Kymco MO P50 Service Manual - chap 02 (info generali)

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2. GENERAL INFORMATION

2-0

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GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER/IDENTIFICATION ........................ 2- 1

SERVICE PRECAUTIONS ........................................................ 2- 2

SERVICE INFORMATION........................................................ 2-10

TORQUE VALUES................................................................... 2-12

SPECIAL TOOLS ..................................................................... 2-13

LUBRICATION POINTS........................................................... 2-15

WIRING DIAGRAM.................................................................. 2-16

CABLE & HARNESS ROUTING ............................................... 2-18

TROUBLESHOOTING.............................................................. 2-22

2. GENERAL INFORMATION

2-1

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Number

2. GENERAL INFORMATION

2-2

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.

2. GENERAL INFORMATION

2-3

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.

2. GENERAL INFORMATION

2-4

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

2. GENERAL INFORMATION

2-5

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!

2. GENERAL INFORMATION

2-6

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 !

2. GENERAL INFORMATION

2-7

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 tight!

Do not press or squeeze the wire.

2. GENERAL INFORMATION

2-8

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.

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

Remove Rust !

2. GENERAL INFORMATION

2-9

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.

: Use special tool.

: Caution

: Warning

Engine Oil

Grease

Special

＊

2. GENERAL INFORMATION

2-10

SERVICE INFORMATION

ENGINE

Standard (mm)

Service Limit (mm)

Item

BA10AB.AC.

Cylinder head warpage

0.10

Piston O.D.(5mm from bottom of piston

38.970_ 38.955

38.90

Cylinder-to- piston clearance

0.10

Piston pin hole I.D.

12.002_ 12.008

12.03

Piston pin O.D.

11.994_ 12.0

11.98

Piston-to-piston pin clearance

Piston ring end gap (top/second)

0.10_ 0.25

0.40

Connecting rod small end I.D.

17.005_ 17.017

17.03

Cylinder bore

39.0_ 39.025

39.05

Drive belt width

Drive pulley collar O.D.

20.01_ 20.025

Movable drive face ID.

20.035_ 20.085

19.97

Weight roller O.D.

13.0

12.4

Clutch outer I.D.

107_ 107.2

107.5

Driven face spring free length

87.9

82.6

Driven face O.D.

Movable driven face I.D.

Connecting rod big end side clearance

Connecting rod big end radial clearance

Crankshaft runout A/B

CARBURETOR

BA10AB.AC

Venturi dia.

14mm

Identification number

PB058

Float level

8.6mm

Main jet

#85

Slow jet

#35

Air screw opening

1_ ± _

Idle speed

2000±100rpm

Throttle grip free play

2_ 6mm

Jet needle clip notch

1st notch

1. SPECIFICATIONS

2-11

FRAME

Standard (mm)

Service Limit (mm)

Item

BA10AB.AC.

Axle shaft runout

0.2

Radial

Front wheel rim runout

Axial

Front shock absorber spring free length

200.0

182.8

Rear wheel rim runout

2.0

Brake drum I.D.

Front/rear

110

111

Brake lining thickness

Front/rear

4.0/4.0

2.0/2.0

Brake disk runout

Front/rearæ0.30

Rear shock absorber spring free length

235.7

218.7

ELECTRICAL EQUIPMENT

BA10AB.AC

Capacity

12V4AH

Voltage

13.0_ 13.2V

Charging

Standard

0.4A/5H

Battery

current

Quick

4A/0.5H

Spark plug

(NGK)

BR8HSA

Spark plug gap

0.6_ 0.7mm

Primary coil

0.153_ 0.187W

Secondary coil (with plug cap)

6.99_ 10.21KW

Ignition coil resistance

Secondary coil (without plug cap)

3.24_ 3.96KW

Pulser coil resistance (20℃ )

80_ 160W

Ignition timing

8°~14°±1.5°BTDC/2000rpm

2. GENERAL INFORMATION

2-12

TORQUE VALUES

ENGINE

Item

Thread dia. (mm)

