Page 1 Sections 4 through 17 give instructions for disassembly, assembly and inspection of lubrication system, engine, fuel system and electrical equipment. Section 18 is the KYMCO clean air system (for EURO 2) By KWANG YANG Motor Co., Ltd. First Edition, May 2004 All rights reserved.
Page 2: Table Of Contents
VITALITY 50 . SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS ..................1 GENERAL INFORMATION ................ 2 INSPECTION/ADJUSTMENT ..............3 LUBRICATION SYSTEM................4 ENGINE REMOVAL/INSTALLATION ............. 5 4-STROKE: CYLINDER HEAD/VALVES ..........6 CYLINDER HEAD (2-STROKE)/CYLINDER/PISTON......7 A.C. GENERATOR..................8 KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY..9 FINAL REDUCTION ..................10...
Page 3: Specifications
SPECIFICATIONS VITALITY 50 SPECIFICATIONS (2-Stroke) Name & Model SF10FA Lubrication oil capacity (liter) Overall length (mm) 1870 Air cleaner type & No. Wet, single Overall width (mm) Fuel capacity (liter) Overall height (mm) 1120 Type Wheel base (mm) 1296 Carburetor Piston dia. (mm) ...
Page 4 VITALITY 50 . SPECIFICATIONS SPECIFICATIONS (4-Stroke) Name & Model No. SG10AA Air cleaner type & No Wet paper Overall length (mm) 1870 Fuel capacity 5.0 liters Overall width (mm) Type Overall height (mm) 1120 Main jet No. #82 (speed limited: #80)
Page 5 VITALITY 50 . GENERAL INFORMATION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ MODEL IDENTIFICATION............... 2- 1 SERVICE PRECAUTIONS..............2- 2 SERVICE INFORMATION (2-STROKE).......... 2- 6 SERVICE INFORMATION (4-STROKE).......... 2- 8 TORQUE VALUES (2-STROKE) ............2-10 TORQUE VALUES (4-STROKE) ............2-11 SPECIAL TOOLS (2-STROKE) ............
Page 6: General Information
. GENERAL INFORMATION VITALITY 50 MODEL IDENTIFICATION The read serial frame number (2), please remove the cover on inner cover (1) with a flat head screwdriver. The engine serial number is stamped on right engine case.
Page 7: Service Precautions
VITALITY 50 . GENERAL INFORMATION Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several...
Page 8 . GENERAL INFORMATION VITALITY 50 If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.
Page 9 VITALITY 50 . GENERAL INFORMATION After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not squeeze wires against the weld or its clamp. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
Page 10 . GENERAL INFORMATION VITALITY 50 After routing, check that the wire harnesses Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. Wire harnesses routed along with handlebar Apply engine oil to the should not be pulled tight, have excessive specified points.
Page 11: Service Information (2-Stroke)
VITALITY 50 . GENERAL INFORMATION SERVICE INFORMATION (2-STROKE) ENGINE Standard (mm) Service Limit (mm) Item VITALITY 50 Cylinder head warpage  0.10 Piston O.D.(5mm from bottom of piston skirt) 38.955 38.970 38.90 Cylinder-to- piston clearance 0.10 Piston pin hole I.D.
Page 12 VITALITY 50 . GENERAL INFORMATION FRAME Standard (mm) Service Limit (mm) Item VITALITY 50 Axle shaft runout  Radial Front wheel rim runout Axial Front shock absorber spring free length 214.7 Rear wheel rim runout Brake drum I.D. Front/rear Brake lining thickness Front/rear 6.4/4.0...
Page 13: Service Information (4-Stroke)
VITALITY 50 . GENERAL INFORMATION SERVICE INFORMATION (4-STROKE) ENGINE Standard (mm) Service Limit (mm) Item VITALITY 50 (4-Stroke) Cylinder head warpage  0.10 38.975 38.99 38.90 Piston O.D.(4.55mm from bottom of piston skirt) Cylinder-to- piston clearance 0.010 0.040 0.10 Piston pin hole I.D.
Page 14 VITALITY 50 . GENERAL INFORMATION FRAME Standard (mm) Service Limit (mm) Item VITALITY 50 4-stdroke Axle shaft runout  Radial Front wheel rim runout Axial Front shock absorber spring free length 214.7 Rear wheel rim runout Brake drum I.D. Front/rear...
Page 15 VITALITY 50 . GENERAL INFORMATION TORQUE VALUES ENGINE (2-STROKE) Item Thread dia. (mm) Torque (kgf-m) Remarks Cylinder head bolt BF7x115 1.0 1.2 (cold) Clutch drive plate nut 3.5 4.0 Clutch outer nut NH10 3.5 4.5 Drive face nut NH12 5.0 6.0 Oil check bolt 1.0 1.5...
Page 16 VITALITY 50 . GENERAL INFORMATION FRAME Item Thread dia. (mm) Torque (kgf-m) Remarks Handlebar lock nut 5.0 6.0 Flange bolt/U-nut Steering stem lock nut 25.4 6.0 8.0 Steering top cone race 25.4 0.5 1.3 Front axle nut 5.0 7.0 Flange U-nut Rear axle nut 11.0 13.0...
Page 17: Special Tools (2-Stroke)
VITALITY 50 . GENERAL INFORMATION SPECIAL TOOLS (2-STROKE) Tool Name Tool No. Remarks Universal bearing puller E037 Lock nut socket wrench F001 Lock nut wrench, F007 Race cone install F005 Crankcase puller E026 Crankshaft bearing puller E030 Oil seal & bearing install...
Page 18: Lubrication Points
VITALITY 50 . GENERAL INFORMATION LUBRICATION POINTS ENGINE (2-STROKE) Lubrication Points Lubricant Crankcase sliding & movable KYMCO 2-STROKE OIL or QUIVALENT Cylinder movable parts KYMCO 2-STROKE OIL or QUIVALENT Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts...
Page 19 VITALITY 50 . GENERAL INFORMATION FRAME Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle. (1) Front/Rear Brake Lever (2) Throttle Cable (3) Seat Lock...
Page 20: Wiring Diagram
VITALITY 50 . GENERAL INFORMATION WIRING DIAGRAM (2-STROKE) 2-15...
Page 21 VITALITY 50 . GENERAL INFORMATION WIRING DIAGRAM (4-STROKE) 2-16...
Page 22: Cable & Harness Routing (2-Stroke)
VITALITY 50 . GENERAL INFORMATION CABLE & HARNESS ROUTING (2-STROKE) Winker Relay Rear Stop Switch Wire Front Stop Switch Wire Right Handlebar Switch Wire Rear Brake Cable Throttle Cable Left Handlebar Switch Wire Front Brake Fluid Tube Front Brake Fluid Tube...
