KYMCO FILLY 50 Service Manual

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.

KYMCO FILLY 50 Specifications

General

Displacement	49.5 cc
Starting System	Electric & Kick
Fuel System	Carburetor
Front Suspension	Telescopic Fork
Rear Brake	Drum
Engine Type	4-Stroke
Cooling System	Air Cooled
Transmission	CVT
Max Torque	3.4 Nm at 6500 rpm

Summary

Preface

General Information

Engine Serial Number

Details on locating and identifying the engine serial number for the motorcycle.

Specifications

Comprehensive technical specifications including dimensions, engine, fuel, and performance data.

Service Precautions

Essential safety guidelines and best practices for performing maintenance and repairs.

Torque Values

Standard torque specifications for important fasteners used in engine and frame assembly.

Special Tools

List of specialized tools required for specific maintenance and repair procedures.

Lubrication Points

Identifies all lubrication points on the engine and frame with recommended lubricants.

Cable and Harness Routing

Illustrates the correct routing of cables and wire harnesses to prevent damage and ensure proper function.

Wiring Diagram

Detailed electrical wiring diagram for troubleshooting and identifying components.

Troubleshooting

Guides for diagnosing and resolving common mechanical and electrical issues.