CPI GTRser - Absolutely Scooters & Supply
Contents
1. IG SPARE PLUG COME SM sete ro EE Ca 4 EX FUEL UNI e GY Br R WB Br Y Y Y ES RMB Br yy Y B GY Br Gry R Br LE e D a 1 1 RAR WHKER 1 I EI e a B GY LE IT TT TT j _ l 1 mi tooto Ee E e Doe HEE J HH en a EE fg 21 IE WIMKER 171 B BLACK Br BROWN LAWBLUEAVHITE Gy GRAY G Y GREEN YELLOW mer He EA G GREEN Ch Chocolete v B YELLOW BLACK Sanco SER 55 Y YELLOW Y R YELLOW RED OwwER Sy SORA Su mer zu R RED W WHITE Br wBrow ware P PINK BR BLACK RED L B BLUE BLACK L HANDLE SWITCH O ORANGLE B W BLACK WHITE L R BLUE RED 10 1 CPI MOTOR GTR1S0O X ELECTRIC SYSTEM ELECTRIC PARTS LOCATION We E I US g 2227 i3 10 2 CPI MOTOR GTR1S0O n wit assis X ELECTRIC SYSTEM BATTERY PRECAUTIONS lt There are a number of important precautions that must to service electrical systems Learn and ob serve all the rules below Do not reverse the battery cable connections This will burn out the diodes on the electrical parts Always check battery condition before condemning2. 3 5 CPI MOTOR GTRIS0 INFORMATION OWe suggest that above maintenance should be executed in designated dealers to ensure driving safe Remarks 1 If you drive to exceed above stipulated kilometers please reduplicate the inspection 2 Must inspect or replace early if you drive in the region which has much dust or it s rainy 3 Must inspect or replace early if you drive on a long distance or bear a heavy burden 4 Please refer to the following chart to replace oil 10 20 30 40 3 6 CPI MOTOR GTRIS0 REMOVAL amp INSTALLATION ENGINE REMOVAL REMOVAL SIDE COVER 3 LEFT Removal 2 socket bolt 2 Disassemble SIDE COVER 3 Disassemble FUEL HOSE 3 ATTENTION Be careful of the gasoline leakage i Removal VACCUM HOSE Removal CARBURATOR VACCUM HOSE 4 1 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION REMOVAL AIR CLEANER 1 Removal 2 flange bolt 2 Removal Iflange bolt Removal the oil hose 3 Disassemble the clamp 4 2 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION REMOVAL ELECTRIC 1 Removal IGNITION 2 Disassemble RECTIFIER joint 3 Disassemble AUTO CHECK joint 4 Removal START MOTOR line 4 3 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION Removal THROTTLE CABLE Removal TEMPERATURE SENSOR joint Removal the bolt Make cooling w
3. Ai CA SS AGE 1 Z Sa lt i REAR FENDER 1 11 2 CPI MOTOR GIR180 XLFRAME HANDLE BAR HANDLE BAR LEG SHIELD 2 COVER I COVER 2 TANK COVER LEG SHIELD COVER MOLE I LEG SHIELD 3 UNDER LEG COVER I INNER SHIELD 1 FENDER 1 LEG SHIELD MOLE 2 LEG SHIELD 4 UNDER COVER 2 LICENSE LIGHT ASSY SIDE COVER 1 REAR LICENSE TAIL LIGHT LUGGAGE 2 FENDER 2 BRACKET ASSY SIDE COVER 2 ADAPTER PLATE SIDE COVER 3 SIDE COVER 4 FRONT FENDER REAR FENDER I 11 3 CPI MOTOR XLFRAME FRAME REMOVAL INSTALLATION COVER REMOVAL Removal the socket bolt LEG SHIELD 1 REMOVAL Removal 2 bolt Removal 2 bolt w washer Removal 4 tapping screw 11 4 GTRIS0 CPI MOTOR XI FRAME Removal HEAD LIGHT connect Inspet cove I amp 2 removal Removal 2 tapping screw Handle bar cover I removal Removal 2 tapping screw Removal 2 tapping screw 11 5 GIR180 CPI MOTOR XI FRAME Removal SPEEDMETER connect Removal 4 tapping screw Removal 3 tapping screw LEG SHIELD MOLE 1 amp 2 REMOVAL Removal 4 tapping screw 11 6 GTRIS0 CPI MOTOR XLFRAME UNDER COVER 1 amp 2 REMOVAL Removal 6 tapping screw LEG SHILED 3 amp 4 REMOVAL Removal 2 tapping screw LEG SHIELD MOLE 1 amp 2 REMOVAL Removal 4 bolt INNER FENDER 1 REMOVAL Removal 6 tapping screw GTRIS0
4. CPI MOTOR GIR180 REMOVAL Install the auto bystarter Install 1 Screws A Remove the 4 float chamber screws and the float chamber Remove 1 Screws A 2 Float Chamber B Remove the float pin float and float valve Remove 1 Float Pin A 2 Float Valve B 3 Float C FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Remove 1 Float Valve Seat A 2 Float Valve B 3 Float C 8 9 CPI MOTOR GTRIS0 REMOVAL Remove the main jet needle jet holder and idle jet Remove the slow jet Remove Main Jet A 2 Needle jet holder B 3 Idle Jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil ATTENTION Be sure to use clean detergent oil Install the main jet needle jet holder gt idle jet Install Main Jet A 2 Needle jet holder B 3 Idle Jet Install the float pin float and float valve Install Float Pin A 2 Float Valve B 3 Float C 8 10 CPI MOTOR VIILCARBURETOR REMOVAL CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold and tighten the band Install the air cleaner connecting tube and tighten the clamp Connect the throttle cable to the carburetor Install 1 Throttle Cable A 2 Air Cleaner Connecting Tube clamp B 3 Int
5. SPECIFICATIOS STANDARD mm SERVICE LIMIT mm WARPAGE pos CYLINDER RING TO GROOVE TOP 0 025 0 060 CLEARANCE 0 090 SECOND 0 015 0 050 0 090 TOP 0 100 0 250 0 500 SECOND 0 250 0 400 0 650 RING END GAP OIL SIDE PISTON 0 200 0 800 RAIL PISTO RING PISTON O D 57 365 57 395 57 3 PISTON O D MEASURING 9mm from bottom of POSITION skirt PISTON TO CYLINDER 0 010 0 040 0 100 CLEARANCE PISTON PIN HOLE 15 002 15 008 15 040 PISTON PIN O D 14 994 15 000 14 960 PISTON TO PISTON PIN CLEARANCE 0 002 0 014 0 020 CONNECTION RID SMALL END LD BORE 15 016 15 034 15 060 5 2 CPI MOTOR GIR180 V CYLINDER amp PISTON TROUBLESHOOTING When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke 1s found it means that the piston rings are worn stuck or broken COMPRESSION TOO LOW OR UNEVEN COMPRESSION Worn or damaged cylinder and piston rings Worn stuck or broken piston rings COMPRESSION TOO HIGH Excessive carbon build up in combustion chamber or on piston head EXCESSIVE SMOKE FROM EXHAUST MUFFLER Worn or damaged piston rings Worn or damaged cylinder and piston ABNORMAL NOISY PISTON Worn cylinder piston and piston rings Worn piston pin hole and piston pin Incorrectly installed piston 5 3 CPI MOTOR V CYLINDER amp PISTON CYLINDER REMOVAL Disassemble the cylinder head comp Disassemble the cylinder head gasket
6. 11 7 CPI MOTOR GTR180 XI FRAME Removal FRONT FORK nut NOTE You can use special tool INNER FENDER 1 REMOVAL Removal 2 bolt w washer A Removal 2 bolt B Removal 2 bolt C TANK COVER REMOVAL Removal bolt 11 8 CPI MOTOR XLFRAME LEG SHIELD 2 REMOVAL Disconnect TANK COVER FRONT FENDER REMOVAL Removal 4 pan head screw REAR FENDER 2 REMOVAL Removal4 screw A Renival 2 bolt B LUGGAGE 2 REMOVAL Removal 6 screw Removal 3 flange bolt 11 9 GTR180 CPI MOTOR XI FRAME FLASHER LIGHT ASSY 3 REMOVAL Removal 2 nut SIDE COVER 1 amp 2 REMOVAL Removal 2 screw Removal 2 flange bolt Removal 2 bolt Removal 2 bolt w washer Removal 1 screw 11 10 GTRIS0 CPI MOTOR XLFRAME LICENSE BRACKET 1 REMOVAL Removal 2 screw LICENSE LIGHT ASSY REMOVAL Remoal socket bolt Removal nut TAIL LIGHT REMOVAL Removal 2 nut REAR FENDER 1 REMOVAL Removal 3 bolt 11 11 GTRIS0 CPI MOTOR XI FRAME Removal 2 nut Removal 2 bolt Removal 2 bolt SIDE COVER 3 amp 4 REMOVAL Removal 4 socket bolt 11 12 GTRIS0 CPI MOTOR GTR180 awu XILWHEEL amp BRAKE SYSTEM WHEEL EXPOLODED VIEW NG 4 8 EX 4 1 0 RO 12 1 CPI MOTOR GTRIS0 XII WHEEL amp BRAKE SYSTEM No Fastener Remark 45 325 gt Frontaise bor 137 14 Q1 3 Reemi 1925
7. CHECK IGNITION TMING INCORRECT TIMING AND 1 INCORRECT TIMING ADJUSTMENT AND VALVE CLEARANCE CLEARANCE 2 INCORRECT VALVE CLEARANCE CORRECT TIMING AND CLEARANCE CHECK CARBURETOR INCORRECTLY ADJUSTED 1 MIXTURE TOO LEAN PILOT SCREW 2 MIXTURE TOO RICH ADJUSTMENT CORRECTLY ADJUSTED CHECK FOR AIR LEAKS AIR LEAKS 1 FAULTY CARBURETOR PACKING 2 CARBURETOR NOT SECURELY TIGHTENED NO AIR LEAKS 3 FAULTY INTAKE PIPE GASKET REMOVE SPARK PLUG AND WEAK OR INTERMITTENT 1 FAULTY OR FOULED PLUG TEST SPARK 2 FAULTY C D I 3 MAGNET AT FAULT 2 4 CPI MOTOR GIR180 II TROUBLE SHOOTING POOR PERFORMANCE AT HIGH SPEED FLOW PATH BADSITUATION PROBABLE CAUSE CHECK IGNITION TIMING AND INCORRECT TIMING 1 INCORRECT TIMING ADJUSTMENT VALVE CLEARANCE AND CLEARANCE 2 INCORRECT VALVE CLEARANCE CORRECT TIMING AND CLEARANCE DISCONNECT FUEL LINE AT RESTRICTED FUEL 1 EMPTY FUEL TANK CARBURETOR AND CHECK FOR FLOW 2 CLOGGED FUEL LINE CLOGGING 3 CLOGGED FUEL TANK CAP BREATHER HOLE 4 CLOGGED FUEL PETCOCK UNRESTRICTED FUEL FLOW CHECK FUEL FILTER FUEL VALVE CLOGGED 1 CLOGGED JET AND CARBURETOR JET FOR 2 CLOGGED FUEL FILTER CLOGGING 3 CLOGGED FUEL VALVE NOT CLOGGED REPLACE CARBURETOR MAIN JET CONDITION 1 JET SIZE TOO SMALL AGGRAVATED 2 IF CONDITION IS IMPROVED WITH SMALL JET CONDITION IMPROVED A CLOGGED AIR CLEANER B CHOKE NOT OPENED FULLY CHECK VALVE TIM
8. The relay is on normal function if hear the Ka Ka sound Remove the luggage Open the wire of negative pole of battery Open the wire of positive pole of battery and the starting motor wire from the big terminal of starting relay Open the power connector of starting relay Connect an Ohmmeter between the big terminal of relay Also connect white red wire to positive pole of battery blue white wire to the negative pole of battery Inspect if it is with passageway between the big terminal of relay Change the starting relay if no good circuit 10 19 LN J ai x Z BATTER 12V8AH CPI MOTOR X ELECTRIC SYSTEM Dismantle the starting motor Close the power of main switch Remove the luggage Open the wire of negative pole of battery Remove the tube clamp on the air cleaner and bolt Please refer 4 1 4 2 Remove the wire of starting motor Remove starting motor bolt x 2 Install the starting motor Install the motor as opposite procedure of dismantling 10 20 GTR1S0O CPI MOTOR GIR180 CIT _ x lt x amp amp tzxx 111__ u XLFRAME FRAME EXPOLODED VIEW FRONT FENDER LEG SHIELD MOLE I 11 1 CPI MOTOR XLFRAME FRAME EXPOLODED VIEW GIR180 Y LICENSE LIGHT ASSY M TNS x SEAT ASSY 1 LUGGAGE 2 S SE BRACKET f 9 o 7 p
