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KYMCO Vitality 50 Manual Download Page 1

VITALITY 50

PREFACE

This Service Manual describes the technical features and servicing
procedures for the KYMCO

VITALITY 50

.

In this manual, many illustrations and drawings are used to help
servicemen have better understanding.

Section 2 contains the service precautions for all operations and
troubleshooting stated in this manual. Read them carefully before starting
any operation.

Section 3 describes the inspection/adjustment procedures, safety rules and
service information for each part, starting from periodic maintenance.

Sections 4 through 17 give instructions for disassembly, assembly and
inspection of lubrication system, engine, fuel system and electrical
equipment.

Section 18 is the KYMCO clean air system (for EURO 2)

By KWANG YANG Motor Co., Ltd.

First Edition, May 2004

All rights reserved. Any reproduction or

unauthorized use without the written permission of

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

4121-LBD5/6-S00

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Summary of Contents for Vitality 50

Page 1: ...ing any operation Section 3 describes the inspection adjustment procedures safety rules and service information for each part starting from periodic maintenance Sections 4 through 17 give instructions for disassembly assembly and inspection of lubrication system engine fuel system and electrical equipment Section 18 is the KYMCO clean air system for EURO 2 By KWANG YANG Motor Co Ltd First Edition ...

Page 2: ...S 6 CYLINDER HEAD 2 STROKE CYLINDER PISTON 7 A C GENERATOR 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 9 FINAL REDUCTION 10 CRANKCASE CRANKSHAFT 11 CARBURETOR 12 FRAME COVERS EXHAUST MUFFLER 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 15 ELECTRICAL EQUIPMENT 16 INSTRUMENT SWITCHES LIGHTS 17 KCAS FOR EURO 2 18 1 ...

Page 3: ...lose Idle speed rpm 2000 100 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full flow filtration Lubrication oil capacity liter 1 3 Air cleaner type No Wet single Fuel capacity liter 5 0 Type PB Carburetor Piston dia mm Venturi dia mm 14 Ignition system type CDI electromagnetic Ignition Ignition timing F mark 13 5 2 3000rpm NGK BR8HSA Spark plug ND Spark plug gap mm 0 6 ...

Page 4: ... 1800rpm Lubrication type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 0 85 liter Oil exchanging capacity 0 7 liter Cooling Type Air cooling Air cleaner type No Wet paper Fuel capacity 5 0 liters Type CVK Main jet No 82 speed limited 80 Venturi dia mm φ17 Throttle type PISTON Type CDI Ignition timing 28 BTDC 4000rpm Contact breaker...

Page 5: ...__________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ MODEL IDENTIFICATION 2 1 SERVICE PRECAUTIONS 2 2 SERVICE INFORMATION 2 STROKE 2 6 SERVICE INFORMATION 4 STROKE 2 8 TORQUE VALUES 2 STROKE 2 10 TORQUE VALUES 4 STROKE 2 11 SPECIAL TOOLS 2 STROKE 2 12 SPECIAL TOOLS 4 STROKE ...

Page 6: ...AL INFORMATION 2 1 VITALITY 50 MODEL IDENTIFICATION The read serial frame number 2 please remove the cover on inner cover 1 with a flat head screwdriver The engine serial number is stamped on right engine case ...

Page 7: ... engine oil before reassembly Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface Aft...

Page 8: ...ng protruding or loose The connector shall be inserted completely If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for proper coverage...

Page 9: ...cted ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed ...

Page 10: ...d the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubri...

Page 11: ...r bore 39 0 39 025 39 05 Drive belt width 18 17 Drive pulley collar O D 19 96 19 974 19 94 Movable drive face ID 20 011 20 052 20 6 Weight roller O D 15 92 16 08 15 4 Clutch outer I D 107 107 2 107 5 Driven face spring free length 87 9 82 6 Driven face O D 33 965 33 985 33 94 Movable driven face I D 34 000 34 025 34 06 Connecting rod big end side clearance Connecting rod big end radial clearance C...

Page 12: ... rear 6 4 4 0 2 0 2 0 Brake disk runout Front rear 0 30 Rear shock absorber spring free length 209 ELECTRICAL EQUIPMENT VITALITY 50 Capacity 12V3AH Voltage 13 0 13 2V Charging Standard 0 4A 5H 10H Battery current Quick 4A 0 5H Spark plug NGK BR8HAS Spark plug gap 0 6 0 7mm Primary coil 0 153 0 187Ω Secondary coil with plug cap 6 99K 10 21KΩ Ignition coil resistance Secondary coil without plug cap ...

Page 13: ... I D 13 016 13 034 13 06 Cylinder bore 39 0 39 01 39 1 Drive belt width 18 17 Drive pulley collar O D 19 96 19 974 19 94 Movable drive face ID 20 011 20 052 20 6 Weight roller O D 15 92 16 08 15 4 Clutch outer I D 107 107 2 107 5 Driven face spring free length 95 90 Driven face O D 33 965 33 985 33 94 Movable driven face I D 34 000 34 025 34 06 Connecting rod small end free play 0 05 0 4 0 6 Conne...

Page 14: ...ckness Front rear 6 4 4 0 2 0 2 0 Brake disk runout Front rear 0 30 Rear shock absorber spring free length 209 ELECTRICAL EQUIPMENT VITALITY 50 4 stroke Capacity 12V4AH Voltage 13 0 13 2V Charging Standard 0 5A 5H 10H Battery current Quick 4A 0 5H Spark plug NGK C7HAS Spark plug gap 0 6 0 7mm Primary coil 0 5Ω Secondary coil with plug cap 8 12KΩ Ignition coil resistance Secondary coil without plug...

Page 15: ...ty Thread dia mm Torque kgf m Remarks Stud bolt Oil filter screen cap L cover Cam shaft holder Tappet ADJ nut Pivot tensioner bolt Lifter tensioner bolt Cam chain adjust bolt Mission case bolt Mission fill bolt Driver face nut Clutch outer nut Drive plate nut ACG flywheel nut Spark plug Mission drain plug Oil pump screw Head CYL stud bolt IN pipe Head CYL stud bolt EX pipe A C G Startor Fan 4 1 8 ...

Page 16: ...0 8 0 0 5 1 3 5 0 7 0 11 0 13 0 1 0 1 4 3 0 3 6 3 0 3 6 2 9 3 5 3 0 4 0 0 3 0 5 3 5 4 5 2 4 3 0 4 5 5 5 Flange bolt U nut Flange U nut Flange U nut Apply locking agent Flange bolt U nut Torque specifications listed above are for important fasteners Others should be tightened to standard torque values below STANDARD TORQUE VALUES SH bolt 8mm Flange 6mm bolt Item Torque kgf m Item Torque kg m 5mm bo...

Page 17: ...030 Oil seal bearing install E014 Clutch spring compressor E034 Crankcase assembly collar E023 Crankcase assembly tool E024 Universal holder E017 Flywheel puller E001 SPECIAL TOOLS 4 STROKE Tool Name Tool No Remarks Universal bearing puller E037 Lock nut socket wrench F001 Lock nut wrench F007 Race cone install F005 Oil seal bearing install E014 Clutch spring compressor E034 Universal holder E017 ...

Page 18: ...NGINE 4 STROKE 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 right side oil seal Crankshaft one way clutch movable part Oil pump drive chain Balan...

Page 19: ...ble parts not specified This will avoid abnormal noise and rise the durability of the motorcycle 1 Front Rear Brake Lever 2 Throttle Cable 3 Seat Lock 4 Rear Wheel Splines 5 Brake Cam Anchor Pin 6 Rear Brake Cable 7 Main Stand Pivot 8 Side Stand Pivot 9 Speedometer Gear Lower Mount Bushings Pivot ...

Page 20: ...2 GENERAL INFORMATION 2 15 VITALITY 50 WIRING DIAGRAM 2 STROKE ...

Page 21: ...2 GENERAL INFORMATION 2 16 VITALITY 50 WIRING DIAGRAM 4 STROKE ...

Page 22: ...ront Brake Fluid Tube Headlight Connector Front Stop Switch Wire Speedometer Cable Left Handlebar Switch Wire Horn Front Brake Fluid Tube Rear Brake Cable Throttle Cable Resistor Ignition Switch Instrument connectors Rear Brake Cable Throttle Cable Right Handlebar Switch Wire Rear Stop Switch Wire Winker Relay ...

Page 23: ...tle Cable Secondary Air Cleaner C D I Unit Oil Tank Oil Level Switch Start Relay Ignition Coil Ignition Coil Wire Spark Plug Wire Auto By Start Wire Oil Throttle Cable Rear Brake Cable Air Inlet Hose V belt Chamber Fuel Throttle Cable Fuel Vacuum Tube Overflow Tube Fuel Tube ...

Page 24: ...el Unit Connector Oil Tank Fuse Box Regulator Rectifier Resistor Headlight Connector Instrument Connectors Ignition Switch Connector Oil Throttle Cable Fuel Throttle Cable Auto By Start Fuel Strainer Start Relay Oil Level Switch Connector Wire Harness Speedometer Cable Battery Cable Battery Cable Oil Throttle Cable ...

Page 25: ...ss Oil Throttle Cable Fuel Unit C D I Unit Auto By Start Ignition Coil Battery Battery Cable Battery Cable Fuse Box A C G Connector Auto By Start Connector Spark Plug Cap Oil Tube Fuel Throttle Cable Secondary Air Hose Secondary Air Cleaner Oil Level Switch Air Inlet Hose V belt Chamber ...

Page 26: ...ront Brake Fluid Tube Headlight Connector Front Stop Switch Wire Speedometer Cable Left Handlebar Switch Wire Horn Front Brake Fluid Tube Rear Brake Cable Throttle Cable Resistor Ignition Switch Instrument connectors Rear Brake Cable Throttle Cable Right Handlebar Switch Wire Rear Stop Switch Wire Winker Relay ...

