CPI ARAGON User manual

JR
ARAGON GP, ARAGON, FORMULA R
Service Manual
PREFACE
This workshop manual contains information about
common service, repair, and maintenance works for all
systems of the model CPI JR.
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
CRANK DRIVE /
CRANKCASE /
CRANKSHAFT CR
VARIOMATIC
TRANSMISSION VT
ELECTRICAL SYSTEM ES
Copyright © 2008
HANS LEEB Zweirad Handel GmbH
Printed in Austria, March 2008
Pub. No.: WHB-JR-08

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
Vehicle Identification number
Engine Number
Oliver Sport / Formula R Aragon / Aragon GP
The VEHICLE IDENTIFICATION NUMBER consists of 17 alphanumeric characters. In the case of versions
11 and 12 (Formula R), it is stamped on the center front steering tube behind the legshield.
In the case of versions 7-10 (Aragon / Aragon GP), the VIN ist stamped on the rear right-hand side of the frame.
The cover must first be removed from there in order to make it visible.
The engine number is stamped on the upper part of the left engine case of all vehicle versions.
RFT JR 45AX6L000110
Serial number
Manufacturer
L=CPI
Year of manufacture
e.g.: 7 = 2007
Model year
X
Extension of vehicle model
A
Variant
45
Vehicle type
JR
Manufacturer code
RFT = CPI MOTOR COMPANY

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 TD-1
TECHNICAL DATA
SPECIFICATIONS TD 2
ARAGON GP 45 KM/H TD-2
ARAGON GP 30 KM/H TD-4
ARAGON GP 25 KM/H TD-6
ARAGON 45 KM/H TD-8
ARAGON 30 KM/H TD-10
ARAGON 25 KM/H TD-12
FORMULA R 45 KM/H TD-14
FORMULA R 30 KM/H TD-16
FORMULA R 25 KM/H TD-18

TECHNICAL DATA TD-2
SPECIFICATIONS
Aragon GP 45km/h
Engine:
Nominal power (EEC) 2,9 / 6000 [kW/min-1]
Nominal torque (EEC) 4,9 / 6000 [Nm]
Bore / Stroke 40 / 39,2 [mm]
Compression ratio 7,8
Compression pressure (hot) --- [bar/min-1]
Piston clearance, max. 0,085 [mm]
Piston ring gap, max. 0,4 [mm]
Fuel supply & adjustments:
Carburetor / Identification no. Dell’Orto PHVA 16 / 08463
Main jet 46
Idling jet 36D
Position jet needle 3 [from top]
Float chamber level 13 ± 0.5
not adjustable [mm]
Air adjustment screw ½ [turns]
Idling speed 1800 ± 100 [min-1]
Automatic cold start equipment, stroke at 12V AC
Working time 4
105
[mm/5 min]
[sec.]
Tires & filling pressure:
Front wheel 120 / 70 – 12 51J
Rear wheel 130 / 70 – 12 56J
Air pressure front 1,9 [bar]
Air pressure rear 2,0 [bar]
Filling quantities & specifications:
Fuel (unleaded) 91 ROZ 7,9 [l]
Engine Oil --- [l]
2 stroke oil (full synthetic) 1,4 [l]
Gearbox oil
(SAE 80W90) 100 [ml]
Front fork oil
(SAE 5W20) 100 [ml]
Brake fluid (DOT 4) in case of need
CVT: 5,8 [g]
Roller weights 12 x 15 [mm]

TECHNICAL DATA TD-3
Torques: [∅mm][Nm]
Front axle nut 12 55
Rear axle nut 14 120
Screw front fork bridge 10 30
Screw brake calliper 8 40
Screw handle bar 10 50
Shock absorber lower fixing 8 25
Engine mounting screw 10 50
12 55
Gearbox cover screw 8 20
Crankcase 6 10
Cylinder head 7 12
Flywheel 10 35
CVT fixing nut 10 35
Clutch fixing nut 10 45
Clutch pads fixing nut 28 45
Drain plug gearbox 8 15
CVT cover 6 12
Kick starter 6 12
Exhaust pipe 6 10
Silencer 8 30
Standard torque for 12 60
screws and nuts without 10 40
special function 8 25
6 12
5 4
Spark plug 14 15
Electrical assy:
Battery charging voltage
(Battery fully charged) 13,5 ± 0,5 [V]
Battery charging current
(Battery empty) 1,8 [A]
Fuse 8 [A]
Bulb low beam
Bulb high beam
Bulb position lamp
55 H1
55 H1
5 [W]
Bulb rear- and stop lamp,
License plate illumination 21 / 5 [W]
Bulb winker --- [W]
Ignition pulse generator (blue/white-green/white) 340 ± 50
1,5 / 1900 [Ω]
[V/ min-1]
Ignition coil ACG 900 ± 100
125 / 800 [Ω]
[V/ min-1]
Charging coil (white)
Plug disconnected
Max. voltage
0,9
22 / 2500
81 / 8500
[Ω]
[V/ min-1]
[V/ min-1]
Light coil (green/white)
Plug disconnected
Max. voltage
0,8
18 / 2500
69 / 8500
[Ω]
[V/ min-1]
[V/ min-1]
Ignition coil primary 0,4 – 0,6 [Ω]
Ignition coil secondary 3 ± 0,5 [kΩ]
Spark plug connector 10 [kΩ]
Spark plug BR7ES [---]
Spark plug gap 0,7 – 0,8 [mm]
Spark gap min.6 [mm]
Ignition point 17 / 1800 [°/min-1]
Distance between pickup and flywheel 0,6 – 0,8 [mm]

