CPI GTR180 Service Manual
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CPI GTR180 Service Manual

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  • Page 2: Table Of Contents

    CONTENTS PREFACE TROUBLE SHOOTING SERVICE INFORMATION ENGINE REMOVAL&INSTALLATION CYLINDER & PISTON OIL PUMP REMOVAL CYLINDER HEAD & CAM SHAFT REMOVAL CARBURETOR REMOVAL DRIVE AND DRIVEN PULLEYS & KICK STARTER ELECTRIC SYSTEM FRAME WHEEL & BRAKE SYSTEM ADDENDUN...

  • Page 3: Preface

    PLEASE GO TO THE TROUBLE SHOOTERS FOR ADDITIONAL HELP. ALL THE CONTENTS OF THIS MANUAL ARE BASED ON THE LATEST MODEL INFORMATION AND CPI RESERVES THE RIGHT TO MAKE CHANGE AT ANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR ENGAGEMENT ON OUR PART.

  • Page 4: Trouble Shooting

    CPI MOTOR GTR180 II.TROUBLE SHOOTING ENGINE WILL NOT BE STARTED OR HARD TO START PROBABLE CAUSE FLOW PATH BAD SITUATION CHECK IF FUEL CAN BE FUEL DOES NOT REACH (1) NO FUEL IN TANK REACHED CARBURETOR CARBURETOR (2) CLOGGED FUEL LINE BETWEEN...
  • Page 5 CPI MOTOR GTR180 II.TROUBLE SHOOTING ENGINE LACKS POWER FLOW PATH BAD SITUATION PROBABLE CAUSE RAISE WHEELS OFF WHEELS DO NOT SPIN (1) DRAGGING BRAKE GROUND AND SPIN FREELY (2) FAULTY WHEEL BEARING (3) OVERTIGHTENED DRIVE CHAIN (4) WHEEL BEARING NOT LUBRICATED...
  • Page 6 CPI MOTOR GTR180 II.TROUBLE SHOOTING TEST CYLINDER LOSS OF COMPRESSION (1)VALVE STUCK OPEN COMPRESSION (2) WORN CYLINDER AND PISTON RINGS (3) BLOWN CYLINDER HEAD GASKET (4) INCORRECT VALVE TIMING NORMAL COMPRESSION (5) FLAWS IN CYLINDER HEAD OR CYLINDER CHECK CARBURETOR FOR...
  • Page 7 CPI MOTOR GTR180 II.TROUBLE SHOOTING POOR PERFORMANCE AT IDLE AND LOW SPEEDS FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TMING INCORRECT TIMING AND (1) INCORRECT TIMING ADJUSTMENT AND VALVE CLEARANCE CLEARANCE (2) INCORRECT VALVE CLEARANCE CORRECT TIMING AND CLEARANCE...

  • Page 8: Poor Performance At High Speed

    CPI MOTOR GTR180 II.TROUBLE SHOOTING POOR PERFORMANCE AT HIGH SPEED FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TIMING AND INCORRECT TIMING (1) INCORRECT TIMING ADJUSTMENT VALVE CLEARANCE AND CLEARANCE (2) INCORRECT VALVE CLEARANCE CORRECT TIMING AND CLEARANCE DISCONNECT FUEL LINE AT...
  • Page 9 CPI MOTOR GTR180 II.TROUBLE SHOOTING SMOKY EXHAUST FLOW PATH BAD SITUATION PROBABLE CAUSE RUN MOTORCYCLE A LONG BLACK SMOKE (1) WORN CYLINDER AND PISTON RINGS DISTANCE AT HIGH SPEED EMITTED (2) OIL LEVEL TOO HIGH THIN EXHAUST EMITTED (3) PISTON RINGS INCORRECTLY INSTALLED...
  • Page 10 CPI MOTOR GTR180 III.SERVICE INFORMATION ITEM STANDARD IGNITION MODE SPARK TYPE SPARK PLUG DPR7EA-9 0.7-0.8㎜ SPARK PLUG CLEARANCE 33°BTDC/5000±100rpm IGNITION TIME ≧0.8V PULSER COIL MAX VOLTAGE ≧150V EXCITER COIL MAX VOLTAGE ITEM STANDARD CAPACITANCE 12V-8AH FULL CHARGE 12.8V (20℃) VOLTAGE...
  • Page 11 CPI MOTOR GTR180 III.SERVICE INFORMATION ITEM STANDARD 30±0.5 FLOAT HEIGHT MAIN JET #97.5 PILOT JET IDLE SPEED 1600±100 rpm PILOT SCREW 1+1/2 ROUND ITEM STANDARD SERVICE PUMP TIP CLEARANCE 0.05~0.10mm 0.12mm ROTOR-TO-BODY 015~0.23mm 0.25mm PUMP INNER ﹠OUTER 0.15mm 0.20mm CLEARANCE UNIT : ㎜...
  • Page 12 CPI MOTOR GTR180 III.SERVICE INFORMATION UNIT : ㎜ ITEM STANDARD SERVICE LIMIT SPEED GEAR MOVABLE DRIVE FACE COMP. 24.007-24.028mm 34.06mm DRIVEN BELT WIDTH 21.7-23.3mm 20.7mm DRIVE PALTE COLLAR O. D. 23.959-23.98mm 23.92mm ─── CLUTCH LINING THINNESS 2.75mm CLUTCH OUTER I. D.
  • Page 13 CPI MOTOR GTR180 III.SERVICE INFORMATION TORQUE TORQUE STANDARD SORTS TORQUE(kg-m) 5mm screw, nut 6mm screw, nut 8mm screw, nut 10mm screw, nut 12mm screw, nut INNER OF ENGING ITEM AMOUNT DIAMETER(mm) TORUQUE(kg-m) REMARKS Cylinder head bolt, A Stud bolt side...