Page 23 VITALITY 50 . GENERAL INFORMATION Ignition Coil Wire C.D.I Unit Secondary Air Cleaner Oil Level Switch Spark Plug Wire Oil Tank Ignition Coil Start Relay Auto By Start Wire Oil Throttle Cable Wire Harness Fuel Tube Fuel Vacuum Throttle Cable...
Page 24 VITALITY 50 . GENERAL INFORMATION Instrument Connectors Fuel Unit Regulator/Rectifier Fuel Tank Oil Level Headlight Connector Switch Ignition Switch Connector Connector Start Relay Fuel Strainer Auto By Start Resistor Ignition Coil Fuel Throttle Cable Oil Throttle Cable Fuse Box Taillight...
Page 25 VITALITY 50 . GENERAL INFORMATION Secondary Air Cleaner Fuel Unit C.D.I Unit Fuel Strainer Auto By Start Oil Level Switch Ignition Coil Spark Plug Cap Secondary Air Hose Air Inlet Hose (V-belt Chamber) Auto By Start Connector Oil Tube Oil Throttle Cable Start Motor Connector A.C.G Connector...
Page 26: Cable & Harness Routing (4-Stroke)
VITALITY 50 . GENERAL INFORMATION CABLE & HARNESS ROUTING (4-STROKE) Winker Relay Rear Stop Switch Wire Front Stop Switch Wire Right Handlebar Switch Wire Rear Brake Cable Throttle Cable Left Handlebar Switch Wire Front Brake Fluid Tube Front Brake Fluid Tube...
Page 27: General Information
VITALITY 50 . GENERAL INFORMATION C.D.I Unit Ignition Coil Auto By Start Wire/ A.C.G. Wire/ Start Motor Wire Ignition Coil Wire Throttle Cable Wire Harness Crankcase Breather Tube Fuel Tube Rear Brake Cable Throttle Cable Air Inlet Hose (V-belt Chamber)
Page 28 VITALITY 50 . GENERAL INFORMATION Instrument Connectors Regulator/Rectifier Fuel Unit Headlight Connector Ignition Switch Connector Fuel Connector Fuel Strainer C.D.I. Resistor Fuel Tube Crankcase Breather Tube Throttle Cable Fuse Box Auto By Starter/ Ignition Coil Wire Harness A.C.G./ Start Motor...
Page 29 VITALITY 50 . GENERAL INFORMATION Fuel Unit Starter Relay Fuel Strainer C.D.I. Unit Auto By Starter/ A.C.G./ Start Motor Wires Auto By Starter Vacuum Tube A Vacuum Tube B Ignition Coil Crankcase Breather Tube Vacuum Tube C Spark Plug Cap...
Page 30: Troubleshooting (2-Stroke)
VITALITY 50 . GENERAL INFORMATION TROUBLESHOOTING (2-STROKE) ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel reaches Fuel does not...
Page 31 VITALITY 50 . GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel does not Fuel reaches Clogged fuel filter carburetor reach carburetor...
Page 32 VITALITY 50 . GENERAL INFORMATION Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks. 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.
Page 33 VITALITY 50 . GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation. Clogged air cleaner Engine speed Clogged fuel filter Engine speed does Clogged exhaust muffler increases not increase Faulty auto bystarter sufficiently Check ignition timing (using a timing light).
Page 34 VITALITY 50 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Faulty CDI unit Correct timing Incorrect timing Faulty A.C. generator Check carburetor air screw adjustment. Mixture too rich (turn screw...
Page 35 VITALITY 50 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Faulty CDI unit Correct timing Incorrect timing Loose A.C.G. stator Faulty A.C. generator Check auto fuel valve for fuel supply. Empty fuel tank...
Page 36 VITALITY 50 . GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken driven face spring Engine starts but Separated clutch lining motor-cycle does not Damaged driven pulley shaft splines move...
Page 37 VITALITY 50 . GENERAL INFORMATION Bent front fork POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) Weak shock spring Suspension is too soft Excessive load Shock damper oil leaking Bent fork tube or shock rod...
Page 38 VITALITY 50 . GENERAL INFORMATION 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 Weak or dead battery...
Page 39 VITALITY 50 . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate...
Page 40 VITALITY 50 . GENERAL INFORMATION Broken or shorted wire in fuel gauge STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of Burned out fuse stop switch by Weak or dead battery applying brake. Faulty stop switch...
Page 41: Troubleshooting (2-Stroke)
VITALITY 50 . GENERAL INFORMATION Starter relay shorted or stuck closed TROUBLESHOOTING (4-STROKE) ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel...
Page 42 VITALITY 50 . GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed does not Engine speed...
Page 43 VITALITY 50 . GENERAL INFORMATION Clutch slipping Mixture too lean Ignition timing too early POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fixed position.
Page 44 VITALITY 50 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fix position. Check carburetor pilot...
Page 45 VITALITY 50 . GENERAL INFORMATION POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
Page 46 VITALITY 50 . GENERAL INFORMATION NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness...
Page 47 VITALITY 50 . GENERAL INFORMATION Faulty ignition coil 2-42...
Page 48: Inspection/Adjustment
VITALITY 50 . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ MAINTENANCE SCHEDULE............3- 1 BRAKE SYSTEM................3- 2 MOVING DEVICE ................3- 4 DAMPING DEVICE................3- 5 TRANSMISSION GEAR OIL............. 3- 5 LUBRICATION SYSTEM (2-STROKE) ........... 3- 6 ENGINE OIL (4-STROKE) ..............3- 8 ENGINE IDLE SPEED................
Page 49: Inspection/Adjustment
Brake lever Brake shoe wear Shock absorber • In the 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.
Page 50: Brake System
VITALITY 50 . INSPECTION/ADJUSTMENT 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.
Page 51 . 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.
Page 52: Moving Device
. INSPECTION/ADJUSTMENT VITALITY 50 MOVING DEVICE TIRES Tire Pressure Check the tire pressure. Tire pressure should be checked when tires are cold. Tire Pressure (one rider) Front: 1.50 kg/cm² Rear: 2.0 kg/cm² 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.
Page 53: Damping Device
. 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.
Page 54: Lubrication System (2-Stroke)
. INSPECTION/ADJUSTMENT VITALITY 50 4-Stroke 3.Remove the oil filler bolt (1) and drain plug (3) to drain the oil. 4.Reinstall the drain plug and tighten it. Torque: 1.0 1.5kgf-m 5.Fill the engine with oil and install the oil filler blot.
