CPI GTR 50, Service Manual

Page 1: ...Collaboration Professional Innovation ...

Page 2: ......

Page 3: ...42 1 2 6 ENGINE REMOVALE INSPECTION 43 1 3 2 LUBRICATION SYSTEM 44 1 4 2 FUEL SYSTEM 45 1 5 4 CYLINDEER HEAD CYLINDER PISTON 46 1 6 5 TRANSMISSION SYSTEM 47 1 7 6 CRANKSHAFT CRANKCASE 48 1 8 4 A C GENERATOR 49 1 9 2 ELECTRIC SYSTEM 410 1 10 4 ...

Page 4: ...AND SPECIFICATIONS THE FOLLOWING PAGES GIVE DETAIL PROCEDURES IF YOU DO NOT KNOW WHAT THE SOURCE OF THE TROUBLE IS PLEASE GO TO THE TROUBLESHOOTERS FOR ADDITIONAL HELP ALL THE CONTENTS OF THIS MANUAL ARE BASED ON THE LATEST MODEL INFORMATION CPI RESERVES THE RIGHT TO MAKE CHANGE AT ANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR ENGAGEMENT ON OUR PART ...

Page 5: ...OKEN OR SHORTED HIGH TENSION CORD 4 FAULTY IGNITION SWITCH 5 INCORRECT IGNITION TIMING 3 TEST CYLINDER COMPRESSION NORMAL COMPRESSION LOW COMPRESSION 1 ENGINE NOT CRANKED 2 NO VALVE CLEARANCE 3 VALVE STUCK OPEN 4 WORN CYLINDER AND PISTON RINGS 5 BLOWN CYLINDER HEAD GASKET 6 FLAW IN CYLINDER HEAD 7 INCORRECT VALVE TIMING 8 BURNED VALVE 4 START ENGINE ENGINE FIRES ENGINE FIRES BUT DOES NOT START 1 C...

Page 6: ... TIRE VALVE 3 RAPIDLY ACCELERATE FROM LOW TO SECOND ACCELERATES DOES NOT ACCELERATE WITH ENGINE SPEED RAISED 1 SLIPPING CLUTCH 2 WORN OR UNEVEN CLUTCH FACINGS 3 CLUTCH PLATE WARPED 4 REV UP GRADUALLY ENGINE SPEED INCREASES ENGINE SPEED DOES NOT INCREASE 1 CARBURETOR CHOKE CLOSED 2 CLOGGED AIR CLEANER 3 CLOGGED FUEL LINE 4 CLOGGED FUEL TANK CAP BREATHER HOLE 5 CLOGGED MUFFLER 5 CHECK IGNITION TIMIN...

Page 7: ...ANGE PLUG 10 CHECK OIL LEVEL AND CONDITION CORRECT ENGINE OIL LEVEL OIL DIRTY OR LEVEL INCORRECT 1 LEVEL TOO LOW OR HIGH 2 CONTAMINATED OIL 11 REMOVE CYLINDER HEAD COVER AND CHECK SUFFICIENTLY LUBRICATION INSUFFICIENTLY LUBRICATED 1 CLOGGED OIL PASSAGE 2 POOR OIL PUMP DELIVERY 12 CHECK IF ENGINE OVERHEATS ENGINE DOES NOT OVERHEAT ENGINE OVERHEATS 1 EXCESSIVE CARBON IN COMBUSTION CHAMBER 2 INCORREC...

Page 8: ...RRECT TIMING ADJUSTMENT 2 INCORRECT VALVE CLEARANCE 2 CHECK CARBURETOR PILOT SCREW ADJUSTMENT CORRECTLY ADJUSTED INCORRECTLY ADJUSTED 1 MIXTURE TOO LEAN 2 MIXTURE TOO RICH 3 CHECK FOR AIR LEAKS NO AIR LEAKS AIR LEAKS 1 FAULTY CARBURETOR PACKING 2 CARBURETOR NOT SECURELY TIGHTENED 3 FAULTY INTAKE PIPE GASKET 4 REMOVE SPARK PLUG AND TEST SPARK WEAK OR INTERMITTENT SPARK 1 FAULTY OR FOULED PLUG 2 FAU...

