GTR 50 SERVICE MANUAL
Contents
1. 1 2 of total indicator reading STANDARD 0 1mm Check the crankshaft bearing play If they are noisy or have recessive play replace a new one 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 Install the dowel pins Install the right crankcase Install the oil seal into the right crankcase Install the setting bolts of crankcase TORQUE 1 0kg m A C GENERATOR Remove the seat amp 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 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 ALTERNATOR AND REGULATOR CHECK for Tracker and GTR 50 ALTERNATOR A C G Set instrument range to 2000 Q Surge coil resistance within 650 to 850 take red black wire as positive and connect negative to body of A C G Pulsor ignition resistance within 80 to 120 Q take blue yellow white red for GTR wire as positive and connect negative to body of A C G If not within range malfunction REGULATOR Set instrument range to 200 Q Take black wire as posit2. 2 OIL LEVEL TOO HIGH THIN EXHAUST BLACK SMOKE 3 PISTON RINGS EMITTED EMITTED INCORRECTLY INSTALLED 4 FAULTY PISTON OR CYLINDER 5 FLAWS IN CYLINDER HEAD RETURN THROTTLE 1 WORN INTAKE VALVE GRIP QUICKLY WHITE SMOKE GUIDE OR STEM EMITTED 2 EXCESSIVE VALVE TO GUIDE CLEARANCE POOR HANDLING FLOWPATH BADSITUATION PROBABLE CAUSE IF STEELING IS 1 STEERING HEAD ADJUSTER HEAVY TOO TIGHT 2 DAMAGED STEERING CONES OR STEEL BALLS IF EITHER WHEEL 1 EXCESSIVE WHEEL IS WOBBLING BEARING PLAY 2 DISTORTED RIM 3 IMPROPERLY INSTALLED WHEEL HUB 4 SWING ARM PIVOT BUSHING EXCESSIVELY WORN 5 DISTORTED FRAME 6 IMPROPER DRIVE CHAIN TENSION OR ADJUSTMENT IF THE 1 MISAPPLIED SHOCK MOTORCYCLE ABSORBER PULLS TO ONE SIDE 2 FRONT AND REAR WHEELS NOT ALIGNED 3 BENT FRONT FORK 4 BENT SWING ARM ENGINE REMOVAL INSTALLATION 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 Disconnect the A C G wire Disconnect the start motor wire Disconnect the starter plunger wire Disconnect the fuel amp 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 The installation sequence is essentially the reverse of removal NOTE Route all t
3. ANDARD 1 1 2round Adjust the idle speed STANDSRD 1800 100 rpm 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 4nm Check the flatness of reed valve SERVOCE LIMIT 7 0mm REED VALVE INSTALLATION The installation sequence is essentially the reverse of removal CYLINDER HEAD CYLINDER PISTON 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 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 05mm CYLINDER REMOVAL Remove the cylinder head Remove the cylinder Remove the cylinder gasket NOTE Clean all the material of cylinder gasket with a scraper 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 Cylinder block flatness inspections SERVICE LIMITS 0 05mm CYLINDER INSPECTION Inspect the cylinder bore for wear or da
