CPI SuperMoto Series Service Manual
  1. Manuals
  2. Brands
  3. CPI Manuals
  4. Motorcycle
  5. SuperMoto Series
  6. Service manual

CPI SuperMoto Series Service Manual

Smsx
Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SuperMoto Series and is the answer not in the manual?

Questions and answers

Related Manuals for CPI SuperMoto Series

Summary of Contents for CPI SuperMoto Series

  • Page 3 Service Manual PREFACE This workshop manual contains information about TABLE OF CONTENTS common service, repair, and maintenance works for all systems of the model CPI SMSX. CHAPTERS GROUP The manual is subdivided in chapters, in which the vehicle GENERAL systems in question are explained. Every component or INFORMATION subsystem is treated in a section of its own.

  • Page 5: General Information

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

  • Page 6: General Information

    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.

  • Page 7: Warning And Safety Symbols

    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.

  • Page 8: Vehicle Identification Numbers

    Year of manufacture 6 = 2006, 7 = 2007 Model year 6 = 2006 Version Variant Vehicle type SM = SuperMoto Manufacturer code RFT = CPI MOTOR COMPANY The ENGINE NUMBER is stamped on the lower right side behind the drive sprocket.

  • Page 9: Maintenance Instructions

    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.
  • Page 10 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.
  • Page 11 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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 GENERAL INFORMATION GI-10 NOTES...

  • Page 15: Technical Data

    TECHNICAL DATA SPECIFICATIONS TD-2 TIGHTENING TORQUES TD-4...

  • Page 16: Technical Data Td

    TECHNICAL DATA TD-2 SYSTEM OVERVIEW...

  • Page 17: Specifications

    TECHNICAL DATA TD-3 SPECIFICATIONS Description Unit Specifications Length 1955 Width Height 1185 Wheel base 1338 Seat height Unladen weight Weight in running order Tech. permissible mass Axle load, front Axle load, rear Frame Split underslung steel tubing framework Front suspension Hydr.
  • Page 18 TECHNICAL DATA TD-4 Type 1 cylinder, two-stroke Arrangement of cylinder 15° inclined to the front Cooling system Water Lubrication Fresh oil Bore / Stroke 40,0 / 39,0 Displacement 49,0 Compression 11:1 Power rating (EC) kW/min 2,2 / 7000 Torque (EC) Nm/min 3,9 / 4000 Combustion pressure...

  • Page 19: Tightening Torques

    TECHNICAL DATA TD-5 Charging voltage 13,5 Charging current 0,9 – 1,2 Fuse Low beam bulb 35 HS1 High beam bulb 35 HS1 Parking light bulb License light Stop / Tail light Turn signal light Nominal power Generator Ignition type Pulse generator Ω...

  • Page 20: Technical Data

    TECHNICAL DATA TD-6 NOTES...
  • Page 21 SPECIAL TOOLS ST-1 SPECIAL TOOLS DESCRIPTION AND USAGE ST-2...
  • Page 22 SPECIAL TOOLS ST-2 DESCRIPTION AND USAGE Description Order number Flywheel puller ABC-111797 Crankshaft puller CPI-D06-82015-25-00 Crankshaft mounting tool CPI-D06-82015-26-00 Shifter shaft seal driver CPI-D06-82015-28-00...