  • Page 14: Maintenance Schedule

    CPI MOTOR GTR180 III.SERVICE INFORMATION MAINTENANCE SCHEDULE To inspect (or to clear, lubricate, replenish, repair and replace if it’s necessary) A ：adjust、C：clear、R：replace、T：tight Which Total kilometers for driving Times Item first 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000...
  • Page 15 CPI MOTOR GTR180 III.SERVICE INFORMATION ◎We suggest that above maintenance should be executed in designated dealers to ensure driving safe. Remarks: 1. If you drive to exceed above stipulated kilometers, please reduplicate the inspection. 2. Must inspect or replace early if you drive in the region which has much dust or it’s rainy.

  • Page 16: Engine Removal&Installation

    CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION ENGINE REMOVAL REMOVAL SIDE COVER,3(LEFT) 1.Removal 2 socket bolt 2. Disassemble “SIDE COVER, 3” Disassemble “FUEL HOSE, 3” ATTENTION!!! Be careful of the gasoline leakage. Removal “VACCUM HOSE” Removal “CARBURATOR VACCUM HOSE” 《 4-1 》...
  • Page 17 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION REMOVAL AIR CLEANER 1. Removal 2 flange bolt 2. Removal 1flange bolt Removal the oil hose 3. Disassemble the clamp 《 4-2 》...
  • Page 18 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION REMOVAL ELECTRIC 1.Removal “IGNITION COIL” 2.Disassemble “RECTIFIER” joint 3.Disassemble “AUTO-CHECK” joint 4.Removal “START MOTOR” line 《 4-3 》...
  • Page 19 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION Removal “THROTTLE CABLE” Removal “TEMPERATURE SENSOR” joint Removal the bolt Make cooling water leak out 《 4-4 》...
  • Page 20 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION You can use leak air bolt to control of leaking out speed. REMOVAL HOT WATER PIPE ASSY. 1.Rmoval the clamp 2.Removal 2 pan head bolt 3.Removal the clamp 《 4-5 》...
  • Page 21 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION REMOVAL ENGINE INSTALL BOLT 1.Removal the nut 2.Removal the bolt 《 4-6 》...
  • Page 22 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION 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. EMPTY INTO COOLING WATER 1.Open 2 cap...
  • Page 23 CPI MOTOR GTR180 IV.ENGINE REMOVAL&INSTALLATION Makes cooling water full in outlet water elbow. Makes cooling water full with lower between upper. 《 4-8 》...
  • Page 24 CPI MOTOR GTR180 .CYLINDER & PISTON CRANK SHAFT/PISTON EXPLODED VIEW 《 5-1 》...

  • Page 25: Service Information

    CPI MOTOR GTR180 V.CYLINDER & PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame. When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 26: Cylinder & Piston

    CPI MOTOR GTR180 V.CYLINDER & PISTON TROUBLESHOOTING When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
  • Page 27 CPI MOTOR GTR180 V.CYLINDER & PISTON CYLINDER REMOVAL Disassemble the cylinder head comp. Disassemble the cylinder head gasket. Remove: 1.Cylinder head comp. [A] 2.Cylinder head gasket. [B] Loosen the tensioner lifter cap. Disassemble the tensioner lifter comp. Remove: 1.Tensioner lifter cap. [A] 2.Tensioner lifter comp.
  • Page 28 CPI MOTOR GTR180 V.CYLINDER & PISTON Clean any gasket material from the cylinder surface. Disassemble the piston pin clip. Remove: 1.Piston pin clip[A] NOTE Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.
  • Page 29 CPI MOTOR GTR180 V.CYLINDER & PISTON INSPECTION PISTON/PISTON RING Disassemble the piston rings. Disassemble: 1.Top Ring [A] 2.Second ring [B] 3.Oil ring set [C] NOTE Take care not to damage or break the piston rings during removal. Clean the grooves for carbon deposit completely.
  • Page 30 CPI MOTOR GTR180 V.CYLINDER & PISTON Measure piston pin bore I. D. in two directions at right angle to each other. SERVICE LIMITS : 15.04 ㎜ Measure the piston pin O. D. at the front, center and rear and in tow directions across from each other.
  • Page 31 CPI MOTOR GTR180 V.CYLINDER & PISTON Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the piston O.D. Service Limit: 57.3mm replace if below NOTE Take measurement at 9mm from the bottom and 90° to the piston pin hole.
  • Page 32 CPI MOTOR GTR180 V.CYLINDER & PISTON PISTON RING INSTALLATION Clean the piston ring groves thoroughly Install the piston ring. Space the piston ring end gaps 120 degrees apart. The gap of the three-piece oil ring should correspond with the gap of spacer.
  • Page 33 CPI MOTOR GTR180 V.CYLINDER & PISTON PISTON INSTALLATION Install the piston. NOTE Position the piston “IN” mark on the intake valve side. Install the piston & piston pin. Install the new piston pin clips. NOTE Use clean cloth stop up the crankcase hole and cam chain hole.
  • Page 34 CPI MOTOR GTR180 V.CYLINDER & PISTON CYLINDER INSTALLION Install the cylinder gasket and dowel pins. Install: 1.Cylinder gasket.[A] 2.Dowel pins [B] NOTE Apply some oil at cylinder wall before piston ring assemble into cylinder. Install the cylinder & dowel pins...
  • Page 35 CPI MOTOR GTR180 V.CYLINDER & PISTON MEMO…. 《 5-12 》...
  • Page 36 CPI MOTOR GTR180 V.CYLINDER & PISTON 《 5-13 》...