Page 27: ...Y 50 Rear Brake Cable Air Inlet Hose V belt Chamber Rear Brake Cable Wire Harness Throttle Cable Ignition Coil Wire Ignition Coil Auto By Start Wire A C G Wire Start Motor Wire Fuel Tube Throttle Cable C D I Unit Crankcase Breather Tube ...

Page 28: ...ent Connectors Ignition Switch Connector Wire Harness Battery Cable Battery Cable Fuel Connector Fuel Unit Taillight Connector C D I Fuse Box Crankcase Breather Tube Fuel Tube Ignition Coil Secondary Air Cleaner Throttle Cable Spark Plug Cap Fuel Strainer Starter Relay Auto By Starter A C G Start Motor Connectors ...

Page 29: ...ire Throttle Cable Secondary Air Cleaner Ignition Coil Vacuum Tube A Vacuum Tube B Vacuum Tube C Crankcase Breather Tube Auto By Starter C D I Unit Fuel Strainer Fuel Unit Starter Relay Spark Plug Cap Air Inlet Hose V belt Chamber Auto By Starter A C G Start Motor Wires Battery Cable Battery Cable ...

Page 30: ...ignition timing Flooded carburetor Throttle valve excessively open Faulty auto bystarter Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment Symptom Probable Cause Fuel reaches carburetor Spark jumps Dry spark plug Not clogged Normal compression Engine does not fire Fuel...

Page 31: ... out Mixture too lean turn screw in Check if fuel reaches carburetor by loosening drain screw Inspection Adjustment Symptom Probable Cause Fuel reaches carburetor Good spark Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Correct timing Correctly adjusted Plug not fouled or discolored Normal compression Not Clogged Fuel does not reach carburetor...

Page 32: ...tarter Faulty auto bystarter Inspection Adjustment Symptom Probable Cause No air leak Not clogged Clogged Air leaks Clogged Not Clogged Check carburetor gasket for air leaks Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Remove auto bystarter connecting wire and check if bypass fuel line is clogged ...

Page 33: ...on chamber Poor quality fuel Clutch slipping Mixture too lean Inspection Adjustment Symptom Probable Cause Engine speed increases Engine overheats Correct timing Engine does not knock Plug not fouled or discolored Normal compression Not Clogged Engine speed does not increase sufficiently Engine does not overheats Incorrect timing Engine knocks Plug fouled or discolored Abnormal compression Clogged...

Page 34: ...Faulty auto bystarter Inspection Adjustment Symptom Probable Cause Clogged Not clogged Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Check ignition timing Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Remove auto bystarter connecting wire and check if b...

Page 35: ...nspection Adjustment Symptom Probable Cause Clogged Not clogged Check ignition timing Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Remove auto bystarter connecting wire and check if bypass fuel line is clogged Check carburetor jets for clogging Check auto fuel valve for fuel supply Correct timing Incorrect...

Page 36: ... fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Front and rear tire pressures are normal Steering stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim Loose axle nut Misaligned front and rear wheels Engine starts but motor cycle does not move Engine lacks power at start of a ...

Page 37: ...s Worn brake cam Worn brake drum Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Sluggish or elongated brake cables Brake shoes improperly contact brake drum Water and mud in brake system Oil or grease on brake linings Faulty brake master cylinder Faulty brake caliper Oil or grease on brake disk Deformed brake disk Leaking brake fluid tube Suspension is too soft...

Page 38: ...nnected wire Faulty float Broken or shorted wire in meter Damaged oil tank Foreign matters in oil tank Inspection Adjustment Symptom Inspection Adjustment Probable Cause Symptom Probable Cause Signals operate properly Signals dim remain on or don t operate Bulb lights Bulb does not light Good Faulty Remove oil meter and check operation of indicator light by moving float Check connectors for proper...

Page 39: ...tom Signals operate properly Signals operate properly Signals dim remain on or don t operate Signals dim remain on or don t operate Pointer does not move Pointer does not move Good Good Pointer moves Pointer moves Pointer moves Pointer does not move in accord ance with float Faulty Faulty Pointer does not move Pointer moves in accordance with float Probable Cause Probable Cause Remove fuel unit an...

Page 40: ...ion Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Signals operate properly Signals operate properly Signals dim remain on or don t operate Signals dim remain on or don t operate Stoplight does not come on Starter motor turns Turns easily Not stopped Stoplight comes on Starter does not turn Hard to turn Stopped Relay operates properly Starter motor turns ...

Page 41: ...ct Worn cylinder piston and piston rings Leaking cylinder head gasket Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it into spark plug ca...

Page 42: ...Ignition timing too early Excessive carbon build up in combustion chamber Poor quality fuel Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause Engine speed increases Correct timing Engine speed does not increase sufficiently Incorrect timing Check ignition timing using a timing light Test cylinder compression Check carburetor for clogging Rapidly accel...

Page 43: ...ed spark plug Faulty CDI unit Faulty A C generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch Faulty air cut off valve Damaged vacuum tube Clogged or damaged air vent hole Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment Symptom Probable Cause Check ignition timing Check air cut off valve C...

Page 44: ...e Faulty auto fuel valve Clean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel supply Correct timing Incorrect timing Check valve spring tension Fuel flows freely Fuel flow restricted Correct Incorrect Not clogged Clogged Correctly adjusted Incorrectly ...

Page 45: ...ectifier coupler red wire and battery wire to engine ground and test voltage Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Battery has voltage with ignition switch ON Normal Voltage does not increase Battery has no voltage with ignition switch ON Resistance too high Normal voltage No voltage Measure resistance between AC generator coil ter...

Page 46: ...ty CDI unit Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Normal Normal Abnormal Normal Abnormal Abnormal Measure resistance between terminals of CDI unit coupler Check related parts Check ignition coil with the CDI unit tester Weak or no spark Not loose Good spark Loose Normal Abnormal Check spark plug cap ...

Page 47: ...2 GENERAL INFORMATION 2 42 VITALITY 50 Faulty ignition coil ...

Page 48: ...__________________________________ __________________________________________________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ MAINTENANCE SCHEDULE 3 1 BRAKE SYSTEM 3 2 MOVING DEVICE 3 4 DAMPING DEVICE 3 5 TRANSMISSION GEAR OIL 3 5 LUBRICATION SYSTEM 2 STROKE 3 6 ENGINE OIL 4 STROKE 3 8 ENGINE IDLE SPEE...

Page 49: ...ote 4 A A A Carburetor I I Air Cleaner Note 2 3 I R I R I Spark plug Clean at every 2000km and replace if necessary Brake system I I I I I I Drive belt I Suspension I I Nut bolt fastener T T I Tire I I Steering head bearing I I I Brake fluid Perform pre ride inspection daily Brake lever I I Brake shoe wear I I Shock absorber I I In the interest of safety we recommend these items be serviced only b...

Page 50: ... free play is incorrect adjust as follows Place the scooter on its center stand Turn the adjusting nut in direction A to decrease play and in direction B to increase play Turn the adjusting nut on the brake hub in direction A to decrease play and in direction B to increase play Make sure the cut out on the adjusting nut 2 is seated on the brake arm pin 1 after making final free play adjustment ...

Page 51: ...oise and brake drum inside for wear or damage BRAKE DISK LINING Brake Disk Surface and Brake Pad Wear Check the brake disk surface for scratch Check if the brake pad wear is within the specified service limit Brake Disk Runout Inspection Jack the scooter wheels off the ground and check if the brake disk runout is within the specified service limit BRAKE FLUID LEVEL INSPECTION Brake Master Cylinder...

Page 52: ...0 12 Rear 130 70 12 Axle Nut Axle Shaft Looseness Check the front 1 and rear axle 2 nuts for looseness If the axle nuts are loose tighten them to the specified torques Torque Front 5 0 7 0kgf m Rear 11 0 13 0kgf m Wheel Rim Spoke Plate Damage Check the wheel rim and spoke plate for wear or damage and measure the rim runout Tire pressure should be checked when tires are cold ...

Page 53: ...hock absorber assembly for looseness or damage TRANSMISSION GEAR OIL TRANSMISSION OIL MRASUREMENT 1 Place the scooter on its main stand on level ground After the engine stops for 2 3 minutes 2 Remove the oil filler bolt 1 and check the oil level 2 It should be up to the brim of the hole If the level is low add oil to raise it to the proper level 3 After refilling securely tighten the bolt 1 Torque...

Page 54: ...eck for the cause LUBRICATION SYSTEM 2 STROKE Oil Filter Cleaning Remove Met in box 13 5 Spark plug cover 13 5 Center cover 13 6 Disconnect the oil tube from the oil pump side and allow oil to drain into a clean container Remove the tube clip from the oil tank side and disconnect the oil tube Remove the oil filter 4 Stroke Add gear oil through the oil check bolt hole 2 After refilling use a rag to...

Page 55: ...djustment is necessary adjust the oil pump control cable by loosening the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut If the oil pump is not synchronized properly the following will occur Excessive white smoke or hard starting due to pump control lever excessively open Seized piston due to pump control lever insufficiently open Filter Screen Connect t...

Page 56: ...REPLACEMENT Place the scooter on a level place Warm up the engine for several minutes and stop it Place a container under the engine Remove the oil filler cap 1 and drain plug 2 to drain the oil Reinstall the drain plug and tighten the drain plug to specification Torque 2 0 3 0kgf m Fill the engine with oil and install the oil filler cap Warm up the engine for several minutes at idle speed Check f...

Page 57: ...e O ring and replace if damaged G Reinstall the O ring oil strainer compression spring and drain plug Tighten the drain plug to specification Torque 1 0 2 0kgf m Oil Capacity At disassembly 0 85L At change 0 7L Be sure no foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts Before reinstall...

