KYMCO Active 50 Service Manual

ACTIVE 50

PREFACE

This Service Manual describes the
technical features and servicing
procedures for the KYMCO ACTIVE 50.

Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.

Section 2 is the inspection/ adjustment
procedures, safety rules and service
information for each part, starting from
periodic maintenance.

Sections 3 and 4 state the servicing
procedures and cautions for the removal
and installation of lubrication and fuel
systems.

Sections 5 through 18 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.

Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1
INSPECTION/ADJUSTMENT 2
LUBRICATION SYSTEM 3
FUEL SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
ALTERANTOR/CAM CHAIN

TENSIONER

8

CLUTCH/GEAR SHIFT MECHANISM 9

ENGINE

CRANKCASE/CRANKSHAFT/KICK
STARTER/TRANSMISSION

10

FRONT WHEEL/SUSPENSION/
STEERING

11

REAR WHEEL/BRAKE/SUSPENSION 12
HYDRAULIC BRAKE 13

CHASSIS

FRAME COVER

14

IGNITION SYSTEM 15
CHARGING SYSTEM 16
STARTING SYSTEM 17

ELECTRICAL

EQUIPMENT

LIGHTS/INSTRUMENTS/SWITCHES

/

HORN/FUEL UNIT

18

Our company reserves right to make
any alteration in the design

.

The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.

1. GENERAL INFORMATION

1-0

ACTIVE 50

1

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER---------------------------------------------- 1- 1
SPECIFICATIONS---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS------------------------------------------------ 1- 3
TORQUE VALUES --------------------------------------------------------- 1-11
SPECIAL TOOLS ----------------------------------------------------------- 1-12
LUBRICATION POINTS -------------------------------------------------- 1-13
CABLE & HARNESS ROUTING ---------------------------------------- 1-14
WIRING DIAGRAM-------------------------------------------------------- 1-18
TROUBLESHOOTING----------------------------------------------------- 1-19

1

1. GENERAL INFORMATION

1-1

ACTIVE 50

ENGINE SERIAL NUMBER

Location of Engine Serial Numbe

r

Location of Frame Serial Numbe

r

1. GENERAL INFORMATION

1-2

ACTIVE 50

SPECIFICATIONS

Motorcycle name & Model No. LCA7
Motorcycle name ACTIVE 50
Overall length (mm) 1995
Overall width (mm) 680
Overall height (mm) 1090
Wheel base (mm) 1275
Engine type 4 ∞
Displacement (cc) 49
Fuel type nonleaded gasoline

Front wheel 46.5
Rear wheel 58

Dry weight (kg)

Front wheel 48.5
Rear wheel 63.5

Gross weight(kg)

Front wheel 2.5-17

Tires

Rear wheel 2.75/17

Ground clearance (mm) 120

Bra k ing d i s t anc e ( m) 7under

Perform­ance

Min. turning radius
(mm)

3800(R/L)

Starting system

Starting motor &

kick starter
Type OHC
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement Single cam, OHC
Bore x stroke (mm) φ52.4x 49.5
Compression ratio 8

Compression pressure
(kg/cm²)

13

Max. output 1.8/7000kw(r/min)
Max. torque 2.6/4500kgm/rpm

Open 0°

Intake
(1mm)

Close 35°

Engine

Open 30°

Port
timin

g

Exhaust
(1mm)

Close 5°

Intake 0.02mm

Valve clearanc

e

(cold)

Exhaust 0.02mm

Idle speed (rpm) 1700rpm

Lubrication type

Forced

p

ressure &

wet sump
Oil pump type Inner/Outer rotor
Oil filter type Wire gauze filter

Lubrication

System

Oil capacity 0.9 liter

Cooling Type Air cooling

Air cleaner type Wet, single
Fuel capacity 4liter

Type PIF
Piston dia. (mm) 14.9
Venturi dia.(mm) φ20equivalent

Fuel System

Carburetor

Throttle type Plunger type
Type CDI
Ignition timing 15±2°/1700rpm
Spark plug CHAMPION-P-PZ9HC