  • Page 37: Oil Pump Removal

    CPI MOTOR GTR180 VI.OIL PUMP REMOVAL OIL PUMP EXPLODED VIEW 《 6-1 》...
  • Page 38 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame. Drain the coolant before starting any operations. Use carefully when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
  • Page 39 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL TORQUE Engine oil filter screen cover 1.3~1.7kgf-m Gear oil filler bolt 1.0~1.4kgf-m Engine oil drain plug bolt 3.5~4.5kgf-m Oil pump screw 0.1~0.3kgf-m Gear oil drain plug bolt 0.8~1.2kgf-m TROUBLE DECIDE Oil too low： Engine oil leak...

  • Page 40: Change Engine Oil

    CPI MOTOR GTR180 VI.OIL PUMP REMOVAL Change engine oil ATTENTION!!! Please drain the engine oil when the warm engine which can assure the engine oil is smooth. Put the dish under the engine, disassemble the drain plug bolt to drain engine oil. If drain plug bolt washer is damaged, it must change new one.
  • Page 41 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL DISASSEMBLE OIL PUMP Disconnect the water hoses from the right crankcase cover. Remove the twelve bolts attaching the right crankcase cover and the cover. Remove: 1. Flange bolts [A] Disassemble right crank case cover gasket & pins.
  • Page 42 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL Use the pneumatic tools disassemble the nut. Remove: 1. Nut and washer [A] FLYWHEEL REMOVAL Hold the flywheel with a flywheel puller and remove the flywheel. ATTENTION!!! When work flywheel puller, it must support the A.C.G fly wheel carefully.
  • Page 43 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL Disassemble the starter driven gear comp. Remove: 1. Starter driven gear comp [A] Disassemble the flange bolts. Remove the oil separator Remove: 1. Flange bolts [A] 2. Oil separator [B] Disassemble the Cir-clip Remove: 1.
  • Page 44 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL Disassemble the oil pump chain & chain wheel. Remove: 1.Pump chain [A] 2.Chain wheel [B] Disassemble the screws. Remove: 1.Screws [A] Disassemble the oil pump driven sprocket Remove: 1.Oil pump driven sprocket [A] 《 6-8 》...
  • Page 45 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown Remove: 1.Screw [A] OIL PUMP INSPECTION Measure the body-to-outer rotor clearance. Service limit: 0.25 ㎜ replace if over. Measure the rotor end-to-pump body clearance.
  • Page 46 CPI MOTOR GTR180 VI.OIL PUMP REMOVAL OIL PUMP INSTALLATION Install the oil pump to the crankcase. Install: 1.Oil pump [A] Install the oil pump and oil separator and tighten the two screws. Make sure that the pump shaft rotates freely Install: 1.Screws [A].

  • Page 47: Cylinder Head & Cam Shaft Removal

    CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL CYLINDER HEAD EXPLODED VIEW...
  • Page 48 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
  • Page 49 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL TROUBLESHOOTING The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. POOR PERFORMANCE AT IDLE SPEED Compression too low COMPRESSION TOO LOW Incorrect valve clearance adjustment Abnormal noise...
  • Page 50 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL CAMSHAFT REMOVAL Remove the cylinder head cover bolts. Remove the cylinder head cover. Remove: 1. Remove two cylinder head bolts. [A] Turn the A.C. generator flywheel so that the “I” mark on the flywheel aligns with the index mark on the crankcase.
  • Page 51 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Disassemble the tensioner lifter comp & tensioner lifter gasket. Remove: 1. Tensioner lifter comp. [A] Disassemble the screw and spring. NOTE Be careful of the missing for the o-ring on the screw.
  • Page 52 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Remove the Cir-clip Remove: 1. Cir-clip [A] Take out the camshaft from the cam shaft holder. Inspection camshaft Check each cam lobe for wear or damage. Measure the cam lobe height.
  • Page 53 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL CAM SHAFT HOLDER DISASSEMBLY Disassemble the rocker arm cir-clip. Disassemble the two rocker arms by using a M5 bolt. Remove: 1. Cir-clip [A] NOTE M5 bolt [B] Inspect the holder, rocker arm shaft is damaged or broken.
  • Page 54 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL CYLINDER HEAD REMOVAL Remove three flange bolts cylinder head. Remove: 1. Flange bolts [A] Remove two intake pipe bolts. Remove: 1. Flange bolts. [A] Remove the intake pipe comp. & carburetor insulator.
  • Page 55 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Remove the thermostat case. Remove: 1. Thermostat case. [A] Remove the cylinder head assy. Remove: 1. Cylinder head assy. [A] Remove the dowel pins & cylinder head gasket. Remove: 1. Cylinder head gasket. [A] 2.
  • Page 56 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL CYLINDER HEAD DISASSEMBLTY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. NOTE Be sure to compress the valve springs with a valve spring compressor.
  • Page 57 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL VALVE/ VALVE GUIDE INSPECT Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. MEASURES : IN : 4.965 m/m replace if below EX : 4.945 m/m replace if below...
  • Page 58 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Install the dowel pins. Install: 1.Dowel pins [A] Install two sides of flange bolts on cylinder head assy. Install: 1.Flange bolts. [A] Install the carburetor heat insulator. ATTENTION Pay attention at direction. [A]...
  • Page 59 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Install the intake pipe comp. Install: 1.Flange bolts. [A] Install thermostat comp. ATTENTION Please check the thermostat comp. oil seal is damaged or broken, if yes, replaced a new one. ASSEMBLE THE CAM SHAFT HOLDER.
  • Page 60 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL Turn the A.C. generator flywheel so that the “I” mark on the flywheel aligns with the index mark on the crankcase. Make sure two parallel lines on cam shaft chain wheel are paralleled with cylinder head surface.
  • Page 61 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL LOOSEN THE TAPPET ADJUSTING NUT Use thickness meter to measure and adjust the valve gap. Adjusting till the standard, fix the bolt and tighten the nut. STANDARD： In valve 0.06 mm。...
  • Page 62 CPI MOTOR GTR180 VII.CYLINDER HEAD & CAM SHAFT REMOVAL MEMO…. 《 7-16 》...
  • Page 63 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL CARBURETOR EXPLODED VIEW 《 8-1 》...
  • Page 64 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline, keep away from sparks and flames. Note the locations of O-rings when disassembling and replace them with new ones during assembly. Before float chamber disassembly, drain the residual gasoline from the float chamber.
  • Page 65 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly No fuel in tank Incorrect idle speed Restricted fuel line Rich mixture Too much fuel getting to cylinder Lean mixture Clogged air cleaner...

