CPI JR50/90 Service Manual 2t
Contents
1. www fineprint com cn CYLINDER INSTALLATION Install the cylinder gasket Coat the cylinder and piston ring with the engine oll Install the cylinder COMPRESSION PREASURE TEST NOTE Worm up the engine before test Remove the seat amp luggage box cD Remove the spark plug cap amp spark plug e Turn the throttle grip with the throttle val on the upset position Start the motor for 7 8 seconds oe the pressure STANDARD 10 0 kg cn 600 rim S eS PDF pdfFactory www fineprint com cn 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 Remove the driven pulley and drive beet EY SS ee Ned Remove the settin of driver face Remove the conical spring washer and the one way clutch Remove the claw washer driver face and plat washer PDF pdfFactory www fineprint com cn Hemove the movable drive and collar Remove the starter clutch and starter wheel Remove the gear boss Hemove 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 w2. PDF pdfFactory www fineprint com cn PREFACE ccccscccssssccessscccssccccesssccessscccssecccesssccessecccesscccesscceceees 1 1 1 2 ENGINE REMOYVE eeeeeee esse 2 1 2 4 ENGINE INSTALLATION cccccccsccoscccccssssecsssccccsscsccsscccceescees 3 1 3 2 LUBRICATION SYSTEML cte x CO 4 1 4 2 FUEL SYSTEM 5 1 5 4 xo CYLINDER HEAD CYLINDER PISTON Q 6 1 6 6 MM SS TANSMISSION Q 7 1 7 6 o CRANKSHAFT CRANKCASE 6 8 1 8 4 N S EMERAJ 0 9 1 9 2 ELECTRIC SYSTEM ccccccssssscsssssccsssccccssccccsssccesssccesscceees Q 10 1 10 6 CHASSIS Q11 1 11 2 PDF pdfFactory www fineprint com cn 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 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 Qv Ka AN e OV AM EN RS S ee QY NO AS lt PDF pdfFactory www fineprint com cn Hemove the s
3. crankcase NO S Install the setting crankcase TORQUE 1 0 PDF pdfFactory www fineprint com cn 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 CHARGING TIME STANDARD 5 hrs SWIFTNESS 30 min A C G COIL INSPECTION Check the continuity between the and the green wire STANDARD S Check the continuity the yellow and the green wire N STANDARD lt RESISTER INSPECTION Check the continuity between the wire of resister and earth STNADARD RESISTER RESISTER PDF pdfFactory www fineprint com cn C D INSPECTION SPARK NO SPARK T 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 20 Check the secondary coil for continuity ce The ignite coil is correct if there is continul D STANDSRD NS With plug cap 7 12 ko NN No plug cap 3 5 kO AS ee Check the coil outpu amp o n a ignition coil tester Set the tester todgnition test dial out the electrodes and observe the spark
4. runout with a dial indicator gauge The actual runout is 1 2 of TIR Total Indicator Reading SERVICE LIMIT 0 2 mm amp S Hemove the du al cover Remove the snap ring with a snap ring c pliers FN SNAP RUN RING d OIL SEAL PDF pdfFactory www fineprint com cn 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 l D SERVICE LIMIT 31 1 mm FRONT FORK ASSEMBLY Before assembly wash the parts in solvent and wipe them off Ps ALLEN WRENCH Insert the seat ipfo the fork tube and set the oil lock pi ce on the end of the seat pipe Insert the parts into the fork slider and tighten the socket bolt with the 6 mm Allen wrench NOTE Apply locking agent to the socket bolt TORQUE 1 8 2 3 kg m SEAT PIPE PDF pdfFactory www fineprint com cn 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 bal FOR SEAL DRIVEN ATT ar Tuan Install the snap ring into the groove of the fork bottom case with snap ring p
