CPI SuperMoto Series User manual

SMSX
Service Manual
PREFACE
This workshop manual contains information about
common service, repair, and maintenance works for all
systems of the model CPI SMSX.
The manual is subdivided in chapters, in which the vehicle
systems in question are explained. Every component or
subsystem is treated in a section of its own. Some chapters
contain a maintenance section with work processes which
apply to several components or subsystems in the chapter.
Every section usually contains a description of the
proceedings, installation, dismantling, assembly and
examination of components. There are tables of special
tools and specifications in chapters of their own.
Where required, the use of the special tools is indicated in
the individual chapter.
Every chapter starts with a chapter contents list, where all
treated parts, work and checking operations are listed with
detail of the page numbers.
The chapter page numbering is built up the following way:
Example: Fl 3 = group of Fl, page 3
The details contained in this manual and vehicle data
correspond to the ones at the moment of printing. HANS
LEEB Zweirad Handel GmbH reserves the right to end a
model production any time and to change specifications
and designs without a previous announcement and without
obligations arising from it.
All rights reserved. This manual or extracts of it may not
be reprinted, duplicated or translated without a written
permission of HANS LEEB Zweirad Handel GmbH. Use
of electronic and mechanical systems inclusively
photocopiers, note equipment and systems for the data
storage and data account is herein included.
TABLE OF CONTENTS
CHAPTERS GROUP
GENERAL
INFORMATION GI
TECHNICAL DATA TD
SPECIAL TOOLS ST
CARBURETOR FL
OIL PUMP LB
PISTON AND CYLINDER PC
CLUTCH AND GEARBOX CG
FRAME AND CHASSIS FC
ELECTRICAL SYSTEM ES
Copyright © 2007
HANS LEEB Zweirad Handel GmbH
Printed in Austria, June 2007
Pub. No.: WHB-SMSX-07

GENERAL INFORMATION
GENERAL INFORMATION GI-2
WARNING AND SAFETY SYMBOLS GI-3
VEHICLE IDENTIFICATION NUMBERS GI-4
MAINTENANCE INSTRUCTIONS GI-5

GENERAL INFORMATION GI-2
GENERAL INFORMATION
CAUTION
Suitable maintenance and repair proceedings are indispensable both for the safe and operationally reliable
operation of a motor vehicle and for the personal safety of the mechanic.
Many proceedings, techniques, tooling and components are known for the various maintenance works that are
required for a vehicle, and the knowledge of motor vehicle technicians differs likewise. Neither can this shop
manual anticipate all eventualities arising from this fact, nor is it intended to point out all potential risks.
Therefore, it is absolutely indispensable to make sure that neither personal safety nor the vehicle’s
roadworthiness is impaired when deviating from the instructions given here.
The following general warning instructions always have to be observed when maintaining the vehicle:
Turn off the ignition, unless otherwise stipulated.
Keep away from moving or rotating components when the engine is running.
Avoid touching of hot components (exhaust manifold, exhaust pipe, catalytic converter, muffler) in
order not to get burnt!
If for maintenance works the engine must run, then pay attention to sufficient ventilation in closed
rooms. Use suitable suctioning units to derive engine exhaust gases! Engine exhaust gases contain
carbon monoxide, which can lead to unconsciousness and to death when in higher concentration.
Batteries contain sulfuric acid (electrolyte). Avoid any contact with skin, eyes and muscous membranes,
since that acid causes severe injuries! Operators have to wear suitable protective clothing and safety
goggles according to the stipulations made by the respective professional organizations.
In the case of contact with sulfuric acid, the concerned areas have to be cleaned with much water. In the
case of contact with eyes, wash them with a lot of water and go to an ophthamologist immediately!
Always keep sulfuric acid out of reach of children!
Fuel is extremely highly inflammable and the gasses are bad for health! During maintenance, closed
rooms must always be sufficiently ventilated. Open flames, smoking or flying sparks are strictly to be
avoided!
Used oils, greases and other used lubricants are bad for health when at a longer / daily skin contact, and
they can cause skin cancer. Avoid any unnecessary skin contact and clean wetted skin areas with water
and soap after every contact.
Brake fluid is extremely bad for health. The same safety instructions apply to works with brake
fluid as in the case of sulfuric acid.
Used acids, greases, oils, brake fluid as well as fuels are hazardous waste. They must be
disposed separatedly and carefully and in accordance with the valid local regulations. This also
applies to contaminated rags and components (e.g. oil filters).