Ignition

System

Spark plug gap 0.6～0.7mm

Electrical

Equipment

Battery Capacity 12V5AH
Clutch Type Wet multi-disc clutch

Type Permanent gear m eshing
Operating method Foot operated
Type Cycle type

1st gear 2.92
2nd gear 1.67
3rd gear 1.17
4th gear 0.92

Power Drive System

Transmission Gear

Reduction
ratio

5th gear -------

Front Caster angle 27°
Axle Wheel base 1305

Tire pressure

Front 1.75

(kg/cm²)(2 riders)

Rear 2.25
Left 45°

Turning angle

Right 45°
Front Disk brake

Brake system
type

Rear Drum brake
Front Telescope

Damping

Device

Shock absorber
type

Rear Mono Shock

Frame type Back bone

Moving Device

1. GENERAL INFORMATION

1-3

ACTIVE 50

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when
reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure

to use special tools for removal and
installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION

1-4

ACTIVE 50

 Apply or add designated greases and

lubricants to the specified lubrication
points.

 After reassembly, check all parts for

proper tightening and operation.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-)

terminal before operation.

 When using a spanner or other tools,

make sure not to damage the motorcycle
surface.

 After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-5

ACTIVE 50

 If the fuse is burned out, find the cause

and repair it. Replace it with a new one
according to the specified capacity.

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock

on the connector shall be released before
operation.

 Hold the connector body when

connecting or disconnecting it.

 Do not pull the connector wire.

 Check if any connector terminal is

bending, protruding or loose.

Confirm
Capacity

1. GENERAL INFORMATION

1-6

ACTIVE 50

 The connector shall be inserted

completely.

 If the double connector has a lock,

lock it at the correct position.

 Check if there is any loose wire.

 Before connecting a terminal, check

for damaged terminal cover or loose
negative terminal.

 Check the double connector cover for

proper coverage and installation.

 Insert the terminal completely.
 Check the terminal cover for proper

coverage.

 Do not make the terminal cover opening

face up.

 Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

Snapping!

1. GENERAL INFORMATION

1-7

ACTIVE 50

 After clamping, check each wire to make

sure it is secure.

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness to

make sure that it is not interfering with
any moving or sliding parts.

 When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

 Route wire harnesses to avoid sharp

edges or corners. Avoid the projected
ends of bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid the
projected ends of bolts and screws.

N

o Contact !

1. GENERAL INFORMATION

1-8

ACTIVE 50

 Route harnesses so they are neither

pulled tight nor have excessive slack.

 Protect wires and harnesses with

electrical tape or tube if they contact a
sharp edge or corner.

 When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

 Do not break the sheath of wire.
 If a wire or harness is with a broken

sheath, repair by wrapping it with
protective tape or replace it.

 When installing other parts, do not press

or squeeze the wires.

Do not pull
too tight!

Do not press o

r

squeeze the wire.

1. GENERAL INFORMATION

1-9

ACTIVE 50

 After routing, check that the wire

harnesses are not twisted or kinked.

 Wire harnesses routed along with

handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

 When a testing device is used, make sure

to understand the operating methods
thoroughly and operate according to the
operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

 Do not bend or twist control cables.

Damaged control cables will not operate
smoothly and may stick or bind.

Do you understand
the instrument? Is the
instrument set correctly?

Remove Rust !

1. GENERAL INFORMATION

1-10

ACTIVE 50

 Symbols:

The following symbols represent the
servicing methods and cautions included
in this service manual.

: Apply engine oil to the

specified points. (Use
designated engine oil for
lubrication.)

: Apply grease for

lubrication.

: Use special tool.

: Caution

: Warning

Grease

＊

Engine Oil

Special

1. GENERAL INFORMATION

1-11

ACTIVE 50

TORQUE VALUES

STANDARD TORQUE VALUES

Ite

m

Torque (kg-m

)

Ite

m

Torque (kg-m

)

