CPI GTR180 Service Manual
CONTENTS
PREFACE 1
TROUBLE SHOOTING 2
SERVICE INFORMATION 3
ENGINE REMOVAL&INSTALLATION 4
CYLINDER & PISTON 5
OIL PUMP REMOVAL 6
CYLINDER HEAD & CAM SHAFT REMOVAL 7
CARBURETOR REMOVAL 8
DRIVE AND DRIVEN PULLEYS & KICK STARTER 9
ELECTRIC SYSTEM 10
FRAME 11
WHEEL & BRAKE SYSTEM 12
ADDENDUN 13
CPI MOTOR GTR180
I.PREFACE
《1-1》
THE CONTENTS OF THIS MANUAL PROVIDE THE AFTER SERVICE
INFORMATION FOR CPI /GTR180
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.
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-1》
ENGINE WILL NOT BE STARTED OR HARD TO START
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IF FUEL CAN BE
REACHED CARBURETOR
FUEL REACHES
CARBURETOR
FUEL DOES NOT REACH
CARBURETOR
(1) NO FUEL IN TANK
(2) CLOGGED FUEL LINE BETWEEN
FUEL TANK AND CARBURETOR
(3) CLOGGED FUEL VALVE
(4) CLOGGED FUEL TANK CAP
BREATHER HOLE
2
REMOVE SPARK PLUG
AND TEST SPARK
GOOD SPARK
WEAK OR NO SPARK
(1) FAULTY OR FOULED PLUG
(2) FAULTY C.D.I.
(3) BROKEN OR SHORTED HIGH
TENSION CORD
(4) FAULTY IGNITION SWITCH
(5) INCORRECT IGNITION TIMING
3
TEST CYLINDER
COMPRESSION
NORMAL COMPRESSION
LOW COMPRESSION
(1) ENGINE NOT CRANKED
(2) NO VALVE CLEARANCE
(3) VALVE STUCK OPEN
(4) WORN CYLINDER AND PISTON
RINGS
(5) BLOWN CYLINDER HEAD GASKET
(6) FLAW IN CYLINDER HEAD
(7) INCORRECT VALVE TIMING
(8) BURNED VALVE
4
START ENGINE
ENGINE FIRES
ENGINE FIRES, BUT
DOES NOT START
(1) CHOKE VALVE OPEN
(2) CARBURETOR PILOT SCREW OPEN
(3) AIR LEAKING THROUGH IN TAKE
PIPE
(4) INCORRECT IGNITION TIMING
5
REMOVE SPARK PLUG
DRY PLUG
WET PLUG
(1) FLOODED CARBURETOR
(2) CHOKE VALVE CLOSED
6
START ENGINE WITH
CHOKE CLOSED
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-2》
ENGINE LACKS POWER
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
RAISE WHEELS OFF
GROUND AND SPIN
WHEELS SPIN FREELY
WHEELS DO NOT SPIN
FREELY
(1) DRAGGING BRAKE
(2) FAULTY WHEEL BEARING
(3) OVERTIGHTENED DRIVE CHAIN
(4) WHEEL BEARING NOT LUBRICATED
PROPERLY
2
CHECK TIRE PRESSURE
NORMAL PRESSURE
INCORRECT TIRE
PRESSURE
(1) PUNCTURED TIRE
(2) FAULTY TIRE VALVE
3
RAPIDLY ACCELERATE
FROM LOW TO SECOND
ACCELERATES
DOES NOT ACCELERATE
WITH ENGINE SPEED
RAISED
(1) SLIPPING CLUTCH
(2) WORN OR UNEVEN CLUTCH
FACINGS
(3) CLUTCH PLATE WARPED
4
REV UP GRADUALLY
ENGINE SPEED INCREASED
ENGINE SPEED DOES NOT
INCREASE
(1) CARBURETOR CHOKE CLOSED (2)
CLOGGED AIR CLEANER
(3) CLOGGED FUEL LINE
(4) CLOGGED FUEL TANK CAP
BREATHER HOLE
(5) CLOGGED MUFFLER
5
CHECK IGNITION TIMING
CORRECT TIMING
INCORRECT TIMING INCORRECT TIMING ADJUSTMENT
6
CHECK VALVE CLEARANCE
CORRECT VALVE
CLEARANCE
INCORRECT VALVE (1) INCORRECT VALVE CLEARANCE
(2) WORN VALVE SEAT