Torque (kg-m)

Remarks

Cylinder head bolt Clutch drive plate nut Clutch outer nut Drive face nut Oil check bolt Engine mounting bolt Engine hanger bracket bolt Exhaust muffler joint lock nut Exhaust muffler lock bolt Spark plug

BF7x115

10 NH10 NH12

BF10x95 BF10x50

NC6mm

BF8x35

1.5_ 1.7

3.5_ 4.0

3.5_ 4.5

5.0_ 6.0

1.0_ 1.5

4.5_ 5.5

3.5_ 4.5

1.0_ 1.4

3.0_ 3.6

1.1_ 1.7

(cold)

FRAME

Item

Thread dia. (mm)

Torque (kg-m)

Remarks

Handlebar lock nut Steering stem lock nut Steering top cone race Front axle nut Rear axle nut Rear brake arm bolt Front shock absorber: upper mount bolt lower mount bolt hex bolt Front damper nut Front pivot arm bolt Rear shock absorber: upper mount bolt lower mount bolt lower joint nut

25.4

25.4 12 16

8 8

4.5_ 5.0

8.0_ 12.0

0.5_ 1.3

5.0_ 7.0

11.0_ 13.0

3.3

1.5_ 3.0

3.5_ 4.5

2.4_ 3.0

1.5_ 2.5

Flange bolt/U-nut

Flange U-nut Flange U-nut Flange nut

Flange bolt/U-nut Cross head Apply locking agent

Flange screw/U-nut

Flange nut

Torque specifications listed above are for important fasteners. Others should be tightened to standard torque values below.

STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt

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

0.8_ 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

1. SPECIFICATIONS

2-13

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Universal bearing puller

Crankshaft bearing removal

Lock nut wrench, 39mm

Drive pulley disassembly/assembly

Lock nut socket wrench

Top cone race holding

Lock nut wrench,

Stem lock nut tightening

Crankcase puller

Crankcase disassembly

Bearing remover set, 12mm (Spindle assy, 15mm)

(Remover weight)

Drive shaft bearing removal/installation

Bearing remover set, 15mm (Spindle assy, 15mm)

(Remover head, 15mm) (Remover shaft, 15mm)

Drive shaft bearing removal/installation

Bearing outer driver, 28x30mm

Bearing installation

Bearing remover

Driven pulley outer bearing installation

Clutch spring compressor

Driven pulley disassembly/assembly

Crankcase assembly collar

Driven shaft, crankshaft & crankcase assembly

Crankcase assembly tool

Crankshaft & crankcase assembly

Rear shock absorber remover

Front shock absorber disassembly/ assembly

Ball race remover

Steering stem bearing races

Rear shock absorber compressor

Rear shock absorber disassembly/assembly

Float level gauge

Carburetor fuel level check

Lock nut socket wrench, 32mm

One-way clutch lock nut removal/ installation

Universal holder

Flywheel holding

Flywheel puller

Flywheel removal

Pilot, 12mm

Drive shaft bearing installation

Bearing outer driver, 32x35mm

Drive shaft bearing installation Final shaft bearing installation

2. GENERAL INFORMATION

2-14

Tool Name

Tool No.

Remarks

Bearing outer driver, 37x40mm

Drive shaft bearing installation Final shaft bearing installation Crankshaft bearing installation

Outer driver, 24x26mm

Driven pulley bearing installation

Pilot, 10mm

Front wheel bearing installation

Bearing driver pilot, 17mm

Drive shaft bearing installation

Snap ring pliers (close)

Circlip removal/installation

Bearing outer driver, 42x47mm

Crankshaft bearing installation

Pilot, 20mm

Crankshaft bearing installation

Bearing outer driver handle A

Bearing installation Drive in ball race

Bearing puller head, 10mm

Front wheel bearing removal

Universal bearing puller

Crankshaft bearing removal

Bearing puller

Front wheel bearing removal

Pressure tester set

Cylinder compression gauge

1. SPECIFICATIONS

2-15

LUBRICATION POINTS

ENGINE

NO.