5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut

0.45～0.6

0.8～1.2

1.8～2.0

3.0～4.0

5.0～6.0

5mm screw
6mm nut, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut

0.35～0.5

0.7～1.1

1.0～1.4

2.0～3.0

3.5～4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item Quantity Thread

Torque (kg-m) Remarks

Kick plate bolt
R/L case bolt
Stopper shift bolt
Cam gear shift bolt
Pin guide bolt
Oil pump bolt
Clutch nut
Rotor oil nut
Rotor oil cover bolt
Motor bolt
Head stud bolt
Cam sprocket bolt
Head cover cap nut
Pivot cam chain bolt
Tensioner bolt
Cylinder head bolt
Hole TP cap nut
Plate L case screw
Sprocket drive bolt
Fly wheel nut
L cover bolt
Head side cover L bolt
Inlet pipe bolt
Carburetor bolt
Head stud bolt
Head side cover R bolt
R cover oil bolt
Filter hole cap
Outer starting

2
8
1
1
1
3
1
1
3
3
4
3
4
1
1
2
2
2
2
1
9
2
2
2
2
2
1
1
3

6
6
6
6
8

6
10
10

6

6

7

5

7

8
14

6

30.8
6
6

10

6
6
6
6
8
6

14

30.8
6

0.8～1.2

0.8～1.2

0.8～1.2

1.0～1.4

0.8～1.2

0.8～1.2

3.8～4.5

3.8～4.5

0.45～0.6

0.8～1.2

0.7～1.1

0.7～1.1

1.2～1.6

1.3～1.8

1.5～2.5

0.6～0.9

1.0～2.0

0.8～1.2

1.0～1.6

3.2～4.0

0.8～1.2

0.8～1.2

0.8～1.2

0.8～1.2

0.7～1.1

0.8～1.2

2.0～3.0

1.0～2.0

1.0～1.5

1. GENERAL INFORMATION

1-12

ACTIVE 50

FRAME

Item Quantity Thread Torque (kg-m) Remarks

Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut

Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt

Rear fork pivot nut
Handlebar lock nut
Rear driven gear bolt
Rear brake panel nut
Intake pipe mounting bolt
Engine hanger upper nut
Engine hanger lower nut

1
1
1
1
1
1
1
1
4
1
2
1
1

25.4

25.4

14
16
10
10
12
10

8
8
6
1
1

6.0～9.0

0.5～1.3

5.5～7.0

6.0～8.0

3.0～4.0

3.0～4.0

5.5～7.0

6.0～9.0

1.8～2.0

1.8～2.5

1.8～2.5

1.8～2.5

1.8～2.5

SPECIAL TOOLS

Tool Name Tool No. Ref. Page Remarks

Flywheel puller E003

8-4

Bearing puller 18mm E008

10-10

Lock nut socket wrench F007、E010、E049

9-5、11-16、11-18

Tappet adjuster E012

2-5

Oil seat & bearing install E014

10-11、11-9

Bearing puller 15mm E018

10-10

Bearing puller 12mm E020

10-10

Flywheel holder E021

8-3、8-7、9-6

Bearing puller 10mm E031

10-10

Clutch holder E039

9-5

Gear holder E038

9-9

Bearing driver handle & Bearing installer E014

11-9、11-17

Race cone install F005

1. GENERAL INFORMATION

1-13

ACTIVE 50

LUBRICATION POINTS

ENGINE

or CABLE LUBRICANT
SPEEDOMETER, THROTTLE, BRAKE CABLE

THROTTLE GRIP

SWING ARM
PIVOT VUSHINGS

CHAIN LUBRICANT
DRIVE CHAIN

BRAKE CAM

WHEEL BEARINGS

BRAKE PEDAL
PIVOT

CENTER & SIDE
STAND PIVOTS

SPEEDOMETER
GEAR

WHEEL BEARINGS

STEERING HEAD
BEARINGS

ENGINE

1. GENERAL INFORMATION

1-14

ACTIVE 50

CABLE & HARNESS ROUTING

Throttle Cable

Ignition Switch

Horn

Front brake
hose

1. GENERAL INFORMATION

1-15

ACTIVE 50

Winker Relay

Horn

Front Brake
Hose

Wire Harness

Ignition Coil

Ignition
Coil Wire

Starte

r

Motor

Regulator/
Rectifier

Choke Cable

1. GENERAL INFORMATION

1-16

ACTIVE 50

WIRING DIAGRAM

1. GENERAL INFORMATION

1-17

ACTIVE 50

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank
Clogged carburetor fuel inlet
tube, vacuum tube or fuel tube
Clogged float oil passage
Clogged fuel filter
Clogged charcoal canister
Clogged auto fuel valve strainer
Faulty valve passage
Faulty fuel pump