Page 9: ...TY FUEL TANK 2 CLOGGED FUEL LINE 3 CLOGGED FUEL TANK CAP BREATHER HOLE 4 CLOGGED FUEL PETCOCK 3 CHECK FUEL FILTER FUEL VALVE AND CARBURETOR JET FOR CLOGGING NOT CLOGGED CLOGGED 1 CLOGGED JET 2 CLOGGED FUEL FILTER 3 CLOGGED FUEL VALVE 4 REPLACE CARBURETOR MAIN JET CONDITION IMPROVED CONDITION AGGRAVATED 1 JET SIZE TOO SMALL 2 IF CONDITION IS IMPROVED WITH SMALL JET A CLOGGED AIR CLEANER B CHOKE NOT...

Page 10: ...AKE VALVE GUIDE OR STEM 2 EXCESSIVE VALVE TO GUIDE CLEARANCE POOR HANDLING FLOW PATH BAD SITUATION PROBABLE CAUSE 1 IF STEELING IS HEAVY CHECK TIRE PRESSURE 1 STEERING HEAD ADJUSTER TOO TIGHT 2 DAMAGED STEERING CONES OR STEEL BALLS 2 IF EITHER WHEEL IS WOBBLING 1 EXCESSIVE WHEEL BEARING PLAY 2 DISTORTED RIM 3 IMPROPERLY INSTALLED WHEEL HUB 4 SWING ARM PIVOT BUSHING EXCESSIVELY WORN 5 DISTORTED FRA...

Page 11: ...nd remove the seat 2 Remove the rear luggage case Remove the side cover Remove the throttle valve from the carburetor Disconnect the earth wire of engine Disconnect the coil wire Disconnect the A C G wire Disconnect the start motor wire Disconnect the starter plunger wire ...

Page 12: ...nect the rear brake cable Remove the setting bolt of rear cushion Remove the setting bolt of engine Remove the engine ENGINE INSTALLATION The installation sequence is essentially the reverse of removal NOTE Route all the wire and cable properly Adjust the throttle cable free play clearance Adjust the rear brake free play ...

Page 13: ... 2 8 3 0 Stud bolt side Cylinder head bolt B 2 8 3 0 Stud bolt side EXH pipe joint bolt 2 8 0 9 Spread on thread Drive face nut 1 17 3 5 4 0 A C G nut 1 17 3 5 4 0 Oil pump bolt 2 6 0 8 Cylinder head cover bolt 2 10 1 5 Spark plug 1 12 1 8 FRAME ITEM AMOUT DIAMETER mm TORQUE kg m Shaft steering nut 1 10 4 5 FR Wheel axle nut 1 12 6 0 RR Wheel axle nut 1 16 9 0 RR shock absorber bolt up 1 10 3 0 RR...

Page 14: ...able Remove the setting bolt of oil pump Remove the oil pump OIL PUMP INSPECTION Check the O ring gear seal for wear or any damage NOTE Do not disassembly the oil pump body to prevent any damage OIL PUMP INSTALLATION Coating some oil on the O ring Install the oil pump onto the crankcase Connect the oil tube Connect the oil pump control cable and adjust the clearance ...

Page 15: ...CATION SYSTEM GTR50 4 2 RELEASE THE AIR OF OIL PUMP Loosen the drain screw Let the oil drain out in smoothly then tight the screw NOTE If the oil can not drain out in smoothly it is mean some air still in the oil pump ...

Page 16: ...EMBLY Remove the retainer and take out the jet needle clip from the throttle valve INSPECTION Check the throttle valve and the jet needle surface of dirt scratches or wear CARBURETOR REMOVAL Remove the side cover Remove the luggage box ASSY Remove the starter plunger wire Remove the throttle cable Remove the fuel tube from the carburetor Loose the screw of the air cleaner band Loose the bolts betw...

Page 17: ... GOOD PASSABLE NG IMPASSABLE BLOW Connect a full charged battery to the starter plunger wore for five minutes Check the current of route as show GOOD IMPASSABLE NG PASSABLE BLOW FLOAT CHAMBER DISASSEMBLY Remove the setting screws Remove the chamber cap Remove the float setting bolt Remove the float pin Remove the float Remove the float valve ...