Lubrication Points

Lubricant

Remarks

Crankcase sliding & movable parts

JASO-FC or API-TC

Cylinder movable parts

Transmission gear (final gear)

SAE-90#

Kick starter spindle bushing

Grease

Drive pulley movable parts

Grease

Starter pinion movable parts

Grease

FRAME

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.

Front/Rear Brake Lever

Seat Lock

Rear Wheel Bearing

Throttle Cable

Speedometer Cable

Main Stand Pivot

Grease

Engine Oil

Grease

Engine Oil

Speedometer Gear/ Brake Cam/Front Shock Absorber Lower Mount Bushings/Pivot

Grease

Engine Oil

Rear Brake Cable

Brake Cam/ Anchor Pin

2. GENERAL INFORMATION

2-16

BA10AB.AC. WIRING DIAGRAM

Black

Brown

Yellow

Orange

Blue

Light blue

Green

Light green

RedPPink

WhiteGrGray

1. SPECIFICATIONS

2-17

CABLE & HARNESS ROUTING

Front Brake Reservoir

Rear Brake Cable

Throttle Cable

Ignition Switch

Regulator/Rectifier

Front Brake Fluid Tube

Ground

Speedometer Cable

Horn

Starter Relay

2. GENERAL INFORMATION

2-18

Wire Harness

Starter Relay

Rear Brake Cable

Throttle Cable

Front Brake Fluid Tube

Speedometer Cable

1. SPECIFICATIONS

2-19

Ignition Coil

Fuel Unit

Fuel Filter

Left Crankcase Breather

Oil Tube

Spark Plug

Fuel Vapor Recovery Tube

Ignition Coil

2. GENERAL INFORMATION

2-20

Ignition Coil

Vacuum Tee

Throttle Cable

Oil Meter

Spark Plug Cap

Oil Filter

Oil Pump Control Cable

Auto Bystarter

Oil Tube

Fuel Unit

Fuel Tank Cap

Fuel Tube

Fuel Filter

Oil Tank Cap

1. SPECIFICATIONS

2-21

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Å Empty fuel tank Ç Clogged float valve É Clogged charcoal

canister

Ñ Clogged fuel filter Ö Faulty auto fuel valve

Å Faulty spark plug Ç Fouled spark plug É Faulty CDI unit Ñ Faulty A.C. generator Ö Broken or shorted

ignit ion coil

Ü Broken or shorted

exciter coil

áFaulty ignition switch

Å Burned or worn

cylinder piston

Ç Faulty reed valve É Blown cylinder head

gasket

Ñ Leaking crankcase Ö Faulty crankcase oil

seal

Å Incorrectly adjusted idle

speed

Ç Air leaking through

intake pipe

É Incorrect ignition

timing

Å Flooded carburetor Ç Throttle valve

excessively open

Å Faulty auto bystarter

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

Symptom

Probable Cause

Fuel reaches carburetor

Spark jumps

Dry spark plug

Not clogged

Normal compression

Engine does not fire

Fuel does not reach carburetor

Weak or no spark

Wet spark plug

Clogged

Low or no compression

Engine fires but does not start

Test cylinder compression.

Remove spark plug and inspect again.

Wait for 30 minutes and then remove the carbu-retor auto choke circuit hose and blow the hose with mouth.

Start engine by following normal starting procedure.