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-3》
7
TEST CYLINDER
COMPRESSION
NORMAL COMPRESSION
LOSS OF COMPRESSION (1)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
8
CHECK CARBURETOR FOR
CLOGGING CARBURETOR
NOT CLOGGED
CARBURETOR
CLOGGED
(1) CARBURETOR JETS CLOGGED
9
REMOVE SPARK PLUG PLUG FOULED OR
DISCOLORED COLORED
(1) FOULED PLUG
(2) INCORRECT HEAT RANGE PLUG
10
CHECK OIL LEVEL AND
CONDITION
CORRECT ENGINE OIL
LEVEL
OIL DIRTY OR LEVEL
INCORRECT
(1) LEVEL TOO LOW OR HIGH
(2) CONTAMINATED OIL
11
REMOVE CYLINDER HEAD
COVER AND CHECK
SUFFICIENTLY
LUBRICATION
INSUFFICIENTLY
LUBRICATED
(1) CLOGGED OIL PASSAGE
(2) POOR OIL PUMP DELIVERY
12
CHECK IF ENGINE
OVERHEATS ENGINE DOES
NOT OVERHEAT
ENGINE OVERHEATS (1) EXCESSIVE CARBON IN COMBUSTION
CHAMBER
(2) INCORRECT FUEL
(3) SLIPPING CLUTCH
13
RAPIDLY ACCELERATE OR
URN AT HIGH SPEED
ENGINE
DOES NOT KNOCK
ENGINE KNOCKS (1) WORN PISTON OR CYLINDER
(2) MIXTURE TOO LEAN
(3) INCORRECT FUEL
(4)EXCESSIVE CARBON IN COMBUSTION
CHAMBER
(5) LGNITION TIMING TOO E ARLY
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-4》
POOR PERFORMANCE AT IDLE AND LOW SPEEDS
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IGNITION TMING
AND VALVE CLEARANCE
CORRECT TIMING AND
CLEARANCE
INCORRECT TIMING AND
CLEARANCE
(1) INCORRECT TIMING ADJUSTMENT
(2) INCORRECT VALVE CLEARANCE
2
CHECK CARBURETOR
PILOT SCREW
ADJUSTMENT
CORRECTLY ADJUSTED
INCORRECTLY ADJUSTED (1) MIXTURE TOO LEAN
(2) MIXTURE TOO RICH
3
CHECK FOR AIR LEAKS
NO AIR LEAKS
AIR LEAKS (1) FAULTY CARBURETOR PACKING
(2) CARBURETOR NOT SECURELY
TIGHTENED
(3) FAULTY INTAKE PIPE GASKET
4
REMOVE SPARK PLUG AND
TEST SPARK
WEAK OR INTERMITTENT
SPARK
(1) FAULTY OR FOULED PLUG
(2) FAULTY C.D.I.
(3) MAGNET AT FAULT
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-5》
POOR PERFORMANCE AT HIGH SPEED
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
CHECK IGNITION TIMING AND
VALVE CLEARANCE
CORRECT TIMING AND
CLEARANCE
INCORRECT TIMING
AND CLEARANCE
(1) INCORRECT TIMING ADJUSTMENT
(2) INCORRECT VALVE CLEARANCE
2
DISCONNECT FUEL LINE AT
CARBURETOR AND CHECK FOR
CLOGGING
UNRESTRICTED FUEL FLOW
RESTRICTED FUEL
FLOW
(1) EMPTY FUEL TANK
(2) CLOGGED FUEL LINE
(3) CLOGGED FUEL TANK CAP
BREATHER HOLE
(4) CLOGGED FUEL PETCOCK
3
CHECK FUEL FILTER, FUEL VALVE
AND CARBURETOR JET FOR
CLOGGING
NOT CLOGGED
CLOGGED (1) CLOGGED JET
(2) CLOGGED FUEL FILTER
(3) CLOGGED FUEL VALVE
4
REPLACE CARBURETOR MAIN JET
CONDITION IMPROVED
CONDITION
AGGRAVATED
(1) JET SIZE TOO SMALL
(2) IF CONDITION IS IMPROVED WITH
SMALL JET:
(A) CLOGGED AIR CLEANER
(B) CHOKE NOT OPENED FULLY
5
CHECK VALVE TIMING
CORRECT
INCORRECT INCORRECT VALVE TIMING
