KYMCO FILLY 50 - Service Manual

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Summary

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.

Summary

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.

Overview

This document is a service manual for the KYMCO FILLY 50, providing comprehensive technical information and servicing procedures for the scooter. It is structured into several sections, each addressing specific components and maintenance aspects, ensuring that technicians can efficiently diagnose, repair, and maintain the vehicle.

The manual begins with a "PREFACE" that outlines its purpose and organization. It emphasizes the importance of reading Section 1, which details general precautions for all operations, before commencing any work. This foundational section ensures safety and proper execution of tasks. Section 2 focuses on the removal and installation procedures for frame covers, which are frequently accessed during routine maintenance and servicing. This highlights a user-friendly design for common service tasks.

Section 3 is dedicated to inspection and adjustment procedures, safety rules, and service information, starting with periodic maintenance. This systematic approach ensures that all critical components are regularly checked and maintained to prevent issues and ensure optimal performance. Subsequent sections, from 6 to 18, provide detailed instructions for the disassembly, assembly, and inspection of the engine, chassis frame, and electrical equipment. Each of these sections typically starts with an illustration of the assembly or system, followed by troubleshooting guides, and then detailed procedures. This visual and structured approach aids in understanding complex operations.

The "TABLE OF CONTENTS" provides a clear overview of the manual's structure, categorizing information into "ENGINE," "CHASSIS," "ELECTRICAL EQUIPMENT," and "EMISSION CONTROL." This organization allows technicians to quickly navigate to the relevant section for specific repairs or maintenance.

"1. GENERAL INFORMATION" is a critical section that covers various essential details. It includes the "ENGINE SERIAL NUMBER," which is crucial for identification and tracking. The "LUBRICATION POINTS" section provides guidance on where and how to lubricate various components, ensuring smooth operation and longevity. The "CABLE & HARNESS ROUTING" diagrams are vital for correct reassembly, preventing interference and damage to electrical and control cables. A "WIRING DIAGRAM" is included for electrical troubleshooting and repair, while "TROUBLESHOOTING" guides help diagnose common problems efficiently.

The "SERVICE PRECAUTIONS" within the general information section are paramount for safe and effective servicing. These precautions include:

Installation of new components: Always use new gaskets, O-rings, circlips, and cotter pins during reassembly to ensure proper sealing and secure fastening.
Tightening procedures: Bolts and nuts should be tightened progressively, starting from larger diameters to smaller ones, and in a diagonal pattern, reaching the specified torque to ensure even pressure distribution and prevent warping.
Use of genuine parts: Emphasizes the importance of using genuine parts and lubricants to maintain the vehicle's integrity and performance.
Special tools: Advises the use of special tools for removal and installation to prevent damage and ensure correct procedures.
Cleaning and lubrication: After disassembly, parts must be cleaned, and sliding surfaces lubricated with engine oil before reassembly to reduce friction and wear.
Application of greases and lubricants: Specific greases and lubricants should be applied to designated points for optimal function.
Post-reassembly checks: After reassembly, all parts must be checked for proper tightening and operation.
Teamwork safety: When two persons work together, attention to mutual working safety is crucial.
Battery disconnection: The battery negative (-) terminal must be disconnected before any operation to prevent electrical shorts.
Protection of surfaces: Care must be taken not to damage the motorcycle surface when using tools.
Connection checks: After operation, all connecting points, fasteners, and lines must be checked for proper connection and installation.
Battery connection order: When connecting the battery, the positive (+) terminal must be connected first, followed by applying grease to the terminals and securely installing terminal caps.
Fuse replacement: If a fuse is burned out, the cause must be identified and repaired, and the fuse replaced with one of the specified capacity.
Connector handling: When removing connectors, release the lock first. Hold the connector body, not the wire, when connecting or disconnecting. Check for bent, protruding, or loose terminals. Ensure connectors are fully inserted and locked if applicable.
Wire harness security: Check for loose wires. Before connecting terminals, inspect for damaged covers or loose negative terminals. Ensure double connector covers are properly installed. Insert terminals completely and ensure covers are correctly positioned, facing downwards.
Wire harness routing: Secure wire harnesses to the frame at designated locations with wire bands, ensuring only insulated surfaces contact the harnesses. After clamping, verify each wire is secure.
Protection from damage: Do not squeeze wires against welds or clamps. Ensure harnesses do not interfere with moving or sliding parts. Avoid contact with high-heat generating parts. Route harnesses to avoid sharp edges, corners, and projected ends of bolts and screws. Ensure harnesses are neither pulled tight nor have excessive slack.
Wire sheath integrity: Protect wires and harnesses with electrical tape or tubing if they contact sharp edges. Do not break the wire sheath. Repair or replace harnesses with broken sheaths. Do not press or squeeze wires when installing other parts. After routing, check for twisted or kinked wire harnesses.
Handlebar wiring: Wire harnesses routed along the handlebar should not be pulled tight, have excessive slack, or interfere with adjacent parts in any steering position.
Testing devices: When using testing devices, thoroughly understand their operating methods and follow instructions.
Part handling: Be careful not to drop any parts.
Terminal rust: Remove rust from terminals with sandpaper or equivalent before connecting.
Control cable handling: Do not bend or twist control cables, as damaged cables may operate unsmoothly or bind.

The manual also includes a section on "TORQUE VALUES," providing standard torque values for various bolts and nuts, as well as specific torque values for engine and frame components. This ensures that all fasteners are tightened to the correct specifications, preventing loosening or damage.

"SPECIAL TOOLS" lists the specialized tools required for specific tasks, ensuring that technicians use the correct equipment for precise and safe operations.

The "LUBRICATION POINTS" section provides a detailed list of engine components that require lubrication, specifying "Genuine KYMCO Engine Oil (SAE10W-30)" or "API-SG Engine Oil" for most parts, "High-temperature resistant grease" for certain moving parts, and "Adhesive" for specific connectors and tubes. For the frame, it recommends general-purpose grease for unlisted parts and clean engine oil or grease for cables and movable parts to prevent abnormal noise and enhance durability.

The "CABLE & HARNESS ROUTING" section provides visual diagrams and descriptions for the correct routing of various cables and harnesses, including front and rear stop switch wires, brake cables, speedometer cable, throttle cable, ignition switch wiring, regulator/rectifier wiring, horn, winker, headlight wire connector, headlight resistor, auto bystarter resistor, battery cables, starter relay, CDI unit, fuel control valve (FCV), purge control valve/charcoal canister, fuel vapor recovery tube, fuel tube, ignition coil primary wire, ignition wire, vacuum tee, carburetor overflow tube, crankcase breather tube, and fuel unit. Correct routing is essential to prevent chafing, interference, and damage, ensuring reliable operation.

Finally, the "WIRING DIAGRAM" provides a comprehensive electrical schematic, using color codes (Red, Black, Orange, Pink, White, Brown, Green, Light Green, Violet, Light Blue, Blue, Gray, Yellow) to represent different wires, which is indispensable for electrical troubleshooting and repair.

The "TROUBLESHOOTING" section is extensive, covering common issues such as "ENGINE WILL NOT START OR IS HARD TO START," "ENGINE LACKS POWER," "POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)," "POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)," and "NO SPARK AT SPARK PLUG." Each troubleshooting guide follows a systematic flow, starting with an inspection/adjustment step and leading to probable causes, allowing technicians to logically narrow down and resolve problems.

Overall, this service manual is a comprehensive guide designed to facilitate the maintenance and repair of the KYMCO FILLY 50, emphasizing safety, precision, and efficiency through its structured content, detailed procedures, and troubleshooting aids.

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