Kymco MO Yup50 Service Manual - chap 02 (info generali)

2. GENERAL INFORMATION

2-0

YUP 5 0

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

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

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

SERVICE INFORMATION........................................................ 2- 6

TORQUE VALUES................................................................... 2- 8

SPECIAL TOOLS ..................................................................... 2- 9

LUBRICATION POINTS........................................................... 2-11

WIRING DIAGRAM.................................................................. 2-12

CABLE & HARNESS ROUTING ............................................... 2-13

TROUBLESHOOTING.............................................................. 2-17

2. GENERAL INFORMATION

2-1

YUP 5 0

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Number

2. GENERAL INFORMATION

2-2

YUP 5 0

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.

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

2-3

YUP 5 0

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.

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.

Easy confirm

2. GENERAL INFORMATION

2-4

YUP 5 0

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.

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.

Don’t touch

2. GENERAL INFORMATION

2-5

YUP 5 0

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 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

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

Engine Oil

Grease

Special

＊

Remove the rest

2. GENERAL INFORMATION

2-6

YUP 5 0

SERVICE INFORMATION

ENGINE

Standard (mm)

Service Limit (mm)

Item

YUP 50

Cylinder head warpage

0.10

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

38.955_ 38.970

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.

8.5

8.2

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

YUP 50

Venturi dia.

14mm

Identification number

014A

Float level

5.0mm

Main jet

#75

Slow jet

#35

Air screw opening

1 ±_

Idle speed

2100±100rpm

Throttle grip free play

2_ 6mm

Jet needle clip notch

1st notch

2. GENERAL INFORMATION

2-7

YUP 5 0

FRAME

Standard (mm)

Service Limit (mm)

Item

YUP50

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

YUP50

Capacity

12V3AH

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

13.5°±2°BTDC/2000rpm

2. GENERAL INFORMATION

2-8

YUP 5 0

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

6.0_ 8.0

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

+ 19 hidden pages

Kymco MO Yup50 Service Manual - chap 02 (info generali)

Specifications and Main Features

Frequently Asked Questions

User Manual