KYMCO FILLY LX 50 - User Manual

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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

FINAL REDUCTION 10

CRANKCASE/CRANKSHAFT 11

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

CHASSIS

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM 15

STARTING SYSTEM 16

ELECTRICAL

EQUIPMEN

LIGHTS/INSTRUMENTS/SWITCHES 17

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

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The device described in this manual is the KYMCO FilLy LX 50 scooter.

Function Description

The KYMCO FilLy LX 50 is a gasoline-powered, 4-stroke, single-cylinder scooter designed for personal transportation. It features an O.H.C. (Overhead Camshaft) engine with a displacement of 49.5cc, providing a maximum output of 2.208 kW at 8000 rpm and a maximum torque of 0.3 kgf·m at 6500 rpm. The scooter is equipped with both a starting motor and a kick starter for engine ignition.

The power drive system utilizes a dry multi-disc clutch and a two-stage reduction, non-stage automatic centrifugal transmission. Braking is handled by a 160mm disk brake at the front and a 110mm drum brake at the rear. The suspension system consists of a telescopic front fork and a unit swing rear suspension. Electrical equipment includes a 12V4AH battery, an A.C. generator, and a CDI (Capacitor Discharge Ignition) system.

Important Technical Specifications

General:

Motorcycle Name & Type: FilLy LX 50
Name & Model No.: SD10BB
Overall Length: 1720 mm
Overall Width: 625 mm
Overall Height: 1035 mm
Wheel Base: 1200 mm
Net Weight: 82 kg (Front: 34 kg, Rear: 48 kg)
Gross Weight: 85 kg (Front: 35 kg, Rear: 50 kg)
Ground Clearance: 110 mm
Min. Turning Radius: 1.8 m
Frame Type: Under Bone

Engine:

Engine Type: O.H.C., Gasoline, 4-stroke, Single cylinder
Displacement: 49.5 cc
Fuel Used: 92# nonleaded gasoline
Bore x Stroke: φ39.0 x 41.4 mm
Compression Ratio: 10.5
Compression Pressure: 14 kg/cm²
Max. Output: 2.208 kW / 8000 rpm
Max. Torque: 0.3 kgf·m / 6500 rpm
Valve Clearance (cold): IN: 0.04 mm, EX: 0.04 mm
Idle Speed: 1900 ± 100 rpm
Lubrication Type: Forced pressure & wet sump
Oil Pump Type: Inner/outer rotor type
Oil Filter Type: Full-flow filtration
Engine Oil Capacity: 0.85 liter (disassembly), 0.7 liter (change)
Cooling Type: Forced air cooling

Fuel System:

Air Cleaner Type: Paper element, wet
Fuel Capacity: 6.1 liter
Carburetor Type: CVK, Butterfly type
Venturi Dia.: φ17 equivalent
Main Jet: #85
Slow Jet: #35
Pilot Screw Opening: 2 ± 1/2 turns

Ignition System:

Type: CDI
Ignition Timing: BTDC 28° / 4000 rpm (at idle), BTDC 28° / 4000 rpm (full advance)
Contact Breaker: Non-contact point type
Spark Plug: NGK C7HSA
Spark Plug Gap: 0.6 – 0.7 mm
Ignition Coil Resistance (20°C): Primary: 0.1 – 1.0 Ω, Secondary (with plug cap): 7 – 12 KΩ, Secondary (without plug): 3 – 5 KΩ
Pulser Coil Resistance (20°C): 40 – 300 Ω

Electrical System:

Battery: 12V4AH
A.C. Generator: 0.144 kW / 5000 rpm
Lighting Coil Resistance (20°C): Yellow-Green: 0.1 – 1.0 Ω
Charging Coil Resistance (20°C): White-Green: 0.2 – 1.2 Ω
Regulator/Rectifier Limit Voltage: Lighting: 13.1 – 13.9 V / 5000 rpm, Charging: 14.5 ± 0.5 V / 5000 rpm

