(1)
12
16,0
-20
+80
Abs. current will all the indicator

lights on (Vbat=13.0V)
259,1
280
mA
Abs. current will all the indicator

lights off (Vbat=13.0V)
105,1
110
mA
Abs. current in sleep

(Vbat=13.0V)
0,36
mA
Supply voltage
Operating temperature
(1) Minimum value of the voltage applicable to the input that

does not jeopardise the correct functioning of the instrument
panel. In this value, the optoelectronic part (indicator lights and
backlighting) are turned off.
CONNECTOR CONFIGURATION
POS.
Terminal insertion side view.
MEANING
POS.
MEANING
Turn indicators
10
Water sensor
Turn indicators
11
Sub-key/under key
Neutral
12
RPM
Main beam
13
GND
NC
14
Battery positive
Button
15
GND sensor
NC
16
Vcc sensor
Oil
17
NC
Fuel
18
NC
RYZ
NOTES:
RYZ
TROUBLESHOOTING 7-1
SECTION 7
TROUBLESHOOTING
CONTENTS
INTRODUCTION............................................................................................................................................................................ 7-2
FAILURE TO START ................................................................................................................................................................... 7-2
Engine ................................................................................................................................................................................ 7-2
Fuel system ....................................................................................................................................................................... 7-2
Electrical systems ............................................................................................................................................................... 7-2
INCORRECT IDLING .................................................................................................................................................................... 7-3
Engine................................................................................................................................................................................. 7-3
Fuel system ....................................................................................................................................................................... 7-3
FAULTY GEAR-CHANGE ............................................................................................................................................................. 7-3
Difculty changing gear....................................................................................................................................................... 7-3
The gear pedal does not move............................................................................................................................................ 7-3
The gears jump.................................................................................................................................................................... 7-4
FAULTY CLUTCH .......................................................................................................................................................................... 7-4
The clutch slips.................................................................................................................................................................... 7-4
The clutch drags.................................................................................................................................................................. 7-4
OVERHEATING.............................................................................................................................................................................. 7-4
Engine ................................................................................................................................................................................ 7-4
Cooling system.................................................................................................................................................................... 7-4
Chassis................................................................................................................................................................................ 7-5
POOR BRAKING............................................................................................................................................................................ 7-5
FAULTY FRONT FORK ARMS ..................................................................................................................................................... 7-5
Leaking oil........................................................................................................................................................................... 7-5
Incorrect functioning............................................................................................................................................................ 7-5
UNSTABLE HANDLING................................................................................................................................................................. 7-5
FAULTY LIGHTS OR TURN INDICATOR SYSTEM ..................................................................................................................... 7-6
The headlight does not come on ........................................................................................................................................ 7-6
Blown headlight bulb........................................................................................................................................................... 7-6
The rear light / Brake light does not come on...................................................................................................................... 7-6
Blown rear light bulb / Brake light bulb................................................................................................................................ 7-7
The turn indicators do not come on..................................................................................................................................... 7-7
The turn indicators ash slowly............................................................................................................................................ 7-7
The turn indicators ash rapidly........................................................................................................................................... 7-7
The horn does not sound ................................................................................................................................................... 7-7
RYZ
7-2 TROUBLESHOOTING
INTRODUCTION
N.B.:
The following troubleshooting guide does not cover all the possible causes of faults. It may however prove useful as a
guide for basic fault nding.
Use this manual to consult the corresponding checking, adjusting and part renewal procedures.
FAILURE TO START
ENGINE
Loose spark plug.

Loose cylinder head or cylinder.
Damaged cylinder head gasket.
Damaged cylinder gasket.
Cylinder worn or damaged.
Incorrect valve clearance.
Seized valve.
Wrongly fitted piston ring.
Damaged, worn or fatigued piston ring.
Seized piston ring.
Seized or damaged piston.
Air filter incorrectly fitted.
Air filter element obstructed.
Crankcase fitted incorrectly.
Seized crankshaft.
FUEL SYSTEM
Fuel tank empty.

Fuel tank drain pipe blocked.
Altered or contaminated fuel.
Carburettor air suction blocked.
ELECTRICAL SYSTEMS
Flat battery.
Faulty battery.
Fuse blown, damaged or incorrect.
Fuse fitted incorrectly.
Incorrect spark plug gap.
Oiled-up spark plug.
Electrode worn or damaged.
Insulation worn or damaged.
Faulty spark plug cap.
Primary or secondary coils broken or short-circuited.
Faulty spark plug cable.
Faulty main switch.
Faulty engine stop switch.
Broken or short-circuited wiring.
Faulty neutral light switch.
Faulty starter switch.
Loose connections.
Faulty starter motor.
RYZ
TROUBLESHOOTING 7-3
INCORRECT IDLING
ENGINE
Incorrect valve clearance.
Air filter element obstructed.
FUEL SYSTEM
Incorrectly adjusted engine idling.

