CPI JR 50, Service Manual

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Page 2: ...4 2 FUEL SYSTEM Q 5 1 5 4 CYLINDER HEAD CYLINDER PISTON Q 6 1 6 6 TANSMISSION SYSTEM Q 7 1 7 6 CRANKSHAFT CRANKCASE Q 8 1 8 4 A C G EMERATOR Q 9 1 9 2 ELECTRIC SYSTEM Q10 1 10 6 CHASSIS Q11 1 11 2 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 3: ...U DO NOT KNOW WHAT THE SOURCE OF THE TROUBLE IS PLEASE GO THE TROUBLESHOOTING FOR ADDITIONAL HELP ALL THE CONTENTS OF THIS MANUAL ARE BASED ON THE LATEST MODEL INFORMATION C P I RESERVE THE RIGHT TO MAKE CHANGE AT ANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR ENGAGEMENT ON OUR PART PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n...

Page 4: ...e the side covers Remove the luggage box Remover the side cover 2 1 Remove the RR Luggage carrier comp 2 Remove the side covers1 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 5: ...t the A C G wire Disconnect the start motor wive Disconnect the throttle valve Disconnect the spark plug cap Disconnect the rear brake cable Remove the setting bolt of rear cushion PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 6: ...Remove the setting bolt of engine Remove the engine PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

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Page 8: ...of removal NOTE Route all the wire and cable properly Adjust the throttle cable free play Adjust the oil pump control cable Clearance Adjust the rear brake free play PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 9: ...r cooling fan and A C G Disconnect the oil tube of oil tube of oil Pump intake and output Remove the oil pump control cable Remove the setting bolt of oil pump Remove the oil pump PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 10: ...p onto the crankcase Connect the oil tube Connect the oil pump control cable and adjust the clearance 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 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e ...

Page 11: ...PECTION Check the throttle valve and the jet needle surface of dirt scratches or wear CARBURETOR REMOVAL Remove the seat Remove the luggage box Remove the side cover 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 between the intake pipe the carburetor Remove the carburetor PDF 文件使用 pdfFactor...

Page 12: ... starter plunger wore for five minutes Check the current of route as show GOOD CHECKED NG CHECKLESS 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 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 13: ...g 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 2 1 2 round Adjust the idle speed STANDSRD 1800 100 rpm PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 14: ...N Measure the height of reed valve stopper STANDARD 6 0 6 4 Check the flatness of reed valve SERVOCE LIMIT 10 REED VALVE INSTALLATION The installation sequence is essentially the reverse of removal PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 15: ...ug 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 scraper PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 16: ...OTE 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 SERVICE LIMITS 40 2 52 2 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o ...

Page 17: ...tions at right angle to each other SERVICE LIMITS 10 05 12 05 Measure the piston pin O D at the front center and rear and in two directions across from each other SERVICE LIMIT 9 95 11 95 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 SERVICE LIMITS Top Second 0 15 0 35 PDF 文件使用 pdfFactory 试用版本创建 www fineprin...

Page 18: ...iston ring damage during installation i All ring should be installed with the mark facing up PISTON INSTALLATION Install the piston piston pin and new piston pin clips NOTE i Piston the EX mark on the exhaust side i Do not let the piston pin clip fall into the crankcase PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 19: ...TE 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 STANDARD 10 0 2 600 rpm PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 20: ...te washer kick spindle bush and spring Remove the setting nut of clutch outer Remove the clutch outer Remove the driven pulley and drive beet Remove the setting nut of driver face Remove the conical spring washer and the one way clutch Remove the claw washer driver face and plat washer PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 21: ... INSPECTION Inspect the belt for crack wear or any damage measure the width of belt SERVICE LIMIT 14 6 WEIGHT ROLLER INSPECTION Measure the weight roller O D SERVICE LIMIT 14 5 MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face I D SERVICE LIMIT 17 5 20 5 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 22: ...MIT 109 5 CLUTCH LINING INSPECTION Measure the lining thickness SERVICE LIMIT 1 5 DRVIEN PULLEY DISASSEMBLY Fix the driven pulley in a compressor Remove the special nut 28 Release the compressor Remove the driven plat assy PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 23: ...n face O D SERVICE LIMIT 33 94 MOVABLE DRIVEN FACE INSPECTION Measure the movable drive face I D SERVICE LIMIT 34 06 Final transmission gear removal Drain the gear oil Remover the mission cover gasket and dowel pin PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 24: ... shaft and final shaft FINAL GEAR TRANSMISSION GEAR INSPECTION Inspect the gears and shafts for wear or damage PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 25: ...case 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 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 26: ...ss from each other SERVICE LIMIT 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 SERVICE LIMIT 0 1 Check the crankshaft bearing play If they are noisy or have recessive play replace a new one PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 27: ... crankcase Install the crankshaft bearing into the right crankcase Install the crankshaft into the left crankcase Install the oil seal into the left crankcase PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 28: ...ll the right crankcase Install the oil seal into the right crankcase Install the setting bolts of crankcase TORQUE 1 0 m PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 29: ...RENT STANDARD 0 4A SWIFTNESS 4A CHARGING TIME STANDARD 5 hrs SWIFTNESS 30 min A C G COIL INSPECTION Check the continuity between the white and the green wire STANDARD Check the continuity between the yellow and the green wire STANDARD RESISTER INSPECTION Check the continuity between the wire of resister and earth STNADARD RESISTER A RESISTER B PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w ...