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Faulty exciter coil
Faulty ignition switch
Broken or shorted ignition coil
wire

Faulty or slipping clutch
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Leaking cylinder head gasket

Faulty choke control system
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air screw

Flooded carburetor
Throttle valve excessively open
Clogged air cleaner

Check if fuel reaches

carburetor by loosening

drain screw

Remove spark plug and
install it into spark plug

cap to test spark by

connecting it to engine

ground

Inspection/Adjustment

Probable Cause

Spark jumps

Normal

compression

Engine does not

fire

Weak or no spark

Low or no
compression

Engine fires but

does not start

Test cylinder
compression

Start engine by follow-

ing normal starting

procedure

Remove spark plug and

inspect again

Symptom

Fuel reaches

carburetor

Fuel does not

reach carburetor

Wet spark plug

Dry spark plug

1. GENERAL INFORMATION

1-18

ACTIVE 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit
Faulty pulser coil

Mixture too lean (turn screw in)
Mixture too rich (turn screw
out)

Faulty intake manifold gasket
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube

Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Faulty ignition switch

Faulty A.C. generator
Damaged vacuum tube
Clogged air vent hole

Remove spark plug and
install it into spark plug

cap to test spark by

connecting it to engine

ground

Inspection/Adjustment Symptom

Probable Cause

Check ignition timing

Check A.C. generator

Check carburetor gasket

for air leaks

Check carburetor air

screw adjustment

Correct

Incorrect

Correctly adjusted

No air leak

Air leaks

Good spark

Weak or inter-

mittent s

p

ark

Good

Faulty

Incorrectly adjusted

1. GENERAL INFORMATION

1-19

ACTIVE 50

POOR PERFORMANCE (ENGINE LACKS POWER)

Clogged air cleaner
Poor fuel flow (Restricted)
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Carburetor fuel level too low
Clogged carburetor high speed fuel
passage

Faulty CDI unit
Faulty pulser coil

Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)

Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing

Clean and unclog

Fouled spark plug
Incorrect heat range plug

Oil level too high
Oil level too low
Oil not changed

Clogged oil cooler
Clogged oil line
Faulty oil pump

Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too advanced

Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too advanced

Start engine and accelerate
lightly for observation

Inspection/Adjustment

Symptom

Probable Cause

Engine speed

increases

Correc

t

Engine speed does no

t

increase sufficiently

Incorrec

t

Check ignition timing using
a timing light

Test cylinder compression

Check carburetor fo

r

clogging

Rapidly accelerate or run a

t

high speed

Remove spark plug and
inspect

Check for engine overheating

Check valve clearance

Correc

t

Incorrec

t

N

ormal

compression

Abnormal

compression

Check crankcase for oil
level and condition

Remove cylinder head oil
pipe bolt and inspect

Engine overheats

Engine does no

t

overheats

Plug not fouled o

r

discolored

Plug fouled o

r

discolored

Correct and no

t

contaminated

Incorrect o

r

contaminated

Valve train lubricated
properly

Valve train no

t

lubricated properly

Engine does not knock

Engine knocks

Not clogged

Clogged

1. GENERAL INFORMATION

1-20

ACTIVE 50

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit
Faulty pulser coil

Improperly adjusted valve clearance
Worn valve seat

Empty fuel tank
Clogged fuel filter or tube
Clogged fuel tank cap breather
hole
Cracked fuel pump vacuum tube

Clean and unclog

Cam timing gear aligning marks
not aligned

Faulty spring

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Check carburetor for

clogged jets

Check fuel filter for

fuel supply

Correct

Incorrect

Check valve spring

tension

Check valve clearance

Fuel flows freely

Fuel f l o w restricted

Correct

Incorrect

Not clogged

Clogged

Correct

Incorrect

Not weakened

Weak spring

Check valve timing

1. GENERAL INFORMATION

1-21

ACTIVE 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging

Dead battery
Faulty battery

Faulty coil
Broken pink and yellow wires
Shorted pink and yellow wires

Broken red wire

Faulty regulator/rectifier
Poorly connected coupler

Faulty A.C. generator

Overcharging

Broken black wire

Poorly connected coupler

Faulty regulator/rectifier

Start engine and test
limit voltage between
battery terminals

Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

B

attery has voltage
with ignition switch
“ON”