4. GTR 50 SERVICE MANUAL CONTENT PRI tue 3 1 1 TROUBLE SHOOTING 2 1 2 6 ENGINE REMOVALE INSPECTION 3 1 3 2 LUBRICATION SYSTEM y4 1 4 2 PURE SYS EE b ss DA CYLINDEER HEAD CYLINDER 8 gt 6 1 6 5 TRANSMISSION SYSTELM 7 1 7 6 CRANKSHAFT CRANKCASEK 8 1 8 4 A C GENERATOR 7 1 29 2 ELECTRIC SYSTEM se 10 1 10 4 THE CONTENTS OF THIS MANUAL PROVIDE THE SERVICE INFORMATION FOR CPI GTRSO MOST CHAPTERS START WITH A SYSTEM OR ASSEMBLY ILLUSTRATION 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 TROUBLE SHOOTING ENGINE WILL NOT START OR IS HARD TO START x PROBABLECAUSE CHECK IF FUEL FUEL DOES NOT 1 NO FUEL IN TANK REACHES REACH 2 CLOGGED FUEL LINE BETWEEN CARBURETOR CARBURETOR FUEL TANK AND CARBURETOR 3 CLOGGED FUEL VALVE 4 CLOGGED FUEL TANK CAP FUEL REACHES B
5. NER 3 CLOGGED FUEL LINE 4 CLOGGED FUEL TANK CAP BREATHER HOLE 5 CLOGGED MUFFLER INCORRECT TIMING INCORRECT VALVE INCORRECT TIMING ADJUSTMENT 1 INCORRECT VALVE CLEARANCE 2 WORN VALVE SEAT TEST CYLINDER COMPRESSION NORMAL COMPRESSION CARBURETOR FOR CLOGGING CARBURETOR NOT CLOGGED REMOVE SPARK PLUG CHECK OIL LEVEL AND CONDITION 10 ENGINE OIL LEVEL CHECK IF ENGINE OVERHEATS 12 ENGINE DOES NOT OVERHEAT RAPIDLY ACCELERATE OR URN AT HIGH 13 SPEEDS ENGINE DOES NOT KNOCK LOSS OF 1 VALVE STUCK OPEN COMPRESSION 2 WORN CYLINDER AND PISTON RINGS 3 BLOWN CYLINDER HEAD GASKET 4 INCORRECT VALVE TIMING 5 FLAWS IN CYLINDER HEAD OR CYLINDER CARBURETOR 1 CARBURETOR JETS CLOGGED CLOGGED PLUG FOULED OR FOULED PLUG DISCOLORED 2 INCORRECT HEAT RANGE COLORED PLUG OIL DIRTY OR LEVEL 1 LEVEL TOO LOW OR HIGH INCORRECT 2 CONTAMINATED OIL INSUFFICIENTLY 1 CLOGGED OIL PASSAGE LUBRICATED 2 POOR OIL PUMP DELIVERY 1 EXCESSIVE CARBON IN COMBUSTION CHAMBER ENGINE OVERHEATS oy INCORRECT FUEL 3 SLIPPING CLUTCH 1 WORN PISTON OR CYLINDER 2 MIXTURE TOO LEAN 3 INCORRECT FUEL ENGINE KNOCKS 4 EXCESSIVE CARBON COMBUSTION CHAMBER 5 LGNITION TIMING TOO EARLY POOR PERFORMANCE AT IDLE AND LOW SPEEDS FLOWPATH BADSITUATION PROBABLE CAUSE CHECK IGNITION TMING AND VALVE 1 INCORRECT TIMING CLEARANCE INCORREC
6. REATHER HOLE CARB URE TOR REMOVE SPARK PLUG NO SPARK 1 FAULTY OR FOULED PLUG AND TEST SPARK 2 FAULTY C D I 3 BROKEN OR SHORTED HIGH TENSION CORD 4 FAULTY IGNITION SWITCH 5 INCORRECT IGNITION TIMING TEST CYLINDER LOW COMPRESSION 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 START ENGINE ENGINE FIRES BUT 1 CHOKE VALVE OPEN ENGINE FIRES DOES NOT START 2 CARBURETOR PILOT SCREW OPEN 3 AIR LEAKING THROUGH IN TAKE PIPE 4 INCORRECT IGNITION TIMING REMOVE SPARK PLUG WET PLUG 1 FLOODED CARBURETOR DRY PLUG 2 CHOKE VALVE CLOSED START ENGINE WITH CHOKE CLOSED ENGINE LACKS POWER FLOWPATH BADSITUATION PROBABLE CAUSE RAISE WHEELS OFF WHEELS DO NOT GROUND AND SPIN SPIN FREELY WHEELS SPIN FROM LOW TO SECOND ENGINE SPEED IN CHECK IGNITION TIMING CORRECT TIMING CHECK VALVE CLEARANCE CORRECT VALVE CLEARANCE INCORRECT TIRE PRESSURE DOES NOT ACCELERATE WITH ENGINE SPEED RAISED 1 DRAGGING BRAKE 2 FAULTY WHEEL BEARING 3 OVERTIGHTENED DRIVE CHAIN 4 WHEEL BEARING NOT LUBRICATED PROPERLY 1 PUNCTURED TIRE 2 FAULTY TIRE VALVE 1 SLIPPING CLUTCH 2 WORN OR UNEVEN CLUTCH FACINGS 3 CLUTCH PLATE WARPED ENGINE SPEED DOES 1 CARBURETOR CHOKE CLOSED 2 CLOGGED AIR CLEA
