KYMCO Active 50 User manual

ACTIVE 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO ACTIVE 50.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the inspection/ adjustment
procedures, safety rules and service
information for each part, starting from
periodic maintenance.
Sections 3 and 4 state the servicing
procedures and cautions for the removal
and installation of lubrication and fuel
systems.
Sections 5 through 18 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
INSPECTION/ADJUSTMENT 2
LUBRICATION SYSTEM 3
FUEL SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
ALTERANTOR/CAM CHAIN
TENSIONER 8
CLUTCH/GEAR SHIFT MECHANISM 9
ENGINE
CRANKCASE/CRANKSHAFT/KICK
STARTER/TRANSMISSION 10
FRONT WHEEL/SUSPENSION/
STEERING 11
REAR WHEEL/BRAKE/SUSPENSION 12
HYDRAULIC BRAKE 13
CHASSIS
FRAME COVER 14
IGNITION SYSTEM 15
CHARGING SYSTEM 16
STARTING SYSTEM 17
ELECTRICAL EQUIPMENT
LIGHTS/INSTRUMENTS/SWITCHES
/
HORN/FUEL UNIT 18
Our company reserves right to make
any alteration in the design.
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.

1. GENERAL INFORMATION
1-0
ACTIVE 50
1
__________________________________________________________________________________
__________________________________________________________________________________
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__________________________________________________________________________________
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GENERAL INFORMATION
__________________________________________________________________________________
ENGINE SERIAL NUMBER---------------------------------------------- 1- 1
SPECIFICATIONS---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS------------------------------------------------ 1- 3
TORQUE VALUES --------------------------------------------------------- 1-11
SPECIAL TOOLS ----------------------------------------------------------- 1-12
LUBRICATION POINTS -------------------------------------------------- 1-13
CABLE & HARNESS ROUTING ---------------------------------------- 1-14
WIRING DIAGRAM-------------------------------------------------------- 1-18
TROUBLESHOOTING----------------------------------------------------- 1-19
1

1. GENERAL INFORMATION
1-1
ACTIVE 50
ENGINE SERIAL NUMBER
Location of Engine Serial Numbe
r
Location of Frame Serial Numbe
r

1. GENERAL INFORMATION
1-2
ACTIVE 50
SPECIFICATIONS
Motorcycle name & Model No. LCA7
Motorcycle name ACTIVE 50
Overall length (mm) 1995
Overall width (mm) 680
Overall height (mm) 1090
Wheel base (mm) 1275
Engine type 4∞
Displacement (cc) 49
Fuel type nonleaded gasoline
Front wheel 46.5
Rear wheel 58
Dry weight (kg)
Front wheel 48.5
Rear wheel 63.5
Gross weight(kg)
Front wheel 2.5-17
Tires Rear wheel 2.75/17
Ground clearance (mm) 120
Braking distance (m) 7under
Perform-
ance Min. turning radius
(mm) 3800(R/L)
Starting system Starting motor &
kick starter
Type OHC
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement Single cam, OHC
Bore x stroke (mm) φ52.4x 49.5
Compression ratio 8
Compression pressure
(kg/cm²)13
Max. output 1.8/7000kw(r/min)
Max. torque 2.6/4500kgm/rpm
Open 0°
Intake
(1mm) Close 35°
Engine
Open 30°
Port
timin
g
Exhaust
(1mm) Close 5°
Intake 0.02mm
Valve clearanc
e
(cold) Exhaust 0.02mm
Idle speed (rpm) 1700rpm
Lubrication type Forced
p
ressure &
wet sump
Oil pump type Inner/Outer rotor
Oil filter type Wire gauze filter
Lubrication System
Oil capacity 0.9 liter
Cooling Type Air cooling
Air cleaner type Wet, single
Fuel capacity 4liter
Type PIF
Piston dia. (mm) 14.9
Venturi dia.(mm) φ20equivalent
Fuel System
Carburetor
Throttle type Plunger type
Type CDI
Ignition timing 15±2°/1700rpm
Spark plug CHAMPION-P-PZ9HC
Ignition System
Spark plug gap 0.6～0.7mm
Electrical Equipment
Battery Capacity 12V5AH
Clutch Type Wet multi-disc clutch
Type Permanent gear meshing
Operating method Foot operated
Type Cycle type
1st gear 2.92
2nd gear 1.67
3rd gear 1.17
4th gear 0.92
Power Drive System
Transmission Gear
Reduction
ratio
5th gear -------
Front Caster angle 27°
Axle Wheel base 1305
Tire
p
ressure Front 1.75
(k
g
/c
m
²)(2 riders) Rear 2.25
Left 45°
Turning angle Right 45°
Front Disk brake
Brake system
type Rear Drum brake
Front Telescope
Damping Device
Shock absorber
type Rear Mono Shock
Frame type Back bone
Moving Device