  • Page 66: Carburetor Removal

    CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL CARBURETOR REMOVAL Remove the air cleaner bolt. Remove: 1. Flange bolt [A] Remove air cleaner bolts. Remove: 1. Flange bolts [A] Loosen the air cleaner connection tube clamp. Remove: 1. Clamp [A] Remove the right crankcase breather tube.
  • Page 67 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL Remove the mission box breather tube. Remove: 1. Tube [A] Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor. Remove: 1. Throttle Cable [A] Disconnect the auto bystarter wire.
  • Page 68 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL Loosen the drain screw and drain the fuel from the float chamber. Remove: 1. Drain Screw [A] Remove the two vacuum chamber cover screws and the cover. Remove: 1. Screws [A] 2. Vacuum Chamber Cover [B] Remove the compression spring and vacuum piston.
  • Page 69 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL AIR CUT-OFF VALVE INSPECTION Inspect the vacuum piston and jet needle for wear or damage. Inspect the diaphragm for deterioration and tears. ACCELERATING PUMP Disassemble the throttle holder screws. Remove: 1. Screws [A] Disassemble the two accelerating pump cover screws and accelerating pump cover.
  • Page 70 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10　 (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.
  • Page 71 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL Install the auto bystarter. Install: 1. Screws [A] Remove the 4 float chamber screws and the float chamber. Remove: 1. Screws [A] 2. Float Chamber [B] Remove the float pin, float and float valve. Remove: 1.
  • Page 72 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL Remove the main jet, needle jet holder and idle jet. Remove the slow jet. Remove: 1. Main Jet [A] 2. Needle jet holder [B] 3. Idle Jet [C] Clean the removed the main jet, needle jet holder, needle jet and slow jet with detergent oil.
  • Page 73 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL CARBURETOR INSTALLATION Tighten the drain screw. Install the carburetor onto the intake manifold and tighten the band. Install the air cleaner connecting tube and tighten the clamp. Connect the throttle cable to the carburetor. Install: 1.
  • Page 74 CPI MOTOR GTR180 VIII.CARBURETOR REMOVAL MEMO…. 《 8-12 》...