GENERAL INFORMATION GI-3
CAUTION
The usage of low-quality fuels and lubricants, which do not correspond to the CPI specifications, can lead to
severe engine and gear failures. Always use high-grade fuels and lubricants, which correspond to the
specifications in the specifications chapter of this manual.
WARNING AND SAFETY SYMBOLS
The following symbols indicate that the vehicle technician must pay extra attention when performing
maintenance works.
Symbol Description Symbol Description
Component parts may get damaged
when this instruction is not oberseved.
It is indispensable to follow
this instruction. Severe
injuries or even the loss of
life may result in the case of
non-observance.
This symbol provides useful information
on how to perform proper repair or
service work.

GENERAL INFORMATION GI-4
VEHICLE IDENTIFICATION NUMBERS
The VEHICLE IDENTIFICATION NUMBER consists of 17 alphanumeric characters. It is stamped onto the
right hand side of the front steering tube.
RFTSM45A66L000110
Serial number
Manufacturer
L=CPI
Year of manufacture
6 = 2006, 7 = 2007
Model year
6=2006
Version
B
Variant
Vehicle type
SM=SuperMoto
Manufacturer code
RFT = CPI MOTOR COMPANY
The ENGINE NUMBER is stamped on the lower right side behind the drive sprocket.

GENERAL INFORMATION GI-5
MAINTENANCE INSTRUCTIONS
PREPARING TOOLS AND MEASURING INSTRUMENTS
Before staring any maintenance works make sure that all necessary
tools and measuring instruments are available.
SPECIAL TOOLS
Use special tools, if stipulated in the chapter.
REMOVAL OF ENGINE PARTS
Before starting any mainrenance works try to track the fault cause.
Decide whether the removal or disassembly of the part in question
is necessary.
CLEANING OF REUSABLE PARTS
All reusable parts have to be cleaned carefully and thoroughly and
in a suitable way.

GENERAL INFORMATION GI-6
SPARE PARTS
If parts have to be replaced, use original CPI spare parts only.
REASSEMBLY
If reassembling engine parts, precisely obey the instructions
regarding defaults of tightening torques and other settings. The
following parts always have to be replaced prior to reassembly.
1. Oil retainers
2. Washers
3. O-rings
4. Lock washers
5. Split cotter pins
6. Plastic nuts
Depending on the mounting place the following should be
carried out:
1. Applying sealant to washers.
2. Oiling of moveable parts.
3. Oil or lubricating grease must be applied to defined spots
(e.g. oil retainers) prior to assembling.
ELECTRICAL EQUIPMENT
1. Always disconnect the cable from the battery’s (-) negative
terminal first.
2. Never pull the cable when disconnecting connections.
Always remove plugs by pulling the plug.
3. Snap-in connections are properly made when you can hear
a click noise.
4. Sensors and relays have to be handled carefully. Do not
drop them and avoid contact with other parts.
RUBBER PARTS, RUBBER-SHEATED CABLES, AND
RUBBER TUBES
Pay attention not to wet rubber parts, rubber-sheated
cables, and rubber rubber tubes with petrol or oil.

GENERAL INFORMATION GI-7
MAINTAINING THE ELECTRICAL SYSTEM
1. Prior to maintaining the electrical system, the ignition has
to be switched off and the battery ground cable has to be
disconnected.
2. To avoid slack, wiring harnesses have to be fixed with
cable clamps or cable fastening ribbons. However, allow a
little play to all wiring harnesses, which are routed to the
engine or other vibrating vehicle parts. This play must be
in such a way that the wiring harnesses do not contact
adjacent parts due to engine vibrations.
3. If any part of a wiring harness is routed along an edge or
corner of a vehicle part, or if it has contact to that edge or
corner, that section of the harness has to be wrapped round
with tape or the like in order to protect it against damage.
4. When mounting or reinstalling vehicle parts, pay attention
not to pinch or damage any of the wiring harnesses.

GENERAL INFORMATION GI-8
5. Do not drop relays, sensors, or other electric components
and do not expose them to vibration.
6. Electric component parts built in the microcomputer or
relay are sensitive to heat and can easily get damaged. If
for maintenace works the temperature must be risen above
80 °C, those electric component parts have to be removed
prior to maintenance.
7. Loose coupling can cause malfunctions. Make sure that all
plug-connections are adequately made.
8. Always pull the connector and not the wiring harness when
disconnecting any plug connections.

GENERAL INFORMATION GI-9
9. If snap-in connections have latching clips, those
connections can be interrupted by pressing the clips down
according to the directions specified in the adjacent
drawing.
10. The latching clips are properly locked in place when you
can hear a click noise. click
11. When conducting continuity checks or voltage
measurements with a circuit tester, the test probe must be
inserted in the terminals at the wiring harness side. In the
case of a shielded connection the probe must be inserted
through the cable opening of the rubber cap until contact is
made with the terminal. Pay attention not to damage the
insulation and wires.
Plug connection
Test probe
Test probe
12. Take into account the electric load caused by additional
equipment in order to avoid wiring overload.

