Kymco MO FILLY 50LX Service Manual - chap 09 (trasmissione)

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-0

FILLY LX 50

9

9

5.0_ 6.0kg-m

3.5-4.5g-m

3.5-4.0g-m

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-1

FILLY LX 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The drive pulley, clutch and driven pulley can be serviced with the engine installed.

• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from

them to minimize the slipping of drive belt and drive pulley.

SPECIFICATIONS

Item

Standard (mm)

Service Limit (mm)

Movable drive face bushing I.D.

23.989~24.025

24.06

Drive face collar O.D.

23.960~23.974

23.94

Drive belt width

17.5

16.5

Clutch lining thickness

æ

1.5

Clutch outer I.D.

107.0-107.2

107.5

Driven face spring free length

æ

154.6

Driven face O.D.

33.965-33.485

33.94

Movable driven face I.D.

34.0-34.025

34.06

Weight roller O.D.

15.920~16.080

15.4

TORQUE VALUES

Drive face nut 5.5~6.5kgf-m
Clutch outer nut 3.5~4.5kgf-m
Clutch drive plate nut 5.0-6.0kg-m

SPECIAL TOOLS

Universal holder Clutch spring compressor

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Broken driven face spring • Fouled drive face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

SERVICE INFORMATION

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

9-1 DRIVE BELT

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

9-5

TROUBLESHOOTING

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

9-1 DRIVE PULLEY

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

9-6

LEFT CRANKCASE COVER

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

9-2 CLUTCH/DRIVEN PULLEY

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

9-9

KICK STARTER

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

9-2

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-2

FILLY LX 50

LEFT CRANKCASE COVER

REMOVAL

Loosen the drive belt air tube band screw.
Remove the eight left crankcase cover bolts
and left crankcase cover.
Remove the seal rubber and dowel pins.
Inspect the seal rubber for damage or
deterioration.

KICK STARTER

REMOVAL

Remove the kick lever from the kick starter
spindle.
Remove the circlip and washer from the kick
starter spindle.

Gently turn the kick starter spindle to remove
the starter driven gear together with the
friction spring.

Remove the kick starter spindle and return
spring from the left crankcase cover.
Remove the kick starter spindle bushings.

Return Spring

Kick Starter Spindle

Friction Spring

Kick Starter Spindle

Circlip

Starter Driven Gear

Washer

Use specified genuine parts for replace­ment.

＊

Air Tube Band

Bolts

Left Crankcase Cover

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-3

FILLY LX 50

INSPECTION

Inspect the kick starter spindle and gear for
wear or damage.
Inspect the return spring for weakness or
damage.
Inspect the kick starter spindle bushings for
wear or damage.

Inspect the starter driven gear for wear or
damage.
Inspect the friction spring for wear or
damage.

Inspect the kick starter spindle and starter
driven gear forcing parts for wear or damage.

INSTALLATION

Install the kick starter spindle bushings and
return spring onto the left crankcase cover.

Starter Driven Gear Shaft Forcing

Friction Spring

Starter Driven Gear

Spindle

Return Spring

Plastic Bushing

Spindle Bushing

Kick Starter Spindle Forcing Part

Kick Starter Spindle

Return Spring

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-4

FILLY LX 50

Install the starter driven gear and friction
spring onto the left crankcase cover as the
figure shown.

First install the washer and then install the
circlip.
Install the kick lever.

LEFT CRANKCASE COVER
INSTALLATION

First install the dowel pins.
Install the seal rubber.

Install the left crankcase cover and tighten the
eight left crankcase cover bolts diagonally.
Connect the drive belt air tube and tighten the
tube band screw.
Install the rear brake cable clamp.

Rear Brake Cable Clamp

Washer

Left Crankcase Cover

Starter Driven Gear

Friction Spring

Circlip

Dowel Pins

Seal Rubber

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-5

FILLY LX 50

DRIVE BELT

REMOVAL

Remove the left crankcase cover.

INSPECTION

Check the drive belt for cracks, separation or
abnormal or excessive wear.
Measure the drive belt width.

Service Limit: 16.5mm

REPLACEMENT

Remove the eight left crankcase cover bolts
and left crankcase cover. (!9-2)
Hold the clutch outer with an universal holder
and remove the clutch outer nut.

Universal Holder

Hold the drive pulley using a holder and
remove the drive face nut, starting ratchet and
washer.
Remove the drive pulley face.

Remove the drive belt from the clutch/driven
pulley.

Drive Pulley Face

Universal Holder

Clutch Outer

Nut

Drive Face Nut

Clutch/Driven Pulley

Special

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-6

FILLY LX 50

INSTALLATION

Turn the driven pulley clockwise to widen
the drive belt groove and lay a new drive belt
on the driven pulley.

Set the drive belt on the drive pulley face
collar.
Install the drive pulley face, starting ratchet
washer. Install and tighten the drive face nut.

DRIVE PULLEY

REMOVAL

Hold the drive pulley using a holder and
remove the drive face nut, starting ratchet and
washer.
Remove the drive pulley face.

DISASSEMBLY

Remove the movable drive face assembly and
drive pulley collar from the crankshaft.

Drive Pulley Collar

When installing, align the tooth space of
the drive pulley face and starting ratchet
with the crankshaft tooth and then
tighten the nut.

