F50LX Cap 01 (Info Generali)

7/30/2019 F50LX Cap 01 (Info Generali)

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1. GENERAL INFORMATION

1-1

FILLY LX 50

Location of Engine Serial Number

1

ENGINE SERIAL NUMBER

1ENGINE SERIAL NUMBER...................1- 1 LUBRICATION POINTS.......................1-13SPECIFICATIONS...................................1- 2 CABLE & HARNESS ROUTING ............1-15

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

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

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

Filly LX 50


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FILLY LX 50

SPECIFICATIONS

Motorcycle Name & Type Filly LX 50

Name & Model No. SD10BB

Overall length (mm) 1720Overall 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 50JTires

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 systemStarting motor &

kick starterType Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.

Bore x stroke (mm) f39.0 x 41.4

Compression ratio 10.5Compression pressure(kg/cm_-rpm) 14

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

)

Max. torque 0.3/6500kg m/rpmOpen 3

PortIntake

Close 7

Engine

timing

Open 9Exhaust

Close 1

Valve clearance Intake 0.04

(cold) (mm) Exhaust 0.04

Idle speed (rpm) 1900 100rpm

Lubrication typeForced pressure &

wet sump

Oil pump type Inner/outer rotor type

Lu

brication

Sy

stem

Oil filter type Full-flow filtration

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)

f17equivalent

Carburetor

Throttle type Butterfly type

Type CDI

Ignition timing BTDC28/4000rpm

Contact breaker Non-contact pointtype

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

centrifugaltype

Type Two-stage reduction

Reduction 1st 0.8-3.1

ratio 2nd 11.05

Front Caster angle 27

Axle Trail length

Tire ressure Front 1.75(kg/cm_) Rear 2.25

Turning Left 45

angle Right 45

Front DISK (160mm)Brake system

type Rear Drum (110mm)

brake

Front TELESCOPESuspension typeRear Unit Swing

Front 70Shock absorberdistance

Rear 66

Frame type Under Bone

FuelSystem

Elec

trical

IgnitionSystem

PowerD

riveSystem

Transm

is-

sionG

ear

Reduction

Gear

MovingDevice

Device


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FILLY LX 50

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. when

reassembling.

nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

n Use genuine parts and lubricants

.

nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oil

before reassembly.


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FILLY LX 50

n Apply or add designated greases andlubricants to the specified lubrication

points.

n After reassembly, check all parts for

proper tightening and operation.

nWhen two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.

nWhen using a spanner or other tools, makesure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.

nWhen connecting the battery, the positive(+) terminal must be connected first.

n After connection, apply grease to thebattery terminals.

n Terminal caps shall be installed securely.


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FILLY LX 50

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,protruding or loose.

ConfirmCapacity


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FILLY LX 50

n The connector shall be insertedcompletely.

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 negativeterminal.

n Check the double connector cover forproper coverage and installation.

n Insert the terminal completely.

n Check the terminal cover for propercoverage.

n Do not make the terminal cover openingface up.

n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

Snapping!


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FILLY LX 50

n After clamping, check each wire to makesure it is secure.

.

n Do not squeeze wires against the weld orits clamp

n After clamping, check each harness to makesure that it is not interfering with any

moving or sliding parts.

nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends of

bolts and screws.n Route wire harnesses passing through the

side of bolts and screws. Avoid theprojected ends of bolts and screws.

No Contact


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FILLY LX 50

n Route harnesses so they are neitherpulled tight nor have excessive slack.

.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner

nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled 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 tapeor replace it.

nWhen installing other parts, do not press orsqueeze the wires.

Do notpull too

Do not press orsqueeze the wire.


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FILLY LX 50

n After routing, check that the wire harnessesare not twisted or kinked.

nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

nWhen rust is found on a terminal, removethe rust with sand paper or equivalent

before connecting.

n Do not bend or twist control cables.Damaged control cables will not operatesmoothly and may stick or bind.

Do you understandthe instrument? Isthe instrument setcorrectly?

