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CPI GTR 50 Service Manual

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Summary of Contents for CPI GTR 50

  • Page 1 Collaboration Professional Innovation...
  • Page 3 §C O N T E N T S § PREFACE..................2-1∼ 2-6 TROUBLE SHOOTING……………….…......... 3-1∼ 3-2 ENGINE REMOVALE INSPECTION........4-1∼ 4-2 LUBRICATION SYSTEM………………..…......5-1∼ 5-4 FUEL SYSTEM………………………………......6-1∼ 6-5 CYLINDEER HEAD-CYLINDER PISTON..…….... 7-1∼ 7-6 TRANSMISSION SYSTEM………........... 8-1∼ 8-4 CRANKSHAFT-CRANKCASE....…......9-1∼9-2 A.C.GENERATOR......………...……..……..
  • Page 4 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: Trouble Shooting

    CPI MOTOR GTR50 TROUBLE SHOOTING ENGINE WILL NOT START OR IS HARD TO START PROBABLE CAUSE CHECK IF FUEL REACHES FUEL DOES NOT REACH (1) NO FUEL IN TANK CARBURETOR CARBURETOR (2) CLOGGED FUEL LINE BETWEEN FUEL TANK AND CARBURETOR...
  • Page 6 CPI MOTOR GTR50 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 WHEELS SPIN FREELY (3) OVERTIGHTENED DRIVE CHAIN (4) WHEEL BEARING NOT...
  • Page 7 CPI MOTOR GTR50 TROUBLE SHOOTING TEST CYLINDER LOSS OF COMPRESSION (1)VALVE STUCK OPEN COMPRESSION (2) WORN CYLINDER AND PISTON RINGS NORMAL (3) BLOWN CYLINDER HEAD GASKET COMPRESSION (4) INCORRECT VALVE TIMING (5) FLAWS IN CYLINDER HEAD OR CYLINDER CHECK CARBURETOR...
  • Page 8 CPI MOTOR GTR50 TROUBLE SHOOTING POOR PERFORMANCE AT IDLE AND LOW SPEEDS FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TMING AND VALVE (1) INCORRECT TIMING CLEARANCE INCORRECT TIMING ADJUSTMENT CORRECT TIMING AND AND CLEARANCE (2) INCORRECT VALVE CLEARANCE CLEARANCE...
  • Page 9 CPI MOTOR GTR50 TROUBLE SHOOTING POOR PERFORMANCE AT HIGH SPEED FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TIMING AND VALVE CLEARANCE INCORRECT TIMING (1) INCORRECT TIMING ADJUSTMENT AND CLEARANCE (2) INCORRECT VALVE CLEARANCE CORRECT TIMING AND CLEARANCE DISCONNECT FUEL...
  • Page 10 CPI MOTOR GTR50 TROUBLE SHOOTING SMOKY EXHAUST FLOW PATH BAD SITUATION PROBABLE CAUSE RUN MOTORCYCLE A (1) WORN CYLINDER AND PISTON LONG DISTANCE AT RINGS HIGH SPEED (2) OIL LEVEL TOO HIGH THIN EXHAUST BLACK SMOKE EMITTED (3) PISTON RINGS INCORRECTLY...
  • Page 11 CPI MOTOR ENGINE REMOVAL/INSTALLATION GTR50 ENGINE REMOVAL 1. Open and 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.
  • Page 12 CPI MOTOR ENGINE REMOVAL/INSTALLATION GTR50 Disconnect the fuel & the vacuum tube. Disconnect the spark plug cap. Disconnect 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.
  • Page 13 CPI MOTOR ENGINE REMOVAL/INSTALLATION GTR50 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 CPI MOTOR LUBRICATION SYSTEM GTR50 OIL PUMP REMOVAL Remove luggage box & side covers. Disconnect the oil tube of oil pump (intake & output). Remove the oil pump control cable. Remove the setting bolt of oil pump. Remove the oil pump.
  • Page 15 CPI MOTOR LUBRICATION SYSTEM GTR50 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 CPI MOTOR FUEL SYSTEM GTR50 THROTTLE VALVE REMOVAL Remove the seat. Remove the luggage box. Loose the carburetor cap of throttle valve. 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 17 CPI MOTOR FUEL SYSTEM GTR50 Remove the carburetor and let it cool down by nature for thirty minutes. Check the current of air route as show. GOOD : PASSABLE NG :IMPASSABLE BLOW Connect a full charged battery to the starter plunger wore for five minutes.
  • Page 18 CPI MOTOR FUEL SYSTEM GTR50 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 ㎜...
