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1. ys d SERVICE INFORMATION 1 2 TROUBLESHOOTING tects ett cee ete ra CYLINDER E MOVA a EIER RRE ereecht 7 4 BISTONANSTAELATION 7 6 CYLINDER INSTALLATION eoe euentus 7 6 7 0 7 CYLINDER PISTON ACTIVE 50 SCHEMATIC DRAWING dC KYMCO 7 CYLINDER PISTON ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder and piston can be serviced with the engine installed in the frame e When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed e After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS Standard Limit mm Service Limit mm ID Cylinder Wapage 00 Cylindricity DO ee ae GENE True roundness 0 05 Ring to groove o O clearance Second _ 02 0 1 0 25 0 top 5 Piston Ring end gap 01 025 Sea 5 0 piston ring Oil side rail 0 55 58 5595 5mm from bottom of 5mm from bottom of skirt Piston O D measuring position MMI Puen Pan ibn Piston to piston pin clearance 0 005 0 014 0 1 Piston pin hole I D 0 01 0 35 13 00 Piston pin O D 12 994 13 000 12 944 Connecting rod small end I D bore 13 016 13 034 13 08 TROUBLESHOOTING e When hard starting or poor perf
2. 7714 mye te H d LLLLIEI Em t gt lag EL SE LL x PTT TTTTTI m HI Ly o AR 10111504 Wt 16 h h G I ILL j pt tty a C Hil Nd HERE y 7 baut EE ZS p d s d EE Im i Ho 2 ss 3 RE S crs Um Wk Mag sa SEH EE EEN ER RN 28 _ ERES 27 1 _ 1 E Mei edt 3 E w wl o xr L ___ 2 prp Mu 1 LH ew 1 3 n sajana l a E AZT D A I mor AZT 7 it MOT 1 16 dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START ispection Adjustmen Check if fuel reaches carburetor by loosening drain screw Probable Cause Empty fuel tank Clogged carburetor fuel inlet tube vacuum tube or fuel tube Clogged float oil passage logged fuel filter Clogged charcoal canister Clogged auto fuel valve strainer Faulty valve passage Faulty fuel pump Fuel reac
3. 11 3 HANIDEBBAR 11 4 FERONT 11 7 FRONT SHOCK ABSORBER cessed ade cinese eade 11 11 STEERING S 11 16 11 0 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 SCHEMATIC DRAWING 11 1 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS SPECIFICATIONS Front axle shaft runout Lex FIRE Front fork spring free length 328 2 Front fork tube runout E o Front fork oil capacit 80 le TORQUE VALUES Steering stem lock nut 6 0 8 0kg m Front axle nut 5 0 6 0kg m Steering top cone race 0 15 0 25kg m Front fork mount bolt 1 8 2 5kg m Master cylinder holder 1 8 2 5kg m Front brake disk nut 1 8 2 5kg m SPECIAL TOOLS Lock nut wrench Lock nut socket wrench Outer driver 28x30mm Rear shock absorber remover Rear shock absorber compfressor Ball race remover Driver handle A Outer driver 37x40mm Pilot 10mm Bearing puller snap ring pliers close Damper compressor 11 2 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 TROUBLESHOOTING Hard steering e nsufficient tire pressure e Excessively tightened steering stem nut e Damaged steering stem bearings e Damaged steering bearing races Steers to one side or does not track straight e Uneven front sho
4. 6 CYLINDER HEAD VALVES CYLINDER HEAD DISASSEMBLY Remove the two bolts and the right side COVer Screw 8mm bolt into the rocker arm shaft and pull it out of the cylinder head Remove the rocker arms and camshaft from the cylinder head While compressing the valve spring with a valve spring compressor remove the valve cotters Loosen the valve spring compressor and remove the valve retainers valve springs spring seats stem seals and valves e To prevent loss of tension do not compress the valve springs more than necessary to remove the valve spring cotters e Mark all parts to insure original assembly Right Side Cover 6 5 KYMCO ACTIVE 50 aul ASA a Rocker Arm Shaft Rocker Arms Camshaft Valve Spring Compressor Remove carbon deposits from the combustion chamber KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 Clean any gasket material from the cylinder head mating surface Be careful not to damage the cylinder head mating surface and valve seat CYLINDER HEAD INSPECTION 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 CAMSHAFT INSPECTION Check each camshaft bearing for play or damage Replace the camshaft assembly with new one if the bearings are noisy or have excessive play Camshaft Bearing Ch
5. dC KYMCO ACTIVE 50 CD e w Snapping rie 1 6 1 GENERAL INFORMATION B clamping check each wire to make sure it 15 secure not squeeze wires against the weld or its clamp B clamping check each harness to make sure that it is not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat B 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 dO KYMCO ACTIVE 50 KYMCO 1 GENERAL INFORMATION 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 E When rubber protecting cover is used to protect the wire harnesses 1 shall be installed securely not break the sheath of wire B a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires 1 8 1 GENERAL INFORMATION B 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 inte
6. Perform the periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate Refill Repair or Replace if necessary A Adjust C Clean R Replace Tighten Regular Service Mileage km comes first gt 4000 6000 8000 9 0000 CHEER Engine oil filter screen Fuel filter screen filter screen Replace at every 5000km Valve clearance Inspect at every 3000km and adjust if necessary Carburetor koe e le Pte ET fe Clean at every 2000km and replace at every 5000km e In the interest of safety we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding for long distance in rain or at full throttle 2 2 GQ KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 Fuel Filter FUEL LINE FILTER Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Do not smoke or allow flames or sparks in your working area THROTTLE OPERATION Check for smooth throttle grip movement in all steering positions Measure the throttle grip free play Free Play 2 6mm Adjust the throttle grip free play by turning the adjusting nut on the throttle cable Slide the dust boot out and adjust by loosening the lock nut and turning t
7. Transmission fork Claw thickness Shaft hole I D Transmission fork shaft O D Transmission Left drum O D Transmission gear Crankshaft Gear LD Countershaft 2nd gear Main Shaft O D Starter gear Countershaft M Runout 2 Runout Standard mm 4 93 5 0 34 02 34 05 33 90 33 96 13 13 02 16 10 16 12 17 0 17 018 17 0 17 018 17 016 17 034 23 020 23 041 20 0 20 021 23 020 23 041 20 0 20 021 11 978 11 9899 25 30 25 50 16 966 16 984 11 978 11 989 16 978 16 989 16 978 16 989 18 80 19 0 19 959 19 98 0 05 0 3 0 0 05 0 03 Service Limit mm 4 43 34 05 33 96 13 16 04 17 058 17 058 17 074 23 081 22 061 23 081 22 061 11 938 25 20 16 926 11 938 16 938 16 938 18 760 19 919 0 05 m 10 2 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 SPECIAL TOOLS Bearing remover Bearing remover block Universal bearing puller Bearing driver handle Pilot 15mm Pilot 17mm Pilot 20mm Pilot 22mm Inner bearing driver handle Bearing outer driver TROUBLESHOOTING Excessive engine noise e Worn main shaft journal bearing e Worn crankshaft pin bearing e Worn transmission bearings Transmission gear tripping e Worn gear teeth e Bent transmission fork e Bent transmission fork shaft e Damaged gear shift cam stopper Hard shifting e adj
8. 11 16 gt 2 5 10 10 10 10 11 18 11 9 8 3 8 7 9 6 11 9 10 10 9 5 9 9 11 17 KYMCO 1 GENERAL INFORMATION ACTIVE 50 LUBRICATION POINTS Po m SPEEDOMETER THROTTLE BRAKE CABLE CHAIN LUBRICANT DRIVE CHAIN THROTTLE GRIP STEERING HEAD BEARINGS a SWING ARM BRAKE CAM PIVOT VUSHINGS amm CENTER amp SIDE STAND PIVOTS i SPEEDOMETER WHEEL BEARINGS BRAKE PEDAL GEAR PIVOT WHEEL BEARINGS 1 13 GQ KYMCO 1 GENERAL INFORMATION ACTIVE 50 CABLE amp HARNESS ROUTING Throttle Cable Front brake hose Ignition Switch 1 14 dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 Winker Relay Lm Wire Harness Horn Front Brake Hose Ignition Coil Starter Ignition Choke Cable Motor Coil Wire 1 15 50 1 GENERAL INFORMATION WIRING DIAGRAM Ae ul 1 5 a PII E DDT BLT nuin Sot nat wazo w CO AS 4015 Ed AS MOILISOd WIS OLLI SOd ESA ura AS 4 MS 3 W3HMIG 11 5 DP d dd ep E 0000 n ui 28 0 5 2 T Arad 5 77 Le SCH D T E 1 x E 85 Ma
9. dC KYMCO 15 IGNITION SYSTEM ACTIVE 50 Black Yellow EXCITER INSPECTION This test is performed with the stator installed in the engine Remove the met im box Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 80 1600 EXCITER COIL INSPECTION Disconnect the exciter coil wire coupler and measure the resistance between the black red wire terminal and ground Resistance 550 650 15 6 GQ KYMCO 16 CHARGING SYSTEM ACTIVE 50 o CHARGING SYSTEM SERVICE INFORMA TION 16 2 DRQUBEESHOOTINGOee e 16 3 EIERE 16 4 PERFORMANCE 16 5 BSC GENERA VO Reese ata cscs ice 16 5 REGULATOR RECTIFIER 16 6 16 0 GQ KYMCO 16 CHARGING SYSTEM ACTIVE 50 Battery Positive Regulator Rectifier able pmo 4 Ka f Starter Relay 12V5AH 16 1 GQ KYMCO 16 CHARGING SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e battery is MF battery which needs no refilling of distilled water e Do not quick charge the battery Be sure to use a MF battery charger and the battery temperature should not exceed 45 e Remove the battery from the motorcycle for charging If the battery must be charged on the motorcycle keep sparks and flames away from a cha
10. 2 INSPECTION ADJUSTMENT ACTIVE 50 VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold below 35 Remove the cylinder head cover Cylinder Head Cover p Rotate the generator flywheel to locate the camshaft on the top dead center TDC and align the mark on the flywheel with the mark on the left crankcase cover After adjustment rotate the crankshaft several turns to make sure that the valve clearance 15 correct Inspect and adjust the valve clearance Valve Clearance IN 0 02mm EX 0 02mm Loosen the lock nut and adjust by turning the adjusting bolt lappet adjuster E012 Check the valve clearance again after the lock nut 15 tightened CARBURETOR IDLE SPEED The engine must be warm for accurate idle speed inspection and adjustment Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700 100rpm When the engine misses or run erratic adjust the air screw When adjusting the carburetor make sure to use a E M tester E 4 Throttle Stop Screw 2 5 dO KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 IGNITION TIMING e The CDI unit 15 not adjustable e If the ignition timing is incorrect check the ignition system Remove the ignition timing eye hole cap on the left crankcase cover Check the ignition timing with a timing light When the engine 1s running at idle speed the ignition timing 15 correct
11. Exhaust muffler joint lock nut 0 8 1 2kg m 5 1 dC KYMCO 5 ENGINE REMOVAL INSTALLATION ACTIVE 50 ENGINE REMOVAL Remove the right and left decorative covers under the seat Remove the carburetor page 4 5 Remove the two exhaust muffler joint lock nuts Remove the exhaust muffler hanger lock bolt and exhaust muffler e Drain the engine oil before engine removal e The exhaust muffler temperature is extremely high Remove it when the engine is cold Screw Bolt Remove the spark plug cap Disconnect the A C generator wire connector Loosen the rear axle nut and adjust the drive chain slack page 2 7 5 2 5 ENGINE REMOVAL INSTALLATION Remove the gear shift lever bolt and gear shift lever Remove the two bolts attaching the left rear crankcase cover and remove the rear crankcase cover Remove the two bolts attaching the drive gear set plate and the set plate Remove the drive gear and chain Remove the engine hanger nuts and pull out the engine hanger bolts Remove the engine ENGINE INSTALLATION Install the engine in the reverse order of removal Install the engine to its original position with a jack or other adjustable support e When installing the engine do not damage the bolt thread and route the wires and cables properly e Install the gear shift lever by align punch mark on the lever with that on the spindle e Fill the crankcase to the proper level wi
12. Light does not come on when ignition Headlight beam does not change when switch is dimmer switch is operated e Burned bulb e Faulty or burned bulb e Faulty ignition or light switch e Faulty dimmer switch e Fuse burned out e wire connection e Dead battery or loose battery wire Light comes on but dims e Weak battery e Wire or switch resistance too high e Aged bulb or faulty lighting circuit 18 1 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 HEADLIGHT REMOVAL Remove the handlebar front cover page 14 5 Remove the headlight unit and disconnect the headlight wire coupler Remove the headlight bulb and bulb socket Check the bulb for damage and replace with a new one if necessary INSTALLATION Install the headlight in the reverse order of removal L After installation adjust the headlight beam INSTRUMENT INSTRUMENT BULBS REPLACEMENT Remove the handlebar rear cover page 14 Remove the bulbs and replace with new ones SPEEDOMETER REMOVAL Disconnect the speedometer cable Disconnect the speedometer wire connector Remove the three screws attaching the speedometer seat Remove the speedometer INSTALLATION The installation sequence is the reverse of removal Screws 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 TURN SIGNAL LIGHT Remove the cover FR handle Renove the two turn si gnal i ght bul b The installation sequ
13. Lower Limit specified engine oil OIL CHANGE The engine oil will drain more easily while the engine 15 warm Remove the drain bolt to drain the engine oil thoroughly Check the drain bolt washer for damage or deformation and replace with a new one if necessary ENGINE OIL FILTER Remove the right crankcase cover attaching bolts and right crankcase cover Remove the dowel pins and gasket Clean oil filter screen Specified Oil SAEI5WA0 API service classification SG Oil Capacity At disassembly 1 0 liter At change 0 9 liter Check for oil leaks and then start the engine and let it idle for few minutes Stop the engine and recheck the oil level Oil Filter Screen Cap 3 LUBRICATION SYSTEM OIL PUMP OIL FILTER ROTOR REMOVAL Remove the right crankcase cover page 9 3 When installing make sure to use a new right crankcase cover gasket OIL FILTER ROTOR Remove the filter rotor cover and gasket pqge 9 3 Clean the oil filter rotor cover and rotor Install the oil filter rotor cover page 9 9 Install the right crankcase cover page 9 11 OIL PUMP The oil pump can be removed with the engine mounted in the frame Remove the oil drain bolt and drain the oil from the engine page 3 3 Remove the right crankcase cover page 9 3 Remove the clutch drum page 9 3 Remove the three oil pump mounting bolts and oil pump DISASSEMBLY Remove the three cover screws and cover Remov