  • Page 23: Special Tools

    SPECIAL TOOLS ST-3 Driver for clutch release lever CPI-D06-82015-29-00 shaft seal Driver for water pump seal CPI-D06-82015-30-00 Crankshaft seal driver CPI-D06-82015-31-00...
  • Page 24 SPECIAL TOOLS ST-4 NOTES...
  • Page 25 CARBURETOR FL-1 CARBURETOR SYSTEM OVERVIEW FL 2 MAINTENANCE NOTICE FL 4 SPECIFICATIONS FL 5 TOOLS FL 5 FAULT TRACKING FL 5 CARBURETOR REMOVAL FL 6 DISASSEMBLY FL 7 FLOAT CHAMBER LEVEL FL 8 MIXTURE CONTROL SCREW FL 9 REED-TYPE INLET-VALVE FL 10...
  • Page 26 CARBURETOR FL-2 SYSTEM OVERVIEW Dell’Orto...
  • Page 27 CARBURETOR FL-3 Mikuni...
  • Page 28 CARBURETOR FL-4 MAINTENANCE NOTICE 1. Before maintaining the carburetor, the engine, the fuel supply, and the ignition system have to be in a faultless state. The carburetor can only properly adjusted and faults in the carburetor system can be detected when there are no mechanical defects in the engine or defectas in the fuel supply or in the ignition system.
  • Page 29 CARBURETOR FL-5 SPECIFICATIONS Description Specification Fuel tank Fuel capacity l Type of fuel Unleaded fuel min. 91 (ROZ) Carburetor Mikuni or Dell’Orto Ø 16 Ø 16 Main jet # 72,5 # 62 Idle jet # 17,5 # 36 Jet needle position (notch from above) Carburetor float chamber level (mm) 11 ±...

  • Page 30: Carburetor Removal

    CARBURETOR FL-6 CARBURETOR REMOVAL Place a suitable container under the drain pipe of the float chamber and open the drain screw. Fuel line Remove the hose clamp of the intake manifold. Remove the connection to the suction hose. Remove the fuel line, the carburetor heating, and Carburetor the oil lead.
  • Page 31 CARBURETOR FL-7 SLIDE VALVE Release the screws in the carburetor cover. Press the spring into the cover and remove the securing plastic stopper (Dell’Orto), or retaining spring respectively (Mikuni), from the slide valve. Then unhook the control cable from the slide valve.
  • Page 32 CARBURETOR FL-8 FLOAT CHAMBER LEVEL It is not possible to carry out the following corrections with a Dell’Orto carburetor as its float is entirely made of plastic. In case of any defects in this part, the float shall be replaced. Dell'Orto Level adjustment (Mikuni) Measure the distance between the reference edge...
  • Page 33 CARBURETOR FL-9 Use a new sealing ring prior to mounting the float chamber cover. Mount the float chamber cover to the carburetor body. Fasten the choke cable and put in the throttle control cable. Mount the carburetor to the intake manifold and to the suction hose of the engine air cleaner box.
  • Page 34 CARBURETOR FL-10 REED-TYPE INLET VALVE Remove the carburetor from the intake manifold by releasing the hose clamp. Release the four screws and the clamp for the clutch cable. Remove the intake manifold. Check the intake manifold for crackings and fissures. Any ageing cracks in the intake manifold can be very harmful to the engine as foreign air can be suctioned...
  • Page 35 CARBURETOR FL-11 NOTES...

  • Page 37: Table Of Contents

    2-STROKE - OIL PUMP SYSTEM OVERVIEW LB-2 REMOVAL LB-3 INSPECTION LB-4 INSTALLATION LB-4 BLEEDING LB-4...

  • Page 38: 2-Stroke Oil Pump

    2-STROKE OIL PUMP LB-2 SYSTEM OVERVIEW...

  • Page 39: Oil Pump Removal

    2-STROKE OIL PUMP LB-3 OIL PUMP REMOVAL Release the mounting bolts of the plastic cover and remove the cover. Plastic cover Mounting bolts After removing the supply line from the oil reservoir and the delivery line, which leads to the carburetor, both lines must Supply line Delivery line be plugged with suitable plugs so that no...

  • Page 40: Inspection

    2-STROKE OIL PUMP LB-4 INSPECTION Check the two-stroke oil pump for damage and leakage. Check the driving Rubber-lipped seal tab for wear. INSTALLATION The O-ring seal has to be replaced prior to reinstalling the pump. The pump body and the delivery line which leads to the carburetor must be bleeded subsequent to the reinstallation.
  • Page 41 2-STROKE OIL PUMP LB-5 NOTES...

  • Page 43: Cylinder Head 7

    PISTON AND CYLINDER PC-1 PISTON AND CYLINDER SYSTEM OVERBIEW PC-2 CYLINDER HEAD PC-3 THERMOSTAT PC-3 THERMOSWITCH PC-4 CYLINDER PC-4 PISTON PC-5 ASSEMBLY PC-7...