  • Page 75: Drive And Driven Pulleys & Kick Starter

    CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER DRIVE AND DRIVEN PULLEY EXPLODED VIEW. 《9 -1 》...
  • Page 76 CPI MOTOR GTR180 X.DRIVE AND DRIVEN PULLEYS & KICK STARTER KICK STARTER EXPLODED VIEW. 《9 -2 》...
  • Page 77 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed. Avoid any grease and oil on the drive belt and pulley faces. Make sure to clean all if there is on the part to minimize the slipping of drive belt and drive pulley.
  • Page 78 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER TROUBLESHOOTING Engine starts but motorcycle won‘t move Worn drive belt. Broken ramp plate. Worn or damaged clutch lining. Broken driven face spring. Engine starts or motorcycle creeps Broken clutch weight spring...
  • Page 79 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Disassemble the flange bolts. Disassemble the Left crankcase cover. Remove: 1. Flange bolts [A] 2. Left crank case cover [B] Disassemble the gasket & dowel pins. Remove: 1. Dowel pins. [A] Disassemble four screws.
  • Page 80 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Disassemble the starter kick spring. Remove: 1. Starter kick spring [A] Disassemble the starter idle gear shaft. ATTENTION!!! Idle gear shaft is dispensable to be disassembled. Disassemble flange bolts. Disassemble the shroud cover.
  • Page 81 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Disassemble flange bolts. Disassemble the element plate. Remove: 1. Flange bolts [A] 2. Element plate [B] Disassemble the filter. NOTE Inspect the filter if it is dirty or damaged. If it is dirty or damage, please change a new one.
  • Page 82 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Disassemble the kick spindle bush. Remove: 1. Bush [A] Install the kick starter comp. Install the kick starter spindle & bush. Install the cir-clip & washer. Install the filter. NOTE When install the filter, please check the direction.
  • Page 83 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Install the element plate. Install flange bolts. Install: 1. Element plate [A] 2. Flange bolts [B] NOTE When install the element plate, please check the direction. Install the inner cover.
  • Page 84 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER INSTALL THE STARTER IDLE GEAR COMP. Install: 1. Idle gear comp.[A] Install the left crankcase cover plate. Install the screws Install: 1. Left crankcase cover plate [A] 2. Screws [B] Install the gasket &...
  • Page 85 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Remove drive belt. Using the multi-Installing(Y shape Installed tool) clip to install the driven face, disassemble the nut, washer ad drive face. Using the multi-Installing clip (Y shape Installing tool) to install the driven pulley outer then remove the nut and driven pulley outer.
  • Page 86 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER INSTALL DRIVEN ASSY. Put apart the drive pulley, then install the drive belt into the drive pulley. Install the driven pulley assy. with drive belt to the drive shaft. Assemble another side of drive belt to movable drive face.
  • Page 87 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER INSPECT MPVABLE DRIVE FACE Disassemble the left crankcase cover. Using the multi-Installing tool (“Y” shape tool) to Install the driven pulley, disassemble the nut & washer. And take away the drive face and the drive belt.
  • Page 88 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Measure drive face I.D. Measure the inner diameter of movable drive face. Replace for new if necessary. Install weight roller. NOTE There are 2 different sides of weight roller, in order to...
  • Page 89 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER DRIVE FACE ASSEMBLY Install drive belt to drive face Tighten up per torque standard. Torque：5.0~6.0kgf-m DISASSEMBLY DRIVEN PULLEY ASSY. Disassemble the drive face and driven pulley assy. Install the clutch spring condenser to driven pulley assy.
  • Page 90 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Inspection clutch outer. Service limit： 125.5mm Measure the inner diameter of friction surface for clutch outer. If it is out of standard , please replace the new one. Inspection clutch brake pad Service limit：2.0mm...
  • Page 91 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER INSPECTION DRIVEN FACE BEARING. Inspection inner bearing seal is damaged or not. Inspection needle bearing is damaged or bigger clearance. INSPECTION REPLACE THE CLUTCH PARTS. Dismantle the C-clip & washer, then disassemble the clutch part &...
  • Page 92 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Install the cir-clip to driven plate comp. Installing pin. Change drive face bearing Remove the inner bearing ATTENTION!!! There is an oil seal at one side of inner bearing in drive face, dismantle the oil seal firstly.
  • Page 93 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER Install the movable driven face comp. to driven face. Install guide roller & roller guide pin. Install oil seal Assemble the drive face driven face spring, and clutch into clutch spring condenser, turn the condenser shaft to press assy.
  • Page 94 CPI MOTOR GTR180 IX.DRIVE AND DRIVEN PULLEYS & KICK STARTER MEMO…. 《9 -20 》...

