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vitality 50 - Kymco Spare Parts

1. 33 9651133 985 34 000034 025 VITALITY 168 14 8 6mm 85 Speed limit type 72 35 2 1 2 1 2 1850 100 2 Gmm Ist notch 2 6 KYMCO 2 GENERAL INFORMATION VITALITY 50 Axle shaft runout Front wheel rim runout N 111 2 0 2 0 gt e 209 ELECTRICAL EQUIPMENT VITALITY 50 Capacity 12V3AH Capacity SH 13 0 13 2V Charging 0 4A 5H 10H in BRSHAS Spark plug gap 0 6 10 7mm 0 15300 1870 6 99 10 21 Primary coil Secondary coil with plug cap Secondary coil without plug cap 3 24 3 96 SU 1600 13 5 2 BTDC 3000 rpm Pulser coil resistance 201 Ignition timing 2 7 2 GENERAL INFORMATION SERVICE INFORMATION 4 STROKE KYMCO VITALITY 50 ENGINE Item Cylinder head warpage Piston O D 4 55mm from bottom of piston skirt Cylinder to piston clearance Piston pin hole I D Piston pin O D Piston to piston pin clearance Ring to groove top second Connecting rod small end LD Cylinder bore Drive belt width Drive pulley collar O D Movable drive face ID Weight roller O D Clutch outer LD Driven face spring free length Driven face O D Movable driven face I D onnecting rod small end free play Connecting rod big end radial clearance Run out CARBURETOR Setting mark Type Float
2. 6 CYLINDER HEAD 2 STROKE CYLINDER PISTON 7 E e a 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 9 FINATZ REECH 10 CRANKCASE CRANKSHAFT 11 CARBURETOR 550 aaa a 12 FRAME COVERS EXHAUST MUFFLER 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORKE 14 REAR WHEEL REAR BRAKE REAR SHOCK 15 ELECTRICAL EQUIPMENT 16 INSTRUMENT SWITCHES LIGHTS 17 KCAS ROR EURO 2 LL LZ ua a Ra qhana qasa 18 VITALITY 50 1 0 1 SPECIFICATIONS SPECIFICATIONS 2 Stroke Gross weight kg 173 1 rider Initial speed Km h Kick starter unleaded gosoline Single cylinder flat C Semi sphere Compression ratio Compression pressure 11 8kg cm kg cm rpm 4 5 6000 Speed limited type 3 9 6000 0 5 6000 Speed limited type 0 48 6000 Automatic controlled i Open Close pump type Max horsepower ps rpm Max torque kg m rpm Port M Exhaust timing 1 1 KYMCO VITALITY 50 1 3 Wet single ubrication oil capacity l
3. 9 1 9 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO VITALITY 50 e Avoid getting grease and oil on the drive belt and pulley faces SPECIFICATIONS Driven face spring free length 87 9 2 stroke 82 6 2 stroke Driven face spring free length 95 4 stroke 90 4 stroke Driven face O D 33 965133 985 33 94 1070107 2 107 5 Movable driven face I D 34 0034 25 34 06 VALUES Drive face nut 3 5114 0 Clutch outer nut 3 5114 5 Clutch drive plate nut 5 006 0 SPECIAL TOOLS Universal holder Clutch spring compressor E017 E034 TROUBLESHOOTING Engine starts but motorcycle won t move e Worn drive belt e Broken ramp plate e Worn or damaged clutch lining Engine stalls or motorcycle creeps e Broken clutch weight spring Drive belt width Poor performance at high speed or lack of power e Worn drive belt e Weak driven face spring e Worn weight roller e Faulty driven face 9 2 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 KICK STARTER Left Crankcase Cover LEFT CRANKCASE COVER REMOVAL Remove left side cover 13 4 Remove the drive belt cooling air tube connector circlip 5 3 Remove air cleaner housing 75 2 Remove the nine left crankcase cover bolts left crankcase cover and dowe
4. 1 0 1 4 Exhaust muffler lock bolt BF8x35 3 03 6 Spark plug 1 101 7 ENGINE 4 STROKE Stud bolt 8 0 71 1 filter screen 1 0 2 0 L cover 1 0 1 4 Cam shaft holder 1 201 6 ADJ nut 0 7 1 1 Pivot tensioner bolt 0 61 2 Lifter tensioner 1 0 1 4 Cam chain adjust bolt 0 4 10 7 Mission case 2 43 0 Mission fill 0 81 11 2 Driver face nut 5 5 16 5 Clutch outer nut 3 504 5 Drive plate nut 5 0 6 0 flywheel nut 3 504 5 Spark plug 1 0 1 4 Mission drain plug 20 30 pump screw 0 10 3 Head stud IN pipe 0 71 1 Head stud pipe 0 7 1 1 Startor 0 61 0 0 61 0 2 10 2 GENERAL INFORMATION KYMCO VITALITY 50 FRAME Thread dia mm Flange bolt U nut Handlebar lock nut Steering stem lock nut Steering top cone race Front axle nut Rear axle nut Rear brake arm bolt Front fork upper mount bolt lower mount bolt Front brake caliper bolt Brake fluid bolt Front pivot arm bolt Rear shock absorber upper mount bolt lower mount bolt Engine hanger bolt Flange U nut Flange U nut Torque specifications listed above are for important fasteners Others should be tightened to standard torque values below STANDARD TORQUE VALUES bolt SH bolt 8mm Flange 6mm 5mm bolt nut 6mm bolt nut 8mm bolt nut 10mm bolt nut 12mm bolt nut 2 11 0 451 10 6 0 8 1 80 3 0 5 00 1 2 2 5
5. INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 100 10 minutes minimum after stopping the engine If the reading is not within the limit replace the auto bystarter with a new one Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage 1s blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter is normal AUTO BYSTARTER REMOVAL Remove the bystarter cap Remove the one set plate screw and set plate and then remove the auto bystarter from the carburetor body BATTERY Bystarter Cap Bystarter Screw Set Plate 12 20 KYMCO 12 CARBURETOR VITALITY 50 AUTO INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part 15 found replace the auto bystarter with a new one Bystarter Needle Bystarter Valve Screws Screws AIR CUT OFF VALVE A C V REMOVAL Remove the two screws and then remove throttle cable holder Remove the two screws and the atr cut off valve cover Throttle Cable Cut off Valve Cover Spring Cut off Val
6. KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 IGNITION SYSTEM 4 STROKE Ignition Coil A C Generator Exciter Coil Pulser Coil Ignition Switch LIY Ignition Coil ulser Coil Spark Plug 16 12 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 IGNITION COIL INSPECTION Continuity Test This test is to inspect the continuity of ignition coil Remove the met in box and center cover gt 13 5 Measure the resistance between the ignition coil primary coil terminals Resistance 200 2 Stroke 0 153110 1870 4 Stroke 0 50 Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 207 with plug 2 Stroke 6 99K 10 21 K 0 4 Stroke 8 12 Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 2011 without plug cap 2 Stroke 3 24K 3 96K O Figure A 4 Stroke 3KQ Performance Test Remove the ignition coil Ignition Coil 16 1 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 Inspect the ignition coil with an ignition coil tester Follow the ignition coil tester manufac turer s instructions 1 Turn the changeover switch to 12V and connect the ignition coil to the tester 2 Turn the power switch ON and check the
7. KYMCO 2 GENERAL INFORMATION VITALITY 50 B If the fuse is burned out find the cause and B The connector shall be inserted repairit Replace it with a new one completely according to the specified capacity B If the double connector has a lock lock it at the correct position B Check if there is any loose wire MARY OE I ty Before connecting a terminal check for After operation terminal caps shall be damaged terminal cover or loose negative terminal Installed securely B When taking out the connector lock the connector shall be released before operation mg Check the double connector cover for proper coverage and Installation AL Ses B Insert the terminal completely Bi Check the terminal cover for proper coverage E Do not make the terminal cover opening B Hold the connector body when connecting or disconnecting it face up E Do not pull the connector wire O BE PPR Bi Check if any connector terminal is bending Secure wire harnesses to frame with protruding or loose their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses TEE a ERE 2 GENERAL INFORMATION KYMCO VITALITY 50 B After clamping check each wire to make sure it 15 secure Q X 5 ki 659 Do not squeeze wires against the weld or
8. Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces 11 11 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 CRANKSHAFT INSPECTION Measure the connecting rod small end I D Service Limit 13 06 mm replace if over Measure the connecting rod small end free play A A Out of specification 0 05 0 4 mm Replace the crankshaft B B Measure the crankshaft run out B Service Limit 0 10mm replace if over Measure the connecting rod big end side clearance C D Service Limit 0 05mm replace if over Measure the crank width D Out of specification 42 2 42 15 mm gt Replace the crankshaft Turn the crankshaft bearings and check for excessive play Measure the crankshaft bearing play Service Limit Axial 0 20mm replace if over Radial 0 05mm replace if over 11 12 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 CRANKCASE BALANCER INSTALLATION Install the cam chain into the left crankcase Install the dowel pins and a new gasket onto the left crankcase Place the right crankcase over the crankshaft and onto the left crankcase Install the crankshaft into the left crankcase When installing the crankshaft be careful not to damage the oil seal Bolt Install the right crankcase Tighten crankcase attaching Torque 0 8 1
9. Throttle Cable Handlebar _ Nut KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT ISL eo BRAKE FRONT SHOCK ABSORBER FRONT FORK INSTALLATION Handlebar Install the handlebar and tighten the handlebar lock nut Torque 5 016 0 Nut Lubricate the throttle cable front end with grease Install the throttle grip and connect the throttle cable Throttle Cable Bolts Brake Master Cylinder Install the rear brake lever holder Install the front brake master cylinder disk brake KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 FRONT WHEEL Speedometer Cable REMOVAL DISK BRAKE Jack the scooter front wheel off the ground Remove the speedometer cable set screw then disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the brake panel side collar Axle Nut INSPECTION Set the axle in V blocks and measure the runout The actual runout is of the total indicator reading Service Limit 0 2mm replace if over Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 14 5 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER ERONT FORK Turn the wheel bearings and replace them if they have excessive play or noise DISASSEMBLY Remove the dust seal
10. CYLINDER PISTON 5 CYLINDER HEAD 2 STROKE CYLINDER PISTON SERVICE INFORMATION O STROKE 152 SERVICE INFORMATION 4 STROKE 724 CYLINDER HEAD C STROK E EE 7 5 CYLINDER PISTON 2 5 4100 7 8 CYLINDER PISTON 4 STROKE 7 13 7 0 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY 50 2 STROKE Torque 1 1 11 7kg m cold Torque 1 001 2 7 1 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON 5 4 STROKE 7 CYLINDER HEAD 2 STROKE CYLINDER PISTON SERVICE INFORMATION 2 STROKE GENERAL INSTRUCTIONS KYMCO VITALITY 50 e The cylinder head cylinder and piston can be serviced with the engine installed in the frame Before disassembly clean the engine to prevent dust from entering the engine Remove all gasket material from the mating surfaces Do not use a driver to pry between the cylinder and cylinder head cylinder and crankcase Do not damage the cylinder inside and the piston surface e After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts SPECIFICATIONS Cylinder head warpage Cylinder to piston clearance Piston pin hole 1 0 Piston pin O D Piston to piston pin clearance Pist
11. KYMCO VITALITY 50 This Service Manual describes technical features and servicing procedures for the KYMCO VITALITY 50 In this manual many illustrations and drawings are used to help servicemen have better understanding Section 2 contains the service precautions for all operations and troubleshooting stated in this manual Read them carefully before starting any operation Section 3 describes the Inspection adjustment procedures safety rules and service Information for each part starting from periodic maintenance Sections 4 through 17 give instructions for disassembly assembly and inspection of lubrication system engine fuel system and electrical equipment Section 18 15 the KYMCO clean system for EURO 2 By KWANG YANG Motor Ltd First Edition May 2004 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Ltd is expressly prohibited 4121 LBD5 6 S00 1 SPECIFICATIONS KYMCO TABLE OF CONTENTS SHEET ereecht 1 GENERAL INFORMATION 2 INSPECTION ADJUSTMENT 3 LUBRICATION SYSTEM 4 ENGINE REMOVAL INSTALLATION 5 4 STROKE CYLINDER HEAD VALVES
12. Use the x KQ range for the Sanwa Tester Use the x 100Q range for the Kowa Tester 2 Stroke Unit KYMCO VITALITY 50 CDI Unit Black Yellow BlgCk Red Blue Yellow Green Black White KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 4 Stroke Unit Black Rlue Q DCH Black Black Bhe G Blue Yellow Yellow reen Probe Black Blue lack 9 2M 9 25 310K 320 310K 320 Yellow M K K Blue 8 81 8 8 310 320 Yellow 5 8 86M 8 8 310 320 ees x IL Black Yellow Blue Yellow 16 16 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 ELECTRIC STARTER Starter Relay NN A N x H SN Wes 2 AN 52217 9 M OZ NU Y R Ignition SW i B Starter Button Stoplight Starter Relay 16 17 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 STARTER RELAY INSPECTION Remove met in box 5 13 5 Disconnect the starter relay coupler and then remove the starter relay Connect the starter relay green yellow terminal to the 12V battery positive terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The relay is normal if there is continuity Red White Green Yellow Starter Relay 4 Stroke 16 18 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 STARTER MOTOR REMOVAL Disconnect the s
13. 12 11 KYMCO VITALITY 50 Float Valve Float Seat Main Jet 4 Throttle Stop Screw Air Screw KYMCO 12 CARBURETOR VITALITY 50 Jet Needle Jet holder FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder Install the air screw and throttle stop screw according to the rotations recorded If the air screw must be replaced be sure to perform the air screw adjustment again Throttle Stop Screw Air Screw Float Pin Install the float valve float and float pin Tighten the float screw securely FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6mm Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws KYMCO 12 CARBURETOR VITALITY 50 O rings CARBURETOR INSTALLATION When Installation do not allow foreign particles to enter the carburetor Check the carburetor insulator and O ring for wear or damage Install the carburetor and insulator onto intake manifold and tighten the two lock nuts Connect the fuel tube and auto bystarter wire connector Route the auto bystarter wire correctly and properly Install the carburetor top 12 5 Install the air cleaner onto the carburetor and tig
14. Connector Oil Tube Wire Harness Battery Cable aoe Speedometer Cable Reed Valve Battery Cable 2 19 KYMCO 2 GENERAL INFORMATION VITALITY 50 Secondary Air Cleaner Fuel Unit C D I Unit Auto By Start Ignition Coil Spark Plug Cap T Ya BS WA zl y s HE Air Inlet Hose Wey be LS SL V belt Chamber CA Eu N A Auto By Start m Connector Oil Tube Oil Throttle Cable Start Motor Connector A C G Connector Wire Harness Fuel Throttle Cable Battery Cable KYMCO 2 GENERAL INFORMATION VITALITY 50 CABLE amp HARNESS ROUTING 4 STROKE Winker Relay Front Stop Switch Wire Right Handlebar Switch Wire Throttle Cable Front Brake Fluid Tube 3 pg Ignition Switch Ci Instrument connectors gt W Z Y N Speedometer Cable EN N B Headlight Connector f Y ELA Regulator Rectifier Main Wire Harness Resistor Horn 2 21 KYMCO 2 GENERAL INFORMATION VITALITY 50 Ignition Coil C D I Unit Auto By Start Wire A C G Wire Start Motor Wire Ignition Coil Wire Throttle Cable Wire Harness Crankcase Breather Tube Rear Brake Cable Fuel Tube Throttle Cable Air Inlet Hose V belt Chamber Rear Brake Cable 2 22 KYMCO
15. Remove the wheel bearings and distance Bearing Remover collar 14 6 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 ASSEMBLY Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Drive the bearing squarely with the sealed end facing out Apply grease to the dust seal lip and install Side Collar the dust seal Install the side collar Dust Seal 14 7 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER ERONT FORK FRONT WHEEL INSTALLATION Axle Bolt Disk Brake Install the front wheel aligning the speedometer gear tab with the front fork groove Connect the speedometer cable Torque 5 0 7 0kg m HYDRAULIC BRAKE Brake Fluid Replacement Air Bleeding Check the brake fluid level on level ground e When operating the brake lever the Groove Tab brake reservoir cap must be tightened securely to avoid spill of brake fluid e When servicing the brake system use Upper Limit shop towels to cover plastic parts and coated surfaces to avoid damage caused by spill of brake fluid Brake Fluid Bleeding In order to avoid spill of brake fluid connect a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and
16. SERVICE INFORMATION RE TROUBLESHOOTING L sas a nn diated ertet FUEC UNIE aan a au EE OIEMEBT Ou SWITCHES EE RRE He RE INSTRUMENT HEADEDIGPPDD eege eege 17 0 17 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS dO KYMCO VITALITY 50 e Wires should be connected to other wires of the same color Connector must be connected to other couplers of the same color e All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting e After installation of each switch a continuity check must be performed TROUBLESHOOTING Lights do not come on when ignition switch is ON e Burned bulb e Faulty switch e Broken or shorted wire e Fuse burned out e Weak battery Poorly connected wire e Faulty winker Light dims e Faulty ignition coil e Wire or switch resistance too high e Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo e Faulty or burned bulb e Faulty dimmer switch 17 1 Motor oil indicator light does not come on when motor oil is insufficient e Fuse burned out e Dead battery e Faulty ignition switch e Faulty instrument e Faulty oil meter Motor oil indicator light winks e Loose wire connection e Broken wire e Faulty oil meter Fuel gauge pointer does not register correctly e Disconnected wire or connector e Broken wire e Faulty float e F
17. 2 25 2 GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Check if fuel reaches carburetor by loosening Symptom drain screw Remove spark plug and install it into spark plug cap to test spark connecting it to engine ground Remove spark plug and install it into spark plug Fuel reaches carburetor Fuel does not reach carburetor KYMCO VITALITY 50 Probable Cause Empty fuel tank Clogged float valve cap to test spark bn connecting it to engine ground compression using a compression gauge Test cylinder x Check carburetor for clogging EE fuel filter Faulty auto fuel valve Q Fouled spark plug Q Incorrect heat range plug Fouled spark plug Faulty CDI unit O Faulty A C generator Faulty ignition coil Broken or shorted high tension wire 9 Faulty ignition switch Worn cylinder and piston rings Blown cylinder head gasket Plug not fouled or Plug fouled or discolored discolored Weak or inter Good spark mittent spark Normal Abnormal compression compression Flaws in cylinder head Not Clogged Check igni