  • Page 44: System Overbiew

    PISTON AND CYLINDER PC-2 SYSTEM OVERVIEW...

  • Page 45: Piston And Cylinder

    PISTON AND CYLINDER PC-3 CYLINDER HEAD Prior to removing the engine the coolant has to be drained. For this pupose loosen the screw of the water pump. All connecting parts, like cables, hoses, spark plug etc. must be removed before. The cooling liquid has to be collected in a suitable vessel.

  • Page 46: Thermoswitch

    PISTON AND CYLINDER PC-4 Put the thermostat in a vessel with water and warm the water to the opening temperature of the Thermometer thermostat. When reaching the nominal temperature the thermostat must be opened completely. After cooling down under the nominal temperature the thermostat must close again.

  • Page 47: Piston

    PISTON AND CYLINDER PC-5 The inside wall of the cylinder must not show any rougher wear or scores. The ovality of the tread must be below the given limit value. Take measurings at several areas of the tread, each staggered by 90°. Limit value: 0.03 mm PISTON Keep the piston on position and remove the circlip...
  • Page 48 PISTON AND CYLINDER PC-6 When mounting new piston rings pay attention to Top piston ring (hard) whether the bevelled side of the piston rings faces upwards. Slightly move the piston rings to the left and to the Positioning spigot right while watching the position spigots. Lubricate the piston rings and the ring grooves with a small amount of two-stroke oil.

