KYMCO Vitality 50 User manual

VITALITY 50
PREFACE
This Service Manual describes the technical features and servicing
procedures for the KYMCO VITALITY 50.
In this manual, many illustrations and dra ings 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)
B
y KWANG
YANG Motor Co.,
Ltd.
First Edition, May 2004
All rig ts reserved. Any reproduction or
unaut orized use wit out t e written permission of
KWANG YANG Motor Co., Ltd.
is expressly pro ibited.
4121-LBD5/6-S00

1. SPECIFICATIONS
1
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0
VITALIT
Y 50
1
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................... 1
GENERAL INFORMATION ........................................................................ 2
INSPECTION/ADJUSTMENT ..................................................................... 3
LUBRICATION SYSTEM............................................................................. 4
ENGINE REMOVAL/INSTALLATION ..................................................... 5
4-STROKE CYLINDER HEAD/VALVES ................................................. 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

1. SPECIFICATIONS
1
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1
VITALITY 50
SPECIFICATIONS
(2-Stroke)
Name & Model SF10FA
Overall length (mm) 1870
Overall width (mm) 700
Overall height (mm) 1120
Wheel ba e (mm) 1296
Engine type Air cooled 2- troke
Di placement (cc) 49.4 cc
Net weight (kg) 97
Seating capacity 1 rider (75kg)
Gro weight(kg) 173 (1 rider)
Front wheel
120/70-12
Tire Rear wheel
130/70-12
Ground clearance (mm) 150
Braking di tance (m)
(Initial peed Km/h)
4.4m (30km/h)
Min. turning radiu (mm) 1920
Starting y tem Starting motor &
Kick tarter
Fuel type #92 or higher
unleaded go oline
Cylinder arrangement Single cylinder, flat
Combu tion chamber type Semi- phere
Valve arrangement Reed valve & pi ton
Bore x troke (mm) 39 x 41.4
Compre ion ratio 7.2 : 1
Compre ion pre ure
(kg/cm² rpm)
11.8kg/cm²
Max. hor epower (p /rpm)
4.5/6000
(Speed limited
type:3.9/6000)
Max. torque (kg-m/rpm)
0.5/6000
(Speed limited
type:0.48/6000)
Open Automatic controlled
Intake Clo e Automatic controlled
Port Open 
timing Exhau t Clo e 
Open 
Scavenge
Clo e 
Idle peed (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, ingle
Fuel capacity (liter) 5.0
Type PB
Carburetor Pi ton dia. (mm) 
Venturi dia. (mm)
14
Ignition y tem type CDI electromagnetic
Ignition
Ignition timing F mark 13.5°±2°/3000rpm
NGK BR8HSA
Spark plug ND 
Spark plug gap (mm) 0.60.7
Battery capacity 12V3AH
Power to tran mi ion gear Power-tran mi ion
gear-clutch
Reduction ratio of power to
tran mi ion

Clutch type Dry multi-di c clutch
Tran mi ion gear operation
type
Automatic centrifugal
type
Tran mi ion ratio
1 peed

Reduction
Type Two- tage reduction
gear 1 t reduction ratio 
2nd reduction ratio

Tran mi ion gear type Non- tage tran mi ion
Tire pre ure
1.50
/2.0 (1 rider)
1.75
(kg/cm²) Front/Rear
wheel 1.75/2.25 (2 rider)
Turning angle Right & left 45°
Brake y tem Front wheel
hydraulic
type Rear wheel Expanding
Su pen ion Front wheel
Tele cope
type Rear wheel Unit wing
Shock ab orber Front wheel
Tele cope
type Rear wheel Unit wing
Frame type Pipe under bone
MASS CO 1.0 g/km
Exhau t
emi ion
concentration MASS
HC+NOX 1.2 g/km

1. SPECIFICATIONS
1
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2
VITALIT
Y 50
SPECIFICATIONS
(4-Stroke)
Name & Model No. SG10AA
Overall length (mm) 1870
Overall width (mm) 700
Overall height (mm) 1120
Wheel ba e (mm) 1296
Engine type O.H.C.
Di placement (cc) 49.5
Fuel U ed 92# nonleaded ga oline
Dry weight (kg) 91
Seating capacity 1 rider (75kg)
Net weight(kg) 97
Front wheel
120/70-12 56J
Rear wheel
130/70-12 59J
Ground clearance (mm) 150
Breaking di tance
(m)(30KPH) 4.4 below
Starting y tem Motor & Kick tarter
Type Ga oline, 4- troke
Cylinder arrangement Single cylinder
Combu tion chamber type Semi- phere
Valve arrangement O.H.C., chain drive
Bore x troke (mm) 39X41.4
Compre ion ratio 10.5:1
Compre ion pre ure 14.0
Max. hor epower 3.8/8000 (p /rpm)
Max. torque (kg m/rpm) 0.35/7000
Open 3°
Port Intake Clo e 11°
timing
Open -9°
Exhau t Clo e 19°
Valve clearance
Intake 0.04
(cold) (mm) Exhau t 0.04
Idle peed (rpm) 1800rpm
Lubrication type Forced pre ure &
Wet ump
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 liter
Type CVK
Main jet No. #82 ( peed limited: #80)
Venturi dia.(mm) φ17
Throttle type PISTON
Type CDI
Ignition timing 28°BTDC/4000rpm
Contact breaker Non-contact point type
Spark plug NGK C7HSA
Spark plug gap 0.60.7mm
Battery Capacity 12V4AH
Clutch
Type CVT
Type Helical gear
Operation Automatic centrifugal
Type
Type V-Belt
Primary
reduction 0.75~2.47
Final
reduction 13.61
FR/RR tire rolling
circumference(mm) 1485/1515
Tire pre ure
Front
1.5
(kgf/cm²) Rear 2.0
Turning Left 45°
angle Right 45°
Brake y tem
Front
Di k brake
type Rear Drum brake
Front Tele cope
Su pen ion
type Rear Under- wing
Frame type Under bone
Tire
Engine