  • Page 95: Electric System

    CPI MOTOR GTR180 X.ELECTRIC SYSTEM 《 10-1 》...
  • Page 96 CPI MOTOR GTR180 X.ELECTRIC SYSTEM ELECTRIC PARTS LOCATION 《 10-2 》...
  • Page 97 CPI MOTOR GTR180 X.ELECTRIC SYSTEM BATTERY PRECAUTIONS There are a number of important precautions that must to service electrical systems. Learn and ob-serve all the rules below. Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts.
  • Page 98 CPI MOTOR GTR180 X.ELECTRIC SYSTEM SPECIFICTION CHARGEABLE SYSTEM ITEM SPECIFICATION YTX9-BS 12 V8Ah CAPACITY ELECTRONIC CHARGED 0.7A / 5~10hr (STANDARD) 3A / 1hr (URGENT USE) VASE RATE ELECTRONIC LAEKAGE OF 1Ma UNDER ELECT. CURRENT CHARGEABLE OF ELECT. 1.2A / 2000 rpm 1.2A / 1600 rpm...
  • Page 99 CPI MOTOR GTR180 X.ELECTRIC SYSTEM CHARGEABLE SYSTEM CHARGEABLE CIRCUIT DIAGRAMR REGULATOR/RECTIFIER CHECKING (KΩ) YELLOW1 YELLOW2 YELLOW3 WHITE/RED BROWN BLACK ∞ YELLOW1 2~20 YELLOW2 ∞ 2~20 YELLOW3 ∞ ∞ 2~20 WHITE/RED ∞ ∞ 10～100 BROWN 10~100 10~100 50~150 10~100 BLACK 2~20...
  • Page 100 CPI MOTOR GTR180 X.ELECTRIC SYSTEM CHARGEABLE DIAGRAM CHECKING REMOVE PROTECTED NET1﹐2& BELOW COVER。 A:RECTIFIER CONNECTOR B:ADJUST REGULATOR OPEN REGULAOR DIAGRAME CONNECTOR, CHECK EVERY DIAGRAM SITUATION. ITEM MEASURE STANDARD VALUE RED─ ELECT. VASE MAIN SW CABLE BROWN PRESSURE ELECT. VASE BATTERY RED─BLACK...
  • Page 101 CPI MOTOR GTR180 X.ELECTRIC SYSTEM BATTERY REMOVAL Remove: Disconnect the negative (–) cable. Slide out the positive (+) terminal cap and then disconnect the positive (+) cable. NOTE Be sure to disconnect the negative (–) cable first. Remove the battery.
  • Page 102 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Do not remove the aluminum sealing sheet “A” from the filler ports “B” until just prior to use. Be sure to use the dedicated electrolyte container for correct electrolyte volume. Place the battery on a level surface.
  • Page 103 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Check the electrolyte flow. If no air bubbles “A” are coming up from the filler ports, or if the container cells have not emptied completely, tap the container “B” a few times. Keep the container in place for 20 minutes or more.
  • Page 104 CPI MOTOR GTR180 X.ELECTRIC SYSTEM NOTE Charging rates will vary depending on how long the battery has been stored, temperature, and the type of charger used. Let battery sit 30 minutes after initial charge, then check voltage using a voltmeter.
  • Page 105 CPI MOTOR GTR180 X.ELECTRIC SYSTEM PRECAUTIONS (1) NO NEED OF TOPPING-UP No topping-up is necessary in this battery until it ends its life under normal use. Forcibly prying off the seal cap to add water is very dangerous. Never do that.
  • Page 106 CPI MOTOR GTR180 X.ELECTRIC SYSTEM WARNING!!! Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 107 CPI MOTOR GTR180 X.ELECTRIC SYSTEM OIL LEAKAGE TESTNG Turn main swich at off position and remove canvas wire from the battery. Connect ampere meter (as right drawing shown) between negative pole (-) and canvas wire.。 ATTENTION!!! Adjust electric current of meter to larger scale when test current, then adjust smaller scale gradually to avoid meter and fuse burn out if current is over the max.
  • Page 108 CPI MOTOR GTR180 X.ELECTRIC SYSTEM ATTENTION!!! Please do not use any wire of short circuit。 By using the Ampere meter to connect between the battery positive connector and ♁ cable, even it can test the electric current and will damage the electric meter when start the motor suddenly; suggest using the foot shaft to start the engine.
  • Page 109 CPI MOTOR GTR180 X.ELECTRIC SYSTEM The Ignition System Turbo CDI Ignition System circuit diagram Turbo CDI Checking (MIS Ignition System) CDI connection Meter(+) Meter(-) 50~250 50`250 100~500 500~∞ 100~500 2~20 2~20 5~50 10~100 50~250 2~20 5~50 50~250 2~20 5~50 100~500...
  • Page 110 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Ignition Coil Dismantle Remove protected net 1.2、under cover Remove spark cover Remove ignition coil – Leading wire ”A”。 Remove the bolt of ignition coil, take out the coil. Installation will be used opposite procedure of dismantling.
  • Page 111 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Min. electric voltage：95 V up ATTENTION!!! The finger shall not touch the metal portion when survey the electric voltage or get an electric shock. Please pay attention to this point specially. INSPECTION Once Coil Open the terminal connecting of ‘once coil’ and test the impedance value of ‘once coil’.
  • Page 112 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Replacement Replace the ignition coil if it’s necessary to remove the bolt (bolt x 1) of ignition coil. SPHYGMOGRAM Coil Inspection Remove the under cover Remove the wire connector of Sphygmogram equipment. Test the impedance value of blue wire beside engine/yellow Terminal and body iron parts.
  • Page 113 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Circuit of Starting System Inspection of Starting Relay Open main switch Pull the brake lever Push the starting button The relay is on normal function if hear the ”Ka Ka” sound. Remove the luggage Open the wire of negative pole (-) of battery...
  • Page 114 CPI MOTOR GTR180 X.ELECTRIC SYSTEM Dismantle the starting motor Close the power of main switch Remove the luggage Open the wire of negative pole (–) of battery Remove the tube clamp on the air cleaner and bolt. Please refer 4-1 ~ 4-2 Remove the wire of starting motor Remove starting motor (bolt ×...