Page 18: ... using high pressure air FUEL HEIGHT INSPECTION Measure the height by using a gauge STANDARD 18 5 CARBURETOR INSTALLATION The installation sequence is essentially the reverse of remove Adjust the clearance of the throttle valve cable Adjust the air screw STANDARD 1 1 2round Adjust the idle speed STANDSRD 1800 100 rpm ...

Page 19: ...retor Remove the intake pipe Remove the reed valve REED VALVE INSPECTION Measure the height of reed valve stopper STANDARD 6 0 6 4 Check the flatness of reed valve SERVOCE LIMIT 7 0 REED VALVE INSTALLATION The installation sequence is essentially the reverse of removal ...

Page 20: ...h or damage of plastic parts Remove the spark plug cap Remove the exhaust muffler Remove the cylinder air shrouds Remove the spark plug Remove the setting bolts of cylinder head Remove the cylinder head Cylinder head flatness inspection SERVICE LIMIT 0 05 CYLINDER REMOVAL Remove the cylinder head Remove the cylinder Remove the cylinder gasket NOTE Clean all the material of cylinder gasket with a s...

Page 21: ...ove the piston rings Clean the grooves for carbon deposit completely NOTE Do not damage the piston ring during removal Cylinder block flatness inspections SERVICE LIMITS 0 05 CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three places top middle and bottom of piston travel and in two directions at right angle to each other STANDARD 39 993 40 013mm SERV...

Page 22: ... D at a point 10 from the bottom STANDARD 39 95 Measure piston pin bore I D in two directions at right angle to each other STANDARD 12 05 Measure the piston pin O D at the front center and rear and in two directions across from each other STANDARD 12 05 Insert each piston ring into cylinder with the piston and measure the ring end gap in the cylinder to a point 10 0 04 in from the bottom STANDARD ...

Page 23: ...ton ring grooves thoroughly Install the piston ring NOTE P Avoid piston and piston ring damage during installation P All ring should be installed with the mark facing up PISTON INSTALLATION Install the piston piston pin and new piston pin clips NOTE P Piston the EX mark on the exhaust side P Do not let the piston pin clip fall into the crankcase ...

Page 24: ...linder and piston ring with the engine oil Install the cylinder COMPRESSION PREASURE TEST NOTE Worm up the engine before test Remove the seat luggage box Remove the spark plug cap spark plug Turn the throttle grip with the throttle valve on the upset position Start the motor for 7 8 seconds for test the pressure ...

Page 25: ...kick Remove the crankcase cover Remove the dowel pin Remove the kick pinion with the kick friction spring Disconnect the kick start spring Remove the cir clip plate washer Remove the kick spindle bush Remove the spindle the spring Remove the O ring Remove the setting nut of clutch outer ...

Page 26: ...7 2 Remove the clutch outer driven pulley Remove the drive belt Remove the setting nut of driver face Remove the conical spring washer the one way clutch Remove the claw washer driver face plat washer Remove the movable drive face collar ...

Page 27: ... wheel Remove the gear boss Remove the plat washer Remove the idle gear plate Remove the idle gear DRIVEN BELT INSPECTION Inspect the belt for crack wear or any damage measure the width of belt SERVICE LIMIT 14 60 WEIGHT ROLLER INSPECTION Measure the weight roller O D SERVICE LIMIT 14 5 14 60mm ...

Page 28: ...NSPECTION Measure the movable driven face I D STANDARD 20 5 BOSS OF DRIVEN FACE INSPECTION Measure the boss I D SERVICE LIMIT 17 90 CLUTCH OUTER INSPECTION Measure clutch outer I D STANDARD 109 5 CLUTCH LINING INSPECTION Measure the lining thickness STANDARD 1 0 ...

Page 29: ...sor Remove the special nut 28 Release the compressor Remove the driven plat assy DRIVEN FACE SPRING INSPECTION Measure the spring free leant STANDARD 89 5 DRIVEN FACE INSPECTION Measure the drive face O D STANDARD 33 94 MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face I D STANDARD 34 06 ...