Page 58: ... Stroke 1850 100rpm Adjust the idle speed to the specified range by turning the throttle stop screw and pilot screw Idle Speed 4 Stroke 1800 100rpm AIR CLEANER Air Cleaner 2 Stroke Remove the air cleaner cover by removing the 7 air cleaner cover screws and air cleaner housing cover 1 2 Stroke 4 Stroke Pilot Screw Throttle Stop Screw The engine must be warm for accurate idle speed adjustment ...

Page 59: ... to dry After washing soak the element in clean engine oil SAE 15W 40 and squeeze out excess oil Reinstall the element Air Cleaner 4 Stroke 1 Remove the air filter case cover by removing the 6 screws Soak in oil Squeeze out and dry Wash Squeeze out excess oil dry Never use gasoline or organic vaporable oil with acid or alkali for washing ...

Page 60: ...ry 4000km 5 For installation reverse the removal procedures Never use oil or solvent to wash the wet type paper element Be careful not to allow water to enter the air cleaner otherwise it may result in hard starting If the air cleaner is not installed properly dust may be sucked into the cylinder directly to reduce engine horsepower and affect the engine life ...

Page 61: ...ush the starter button for 7 8 seconds to test the compression Compression 2 Stroke 11 8kg cm 4 Stroke 14kg cm If the compression is low check for the following Leaking cylinder head gasket Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head Warm up the engine before compression test ...

Page 62: ...he round hole on the cam sprocket are facing down turn the crankshaft clockwise one full turn and realign the timing marks with the cylinder head surface so it is facing up Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm If the clearance is out of specification bring it into the specified range Valve Clearance IN 0 04mm EX 0 04mm Loosen the lock nut an...

Page 63: ...an cover 8 3 Remove the four bolts from the fan and then remove the fan 8 3 Warm up the engine and check the ignition timing with a timing light When the engine is running at the specified rpm the ignition timing is correct if the F mark on the flywheel aligns with the index mark on the crankcase within 2 Ignition Timing 2 stroke 13 5 2 3000rpm 4 stroke 28 2 4000rpm Gap Wear and Fouling Deposits W...

Page 64: ... free play Free Play 2 6mm If the throttle grip free play does not fall within the specified range adjust by loosening the lock nut 1 and turning the adjusting nut 2 OTHERS LIGHTS Headlight Turn on the headlight switch Adjust the headlight beam by turning the headlight beam adjusting screw 1 ...

Page 65: ...__________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION 2 STROKE 4 3 SERVICE INFORMATION 4 STROKE 4 4 OIL PUMP 2 STROKE 4 5 OIL TANK 2 STROKE...

Page 66: ...4 LUBRICATION SYSTEM 4 1 VITALITY 50 LUBRICATION SYSTEM 2 STROKE ...

Page 67: ...4 LUBRICATION SYSTEM 4 2 VITALITY 50 4 STROKE Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft ...

Page 68: ... before connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20 2 stroke Motor Oil Oil Capacity 1 3 liter Light comes on 0 5 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged o...

Page 69: ...must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm Inner rotor to outer rotor clearance 0 15 0 20 Oil pump Outer rotor to pump body clearance 0 15 0 20 0 25 Rotor end to pump body clearance 0 04 0 09 0 12 TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil con...

Page 70: ...p 2 from the crankcase INSPECTION Remove the oil pump and inspect the following items Weakened O ring 1 Damage to crankcase mating surface Damage to pump body Control lever operation 2 Oil leaks through oil seals Worn or damaged pump pinion 3 Do not allow foreign matters to enter the crankcase Before removing the oil pump clean the oil pump and crankcase surfaces Do not disassemble the oil pump wh...

Page 71: ...and tighten the two bolts Connect the oil inlet line 1 and oil outlet line 2 properly Connect the oil pump control cable 3 Bleed air from the oil pump Lubricate the O ring 1 with grease or engine oil before installation Make sure that the oil pump is inserted into the crankcase Apply molybdenum disulfide or grease to the pump pinion ...

Page 72: ...rce air out of the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump Air in the oil lines will block oil flow and result in severe engine damage Bleed air from the oil lines and oil pump whenever the oil ...

Page 73: ...two bolts from the oil tank Disconnect the oil inlet line 2 Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal Connect the oil line properly Bleed air from the oil pump after installation The oil tube clip at the oil tank side must be locked from inside of the oil tube joint ...

Page 74: ...cement and oil filter cleaning OIL PUMP 4 STROKE REMOVAL Place a container under the engine Remove the drain plug to drain the oil 3 8 Remove the A C generator flywheel 8 3 Remove the A C generator stator and pulsar coil 8 3 Remove the eight right crankcase cover bolts and the right crankcase cover Remove the oil pump gear nut and oil pump gear Oil Pump Gear Nut Bolts Right Crankcase Cover ...

Page 75: ...4 LUBRICATION SYSTEM 4 10 VITALITY 50 Remove three oil pump mounting bolts and the oil pump Remove O rings and dowel pin Bolts Oil Pump O rings Dowel Pin ...

Page 76: ...otor Pump Body Outer Rotor Inner Rotor DISASSEMBLY Remove the screws and disassemble the oil pump INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 25mm Measure the inner rotor to outer rotor clearance Service Limit 0 2mm Screws ...

Page 77: ...the outer rotor inner rotor and pump shaft into the pump body Install the dowel pin Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor ...

Page 78: ...O rings and dowel pin Install the oil pump and tighten the bolts Make sure that the pump shaft rotates freely without binding Install the oil pump gear and tighten the nut Bolts Oil Pump O rings Dowel Pin Inspect the O rings and replace if damaged Oil Pump Gear Nut ...

Page 79: ...4 LUBRICATION SYSTEM 4 14 VITALITY 50 Install the right crankcase cover and tighten the bolts Right Crankcase Cover Bolts ...

Page 80: ...____________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION 5 1 ENGINE REMOVAL 2 STROKE 5 2 ENGINE INSTALLATION 2 STROKE 5 5 E...

Page 81: ...50 SERVICE INFORMATION GENERAL INSTRUCTIONS Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Engine hanger bracket bolt 4 5 5 5kg m ...

Page 82: ...tor and starter motor wire connector 2 Loosen the band screw 1 and remove the two mounting bolts 2 then remove air cleaner housing Slide the rubber sleeve up to expose the carburetor Disconnect the fuel tube 2 from the carburetor Disconnect the fuel vacuum tube from the intake manifold 3 Loosen the carburetor top 1 Remove the carburetor top and throttle valve from the carburetor 12 3 After the oil...

Page 83: ... crankcase Remove the cooling air tube band 6 from the left crankcase cover and disconnect the cooling air tube Remove the rear shock absorber lower mounting bolt 5 Remove the secondary air hose band 1 from the exhaust muffler and disconnect the secondary air hose Remove the right and left engine mounting nuts 1 Take out the right and left engine mounting bolts ...

Page 84: ...he frame forward to separate it from the engine and be careful not to damage the rear fender ENGINE HANGERBRACKET REMOVAL Remove the engine hanger bracket bolts and engine hanger bracket The installation sequence is the reserve of removal Torque 4 5 5 5kg m Engine Hanger Bracket Bolt ...

Page 85: ...TION Install the engine in the reverse order of removal Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Perform the following inspections and adjustments after installation Throttle cable Oil pump control cable 3 7 Rear brake cable 3 2 Oil pump bleeding 4 7 Bushings Engine Hanger Stopper Rubbers Cables and wires should be routed properly ...

Page 86: ...ire connector Remove the spark plug cap Disconnect the secondary air apply hose and crankcase breather hose Disconnect vacuum tube Loosen the air cleaner connecting tube band screw and intake manifold band screw A C Generator Wire Starter Motor Wire Auto Bystarter Wire Spark Plug Cap Crankcase Breather Hose Secondary Air Apply Hose Vacuum Tube Band Screw Band Screw ...

Page 87: ...VITALITY 50 Remove the bolts from air cleaner housing Release the wire band auto bystarter A C generator starter motor wire Remove the carburetor Remove rear brake adjusting nut arm pin and spring Bolts Wire Band Spring Arm Pin Arm Pin ...

Page 88: ...e rear brake cable from the transmission cover Remove the rear shock absorber lower mount bolt Disconnect the inlet hose Remove the right and left engine mounting nuts Take out the right and left engine mounting bolts Rear Brake Cable Bolt Inlet Hose Bolts Nuts ...

Page 89: ...orward to separate it from the engine and be careful not to damage the rear fender ENGINE HANGERBRACKET REMOVAL Remove the engine hanger bracket nuts Remove the engine hanger bracket bolts and engine hanger bracket The installation sequence is the reserve of removal Torque 4 5 5 5kg m Nut Bolts ...

Page 90: ... with new ones if necessary ENGINE INSTALLATION Install the engine in the reverse order of removal Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Perform the following inspections and adjustments after installation Rear brake cable 3 2 Cables and wires should be routed properly Bushings Bushings ...

Page 91: ...ES 6 0 VITALITY 50 6 __________________________________________________________________________________ 4 STROKE CYLINDER HEAD VALVES SERVICE INFORMATION 6 2 CYLINDER HEAD COVER 6 4 CAMSHAFT CAMSHAFT HOLDER 6 4 CYLINDER HEAD 6 10 6 ...

Page 92: ...6 4 STROKE CYLINDER HEAD VALVES 6 1 VITALITY 50 ...

Page 93: ...r head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Item Standard mm Service Limit mm IN 0 04 EX 0 04 Cylinder head compression pressure 14 2kg cm Cylinder head warpage 0 05 IN 25 761 25 65 EX 25 563 25 45 Valve rocker...

Page 94: ...ce at idle speed White smoke from exhaust muffler Compression too low Worn valve stem or valve guide Damaged valve stem seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve spring Broken valve spring Damaged or worn camshaft Poor valve and seat contact Worn cam c...