18. Incorrectly connected wire check operation of indicator light by gt moving float i E Faulty float Pee aD Ic OM Panli Q Broken or shorted wire in Float down Light on meter Damaged oil tank Foreign matters in oil tank 2 33 2 GENERAL INFORMATION KYMCO VITALITY 50 ZEN FUEL GAUGE 1 Pointer does not register correctly Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals O Burned out fuse i Weak or dead battery Signals operate Signals dim remain __ Faulty ignition switch properly on or don t operate Loose or disconnected Remove fuel unit and connector check operation of Broken wire harness pointer by moving float up and down Pointer does not Pointer moves Faulty float Check operation of Move pointer by opening and shorting fuel unit gt terminal on wire harness side Pointer does not Pointer moves Broken or shorted fuel unit move wire Check connectors for EN proper connection 2 m O Loose or disconnected Good Faulty connector Incorrectly connected connector Broken or shorted wire fu
19. KYMCO 4 LUBRICATION SYSTEM VITALITY 50 OIL TANK 2 STROKE OIL TANK REMOVAL Remove the rear body cover 213 6 Disconnect the oil meter connector 1 Remove the two bolts from the oil tank Disconnect the oil inlet line 2 Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal Connect the oil line properly Bleed air from the oil pump after installation e The oil tube clip at the oil tank side must be locked from inside of the oil tube joint KYMCO 4 LUBRICATION SYSTEM VITALITY 50 ENGINE OIL OIL FILTER 4 STROKE OIL LEVEL AND OIL CHANGE Refer to the ENGINE OIL section in the chapter 3 to check the oil level and replacement and oil filter cleaning OIL PUMP 4 STROKE REMOVAL Place a container under the engine Remove the drain plug to drain the oil 53 8 Remove A C generator flywheel 8 3 Remove the A C generator stator and pulsar coil 58 3 Remove the eight right crankcase cover bolts and the right crankcase cover Remove the oil pump gear nut and oil pump gear KYMCO 4 LUBRICATION SYSTEM VITALITY 50 Remove three oil pump mounting bolts and the oil pump Remove O rings and dowel pin KYMCO 4 LUBRICATION SYSTEM VITALITY 50 DISASSEMBLY Remove the screws and disassemble the oil pump Screws Outer Rot P B INSPECT
20. Oil seal amp bearing install E014 The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm When installing the oil seal be careful to press it with even force 11 7 Bearing Outer Driver 42x47mm Pilot 20mm KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Dowel Pins ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves Crankcase assembly tool E024 Crankcase Assembly Tool 11 8 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Install and tighten crankcase bolts in a crisscross pattern in several steps After assembly check the crankshaft for smooth operation 11 9 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Nuts Bolts CRANKCASE CRANKSHAFT 4 STROKE REMOVAL Remove nuts and take out the bolts from center stand Center Stand Spring Remove spring and center stand from crankcase Bolt Remove the crankcase attaching bolt Separate the left and right crankcase halves e Do not dama e the crankcase gasket surface e Never use a driver to pry the crankcase mating surfaces apart KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Remove crankshaft from left Crankshaft crankcase Dowel Pins Remove the cam chain N Remove the gasket and dowel pins Cam Chain Gasket
21. Probable Cause r O Empty fuel tank Clogged float valve GE fuel filter Faulty auto fuel valve mO Faulty spark plug O Fouled spark plug r 9 Faulty CDI unit Faulty A C generator Fuel reaches 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 Spark jumps Weak or no spark Test cylinder compression Normal Low or no compression compression Start engine by follow ing normal starting procedure d Engine does not Engine fires but fire does not start Remove spark plug and inspect again Broken shorted ignition coil Broken or shorted exciter coil Faulty ignition switch O Burned or worn cylinder piston 0 Faulty reed valve 8 Blown cylinder head gasket Leaking crankcase OG Faulty crankcase oil seal O Incorrectly adjusted idle speed Air leaking through intake pipe Incorrect ignition timing r O Flooded carburetor Dry spark plug Wet spark plug L Q Throttle valve excessively open Wait for 30 minutes and then remove carbu retor auto choke gt circuit hose and blow the hose with mouth Not clogged Clogged Faulty auto bystarter
22. disconnected Check battery circuit connector Broken or shorted ignition Drop ang ne switch wire Seas operate SE dim remain Faulty weak battery Check operation of properly on or 1 operate starter relay by une starter 2 utton Relay operates Relay doesnot Q Poor starter bution connection properly QO Loose or disconnected Connect starter connector motor directly to gt battery Starter motor turns Starter does not turn Faulty starter motor Faulty wire harness 2 Starter motor turns slowly or idles Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Sa Signals operate Signals dim remain properly on or don t operate Weak or dead battery Connect starter motor directly to gt battery Starter motor Starter motor O EE turns slowly turns normally Faulty starter relay Rotate crankshaft x Hard to turn o Seized cylinder CH Broken or shorted starter motor cable Faulty starter pinion 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Turn ignition switch OFF 1 Not stopped Stopped 0O Faulty starter pinion 2 35 2 GENERAL INFORMATION KYMCO VITALITY 50
23. 2 stroke Motor e Oil Capacity 1 3 liter Light comes 0 5 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged oil line Oil pump not properly adjusted insufficient oiling e Air in oil line e Faulty oil pump Oil not flowing out of tank to engine Clogged oil tank cap breather hole Clogged oil filter 4 3 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 SERVICE INFORMATION 4 STROKE GENERAL INSTRUCTIONS e The maintenance of lubrication system 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 Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After the oil pump is installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm Oil pump Outer rotor to pump body clearance 0 15 0 20 Rotor end to pump body clearance 0 0410 09 TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter or oil passages e Worn or poorly installed piston
24. Faulty regulator rectifier 2 40 2 GENERAL INFORMATION SPARK PLUG Inspection Adjustment Replace with a new spark plug and inspect again nw high tension wire for looseness Check CDI unit coupler P for looseness Measure resistance i between terminals of CDI unit coupler Check CDI unit with x the CDI unit tester Check ignition coil Good spark O Weak or no spark KYMCO VITALITY 50 Probable Cause Faulty ignition switch Weak battery Faulty pulser coil Faulty ignition coil Faulty kas a system Broken wire harness Poorly connected coupler CDI unit KYMCO 2 GENERAL INFORMATION VITALITY 50 crTauign oncol 2 2 42 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 INSPECTION ADJUSTMENT MAINTENANCE SCHEDULE ttn a c DRAKE SYSTEM a u 4 2 MOVING DEVICE 3 4 EE Luna a 3 5 TRANSMISSION GEAR OI 3 05 LUBRICATION SYSTEM 2 STROKE c 3 6 ENGINE OIL 4 STROKE ttt 3 8 ENGINE IDLE SPEED ettet 3 10 AIR CLEANER aetate tea vate atate educa 3 10 CYLINDER COMPRESSION 3 13 VALVE CLEARANCE 4 STROKE cu nette eto onu 3 14 IGNITION APPARATUS treten 3 15 THROTTLE GRIP PLAY ot cuit aes hono ttbi atten s 3 16 OTHERS ericsson 3 16 3 0 KYMCO 3 INSPECTION ADJUSTM
25. Lock Nut Socket Wrench Remove steering stem lock nut with lock the lock nut socket wrench Remove the top cone race and remove the front fork SPECIAL TOLLS Long socket wrench F007 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 14 19 Top Cone Race KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER ERONT FORK BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and front fork Bottom Cone Race BALL RACE REPLACEMENT Drive out the ball races Ball Race Remover Driver Handle A Drive in new ball races m SPECIAL TOOLS Race cone install F005 Be sure to drive the ball races into place completely 14 20 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 INSTALLATION Apply grease to top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Apply grease to the ball races again and then install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make stee
26. and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one Auto Bystarter AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Screws Set Plate Check the auto bystarter valve and needle O ring for wear or damage Check the O ring for wear or damage Bystarter Valve Bystarter Needle 12 9 KYMCO 12 CARBURETOR VITALITY 50 Auto Bystarter AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms Install the set plate and then tighten the two screws Screws Set Plate FLOAT CHAMBER Remove the two float chamber screws and the float chamber Screws Float Pin O ring Remove the screw and O ring Remove the float pin float and float valve Float 12 10 12 CARBURETOR FLOAT FLOAT INSPECTION Inspect the float for damage or fuel inside the float Check the float valve seat for wear or damage JETS SCREWS REMOVAL Before removing the throttle stop screw or alr screw record the number of rotations until it seats lightly Then remove them Do not force the air screw against its seat to prevent damage Remove the main jet and needle jet holder CARBURETOR PASSAGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun
27. and retainer bolt 4 and disconnect the brake cable 3 from the crankcase Remove the cooling tube band 6 from the left crankcase cover and disconnect the cooling atr tube Remove the rear shock absorber lower mounting bolt 5 Remove the secondary atr hose band 1 from the exhaust muffler and disconnect the secondary atr hose Remove the right and left engine mounting nuts 1 Take out the right and left engine mounting bolts KYMCO VITALITY 50 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 Lift the frame rear upward and move the frame forward to separate 1 from the engine and be careful not to damage the rear fender ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket bolts and engine hanger bracket The installation sequence 15 the reserve of removal Torque 4 5115 5 Engine Hanger Bracket Bolt 5 4 KYMCO Z ENGINE REMOVAL INS TALE AION VITALITY 50 _ ENGINE HANGER BRACKET Bushings INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary ENGINE INSTALLATION Install the engine in the reverse order of removal Cables and wires should be routed properly Torque Values Engine mounting bolt 4 5115 5 Rear shock absorber lower mount bolt 2 4 13 0kg m Stopper Rubbers Engine Hanger Perform the following inspections and adjustm
28. increases using a timing light Check ignition timing KYMCO VITALITY 50 Probable Cause Engine speed does not increase Clogged air cleaner Clogged fuel filter SE exhaust muffler Faulty auto bystarter Correct timing Incorrect timing r Faulty CDI unit Faulty A C generator compression using a compression gauge Test cylinder x Worn cylinder and piston rings Blown cylinder head gasket Check carburetor for clogging Remove spark plug and Faulty reed valve O Clogged carburetor jets inspect Normal Abnormal compression compression Not Clogged Clogged Plug not fouled or Plug fouled or discolored discolored mO Fouled spark plug Q Incorrect heat range plug Check if engine overheats Rapidly accelerate or run at high speed Engine does not overheats Engine overheats Mixture too lean Poor quality fuel Excessive carbon build up in combustion chamber Engine does not knock Ignition timing too early Excessive carbon build up in Engine knocks combustion chamber Q Poor quality fuel Clutch slipping Mixture too l
29. 3 Dowel Pins 6 8 QC KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 Install the camshaft dowel pins and holder e Apply engine oil to the threads of the cylinder head nuts Diagonally tighten the cylinder head nuts in 2 3 times Position the camshaft holder mark on the exhaust valve side Torque Cam shaft hold nut 1 2 1 6kgf m Nuts Washers 2 Press the tensioner key to release it e Check one way cam operaiton tensioner for unsmooth operation If necessary replace the tensioner Tensioner Key Spring Tensioner Cap Install tensioner to cylinder and gasket Install two bolts and tighten it Install spring and tensioner cap then tighten the tensioner cap 3 Adjust the valve clearance Refer to the VALVE CLEARANCE section in the chapter 3 6 9 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 CYLINDER HEAD REMOVE Remove the camshaft Refer to the camshaft remove section in the chapter 6 Remove the carburetor Refer to the CARBURETOR REMOVE section in the chapter 12 Remove the exhaust muffler Refer to the EXHAUST MUFFLER REMOVE section in the chapter 13 Remove the two nuts and then remove the carburetor intake manifold and insulator Remove the cooling fan cover 8 3 Remove the engine cover bolts and screws Separate the engine cover joint claws Seal Shroud Remo
30. 4 0 6 0 5mm screw 6mm screw SH bolt 6mm flange nut 8mm flange nut 10mm flange bolt nut KYMCO 2 GENERAL INFORMATION VITALITY 50 SPECIAL TOOLS 2 STROKE SPECIAL TOOLS 4 STROKE m Remarks Valve adjuster E036 2 12 KYMCO 2 GENERAL INFORMATION VITALITY 50 LUBRICATION POINTS ENGINE 2 STROKE Riek at ae Guang 6 Starter pinion movable par LUBRICATION POINTS ENGINE 4 STROKE Valve guide valve stem movable part eGenuine KYMCO Engine Oil 5 15 40 Cam lobes eAPI SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one way clutch movable part Oil pump drive chain Balance gear A C generator Starter one way clutch Bearing movable part O ring face Oil seal lip Transmission gear and movable parts Gear oil SAE90 2 13 2 GENERAL INFORMATION FRAME Apply clean engine oll or grease to cables and movable parts not specified abnormal noise and rise the durability of the motorcycle 1 Front Rear Brake Lever 2 Throttle Cable 3 Seat Lock E B 4 Rear Wheel Splines 1 kami 5 Brake Cam Anchor Pin 2 6 Rear Brake Cable 7 Main Stand Pivot 8 Side Stand Pivot 9
31. Adjustment i Start engine and accelerate lightly for iobservation i Engine speed increases Engine speed does not increase sufficiently Check ignition timing Check valve clearance x E cylinder compression gt x Check carburetor for _ clogging i Remove oil dipstick and check oil level and conditi Remove cylinder head i pipe bolt and inspect Check if engine overheats Rapidly accelerate run iat high speed KYMCO VITALITY 50 Probable Cause Clogged air cleaner Restricted fuel flow Clogged fuel tank cap breather hole logged exhaust mutfler Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Faulty CDI unit Faulty pulser coil Improper valve clearance adjustment Worn valve seat valve stem too protruding Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Clogged carburetor jets Fouled spark plug Incorrect heat range plug Oil level too high Oil level too low Oil not changed logged oil pipe Faulty oil pump Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Excessive carbon build up in combustion chamber Poor quality fuel KYMCO 2 GENERAL INFORMATION _ VITALITY 50 utcn
32. Contaminated brake linings Worn brake linings Worn brake shoes at cam contacting area e Worn brake cam mproper engagement between brake arm and wear indicator plate 15 2 15 REAR WHEEL REAR BRAKE REAR KYMCO ____ SHOCK ABSORBER VITALITYSO __ REAR WHEEL Rear Axle SS d REMOVAL Remove the exhaust muffler gt 13 10 Remove the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION Install the rear wheel and apply SAE30 Rear Axle Nut engine oil to the axle threads Then tighten the rear axle nut Torque values Rear axle nut 11 0 13 0kg m 15 3 15 REAR WHEEL REAR BRAKE REAR KYMCO SHOCK ABSORBER VITALITY 50 REAR BRAKE Remove the rear wheel gt 15 3 Inspect the rear brake drum Measure the rear brake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil off brake linings Arm Brake Shoes REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut 15 4 15 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER VITALITY 50 Remove the brake cam bolt to remove the
33. Installation is in the reverse order of removal BOTTOM COVER REMOVAL INSTALLATION Remove right and left side covers gt 13 4 Remove the nut from the bottom cover left side 13 7 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 Remove the two nuts from the bottom cover right side and then remove bottom cover Installation is in the reverse order of removal FLOOR BOARD REMOVAL INSTALLATION Remove the following Rear carrier gt 13 5 Right and left side cover gt 13 4 Met in box 213 5 Center cover gt 13 6 Rear body cover 213 6 Battery cover 1 216 5 Battery 2 16 5 Fuse 3 216 5 Remove the four bolts and then remove floor board Installation is in the reverse order of removal 13 8 13 COVERS LEG SHIELD REMOVAL INSTALLATION Remove the following Rear carrier 13 5 Right and left side cover gt 13 4 Met in box 413 5 Center cover gt 13 6 Rear body cover 13 6 Battery cover 16 5 Battery gt 16 5 Fuse gt 16 5 Floor board gt 13 8 Remove the ten screws and one bolt from the leg shield Turn the ignition switch cover 1 counterclockwise and remove ignition switch cover then remove leg shield When removing the right and left side rails pull them backward not to damage the joint claws Installation is in the reverse order of removal FRONT BODY COVER REMOVAL INSTALLATION Remo
34. Speedometer Gear Lower d Mount Bushings Pivot 3 KYMCO VITALITY 50 This will avoid 2 14 KYMCO 2 GENERAL INFORMATION VITALITY 50 WIRING DIAGRAM 2 5 VITALITY 50 KYMCO 2 GENERAL INFORMATION FR SIOP SW COMB sw BATTERY FUEL START 42V3AH REG REC DETECTOR RELAY UNIT LIT UNIT Le EE a gt YR on RAN RO Y w riw R G Ww FUSE 7A sB RH RR WINKER 12 104 em BF TA USTOP LIGHT ILLUMI G XL B FUSE 7 a PILOT LAMP oo v Soo v RH FR WINKER 12v 10W RTURN PILOT YR YR 12v521w PILOT vw vw 12v1 TW Sp SB o o GY Gv J x LH RR wINKER 12V 10W 9 LTURN PLOT J RH FR POSITION 12 TW 12V 3w HEAD LIGHT EE LH FR POSITION EEN Le IGN COIL SPARK PLUG 3 750 FRAME PULSER 30W 5W EARTH 68 E LW LG SB GR DC ev 8 TOSI 3 d 84 d d 12V 10W LH FR WINKER WINKER START MOTOR RELAY RR STOP DIMMER PASSI