Page 55 . 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. Bleed air from the oil pump and oil lines.
Page 56: Engine Oil (4-Stroke)
. INSPECTION/ADJUSTMENT VITALITY 50 Dipstick/Oil Filler Cap ENGINE OIL (4-STROKE) OIL LEVEL Place the scooter on 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.
Page 57 . 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 several 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.
Page 58: Engine Idle Speed
. INSPECTION/ADJUSTMENT VITALITY 50 2-Stroke ENGINE IDLE SPEED At High and Low Speeds The engine must be 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).
Page 59 . LUBRICATION SYSTEM VITALITY 50 Remove the air cleaner element (1). Wash the air cleaner element in detergent oil, squeeze out and allow to dry. Never use gasoline or organic vaporable oil with acid or alkali for washing. After washing, soak the element in clean engine oil SAE 15W-40# and squeeze out excess oil.
Page 60 . 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.
Page 61: Cylinder Compression
. 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 and push the starter button for 7 8 seconds to test the compression.
Page 62: Valve Clearance (4-Stroke)
. INSPECTION/ADJUSTMENT VITALITY 50 “T” Mark VALVE CLEARANCE (4-STROKE) • Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the met-in box ( 13-5 ) and center cover. ( 13-6 ) Remove cylinder head cover. ( 6-4 ) Turn the A.C.
Page 63: Ignition Apparatus
. LUBRICATION SYSTEM VITALITY 50 IGNITION APPARATUS Spark Plug Gap, Wear and 0.6-0.7mm Remove the frame center cover. Fouling Deposits Remove the spark plug cap and spark plug. Check the spark plug for wear, fouling and carbon deposits. Washer Damage Remove the fouling and carbon deposits with a spark plug cleaner or wire brush.
Page 64: Throttle Grip Play
. INSPECTION/ADJUSTMENT VITALITY 50 THROTTLE GRIP FREE PLAY Measure the throttle grip free play. Free Play: 2 6mm 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).
Page 65: Lubrication System
VITALITY 50 . LUBRICATION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION (2-STROKE).......... 4-3 SERVICE INFORMATION (4-STROKE).......... 4-4 OIL PUMP (2-STROKE) ..............4-5 OIL TANK (2-STROKE)..............4-8 ENGINE OIL/OIL FILTER (4-STROKE)........... 4-9 OIL PUMP (4-STROKE) ..............4-9...
Page 66: Lubrication System
VITALITY 50 . LUBRICATION SYSTEM LUBRICATION SYSTEM (2-STROKE)
Page 67 VITALITY 50 . LUBRICATION SYSTEM (4-STROKE) Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 68: Service Information (2-Stroke)
VITALITY 50 . LUBRICATION SYSTEM SERVICE INFORMATION (2-STROKE) GENERAL INSTRUCTIONS • 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.
Page 69: Service Information (4-Stroke)
VITALITY 50 . LUBRICATION SYSTEM SERVICE INFORMATION (4-STROKE) GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 70: Oil Pump (2-Stroke)
VITALITY 50 . LUBRICATION SYSTEM 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 the met-in box ( 13-5), spark plug cover ( 13-5), center cover ( 13-6).
Page 71 VITALITY 50 . LUBRICATION SYSTEM INSTALLATION • Lubricate the O-ring (1) with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion.
Page 72 VITALITY 50 . LUBRICATION SYSTEM BLEEDING • Air in the oil lines will block oil flow and result in severe engine damage. • 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.
Page 73: Oil Tank (2-Stroke)
VITALITY 50 . LUBRICATION SYSTEM OIL TANK (2-STROKE) OIL TANK REMOVAL Remove the rear body cover. ( 13-6) 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.
Page 74: Engine Oil/Oil Filter (4-Stroke)
VITALITY 50 . LUBRICATION SYSTEM 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. Bolts OIL PUMP (4-STROKE) REMOVAL Place a container under the engine.
Page 75 VITALITY 50 . LUBRICATION SYSTEM Bolts Remove three oil pump mounting bolts and the oil pump. Oil Pump O-rings Dowel Pin Remove O-rings and dowel pin. 4-10...
Page 76 VITALITY 50 . LUBRICATION SYSTEM DISASSEMBLY Remove the screws and disassemble the oil pump. Bolts Screws Outer Rotor Pump Body INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.2mm...
Page 77 VITALITY 50 . LUBRICATION SYSTEM Measure the rotor end-to-pump body clearance. Service Limit: 0.12mm Inner Rotor ASSEMBLY Dowel Pin Install the outer rotor, inner rotor and pump shaft into the pump body. Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
Page 78 VITALITY 50 . LUBRICATION SYSTEM O-rings Dowel Pin INSTALLATION Install the O-rings and dowel pin. Inspect the O-rings and replace if damaged. Bolts Install the oil pump and tighten the bolts. Make sure that the pump shaft rotates freely without binding.
Page 79 VITALITY 50 . LUBRICATION SYSTEM Bolts Install the right crankcase cover and tighten the bolts. Right Crankcase Cover 4-14...
Page 80: Engine Removal/Installation
VITALITY 50 . ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ..............5- 1 ENGINE REMOVAL (2-STROKE)............ 5- 2 ENGINE INSTALLATION (2-STROKE) .......... 5- 5 ENGINE REMOVAL (4-STROKE)............ 5- 6 ENGINE INSTALLATION (4-STROKE) ------------------------------- 5-10...
Page 81: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Parts requiring engine removal for servicing: Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4.5 5.5kg-m Rear shock absorber lower mount bolt 2.4 3.0kg-m Engine hanger bracket bolt 4.5 5.5kg-m...
Page 82: Engine Removal (2-Stroke)
VITALITY 50 . ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (2-STROKE) Remove the frame body cover. ( 13-6) Disconnect the oil pump control cable from the pump body. ( 4-5) Disconnect the oil inlet line from the oil pump. ( 4-5) After the oil inlet line is disconnected, plug the oil line opening to prevent oil from flowing out.
Page 83 . ENGINE REMOVAL/INSTALLATION VITALITY 50 Remove the rear brake adjusting nut (1), brake arm pin (2) and retainer bolt (4) and disconnect the brake cable (3) from the crankcase. Remove the cooling air tube band (6) from the left crankcase cover and disconnect the cooling air tube.
Page 84 VITALITY 50 . ENGINE REMOVAL/INSTALLATION Lift the frame rear upward and move the frame forward to separate it 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.
Page 85: Engine Installation (2-Stroke)
. ENGINE REMOVAL/INSTALLATION VITALITY 50 Bushings ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary. ENGINE INSTALLATION Engine Hanger Stopper Rubbers Install the engine in the reverse order of removal.