Page 95: ...hen remove the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and gasket Install the cylinder head cover Install and tighten the cylinder head cover bolts and nuts Torque 0 8Д1 2kgf m CAMSHAFT CAMSHAFT HOLDER REMOVAL Remove the cylinder head cover Refer to the CYLINDER HEAD COVER REMOVAL Remove the cam chain tensioner cap spring Remove two bolts and cam chain tensioner C...

Page 96: ...index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Remove the four camshaft holder nuts and washers Remove the camshaft holder and dowel pins Round Hole Time Marks Nuts Washers Camshaft Holder Diagonally loosen the cylinder head nuts in 2 or 3 times Ϡ ...

Page 97: ... a 5mm bolt Remove the valve rocker arms and arm shafts CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder for wear or damage Inspect the rocker arm shaft for blue discoloration or grooves If any defects are found replace the rocker arm shaft with a new one then inspect lubrication system Camshaft Rocker Arms Rocker Arm Shafts Camshaft Holder Rocker Arm Shafts Rocker Arm Rocker Arm ...

Page 98: ...ew one then inspect lubrication system Measure each rocker arm shaft O D Measure the I D of each valve rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 10mm CAMSHAFT HOLDER ASSEMBLY Reverse the CAMSHAFT HOLDER DISASSEMBLY procedures Rocker Arm Bore Contact Surface Adjuster Surface Align the cross cutout on the exhaust valve rocker arm shaft with t...

Page 99: ... defects are found replace the camshaft with a new one then inspect lubrication system INSTALLATION Reverse the CAMSHAFT REMOVAL procedures Note the following points 1 Turn the flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase Keep the round hole on the camshaft gear facing up and align the index marks on the camshaft gear with the cylinder head surface Positi...

Page 100: ...nstall spring and tensioner cap then tighten the tensioner cap 3 Adjust the valve clearance Refer to the VALVE CLEARANCE section in the chapter 3 Nuts Washers Apply engine oil to the threads of the cylinder head nuts Diagonally tighten the cylinder head nuts in 2Д3 times Position the camshaft holder EX mark on the exhaust valve side Ϡ Tensioner Key Bolts Spring Tensioner Cap Check one way cam oper...

Page 101: ...tion in the chapter 12 Remove the exhaust muffler Refer to the EXHAUST MUFFLER REMOVE section in the chapter 13 Remove the two nuts and then remove the carburetor intake manifold and insulator Remove the cooling fan cover 8 3 Remove the engine cover bolts and screws Separate the engine cover joint claws Remove seal shroud then remove two bolts and cylinder head Nuts Intake Manifold Seal Shroud Bol...

Page 102: ...btract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Service limits IN 0 06mm replace if over EX 0 08mm replace if over CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over Valve Cotter Retainer Springs Springs...

Page 103: ...and outer valve springs Service Limit Inner 28 4mm replace if below Outer 31 5mm replace if below Measure compressed force valve spring and installed length Replace if out of specification Service limits IN 5Д6kg at 20 45mm EX 9 5Д11 5kg at 23 5mm Check the intake manifold and O rings for wear or damage O ring ...

Page 104: ...nd retainers Compress the valve springs using the valve spring compressor then install the valve cotters Valve Spring Compressor E040 Tap the valve stems gently with a plastic hammer for 2Д3 times to firmly seat the cotters O ring When assembling a valve spring compressor must be used Install the cotters with the pointed ends facing down from the upper side of the cylinder head Ϡ Special Be sure t...

Page 105: ...OKE CYLINDER HEAD VALVES 6 14 VITALITY 50 INSTALLATION Install the dowel pins and a new cylinder head gasket Reverse the CYLINDER HEAD REMOVAL procedures Torque Cylinder head bolt 0 8Д1 2kgf m Gasket Dowel Pin ...

Page 106: ..._________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD 2 STROKE CYLINDER PISTON __________________________________________________________________________________ SERVICE INFORMATION 2 STROKE 7 3 SERVICE INFORMATION 4 STROKE 7 4 CYLINDER HEA...

Page 107: ...7 CYLINDER HEAD 2 STROKE CYLINDER PISTON 7 1 VITALITY 50 2 STROKE Torque 1 0 1 2kg m Torque 1 1 1 7kg m cold ...

Page 108: ...7 CYLINDER HEAD 2 STROKE CYLINDER PISTON 7 2 VITALITY 50 4 STROKE ...

Page 109: ... Cylinder to piston clearance 0 10 Piston pin hole I D 12 002 12 008 12 03 Piston pin O D 11 994 12 0 11 98 Piston to piston pin clearance 0 03 Piston ring end gap top second 0 10 0 25 0 40 Connecting rod small end I D 17 005 17 017 17 03 Cylinder bore 39 0 39 025 39 05 TORQUE VALUES Cylinder head bolt 1 0 1 2kg m Exhaust muffler joint lock nut 1 0 1 4kg m Exhaust muffler lock bolt 3 0 3 6kg m Spa...

Page 110: ... Piston Ring end gap Second 0 3 0 45 0 65 piston ring Oil ring 0 2 0 7 0 9 Piston O D 38 975 38 99 38 9 Piston O D measuring position 4 5mm from bottom of skirt Piston to cylinder clearance 0 010 0 040 0 1 Piston pin hole I D 13 002 13 008 13 04 Piston pin O D 12 994 13 000 12 96 Piston to piston pin clearance 0 002 0 014 0 02 Connecting rod small end I D bore 13 016 13 034 13 06 TROUBLESHOOTING W...

Page 111: ... the fan cover 8 3 Remove the exhaust muffler 13 10 Remove the bolt from the engine hood then remove the engine hood Remove the spark plug Remove the cylinder head bolts and the cylinder head Remove the cylinder head gasket Cylinder head Bolts Spark Plug Cap Fan Cover Engine Hood Bolts Cylinder Head Spark Plug Loosen the bolts diagonally in 2 or 3 times ...

Page 112: ...ead for warpage with a straight edge and feeler gauge Service Limit 0 10mm replace if over CYLINDER HEAD INSTALLATION Install a new cylinder head gasket onto the cylinder Install the cylinder head on the cylinder properly Avoid damaging the combustion chamber wall and cylinder mating surface Be careful not to damage the mating surfaces Cylinder head Gasket Combustion Chamber Mating Surface ...

Page 113: ...rque 1 0 1 2kg m Install the spark plug Torque 1 1 1 7kg m Engine Hood Installation Install the engine hood 7 5 Install the spark plug cap 7 5 Remove the exhaust muffler 13 10 Perform the following inspections after installation Compression test Abnormal engine noise Cylinder air leaks Cylinder head Bolts Bolts Bolt Cylinder Head Spark Plug Spark Plug Engine Hood ...

Page 114: ...emove the piston pin and piston Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander Piston Pin Clip Piston Piston Pin Cylinder Do not pry between the cylinder and crankcase or strike the fins Do not damage or scratch the piston Do not apply side force to the connecting rod when removing the piston pin Place clean shop towels in the crankcase to ...

Page 115: ...om the exhaust port area Measure the cylinder bore at three levels of A B and C in both X and Y directions Avoid the port area Take the maximum figure measured to determine the cylinder bore Service Limit 39 05mm replace if over Inspect the top of the cylinder for warpage Service Limit 0 10mm replace if over Be careful not to damage the cylinder inside wall ...

Page 116: ...learance Service Limit 0 10mm replace if over Measure the piston pin hole I D Service Limit 12 03mm replace if over Measure the piston pin O D Service Limit 11 98mm replace if below Measure the piston to piston pin clearance Service Limit 0 03mm replace if over The cylinder has a A mark or no mark on it When replacing the cylinder with a new one use a cylinder having the same mark as the old one A...

Page 117: ...r PISTON CYLINDER INSTALLATION First install the expander in the second ring groove Then install the top and second rings in their respective ring grooves The piston rings should be pressed into the grooves with even force After installation check and make sure that each ring is flush with the piston at several points around the ring A ring that will not compress means that the ring groove has car...

Page 118: ...in the ring grooves Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Install the cylinder head Torque 1 0 1 2kg m Install the exhaust muffler and tighten the exhaust muffler joint lock nuts Torque 1 0 1 4kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m Cylinder Gasket Ring Pins Be careful not to...

Page 119: ...Refer to the chapter 6 Remove the two dowel pins and cylinder head gasket Remove cam chain guide and then remove cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface Cam Chain Guide Dowel Pins Dowel Pin Gasket Be careful not to drop foreign matters into the crankcase ...

Page 120: ... grooves Inspect the piston wall for wear scratches damage If any defects are found replace the piston with a new one Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Piston Clip Piston Pin...

Page 121: ...m Measure the piston ring end gap Service Limit Top 0 5mm replace if over 2nd 0 65mm replace if over Oil ring 0 9mm replace if over Measure the piston pin hole I D Service Limit 13 04mm replace if over Measure the piston pin O D Service Limit 12 96mm replace if below Use the piston head to push each piston ring into the cylinder 20mm ...

Page 122: ...in both X and Y directions Cylinder I D Service Limit 39 1mm replace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels is subject to the maximum value calculated Service Limits True Roundness ...

Page 123: ...cting rod small end I D Service Limit 13 06mm replace if over Measure the connecting rod to piston pin clearance Service Limit 0 06mm replace if over Second Side Rail Top Side Rail Oil Ring Be careful not to damage or break the piston and piston rings All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking ...

Page 124: ...at the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Intake Side Guide Exhaust Side Guide Apply proper clean engine oil around cylinder wall Be careful not to damage or break the piston rings Stagger the ring end gaps at 120 to the piston pin Be careful not to drop foreign matters into the crankcase Position...

Page 125: ..._____ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A C GENERATOR __________________________________________________________________________________ SERVICE INFORMATION 8 2 A C GENERATOR 8 3 8 ...

Page 126: ...8 A C GENERATOR 8 1 VITALITY 50 Torque 3 5 4 0kg m Torque 0 8 1 2kg m Torque 0 6 1 0kg m Torque 0 8 1 2kg m ...