35. TROUBLESHOOTING 4 STROKE ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment i Check if fuel reaches carburetor by loosening EEN drain screw Remove spark plug and install it into spark plug to test spark I connecting it to engine i ground Test cylinder i compression follow ing normal Starting procedure Remove spark plug a Inspect again Fuel reaches Fuel does not carburetor reach carburetor Dry spark plug Wet spark plug tarter relay shorted or stuc closed Probable Cause Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage S logged fuel tank cap breather ole Clogged fuel filter Clogged fuel strainer Faulty auto fuel valve Faulty charging system Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch Weak or dead battery aulty starter clutch Valve clearance too small proper valve and seat contact Worn cylinder piston and piston rings eaking cylinder head gasket Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open 2 36 2 GENERAL INFORMATION ENGINE LACKS POWER Inspection
36. VITALITY 50 CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test Start the engine and warm it up to operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the DCV battery Tester To prevent a short make absolutely certain which are the positive and negative terminals or cable With the headlight on high beam restart the engine Measure the voltage on the multimeter when the engine runs at 8000 rpm Charging Limit Voltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check the regulator rectifier A C GENERATOR CHARGING COIL INSPECTION Inspect with the engine installed Remove the met in box and center cover gt 13 5 Disconnect the A C generator connector Measure the resistances between the charging coil terminals white ground and lighting coil terminals yellow ground Resistance 2 Stroke S A C G tor C t Charging coil white ground 02120 EE Lighting coil yellow ground 0 3 1 00 Refer to 8 section for A C generator removal 16 8 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 Resistance 4 Stroke Charging coil Refer to 8 section for A C generator removal A C Generator Connector RESISTOR INSPECTION Resister B Remove frame fr
37. VITALITY 50 2 GENERAL INFORMATION Instrument Connectors Regulator Rectifier Fuel Unit 2 8 9 o a O S S T Q 9 Rz 30 gt 5 3 3 x E S m 2 O m 5 o ke gt K o o xF 8 oO O D O 5 En 5 2 3 SE lt 5 gt mM zo 550 lt lt Fuel Connector Start Motor Connectors Battery Cable Speedometer Cable Starter Relay Battery Cable Spark Plug Cap Taillight Connector Secondary Air Cleaner 2 23 KYMCO 2 GENERAL INFORMATION VITALITY 50 Starter Relay y I C D I Unit Auto By Starter A C G Start Motor Wires Auto By Starter Vacuum Tube A Vacuum Tube B Ignition Coil Vacuum Tube C 13 Y _ Crankcase Breather Tube Ji m 8 Spark Plug Cap Air Inlet Hose V belt Chamber Secondary Air Cleaner Throttle Cable Harness Wire Battery Cable Fuse Box Throttle Cable a Rear Cable Mo 2 2 724 2 GENERAL INFORMATION KYMCO VITALITY 50 TROUBLESHOOTING 2 STROKE ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Symptom Check if fuel reaches carburetor by loosening drain screw Y
38. Vee ee Pate brake arm wear indicator plate and felt gt 7 IL seal gt Remove brake arm Brake Arm Brake Cam Grease REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts Apply grease to the brake cam and install it Apply engine oil to the felt seal and install Kee Punch Mark it to the brake cam Install the wear indicator plate Align the wide tooth of the wear indicator plate with the wide groove on the brake cam Install the brake arm onto the brake cam gt Align the punch mark on the brake arm with the scribed line on the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes Brake Arm 15 5 15 REAR WHEEL REAR BRAKE REAR KYMCO SHOCK ABSORBER Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel 15 3 Adjust the rear brake lever free play 23 2 REAR SHOCK ABSORBER REMOVAL Remove the rear body cover gt 13 6 Remove air cleaner case 45 2 or gt 5 7 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber INSTALLATION Install the rear shock absorber Install the rear shock absorber upper mount bolt and then install the lower mount bolt Torque Upper Mount Bolt 3 5 4 5kgf m Lower Mount Bolt 2 4 3 0kgf m VITALITY 50 Brake Cable Brake Arm Brake Arm Pi
39. _ CLUTCH DRIVEN PULLEY CLUTCH DRIVEN PULLEY REMOVAL Remove the drive pulley gt 9 9 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut Remove the clutch outer Universal holder E017 Remove the clutch driven pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS ASSEMBLY Compress the clutch driven pulley spring with the clutch spring compressor and remove the 39mm drive plate nut Remove the driven face spring Universal holder E034 Clutch spring compressor 9 12 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Remove the seal collar Seal Collar Driven Pulley Pull out the guide roller pins from the driven pulley and then remove the O rings and oil seal from the driven pulley O rings Guide Roller Pin CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 107 5mm replace if below 9 13 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Measure the driven face spring free length Service Limit 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 04mm replace if below Check the mova
40. and push the starter button for 7 18 seconds to test the compression Compression 2 Stroke 11 8kg cm 4 Stroke 14 If the compression is low check for the following e Leaking cylinder head gasket e Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 VALVE CLEARANCE Mark 4 STROKE e Inspect and adjust valve clearance while the engine 15 cold below 35 wn Remove the met in box gt 13 5 and center cover gt 13 6 Remove cylinder head cover gt 6 4 Turn the A C generator flywheel to the top dead center TDC on the compression stroke so that the T mark on the flywheel aligns with the index mark on the left crankcase cover The time marks on the cam sprocket must be flush with the cylinder head surface and round hole on the cam sprocket must be facing up as shown If the round hole on the cam sprocket are facing down turn the crankshaft clockwise one full turn and realign the timing marks with the cylinder head surface so it is facing up Round Hole Time Marks Thickness Gau Insert thickness gauge between valve stem end and the adjusting screw on the rocker arm If the clearance 15 out of specification bring it into the specified range Valve Clearance IN 0
41. assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts valve arm and camshaft sliding surfaces for initial lubrication The camshaft is 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 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 SPECIFICATIONS Standard mm nr mwm Valve large nk p i Cylinder head compression pressure 14 2 2 C Cylinder head warpage E o O 58 7 25 761 25 65 Camshaft cam height 25 563 25 45 Valve rocker arm to shaft clearance 0 034 0 09 Valve stem to guide 0 010 0 037 006 clearance 0 025 0 052 Valve spring 5 6kg at20 55mm compressed 9 5 11 5kg at 23 5mm 6 2 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 TORQUE VALUES Cylinder head cover bolt 0 8 1 2kgf m Cam shaft hold nut 1 2 1 6kgf m Apply engine oil to threads Tappet adjusting nut 0 7 1 1kgf m SPECIAL TOOLS Valve spring compressor E040 Tappet adjuster E036 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
42. before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm 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 Throttle free play Pilot serew opening 12 3 12 CARBURETOR TROUBLESHOOTING Engine is hard to start No spark at plug gt Section 16 Compression too low No fuel to carburetor Clogged fuel filter Restricted fuel line Faulty float valve Incorrectly adjusted float level Engine flooded with fuel Clogged air cleaner Fuel overflowing e Intake air leak e Contaminated fuel e Faulty auto bystarter Clogged idle system or auto bystarter passages Rich mixture e Faulty auto bystarter e Faulty float valve e Float level too high Clogged air jets e Dirty air cleaner Flooded carburetor Backfiring at deceleration e Lean mixture in idle system e Improper air cut off valve operation KYMCO VITALITY 50 Misfiring during acceleration e Faulty ignition system e Lean mixture e Faulty accelerating pump Engine idles roughly stalls or runs poorly Clogged fuel system e Ignition malfunction Rich or lean mixture e Contaminated fuel e Intake air leak Incorrect idle speed e Incorrectly adjusted pilot screw Clogged idle system or auto bystart
43. cover bearings using the bearing remover Remove the final shaft oil seal Universal bearing puller E037 Drive new bearings into the transmission case cover Oil seal amp bearing install E014 BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Universal bearing puller E037 10 5 KYMCO VITALITY 50 Bearing Remover Set Drive Shaft Bearing Bearing Outer Driver Handle Bearing Remove r Set 15mm KYMCO 10 FINAL REDUCTION VITALITY 50 Drive new bearings into the left crankcase Install a new drive shaft oil seal Oil seal amp bearing install E014 Bearing Outer Driver Drive Shaft FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase 10 6 KYMCO 10 FINAL REDUCTION VITALITY 50 Gasket Dowel Pins Install the countershaft and gear into the left crankcase Install the resin washer onto the counter shaft Install the dowel pins and a new gasket Resin Washer Countershaft Transmission Case Cover Install the transmission case cover Install and tighten the transmission case cover bolts 10 7 KYMCO 10 FINAL REDUCTION VITALITY 50 Oil Check Bolt Hole Filler wy gt After Installation fill tran
44. crankshaft is not fix position Improperly adjusted valve clearance Worn valve seat Empty fuel tank logged fuel tube or filter logged Fuel tank cap breather hole Faulty auto fuel valve Clean and unclog Cam pud gear aligning marks not aligne Faulty spring KYMCO 2 GENERAL INFORMATION VITALITY 50 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause Q Start engine and test i volpe of bal tery 52 terminals Dead batte Normal voltage Voltage does not Faulty battery Measure resistance coil terminals Faulty A C generator coil Resistance too high Broken yellow wire Loose connector Connect battery wire to regulator rectifier icoupler red wire and battery wire to engine Normal voltage No voltage Broken red wire Check regulator rectifier _coupler loose connection Faulty regulator rectifier L Poorly connected coupler Faulty A C generator Overcharging Inspection Adjustment Probable Cause Decet Wire to iregulator rectifier coupler green wire battery wire to engine Battery has no with ignition switch ON Battery has voltage with ignition Broken green wire switch ON Check regulator rectifier coupler loose connection Poorly connected coupler
45. cylinder e Clogged fuel cap vent Float level too low Clogged fuel filter Clogged fuel filter e Clogged air cleaner Clogged air cleaner e Bent kinked or restricted fuel line Engine idles roughly stalls or runs poorly Rich mixture e Incorrect idle speed Clogged air cleaner e Faulty float valve e Ignition malfunction e Intake air leaks Float level too high Compression too low Fuel contaminated Clogged air jets Incorrectly adjusted air screw Faulty reed valve Incorrect float level Clogged fuel jets 12 2 KYMCO 12 CARBURETOR VITALITY 50 SERVICE INFORMATION 4 STROKE GENERAL INSTRUCTIONS V Gasoline is very dangerous When working with gasoline keep sparks and flames away from the working area Gasoline is extremely flammable and is explosive under certain conditions sure to work in a well ventilated area When disassembling the carburetor be sure to service the vacuum piston and float chamber e Do not bend or twist control cables Damaged control cables will not operate smoothly When disassembling fuel system parts note the locations of O rings Replace them with new ones during assembly 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 Remove the vacuum diaphragm
46. e Stagger the ring end gaps at 120 to the piston pin 7 18 KYMCO 8 A C GENERATOR VITALITY 50 A C GENERATOR SERVICE INFORMATION sto 8 2 GENERATOR 5 a edt died eed 8 3 8 0 KYMCO 8 A C GENERATOR VITALITY 50 orque 0 801 2kg m orque 3 on 56 oe ia Torque 0 801 2kg m 8 1 KYMCO 8 A C GENERATOR VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e All A C generator maintenance and inspection can be made with the engine installed e Refer to Section 16 for A C generator inspection TORQUE VALUE Flywheel nut 3 504 SPECIAL TOOLS Flywheel puller E001 Universal holder E017 8 A C GENERATOR A C GENERATOR REMOVAL Remove right side cover 513 4 Remove the three bolts attaching the fan cover to remove the fan cover Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the 10mm flywheel nut Universal holder E017 8 3 KYMCO VITALITY 50 Fan Cover Cooling Fan Universal Holder KYMCO 8 A C GENERATOR VITALITY 50 Remove the A C generator flywheel using the flywheel puller Flywheel puller E001 Flywheel Puller Lock Nut Wrench A C Generator Wire Connector Remove the A C generator wire connector Remove the two pulser coil bolts and pul
47. its clamp X B After clamping check each harness to make sure that it is not interfering with any moving or sliding parts O UN E B When fixing wire harnesses do make it contact the parts which will generate high heat vm Don t touch aK 2 TR i 5s y 2 Route wire harnesses to avoid sharp edges orcorners Avoid projected ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner E When rubber protecting cover is used to protect the wire harnesses it shall be installed securely oF A i i i IS Do not break the sheath of wire B If 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 squeeze the wires 2 4 KYMCO 2 GENERAL INFORMATION VITALITY 50 B After routing check that the wire harnesses Symbols are not twisted or kinked The following symbols represent the servicing methods and cautions included in O gt this service manual B Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with ad
48. lubrication system Contact Surface Adjuster Surface Measure each rocker arm shaft O D Measure the I D of each valve rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 10mm CAMSHAFT HOLDER ASSEMBLY Reverse the CAMSHAFT HOLDER DISASSEMBLY procedures Align the cross cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 CAMSHAFT INSPECTION Camshaft Bearings Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play Inspect camshaft lobes for pitting scratches blue discoloration Measure the cam lobe height Service Limits IN 25 65mm replace if below EX 25 45mm replace if below If any defects are found replace the camshaft with a new one then inspect lubrication system INSTALLATION Camshaft Reverse the CAMSHAFT REMOVAL procedures Note the following points 1 Turn the flywheel so that mark on the flywheel aligns with the index mark on the crankcase Keep the round hole on the camshaft gear facing up and align the index marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the camshaft onto the cylinder head Refer to the VALVE CLEARANCE section in the chapter
49. rings e Not use the specified oil e Worn valve guide or seal 44 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 OIL PUMP 2 STROKE REMOVAL Do not allow foreign matters to enter the crankcase Before removing the oil pump clean the oil pump and crankcase surfaces Remove met in 5213 5 spark plug cover gt 13 5 center cover gt 13 6 Disconnect the oil pump control cable 3 from the pump body Disconnect the oil inlet line 1 from the oil pump Then disconnect the oil outlet line 2 Before disconnecting the oil line clip the oil line to avoid oil flowing out and then plug the oil line after it is disconnected Remove the two bolts and oil pump control cable plate 1 Pull up and remove the oil pump 2 from the crankcase INSPECTION Remove the oil pump and inspect the following items e Weakened O ring 1 Damage to crankcase mating surface e Damage to pump body Control lever operation 2 e Oil leaks through oil seals e Worn or damaged pump pinion 3 Do not disassemble the oil pump which cannot be used after disassembly 4 5 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 INSTALLATION e Lubricate the O ring 1 with grease or engine oil before installation e Make sure that the oil pump is inserted into the crankcase e Apply molybdenum disulfide or grease to the pump pinion I
50. rod big end radial clearance ee DD ___ SPECIFICATIONS 4 Stroke Standard Gm Service Gn Connecting rod small end free play 0 05110 4 Crankshaft Connecting rod big end radial clearance 010 008 am n S TORQUE VALUES Crankcase bolt 0 801 2kgf m Cam chain tensioner slipper bolt 0 811 2kgf m 4 Stroke SPECIAL TOOLS 2 stroke Crankcase puller E026 Universal bearing puller E030 Crankshaft install tool E016 Crankcase assembly tool E024 Oil seal and bearing install tool E014 TROUBLESHOOTING Abnormal engine noise Excessive crank journal bearing play Excessive crankpin bearing play Excessive transmission bearing play 11 3 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 CRANKCASE CRANKSHAFT 2 STROKE SEPARATION Remove the crankcase attaching bolts Bolt Attach the crankcase puller on the right Crankcase Puller crankcase and remove the right crankcase from the left crankcase Crankcase puller E026 CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase When removing the crankshaft do it slowly and gently Crankcase puller E026 Crankcase Puller 11 4 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Remove remaining bearing crankshaft side using universal bearing puller When separating the crankcase the oil
51. slipping Mixture too lean lgnition timing too early POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing Correct timing Incorrect timing The woodruff key in the crankshaft is not fixed position Check carburetor pilot screw adjustment ixture too rich turn screw out ixture too lean turn screw in Incorrectly adjusted Correctly adjusted Check carburetor gasket for air leaks Deteriorated O ring Carburetor is not securely tightened Damaged insulator rubber Broken vacuum tube Remove spark plug and install it into spark plug i cap to test spark by i connecting it to engine ground Faulty or fouled spark plug Faulty CDI unit aulty A C generator aulty ignition coil Broken or shorted spark plug wire Faulty ignition switch Weak or inter Good spark mittent spark aulty air cut off valve Damaged vacuum tube logged or damaged air vent ole 2 38 2 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing gt Check carburetor pilot Screw adjustment Check fuel pump for 1 Check carburetor jets E i tension 2 39 KYMCO VITALITY 50 Probable Cause aulty CDI unit Faulty pulser coil he woodruff key in the