Incorrect throttle cable clearance.
Flooded throttle body.
Faulty air intake system.
ELECTRICAL SYSTEMS
Flat battery.
Faulty battery.
Fuse blown, damaged or incorrect.
Fuse fitted incorrectly.
Incorrect spark plug gap.
Oiled-up spark plug.
Electrode worn or damaged.
Insulation worn or damaged.
Faulty spark plug cap.
Primary or secondary coils broken or short-circuited.
Faulty spark plug cable.
7
FAULTY GEAR-CHANGE
DIFFICULTY CHANGING GEAR
See The clutch is dragging in this section.
THE GEAR PEDAL DOES NOT MOVE
Bent gear-change shaft.

Foreign object in the selection drum slot.
Seized gear change fork.
Bent gear-change fork guide bar.
Seized gearbox gearing.
Foreign object between the gearbox gears.
Incorrectly fitted gearbox.
RYZ
7-4 TROUBLESHOOTING
THE GEARS JUMP
Incorrect gear change pedal position.

Incorrect stop lever return.
Worn gear selector fork.
Worn selection drum slot.
Worn gear securing device.
FAULTY CLUTCH
THE CLUTCH SLIPS
Clutch incorrectly fitted.

Clutch cable incorrectly adjusted.
Loose or fatigued clutch spring.
Worn friction plate.
Worn clutch plate.
Incorrect oil level.
Incorrect oil viscosity (low).
Oil altered.
THE CLUTCH DRAGS
Uneven clutch spring tension.

Bent pressure plate.
Bent clutch plate.
Distorted friction plate.
Bent clutch push bar.
Broken clutch lobe.
Marks not aligned.
Incorrect oil level.
Incorrect oil viscosity (high).
Oil altered.
OVERHEATING
ENGINE
Coolant passages blocked.

Large accumulation of carbon deposits.
Incorrect oil level
Incorrect oil viscosity.
Inferior oil quality.
COOLING SYSTEM
Low coolant level.
Radiator damaged or leaking.
Defective radiator cap.
RYZ
TROUBLESHOOTING 7-5
Radiator fins bent or damaged.

Water pump damaged or failed.
Pipe connected incorrectly.
Damaged piping.
CHASSIS
Brakes activated.
ELECTRICAL SYSTEMS
Incorrect spark plug electrode gap.
POOR BRAKING
Worn brake pad.

Worn brake pad.
Air in the hydraulic brake system.
Leaking brake fluid.
Damaged brake calliper seal.
Damaged brake pipe.
Oil or grease on the brake disk.
Oil or grease on the brake pad.
Incorrect brake fluid level.
7
DAMAGED FRONT FORK ARMS
LEAKING HYDRAULIC FLUID
Inner tube bent, damaged or rusted.

Outer tube cracked or damaged.
Oil seal fitted incorrectly
Damaged oil seal lip.
Incorrect fluid level (high).
Loose shock absorber bar assembly bolt.
Damaged shock absorber bar assembly copper washer.
INCORRECT FUNCTIONING
Inner tube bent or damaged.

Outer tube bent or damaged.
Damaged forks spring.
Outer tube hose worn or damaged.
Shock absorber bar bent or damaged.
Incorrect fluid viscosity.
Incorrect fluid level.
RYZ
7-6 TROUBLESHOOTING
UNSTABLE HANDLING
Handlebars bent or incorrectly fitted.

Top support incorrectly fitted.
Bottom support fitted incorrectly (badly tightened lock nut).
Bent steering shaft.
Damaged ball bearings or bearing guide ring.
Uneven fluid levels (in the two front fork arms).
Uneven fork spring tension (in the two front fork arms).
Broken fork spring.
Inner tube bent or damaged.
Outer tube bent or damaged.
Worn bearing or hose.
Swinging arm bent or damaged.
Faulty rear shock absorber spring.
Oil or petrol leak.
Uneven tire pressures (front and rear).
Incorrect tyre pressure.
Uneven tyre wear.
Incorrect wheel balancing.
Broken or loose spokes.
Damaged wheel bearing.
Bent or loose wheel shaft.
Excessive decentring of the wheel.
Bent frame.
Damaged steering column tube.
Incorrectly tted bearing guide ring.
FAULTY LIGHTING SYSTEM OR TURN INDICATORS

HEADLIGHT DOES NOT COME ON
Incorrect headlight bulb.