Normal

Voltage does no

t

increase

B

attery has no
voltage with ignition
switch “ON”

Resistance too high

Normal voltage

No voltage

Measure resistance
between AC generator
coil terminals

Normal

Abnormal

Check regulator/rectifier
coupler for loose
connection

Normal

Abnormal

Connect battery (+) wire
to regulator/rectifier
coupler black wire and
battery (-) wire to engine
ground and test voltage

Check regulator/rectifier
coupler for loose
connection

1. GENERAL INFORMATION

1-22

ACTIVE 50

NO SPARK AT SPARK PLUG

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Faulty ignition switch
Faulty exciter coil
Faulty pulser coil
Faulty ignition coil

Broken wire harness
Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

Replace with a new spark

p

lug and inspect again

Check CDI unit coupler
for looseness

Inspection/Adjustment Symptom

Probable Cause

Normal

Abnormal

Normal

Abnormal

Normal

Abnormal

Abnormal

Measure resistance
between CDI unit
coupler wire terminals

Check related parts

Check ignition coil with
a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Normal

Abnormal

Check spark plug cap
and ignition coil wire for
looseness

Check CDI unit with a
CDI unit tester

2. INSPECTION/ADJUSTMENT

2-0

ACTIVE 50

2

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

INSPECTION/ADJUSTMENT

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 2- 1
MAINTENANCE SCHEDULE-------------------------------------------- 2- 2
FUEL LINE/FILTER-------------------------------------------------------- 2- 3
THROTTLE OPERATION/CHOKE-------------------------------------- 2- 3
AIR CLEANER -------------------------------------------------------------- 2- 4
SPARK PLUG---------------------------------------------------------------- 2- 4
VALVE CLEARANCE----------------------------------------------------- 2- 5
CARBURETOR IDLE SPEED -------------------------------------------- 2- 5
IGNITION TIMING--------------------------------------------------------- 2- 6
CYLINDER COMPRESSION--------------------------------------------- 2- 6
ENGINE OIL----------------------------------------------------------------- 2- 7
DRIVE CHAIN -------------------------------------------------------------- 2- 7
CLUTCH---------------------------------------------------------------------- 2- 8
BRAKE SHOE --------------------------------------------------------------- 2- 8
BRAKE FLUID -------------------------------------------------------------- 2- 8
SUSPENSION---------------------------------------------------------------- 2- 9
NUTS/BOLTS/FASTENERS ---------------------------------------------- 2- 9
WHEELS/TIRES ------------------------------------------------------------ 2- 9
STEERING HANDLEBAR ------------------------------------------------ 2-10

2

2. INSPECTION/ADJUSTMENT

2-1

ACTIVE 50

SERVICE INFORMATION

GENERAL

！ WARNING

•Before running the engine, make sure that the working area is well-ventilated. Never run the
engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may
cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. The working area
must be well-ventilated and do not smoke or allow flames or sparks near the working area or
fuel storage area.

SPECIFICATIONS
ENGINE CHASSIS

Throttle grip free play : 2～6mm Front brake free play: 10～20mm
Spark plug gap : 0.6～0.7mm Rear brake free play : 20～30mm
Spark plug specification : NGK–DR8EA Brake fluid : DOT-4
Valve clearance : IN: 0.02mm

EX: 0.02mm
Cylinder compression : 13±2kg/cm²
Ignition timing : 15±2°/1700rpm

Idle speed : 1700±100rpm
Engine oil capacity:
At disassembly : 1.0 liter
At change : 0.9 liter

TIRE PRESSURE

1 Rider 2 Riders

Front 1.75kg/cm² 2.0kg/cm²

Rear 2.25kg/cm² 2.25kg/cm²

TIRE SIZE:
Front : 2.5-17
Rear : 2.75-17

TORQUE VALUES

Front axle nut 5.5～7.0kg-m
Rear axle nut 6.0～8.0kg-m

2. INSPECTION/ADJUSTMENT

2-2

ACTIVE 50

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate, Refill, Repair or Replace if necessary.
A: Adjust C: Clean R: Replace T : Tighten

