KYMCO FILLY LX 50 Manuel utilisateur

FILLY LX 50

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO FilLy LX 50

Section 1 contains the precautions for all

operations stated in this manual. Read

them carefully before starting any

operation.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 6 through 17 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

FRAME COVERS/EXHAUST MUFFLER 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

FUEL SYSTEM 5

ENGINE REMOVAL/INSTALLATION 6

CYLINDER HEAD/VALVES 7

CYLINDER/PISTON 8

ENGINE

DRIVE AND DRIVEN PULLEYS/KICK

STARTER 9

FINAL REDUCTION 10

CRANKCASE/CRANKSHAFT 11

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION 12

CHASSIS

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION 13

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR 14

IGNITION SYSTEM 15

STARTING SYSTEM 16

ELECTRICAL

EQUIPMENT

LIGHTS/INSTRUMENTS/SWITCHES 17

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

1. GENERAL INFORMATION

1-1

FILLY LX 50

SPECIAL TOOLS.....................................1-12

TORQUE VALUES..................................1-11 TROUBLESHOOTUNG ..........................1-21

SERVICE PRECAUTIONS......................1- 3 WIRINGDIAGRAM................................1-20

SPECIFICATIONS ...................................1- 2 CABLE & HARNESS ROUTING............1-15

ENGINE SERIAL NUMBER...................1- 1 LUBRICATION POINTS .......................1-13 1

ENGINE SERIAL NUMBER

Fill

LX 50

Location of Engine Serial Numbe

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) φ39.0 x 41.4

Compression ratio 10.5

Compression pressure

(kg/cm²-rpm) 14

Max. output 2.208/8000kw/(r/min)

Max. torque 0.3/6500kg m/rpm

Open 3°

Port Intake Close 7°

Engine

timing 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

Oil filter type Full-flow filtration

Lubrication

System

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) φ17equivalent

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 ⎯

Tire pressure

Fron

1.75

(kg/cm²) Rear 2.25

Turning Left 45°

angle Right 45°

Front DISK

(

160mm

)

rake

Brake system

type

Rear Drum (110mm) brake

Fron

TELESCOPE

Suspension type Rear Unit Swing

Front 70

Shock absorber

distance Rear 66

Frame type Under Bone

Fuel S

stem Electrical E

ment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-3

FILLY LX 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

FILLY LX 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

FILLY LX 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

FILLY LX 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.

Sna

1. GENERAL INFORMATION

1-7

FILLY LX 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.

o Contact !

1. GENERAL INFORMATION

1-8

FILLY LX 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 ti

ht!

Do not press or

ueeze the wire.

1. GENERAL INFORMATION

1-9

FILLY LX 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 !

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