2. GENERAL INFORMATION

2-22

ENGINE STOPS IMMEDIATELY AFTER IT STARTS

Å Empty fuel tank Ç Clogged float valve É Clogged charcoal

canister

Ñ Clogged fuel filter Ö Faulty auto fuel valve

Å Fouled spark plug Ç Incorrect heat range

plug

Å Fouled spark plug Ç Faulty CDI unit É Faulty A.C. generator Ñ Faulty ignition coil Ö Broken or shorted high

tension wire

Ü Faulty ignition switch

Å Worn cylinder and

piston rings

Ç Blown cylinder head

gasket

É Flaws in cylinder head Ñ Faulty reed valve Ö Seized piston

Å Clogged carburetor jets

Å Faulty CDI unit or A.C.

generator

Ç A.C.G. flywheel not

aligned

Å Mixture too rich (turn

screw out)

Ç Mixture too lean (turn

screw in)

Check if fuel reaches carburetor by loosening drain screw.

Inspection/Adjustment

Symptom

Probable Cause

Fuel reaches carburetor

Good spark

Correct timing

Correctly adjusted

Plug not fouled or discolored

Normal compression

Not Clogged

Fuel does not reach carburetor

Weak or inter mittent spark

Incorrect timing

Incorrectly adjusted

Plug fouled or discolored

Abnormal compression

Clogged

Remove spark plug.

Test cylinder compression (using a compression gauge).

Check carburetor for clogging.

Check ignition timing.

Check carburetor air screw adjustment.

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground.

1. SPECIFICATIONS

2-23

Å Carburetor not securely

tightened

Ç Faulty intake manifold

gasket

É Deformed or broken

carburetor O-ring

Å Broken cable Ç Dirty auto bystarter É Faulty auto bystarter

Å Faulty auto bystarter

Inspection/Adjustment

Symptom

Probable Cause

No air leak

Not clogged

Clogged

Air leaks

Clogged

Not Clogged

Check carburetor gasket for air leaks.

Connect auto bystarter wire to battery. Wait for 5 minutes, then connect a hose to fuel enriching circuit and then blow the hose with mouth.

Remove auto bystarter connecting wire and check if bypass fuel line is clogged.

2. GENERAL INFORMATION

2-24

ENGINE LACKS POWER

Å Clogged air cleaner Ç Clogged fuel filter É Clogged exhaust

muffler

Ñ Faulty auto bystarter Ö Faulty charcoal canister

Å Faulty CDI unit Ç Faulty A.C. generator

Å Worn cylinder and

piston rings

Ç Blown cylinder head

gasket

É Faulty reed valve

Å Clogged carburetor jets

Å Fouled spark plug Ç Incorrect heat range

plug

Å Mixture too lean Ç Poor quality fuel É Excessive carbon build-

up in combustion chamber

Ñ Ignition timing too

early

Å Excessive carbon build-

up in combustion chamber

Ç Poor quality fuel É Clutch slipping Ñ Mixture too lean

Inspection/Adjustment

Symptom

Probable Cause

Engine speed increases

Engine overheats

Correct timing

Engine does not knock

Plug not fouled or discolored

Normal compression

Not Clogged

Engine speed does not increase sufficiently

Engine does not overheats

Incorrect timing

Engine knocks

Plug fouled or discolored

Abnormal compression

Clogged

Start engine and accelerate lightly for observation.

Check ignition timing (using a timing light).

Rapidly accelerate or run at high speed

Test cylinder compression (using a compression gauge)

Check carburetor for clogging

Remove spark plug and

inspect

Check if engine overheats

1. SPECIFICATIONS

2-25

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Å Faulty CDI unit Ç Faulty A.C. generator

Å Mixture too rich (turn

screw out)

Ç Mixture too lean (turn

screw in)

Å Carburetor not securely

tightened

Ç Faulty int ake manifold

gasket

É Deformed carburetor

O-ring

Å Faulty or fouled spark

plug

Ç Faulty CDI unit É Faulty A.C. generator Ñ Faulty ignition coil Ö Broken or shorted high

tension wire

Ü Faulty ignition switch

Å Broken auto bystarter

wire

Ç Faulty auto bystarter

Inspection/Adjustment

Symptom

Probable Cause

Clogged

Not clogged

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground.

Check ignition timing.