Remove Rust


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FILLY LX 50

n Symbols:

The following symbols represent theservicing methods and cautions included in

this service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

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

Engine Oil

Grease

Gear Oil

Special


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1-11

FILLY LX 50

TORQUE VALUES

STANDARD TORQUE VALUES

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

0.6-1.2

1.8-2.5

3.0-4.0

5.0-6.0

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut



0.35-0.5

0.7-1.1

1.0-1.4

2.4-3.0

3.5-4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item Qty Thread dia.(mm) Torque (kg-m) Remarks

Cylinder head bolt A

Cylinder head bolt B

Oil filter screen cap

Exhaust muffler lock bolt

Cylinder head flange nut

Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt

Clutch outer nut

Clutch drive plate nut

Starter motor mounting bolt

Oil pump bolt

Drive face nut

Spark plug

A.C. generator stator bolt

Cam chain tensioner bolt

2

4

1

2

4

2

1

1

1

1

2

3

1

1

2

1

6

6

30

6

7

3

8

8

10

28

6

4

10

10

6

6

0.7-1.1

0.7-1.1

1.0-2.0

0.7-1.1

1.2-1.6

0.07-0.09

0.4-0.7

1.1-1.5

3.5-4.5

5.0-6.0

0.8-1.2

0.1-0.3

5.5-6.5

1.0-1.4

0.8-1.2

0.8-1.2

Double end bolt

Double end bolt

Apply oil to

threads

FRAME

Item Qty Thread dia.(mm) Torque (kg-m) Remarks

Steering stem lock nut

Front axle nut

Rear axle nut

Rear shock absorber upper bolt

Rear shock absorber lower bolt

Speedometer cable set screw

Rear shock absorber lock nut

1

1

1

1

1

1

1

25.4

10

14

10

8

5

8

8.0-12.0

5.0-7.0

11.0-13.0

4.0-5.0

2.0-3.0

0.45-0.6

3.0-3.6

U-nut

U-nut

U-nut

Apply locking agent


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1-12

FILLY LX 50

SPECIAL TOOLS

Tool Name Tool No. Remarks

Ref.

Page

10-310-4

Bearingpuller10.12.15.18 mm

E03710.12.15.18mm

bearing 12-6

Bushingremover L

E03211102

bush

Bushingremover S

EO1911203

bush rear

Crankshaftbearing E030

91005radial

Crankshaftprotector E029 13000crankshaft

Clutchspringcompressor

E0272301adriven

pully assy

9-99-12

Cushionassemble F004

52400cushion 13-4

Flywheelholder

E017

31110flywheelcomp.2310a pullyassy driven

9-59-99-1314-714-9

Flywheelpuller E002 Left handthread 14-7

Longsocket F002

50306steering

12-2112-22

Oil sealbearing E014

Oil seal &bearing

Tool boox E033Specialtools

Tappetadjuster

E03690012screw 3-5

7-7Valvespring

compressor

E038Valvespring

7-8


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1-13

FILLY LX 50

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part

Cam lobes

Valve rocker arm friction surface

Cam chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings

Cylinder inside wall

Connecting rod/piston pin hole

Connecting rod big end

Crankshaft R/L side oil seal

Starter reduction gear engaging part

Countershaft gear engaging part

Final gear engaging partBearing movable part

O-ring face

Oil seal lip

Genuine KYMCO Engine Oil (SAE15W-40)

API-SG Engine Oil

Starter idle gear

Friction sp ring movable part /shaft movable part

Shaft movable grooved part

Kick starter spindle movable part

High-temperature resistant grease

A.C. generator connector

Transmission case breather tubeAdhesive


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1-14

FILLY LX 50

FRAME

The following is the lubrication points for the frame.Use general purpose grease for parts not listed.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.