TECHNICAL DATA TD-4
Aragon GP 30 km/h
Engine:
Nominal power (EEC) 1,4 / 5000 [kW/min-1]
Nominal torque (EEC) 3,5 / 3000 [Nm]
Bore / Stroke 40 / 39,2 [mm]
Compression ratio 7,8
Compression pressure (hot) --- [bar/min-1]
Piston clearance, max. 0,085 [mm]
Piston ring gap, max. 0,4 [mm]
Fuel supply & adjustments:
Carburetor / Identification no. Dell’Orto PHVA 16 / 08461
Main jet 46
Idling jet 36
Position jet needle 2 [from top]
Float chamber level 13 ± 0.5
not adjustable [mm]
Air adjustment screw ½ [turns]
Idling speed 1800 ± 100 [min-1]
Automatic cold start equipment, stroke at 12V AC
Working time 4
105
[mm/5 min]
[sec.]
Tires & filling pressure:
Front wheel 120 / 70 – 12 51J
Rear wheel 130 / 70 – 12 56J
Air pressure front 1,9 [bar]
Air pressure rear 2,0 [bar]
Filling quantities & specifications:
Fuel (unleaded) 91 ROZ 7,9 [l]
Engine Oil --- [l]
2 stroke oil (full synthetic) 1,4 [l]
Gearbox oil
(SAE 80W90) 100 [ml]
Front fork oil
(SAE 5W20) 100 [ml]
Brake fluid (DOT 4) in case of need
CVT: 6,3 [g]
Roller weights 12 x 15 [mm]

TECHNICAL DATA TD-5
Torques: [∅mm][Nm]
Front axle nut 12 55
Rear axle nut 14 120
Screw front fork bridge 10 30
Screw brake calliper 8 40
Screw handle bar 10 50
Shock absorber lower fixing 8 25
Engine mounting screw 10 50
12 55
Gearbox cover screw 8 20
Crankcase 6 10
Cylinder head 7 12
Flywheel 10 35
CVT fixing nut 10 35
Clutch fixing nut 10 45
Clutch pads fixing nut 28 45
Drain plug gearbox 8 15
CVT cover 6 12
Kick starter 6 12
Exhaust pipe 6 10
Silencer 8 30
Standard torque for 12 60
screws and nuts without 10 40
special function 8 25
6 12
5 4
Spark plug 14 15
Electrical assy:
Battery charging voltage
(Battery fully charged) 13,5 ± 0,5 [V]
Battery charging current
(Battery empty) 1,8 [A]
Fuse 8 [A]
Bulb low beam
Bulb high beam
Bulb position lamp
55 H1
55 H1
5 [W]
Bulb rear- and stop lamp,
License plate illumination 21 / 5 [W]
Bulb winker --- [W]
Ignition pulse generator (blue/white-green/white) 340 ± 50
1,5 / 1900 [Ω]
[V/ min-1]
Ignition coil ACG 900 ± 100
125 / 800 [Ω]
[V/ min-1]
Charging coil (white)
Plug disconnected
Max. voltage
0,9
22 / 2500
81 / 8500
[Ω]
[V/ min-1]
[V/ min-1]
Light coil (green/white)
Plug disconnected
Max. voltage
0,8
18 / 2500
69 / 8500
[Ω]
[V/ min-1]
[V/ min-1]
Ignition coil primary 0,4 – 0,6 [Ω]
Ignition coil secondary 3 ± 0,5 [kΩ]
Spark plug connector 10 [kΩ]
Spark plug BR7ES [---]
Spark plug gap 0,7 – 0,8 [mm]
Spark gap min.6 [mm]
Ignition point 17 / 1800 [°/min-1]
Distance between pickup and flywheel 0,6 – 0,8 [mm]

TECHNICAL DATA TD-6
Aragon GP 25 km/h
Engine:
Nominal power (EEC) 1,4 / 5000 [kW/min-1]
Nominal torque (EEC) 3,5 / 3000 [Nm]
Bore / Stroke 40 / 39,2 [mm]
Compression ratio 7,8
Compression pressure (hot) --- [bar/min-1]
Piston clearance, max. 0,085 [mm]
Piston ring gap, max. 0,4 [mm]
Fuel supply & adjustments:
Carburetor / Identification no. Dell’Orto PHVA 16 / 08461
Main jet 46
Idling jet 36
Position jet needle 2 [from top]
Float chamber level 13 ± 0.5
not adjustable [mm]
Air adjustment screw ½ [turns]
Idling speed 2000 ± 100 [min-1]
Automatic cold start equipment, stroke at 12V AC
Working time 4
105
[mm/5 min]
[sec.]
Tires & filling pressure:
Front wheel 120 / 70 – 12 51J
Rear wheel 130 / 70 – 12 56J
Air pressure front 1,9 [bar]
Air pressure rear 2,0 [bar]
Filling quantities & specifications:
Fuel (unleaded) 91 ROZ 7,9 [l]
Engine Oil --- [l]
2 stroke oil (full synthetic) 1,4 [l]
Gearbox oil
(SAE 80W90) 100 [ml]
Front fork oil
(SAE 5W20) 100 [ml]
Brake fluid (DOT 4) in case of need
CVT: 6,3 [g]
Roller weights 12 x 15 [mm]