Page 86: Engine Removal (4-Stroke)
VITALITY 50 . ENGINE REMOVAL/INSTALLATION A.C. Generator Wire ENGINE REMOVAL (4-STROKE) Remove the frame body cover. ( 13-6) Disconnect the auto bystarter, A.C. generator and starter motor wire connector Starter Motor Wire Auto Bystarter Wire Crankcase Breather Hose Remove the spark plug cap.
Page 87 . ENGINE REMOVAL/INSTALLATION VITALITY 50 Remove the bolts from air cleaner housing. Bolts Wire Band Release the wire band (auto bystarter/A.C. generator/starter motor wire). Remove the carburetor. Spring Arm Pin Arm Pin Remove rear brake adjusting nut, arm pin and spring.
Page 88 VITALITY 50 . ENGINE REMOVAL/INSTALLATION Rear Brake Cable Disconnect the rear brake cable from the transmission cover. Remove the rear shock absorber lower mount bolt. Disconnect the inlet hose. Bolt Inlet Hose Remove the right and left engine mounting nuts..
Page 89 . ENGINE REMOVAL/INSTALLATION VITALITY 50 Lift the frame rear upward and move the frame forward to separate it from the engine and be careful not to damage the rear fender. ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket nuts.
Page 90: Engine Installation (4-Stroke)
VITALITY 50 . ENGINE REMOVAL/INSTALLATION 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.
Page 91: 4-Stroke: Cylinder Head/Valves
6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 __________________________________________________________________________________ 4-STROKE: CYLINDER HEAD/VALVES SERVICE INFORMATION------------------------------------------------ 6- 2 CYLINDER HEAD COVER----------------------------------------------- 6- 4 CAMSHAFT/CAMSHAFT HOLDER------------------------------------ 6- 4 CYLINDER HEAD---------------------------------------------------------- 6-10...
Page 92 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50...
Page 93: Service Information
6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x The cylinder head can be serviced with the engine installed in the frame. x When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication.
Page 94 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 x The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.
Page 95: Cylinder Head Cover
6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the rear body cover. ( Ö 13-6) Disconnect the crankcase breather tube from the cylinder head cover. ( Ö 5-6) Disconnect the secondary air apply hose from the cylinder head cover.
Page 96 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Turn the cooling fan clockwise so that the “T” 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.
Page 97 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Camshaft Remove the camshaft gear from the cam chain and remove the camshaft. Rocker Arms CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt. Remove the valve rocker arms and arm shafts.
Page 98 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Inspect the 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 lubrication system.
Page 99 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Camshaft Bearings CAMSHAFT INSPECTION 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.
Page 100 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Install the camshaft dowel pins and holder. x Apply engine oil to the threads of the cylinder head nuts. x Diagonally tighten the cylinder head nuts in 2 3 times. x Position the camshaft holder “EX”...
Page 101: Cylinder Head
6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Nuts 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”...
Page 102 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 Valve Cotter Retainer Springs Springs Seat CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. x Be sure to compress the valve springs with a valve spring compressor.
Page 103 6. 4-STROKE: CYLINDER HEAD/VALVES VITALITY 50 VALVE SPRING INSPECTION Measure the free length of the inner and outer valve springs. Service Limit: Inner: 28.4mm replace if below Outer: 31.5mm replace if below Measure compressed force (valve spring) and installed length.
Page 104 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. Be sure to install new oil seal. Lubricate each valve with engine oil and insert the valves into the valve guides.
Page 105 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...
Page 106: Cylinder Head (2-Stroke)/Cylinder/Piston
7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTON __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD(2-STROKE)/CYLINDER/PISTON __________________________________________________________________________________ SERVICE INFORMATION (2-STROKE).......... 7- 3 SERVICE INFORMATION (4-STROKE).......... 7- 4 CYLINDER HEAD (2-STROKE) ............7- 5 CYLINDER/PISTON (2-STROKE) ............ 7- 8 CYLINDER/PISTON (4-STROKE) -------------------------------------- 7-13...
Page 107: Cylinder Head (2-Stroke)/Cylinder/Piston
7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO (2-STROKE) Torque: 1.1 1.7kg-m (cold) Torque: 1.0 1.2kg-m...
Page 108 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 (4-STROKE)
Page 109: Service Information (2-Stroke)
7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO SERVICE INFORMATION (2-STROKE) GENERAL INSTRUCTIONS • 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.
Page 110: Cylinder/Piston (4-Stroke)
7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 SERVICE INFORMATION (4-STROKE) GENERAL INSTRUCTIONS • 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.
Page 111 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO Spark Plug Cap CYLINDER HEAD (2-STDROKE) REMOVAL Remove the rear body cover. ( 13-6) Remove the spark plug cap Fan Cover/Engine Hood Remove the fan cover. ( 8 -3) Remove the exhaust muffler. ( 13-10) Remove the bolt from the engine hood, then remove the engine hood.
Page 112 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 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.
Page 113 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO 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 Install the spark plug. Torque: 1.1 1.7kg-m Cylinder Head...
Page 114 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 Cylinder CYLINDER/PISTON (2-STROKE) CYLINDER REMOVAL Remove the cylinder head. ( 7 -5) Remove the exhaust muffler. ( 13-10) Remove the cylinder. Remove the cylinder gasket. Do not pry between the cylinder and crankcase or strike the fins.
Page 115 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO 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 cylinder bore at three levels of A, B and C in both X and Y directions.
Page 116 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 A Mark The cylinder has a “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.
Page 117 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO 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...
Page 118 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 Cylinder Gasket Install a new cylinder gasket on the mating surface between the cylinder and crankcase. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.
Page 119 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO Dowel Pin CYLINDER/PISTON (4-STROKE) REMOVAL Remove the cylinder head. (Refer to the chapter 6) Remove the two dowel pins and cylinder head gasket. Gasket Remove cam chain guide and then remove cylinder. Cam Chain Guide Dowel Pins Remove the cylinder gasket and dowel pins.
Page 120 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 Piston 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.
Page 121 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO 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. 20mm Measure the piston ring end gap. Service Limit: Top: 0.5mm replace if over 2nd: 0.65mm replace if...
Page 122 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 Measure the piston O.D. Take measurement at 4.5mm from the bottom and 90° to the piston pin hole. 4.5mm 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.
Page 123 7. CYLINDER HEAD (2-STROKE)/ VITALITY 50 CYLINDER/PISTO PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring. • Be careful not to damage or break the piston and piston rings. • All rings should be installed with the markings facing up.