Lubrication
Sy tem

Fuel Sy tem

Carburetor

Electrical Equipment

Ignition Sy tem

Power Drive Sy tem

Tran mi
-
ion Gear

Reduction
Gear

Moving Device

Damping
Device


2. GENERAL INFORMATION
2
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VITALITY 50
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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) ......................................................... 2-12
LUBRICATION POINTS.................................................................... 2-1
WIRING DIAGRAM ........................................................................... 2-15
CABLE & HARNESS ROUTING (2-STROKE)................................ 2-17
CABLE & HARNESS ROUTING (4-STROKE)................................ 2-21
TROUBLESHOOTING (2-STROKE)................................................. 2-25
TROUBLESHOOTING (2-STROKE)------------------------------------ 2- 6
2

2. GENERAL INFORMATION
2
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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.

2. GENERAL INFORMATION
2
-
2
VITALITY 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.
 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.

2. GENERAL INFORMATION
2
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3
VITALITY
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.
 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.
Easy confirm

2. GENERAL INFORMATION
2
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4
VITALITY 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.
 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.
Don’t touch

2. GENERAL INFORMATION
2
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5
VITALITY
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.
 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
(12- ) Refer to page 12- .
Oil
Grease
Special

Remove the rest

2. GENERAL INFORMATION
2
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6
VITALITY 50
SERVICE INFORMATION (2-STROKE)
ENGINE
Standard (mm) Service Limit (mm)
Item VITALITY 50
Cylinder head warpage  0.10
Piston O.D.(5mm from bottom of piston skirt) 8.9558.970 8.90
Cylinder-to- piston clearance 0.10
Piston pin hole I.D. 12.00212.008 12.0
Piston pin O.D. 11.99412.0 11.98
Piston-to-piston pin clearance  
Piston ring end gap (top/second) 0.100.25 0.40
Connecting rod small end I.D. 17.00517.017 17.0
Cylinder bore 9.09.025 9.05
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. .965.985 .94
Movable driven face I.D. 4.0004.025 4.06
Connecting rod big end side clearance  
Connecting rod big end radial clearance
 
Crankshaft runout A/B  
CARBURETOR VITALITY
Setting mark PB168A
Type PB 14
Float level 8.6mm
Main jet #85 (Speed limit type: #72)
Slow jet # 5
Air screw opening 2 1/2±1/2
Idle speed 1850±100rpm
Throttle grip free play 26mm
Jet needle clip notch 1st notch

2. GENERAL INFORMATION
2
-
VITALITY 50
FRAME Standard (mm) Service Limit (mm)
Item VITALITY 50
Axle shaft runout  0.2
Radial
Front wheel rim runout
Axial
Front shock absorber spring free length 214.7
Rear wheel rim runout 2.0
Brake drum I.D. Front/rear 110 111
Brake lining thickness Front/rear 6.4/4.0 2.0/2.0
Brake disk runout Front/rear  0. 0
Rear shock absorber spring free length 209
ELECTRICAL EQUIPMENT VITALITY 50
Capacity 12V AH
Voltage 1 .01 .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 0.15 0.187Ω
Secondary coil
(with plug cap) 6.99K10.21KΩ
Ignition coil resistance
Secondary coil
(without plug cap) .24K.96KΩ
Pulser coil resistance (20) 80160Ω
Ignition timing 1 .5°±2°BTDC/ 000 rpm

2. GENERAL INFORMATION
2
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8
VITALITY 50
SERVICE INFORMATION (4-STROKE)
ENGINE
Standard (mm) Service Limit (mm)
Item VITALITY 50 (4-Stroke)
Cylinder head warpage  0.10
Piston O.D.(4.55mm from bottom of piston skirt) 8.9758.99 8.90
Cylinder-to- piston clearance 0.0100.040 0.10
Piston pin hole I.D. 1 .0021 .008 1 .04
Piston pin O.D. 12.9941 .0 12.96
Piston-to-piston pin clearance 0.0020.014 0.02
Ring-to-groove (top/second) 0.150.55 0.09
Connecting rod small end I.D. 1 .0161 .0 4 1 .06
Cylinder bore 9.09.01 9.1
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. .965.985 .94
Movable driven face I.D. 4.0004.025 4.06
Connecting rod small end free play 0.050.4 0.6
Connecting rod big end radial clearance
00.008 0.05
Run out  0.10
CARBURETOR Standard
Setting mark CVK104A
Type CVK 18
Float level 20.5
Main jet #82 (speed limited: #80)
Slow jet # 5
Pilot screw opening 2±1/2
Idle speed 1800±100rpm
Throttle grip free play 26mm