Rear Wheel BearingsMain Stand Pivot

Speedometer Gear/ Front Wheel

Bearings/ Brake Cam/ Anchor Pin/Front Shock Absorber LowerMount Bushings/Pivot

Grease Grease

Grease

Engine Oil

Rear Brake Cable

Brake Cam/

Anchor Pin

Grease

Grease

Front Brake LeverPivot

Front Brake Cable/Speedometer Cable/Throttle Cable

Engine/ Oil


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1-15

FILLY LX 50

CABLE & HARNESS ROUTING

Front Stop Switch Wire

Rear Stop Switch Wire

Throttle Cable

Regulator/Rectifier

Rear Brake Cable

Speedometer Cable

Horn

Ignition Switch

Winker

Headlight Resistor

Front Brake Fluid Tube

Brake Master Cylinder


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FILLY LX 50

Regulator/Rectifier

Speedometer Cable

Ignition Switch

Fuel Filler

Throttle Grip

Rear Brake Lever

Fuel TankInlet Tube

Fuel TankBreather Tube

Front Brake Fluid Tube

Fuel Tank


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1-17

FILLY LX 50

Starter Relay

Fuse

Battery (+) Cable

Battery (-) Cable

CDI Unit

Battery (+) Cable

Battery (-) Cable

CDI Unit

Ignition Coil


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1-18

FILLY LX 50

Throttle Cable

Fuel VaporRecovery Tube

Vacuum Tee

CarburetorOverflow Tube

Fuel Tube

Crankcase BreathTube

Ignition CoilPrimary Wire

Ignition Wire

Fuel


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1-19

FILLY LX 50

Throttle Cable

Fuel Tube

Vacuum Tube

Auto Bystarter

Fuel Unit

Crankcase BreatherTube

Ignition Coil

Fuel VaporRecovery Tube

Wire Harness

Crankcase BreatherTube

Throttle Cable

Vacuum Tube

Fuel Filter

Fuel

Pump


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1-20

FILLY LX 50

WIRING DIAGRAM


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1-21

FILLY LX 50

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tankClogged fuel line between fueltank and carburetorClogged float oil passageClogged fuel tank cap breatherholeClogged fuel filter

Clogged fuel strainerFaulty auto fuel valve

Faulty spark plugFouled spark plugFaulty CDI unitFaulty pulser coilBroken or shorted ignition coilBroken or shorted high-

tensionwireFaulty ignition switch

Faulty starter clutchValve clearance too smallImproper valve and seat contactWorn cylinder, piston and pistonringsLeaking cylinder head gasketSeized valveImproper valve timing

Faulty auto bystarterAir leaking through intake

pipeIncorrect ignition timingIncorrectly adjusted pilot screw

Flooded carburetorFaulty auto bystarterThrottle valve excessively

open

Check if fuel reachescarburetor byloosening drain screw

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground

Inspection/Adjustment Probable Cause

Spark jumps

Normalcompression

Engine does not

fire

Weak or no spark

Low or nocompression

Engine fires but

does not start

Test cylindercompression

Start engine by follow-ing normal starting

procedure

Remove spark plug andinspect again

Symptom

Fuel reachescarburetor

Fuel does notreach carburetor

Wet spark plugDry spark plug


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1-22

FILLY LX 50

ENGINE LACKS POWER

Clogged air cleanerPoor quality fuel (Restricted)Clogged fuel tank cap breather holeClogged exhaust mufflerFaulty auto bystarterSplit carburetor vacuum pistondiaphragmFaulty auto fuel valve

Faulty CDI unitFaulty pulser coil

Improper valve clearanceadjustmentWorn valve seat (valve stem tooprotruding

Improper valve and seat contactWorn cylinder and piston ringsLeaking cylinder head gasketImproper valve timing

Clogged carburetor jets

Fouled spark plugIncorrect heat range plug

Oil level too highOil level too lowOil not changed

Clogged oil pipe

Faulty oil pump

Worn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup incombustion chamberIgnition timing too early

