This manual covers the CPI JW Series ATV Motorcycle, encompassing engine variants JW50, JW90, and JW100. These 2-stroke models represent a line of entry-level to mid-range off-road vehicles, likely produced during the 2000s or early 2010s, designed for recreational or light utility purposes. Built with a focus on reliability and robust construction, the JW Series features an air-cooled, single-cylinder engine, a CDI ignition system, and a carburetor-based fuel delivery system. Its engineering prioritizes durability for off-road conditions, with a sturdy frame and essential components designed for consistent performance.
This comprehensive workshop service manual provides essential factory-level information for owners, independent repair shops, and technicians. It details technical procedures, troubleshooting guides, and maintenance schedules for the JW Series. Key areas covered include the engine system, carburetor system, frame, and electrical system. The manual offers in-depth guidance on routine maintenance, component diagnostics, and repair for major systems, ensuring the longevity and optimal performance of your CPI JW Series ATV Motorcycle.
CPI JW50 JW90 JW100 ATV MOTORCYCLE FACTORY WORKSHOP SERVICE MANUAL
2 STROKE ENGINE
50CC 90CC 100CC
§CONTENTS §
一、TECHNICAL INFORMATION…………………………………………………………………1~4
二、TROUBLE SHOOTING…………………………………………………………………………..5~9
三、MAINTENANCE……………………………………………………………………………….10~15
3-1 MAINTENANCE SCHEDULE……………………………………………... ……………...10
3-2 MAINTENANCE DATA……………………………………………………………………...10
3-3 FUEL TUBE…………………………………………………………………………………...11
3-4 THROTTLE OPERATION…………………………………………………………………..11
3-5 THROTTLE CABLE ADJUSTMENT……………………………………………………...11
3-6 AIR CLEANER……………………………………………………………………………….11
3-7 SPARKK PLUG………………………………………………………………………………12
3-8 IDLE SPEED………………………………………………………………………………….12
3-9 DRIVE CHAIN……………………………………………………………………………12~13
3-10 BRAKE SYSTEM……………………………………………………………………….13~14
3-11 WHEELS AND TIRES……………………………………………………………………...14
3-12 STEERING SYSTEM……………………………………………………………………….14
3-13 TOE-IN……………………………………………………………………………………….15
3-14 GEAR OIL…………………………………………………………………………………...15
四、ENGINE SYSTEM……………………………………………………………………………..16~36
4-1 ENGINE REMOVAL AND INSTALLATION……………………………………………...16
4-2 ENGINE FUEL SYSTEM………………………………………………………………..17~18
4-3 ENGINE LUBRICATION AND COOLING SYSTEM………………………………..18~20
4-4 ENGINE COMBUSTION SYSTEM…………………………………………………….20~25
4-5 TANSMISSION SYSTEM………………………………………………………………..25~31
4-6 CRANKSHAFT / CRANKCASE……………………...………………………………...31~35
4-7 A.C.G ENERATOR……………………………………………………………………….35~36
五、CARBURETOR SYSTEM……………………………………………………………………..37~40
5-1 CARBURETOR REMOVAL………………………………………………………………...37
5-2 STARTER PLUNGER INSPECTION………………………………………………………38
5-3 FLOAT CHAMBER DISASSEMBLY…………………………………………………..38~39
5-4 FUEL HEIGHT INSPECTION……………………………………………………………...39
5-5 CARBURETOR INSTALLATION……………………………………………………...39~40
5-6 REED VALVE…………………………………………………………………………………40
六、FRAME SYSTEM………………………………………………………………………………41~57
6-1 FRONT WHEEL AND STEERING SYSTEM…………………………………………41~50
