CPI SuperCross Series Service Manual Download

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Summary of Contents for SuperCross Series

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Page 3: ...e listed with detail of the page numbers The chapter page numbering is built up the following way Example Fl 3 group of Fl page 3 The details contained in this manual and vehicle data correspond to th...

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

Page 6: ...es contain carbon monoxide which can lead to unconsciousness and to death when in higher concentration Batteries contain sulfuric acid electrolyte Avoid any contact with skin eyes and muscous membrane...

Page 7: ...of this manual WARNING AND SAFETY SYMBOLS The following symbols indicate that the vehicle technician must pay extra attention when performing maintenance works Symbol Description Symbol Description Co...

Page 8: ...mped onto the right hand side of the front steering tube R F T S M 4 5 A 6 6 L 0 0 0 1 1 0 Serial number Manufacturer L CPI Year of manufacture 6 2006 7 2007 Model year 6 2006 Version B Variant Vehicl...

Page 9: ...ring instruments are available SPECIAL TOOLS Use special tools if stipulated in the chapter REMOVAL OF ENGINE PARTS Before starting any mainrenance works try to track the fault cause Decide whether th...

Page 10: ...sealant to washers 2 Oiling of moveable parts 3 Oil or lubricating grease must be applied to defined spots e g oil retainers prior to assembling ELECTRICAL EQUIPMENT 1 Always disconnect the cable fro...

Page 11: ...sses which are routed to the engine or other vibrating vehicle parts This play must be in such a way that the wiring harnesses do not contact adjacent parts due to engine vibrations 3 If any part of a...

Page 12: ...ay are sensitive to heat and can easily get damaged If for maintenace works the temperature must be risen above 80 C those electric component parts have to be removed prior to maintenance 7 Loose coup...

Page 13: ...conducting continuity checks or voltage measurements with a circuit tester the test probe must be inserted in the terminals at the wiring harness side In the case of a shielded connection the probe mu...

Page 14: ...GENERAL INFORMATION GI 10 NOTES...

Page 15: ...TECHNICAL DATA SPECIFICATIONS TD 2 TIGHTENING TORQUES TD 4...

Page 16: ...TECHNICAL DATA TD 2 SYSTEM OVERVIEW...

Page 17: ...suspension travel Rear suspension travel Front braking system Rear braking system Brake fluid DOT 4 Fresh oil Fork oil Transmission oil mm mm l ml ml Split underslung steel tubing framework Hydr teles...

Page 18: ...3 9 4000 9 8 at operating temperature 0 047 0 36 0 13 Fuel System Carburetor Fuel tank capacity Fuel unleaded Fuel consumption l ROZ l 100 km Optional VM MIKUNI 16 DELL ORTO PHVA16 6 8 min 91 _______...

Page 19: ...5 0 9 1 2 7 35 HS1 35 HS1 5 LED LED LED 85 CDI 100 150 2 7 1800 750 850 80 800 0 5 0 9 0 5 0 9 0 3 0 5 3 0 8 10 BR8ES 0 4 0 6 min 0 7 17 1800 TIGHTENING TORQUES Description mm Torque Nm Front axle nut...

Page 20: ...TECHNICAL DATA TD 6 NOTES...

Page 21: ...SPECIAL TOOLS ST 1 SPECIAL TOOLS DESCRIPTION AND USAGE ST 2...

Page 22: ...LS 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 8...

Page 23: ...SPECIAL TOOLS ST 3 Driver for clutch release lever shaft seal CPI D06 82015 29 00 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: ...ETOR 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 T...

Page 26: ...CARBURETOR FL 2 SYSTEM OVERVIEW Dell Orto...

Page 27: ...CARBURETOR FL 3 Mikuni...

Page 28: ...rbon monoxide and can lead to the unconsciousness and to death 6 Petrol is bad for health and can cause skin cancer Any unnecessary skin contact has to be avoided 7 Used fuels are hazardous waste They...

