Kymco MO FILLY 50LX Service Manual - chap 01 (info generali)

1. GENERAL INFORMATION

1-1

FILLY LX 50

Location of Engine Serial Number

1

ENGINE SERIAL NUMBER

1

ENGINE SERIAL NUMBER

...................

1- 1 LUBRICATION POINTS

.......................

1-13

SPECIFICATIONS

...................................

1- 2 CABLE & HARNESS ROUTING

............

1-15

SERVICE PRECAUTIONS

......................

1- 3 WIRING DIAGRAM

...............................

1-20

TORQUE VALUES

..................................

1-11 TROUBLESHOOTUNG

..........................

1-21

SPECIAL TOOLS

.....................................

1-12

Filly LX 50

1. GENERAL INFORMATION

1-2

FILLY LX 50

SPECIFICATIONS

Motorcycle Name & Type

Filly LX 50

Name & Model No.

SD10BB

Overall length (mm)

1720

Overall width (mm)

625

Overall height (mm)

1035

Wheel base (mm)

1200

Engine type

O.H.C.

Displacement

49.5cc

Fuel Used

92# nonleaded gasoline

Front wheel

34

Net weight (kg)

Rear wheel

48

Total

82

Front wheel

35

Gross weight(kg)

Rear wheel

50

Total

85

Front wheel

90/90-10 50J

Tires

Rear wheel

100/80-10 53J

Ground clearance (mm)

110

Perform

-

Braking distance (m)

7.9 (Initial speed
40km/h)

ance

Min. turning radius (m)

1.8

Starting system

Starting motor &

kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

f39.0 x 41.4

Compression ratio

10.5

Compression pressure
(kg/cm_-rpm)

14

Max. output

2.208/8000kw/(r/min
)

Max. torque

0.3/6500kg m/rpm

Open

3°

Port

Intake

Close

7°

Engine

timin
g

Open

9°

Exhaust

Close

1°

Valve clearance

Intake

0.04

(cold) (mm)

Exhaust

0.04

Idle speed (rpm)

1900± 100rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Lubrication

System

Oil filter type

Full-flow filtration

Oil capacity

0.85 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

6.1 liter

Type

CVK
Piston dia. (mm)
Venturi

dia.(mm)

f17equivalent

Carburetor

Throttle type

Butterfly type

Type

CDI

Ignition timing

BTDC28°/4000rpm
Contact breaker

Non-contact point

type

Spark plug

NGK

C7HSA

Spark plug gap

0.6_ 0.7mm

Battery

Capacity

12V4AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic
centrifugal

type

Type

Two-stage reduction

Reduction

1st

0.8-3.1

ratio

2nd

11.05

Front

Caster angle

27°

Axle

Trail length

æ

Tire pressure

Front

1.75

(kg/cm_)

Rear

2.25

Turning

Left

45°

angle

Right

45°

Front

DISK (160mm)

Brake system

type

Rear

Drum (110mm)

brake

Front

TELESCOPE

Suspension type
Rear

Unit Swing

Front

70

Shock absorber
distance

Rear

66

Frame type

Under Bone

Fuel System

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Device

1. GENERAL INFORMATION

1-3

FILLY LX 50

SERVICE PRECAUTIONS

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

circlips, cotter pins, etc. when
reassembling.

n When tightening bolts or nuts, begin with

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

n Use genuine parts and lubricants

.

n When servicing the motorcycle, be sure to

use special tools for removal and
installation.

n After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION

1-4

FILLY LX 50

n Apply or add designated greases and

lubricants to the specified lubrication
points.

n After reassembly, check all parts for

proper tightening and operation.

n When two persons work together, pay

attention to the mutual working safety.

n Disconnect the battery negative (-) terminal

before operation.

n When using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connecting

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

n When connecting the battery, the positive

(+) terminal must be connected first.

n After connection, apply grease to the

battery terminals.

n Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-5

FILLY LX 50

n If the fuse is burned out, find the cause and

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

n After operation, terminal caps shall be

installed securely.

n When taking out the connector, the lock on

the connector shall be released before
operation.

n Hold the connector body when connecting

or disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,

protruding or loose.

Confirm
Capacity

1. GENERAL INFORMATION

1-6

FILLY LX 50

n The connector shall be inserted

completely.

n If the double connector has a lock, lock

it at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check for

damaged terminal cover or loose negative
terminal.

n Check the double connector cover for

proper coverage and installation.

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

coverage.

n Do not make the terminal cover opening

face up.

n 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

FILLY LX 50

n After clamping, check each wire to make

sure it is secure.

.

n Do not squeeze wires against the weld or

its clamp

n After clamping, check each harness to make

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

n When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

n Route wire harnesses to avoid sharp edges

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

n Route wire harnesses passing through the

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

No Contact

1. GENERAL INFORMATION

1-8

FILLY LX 50

n Route harnesses so they are neither

pulled tight nor have excessive slack.