Page 127: ...ON GENERAL INSTRUCTIONS All A C generator maintenance and inspection can be made with the engine installed Refer to Section 16 for A C generator inspection TORQUE VALUE Flywheel nut 3 5 4 0kg m SPECIAL TOOLS Flywheel puller E001 Universal holder E017 ...

Page 128: ...4 Remove the three bolts attaching the fan cover to remove the fan cover Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the 10mm flywheel nut Universal holder E017 Fan Cover Bolts Bolt Nut Universal Holder Cooling Fan Special ...

Page 129: ...connector Remove the two pulser coil bolts and pulser coil from the right crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator Be careful not to damage the disconnected wire Lock Nut Wrench A C Generator Wire Connector Stator Flywheel Puller Pulser Coil Wire Clamp Special ...

Page 130: ...heel off any burrs and dirt Install the woodruff key in the crankshaft keyway Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the 10mm flywheel flange nut Torque 3 5 4 0kg m Start the engine and check the ignition timing 3 14 or 3 15 Universal holder E017 A C Generator Wire Connector ...

Page 131: ...________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 KICK STARTER 9 3 DR...

Page 132: ...9 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 9 1 VITALITY 50 Torque 3 5 4 5kg m Torque 5 0 6 0kg m Torque 3 5 4 0kg m ...

Page 133: ...roke Driven face spring free length 95 4 stroke 90 4 stroke Driven face O D 33 965 33 985 33 94 Movable driven face I D 34 0 34 25 34 06 Drive belt width 18 17 TORQUE VALUES Drive face nut 3 5 4 0kg m Clutch outer nut 3 5 4 5kg m Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Universal holder E017 Clutch spring compressor E034 TROUBLESHOOTING Poor performance at high speed or Engine starts but m...

Page 134: ...ver bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Left Crankcase Cover Bolt ...

Page 135: ...NSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Kick Starter Spindle Return Spring Spindle Plastic Bushing Spindle Bushing Return Spring Friction Spring Kick Starter Dri...

Page 136: ... and return spring onto the left crankcase cover Properly install the kick starter driven gear and friction spring as the figure shown If the hooks of the return spring can not be installed properly use a screw driver to press them into their locations respectively Kick Starter Spindle Forcing Part Kick Starter Driven Gear Forcing Part Friction Spring Kick Starter Spindle Friction Spring Kick Star...

Page 137: ...LLATION First install the dowel pins and then the seal gasket Install the left crankcase cover and tighten the ten bolts diagonally Connect the drive belt cooling air tube and install the circlip Left Crankcase Cover Rear Brake Cable Clamp Seal Gasket Dowel Pins Washer Circlip For drum brake note the location of the brake cable clamp and install the rear brake cable in place with the clamp ...

Page 138: ...LACEMENT Remove the ten left crankcase cover bolts and left crankcase cover 9 3 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut and clutch outer Universal holder E017 Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet Remove the drive pulley face Use specified genuine parts for replacement Clutch Outer Drive Fac...

Page 139: ...ll a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and 12mm drive face nut then tighten the drive face nut Torque 3 5 4 0kg m Clutch Driven Pulley Drive Belt Drive Belt Drive Pulley Face Drive Belt Starting Ratchet Drive Face Nut When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet al...

Page 140: ...lder and remove the 12mm drive face nut Remove the starting ratchet and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove the ramp plate Movable Drive Face Ramp Plate Drive Pulley Collar 12mm Drive Face Nut Starting Ratchet Drive Pulley Face ...

Page 141: ...s MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 15 4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Weight Roller Movable Drive Face Drive Pulley Collar ...

Page 142: ...lley 9 9 Remove the starter pinion INSPECTION Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Keep grease or oil off the drive belt and drive pulley faces Drive ...

Page 143: ...e the clutch outer Universal holder E017 Remove the clutch driven pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS ASSEMBLY Compress the clutch driven pulley spring with the clutch spring compressor and remove the 39mm drive plate nut Remove the driven face spring Universal holder E034 Clutch Driven Pulley Universal Holder Clutch Outer 14mm Clutch Outer Nut Speci...

Page 144: ...e guide roller pins from the driven pulley and then remove the O rings and oil seal from the driven pulley CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 107 5mm replace if below Seal Collar O rings Guide Roller Pin Driven Pulley ...

Page 145: ...f below Measure the driven face spring free length Service Limit 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for stepped wear ...

Page 146: ...amage or abnormal noise Drive the inner bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Bearing Outer Driver Inner Bearing Outer Bearing Pack all bearing cavities with 5 0 5 6g grease Specified grease 230 Heat resistant grease ...

Page 147: ...ng into the driven face with the mark facing up CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal Install the seal collar Seal Collar O rings Guide Roller Pin Driven Pulley Bearing Driver Pilot ...

Page 148: ...ied torque Torque 5 0 6 0kg m Universal holder E034 CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the 14mm clutch outer nut Torque 3 5 4 5kg m Universal holder E017 Universal Holder Clutch Outer Clutch Dri...

Page 149: ...________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 2 FINAL REDUCTION DISASSEMBLY 10 3 FINAL REDUCTION...

Page 150: ...10 FINAL REDUCTION 10 1 VITALITY 50 ...

Page 151: ...E90 At disassembly 0 12 liter At change 0 11 liter SPECIAL TOOLS Universal bearing puller E037 Oil seal bearing install E014 TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged oil seal ...

Page 152: ...e transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Final Shaft Final Gear Countershaft Dowel Pin Countershaft Driver shift Driver shift Bolts ...

Page 153: ...the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Oil Seal Drive Shaft Bearing Final Shaft Bearing Drive Shaft Bearing Countershaf...

Page 154: ...g puller E037 Drive new bearings into the transmission case cover Oil seal bearing install E014 BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Universal bearing puller E037 Drive Shaft Bearing Bearing Remover Set Bearing Remover Set 15mm Bearing Outer Driver Handle Special Special Special ...

Page 155: ... the left crankcase Install a new drive shaft oil seal Oil seal bearing install E014 FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase Drive Shaft Bearing Outer Driver Special ...

Page 156: ...to the left crankcase Install the resin washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Resin Washer Countershaft Transmission Case Cover Bolts Dowel Pins Gasket ...

Page 157: ...fied Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 11 liter Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Place the motorcycle on its main stand on level ground Check the sealing washer for wear or damage Drain Bolt Oil Check Bolt Hole Filler ...

Page 158: ...______________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION 11 3 CRANKCASE CRANKSHAFT 2 STROKE 11 4 CRANKCA...

Page 159: ...11 CRANKCASE CRANKSHAFT 11 1 VITALITY 50 2 STROKE Torque 0 8 1 2kg m ...

Page 160: ...11 CRANKCASE CRANKSHAFT 11 2 VITALITY 50 4 STDROKE ...

Page 161: ...e 0 6 Crankshaft Connecting rod big end radial clearance 0 04 Run out A B 0 1 0 15 SPECIFICATIONS 4 Stroke Item Standard mm Service Limit mm Connecting rod small end free play 0 05 0 4 0 6 Crankshaft Connecting rod big end radial clearance 0 0 008 0 05 Run out 0 10 TORQUE VALUES Crankcase bolt 0 8 1 2kgf m Cam chain tensioner slipper bolt 0 8 1 2kgf m 4 Stroke SPECIAL TOOLS 2 stroke Crankcase pull...

Page 162: ...on the right crankcase and remove the right crankcase from the left crankcase Crankcase puller E026 CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase Crankcase puller E026 When removing the crankshaft do it slowly and gently Crankcase Puller Crankcase Puller Bolt Special Special ...

Page 163: ...ANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit 0 04mm replace if over When separating the crankcase the oil seals must be removed Replace the oil seals with new ones Universal Bearing Puller Special ...

Page 164: ...y The bearings must be replaced if they are noisy or have excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults After check apply clean engine oil to all moving and sliding parts Remove all gasket material from the crankcase mating surfaces Dress any roughness or irregularities with an oil stone Axial Play Play Radial ...

Page 165: ...new crankshaft bearing into the left crankcase Oil seal bearing install E014 The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm Bearing Outer Driver Handle A Bearing Outer Driver Handle A Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver 42x47mm Pilot 20mm Special Special When installing the oil seal be careful to press it with ev...

Page 166: ... 11 8 VITALITY 50 ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves Crankcase assembly tool E024 Dowel Pins Crankcase Assembly Tool Crankcase Assembly Tool Special ...

Page 167: ...11 CRANKCASE CRANKSHAFT 11 9 VITALITY 50 Install and tighten the crankcase bolts in a crisscross pattern in several steps Bolt After assembly check the crankshaft for smooth operation ...

Page 168: ...e out the bolts from center stand Remove spring and center stand from crankcase Remove the crankcase attaching bolt Separate the left and right crankcase halves Nuts Bolts Spring Bolt Center Stand Do not damage the crankcase gasket surface Never use a driver to pry the crankcase mating surfaces apart ...

Page 169: ...e crankshaft from the left crankcase Remove the cam chain Remove the gasket and dowel pins Clean off all gasket material from the crankcase mating surfaces Dowel Pins Gasket Radial Axial Avoid damaging the crankcase mating surfaces Crankshaft Cam Chain ...

Page 170: ...aft Measure the crankshaft run out B Service Limit 0 10mm replace if over Measure the connecting rod big end side clearance C Service Limit 0 05mm replace if over Measure the crank width D Out of specification 42 2 42 15 mm Replace the crankshaft Turn the crankshaft bearings and check for excessive play Measure the crankshaft bearing play Service Limit Axial 0 20mm replace if over Radial 0 05mm re...