14. SUSPENSION 2 9 NUTS BOLTS FASTENERS 2 9 WHEELS TIRES 2 9 STEERING HANDLEBAR 2 10 GQ KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 SERVICE INFORMATION GENERAL N WARNING eBefore running the engine make sure that the working area 1s well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline 15 extremely flammable and 15 explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE CHASSIS Throttle grip free play 276mm Front brake free play 10 20mm Spark plug gap 0 6 0 7mm Rear brake free play 20 30mm Spark plug specification NGK DRSEA Brake fluid DOT 4 Valve clearance IN 0 02mm EX 0 02mm Cylinder compression 1342kg cm Ignition timing 15 2 1700rpm Idle speed 1700 100 Engine oil capacity At disassembly 1 0 liter At change 0 9 liter TIRE PRESSURE MM me TIRE SIZE Front 2 5 17 Rear 2 75 17 TORQUE VALUES Front axle nut 5 5 7 0kg m Rear axle nut 6 0 8 0kg m 2 1 dC KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 MAINTENANCE SCHEDULE
15. between the front stop switch wires Brake lever applied There is continuity Brake lever released There 15 no continuity REAR STOP SWITCH Remove the right side cover Disconnect the rear stop switch wire coupler Check for continuity between the rear stop switch wires Brake pedal depressed There 15 continuity Brake pedal released There is no continuity TURN SIGNAL SWITCH Disconnect the turn signal switch wire coupler Check for continuity between the turn signal switch wires Turn Signal Switch HEADLIGHT SWITCH Disconnect the headlight switch wire coupler Check for continuity between the headlight switch wires 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 Passing Switch Dimmer Switch DIMMER SWITCH Disconnect the dimmer switch wire coupler Check for continuity between the dimmer switch wires nto oto Oo H PASSING SWITCH GEARSHIFT DISPLAYER I Disconnect the gearshift displayer wire coupler 2 Check if all the gearshift displayer wire connect correctly or not Lr N 1 LET lt gearshift displayer wire LUN um 18 6 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 FUEL UNIT L No Smoking REMOVAL Remove the seat Refer to 4 10 Disconnect the fuel unit wire connectors I Do not damage the fuel unit wire Remove the fuel unit M r Be careful not to bend or
16. e 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 Venturi dia SPECIAL TOOL Float level gauge 4 FUEL SYSTEM TROUBLESHOOTING Engine cranks but won t start e No fuel in tank e No fuel to carburetor e Cylinder flooded with fuel e No spark at plug e Faulty fuel pump e Clogged air cleaner e Intake air leak e Improper throttle operation Engine idles roughly stalls or runs poorly e Faulty charcoal canister e Ignition malfunction e Faulty carburetor e Poor quality fuel e Lean or rich mixture e Clogged air cleaner e Incorrect idle speed e Worn throttle needle Misfiring during acceleration e Faulty ignition system e Faulty carburetor e Faulty accelerating pump e Faulty charcoal canister Backfiring at deceleration e Float level too low e Incorrectly adjusted carburetor e Faulty exhaust muffler KYMCO ACTIVE 50 Engine lacks power e Clogged air cleaner e Faulty carburetor e Faulty ignition system Lean mixture e Clogged carburetor fuel jets e Float level too low e ntake air leak e Faulty charcoal canister e Restricted fuel line Rich mixture e Float level too low e Clogged air jets e Clogged air cleaner dO KYMCO 4 FUEL SYSTEM ACTIVE 50 AIR CLEANER REMOVAL Remove the front cover page 14 3 Remove the screw attaching the car
17. if the index mark on the left crankcase cover aligns with the mark on the flywheel Timing Light Mark CYLINDER COMPRESSION Se Warm up the engine before compression test Stop the engine then remove the spark plug and insert a compression gauge Open the throttle valve fully and crank the engine with the starter motor or kick lever Measure the compression Compression 13 2kg cm Compression Gauge 5 If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn piston rings Worn piston cylinder If the compression 15 high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head dC KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 Upper Limit ENGINE OIL Lower Limit When checking the oil level place the motorcycle on its main stand on level eround for oil level check After the engine is stopped for 10 minutes check if the oil level 15 between the upper and lower limits If the oil level 1s low add the recommended oil to the proper level Recommended Oil SAE15W40 API SG After oil change be sure to tighten the drain bolt securely Check the drain bolt washer for damage Oil Capacity At disassembly 1 0 liter At change 0 9 liter Drain Bolt DRIVE CHAIN Rear Axle Nut Check the drive chain slack Specified Slack 1 2cm Driv
18. in this manual may be different from the motorcycle in case specifications are changed KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION dO KYMCO 1 GENERAL INFORMATION ACTIVE 50 GENERAL INFORMATION ENGINE SERIAL NUMDER eerca 1 1 SPECICATION ec 1 2 SERVICE PRECAUTION 1 3 TOROUE VALUES 1 11 SPECIAL ee eee 1 12 LUBRICATION RER 1 13 CABLE amp HARNESS ROUTING 1 14 WIRING 1 18 TROUBLESHOOTING ee 1 19 1 0 dO KYMCO 1 GENERAL INFORMATION ACTIVE 50 ENGINE SERIAL NUMBER Location of Frame Serial Number 1 1 GQ KYMCO 1 GENERAL INFORMATION ACTIVE 50 SPECIFICATIONS Aliter Dry weight kg l Wet multi disc clutch Operating method NEN Cycle type 25 17 Tires 2 5 1 Ground clearance mm 120 Braking distance m under Perform ance 54 ony jueuidimbq 621299 215 lt uonius H lt lt Lei eM ICIN UOISSTUISUPI J Min turning radius 3800 R L mm Starting motor amp Starting system Ei cis Va Front Axle Wheel base 1305 Tire pressure C Turning angle 45 Brake system Telescope Zz Mono Shock Cylinder arrangement Single cylinder Combustion chamber type Semi sphere Single cam OHC g
19. parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal Item Standard mm Service Limit mm IN Mois linder head compression pressure 13ke cm EE head warpage 005 N 258 o aCe exe E e O 0 NaNO Ue i exe Valve rocker am shalt EO O a 9 IN 1492 4970 4 90 4 950 E E Midi pe NEC NU ENCORE NNI CON Valve stem to guide IN EL _ TORQUE VALUES Cylinder head cap nut 1 0 2 0kg m Valve clearance adjusting nut 0 9kg m Cylinder head cover nut 1 2 1 6kg m SPECIAL TOOLS Valve spring compressor 6 2 KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 TROUBLESHOOTING e The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler e Compression too low e Worn valve stem or valve guide e Damaged valve stem oil seal Compression too low e ncorrect valve clearance adjustment Abnormal noise e Burned or bend valves e Incorrect valve clearance adjustment e ncorrect valve timing e Sticking valve or broken valve spring e Broken valve spring e Damaged or worn camshaft e Poor valve and seat contact e Worn cam chain tensioner e Leaking cylinder head gasket e Worn camshaft and rocker arm e Warped or cracked cyli
20. tighten the four bolts Torque 0 8 1 2kg m 8 8 dC KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 CLUTCH GEAR SHIFT MECHANISM SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 3 RIGHT CRANKCASE COVER REMOVAL 9 4 CENTRIFUGAL CLUTCH MANUAL CLUTCH REMOVAL 9 4 CENTRIFUGAL CLUTCH MANUAL CLUTCH INSTALLATION 9 8 GEAR SHIFT MECHANISM 9 11 RIGHT CRANKCASE COVER INSTALLAION 9 12 9 0 KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 9 1 KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The clutch and gear shift mechanism can be serviced in the frame e nstall the clutch plates in the same chamfer direction e Install the thrust washer with the chamfer facing up and the flat facing down SPECIFICATIONS ITEM STANDARD SERVICE mat Clutch outer LD 110 4mm 45 80mm Gear primary drive O D 34 25mm 34 15 Center clutch O D 68 00mm 67 7mm Guide clutch center O D 21 00 20 97 20 93 Centrifugal clutch Spring clutch U5mm Spring clutch free 21mm thickness thickness TORQUE VALUES Centrifugal clutch lock nut 3 8 4 5kg m Manual clutch lock nut 3 8 4 5kg m Drum stopper bolt 0 8 1 2kg m SPECIAL TOOLS Clutch holder E01
21. to draw the brake fluid out through the hose BRAKE FLUID REFILLING Bleed Valve Connect a transparent hose and syringe to the brake caliper bleed valve and then loosen the bleed valve nut Brake Reservoir Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there 15 no air bubbles in the hose Then tighten the bleed valve nut e When drawing brake fluid with the syringe the brake fluid level should be kept over 1 2 of the brake reservoir height e Use only the recommended brake fluid Recommended Brake Fluid DOT 4 Bleed Valve Brake Lever BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever after continuously pull it several times Then loosen the bleed valve nut to bleed air from the brake system Repeat these steps until the brake system 15 free of air When bleeding air from the brake system the brake fluid level should be kept over 1 2 of the brake reservoir height Bleed Valve 13 4 dC KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 BRAKE PAD DISK BRAKE PAD REPLACEMENT Remove the two bolts attaching the brake caliper holder I The brake pads can be replaced without removine the brake fluid tube Remove the brake caliper Remove the pad pin bolts and brake pads Remove the pad springs Pin Bolts ASSEMBLY Assemble the brake pads in the reverse order of removal Tighten the pad pi
22. top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely and that there 1s no vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 6 0 8 0kg m Install the handlebar Install the speedometer cable Lock nut socket wrench Lock Nut Wrench Steel Balls 11 18 dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 REAR WHEEL BRAKE SUSPENSION SERVICE ENFORIVIA LION WE 12 2 EECH EE 12 3 REAR WHEED oos opui HC MINUM RDUM EAM EM E 12 4 REARBRAKE deat cpu 12 7 REAR SHOCK ABSORBER 12 10 Co 12 11 12 0 KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 SCHEMATIC DRAWING 12 1 dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e When installing the drive chain joint clip the cutout of the clip should be opposite to the rotating direction e After the drive chain 15 adjusted make sure that the rear brake pedal free play 15 normal and adjust it 1f necessary SPECIFICATIONS Item Standard mm Service Limit mm Rear axle shaft runout Hue ee Rear rim runout Rear brake drum LD Rear brake lining thickness Rear shock absorber spring free length 266 266 TORQUE VALUES Rear shock absorber up
23. 4 4 Remove the two screws from right side and left side of the rear frender Remove the rear frender The installation sequence 15 the reverse of removal HANDLEBAR FRONT REAR COVER REMOVAL Remove the three screws attaching the handlebar rear cover Disconnect the handlebar rear cover Remove the handlebar front cover Disconnect the headlight and the signal wire connector The installation sequence 15 the reverse of removal 14 5 dC KYMCO ACTIVE 50 Rear Cover KYMCO 14 FRAME COVER ACTIVE 50 Horn Wire Disconnect the instrument light and the horn wire connector Instrument Light Wire Disconnect the speedometer cable Remove the handlebar rear cover The installation sequence 15 the reverse of removal Speedometer Cable EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the exhaust muffler lock nut Remove the exhaust muffler INSPECTION Inspect the exhaust muffler joint and gasket for damage deformation or leakage Replace if necessary INSTALLATION Install the exhaust muffler joint and gasket and then install the exhaust muffler First tighten the two exhaust muffler joint lock nuts and then tighten the exhaust muffler lock nut Torques Exhaust muffler joint lock nut 0 8 1 2kg m Exhaust muffler hanger lock bolt 2 4 3 0kg m 14 6 dC KYMCO 15 IGNITION SYSTEM ACTIVE 50 gt IGNITION SYSTEM SERVICE INF
24. 7 Lock nut wrench 18mm E010 Gear holder Lock nut wrench 20mm E009 Flywheel holder E021 TROUBLESHOOTING dC KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Faulty clutch operation can usually be corrected by adjusting the clutch Clutch slips when accelerating e Faulty clutch lifter mechanism e Discs worn e Weak spring e ncorrect clutch adjustment Clutch will not disengage e Faulty clutch lifter e ncorrect clutch adjustment e Plates warped ATC creeps with engine idling e Faulty centrifugal clutch Clutch operation feels rough e Rough manual clutch outer slots e Worn or damaged centrifugal clutch shoes or drum Gearshift pedal will not return e Weak or broken gearshift spindle return spring e Binding gearshift spindle Hard to shift e Gearshift spindle damaged e Stopper plate and pin damaged e Stopper plate bolt loosened e Clutch adjustment incorrect Transmission jumps out of gear e Stopper arm damaged e Stopper plate damaged e Stopper plate bolt loosen 9 3 dC KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 RIGHT CRANKCASE COVER REMOVAL Drain the engine oil page 3 3 Remove the kickstarter pedal Remove the right crankcase cover attaching bolts and right crankcase cover Remove the dowel pins and gasket CLUTCH LIFTER REMOVAL INSPECTION Remove the lock nut and O ring Remove the clutch adjusting bolt and clutch lifter Check the removed parts for wear or damage and replace them i
25. ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with Ist rubber cup e During assembly the master cylinder main piston and spring must be installed as a unit without exchange e When assembling the piston soak the cups in brake fluid for a while Install the main piston and snap ring Install the rubber cover Install the brake lever Place the brake master cylinder on the handlebar and install the master cylinder holder with the UP mark facing up aligning the tab on the holder with the hole in the handlebar First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Install the brake fluid tube with the bolt and two sealing washers Then install the rearview mirror Fill the brake reservoir with recommended brake fluid to the upper level Bleed air from the hydraulic brake system Refer to 13 4 GQ KYMCO ACTIVE 50 Fluid Tube Bolt UP Mark Sealing Washer Bolt dC KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 BRAKE CALIPER REMOVAL Remove the brake caliper and brake pad springs Place a clean container under the brake caliper and disconnect the brake fluid tube from the brake caliper Be careful not to splash brake fluid on rtl y any coated surfaces Caliper Seat Caliper Seat DISASSEMBLY Remove the brake caliper seat from the brake caliper Remove the pistons from the brake cal