52. spark from the watch window Good Normal and continuous spark Faulty Weak or intermittent spark The test is performed at both conditions that the ignition coil is cold and hot A C GENERATOR Blue Yellow Exciter Coil Pulser Coil Inspection This test is performed with the stator installed in the engine Remove the met in box and center cover gt 13 5 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 200 2 Stroke 8001600 Blue Yellow Resistance 20 4 Stroke 118 17118 20 16 ELECTRICAL EQUIPMENT CDI UNIT INSPECTION Remove the met in box 5 13 5 Disconnect the CDI coupler and remove the CDI unit CDI CIRCUIT INSPECTION Measure the resistance between the 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 is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester TH 5H e In this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the condenser is discharged
53. 04mm EX 0 04mm Loosen the lock nut and adjust by turning the adjusting nut Valve Adjuster E036 e Check the valve clearance again after the lock nut is tightened KYMCO 3 LUBRICATION SYSTEM VITALITY 50 IGNITION APPARATUS Spark Plug Gap Wear and Remove the frame center cover Fouling Deposits Gs Remove the spark plug cap and spark plug Check the spark plug for wear fouling and carbon deposits Remove the fouling and carbon deposits with a spark plug cleaner wire brush 20 Specified ss Cracks 2 Stroke NGK BR8HSA 4 Stroke NGK C7HSA Spark Plug Gap 0 6 10 7 Ignition Apparatus S Index The CDI ignition timing is not adjust able If the timing is incorrect check the CDI unit ignition coil and A C generator and replace any faulty Remove the A C generator fan cover 58 3 Remove four bolts from fan then remove fan 8 3 Warm up the engine and check the ignition timing with a timing light When the engine is running at the specified rpm the ignition timing is correct if the mark on the flywheel aligns with the index mark on the crankcase within 2 Ignition Timing 2 stroke 13 5 2 3000rpm 4 stroke 28 2 4000rpm 3 15 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 THROTTLE GRIP FREE PLAY Measure the throt
54. 2kgf m 11 1 KYMCO 12 CARBURETOR VITALITY 50 SERVICE INFORMATION 2 STROKLE ce 12 23 SERVICE INFORMATION 4 STROKE e 12 5 THROTTLE eg e EE 12 5 CARBURETOR STROKE 12 7 AIR SCREW ADJUSTMENT 2 8 12 13 REENEN ege 12 14 CARBURETOR 4 STROKE eerte 12 15 enc d RAUM E aU ES 12 28 12 0 KYMCO VITALITY 50 12 CARBURETOR O Samo OF Den BES ON a EE f Ww ON 4 gt j 12 1 KYMCO 12 CARBURETOR VITALITY 50 SERVICE INFORMATION 2 STROKE GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly All cables fuel lines and wires must be routed and secured at correct locations Bleed air from the oil lines whenever they are disconnected SPECIFICATIONS VITALITY 50 Setting mark PB168 A Type PB 14 Float level 8 6mm Main jet 80 Speed limit type 72 Slow jet 35 Air screw opening 2 1 2 1 2 Idle speed 1850 100rpm Throttle grip free play 2 SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture e No fuel in tank e Clogged fuel jets e Faulty float valve Too much fuel getting to
55. 5 ENGINE REMOVAL H STROKE 5 6 ENGINE INSTALLATION 4 STROKE 5 10 5 0 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4 5115 5 Rear shock absorber lower mount 2 4 3 Engine hanger bracket bolt 4 5115 5 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 ENGINE REMOVAL 2 STROKE Remove the frame body cover 13 6 Disconnect the oil pump control cable from the pump body 24 5 Disconnect the oil inlet line from the oil pump gt 4 5 IEE 3 NEI After oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Remove the spark plug cap 1 Disconnect the auto bystarter A C generator and starter motor wire connector 0 Loosen band screw 1 and remove two mounting bolts 2 then remove air cleaner housing Slide the rubber sleeve up to expose the carburetor Disconnect the fuel tube 2 from the carburetor Disconnect the fuel vacuum tube from the intake manifold 3 Loosen the carburetor top 1 Remove the carburetor top and throttle valve from the carburetor gt 12 3 5 ENGINE REMOVAL INSTALLATION Remove the rear brake adjusting nut 1 brake arm pin 2
56. AL LIGHT REPLACEMENT Remove two screws from the turn signal light lens Slightly press down on the bulb and turn it counterclockwise Install a new bulb in the reverse order of removal Replace with new bulbs of the same specifications Cures TAILLIGHT STOPLIGHT REPLACEMENT Taillight lens Removal Remove two screws from the taillight lens Slightly press down on the bulb and turn it counterclockwise Install a new bulb in the reverse order of removal Replace with new bulbs of same specifications REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove two screws from the taillight lens gt 17 7 Screws Remove screw from the rear turn signal light lens Slightly press down on the bulb and turn it counterclockwise Install a new bulb in the reverse order of removal Replace with new bulbs of the same specifications 17 7 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 INSTRUMENT HEADLIGHT Bulb Sockets Instrument Bulbs Replacement Remove the handlebar rear cover 13 3 Remove the front body cover gt 13 9 Remove the bulbs and replace with new ones Instrument Instrument Connectors INSTRUMENT REMOVAL Remove the handlebar rear cover 413 3 Disconnect the speedometer cable Disconnect the all instrument connectors Remove the instrument Installation is in the reverse order of removal POSITION LIGHT BULB REPLACEMENT Remove th
57. ANSMISSION OIL REPLACEMENT 1 Place the scooter on a level place 2 Place a container under the engine 3 5 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 3 Remove the oil filler bolt 1 and drain 4 Stroke plug 3 to drain the oil 4 Reinstall the drain plug and tighten it Torque 10 1 5kgf m 5 Fill the engine with oil and install the oil filler blot 6 Start the engine and warm up for a few minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause LIA dd gear oil through the oil check bolt hole 2 After refilling use a rag to wipe clean Excess or insufficient gear oil will affect the engine performance ever use gear oil of different brand or inferior quality which may result in engine breakdown LUBRICATION SYSTEM 2 STROKE Oil Filter Cleaning Remove Met in box 213 5 Spark plug cover gt 13 5 Center cover 13 6 Disconnect the oil tube from the oil pump side and allow oil to drain into a clean container Remove the tube clip from the oil tank side and disconnect the oil tube Remove the oil filter KYMCO 3 LUBRICATION SYSTEM VITALITY 50 Filter Screen Clean the oil filter screen with compressed air Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level
58. ATION eee TROUBLESHOOTING eitis Eeer STEERING HANDLEBAR ite ettet FRONT WHEE D ea A ente HYDRAULIC BRARKPE EE rra oes Sebast FRONT SHOCK ABSORBER FERON TEORK 14 0 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK VITALITY 50 6 08 0kgf m E ss 5 0 7 0kgf m 14 1 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE INFORMATION SPECIFICATIONS Item Axle shaft runout Front wheel rim runout ront shock absorber spring free length rake disk thickness rake disk runout rake master cylinder I D rake master cylinder piston O D rake caliper piston O D rake caliper piston I D TORQUE VALUES Handlebar lock nut 5 0 16 0kgf m Steering stem lock nut 0 5 1 3kgfm Steering top cone race 6 0 8 0kgf m SPECIAL TOOLS Lock nut wrench F007 Lock nut socket wrench F001 Race cone install 005 TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Broken clutch weight spring e Bent front fork e Bent front axle or uneven tire Poor brake performance e Incorrectly adjusted brake e Worn brake linings e Contaminated brake lining surface e Worn brake cam e Worn brake drum e Poorly co
59. Absorber Damper Nut B 4 Seal 8 Pu 14 17 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 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 nut Install the front shock absorber spring with the loosely wound coils facing up Use a vise to hold the front shock absorber Tighten the hex bolt Apply locking agent to the washer and socket hex bolt and install them together Torque 1 5 3 0kgf m Specified 55 8 Capacity 5 Install circlip Install the dust boot KYMCO VITALITY 50 Damper Nut Front Shock Absorber Bolt Washer Dust Boot Circlips 14 18 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 INSTALLATION Mount Bolt Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Torque 3 0 3 6kgf m Install the front body cover 213 9 Install the front wheel 14 5 Front Shock Absorber Lock Nut FRONT FORK Remove steering handlebar 14 3 Disconnect speedometer cable and front brake fluid tube and remove the front brake caliper gt 14 8 Remove front wheel gt 14 5
60. Bleed air from the oil pump and oil lines Connect the oil tubes securely e Install the tube clip at the oil tank side and also install the clip to the lower oil tube that goes to the oil pump e Check for oil leaks Oil Pump Condition Adjust oil pump control cable after the throttle grip free play is adjusted Remove Met in box 513 5 park plug cover 213 5 Center cover gt 13 6 Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever Reference tip alignment within 1mm of index mark on open side is acceptable Start and idle the engine then slowly open the throttle to increase engine rpm and check the operation of the oil pump control lever If adjustment is necessary adjust the oil pump control cable by loosening the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut Reference tip alignment within 1mm of index mark on open side is acceptable However the aligning mark on the control lever must never be on the closed side of the index mark otherwise engine damage will occur because of insufficient lubrication If the oil pump is not synchronized properly the following will occur e Excessive white smoke or hard starting due to pump control lever excessively open eSeized piston due to pump control lever in
61. Drive Face R Plat Remove the ramp plate x e 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Weight Roller Remove the weight rollers MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 15 4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Movable Drive Face Drive Pulley Collar 9 10 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 f Drive Pulley Face Install the drive belt on the crankshaft Install the drive face starting ratchet and washer then tighten the 12mm drive face nut Torque 3 5 4 0kg m Keep grease or oil off the drive belt and drive pulley faces Drive Face Nut Starting Ratchet Starter Pinion STARTER PINION REMOVAL Remove the left crankcase cover 9 3 Remove the drive pulley 9 9 Remove the starter pinion INSPECTION Shaft Forcing Parts Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion 9 11 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVENPULLEY VITALITYSO
62. ENT VITALITY 50 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary A Adjust C Clean R Replace T Tighten Whichever Regular Service Mileage km comes first ii 9000 Engine oil filter screen Engine oil filter screen filter na Fuel filter filter at every Se Valve clearance clearance Note 4 4 EE 22 1 R 1 R 1 Spark plug EMEN Clean at every 2000km and replace if necessary ELE E EE eee e In interest of safety we recommend these items 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 in rain or at full throttle 4 4 stroke engine only 3 1 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 BRAKE SYSTEM BRAKE LEVER FREE PLAY ADJUSTMENT The rear brake lever free play should be adjusted to 10 20mm 0 4 0 8 in at the tip of the brake lever If the free play is incorrect adjust as follows Place the scooter on its center stand Turn the adjusting nut in direction A to decrease play and in direction B to increase play Turn the adjusting nut on the brake hub in direction A to decrease play and in dire
63. INSPECTION Remove the handlebar front cover 13 2 Disconnect the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever is applied KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 HEADLIGHT SWITCH INSPECTION Remove the handlebar front cover gt 13 2 Disconnect the headlight switch wire coupler and check for continuity between wire terminals Headlight Switch DIMMER PASSING SWITCH INSPECTION Check for continuity between wire terminals Dimmer Switch TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Turn Signal Switch 17 5 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 STARTER SWITCH INSPECTION Check for continuity between wire terminals Push the starter button when measuring Yellow Red Symbol mE R ruse j Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Light Green Brown Blue Symbol BAT i ae i aen ef si Horn Switch HORN INSPECTION Remove frame front cover gt 13 4 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals 17 6 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 REPLACEMENT FRONT TURN SIGN
64. ION DS Measure pump body to outer rotor clearance Service Limit 0 25mm Outer Rotor Measure the Imner rotor to outer rotor clearance Service Limit 0 2mm 4 11 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 Measure the rotor end to pump body clearance Service Limit 0 12mm ASSEMBLY Install the outer rotor inner rotor and pump Dowel Pin shaft into the pump body Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding Screws 4 12 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 INSTALLATION I n Pin Install the O rings and dowel pin Inspect the O rings and replace if damaged Install the oil pump and tighten the bolts Make sure that the pump shaft rotates freely without binding Install the oil pump gear and tighten the nut 4 13 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 Bolts Install the right crankcase cover and tighten the bolts IT m Right Crankcase Cover 4 14 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION 5 1 ENGINE REMOVAL O STROKE 5 2 ENGINE INSTALLATION 2 STROKE 5
65. LD Service Limit 17 03mm replace if over PISTON CYLINDER INSTALLATION First install the expander in the second ring groove Then install the top and second rings in their respective ring grooves The piston rings should be pressed into the grooves with even force After installation check and make sure that each ring is flush with the piston at several points around the ring Second Ring A ring that will not compress means that the ring groove has carbon deposits in it and should be cleaned Top Ring 1st Ring Expander 7 11 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON 50 _ Cylinder Gasket Install a new cylinder gasket on the mating surface between the cylinder and crankcase Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Be careful not to damage the piston Install the cylinder head Torque 1 0 1 2kg m Install the exhaust muffler and tighten the exhaust muffler joint lock nuts Torque 1 0 1 4kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m 7 12 7 CYLINDER HEAD 2 STROKE KYMCO _ CYLINDER PISTON VITALITYSO Dowel Pin CYLINDER PISTON 3 4 STROKE REMOVAL Remove the cylinder head Re
66. NERAL INFORMATION VITALITY 50 MODEL IDENTIFICATION The read serial frame number 2 please remove the cover on inner cover 1 with a flat head screwdriver 2 GENERAL INFORMATION KYMCO VITALITY 50 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 B Use genuine parts and lubricants Q Bi 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 B Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation Bi When two persons work together attention to the mutual working safety Disconnect the battery negative terminal before operation E When using a spanner or other tools make sure not to damage the motorcycle surface BM After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first After connection apply grease to the battery terminals B Terminal caps shall be installed securely 2 2
67. NG sw WINKER amp HORN SW hg COMB Sw WINKER SW STARTSW PASSING SW WIRING DIAGRAM 4 STROKE 2 16 KYMCO 2 GENERAL INFORMATION VITALITY 50 CABLE amp HARNESS ROUTING 2 STROKE Winker Relay a SSS Rear Stop Switch Wire a qn 7 Right Handlebar Switch Wire fi lt Rear Brake Cable Throttle Cable 1 Front Brake Phd Tube Left Handlebar Switch Wire Front Brake Fluid Tube Instrument connectors Speedometer Cable Headlight Connector Regulator Rectifier Main Wire Harness Resistor Hom 2 17 KYMCO 2 GENERAL INFORMATION VITALITY 50 Ignition Coil Wire C D 1 Unit Oil Level Switch Secondary Air Cleaner Spark Plug Wire Ienition Tank Start Relay Auto By Start Wire Wire Harness N lt lt N NES Throttle Cable Fuel Vacuum Fuel Tube Tube Inlet Hose i Rear Brake Cable V belt Chamber Fuel Throttle Cable Rear Brake Cable Overflow Tube 2 18 dO KYMCO 2 GENERAL INFORMATION VITALITY 50 Instrument Connectors Fuel Unit Regulator Rectifier Fuel Tank Oil Level Headlight Connector Switch dk Connector Ignition Switch Connector tart Relay Fuel Strainer Resistor Ignition Coil ij Fuel Throttle Cable Oil Throttle Cable Fuse Taillight S s lt 4 Connector x i i ES A A Fuel Unit
68. TION deefe eege 13 1 FRAME COVERS REMOVAL ierit 13 2 EXHAUST MUFFLER eet an te loe 13 10 13 0 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 SERVICE INFORMATION e When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Items Related for Removal e Handlebar front cover Handlebar rear cover e Front cover Headlight wire e Handlebar rear cover Speedometer cable and instrument light wire connectors etc Frame body cover Met in box rear carrier e Floor board Rear carrier frame body cover right and left side cover battery e Leg shield Front body cover front right and left side covers rear body cover floor board 13 1 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 FRAME COVERS REMOVAL HANDLEBAR FRONT COVER REMOVAL INSTALLATION Remove the screw from the handlebar front cover Remove the two screws from the handlebar rear cover Separate the handlebar front cover from handlebar rear cover During removal be careful not to pull the joint claws forcibly and remove the front cover downward Disconnect the winker relay from the handlebar front cover and then remove handlebar front cover Installation is in the reverse order of removal 13 2 13 COVERS HANDLEBAR COVER REMOVAL INSTALLATION Remove the handle