5. D SERVICE LIMIT 11 03mm Measure the piston of master cylinder SERVICE LIMIT 10 97mm BRAKE CALIPER REMOVAL f Remove the caliper from the front fork S Disconnect the brake oil tube S 9 o ee Qr NO DISASSEMBLY SN Remove the brake pad PDF pdfFactory www fineprint com cn Remove the caliper piston Remove the oil seal Measure the caliper cylinder I D SERVICE LIMIT 30 25mm S O Measure the calfper PISTON O D SERVICE LIMIT 30 20 mm PDF pdfFactory www fineprint com cn 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 FRONT FORK INSPECTION Measure the fork spring free length SERVICE LIMIT 235 7 SU ee Drain the fork from th top of the front fork Pour out any remaining fluid by pumping the fork up and down several times PDF pdfFactory www fineprint com cn Hold the bottom case in a vice Hemove 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
6. Disconnect the speedometer cable Hemove the axle shaft Hemove the front wheel AXLE SHAFT INSPECTION Measure the axle shaft runout SERVICE LIMIT 0 2 nn FRONT WHEEL RIM RUNOUT INSPECTION Measure the wheel rim runout RNY SERVICE LIMIT amp Radial 2 0 mn O Axial 2 0 mm o ee C cS DISK BRAKE SYSTEM BRAKE OIL INSPECTION Normal fluid lever is between upper and lower PDF pdfFactory www fineprint com cn 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 AN Remove the brake lining setting bolts sS Remove the brake lining O NS e C The installation ence Is essentially the reverse of removal PDF pdfFactory www fineprint com cn BRAKE DISK INSPECTION Brake disc thickness SERVICE LIMIT 3 0 mm Brake disk flatness SERVICE LIMIT 0 3 mm BRAKE MASTER CYLINDER REMOVAL Drain the brake oll Remove the brake oil tube Remove the master cylinder DISASSENBLY Remove the cir clip ee SN Remove the masteryiinder kit Clean all the PDF pdfFactory 211755 www fineprint com cn INSPECTION Inspect the master cylinder for wear or crack Measure the master cylinder I
7. F pdfFactory www fineprint com cn 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 AM G lt Remove the pearing crankcase by using a bearing pulley PDF pdfFactory www fineprint com cn CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge SERVICE LIMIT 0 55 mm Measure the connecting rod big end radial clearance at two different point across from each other SERVICE LIMIT 0 05 mm O Place the crankshaft on a stand or V blockg C and measure the run out using a dial gauge Actual bend is 1 2 of total indicator readtag SERVICE LIMIT 0 1 mm G Check the cranksh earing play If they are Noisy OV ave recessive play replace a new one PDF pdfFactory www fineprint com cn CRANKCASE INSTALLATION Install the crankshaft bearing into the left crankcase Install the crankshaft bearing into the right crankcase Install the crankshaft into the left S O o ee Ned Install the oil seal into he left crankcase Q PDF pdfFactory www fineprint com cn Install the dowel pins Install the right crankcase Install the oil seal into the right
8. Remove the setting bolt of oil pump Remove the oil pump PDF pdfFactory 211735 www fineprint com cn Oil pump inspection Check the O ring gear amp 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 ce Connect the oil tube AM E Connect the oil pump control cable ands JN Y adjust the clearance RN be SS EOM 9 Em B RELEASE THE JR 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 pdfFactory www fineprint com cn 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 a needle clip from the throttle valve AN INSPECTION Check the throttle valve and th needle surface of dirt or wear amp S CARBURETO MOVAL 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