9. up and down several times Hold the bottom case 1n a vice Remove the socket bolt with an Allen wrench REMOVE THE FORK PISTON A REMOVE THE FORK TUBE FORK PISTON Check each part for wear or damage and replace if necessary NU MI 1 NZ SN DE BD 5 ZA CYA YA S e RU e JAG i J Nf A etes dI No 12 21 CPI MOTOR GIR180 XI WHEEL amp BRAKE SYSTEM FORK TUBE INSPECTION u Place the fork tube in V blocks and measure the SN run out with a dial indicator gauge 4 A The actual run out is 1 2 of TIR Total Indicator NI b Reading A SERVICE LIMIT 0 2mm Measure the fork tube O D at the several points along the sliding surface SERVICE LIMIT 30 9mm Remove the dust seal cover Remove the snap ring with a snap ring pliers 12 22 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM REMOVE THE OIL SEAL 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 I D SERVICE LIMIT 31 1mm 12 23 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM FRONT FORK ASSEMBLY a waqu Before assembly wash the parts in solvent and wipe them off completely SOCKET BOLT Insert the fork piston into the fork outer
10. 9 12 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER INSPECT MPVABLE DRIVE FACE Disassemble the left crankcase cover Using the multi Installing tool Y shape tool to Install the driven pulley disassemble the nut amp washer And take away the drive face and the drive belt Disassemble the movable drive face comp amp drive face boss from crank Remove the ramp plate Disassemble the weight roller from movable drive face comp CHECK Measure weight roller if damage or wear Service limits 19mm The function of movable drive face comp 1s to use the centrifugation of weight roller to roll per angle of ramp plate in order to move the drive face for speed changing So if weight roller is worm or centrifugatio from weight rollers Therefore the outer diameter of weight roller shorld be checked per stadard and replace them if necessary Measure drive face boss 1f damage or wear Service limits 23 8mm Check the outer diameter of drive face boss if it is damaged or worm Replace for new part if necessary 9 13 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Measure drive face I D Measure the inner diameter of movable drive face Replace for new if necessary Install weight roller There are 2 different sides of weight roller in order to extend the part life ad avoid the extraordinary worm please put close side of weight roller on movable driv
11. Removal 2 bolt Brake pad Remove Removal 2 pin Change brake pad The installation sequence 1s essentially the reverse of removal 12 10 GTRIS0 h 1 Ta i R w Es R 3 s g r Fe f i 1 us od yn ret a GENS x ET Fa a f Non Y a v uL Ti F rua uL di i vi A d Y a E J la T JER on i r E Bs TE hri 5 in 1 5 te a E J s la i 5 i gt 1 K E 5 J es W Fehr FE d uw 1 a 5 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM CALIPER RESOLVE FRONT Removal 2 bolt Removal 1 pin Measure the caliper PISTON O D SERVICE LIMIT 30 20 mm Measure the caliper cylinder I D SERVICE LIMIT 30 25mm 12 11 CPI MOTOR GTR180 XII WHEEL amp BRAKE SYSTEM CALIPER RESOLVE REAR BRAKE PAD REMOVAL Removal 2 pin REMOVAL PISTON Measure the caliper PISTON O D SERVICE LIMIT 30 20 mm Measure the caliper cylinder I D SERVICE LIMIT 30 25mm The installation sequence 1s essentially the reverse of removal 12 12 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM DISK BRAKE SYSTEM BRAKE OIL INSPECTION Normal fluid lever 1s between upper and lower DISK BRAKE SYSTEM
12. TORQUE TORQUE STANDARD SORTS TORQUE kg m ie 3 GIR180 INNER OF ENGING ITEM AMOUNT DIAMETER mm TORUQUE kg m REMARKS 2 _ m 3 adj nut om a Gilpumpboli 2 6 tea coverbo 2 6 Sup 1 2 Cam chain adj bolt 1 7 FRAME us gt m 3 0 3 0 1 5 0 9 0 9 0 9 1 3 5 5 5 5 5 5 0 4 1 2 2 0 9 1 4 1 p 1 Ge 99 3 4 CPI MOTOR GIR180 III SERVICE INFORMATION MAINTENANCE SCHEDULE To inspect or to clear lubricate replenish repair and replace if it s necessary A adjust C clear R replace gt tight Ti Which gt Total kilometers for driving iten d first vw Km Km Km Km Km Km Km Km Km Km 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Engine oil Oil filter New C C C screen 300km Fuel filter screen Gear oil M LL jej Cau Pr P T T I LI E L E pp fa Spark plug Drive belt Engine bracket Whole nuts amp bolts T T T T T T T T T T Tire Inspect before driving i Inspect before driving Steering bolts Brake liquid Cooling liquid Cooling tank 7 Per year or 10000 kilometers R e LE PL LG I NEN _ PT TT It s Cooling tank cap Brake lever Brake disc Shock absorber T IT j gt mama EG Li diti d li
13. plug ATTNENTION Each electric circuit need to match the proper connection and test It ll have no good testing sometime even have the proper connection Connect the high pressure Shunt on the electric meter or use the meter with input impedance of Q 100V up Remove the middle cover Connect the meter cable with once coil terminal black wire and pink wire Push the starter button or step on the starter lever test the maximum electric voltage of Ignition coll Connection terminal connect green terminal connect black yellow 10 16 CPI MOTOR GTR1S0O X ELECTRIC SYSTEM Min electric voltage 95 V up ATTENTION The finger shall not touch the metal portion when survey the electric voltage or get an electric shock Please pay attention to this point specially INSPECTION Once Coil Open the terminal connecting of once coil and test the impedance value of once coil Standard 0 4Q 10 20 Impedance value is within standard to be good Impedance value express the coil to be broken it s need to change a new one Twice Coil Enclosed the spark plug cover test impedance value of the high pressured guide wire of spark plug and the green terminal Standard Value 13 6 KQ 10 20 C Open the cover of spark plug test impedance value of the high pressured guide wire of spark plug and the green terminal Standard Value 3 6KQ
14. GOOD SPARK 4 FAULTY IGNITION SWITCH 5 INCORRECT IGNITION TIMING TEST CYLINDER LOW COMPRESSION 1 ENGINE NOT CRANKED COMPRESSION 2 NO VALVE CLEARANCE 3 VALVE STUCK OPEN 4 WORN CYLINDER AND PISTON 3 NORMAL COMPRESSION RINGS 5 BLOWN CYLINDER HEAD GASKET 6 FLAW IN CYLINDER HEAD 7 INCORRECT VALVE TIMING 8 BURNED VALVE START ENGINE ENGINE FIRES BUT 1 CHOKE VALVE OPEN DOES NOT START 2 CARBURETOR PILOT SCREW OPEN 4 3 AIR LEAKING THROUGH IN TAKE ENGINE FIRES PIPE 4 INCORRECT IGNITION TIMING DRY PLUG 2 CHOKE VALVE CLOSED START ENGINE WITH 2 1 CPI MOTOR GIR180 II TROUBLE SHOOTING ENGINE LACKS POWER FLOW PATH BAD SITUATION PROBABLE CAUSE RAISE WHEELS OFF WHEELS DO NOT SPIN 1 DRAGGING BRAKE GROUND AND SPIN FREELY 2 FAULTY WHEEL BEARING 3 OVERTIGHTENED DRIVE CHAIN 4 WHEEL BEARING NOT LUBRICATED WHEELS SPIN FREELY PROPERLY CHECK TIRE PRESSURE INCORRECT TIRE 1 PUNCTURED TIRE PRESSURE 2 FAULTY TIRE VALVE NORMAL PRESSURE RAPIDLY ACCELERATE DOES NOT ACCELERATE 1 SLIPPING CLUTCH FROM LOW TO SECOND WITH ENGINE SPEED 2 WORN OR UNEVEN CLUTCH ACCELERATES RAISED FACINGS 3 CLUTCH PLATE WARPED REV UP GRADUALLY ENGINE SPEED DOES NOT 1 CARBURETOR CHOKE CLOSED 2 ENGINE SPEED INCREASED INCREASE CLOGGED AIR CLEANER 3 CLOGGED FUEL LINE 4 CLOGGED FUEL TANK CAP BREATHER HOLE 5 CLOGGED MUFFLER CHECK IGNITION TIMING INCORRECT TIMING INCORRECT TIMING ADJUSTM
15. Loose cylinder head bolts Poor lubrication pressure Oil level too low Clogged oil filter or oil passage Faulty oil pump Drain the engine oil Turn off the engine put the motor vertical the s gauge to check the oil reserve Please don t return the oil level gauge into right crankcase cover 9 If the oil reserve closed the lower limit add the engine oil to max OIL LEVEL GAUGE E Remove the setting bolts of the right crankcase Cover smooth road after 3 5 minutes and use the oil level h 6 3 CPI MOTOR GTRIS0 VI OIL PUMP REMOVAL Change engine oil ATTENTION Please drain the engine oil when the warm engine which can assure the engine oil 1s smooth Put the dish under the engine disassemble the drain plug bolt to drain engine oil If drain plug bolt washer is damaged it must change new one Lock the drain plug bolt Torque 3 5 4 5kgf m Clean the engine oil filter screen Disassemble the tappet ad cap assy Get out of the engine filter screen and spring Clean the engine oil filter screen Check the tappet adj cap assy ring and filter if it was damaged it must change new one Install the engine oil filter and spring P3 ES OIL FILTER SCREEN Lock the tappet adj cap assy Torque 1 3 1 7kgf m Put engine oil pour tank filler sleeve Engine oil volume change 800 c c Install oil level gauge comp to start the engine