Page 124 7. CYLINDER HEAD (2-STROKE)/ CYLINDER/PISTON VITALITY 50 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.
Page 125: A.c. Generator
VITALITY 50 8. A.C. GENERATOR __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION ..............8-2 A.C. GENERATOR ................8-3...
Page 126 8. A.C. GENERATOR VITALITY 50 Torque: 0.8 1.2kg-m Torque: 3.5 4.0kg-m Torque: 0.6 1.0kg-m Torque: 0.8 1.2kg-m...
Page 127 VITALITY 50 8. A.C. GENERATOR SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 16 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5 4.0kg-m SPECIAL TOOLS...
Page 128 8. A.C. GENERATOR VITALITY 50 Fan Cover A.C. GENERATOR REMOVAL Remove the right side cover. ( 13-4) Remove the three bolts attaching the fan cover to remove the fan cover. Bolts Bolt Remove the cooling fan by removing the four bolts.
Page 129 VITALITY 50 8. A.C. GENERATOR Remove the A.C. generator flywheel using the flywheel puller. Special Flywheel puller E001 Flywheel Puller Lock Nut Wrench A.C. Generator Wire Connector Remove the A.C. generator wire connector. Wire Clamp Remove the two pulser coil bolts and pulser Stator coil from the right crankcase.
Page 130 8. A.C. GENERATOR VITALITY 50 A.C. Generator Wire Connector INSTALLATION Install the A.C. generator stator and pulser coil wire clamp onto the right crankcase, and then install the pulser coil. Connect the A.C. generator wire connector. Clean the taper hole in the flywheel off any burrs and dirt.
Page 131: Kick Starter/Drive Pulley/Clutch/Driven Pulley
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION ..............9- 2 TROUBLESHOOTING ............... 9- 2 KICK STARTER.................. 9- 3 DRIVE BELT ..................9- 7 DRIVE PULLEY.................. 9- 9 STARTER PINION................
Page 132 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Torque: 5.0 6.0kg-m Torque: 3.5 4.5kg-m Torque: 3.5 4.0kg-m...
Page 133: Service Information
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS VITALITY 50 Item Standard (mm) Service Limit (mm) Drive pulley collar O.D. 19.96 19.974 19.94...
Page 134: Kick Starter
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Left Crankcase Cover KICK STARTER 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. ( 5-2) Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins.
Page 135 . KICK STARTER/DRIVE PULLEY/ 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 Return Spring Spindle KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage.
Page 136 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 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 Friction Spring Install the kick starter spindle bushing and return spring onto the left crankcase cover.
Page 137 . KICK STARTER/DRIVE PULLEY/ 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 LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal gasket.
Page 138: Drive Belt
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 DRIVE BELT Remove the left crankcase cover. ( 9 -3) INSPECTION 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.
Page 139 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt 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.
Page 140: Drive Pulley
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Drive Pulley Face Starting Ratchet 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...
Page 141 . KICK STARTER/DRIVE PULLEY/ 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 Movable Drive Face Install the drive pulley collar and movable drive face onto the crankshaft.
Page 142: Starter Pinion
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 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.
Page 143 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Universal Holder Clutch Outer CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9 -9) Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut. Remove the clutch outer.
Page 144 . KICK STARTER/DRIVE PULLEY/ 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...
Page 145 . KICK STARTER/DRIVE PULLEY/ 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.
Page 146 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Inner Bearing DRIVEN PULLEY FACE 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.
Page 147 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Drive in a new needle bearing into the driven face with the mark facing up. 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.
Page 148 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY VITALITY 50 Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 39mm drive plate nut. Tighten the 39mm nut to the specified torque.
Page 149: Final Reduction
VITALITY 50 . FINAL REDUCTION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION ..............10-2 TROUBLESHOOTING ............... 10-2 FINAL REDUCTION DISASSEMBLY ..........10-3 FINAL REDUCTION INSPECTION..........10-3 FINAL REDUCTION ASSEMBLY............ 10-6 10-0...
Page 150 . FINAL REDUCTION VITALITY 50 10-1...
Page 151: Final Reduction
VITALITY 50 . FINAL REDUCTION SERVICE INFORMATION • 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 & bearing install...
Page 152: Final Reduction Disassembly
. FINAL REDUCTION VITALITY 50 Bolts FINAL REDUCTION DISAS-SEMBLY Remove the rear wheel. ( 15-3) Remove the left crankcase cover. ( 9 -3) Remove the clutch/driven pulley. ( 9-12) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.
Page 153 VITALITY 50 . FINAL REDUCTION 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.
Page 154 . FINAL REDUCTION VITALITY 50 BEARING REPLACEMENT (Transmission Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Special Universal bearing puller E037 Bearing Remover Set Drive Shaft Bearing Drive new bearings into the transmission case cover.
Page 155: Final Reduction Assembly
VITALITY 50 . FINAL REDUCTION Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Special Oil seal & bearing install E014 Bearing Outer Driver Drive Shaft FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase.
Page 156 . 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.
Page 157 VITALITY 50 . FINAL REDUCTION Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil. ( 3-5) • Place the motorcycle on its main stand on level ground. • Check the sealing washer for wear or damage.
Page 158: Crankcase/Crankshaft
VITALITY 50 . CRANKCASE/CRANKSHAFT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION ..............11- 3 CRANKCASE/CRANKSHAFT (2-STROKE) ........11- 4 CRANKCASE/CRANKSHAFT (4-STROKE) ........11-10 11-0...
Page 159 . CRANKCASE/CRANKSHAFT VITALITY 50 (2-STROKE) Torque: 0.8 1.2kg-m 11-1...
Page 160 VITALITY 50 . CRANKCASE/CRANKSHAFT (4-STDROKE) 11-2...
Page 161 . CRANKCASE/CRANKSHAFT VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( Chapter 6 (2-stroke)) −Cylinder/piston ( Chapter 7)
Page 162 VITALITY 50 . CRANKCASE/CRANKSHAFT CRANKCASE/CRANKSHAFT (2-STROKE) SEPARATION Remove the crankcase attaching bolts. Bolt Crankcase Puller Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Special Crankcase puller E026 CRANKSHAFT REMOVAL Attach the crankcase puller on the left...
Page 163 . CRANKCASE/CRANKSHAFT VITALITY 50 Remove the remaining bearing on the crankshaft side using the universal bearing puller. When separating the crankcase, the oil seals must be removed. Replace the oil seals with new ones. Special Crankshaft bearing puller E030 Universal Bearing Puller...
Page 164 VITALITY 50 . CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit 0.150mm 0.100mm replace if over replace if over Check the crankshaft bearings for excessive Play play. The bearings must be replaced if they Play are noisy or have excessive play.
