CPI GTR180 User manual

CONTENTS
PREFACE 1
TROUBLE SHOOTING 2
SERVICEINFORMATION 3
ENGINE REMOVAL&INSTALLATION 4
CYLINDER&PISTON 5
OILPUMPREMOVAL 6
CYLINDER HEAD & CAM SHAFT REMOVAL 7
CARBURETORREMOVAL 8
DRIVE AND DRIVEN PULLEYS & KICK STARTER 9
ELECTRICSYSTEM 10
FRAME 11
WHEEL & BRAKE SYSTEM 12
ADDENDUN 13

CPIMOTOR GTR180
I.PREFACE
《1-1》
THE CONTENTS OF THIS MANUAL PROVIDE THE AFTER SERVICE
INFORMATION FOR CPI /GTR180
MOST CHAPTERS START WITH A SYSTEM OR ASSEMBLY
ILLUSTRATION AND SPECIFICATIONS THE FOLLOWING PAGES GIVEN
DETAILED PROCEDURES.
IF YOU DO NOT KNOW WHAT THE SOURCE OF THE TROUBLE IS,
PLEASE GO TO THE TROUBLE SHOOTERS FOR ADDITIONAL HELP.
ALL THE CONTENTS OF THIS MANUALARE BASED ON THE LATEST
MODEL INFORMATION AND CPI RESERVES THE RIGHT TO MAKE CHANGE
ATANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR
ENGAGEMENT ON OUR PART.

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-1》
ENGINE WILL NOT BE STARTED OR HARD TO START
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IF FUEL CAN BE
REACHED CARBURETOR
FUEL REACHES
CARBURETOR
FUEL DOES NOT REACH
CARBURETOR
(1) NO FUEL IN TANK
(2) CLOGGED FUEL LINE BETWEEN
FUEL TANK AND CARBURETOR
(3) CLOGGED FUEL VALVE
(4) CLOGGED FUEL TANK CAP
BREATHER HOLE
2
REMOVE SPARK PLUG
AND TEST SPARK
GOOD SPARK
WEAK OR NO SPARK (1) FAULTY OR FOULED PLUG
(2) FAULTY C.D.I.
(3) BROKEN OR SHORTED HIGH
TENSION CORD
(4) FAULTY IGNITION SWITCH
(5) INCORRECT IGNITION TIMING
3
TEST CYLINDER
COMPRESSION
NORMAL COMPRESSION
LOW COMPRESSION (1) 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
4
START ENGINE
ENGINE FIRES
ENGINE FIRES, BUT
DOES NOT START
(1) CHOKE VALVE OPEN
(2) CARBURETOR PILOT SCREW OPEN
(3) AIR LEAKING THROUGH IN TAKE
PIPE
(4) INCORRECT IGNITION TIMING
5 REMOVE SPARK PLUG
DRY PLUG
WET PLUG (1) FLOODED CARBURETOR
(2) CHOKE VALVE CLOSED
6 START ENGINE WITH
CHOKE CLOSED

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-2》
ENGINE LACKS POWER
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
RAISE WHEELS OFF
GROUND AND SPIN
WHEELS SPIN FREELY
WHEELS DO NOT SPIN
FREELY
(1) DRAGGING BRAKE
(2) FAULTY WHEEL BEARING
(3) OVERTIGHTENED DRIVE CHAIN
(4) WHEEL BEARING NOT LUBRICATED
PROPERLY
2
CHECK TIRE PRESSURE
NORMAL PRESSURE
INCORRECT TIRE
PRESSURE
(1) PUNCTURED TIRE
(2) FAULTY TIRE VALVE
3
RAPIDLY ACCELERATE
FROM LOW TO SECOND
ACCELERATES
DOES NOT ACCELERATE
WITH ENGINE SPEED
RAISED
(1) SLIPPING CLUTCH
(2) WORN OR UNEVEN CLUTCH
FACINGS
(3) CLUTCH PLATE WARPED
4
REV UP GRADUALLY
ENGINE SPEED INCREASED
ENGINE SPEED DOES NOT
INCREASE
(1) CARBURETOR CHOKE CLOSED (2)
CLOGGED AIR CLEANER
(3) CLOGGED FUEL LINE
(4) CLOGGED FUEL TANK CAP
BREATHER HOLE
(5) CLOGGED MUFFLER
5
CHECK IGNITION TIMING
CORRECT TIMING
INCORRECT TIMING INCORRECT TIMING ADJUSTMENT
6
CHECK VALVE CLEARANCE
CORRECT VALVE
CLEARANCE
INCORRECT VALVE (1) INCORRECT VALVE CLEARANCE
(2) WORN VALVE SEAT

