KYMCO FILLY 50 User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO FILLY 50.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 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
FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
ENGINE
DRIVE AND DRIVEN PULLEYS/KICK
STARTER 9
FINAL REDUCTION 10
CRANKCASE/CRANKSHAFT 11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION 12
CHASSIS
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION 13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR 14
IGNITION SYSTEM 15
STARTING SYSTEM 16
INSTRUMENTS/SWITCHES/LIGHTS 17
ELECTRICAL EQUIPMENT
EVAPORATIVE EMISSION CONTROL
SYSTEM 18
EXHAUST EMISSION CONTROL
SYSTEM 18
EMISSION CONTROL
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.

1. GENERAL INFORMATION
1-1
1
SERVICE PRECAUTIONS ...................................1- 3 WIRING DIAGRAM ...........................................1-20
TORQUE VALUES................................................1- 11 TROUBLESHOOTING........................................1-21
SPECIAL TOOLS ..................................................1-12
SPECIFICATION...................................................1- 2 CABLE & HARNESS ROUTING..........................1-15
ENGINE SERIAL NUMBER..............................1- 1 LUBRICATION POINTS..................................1-13 1
ENGINE SERIAL NUMBER
Location of Engine Serial Numbe
r

1. GENERAL INFORMATION
1-2
SPECIFICATIONS
Motorcycle Name & Type
Name & Model No. SD10AA
Overall length (mm) 1660
Overall width (mm) 680
Overall height (mm) 1070
Wheel base (mm) 1195
Engine type O.H.C.
Displacement 49.5cc
Fuel Used 92# nonleaded gasoline
Front wheel 33
Net weight (kg) Rear wheel 46
Total 79
Front wheel 32
Gross weight(kg) Rear wheel 52
Total 84
Front wheel 90/90-10 50J
Tires Rear wheel 90/90-10 50J
Ground clearance (mm) 100
Perform- Braking distance (m) 4.4 (Initial speed
30km/h)
ance Min. turning radius (m) 1.6
Starting system Starting motor &
kick starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) φ39 x 41.4
Compression ratio 10.5
Compression pressure
(kg/cm²-rpm) 14−600
Max. output (ps/rpm) 4.0/8000
Max. torque (kg m/rpm) 1.04/6000
Intake
Open 0°BTDC
Port (1mm) Close 34°ABDC
Engine
timing Exhaust Open 32°BBDC
(1mm)
Close 0°TDC
Valve clearance Intake 0.10
(cold) (mm) Exhaust 0.10
Idle speed (rpm) 1700rpm
Lubrication type Forced pressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.9 liter
Lubrication System
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 6.2 liter
Type CVK
Piston dia. (mm)
Venturi dia.(mm) φ18 equivalent
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing 15±2°BTDC/1700rpm
Contact breaker Non-contact point type
Spark plug
NGK
C7HSA
ND
U22FS-U
Spark plug gap 0.60.7mm
Battery Capacity 12V4AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 10.853.0
ratio 2nd 11.05
Front Caster angle 26.5°
Axle Trail length ⎯
Tire pressure
Fron
t
1.75
(kg/cm²) Rear 2.25
Turning Left 45°
angle Right 45°
Brake system
Front Drum
(
110mm
)
brake
type Rear Drum (110mm) brake
Fron
t
Telesco
p
e
Suspension type Rear Unit Swing
Front Telescope
Shock absorber
type Rear Unit Swing
Frame type Under bone
Fuel S
y
stem Electrical E
q
ui
p
ment
I
g
nition S
y
stem
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device

1. GENERAL INFORMATION
1-3
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.
Apply or add designated greases and lubricants to

1. GENERAL INFORMATION
1-4
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.
If the fuse is burned out, find the cause and repair
it. Replace it with a new one according to the
specified capacity.

1. GENERAL INFORMATION
1-5
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.
The connector shall be inserted completely.
Confirm
Capacity If the double connector has a lock, lock it at
the correct position.

1. GENERAL INFORMATION
1-6
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.
After clamping, check each wire to make sure it is
secure.
Sna
pp
in
g
!

1. GENERAL INFORMATION
1-7
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 !
Route harnesses so they are neither pulled
tight nor have excessive slack.

1. GENERAL INFORMATION
1-8
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 press or
s
q
ueeze the wire.
Do not pull
too ti
g
ht! After routing, check that the wire harnesses are
not twisted or kinked.

1. GENERAL INFORMATION
1-9
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 !
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.)
Engine Oil

1. GENERAL INFORMATION
1-10
Grease
: Apply grease for lubrication.
Gear Oil
: Transmission Gear Oil (90#)
Special
: Use special tool.