ADJUSTMENT
6
CHECK VALVE SPRING TENSION
SPRING TENSION CORRECT
WORN OR BROKEN
SPRING
FAULTY VALVE SPRING
CPI MOTOR GTR180
II.TROUBLE SHOOTING
《2-6》
SMOKY EXHAUST
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
RUN MOTORCYCLE A LONG
DISTANCE AT HIGH SPEED
THIN EXHAUST EMITTED
BLACK SMOKE
EMITTED
(1) WORN CYLINDER AND PISTON RINGS
(2) OIL LEVEL TOO HIGH
(3) PISTON RINGS INCORRECTLY INSTALLED
(4) FAULTY PISTON OR CYLINDER
(5) FLAWS IN CYLINDER HEAD
2
RETURN THROTTLE GRIP
QUICKLY
WHITE SMOKE
EMITTED
(1) WORN INTAKE VALVE GUIDE OR STEM
(2) EXCESSIVE VALVE-TO-GUIDE CLEARANCE
POOR HANDLING
FLOW PATH BAD SITUATION PROBABLE CAUSE
1
IF STEELING IS HEAVY CHECK TIRE
PRESSURE
(1) STEERING HEAD ADJUSTER TOO TIGHT
(2) DAMAGED STEERING CONES OR STEEL
BALLS
2
IF EITHER WHEEL IS
WOBBLING
(1) EXCESSIVE WHEEL BEARING PLAY
(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
3
IF THE MOTORCYCLE PULLS
TO ONE SIDE
(1) MISAPPLIED SHOCK ABSORBER
(2) FRONT AND REAR WHEELS NOT ALIGNED
(3) BENT FRONT FORK
(4) BENT SWING ARM
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-1》
ITEM STANDARD
IGNITION MODE CDI
SPARK TYPE NGK
SPARK PLUG DPR7EA-9
SPARK PLUG CLEARANCE
0.7-0.8㎜
IGNITION TIME MAX
33°BTDC/5000±100rpm
PULSER COIL MAX VOLTAGE
≧0.8V
EXCITER COIL MAX VOLTAGE
≧150V
ITEM STANDARD
CAPACITANCE 12V-8AH
FULL CHARGE 12.8V
(20℃) VOLTAGE
UNDER CHARGE 11.8V
CHARGING AMPERAGE 0.4A STANDAR D, PRE STO4.0 A
BATTERY
CHARGING PERIOD0 5-10hr STANDARD, PRESTO 30min
TYPE MAGNETO
OUTPUT Three-phase alternating current
A. C.
GENERAT
OR
(20℃)CHARGING COIL 0.2-0.3Ω
ITEM STANDARD
COMPRESSION
700kPa(7.0kgf/c㎡)-260r/min
FRONT BARKE LEVER CLEARANCE
10-30㎜
REAR BARKE LEVER CLEARANCE
10-30㎜
FRONT TYPE 110/70-17PR
REAR TYPE 120/80-16PR
SPARK PLUG CLEARANCE
0.7-0.8㎜
SPARK PLUG DPR7EA(NGK)
IN
0.05㎜
VALVE CLEARANCE
EX
0.20㎜
IDLE SPEED 1600±100rpm
FULL
1.0l
OIL CAPACITY
CHANGING
0.8l
DISASSEMBLY
200㏄
GAER OIL CAPACITY
CHANGING
150㏄
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-2》
ITEM STANDARD
FLOAT HEIGHT
30±0.5
MAIN JET #97.5
PILOT JET #15
IDLE SPEED 1600±100 rpm
PILOT SCREW 1+1/2 ROUND
ITEM STANDARD SERVICE
PUMP TIP CLEARANCE 0.05~0.10mm 0.12mm
ROTOR-TO-BODY 015~0.23mm 0.25mm
OIL
PUMP
INNER ﹠OUTER
CLEARANCE
0.15mm 0.20mm
UNIT : ㎜
ITEM
STANDARD SERVICE LIMIT
IN 0.05mm
───
VALVE CLEARANCE
EX 0.20mm
───
COMPRESSION
700kPa(7.0kgf/c㎡)-260rpm
───
IN 30.74-30.86mm 30.69mm
CAM LOBE HEIGHT
EX 30.33-30.45mm 30.28mm
IN 10.000-10.015mm 10.10mm
ROCKER ARM I. D.
EX 10.000-10.015mm 10.10mm
IN 9.972-9.987mm 9.91mm
ROCKER ARM SHAFT O. D.
EX 9.972-9.987mm 9.91mm
IN 0.9-1.1mm 1.8mm
VALVE SEAT WIDTH
EX 0.9-1.1mm 1.8mm
IN 4.975-4.990mm 4.965mm
VALVE STEM O. D.