GENERAL INFORMATION GI-10
NOTES

TECHNICAL DATA
SPECIFICATIONS TD-2
TIGHTENING TORQUES TD-4

TECHNICAL DATA TD-2
SYSTEM OVERVIEW

TECHNICAL DATA TD-3
SPECIFICATIONS
Description Unit Specifications
Masses And Dimensions
Length
Width
Height
Wheel base
Seat height
Unladen weight
Weight in running order
Tech. permissible mass
Axle load, front
Axle load, rear
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
1955
790
1185
1338
920
92
100
270
100
190
Frame, Chassis, Brakes,
Frame
Front suspension
Rear suspension
Front suspension travel
Rear suspension travel
Front braking system
Rear braking system
Brake fluid (DOT 4)
Fresh oil
Fork oil
Transmission oil
--
--
--
mm
mm
--
--
l
ml
ml
Split underslung steel tubing framework
Hydr. telescopic fork
Swing arm with spring strut shock absorber
240
30
Disk brake (Ø 270 mm)
Disk brake (Ø 210 mm)
Every 2 years
1 (2-stroke, fully synthetic)
315 per bar (SAE 15W)
650 (ESSO ATF D 21611)
Wheels / Tires
Material of wheels
Front rim size
Rear rim size
Front tire
Rear tire
Tires – pressure
front
rear
bar
bar
Aluminum
J17 x 2,50
J17 x 3,50
110/80-17 57H
130/70-17 62H
1,8
2,0

TECHNICAL DATA TD-4
Engine
Type
Arrangement of cylinder
Cooling system
Lubrication
Bore / Stroke
Displacement
Compression
Power rating (EC)
Torque (EC)
Combustion pressure
Piston-to-wall clearance
(max)
Radial clearance of the piston
ring (max)
Axial clearance of the piston
ring (max)
mm
cm3
kW/min-1
Nm/min-1
bar
mm
mm
mm
1 cylinder, two-stroke
15° inclined to the front
Water
Fresh oil
40,0 / 39,0
49,0
11:1
2,2 / 7000
3,9 / 4000
9,8 (at operating temperature)
0,047
0,36
0,13
Fuel System
Carburetor
Fuel tank capacity
Fuel (unleaded)
Fuel consumption
l
ROZ
l/100 km
Optional VM MIKUNI Ø 16
DELL’ORTO PHVA16
6,8
min. 91
_______________
Transmission
Clutch type
Gearbox type
Gear ratio
First gear
Second gear
Third gear
Fourth gear
Fifth gear
Sixth gear
Gearshift
Oil-immersed multiple plate clutch
Constant-mesh gearbox
R1 R2 R3 Rt
3,00 (36/12) 51,51
2,06 (33/16) 35,37
1,52 (29/19) 26,10
1,22 (27/22) 20,94
1,04 (25/24) 17,85
3,05
(61/20)
0,96 (24/25)
5,63
(62/11)
16,48
Drum switch, controlled by left pedal, sequence: (down) 1-
Neutral-2-3-4-5-6 (up).

TECHNICAL DATA TD-5
Electrical System
Charging voltage
Charging current
Fuse
Low beam bulb
High beam bulb
Parking light bulb
License light
Stop / Tail light
Turn signal light
Nominal power
Generator
Ignition type
Pulse generator
(red/white)
Excitation winding
(black/red)
Charging coil (white)
Light coil (yellow/red)
Primary coil
Secondary coil or spark
plug connector
Spark plug
Spark plug gap
Spark energy
Ignition point
V
A
A
W
W
W
W
Ω
V/min-1
Ω
V/min-1
Ω
Ω
Ω
k Ω
k Ω
mm
mm
° / min-1
13,5
0,9 – 1,2
7
35 HS1
35 HS1
5
LED
LED
LED
85
CDI
100 – 150
2,7 / 1800
750 - 850
80 / 800
0,5 - 0,9
0,5-0,9
0,3 - 0,5
3,0
8 - 10
BR8ES
0,4 – 0,6
min. 0,7
17 / 1800
TIGHTENING TORQUES
Description ∅(mm) Torque (Nm)
Front axle nut 12 60
Rear axle nut 16 120
Front fork bridge clamping screws 8 20
Brake caliper bolts 8 25
Handlebar mounting bolts 34 ---
Suspension strut lower fastening bolt 6 12
Engine hanger bolts 8 20
Transmission housing fastening screws --- ---
Engine case 6 12
Cylinder head 7 14 - 16
Flywheel 12 45
Clutch drum --- ---
Clutch --- ---
Transmission oil draining plug 8 10
Kick starter 6 12
Manifold 6 12
Muffler 6 / 8 12 / 20
Bolts / nuts without defined stipulations 6 12
8 20
10 40
12 60
Spark plug 14 15

TECHNICAL DATA TD-6
NOTES