Page 165 . CRANKCASE/CRANKSHAFT VITALITY 50 Bearing Outer Driver Handle A Drive a new crankshaft bearing into the right crankcase. Special Oil seal & 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.
Page 166 VITALITY 50 . CRANKCASE/CRANKSHAFT Dowel Pins ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Assemble the crankcase halves. Special Crankcase assembly tool E024 Crankcase Assembly Tool Crankcase Assembly Tool 11-8...
Page 167 . CRANKCASE/CRANKSHAFT VITALITY 50 Install and tighten the crankcase bolts in a crisscross pattern in several steps. After assembly, check the crankshaft for smooth operation. Bolt 11-9...
Page 168 VITALITY 50 . CRANKCASE/CRANKSHAFT 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.
Page 169 . CRANKCASE/CRANKSHAFT VITALITY 50 Crankshaft Remove the crankshaft from the left crankcase. Dowel Pins Remove the cam chain. Remove the gasket and dowel pins. Gasket Cam Chain Clean off all gasket material from the crankcase mating surfaces. Avoid damaging the crankcase mating surfaces.
Page 170 VITALITY 50 . CRANKCASE/CRANKSHAFT 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). Out of specification (0.05 ~ 0.4 mm) → Replace the crankshaft.
Page 171 . 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.
Page 172: Carburetor
VITALITY 50 . CARBURETOR __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CARBURETOR __________________________________________________________________________________ SERVICE INFORMATION (2-STROKE).......... 12- 2 SERVICE INFORMATION (4-STROKE).......... 12- 3 THROTTLE VALVE (2-STROKE) ............ 12- 5 CARBURETOR (2-STROKE)............. 12- 7 AIR SCREW ADJUSTMENT (2-STROKE) ........12-13 REED VALVE (2-STROKE)............... 12-14 CARBURETOR (4-STROKE).............
Page 173 . CARBURETOR VITALITY 50 12-1...
Page 174: Carburetor
VITALITY 50 . CARBURETOR 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.
Page 175: Service Information (4-Stroke)
. CARBURETOR VITALITY 50 SERVICE INFORMATION (4-STROKE) GENERAL INSTRUCTIONS 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. Be sure to work in a well-ventilated area.
Page 176 VITALITY 50 . CARBURETOR TROUBLESHOOTING Engine is hard to start Misfiring during acceleration • No spark at plug ( Section 16) • Faulty ignition system • Compression too low • Lean mixture • No fuel to carburetor • Faulty accelerating pump −Clogged fuel filter...
Page 177: Throttle Valve (2-Stroke)
. CARBURETOR VITALITY 50 THROTTLE VALVE (2-STROKE) DISASSEMBLY Remove the met-in box. ( 13-5) Remove the center cover and spark plug cover. ( 13-6) Loosen the carburetor top and remove the throttle valve. Carburetor Top Throttle Valve Disconnect the throttle cable from the throttle valve.
Page 178 VITALITY 50 . CARBURETOR Remove the jet needle by removing the needle clip. Needle Clip Check the jet needle and throttle valve for wear or damage. Needle Retainer 2nd Notch (STD) Jet Needle Throttle Valve Carburetor Top Rubber Seal THROTTLE VALVE INSTALLATION Install the jet needle on the throttle valve and secure with the needle clip.
Page 179 . CARBURETOR VITALITY 50 Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw. Carburetor Top Tighten the carburetor top. After installation, perform the following adjustments and inspections. • Throttle cable free play ( 3-16) •...
Page 180 VITALITY 50 . CARBURETOR Remove the two carburetor lock nuts. Remove the carburetor and carburetor insulator. Nuts AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5Ω (10 minutes minimum after stopping the engine) If the resistance exceeds 5Ω, replace the...
Page 181 . CARBURETOR VITALITY 50 Connect the 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 and blow the hose with mouth.
Page 182 VITALITY 50 . CARBURETOR 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.
Page 183 . CARBURETOR VITALITY 50 Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
Page 184 VITALITY 50 . CARBURETOR Needle Jet holder Main Jet 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.
Page 185: Air Screw Adjustment (2-Stroke)
. 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 the intake manifold and tighten the two lock nuts.
Page 186: Reed Valve (2-Stroke)
VITALITY 50 . CARBURETOR Bolts REED VALVE (2-STROKE) REMOVAL Remove the rear body cover. ( 13-6) Disconnect the fuel vacuum tube. ( 5-2) Remove oil pump control cable plate. ( 4-3) Remove carburetor. ( 12-7) Remove the three intake manifold bolts and gasket.
Page 187: Carburetor (4-Stroke)
. CARBURETOR VITALITY 50 Auto Bystarter Wire CARBURETOR (4-STROKE) REMOVAL Remove the met-in box. ( 13-5) Disconnect the auto bystarter connector. Disconnect the fuel tube from carburetor. Fuel Tube Lock Nut Throttle Cable Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor.
Page 188 VITALITY 50 . CARBURETOR Band Screws Loosen the air cleaner connecting tube 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.
Page 189 . CARBURETOR VITALITY 50 Vacuum Piston Spring Remove the compression spring and vacuum piston. Vacuum Piston Remove the needle holder, spring and jet needle from the piston. • Be careful not to damage the vacuum piston diaphragm. VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage.
Page 190 VITALITY 50 . CARBURETOR 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 • Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns.
Page 191 . CARBURETOR VITALITY 50 Main Jet/Needle Jet Holder/Needle Jet Remove the main jet, needle jet holder and needle jet. Remove the slow jet. Slow Jet Spring Washer O-ring Slow Jet Clean the removed the main jet, needle jet holder, needle jet and slow jet with detergent oil.
Page 192 VITALITY 50 . CARBURETOR AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10Ω (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.
Page 193 . CARBURETOR VITALITY 50 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle Bystarter Valve Screws Screws AIR CUT-OFF VALVE (A.C.V.)
Page 194 VITALITY 50 . CARBURETOR CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body. • Make sure that no fuel jet is clogged. Spring Cut-off Valve Cover Install the O-ring onto the air-cut-off valve body securely. • Install the O-ring with the flat face toward the valve body side.
Page 195 . CARBURETOR VITALITY 50 Screws ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. Spring Cover INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration. Replace if necessary.
Page 196 VITALITY 50 . CARBURETOR Main 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. • Be sure to record the rotating turns when it is removed.
Page 197 . 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.
Page 198 VITALITY 50 . CARBURETOR 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. Lock Nut Throttle Cable Connect the throttle cable to the carburetor.