16. VILCYLINDER HEAD amp CAM SHAFT REMOVAL CYLINDER HEAD REMOVAL Remove three flange bolts cylinder head Remove 1 Flange bolts A Remove two intake pipe bolts Remove 1 Flange bolts A Remove the intake pipe comp amp carburetor insulator Remove 1 Intake pipe comp A 2 Carburetor insulator B Remove the flange bolt Remove 1 Flange bolt A 7 8 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Remove the thermostat case Remove Thermostat case A Remove the cylinder head assy Remove 1 Cylinder head assy A Remove the dowel pins amp cylinder head gasket Remove 1 Cylinder head gasket A 2 Dowel pins B 7 9 CPI MOTOR GIR180 VII CYLINDER HEAD amp CAM SHAFT REMOVAL CYLINDER HEAD DISASSEMBLTY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor NOTE Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks NOTE Be careful not to damage the cylinder head mating surface Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace 1f over INSPECT VALVE SPRING FREE LENGTH Tan aspa OUTER sPRIN Ge Measure the free length
17. amp chain wheel Remove 1 Pump chain A 2 Chain wheel B Disassemble the screws Remove 1 Screws A Disassemble the oil pump driven sprocket Remove 1 011 pump driven sprocket 6 8 CPI MOTOR GTR180 VI OIL PUMP REMOVAL OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown Remove 1 Screw A OIL PUMP INSPECTION Measure the body to outer rotor clearance Service limit 0 25 mm replace if over Measure the rotor end to pump body clearance Service limit 0 12 mm replace if over 6 9 CPI MOTOR VI OIL PUMP REMOVAL OIL PUMP INSTALLATION Install the oil pump to the crankcase Install I Oil pump A Install the oil pump and oil separator and tighten the two screws Make sure that the pump shaft rotates freely Install 1 Screws A Install the pump drive chain and driven gear then set the cir clip securely on the pump shaft Install 1 Pump chain A 2 Cir clip B 3 Pump chain wheel C 6 10 GTR180 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL CYLINDER HEAD EXPLODED VIEW CPI MOTOR GIR180 VILCYLINDER HEAD amp SHAFT REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water Jacket must be drained first When assembling apply molybdenum disulfide grease or engine oil to the
18. are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times Keep the container in place for 20 minutes or more Don t remove the container from the battery until its empty battery requires all entire electrolytes from the container for proper operation Removal of the container before it 1s completely empty can shorten the service life of the battery Do not remove the electrolyte container until it is completely empty and 20 minutes have elapsed Gently remove the container from the battery Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance Charging the battery immediately after filling can shorten service life Let the battery sit for at least 30 minutes after filling Initial Charge Place the strip of caps loosely over the filler ports Newly activated sealed batteries require an initial charge standard Charge 1 2 A x 5 10 hours If using a recommended battery charger follow the charger s instructions for newly activated sealed battery Te Yuasa 1 5 Amp Automatic Charger Battery Mate If the above chargers are not available use equivalent one 10 9 CPI MOTOR X ELECTRIC SYSTEM Charging rates will vary depending on how long the battery has been stored temperature and the type of charger used Let battery sit 30
19. 10 20 C The impedance value is within the standard to be good The impedance value express the coil to be broken and have to change a new one If it enclose spark plug cover survey value is no met the standard it s expressed the defection of spark plug 10 17 CPI MOTOR GTR1S0O X ELECTRIC SYSTEM Replacement Replace the ignition coil if it s necessary to remove the bolt bolt x 1 of ignition coil SPHYGMOGRAM Coil Inspection Remove the under cover Remove the wire connector of Sphygmogram equipment Test the impedance value of blue wire beside engine yellow Terminal and body iron parts Standard 100 15 20 C Change Generator if test the value over the standard ATTENTION When check the sphygmogram coil please make sure this testing 15 under the normal compress pressure condition of the cylinder and the spark plug is installed on the cylinder head 10 18 CPI MOTOR GTR180 SL X ELECTRIC SYSTEM Circuit of Starting System OFF FRISTOP E O O TARTER MOTOR Br Ep Op b o 2 r START SW B START RELA ue EM ID us TAIL LIGHT RR STOP Inspection of Starting Relay Open main switch Pull the brake lever Push the starting button
20. 10 30mm REAR BARKE LEVER CLEARANCE 10 30mm FRONT TYPE 110 70 17PR REAR TYPE 120 80 16PR SPARK PLUG CLEARANCE 0 7 0 8mm SPARK PLUG DPR7EA NGK VALVE CLEARANCE IDLE SPEED 1600 100rpm OIL CAPACITY GAER OIL CAPACITY 3 1 CPI MOTOR GIR180 INFORMATION MAIN JET ITEM STANDARD SERVICE PUMP TIP CLEARANCE 0 05 0 10mm OIL ROTOR TO BODY 015 0 23mm PUMP INNER amp OUTER CLEARANCE 0 15mm 0 20mm UNIT mm ITEM STANDARD SERVICE LIMIT om VALVE CLEARANCE um IN 30 74 30 86 30 69 CAM LOBE HEIGHT LE 30 33 30 45mm 30 28mm IN 10 000 10 015 10 10 ROCKER ARM I D E 10 000 10 015mm 10 10mm ROCKER ARM SHAFT O D N a VALVE SEAT WIDTH IN 4 975 4 990 4 965 VALVE STEM O D N ae 4 955 4 970mm 4 945mm VALVE GUIDE I D Ev VALVE STEM TO VALVE 0 010 0 037mm 0075 GUIDE CLEARANCE 0 030 0 057mm 0 095mm 3 2 CPI MOTOR GIR180 III SERVICE INFORMATION UNIT mm SPRING FREE LENGTH 144 146mm 140mm ITEM STANDARD SERVICE LIMIT GROOVE CLEARANCE SECOND 0 02 0 044 mm PISTON RING END SECOND 0 10 0 25 mm PISTON CLEARANCE OIL SIDE RAIL 0 2 0 7 mm PISTON O D AT SKIRT 57 97 57 99mm ST 020im PISTON TO CYLINDER CLLEARANCE 0 02 0 04 PISTON PIN BORE I D 15 002 15 008 15 04 PISTON PIN O D 14 994 15 000 14 98 OT J STANDARD SERVICELIMIT nor om 3 3 CPI MOTOR INFORMATION
21. 125 92 4 Rerdsbot 274 28 302 5 245 25 18 6 SocketbonMo 147 15 108 G APPLY GREASE WHEEL RIM TIRE INFORMATION im pem 5 FRONT 1 5 32PSI 2 3BAR AVANT 36PSI2 5BAR REAR PERSON 32PSI 2 3BAR ARRIERE 2PEOPLE 36PSI 2 5BAR 12 2 CPI MOTOR GTRIS0 XII WHEEL amp BRAKE SYSTEM METHOD TO REMOVE THE REAR WHEEL REMOVAL EXHAUST PIPE Removal 3 bolt Removal 2 nut REMOVAL REAR FENDER Removal 2 bolt Removal 2 bolt 12 3 CPI MOTOR XII WHEEL amp BRAKE SYSTEM R R CALIPER ASSY REMOVAL Removal 2 bolt R R SWING ARM REMOVAL Removal REAR WHEEL Removal 2 bolt Removal 1 bolt REMOVAL THE REAR WHEEL INSTALL REAR WHEEL OPPSITE TO THE REMOVING OF IT TORQUE M6 1 2 1 5 kg m M8 2 2 3 0 kg m M10 4 0 5 0 kg m M14 11 5 12 5 kg m 12 4 GTRIS0 CPI MOTOR GTRIS0 XII WHEEL amp BRAKE SYSTEM FRONT WHEEL REMOVAL Raise the front wheel off the grand ground by placing a block or safety stand Disconnect the speedometer cable Remove 2 pan head bolt REMOVE THE AXLE SHAFT Remove front axle nut Remove 2 socket bolt M6 12 5 CPI MOTOR GTR180 XII WHEEL amp BRAKE SYSTEM REMOVE THE FRONT WHEEL Removal front axle Removal front wheel AXLE SHAFT INSPECTION Measure the axle shaft run out SERV
22. BRAKE OIL INSPECTION Normal fluid lever 1s between upper and lower BRAKE OIL CHANGING FRONT DRAIN THE BRAKE OIL 1 Release the brake oil passage A 7 Brake oil passage 2 Drain the brake oil 12 13 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM 3 Open the cap to help drain Removal 2 bolt EMPTY INTO NEW BRAKE OIL 1 Fill with new brake oil DOT 3 DOT 4 2 Leak out the air ATTENTION This step 1 amp 2 must working together until not have air in brake oil tube 12 14 CPI MOTOR XILWHEEL amp BRAKE SYSTEM BRAKE OIL CHANGING REAR DRAIN THE BRAKE OIL 1 Release the brake oil passage 2 Drain the brake oil 3 Open the cap to help drain Removal 2 bolt EMPTY INTO NEW BRAKE OIL Fill with new brake oil DOT 3 DOT 4 12 15 GTRIS0 CPI MOTOR GTR180 XII WHEEL amp BRAKE SYSTEM 2 Leak out the air ATTENTION This step 1 amp 2 must working together until not have air in brake oil tube BRAKE LINING CHANGE FRONT 1 Drain the brake oil Refer to 12 13 12 14 2 Remove the brake caliper setting bolts Remove the brake lining md gt E 3 Removal STOP SWITCH ASSY on MASTER CYLINDER ASSY 1 4 Change brake lining D Install process to refer to reverse of removal 12 16 CPI MOTOR XII WHEEL amp BRAKE SYSTEM BRAKE LINING CHANGE REAR 1 Drain the brake oil Refer to 12 15 2 Remove the brake caliper
23. Remove the piston rings insert each piston ring into the cylinder with the piston and measure the ring end gap in the cylinder to a point 10 mm 0 4in from the bottom Use the piston head to push each piston ring into the cylinder SERVICE LIMITS 0 5 mm 5 6 CPI MOTOR GIR180 V CYLINDER amp PISTON Measure piston pin bore I D in two directions at right angle to each other SERVICE LIMITS 15 04 mm Measure the piston pin O D at the front center and rear and in tow directions across from each other SERVICE LIMIT 14 98 mm Measure the cylinder I D at a point 10 mm from the bottom SERVICE LIMITS 57 1 mm Measure the connecting rod small end I D Service Limit 17 06mm replace if over 5 7 CPI MOTOR V CYLINDER amp PISTON Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if over Measure the piston O D Service Limit 57 3mm replace if below Take measurement at 9mm from the bottom and 90 to the piston pin hole Measure the piston to piston pin clearance Service Limit 0 1 mm replace if over 5 8 GIR180 CPI MOTOR V CYLINDER amp PISTON PISTON RING INSTALLATION Clean the piston ring groves thoroughly Install the piston ring Space the piston ring end gaps 120 degrees apart The gap of the three piece oil ring should correspond with the gap of spacer PS When installing the oil ring install the spacer first a