9. TANDARD 6 0 6 4 mm Check the flatness of reed valve SERVOCE LIMIT 10 REED VALVE INSTALLATION The installation sequence is essentiall the reverse of removal SU ee SN e PDF pdfFactory 261735 www fineprint com cn CYLINDER HEAD REMOVAL Hemove the seat amp 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 AM SERVICE LIMIT 0 05 mm RN CYLINDER RE AL Remove the cylinder head Remove the cylinder Remove the cylinder gasket NOTE Clean all the material of cylinder gasket with a scraper PDF pdfFactory www fineprint com cn PISTON REMOVAL Hemove the piston pin clip NOTE Do not let the clip fall into the crankcase Remove the piston pin Hemove 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 05 mm NO CYLINDER INSPEGTION Inspect the cylindgPbore for wear or damage Measure the cylinder 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 mm 52 2
10. bolts between the intake pipe amp the carburetor Remove the carburetor PDF pdfFactory www fineprint com cn 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 Connect a full charged battery to the starter plunger wore for five minutes Check the current of route as show GOOD CHECKED NG CHECKLESS FLOAT CHAMBER DISASSEMBLY Hemove the setting screws Hemove the chamber cap S Hemove the float setting bolt Hemove the float pin Remove the float Remove the float valve PDF pdfFactory www fineprint com cn 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 5 mm CARBURETOR INSTALLATION The installation sequence is essentially ws the reverse of remove RS O O ee NN SN O Adjust the clearaace of the throttle valve cable Adjust the air screw STANDARD 15 round Adjust the idle speed STANDSRD 1800 100 rpm PDF pdfFactory www fineprint com cn REED VALVE REMOVAL Remove the carburetor Remove the intake pipe Remove the reed valve REED VALVE INSPECTION Measure the height of reed valve stopper S
11. eat amp the luggage box Remove the side covers Remove the luggage box Remover the side cover 2 NO 1 Remove the RR age carrier comp 2 Remove the sid toversi PDF pdfFactory 261735 www fineprint com cn 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 NO Remove the setting Bol of rear cushion PDF pdfFactory www fineprint com cn Remove the setting bolt of engine Remove the engine PDF pdfFactory www fineprint com cn PDF pdfFactory www fineprint com cn ENGIME INS 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 pdfFactory www fineprint com cn OIL PUMP REMOVAL Remove the seat luggage box and side covers Remove the cooling fan cover cooling fan A C G Disconnect the oil tube of oil tube of oll Pump intake and output Remove the oil pump control cable
12. gap GOOD Continuous spark NG Discontinuous spark NOTE Follow the instructions supplied with the tester A C G INSPECTION PDF pdfFactory www fineprint com cn EXCITER COIL INSPECTION Disconnect the black red wire of A C Check the black red and earth wire for continuity STANDARD 3000 1 20C PLUSER COIL INSPECTION Disconnect the blue yellow wire of A C G Check the blue yellow wire and green wire for continuity STANDARD 40 300 20 C IGNITION TIMING INSPECTION Check the ignition timing by using a timing light after warm up the engine AN STANDARD BTDC 13 1 1700 100rpm S eo NO START MOROTR S START MORTQR INSPECTION Connect a battery 12 V to the motor Check the performance of the motor NOTE Use a fully charged battery PDF pdfFactory www fineprint com cn 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 FLOATUP FLOAT DOWNA GREEN YELLOW WHITE 30 450 CN GREEN BLUE WHITE 400 7002 Qro YELLOW WHITE CIN gt 450 75 450 750 BLUE WHITE O FUEL INDICATOR INSPECTION Remove the fuel gauge from the fuel tank Turn the main switc