: Caution
: Warning
(Ö12-3) : Refer to page 12-3.
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Tor
q
ue
(
k
g
-m
)
Ite
m
Tor
q
ue
(
k
g
-m
)
5mm bolt, nut 0.5 5mm screw 0.4

1. GENERAL INFORMATION
1-11
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
1.0
2.2
3.5
5.5
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.9
1.2
2.7
4.0
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
8
8
30
6
8
5
6
8
10
28
6
6
10
10
6
6
0.9
0.9
1.5
3.5
2.0
0.9
1.0
1.3
5.5
5.5
1.0
1.2
3.8
1.2
0.9
0.4
Double end bolt
Double end bolt
Apply oil to threads
FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Speedometer cable set screw
Rear shock absorber lock nut
1
1
1
1
1
1
1
25.4
10
14
10
8
5
8
8.012.0
4.05.0
8.010.0
3.04.5
2.03.0
0.45
2.5
U-nut
U-nut
U-nut
Apply locking agent
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Valve adjuster
Valve guide driver
Valve guide reamer

1. GENERAL INFORMATION
1-12
Valve spring compressor
Lock nut wrench, 39mm
Bearing driver
Bearing driver
Bearing remover, 12mm
Remover set, 12mm
Remove head, 12mm
Remover shaft
Remover weight
Bearing remover, 15mm
Driver set, 15mm
Driver shaft, 15mm
Driver head, 15mm
Driver weight
Bearing driver
Driver handle
Driver weight
Outer extension
Crankshaft assembly tool
Crankshaft assembly collar
Crankshaft assembly shaft
Attachment
Lock nut wrench
Lock nut wrench
Ball race remover extension
Ball race remover
Spring compressor
Spring compressor attachment
Spring compressor attachment
Spring compressor attachment
Lock nut wrench
Driver outer extension
Float level gauge
Valve spring compressor
Valve seat cutter, 24.5mm Seat cutter 45°IN/EX
Valve seat cutter, 25mm Plane cutter 32°IN
Valve seat cutter, 22mm Plane cutter 32°EX
Valve seat cutter, 26mm Plane cutter 60°IN/EX
Cutter clip, 5mm
Universal holder
Outer driver, 32x35mm
Outer driver, 37x40mm
Outer driver, 42x47mm
Pilot, 12mm
Pilot, 15mm
Pilot, 17mm
Pilot, 20mm
Driver handle A
Bearing remover shaft
Bearing remover head, 12mm
Flywheel puller
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant

1. GENERAL INFORMATION
1-13
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 R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE10W-30)
•API−SG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube Adhesive
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.

1. GENERAL INFORMATION
1-14
Engine/ Oil Grease
Front Brake Lever
Pivot
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Seat Lock
Grease
Engine Oil
Grease Rear Brake Cable
Main Stand Pivot
Grease
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin /Front
Shock Absorber Lower Mount
Bushings/Pivot
Brake Cam/
Anchor Pin
Grease
Rear Wheel Bearings
Grease
CABLE & HARNESS ROUTING
Front Stop Switch Wire
Rear Stop Switch Wire
Front Brake Cable
Rear Brake Cable

1. GENERAL INFORMATION
1-15
Throttle Cable Speedometer Cable
Headlight Wire
Connecto
r
Ignition Switch
Headlight Resistor
Regulator/Rectifier
Auto Bystarter
Resistor
Horn
Winker

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

1. GENERAL INFORMATION
1-17
Battery (+) Cable
Battery (-) Cable
Battery (-) Cable Battery (+) Cable
Fuse
Starter Relay

1. GENERAL INFORMATION
1-18
FCV (Fuel Control
Valve
Fuel Vapor
Recover
y
Tube
Purge Control Valve
/Charcoal Canister
Fuel Tube
Ignition Coil
Primary Wire
Throttle Cable
Ignition Wire
Carburetor
Overflow Tube
Vacuum Tee
Crankcase Breather
Tube
Fuel Unit
Fuel Vapor
Recover
y
Tube
Fuel Tube Carburetor
Breather Tube

1. GENERAL INFORMATION
1-19
Throttle Cable
WIRING DIAGRAM
R Red O Orange
B Black P Pink
W White Br Brown
G Green LG Light green
V Violet SB Light blue
FCV (Fuel Control
Valve
Purge Control Valve
/Charcoal Canister
Crankcase Breather
Tube
Auto Bystarter Starter Motor Wire
Vacuum Tube
Auto Bystarter Wire
Vacuum TubeWire Harness
Spark Plug Cap
Ignition Coil
FCV (Fuel Control
Valve
Wire Harness