6-2 REAR WHEELS………………………………………………………………………….50~54
6-3 FENDERS AND EXHAUST PIPE………………………………………………………55~57
七、ELECTRICAL SYSTEM………………………………………………………………………58~62
7-1 TROUBLESHOOTING………………………………………………………………………58
7-2 BATTERY REMOVAL / INSTALLATION ………………………………………...……...59
7-3 A.C.G. INSPECTION………………………………………………………………….....59~60
7-4 RESISTER INSPECTION…………………………………………………………………...60
7-5 C.D.I. INSPECTION………………………………………………………………………….60
7-6 IGNITION COIL INSPECTION………………………………………………………..60~61
7-7 START MOROTR…………………………………………………………………………….61
7-8 START RELLEY INSPECTION…………………………………………………………….61
CPI JW50 JW90 JW100 ATV MOTORCYCLE FACTORY WORKSHOP SERVICE MANUAL
2 STROKE ENGINE
50CC 90CC 100CC
§CONTENTS §
一、TECHNICAL INFORMATION…………………………………………………………………1~4
二、TROUBLE SHOOTING…………………………………………………………………………..5~9
三、MAINTENANCE……………………………………………………………………………….10~15
3-1 MAINTENANCE SCHEDULE……………………………………………... ……………...10
3-2 MAINTENANCE DATA……………………………………………………………………...10
3-3 FUEL TUBE…………………………………………………………………………………...11
3-4 THROTTLE OPERATION…………………………………………………………………..11
3-5 THROTTLE CABLE ADJUSTMENT……………………………………………………...11
3-6 AIR CLEANER……………………………………………………………………………….11
3-7 SPARKK PLUG………………………………………………………………………………12
3-8 IDLE SPEED………………………………………………………………………………….12
3-9 DRIVE CHAIN……………………………………………………………………………12~13
3-10 BRAKE SYSTEM……………………………………………………………………….13~14
3-11 WHEELS AND TIRES……………………………………………………………………...14
3-12 STEERING SYSTEM……………………………………………………………………….14
3-13 TOE-IN……………………………………………………………………………………….15
3-14 GEAR OIL…………………………………………………………………………………...15
四、ENGINE SYSTEM……………………………………………………………………………..16~36
4-1 ENGINE REMOVAL AND INSTALLATION……………………………………………...16
4-2 ENGINE FUEL SYSTEM………………………………………………………………..17~18
4-3 ENGINE LUBRICATION AND COOLING SYSTEM………………………………..18~20
4-4 ENGINE COMBUSTION SYSTEM…………………………………………………….20~25
4-5 TANSMISSION SYSTEM………………………………………………………………..25~31
4-6 CRANKSHAFT / CRANKCASE……………………...………………………………...31~35
4-7 A.C.G ENERATOR……………………………………………………………………….35~36
五、CARBURETOR SYSTEM……………………………………………………………………..37~40
5-1 CARBURETOR REMOVAL………………………………………………………………...37
5-2 STARTER PLUNGER INSPECTION………………………………………………………38
5-3 FLOAT CHAMBER DISASSEMBLY…………………………………………………..38~39
5-4 FUEL HEIGHT INSPECTION……………………………………………………………...39
5-5 CARBURETOR INSTALLATION……………………………………………………...39~40
5-6 REED VALVE…………………………………………………………………………………40
六、FRAME SYSTEM………………………………………………………………………………41~57
6-1 FRONT WHEEL AND STEERING SYSTEM…………………………………………41~50
6-2 REAR WHEELS………………………………………………………………………….50~54
6-3 FENDERS AND EXHAUST PIPE………………………………………………………55~57
七、ELECTRICAL SYSTEM………………………………………………………………………58~62
7-1 TROUBLESHOOTING………………………………………………………………………58
7-2 BATTERY REMOVAL / INSTALLATION ………………………………………...……...59
7-3 A.C.G. INSPECTION………………………………………………………………….....59~60
7-4 RESISTER INSPECTION…………………………………………………………………...60
7-5 C.D.I. INSPECTION………………………………………………………………………….60
7-6 IGNITION COIL INSPECTION………………………………………………………..60~61
7-7 START MOROTR…………………………………………………………………………….61
7-8 START RELLEY INSPECTION…………………………………………………………….61