EX 4.955-4.970mm 4.945mm
IN 5.000-5.012mm 5.04mm
VALVE GUIDE I. D.
EX 5.000-5.012mm 5.04mm
IN 0.010-0.037mm 0.075mm VALVE STEM-TO-VALVE
GUIDE CLEARANCE
EX 0.030-0.057mm 0.095mm
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-3》
UNIT : ㎜
ITEM STANDARD SERVICE LIMIT
SPEED GEAR MOVABLE DRIVE FACE COMP. 24.007-24.028mm 34.06mm
DRIVEN BELT WIDTH 21.7-23.3mm 20.7mm
DRIVE PALTE COLLAR O. D. 23.959-23.98mm 23.92mm
CLUTCH LINING THINNESS
───
2.75mm
CLUTCH OUTER I. D. 124.5-124.2mm 125mm
SPRING FREE LENGTH 144-146mm 140mm
DRIVEN FACE O. D. 33.95-33.975mm 33.92mm
MOVABLE DRIVEN FACE I. D. 34.000-34.025mm 34.06mm
WEIGHT ROLLER O. D. 19.95-20.05mm 19.45mm
ITEM STANDARD SERVICE LIMIT
I. D. 58-58.019mm 58.049 mm
TAPER
───
0.05 mm
OUT OF ROUND
───
CYLIND
ER
WAR PAGE ACROSS TOP
───
0.05 mm
TOP 0.02-0.044 mm 0.07 mm
RING-TO-RING
GROOVE CLEARANCE
SECOND 0.02-0.044 mm 0.07 mm
TOP 0.15-0.30 mm 0.45 mm
SECOND 0.10-0.25 mm 0.45 mm
PISTON RING END
CLEARANCE
OIL SIDE RAIL 0.2-0.7 mm 0.9 mm
PISTON O. D. AT SKIRT 57.97-57.99mm 57.92mm
PISTON-TO-CYLINDER CLLEARANCE 0.02-0.04mm 0.08mm
PISTON
PISTON PIN BORE I. D. 15.002-15.008 15.04
PISTON PIN O. D. 14.994-15.000 14.98
ITEM STANDARD SERVICE LIMIT
ROD BIG SIDE AXIAL CLEARANCE 0.16-0.304mm 0.5mm
ROD BIG END RADIAL CLEARANCE 0.005-0.017mm 0.05mm
CRANK
SHAFT
RUNOUT
───
0.10mm
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-4》
TORQUE
TORQUE STANDARD
SORTS TORQUE(kg-m)
5mm screw, nut 0.5
6mm screw, nut 1.2
8mm screw, nut 2.7
10mm screw, nut 4.0
12mm screw, nut 5.5
INNER OF ENGING
ITEM AMOUNT DIAMETER(mm) TORUQUE(kg-m) REMARKS
Cylinder head bolt, A 2 8 3.0 Stud bolt side
Cylinder head bolt, B 2 8 3.0 Stud bolt side
Strainer cover 1 36 1.5 Spread on thread
EXH. pipe joint bolt 2 8 0.9 Spread on thread
Tappet adj. nut 2 5 0.9
C.C guide COMP. bolt 1 8 0.9
Oil bolt 1 12 1.3
Clutch outer nut 1 12 5.5
Drive face nut 1 14 5.5
A.C.G. nut 1 14 5.5
Oil pump bolt 2 6 0.4
Cylinder head cover bolt 2 6 1.2
Spark plug 1 12 1.2
Cam chain adj. bolt 2 6 0.9
Impeller shaft(L-thread) 1 7 1.4
FRAME
ITEM AMOUT DIAMETER(mm) TORQUE(kg-m)
Shaft steering nut 1 10 4.5
FR. Wheel axle nut 1 12 6.0
RR. Wheel axle nut 1 16 9.0
RR. shock absorber bolt (up) 1 10 3.0
RR. shock absorber bolt (down) 1 8 3.0
ENG. Hanger BRKT. Bolt 1 10 5.5
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-5》
MAINTENANCE SCHEDULE
To inspect (or to clear, lubricate, replenish, repair and replace if it’s necessary)
A ：adjust、C：clear、R：replace、T：tight
Total kilometers for driving
Times
Item
Which
first
Km
1000
Km
2000
Km
3000
Km
4000
Km
5000
Km
6000
Km
7000
Km
8000
Km
9000
Km
10000
Engine oil
New R
300km
R R R R R R R R R
Oil filter
screen
New C
300km
C C C
Fuel filter
screen
New C
300km
C C
Gear oil 3 ※
New C
300km
R R
Valve
clearance
A、T A、T A、T
Carburetor
T T T
Air cleaner 2※ 、3 C R R
Spark plug
T R
Drive belt
T T T
Engine
bracket
T T
Whole nuts
& bolts
T T T T T T T T T T
Tire
Inspect before driving
Steering
bolts
T T T
Brake liquid
Inspect before driving
Cooling
liquid
Per year or 10000 kilometers（R）
Cooling tank
T T T
Cooling tank
cap
T T T
Brake lever
Brake disc
T T T
Shock
absorber
T T
CPI MOTOR GTR180
III.SERVICE INFORMATION
《3-6》
◎We 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:
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-1》
ENGINE REMOVAL
REMOVAL SIDE COVER,3(LEFT)
1.Removal 2 socket bolt
2. Disassemble “SIDE COVER, 3”
Disassemble “FUEL HOSE, 3”
ATTENTION!!!