69. TROKE KYMCO CYLINDER PISTON VITALITY 50 Spark Plug Cap CYLINDER HEAD 2 STDROKE REMOVAL Remove the rear body cover 13 6 Remove the spark plug cap Remove fan cover gt 8 3 Remove the exhaust muffler gt 13 10 Remove the bolt from the engine hood then remove the engine hood Remove the spark plug Remove the cylinder head bolts and the cylinder head Loosen the bolts diagonally in 2 or 3 times Remove the cylinder head gasket t Spark Plug 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON 5 Combustion Chamber COMBUSTION CHAMBER DECARBONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion chamber wall and cylinder mating surface Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 10mm replace if over Cylinder head Gasket CYLINDER HEAD INSTALLATION Install a new cylinder head gasket onto the cylinder Install the cylinder head on the cylinder properly Be careful not to damage the mating surfaces 7 6 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY 50 Cylinder head Bolts Spark Plug Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times Torque 1 0 1 2kg m Insta
70. areful not to damage the rear fender ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket nuts Nut Remove the engine hanger bracket bolts and engine hanger bracket The installation sequence is the reserve of removal Torque 4 5115 5 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary Bushings Bushings ENGINE INSTALLATION Install the engine in the reverse order of removal Cables and wires should be routed properly Torque Values Engine mounting bolt 4 5115 5 Rear shock absorber lower mount bolt 2 413 0 Perform following inspections and adjustments after installation Rear brake cable 3 2 5 10 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 SERVICE INFORMATION 6 2 CYLINDER HEAD 6 4 CAMSHAFT CAMSHAFT HOLDER 6 4 CYLINDER 6 10 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 6 1 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame e When
71. aulty fuel unit e Faulty instrument Fuel gauge pointer fluctuates or swings e Loose wire connection e Faulty fuel unit e Faulty instrument KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 FUEL UNIT Fuel Unit No Smoking REMOVAL Remove met in box gt 13 5 Disconnect the fuel unit wire connectors Remove the three bolts attaching from the fuel unit retainer Do damage fuel unit wire Remove fuel unit Be careful not to bend or damage the fuel unit float arm um Fuel Unit Wire INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions 530 YW CUN L W G FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing the 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 Position F Full E Empty 17 2 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 INSTALLATION The installation sequence 15 the reverse of removal e Align the groove on the fuel unit with the flange on the fuel tank OIL METER 2 STROKE INSPECTION Remove the rear body cover 13 6 Disconnect t
72. bar front cover 13 2 Remove the bolt from handlebar rear cover Remove the two mounting screws and disconnect speedometer cable 1 Disconnect the wire connectors 2 and separate handlebar rear cover Remove the three screws from the instrument and then remove handlebar rear cover Installation is in the reverse order of removal 13 3 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 FRONT COVER REMOVAL Remove the screw and front cover 1 During removal be careful not to pull the joint claws forcibly and remove the front cover downward Installation is in the reverse order of removal RIGHT LEFT SIDE COVERS REMOVAL INSTALLATION Remove the two screws and then remove right left side cover 1 During removal be careful not to pull the joint claws forcibly and remove the front cover downward Installation is in the reverse order of removal FRONT FENDER REMOVAL INSTALLATION Remove the four screws and then remove front fender Installation is in the reverse order of removal 13 4 13 COVERS CARRIER REMOVAL INSTALLATION Remove the three bolts and then remove rear carrier 1 Installation is in the reverse order of removal MET IN BOX REMOVAL INSTALLATION Unlock the seat with ignition key and open the seat Remove the screw two bolts and two nuts from met in box Remove the oil tank cap 1 and then r
73. ble driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for stepped wear 9 14 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVENPULLEY VITALITY 50 _ DRIVEN PULLEY FACE BEARING Inner Bearing REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play damage or abnormal noise Drive the inner bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Outer Bearing Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Pack all bearing cavities with 5 005 690 grease Specified grease 230 Heat resistant grease Bearing Outer Driver 9 15 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Drive in a new needle bearing into the driven face with the mark facing up p Bearing Driver Pilot Driven Pulley CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal O rings Guide Roller Pin Install the seal collar Seal Collar 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Set the driven pulley driven face spring and clutch assembly onto th
74. brake disk with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Brake Fluid Refilling Add DOT 4 brake fluid to the brake reservoir e When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e When using a brake bleeder follow the manufacturer s instructions e Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake Bleed Valve 14 8 Make sure to bleed air from the brake system KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 Brake Pad Disk Replacement The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Remove the brake pads Front Brake Caliper Install the brake pads in the reverse order of removal Torque 1 5 2 0kgf m Installation the caliper in the reverse order of removal Torque 29 3 5kgf m Keep grease or oil off the brake pads to avoid brake failure Brake Pads Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure
75. carburetor top After installation perform the following adjustments and inspections e Throttle cable free play 3 16 Idle speed adjustment 3 10 CARBURETOR 2 STROKE REMOVAL Remove met in box 13 5 Remove the center cover gt 13 6 Remove the air cleaner housing 5 2 Disconnect the fuel tube 5 2 Disconnect the auto bystarter wire connector 5 2 Remove the carburetor top and throttle valve from the carburetor gt 12 5 Loosen the drain bolt to drain fuel from the carburetor Disconnect oil outlet tube from carburetor 12 7 Drain Bolt KYMCO 12 CARBURETOR VITALITY 50 Remove two carburetor lock nuts Remove the carburetor and carburetor insulator AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5Q 10 minutes minimum after stopping the engine If the resistance exceeds 5Q replace the auto bystarter with a new one After the engine stops for 30 minutes connect a hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one 12 8 dO KYMCO 12 CARBURETOR VITALITY 50 Connect auto bystarter yellow wire to the battery positive terminal and green black wire to the battery negative terminal and wait 5 minutes Connect a hose to the fuel enriching circuit
76. changing a significant portion of the poisonous carbon monoxide into harmless carbon dioxide 18 2 STROKE ze Fresh air Catalytic converter 18 0 18 SPECIFICATIONS 4 STROKE Air cleaner Carburetor Vacuum tube Fresh air Inlet pipe Secondary air pipe Air suction valve ELI J bar Exhaust valve Ge Catalytic converter x Cylinder 18 1
77. ction B to increase play Make sure the cut out on the adjusting nut 2 is seated on the brake arm pin 1 after making final free play adjustment KYMCO 3 LUBRICATION SYSTEM VITALITY 50 BRAKE DRUM SHOE Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm 1 aligns with reference mark 2 on the brake panel when the brake is fully applied Brake Drum Wear Damage Check the brake drum appearance for damage Check if the brake lining wear is within the specified service limit Check the brake operation for abnormal noise and brake drum inside for wear or damage BRAKE DISK LINING Brake Disk Surface and Brake Pad Wear Check the brake disk surface for scratch Check if the brake pad wear is within the specified service limit Brake Disk Runout Inspection Jack the scooter wheels off the ground and check if the brake disk runout is within the specified service limit BRAKE FLUID LEVEL INSPECTION Brake Master Cylinder Fluid Level Inspection Turn the steering handlebar upright and check if the front brake fluid level is within the specified limits through the front brake master cylinder check hole KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 MOVING DEVICE TIRES Tire Pressure Check the tire pressure Tire pressure should be checked when tir
78. d as a unit without exchange e When assembling the piston soak the cups in brake fluid for a while e Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber cover A Install the brake lever 14 11 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER ERONT FORK Punch Mark Place the brake master cylinder on the handlebar and install the holder with up mark facing up Be sure to align the punch mark with the holder joint First tighten the upper bolt and then tighten the lower bolt Torque 1 0_11 4kgf m Up Mark Install the brake fluid pipe with the attaching bolt and two sealing washers Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 14 8 BRAKE CALIPER FRONT Remove brake caliper gt 14 9 Place a clean container under brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces 14 12 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 Disassembly Remove the brake caliper seat from the brake caliper Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the b
79. e clutch spring compressor Compress the tool and install the 39mm drive plate nut Tighten the 39mm nut to the specified torque Torque 5 0 16 0kg m Universal holder E034 Clutch sprin CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the 14mm clutch outer nut Torque 3 5 4 5kg m Universal holder E017 Clutch Outer 9 17 g compressor KYMCO 10 FINAL REDUCTION VITALITY 50 FINAL REDUCTION SERV ICE INFORMATION annassa 10 2 TROUBLESHOOTING Mo chit Qam 10 2 FINAL REDUCTION DISASSEMBLY 10 3 FINAL REDUCTION INSPECTION eene 10 3 FINAL REDUCTION ASSEMBLY eene 10 6 10 0 KYMCO 10 FINAL REDUCTION VITALITY 50 10 1 KYMCO 10 FINAL REDUCTION VITALITY 50 SERVICE INFORMATION e These parts can be serviced with the engine installed in the frame Specified Oil SAE90 At disassembly 0 12 liter At change 0 11 liter SPECIAL TOOLS Universal bearing puller E037 Oil seal amp bearing install E014 TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks Oil lev
80. e front body cover gt 13 9 Turn the bulb socket counterclockwise then pull it out toward you Pull the bulb out of the socket and replace it with a new one Make sure the seal rubber is installed in the correct position and is in good condition Installation is in the reverse order of removal Bulb 17 8 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 HEADLIGHT BULB REPLACEMENT Remove the front body cover gt 13 6 Pull off the socket without turning Remove the dust cover Dust Cover Pin Bulb Remove the bulb while pressing down on the pin Pull out the bulb without turning Biggest Flange Install a new bulb in the reverse order of removal e When installing the bulb make sure its biggest flange upward e The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers Use bulbs of the same specifications for replacement 17 9 KYMCO 18 KCAS FOR EURO 2 VITALITY 50 KYMCO Clean Air System For EURO 2 The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely When the spent fuel charge is released into the exhaust system it is still hot enough to burn The system allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as
81. e loss of engine power and engine damage If any of the stopper reed or valve seat is faulty replace them as unit Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal Install a new gasket with the gasket indentation aligned with the reed valve After installation check for intake air leaks 12 14 KYMCO 12 CARBURETOR VITALITY 50 Auto Bystarter Wire CARBURETOR 4 STROKE REMOVAL Remove the met in box gt 13 5 Disconnect the auto bystarter connector Disconnect the fuel tube from carburetor Fuel Tube Lock Nut Throttle t Cable Loosen the throttle cable adjusting nut and lock nut disconnect throttle cable from the carburetor Adjusting Nut 12 1 KYMCO 12 CARBURETOR VITALITY 50 Loosen air cleaner connecting tube band Band screw and carburetor intake manifold band screw and then remove the carburetor Vacuum Chamber Cover VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Drain Screw Remove the two vacuum chamber cover Screws screws and the cover Vacuum Chamber Cover 12 16 12 CARBURETOR Remove compression spring and vacuum piston Remove the needle holder spring and Jet needle from the piston e Be careful not to damage the vacuum piston diaphragm VACUUM PISTON INSPECTION Inspect the vacuum
82. ean 2 28 2 GENERAL INFORMATION KYMCO VITALITY 50 A POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Symptom Check ignition timing Probable Cause Correct timing Incorrect timing Faulty CDI unit L Faulty A C generator screw adjustment Check carburetor air Correctly adjusted Incorrectly adjusted O Mixture too rich turn screw ut H gasket for air leaks Check carburetor o Mixture too lean turn screw in mO Carburetor not securely No air leak leaks tightened Faulty intake manifold gasket Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground li Remove auto bystarter connecting wire and check if bypass fuel line is clogged Good spark Weak or inter mittent spark gt Not clogged Clogged Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with 2 29 Clogged Not clogged Deformed carburetor O ring Faulty or fouled spark plug r Q Faulty CDI unit GO Faulty A C generator Faulty i
83. el gauge 2 Pointer fluctuates or swings Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals gt and horn Q Burned out fuse Signal Weak or dead battery ignals operate Signals dim remain __ Faulty ignition switch properly or operate CG Loose or disconnected Remove fuel unit and check operation of pointer by moving float up and down connector Broken wire harness Move float up and down rapidly 1 round sec to check the operation of pointer Pointer does not Pointer moves in accordance with move in float accord ance with Check connectors for E proper connection Good Faulty Pointer Ss not _ Poor contact in fuel unit move Insufficient damping oil in fuel gauge O Loose or disconnected connector 2 34 KYMCO 2 GENERAL INFORMATION VITALITY 50 sO Broken OF Shorted wire in fuel gauge STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Symptom Probable Cause Check operation of stop switch b gt r O Burned out fuse plina brake Gi dead eet Stoplight comes Stoplight does not Q Loose
84. el too high e Worn or damaged oil seal 10 2 KYMCO 10 FINAL REDUCTION VITALITY 50 FINAL REDUCTION DISAS SEMBLY Remove the rear wheel gt 15 3 Remove the left crankcase cover gt 9 3 Remove clutch driven pulley 49 12 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Driver shift Driver shift Final Gear Remove the final gear and countershaft Countershaft Final Shaft Dowel Pin haft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage 10 3 KYMCO 10 FINAL REDUCTION VITALITY 50 Inspect the final gear and final shaft for wear damage or seizure Check the left crankcase bearings for Drive Shaft Bearing Final Shaft Bearing excessive play and inspect the oil seal for wear or damage Countershaft Bearing Oil Seal Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil Drive Shaft Bearing 10 4 10 FINAL REDUCTION BEARING REPLACEMENT Transmission Case Cover Remove the transmission case
85. em connection e Fuse burned out e Loose connection or short circuit in ignition system e Faulty ignition switch e Loose connection or short circuit in lighting system Low power Charging system failure e Weak battery Loose broken or shorted wire or connector Loose battery connection e Faulty regulator rectifier e Charging system failure e Faulty A C generator e Faulty regulator rectifier 16 1 16 ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug e Faulty spark plug Poorly connected broken or shorted wire Between A C generator and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spark plug e Faulty ignition switch e Faulty ignition coil e Faulty CDI unit e Faulty A C generator STARTING SYSTEM Starter motor won t turn Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter switch e Faulty front or rear stop switch e Faulty starter relay Poorly connected broken or shorted wire e Faulty starter motor KYMCO VITALITY 50 Engine starts but turns poorly e Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Ignition secondary circuit Faulty ignition coil Faulty spark plug Poorly insulated plug cap Improper ignition timing Battery voltage too low 6V max Faulty CDI unit Lack of power e Weak battery e Loose wire or connecti
86. emove met in box Installation is in the reverse order of removal SPARK PLUG COVER REMOVAL INSTALLATION Remove the screw and then remove spark plug cover 1 Installation is in the reverse order of removal 13 5 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 CENTER COVER REMOVAL INSTALLATION Remove the met in box gt 13 5 Remove the two screws and then remove center cover When removing the right and left side rails pull them backward not to damage the joint claws Installation is in the reverse order of removal REAR BODY COVER REMOVAL INSTALLATION Remove the following Met in box 413 5 Center cover gt 13 6 Rear carrier gt 13 5 Remove the two screws from the rear fender Remove the two screws form the rear body cover Disconnect the seat lock cable and then remove rear body cover When removing the right and left side rails pull them backward not to damage the joint claws Installation is in the reverse order of removal 13 COVERS REAR UPPER FENDER amp TAILLIGHT REMOVAL INSTALLATION Remove the following Met in box 413 5 Rear carrier gt 13 5 Center cover gt 13 6 Rear body cover 13 6 Remove the two bolts from the taillight and two nuts from the rear upper fender Slide the two clips 1 for disconnect fuel hose and vacuum hose 2 Remove the rear upper fender taillight