24. amp washer Remove 1 Cir clip amp washer A Disassemble the kick starter spindle comp 9 7 GIR180 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Disassemble the kick spindle bush Remove Bush A Install the kick starter comp Install the kick starter spindle amp bush Install the cir clip amp washer Install the filter NOTE When install the filter please check the direction 9 8 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Install the element plate J Ez Install flange bolts Install An 1 Element plate A 2 Flange bolts B Ae NOTE S When install the element plate please check the direction iu Install the inner cover Install the screws Install 1 Inner cover A 2 Screws B Install the shroud cover Install flange bolts Install 1 Shroud cover A 2 Flange bolts B Install the kick starter spindle comp Install the starter kick spring 9 9 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER INSTALL THE STARTER IDLE GEAR COMP Install 1 Idle gear comp A Install the left crankcase cover plate Install the screws Install 1 Left crankcase cover plate A 2 Screws B Install the gasket amp dowel pins ATTENTION The gasket needed to change new n 9 10 CPI MO
25. and idle several minutes Stop the engine after 3 5 minutes use the oil level gauge check the oil reserve which is stand or not Check the engine appearance leak of engine oil 6 4 CPI MOTOR VI OIL PUMP REMOVAL DISASSEMBLE OIL PUMP Disconnect the water hoses from the right crankcase cover Remove the twelve bolts attaching the right crankcase cover and the cover Remove 1 Flange bolts A Disassemble right crank case cover gasket amp pins Disassemble the oil through and spring Remove 1 Right crank case cover gasket A 2 Oil through and spring B 3 Pins C 6 5 GTRIS0 CPI MOTOR GTR180 VI OIL PUMP REMOVAL Use the pneumatic tools disassemble the nut Remove 1 Nut and washer A FLYWHEEL REMOVAL Hold the flywheel with a flywheel puller and remove the flywheel ATTENTION When work flywheel puller it must support the A C G fly wheel carefully Remove 1 Flywheel puller A Disassemble the starter reduction gear comp Remove 1 Holder amp bolt A 6 6 CPI MOTOR VI OIL PUMP REMOVAL Disassemble the starter driven gear comp Remove 1 Starter driven gear comp A Disassemble the flange bolts Remove the oil separator Remove 1 Flange bolts A 2 Oil separator B Disassemble the Cir clip Remove 1 Cir clip A 6 7 GTRIS0 CPI MOTOR GTRIS0 VI OIL PUMP REMOVAL Disassemble the oil pump chain
26. it is out of standard please replace the new one Inspection clutch brake pad Service limit 2 0mm Measure the width of each pad if itis notas standard replace the new parts Inspection clutch spring Measure the clutch spring s free length if it is out of standard please replace for new part Inspection driven pulley assy Inspection driven pulley face Measure the driven face O D SERVICE LIMIT 33 92 mm Inspection movable driven face Measure the movable drive face I D SERVICE LIMIT 34 06 mm 9 16 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER INSPECTION DRIVEN FACE BEARING Inspection inner bearing seal is damaged or not Inspection needle bearing is damaged or bigger clearance INSPECTION REPLACE THE CLUTCH PARTS Dismantle the C clip amp washer then disassemble the clutch part amp spring from drive plate Inspect if the spring is damaged or with enough tension Inspection clutch damper rubber is damaged out of shape Apply some grease installing pin Apply some grease on installing pin but not on clutch parts If there 1s grease on clutch parts then replacement required Put new clutch parts on installing pin and make sure the position Use vise to install the spring into groove 9 17 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Install the cir clip to driven plate comp Installing pin EUR gt Change drive fac
27. minutes after initial charge then check voltage using a voltmeter If it 1s not at least 12 8 V repeat charging cycle After charging 1s completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or hammer When properly installed the strip of the caps will be level with the top of the battery Once the strip of the caps 15 installed onto the battery never remove the caps nor add water or electrolyte to the battery To ensure maximum battery life and customer satisfaction it 15 recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 8 V repeat the charging cycle and load test If still below 12 8 V the battery 1s defective 10 10 GTR180 V l Y CPI MOTOR GTR1S0O X ELECTRIC SYSTEM PRECAUTIONS 1 NO NEED OF TOPPING UP No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the seal cap to add water 1s very dangerous Never do that 2 REFRESHING CHARGE If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see Specifications section When a fast charge 1s inevitably required do it following precisely the maximum charge current and time con
28. of the inner and outer valve springs Service Limits Inner IN EX mm replace if below Outer IN EX mm replace if below 7 10 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL VALVE VALVE GUIDE INSPECT Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D MEASURES IN 4 965 m m replace if below EX 4 945 m m replace if below CYLINDER HEAD ASSEMBLY Lubricate each valve stem and valve stem seal with the engine oil Insert the valve stem seal and valve stems into the valve guides Be careful not to damage the valves INSTALL CYLINDER HEAD Install the cam chain guide Install the dowel pins and a new cylinder head gasket Install I CAM CHAIN GUIDE A 2 Dowel pins B 3 Cylinder head gasket C Install the cylinder head and take out the cam chain Attention Cam chain A 7 11 CPI MOTOR GIR180 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Install the dowel pins Install 1 Dowel pins A Install two sides of flange bolts on cylinder head assy Install 1 Flange bolts A Install the carburetor heat insulator ATTENTION Pay attention at direction A 7 12 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Install the intake pipe comp Install 1 Flange bolts A Install thermostat comp ATTENTION Please check the t
29. other parts of an electrical system a fully charged battery 1s a must for conducting accurate electrical system tests lt electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them lt prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch 1s on or while the engine 1s running lt Because ofthe large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor windings lt not use a meter illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb lt gt Take care not to short the leads that are directly connected to the battery positive terminal to the chassis ground lt Troubles may involve one or in some cases all items lt Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they must be repaired or replaced or the new replacement will soon fail again lt Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation lt oMeasure coil and
30. setting bolts Remove the brake lining 3 Removal STOP SWITCH ASSY on MASTER CYLINDER ASSY 2 4 Change brake lining S Install process to refer to reverse of removal 12 17 GTRIS0 GTRIS0 CPI MOTOR XII WHEEL amp BRAKE SYSTEM FRONT FORK EXPOLODED VIEW 12 18 CPI MOTOR GTRIS0 XII WHEEL amp BRAKE SYSTEM FRONT FORK REMOVAL REMOVE THE FRONT WHEEL SETTING BOLT Refer to 13 5 13 6 Remove the front for setting bolt Refer to 12 8 Remove the front fork FORK TUBE REMOVAL Removal 4 socket bolt FORK TUBE RESOLVE UB CAP Removal the rubber cap 12 19 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM P FORK TUBE RESOLVE 1 Hold the fork tube in a vice ad 14 2 To bring pressure to bear on center for 5 to 7kg sd 3 Removal clip N CLIP 4 Removal cap bolt 5 Removal o ring RING 6 Removal front fork spring ES NOTE Does not damage the fork tube while NT FORK SPRING this operation 12 20 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM FRONT FORK INSPECTION Measure the fork spring free length SERVICE LIMIT 235 7mm Drain the fork from the top of the front fork Pour out any remaining fluid by pumping the fork