Excessive carbon build-up incombustion chamberPoor quality fuel

Clutch slippingMixture too leanIgnition timing too early

Start engine and acceleratelightly for observation

Inspection/Adjustment Symptom Probable Cause

Engine speedincreases

Correct timing

Engine speed does notincrease sufficiently

Incorrect timing

Check ignition timingusing a timing light

Test cylinder compression

Check carburetor forclogging

Rapidly accelerate or runat high speed

Remove spark plug andinspect

Check if engine overheats

Check valve clearance

Correct Incorrect

Normalcompression

Abnormalcompression

Remove oil dipstick andcheck oil level and condition

Remove cylinder head oilpipe bolt and inspect

Engine overheatsEngine does notoverheats

Plug not fouled ordiscolored

Plug fouled ordiscolored

Correct and notcontaminated

Incorrect orcontaminated

Valve train lubricatedproperly Valve train notlubricated properly

Engine does not knock Engine knocks

Not clogged Clogged


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FILLY LX 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit

Faulty pulser coil

Mixture too rich (turn screwout)Mixture too lean (turn screw

in)

Deteriorated O-ringCarburetor not securelytightened

Damaged insulator rubberBroken vacuum tube

Faulty or fouled spark plugFaulty CDI unitFaulty A.C. generatorFaulty ignition coilBroken or shorted spark plugwireFaulty ignition switch

Faulty air cut-off valveDamaged vacuum tubeClogged or damaged air venthole

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground


Check ignition timing

Check air cut-off

Check carburetorgasket for air leaks

Check carburetor pilot

screw adjustment

Correct timing Incorrect timing

Correctly adjusted

No air leak Air leaks

Good sparkWeak or inter-mittent spark

Good Faulty

Incorrectly


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1-24

FILLY LX 50

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit

Faulty pulser coil

Improperly adjusted valveclearanceWorn camshaftWorn valve seat

Empty fuel tankClogged fuel tube or filterFaulty charcoal canisterFaulty auto fuel valve

Clean and unclog

Cam timing gear aligningmarks not aligned

Faulty spring


Check ignition timing

Check carburetor jetsfor clogging

Check fuel pump forfuel supply

Correct timing Incorrect timing

Check valve springtension

Check valve clearance

Fuel flows freelyFuel flow restricted

Correct Incorrect

Not clogged Clogged

Correctly adjusted Incorrectly adjusted

Not weakened Weak spring

Check valve timing


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1-25

FILLY LX 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Dead battery

Faulty battery

Faulty A.C. generator coilBroken yellow wireLoose connector

Broken red wire

Faulty regulator/rectifier

Poorly connected coupler

Faulty A.C. generator

Overcharging

Broken green wire


Faulty regulator/rectifier

Start engine and testlimit voltage between

battery terminals

Connect battery (+)wire toregulator/rectifiercoupler red wire and

battery (-) wire to engineground and test voltage

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Battery hasvoltage withi nition switch

Normal

Voltage does notincrease

Battery has novoltage withi nition switch

Resistance too

Normal voltage No voltage

Measure resistance

between AC generatorcoil terminals

Normal Abnormal

Check

regulator/rectifiercoupler for looseconnection

Normal Abnormal

Connect battery (+)

wire toregulator/rectifiercoupler green wire and

battery (-) wire to engineground and test voltage

Checkregulator/rectifiercoupler for looseconnection


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1. GENERAL INFORMATION FILLY LX 50

NO SPARK AT SPARK PLUG

Faulty old spark plug

Loose spark plug cap


Faulty ignition switchFaulty pulser coilFaulty ignition coil

Broken wire harnessPoorly connected coupler

Faulty CDI unit

Faulty ignition coil

Replace with a newspark plug and inspectagain

Check CDI unitcoupler for looseness


Normal

Abnormal

Normal

Abnormal

Normal Abnormal

Abnormal

Measure resistancebetween CDI unitcoupler wire terminals

Check related parts

Check ignition coil

with a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good Good

Check spark plug capand high-tension wirefor looseness

Check CDI unit with aCDI unit tester

Date post:	04-Apr-2018
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F50LX Cap 01 (Info Generali)

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