Page 171: ... dowel pins and a new gasket onto the left crankcase Install the crankshaft into the left crankcase Install the right crankcase Tighten the crankcase attaching bolt Torque 0 8 1 2kgf m Bolt Place the right crankcase over the crankshaft and onto the left crankcase When installing the crankshaft be careful not to damage the oil seal ...

Page 172: ...________________________________________________________________________________ __________________________________________________________________________________ CARBURETOR __________________________________________________________________________________ SERVICE INFORMATION 2 STROKE 12 2 SERVICE INFORMATION 4 STROKE 12 3 THROTTLE VALVE 2 STROKE 12 5 CARBURETOR 2 STROKE 12 7 AIR SCREW ADJUSTMENT...

Page 173: ...12 CARBURETOR 12 1 VITALITY 50 ...

Page 174: ...ing 2 1 2 1 2 Idle speed 1850 100rpm Throttle grip free play 2 6mm SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture No fuel in tank Clogged fuel jets Faulty float valve Too much fuel getting to cylinder Clogged fuel cap vent Float level too low Clogged fuel filter Clogged fuel filter Clogged air cleaner Clogged air cleaner Bent kinked or restricted fuel line Engine...

Page 175: ...revent foreign matters from entering Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel SPECIFICATIONS Item Standard Setting mark CVK104A T...

Page 176: ...logged air cleaner Intake air leak Fuel overflowing Incorrect idle speed Intake air leak Incorrectly adjusted pilot screw Contaminated fuel Clogged idle system or auto bystarter passages Faulty auto bystarter Incorrectly adjusted float level Clogged idle system or auto bystarter passages Lean mixture Rich mixture Clogged fuel jets Faulty auto bystarter Faulty float valve Faulty float valve Float l...

Page 177: ...3 5 Remove the center cover and spark plug cover 13 6 Loosen the carburetor top and remove the throttle valve Disconnect the throttle cable from the throttle valve Remove the throttle valve spring carburetor top and rubber seal Carburetor Top Throttle Valve Rubber Seal Carburetor Top Spring ...

Page 178: ...ll the jet needle on the throttle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor top and throttle valve spring Connect the throttle cable to the throttle valve Carburetor Top Throttle Valve Rubber Seal Throttle Cable Throttle Valve Spring Needle Retainer 2nd Notch STD Throttle Valve Jet Needle Needle Clip ...

Page 179: ...lay 3 16 Idle speed adjustment 3 10 CARBURETOR 2 STROKE REMOVAL Remove the met in box 13 5 Remove the center cover 13 6 Remove the air cleaner housing 5 2 Disconnect the fuel tube 5 2 Disconnect the auto bystarter wire connector 5 2 Remove the carburetor top and throttle valve from the carburetor 12 5 Loosen the drain bolt to drain fuel from the carburetor Disconnect oil outlet tube from carbureto...

Page 180: ...een the auto bystarter wire terminals Resistance 5Ω 10 minutes minimum after stopping the engine If the resistance exceeds 5Ω replace the auto bystarter with a new one After the engine stops for 30 minutes connect a hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one Nuts ...

Page 181: ... and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage Auto Bystarter Screws O ring Set Plate Bystarter ...

Page 182: ...he carburetor body until it bottoms Install the set plate and then tighten the two screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber Remove the screw and O ring Remove the float pin float and float valve Auto Bystarter Float O ring Set Plate Float Pin Screws Screws ...

Page 183: ...emoving the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Remove the main jet and needle jet holder CARBURETOR PASSAGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun Float Valve Float Seat Main Jet Throttle Stop Screw Air Screw Do not force the air screw against its seat to prevent damage ...

Page 184: ...T LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6mm Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws Air Screw Throttle Stop Screw Needle Jet holder Float Pin Main Jet If the air screw mus...

Page 185: ...Opening 2 1 2 1 2 turns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Turn the throttle stop screw 2 to obtain the specified idle speed Idle Speed 1850 100rpm Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of 1 2 turn makes no difference to the engine per...

Page 186: ...heck the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary INSTALLATION Install the reed valve in the reverse order of removal Bolts Reeds Intake Manifold Reed Valve Seat Reed Stopper Do not disassemble or bend the reed stopper To do so can cause loss of engine power and engine damage If any of the stopper reed or valve seat is faulty replace t...

Page 187: ... met in box 13 5 Disconnect the auto bystarter connector Disconnect the fuel tube from carburetor Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Auto Bystarter Wire Fuel Tube Adjusting Nut Throttle Cable Lock Nut ...

Page 188: ...arburetor intake manifold band screw and then remove the carburetor VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Remove the two vacuum chamber cover screws and the cover Vacuum Chamber Cover Screws Band Screws Drain Screw Vacuum Chamber Cover ...

Page 189: ...UM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber Spring Needle Holder Vacuum Piston Jet Needle Float Chamber Vacuum Piston Screw Be careful not to damage the vacuum piston diaphragm ...

Page 190: ... the float valve seat contact area for wear JETS SCREWS REMOVAL Screw Pilot Screw Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record the rotating turns Do not force the pilot screw against its seat to avoid seat damage Float Float Pin Float Valve Float Valve Float Valve Seat ...

Page 191: ... removed the main jet needle jet holder needle jet and slow jet with detergent oil Check the pilot screw spring washer and O ring for bend wear or damage Needle Jet Slow Jet Spring Main Jet Be sure to use clean detergent oil Slow Jet Main Jet Needle Jet Holder Needle Jet O ring Washer Pilot Screw Needle Jet Holder ...

Page 192: ...ter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter is normal AUTO BYSTARTER REMOVAL Remove the bystart...

Page 193: ...r with a new one AIR CUT OFF VALVE A C V REMOVAL Remove the two screws and then remove throttle cable holder Remove the two screws and the air cut off valve cover Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage Bystarter Needle Bystarter Valve Screws Screws Throttle Cable Cut off Valve Cover Diaphragm Spring Cut off Valve Cover O ring ...

Page 194: ...ely Install the diaphragm spring and cover Install and tighten the two screws attaching the air cut off valve cover Install the throttle cable holder and tighten the two screws Diaphragm Spring Cut off Valve Cover O ring Screws Cut off Valve Cover Make sure that no fuel jet is clogged Install the O ring with the flat face toward the valve body side Screws Throttle Cable Holder ...

Page 195: ...eterioration Replace if necessary Assemble the accelerating pump in the reverse order of disassembly AUTOBYSTARTERINSTALLATION Install the auto bystarter and set plate Install and tighten the two screws Bystarter Screw Set Plate Insert the auto bystarter into the carburetor body until it bottoms and position the set plate into the upper groove in the bystarter Install the set plate with its round ...

Page 196: ...t holder and main jet Install the slow jet Install the pilot screw Install the float valve float and float pin Install and tighten the screw Pilot Screw Slow Jet Main Jet Needle Jet Holder Needle Jet Screw Float Float Pin Float Valve Be sure to record the rotating turns when it is removed ...

Page 197: ... plane VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Install the vacuum piston into the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Vacuum Piston Spring Needle Holder Vacuum Piston Jet Needle Be careful not to let the diaphragm slip If the diaphragm cannot be posi...

Page 198: ...d tighten the band screw Install the air cleaner connecting tube and tighten the band screw Connect the throttle cable to the carburetor Connect the fuel tube and vacuum tube to the carburetor Band Screws Adjusting Nut Throttle Cable Lock Nut Fuel Tube After connecting the throttle cable adjust the throttle grip free play to 2 6mm ...

Page 199: ... 27 VITALITY 50 Connect the auto bystarter connector Perform the following inspections and adjustments Throttle grip free play 3 16 Idle speed 3 10 Idle Speed 1800 100rpm Install the met in box 13 5 Auto Bystarter Wire ...

Page 200: ... the auto fuel valve Disconnect the fuel unit wire connector Remove the three nuts and remove retainer plate Remove the fuel tank mounting bolts and fuel tank Installation is in the reverse order of removal Inspect the fuel unit 17 2 Replace the fuel unit if necessary 17 2 Fuel Tube Vacuum Tube Fuel Unit Connector Nuts Bolts ...

Page 201: ...__________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS EXHAUST MUFFLER __________________________________________________________________________________ SERVICE INFORMATION 13 1 FRAME COVERS REMOVAL 1...

Page 202: ...ems Related for Removal Handlebar front cover Handlebar rear cover Front cover Headlight wire Handlebar rear cover Speedometer cable and instrument light wire connectors etc Frame body cover Met in box rear carrier Floor board Rear carrier frame body cover right and left side cover battery Leg shield Front body cover front right and left side covers rear body cover floor board ...

Page 203: ...er Remove the two screws from the handlebar rear cover Separate the handlebar front cover from handlebar rear cover Disconnect the winker relay from the handlebar front cover and then remove handlebar front cover Installation is in the reverse order of removal During removal be careful not to pull the joint claws forcibly and remove the front cover downward ...

Page 204: ...Remove the bolt from handlebar rear cover Remove the two mounting screws and disconnect speedometer cable 1 Disconnect the wire connectors 2 and separate handlebar rear cover Remove the three screws from the instrument and then remove handlebar rear cover Installation is in the reverse order of removal ...

Page 205: ...and then remove right left side cover 1 Installation is in the reverse order of removal FRONT FENDER REMOVAL INSTALLATION Remove the four screws and then remove front fender Installation is in the reverse order of removal During removal be careful not to pull the joint claws forcibly and remove the front cover downward During removal be careful not to pull the joint claws forcibly and remove the f...

Page 206: ... REMOVAL INSTALLATION Unlock the seat with ignition key and open the seat Remove the screw two bolts and two nuts from met in box Remove the oil tank cap 1 and then remove met in box Installation is in the reverse order of removal SPARK PLUG COVER REMOVAL INSTALLATION Remove the screw and then remove spark plug cover 1 Installation is in the reverse order of removal ...