Page 30: ...al transmission gear removal Drain the gear oil Remove the mission cover Remove mission cover gasket dowel pin Remove final shaft final gear Remove counter shaft FINAL GEAR TRANSMISSION GEAR INSPECTION Inspect the gears shafts for wear or damage ...

Page 31: ...CRANKCASE REMOVAL Remove the crankcase setting bolts Remove the right crankcase from the left crankcase by using a pulley Remove the crankcase from the left crankcase by using a pulley Remove the bearing of crankcase by using a bearing pulley ...

Page 32: ...easure the connecting rod big end radial clearance at two different point across from each other STANDARD 0 05 Place the crankshaft on a stand or V blocks and measure the run out using a dial gauge Actual bend is 1 2 of total indicator reading STANDARD 0 1 Check the crankshaft bearing play If they are noisy or have recessive play replace a new one ...

Page 33: ...TR50 8 3 CRANKCASE INSTALLATION Install the crankshaft bearing into the left crankcase Install the crankshaft bearing into the right crankcase Install the crankshaft into the left crankcase Install the oil seal into the left crankcase ...

Page 34: ...CPI MOTOR CRANKSHAFT CRANKCASE GTR50 8 4 Install the dowel pins Install the right crankcase Install the oil seal into the right crankcase Install the setting bolts of crankcase TORQUE 1 0 m ...

Page 35: ...0 9 1 A C GENERATOR REMOVAL Remove the seat luggage box Remove the side covers Remove the cylinder air should Remove the fly wheel setting nut by using a Y fixer Remove the fly wheel by using a pulley Disconnect the wires of A C G ...

Page 36: ...CPI MOTOR A C GENERATOR GTR50 9 2 Remove the A C G setting bolts Remove the A C G A C G INSTALLATION The installation sequence is essentially the reverse of removal ...

Page 37: ...tion cable to the battery positive termini Connect the charge negative cable to the battery negative terminal CHARGING CURRENT STANDARD 0 4A SWIFTNESS 4A CHARGING TIME STANDARD 5 hrs SWIFTNESS 30 min RESISTER INSPECTION Check the continuity between the wire of resister and earth C D I INSPECTION AC110V GOOD NG 1 OFF 2 P 3 EXT 4 ON 1 5 ON 2 NO SPARK SPARK SPARK NO SPARK ...

Page 38: ...ANDARD 0 1 1 0 Ω 20 Check the secondary coil for continuity The ignite coil is correct if there is continuity STANDSRD With plug cap 7 12 kΩ No plug cap 3 5 kΩ Check the coil output on a ignition coil tester Set the tester to ignition test dial out the electrodes and observe the spark gap GOOD Continuous spark NG Discontinuous spark NOTE Follow the instructions supplied with the tester ...

Page 39: ...PECTION Check the ignition timing by using a timing light after warm up the engine STANDARD BTDC 17 1 1800 100rpm START MOROTR START MORTOR INSPECTION Connect a battery 12 V to the motor Check the performance of the motor NOTE Use a fully charged battery 刪除 ...

Page 40: ...CPI MOTOR ELECTRIC SYSTEM GTR50 10 4 ...

Page 41: ...0 Km 10000 Km 11000 Km 12000 Km Months Item new scooter period 1 month 2 months 3 months 4 months 5 months 6 months 7 months 8 months 9 months 10 months 11 months 12 months Battery I I I I I I I I I I I I I Tire I I I I I I I I I I I I I Brake I I I I I I I I I I I I I Brake fluid I I R I R Bolts and nuts I I I I I I I I I I I I I Spark plug I I I I I Air cleaner I I I I Final gear oil R R R Cylin...

Page 42: ...CPI MOTOR ADDENDUM GTR50 11 2 SPECIAL TOOLS 1 FOR FRAME ASSEMBLY i For the front fork ii For the brake sensor 2 FOR ENGINE ASSEMBLY i For A C G ...

Page 43: ...CPI MOTOR ADDENDUM GTR50 11 3 COOLING SYSTEM DRAWING PLIERS clamp 2 ...