31. tube and set 4 7 ORK PISTON the inner tube plug on the end of the fork piston Insert the parts into the fork slider and tighten the socket bolt with the 6mm Allen wrench NOTE Aer Apply locking agent to the socket bolt ur TORQUE 1 8 2 3 Kg m Install the oil seal in the top of the slider with a fork seal driver 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 Install the snap ring into the groove of the fork bottom case with snap ring pliers Fill the forks with good quality ATF Automatic Transmission Florid CAPACITY 86 1 cc 12 24 CPI MOTOR GIR180 XII WHEEL amp BRAKE SYSTEM Install the fork spring into the fork tube ED OW 1 Install the fork spring into the fork tube Be care for fork spring rebound 2 Install the cap bolt gt 3 To bring pressure to bear on cap bolt for 5 to 7kg ET 4 Install the clip into the fork tube on the cap bolt 0 Hold the fork tube in a vice A 2 o Tighten the fork bolt T_T TORQUE SLAG 4 0 5 0 Kg m E 12 25 CPI MOTOR GIR180 XI WHEEL amp BRAKE SYSTEM MEMO 12 26 CPI MOTOR GIR180 XIIIL ADDENDUN SPECIAL TOOLS 1 FOR FRAME ASSEMB
32. BURETOR REMOVAL Remove the mission box breather tube Remove Tube A Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Remove Throttle Cable A Disconnect the auto bystarter wire Remove 1 Auto Bystarter A Loosen the air cleaner connecting tube band and carburetor Remove 1 Air Cleaner Connecting Tube Band A 8 5 CPI MOTOR GIR180 REMOVAL Loosen the drain screw and drain the fuel from the float chamber Remove 1 Drain Screw A Remove the two vacuum chamber cover screws and the cover Remove 1 Screws A 2 Vacuum Chamber Cover B Remove the compression spring and vacuum piston Remove 1 Spring A 2 Vacuum Piston B Remove the needle holder spring and Jet needle from the vacuum piston Remove 1 Vacuum Piston A 2 Needle Holder B 3 Jet Needle C 4 SPRING D NOTE Be caretul not to damage the vacuum piston diaphragm 8 6 CPI MOTOR GIR180 VIILCARBURETOR REMOVAL AIR CUT OFF VALVE INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears ACCELERATING PUMP Disassemble the throttle holder screws Remove 1 Screws A Disassemble the two accelerating pump cover screws and accelerating pump cover Disassemble the spring and accelerating pump diaphragm Rem
33. ENT CORRECT TIMING CHECK VALVE CLEARANCE INCORRECT VALVE 1 INCORRECT VALVE CLEARANCE 2 WORN VALVE SEAT CORRECT VALVE CLEARANCE 2 2 CPI MOTOR II TROUBLE SHOOTING TEST CYLINDER LOSS OF COMPRESSION COMPRESSION NORMAL COMPRESSION CHECK CARBURETOR FOR CARBURETOR CLOGGING CARBURETOR CLOGGED NOT CLOGGED REMOVE SPARK PLUG PLUG FOULED OR DISCOLORED COLORED CHECK OIL LEVEL AND OIL DIRTY OR LEVEL CONDITION INCORRECT 10 CORRECT ENGINE OIL LEVEL REMOVE CYLINDER HEAD INSUFFICIENTLY COVER AND CHECK LUBRICATED SUFFICIENTLY LUBRICATION CHECK IF ENGINE ENGINE OVERHEATS OVERHEATS ENGINE DOES NOT OVERHEAT RAPIDLY ACCELERATE OR ENGINE KNOCKS URN AT HIGH SPEED ENGINE DOES NOT KNOCK 2 3 GTRIS0 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 1 CARBURETOR JETS CLOGGED 1 FOULED PLUG 2 INCORRECT HEAT RANGE PLUG 1 LEVEL TOO LOW OR HIGH 2 CONTAMINATED OIL 1 CLOGGED OIL PASSAGE 2 POOR OIL PUMP DELIVERY 1 EXCESSIVE CARBON IN COMBUSTION CHAMBER 2 INCORRECT FUEL 3 SLIPPING CLUTCH 1 WORN PISTON OR CYLINDER 2 MIXTURE TOO LEAN 3 INCORRECT FUEL 4 EXCESSIVE CARBON IN COMBUSTION CHAMBER 5 LGNITION TIMING TOO EARLY CPI MOTOR GIR180 II TROUBLE SHOOTING POOR PERFORMANCE AT IDLE AND LOW SPEEDS FLOW PATH BAD SITUATION PROBABLE CAUSE
34. GIRISO Service Manual PREFACE TROUBLE SHOOTING SERVICE INFORMATION ENGINE REMOVAL amp INSTALLATION CYLINDER amp PISTON OIL PUMP REMOVAL CYLINDER HEAD amp CAM SHAFT REMOVAL CARBURETOR REMOVAL DRIVE AND DRIVEN PULLEYS amp KICK STARTER ELECTRIC SYSTEM FRAME WHEEL amp BRAKE SYSTEM ADDENDUN CONTENTS 10 11 12 13 CPI MOTOR GIR180 I PREFACE THE CONTENTS OF THIS MANUAL PROVIDE THE AFTER SERVICE INFORMATION FOR CPI GTR 180 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 MANUAL ARE BASED ON THE LATEST MODEL INFORMATION AND CPI RESERVES THE RIGHT TO MAKE CHANGE AT ANY TIME WITHOUT NOTICE AND WITHOUT ANY RESPONSIBILITY OR ENGAGEMENT ON OUR PART 1 1 CPI MOTOR GIR180 II TROUBLE SHOOTING ENGINE WILL NOT BE STARTED OR HARD TO START FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IF FUEL CAN BE FUEL DOES NOT REACH 1 NO FUEL IN TANK REACHED CARBURETOR CARBURETOR 2 CLOGGED FUEL LINE BETWEEN FUEL TANK AND CARBURETOR 3 CLOGGED FUEL VALVE FUEL REACHES 4 CLOGGED FUEL TANK CAP CARBURETOR BREATHER HOLE REMOVE SPARK PLUG WEAK OR NO SPARK 1 FAULTY OR FOULED PLUG AND TEST SPARK 2 FAULTY C D I 3 BROKEN OR SHORTED HIGH TENSION CORD
35. ICE LIMIT 0 2 mm FRONT WHEEL RIM RUNOUT INSPECTION Measure the wheel rim run out SERVICE LIMIT Radial 2 0mm Axial 2 0mm 12 6 CPI MOTOR GTR180 XIL WHEEL amp BRAKE SYSTEM FRONT BRAKE DISK CHANGE REMOVEAL FRONT WHEEL Refer to 12 5 12 6 BRAKE DISC REMOVAL Removal 5 bolt BRAKE DISK INSPECTION Brake disc thickness SERVICE LIMIT 3 0mm Brake disk flatness SERVICE LIMIT 0 3mm INSTALL FRONT BRAKE DISC The installation sequence 1s essentially the reverse of removal Opposite to the removing of it torque M6 1 2 1 5kg m 12 7 CPI MOTOR GTR180 XII WHEEL amp BRAKE SYSTEM REAR BRAKE DISK CHANGE REMOVEAL REAR WHEEL Refer to 12 3 12 4 BRAKE DISC REMOVAL Removal 3 bolt BRAKE DISK INSPECTION Brake disc thickness SERVICE LIMIT 3 0mm Brake disk flatness SERVICE LIMIT 0 3mm INSTALL REAR BRAKE DISC The installation sequence 15 essentially the reverse of removal Opposite to the removing of it torque M6 1 2 1 5kg m 12 8 CPI MOTOR GTR180 XII WHEEL amp BRAKE SYSTEM BRAKE PAD CHANDGE FRONT BRAKE MASTER CYLINDER REMOVAL Removal the caliper from the front fork Removal 2 bolt Brake pad Remove Removal pin Change brake pad x The installation sequence 1s essentially the reverse of removal 12 9 CPI MOTOR XII WHEEL amp BRAKE SYSTEM BRAKE PAD CHANGE REAR BRAKE MASTER CYLINDER REMOVAL Removal the caliper from the R R SWING ARM
36. ING INCORRECT INCORRECT VALVE TIMING ADJUSTMENT CORRECT CHECK VALVE SPRING TENSION WORN OR BROKEN FAULTY VALVE SPRING SPRING SPRING TENSION CORRECT 2 5 CPI MOTOR GIR180 II TROUBLE SHOOTING SMOKY EXHAUST FLOW PATH BADSITUATION PROBABLE CAUSE RUN MOTORCYCLE A LONG BLACK SMOKE 1 WORN CYLINDER AND PISTON RINGS DISTANCE AT HIGH SPEED EMITTED 2 OIL LEVEL TOO HIGH THIN EXHAUST EMITTED 3 PISTON RINGS INCORRECTLY INSTALLED 4 FAULTY PISTON OR CYLINDER 5 FLAWS IN CYLINDER HEAD RETURN THROTTLE GRIP WHITE SMOKE 1 WORN INTAKE VALVE GUIDE OR STEM QUICKLY EMITTED 2 EXCESSIVE VALVE TO GUIDE CLEARANCE POOR HANDLING FLOW PATH BADSITUATION PROBABLE CAUSE IF STEELING IS HEAVY CHECK TIRE 1 STEERING HEAD ADJUSTER TOO TIGHT PRESSURE 2 DAMAGED STEERING CONES OR STEEL BALLS IF EITHER WHEEL IS 1 EXCESSIVE WHEEL BEARING PLA Y WOBBLING 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 IF THE MOTORCYCLE PULLS 1 MISAPPLIED SHOCK ABSORBER TO ONE SIDE 2 FRONT AND REAR WHEELS NOT ALIGNED 3 BENT FRONT FORK 4 BENT SWING ARM 2 6 CPI MOTOR GIR180 INFORMATION IGNITION TIME 33 BTDC 5000 100rpm Q CHARGING AMPERAGE OR 20 C CHARGING COIL 0 2 0 3 STANDARD COMPRESSION 700kPa 7 0kgf cm 260r min FRONT BARKE LEVER CLEARANCE
37. LY For the front fork 2 FOR ENGINE ASSEMBLY For A C G 13 1 GIR180 CPI MOTOR XIILADDENDUN COOLING SYSTEM 2 MP WATER TANK FAN ADJUSTER A FAN gt M 17 j HATER TANK Temp Adjuster 72 2 C open 88 C full open Stroke 3 5 4 5mm Fan switch Turn on 90 2 C 13 2 CPI MOTOR GTR180 XIIIL ADDENDUN MEMO 13 3 CPI MOTOR GTRIS0 XIIIL ADDENDUN Collaboration Professional I nnovation 13 4
38. NSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed 1n the frame Drain the coolant before starting any operations Use carefully when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed please check each part for oil leaks ENGINE OIL CAPACITY Dissolution 1050 c c Change 800 c c The engine oil viscosity is SAE 10W 30 ENGINE OIL VISCOSITY SAE 20W 50 SAE 20W 40 SAE 10W 40 SAE 10W 30 _ Gear oil Dissolution 150 Change 120 c c The gear oil viscosity 1s SAE 140 Unit mm BM STANDARD SERVICE LIMIT EN pump Outer rotor to pump body clearance 0 15 0 2 Rotor end to pump body clearance 0 04 0 09 6 2 CPI MOTOR GTRIS0 VI OIL PUMP REMOVAL TORQUE Engine oil filter screen cover 1 3 1 7kgf m Gear oil filler bolt 1 0 1 4kgf m Engine oil drain plug bolt 3 5 4 5kgf m Oil pump screw 0 1 0 3kgf m Gear oil drain plug bolt 0 8 1 2kgf m TROUBLE DECIDE Oil too low Engine oil leak Valve guide tube or oil seal 1s damage Piston rings damage Natural oil consumption Worn piston rings Worn valve guide Worn valve guide seal Oil contamination Oil not changed often enough Faulty cylinder head gasket
39. OVE PROTECTED 2 amp BELOW COVER A RECTIFIER CONNECTOR B ADJUST REGULATOR OPEN REGULAOR DIAGRAME CONNECTOR CHECK EVERY DIAGRAM SITUATION MAIN SW CABLE RED ELECT VASE BROWN PRESSURE BATTERY ELECT VASE RED BLACK CONNECTOR PRESSURE CHARGEABLE YELLOW ui COIL YELLOW IFCHECK WITH UNREGUAR VALUE PLEASE CHECK UNREGULAR DIAGRAM IF PART IS WITH NORMAL THEN HAVE THE DEFECTIVE PAIR WIRES IF ABOVE IS OK AFTER CHECKING CHANGE RECTIFIER CHECK ACG COIL OPEN ACG PLUGS USE METER TO CHECK THERESISTANCE BETWEEN EACH OIL AND DIRGRAM BETWEEN THE FRME RESISTENACE VALUE CHECK IF THERE IS ANYSHORTAGE IF THERE IS ANY UNNORMAL PLEASE CHANGE NEW COIL SET 2 1 YELLOW 0 4 1 2 2 YELLOW 0 4 1 2 3 YELLOW 0 4 1 2 10 6 CPI MOTOR GTR180 X ELECTRIC SYSTEM BATTERY REMOVAL Remove Disconnect the negative cable Slide out the positive terminal cap and then disconnect the positive cable NOTE Be sure to disconnect the negative cable first Remove the battery BATTERY INSTALLION Put the battery into the battery case Apply a light coat of grease on the terminals to prevent corrosion Install the positive cable first Cover the positive terminal with the cap Install the negative cable BATTERY ACTIVATION mE amp ELECTROLYTE FILLING Make sure that the model name A of the electrolyte container ma