Page 29: ...speed adjustment Mixture too rich too lean Air cleaner clogged or soiled Choke system defective Carburetor float chamber level wrongly adjusted A F mixture too lean Carburetor jets bores clogged Fuel...

Page 30: ...cover remains mounted to the vehicle DISASSEMBLY Release the fastening screws of the choke cable support bracket and remove the choke cable Release the fastening screws of the float chamber cover and...

Page 31: ...ve The position of the retaining clip has influence on the A F mixture when the engine is running at middle and upper load A deviation from the above setting is usually not required except for extreme...

Page 32: ...ace vertically up since then its weight exerts pressure on the needle valve and a correct adjustment is not possible Float standard level H 10 12 mm H Mikuni If the measured value deviates from the de...

Page 33: ...the throttle control cable MIXTURE CONTROL SCREW Carefully turn the screw clockwise to the stop and then release it by 1 1 5 turns Pay attention not to damage the seat For the proper adjustment of th...

Page 34: ...e suctioned and will cause leaning Remove the reed type inlet valve and check the reeds for tightness Also check the inlet valve for damage and replace it if necessary Install the inlet valve and the...

Page 35: ...CARBURETOR FL 11 NOTES...

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Page 37: ...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 LB 2 SYSTEM OVERVIEW...

Page 39: ...After removing the supply line from the oil reservoir and the delivery line which leads to the carburetor both lines must be plugged with suitable plugs so that no oil can flow out Supply line Delive...

Page 40: ...e ratio in order to ensure that it is sufficiently lubricated Bleeding Connect the supply and the delivery lines Open the bleeder bolt and wait until oil runs out without formation of bubbles Put the...

Page 41: ...2 STROKE OIL PUMP LB 5 NOTES...

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Page 43: ...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: ...PISTON AND CYLINDER PC 2 SYSTEM OVERVIEW...

Page 45: ...n the securing nuts and remove the cylinder head and the gasket Check the cylinder head for damage and fissures Use a new gasket for reassembling The cylinder head nuts have to be tightened crosswise...

Page 46: ...SWITCH Thermometer Thermostat Water Immerse the thermoswitch into a vessel with water so that its thread is completely covered with water Heat up the water to the respective nominal temperature and me...

Page 47: ...boss Fill the opening of the engine with a rag to prevent that the cicrclips fall into the engine The piston must not have any rougher signs of scores or wear Carefully clean the piston top and the ri...

Page 48: ...d side must face up Measure the ring gap of the piston with a feeler gauge to ensure that the values are within the specified tolerance Ring gap S mm 0 36 mm Put the oiled needle bearing into the conn...

Page 49: ...et 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 Tighten the cylinder head nuts crosswise Tightenin...

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: ...the casing CLUTCH COVER REMOVAL Remove the bleeder bolt together with the washer Drain the oil Loosen the fastening screws and remove the clutch cover together with the gasket Remove the circlips of...

Page 54: ...oil level In case of a slipping clutch the quality and the fill quantity of the lubricant shall be checked prior to dismantling the engine Compress the clutch spring fastening screws and remove the s...

Page 55: ...uring nut completely with a 17 mm spanner Remove the parts in the following order clutch drum spacer clutch gear the scraper ring observe its mounting direction and the coned washer COUNTERSHAFT REMOV...

Page 56: ...together with the return spring the plain washer and the shaft seal Note that a new shaft seal has to be used during reassembly Free play of the release lever 1 2 mm To avoid any frictional connectio...

Page 57: ...e thickness and position of the scraper rings that are mounted on the respective shafts Make sure that no plain washers remain on the housing parts Special tool Crankshaft puller CPI D06 82015 25 00 C...

Page 58: ...ngs with a rubber mallet Driving shaft Shifter drum Pay attention not to damage the thread CRANKSHAFT REMOVAL Remove the connecting rod system from the crankcase clutch side For this purpose use a rub...

Page 59: ...connecting rod pin It must be replaced when the connecting rod does not rotate freely or shows an excessive play in spite of having all components adequately cleaned Do not replace the connecting rod...