Be careful of the gasoline leakage.
Removal “VACCUM HOSE”
Removal “CARBURATOR VACCUM HOSE”
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-2》
REMOVAL AIR CLEANER
1. Removal 2 flange bolt
2. Removal 1flange bolt
Removal the oil hose
3. Disassemble the clamp
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-3》
REMOVAL ELECTRIC
1.Removal “IGNITION COIL”
2.Disassemble “RECTIFIER” joint
3.Disassemble “AUTO-CHECK” joint
4.Removal “START MOTOR” line
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-4》
Removal “THROTTLE CABLE”
Removal “TEMPERATURE SENSOR” joint
Removal the bolt
Make cooling water leak out
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-5》
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
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-6》
REMOVAL ENGINE INSTALL BOLT
1.Removal the nut
2.Removal the bolt
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-7》
ENGINE INSTALLATION
The installation sequence is essentially the
reverse of removal.
NOTE
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” & “RESERVE TANK”
CPI MOTOR GTR180
IV.ENGINE REMOVA L&INSTALLATION
《4-8》
Makes cooling water full in outlet water elbow.
Makes cooling water full with lower between
upper.
CPI MOTOR GTR180
.CYLINDER & PISTON
《5-1》
V
CRANK SHAFT/PISTON EXPLODED VIEW
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-2》
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.
SPECIFICATIOS
STANDARD (mm) SERVICE LIMIT(mm)
I.D. 57.4~57.401 57.3
WARPAGE
－
0.05
CYLINDRICITY
－
0.05
CYLINDER
TRUE ROUNDNESS
－
0.05
TOP
0.025~0.060
0.090
RING-TO-GROOVE
CLEARANCE
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
RAIL
0.200~0.800
－
PISTON O.D. 57.365~57.395 57.3
PISTON O.D MEASURING
POSITION.
9mm from bottom of
skirt
－
PISTON-TO-CYLINDER
CLEARANCE
0.010~0.040 0.100
PISTON,
PISTO RING
PISTON PIN HOLE I.D. 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 I.D.
BORE
15.016~15.034 15.060
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-3》
TROUBLESHOOTING
When hard starting or poor performance at low speed occurs, check the crankcase breather for white
smoke. If white smoke is 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
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-4》
CYLINDER REMOVAL
Disassemble the cylinder head comp.
Disassemble the cylinder head gasket.
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]
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-5》
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.
A
Disassemble the piston pin.
Press the piston pin out of the piston
A
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.
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-6》
INSPECTION PISTON/PISTON RING
Disassemble the piston rings.
Disassemble:
1.Top Ring [A]
2.Second ring [B]
3.Oil ring set [C]
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: 0.07㎜
SECOND: 0.07㎜
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 ㎜(0.4in) from the bottom.
Use the piston head to push each piston ring into the
cylinder.
SERVICE LIMITS : 0.5 ㎜
CPI MOTOR GTR180
V.CYLINDER & PISTON
《5-7》
Measure piston pin bore I. D. in two directions at
right angle to each other.
SERVICE LIMITS : 15.04 ㎜
Measure the piston pin O. D. at the front, center and rear
and in tow directions across from each other.
SERVICE LIMIT : 14.98 ㎜
Measure the cylinder I.D. at a point 10 ㎜ from the bottom.
SERVICE LIMITS:57.1 ㎜
Measure the connecting rod small end I.D.
Service Limit: 17.06mm replace if over.
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