40. Remove 1 Cylinder head comp A 2 Cylinder head gasket B Loosen the tensioner lifter cap Disassemble the tensioner lifter comp Remove 1 Tensioner lifter cap A 2 Tensioner lifter comp B Disassemble the cam chain guide Remove 1 Cam chain guide A Disassemble the flange bolt Disassemble the cylinder Remove 1 Cylinder A 5 4 GIR180 CPI MOTOR GIR180 V CYLINDER amp PISTON Clean any gasket material from the cylinder surface Disassemble the piston pin clip Remove 1 Piston pin clip A NOTE Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Disassemble the piston pin Press the piston pin out of the piston Disassemble 1 Piston Pin A NOTE Do not reuse pin clip as removal weakens and deform them They could fall out and score the cylinder wall Inspect the piston piston pin and piston rings Remove the piston rings Clean carbon deposits from the piston ring grooves 5 5 CPI MOTOR GTR180 V CYLINDER amp PISTON INSPECTION PISTON PISTON RING Disassemble the piston rings Disassemble 1 Top Ring A 2 Second ring B 3 O1l ring set NOTE Take care not to damage or break the piston rings during removal Clean the grooves for carbon deposit completely Measure the piston ring to groove clearance with a feeler gauge SERVICE LIMITS TOP 0 07mm SECOND 0 071
41. STANDARD In valve 0 06 mm Ex valve 0 08 mm Install the cylinder head gasket amp dowel pins Install 1 Dowel pins A 2 Cylinder head gasket B Install cylinder head cover amp two special bolts Install Special bolts A 7 15 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL MEMO 7 16 CPI MOTOR GIR180 REMOVAL CARBURETOR EXPLODED VIEW 8 1 CPI MOTOR GIR180 VIILCARBURETOR REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly Before float chamber disassembly drain the residual gasoline from the float chamber Do not try to disassemble the auto bystarter When assembling the vacuum chamber and air cut off valve be careful not to damage the diaphragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away from the working area When removing the fuel tank the remaining fuel in the tank must be lower than _ of the fuel tank capacity to avoid gasoline overflowing Fuel tank capacity 10 5 liters 8 2 CPI MOTOR GIR180 VIILCARBURETOR REMOVAL TROUBLESHOOTING Engine does not start Engine idles roughly stalls or runs poorly No fuel in tank Incorrect idle speed Restricted
42. TOR GTR180 X ELECTRIC SYSTEM The Ignition System Turbo CDI Ignition System circuit diagram RB ON COME OFF Turbo CDI Checking MIS Ignition System CDI connection Da EE ie 7 me gt LA P E 7 d NINE 7 O O 50 250 1100 500 s ID TG ke se _ mb MCN 10 15 CPI MOTOR GTR1S0 w X ELECTRIC SYSTEM Ignition Coil Dismantle Remove protected net 1 2 under cover Remove spark cover Remove ignition coil Leading wire A Remove the bolt of ignition coil take out the coil Installation will be used opposite procedure of dismantling ATTENTION Once coil is black wire to connect the black connector pink wire connect the green connector Spark Plug confirmation Remove spark plug as the right drawing install good spark on the spark cap and match the engine starting situation to make sure if the spark plug to have normal function Ifthe ignition situation is no good or the spark plus have been burned please change a new spark
43. TOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Remove drive belt Using the multi Installing Y shape Installed tool clip to install the driven face disassemble the nut washer ad drive face Using the multi Installing clip Y shape Installing tool to install the driven pulley outer then remove the nut and driven pulley outer DRIVEN BELT INSPECT Put drive belt into driven pulley groove same as the picture make ir loosen then take out belt and driven pulley together Disassamble the belt from groove Inspect the belt for crack wear damage Measure the width of belt M Weight SERVICE LIMIT 20 7mm 9 11 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER INSTALL DRIVEN ASSY Put apart the drive pulley then install the drive belt into the drive pulley Install the driven pulley assy with drive belt to the drive shaft Assemble another side of drive belt to movable drive face Install the driven pulley assy outer Using the multi Installing tool Y shape tool to install the driven pulley assy outer and tighten the nut by standard torque Torque 5 0 6 0kgf m Install the movable drive face washer amp nut Using the multi Installing tool Y shape tool to install the drive face PAY ATTENTION It must be no any grease on both sides of drive face use grease stripper to clean the unnecessary grease Torque 5 0 6 0kgf m
44. ake Manifold Band C Connect the auto bystarter wire Connect the fuel tube and vacuum tube to the carburetor Perform the following inspections and adjustments 1 Throttle grip free play 2 Idle speed 8 11 GTRIS0 CPI MOTOR GIR180 VIILCARBURETOR REMOVAL MEMO 8 12 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER DRIVE AND DRIVEN PULLEY EXPLODED VIEW 9 1 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER KICK STARTER EXPLODED VIEW 9 2 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley clutch and driven pulley can be serviced with the engine installed Avoid any grease and oil on the drive belt and pulley faces Make sure to clean all if there 1s on the part to minimize the slipping of drive belt and drive pulley Specification Movable drive face inner diameter Weight roller outer diameter Driven pulley inside diameter Driven pulley spring length 128 400 123 400 Driven pulley outer diameter 33 965 33 985 33 940 Driven pulley inside diameter 34 000 34 025 34 060 TORQUE VALUES Clutch outer nut 5 0 6 0 kg m Clutch drive plate nut 5 0 6 0kg m Driven pulley pad thickness 4 000 4 100 2 000 9 3 CPI MOTOR IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER TROUBLESHOOTING Engine starts but motorcycle won t move Worn drive belt Broken ramp plat
45. ater leak out 4 4 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION You can use leak air bolt to control of leaking out speed REMOVAL HOT WATER PIPE ASSY 1 Rmoval the clamp 2 Removal 2 pan head bolt 3 Removal the clamp 4 5 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION REMOVAL ENGINE INSTALL BOLT 1 Removal the nut 2 Removal the bolt 4 6 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION ENGINE INSTALLATION The installation sequence 1s essentially the reverse of removal Route all the wire and cable properly Adjust the throttle cable free play clearance Adjust the rear brake free play EMPTY INTO COOLING WATER 1 Open 2 cap 2 Make cooling water empty into OUTLET WATER ELBOW amp RESERVE TANK 4 7 CPI MOTOR GTR180 IV ENGINE REMOVAL amp INSTALLATION Makes cooling water full in outlet water elbow Makes cooling water full with lower between upper 4 8 CPI MOTOR GIR180 V CYLINDER amp PISTON CRANK SHAFT PISTON EXPLODED VIEW 5 1 CPI MOTOR GTR180 V CYLINDER amp PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed After disassembly clean the removed parts and dry them with compressed air before inspection
46. ble controlled electric current 14 5 V 2000rpm ATTENTION Make sure the rechargeable current and voltage to be normal when change a new battery Most of question 1s relative with rechargeable system for the following various condition please follow the failure checking step to check one by one Rechargeable electric voltage can not be increased and surpass the voltage of battery connector the rechargeable electric current 1s on the direction of discharge electricity Rechargeable electric voltage and current is larger than the standard If the condition 1s no relationship with the above the most condition has nothing to do with the rechargeable system Please execute the following checking and follow the failure sheet to check one by one D be reached the standard rechargeable electric voltage current when engine rotational speed surpasses the regulated rotational speed per minute The surpassed electronic power is cause by using the bulb over the regulated power Change the battery of old or no enough capacity 2 Normal rechargeable electric voltage but un normal rechargeable electric current Change the battery of old or no enough capacity Use the battery with insufficient power or surpassed battery of recharging The fuse of Ampere meter 1s burnt Un proper connection of Ampere meter With normal rechargeable current but with un normal rechargeable voltage The fuse of voltmeter 1s burnt 10 14 CPI MO