Connect auto bystarter wire to battery. Wait for 5 minutes, then connect a hose to fuel enriching circuit and then blow the hose with mouth.

Remove auto bystarter connecting wire and check if bypass fuel line is clogged.

Check carburetor gasket for air leaks.

Check carburetor air screw adjustment.

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

No air leak

Air leaks

Good spark

Weak or inter mittent spark

Not clogged

Clogged

2. GENERAL INFORMATION

2-26

POOR PERFORMANCE (AT HIGH SPEED)

Å Faulty CDI unit Ç Loose A.C.G. stator É Faulty A.C. generator

Å Empty fuel tank Ç Clogged fuel tube or

filter

É Clogged charcoal

canister

Å Clean and unclog

Å Broken auto bystarter

wire

Ç Faulty auto bystarter

Å Faulty auto bystarter

Inspection/Adjustment

Symptom

Probable Cause

Clogged

Not clogged

Check ignition timing.

Connect auto bystarter wire to battery. Wait for 5 minutes, then connect a hose to fuel enriching circuit and then blow the hose with mouth.

Remove auto bystarter connecting wire and check if bypass fuel line is clogged.

Check carburetor jets for clogging.

Check auto fuel valve for fuel supply.

Correct timing

Incorrect timing

Fuel flows freely

Fuel flow

Not clogged

Clogged

Not clogged

Clogged

1. SPECIFICATIONS

2-27

CLUTCH, DRIVE AND DRIVEN PULLEYS

Å Worn or slipping drive belt Ç Broken ramp plate É Broken driven face spring Ñ Separated clutch lining Ö Damaged driven pulley shaft

splines

Ü Damaged final gear á Seized final gear

Å Broken shoe spring Ç Clutch outer and clutch weight

stuck

ÉSeized pivot

Å Worn or slipping drive belt Ç Worn weight rollers É Seized drive pulley bearings Ñ Weak driven face spring Ö Worn or seized driven pulley

bearings

Å Worn or slipping drive belt Ç Worn weight rollers É Worn or seized driven pulley

bearings

Å Oil or grease fouled drive belt Ç Worn drive belt É Weak driven face spring Ñ Worn or seized driven pulley

bearings

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Å Steering stem nut too tight Ç Broken steering steel balls

Å Excessive wheel bearing play Ç Bent rim É Loose axle nut

Å Misaligned front and rear wheels Ç Bent front fork

Engine starts but motor-cycle does not move

Engine lacks power at start of a grade (poor slope performance)

Steering is heavy

Front or rear wheel is wobbling

Symptom

Probable Cause

Engine lacks power at high speed

There is abnormal noise or smell while running

Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)

Steering handlebar pulls to one side

2. GENERAL INFORMATION

2-28

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Å Weak shock spring Ç Excessive load É Shock damper oil leaking

Å Bent fork tube or shock rod Ç Fork slider and tube binding

Å Fork tube and spring binding Ç Fork slider and tube binding

POOR BRAKE PERFORMANCE

(Adjust brake according to standards)

Å Worn brake linings Ç Worn brake cam contacting area

on brake shoes

É Worn brake cam Ñ Worn brake drum

Å Worn brake linings Ç Foreign matter on brake linings É Rough brake drum contacting area

Å Sluggish or elongated brake cables Ç Brake shoes improperly contact

brake drum

É Water and mud in brake system Ñ Oil or grease on brake linings

Å Faulty brake master cylinder Ç Faulty brake caliper É Oil or grease on brake disk Ñ Deformed brake disk Ö Leaking brake fluid tube

Suspension is too soft

Brake squeaks

Symptom

Probable Cause

Suspension is too hard

Suspension is noisy

Brake performance is poor

Index mark on brake panel aligns with wear indicator arrow

Expanding Brake

Hydraulic Brake

1. SPECIFICATIONS

2-29

Faulty

OIL METER

1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)