87. ents after installation e Throttle cable Oil pump control cable 253 7 e Rear brake cable 3 2 e Oil pump bleeding 24 7 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 ENGINE REMOVAL 4 STROKE Remove the frame body cover gt 13 6 Disconnect the auto bystarter A C generator and starter motor wire connector Remove the spark plug cap Disconnect the secondary air apply hose and crankcase breather hose Spark Plug Cap Secondary Air App y Hose Band Screw Band Screw Disconnect vacuum tube Loosen the air cleaner connecting tube band screw and intake manifold band screw Vacuum Tube 5 6 KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 Remove the bolts from air cleaner housing Wire Band Release the wire band auto bystarter A C WH generator starter motor wire Remove the carburetor Spring Arm Pin Arm Pin Remove rear brake adjusting nut arm pin and spring KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 Rear Brake Cable Disconnect the rear brake cable from the transmission cover Remove the rear shock absorber lower mount bolt Disconnect inlet hose Remove the right and left engine mounting nuts Take out the right and left engine mounting bolts Bolts Nuts KYMCO 5 ENGINE REMOVAL INSTALLATION VITALITY 50 Lift the frame rear upward and move the frame forward to separate it from the engine and be c
88. er housing cover 1 3 10 KYMCO 3 LUBRICATION SYSTEM VITALITY 50 Remove the air cleaner element 1 Wash the ar cleaner element in detergent oil squeeze out and allow to dry Never use gasoline or organic vaporable oil with acid or alkali for washing After washing soak element in clean engine oil SAE 15W 40 and squeeze out excess oil Reinstall the element Squeeze out Soak in Squeeze out and dry excess oil Air Cleaner 4 Stroke 1 Remove the air filter case cover by removing the 6 screws 3 11 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 2 Remove the air cleaner 1 3 Clean the air cleaner element with compressed air 4 Replace the air cleaner element at very 4000km 5 For installation reverse the removal procedures Never use oil or solvent to wash the wet type paper element Be careful not to allow water to enter the air cleaner otherwise it may result in hard starting If the air cleaner is not installed properly dust may be sucked into the cylinder directly to reduce engine horsepower and affect the engine life 3 12 KYMCO 3 LUBRICATION SYSTEM VITALITY 50 CYLINDER COMPRESSION Warm up the engine before compression test Remove spark plug cover 13 5 Remove the spark plug and insert a compression gauge Open the throttle valve fully
89. er passages e Incorrectly adjusted float level Lean mixture Clogged fuel jets e Faulty float valve e Float level too low Clogged fuel system Intake air leak e Improper vacuum piston operation e Improper throttle operation 12 4 KYMCO 12 CARBURETOR VITALITY 50 THROTTLE VALVE 2 STROKE DISASSEMBLY Remove the met in box gt 13 5 Remove the center cover and spark plug cover gt 13 6 Loosen the carburetor top and remove the throttle valve lt Carburetor Top Throttle Valve Disconnect the throttle cable from the throttle valve Remove the throttle valve spring carburetor top and rubber seal 12 5 KYMCO 12 CARBURETOR VITALITY 50 Remove needle removing needle clip Needle Cli Check jet needle and throttle valve for e pooner wear or damage Needle Retainer 2nd Notch STD Jet Needle 5 2 Throttle Valve Rubber Seal Carburetor Top THROTTLE VALVE INSTALLATION Install the jet needle on the throttle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor top and throttle valve spring Connect the throttle cable to the throttle Throttle Valve valve X Throttle Cable KYMCO 12 CARBURETOR VITALITY 50 Groove wS Install the throttle valve by aligning the groove in throttle valve with the throttle stop screw Tighten the
90. er valve springs Service Limit Inner 28 4mm replace if below Outer 31 5mm replace if below Measure compressed force valve spring and installed length Replace if out of specification Service limits IN 5 6kg at 20 45mm EX 9 5 11 5kg at 23 5mm Check the intake manifold and O rings for wear or damage O ring 6 12 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 O ring Check the insulator and O rings for wear or damage ASSEMBLY Install the valve spring seats and oil seal i Be sure to install new oil seal Lubricate each valve with engine oil 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 When assembling valve spring compressor must be used e Install the cotters with the pointed ends facing down from the upper side of the cylinder head Valve Spring Compressor E040 Tap the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters i Be careful not to damage the valves 6 13 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 Dowel Pin INSTALLATION Install the dowel pins and a new cylinder head gasket Reverse the CYLINDER HEAD REMOVAL procedures Torque Cylinder head bolt 0 8 1 2kgf m Gasket 6 14 7 CYLINDER HEAD 2 STROKE KYMCO
91. es are cold Tire Pressure one rider Front 1 50 ke cm2 Rear 2 0 kg cm Tire Size Front 120 70 12 Rear 130 70 12 Axle Nut Axle Shaft Looseness Check the front 1 and rear axle 2 nuts for looseness If the axle nuts are loose tighten them to the specified torques Torque Front 5 0 7 0kgf m Rear 11 0 13 0kgf m Wheel Rim Spoke Plate Damage Check the wheel rim and spoke plate for wear or damage and measure the rim runout KYMCO 3 LUBRICATION SYSTEM VITALITY 50 DAMPING DEVICE SHOCK ABSORBERS Oil Leak Damage Fully apply the front brake and check the action of the front shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage Check the action of the rear shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage TRANSMISSION GEAR OIL TRANSMISSION OIL MRASUREMENT 1 Place the scooter on its main stand on level ground After the engine stops for 2 3 minutes 2 Remove the oil filler bolt 1 and check the oil level 2 It should be up to the brim of the hole If the level is low add oil to raise it to the proper level 3 After refilling securely tighten the bolt 1 Torque 1 001 5kgf m Specified Gear Oil SAE10W90 TR
92. es not Probable Cause O Worn or slipping drive belt O Broken ramp plate OG Broken driven face spring Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Separated clutch lining O Damaged driven pulley shaft splines Damaged final gear 0 Seized final gear O Broken shoe spring Engine lacks power at start of a grade poor slope performance Clutch outer and clutch weight stuck GSeized pivot Worn or slipping drive belt Worn weight rollers Engine lacks power at high speed Q Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings O Worn or slipping drive belt There is abnormal noise or smell while running Worn weight rollers Worn or seized driven pulley bearings mO Oil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Steering is heavy Probable Cause Front and rear tire pressures are normal Steering stem nut too tight Front or rear wheel is wobbling Steering handlebar pulls to one side 0 Broken steering steel balls Excessive wheel bearing play Bent rim Loose axle n
93. fer to the chapter 6 Remove the two dowel pins and cylinder head gasket Remove cam chain guide and then remove cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface Be careful not to drop foreign matters into the crankcase 7 13 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY San Towel Remove the piston pin clip Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Press the piston pin out of the piston and remove the piston Clip i Piston Pin INSPECTION Inspect the piston piston pin and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves Inspect the piston wall for wear scratches damage If any defects are found replace the piston with a new one Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over 7 14 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY 50 Remove the piston rings and insert each piston ring into the cylinder bottom Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit Top 0 5mm replace
94. fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 230 4 0kgf m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system gt 14 8 14 15 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK LITY 50 FRONT SHOCK ABSORBER Mount Bolt REMOVAL Remove the front wheel gt 14 5 Remove the front body cover 13 9 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Front Shock Absorber Circlip LEFT FRONT SHOCK ABSORBER DISASSEMBLY Remove the dust boot Remove the Dust Boot Front Shock Absorber Use a vise to hold the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Mese Ath Bes D EN M Bolt Washer KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 Use a vise to hold the front shock absorber tube and remove the damper from the shock absorber tube When holding the shock absorber tube place a shop towel under it and do not apply too much force Measure the front shock absorber spring free length Standard Limit 214 7 FRONT SHOCK ABSORBER ASSEMBLY Damping Absorber Spring Tube amper Front Shock 2 Absorber Dust Seal Circlip 2 ront Shock
95. from exhaust muffler e Compression too low e Worn valve stem or valve guide e Damaged valve stem seal Compression too low e Incorrect valve clearance adjustment Abnormal noise e Burned or bend valves e Incorrect valve clearance adjustment e Incorrect 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 guide e Leaking cylinder head gasket e Worn camshaft and rocker arm Warped or cracked cylinder head Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber 6 3 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 CYLINDER HEAD COVER REMOVAL Remove the rear body cover gt 13 6 Disconnect the crankcase breather tube from the cylinder head cover 5 6 Disconnect the secondary air apply hose from the cylinder head cover 45 6 Remove the four bolts and two nuts from the cylinder head cover then remove the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and gasket Install the cylinder head cover Install and tighten the cylinder head cover bolts and nuts Torque 0 8 1 2kgf m sure to install the O ring into groove properly CAMSHAFT CAMSHAFT Tensioner Cap HOLDER Remove cylinder head cover Refer to the CYLINDER HEAD COVER REMOVAL Remove the cam chain tensioner cap sp
96. gnition coil Broken or shorted high tension wire 6 Faulty ignition switch Broken auto bystarter wire L Faulty auto bystarter 2 GENERAL INFORMATION KYMCO VITALITY 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Symptom Probable Cause Check ignition timing gt KT Faulty CDI unit Correct timing Incorrect timing Loose A C G stator for fuel supply Check auto fuel valve Faulty A C generator Fuel flows freely Fuel flow restricted Empty fuel tank Clogged fuel tube or filter Check carburetor jets for clogging Clogged charcoal canister Not clogged Clogged 0O Clean and unclog Remove auto bystarter connecting wire and check if bypass fuel gt line is clogged Not clogged Clogged 0 Broken auto bystarter wire Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with Faulty auto bystarter Clogged Not clogged 0 Faulty auto bystarter aS 2 30 2 GENERAL INFORMATION KYMCO VITALITY 50 CLUTCH DRIVE AND DRIVEN PULLEYS Symptom Engine starts but motor cycle do
97. h the universal holder and remove the 10mm clutch outer nut and clutch outer Universal holder E017 Universal Holder Ratchet Drive Face Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet Remove the drive pulley face Drive Face Nut 9 7 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Clutch Driven Pulley Remove the drive belt from the clutch driven pulley Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and 12mm drive face nut then tighten the drive face nut Torque 3 5 4 0kg m Drive Face Nut Drive Pulley Face When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet align with the teeth of the crankshaft Starting Ratchet Drive Belt 9 8 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet and drive pulley face 12mm Drive Face Nut Drive Pulley Collar MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Movable
98. he oil meter wire connectors and remove the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as and shown in the left figure Wire Terminals Resistance Before removing oil meter sure to drain the motor oil and do not allow sparks or flames near the working area 17 3 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 Meter Operation Inspection Connect the oil meter wire connectors and turn the ignition switch ON Measure the resistance between the wire terminals with the float at upper position Green Red _Black About 340Q Before performing the following test operate the turn signals to determine that the battery circuit is normal Move the oil meter float up and down to see Oil Indicator Lieht if the oil indicator light will go out and TTE IN come on If the oil indicator light does not light check for burned bulb loose wire or connector After correction check again according to the method mentioned above SWITCHES IGNITION SWITCH INSPECTION Remove the front cover gt 13 4 Disconnect the ignition switch wire couplers and check for continuity between the wire terminals ILOCDK o o Ignition Switch Connector c y STOP SWITCH
99. hten the band screw AIR SCREW ADJUSTMENT 2 STROKE Do not force the air screw against its seat to prevent damage Turn the air screw 1 clockwise until it seats lightly and back it to the specification given Air Screw Opening 2 1 2 1 2 turns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Do not force the air screw against its seat to prevent damage Turn the throttle stop screw 2 to obtain the specified idle speed Idle Speed 1850 100rpm Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of 1 2 turn makes no difference to the engine performance check other related items 12 13 A PP9 P KYMCO 12 CARBURETOR VITALITY 50 REED VALVE 2 STROKE REMOVAL Remove the rear body cover 13 6 Disconnect the fuel vacuum tube 75 2 Remove oil pump control cable plate 24 3 Remove carburetor gt 12 7 Remove the three intake manifold bolts and gasket Remove the reed valve and gasket Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary Do not disassemble or bend the reed stopper To do so can caus
100. if over 2nd 0 65mm replace if over Oil ring 0 9mm replace if over Measure the piston pin hole 1 0 Service Limit 13 04mm replace if over Measure the piston pin O D Service Limit 12 96mm replace if below LAUR OY 554 2955999 7 15 7 CYLINDER HEAD 2 STROKE QC KYMCO CYLINDER PISTON 3 J VITALITYSO Measure the piston O D Take measurement at 4 5mm from the bottom and 90 to the piston pin hole Service Limit 38 9mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder 1 0 at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Cylinder I D Service Limit 39 1 mm replace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness 15 the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels 15 subject to the maximum value calculated Service Limits True Roundness 0 05mm repair or replace if over Cylindricity 0 05mm repair or replace if over 7 16 7 CYLINDER HEAD 2 STROKE CYLINDER PISTON PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oll to each piston ring e Be caref
101. iter ir cleaner type amp No uel capacity liter ype Piston dia mm Venturi dia mm Carburetor CDI electromagnetic Ignition 13 59 29 3000 NGK BR8HSA I Spark plug d J 0 6 12V3AH Power transmission gear clutch park plug gap mm attery capacity transmission lutch type Dry multi disc clutch Transmission gear operation Automatic centrifugal type type Transmission rato isped Reduction Two stage reduction gear m e x e ce A o c 5 ct n 5 Em H 3 lt E Eg 5 09 B 5 n z 3 2 2 8 2 8 8 5 EI lst reduction ratio 2nd reduction ratio Transmission gear type Non stage transmission Tire pressure Front Rear 1 50 2 0 1 rider kg cm wheel 1 75 2 25 2 rider angle Right amp left 45 F Brake system hydraulic l type l l l Expanding Telescope Suspension Rear whee MASS CO MASS HC NOX Unit swing Telescope type Shock absorber type Frame type Unit swing Pipe under bone Exhaust 1 0 g km emission concentration 1 2 g km 1 SPECIFICATIONS SPECIFICATIONS 4 Stroke Engine type Fuel Used Rear wheel 150 4 4 below Motor amp Kick starter Gasoline 4 stroke Tires Open id Port make timing Exhaust 3 Valve clea
102. jacent or Qil surrounding parts in all steering positions Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication E When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Use special tool Nid Caution E Be careful not to drop any parts V Warning ay When rust is found a terminal remove the rust with sand paper or equivalent before connecting gt 12 3 Refer to page 12 3 Remove the rest 2 5 2 GENERAL INFORMATION KYMCO VITALITY 50 SERVICE INFORMATION 2 STROKE ENGINE Item Cylinder head warpage Piston O D 5mm from bottom of piston Cylinder skirt to piston clearance Piston pin hole LD Piston pin O D Piston to piston pin clearance Piston ring end gap top second Connecting rod small end I D Cylinder bore Drive belt width Drive pulley collar O D Movable drive face ID Weight roller O D Clutch outer LD Driven face spring free length Driven face O D Movable driven face I D Connecting rod big end side clearance Connecting rod big end radial clearance Crankshaft runout A B CARBURETOR Setting mark Type Float level Main jet Slow jet Air screw opening Idle speed Throttle grip free play Jet needle clip notch Service Limit mm Ee 19 E
103. l balls contact each other closely Torque 0 501 3kgf m Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 6 0 8 0kgf m SPECIAL TOOLS Lock nut socket wrench F007 Install the handlebar 5 14 3 Install the speedometer cable Top Con Race Wrench 14 21 15 REAR WHEEL REAR BRAKE REAR KYMCO SHOCK ABSORBER VITALITY 50 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SERVICE INFORMATION EE TROUBLESHOOTING REAR TE EE IRE AR E 15 0 15 REAR WHEEL REAR BRAKE REAR KYMCO ___ SHOCK ABSORBER 9 VITALITYSO __ 3 5 4 5kgf m 1 0 1 4kgf m 11 0 13 0kgf m 15 1 15 WHEEL REAR BRAKE REAR KYMCO SHOCK ABSORBER VITALITY 50 SERVICE INFORMATION SPECIFICATIONS Standard mm Service Limit mm Rear wheel rim runout 2 0 Rear brake drum I D 111 Rear brake lining thickness 6 4 2 0 Rear shock absorber spring free length 209 TORQUE VALUES Rear axle nut 11 0 13 0kgf m Rear shock absorber upper mount 3 5 4 5kg m Rear shock absorber lower mount 2 4 3 0kg m TROUBLESHOOTING Rear wheel wobbling e Bent rim e Faulty tire e Axle not tightened properly Soft rear shock absorber e Weak shock absorber spring Poor brake performance Brake not adjusted properly e