47. c current volume maybe change suddenly Don t use the starter motor for engine starting or large electric current will be flowed out and lose much electric power Remove the original battery and install battery of full power after engine starting for a while Use the digital voltmeter to test the voltage of battery connector Use Ampere meter to test electric current between the two connectors of main fuse ATTENTION Please use the Ampere meter to have the signal of positive negative pole if use the Ampere meter to have one direction to test the discharge electricity shall be 0 ampere 10 13 CPI MOTOR GTR1S0O GE opo X ELECTRIC SYSTEM ATTENTION Please do not use any wire of short circuit By using the Ampere meter to connect between the battery positive connector and cable even it can test the electric current and will damage the electric meter when start the motor suddenly suggest using the foot shaft to start the engine Please put main switch to OFF position when connect the Ampere meter If open the Ampere meter or cable it will be damaged when electric current is running Connect one engine rotation meter start the engine and turn on the head lamp on the far reaching position Add the engine rotational speed gradually and test the chargeable voltage current for rotational speed of per minute Rechargeable electric current 0 6A up 2500rpm amp 1 2A up 6000rpm Rechargea
48. ditions indicated on the battery This battery 1s designed to sustain no unusual deterioration if refresh charged according to the method specified above However the battery s performance may be reduced noticeably if charged under conditions other than given above Never remove the seal cap during refresh charge If by chance an excessive amount of gas 1s generated due to overcharging the relief valve releases the gas to keep the battery normal 3 WHEN YOU DO NOT USE THE MOTORCYCLE FOR MONTHS Give a refresh charge before you store the motorcycle and store it with the negative cable removed Give a refresh charge once a month during storage 4 BATTERY LIFE If the battery will not start the engine even after several refresh charges the battery has exceeded its useful life Replace it Provided however the vehicle s starting system has no problem 10 11 CPI MOTOR GTR1S0O X ELECTRIC SYSTEM WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loosened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or e
49. e face by anticlockwise direction Install the three slide pieces to ramp plate Install the ramp plate Install 1 Slide pieces A 2 Ramp plate B Smear a little grease inside of drive face shaft hole Install the drive face boss ATTENTION It can not have any grease on belt and surface of drive face 1t can use grease stripper to clean the unnecessary grease Install drive face comp to crankshatt 9 14 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER DRIVE FACE ASSEMBLY Install drive belt to drive face Tighten up per torque standard Torque 5 0 6 0kgf m DISASSEMBLY DRIVEN PULLEY ASSY Disassemble the drive face and driven pulley assy Install the clutch spring condenser to driven pulley assy then tighten it for fitting with nut easily Per picture to put the clutch spring condenser on vise and use special wrench dismount the nut Loosen the driven pulley spring condenser disassemble the driven pulley and spring from drive face Dismount the oil seal cover from drive face Dismount the oil seal cover from driven face assy Disassemble the guide pin roller guide pin amp movable driver face dismount the O ring and oil seal gasket from driver face 9 15 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Inspection clutch outer Service limit 125 5mm Measure the inner diameter of friction surface for clutch outer If
50. e Worn or damaged clutch lining Broken driven face spring Engine starts or motorcycle creeps Broken clutch weight spring Worn drive belt Lack of power Weak driven face spring Worn weight roller Faulty driven face 9 4 GTRIS0 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Disassemble the flange bolts Disassemble the Left crankcase cover Remove 1 Flange bolts A 2 Left crank case cover B Disassemble the gasket amp dowel pins Remove 1 Dowel pins A Disassemble four screws Disassemble the left crankcase cover plate Remove 1 Screws A Disassemble the start idle gear comp 9 5 CPI MOTOR GTRIS0 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Disassemble the starter kick spring Remove 1 Starter kick spring A Disassemble the starter idle gear shaft ATTENTION Idle gear shaft 1s dispensable to be disassembled Disassemble flange bolts Disassemble the shroud cover Remove 1 Flange bolts A Disassemble three screws Disassemble the inner cover Remove 1 Screws A 9 6 CPI MOTOR IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Disassemble flange bolts Disassemble the element plate Remove 1 Flange bolts A 2 Element plate B Disassemble the filter Inspect the filter 1f it 1s dirty or damaged If it 1s dirty or damage please change a new one Disassemble the cir clip
51. e bearing Remove the inner bearing ATTENTION There 1s an oil seal at one side of inner bearing in drive face dismantle the oil seal firstly For needle bearing disassemble the c clip first then for bearing Install the new bearing the seal side should towards to outside Apply the required grease Install the cir clip to install the bearing Install the new inner bearing Assembly of clutch drive face assy Install the new oil seal amp o ring on movable driven face assy 9 18 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER Install the movable driven face comp to driven face Install guide roller amp roller guide pin Install oil seal Assemble the drive face driven face spring and clutch into clutch spring condenser turn the condenser shaft to press assy part until the installing nut can be assembled on Put clutch spring condenser on vise use special nut wrench to tighten the nut with required torque torque 5 0 6 0kgf m Install transmission shaft to clutch drive face and drive belt 9 19 CPI MOTOR GIR180 IX DRIVE AND DRIVEN PULLEYS amp KICK STARTER MEMO 9 20 GTR180 CPI MOTOR X ELECTRIC SYSTEM DIAGRAM CIRCUIT 150 GIR POSTION LIGHT 12y Sw LOW BEAM LIGHT TNJSEN HIGH BEAM LIGHT TAV DEN POSITION LIGHT 12v Sw LFR WIMKER 12v 16 R HANDLE SWITCH SE NL er NATA oi PL T Mistet
52. fuel line Rich mixture Too much fuel getting to cylinder Lean mixture Clogged air cleaner Clogged air cleaner Contaminated fuel Intake air leak Faulty fuel pump Contaminated fuel Faulty air cut off valve Throttle does not open fully so engine stalls Damaged vacuum tube and connectors Damaged vacuum piston diaphragm Damaged carburetor insulator Clogged diaphragm hole Rich mixture Lean mixture Auto bystarter valve opens excessively Clogged fuel jets Faulty float valve Clogged fuel tank cap breather hole Float level too high Clogged fuel filter Clogged air jets Bent kinked or restricted fuel line Auto bystarter valve set plate installed 1n the Faulty float valve wrong groove Float level too low Clogged air cleaner Faulty fuel pump or insufficient output Engine is hard to start No fuel in tank Restricted fuel line Clogged fuel strainer Faulty fuel pump Broken or clogged vacuum tube Faulty or clogged charcoal canister Lean mixture Clogged charcoal canister Bent kinked or restricted fuel line Clogged fuel strainer Float level too low 8 3 CPI MOTOR REMOVAL CARBURETOR REMOVAL Remove the air cleaner bolt Remove 1 Flange bolt A Remove air cleaner bolts Remove 1 Flange bolts A Loosen the air cleaner connection tube clamp Remove 1 Clamp A Remove the right crankcase breather tube Remove 1 Tube A 8 4 GTRIS0 CPI MOTOR GTR180 VIII CAR
53. hermostat comp oil seal is damaged or broken if yes replaced a new one ASSEMBLE THE CAM SHAFT HOLDER First install the intake and exhaust valve rocker arms then install the rocker arm shafts Install dowel pins to cylinder head assy Clean the intake valve rocker arm shaft off any grease D before installation M ia Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder Install washers and nuts Install 1 Washers and nuts A 7 13 CPI MOTOR GIR180 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Turn the A C generator flywheel so that the I mark on T the flywheel aligns with the index mark on the crankcase Make sure two parallel lines on cam shaft chain wheel are paralleled with cylinder head surface Meanwhile make sure the position 1s at the top dead center of the compression stroke Install the oil plug oil plug spring Install the tension device Before assembly the tensioner device must check if the tension device gasket is broken Before assembly the tensioner device 15 pressed to the top Install the screw CHECK Make sure to put tensioner lifter spring and o ring into tensioner 7 14 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL LOOSEN THE TAPPET ADJUSTING NUT Use thickness meter to measure and adjust the valve gap Adjusting till the standard fix the bolt and tighten the nut