26. Commutator bar pairs Continuity normal Commutator bars and armature shaft No continuity normal 17 3 dC KYMCO ACTIVE 50 Mounting Bolts O Ring Case Starter Gear Gasket Gear Cover Commutator Bearing Continuity e No Continuity C KYMCO 17 STARTING SYSTEM ACTIVE 50 Continuity Check for continuity from the cable terminal to the brush holder and from the cable terminal to the brush Cable terminal and brush holder No continuity normal Cable terminal and brush Continuity normal Inspect the brushes for wear or damage Measure the brush length Service limit 8 5mm Inspect the brush springs for wear or fatigue INSDTALLATION Install a new O ring and apply oil to it Install the starter motor and tighten the three mounting bolts securely Install the ground terminal properly as shown with starter motor mounting bolt Connect the starter motor connector Install the starter clutch page _ Install the front cover Mounting Bolts 17 4 C KYMCO 17 STARTING SYSTEM ACTIVE 50 Starter Relay STARTER RELAY INSPECTION Remove the left side cover Disconnect the starter relay coupler and then remove the starter relay Connect the starter relay yellow red terminal to the 12V battery positive terminal and the relay green terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The
27. Fuel Unit Wire FUEL TANK INSTALLATION Install the fuel tank in the reverse order of removal Check that there is no fuel leakage Check the wire connectors for proper connection Fuel Strainer 4 11 GQ KYMCO 5 ENGINE REMOVAL INSTALLATION ACTIVE 50 2 B ENGINE REMOVAL INSTALLATION SERVICE INFORMATIONS 5 1 BIN Go RE e E Le 5 2 ENGINE INSTAL EN E 5 3 5 0 dC KYMCO 5 ENGINE REMOVAL INSTALLATION ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e A engine stand or floor jack is required to support and maneuver the engine e The following parts can be serviced with the engine installed in the frame Cylinder head valves Section 6 Cylinder piston Section 7 Alterantor cam chain tensioner Section 8 Clutch gear shift mechanism Section 9 e When removing and installing the engine do not use a hammer or screw driver to strike or pry the engine e Do not damage the crankcase mating surfaces and clean off all gasket materials from the mating surfaces e After crankcase assembly check that the transmission system operates smoothly e After engine installation start the engine and check that the lubrication system is normal Engine oil capacity At disassembly 1 0 liter At change 0 9 liter TORQUE VALUES Engine bracket bolt 2 0 2 5kg m Drive gear lock bolt 0 8 1 2 Exhaust muffler hanger lock bolt 2 4 3 0kg m Rear fork pivot nut 5 57 6 5kg m
28. LIC BRAKE SERVICE INFORMATION 1322 TROUBLESHOOTING 13 3 BRAKE FLUID CHANGE AIR BLEED 13 4 BRAKE PAD DISK 13 5 BRAKE MASTER CYLINDER 13 6 BRAKE CALIPER 13 9 13 0 GQ KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 SCHEMATIC DRAWING 2 5 3 5 2 4 3 0kg m 13 1 KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e Drain the brake fluid from the hydraulic brake system before disassembly e Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir with brake fluid e Be careful not to splash brake fluid on any coated surfaces and instrument covers to avoid damage e Inspect the brake operation before riding e Brake fluid will damage painted coated surfaces and plastic parts When working with brake fluid use shop towels to cover and protect painted rubber and plastic parts Wipe off any splash of brake fluid with a clean towel Do not wipe the motorcycle with a towel contaminated by brake fluid e Make sure to use recommended brake fluid Use of other unspecified brake fluids may cause brake failure SPECIFICATIONS Brake dis
29. LY Install new valve stem seals when assembling Lubricate each valve stem with oil Insert the valves into the valve guides Install the valve spring seats and valve stem seals Be sure to install new valve stem seals Apply engine oil to the inside of the valve stem seals and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters e When assembling a valve spring compressor must be used e Install the cotters with the pointed ends facing down from the upper side of the cylinder head Special Tool Valve Spring Compressor GQ KYMCO ACTIVE 50 Valve Outer Spring Inner Spring Stem Seal Retainer Valve Cotters Tap the valve stems gently with a plastic hammer to firmly seat the cotters Be careful not to damage the valves KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 Camshaft Rocker Arms Coat the camshaft camshaft bearings and automatic decompressor cam with clean engine oil Install the camshaft into the cylinder head with the cam lobes facing the piston Install the rocker arms as shown Coat the rocker arm shafts with clean engine oil Install the rocker arm shafts by screwing an 8 mm bolt into the thread end as shown Install a new Gasket on the right side cover Install the right side cover Gasket CYLINDER HEAD INSTALLATION Clean the cy
30. MCO ACTIVE 50 Clutch Lifter Cam Punch Mark And Notch Mark An Z Clutch Lifter Lever Retainer Clutch Bot Clutch Lift Comp MEE rough Spring Cam Plate Side 9 10 9 CLUTCH GEAR SHIFT MECHANISM Remove the cenrifugal clutch and manual clutch page 9 3 Remove the warcher Remove the gear shift spindle and washer Remove the gear shift pedal Remove the bolt drum stopper and spring Remove the gearshift stopper plate bolt and the plate INSTALL Install the pin in the holes Install the warcher Install the stopper plate aligning the holes in the stopper plate with the dowel pin Tighten the stopper plate bolt security Install the gear shift cam stopper and spring Tighten the 6mm lock bolt Torque 0 8 1 2kg m Drum stopper gear shift pedal warcher 9 11 GQ KYMCO ACTIVE 50 Bolt Gearshift Stopper Plate Bolt Spring e x am e EF d f D L b i e T E 7 4 i i a A n iJ i 1 i d a T a i 4 1 aM T Stopper Plate dC KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Install the gear shift spindle and washer During installation make sure that the return spring aligns with the crankcase tab Spring Adjusting Bolt RIGHT CRANKCASE COVER INSTALLATION Install the new O ring and lock nut O ring Install the dowel pin and a new gasket Ins
31. ORMATION 15 2 TROUBLESHOOTING 15 3 IGNITION COIL 15 4 CDI UNIT 15 5 PULSER COIL EXCITER COIL 15 6 15 0 GQ KYMCO 15 IGNITION SYSTEM ACTIVE 50 CDI Unit Wi Wire Harness lenition Switch Pulser Coil Generator x Coil Wire Connector MAIN SW IGN COIL ISS 15 1 GQ KYMCO 15 IGNITION SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e nspect the ignition system according to the sequence specified the Troubleshooting 15 2 e The ignition system has an electrical auto aligner in the CDI unit so the ignition timing 15 not adjustable e Do not drop or impact the CDI unit with strong force to avoid damage Be careful when removing it e Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation e Check the spark plug heat range Use of spark plug with improper heat range 15 the main cause of poor engine performance or burned engine e Perform inspections according to the servicing procedures specified in each section SPECIFICATIONS Item Standard type CHAMPION P RZ9HC Spark plug EMEN MEME Spark plug gap 0 6 0 7mm Ignition tim
32. RGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause Start engine and test limit voltage between battery terminals oltage does not Dead battery Normal voltage increase Faulty battery Measure resistance between AC generator coll terminals Faulty coil Resistance too high Broken pink and yellow wires Shorted pink and yellow wires Connect battery wire o regulator rectifier coupler red wire and battery wire to engine eround and test voltage Normal voltage Broken red wire Check regulator rectifier coupler for loose connection Faulty regulator rectifier Abnormal 752 Faulty generator Overcharging Inspection Adjustment Probable Cause Connect battery wire o regulator rectifier coupler black wire and battery wire to engine eround and test voltage iM 145 VO 22 25 DO with 1gnition switc voltage with ignition ON Soe ON Broken black wire Check regulator rectifier coupler for loose connection Faulty regulator rectifier 1 21 dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 NO SPARK AT SPARK PLUG Inspection Adjustment Symptom Probable Cause Replace with a new spark T plug and inspect again Weak or no spark Check spark plug cap and ignition coil wire for looseness Check CDI unit coupler for looseness Measure resistance between CDI unit coupler wire terminals Good spark Faulty old spark plug Poorly
33. RICATION SYSTEM ACTIVE 50 CAMSHAFT oio ge eile SA d MAINSHAFT OIL 7 CENTRIFUG FILTER COVER MEL ULT 1 OUNTERSHAFT Se AS D TES doe e OIL STRAINER SCREEN 3 1 KYMCO 3 LUBRICATION SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The service and maintenance of this section can be performed with the engine installed in the frame e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line e The oil pump must be replaced as a set when it reaches its service life e After the oil pump 15 installed check each part for oil leaks and improper lubrication e When removing and installing the oil cooler be careful not to bend or deform the oil pipe SPECIFICATIONS Oil pump Body clearance 02 O TROUBLESHOOTING Oil level too low Engine burns e External oil leak e Oil not changed often enough e Worn valve guide or seal e Head gasket faulty e Worn piston rings e Worn piston rings GQ KYMCO 3 LUBRICATION SYSTEM ACTIVE 50 Upper Limit ENGINE OIL OIL FILTER OIL LEVEL e Place the motorcycle upright on level ground for engine oil level check e Run the engine for 2 3 minutes and check the oil level after the engine 1s stopped for 2 3 minutes Check the oil level If the level 15 near the 7 lower limit fill to the upper limit with the
34. Remover Block Drive in new bearings using a bearing installer 10 10 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 e Apply engine oil to the bearings before installation e Drive in bearings squarely GE Bearing installer Countershaft Oil Seal Install a new left countershaft oil seal 1n the T left crankcase and grease the oil seal lip RIGHT CRANKCASE Drive the mainshaft and countershaft bearings out of the right crankcase Drive in new bearings using a bearing installer e Apply engine oil to the bearings before installation e Drive in bearings squarely Bearing Driver Main shaft Bearing Counter Bearing CRANKCASE INSTALLATION Install the dowel pins and a new gasket onto the left crankcase 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 Dowel Pins Install the right crankcase over the left crankcase L Make sure that the gasket stays in place Install and tighten the crankcase bolts securely in a crisscross pattern in 2 3 steps Install the return spring and spring retainer onto the kick starter spindle Install the snap ring Refer to the sections on page 10 4 for installation of the removed parts Retainer Snap Ring 10 12 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 FRONT WHEEL SUSPENSION STEERING SERVICE INFORMA TION sedit 2 OT eS OO IN
35. STEERING ACTIVE 50 Remove the front wheel Hold the steering stem top cone race and remove the steering stem lock nut Special Lock nut socket wrench Lock Nut Socket Wrench QU Remove the top cone race and remove the steering stem Be careful not to lose the steel balls 26 on top race and 19 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary Lock Nut Wrench Top Cone Race Bolts BALL RACE REPLACEMENT Remove the top and bottom ball races 11 16 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 Ball Race Remover Bearing Driver Handle Drive the top and bottom ball races into the steering head using a bearing driver Bearing driver handle Bearing installer Attachment 37x40mm BOTTOM CONE RACE REPLACEMENT Attachment 37x40mm Drive out the bottom cone race Install a new washer and dust seal onto the steering stem and then drive in a new bottom cone race onto the steering stem Bottom Cone Race STEERING STEM INSTALLATION Apply grease to the top and bottom ball races and steel balls Install 23 steel balls each on the top and 29 steel balls on the bottom ball races Apply erease to the ball races again and then install 11 FRONT WHEEL SUSPENSION KYMCO STEERING ACTIVE 50 the steering stem Steel balls 6mm Lock nut wrench Apply grease to the top cone race and install it Tighten the
36. Tighten the oil pump mounting bolts securely Check the cover screws for loose retighten if necessary Install the right crankcase cover kick starter pedal the crankcase with the recommended engine oil d s Pump Cover 3 6 dC KYMCO 4 FUEL SYSTEM ACTIVE 50 E FUEL SYSTEM SERVICE INFORMATION 4 2 EIERE 4 3 AIR CIDR AINE RE MOV A 4 4 THROTTLE VALVE DISASSEMBLY 4 5 THROTTLE VALVE INSTALLATION 4 6 CARBURETOR REMOVA ereechen 4 7 dC KYMCO 4 FUEL SYSTEM ACTIVE 50 4 1 dC KYMCO 4 FUEL SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous When working with gasoline keep sparks and flames away from the working area Gasoline 15 extremely flammable and 15 explosive under certain conditions sure to Work in a well ventilated area e Do not bend or twist control cables Damaged control cables will not operate smoothly e When disassembling fuel system parts note the locations of O rings Replace them with new ones during reassembly e Before float chamber disassembly loosen the drain screw to drain the residual gasoline into a clean container e After the carburetor is removed plug the intake manifold side with a clean shop towel to prevent foreign matters from entering e The carburetor air jets and fuel jets must be cleaned with compressed air
