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CPI JR 50 Service Manual

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  • Page 1 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 2 § C O N T E N T S § 1-1∼ 1-2 PREFACE..................2-1∼ 2-4 ENGINE REMOVE… … … … … … … … … ......... 3-1∼ 3-2 ENGINE INSTALLATION............4-1∼ 4-2 LUBRICATION SYSTEM............5-1∼ 5-4 FUEL SYSTEM… … … … … … … … … … … ......6-1∼...
  • Page 3 THE CONTENTS OF THIS MANUAL PROVIDE THE SREVICE INFORMATION FOR C.P.I JR50/90. MOST CHAPTERS START WITH A SYSTEM OR ASSEMBLY ILLUSTRATION AND SPECIFICATIONS THE FOLLOWED PAGES GIVE DETAIL PROCEDURES. IF YOU DO NOT KNOW WHAT THE SOURCE OF THE TROUBLE IS, PLEASE GO THE TROUBLESHOOTING FOR ADDITIONAL HELP.
  • Page 4 Remove the seat & the luggage box. Remove 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...
  • Page 5 Disconnect the Vacuum hose.1. Disconnect the Fuel hose 1. Disconnect the oil tube. Disconnect 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...
  • 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...
  • Page 7 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 8 ENGIME INS TALLATION The installation sequence is essentially the reverse 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...

  • Page 9: Oil Pump Removal

    OIL PUMP REMOVAL Remove the seat, luggage box, and side covers, Remove the cooling fan cover ,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.

  • Page 10: Oil Pump Installation

    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 the O-ring. Install the oil pump onto the crankcase. Connect the oil tube.
  • Page 11 THROTTLE VALVE REMOVAL Remove the seat. Remove the luggage box. Loose the carburetor cap. Remove the throttle valve from the carburetor. Remove the throttle valve from the throttle cable. THROTTLE VALVE DISASSEMBLY Remove the retainer and take out the jet needle clip from the throttle valve.
  • Page 12 Remove the carburetor and let it cool down by nature for thirty minutes. Check the current of air route as show. GOOD : CHECKLESS NG : CHECKED BLOW Connect a full charged battery to the starter plunger wore for five minutes. Check the current of route as show.

  • Page 13: Carburetor Installation

    Remove the main jet, slow jet, needle seat & air screw. Clean all the jet & all the hole by 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.

  • Page 14: Reed Valve Inspection

    REED VALVE REMOVAL Remove the carburetor. 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 : 10 ㎜ REED VALVE INSTALLATION The installation sequence is essentially the reverse of removal.

  • Page 15: Service Limit

    CYLINDER HEAD REMOVAL Remove the seat & the luggage box. Remove the spark plug cap. Remove the exhaust muffler. Remove the side covers. Remove the cylinder air shrouds. Remove the spark plug. Remove the setting bolts of cylinder head. Remove the cylinder head. Cylinder head flatness inspection.

  • Page 16: Service Limits

    PISTON REMOVAL Remove the piston pin clip. NOTE: Do not let the clip fall into the crankcase. Remove the piston pin. Remove the piston. PISTON / PISTON RING INSPECTION Remove the piston rings. Clean the grooves for carbon deposit completely. NOTE: Do not damage the piston ring during removal.
  • Page 17 Calculate the piston-to-cylinder clearance. SERVICE LIMITS : 0.1 ㎜ Calculate the taper and out of round. SERVICE LIMITS: Out of round: 0.05 ㎜ Taper: 0.05 ㎜ Measure piston pin bore O. D. at a point 10 ㎜ from the bottom. SERVICE LIMITS: 39.95 ㎜.
  • Page 18 Connecting rod small end inspections: SERVICE LIMITS: 14.06 ㎜. 15.06 ㎜. PISTON RING INSTALLATION Clean the piston ring grooves thoroughly. Install the piston ring. NOTE: i Avoid piston and piston ring damage during installation. i All ring should be installed with the mark facing up.

  • Page 19: Cylinder Installation

    CYLINDER INSTALLATION Install the cylinder gasket. Coat the cylinder 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.
  • Page 20 LEFT CRANKCASE COVER REMOVAC Remove the start kick. Left crankcase cover and dowel pin. Remove the kick pinion with the kick friction spring. Disconnect the kick start spring. Remove the cir-clip,plate washer,kick spindle bush,and spring. Remove the setting nut of clutch outer. Remove the clutch outer.
  • Page 21 Remove the movable drive and collar. Remove the starter clutch and starter wheel. Remove the gear boss. Remove the plat washer. Remove the idle gear plate and idle gear. DRIVEN BELT INSPECTION Inspect the belt for crack wear or any damage measure the width of belt.
  • Page 22 BOSS OF DRIVEN FACE INSPECTION Measure the boss I. D. SERVICE LIMIT : 23.94 ㎜ CLUTCH OUTER INSPECTION Measure clutch outer I. D. SERVICE LIMIT : 109.5 ㎜ CLUTCH LINING INSPECTION Measure the lining thickness. SERVICE LIMIT : 1.5 ㎜ DRVIEN PULLEY DISASSEMBLY Fix the driven pulley in a compressor.
  • Page 23 DRIVEN FACE SPRING INSPECTION Measure the spring free leant. SERVICE LIMIT : 67 ㎜ 89.5 ㎜ DRIVEN FACE INSPECTION Measure the driven face O. D. SERVICE LIMIT : 33.94 ㎜ MOVABLE DRIVEN FACE INSPECTION Measure the movable drive face I. D. SERVICE LIMIT : 34.06 ㎜...
  • Page 24 Remove the counter 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...