Page 30: ...nuity 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 A C G INSPECTION GOOD NG 1 OFF 2 P 3 EXT 4 ON 1 5 ON 2 NO SPARK SPARK SPARK NO SPARK PDF 文件使用 pdfFactory 试用版本创建 www...

Page 31: ... green wire for continuity STANDARD 40 300 Ω 20 IGNITION TIMING INSPECTION Check the ignition timing by using a timing light after warm up the engine STANDARD BTDC 13 1 1700 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 PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w ...

Page 32: ...ve the fuel gauge from the fuel tank Turn the main switch on Move the float from down to up if the guideline of indicator from E to F Move the float from up to down if the guideline of indicator from F to E FLOAT UP FLOAT DOWN GREEN YELLOW WHITE 30 45Ω 500 850Ω GREEN BLUE WHITE 400 700Ω 100 700Ω YELLOW WHITE BLUE WHITE 450 750Ω 450 750Ω PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a...

Page 33: ...eck the continuity between the brown wire and gray wire as bellow DIMMER SWITCH START SWITCH OIL FLOAT POSITION GOOD NG A UP B DOWN Color POSITION YELLOW RED GREEN OFF ON COLOR POSITION BLUE WHITE BULE WHITE HI N LO PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 34: ...te yello w Black Red Umber white Peac h OFF N Ÿ N Ÿ position COLOR position ORANGE LIGHT BLUE ASH L N R COLOR GREEN LIGHT GREEN OFF ON POSITIO N COLOR RED BLACK WHITE GREEN BLACK OFF ON POSITION PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 35: ... 1 5kg m M8 2 2 3 0kg m M14 11 5 12 5kg m 1 METHOD TO CHECK REAR BRAKE HUB 1 MEASURE THE INTERNAL DIAMETER OF THE REAR BRAKE HUB 2 USE LIMITATION REPLACED WHEN OVER 110 5MM 2 METHOD TO CHECK BRAKE SHOE 1 CHECK THE THICKNESS OF REAR BRAKE SHOE 2 USE LIMITATION REPLACED WHEN UNDER 2 0MM PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 36: ...t wheel AXLE SHAFT INSPECTION Measure the axle shaft runout SERVICE LIMIT 0 2 FRONT WHEEL RIM RUNOUT INSPECTION Measure the wheel rim runout SERVICE LIMIT Radial 2 0 Axial 2 0 DISK BRAKE SYSTEM BRAKE OIL INSPECTION Normal fluid lever is between upper and lower PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 37: ...assage BRAKE LINING CHANDGE Remove the brake caliper setting bolts Remove the brake caliper Remove the brake lining setting bolts Remove the brake lining The installation sequence is essentially the reverse of removal PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 38: ...3 BRAKE MASTER CYLINDER REMOVAL Drain the brake oil Remove the brake oil tube Remove the master cylinder DISASSENBLY Remove the cir clip Remove the master cylinder kit Clean all the device PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 39: ...T 11 03mm Measure the piston of master cylinder SERVICE LIMIT 10 97mm BRAKE CALIPER REMOVAL Remove the caliper from the front fork Disconnect the brake oil tube DISASSEMBLY Remove the brake pad PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 40: ...e the oil seal Measure the caliper cylinder I D SERVICE LIMIT 30 25mm Measure the caliper PISTON O D SERVICE LIMIT 30 20 mm PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 41: ... tube while this operation Remove the fork bolt Remove the fork spring FRONT FORK INSPECTION Measure the fork spring free length SERVICE LIMIT 235 7 Drain the fork from the top of the front fork Pour out any remaining fluid by pumping the fork up and down several times PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 42: ...rk tube in V blocks and measure the runout with a dial indicator gauge The actual runout is 1 2 of TIR Total Indicator Reading SERVICE LIMIT 0 2 Measure the fork tube O D at the several points along the sliding surface SERVICE LIMIT 30 9 Remove the dust seal cover Remove the snap ring with a snap ring pliers PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o ...

Page 43: ...IT 31 1 FRONT FORK ASSEMBLY Before assembly wash the parts in solvent and wipe them off completely Insert the seat pipe into the fork tube and set the oil lock piece on the end of the seat pipe Insert the parts into the fork slider and tighten the socket bolt with the 6 Allen wrench NOTE Apply locking agent to the socket bolt TORQUE 1 8 2 3 m PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n...

Page 44: ...ap ring pliers Fill the forks with good quality ATF Automatic Transmission Florid CAPACITY 61 cc Install the fork spring into the fork tube NOTE Install the fork spring with the tightly wound coils facing up Hold the fork tube in a vice Tighten the fork bolt TORQUE 4 0 5 0 m STEERING STEM REMOVAL Remove the steering handle Remove the speedometer cable front brake cable from the fork Remove the ste...

Page 45: ...nstall the steering top one race Install the steering top thread nut and tighten it until snug against the top cone race NOTE Back the top thread nut out 1 8 turn after it is tightened snug Against the cone race Make sure that there is no vertical movement and the stem and rotates freely PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...

Page 46: ...LATION Grease the steel balls ball races and cone races Slide the steering stem through the steering head pipe from the bottom Install the steering top one race PDF 文件使用 pdfFactory 试用版本创建 www fineprint com cn D o w n l o a d e d f r o m w w w S c o o t e r T i m e n e t ...