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-3》
7
TEST CYLINDER
COMPRESSION
NORMAL COMPRESSION
LOSS OF COMPRESSION (1)VALVE STUCK OPEN
(2) WORN CYLINDER AND PISTON RINGS
(3) BLOWN CYLINDER HEAD GASKET
(4) INCORRECT VALVE TIMING
(5) FLAWS IN CYLINDER HEAD OR
CYLINDER
8
CHECK CARBURETOR FOR
CLOGGING CARBURETOR
NOT CLOGGED
CARBURETOR
CLOGGED
(1) CARBURETOR JETS CLOGGED
9 REMOVE SPARK PLUG PLUG FOULED OR
DISCOLORED COLORED
(1) FOULED PLUG
(2) INCORRECT HEAT RANGE PLUG
10
CHECK OIL LEVEL AND
CONDITION
CORRECT ENGINE OIL
LEVEL
OIL DIRTY OR LEVEL
INCORRECT
(1) LEVEL TOO LOW OR HIGH
(2) CONTAMINATED OIL
11
REMOVE CYLINDER HEAD
COVER AND CHECK
SUFFICIENTLY
LUBRICATION
INSUFFICIENTLY
LUBRICATED
(1) CLOGGED OIL PASSAGE
(2) POOR OIL PUMP DELIVERY
12
CHECK IF ENGINE
OVERHEATS ENGINE DOES
NOT OVERHEAT
ENGINE OVERHEATS (1) EXCESSIVE CARBON IN COMBUSTION
CHAMBER
(2) INCORRECT FUEL
(3) SLIPPING CLUTCH
13
RAPIDLY ACCELERATE OR
URN AT HIGH SPEED
ENGINE
DOES NOT KNOCK
ENGINE KNOCKS (1) WORN PISTON OR CYLINDER
(2) MIXTURE TOO LEAN
(3) INCORRECT FUEL
(4)EXCESSIVE CARBON IN COMBUSTION
CHAMBER
(5) LGNITION TIMING TOO EARLY

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-4》
POOR PERFORMANCE AT IDLEAND LOW SPEEDS
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IGNITION TMING
AND VALVE CLEARANCE
CORRECT TIMING AND
CLEARANCE
INCORRECT TIMING AND
CLEARANCE
(1) INCORRECT TIMING ADJUSTMENT
(2) INCORRECT VALVE CLEARANCE
2
CHECK CARBURETOR
PILOT SCREW
ADJUSTMENT
CORRECTLY ADJUSTED
INCORRECTLY ADJUSTED (1) MIXTURE TOO LEAN
(2) MIXTURE TOO RICH
3
CHECK FOR AIR LEAKS
NO AIR LEAKS
AIR LEAKS (1) FAULTY CARBURETOR PACKING
(2) CARBURETOR NOT SECURELY
TIGHTENED
(3) FAULTY INTAKE PIPE GASKET
4
REMOVE SPARK PLUG AND
TEST SPARK
WEAK OR INTERMITTENT
SPARK
(1) FAULTY OR FOULED PLUG
(2) FAULTY C.D.I.
(3) MAGNET AT FAULT