1. GENERAL INFORMATION
1-3
ACTIVE 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure
to use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
ACTIVE 50
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.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
ACTIVE 50
If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock
on the connector shall be released before
operation.
Hold the connector body when
connecting or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is
bending, protruding or loose.
Confirm
Capacity

1. GENERAL INFORMATION
1-6
ACTIVE 50
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.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
ACTIVE 50
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !

1. GENERAL INFORMATION
1-8
ACTIVE 50
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 securely.
Do not break the sheath of wire.
If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.
When installing other parts, do not press
or squeeze the wires.
Do not pull
too tight!
Do not press o
r
squeeze the wire.

1. GENERAL INFORMATION
1-9
ACTIVE 50
After routing, check that the wire
harnesses are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
When a testing device is used, make sure
to understand 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.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is the
instrument set correctly?
Remove Rust !

1. GENERAL INFORMATION
1-10
ACTIVE 50
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
lubrication.)
: Apply grease for
lubrication.
: Use special tool.
: Caution
: Warning
Grease
＊
Engine Oil
Special

1. GENERAL INFORMATION
1-11
ACTIVE 50
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Tor
q
ue
(
k
g
-m
)
Ite
m
Tor
q
ue
(
k
g
-m
)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45～0.6
0.8～1.2
1.8～2.0
3.0～4.0
5.0～6.0
5mm screw
6mm nut, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35～0.5
0.7～1.1
1.0～1.4
2.0～3.0
3.5～4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Quantity Thread
di ( )
Torque (kg-m) Remarks
Kick plate bolt
R/L case bolt
Stopper shift bolt
Cam gear shift bolt
Pin guide bolt
Oil pump bolt
Clutch nut
Rotor oil nut
Rotor oil cover bolt
Motor bolt
Head stud bolt
Cam sprocket bolt
Head cover cap nut
Pivot cam chain bolt
Tensioner bolt
Cylinder head bolt
Hole TP cap nut
Plate L case screw
Sprocket drive bolt
Fly wheel nut
L cover bolt
Head side cover L bolt
Inlet pipe bolt
Carburetor bolt
Head stud bolt
Head side cover R bolt
R cover oil bolt
Filter hole cap
Outer starting
2
8
1
1
1
3
1
1
3
3
4
3
4
1
1
2
2
2
2
1
9
2
2
2
2
2
1
1
3
6
6
6
6
8
6
10
10
6
6
7
5
7
8
14
6
30.8
6
6
10
6
6
6
6
8
6
14
30.8
6
0.8～1.2
0.8～1.2
0.8～1.2
1.0～1.4
0.8～1.2
0.8～1.2
3.8～4.5
3.8～4.5
0.45～0.6
0.8～1.2
0.7～1.1
0.7～1.1
1.2～1.6
1.3～1.8
1.5～2.5
0.6～0.9
1.0～2.0
0.8～1.2
1.0～1.6
3.2～4.0
0.8～1.2
0.8～1.2
0.8～1.2
0.8～1.2
0.7～1.1
0.8～1.2
2.0～3.0
1.0～2.0
1.0～1.5