104. l it bottoms and position the set plate into the upper groove in the bystarter e Install the set plate with its round face facing down Set Plate 12 25 O KYMCO 12 CARBURETOR VITALITY 50 Jet Needle Jet Holder Needle Jet FLOAT CHAMBER ASSEMBLY Install the needle jet needle jet holder and main jet Install the slow jet Slow Jet Install the pilot screw e Be sure to record the rotating turns when it is removed Pilot Screw Install the float valve float and float pin WS Install and tighten screw Float Valve 12 24 KYMCO 12 CARBURETOR VITALITY 50 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet just contacting the float valve Float Level 20 5 1 0mm Replace the float if the level is incorrect Check the operation of the float and then reinstall the float chamber Datum plane Datum Plane Vacuum Piston VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Needle Holder Jet Needle Vacuum Piston Spring Install the vacuum piston into the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws e Be careful not to let the diaphragm slip e If the diaphragm cannot be positioned correctly because of expansion dry the diaphrag
105. l pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Friction Spring Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Kick Starter Driven Gear 9 3 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Return Spring Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing Kick Starter Spindle Spindle Return Spring Plastic Bushing Spindle Bushing KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick starter driven gear for wear Sate Daven IRE or damage Check the friction spring for wear or damage o Friction Spring 9 4 9 KICK STARTER DRIVE PULLEY QC KYMCO VITALITY 50 CLUTCH DRIVEN PULLEY Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Fiction Spins Install the kick starter spindle bushing and return spring onto the left crankcase co
106. level Main jet Slow jet Pilot screw opening Idle speed Throttle grip free play Service Limit mm EE 015055 8 L s 99 15 92 16 08 33 9651133 985 33 94 107 107 2 107 5 34 000134 025 34 06 0110 008 Standard CVK104A CVK 18 20 5 82 speed limited 80 35 2 1 1800 100rpm 216mm 2 8 KYMCO 2 GENERAL INFORMATION VITALITY 50 VITALITY 50 4 stdroke Axle shaft runout Front wheel rim runout N 111 2 0 2 0 e N e 209 ELECTRICAL EQUIPMENT VITALITY 50 4 stroke Capacity 12V4AH Capaity SH 13 0 13 2V Charging 0 5 5 10 CTHAS Spark plug gap 0 7mm e 8 Primary coil Secondary coil with plug cap Secondary coil without plug cap 8 12KQ 118 1011820 28 2 BTDC 4000 rpm Pulser coil resistance 201 Ignition timing 2 9 KYMCO 2 GENERAL INFORMATION VITALITY 50 TORQUE VALUES ENGINE 2 STROKE Thread dia mm Torque kgf m Cylinder head bolt BF7x115 1 001 2 cold Clutch drive plate nut 10 3 5 A0 Clutch outer nut NH10 3 504 5 Drive face nut NH12 5 0 6 0 Oil check bolt 10 1 01 5 Engine mounting BF10x95 4 505 5 Engine hanger bracket 10 50 3 54 5 Exhaust muffler joint lock nut
107. ll the spark plug Torque 1 101 7 Engine Hood Installation Install the engine hood 27 5 Install the spark plug cap 7 5 Remove the exhaust muffler 213 10 Perform the following inspections after installation e Compression test e Abnormal engine noise e Cylinder air leaks Engine Hood Bolt 7 7 7 CYLINDER HEAD 2 STROKE dC KYMCO CYLINDER PISTON VITALITY 50 Cylinder CYLINDER PISTON 2 STROKE CYLINDER REMOVAL Remove the cylinder head 7 5 Remove the exhaust muffler 213 10 Remove the cylinder Remove the cylinder gasket Do not pry between the cylinder and crankcase or strike the fins Piston Piston Pin PISTON REMOVAL NN Remove piston pin clip to remove piston pin and piston e Do not damage or scratch the piston e Do not apply side force to the connecting rod when removing the piston pin e Place clean shop towels in the crankcase to keep the piston pin clip from falling into the crankcase Piston Pin Clip Spread each piston ring and remove by lifting it up at a point Just opposite the gap Remove the expander 7 8 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY 50 CYLINDER PISTON INSPECTION Check the cylinder and piston for wear or damage Clean carbon deposits from the exhaust port area Be careful not to damage the cylinder inside wall Measure the cyli
108. m before installation KYMCO 12 CARBURETOR VITALITY 50 Band Screws CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold and tighten the band screw Install the air cleaner connecting tube and tighten the band screw N A gt T e Connect throttle cable carburetor e After connecting the throttle cable adjust the throttle grip free play to 2 6mm Connect the fuel tube and vacuum tube to the carburetor KYMCO 12 CARBURETOR VITALITY 50 Auto Bystarter Wire Connect the auto bystarter connector Perform the following inspections and adjustments eThrottle grip free play gt 3 16 eldle speed 3 10 Idle Speed 1800 100rpm Install the met in box 5 13 5 12 27 KYMCO 12 CARBURETOR VITALITY 50 FUEL TANK REMOVAL Remove the rear body cover 13 6 Disconnect the fuel tube and vacuum tube at the auto fuel valve Disconnect the fuel unit wire connector Nuts Bolts Remove the three nuts and remove retainer plate Remove the fuel tank mounting bolts and fuel tank Installation is in the reverse order of removal Inspect the fuel unit 17 2 Replace the fuel unit if necessary 17 2 Fuel Unit Connector 12 28 KYMCO 13 FRAME COVERS EXHAUST MUFFLER _ VITALITY 50 FRAME COVERS EXHAUST MUFFLER SERVICE INEORNDA
109. n Adjusting Nut Upper Mount Bolt 77 Lower Mount Bolt 15 6 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 ELECTRICAL EQUIPMENT SERV ICE INFORMATION annassa 16 1 16 1 EEN 16 3 EE 16 5 IGNITION SYSTEM eege 16 11 PLECTRICSTARTER S Su u Da 16 17 N 16 0 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e It is not necessary to check the battery electrolyte or fill with distilled water e Remove the battery from the motorcycle for charging Do not remove the electrolyte cap Do not quick charge the battery Quick charging should only be done in an emergency e Charge the battery according to the charging current and time specified on the battery e When charging check the voltage open voltage with an electric tester e When replacing the battery do not use a traditional battery SPECIFICATIONS Battery Charging Standard Spark plug aati ole 6 99k 110 21 8 12KQ Secondary coil withoutplugeap 3243960 Pulser coil resistance 2011 80711600 118 10118 20 Ignition timing 13 5 2 2BTDC 3000rpm 28 2 BTDC 4000rpm TROUBLESHOOTING CHARGING SYSTEM No power Intermittent power e Dead battery e Loose battery cable connection e Disconnected battery cable e Loose charging syst
110. nder bore at three levels of A B and C in both X and Y directions Avoid the port area Take the maximum figure measured to determine the cylinder bore Service Limit 39 05mm replace if over Inspect the top of the cylinder for warpage Service Limit 0 10mm replace if over 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITYSO A Mark The cylinder has a mark or no mark on it When replacing the cylinder with a new one use a cylinder having the same mark as the old one Measure the piston O D at a point 5mm from the bottom of the piston skirt Service Limit 38 90mm replace if below Measure the piston to cylinder clearance Service Limit 0 10mm replace if over Measure the piston pin hole I D Service Limit 12 03mm replace if over Measure the piston pin O D Service Limit 11 98mm replace if below Measure the piston to piston pin clearance Service Limit 0 03mm replace if over 7 10 7 CYLINDER HEAD 2 STROKE KYMCO CYLINDER PISTON VITALITY 50 PISTON RING INSPECTION Measure each piston ring end gap Service Limits Top Second 0 40mm replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure the connecting road small end
111. near the battery e Charge the battery according to the current specified on the battery surface Black Red Charging current Standard 0 4A Quick 4A Charging time Standard 5 10hours Quick 0 5 hour After charging Open circuit voltage 12 8V min e Quick charging should only be done in an emergency e During quick charging the battery temperature should not exceed 451 Measure the voltage 30 minutes after the battery is charged 16 6 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 CURRENTD LEAKAGE TEST Turn the ignition switch OFF Remove the battery cover Disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe to the battery terminal With the ignition switch OFF check for current leakage e When measuring current using a tester set it to high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in the tester e While measuring current do not turn the ignition switch ON A sudden surge of current may blow out the fuse in the tester Specified current leakage maximum If current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current 16 7 KYMCO 16 ELECTRICAL EQUIPMENT
112. nnected brake arm Poor brake performance disk brake Air in brake system Deteriorated brake fluid KYMCO VITALITY 50 pts rg 0 2 2 3 px 1 0 30 25 400 25 405 25 45 25 318 25 368 25 30 B 0 0 A Front axle nut Brake caliper bolt 5 0 7 0kgf m 2 9 3 5kgf m e Contaminated brake disk or disk pad e Worn brake bushing e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Deformed brake disk e Unevenly worn brake caliper Front wheel wobbling e Bent rim Loose front axle Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs e Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 14 2 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers gt 13 3 Remove front body cover gt 13 9 Remove two bolts attaching the left brake lever holder Remove two bolts attaching the brake master cylinder disk brake to the right brake lever Remove the two right handlebar switch housing bolts and separate the housing Disconnect the throttle cable and then remove the throttle grip from the handlebar Remove the handlebar lock nut to remove the handlebar 14 3 KYMCO VITALITY 50 Bolts Brake Master Cylinder Bolts
113. nstall the oil pump into the crankcase Install the oil pump control cable plate 1 and tighten the two bolts Connect the oil inlet line 1 and oil outlet line 2 properly Connect the oil pump control cable 3 Bleed air from the oil pump KYMCO 4 LUBRICATION SYSTEM VITALITY 50 BLEEDING e Air in the oil lines will block oil flow and result in severe engine damage e Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines OIL INLET LINE OIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc Fill the oil line with oil and connect it to the oil pump Bleed air from the oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into U shape Force air out of the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump Oil Outlet Line e Never run the engine in a closed area Do not increase the engine speed at will 4 7
114. on Foreign matter stuck in starter motor or pinion Starter motor rotates but engine does not start e Faulty starter pinion e Starter motor rotates reversely e Faulty starter clutch e Weak battery 16 2 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 CHARGING SYSTEM 2 STROKE Resistor Battery Cable Fuse 7A Y Y w R Light Switch 7A 2 x CO x x x Resistor d e B Il E x aie G Batter REG RECT AG Generator 12V3AH ala 16 3 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 CHARGING SYSTEM 4 STROKE Regulator Rectifier Resistor Battery Cable Fuse 7A Y Y w R Light Switch 7A LJ CD x x x BR P Resistor d eg G Pulser Coil REG RECT A C HT x Ge erator _ Battery 12V3AH 16 4 KYMCO 16 ELECTRICAL 50 BATTERY REMOVAL 1 Make sure the ignition switch is OFF 2 Remove the screw 1 3 Push the two retainer clips 2 and remove the battery cover 3 4 Disconnect the negative terminal lead 1 from the battery first then disconnect the positive terminal lead 2 5 Remove the battery e This model adopts the battery which needs no refilling of distilled water e When cleaning the terminals remove the screws attaching the battery cover on the footboard and then
115. on ring end gap top second onnecting rod small end 1 0 oro a lt A S 8 z E S B 5 VALUES Cylinder head 1 001 2kg m Exhaust muffler joint lock nut 1 001 4kg m Exhaust muffler lock bolt 3 003 6kg m Spark plug 1 101 7kg m TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Loose spark plug Worn stuck or broken piston and piston rings Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon build up in cylinder head or on piston head 7 3 Standard mm Item MEN 3897038955 an E EEN Lol x p au 39 0 39 025 Service Limit mm 12 03 39 05 Abnormal noisy piston e Worn cylinder and piston e Worn piston pin or piston pin hole e Worn connecting rod small end bearing Abnormal noisy piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder 7 CYLINDER HEAD 2 STROKE CYLINDER PISTON SERVICE INFORMATION 4 STROKE GENERAL INSTRUCTIONS KYMCO VITALITY 50 e The cylinder and piston can be serviced with the engine installed in the frame Before disassembly clean the engine to prevent dust from entering the engine Remove all gasket material from the mating surfaces Do not use a driver to pry between the cylinde
116. ont cover gt 13 4 Measure the resistance between the resistor B pink wire and ground Measure the resistance between the resistor A green black wire and ground Resistance 2 Stroke Resistor A 9 2011 2Q Resistor B 5 306 50 Resistance 4 Stroke Resistor 7 718 30 Resistor B 12 0012 8Q Faulty resistor 15 the cause of faulty operation of the auto bystarter Resister 16 9 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 Regulator Rectifier Nut REGULATOR RECTIFIER K 3 INSPECTION Remove the front cover 13 4 Disconnect the regulator rectifier wire coupler and remove the nut to remove the regulator rectifier Measure the resistances between the terminals Replace the regulator rectifier if the readings are not within the specifications in the table below e Due to the semiconductor in circuit it Coupler is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range A Red C Yellow may give false readings 2 Stroke B White D Green 16 10 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 IGNITION SYSTEM 2 STROKE C D I Unit Ignition Coil EAD Pk S A be x gt Se AM ANN E A S z N NS ki x gt AC b a A C Generator Exciter Coil Pulser Coil Ignition Switch 16 11
117. open the battery cover When battery terminals are corroded take out the battery for cleaning e After cleaning apply a thin coat of grease or vaseline to battery terminals and then install the battery e Never open the closed type battery electrolyte cap e If the scooter will not be used for a long time the battery will discharge electricity by itself Remove the battery and put it in a cool place after it is fully charged to prevent electricity leakage e If the scooter will not be used for a long time remove the negative terminal e Do not smoke or allow flames or sparks near the battery while removing and installing it e Turn off the ignition switch before removal or installation The negative terminal shall be removed first and the positive terminal shall be installed first e Tighten the loose terminal nuts securely 16 5 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 BATTERY INSPECTION Remove the battery cover and disconnect the battery cables Measure the voltage 20 C 68 F between the battery terminals Fully charged 13 0V13 2V Undercharged 12 3V max CHARGING METHOD Connect the charger positive cable to the battery positive cable Connect the charger negative cable to the battery negative cable 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
118. piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber 12 17 KYMCO VITALITY 50 Vacuum Piston Spring Vacuum Piston Needle Holder Jet Needle Screw Float Chamber KYMCO 12 CARBURETOR VITALITY 50 Float Screw Float Pin Remove screw then remove float pin float and float valve Float Valve Float Valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Valve Seat JETS SCREWS REMOVAL e Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record rotating turns Do not force the pilot screw against its seat to avoid seat damage Pilot Screw 12 18 12 CARBURETOR Remove main jet needle jet holder and needle jet Remove the slow jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil e Be sure to use clean detergent oil Check the pilot screw spring washer and O ring for bend wear or damage KYMCO VITALITY 50 Main Jet Needle Jet Holder Needle Jet Slow Jet Washer Spring Slow Jet EN Needle Jet Holder Main Jet Needle Jet Pilot Screw 12 19 o T 12 CARBURETOR KYMCO VITALITY 50 AUTO
119. r and cylinder head cylinder and crankcase Do not damage the cylinder inside and the piston surface e After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts SPECIFICATIONS x Sundad mm 39 00 30 01 geg Cylinder Ring to groove 0 015 10 055 clearance Second 0 015110 055 KEREN Piston Ring end gap 03 10 45 02707 38 75 3839 piston ring Piston O D measuring position 4 5mm from bottom of skirt Piston pin hole LD 13 002 113 008 Piston O D 12 9941113 000 Piston to piston pin clearance 0 002 0 014 Connecting rod small end I D bore 13 016113 034 Piston to cylinder clearance 0 010 0 040 TROUBLESHOOTING 0 65 0 5 38 9 0 1 13 04 12 96 13 06 e When hard starting or poor performance 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 stuck or broken piston rings e Worn or damaged piston rings e Worn or damaged cylinder and piston 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 7 4 7 CYLINDER HEAD 2 S
120. rake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Compressed Air Piston Oil Seal Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface 14 13 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK LITY 50 Check the piston for scratch or wear Measure the piston O D with a micrometer Service Limit 25 45mm Check the caliper cylinder for scratch or wear and measure the cylinder bore Service Limit 25 30mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end 3 5mm protruding 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 14 14 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 Installation Install the brake caliper and tighten the two P bolts Torque 2 9 3 5kgf m Connect the brake
121. rake fluid tube 2 32 KYMCO 2 GENERAL INFORMATION VITALITY 50 OIL METER 1 Motor oil indicator light does not come on when there is no motor oil Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Burned out fuse Q Weak or dead battery Signals operate Signals dim remain _ Faulty ignition switch properly on or don t operate Loose or disconnected Connect indicator light bulb to battery for bulb gt L wate Mantes Inspection Bulb lights Bulb does not light Burned out bulb Check connectors for proper operation Loose wire connector Good Faulty Q Broken wire harness Remove oil meter and Incorrectly connected wire check operation of indicator light by n moving float O Faulty float m Good L Broken or shorted wire Float up Light off meter Float down Light on A 2 Motor oil is sufficient but the indicator light remains on Ignition switch ON Inspection Adjustment Symptom Probable Cause Check connectors for proper connection Loose or disconnected E Broken wire harness Remove oil meter and