  • Page 115: Frame

    CPI MOTOR GTR180 XI.FRAME FRAME EXPOLODED VIEW HANDLE BAR COVER,1 INSPEDT COVER,2 HANDLE BAR COVER,2 TANK-COVER LEG SHIELD,2 COVER,1 INSPEDT COVER,1 HEAD LIGHT ASSY,2 LEG SHIELD MOLE,2 LEG SHIELD,1 LEG SHIELD,4 HEAD LIGHT ASSY,1 COOLER COVER INNER FENDER,1 FRONT FENDER...
  • Page 116 CPI MOTOR GTR180 XI.FRAME FRAME EXPOLODED VIEW SEAT ASSY,2 LICENSE LIGHT ASSY. LUGGAGE 2 SEAT ASSY,1 LICENSE BRACKET TAIL LIGHT ASSY. ADAPTER PLATE LUGGAGE 1 SIDE COVER,2 SIDE COVER,1 REAR FENDER,2 SIDE COVER,4 UNDER COVER,2 SIDE COVER,3 REAR FENDER,1 UNDER COVER,1...
  • Page 117 CPI MOTOR GTR180 XI.FRAME HANDLE BAR HANDLE BAR LEG SHIELD,2 COVER,1 COVER,2 TANK-COVER LEG SHIELD COVER,1 MOLE,1 SHIELD,3 UNDER COVER,1 INNER SHIELD,1 FENDER,1 LEG SHIELD MOLE,2 SHIELD,4 UNDER COVER,2 LICENSE LIGHT ASSY SIDE COVER,1 REAR LICENSE TAIL LIGHT LUGGAGE,2 FENDER,2...
  • Page 118 CPI MOTOR GTR180 XI.FRAME FRAME REMOVAL/INSTALLATION COVER,1 REMOVAL Removal the socket bolt LEG SHIELD,1 REMOVAL Removal 2 bolt Removal 2 bolt w/washer Removal 4 tapping screw 《 11-4 》...
  • Page 119 CPI MOTOR GTR180 XI.FRAME Removal “HEAD LIGHT” connect Inspet cove,1&2 removal Removal 2 tapping screw Handle bar cover,1 removal Removal 2 tapping screw Removal 2 tapping screw 《 11-5 》...
  • Page 120 CPI MOTOR GTR180 XI.FRAME Removal “SPEEDMETER” connect Removal 4 tapping screw Removal 3 tapping screw LEG SHIELD MOLE,1&2 REMOVAL Removal 4 tapping screw 《 11-6 》...
  • Page 121 CPI MOTOR GTR180 XI.FRAME UNDER COVER,1&2 REMOVAL Removal 6 tapping screw LEG SHILED,3&4 REMOVAL Removal 2 tapping screw LEG SHIELD MOLE,1&2 REMOVAL Removal 4 bolt INNER FENDER,1 REMOVAL Removal 6 tapping screw 《 11-7 》...
  • Page 122 CPI MOTOR GTR180 XI.FRAME Removal “FRONT FORK” nut NOTE You can use special tool INNER FENDER,1 REMOVAL Removal 2 bolt w/washer (A) Removal 2 bolt (B) Removal 2 bolt (C) TANK-COVER REMOVAL Removal bolt 《 11-8 》...
  • Page 123 CPI MOTOR GTR180 XI.FRAME LEG SHIELD,2 REMOVAL Disconnect “TANK-COVER” FRONT FENDER REMOVAL Removal 4 pan head screw REAR FENDER,2 REMOVAL Removal4 screw (A) Renival 2 bolt (B) LUGGAGE,2 REMOVAL Removal 6 screw Removal 3 flange bolt 《 11-9 》...
  • Page 124 CPI MOTOR GTR180 XI.FRAME FLASHER LIGHT ASSY,3 REMOVAL Removal 2 nut SIDE COVER,1&2 REMOVAL Removal 2 screw Removal 2 flange bolt Removal 2 bolt Removal 2 bolt w/washer Removal 1 screw 《 11-10 》...
  • Page 125 CPI MOTOR GTR180 XI.FRAME LICENSE BRACKET,1 REMOVAL Removal 2 screw LICENSE LIGHT ASSY REMOVAL Remoal socket bolt Removal nut TAIL LIGHT REMOVAL Removal 2 nut REAR FENDER,1 REMOVAL Removal 3 bolt 《 11-11 》...
  • Page 126 CPI MOTOR GTR180 XI.FRAME Removal 2 nut Removal 2 bolt Removal 2 bolt SIDE COVER,3&4 REMOVAL Removal 4 socket bolt 《 11-12 》...