1. GENERAL INFORMATION
1-12
ACTIVE 50
FRAME
Item Quantity Thread Torque (kg-m) Remarks
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear fork pivot nut
Handlebar lock nut
Rear driven gear bolt
Rear brake panel nut
Intake pipe mounting bolt
Engine hanger upper nut
Engine hanger lower nut
1
1
1
1
1
1
1
1
4
1
2
1
1
25.4
25.4
14
16
10
10
12
10
8
8
6
1
1
6.0～9.0
0.5～1.3
5.5～7.0
6.0～8.0
3.0～4.0
3.0～4.0
5.5～7.0
6.0～9.0
1.8～2.0
1.8～2.5
1.8～2.5
1.8～2.5
1.8～2.5
SPECIAL TOOLS
Tool Name Tool No. Ref. Page Remarks
Flywheel puller E003 8-4
Bearing puller 18mm E008 10-10
Lock nut socket wrench F007、E010、E049 9-5、11-16、11-18
Tappet adjuster E012 2-5
Oil seat & bearing install E014 10-11、11-9
Bearing puller 15mm E018 10-10
Bearing puller 12mm E020 10-10
Flywheel holder E021 8-3、8-7、9-6
Bearing puller 10mm E031 10-10
Clutch holder E039 9-5
Gear holder E038 9-9
Bearing driver handle & Bearing installer E014 11-9、11-17
Race cone install F005

1. GENERAL INFORMATION
1-13
ACTIVE 50
LUBRICATION POINTS
ENGINE
or CABLE LUBRICANT
SPEEDOMETER, THROTTLE, BRAKE CABLE
THROTTLE GRIP
SWING ARM
PIVOT VUSHINGS
CHAIN LUBRICANT
DRIVE CHAIN
BRAKE CAM
WHEEL BEARINGS BRAKE PEDAL
PIVOT
CENTER & SIDE
STAND PIVOTS
SPEEDOMETER
GEAR
WHEEL BEARINGS
STEERING HEAD
BEARINGS
ENGINE

1. GENERAL INFORMATION
1-14
ACTIVE 50
CABLE & HARNESS ROUTING
Throttle Cable
Ignition Switch
Horn
Front brake
hose

1. GENERAL INFORMATION
1-15
ACTIVE 50
Winker Relay Horn
Front Brake
Hose
W
i
re Harness
Ignition Coil
Ignition
Coil Wire
Starte
r
Motor
Regulator/
Rectifier
Choke Cable

1. GENERAL INFORMATION
1-16
ACTIVE 50
WIRING DIAGRAM

1. GENERAL INFORMATION
1-17
ACTIVE 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged carburetor fuel inlet
tube, vacuum tube or fuel tube
Clogged float oil passage
Clogged fuel filter
Clogged charcoal canister
Clogged auto fuel valve strainer
Faulty valve passage
Faulty fuel pump
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Faulty exciter coil
Faulty ignition switch
Broken or shorted ignition coil
wire
Faulty or slipping clutch
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Leaking cylinder head gasket
Faulty choke control system
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air screw
Flooded carburetor
Throttle valve excessively open
Clogged air cleaner
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 Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder
compression
Start engine by follow-
ing normal starting
procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor Fuel does not
reach carburetor
Wet spark plug
Dry spark plug

1. GENERAL INFORMATION
1-18
ACTIVE 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
Mixture too lean (turn screw in)
Mixture too rich (turn screw
out)
Faulty intake manifold gasket
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Faulty ignition switch
Faulty A.C. generator
Damaged vacuum tube
Clogged 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 A.C. generator
Check carburetor gasket
for air leaks
Check carburetor air
screw adjustment
Correct Incorrect
Correctly adjusted
No air leak Air leaks
Good spark Weak or inter-
mittent s
p
ark
Good Faulty
Incorrectly adjusted