Regular Service Mileage (km)

Frequenc

y

Item

comes
first

Ö

Ø

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

Engine oil

R

RRRRR

RRR

RRR

Engine oil filter
screen

CC C C

Fuel filter screen Replace at every 5000km
Valve clearance Inspect at every 3000km and adjust if necessary
Carburetor I I I I
Air Cleaner Note 2,3 C C C
Spark plug Clean at every 2000km and replace at every 5000km
Brake system I I I I I I
Drive chain A A A A A A
Suspension I I I I
Nuts, bolts, fasteners Inspect at every 8000km
Tire I I I I
Steering head bearing I I I I

• In the interest of safety, we recommend these items should be serviced only by an authorized

KYMCO motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding for long distance, in rain or at full throttle.

Whicheve

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2. INSPECTION/ADJUSTMENT

2-3

ACTIVE 50

FUEL LINE/FILTER

Check the fuel lines and replace any parts
which show signs of deterioration, damage
or leakage.

THROTTLE OPERATION

Check for smooth throttle grip movement in
all steering positions.
Measure the throttle grip free play.

Free Play: 2～6mm

Adjust the throttle grip free play by turning
the adjusting nut on the throttle cable.
Slide the dust boot out and adjust by
loosening the lock nut and turning the
adjusting nut.

CHOKE

Check choke lever operation.
If the choke lever moves stiffly, clean and

lubricate the pivot.
After cleaning, recheck the lever movement.

Lock Nu

t

Adjusting Nu

t

Dust Boo

t

Do not smoke or allow flames or sparks
in your working area.

＊

Fuel Filte

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2. INSPECTION/ADJUSTMENT

2-4

ACTIVE 50

Gap, Wear, and
Fouling Deposits

AIR CLEANER

AIR CLEANER REPLACEMENT

Remove the right center cover. (page 14-3)
Remove the air cleaner case. (page 4-5)
Remove the air cleaner case cover screws
and the cover. (page 4-5)
Remove the air cleaner screen and element.
Check the element and replace it with a new
one if it is excessively dirty or damaged.

CHANGE INTERVAL

Wash the air cleaner element in detergent oil,
squeeze out and allow to dry.

After washing, soak the element in clean
engine oil SAE 15W-40# and squeeze out
excess oil. Reinstall the element.

SPARK PLUG

Remove the spark plug.
Check the spark plug for wear, damage and
fouling deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.

Specified Spark Plug: CHAMPION-P-PZ9HC

Measure the spark plug gap.
Spark Plug Gap: 0.6～0.7mm

Cracks
Damage

Squeeze ou

t

and dry

Air Cleaner Case

Washe

r

Deformation

Spark Plug

Air Cleaner Case Cove

r

Wash

Engine
oil

Squeeze ou

t

and dry

Never use gasoline or organic vaporable

oil with acid or alkali for washing.

＊

0.6～0.7m

m

When installing, first screw in the spar

k

plug by hand and then tighten it with a
spark plug wrench.

＊

Choke Leve

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2. INSPECTION/ADJUSTMENT

2-5

ACTIVE 50

VALVE CLEARANCE

Remove the cylinder head cover.

Rotate the generator flywheel to locate the
camshaft on the top dead center (TDC) and
align the “T” mark on the flywheel with the
mark on the left crankcase cover.

Inspect and adjust the valve clearance.
Valve Clearance: IN : 0.02mm

EX: 0.02mm

Loosen the lock nut and adjust by turning the
adjusting bolt.

Tappet adjuster E012

CARBURETOR IDLE SPEED

Turn the throttle stop screw to obtain the
specified idle speed.

Idle Speed: 1700±100rpm
When the engine misses or run erratic, adjust

the air screw.

Throttle Stop Screw

“T” Mark

Bolts

Air Screw

Inspect and adjust valve clearance while
the engine is cold (below 35℃).

＊

After adjustment, rotate the crankshaft
several turns to make sure that the valve
clearance is correct.

＊

Check the valve clearance again after the
lock nut is tightened.

＊

The engine must be warm for accurate
idle speed inspection and adjustment.

＊

When adjusting the carburetor, make
sure to use a E/M tester.

＊

Cylinder Head Cove

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Special