CPI JR 50 User manual
CONTENTS
PREFACE.....................................................................................Q1-1∼1-2
ENGINEREMOVE……………………….................................Q2-1∼2-4
ENGINEINSTALLATION......................................................Q3-1∼3-2
LUBRICATIONSYSTEM.......................................................Q4-1∼4-2
FUEL SYSTEM……………………………............................Q5-1∼5-4
CYLINDERHEAD/CYLINDER/PISTON...........................Q6-1∼6-6
TANSMISSIONSYSTEM................................…….............Q7-1∼7-6
CRANKSHAFT/CRANKCASE............................................Q8-1∼8-4
A.C.G. EMERATOR.............................................................Q9-1∼9-2
ELECTRICSYSTEM............................................................Q10-1∼10-6
CHASSIS…………………………………………………………Q11-1~11-2
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
THECONTENTSOFTHISMANUALPROVIDETHESREVICE
INFORMATIONFORC.P.IJR50/90.
MOSTCHAPTERSSTARTWITHASYSTEMORASSEMBLY
ILLUSTRATIONAND SPECIFICATIONSTHEFOLLOWEDPAGES GIVE
DETAILPROCEDURES.
IFYOUDO NOTKNOWWHATTHESOURCEOFTHETROUBLEIS,
PLEASE GO THETROUBLESHOOTING FORADDITIONALHELP.
ALL THECONTENTSOFTHISMANUALAREBASEDONTHELATEST
MODELINFORMATIONC.P.IRESERVE THERIGHTTO MAKE CHANGE
ATANYTIMEWITHOUTNOTICEAND WITHOUTANYRESPONSIBILITY
ORENGAGEMENTONOUR PART.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Disconnect the Vacuumhose.1.
Disconnect the Fuelhose1.
Disconnect the oil tube.
Disconnect the A.C.G wire.
Disconnect the start motor wive.
Disconnect the throttlevalve.
Disconnect the sparkplug cap.
Disconnect the rear brakecable.
Removethe setting bolt of rear cushion.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
ENGIMEINSTALLATION
The installation sequenceisessentiallythe
reverseof removal.
NOTE:
Routeall thewireandcable
properly.
Adjustthethrottlecablefree play.
Adjusttheoil pumpcontrol cable
Clearance.
Adjusttherear brakefree play.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
OILPUMPREMOVAL
Removethe seat, luggage box, and side
covers,
Removethe cooling fan cover ,cooling
fan ,and A.C.G.
Disconnect the oil tube of oil tube of oil.
Pump(intakeand output).
Removethe oil pumpcontrolcable.
Removethe setting bolt of oil pump.
Removethe oil pump.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Oil pumpinspection
Checkthe O-
ring, gear &sealfor wear or
anydamage.
NOTE:
Donotdisassemblytheoil
pump
bodytopreventanydamage.
OILPUMPINSTALLATION
Coating someoil the O-ring.
Install the oil pumpontothe crankcase.
Connect the oil tube.
Connect the oil pumpcontrolcableand
adjust the clearance.
RELEASE THEAIROFOILPUMP
Loosen the drainscrew.
Let the oil drainout insmoothlythen tight
the screw.
NOTE:
Iftheoil cannotdrainoutin
smoothly, itismeansomeairstill
intheoil pump.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
THROTTLEVALVE REMOVAL
Removethe seat.
Removethe luggage box.
Loosethe carburetor cap.
Removethe throttlevalvefromthe
carburetor.
Removethe throttlevalvefromthe
throttlecable.
THROTTLEVALVE DISASSEMBLY
Removethe retainer and takeout the jet
needleclipfromthe throttlevalve.
INSPECTION
Checkthe throttlevalveand the jet
needlesurfaceof dirt, scratchesor wear.
CARBURETORREMOVAL
Removethe seat.
Removethe luggage box.
Removethe side cover.
Removethe starter plunger wire.
Removethe throttlecable.
Removethe fueltube fromthe
carburetor.
Loosethe screwof the aircleaner band.
Loosethe boltsbetween the intakepipe
&the carburetor.
Removethe carburetor.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Removethe carburetor and let it cool
downbynature for thirtyminutes.
Checkthe current of airrouteasshow.
GOOD:CHECKLESS
NG :CHECKED BLOW
Connect afull charged batterytothe
starter plunger wore for fiveminutes.
Checkthe current of routeasshow.
GOOD:CHECKED
NG :CHECKLESS
BLOW
FLOATCHAMBERDISASSEMBLY
Removethe setting screws.
Removethe chamber cap.
Removethe float setting bolt.
Removethe float pin.
Removethe float.
Removethe float valve.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Removethe mainjet, slowjet, needle
seat &airscrew.