54. learance adjustment Sticking valve or broken valve spring Damaged or worn camshaft Worn cam chain tensioner Worn camshaft and rocker arm Warped or cracked cylinder head Poorly installed spark plug COMPRESSION TOO HIGH Excessive carbon build up in combustion chamber TORQUE CYLINDER HEAD NUT 2 0 2 4kgf m TAPPET ADJUSTING NUT CYLINDER HEAD COVER BOLT 1 0 1 4kgf m PLUG CAM CHAIN WHEEL BOLT 1 0 1 4kgf m 0 7 1 1kgf m 1 0 1 2kgf m CPI MOTOR GIR180 VILCYLINDER HEAD amp CAM SHAFT REMOVAL CAMSHAFT REMOVAL Remove the cylinder head cover bolts Remove the cylinder head cover Remove 1 Remove two cylinder head bolts A Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Make sure two parallel limes on cam shaft chain wheel are paralleled with cylinder head surface Meanwhile make sure the position is at the top dead center of the compression stroke Remove the oil plug oil plug spring Remove two cam shaft chain wheel bolts Remove 1 Oil through set A 2 Flange bolts B Remove the two flange bolts Remove 1 Flange bolts A 7 4 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Disassemble the tensioner lifter comp amp tensioner lifter gasket Remove 1 Tensioner lifter comp A Disassemble the screw and spring NOTE Be careful of the missing for the o ring on the screw Firs
55. nd then the rails Avoid piston and piston ring damage during installation All ring should be installed with the markings facing up After installation the piston rings should be free to rotate in the grooves Do not mix the top and second rings 5 9 180 CPI MOTOR GTR180 V CYLINDER amp PISTON PISTON INSTALLATION Install the piston NOTE Position the piston IN mark on the intake valve side A Install the piston amp piston pin Install the new piston pin clips Use clean cloth stop up the crankcase hole and cam chain hole Be avoiding the clip fall into the crankcase The piston ring end gaps should not be parallel with or at 90 to the piston pin Fabricate gap End gaps 5 10 CPI MOTOR V CYLINDER amp PISTON CYLINDER INSTALLION Install the cylinder gasket and dowel pins Install 1 Cylinder gasket A 2 Dowel pins B Apply some oil at cylinder wall before piston ring assemble into cylinder Install the cylinder amp dowel pins Coat the cylinder and piston ring with the clean engine oil Install 1 Cylinder A 2 Dowel pins B 5 11 180 CPI MOTOR GTRIS0 V CYLINDER amp PISTON MEMO 5 12 CPI MOTOR GTRIS0 V CYLINDER amp PISTON 5 13 CPI MOTOR GIR180 VI OIL PUMP REMOVAL OIL PUMP EXPLODED VIEW 6 1 CPI MOTOR GTRIS0 VI OIL PUMP REMOVAL GENERAL I
56. ove 1 Screws A INSPECTION Inspect the accelerating pump diaphragm for cracks damage or deterioration Replace if necessary Inspect 1 Cover A 2 Diaphragm B 3 Spring C Assemble the accelerating pump in the reverse order of disassemble 8 7 CPI MOTOR GTRIS0 REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 10 10 minutes minimum after stopping the engine If the reading is not within the limit replace the auto bystarter with a new one Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage 1s blocked the auto bystarter 1s normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter 1s normal AUTO BYSTARTER REMOVAL Remove the one set plate screw and then remove the auto bystarter from the carburetor body Remove 1 Screws A 2 Auto Bystarter B AUTO BYSTARTER INSPECTION Check the auto bystarter valvend needle for nicks wear or damage If any faulty part 1s found replace the auto bystarter with a new one Check 1 Bystarter Needle A 2 Bystarter Valve B 8 8
57. t drain the coolant from the radiator and water jacket Disassemble the four flange nuts amp washers of cam shaft holder NOTE Diagonally loosen the cylinder head flange nuts in 2 or 3 times Loosen the screws and take out the cam shaft Disassemble the dowel pins 7 5 CPI MOTOR GIR180 VILCYLINDER HEAD amp CAM SHAFT REMOVAL Remove the Cir clip F 3 Remove 1 Cir clip A Take out the camshaft from the cam shaft holder Inspection camshaft Check each cam lobe for wear or damage Measure the cam lobe height SERVICE LIMITS IN 30 69 mm EX 30 28 mm Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play INSPECTION I BEARINGS A 7 6 CPI MOTOR GTRIS0 VILCYLINDER HEAD amp CAM SHAFT REMOVAL CAM SHAFT HOLDER DISASSEMBLY Disassemble the rocker arm cir clip Disassemble the two rocker arms by using a M5 bolt Remove 1 Cir clip A NOTE M5 bolt B Inspect the holder rocker arm shaft is damaged or broken NOTE If the valve rocker arm contact surface 1s worn check each cam lobe for wear or damage Measure the I D of each valve rocker arm A Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D B Service Limits IN 9 90mm replace if below EX 9 90mm replace if below 7 7 CPI MOTOR GIR180
58. tches the model name Li EF ip of battery These x Q 24 ATTENTION 10 7 CPI MOTOR GTR1S0O lt X ELECTRIC SYSTEM Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use P Be sure to use the dedicated electrolyte container for correct electrolyte volume hue Place the battery on a level surface Check to see that the sealing sheet has no peeling tears or holes in it REMOVE THE SEALING SHEET The battery 1s vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge Remove the electrolyte container from the vinyl bag Detach the strip of caps A from the container and set 7 G3 aside these will be used later to seal battery px E Do not pierce otherwise open the sealed cells of the electrolyte container DR Do not attempt to separate individual cells Place the electrolyte container upside down with the six AE Q sealed cells into the filler ports of the battery Hold the container level push down to break the seals of all six cells x E u You will see air bubbles rising into each cell as the ports Es i I ve Q i fill NOTE Do not tilt the electrolyte container 10 8 CPI MOTOR GTR1S0O n wit assis X ELECTRIC SYSTEM Check the electrolyte flow If no air bubbles A
59. valve guide movable parts and valve arm sliding surfaces for initial lubrication The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Standard mm IN 0906 J O Valve clearance cold LEX om oo Cylinder head compression pressure 12 2 kg cm2 ee Cylinder head warpage 90 2 26 540 26 142 Camshaft cam height 26 050 25 651 10 000 10 018 10 100 Valve rocker arm I D 10 000 10 018 10 100 Valve rocker arm shaft 9972 998 99 1 000 1 600 Valve seat width 1 000 1 600 4 990 4 975 4 925 Valve stem O D 4 970 4 955 4 915 Valve guide I D CPI MOTOR VILCYLINDER HEAD amp CAM SHAFT REMOVAL TROUBLESHOOTING GIR180 The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises POOR PERFORMANCE AT IDLE SPEED Compression too low COMPRESSION TOO LOW Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plug ABNORMAL NOISE Incorrect valve c
60. winding resistance when the part 15 cold at room temperature 10 3 CPI MOTOR GTR180 X ELECTRIC SYSTEM SPECIFICTION CHARGEABLE SYSTEM ITEM SPECIFICATION YTX9 BS 12 V8Ah 0 7A 5 10hr STANDARD Ihr URGENT USE RATE ELECTRONIC LAEKAGE OF ELECT CURRENT CHARGEABLE OF ELECT a L2A 2000 mm L2A 1600 rpm CURRENT CONTROL CHARGED 14 5 0 5 V 2000 rpm CURRENT IGNITION SYSTEM ITEM SPECITICATION TYPE NGK DPR7EA 9 SPARK PLUG TYPE SPACE 0 7 0 8mm COIL 0 40 10 20 C RESISTANCE TWICE COIL 3 6KO 10 VALVE PULSE WAVE COIL RESISTANCE 1100 15 VALVE IGNITION 15 2500 200rpm MOVING ANGLE STARTING 38 6200 200rpm FEATURE BTDC 40 1 5 7000rpm STARTING SYSTEM ITEM SPECIFITION SHAPE TURBO DYNAMO TYPE STARTING MOTOR CONTRIBUTED POWER 0 5 KWw60 FEATURE FUSE ITEM SPECIFICATION VEHICLE LOADING 30A 10 4 CPI MOTOR GTR180 X ELECTRIC SYSTEM CHARGEABLE SYSTEM CHARGEABLE CIRCUIT DIAGRAMR a y Jo 2 NZ X VW v VV N N BATTER 12VOAH AC GEN 10 5 CPI MOTOR GTR1S0 X ELECTRIC SYSTEM CHARGEABLE DIAGRAM CHECKING REM
61. yes If touched wash 1t off with liberal amount of water Get medial attention if severe INTERCHANGE A sealed battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a sealed battery only on a motorcycle which was originally equipped with a sealed battery Be careful if a sealed battery is installed on a motorcycle which had an ordinary battery as original equipment the sealed battery s life will be shortened 10 12 CPI MOTOR GTR180 X ELECTRIC SYSTEM OIL LEAKAGE TESTNG Turn main swich at off position and remove canvas wire from the battery Connect ampere meter as right drawing shown between negative pole and canvas wire ATTENTION Adjust electric current of meter to larger scale when test current then adjust smaller scale gradually to avoid meter and fuse burn out if current is over the max Of meter Main switch can t be at on position when test electric current leakage If electric current leakage is over standard value it has short circuit status Electric current leakage 1 ma under Open each connector to find out short ciucuit under situation of current leakage Chargeable electric voltage current inspection Make sure the battery have been charged completely before checking The battery voltage shall be over 13 0V when complete the charge if it s with insufficiency power the electri
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