  • Page 49: Assembly

    PISTON AND CYLINDER PC-7 ASSEMBLY Mount the following parts as per specified order: Cooling water Spark plug connection a new cylinder base gasket, the cylinder, a new O-ring to the cylinder, and new O- rings for the stud bolts. a new O ring to the clean cylinder head and install the cylinder head.
  • Page 50 PISTON AND CYLINDER PC-8 NOTES...
  • Page 51 CLUTCH GEARBOX CG-1 CLUTCH GEARBOX SYSTEM OVERVIEW CG-2 DISMANTLING CG-3 ASSEMBLY CG-12...
  • Page 52 CLUTCH GEARBOX CG-2 SYSTEM OVERVIEW...
  • Page 53 CLUTCH GEARBOX CG-3 DISMANTLING WATER PUMP REMOVAL Drain the coolant by opening the drain plug and collect the coolant in a suitable vessel. Loosen the hose clamp screw, remove the hose clamp and the sleeve. Loosen the fastening screws and remove the pump casing. Pay attention to also remove the two reference pins below the casing.
  • Page 54 CLUTCH GEARBOX CG-4 PINION GEAR REMOVAL Loosen and remove the circlip of the chain pinion gear by means of circlip pliers. Remove the chain pinion gear. Pull out the pinion gear and remove the circlip under the pinion gear. REMOVAL OF THE CLUTCH The proper functioning of the wet clutch depends to a great extent on the choice of the right engine oil and of the oil level.
  • Page 55 CLUTCH GEARBOX CG-5 Straighten the petal of the lock washer under the securing nut of the clutch drum. Fix the clutch drum with a clutch wrench and unscrew the securing nut completely with a 17 mm spanner. Remove the parts in the following order: Clutch drum Clutch gear clutch drum,...
  • Page 56 CLUTCH GEARBOX CG-6 DRIVE PINION REMOVAL Block the flywheel and loosen the nut with a 19mm spanner. Remove the parts in the following order: drive pinion (1), guiding gear of the countershaft (2), key, distance sleeve, sealing ring. REMOVING THE RELEASE LEVER Remove the clutch release lever together with the return spring, the plain washer and the shaft seal.
  • Page 57 Make sure that no plain washers remain on the housing parts. Special tool: Crankshaft puller CPI-D06-82015-25-00 COUNTERSHAFT REMOVAL After separating the two crankcase halves, the countershaft shall be removed. Heat up the bearing seat of the countershaft bearing to approx.
  • Page 58 CLUTCH GEARBOX CG-8 DRIVEN SHAFT REMOVAL Driving shaft Shifter drum Slightly lift the driving shaft and pull out the driven shaft as well as the shifter drum from the shifter fork and the lower scraper rings. Pay attention not to damage the threads. Remove the ball and the spring below the shift drum.
  • Page 59 CLUTCH GEARBOX CG-9 PREPARATIONS Clean the two crankcase halves and the bearings with a hardly flammable solvent and clean them with compressed air. Note that the bearings must not rotate during the cleaning with compressed air. Otherwise they might get damaged. Rotate the inner ring of the bearings with the finger.
  • Page 60 CLUTCH GEARBOX CG-10 REASSEMBLING DRIVING AND DRIVEN SHAFT GEARS All parts must be greased prior to reassembling. Use new circlips (1). Note that their pointed edge must be oriented to the outside, i.e. on the opposite side to the maximum stress direction. CHECKING THE END PLAY The shafts to be checked have to be mounted individually.
  • Page 61 CLUTCH GEARBOX CG-11 SHIFTER DRUM Measure the distance of the shifter shaft thrust rings at the shifter drum and the crankcase. Compensate the distance with a washer if required. End play without spring and ball: 0,1 – 0,2 mm SHIFTER SHAFT Washer Measure the distance of the washers on the crankcase and the part and compensate the distance...
  • Page 62 CLUTCH GEARBOX CG-12 ASSEMBLY MOUNTING THE COUNTERSHAFT Install the countershaft into the right crankcase. TRANSMISSION ASSEMBLY Driven shaft Grease the spring and the gear indicator ball and mount them into the right crankcase (s. arrow). Grease the thrust ring (0.6mm) and mount it on the primary shaft.
  • Page 63 CLUTCH GEARBOX CG-13 CHECK TRANSMISSION Put both housing parts together and fix them by tightening at least three fixing screws that are opposite to each other. Check whether the gears can be engaged. When engaging the gears, they must not jam. CONNECTING ROD SYSTEM Mount the two crankshaft seals with a seal driver.
  • Page 64 CLUTCH GEARBOX CG-14 CRANKCASE ASSEMBLY Make sure that the scraper rings are mounted. Apply liquid gasket to the mating surfaces of the housing parts. Grease the shafts and join both crankcase halves with soft tappings by a rubber-headed mallet. Mount the fixing bolts and tighten them crosswise. Tightening torque: 10 –...
  • Page 65 CLUTCH GEARBOX CG-15 COUNTERSHAFT GEAR Mount the parts according to the following order on the crankshaft: oil seal, O-ring, spacer, key, countershaft drive gear, main drive gear nut. Tighten the nut with the magneto flywheel wrench. Mount the key and the balance gear to the countershaft.
  • Page 66 CLUTCH GEARBOX CG-16 CLUTCH POSITION The clutch is properly positioned when the lever is parallel with the cover rest surface. This position can achieved via the adjuster that is located on the end disc plus the use of a suitable screwdriver.
  • Page 67 CLUTCH GEARBOX CG-17 NOTES...
  • Page 69 FRAME - CHASSIS REAR SUSPENSION STRUT FC-2 DRIVE CHAIN FC-2 ENGINE AIR CLEANER FC-2 FOOT BRAKE LEVER FC-3...

  • Page 70: Drive Chain

    FRAME - CHASSIS FC-2 REAR SUSPENSION STRUT Adjust the spring tension of the rear suspension strut with the aid of the adjusting nut. For this purpose a universal tool shall be used. DRIVE CHAIN The tension of the drive chain shall be adjusted according to the following procedure: Loosen the axle nut of the rear wheel.

  • Page 71: Foot Brake Lever

    FRAME - CHASSIS FC-3 Take out the filter element and check it for damages. Filter element Clean the filter element and replace it if required. FOOT BRAKE LEVER Press down the foot brake lever. Loosen the lock nut of the adjusting screw. Turn the screw until it meets the stop and tighten the lock nut.
  • Page 72 FRAME - CHASSIS FC-4 NOTES...