Page 60: ...xles by hand and measure the end play at the threaded part with a dial gauge Driving shaft end play limit 0 5 mm Driven shaft end play limit 0 5mm Measure the end play at the threaded end 1 of the dri...

Page 61: ...r Verify that the driving notches of the cork disks are not excessively worn bent or burnt Desired value of iron disk thickness 3 0mm Disk thickness limit value 2 6 mm Limit value friction disk warpag...

Page 62: ...r drum Fit the fork s guide pin in the slide way of the second and third gear GEARSHIFT UNIT Mount the gearshift unit together with the lower washer 0 6 mm and the return spring The ends of the spring...

Page 63: ...g the transmission Thus the gears will not be displaced by any impact during mounting of the oil seals Mount the new O ring in the seat for the driving shaft and mount the spacer Install the crankshaf...

Page 64: ...can be rotated freely Adjust it if necessary by slightly tapping on the axles The axles must not show an excessive play If required separate the housing parts and replace the upper washer by a more s...

Page 65: ...f disassembly A new circlip for the clutch nut has to be used when installing the clutch Tighten the securing nut of the clutch drum and bend the petal of the circlip Mount the coupling rod the ball a...

Page 66: ...e crankcase and fix the clutch cover with the corresponding screws Install the drain screw together with a new seal Refill the specified amount of engine oil Engine oil filling amount 0 75 l Clutch co...

Page 67: ...CLUTCH GEARBOX CG 17 NOTES...

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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: ...CHAIN The tension of the drive chain shall be adjusted according to the following procedure Loosen the axle nut of the rear wheel Loosen the lock nut of the chain tensioner Adjust the slack of the ch...

Page 71: ...and check it for damages 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 t...

Page 72: ...FRAME CHASSIS FC 4 NOTES...

Page 73: ...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 DIAG...

Page 74: ...ELECTRICAL SYSTEM ES 2 LOCATION OF ELECTRIC COMPONENTS Ground wire Carburetor heating relay Starter relay Ignition coil CDI Regulator rectifier Indicator relay 2 stroke oil level sensor...

Page 75: ...e the measuring instrument during the engine start the instrument has only then to be connected when the engine is already running Desired value 13 0 14 5 V at 6000 min 1 Generator Stator The 6 pole p...

Page 76: ...at the connection B measurement in case of deviations from the desired value If deviations are no lonnger measurable check the wiring CDI C Stator B Voltage regulator A 1 2 3 4 1 1 2 2 3 3 4 4 5 5 6 6...

Page 77: ...ion B measurement in case of deviations from the desired value If deviations are no lonnger measurable check the wiring CDI C Stator B Voltage regulator A 1 2 3 4 1 1 2 2 3 3 4 4 5 5 6 6 Note Always c...

Page 78: ...es and will be set when the mode button is pressed down for three seconds When the wheel size is changed TD LAP und AVE values are automatically set back to zero If the wheel size menu is selected and...

Page 79: ...e front brake A brake applied 0 B brake let off REAR Disconnect the cables from the switch and check the continuity between both terminals while applying the rear brake A brake applied 0 B brake let o...

Page 80: ...ICAL 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...

Page 81: ...in the threaded seat of the rotor Keep the spanner in place and loosen the nut with a 17 mm spanner STATOR REMOVAL Prior to removing the stator the seats on the crankcase and on the stator plate have...

Page 82: ...WHEEL INSTALLATION Mount the anchoring plate of the stator Make sure that the previously provided reference marks are correctly aligned Mount the flywheel magneto key pull the stator cables through th...

Page 83: ...mets Tighten the screws Torque 1 2 Nm STARTER MOTOR REMOVAL Remove the two screws below the left crankcase and the fixing bolt at the rear part of the starter motor INSTALLATION Make sure that the O r...

Page 84: ...ELECTRICAL SYSTEM ES 12 ELECTRICAL SYSTEM ES 12 WIRING DIAGRAM...

Page 85: ...ELECTRICAL SYSTEM ES 13 NOTES...

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CPI SuperCross Series, Service Manual

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