  • Page 19 CPI MOTOR FUEL SYSTEM GTR50 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 : 7.0 ㎜...
  • Page 20 CPI MOTOR CYLINDER HEAD/CYLINDER/PISTON GTR50 CYLINDER HEAD REMOVAL Put the right side of vehicle on the ground. Attention! Please have a protected pad on the proper location of the ground to avoid crash or damage of plastic parts. Remove the spark plug cap.
  • Page 21 CPI MOTOR CYLINDER HEAD/CYLINDER/PISTON GTR50 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.
  • Page 22 CPI MOTOR CYLINDER HEAD/CYLINDER/PISTON GTR50 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.
  • Page 23 CPI MOTOR CYLINDER HEAD/CYLINDER/PISTON GTR50 Connecting rod small end inspections: SERVICE LIMITS: 14.06 ㎜. PISTON RING INSTALLATION Clean the piston ring grooves thoroughly. Install the piston ring. NOTE: Avoid piston and piston ring damage during installation. All ring should be installed with the mark facing up.
  • Page 24 CPI MOTOR CYLINDER HEAD/CYLINDER/PISTON GTR50 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.
  • Page 25 CPI MOTOR TRANSMISSION SYSTEM GTR50 LEFT CRANKCASE COVER REMOVAL Remove the start 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.
  • Page 26 CPI MOTOR TRANSMISSION SYSTEM GTR50 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.
  • Page 27 CPI MOTOR TRANSMISSION SYSTEM GTR50 START CLUTCH REMOVAL Remove the starter clutch & starter 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 14.60mm...
  • Page 28 CPI MOTOR TRANSMISSION SYSTEM GTR50 MOVABLE DRIVEN FACE INSPECTION 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.
  • Page 29 CPI MOTOR TRANSMISSION SYSTEM GTR50 DRVIEN PULLEY DISASSEMBLY Fix the driven pulley in a compressor. 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 ㎜...
  • Page 30 CPI MOTOR TRANSMISSION SYSTEM GTR50 Final 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 CPI MOTOR CRANKSHAFT/CRANKCASE GTR50 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 CPI MOTOR CRANKSHAFT/CRANKCASE GTR50 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge. STANDARD: 0.55 ㎜ Measure 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.
  • Page 33 CPI MOTOR CRANKSHAFT/CRANKCASE GTR50 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. 《8-3》...
  • Page 34 CPI MOTOR CRANKSHAFT/CRANKCASE GTR50 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. 《8-4》...
  • Page 35 CPI MOTOR A.C.GENERATOR GTR50 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.
  • Page 36 CPI MOTOR A.C.GENERATOR GTR50 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. 《9-2》...
  • Page 37 CPI MOTOR ELECTRIC SYSTEM GTR50 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.
  • Page 38 CPI MOTOR ELECTRIC SYSTEM GTR50 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 ( 20℃) Check the secondary coil for continuity.
  • Page 39 CPI MOTOR ELECTRIC SYSTEM GTR50 IGNITION TIMING INSPECTION 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.
  • Page 40 CPI MOTOR ELECTRIC SYSTEM GTR50 《10-4》...
  • Page 41 CPI MOTOR GTR50 ADDENDUM REGULAR INSPECTION The chart below lists the recommended intervals for all the returned periodic service work necessarily to keep the motorcycle operating at peak performance and utmost efficiency. Mileages are expressed in terms of kilometers and months.
  • Page 42 CPI MOTOR GTR50 ADDENDUM 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. 《11-2》...
  • Page 43 CPI MOTOR GTR50 ADDENDUM COOLING SYSTEM DRAWING clamp ×2 PLIERS 《11-3》...

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