37. Torque 2 4 3 0kg m Add the recommended brake fluid into the brake reservoir and bleed air from the brake system Refer to 13 4 13 1 MRA m _2 qJ 7 GQ KYMCO 14 FRAME COVER ACTIVE 50 FRAME COVER SERVICE 14 2 FRAME COVER 14 3 14 0 GQ KYMCO 14 FRAME COVER ACTIVE 50 SCHEMATIC DRAWING 14 1 KYMCO 14 FRAME COVER ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The exhaust muffler must be removed when it 1s cold to avoid burns e When installing the exhaust muffler first tighten the exhaust muffler joint lock nuts and then tighten the exhaust muffler hanger lock bolt TORQUE VALUES Rear carrier lock bolt 3 0 4 0kg m Exhaust muffler joint lock nut 0 8 1 2kg m 14 2 dC KYMCO 14 FRAME COVER ACTIVE 50 Back Cover FRAME COVER BACK COVER REMOVAL Remove the key molding Remove the two screws attaching the back COVer Remove the back cover The installation sequence 15 the reverse of removal MET IN BOX REMOVAL Open seat with key and remove five screws of the rear hand grip cover Remove the rear hand grip Remove the met in box The installation sequence 15 the reverse of removal Met in Box FRAME BODY COVER REMOVAL seat cable Screw Open the seat T Remove the back cover page 14 3 ZE Disconnect the se
38. ace if over 10 5 10 CRANKCASE CRANKSHAFT KICK STARTER TRANSMISSION Turn the outer races of the crankshaft bearings with your fingers The bearings should turn smoothly and quietly Also check that the inner races of the bearings fit tightly on crankshaft Check the timing sprocket for wear or damage Timing Sprocket Spring Snap Ring KICK STARTER DISASSEMBLY Remove the Snap Ring Remove the circlip Remove the Starter ratchet Starter ratchet Starter Ratchet Circlip And Trust Washer Remove the starter ratchet and spring Pry out the circlip and thrust washer Removethe kick starter pinion Kick Starter Spindle Circlips KICK STARTER ASSEMBLY Assemble the kick starter spindle in the reverse order of disassembly INSTALLATION Install the crankshaft and kick starter to the left crankcase Align the punch mark of the kick starter spindle with the punch mark on the starter driven ratchet Pinion Gear Starter Driven Ratchet Spring 10 6 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 TRANSMISSION DISASSEMBLY Remove the kick starter spindle from the left crankcase Main Shaft Countershaft Remove the transmission main shaft and countershaft and transmission drum and transmission forks from the left crankcase When removing the transmission gears must be removed as a set INSPECTION Inspect each gear for wear
39. at cable Remove the met in box page 14 3 Remove the two screws from right side and left side of the frame body cover Remove the frame body cover The installation sequence 15 the reverse of removal R L SIDE COVER REMOVAL Remove the three screws attaching the side COVer Remove the side cover The installation sequence 15 the reverse of removal 14 3 KYMCO 14 FRAME COVER ACTIVE 50 FRONT COVER REMOVAL Remove the R L side cover page 14 3 Remove the six screws from right side and left side of the front cover Remove the screw from front side of the front cover Remove the front cover The installation sequence 15 the reverse of removal Screws Conter covers CETER COVER REMOVAL Remove the back cover page 14 3 Remove the met in box page 14 3 Remove the center cover The installation sequence 15 the reverse of removal REAR LIGHT SET REMOVAL Open the seat Remove the R L side cover page 14 3 Remove the rear carrier page 14 3 Remove the frame body cover page 14 4 Remove the two screws from right side and left side of the rear light set Disconnect the wire connector of rear light set Remove the rear light set Rear light set The installation sequence 15 the reverse of removal 14 4 14 FRAME COVER REAR FRENDER REMOVAL Open the seat Remove the R L side cover page 14 3 Remove the frame body cover page 14 4 Remove the rear light set page 1
40. between the values measured at the three levels is subject to the maximum value calculated Middle Service Limits True Roundness 0 05mm repair or replace if over Bottom Top Cylindricity 0 05mm repair or replace if over 7 3 KYMCO 7 CYLINDER PISTON ACTIVE 50 Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if over Piston Clip PISTON REMOVAL Remove the piston pin clip TU IT Press the piston pin out of the piston NC m 77 zw i ie pony d A al m h Lu WE i ZS Y L La T L IT c x CERE a aie X Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase a p J Piston Pin Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits 0 12mm replace if over 2nd 0 12mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom X e Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over 7 CYLINDER PISTON Measure the piston O D K e Take measurement at 5mm from the bottom and 90 to the piston pin hole Service Limit 51 6mm replace if below Measure the piston to piston pin clearance Service Limit 0 10mm replace
41. buretor Remove the air cleaner case by removing the attaching bolts Element Screw Remove the four screws with the air cleaner case Cover i Element Holder Air Cleaner Case Cover Remove the element and the element holder from the air cleaner case INSTALLATION Install the air cleaner case in the reverse order of removal 4 4 KYMCO 4 FUEL SYSTEM ACTIVE 50 THROTTLE VALVE DIS ASSEMBLY Remove the front cover page 14 3 Loosen the carburetor cap and remove the throttle valve Disconnect the throttle cable from the throttle valve Throttle Cable Throttle Valve Remove the throttle valve spring and carburetor top The carburetor top is an integral part of the throttle cable assembly The top can not be separated from the assembly without causing damage to the cable Needle Clip Throttle Valve Remove the jet needle by removing the needle clip Check the jet needle and throttle valve for wear or damage VV Spring Jet Needle 4 5 GQ KYMCO 4 FUEL SYSTEM ACTIVE 50 Throttle Cable Throttle Valve THROTTLE VALVE INSTALLA TION Set the needle clip on the jet needle clip Standard podition 3rd groove from the top Install the jet needle on the throttle valve Install the retainer on the throttle valve and secure the jet needle Carburetor Top Install the throttle cable to the throttle valve while depressing the throttle valve spring Insert
42. ck absorbers e Dent front fork e Dent front axle or uneven tire Front wheel wobbling e Improperly tightened axle nut e Bent rim e Worn front wheel bearing e Faulty tire Soft suspension e Weak fork springs e Insufficient front fork oil Hard suspension e Incorrect front fork oil level e Bent front fork tube e Clogged front fork oil passages Front suspension noise e Slider bending e Loose front fork fasteners e nsufficient front fork oil e Worn front fork bearing e nsufficient speedometer gear grease 11 3 11 FRONT WHEEL SUSPENSION OK KYMCO STEERING ACTIVE 50 cover top throttle cover FR handle HANDLEBAR REMOVAL Remove the cover RR handle Remove the cover FR handle Remove the throttle pipe holder screws Remove the cover top throttle Remove the cover up throttle Disconnect the throttle cable from the throttle grip and then remove the throttle pipe from the handlebar Throttle Cable Remove the two master cylinder holder bolts Holder and the master cylinder Bolts Remove the handlebar lock nut to remove the handlebar 11 4 11 FRONT WHEEL SUSPENSION KYMCO STEERING eit Handlebar INSTALLATION Tab Groove Install the handlebar aligning the tabs of the handlebar with the grooves in the steering stem Install and tighten the handlebar lock nut Torque 4 5 5 0kg m Hole When installing the right and left handlebar switch housings align the pin o
43. cm as IMAA SUIAOJAI Bore x stroke mm 52 4 49 5 Compression ratio kg cm 1 8 7000kw r min 2 6 4500kgm rpm Port mm 3 timing Exhaust 3 1mm 5 Valve clearance Intake 0 02mm Idle speed rpm 1700rpm T EC Inner Outer rotor Wire gauze filter Oil capacity 0 9 liter Cooling Type Air cooling 99 5 ES 15 d e e 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B 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 B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly ett dO KYMCO ACTIVE 50 GQ KYMCO 1 GENERAL INFORMATION ACTIVE 50 Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B 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 B After operation check all con
44. connected coupler Check related parts Faulty ignition switch Faulty exciter coil Faulty pulser coil Faulty 1gnition coil wire harness Poorly connected coupler Normal Abnormal Check CDI unit with a CDI unit tester Check ignition coil with a CDI unit tester Faulty ignition coil 1 22 GQ KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 gt INSPECTION ADJUSTMENT SERVICE INFORMATION 2 1 MAINTENANCE SCHEDULE 22 0 FUEL LINE FILTER 2 3 THROTTLE OPERATION CHOKE 2 3 AIR CLEANER 2 4 SPARK PLUG 2 4 VALVE CLEARANCE 2 5 CARBURETOR IDLE SPEED 2 5 IGNITION TIMIN Gs EER 2 6 CYLINDER COMPRESSION 2 6 ENGINE Ja DRIVE CHAIN 2520 ener ee ee ee iic desees eeu 2 8 BRAKE SHOE 2 08 BRAKE FLUID 2 8
45. dC KYMCO ACTIVE 50 PREFACE TABLE OF CONTENTS This Service Manual describes the CE ERI RCM technical features and servicing procedures for the KYMCO ACTIVE 50 INSPECTION ADJUSTMENT LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL INSTALLATION CYLINDER HEAD V ALVES CYLINDER PISTON Section 1 contains the precautions for all operations stated 1n this manual Read them carefully before starting any operation HNIDONH Section 2 1s the inspection adjustment procedures safety rules and service ALTERANTOR CAM CHAIN information for each part starting from FENDER CLUTCH GEAR SHIFT MECHANISM periodic maintenance CRANKCASE CRANKSHAFT KICK Sections 3 and 4 state the servicing STARTER TRANSMISSION procedures and cautions for the removal FRONT WHEEL SUSPENSION and installation of lubrication and fuel STEERING REAR WHEEL BRAKE SUSPENSION 12 systems Sections 5 through 18 give instructions HYDRAULIC BRAKE for disassembly assembly and inspection FRAME COVER of engine chassis frame and electrical IGNITION SYSTEM equipment CHARGING SYSTEM STARTING SYSTEM LIGHTS INSTRUMENTS SWITCHES HORN FUEL UNIT SISSVHO Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section LNAWdINOF IVORILLOH IH Our company reserves right to make any alteration in the design The information and contents included
46. damage the c Lo fuel unit float arm Fuel Unit Wire L W Y W INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions 7000 5500 1600 Y W L W 6000 6000 FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Needle Postion att Fuel Unit 18 7 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 INSTALLATION The installation sequence 15 the reverse of removal Align the groove on the fuel unit with the flange on the fuel tank Flange Groove 18 8
47. dard mm Service Limit mm Push rod O D 11 985 12 00 11 945 Driven sprocket 37 87 37 90 37 60 Driven sprocket I D 19 01 19 02 19 041 Tensioner spring free length 110 107 TORQUE VALUES Flywheel lock nut 3 2 4 0kg m SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING Hard starting and poor performance at high speed e Improperly tightened flywheel lock bolt Starting noise e Worn reduction gear Starter clutch slips e Worn starter gear e Worn starter clutch roller e Worn starter clutch roller e Faulty starter clutch roller or spring e Faulty reduction gear shaft bearing e Worn starter gear shaft O D 8 2 8 ALTERNATOR STATER CLUTCH KYMCO CAMCHAINTENSIONER ACTIVE 0 ALTERNATOR REMOVAL Remove the four bolts Remove the left crankcase cover Remove the gasket and dowel pins 7 Dowel Pins Remove the flywheel nut and washer while holding the flywheel with a flywheel holder Flywheel holder Remove the flywheel using a flywheel puller as shown Flywheel puller 8 3 8 ALTERNATORSTARTER CLUTCH KYMCO 2 CAM CHAIN TENSIONER ACTIVE 50 Remove the clamp Remove the five bolts and alternator stator base from the crankcase cover e Do not disassemble the stator and pulse generator coils STARTER CLUTCH REMOVAL REMOVAL Drain the engine oil page 3 3 Remove the alternator page 8 3 Remove the stopper plate and chain sliders Remove the sna
48. e Chain Adjustment 1 Loosen the rear axle nut 2 Adjust the right and left adjusting nuts to align the right punch mark with the left punch mark 3 Turn the rear wheel to see if the drive chain slack 15 within the specified range 4 Tighten the rear axle nut After drive chain adjustment check the rear brake pedal free play and adjust if necessary Punch Mark Adjusting Nut 2 7 dO KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 BRAKE SHOE Inspect the front brake linings for wear BRAKE LEVER PEDAL Measure the rear brake pedal free play Free Play 20 30mm Lock Nut Adjusting Bolt CLUTCH Stop the engine Loosen the lock nut Slowly turn the adjusting bolt counterclockwise and stop when resistance 1s felt From this point turn the adjusting bolt clockwise 1 8 turn and tighten the lock nut Check that the clutch is not slipping and 15 properly disengaging BRAKE FLUID Turn the steering handlebar upright and check if the brake fluid level is between the upper and lower limits Specified Brake Fluid DOT 4 2 INSPECTION ADJUSTMENT ACTIVE 50 SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Check the action of the rear shock absorber by compressing it several times Check the entire shock absorber asse
49. e for scratches caused by the friction disks Measure the clutch outer I D Service Limit 110mm Measure the driven gear outer O D Service Limits 46mm Measure the gear primary drive O D Service Limits 34 25 mm Measure the center clutch O D Service Limits 68mm Measure the Center clutch O D Service Limits 21 mm INSPECTION CLUTCH TENSION SPRING Measure each spring clutch damper Service Limit 11 3 mm Measure each spring clutch Service Limit 17 5mm Measure each spring clutch free Service Limit 21mm Replace the spring with a new one 1f it is shorter than the service limit CLUTCH FRICTION DISK Measure each di sk B cl utch fri cti on thi ckness Service Limit 3 7 mm Measure each di Sk A cl utch fri cti on thi ckness Service Limit 2 7 mm Li sk utch Friction DO sk AQ utch Fri cti on 9 7 C KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 CLUTCH A PLATE CLUTCH A PLATE Measure each clutch plate bending using a feeler gauge Service Limit 0 20mm Plate Drive Center Clutch Driven Gear Outer CENTRIFUGAL CLUTCH MANUAL CLUTCH INSTALLATION MANUAL CLUTCH ASSEMBLY Coat the clutch discs and plates with clean engine oil Assemble the clutch plate drive driven gear outer center clutch plate A clutch disk clutch friction plate B clutch and set ring Plate A Clutch Disk Clutch Friction Plate B Clutch Outer Clutch Outer Clutch Set Ring Install the clutch four bolts In
