KYMCO FILLY 50 Service Manual Download Page 21 | Manualshive

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1

. GENERAL INFORMATION

1-20

L Blue GR Gray

Y Yellow

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment

Probable Cause

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Summary of Contents for FILLY 50

Page 1: ...stem 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...

Page 2: ...AUTIONS 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...

Page 3: ...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 Co...

Page 4: ...th 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 remov...

Page 5: ...ing 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 b...

Page 6: ...e 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...

Page 7: ...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 respe...

Page 8: ...en 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...

Page 9: ...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...

Page 10: ...uctions 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 wil...

Page 11: ...e Apply grease for lubrication Gear Oil Transmission Gear Oil 90 Special Use special tool Caution Warning 12 3 Refer to page 12 3 TORQUE VALUES STANDARD TORQUE VALUES Item Torque kg m Item Torque kg m...

Page 12: ...or 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 8 8 30 6 8 5 6 8 10 28 6 6 10 10 6 6 0 9 0 9 1 5 3 5 2 0 0 9...

Page 13: ...er extension Ball race remover Spring compressor Spring compressor attachment Spring compressor attachment Spring compressor attachment Lock nut wrench Driver outer extension Float level gauge Valve s...

Page 14: ...engaging part Bearing movable part O ring face Oil seal lip Genuine KYMCO Engine Oil SAE10W 30 API SG Engine Oil Starter idle gear Friction spring movable part shaft movable part Shaft movable groove...

Page 15: ...Grease Engine Oil Grease Rear Brake Cable Main Stand Pivot Grease Speedometer Gear Front Wheel Bearings Brake Cam Anchor Pin Front Shock Absorber Lower Mount Bushings Pivot Brake Cam Anchor Pin Grease...

Page 16: ...1 GENERAL INFORMATION 1 15 Throttle Cable Speedometer Cable Headlight Wire Connector Ignition Switch Headlight Resistor Regulator Rectifier Auto Bystarter Resistor Horn Winker...

Page 17: ...1 GENERAL INFORMATION 1 16 Regulator Rectifier Wire Harness Headlight Resistor Auto Bystarter Resistor Throttle Cable Rear Brake Cable Speedometer Cable Front Brake Cable Starter Relay CDI Unit...

Page 18: ...1 GENERAL INFORMATION 1 17 Battery Cable Battery Cable Battery Cable Battery Cable Fuse Starter Relay...

Page 19: ...Vapor Recovery Tube Purge Control Valve Charcoal Canister Fuel Tube Ignition Coil Primary Wire Throttle Cable Ignition Wire Carburetor Overflow Tube Vacuum Tee Crankcase Breather Tube Fuel Unit Fuel...

Page 20: ...Br Brown G Green LG Light green V Violet SB Light blue FCV Fuel Control Valve Purge Control Valve Charcoal Canister Crankcase Breather Tube Auto Bystarter Starter Motor Wire Vacuum Tube Auto Bystarter...

Page 21: ...1 GENERAL INFORMATION 1 20 L Blue GR Gray Y Yellow TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause...

Page 22: ...ly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open ENGINE LACKS POWER Clogged air cleaner Poor quality fuel Restricted Clogged fuel tank cap breather hole...

Page 23: ...ion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Correct timing Incorrect timing Check ignition timing using...

Page 24: ...ulty ignition switch Faulty air cut off valve Damaged vacuum tube Clogged or damaged air vent hole POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Symptom Remove spark plug and install it into sp...

Page 25: ...ring Check valve timing Check carburetor jets for clogging Check fuel pump for fuel supply Correct timing Fuel flows freely Fuel flow restricted Correct Not weakened Weak spring Not clogged Clogged In...

Page 26: ...pler red wire and battery wire to engine ground and test voltage Symptom Probable Cause Inspection Adjustment Symptom Connect battery wire to regulator rectifier coupler green wire and battery wire to...

Page 27: ...Faulty CDI unit Faulty ignition coil Check CDI unit coupler for looseness Normal Abnormal Normal Abnormal Normal Abnormal Abnormal Measure resistance between CDI unit coupler wire terminals Check rel...

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