  • Page 25: Crankcase Removal

    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. PDF 文件使用...

  • Page 26: Crankshaft Inspection

    CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge. SERVICE LIMIT: 0.55 ㎜ Measure the connecting rod big end radial clearance at two different point across 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.

  • Page 27: Crankcase Installation

    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. PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 28 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. PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 29 BATTERY INSPECTION Check the voltage of the battery. FULL CHARGE : 13.0∼13.2 v UNDER CHARGE : 12.3 v BATTERY CHARGING Connect charge position (+) cable to the battery positive termini. Connect the charge negative (-) cable to the battery negative (-) terminal. CHARGING CURRENT : STANDARD : 0.4A SWIFTNESS : 4A...
  • Page 30 C.D. I. INSPECTION AC110V GOOD  NO SPARK ↑  ↑ SPARK ON.1 SPARK NO SPARK ↑ ↑ ON.2 IGNITION COIL INSPECTION Check the primary coil for continuity. Mark connections with an ohmmeter as shown. The coil is normal if there is continuity. STANDARD: 0.1∼1.0 Ω...

  • Page 31: Exciter Coil Inspection

    EXCITER COIL INSPECTION Disconnect the black / red wire of A. C. Check the black / red and earth wire for continuity. STANDARD: 300Ω ∼1. KΩ ( 20 ℃ ) PLUSER COIL INSPECTION Disconnect the blue / yellow wire of A. C. Check the blue / yellow wire and green wire for continuity.

  • Page 32: Fuel Gauge Inspection

    START RELLEY INSPECTION Connect a battery (12V) between (D) and (C ) as show. Check the continuity between the (A) pole (B) pole. GOOD : continuity NG : discontinuity FUEL GAUGE INSPECTION Check the fuel gauge for continuity as below : FLOAT UP FLOAT DOWN GREEN〜YELLOW / WHITE...

  • Page 33: Dimmer Switch

    OIL LEVEL GAUGE REMOVAL Remove the seat & luggage box. Disconnect the gauge wire. Remove the gauge. OIL LEVEL GAUGE INSPECTION Check the continuity between the brown wire and gray wire as bellow. OIL FLOAT GOOD POSITION × × ¡ ¡...

  • Page 34: Headlight Switch

    HEAD LIGHT SWITCH Color yello Peac yellow / white Black / Red Umber / white position ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ Ÿ ¡ ¡ ¡ ¡ ¡ ¡ Ÿ TRUN SIDNAL SWITCH COLOR ORANGE LIGHT-BLUE position ¡ ¡...
  • Page 35 METHOD TO REMOVE THE REAR WHEEL 1. REMOVE REAR FENDER. 2. REMOVE EXHAUST PIPE 3.REMOVE REAR WHEEL NUT. 4.REMOVE THE REAR WHEEL. 5.TO PUT IN THE REAR WHEEL: OPPSITE TO THE REMOVING OF IT TORQUE: M6:1.2-1.5kg-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...
  • Page 36 FRONT WHEEL REMOVAL Raise the front wheel off the grand ground by placing a block or safety stand. Disconnect the speedometer cable. Remove the axle shaft. Remove the front wheel. AXLE SHAFT INSPECTION Measure the axle shaft runout. SERVICE LIMIT : 0.2 ㎜ FRONT WHEEL RIM RUNOUT INSPECTION Measure the wheel rim runout.
  • Page 37 BRAKE OIL CHANGING Drain the brake oil by coos the breath nut. Fill with new brake oil (DOT-3) Release the air in the brake oil passage. BRAKE LINING CHANDGE Remove the brake caliper setting bolts. Remove the brake caliper. Remove the brake lining setting bolts. Remove the brake lining.
  • Page 38 BRAKE DISK INSPECTION Brake disc thickness. SERVICE LIMIT : 3.0 ㎜ Brake disk flatness. SERVICE LIMIT : 0.3 ㎜ 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.
  • Page 39 INSPECTION Inspect the master cylinder for wear or crack. Measure the master cylinder I. D. SERVICE LIMIT : 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.
  • Page 40 Remove the caliper piston. Remove 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...

  • Page 41: Front Fork Disassembly

    FRONT FORK REMOVAL Remove the front wheel. Remove the front for setting bolt. Remove the front fork. FRONT FORK DISASSEMBLY Hold the fork tube in a vice. NOTE : Do not damage the fork tube while this operation. Remove the fork bolt. Remove the fork spring.
  • Page 42 Hold the bottom case in a vice. Remove the socket bolt with an Allen wrench. Remove the fork pipe, seat pipe and oil lock piece. Check each part for wear or damage and replace if necessary. FORK TUBE INSPECTION Place the fork tube in V-blocks and measure the runout with a dial indicator gauge.

  • Page 43: Front Fork Assembly

    Remove the oil seal. NOTE : Avoid damaging the inner and outer surfaces of the slider when removing the seal and set ring. BOTTOM CASE INSPECTION Check the inside sliding surface of the bottom case for wear or damage. Measure the bottom case I. D. SERVICE LIMIT : 31.1 ㎜...
  • Page 44 Install the oil seal in the top of the slider with a fork seal driver. NOTE : `.Apply ATF (Automatic Transmission Fluid)to the oil seal and install it with the fork seal driver. `.The fork seal is seated when the groove in the slider is visible at the top of the seal.
  • Page 45 Remove the steering top con race. Remove the front fork. RON FORK INSTALATION 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. Install the steering top thread nut and tighten it until snug against the top cone race.
  • Page 46 Remove the steering top con race. Remove the front fork. RON FORK INSTALATION 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...

This manual is also suitable for:

Jr 90

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