50. e the rotor shaft Remove the inner and outer rotors from the pump body Clean the disassembled parts m non flammable or high flash point solvent Check all parts for damage or wear dO KYMCO ACTIVE 50 H 27 Right Crankcase Cove Oil Filter Rotor Cover Oil Pump Mounting Bolts Pd d d P aa Y Pump Cover dC KYMCO 3 LUBRICATION SYSTEM ACTIVE 50 INSPECTION Install the drive shaft and rotors Measure the rotor tip clearance Service limit 0 2mm Measure the pump body clearance Service limit 0 2mm Install the gasket and measure the rotor end clearance Service limit 0 15mm Pump Body Align Flats Drive Shaft OIL PUMP ASSEMBLY Install the outer and inner rotors Insert the drive shaft and align the flat on the shaft with the flat 1n the 1nner rotor Inner Rotor Outor Rotor dC KYMCO 3 LUBRICATION SYSTEM ACTIVE 50 Install a new pump body cover gasket and the cover Make sure that the pump rotates freely without binding Gasket INSTALLATION Install the pump with a new gasket under it by aligning the slot if the drive shaft with the cam chain guide spindle A We WW d Cr un A Ju i A Ka d Lef at Me AN us Ce TN am Chain Guide pindle Drive Shaft Pump Mounting Bolts
51. eck each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 25 8mm replace if below EX 25 6mm replace if below ROCKER ARM INSPECTION 6 6 GQ KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 Measure the I D of each valve rocker arm Service Limits IN 10 mm replace if over EX 10 mm replace if over ROCKER ARM SHAFT INSPECTION Measure each rocker arm shaft O D Service Limits IN 9 78mm replace if below EX 9 88mm replace if below VALVE SPRING INSPECTION Measure the free length of the inner and outer valve springs Service Limits Inner IN 32 41mm replace if below Outer IN 35 25mm replace if below VALVE VALVE GUIDE INSPECTION Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits p IN 4 90mm replace if below Pp EX 4 90mm replace if below A d M Measure each valve guide I D 6 CYLINDER HEAD VALVES Service Limits IN 5 00mm replace if over EX 5 00mm replace if over Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Service Limits IN 0 10mm replace if over EX 0 10mm replace if over If the stem to guide clearance exceeds the service limits replace the guides as necessary the valve seats whenever the valve guides are replaced CYLINDER HEAD ASSEMB
52. efully bend the float pin Float Level Gauge Check the float for proper operation and then install the float chamber Choke Cable CARBURETOR INSTALLATION Install the carburetor onto the intake manifold and tighten the two mounting bolts Install the fuel tube and the choke cable Torque 0 8 1 2kg m Install the air cleaner connector and tighten the band screw Fuel Tube Carburetor To Assemble the carburetor top and throttle valve spring Connect the throttle cable to the throttle valve 4 10 dO KYMCO 4 FUEL SYSTEM ACTIVE 50 Fuel Unit Wire FUEL TANK FUEL TANK REMOVAL e Keep sparks and flames away from the work area e Wipe off any spilled gasoline Turn the fuel valve to OFF Remove the three bolts attaching the rear carrier Remove the four seat lock nuts Fuel Strainer Remove the tool box mounting bolt and tool box Disconnect the fuel strainer and remove the nuts on the end of the fuel tank Disconnect the fuel unit wire connector and fuel gauge wire Remove the fuel tank FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank INSPECTION Inspect if the fuel strainer 15 clogged and clean it with compressed air e When removing the fuel strainer do not allow flames or sparks near the working area and drain the residual gasoline into a container INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump
53. ence 15 the reverse of removal Light Shell Bulb Light Shell STOP LIGHT TAILLIGHT Remove the two taillight shell screws and the shell Remove the bulb and check the bulb for damage Replace with a new one if necessary Bulb Specification 12V 21 5W The installation sequence 15 the reverse of removal Screws IGNITION SWITCH Disconnect the ignition switch wire coupler Remove the two bolts attaching the ignition switch Remove the ignition switch INSPECTION Check for continuity between the wires indicated below 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 STARTER BUTTON Disconnect the right switch wire coupler Check for continuity between the black and yellow red wires Pear Black Yellow Red FREE PUSH oo HORN BUTTON Remove the decorative covers under the fuel tank Disconnect the left switch wire coupler Check for continuity between the black and light green wires Pear Black Light Green FREE FREE PUSH O HORN Remove the steering head decorative cover Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery 15 connected across the horn wire terminals Replace the horn if it does not sound 18 4 18 LIGHTSINSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 HANDLEBAR SWITCHES FRONT STOP SWITCH Disconnect the front stop switch wire coupler Check for continuity
54. f necessary CENTRIFUGAL CLUTCH MANUAL CLUTCH REMOVAL REMOVEAL Remove the clutch lifter lever and clutch lifter cam Remove the four bolts oil filter rotor cover and gasket Lifter Lever Rotor Cover And Gasket Bearing Rotor Cover And Gasket Remove the clutch lifter bearing GQ KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Clutch Holder Install the clutch holder and secure it with the bolts Remove the lock nut and plane washer using a lock nut wrench Remove the clutch Special Clutch holder Lock nut wrench UU zm ww od Lock Nut Wrench Remove the clutch square nut Washer square Nut Remove the washer and clutch square nut lock nuts Remove the clutch Remove the clutch circlip Remove the gear primarv driven Gear Primarv Driven 9 5 GQ KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Remove the follows Washer Gear primary drive Guide clutch center Washer MANUAL CLUTCH DISASSEMBLY Remove the set ring 101 5mm Remove the four bolts 5 10mm Bolts 5 10mm Plate Drive Center Clutch Driven Gear Outer Set Ring Plate A Clutch Disk Clutc Friction Plate A Clutch Guide Clutch Center 9 6 GQ KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Measure the O D of the crankshaft at the primary drive gear OW crankshaft SERVICE LIMIT 17 00mm INSPECTION CLUTCH GEAR O D I D Inspect the clutch outer groov
55. he adjusting nut 5 Dust Boot Adjusting Nut Lock Nut CHOKE Check choke lever operation If the choke lever moves stiffly clean and lubricate the pivot After cleaning recheck the lever movement 2 3 KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 Choke Lever Air Cleaner Case Air Cleaner Case Cover AIR CLEANER AIR CLEANER REPLACEMENT Remove the right center cover page 14 3 Remove the air cleaner case page 4 5 Remove the air cleaner case cover screws and the cover page 4 5 Remove the air cleaner screen and element Check the element and replace it with a new one if it is excessively dirty or damaged CHANGE INTERVAL Wash the air cleaner element in detergent oil squeeze out and allow to dry Never use gasoline or organic vaporable oil with acid or alkali for washing Wash Squeeze out Engine Squeeze After washing soak the element in clean 01 and dry engine oil SAE 15W 40 and squeeze out excess oil Reinstall the element SPARK PLUG Remove the spark plug Check the spark plug for wear damage and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug CHAMPION P PZ9HC Gap Wear and Fouling Deposits Measure the spark plug Spark Plug Gap 0 6 0 7mm When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench Cracks Washer Damage Deformation 2 4 GQ KYMCO
56. he socket head bolt e When using the vise do not tighten the front fork bottom tube excessively e f it is difficult to remove the socket head bolt temporarily install the front fork spring and front fork bolt Remove the front fork piston and return spring Remove the front fork bottom tube and the oil stopper 6mm Socket Spanner Oil Seal lt Remove dust seal and snap ring Take ge Snap Ring out the oil seal and circlip e Do not damage the bottom tube when taking out the oil seal and circlip e Be sure to replace the removed oil seal and circlip with new ones during assembly INSPECTION Measure the front fork spring free length 11 12 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 Service Limit 328 2mm replace if below Replace the spring with a new one if it exceeds the service limit Set the front fork tube in V blocks and measure the tube runout Service Limit 0 2mm replace if over Check the front fork tube bottom tube and piston for abnormal wear or damage and Piston Ring Front Fork Tube replace if necessary Check the front fork piston ring for wear Check the return spring for weakness or damage Front Fork Bottom Tube ASSEMBLY 11 13 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 Before assembly clean the removed parts with high flash or non flammable solvent e CH o Install the return spring and piston into the front fo
57. hes Fuel does not carburetor reach carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Faulty exciter coil Faulty ignition switch Broken or shorted ignition coil wire Spark jumps Weak or no spark Test cylinder compression Faulty or slipping clutch Valve clearance too small compression compression Worn cylinder and piston rings Leaking cylinder head gasket Start engine by follow ing normal starting procedure Faulty choke control system Engine does not Engine fires but Leaking intake manifold fire does not start Incorrect ignition timing Incorrectly adjusted air screw Remove spark plug and inspect again Flooded carburetor Dry spark plug Wet spark plug Throttle valve excessively open Clogged air cleaner 1 17 dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty pulser coil Check carburetor air screw adjustment Mixture too lean turn screw in Correctly adjusted Incorrectly adjusted Mixture ooi um EE out Check carburetor gasket for air leaks Faulty intake manifold gasket Carburetor not securely Damaged insulator rubber Broken vacuum tube Remove spark plug and install it int
58. if over Measure the piston pin hole I D Service Limit 13 06mm replace if over Measure the piston pin O D Service Limit 12 944mm replace if below Measure the connecting rod small end I D Service Limit 13 016mm replace if over 7 5 dO KYMCO ACTIVE 50 7 CYLINDER PISTON PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring e careful not to damage the piston and piston rings during assembly e All rings should be installed with the markings facing up e After installing the rings they should rotate freely without sticking e Stagger the ring end gaps as the figure shown Install the piston piston pin and a new piston pin clip e Position the piston IN mark on the intake valve side e Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase dC KYMCO ACTIVE 50 Second Side Rail Oil Ring Side Rail Mark Piston Pin Clip 1 Piston Piston Pin Dowel Pins 5224 Gasket 7 6 dC KYMCO 7 CYLINDER PISTON ACTIVE 50 Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings e careful not to damage break the p
59. ing F mark 1542 1700rpm 1 Primary coil 0 2 0 30 Ignition coil resistance 20 Secondary with plug without plug Pulser coil resistance 20 Exciter coil resistance 20 Ignition coil primary side max voltage Pulser coil max voltage Exciter coil max voltage TESTING INSTRUMENT Electric Tester Timing light Tachometer 15 2 KYMCO 15 IGNITION SYSTEM ACTIVE 50 TROUBLESHOOTING Engine stalls immediately after it starts e Weak spark e mproper ignition timing e Faulty CDI unit No spark at plug e Faulty ignition switch e Poorly connected broken or shorted wire Between pulser coil CDI unit and ignition coil Between exciter coil and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spark plug Engine starts but runs poorly e Faulty ignition coil e Poorly connected wire e Faulty spark plug e Spark plug cap electricity leakage e Faulty A C generator e Stator not installed properly Loose e Faulty CDI unit 15 3 gO KYMCO 15 IGNITION SYSTEM ACTIVE 50 IGNITION COIL CONTINUITY TEST This test 1s to inspect the continuity of ignition coil Remove the right decorative cover Measure the resistance between the ignition coil primary coil terminals Resistance 20 0 2 0 30 Ignition Coil Measure the secondary coil resistance between the spark plrg cap and the primary coi
60. iper Use compressed air to press out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons Piston Oil Seals Push the piston oil seals inward to remove them Clean each oil seal groove with brake fluid Be careful not to damage the piston surface 13 9 KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 INSPECTION Check each piston for scratches or wear Measure each piston O D with a micrometer gauge Service Limit 25 45mm replace if below Check each caliper and caliper cylinder for scratches or wear and measure the caliper cylinder I D Service Limit 25 30 mm replace if over ASSEMBLY Clean all removed parts Apply silicon grease to the pistons and oil seals Lubricate the brake caliper cylinder inside wall with brake fluid Install the oil seals and then install the brake caliper pistons with the grooved side facing out Install the piston with its outer end protruding 3 5mm beyond the brake caliper 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 13 10 dC KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 INSTALLATION Install the brake caliper onto the right front fork and tighten the bolts Torque 2 4 3 0kg m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt
61. iston rings The piston ring end gaps should not be parallel with or at 90 to the piston pin Roller Bolt Install the cam chain guide roller and tighten the roller bolt Guide Roller Temporarily install the cylinder bolts Install the cylinder head page 6 10 Tighten the cylinder bolt to the specified torque TORQUE 0 6 0 9kg m Bolt 7 7 8 ALTERNATOR STARTER CLUTCH OK KYMCO 2 CAM CHAIN TENSIONER ACTIVE 50 ALTERNATOR STARTER CLUTCH CAM CHAIN TENSIONER SERVICE 8 2 TROUBLESHOOTING wees cers ee 8 2 ALTERNA TOR REMOVAL E 8 3 STARTER CLUTCH REMOVAL 8 4 CAM CHAIN TRNSIONER eebe 8 5 TENSIONER SPRING AND PUSH ROD 8 5 STARTER CLUTCH INSTALLATION 8 6 8 ALTERNATOR STATER CLUTCH KYMCO ___CAM CHAIN TENSIONER ACTIVE 50 SCHEMATIC DRAWING 8 ALTERNATOR STARTER CLUTCH O KYMCO o CAM CHAIN TENSIONER ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The starter motor generator left crankcase and starter clutch can be serviced in the frame e Do not install the starter clutch forcedly e Install the generator by aligning the groove in the flywheel with the key on the crankshaft e Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove SPECIFICATIONS Stan