＊

Movable Drive Face Assembly

Starting Ratchet

Drive Belt

Drive Belt

Drive Pulley Face

Drive Face Nut

Starting Ratchet

10mmWasher

Drive Pulley Face

Drive Face Nut (10mm)

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-7

FILLY LX 50

Remove the ramp plate.

Remove the weight rollers.

INSPECTION

Check each weight roller for wear or damage.
Measure each weight roller O.D.

Service Limit: 12.4mm replace if below

Check the drive pulley collar for wear or
damage.
Measure the O.D. of the drive pulley collar
sliding surface.

Service Limit: 19.97mm replace if below

Ramp Plate

Weight Roller

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-8

FILLY LX 50

INSTALLATION

Install the drive pulley collar and movable
drive face onto the crankshaft.

Set the drive belt on the drive pulley collar.
Install the drive pulley face and tighten the
drive face nut. (!9-6)

Torque: 5.5~6.5kgf-m

STARTER PINION

REMOVAL

Remove the left crankcase cover.
Remove the drive pulley.
Remove the starter pinion holder.
Remove the starter pinion.

INSPECTION

Inspect the starter pinion shaft forcing part
for wear or damage.
Inspect the starter pinion for smooth
operation.
Inspect the starter pinion and shaft for wear
or damage.

INSTALLATION

Apply a small amount of grease to the starter
pinion shaft and install it in the reverse order
of removal.

Do not get oil or grease on the drive belt
or pulley faces.

＊

Movable Drive Face

Starter Pinion

Drive Pulley Collar

Starter Pinion Shaft

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-9

FILLY LX 50

CLUTCH/DRIVEN PULLEY

REMOVAL

Remove the drive pulley. (!9-6)
Hold the clutch outer with the universal
holder and remove the clutch outer nut.
Remove the clutch outer.

Universal Holder

Remove the clutch/driven pulley assembly
Remove the drive belt from the clutch/driven
pulley assembly.

DISASSEMBLY

Hold the clutch/driven pulley assembly with
the clutch spring compressor.
Set the clutch spring compressor in a vise and
remove the 39mm clutch drive plate nut.
Loosen the clutch spring compressor and
disassemble the driven pulley assembly.

Clutch Spring Compressor

Remove the seal collar.

Clutch Outer

Universal Holder

Seal Collar

Clutch Spring Compressor

Lock Nut Wrench, 39mm

Nut

Clutch/Driven Pulley

Special

Special

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-10

FILLY LX 50

Pull out the guide roller pins and guide rollers.
Remove the movable driven face from the
driven face.
Remove the O-rings and oil seal from the
movable driven face.

INSPECTION

Inspect the clutch outer for wear or damage.
Measure the clutch outer I.D.

Service Limit: 107.5mm replace if over

Check the clutch shoes for wear or damage.
Measure the clutch lining thickness.

Service Limit: 2.0mm replace if below

Measure the driven face spring free length.
Service Limit: 92.8mm replace if below

Guide Roller Pin

Movable Driven Face

O-rings

Oil Seal

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-11

FILLY LX 50

Check the driven face for wear or damage.
Measure the driven face O.D.

Service Limit: 33.94mm replace if below
Check the movable driven face for wear or

damage.
Measure the movable driven face I.D.

Service Limit: 34.06mm replace if over

DRIVEN PULLEY FACE BEARING
REPLACEMENT

Drive the inner needle bearing out of the
driven pulley face.
Discard the removed bearing and replace with
a new one.

Remove the snap ring and drive the outer
bearing out of the driven face.

Apply grease to the outer bearing.
Drive a new outer bearing into the driven face
with the sealed end facing up.
Seat the snap ring in its groove.

Inner Bearing

Outer Bearing

Pack all bearing cavities with

5.0_ 5.6g grease.
Specified grease: Heat resistance 230°C

＊

Snap Ring

Bearing Remover

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-12

FILLY LX 50

Press a new needle bearing into the driven
face.

ASS EMBLY

Install the movable driven face onto the
driven face.
Install the O-rings, guide rollers and guide
roller pins.
Install the a new oil seal.

Install the seal collar.

Set the driven pulley assembly, driven face
spring and clutch assembly onto the clutch
spring compressor.
Compress the clutch spring compressor and
install the 39mm drive plate nut.
Set the clutch spring compressor in a vise and
tighten the drive plate nut to the specified
torque.

Torque: 5.0_ 6.0kgf-m

Clutch Spring Compressor

Movable Driven Face

Guide Roller Pin

Outer Driver, 24x26mm

Clutch Spring Compressor

Lock Nut Wrench, 39mm

O-rings

Oil Seal

Seal Collar

Driver Handle

Pilot, 17mm

Special

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-13

FILLY LX 50

INSTALLATION

Lay the drive belt on the driven pulley and
install the clutch/driven pulley onto the drive
shaft.

Install the clutch outer.
Hold the clutch outer with the universal
holder.
Install and tighten the 10mm clutch outer nut.

Torque: 3.5~4.5kgf-m
Install the left crankcase cover. (!9-4)

Clutch Outer

Universal Holder

Clutch/Driven Pulley

Nut