Too many electrical accessories.
Excessive load.
Incorrect connection.
Circuit incorrectly connected to earth.
Faulty contacts (main switch).
Blown headlight bulb.
BLOWN HEADLIGHT BULB

Incorrect headlight bulb.
Battery faulty.
Headlight bulb has reached end of life.
REAR LIGHT/BRAKE LIGHT DOES NOT COME ON
Incorrect rear light/brake light bulb.

Too many electrical accessories.
Blown rear light/brake light bulb.
RYZ
TROUBLESHOOTING 7-7
BLOWN REAR LIGHT/BRAKE LIGHT BULB
Incorrect rear light/brake light bulb.

Battery faulty.
Incorrectly adjusted rear brake light switch.
Rear light/brake light bulb reached end of life.
TURN INDICATORS DO NOT COME ON
Faulty turn indicator switch.

Blown turn indicator bulb.
Damaged or faulty wiring loom.
Battery faulty.
Fuse blown damaged or incorrect.
TURN INDICATORS FLASH SLOWLY

Faulty turn indicator switch.
Incorrect turn indicator bulb.
TURN INDICATORS FLASH QUICKLY

Incorrect turn indicator bulb.
Blown turn indicator bulb.
HORN DOES NOT SOUND
Horn incorrectly adjusted.

Horn damaged or faulty.
Faulty horn switch.
Battery faulty.
Faulty wiring loom.
RYZ
NOTES:
G.H.E. ENGINEHISPANIA, S.L. RYZ 50 SERVICE MANUAL

1st Edition
Published November, 2006
2006 G.H.E. ENGINEHISPANIA, S.L. All rights reserved.

No part of this publication may be reproduced or transmitted in any form, nor by any electronic or mechanical means for any use whatsoever, without the written authorisation of
ENGINEHISPANIA, S.L.
G.H.E. ENGINEHISPANIA, S.L.

Service Department
Parque Sevilla Industrial-Calle 3
41016 Seville, Spain
Tel.: +34 954 475 687
Fax: +34 954 409 122
Traduction: www.ciandisseny.com
Reproduction of this material is prohibited
PUBLICATION REF:
0634111000004
* 06 34 111 0 0 0 0 0 2 *
1st EDITION
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2007-10

MH Verkstadshandbok

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SERVICE MANUAL

USE THIS SERVICE MANUAL WITH THE RELATED MANUALS INDICATED IN

TITLE OF THE MANUAL

RYZ50 SPARE PARTS CATALOGUE

G.H.E. ENGINEHISPANIA, S.L.

COPYRIGHT G.H.E. ENGINEHISPANIA, S.L. 2006

USING THIS MANUAL

2) Immobilise the clutch dog with the special tool.

RYZ TL: 2.095 mm

Height without rear-view mirror

RYZ TL: 1.210 mm

Distance between axles

Maximum permittable weight

AM6.(EU.2)-liquid cooled 2-stroke

1,4 Kw a 5.000 rev/min

2.89 Nm a 4.000 rev/min

Volumetric compression ratio

Only 95 octane lead-free petrol

Total capacity of fuel tank

Separate lubrication by a variable rate piston pump, synchronised

Semi-synthetic Motul 510 2St special

Oil tank capacity

Circulation of water coolant by a pump driven by geared take-off

Cooling circuit capacity

Initial position of air screw

0.75 litres Motul TRANSOIL (SAE 10W30)

Multi-disk with oil bath and cable control

RYZ TL: 1,85X21

Disk with hydraulic calliper

RYZ TL: 200 mm; RYZ TOP TL: 220 mm

main piston (cylinder)

Disk with hydraulic calliper

RYZ TL: 240 mm; RYZ TOP TL: 260 mm

main piston (cylinder)

Type of front forks

Hydraulic uid shock absorber

0.3 litres per tube

Variable exibility swinging arm, combined with a 44 mm central

Travel of central single hydraulic shock absorber

Steering column mounted on ball bearings

0,1 daNm (1 Nm)

0,1 daNm (1 Nm)

0,8/0,1 daNm (8/1 Nm)

0,8/0,1 daNm (8/1 Nm)

4,5 daNm (45 Nm)

Rear wheel shaft

1,2 daNm (12 Nm)

Rear wheel shaft nut

6,5 daNm (65 Nm)

Suspension arm nut

6,5 daNm (65 Nm)

Chassis engine mounting

2,8 daNm (28 Nm)

Shock absorber top mounting

4,3 daNm (43 Nm)

Shock absorber top mounting

4,3 daNm (43 Nm)

1,5 daNm (15 Nm)

Front brake calliper

2,5 daNm (25 Nm)

Rear brake calliper

2,5 daNm (25 Nm)

Front brake disk