62. ith tool otherwise 1 will cause short circuit and sparks to damage the battery and ignite the gasoline The installation sequence 15 the reverse of removal First connect the positive cable and then the negative cable to avoid short circuit BATTERY VOLTAGE OPEN CIRCUIT VOLTAGE INSPECTION Remove the left side cover Disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 1V Undercharged 12 3V Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal e Keep flames and sparks away from a charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery to avoid explosion e Charge the battery according to the current specified on the battery e Quick charging should only be done in an emergency e Measure the voltage 30 minutes after the battery 15 charged Charging current Standard 0 5A Charging time Standard 5 10 hours After charging Open circuit voltage 12 8V min 16 4 KYMCO 16 CHARGING SYSTEM ACTIVE 50 PERFORMANCE TEST Perform this test with a fully charged battery Start and warm up the engine for 10 minutes Connect the battery positive cable to the ammeter positive probe a
63. k runout SP Brake master cylinder piston O D 12 657 12 684 12 64 Brake caliper piston O D 25 4 25 45 25 50 Brake caliper cylinder I D 25 335 25 368 25 30 TORQUE VALUES Caliper holder bolt 2 40 3 0kg m Pad pin bolt 1 5 2 0kg m Brake fluid tube bolt 2 5 3 5kg m Caliper bleed valve 0 4 0 7kg m Master cylinder holder bolt 1 0 1 4kg m SPECIAL TOOL Snap ring pliers 13 2 dC KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 TROUBLESHOOTING Loose brake lever e Air in hydraulic brake system e Brake fluid level too low e Hydraulic brake system leakage Tight brake lever e Seized piston e Clogged hydraulic brake system e Smooth or worn brake pad Hard braking e Seized hydraulic brake system e Seized piston Poor brake performance e Contaminated brake pad surface e Brake disk or wheel not aligned Brake noise e Contaminated brake pad surface e Excessive brake disk runout e ncorrectly installed caliper e Brake disk or wheel not aligned 13 3 dC KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 Screws BRAKE FLUID CHANGE AIR BLEED Place the motorcycle on its main stand on level ground and set the handlebar upright Remove the two screws attaching the brake fluid reservoir cap Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut Use a syringe
64. l terminal as Figure A shown Resistance 20 C with plug cap 7 2 8 2KQ Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 C without plug 4 2 5 2KQ 15 4 dC KYMCO 15 IGNITION SYSTEM ACTIVE 50 CDI Coupler SS d CDI UNIT REMOVAL Remove the left side cover page 14 3 Disconnect the CDI coupler and remove the CDI unit CDI Unit INSPECTION Black Yellow Black Red Measure the resistance between the CDI unit terminals Replace the CDI unit if the readings are not within the specifications in the table below e Due to the semiconductor in circuit it 18 necessary to use a specified tester for accurate testing Use of an improper tester or measurements an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester TH 5H for testing e n this table Needle swings then Blue Yellow Green Black White returns indicates that there 1s a charging current applied to a condenser The needle will then remain at unless the condenser 15 discharged Testing Range Use the XKQ range for the Sanwa Tester Use the X100Q range for the Kowa Tester Unit Probe Biack Black Black Yellow Red White Yellow Probe Black Yellow Black Red Blue Y ellow 15 5 0 1 10 0 2 30 1 100 Pe P Ea E E me ML oe
65. linder head gasket surface of any gasket material Be careful not to enter dust and dirt 1nto the cylinder GQ KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 Install the dowel pins and a new cylinder head gasket Gasket Gasket Inspection Hole Caps Install the cylinder head Install the new cylinder head cover gasket Install the cylinder head cover with its arrow And mark facing the inlet side Install one copper washer and three washers Install the four cylinder head cover cap nuts cylinder head bolt and cylinder bolt Tighten the four cap nuts in a crisscross pattern in 2 3 steps first then tighten the cylinder head bolt and cylinder bolt TORQUE Cylinder head cover cap nut 1 2 1 6kg m gt ane Cylinder head bolt 0 6 0 9kg m Cap Nut And Arrow Cylinder Head Bolt Cylinder bolt 0 6 0 9kg m Copper Washer Align Bolt Rotate the flywheel counterclockwise to align n the T mark on the cylinder head Install the cam chain over the cam sprocket and install the cam sprocket on the camshaft Install and tighten the cam sprocket bolts TORQUE 0 7 1 1 kg m Cam Chain Cam Sprocket Dowel Pins Install the left side cover Gasket on the left side cover Install the left side cover Adjust the valve clearance 6 10 KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 Gasket Left Side KYMCO 7 CYLINDER PISTON ACTIVE 50 CYLINDER PISTON SCHEMATIC
66. mbly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see 1f the engine hanger bushings are worn NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness 15 found WHEELS TIRES Check the tires for cuts imbedded objects or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE D me omes 1 75kg cm 1 75 2 1 75kg cm 2 25 2 Tire Pressure Gauge TIRE SIZE Front 2 5 17 Rear 2 75 17 2 9 dC KYMCO 2 INSPECTION ADJUSTMENT ACTIVE 50 Check the front and rear axle nuts for looseness If the axle nuts are loose tighten them to the specified torques Torques Front 5 5 7 0kg m Rear 6 0 8 0kg m STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing 2 10 dC KYMCO 3 LUBRICATION SYSTEM ACTIVE 50 RH LUBRICATION SYSTEM SERVICE INFORMATION s e25532222555552 3ceteccssce suec eee cts EES 3 2 ENGINE OIE OID EE 3 3 OIL PUMP OIL FILTER ROTOR 3 4 3 0 dC KYMCO 3 LUB
67. n bolts Torque 1 2 2 0kg m Tighten the pad pin bolt caps I Do not tighten the pad pin bolt caps excessively Torque 0 2 0 4kg m 13 5 1 GQ KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 BRAKE DISK Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic brake system Do not splash brake fluid onto any rubber plastic and coated parts When working with brake fluid use shop towels to cover these parts Remove the two master cylinder holder bolts and remove the master cylinder When removing the brake fluid tube bolt be sure to place towels under the tube and plug the tube end to avoid brake fluid leakage and contamination 13 6 KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder Snap Ring Pliers A Master Cylinder Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid Spring Snap Ring INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm replace if over Measure the brake master cylinder piston O D Service Limit 12 64mm replace if below 13 7 13 HYDRAULIC BRAKE
68. n the housing with the hole in the handlebar Tighten the two switch housing screws When installing the master cylinder align the Hole tab on the holder with the hole in the handlebar with the holder UP mark facing up First tighten the upper bolt and then the lower bolt Torque 1 0 1 4 UP Mark Nut Bolt THROTTLE PIPE INSTALLATION 11 FRONT WHEEL SUSPENSION OK KYMCO STEERING ACTIVE 50 Clean the handlebar surface and install the throttle pipe Check the throttle grip for proper operation Throttle Pipe Connect the throttle cable to the throttle grip Apply grease to the throttle cable Install the throttle cover by aligning the pin on the cover with the hole in the handlebar and then tighten the one screws Pin Throttle Cable FRONT WHEEL REMOVAL 11 6 11 FRONT WHEEL SUSPENSION gt STEERING ACTIVE 50 Place a jack or other adjustable support under the engine to raise the front wheel off the ground Remove the front axle nut and pull out the axle Remove the front wheel Axle Nut INSPECTION Set the axle in V blocks and measure the runout using a dial gauge Service Limit 0 2mm replace if over WHEEL RIM INSPECTION NA Place the front wheel in a turning stand STAGE A Spin the wheel by hand and measure the rim DISC SA Ud Yu C runout using a dial gauge Service Limits Axial 2 0mm adjust if over Radial 2 0mm adjust if o
69. nd the battery negative cable to the ammeter negative probe Ne gative Probe Then connect the voltmeter across the battery terminals to test the charging voltage CHARGING PERFORMANCE Headlight Switch CParging 13000 rpm 8000 rpm Position OFF Day 2150 0 16V 63A 167V max 2242150 14V 2 1A 14V ON 1 0 min 3 7A min Limit Voltage Test Start the engine and gradually increase the engine speed to measure the limit voltage Limit Voltage 14 5 0 5V Note Test when the battery 1s fully charged When testing the limit voltage use tachometer for operation A C GENERATOR INSPECTION Disconnect the generator pink and yellow wires and measure the resistance between the pin and yellow wires Resistance 0 3 1 50 Do not connect the generator pink and yellow wires to ground wire 1 6 5 Positive Probe KYMCO 16 CHARGING SYSTEM ACTIVE 50 REGULATOR RECTIFIER REMOVAL Remove the front cover page 14 4 Remove the regulator rectifier lock nut and disconnect the regulator rectifier wire coupler Measure the resistances between the regulator rectifier wire terminals Replace the regulator rectifier if the readings are not within the specifications in the table below j E JA x Sulator Rectifier A Red B Yellow e Due to the semiconductor in circuit it 1s necessary to use a specified tester for accurate te
70. nder head e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber 6 3 KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 CYLINDER HEAD REMOVAL Remove the left crankcase cover bolt Remove the left crankcase cover Remove the crankshaft hole cap and timing hole cap Remove the left side cover and gasket Remove the cam chain tensioner sealing bolt washer spring and tensioner shaft See the diagramp6 4 4 Remove the valve inspection hole caps Turn the crankshaft counterclockwise until the o mark on the cam sprocket aligns with the index mark on the cylinder head Make sure there slight clearances between the valve stems and rocker arms by moving the rocker arms up and down If the rocker arms are tight turn the crankshaft counterclockwise one full turn and realign the mark with the index mark Remove the cam sprocket bolts and cam sprocket e Suspend the cam chain with a wire or cord to prevent it from falling into the cylinder Loosen the cylinder bolts Remove the bolt attaching the cylinder head to the cylinder Remove the four nuts holding the cylinder head cover Remove the cylinder head cover Nuts And Washers Cylinder Head Bolt Gasket Inspection Hole Caps Remove the cylinder head cover gasket Remove the cylinder head Remove the cylinder head gasket and dowel pins Tensioner Sealing Bolt Left Side Cover 6 4
71. necting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to battery terminals B Terminal caps shall be installed securely dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 B the fuse is burned out find the cause andrepairit Replace it with a new one according to the specified capacity B After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation B Hold the connector body when connecting or disconnecting it B Do not pull the connector wire E Check if any connector terminal is bending protruding or loose 1 5 1 GENERAL INFORMATION B The connector shall be inserted completely B the double connector has a lock lock it at the correct position B Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal E Check the double connector cover for proper coverage and installation B Insert the terminal completely B Check the terminal cover for proper coverage Bi 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
72. nel Remove the rear brake panel Remove the drive chain Remove the rear wheel INSPECTION Set the rear axle in V blocks and measure the runout with a dial gauge Service Limit 0 2mm Rear Axle Nut Ge Place the rear wheel a turning stand 12 4 KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 measure the rim runout Service Limits Axial 2 0mm Radial 2 0mm Check the wheel spoke wires for looseness Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand Radial Check the drive chain gear teeth for wear or damage Replace the drive chain gear if necessary Replace If the drive chain gear teeth are worn or damaged also check the drive chain and replace if necessary GQ KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 emove the side collar and dust seal trom the left side of the rear wheel First tap the safety piece flat and then remove the four drive chain gear lock nuts Remove the safety piece and drive chain gear Remove the snap ring and gear gasket Check the damping bushings for damage Collar RR dist Lock Nuts Collar RR dist Remove the Collar RR dist Drive out the wheel bearings and remove the distance collar Bearing Remover ASSEMBLY Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing e Drive in the bea
73. 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 CG DJ Jh hee hh Ch Ch Ch Ch Ch 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 LA 1 11 1 GENERAL INFORMATION FRAME Tonge dc 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 SPECIAL TOOLS Flywheel puller Bearing puller 18mm Lock nut socket wrench Tappet adjuster Oil seat amp bearing install Bearing puller 15mm Bearing puller 12mm Flywheel holder Bearing puller 10mm Clutch holder Gear holder Bearing driver handle amp Bearing installer Race cone install Fesch Eme 003 008 E010 gt E012 E014 E018 E020 E021 E031 E039 E038 E014 F005 E049 9 5 gt 10 11 gt dO KYMCO ACTIVE 50 bei
74. o spark plug cap to test spark by connecting it to engine ground Faulty or fouled spark plug Faulty CDI unit Good spark ere A C generator mittent spark aulty ignition coil aulty ignition switch Check A C generator aulty A C generator logged air vent hole A 1 18 1 1 KYMCO GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE ENGINE LACKS POWER Inspection Adjustment Probable Cause Start engine and accelerate lightly for observation Clogged air cleaner Poor fuel flow Restricted Engine speed Engine speed does not Clogged fuel tank cap breather hole increases increase sufficiently Clogged exhaust muffler arburetor fuel level too low Clogged carburetor high speed fuel passage Faulty pulser coil a timing light Check valve clearance Improper valve clearance Excessively worn valve seat protruded valve stem est cylinder compression Improper valve and seat contact Normal Abnormal Worn cylinder and piston rings compression compression Leaking cylinder head gasket Improper valve timing Check carburetor for clogging Not clogged Clogged Clean and unclog Remove spark plug and inspect Plug not fouled or Plug fouled or Fouled spark plug discolored discolored Incorrect heat range plug Correct and not Incorrect or Oil level too high contaminated contaminated Oil level too low Oil not changed i Valve train lubricated alve train not logged oil cooler properly lubrica