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-5》
POOR PERFORMANCE AT HIGH SPEED
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IGNITION TIMING AND
VALVE CLEARANCE
CORRECT TIMING AND
CLEARANCE
INCORRECT TIMING
AND CLEARANCE
(1) INCORRECT TIMING ADJUSTMENT
(2) INCORRECT VALVE CLEARANCE
2
DISCONNECT FUEL LINE AT
CARBURETOR AND CHECK FOR
CLOGGING
UNRESTRICTED FUEL FLOW
RESTRICTED FUEL
FLOW
(1) EMPTY FUEL TANK
(2) CLOGGED FUEL LINE
(3) CLOGGED FUEL TANK CAP
BREATHER HOLE
(4) CLOGGED FUEL PETCOCK
3
CHECK FUEL FILTER, FUEL VALVE
AND CARBURETOR JET FOR
CLOGGING
NOT CLOGGED
CLOGGED (1) CLOGGED JET
(2) CLOGGED FUEL FILTER
(3) CLOGGED FUEL VALVE
4
REPLACE CARBURETOR MAIN JET
CONDITION IMPROVED
CONDITION
AGGRAVATED
(1) JET SIZE TOO SMALL
(2) IF CONDITION IS IMPROVED WITH
SMALL JET:
(A) CLOGGED AIR CLEANER
(B) CHOKE NOT OPENED FULLY
5
CHECK VALVE TIMING
CORRECT
INCORRECT INCORRECT VALVE TIMING
ADJUSTMENT
6
CHECK VALVE SPRING TENSION
SPRING TENSION CORRECT
WORN OR BROKEN
SPRING
FAULTY VALVE SPRING

CPIMOTOR GTR180
II.TROUBLE SHOOTING
《2-6》
SMOKY EXHAUST
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
RUN MOTORCYCLE A LONG
DISTANCE AT HIGH SPEED
THIN EXHAUST EMITTED
BLACK SMOKE
EMITTED
(1) WORN CYLINDER AND PISTON RINGS
(2) OIL LEVEL TOO HIGH
(3) PISTON RINGS INCORRECTLY INSTALLED
(4) FAULTY PISTON OR CYLINDER
(5) FLAWS IN CYLINDER HEAD
2 RETURN THROTTLE GRIP
QUICKLY
WHITE SMOKE
EMITTED
(1) WORN INTAKE VALVE GUIDE OR STEM
(2) EXCESSIVE VALVE-TO-GUIDE CLEARANCE
POOR HANDLING
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
IF STEELING IS HEAVY CHECK TIRE
PRESSURE
(1) STEERING HEAD ADJUSTER TOO TIGHT
(2) DAMAGED STEERING CONES OR STEEL
BALLS
2
IF EITHER WHEEL IS
WOBBLING
(1) EXCESSIVE WHEEL 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
3
IF THE MOTORCYCLE PULLS
TO ONE SIDE
(1) MISAPPLIED SHOCK ABSORBER
(2) FRONT AND REAR WHEELS NOT ALIGNED
(3) BENT FRONT FORK
(4) BENT SWING ARM

CPIMOTOR GTR180
III.SERVICE INFORMATION
《3-1》
ITEM STANDARD
IGNITION MODE CDI
SPARK TYPE NGK
SPARK PLUG DPR7EA-9
SPARK PLUG CLEARANCE 0.7-0.8㎜
IGNITION TIME MAX 33°BTDC/5000±100rpm
PULSER COIL MAX VOLTAGE ≧0.8V
EXCITER COIL MAX VOLTAGE ≧150V
ITEM STANDARD
CAPACITANCE 12V-8AH
FULL CHARGE 12.8V
(20℃) VOLTAGE UNDER CHARGE 11.8V
CHARGING AMPERAGE 0.4A STANDARD, PRESTO4.0A
BATTERY
CHARGING PERIOD0 5-10hr STANDARD, PRESTO 30min
TYPE MAGNETO
OUTPUT Three-phase alternating current
A. C.
GENERAT
OR (20℃)CHARGING COIL 0.2-0.3Ω
ITEM STANDARD
COMPRESSION 700kPa(7.0kgf/c㎡)-260r/min
FRONT BARKE LEVER CLEARANCE 10-30㎜
REAR BARKE LEVER CLEARANCE 10-30㎜
FRONT TYPE 110/70-17PR
REAR TYPE 120/80-16PR
SPARK PLUG CLEARANCE 0.7-0.8㎜
SPARK PLUG DPR7EA(NGK)
IN 0.05㎜
VALVE CLEARANCE EX 0.20㎜
IDLE SPEED 1600±100rpm
FULL 1.0l
OIL CAPACITY CHANGING 0.8l
DISASSEMBLY 200㏄
GAER OIL CAPACITY CHANGING 150㏄