Page 199 . CARBURETOR VITALITY 50 Auto Bystarter Wire Connect the auto bystarter connector. Perform the following inspections and adjustments: •Throttle grip free play ( 3-16) •Idle speed ( 3-10) Idle Speed: 1800±100rpm Install the met-in box. ( 13 -5) 12-27...
Page 200: Fuel Tank
VITALITY 50 . CARBURETOR FUEL TANK REMOVAL Remove the rear body cover. ( 13-6) Disconnect the fuel tube and vacuum tube at the auto fuel valve. Fuel Tube Vacuum Tube Nuts Bolts Disconnect the fuel unit wire connector. Remove the three nuts and remove retainer plate.
Page 201: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER VITALITY 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER __________________________________________________________________________________ SERVICE INFORMATION ..............13- 1 FRAME COVERS REMOVAL............13- 2 EXHAUST MUFFLER ................ 13- 10 13-0...
Page 202 . FRAME COVERS/EXHAUST MUFFLER VITALITY 50 SERVICE INFORMATION • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. Items Related for Removal • Handlebar front cover Handlebar rear cover •...
Page 203 . 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.
Page 204: Frame Covers
. FRAME COVERS HANDLEBAR REAR COVER REMOVAL/INSTALLATION Remove the handlebar 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.
Page 205 . 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.
Page 206 . FRAME COVERS REAR 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.
Page 207 . FRAME COVERS/EXHAUST MUFFLER VITALITY 50 CENTER COVER REMOVAL/INSTALLATION Remove the met-in box. ( 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.
Page 208 . FRAME COVERS REAR UPPER FENDER & TAILLIGHT REMOVAL/INSTALLATION Remove the following: Met-in box ( 13-5) Rear carrier ( 13-5) Center cover ( 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).
Page 209 . 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 ( 13-5) Right and left side cover ( 13-4)
Page 210 . FRAME COVERS LEG SHIELD REMOVAL/INSTALLATION Remove the following: Rear carrier ( 13-5) Right and left side cover ( 13-4) Met-in box ( 13-5) Center cover ( 13-6) Rear body cover ( 13-6) Battery cover ( 16-5) Battery ( 16-5) Fuse ( 16-5) Floor board ( 13-8) Remove the ten screws and one bolt from the...
Page 211 . FRAME COVERS/EXHAUST MUFFLER VITALITY 50 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.
Page 212 . FRAME COVERS Inspect the gasket (1). If the exhaust gas leaks, the gasket should be replaced. Installation is 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: 3.0 3.6kgf-m exhaust pipe joint lock nuts: 1.0 1.4kgf-m...
Page 213: Steering Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Front Fork
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SERVICE INFORMATION ..............14- 2 TROUBLESHOOTING ............... 14- 2 STEERING HANDLEBAR ..............14- 3 FRONT WHEEL .................. 14- 5 HYDRAULIC BRAKE ................
Page 214 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK VITALITY 50 5.0~6.0kgf-m 6.0~8.0kgf-m 0.5~1.3kgf-m 3.0~3.6kgf-m 2.9~3.5kgf-m 5.0~7.0kgf-m 14-1...
Page 215: Service Information
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION SPECIFICATIONS Item Standard (mm) Service Limit (mm) Axle shaft runout  Radial  Front wheel rim runout Axial  Front shock absorber spring free length 214.7 Brake disk thickness Brake disk runout 0.30...
Page 216: Steering Handlebar
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinder Bolts STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 13-3) Remove front body cover. ( 13-9) Remove two bolts attaching the left brake lever holder.
Page 217 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolt Handlebar INSTALLATION Install the handlebar and tighten the handlebar lock nut. Torque: 5.0 6.0kg-m Lubricate the throttle cable front end with grease. Install the throttle grip and connect the throttle cable.
Page 218: Front Wheel
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Speedometer Cable FRONT WHEEL 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.
Page 219 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Turn the wheel bearings and replace them if Play they have excessive play or noise. Play Axial Radial Dust Seal DISASSEMBLY Remove the dust seal. Bearing Remover Remove the wheel bearings and distance collar.
Page 220 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Grease 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.
Page 221: Hydraulic Brake
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Axle Bolt FRONT WHEEL INSTALLATION (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.
Page 222 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 223 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinder Bolts BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system. • When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid.
Page 224 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 lst and 2nd rubber cups for wear.
Page 225 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT 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.
Page 226 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Disassembly Remove the brake caliper seat from the brake caliper. Brake Caliper Seat Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet...
Page 227 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 228 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Installation Install the brake caliper and tighten the two bolts. Torque: 2.9 3.5kgf-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 3.0 4.0kgf-m...
Page 229: Front Shock Absorber
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Mount Bolt FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. ( 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.
Page 230: Front Fork
STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 231 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 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.
Page 232 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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. ( 13-9) Install the front wheel.
Page 233 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT 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.
Page 234 STEERING HANDLEBAR/FRONT WHEEL/FRONT VITALITY 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 235: Rear Wheel/Rear Brake/Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER __________________________________________________________________________________ SERVICE INFORMATION ..............15-2 TROUBLESHOOTING ............... 15-2 REAR WHEEL..................15-3 REAR BRAKE ..................15-4 REAR SHOCK ABSORBER............... 15-6 15-0...
Page 236 . REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER 3.5~4.5kgf-m 2.4~3.0kgf-m 1.0~1.4kgf-m 3.0~3.6kgf-m 1.0~1.4kgf-m 11.0~13.0kgf-m 15-1...
Page 237: Service Information
. REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Standard (mm) Service Limit (mm) Item Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11.0 13.0kgf-m...
Page 238: Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER Rear Axle Nut REAR WHEEL REMOVAL Remove the exhaust muffler. ( Ö 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...
Page 239: Rear Brake
. REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER REAR BRAKE Remove the rear wheel. ( Ö 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.
Page 240 . REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER Brake Arm Bolt Wear Indicator Plate Remove the brake cam bolt to remove the brake arm, wear indicator plate and felt seal. Remove the brake arm. Brake Arm Brake Cam Grease REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
Page 241: Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR VITALITY 50 SHOCK ABSORBER Brake Cable Brake Arm Install the brake arm pin. Connect the brake cable and install the adjusting nut. Install the rear wheel. ( Ö 15-3) Adjust the rear brake lever free play.
Page 242 . ELECTRICAL EQUIPMENT VITALITY 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ELECTRICAL EQUIPMENT __________________________________________________________________________________ SERVICE INFORMATION ..............16- 1 TROUBLESHOOTING ............... 16- 1 CHARGING SYSTEM ................ 16- 3 BATTERY.................... 16- 5 IGNITION SYSTEM ................16-11 ELECTRIC STARTER ................ 16-17 16-0...