75. oles the left and right crankcase halves for wear or damage TRANSMISSION BEARING INSPECTION Turn the inner races of the bearings with your finger The bearings should turn smoothly and quietly Also check that the outer races of the bearings fit tightly the crankcase Replace the bearings if they are abnormal page 10 10 ASSEMBLY Apply clean engine oil to the sliding and rotating surfaces of the gears bushings and shafts Assemble the main shaft and countershaft Install the snap rings aligning their end gaps between the shaft teeth as shown Make sure the snap rings are seated securely in the grooves of the shafts Main Shaft M4 24T M3 21T M2 17T 12T Snap Ring NU C1 Bushing O C4 23T C2 30T C1 34T Cam Spring 26T Countershaft locating plate Install the main shaft countershaft and shift Right Left drum as an assembly Install the kick starter spindle page 10 6 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 CRANKCASE BEARING REPLACEMENT Remove the oil pump drive shaft and drive sprocket LEFT CRANKCASE Remove the countershaft oil seal Drive the countershaft bearing out of the left crankcase BEARING REPLACEMENT Remove the main shaft and countershaft bearings from the left and right crankcase halves using the following tools Bearing Remover Bearing Remover Block Bearing
76. or damage and replace if necessary Check the gear teeth and engagement dogs for wear or damage Check the mainshaft and countershaft splines and sliding surfaces for wear or damage Measure the I D of each spinning gear Service limit M2 17 058mm 17 074mm 23 08 C3 20 081mm Measure I D and O D of C1 bushing Service limit I D 20 08mm O D 22 75mm 10 7 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 Measure the O D of the mainshaft and MA M2 countershaft the locations as shown Service limit M2 M4 16 926mm C3 C4 19 919mm Measure each transmission fork shaft hole I D Service Limit 34 05mm replace if over Check the transmission fork shaft for bending or damage Measure the transmission fork shaft O D Service Limit 33 96mm replace if below TRANSMISSION FORK DRUM INSPECTION Inspect each transmission fork for bending or damage Measure each transmission fork claw thickness Service Limit 5mm replace if below Inspect the transmission drum for scratches or poor lubrication 10 8 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 Check the transmission drum grooves for damage Check the bearing for excessive free play Measure the transmission drum O D Service Limits Left 13 05mm replace if below Right 16 10mm replace if below Check the transmission drum and transmission fork shaft h
77. ormance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler e Worn or damaged cylinder and piston rings e Worn or damaged piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high Abnormal noisy piston e Excessive carbon build up in combustion e Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and piston pin e ncorrectly installed piston 7 2 KYMCO 7 CYLINDER PISTON ACTIVE 50 Guide Roller Bolt CYLINDER REMOVAL Remove the cylinder head Remove the cam chain guide roller Remove the cylinder by removing the cylinder bolt Remove all gasket material from the cylinder surface Guide Roller Cylinder Bolt Dowel Pins Gasket Remove the gasket and dowel pins CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Service Limit 52 4mm repair or replace if over 52 4mm repair or replace if below Measure the cylinder to piston clearance Service Limit 0 35mm repair or replace if over The true roundness 1s the difference between the values measured in X and Y directions The cylindricity difference
78. p ring Remove the chain starter drive sprocket and driven sprocket as an assembly Remove the two screws base plate and three O rings INSPECTION Chain Sliders Inspect the chain sliders for wear or damage Replace them if necessary 8 4 8 ALTERNATORSTATER CLUTCH KYMCO CAM CHAIN TENSIONER ACTIVE 50 INSPECTION Measure the driven sprocket O D Service Limit 37 83mm replace if over Measure the driven sprocket I D Service Limit 19 06mm replace if over Check the one way clutch rollers spring caps and springs for wear or damage Spring Spring Cap Roller CAM CHAIN TENSIONER REMOVAL Drain the engine oil page 3 3 Remove the alternator page 8 3 Remove the starter clutch page 8 4 Remove the tensioner sealing bolt washer spring and tensioner rod Remove the pivot bolt and cam chain tensioner Cam Chain Tensioner Tensioner Rod UE PE EN Spring Washer And Bolt TENSIONER SPRING AND PUSH ROD INSPECTION Measure the tensioner spring free length Service limit 90mm 8 5 Check the push rod valve for clogged Check the push rod for wear or scraches Measure the push rod O D Service limit 11 945 mm INSTALLATION Install the cam chain tensioner and secure 1 with the pivot bolt Install the tensioner rod spring sealing washer bolt Tighten the tensioner sealing bolt TORUQE 1 5 2 5 kg m Install the tensioner spring with its small coil end up Ins
79. per mount nut 3 0 4 0kg m Rear shock absorber lower mount nut 3 0 4 0kg m Rear axle nut 8 0 10 0kg m Rear fork pivot nut 6 0 8 0kg m Rear shock absorber damper nut 1 0 1 4kg m SPECIAL TOOLS Bearing remover set Pivot set Remover handle Block Rear shock absorber attachment A Rear shock absorber attachment Bearing outer driver Pilot Rear shock absorber compressor Bearing remover shaft Bearing remover head 12 2 dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Improperly adjusted brake e Worn rear wheel bearing e Worn brake linings e or broken wheel spoke wires e Contaminated or damaged brake linings e Faulty tire e Worn brake cam e Improperly tightened axle nut e Worn brake drum e Loose rear fork pivot nut e Improperly installed brake linings e Worn brake shoes at cam contacting area Soft suspension e Worn camshaft e Weak shock absorber spring e Improperly adjusted shock absorber e Damper oil leaks Hard suspension e Improperly adjusted shock absorber Rear suspension noise e Bent rear shock absorber e Loose shock absorber fasteners e Insufficient damper oil 12 3 dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 REMOVAL Remove the rear axle nut Remove the rear brake adjusting nut Remove the pin nut and rear panel fixing arm bolt Ps Rear Brake Adjusting Nut Pin Nut and Bolt Drive Chain Rear Brake Pa
80. relay 1s normal if there 1s continuity 17 5 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 f LIGHTS INSTRUMENTS SWITCHES HORN FUEL UNIT SERVICE INFOR MATION neei aaa 18 1 TROUBLESHOOTING nisana 18 1 HEADLIGHT INSTRUMENT 18 2 TURN SIGNAL LIGHT ekien E 18 3 STOPTIGHT DAI Ee WE 18 3 IGNITION SWPDCH 18 3 STARTER BUTTON HORN BUTTON 18 4 HANDLEBAR 5 5 18 5 DIMMER SWITCH GEARSHIFT DISPLAYER 18 6 FUEL Eege 18 7 18 0 18 LIGHTS INSTRUMENTS SWITCHES HORN KYMCO FUEL UNIT ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e plastic plugs have locking tabs that must be released before disconnecting e An electric tester must be used for checking the continuity between two points The electric tester also contains a voltmeter which can be used to measure voltage e Different bulbs have different specifications When replacing use a new bulb of the same specifications to avoid damage of the electrical equipment e The continuity check of switches can be made without removing the switches from the motorcycle SPECIFICATIONS Headlight 2 35 35W Stoplight Taillight 12V 21 5W Turn signal light 12 10Wx4 Turn signal indicator light 12V 3 4W x2 Instrument light 12V 1 7Wx2 High beam indicator light 12 1 7W Fuse 10 TROUBLESHOOTING
81. rfere with adjacent or surrounding parts in all steering positions B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions De careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting E Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind 1 9 KYMCO ACTIVE 50 you understand the instrument Is the instrument set correctly Remove Rust dC KYMCO 1 GENERAL INFORMATION 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 Engine Oil lubrication Apply grease for m lubrication Grease Use special tool Caution Warning 1 10 dO KYMCO 1 GENERAL INFORMATION ACTIVE 50 TORQUE VALUES STANDARD TORQUE VALUES Torque kg m 5mm bolt nut 5mm screw 6mm bolt nut 6mm nut SH bolt 8mm bolt nut 6mm flange bolt nut 10mm bolt nut i omm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE recen Kick plate bolt R L case bolt Stopper shift bolt Cam gear shift bolt Pin guide bolt Oil pump bolt Clutch
82. rging battery e When inspecting the A C generator use an electric tester e Route the charging system wires properly to avoid shorted wire due to wires being twisted or kinked SPECIFICATIONS Battery capacity I2V5AH Electrolyte specific gravity 1 260 1 280 20 Charging rpm 2 500 rpm min generator 1 min 6 000 rpm Regulator Rectifier No contact point type Charging coil resistance 0 2 0 30 TORQUE VALUES A C generator stator bolt A C generator rotor bolt SPECIAL TOOLS Flywheel holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester 16 2 KYMCO 16 CHARGING SYSTEM ACTIVE 50 TROUBLESHOOTING No power e Dead battery e Fuse burned out e Disconnected battery cable e Faulty ignition switch Low power e Weak battery e battery connection terminal e Charging system failure e Faulty regulator rectifier Intermittent power e battery cable connection e charging system connection e lighting system connection Charging system failure e Loose broken or shorted wire or connector e Faulty regulator rectifier e Faulty A C generator 16 3 GQ KYMCO 16 CHARGING SYSTEM ACTIVE 50 BATTERY REMOVAL Open the seat and battery cover First disconnect the battery negative cable and then the positive cable Remove the battery V When disconnecting the battery positive cable do not touch the frame w
83. rings squarely e nstall the bearings with the sealed end facing out Bearing Outer Driver Dust Seal Je Install the drive chatiegeGnsind secure it with 12 6 GQ KYMCO 12 REAR WHEEL BRAKE SUSPENSION 50 snap ring Apply grease to the dust seal and install it to the bearing Install the side collar INSTALLATION Install the rear wheel 1n the reverse order of removal Drive Chain Slack 1 2cm After rear wheel installation be sure to adjust the drive chain slack and rear brake pedal free play Torque 8 0 10 0kg m REAR BRAKE REMOVAL pe m Remove the rear wheel and rear brake panel INSPECTION Measure the rear brake lining thickness Service Limit 2 0mm replace if below Side Collar Measure the brake drum I D GQ KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 ervice Limit mm replace 11 over Brake Shoes DISASSEMBLY Remove the springs and brake shoes Springs Brake Cam Brake Arm Remove the brake arm bolt to remove the brake arm Remove the oil seal Remove the brake cam ASSEMBLY contaminated brake linings reduce stopping power e During installation wipe any excess grease off the brake cam GQ KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 Springs Grease Brake Lining Apply grease to the brake cam and anchor Brake Cam pin then install the brake cam to the brake panel Apply engine oil to the oil
84. rk tube and then install oil stopper to the piston end Install the front fork tube into the bottom tube Piston Front Fork Tube Place shop towels under the bottom tube and set it in a vise Apply locking agent to the Return Spring socket head bolt and then install 1t into the piston Tighten the socket head bolt using the socket spanner When tightening the socket head 44 14 11 FRONT WHEEL SUSPENSION STEERING Torque 1 5 2 5kg m Apply engine oil to a new oil seal and install the oil seal using the fork seal driver Then install the snap ring and dust seal Fully compress the front fork and fill SAE8 engine oil into the front fork tube i Do not fill too much engine oil Specified Capacity 50cc Install the damping spring to the damper and then install them into the front shock absorber tube Install the front shock absorber spring and tighten the damper mut Torque 1 5 3 0kg m Install the front shock absorber spring with the loosely wound coils facing up 6mm Socket Spanner KYMCO ACTIVE 50 STROKE 1 05mm Compress INSTALLATION Install the front shock absorbers onto the steering stem Tighten the lower mount bolts Install the front fender Install the front wheel STEERING STEM REMOVAL Remove the steering handlebar Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper 11 FRONT WHEEL SUSPENSION KYMCO
85. seal and install it to the brake cam Brake Cam Install the brake arm onto the brake cam Grease m dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 aligning punch mark on cam wit the scribed line on the arm Install and tighten the brake arm bolt Torque 0 8 1 2kg m INSTALLATION Install the brake panel and rear wheel in the reverse order of removal After the rear wheel installation check the drive chain slack and rear brake pedal free play REAR FORK REMOVAL P 12 10 dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 emove the rear wheel Remove the rear shock absorbers Remove the cover the rear fork pivot nut to remove the pivot and rear fork Rear Fork Pivot Nut e Remove the drive chain slider and check for wear or damage P e d 5 4 c A ON LoCo OLK DIVO bushings press in the new bushings to make them flush with the rear fork dC KYMCO 12 REAR WHEEL BRAKE SUSPENSION ACTIVE 50 INSTALLATION Install the rear fork 1n the reverse order of removal Tighten the rear fork pivot nut Torque 5 5 7 0kg m After the rear fork 1s installed install the following parts Rear shock absorbers Rear wheel Drive chain cover emm Rear brake adjustment Rear Fork Pivot Rear Fork Pivot Bushing 12 12 KYMCO 13 HYDRAULIC BRAKE ACTIVE 50 HYDRAU