  • Page 73: Electrical System

    ELECTRICAL SYSTEM LOCATION OF ELECTRIC COMPONENTS ES-2 CHARGING SYSTEM ES-3 SPEEDOMETER SETTING ES-6 HORN ES-6 BRAKE LIGHT SWITCH ES-7 OIL LEVEL SENSOR ES-7 FLYWHEEL MAGNETO ES-8 STARTER MOTOR ES-11 WIRING DIAGRAM ES-12...

  • Page 74: Location Of Electric Components

    ELECTRICAL SYSTEM ES-2 LOCATION OF ELECTRIC COMPONENTS Ground wire Carburetor heating relay Starter relay Regulator rectifier Ignition coil Indicator relay 2-stroke oil level sensor...

  • Page 75: Charging System

    ELECTRICAL SYSTEM ES-3 Charging System Checking the charging voltage The charging voltage directly is related to the charge state of the battery. All measurings have Voltmeter therefore to be carried out when the battery is fully charged. Since the high current consumption of the starter motor (E starter) can damage the measuring instrument during the engine start, the instrument has only then to be connected when...
  • Page 76 ELECTRICAL SYSTEM ES-4 Generator (Stator) • Put the test probes to the plug-in connection [C] and measure the values according to the table. • Repeat the connection [B] measurement in case of deviations from the desired value. • If deviations are no lonnger measurable check the wiring.
  • Page 77 ELECTRICAL SYSTEM ES-5 Generator (Stator) • Attach the test probes to connection [A] and measure the values as per table. • Repeat the connection [B] measurement in case of deviations from the desired value. • If deviations are no lonnger measurable check the wiring.

  • Page 78: Speedometer Setting

    ELECTRICAL SYSTEM ES-6 SPEEDOMETER SETTING Changing the wheel size Press down the mode button until the settings for the wheel size are displayed. The wheel size can be changed by short tappings on the button. Save the setting by pressing down the mode button for approx.

  • Page 79: Brake Light Switch

    ELECTRICAL SYSTEM ES-7 BRAKE LIGHT SWITCH FRONT Disconnect the cables from the switch and check the continuity between both terminals while applying the front brake. A: brake applied: 0 Ω B: brake let off: ∞ REAR Disconnect the cables from the switch and check the continuity between both terminals while applying the rear brake.

  • Page 80: Flywheel Magneto

    ELECTRICAL SYSTEM ES-8 FLYWHEEL MAGNETO FLYWHEEL COVER REMOVAL Loosen the fastening screws and remove the flywheel cover. Check the cover gasket for aging or damage. Check the cable grommets for fissures and aging.

  • Page 81: Flywheel Removal

    ELECTRICAL SYSTEM ES-9 FLYWHEEL REMOVAL Block the flywheel magneto rotor and loosen the locknut with a 15mm – spanner. Remove the rotor with a properly dimensioned puller. Screw the puller in the threaded seat of the rotor. Keep the spanner in place and loosen the nut with a 17 mm spanner.

  • Page 82: Flywheel Inspection

    ELECTRICAL SYSTEM ES-10 FLYWHEEL INSPECTION Check the mechanical state of all flywheel components. If the ring gear, the key seat, or the keyway on the crankshaft are worn, the part in question must be replaced. Measure the resistance with a digital multimeter: Check Cable color Value...

  • Page 83: Starter Motor

    ELECTRICAL SYSTEM ES-11 FLYWHEEL COVER MOUNTING Mount the gasket and the cover of the flywheel. Verify the seat of the grommets. Tighten the screws. Torque: 1 2 Nm Gasket Cable grommet Cover STARTER MOTOR REMOVAL Remove the two screws below the left crankcase and the fixing bolt at the rear part of the starter motor.

  • Page 84: Wiring Diagram

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM ES-12 ES-12 WIRING DIAGRAM...
  • Page 85 ELECTRICAL SYSTEM ES-13 NOTES...

This manual is also suitable for:

Supercross seriesSupermoto-x series

Table of Contents

Save PDF