7. T TIMING ADJUSTMENT CORRECT TIMING AND CLEARANCE _ 2 INCORRECT VALVE AND CLEARANCE CLEARANCE CARBURETOR PILOT SCREW ADJUSTMENT CORRECTLY INCORRECTLY 1 MIXTURE TOO LEAN ADJUSTED 2 MIXTURE TOO RICH ADJUSTED CHECK FOR AIR 1 FAULTY CARBURETOR LEAKS PACKING 2 CARBURETOR NOT NO AIR LEAKS SECURELY TIGHTENED 3 FAULTY INTAKE PIPE GASKET WEAK OR 1 FAULTY OR FOULED PLUG INTERMITTENT 2 FAULTY C D I SPARK 3 MAGNET AT FAULT POOR PERFORMANCE AT HIGH SPEED FLOWPATH BADSITUATION PROBABLE CAUSE CHECK IGNITION TIMING AND VALVE 1 INCORRECT TIMING CLEARANCE INCORRECT TIMING ADJUSTMENT AND CLEARANCE _ 2 INCORRECT VALVE CORRECT TIMING CLEARANCE AND CLEARANCE DISCONNECT FUEL LINE AT CARBURETOR AND RESTRICTED FUEL FLOW 1 EMPTY FUEL TANK 2 CLOGGED FUEL LINE 3 CLOGGED FUEL TANK CAP BREATHER HOLE 4 CLOGGED FUEL PETCOCK 1 CLOGGED JET CARBURETOR JET CLOGGED 2 CLOGGED FUEL FILTER FOR CLOGGING 3 CLOGGED FUEL VALVE NOT CLYGGED 1 JET SIZE TOO SMALL 2 IF CONDITION IS IMPROVED CONDITION WITH SMALL JET AGGRAVATED A CLOGGED AIR CLEANER B CHOKE NOT OPENED FULLY INCORRECT VALVE TIMING EN ADJUSTMENT CHECK VALVE SPRING TENSION WORN OR BROKEN SPRING TENSION SPRING CORRECT FAULTY VALVE SPRING SMOKY EXHAUST FLOWPATH BADSITUATION PROBABLE CAUSE RUN MOTORCYCLE 1 WORN CYLINDER AND A LONG DISTANCE PISTON RINGS AT HIGH SPEED
8. he wire and cable properly Adjust the throttle cable free play clearance Adjust the rear brake free play TORQUE TORQUE STANDARD INNER OF ENGING side side thread 3 Cylinder head 3 bolt B EXH pipe joint bolt Drivefacenut 1 17 7 35 40 5 0 O Oil pump bolt 08 Cylinder head 2 10 1 5 cover bolt 1 8 Spark plug 1 ITEM AMOUT DIAMETER mm TORQUE kg m 4 5 Shaft steering nut 1 10 45 Wheelaxlemt 1 12 1 60 RR Wheelaxlemut 1 16 90 3 0 up RR shock absorber bolt 3 0 down ENG Hanger BRKT Bolt LUBRIFICATION SYSTEM Remove luggage box amp side covers Disconnect the oil tube of oil pump intake amp output Remove the oil pump control cable Remove the setting bolt of oil pump Remove the oil pump Check the O ring gear amp seal for wear or any damage NOTE Do not disassembly the oil pump body to prevent any damage 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 LUBRIFICATION SYSTEM 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 FUEL SYSTEM Remove the seat Remove the luggage box Loose the carburetor cap of throttle valve Remove the throttle val
9. ive Black to red 2 680 Black to pink 2 140 Black to yellow 1 279 Black to green 556Q Must have those values if not malfunction NOIR black JAUNE vellow VERT green
10. mage 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 2mm Calculate the piston to cylinder clearance SERVICE LIMITS 0 1mm Calculate the taper and out of round SERVICE LIMITS Out of round 0 05mm Taper 0 05nn Measure piston pin bore O D at a point 10mm from the bottom A STANDARD 39 95mnm Measure piston pin bore I D in two directions at right angle to each other STANDARD 12 05mm Measure the piston pin O D at the front center and rear and in two directions across from each other STANDARD 12 05mm Insert each piston ring into cylinder with the piston and measure the ring end gap in the cylinder to a point 10mm 0 04 in from bottom STANDARD Top Second 0 15 0 35mm Connecting rod small end inspections SERVICE LIMITS 14 06mn 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 PISTON INSTALLATION Install the piston piston pin and new piston pin clips NOTE X Piston the EX mark on the exhaust side Do not let the piston pin clip fall into the crankcase Install the cylinder gasket Coat the cylinder and piston ring with the engine oil Install the cylinder COMPRESSION PREASURE TEST NOTE Wo