.

n Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or
corner

n When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

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

repair by wrapping it with protective tape
or replace it.

n When installing other parts, do not press or

squeeze the wires.

Do not
pull too

Do not press or
squeeze the wire.

1. GENERAL INFORMATION

1-9

FILLY LX 50

n After routing, check that the wire harnesses

are not twisted or kinked.

n 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.

n When a testing device is used, make sure to

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

n Be careful not to drop any parts.

n When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

n 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

FILLY LX 50

n 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.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

(!12-3) : Refer to page 12-3.

Engine Oil
Grease

Gear Oil

Special

＊

1. GENERAL INFORMATION

1-11

FILLY LX 50

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kg-m)

Item

Torque (kg-m)

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

0.45-0.6

0.6-1.2

1.8-2.5

3.0-4.0

5.0-6.0

5mm screw
6mm screw, 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

2.4-3.0

3.5-4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt

2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1

6
6

30

6
7
3
8

8
10
28

6

4
10
10

6

6

0.7-1.1

0.7-1.1

1.0-2.0

0.7-1.1

1.2-1.6

0.07-0.09

0.4-0.7

1.1-1.5

3.5-4.5

5.0-6.0

0.8-1.2

0.1-0.3

5.5-6.5

1.0-1.4

0.8-1.2

0.8-1.2

Double end bolt

Double end bolt
Apply oil to
threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Speedometer cable set screw
Rear shock absorber lock nut

1
1
1
1
1
1
1

25.4
10
14
10

8
5
8

8.0-12.0

5.0-7.0

11.0-13.0

4.0-5.0

2.0-3.0

0.45-0.6

3.0-3.6

U-nut
U-nut
U-nut

Apply locking agent

1. GENERAL INFORMATION

1-12

FILLY LX 50

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref.

Page

10-3
10-4

Bearing
puller

10.12.15.1
8 mm

E037

10.12.15.1
8mm
bearing

12-6

Bushing
remover L

E032

11102
bush

Bushing
remover S

EO19

11203
bush rear

Crankshaft
bearing

E030

91005
radial

Crankshaft
protector

E029

13000
crankshaft

Clutch
spring
compressor

E027

2301a
driven
pully assy

9-9
9-12

Cushion
assemble &

F004

52400
cushion

13-4

Flywheel
holder

E017

31110
flywheel
comp.231
0a pully
assy driven

9-5
9-9
9-13
14-7
14-9

Flywheel
puller

E002

Left hand
thread

14-7

Long
socket

F002

50306
steering

12-21
12-22

Oil seal &
bearing

E014

Oil seal &
bearing

Tool boox

E033

Special
tools

Tappet
adjuster

E036

90012
screw

3-5

7-7

Valve
spring
compressor

E038

Valve
spring

7-8

1. GENERAL INFORMATION

1-13

FILLY LX 50

LUBRICATION POINTS

ENGINE

Lubrication Points

Lubricant

Valve guide/valve stem movable part

Cam lobes

Valve rocker arm friction surface

Cam chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings

Cylinder inside wall

Connecting rod/piston pin hole

Connecting rod big end

Crankshaft R/L side oil seal

Starter reduction gear engaging part

Countershaft gear engaging part

Final gear engaging part

Bearing movable part

O-ring face

Oil seal lip

•Genuine KYMCO Engine Oil (SAE15W-40)

•API-SG Engine Oil

Starter idle gear

Friction spring movable part/shaft movable part

Shaft movable grooved part

Kick starter spindle movable part

High-temperature resistant grease

A.C. generator connector

Transmission case breather tube

Adhesive

1. GENERAL INFORMATION

1-14

FILLY LX 50

FRAME

The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.