13. h on Move the float from down to up if the guideline of indicator from E to Move the float from up to down if the guideline of indicator from F to E PDF pdfFactory www fineprint com cn OIL LEVEL GAUGE REMOVAL Hemove the seat amp 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 BLUE WHITE aue o AS Ww w PDF pdfFactory www fineprint com cn HEAD LIGHT SWITCH Bad yellow white Black Red Umber whi SWITCH INSPECTION MAIN SWITCH PDF pdfFactory www fineprint com cn 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 M 2 2 3 0kg m M14 11 5 12 5kg m 1 METHOD TO CHECK REAR BRAKE H 69 1 MEASURE THE INTERNAL DIAMETER OF THE REAR BRAKE 2 USE LIMITATION EC WHEN OVER 110 5MM 2 METHOD TO CHECK mE 1 CHECK THE SS OF REAR BRAKE SHOE 2 USE LIMITATI N REPLACED WHEN UNDER 0MM PDF pdfFactory www fineprint com cn FRONT WHEEL REMOVAL Raise the front wheel off the grand ground by placing a block or safety stand
14. idth of belt SERVICE LIMIT 14 6 mm WEIGHT ROLLER INSPECTION Measure the weight roller O D SERVICE LIMIT 14 5 mm S 2 Ned lt MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face I D SERVICE LIMIT 17 5 mm 20 5 mm PDF pdfFactory www fineprint com cn BOSS OF DRIVEN FACE INSPECTION Measure the boss l D SERVICE LIMIT 23 94 mn CLUTCH OUTER INSPECTION Measure clutch outer I D SERVICE LIMIT 109 5 mm CLUTCH LINING INSPECTION Measure the lining thickness SERVICE LIMIT 1 5 mm I lt O O ee NN DRVIEN PULLEY DISASSEMBLY Fix the driven p in a compressor Remove the special nut 26 mm Release the compressor Remove the driven plat assy PDF pdfFactory www fineprint com cn DRIVEN FACE SPRING INSPECTION Measure the spring free leant SERVICE LIMIT 67 mn Te 89 5 mm DRIVEN FACE INSPECTION Measure the driven face O D SERVICE LIMIT 33 94 mn MOVABLE DRIVEN FACE INSPECTION Measure the movable drive face 1 Qs SERVICE LIMIT 34 06 mm 9 Final transmission gear removal Drain the gear oll Remover the mission cover gasket and dowel pin PDF pdfFactory www fineprint com cn Remove the counter shaft and final shaft FINAL GEAR TRANSMISSION GEAR INSPECTION Inspect the gears and shafts for wear or damage PD
15. liers Fill the forks with good quality ATF Automatic Transmission Florid CAPACITY 61 cc Install the fork spring into the fork tube sS NOTE Install the fork spring wap he tightly wound coils fa p Hold the fork tube in a Vice c Tighten the fork bolt TORQUE 4 0 5 0 e STEERING STEM REMOVAL Remove the steering handle Hemove the speedometer cable amp front brake cable from the fork Remove the steering top thread nut PDF pdfFactory 211735 www fineprint com cn Hemove 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 Ka Install the steeri Sea nut and tighten it until dd 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 pdfFactory www fineprint com cn Hemove 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 pdfFactory www fineprint com cn
16. mm PDF pdfFactory www fineprint com cn Calculate the piston to cylinder clearance SERVICE LIMITS 0 1 mm Calculate the taper and out of round SERVICE LIMITS Out of round 0 05 mm Taper 0 05 mm Measure piston pin bore O D at a point 10 mm from the bottom SERVICE LIMITS 39 95 mn 51 95 mm Measure piston pin bore l D in two a directions at right angle to each other A SERVICE LIMITS 10 05 mn 12 05 mm Measure the piston pin D front center and rear and in two difettions across from each other QY SERVICE LIMIT 9 95 11 CQ Insert each pistowring into cylinder with the piston and measure the ring end gap in the cylinder to a point 10 mm 0 04 in from the bottom SERVICE LIMITS Top Second 0 15 0 35 mm PDF pdfFactory www fineprint com cn Connecting rod small end inspections SERVICE LIMITS 14 06 nn 15 06 mm PISTON RING INSTALLATION Clean the piston ring grooves thoroughly Install the piston ring NOTE Avoid piston and piston ring damage during installation i All ring should be installed X with the mark facing lt lt ee S PISTON INSTAEKATION Install the piston piston pin and new piston pin clips NOTE Piston the EX mark on the exhaust side i Do not let the piston pin clip fall into the crankcase PDF pdfFactory
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