2. GENERAL INFORMATION
2
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9
VITALITY 50
FRAME Standard (mm) Service Limit (mm)
Item VITALITY 50 4-stdroke
Axle shaft runout  0.2
Radial
Front wheel rim runout
Axial
Front shock absorber spring free length 214.7
Rear wheel rim runout 2.0
Brake drum I.D. Front/rear 110 111
Brake lining thickness Front/rear 6.4/4.0 2.0/2.0
Brake disk runout Front/rear  0. 0
Rear shock absorber spring free length 209
ELECTRICAL EQUIPMENT VITALITY 50 (4-stroke)
Capacity 12V4AH
Voltage 1 .01 .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 cap) KΩ
Pulser coil resistance (20) 118.1118.2Ω
Ignition timing 28°±2°BTDC/4000 rpm

2. GENERAL INFORMATION
2
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10
VITALITY 50
TORQUE VALUES
ENGINE (2-STROKE)
Item
Thread dia. (mm)
Torque (kgf
-
m)
Remarks
Cylinder head bolt
Clutch drive plate nut
Clutch outer nut
Drive face nut
Oil check bolt
Engine mounting bolt
Engine hanger bracket bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
BF7x115
10
NH10
NH12
10
BF10x95
BF10x50
NC6mm
BF8x 5
1.01.2
.54.0
.54.5
5.06.0
1.01.5
4.55.5
.54.5
1.01.4
.0.6
1.11.7
(cold)
(cold)
ENGINE (4-STROKE)
Item Q‘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
4
2
1
2
1
7
1
1
1
1
1
1
1
1
2
2
4
8
0
6
8
5
6
6
8
8
8
12
10
28
10
10
10
6
8
5
6
0.71.1
1.02.0
1.01.4
1.21.6
0.71.1
0.81.2
1.01.4
0.40.7
2.4.0
0.81.2
5.56.5
.54.5
5.06.0
.54.5
1.01.4
2.0.0
0.10.
0.71.1
0.71.1
0.81.0
0.61.0
Apply oil
Apply oil
Apply oil

2. GENERAL INFORMATION
2
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11
VITALITY 50
FRAME
Item
Thread dia. (mm)
Torque (kgf
-
m)
Remarks
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
Rear brake arm bolt
Front fork
upper mount bolt
lower mount bolt
Front brake caliper bolt
Brake fluid bolt
Front pivot arm bolt
Rear shock absorber:
upper mount bolt
lower mount bolt
Engine hanger bolt
10
25.4
25.4
12
16
6
8
8
8
10
5
10
8
10
5.06.0
6.08.0
0.51.
5.07.0
11.01 .0
1.01.4
.0.6
.0.6
2.9.5
.04.0
0. 0.5
.54.5
2.4.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 bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.450.6
0.81.2
1.82.5
.04.0
5.06.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0. 50.5
0.71.1
1.01.4
2.4.0
.54.5

2. GENERAL INFORMATION
2
-
12
VITALITY 50
SPECIAL TOOLS (2-STROKE)
Tool Name Tool No. Remarks
Universal bearing puller E0 7
Lock nut socket wrench F001
Lock nut wrench, F007
Race cone install F005
Crankcase puller E026
Crankshaft bearing puller E0 0
Oil seal & bearing install E014
Clutch spring compressor E0 4
Crankcase assembly collar E02
Crankcase assembly tool E024
Universal holder E017
Flywheel puller E001
SPECIAL TOOLS (4-STROKE)
Tool Name Tool No. Remarks
Universal bearing puller E0 7
Lock nut socket wrench F001
Lock nut wrench, F007
Race cone install F005
Oil seal & bearing install E014
Clutch spring compressor E0 4
Universal holder E017
Flywheel puller E001
Valve adjuster E0 6

2. GENERAL INFORMATION
2
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13
VITALITY 50
LUBRICATION POINTS
ENGINE (2-STROKE)
NO.
Lubrication Points
Lubricant
1 Crankcase sliding & movable KYMCO 2-STROKE OIL or QUIVALENT
2 Cylinder movable parts KYMCO 2-STROKE OIL or QUIVALENT
Transmission gear (final gear) SAE-90#
4 Kick starter spindle bushing Grease
5 Drive pulley movable parts Grease
6 Starter pinion movable parts Grease
LUBRICATION POINTS
ENGINE (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
Balance gear
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SG Engine Oil
Transmission gear and movable parts Gear oil: SAE90#

2. GENERAL INFORMATION
2
-
14
VITALITY 50
FRAME
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) Front/Rear Brake Lever
(2) Throttle Cable
( ) 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

2. GENERAL INFORMATION
2
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15
VITALITY 50
WIRING DIAGRAM (2-STROKE)