11. rm up the engine before test Remove the seat amp luggage box Remove the spark plug cap amp 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 TRANSMISSION SYSTEM 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 amp plate washer Remove the kick spindle bush Remove the spindle amp the spring Remove the O ring Remove the setting nut of clutch outer Remove the clutch outer amp driven pulley Remove the drive belt Remove the setting nut of driver face Remove the conical spring washer amp the one way clutch Remove the claw washer driver face amp plat washer Remove the movable drive face amp collar Remove the starter clutch amp 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 measure the width of belt SERVICE LIMIT 14 60mm WEIGHT ROLLER INSPECTION Measure the weight roller O D SERVICE LIMIT 14 5mm 4 am wz O Q QOS 14 60mm MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face I D STANDARD 20 5mm BOSS OF DRIVEN FACE INSPECTION Measure the bos
12. s I D SERVICE LIMIT 17 90nn CLUTCH OUTER INSPECTION Measure clutch outer I D STANDARD 109 5mm CLUTCH LINING INSPECTION Measure the lining thickness STANDARD 1 0mm Fix the driven pulley in a compressor Remove the special nut 28mm Release the compressor Remove the driven plat assy DRIVEN FACE SPRING INSPECTION Measure the spring free leant STANDARD 89 5mm DRIVEN FACE INSPECTION Measure the drive face O D STANDARD 33 94mm MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face I D STANDARD 34 06mm Final transmission gear removal Drain the gear oil Remove the mission cover Remove mission cover gasket amp dowel pin Remove final shaft amp final gear Remove counter shaft FINAL GEAR TRANSMISSION GEAR INSPECTION Inspect the gears amp shafts for wear or damage CRANKSHAFT CRANKCASE 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 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge STANDARD 0 55 mm Measure the connecting rod big end radial clearance at two different point across from each other STANDARD 0 05nn Place the crankshaft on a stand or V blocks and measure the run out using a dial gauge Actual bend is
13. ve 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 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 between the intake pipe amp the carburetor Remove the carburetor 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 Connect a full charged battery to the starter plunger wore for five minutes Check the current of route as show GOOD IMPASSABLE NG PASSABLE 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 Remove the main jet slow jet needle seat amp air screw Clean all the jet amp all the hole by using high pressure air FUEL HEIGHT INSPECTION Measure the height by using a gauge STANDARD 18 5mm CARBURETOR INSTALLATION The installation sequence is essentially the reverse of remove Adjust the clearance of the throttle valve cable Adjust the air screw ST
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