Page 207: ... the following Met in box 13 5 Center cover 13 6 Rear carrier 13 5 Remove the two screws from the rear fender Remove the two screws form the rear body cover Disconnect the seat lock cable and then remove rear body cover Installation is in the reverse order of removal When removing the right and left side rails pull them backward not to damage the joint claws When removing the right and left side r...

Page 208: ...3 6 Remove the two bolts from the taillight and two nuts from the rear upper fender Slide the two clips 1 for disconnect fuel hose and vacuum hose 2 Remove the rear upper fender taillight Installation is in the reverse order of removal BOTTOM COVER REMOVAL INSTALLATION Remove the right and left side covers 13 4 Remove the nut from the bottom cover left side 1 ...

Page 209: ...ion is in the reverse order of removal FLOOR BOARD REMOVAL INSTALLATION Remove the following Rear carrier 13 5 Right and left side cover 13 4 Met in box 13 5 Center cover 13 6 Rear body cover 13 6 Battery cover 1 16 5 Battery 2 16 5 Fuse 3 16 5 Remove the four bolts and then remove floor board Installation is in the reverse order of removal ...

Page 210: ...he ten screws and one bolt from the leg shield Turn the ignition switch cover 1 counterclockwise and remove ignition switch cover then remove leg shield Installation is in the reverse order of removal FRONT BODY COVER REMOVAL INSTALLATION Remove the following Front cover 13 4 Right and left side cover 13 4 Remove the two nuts form the front body cover When removing the right and left side rails pu...

Page 211: ...lation is in the reverse order of removal EXHAUST MUFFLER REMOVAL INSTALLATION Disconnect the secondary air hose 2 stroke 5 3 Remove the two exhaust pipe joint lock nuts 1 Remove the bolt from the rear lower fender and two Exhaust muffler lock bolts from the exhaust muffler When removing the right and left side rails pull them backward not to damage the joint claws ...

Page 212: ...replaced Installation is in the reverse order of removal Torque Exhaust muffler lock bolt 3 0 3 6kgf m exhaust pipe joint lock nuts 1 0 1 4kgf m When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Be sure to install a new exhaust gasket ...

Page 213: ...________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK __________________________________________________________________________________ SERVICE INFORMATION 14 2 TROUBLESHOOTING 14...

Page 214: ...14 STEERINGHANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 14 1 VITALITY 50 5 0 6 0kgf m 2 9 3 5kgf m 5 0 7 0kgf m 3 0 3 6kgf m 6 0 8 0kgf m 0 5 1 3kgf m ...

Page 215: ...001 Race cone install F005 TROUBLESHOOTING Hard steering heavy Contaminated brake disk or disk pad Excessively tightened steering stem top Worn brake bushing cone race Worn brake master cylinder piston oil seal Broken steering balls Clogged brake fluid line Insufficient tire pressure Deformed brake disk Steers to one side or does not track straight Unevenly worn brake caliper Broken clutch weight ...

Page 216: ...g the left brake lever holder Remove two bolts attaching the brake master cylinder disk brake to the right brake lever Remove the two right handlebar switch housing bolts and separate the housing Disconnect the throttle cable and then remove the throttle grip from the handlebar Remove the handlebar lock nut to remove the handlebar Brake Master Cylinder Bolts Bolts Nut Throttle Grip Throttle Cable ...

Page 217: ...ndlebar and tighten the handlebar lock nut Torque 5 0 6 0kg m Lubricate the throttle cable front end with grease Install the throttle grip and connect the throttle cable Install the rear brake lever holder Install the front brake master cylinder disk brake Throttle Cable Nut Handlebar Bolt Brake Master Cylinder Bolts ...

Page 218: ...disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the brake panel side collar INSPECTION Set the axle in V blocks and measure the runout The actual runout is of the total indicator reading Service Limit 0 2mm replace if over Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Axle Nut Speedo...

Page 219: ...NTSHOCKABSORBER FRONTFORK 14 6 VITALITY 50 Turn the wheel bearings and replace them if they have excessive play or noise DISASSEMBLY Remove the dust seal Remove the wheel bearings and distance collar Bearing Remover Dust Seal Play Radial Axial Play ...

Page 220: ...LY Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Apply grease to the dust seal lip and install the dust seal Install the side collar Pilot Dust Seal Drive the bearing squarely with the sealed end facing out Side Collar Grease ...

Page 221: ...m is free of air Brake Fluid Refilling Add DOT 4 brake fluid to the brake reservoir Make sure to bleed air from the brake system When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder follow the manufacturer s instructions Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake sys...

Page 222: ... in the reverse order of removal Torque 1 5 2 0kgf m Installation the caliper in the reverse order of removal Torque 2 9 3 5kgf m Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm The brake pads must be replaced as a set to ensure the balance of the brake disk Keep grease or oil off the brake pads to avoid brake failure Front Brake Ca...

Page 223: ...ove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removing the brake fluid pipe bolt be sure to plug the pipe to avoid brake fluid leakage Snap Ring Bolts...

Page 224: ...e assembly inspect the lst and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and snap ring Install the rubber cover Install the brake lever During assembly the main piston and spring must be installed as a unit without exchange When assembling the piston soak the cups in br...

Page 225: ...ighten the lower bolt Torque 1 0 1 4kgf m Install the brake fluid pipe with the attaching bolt and two sealing washers Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 14 8 BRAKE CALIPER FRONT Removal Remove the brake caliper 14 9 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the cali...

Page 226: ...essed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface Brake Caliper Seat Compressed...

Page 227: ...e Service Limit 25 30mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat Install the...

Page 228: ...Installation Install the brake caliper and tighten the two bolts Torque 2 9 3 5kgf m Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 3 0 4 0kgf m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system 14 8 Bolts Bolt ...

Page 229: ...nt shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers LEFT FRONT SHOCK ABSORBER DISASSEMBLY Remove the dust boot Remove the circlip Use a vise to hold the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Front Shock Absorber Bolt Washer Circlip Front Shock Absorber Mount Bolt Dust Boot ...

Page 230: ...damper from the shock absorber tube Measure the front shock absorber spring free length Standard Limit 214 7 FRONT SHOCKABSORBER ASSEMBLY When holding the shock absorber tube place a shop towel under it and do not apply too much force Oil Seal Damper Nut Absorber Tube Damping Spring Front Shock Absorber Dust Seal Front Shock Absorber Spring Damper Circlip ...

Page 231: ...r spring and tighten the damper nut Use a vise to hold the front shock absorber Tighten the hex bolt Apply locking agent to the washer and socket hex bolt and install them together Torque 1 5 3 0kgf m Specified Oil ss 8 Oil Capacity 53cc Install the circlip Install the dust boot Install the front shock absorber spring with the loosely wound coils facing up Damper Nut Circlips Front Shock Absorber ...

Page 232: ...e steering handlebar 14 3 Disconnect the speedometer cable and front brake fluid tube and remove the front brake caliper 14 8 Remove the front wheel 14 5 Remove steering stem lock nut with lock the lock nut socket wrench Remove the top cone race and remove the front fork SPECIAL TOLLS Long socket wrench F007 Inspect the ball races cone races and steel balls for wear or damage Replace if necessary ...

Page 233: ...e using a chisel Drive a new bottom cone race into place with a proper driver BALL RACE REPLACEMENT Drive out the ball races Drive in new ball races SPECIAL TOOLS Race cone install F005 Bottom Cone Race Ball Race Remover Be sure to drive the ball races into place completely Driver Handle A Be careful not to damage the steering stem and front fork ...

Page 234: ...o the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Torque 0 5 1 3kgf m Install the steering stem lock nut and tighten it while holding the top cone race Torque 6 0 8 0kgf m SPECIAL TOOLS Lock nut socket wrench F007 Install the handlebar 14 3 Install the speedometer cable Check that...

Page 235: ...____________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REARWHEEL REARBRAKE REAR SHOCKABSORBER __________________________________________________________________________________ SERVICE INFORMATION 15 2 TROUBLESHOOTING 15 2 REAR ...

Page 236: ...15 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 15 1 VITALITY 50 2 4 3 0kgf m 1 0 1 4kgf m 11 0 13 0kgf m 1 0 1 4kgf m 3 5 4 5kgf m 3 0 3 6kgf m ...

Page 237: ... Rear axle nut 11 0Д13 0kgf m Rear shock absorber upper mount bolt 3 5Д4 5kg m Rear shock absorber lower mount bolt 2 4Д3 0kg m TROUBLESHOOTING Rear wheel wobbling Bent rim Faulty tire Axle not tightened properly Soft rear shock absorber Weak shock absorber spring Poor brake performance Brake not adjusted properly Contaminated brake linings Worn brake linings Worn brake shoes at cam contacting are...

Page 238: ...xle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle threads Then tighten the rear axle nut Torque values Rear axle nut 11 0Д13 0kg m Rear Axle Nut Rear Axle Nut ...

Page 239: ...rake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut Brake Arm Brake Shoes Keep oil or grease off the brake linings Ϡ ...

Page 240: ...ine oil to the felt seal and install it to the brake cam Install the wear indicator plate Install the brake arm onto the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes Align the wide tooth of the wear indicator plate with the wide groove on the brake cam Ϡ Brake Arm Bolt Wear Indicator Plate Brake Arm Brake Cam Grease Brake Arm Punch Ma...

Page 241: ...move the rear body cover 13 6 Remove the air cleaner case 5 2 or 5 7 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber INSTALLATION Install the rear shock absorber Install the rear shock absorber upper mount bolt and then install the lower mount bolt Torque Upper Mount Bolt 3 5Д4 5kgf m Lower Mount Bolt 2 4Д3 0kgf m Brake Arm Adjusting Nut Brake Arm Pin B...

Page 242: ...________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ELECTRICAL EQUIPMENT __________________________________________________________________________________ SERVICE INFORMATION 16 1 TROUBLESHOOTING 16 1 CHARGING SYSTEM 16 3 BATTERY 16 5 I...