86. stall the four spring clutch damper Install the clutch Set Ring Spring Clutch Damper Collapsible Guide Clutch Center INSTALLATION Je Install the collapsible Install the guide clutch center 9 5 KYMCO 9 CLUTCH GEAR SHIFT MECHANISM ACTIVE 50 Install the clutch outer guide onto the main shaft Install the washer over the crankshaft Gear Primary Driver Gear prim ry drive Install the clutch drum and manual clutch Manual Clutch Assembly assembly Washer Washer Lock d i ee Install the washer with the OUT SIDE d d AN E mark facing out T OUT SIDE Mark clutch lock nut Install the clutch holder and secure it with two bolts Tighten the lock nut to the specified torque TORQUE 3 8 4 5kg m Clutch holder Lock nut wrench Install the plane washer and centrifugal Lock Nut Wrench Gear Holder 9 CLUTCH GEAR SHIFT MECHANISM Install the oil filter rotor cover and a new gasket Secure the oil filter rotor with the three bolts Install the clutch Bearing Install the clutch lifter bearing and clutch lifter Cam page9 10 4 Install the clutch lifter lever onto the Gearshift spindle aligning its punch mark with The notch mark on the spindle Install the right crankcase cover page9 12 Install the clutch lift comp Install the through oil through and through oil Install the spring cam plate sid e Install the Retainer Clutch Bot Gasket Cover KY
87. sting Use of an improper tester or measurements in an improper range may give false readings Use a Sanwa Electric Tester or Kowa Electric Tester for testing C White D Green C D Testing Range Red Yellow White green Range for the Sanwa Tester XKQ Probe Range for the Kowa Tester 1000 A co Red b Yellow White D green SB Note The readings in this table are taken with a Sanwa Tester 16 6 dC KYMCO 17 STARTING SYSTEM ACTIVE 50 Wd STARTING SYSTEM STARTING SYSTEM DIAGRAM 17 1 SER VICE INFORMATION 9 TROUBLE SHOOTING 255592225602 jus STARTER echan cc 17 3 STARTER E 17 5 17 0 dC KYMCO 17 STARTING SYSTEM ACTIVE 50 STARTING SYSTEM DIAGRAM Battery Starter Motor Starter Relay STARTER SW MAIN SW 7A E Tu Y R SIARTER MAC R G o O 12V5AH 1 17 1 KYMCO 17 STARTING SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed the frame e Refer to Section 8 3 for the removal of starter clutch e When connecting the starting system wires connect them securely to avoid hard starting due to poor connection SPECIFICATIONS Standard Limit mm Service Limit mm TORQUE VALUES SPECIAL TOOLS S
88. t side of the wheel 11 FRONT WHEEL SUSPENSION KYMCO STEERING ACTIVE 50 Groove INSTALLATION Install the front wheel onto the front fork aligning the tab on the front fork with the groove in the speedometer gearbox Insert the axle shaft and tighten the axle nut Torque 5 5 7 0kg m Install the speedometer cable by aligning the groove with the tab Gd n Front Axle Nut Axle io NN FRONT SHOCK ABSORBER 11 10 11 FRONT WHEEL SUSPENSION O KYMCO STEERING ACTIVE 50 REMOVAL Remove the front wheel Refer to 11 7 Remove the fender FR bolts Remove the fender FR Remove the four front fender Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Fender FR Bolts Remove the dust boot Remove the circlip Dust Boot Circlip Front Shock Absorber Use a vise to hold the front shock absorber E and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Use a vise to hold the front shock absorber Fender FR r Upper Fork Bridge Bolts tube and remove the damper from the shock absorber tube 11 FRONT WHEEL SUSPENSION KYMCO STEERING ACTIVE 50 When holding the shock absorber tube place a shop towel under it and do not applv too much force Front Fork Spring Use a vise to hold the front fork bottom tube and place shop towels under the bottom tube Remove t
89. tall the right crankcase cover and tighten the cover bolts Install the kickstarter pedal Adjust the clutch page 2 8 Gear Shift Spindle Ps 9 12 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 CRANKCASE GRANKSHAFT TRANS MISSION SYSTEM STARTER SPINDLE SERVICE INFORMATION TROUBLESHOOTING CRANKCASE REMOVAL CRANKSHAFT KICK STARTER TRANSMISSION eege CRANKCASE BEARING REPLACEMENT CRANKCASE INSTALLATION 10 0 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 10 1 10 CRANKCASE CRANKSHAFT KICK STARTER TRANSMISSION SERVICE INFORMATION GENERAL INSTRUCTIONS e During crankcase separation do not separate the crankcase halves with an iron hammer to avoid crankcase deformation or damage e After separation be careful not to damage the right and left crankcase mating surfaces to avoid oil leakage GQ KYMCO ACTIVE 50 e Replace the gasket with a new one during reassembly of the crankcase halves e After transmission system disassembly make sure that the gear shifting operation 1s normal before reassembly of the remaining parts e Apply engine oil to the transmission system and crankshaft before reassembly SPECIFICATIONS
90. tall the starter clutch and alternator page 8 6 STARTER CLUTCH INSTALLATION Install the new O rings onto the left crankcase and base plate Install the base plate being careful not to damage the O ring Tighten the base plate screws 8 ALTERNATOR STARTER CLUTCH gt CAM CHAIN TENSIONER KYMCO ACTIVE 50 5 One Way Valve Tensioner Tensioner Rod EN SU Ce mb Jat Sealing Washer And Bolt Base Plate 8 ALTERNATORSTATER CLUTCH KYMCO CAM CHAIN TENSIONER ACTIVE 50 Install the chain drive sprocket and driven sprocket as an assembly Install the following components snap ring stopper plate chain sliders Y Chain Sliders Grommet Clamp Bolts Install the alternator stator base and secure it with the two bolts Install the grommet into the grove of the left crankcase cover Install the wire clamp Nut Install the woodruff key on the crankshaft Wipe all oil Iff the inside of the flywheel amd crankshaft and install the flywheel aligning its groove with the woodruff key Install the flywheel turning it counterclockwise Install and tighten the flywheel nut while holding the flywheel with a flywheel holder TORQUE 3 2 4 0 kg m Flywheel Holder Flywheel Holder Drive Sprocket 9 7 8 ALTERNATORATARTER CLUTCH KYMCO gt CAM CHAIN TENSIONER ACTIVE 50 Gasket Install the dowel pins and a new gasket Install the left crankcase cover and
91. tarter motor bolt 0 8 1 2kg m Starter clutch lock nut 3 2 4 0kg m TROUBLESHOOTING Starter motor won t turn Lack of power e Fuse burned out e Weak battery e Weak battery e Loose wire or connection e Faulty ignition switch e Foreign matter stuck in starter motor or gear e Faulty starter clutch e Faulty starter relay Starter motor rotates but engine does e Poorly connected broken or shorted wire not start e Faulty starter motor e Faulty starter clutch e Reverse rotation of starter motor e Weak battery 17 2 17 STARTING SYSTEM STARTER MOTOR REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly Disconnect the starter motor wire Remove the three starter motor mounting bolts and the motor DISASSEMBLY Remove the four starter motor case mounting Screws and disassemble them INSPECTION Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature coils Turn the outer race of the bearing with your fingers The bearing should turn smoothly and quietly Also check that the inner race of the bearing fits tightly on the armature shaft Check for continuity between pairs of commutator bars Also make a resistance check between individual commutator bars and the armature shaft There should be no continuity
92. ted properly logged oil line Faulty oil pump Worn cylinder and piston rings Mixture too lean Engine does not Engine overheats Poor quality fuel overheats Excessive carbon buildup in combustion chamber Ignition timing too advanced Remove cylinder head oil pipe bolt and inspect Check for engine overheating Rapidly accelerate or run at high speed Q C lt 5 3A e de o amp Jia gt Ex x E 2 eg z eU ct m E 5 5 B gt c un gt ga Excessive carbon build up in combustion chamber Poor quality fuel lutch slipping Mixture too lean Ignition timing too advanced Engine does not knock Engine knocks 19 dC KYMCO 1 GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing Probable Cause aulty CDI unit Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Worn valve seat Check fuel filter for fuel supply Fuel flows freely Check carburetor for clogged jets Not clogged Clogged Clean and unclog Check valve timing not aligned Check valve spring tension Weak spring Faulty spring Empty fuel tank logged fuel filter or tube logged fuel tank cap breather hole racked fuel pump vacuum tube Fuel flow restricted 1 20 KYMCO 1 GENERAL INFORMATION ACTIVE 50 POOR CHARGING BATTERY OVER DISCHA
93. th recommended engine oil e After installation perform the following inspections and adjustments 1 Throttle operation 2 Drive chain adjustment 5 3 GQ KYMCO ACTIVE 50 Bolts ra v Rear Crankcase Cover Drive Chain Bolts Drive Gear Engine Hanger Bolt Nut Set Plate dC KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 CYLINDER HEAD VALVES 3 SCHEMATIC DRAWING 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING detects ae edet 6 3 CYLINDER HEAD REMOVAL E 6 4 CYLINDER HEAD DISASSEMBLY 6 5 CYLINDER HEAD ASSEMBLY 6 8 CYLINDER HEAD INSTALLATION cerre 6 10 6 0 dO KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 SCHEMATIC DRAWING dC KYMCO 6 CYLINDER HEAD VALVES ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water jacket must be drained first e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication e The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head e After disassembly clean the removed
94. the throttle valve into the carburetor aligning the throttle valve groove with the throttle stop Screw Install the carburetor top onto the carburetor After installing the carburetor and throttle valve perform the following adjustments Throttle grip free play page 2 3 Carburetor air screw adjustment 1f the carburetor was overhauled or cleaned 4 6 KYMCO 4 FUEL SYSTEM ACTIVE 50 CARBURETOR REMOVAL Remove the front cover page 14 3 Loosen the air cleaner connecting tube band Remove the carburetor top page 4 6 Remove the fuel tube from the carburetor Remove the choke cable Remove the carburetor mounting bolts Remove the insulator O ring and carburetor Fuel Tube CARBURETOR DISASSEMBLY Loosen the drain screw to drain the gasoline from the float chamber e Keep sparks and flames away from the work area e Drain gasoline into a clean container Drain Screw 4 7 4 FUEL SYSTEM Float Float Valve Disassembly Remove the four float chamber attaching screws and remove the float chamber Remove the float pin float and float valve FLOAT FLOAT VALVE INSPECTION Inspect the float valve seat for wear or damage Inspect the float for damage or fuel level inside the float chamber Float Valve Seat Float Pin Needle J et Holder Needle Jet MAIN JET SLOW JETS AIR SCREW THROTTLE STOP SCREW REMOVAL Remove the main jet needle jet holder and needle Jet Remo
95. usted clutch e Bent or damaged transmission fork e Bent transmission fork shaft e Bent gear shift spindle e Damaged transmission drum grooves 10 3 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 CRANKCASE REMOVAL The following parts must be removed before removing the crankcase e Cylinder head Refer to Section 6 e Cylinder piston Refer to Section 7 e Alterantor cam chain tensioner Refer to Section 8 e Clutch gear shift mechanism Refer to Section 9 Turn the engine so that the left crankcase 15 facing up Remove the eight crankcase attaching bolts Lay the crankcase on the right side Remove the snap ring on the kick starter spindle Remove the spring retainer and spring Spring R etainer Snap Ring Lay the crankcase on the left side Right Crankcase Separate the right and the left crankcase halves Remove the gasket and dowel pins Dowel Pins 10 CRANKCASE CRANKSHAFT KICK KYMCO STARTER TRANSMISSION ACTIVE 50 Kick starter spindle Crankshaft LY CRANKSHAFT KICK STARTER REMOVAL Remove the crankshaft Remove the kick starter spindle CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 80mm replace if over Measure the connecting rod big end radial clearance at two points at right angles to the shaft Service Limit 0 05mm replace if over Measure the crankshaft runout Service Limit 0 1 mm repl
96. ve the slow jet Slow Jet Main Jet 4 FUEL SYSTEM ACTIVE 50 Remove the air screw and throttle stop screw Throttle Stop Screw CAUTIONS e Be careful not to damage the jets and jet holder when removing them e Before removing turn the throttle stop screw and air screw in and carefully count the number of turns until they seat lightly and then make a note of this e Do not force the screw against its seat to avoid seat damage e Be sure to install the O ring in the reverse order of removal Carburetor Cleaning Blow compressed air through all passages of the carburetor body Slow Jet Main Jet Installation Install the slow jet Install the needle jet needle jet holder and main jet Install the throttle stop screw and air screw e When installing the air screw return it to the original position as noted during removal e After the carburetor 15 installed be sure to perform the Exhaust Emission Test Install the float valve float and float pin Main Jet Throttle Stop Screw Float 4 9 dC KYMCO 4 FUEL SYSTEM ACTIVE 50 FLOAT LEVEL INSPECTION Turn the carburetor upside down so that the float will go down to make the float valve contact the float valve seat Then slowly tilt the carburetor and measure the float level with the float level gauge while the float pin just contacts with float valve Float Level 20mm When adjusting car
97. ver Check the wheel spoke wires for looseness If the wheel rim is made of aluminum alloy replace with a new one if necessary 4 1 Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand Replace the bearings if they are noisy or have excessive play Radial DISASSEMBLY Remove the speedometer gearbox and dust 11 FRONT WHEEL SUSPENSION KYMCO STEERING ACTIVE 50 seal from the left side of the wheel Dust Seal Remove the axle collar from the right side of the wheel Remove the dust seal Remove the five nuts and the brake disk Drive out the wheel bearings and distance collar Bearing Remover Shaft ASSEMBLY Pack all bearing cavities with grease First 11 8 Speedometer Gearbox 11 FRONT WHEEL SUSPENSION KYMCO STEERING ACTIVE 50 drive in the right bearing and then install the distance collar Finally drive in the left bearing Special Bearing driver handle Bearing installer Attachment 37x40mm Dust Seal Apply grease to the dust seal and install the dust seal Install the brake disk and tighten the five nuts _ Tabs Install the speedometer gearbox by aligning the tabs with the grooves Groove Speedometer Gearbox Apply grease to the speedometer gearbox and dust seal then install them to the wheel from the left side Bearing Driver Handle Install the axle collar to the righ

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