  • Page 127: Wheel & Brake System

    CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM WHEEL EXPOLODED VIEW 《12 -1 》...
  • Page 128 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM Torque Fastener Remark Kgf-m Ft-lb Front axle nut 44.1 32.5 Front disc bolt 13.7 10.1 Rear axle nut 122.5 12.5 90.2 Rear disc bolt 27.4 20.2 Socket bolt(M8) 24.5 Socket bolt(M6) 14.7 10.8...
  • Page 129 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM METHOD TO REMOVE THE REAR WHEEL REMOVAL EXHAUST PIPE Removal 3 bolt Removal 2 nut REMOVAL REAR FENDER. Removal 2 bolt Removal 2 bolt 《12 -3 》...
  • Page 130 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM R.R. CALIPER ASSY REMOVAL Removal 2 bolt R.R. SWING ARM REMOVAL Removal “REAR WHEEL NUT“ Removal 2 bolt Removal 1 bolt REMOVAL THE REAR WHEEL. INSTALL REAR WHEEL: OPPSITE TO THE REMOVING OF IT TORQUE: M6:1.2-1.5 kg-m...
  • Page 131 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT WHEEL REMOVAL Raise the front wheel off the grand ground by placing a block or safety stand. Disconnect the speedometer cable. Remove 2 pan head bolt REMOVE THE AXLE SHAFT. Remove front axle nut Remove 2 socket bolt (M6) 《12 -5 》...
  • Page 132 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM REMOVE THE FRONT WHEEL. Removal front axle Removal front wheel AXLE SHAFT INSPECTION Measure the axle shaft run out. SERVICE LIMIT: 0.2 mm FRONT WHEEL RIM RUNOUT INSPECTION Measure the wheel rim run out.
  • Page 133 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT BRAKE DISK CHANGE REMOVEAL FRONT WHEEL Refer to 12-5~12-6 BRAKE DISC REMOVAL Removal 5 bolt BRAKE DISK INSPECTION Brake disc thickness. SERVICE LIMIT: 3.0mm Brake disk flatness. SERVICE LIMIT: 0.3mm INSTALL FRONT BRAKE DISC The installation sequence is essentially the reverse of removal.
  • Page 134 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM REAR BRAKE DISK CHANGE REMOVEAL REAR WHEEL Refer to 12-3~12-4 BRAKE DISC REMOVAL Removal 3 bolt BRAKE DISK INSPECTION Brake disc thickness. SERVICE LIMIT: 3.0mm Brake disk flatness. SERVICE LIMIT: 0.3mm INSTALL REAR BRAKE DISC The installation sequence is essentially the reverse of removal.
  • Page 135 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM BRAKE PAD CHANDGE (FRONT) BRAKE MASTER CYLINDER REMOVAL Removal the caliper from the front fork. Removal 2 bolt Brake pad Remove Removal pin Change brake pad The installation sequence is essentially the reverse of removal.
  • Page 136 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM BRAKE PAD CHANGE (REAR) BRAKE MASTER CYLINDER REMOVAL Removal the caliper from the R.R. SWING ARM Removal 2 bolt Brake pad Remove Removal 2 pin Change brake pad The installation sequence is essentially the reverse of removal.
  • Page 137 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM CALIPER RESOLVE (FRONT) Removal 2 bolt Removal 1 pin Measure the caliper PISTON O.D. SERVICE LIMIT: 30.20 mm Measure the caliper cylinder I. D. SERVICE LIMIT: 30.25mm 《12 -11 》...
  • Page 138 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM CALIPER RESOLVE (REAR) BRAKE PAD REMOVAL Removal 2 pin REMOVAL PISTON Measure the caliper PISTON O.D. SERVICE LIMIT: 30.20 mm Measure the caliper cylinder I. D. SERVICE LIMIT: 30.25mm The installation sequence is essentially the reverse of removal.
  • Page 139 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM DISK BRAKE SYSTEM BRAKE OIL INSPECTION Normal fluid lever is between upper and lower. DISK BRAKE SYSTEM BRAKE OIL INSPECTION Normal fluid lever is between upper and lower. BRAKE OIL CHANGING (FRONT) DRAIN THE BRAKE OIL 1.Release the brake oil passage...
  • Page 140 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM 3.Open the cap to help drain Removal 2 bolt EMPTY INTO NEW BRAKE OIL 1..Fill with new brake oil (DOT-3, DOT-4) 2.Leak out the air ATTENTION!!! This step(1&2) must working together until not have air in brake oil tube 《12 -14 》...
  • Page 141 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM BRAKE OIL CHANGING (REAR) DRAIN THE BRAKE OIL 1.Release the brake oil passage 2.Drain the brake oil 3.Open the cap to help drain Removal 2 bolt EMPTY INTO NEW BRAKE OIL 1.Fill with new brake oil (DOT-3, DOT-4)
  • Page 142 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM 2.Leak out the air ATTENTION!!! This step(1&2) must working together until not have air in brake oil tube BRAKE LINING CHANGE(FRONT) 1. Drain the brake oil (Refer to 12-13 ~ 12-14) 2. Remove the brake caliper setting bolts.
  • Page 143 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM BRAKE LINING CHANGE(REAR) 1. Drain the brake oil Refer to 12-15 2. Remove the brake caliper setting bolts. Remove the brake lining. 3.Removal “STOP SWITCH ASSY” on “MASTER CYLINDER ASSY.2” 4.Change brake lining 5.Install process to refer to reverse of removal.
  • Page 144 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT FORK EXPOLODED VIEW 《12 -18 》...
  • Page 145 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT FORK REMOVAL REMOVE THE FRONT WHEEL. Refer to 13-5~13-6 Remove the front for setting bolt. Refer to 12-8 Remove the front fork. FORK TUBE REMOVAL Removal 4 socket bolt FORK TUBE RESOLVE Removal the rubber cap 《12 -19 》...
  • Page 146 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FORK TUBE RESOLVE 1. Hold the fork tube in a vice 2. To bring pressure to bear on center for 5 to 7kg 3. Removal clip 4. Removal cap bolt 5. Removal o-ring 6.
  • Page 147 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT FORK INSPECTION Measure the fork spring free length. SERVICE LIMIT: 235.7mm Drain the fork from the top of the front fork. Pour out any remaining fluid by pumping the fork up and down several times.
  • Page 148 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FORK TUBE INSPECTION Place the fork tube in V-blocks and measure the run out with a dial indicator gauge. The actual run out is 1/2 of TIR (Total Indicator Reading). SERVICE LIMIT: 0.2mm Measure the fork tube O.
  • Page 149 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM 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.
  • Page 150 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM FRONT FORK ASSEMBLY Before assembly, wash the parts in solvent and wipe them off completely. Insert the fork piston into the fork outer tube and set the inner tube plug on the end of the fork piston.
  • Page 151 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM Install the fork spring into the fork tube. 1. Install the fork spring into the fork tube. Be care for fork spring rebound. 2. Install the cap bolt 3. To bring pressure to bear on cap bolt for 5 to 7kg.
  • Page 152 CPI MOTOR GTR180 XII.WHEEL & BRAKE SYSTEM MEMO…. 《12 -26 》...
  • Page 153 CPI MOTOR GTR180 III.ADDENDUN SPECIAL TOOLS 1. FOR FRAME ASSEMBLY For the front fork For the brake sensor 2. FOR ENGINE ASSEMBLY For A.C.G. 《13 -1 》...
  • Page 154 CPI MOTOR GTR180 XIII.ADDENDUN 《13 -2 》...

  • Page 155: Addendun

    CPI MOTOR GTR180 III.ADDENDUN MEMO…. 《13 -3 》...
  • Page 156 CPI MOTOR GTR180 XIII.ADDENDUN Collaboration Professional Innovation 《13 -4 》...

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