122. rance cold mm 1800rpm 0 85 liter Oil exchanging 0 7 liter capacity Cooling Type Idle speed rpm Zig wash ur s ond 5 1 eougooq wN uononp q Brake system SIA9G SuIAO A KYMCO VITALITY 50 CDI 28 BTDC 4000rpm Spark plug NGK C7HSA Spark plug gap 0 6L0 7mm 12V4AH Operation Automatic centrifugal Type x FR RR tire rolling circumference mm 1485 1515 Tire pressure kgf cm anal Telescope l0jonq1e uonrus Front Under swing 1 2 KYMCO 2 GENERAL INFORMATION VITALITY 50 GENERAL INFORMATION MODEL IDENTIEICATION 253 SERVICE PRECAUTIONS Soerat E 229 SERVICE INFORMATION O STROKEN 2 6 SERVICE INFORMATION 4 STROKLE e 2 8 TORQUE VALUES 2 STROKE 2 10 TORQUE VALUES 4 STROKE sier 24h SPECIAL TOOLS 2 STROKE rettet tetti ttt 2 19 SPECIAL TOOLS 4 6 4 4 41400 2 12 UUBRICATION POINEDS te EO ad WIRING DIAGRAM is uitis sae 2 15 CABLE amp HARNESS ROUTING 2 8 247 CABLE amp HARNESS ROUTING 4 8 es 2 21 TROUBLESHOOTING STROKE enne 2 25 TROUBLESHOOTING 2 STROKE 2 36 2 0 KYMCO 2 GE
123. ring Remove two bolts and cam chain tensioner KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 Turn the cooling fan clockwise so that the mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Round Hole Remove the four camshaft holder nuts and washers Diagonally loosen the cylinder head nuts 2 or 3 times Remove the camshaft holder and dowel pins 6 5 6 4 STROKE CYLINDER HEAD VALVES Remove the camshaft gear from the cam chain and remove the camshaft CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt Remove the valve rocker arms and arm shafts CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder for wear or damage Inspect the rocker arm shaft for blue discoloration or grooves If any defects are found replace the rocker arm shaft with a new one then inspect lubrication system KYMCO VITALITY 50 Camshaft Rocker Arms Rocker Arm Shafts Holder Rocker Arm Arm Shafts Rocker Arm 6 6 KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 Inspect rocker arm bore cam lobe Rocker Arm Bore contact surface and adjuster surface for wear pitting scratches blue discoloration If any defects are found replace the rocker arm shaft with a new one then inspect
124. seals must be removed Replace the oil seals with new ones Crankshaft bearing puller E030 k Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit 0 04mm replace if over 11 5 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Measure crankshaft runout ee 0 150mm 0 100mm replace if over replace if over Check the crankshaft bearings for excessive play The bearings must be replaced if they are noisy or have excessive play Radial CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults e After check apply clean engine oil to all moving and sliding parts e Remove all gasket material from the crankcase mating surfaces Dress any roughness or irregularities with an oil stone KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 Bearing Driver Handle Drive a new crankshaft bearing into the right crankcase seal amp bearing install E014 Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm The distance between the left crankcase oil seal and crankcase surface is about 1 0mm Bearing Outer Driver Handle A Drive a new crankshaft bearing into the left crankcase
125. ser coil from the right crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator Be careful not to damage the disconnected wire Pulser Coil 8 4 KYMCO 8 A C GENERATOR VITALITY 50 A C Generator Wire Connector INSTALLATION Install the A C generator stator and pulser coll wire clamp onto the right crankcase and then install the pulser coll Connect the A C generator wire connector Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway Woodruff Key Universal Holder Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the 10mm flywheel flange nut Torque 3 5 4 0kg m Start the engine and check the ignition timing 3 14 or 3 15 Universal holder E017 8 5 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SERVICE INFORMA 9 2 EECHER 9 2 KICK SI TIER E 9 3 DRIVE E 9 7 E GE 9 9 STARTER E 9 11 CLUTCH DRIVEN PULLEY stehe L tee 9 12 9 0 9 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 Ch 272 NOM GET 2 REZ orque 3 5 4 5kg m
126. smission case with the specified oil 3 5 e Place the motorcycle on its main stand on level ground Check the sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 11 liter Install and tighten the oil check bolt Torque 1 011 5 Drain Bolt Start the engine and check for oil leaks 10 8 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 CRANKCASE CRANKSHAFT SERVICE INFORMATION cete tete testate tette cnt et eu 11 3 CRANKCASE CRANKSHAFT 2 STROKE 11 4 CRANKCASE CRANKSHAFT STROKE 11 10 11 0 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 2 STROKE Torque 0 801 2kg m 11 1 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 4 STDROKE 11 2 KYMCO 11 CRANKCASE CRANKSHAFT VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e The following parts must be removed before separating the crankcase Cylinder head c Chapter 6 2 stroke Cylinder piston c Chapter 7 Drive and driven pulleys Chapter 9 A C generator gt Chapter 8 SPECIFICATIONS 2 Stroke Sud Service Limit mm Connecting rod big end side clearance I Crankshaft Connecting
127. sufficiently open 3 7 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 ENGINE OIL 4 STROKE Dipstick Oil Filler Cap OIL LEVEL Place scooter a level place Warm up the engine for several minutes and stop it Remove the dipstick and wipe it off with a clean rag Insert the dipstick in the filler hole without screwing it in Run the engine for 2 13 minutes and check the oil level after the engine is stopped for 2 13 minutes Remove the dipstick and inspect the oil level The oil level should be between the maximum and minimum marks If the level is low add oil to raise it to the proper level ENGINE OIL REPLACEMENT Place the scooter on a level place Warm up the engine for several minutes and stop 1t Place a container under the engine Remove the oil filler cap 1 and drain plug 2 to drain the oil Reinstall the drain plug and tighten the drain plug to specification Torque 20 3 0kgf m Fill the engine with oil and install the oil filler cap Warm up the engine for several minutes at idle speed Check for oil leakage while warming up Be sure no foreign material enters the crankcase Oil Capacity At disassembly 0 85L At change 0 7L 3 8 KYMCO 3 LUBRICATION SYSTEM VITALITY 50 ENGINE OIL REPLACEMENT AND OIL FILTER CLEANING A Place the machine on a level place B Warm up the engine for se
128. tarter motor cable Remove the two bolts attaching the starter motor and remove the starter motor The installation sequence is the reverse of removal Connect the starter motor cable connector Check the O ring for wear or damage and replace it if necessary Apply grease to the O ring and install the starter motor Tighten the two mounting bolts Starter Motor Torque 0 81 2kgf m The starter motor cable connector must be installed properly STARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation Battery 16 19 i KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 er Pinion deat a 4 gt STARTER PINION REMOVAL Remove the left crankcase cover Remove the drive pulley Refer to chapter 9 Remove the starter pinion cover 2 stroke Remove the starter pinion Starter Pinion Cover 2 Stroke INSPECTION Sh cing Parts Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion 16 20 KYMCO 16 ELECTRICAL EQUIPMENT VITALITY 50 16 21 KYMCO 17 INSTRUMENT SWITCHES LIGHTS VITALITY 50 INSTRUMENT SWITCHES LIGHTS
129. the brake disk runout Service Limit 0 3mm 14 9 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER ERONT FORK Brake Master Cylinder Bolts BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system e When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid pipe bolt be sure to plug the pipe to avoid brake fluid leakage Snap Ring Disassembly Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring Piston from brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid Washer Snap Ring 14 10 KYMCO 14 STEERING HANDLEBAR FRONT WHEEL FRONT qo BRAKE FRONT SHOCK ABSORBER FRONTFORK VITALITY 50 Inspection Measure the brake master cylinder I D Service Limit 12 75mm Inspect the master cylinder for scratch or crack Measure the brake master cylinder piston O D Service Limit 12 64mm Before assembly inspect the Ist and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the Ist rubber cup e During assembly the main piston and spring must be installe
130. tion timing Faulty reed valve Q Seized piston Clogged 0O Clogged carburetor jets Correct timing Check carburetor air screw adjustment gt Incorrect timing Faulty CDI unit or generator GA CO flywheel not aligned mO Mixture too rich turn screw Correctly adjusted Incorrectly adjusted out Mixture too lean turn screw in 2 26 2 GENERAL INFORMATION KYMCO VITALITY 50 2 27 Inspection Adjustment Symptom Probable Cause Check carburetor gasket for air leaks 4 Carburetor not securely tightened No air leak Air leaks Faulty intake manifold gasket Deformed or broken carburetor O ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged Broken cable Not clogged Clogged _ Dirty auto bystarter auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel d enriching circuit and then blow the hose with Clogged Not Clogged Faulty auto bystarter 2 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Symptom accelerate lightly for observation Start engine and x Engine speed
131. tle grip free play Free Play 2 Gmm If the throttle grip free play does not fall within the specified range adjust by loosening the lock nut 1 and turning the adjusting nut 2 OTHERS LIGHTS Headlight Turn on the headlight switch Adjust the headlight beam by turning the headlight beam adjusting screw 1 3 16 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 LUBRICATION SYSTEM SERVICE INFORMATION 2 STROKLE e 4 3 SERVICE INFORMATION 4 STROKE 4 4 Ol PUMP O STROKE 4 5 OTANK O SPROREJ Tan a e 4 8 ENGINE OIL OIL FILTER 4 STROKE 4 9 OIDPUMP STROKE dta ae a iod tes 4 9 4 0 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 LUBRICATION SYSTEM 2 STROKE 4 1 KYMCO 4 LUBRICATION SYSTEM VITALITY 50 4 STROKE Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump KYMCO 4 LUBRICATION SYSTEM VITALITY 50 SERVICE INFORMATION 2 STROKE GENERAL INSTRUCTIONS e Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line Do not attempt to disassemble the oil pump e Bleed air from the oil pump if there is air between the oil pump and oil line e If the oil is disconnected refill the oil line with motor oil before connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20
132. ul not to damage or break the piston and piston rings e All rings should be installed with the markings facing up e After installing the rings they should rotate freely without sticking Measure the connecting rod small end 1 0 Service Limit 13 06mm replace if over Measure the connecting rod to piston pin clearance Service Limit 0 06mm replace if over 7 17 KYMCO VITALITY 50 Second Side Rail Oi2l Ring Side Rail 7 CYLINDER HEAD 2 STROKE QC KYMCO CYLINDER PISTON 5 Intake Side Guide Inspect the exhaust side and intake side chain guides Wear Damage Replace Exhaust Side Guide IN Mark PISTON INSTALLATION Remove any gasket material from the crankcase surface Be careful not to drop foreign matters into the crankcase 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 Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Apply proper clean engine oil around cylinder wall Be careful not to damage or break the piston rings
133. ut mO Misaligned front and rear wheels 2 31 KYMCO 2 GENERAL INFORMATION VITALITY 50 A POOR SUSPENSION PERFORMANCE Symptom Suspension 15 too soft Probable Cause lt Front and rear tire pressures are normal Weak shock spring Excessive load Suspension is too hard L Shock damper oil leaking Bent fork tube or shock rod Suspension is noisy Q Fork slider and tube binding O Fork tube and spring binding POOR BRAKE PERFORMANCE Symptom Index mark on brake panel aligns with wear indicator arrow Q Fork slider and tube binding Probable Cause Adjust brake according to standards O Worn brake linings Worn brake cam contacting area on brake shoes Brake squeaks 0O Worn brake cam Worn brake drum O Worn brake linings Brake performance is A poor Foreign matter on brake linings Rough brake drum contacting area mO Sluggish or elongated brake cables Brake shoes improperly contact ding brake drum Water and mud in brake system Oil or grease on brake linings Faulty brake master cylinder O Faulty brake caliper or grease on brake disk Deformed brake disk Leaking b
134. ve Cover Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage O ring Diaphragm 12 21 KYMCO 12 CARBURETOR VITALITY 50 CLEANING Blow compressed atr through all passages of the carburetor body Make sure that no fuel jet is clogged Ki Cut off Valve Cover Install the O ring onto the air cut off valve body securely e Install the O ring with the flat face D toward valve body side y RE Install the diaphragm spring and cover O ring Diaphragm Screws Install and tighten the two screws attaching the air cut off valve cover Install the throttle cable holder and tighten the two screws Cut off Valve Cover Throttle Cable Holder 12 22 KYMCO 12 CARBURETOR VITALITY 50 ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover Remove the spring and accelerating pump diaphragm Cover Spring INSPECTION Inspect the accelerating pump diaphragm for cracks damage or deterioration Replace if necessary Assemble the accelerating pump in the reverse order of disassembly Diaphragm Bystarter Screw Bystarter Cap AUTO BYSTARTER INSTALLATION Install the auto bystarter and set plate Install and tighten the two screws e Insert the auto bystarter into the carburetor body unti
135. ve seal shroud then remove two bolts and cylinder head 6 4 STROKE CYLINDER HEAD VALVES CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats oil seals and valves using a valve spring compressor sure to compress valve springs with a valve spring compressor e Mark all disassembled parts to ensure correct reassembly Valve Spring Compressor E040 VALVE VALVE GUIDE INSPECTION Inspect each valve for bending burning scratches or abnormal stem wear If any defects are found replace the valve with a new one Check valve movement in the guide Measure each valve stem O D Measure each valve guide I D Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Service limits IN 0 06mm replace if over EX 0 08mm replace if over gt If the stem to guide clearance exceeds the service limits replace the cylinder head as necessary CYLINDER HEAD INPECTION 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 6 11 KYMCO VITALITY 50 Valve Cotter Retainer Springs Springs Seat Spring Compressor Seal Valve KS e KYMCO 6 4 STROKE CYLINDER HEAD VALVES VITALITY 50 VALVE SPRING INSPECTION Measure the free length of the inner and out
136. ve the following Front cover gt 13 4 Right and left side cover 5 13 4 Remove the two nuts form the front body cover 13 9 13 FRAME COVERS EXHAUST MUFFLER Remove the ten screws from the leg shield Disconnect the headlight connector and then remove front body cover When removing the right and left side rails pull them backward not to damage the joint claws Installation is in the reverse order of removal EXHAUST MUFFLER REMOVAL INSTALLATION Disconnect the secondary air hose 2 stroke 55 3 Remove two exhaust pipe Joint lock nuts 1 Remove from lower fender and two Exhaust muffler lock bolts from the exhaust muffler KYMCO VITALITY 50 13 10 13 COVERS Inspect gasket 1 If the exhaust gas leaks gasket should replaced Installation 18 In the reverse order of removal When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Torque Exhaust muffler lock bolt 3 03 6kgf m exhaust pipe joint lock nuts 10 1 4kgf m Be sure to Install new exhaust gasket 13 11 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK KYMCO VITALITY 50 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE INFORM
137. ver If the hooks of the return spring can not be installed properly use a screw driver to press them into their locations respectively Kick Starter Spindle Friction Spring Properly install the kick starter driven gear and friction spring as the figure shown Kick Starter Driven Gear 9 5 9 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 First Install the washer and then the circlip onto the kick starter spindle Install the kick lever Washer Circlip Dowel Pins 223 Ge LEFT CRANKCASE COVER INSTALLATION First Install the dowel pins and then the seal gasket Seal Gasket Install the left crankcase cover and tighten ten bolts diagonally Connect the drive belt cooling air tube and install the circlip For drum brake note the location of the brake cable clamp and install the rear brake cable in place with the clamp Rear Brake Cable Clamp 9 KICK STARTER DRIVE PULLEY dC KYMCO CLUTCH DRIVEN PULLEY VITALITY 50 DRIVE BELT Remove the left crankcase cover 9 3 INSPECTION gt es Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 17mm replace if below Use specified genuine parts for replacement REPLACEMENT Remove the ten left crankcase cover bolts and left crankcase cover 529 3 Hold the clutch outer wit
138. veral minutes and stop it C Place a container under the engine D Remove the oil filler cap and oil filter cap to drain the oil Be sure no foreign material enters the crankcase When removing the drain plug the compression spring oil strainer and O ring will fall out Take care not to lose these parts O ring Spring Oil Strainer E Clean the oil strainer with solvent Inspect O ring and replace if damaged G Reinstall the O ring oil strainer compression spring and drain plug Tighten the drain plug to specification Torque 1 0 2 0kgf m Before reinstalling the drain plug be sure to install the O ring compression spring and oil strainer Oil Capacity At disassembly 0 85L At change 0 7L 3 9 KYMCO 3 INSPECTION ADJUSTMENT VITALITY 50 ENGINE IDLE SPEED oss At High and Low Speeds 9 engine must warm for accurate idle speed adjustment Adjust the idle speed to the specified range by turning the throttle stop screw 2 and air screw 1 Idle Speed 2 Stroke 1850 100rpm Adjust the idle speed to the specified range SE SS by turning the throttle stop screw and pilot screw Idle Speed 4 Stroke 1800 100rpm AIR CLEANER Air Cleaner 2 Stroke Remove the air cleaner cover by removing the 7 air cleaner cover screws and air clean

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