KYMCO FILLY 50 Manuale utente

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO FILLY 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 18 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

INSTRUMENTS/SWITCHES/LIGHTS 17

ELECTRICAL

EQUIPMENT

EVAPORATIVE EMISSION CONTROL

SYSTEM 18

EXHAUST EMISSION CONTROL

SYSTEM 18

EMISSION

CONTROL

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

1. GENERAL INFORMATION

1-1

SERVICE PRECAUTIONS ...................................1- 3 WIRING DIAGRAM ...........................................1-20

TORQUE VALUES................................................1- 11 TROUBLESHOOTING........................................1-21

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

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

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

ENGINE SERIAL NUMBER

Location of Engine Serial Numbe

1. GENERAL INFORMATION

1-2

SPECIFICATIONS

Motorcycle Name & Type

Name & Model No. SD10AA

Overall length (mm) 1660

Overall width (mm) 680

Overall height (mm) 1070

Wheel base (mm) 1195

Engine type O.H.C.

Displacement 49.5cc

Fuel Used 92# nonleaded gasoline

Front wheel 33

Net weight (kg) Rear wheel 46

Total 79

Front wheel 32

Gross weight(kg) Rear wheel 52

Total 84

Front wheel 90/90-10 50J

Tires Rear wheel 90/90-10 50J

Ground clearance (mm) 100

Perform- Braking distance (m) 4.4 (Initial speed

30km/h)

ance Min. turning radius (m) 1.6

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 x 41.4

Compression ratio 10.5

Compression pressure

(kg/cm²-rpm) 14−600

Max. output (ps/rpm) 4.0/8000

Max. torque (kg m/rpm) 1.04/6000

Intake

Open 0°BTDC

Port (1mm) Close 34°ABDC

Engine

timing Exhaust Open 32°BBDC

(1mm)

Close 0°TDC

Valve clearance Intake 0.10

(cold) (mm) Exhaust 0.10

Idle speed (rpm) 1700rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 0.9 liter

Lubrication

System

Cooling Type Forced air cooling

Air cleaner type & No Paper element, wet

Fuel capacity 6.2 liter

Type CVK

Piston dia. (mm)

Venturi dia.(mm) φ18 equivalent

Carburetor

Throttle type Butterfly type

Type CDI

Ignition timing 15±2°BTDC/1700rpm

Contact breaker Non-contact point type

Spark plug

NGK

C7HSA

U22FS-U

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 10.853.0

ratio 2nd 11.05

Front Caster angle 26.5°

Axle Trail length ⎯

Tire pressure

Fron

1.75

(kg/cm²) Rear 2.25

Turning Left 45°

angle Right 45°

Brake system

Front Drum

(

110mm

)

brake

type Rear Drum (110mm) brake

Fron

Telesco

Suspension type Rear Unit Swing

Front Telescope

Shock absorber

type Rear Unit Swing

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

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.

Apply or add designated greases and lubricants to

1. GENERAL INFORMATION

1-4

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.

If the fuse is burned out, find the cause and repair

it. Replace it with a new one according to the

specified capacity.

1. GENERAL INFORMATION

1-5

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.

The connector shall be inserted completely.

Confirm

Capacity If the double connector has a lock, lock it at

the correct position.

1. GENERAL INFORMATION

1-6

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.

After clamping, check each wire to make sure it is

secure.

Sna

1. GENERAL INFORMATION

1-7

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 !

Route harnesses so they are neither pulled

tight nor have excessive slack.

1. GENERAL INFORMATION

1-8

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 press or

ueeze the wire.

Do not pull

too ti

ht! After routing, check that the wire harnesses are

not twisted or kinked.

1. GENERAL INFORMATION

1-9

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 !

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.)

Engine Oil

Indice

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