Rear Wheel Bearings

Main Stand Pivot

Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot

Grease

Grease

Grease

Engine Oil

Rear Brake Cable

Brake Cam/
Anchor Pin

Grease

Grease

Front Brake Lever
Pivot

Front Brake Cable/
Speedometer Cable/
Throttle Cable

Engine/ Oil

1. GENERAL INFORMATION

1-15

FILLY LX 50

CABLE & HARNESS ROUTING

Front Stop Switch Wire

Rear Stop Switch Wire

Throttle Cable

Regulator/Rectifier

Rear Brake Cable

Speedometer Cable

Horn

Ignition Switch

Winker

Headlight Resistor

Front Brake Fluid Tube

Brake Master Cylinder

1. GENERAL INFORMATION

1-16

FILLY LX 50

Regulator/Rectifier

Speedometer Cable

Ignition Switch

Fuel Filler

Throttle Grip

Rear Brake Lever

Fuel Tank
Inlet Tube

Fuel Tank
Breather Tube

Front Brake Fluid Tube

Fuel Tank

1. GENERAL INFORMATION

1-17

FILLY LX 50

Starter Relay

Fuse

Battery (+) Cable

Battery (-) Cable

CDI Unit

Battery (+) Cable

Battery (-) Cable

CDI Unit

Ignition Coil

1. GENERAL INFORMATION

1-18

FILLY LX 50

Throttle Cable

Fuel Vapor
Recovery Tube

Vacuum Tee

Carburetor
Overflow Tube

Fuel Tube

Crankcase Breather
Tube

Ignition Coil
Primary Wire

Ignition Wire

Fuel

1. GENERAL INFORMATION

1-19

FILLY LX 50

Throttle Cable

Fuel Tube

Vacuum Tube

Auto Bystarter

Fuel Unit

Crankcase Breather
Tube

Ignition Coil

Fuel Vapor
Recovery Tube

Wire Harness

Crankcase Breather
Tube

Throttle Cable

Vacuum Tube

Fuel Filter
Fuel

Pump

1. GENERAL INFORMATION

1-20

FILLY LX 50

WIRING DIAGRAM

1. GENERAL INFORMATION

1-21

FILLY LX 50

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel strainer
Faulty auto fuel valve

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted high-

tension
wire
Faulty ignition switch

Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket
Seized valve
Improper valve timing

Faulty auto bystarter
Air leaking through intake

pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw

Flooded carburetor
Faulty auto bystarter
Throttle valve excessively

open

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 follow­ing 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

1-22

FILLY LX 50

ENGINE LACKS POWER

Clogged air cleaner
Poor quality fuel (Restricted)
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
diaphragm
Faulty auto fuel valve

Faulty CDI unit
Faulty pulser coil

Improper valve clearance
adjustment
Worn valve seat (valve stem too
protruding

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

Clogged carburetor jets

Fouled spark plug
Incorrect heat range plug

Oil level too high
Oil level too low
Oil not changed

Clogged oil pipe

Faulty oil pump

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

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

Start engine and accelerate
lightly for observation

Inspection/Adjustment

Symptom

Probable Cause

Engine speed
increases

Correct timing

Engine speed does not
increase sufficiently

Incorrect timing

Check ignition timing
using a timing light

Test cylinder compression

Check carburetor for
clogging

Rapidly accelerate or run
at high speed

Remove spark plug and
inspect

Check if engine overheats
Check valve clearance

Correct

Incorrect

Normal

compression

Abnormal
compression

Remove oil dipstick and
check oil level and condition

Remove cylinder head oil
pipe bolt and inspect

Engine overheats

Engine does not
overheats

Plug not fouled or
discolored

Plug fouled or
discolored

Correct and not
contaminated

Incorrect or
contaminated

Valve train lubricated
properly

Valve train not
lubricated properly

Engine does not knock

Engine knocks

Not clogged

Clogged

1. GENERAL INFORMATION

1-23

FILLY LX 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit
Faulty pulser coil

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

in)

Deteriorated O-ring
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
Broken or shorted spark plug
wire
Faulty ignition switch

Faulty air cut-off valve
Damaged vacuum tube
Clogged or damaged 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 air cut-off

Check carburetor
gasket for air leaks

Check carburetor pilot
screw adjustment

Correct timing

Incorrect timing

Correctly adjusted

No air leak

Air leaks

Good spark

Weak or inter­ mittent spark

Good

Faulty

Incorrectly

1. GENERAL INFORMATION

1-24

FILLY LX 50

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit
Faulty pulser coil

Improperly adjust ed valve
clearance
Worn camshaft
Worn valve seat

Empty fuel tank
Clogged fuel tube or filter
Faulty charcoal canister
Faulty auto fuel valve

Clean and unclog

Cam timing gear aligning
marks not aligned

Faulty spring

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor jets
for clogging

Check fuel pump for
fuel supply

Correct timing

Incorrect timing

Check valve spring
tension

Check valve clearance

Fuel flows freely

Fuel flow restricted

Correct

Incorrect

Not clogged

Clogged

Correctly adjusted

Incorrectly adjusted

Not weakened

Weak spring

Check valve timing

1. GENERAL INFORMATION

1-25

FILLY LX 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Dead battery
Faulty battery

Faulty A.C. generator coil
Broken yellow wire
Loose connector

Broken red wire

Faulty regulator/rectifier
Poorly connected coupler

Faulty A.C. generator

Overcharging

Broken green 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
batt ery (-) wire to engine
ground and test voltage

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Battery has
voltage with
ignition switch

Normal

Voltage does not
increase

Battery has no
voltage with
ignition switch

Resistance too

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 green wire and
batt ery (-) wire to engine
ground and test voltage

Check
regulator/rectifier
coupler for loose
connection

1. GENERAL INFORMATION

1-26

FILLY LX 50

NO SPARK AT SPARK PLUG

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Faulty ignition switch
Faulty pulser coil
Faulty ignition coil

Broken wire harness
Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

Replace with a new
spark plug 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

Good

Good

Check spark plug cap
and high-tension wire
for looseness

Check CDI unit with a
CDI unit tester