Clean all the jet &all the holebyusing
high pressure air.
FUELHEIGHTINSPECTION
Measure the height byusing agauge.
STANDARD:18.5
CARBURETORINSTALLATION
The installation sequenceisessentially
the reverseof remove.
Adjust the clearanceof the throttlevalve
cable.
Adjust the airscrew.
STANDARD : 11
21
2
±round
Adjust the idlespeed.
STANDSRD:1800±100 rpm
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
REEDVALVE REMOVAL
Removethe carburetor.
Removethe intakepipe.
Removethe reed valve.
REEDVALVE INSPECTION
Measure the height of reed valve
stopper.
STANDARD:6.0-6.4
Checkthe flatness of reed valve.
SERVOCELIMIT:10
REEDVALVE INSTALLATION
The installation sequenceisessentially
the reverseof removal.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
CYLINDERHEADREMOVAL
Removethe seat &the luggage box.
Removethe sparkplug cap.
Removethe exhaust muffler.
Removethe side covers.
Removethe cylinder airshrouds.
Removethe sparkplug.
Removethe setting boltsof cylinder head.
Removethe cylinder head.
Cylinder head flatness inspection.
SERVICELIMIT:0.05
CYLINDERREMOVAL
Removethe cylinder head.
Removethe cylinder.
Removethe cylinder gasket.
NOTE:
Cleanall thematerial ofcylinder
gasket withascraper.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
PISTONREMOVAL
Removethe piston pinclip.
NOTE:
Donotlet theclipfall intothe
crankcase.
Removethe piston pin.
Removethe piston.
PISTON/ PISTONRING INSPECTION
Removethe piston rings.
Clean the groovesfor carbon deposit
completely.
NOTE:
Donotdamagethepiston ring
during removal.
Cylinder blockflatness inspections:
SERVICELIMITS:0.05
CYLINDERINSPECTION
Inspect the cylinder bore for wear or
damage.
Measure the cylinder I. D. at three
places; top, middleand bottomof piston
traveland intwodirectionsat right angle
toeachother.
SERVICELIMITS:40.2
52.2
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Calculatethe piston-to-cylinder clearance.
SERVICELIMITS:0.1
Calculatethe taper and out of round.
SERVICELIMITS:
Outofround:0.05
Taper:0.05
Measure piston pinbore O. D. at apoint 10
fromthe bottom.
SERVICELIMITS:39.95 .
51.95 .
Measure piston pinbore I. D. intwo
directionsat right angletoeachother.
SERVICELIMITS:10.05
12.05
Measure the piston pinO. D. at the front,
center and rear and intwodirectionsacross
fromeachother.
SERVICELIMIT:9.95
11.95
Insert eachpiston ring intocylinder withthe
piston and measure the ring end gap inthe
cylinder toapoint 10 (0.04 in)fromthe
bottom.
SERVICELIMITS:
Top / Second:0.15~0.35
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
Connecting rod small end inspections:
SERVICELIMITS:14.06 .
15.06 .
PISTONRING INSTALLATION
Clean the piston ring groovesthoroughly.
Install the piston ring.
NOTE:
iAvoidpiston and piston ring
damageduring installation.
iAll ring shouldbeinstalled
withthemarkfacing up.
PISTONINSTALLATION
Install the piston, piston pinand new
piston pinclips.
NOTE:
iPiston the“EX”markon the
exhaust side.
iDonotlet thepiston pinclip
fall intothecrankcase.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
CYLINDERINSTALLATION
Install the cylinder gasket.
Coat the cylinder and piston ring withthe
engine oil.
Install the cylinder.
COMPRESSIONPREASURETEST
NOTE:
Worm up theenginebeforetest.
Removethe seat &luggage box.
Removethe sparkplug cap &sparkplug.
Turn the throttlegripwiththe throttlevalve
on the upset position.
Start the motor for 7-8 secondsfor test the
pressure
STANDARD:10.0 ㎏/㎝2 -600 rpm.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
LEFTCRANKCASE COVERREMOVAC
Removethe start kick.
Left crankcasecover and dowelpin.
Removethe kickpinion withthe kick
friction spring.
Disconnect the kickstart spring.
Removethe cir-clip,platewasher,kick
spindlebush,and spring.
Removethe setting nut of clutchouter.
Removethe clutchouter.
Removethe driven pulleyand drivebeet.
Removethe setting nut of driver face.
Removethe conicalspring washer and
the one wayclutch.
Removethe clawwasher,driver faceand
plat washer.
PDF 件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn
Downloaded from www.ScooterTime.net
This manual suits for next models
1
Table of contents
Other CPI Scooter manuals
