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)

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

VITALIT

Y 50

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. SPECIFICATIONS

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)

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

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

VITALITY 50

__________________________________________________________________________________

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. GENERAL INFORMATION

VITALITY

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

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

VITALITY

 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

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

VITALITY

 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

Other manuals for Vitality 50

Table of contents

Popular Scooter manuals by other brands

TEKTRO

TEKTRO CHEETAH owner's manual

Douglas

Douglas Vespa Sprint Operation and maintenance

PLAYTIVE

PLAYTIVE AS-2448 Instructions for use

Ebinger

Ebinger DONKEY XL User instructions

Flyer

Flyer Mountain Original instruction manual

BackCountry eBikes

BackCountry eBikes Storm owner's manual

equipmed

equipmed FreeRoam II user manual

Yoto

Yoto Lion owner's manual

WESTHILL BIKES

WESTHILL BIKES LINK user manual

BAnff

BAnff eProdigy series Assembly manual

Winther

Winther 475 Assembly instruction

Jetson

Jetson JBZL17 user manual

First Choice Mobility

First Choice Mobility Roma Medical Corella S741 user manual

Carrera

Carrera impel manual

Afikim

Afikim Superlight SL-3 user manual

CareCo

CareCo ZOOM owner's manual

Douglas

Douglas Vespa G.S. Service manual

Gazelle

Gazelle with BOSCH System user manual