Chassis:

Tires: Front: 90/90-10 50J, Rear: 100/80-10 53J
Tire Pressure (cold): Front: 1.5 kg/cm² (1 rider), 1.75 kg/cm² (2 riders); Rear: 2.0 kg/cm² (1 rider), 2.25 kg/cm² (2 riders)
Brake System: Front: DISK (160mm), Rear: Drum (110mm)
Brake Free Play: Front: 10 – 20 mm, Rear: 10 – 20 mm
Brake Fluid: DOT-4
Front Brake Drum I.D. Service Limit: 111 mm
Front Brake Lining Thickness Service Limit: 2.0 mm
Rear Brake Drum I.D. Service Limit: 111 mm
Rear Brake Lining Thickness Service Limit: 2.0 mm
Suspension: Front: TELESCOPE, Rear: Unit Swing
Shock Absorber Distance: Front: 70 mm, Rear: 66 mm
Front Shock Absorber Spring Free Length Service Limit: 206.4 mm (Right), 206.4 mm (Left)
Rear Shock Absorber Spring Free Length Service Limit: 198 mm
Steering Angle: Left: 45°, Right: 45°
Caster Angle: 27°

Final Reduction Gear Oil:

Specified Oil: GEAR OIL SAE 90#
Capacity: 0.11 liter (disassembly), 0.10 liter (change)

Usage Features

The FilLy LX 50 is designed for ease of use, featuring an automatic centrifugal transmission that simplifies riding by eliminating manual gear shifting. The scooter's compact dimensions and light weight (82 kg net) contribute to its maneuverability in urban environments. Both electric and kick starters are provided for convenient engine ignition. The fuel pump is a vacuum-type, utilizing engine crankcase pulsations to deliver fuel to the carburetor, ensuring reliable fuel supply.

Maintenance Features

The manual emphasizes several key maintenance practices:

Periodic Maintenance: A detailed schedule outlines inspection, adjustment, cleaning, lubrication, and replacement intervals for various components, including engine oil, oil filter, fuel filter, spark plug, valve clearance, carburetor, air cleaner, brake system, drive belt, suspension, and steering head bearing.
Genuine Parts and Lubricants: The use of genuine KYMCO parts and specified lubricants (e.g., SAE15W-40 engine oil, API-SG engine oil, high-temperature resistant grease, SAE90# gear oil, DOT-4 brake fluid) is strongly recommended for optimal performance and durability.
Torque Values: Specific torque values are provided for critical fasteners to ensure proper assembly and prevent damage. Diagonal tightening is advised for multi-bolt components like cylinder heads.
Safety Precautions: Warnings are given regarding handling gasoline (flammable and explosive), working in well-ventilated areas to avoid carbon monoxide poisoning, and using special tools for removal and installation. Disconnecting the battery negative terminal before electrical work is crucial.
Cable and Harness Routing: Detailed instructions and illustrations are provided for proper routing of cables and wire harnesses to prevent interference with moving parts, sharp edges, or heat-generating components, ensuring longevity and safe operation.
Troubleshooting Guides: Flowcharts are included for common issues like "Engine Will Not Start or Is Hard To Start," "Engine Lacks Power," "Poor Performance (Especially at Idle and Low Speeds)," "Poor Performance (At High Speed)," "Poor Charging," and "No Spark at Spark Plug," guiding technicians through diagnostic steps.
Component-Specific Maintenance: The manual provides step-by-step procedures for disassembly, inspection, assembly, and installation of major systems, including engine, fuel system, lubrication system, electrical components, brakes, suspension, and frame covers. Service limits are specified for wear parts, indicating when replacement is necessary.
Exhaust Emission Control System: Maintenance for the evaporative/exhaust emission control system, including the secondary air cleaner, air injection cut-off valve, and reed valve, is detailed, with emphasis on proper function to minimize emissions and prevent issues like backfiring.