Å Burned out fuse Ç Weak or dead battery

É Faulty ignition switch Ñ Loose or disconnected

connector

Ö Broken wire harness

ÅBurned out bulb

Å Loose wire connector Ç Broken wire harness É Incorrectly connected

wire

Å Faulty float Ç Broken or shorted wire

in meter

2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)

Å Loose or disconnected

connector

Ç Broken wire harness É Incorrectly connected

wire

Å Faulty float Ç Broken or shorted wire

in meter

Å Damaged oil tank Ç Foreign matters in oil

tank

Inspection/Adjustment

Symptom

Inspection/Adjustment

Probable Cause

Symptom

Probable Cause

Signals operate properly

Signals dim, remain on or don‘t

Bulb lights

Bulb does not light

Good

Faulty

Remove oil meter and check operation of indicator light by moving float

Check connectors for proper connection.

Good

Faulty

Remove oil meter and check operation of indicator light by moving float

Check connectors for proper operation.

Connect indicator light bulb to battery for bulb inspection.

Check battery circuit by operating turn signals.

Good

Faulty

Float up = Light off Float down = Light on

2. GENERAL INFORMATION

2-30

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)

Å Burned out fuse Ç Weak or dead battery É Faulty ignition switch Ñ Loose or disconnected

connector

Ö Broken wire harness

Å Faulty float

Å Broken or shorted fuel

unit wire

Å Loose or disconnected

connector

Ç Incorrectly connected

connector

Å Broken or shorted wire

in fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)

Å Burned out fuse Ç Weak or dead battery É Faulty ignition switch Ñ Loose or disconnected

connector

Ö Broken wire harness

Å Poor contact in fuel

unit

Å Insufficient damping oil

in fuel gauge

Å Loose or disconnected

connector

Å Broken or shorted wire

in fuel gauge

Inspection/Adjustment

Symptom

Signals operate properly

Signals dim, remain on or don‘t

Pointer does not move

Good

Pointer moves

Pointer does not move in accordance with float

Faulty

Pointer does not move

Pointer moves in accordance with float

Probable Cause

Remove fuel unit and check operation of pointer by moving float up and down.

Check battery circuit by operating turn signals.

Check operation of pointer by opening and shorting fuel unit terminal on wire harness side.

Check connectors for proper connection.

Remove fuel unit and check operation of pointer by moving float up and down.

Check battery circuit by operating turn signals and horn.

Move float up and down rapidly (1 round /sec.) to check the operation of pointer.

Check connectors for proper connection.

1. SPECIFICATIONS

2-31

STARTER MOTOR

1. Starter motor won‘t turn

Å Burned out fuse Ç Weak or dead battery É Faulty stop switch Ñ Loose or disconnected

connector

Ö Broken or shorted

ignition switch wire

Å Faulty or weak battery

Å Poor starter button

connection

Ç Faulty starter relay É Loose or disconnected

connector

Å Faulty starter motor

Å Faulty wire harness

2. Starter motor turns slowly or idles

Å Weak or dead battery

Å Loose or disconnected

connector

Ç Faulty starter relay

Å Seized cylinder Å Broken or shorted

starter motor cable

Ç Faulty starter pinion

3. Starter motor does not stop turning

Å Faulty starter pinion

Å Starter relay shorted or

stuck closed

Inspection/Adjustment

Symptom

Signals operate properly

Signals dim, remain on or don‘t

Stoplight does not come on

Starter motor

Turns easily

Not stopped

Stoplight comes

St arter does not

Hard to turn

Stopped

Relay operates properly

Starter motor turns slowly

Probable Cause

Relay does not operate

Starter motor turns normally

Check operation of stop switch by applying brake.

Check battery circuit by operating turn signals.

Turn ignition switch OFF.

Check operation of starter relay by depressing starter button.

Connect starter motor directly to battery.

Rotate crankshaft.

Kymco MO P50 Service Manual - chap 02 (info generali)

Specifications and Main Features

Frequently Asked Questions

User Manual