Page 243: ...Battery current Quick 4A 0 5H 4A 0 5H Spark plug NGK BR8HSA C7HSA Spark plug gap 0 6 0 7mm 0 6 0 7mm Primary coil 0 153 0 187Ω 0 5Ω Secondary coil with plug cap 6 99k 10 21KΩ 8 12KΩ Ignition coil resistance Secondary coil without plug cap 3 24k 3 96KΩ 3KΩ Pulser coil resistance 20 80 160Ω 118 1 118 2Ω Ignition timing 13 5 2 BTDC 3000rpm 28 2 BTDC 4000rpm TROUBLESHOOTING CHARGING SYSTEM No power In...

Page 244: ...plug Faulty ignition switch Poorly insulated plug cap Faulty ignition coil Improper ignition timing Faulty CDI unit Battery voltage too low 6V max Faulty A C generator Faulty CDI unit STARTING SYSTEM Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter switch or pinion F...

Page 245: ...16 ELECTRICAL EQUIPMENT 16 3 VITALITY 50 CHARGING SYSTEM 2 STROKE A C Generator Regulator Rectifier Resistor Fuse 7A Battery Cable Battery Cable Light Switch Resistor 5 9Ω 30W ...

Page 246: ...16 ELECTRICAL EQUIPMENT 16 4 VITALITY 50 CHARGING SYSTEM 4 STROKE A C Generator Regulator Rectifier Resistor Fuse 7A Battery Cable Battery Cable Light Switch Resistor 7 5Ω 30W ...

Page 247: ... take out the battery for cleaning After cleaning apply a thin coat of grease or vaseline to battery terminals and then install the battery Never open the closed type battery electrolyte cap If the scooter will not be used for a long time the battery will discharge electricity by itself Remove the battery and put it in a cool place after it is fully charged to prevent electricity leakage If the sc...

Page 248: ...egative cable Charging current Standard 0 4A Quick 4A Charging time Standard 5 10hours Quick 0 5 hour After charging Open circuit voltage 12 8V min Red Black Quick charging should only be done in an emergency During quick charging the battery temperature should not exceed 45 Measure the voltage 30 minutes after the battery is charged Keep flames and sparks away from a charging battery Turn power O...

Page 249: ...ge Specified current leakage 1mA maximum If current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current When measuring current using a tester set it to high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in the tester While me...

Page 250: ...range check the regulator rectifier A C GENERATOR CHARGING COIL INSPECTION Remove the met in box and center cover 13 5 Disconnect the A C generator connector Measure the resistances between the charging coil terminals white ground and lighting coil terminals yellow ground Resistance 2 Stroke Charging coil white ground 0 2 1 2Ω Lighting coil yellow ground 0 3 1 0Ω Refer to 8 section for A C generat...

Page 251: ...frame front cover 13 4 Measure the resistance between the resistor B pink wire and ground Measure the resistance between the resistor A green black wire and ground Resistance 2 Stroke Resistor A 9 2 11 2Ω Resistor B 5 3 6 5Ω Resistance 4 Stroke Resistor A 7 7 8 3Ω Resistor B 12 0 12 8Ω Resister A Resister B A C Generator Connector Faulty resistor is the cause of faulty operation of the auto bystar...

Page 252: ...r rectifier if the readings are not within the specifications in the table below 2 Stroke Probe Probe A R B W C Y D G A R B W 3 10KΩ C Y 33 35KΩ D G 33 35KΩ 4 Stroke Probe Probe A R B W C Y D G A R 3 4MΩ B W 6 8MΩ C Y 14 15MΩ D G 14 15MΩ Coupler A Red C Yellow D Green B White Regulator Rectifier Nut Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing ...

Page 253: ...16 ELECTRICAL EQUIPMENT 16 11 VITALITY 50 IGNITION SYSTEM 2 STROKE Ignition Coil Ignition Switch Spark Plug A C Generator Exciter Coil Pulser Coil C D I Unit ...

Page 254: ...16 ELECTRICAL EQUIPMENT 16 12 VITALITY 50 IGNITION SYSTEM 4 STROKE Ignition Coil Ignition Switch Spark Plug A C Generator Exciter Coil Pulser Coil C D I Unit ...

Page 255: ...oil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 20 with plug cap 2 Stroke 6 99K 10 21KΩ 4 Stroke 8 12KΩ Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 without plug cap 2 Stroke 3 24K 3 96KΩ 4 Stroke 3KΩ Performance Test Remove the ignition coil Ignition Coil ...

Page 256: ...ark A C GENERATOR Exciter Coil Pulser Coil Inspection Remove the met in box and center cover 13 5 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20 2 Stroke 80 160Ω Resistance 20 4 Stroke 118 1 118 2Ω Blue Yellow Follow the ignition coil tester manufac turer s instructions The test is performed at both conditions th...

Page 257: ...obe Black Yellow Black Red Black White Blue Yellow Green Black Yellow Black Red 1 10 Black White Blue Yellow 3 40 80 120 10 30 Green 2 10 10 30 CDI Unit Blue Yellow Green Black Yellow Black Red Black White Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use a Sanwa Electric Tes...

Page 258: ... 4 Stroke Unit Ω Probe Probe Black Blue Black Yellow Blue Yellow Green Black Blue Black Yellow 9 2M 9 25 M 310K 320 K 310K 320 K Blue Yellow 8 81M 8 8 5M 310K 320 K 1K Green 8 86M 8 8 8M 310K 320 K 1K Blue Yellow Green Black Yellow Black Blue ...

Page 259: ...16 ELECTRICAL EQUIPMENT 16 17 VITALITY 50 ELECTRIC STARTER Starter Motor Starter Relay ...

Page 260: ...Connect the starter relay green yellow terminal to the 12V battery positive terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The relay is normal if there is continuity Starter Relay Green Yellow Red White Yellow Red Red Starter Relay 4 Stroke Starter Relay 2 Stroke ...

Page 261: ... Connect the starter motor cable connector Check the O ring for wear or damage and replace it if necessary Apply grease to the O ring and install the starter motor Tighten the two mounting bolts Torque 0 8 1 2kgf m STARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation Starter Motor Bolts The starter motor cable connector must be installed properly Battery ...

Page 262: ... starter pinion INSPECTION Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion Shaft Forcing Parts Starter Pinion Starter Pinion Cover 2 Stroke ...

Page 263: ...16 ELECTRICAL EQUIPMENT 16 21 VITALITY 50 ...

Page 264: ..._________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSTRUMENT SWITCHES LIGHTS __________________________________________________________________________________ SERVICE INFORMATION 17 1 TROUBLESHOOTING 17 1 FUEL UNIT 17 2 OIL METER 17 3 SWITCH...

Page 265: ...ufficient Burned bulb Fuse burned out Faulty switch Dead battery Broken or shorted wire Faulty ignition switch Fuse burned out Faulty instrument Weak battery Faulty oil meter Poorly connected wire Faulty winker Motor oil indicator light winks Loose wire connection Light dims Broken wire Faulty ignition coil Faulty oil meter Wire or switch resistance too high Faulty regulator rectifier Fuel gauge p...

Page 266: ...Terminals Upper Lower G Y W 36Ω 686Ω G L W 566Ω 53Ω Y W L W 600Ω 600Ω FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Float Position Needle Position Upper F Full Lower E Empty No Smoking Before performing the following test operate the turn signals to determine t...

Page 267: ... the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as and shown in the left figure Wire Terminals Resistance Green Red Black 46Ω Green Black Align the groove on the fuel unit with the flange on the fuel tank Oil Meter Float G R B B G Groove Flange Before removing the oil meter be sure to drain the motor oil and do not allow sparks or fl...

Page 268: ...re couplers and check for continuity between the wire terminals Color Red Black White Green Black Symbol BAT1 IG E BAT2 LOCK OFF ON STOP SWITCH INSPECTION Remove the handlebar front cover 13 2 Disconnect the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever is applied Oil Indicator Light Ignition Switch Connector Before perform...

Page 269: ...als Color Yellow Pink Brown Blue White Brown white Symbol CI RE TL HL PO OFF N P N H DIMMER PASSING SWITCH INSPECTION Check for continuity between wire terminals Color Blue White Blue White Black Symbol HL HI LO BAT HI LO PASSING TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Color Light Blue Orange Gray Symbol R L WR R L Headlight Switch Dimmer Switch Turn Signal Sw...

Page 270: ...ol ST E FREE PUSH HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Color Light Green Brown Blue Symbol HO BAT FREE PUSH HORN INSPECTION Remove the frame front cover 13 4 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals Horn Switch Horn Starter Switch ...

Page 271: ...ly press down on the bulb and turn it counterclockwise Install a new bulb in the reverse order of removal REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove two screws from the taillight lens 17 7 Remove screw from the rear turn signal light lens Slightly press down on the bulb and turn it counterclockwise Install a new bulb in the reverse order of removal Bulb Screws Turn Signal Light Bulb Screws Len...

Page 272: ...e Disconnect the all instrument connectors Remove the instrument Installation is in the reverse order of removal POSITION LIGHT BULB REPLACEMENT Remove the front body cover 13 9 Turn the bulb socket counterclockwise then pull it out toward you Pull the bulb out of the socket and replace it with a new one Make sure the seal rubber is installed in the correct position and is in good condition Instal...

Page 273: ...lb while pressing down on the pin Pull out the bulb without turning Install a new bulb in the reverse order of removal When installing the bulb make sure its biggest flange upward The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers Use bulbs of the same specifications for replacement Bulb Socket Dust Cover Pin Bulb Biggest Flange ...

Page 274: ...e spent fuel charge is released into the exhaust system it is still hot enough to burn The system allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as changing a significant portion of the poisonous carbon monoxide into harmless carbon dioxide 2 STROKE 18 ...

Page 275: ...18 SPECIFICATIONS 18 1 4 STROKE ...

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