Page 243: Service Information
. ELECTRICAL EQUIPMENT VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • It is not necessary to check the battery electrolyte or fill with distilled water. • 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..
Page 244 . ELECTRICAL EQUIPMENT VITALITY 50 IGNITION SYSTEM No spark at plug Engine starts but turns poorly • Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil —Between A.C. generator and CDI unit —Poorly connected wire or connector...
Page 245 . ELECTRICAL EQUIPMENT VITALITY 50 CHARGING SYSTEM (2-STROKE) Regulator/Rectifier Resistor Battery (-) Cable A.C. Generator Fuse 7A Battery (+) Cable Light Switch Resistor 5.9 /30W 16-3...
Page 246 . ELECTRICAL EQUIPMENT VITALITY 50 CHARGING SYSTEM (4-STROKE) Regulator/Rectifier Resistor Battery (-) Cable A.C. Generator Fuse 7A Battery (+) Cable Light Switch Resistor 7.5 /30W 16-4...
Page 247: Battery
. ELECTRICAL EQUIPMENT VITALITY 50 BATTERY 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).
Page 248 . 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 : 13.0V～13.2V Undercharged : 12.3V max. CHARGING METHOD Connect the charger positive (+) cable to the battery positive (+) cable.
Page 249 . 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.
Page 250 . ELECTRICAL EQUIPMENT 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 battery.
Page 251 . ELECTRICAL EQUIPMENT VITALITY 50 Resistance (4-Stroke): Charging coil white– ground 0.9Ω Lighting coil yellow– ground 0.7Ω Refer to 8 section for A.C. generator removal. A.C. Generator Connector Resister B RESISTOR INSPECTION Remove the frame front cover. ( 13-4) Measure the resistance between the resistor B pink wire and ground.
Page 252 . ELECTRICAL EQUIPMENT VITALITY 50 Regulator/Rectifier REGULATOR/RECTIFIER 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.
Page 253: Ignition System
. ELECTRICAL EQUIPMENT VITALITY 50 IGNITION SYSTEM (2-STROKE) C.D.I Unit Ignition Coil Spark Plug Ignition Switch A.C. Generator (Exciter Coil)/ Pulser Coil 16-11...
Page 254 . ELECTRICAL EQUIPMENT VITALITY 50 IGNITION SYSTEM (4-STROKE) C.D.I Unit Ignition Coil Spark Plug Ignition Switch A.C. Generator (Exciter Coil)/ Pulser Coil 16-12...
Page 255 . 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. ( 13-5) Measure the resistance between the ignition coil primary coil terminals. Resistance (20～): 2-Stroke: 0.153～0.187Ω...
Page 256 . 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 spark from the watch window.
Page 257 . ELECTRICAL EQUIPMENT VITALITY 50 CDI UNIT INSPECTION Remove the met-in box. ( 13-5) Disconnect the CDI coupler and remove the CDI unit. CDI CIRCUIT INSPECTION Measure the resistance between the terminals. CDI Unit Replace the CDI unit if the readings are not within the specifications in the table below.
Page 258 . ELECTRICAL EQUIPMENT VITALITY 50 Black/ Blue Green (4-Stroke) Unit: Ω Probe⊕ Black/ Black/ Blue/ Green Blue Yellow Yellow (-)Probe Black/ ∞ ∞ ∞ Blue Black/ 9.2M-9.25 310K-320 310K-320 Yellow Blue/ 8.81M-8.8 310K-320 Yellow 8.86M-8.8 310K-320 Green Black/ Yellow Blue/ Yellow...
Page 259: Electrical Equipment
. ELECTRICAL EQUIPMENT VITALITY 50 ELECTRIC STARTER Starter Relay Starter Motor 16-17...
Page 260 . ELECTRICAL EQUIPMENT VITALITY 50 STARTER RELAY INSPECTION Starter Relay Remove the met-in box. ( 13-5) Disconnect the starter relay coupler and then remove the starter relay. Connect the starter relay green/yellow Starter Relay (2-Stroke) Yellow/Red terminal to the 12V battery positive (+) terminal and the relay yellow/red terminal to the battery negative (-) terminal.
Page 261 . ELECTRICAL EQUIPMENT VITALITY 50 Bolts STARTER MOTOR REMOVAL Disconnect the starter 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.
Page 262 . ELECTRICAL EQUIPMENT VITALITY 50 Starter Pinion 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 Shaft Forcing Parts Inspect the starter pinion seat for wear.
Page 263 . ELECTRICAL EQUIPMENT VITALITY 50 16-21...
Page 264: Instrument/Switches/Lights
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSTRUMENT/SWITCHES/LIGHTS __________________________________________________________________________________ SERVICE INFORMATION ..............17-1 TROUBLESHOOTING ............... 17-1 FUEL UNIT..................17-2 OIL METER ..................17-3 SWITCHES ..................17-4 BULB REPLACEMENT ..............17-7 INSTRUMENT/HEADLIGHT ............17-8 17-0...
Page 265: Instrument/Switches/Lights
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Wires should be connected to other wires of the same color. Connector must be connected to other couplers of the same color. • All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
Page 266: Fuel Unit
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 Fuel Unit FUEL UNIT No Smoking! REMOVAL Remove the met-in box. ( 13-5) Disconnect the fuel unit wire connectors. Remove the three bolts attaching from the fuel unit retainer . Do not damage the fuel unit wire.
Page 267: Oil Meter
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 Flange INSTALLATION The installation sequence is the reverse of removal. • Align the groove on the fuel unit with the flange on the fuel tank. Groove OIL METER (2-STROKE) INSPECTION Remove the rear body cover. ( 13-6)
Page 268: Switches
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 Oil 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 340Ω Before performing the following test, operate the turn signals to determine that the battery circuit is normal.
Page 269 . INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 HEADLIGHT SWITCH INSPECTION Remove the handlebar front cover. ( 13-2) Disconnect the headlight switch wire coupler and check for continuity between wire terminals. Color Yellow Pink Brown Blue/White Brown/white Symbol ○ ○ ○ ○ ○ ○...
Page 270 . INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 STARTER SWITCH INSPECTION Check for continuity between wire terminals. Push the starter button when measuring. Color Yellow/Red Green Symbol FREE PUSH ○ ○ Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals. Push the horn button when measuring.
Page 271: Bulb Replacement
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 BULB REPLACEMENT FRONT TURN SIGNAL 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.
Page 272: Instrument/Headlight
. INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 Bulb Sockets INSTRUMENT/HEADLIGHT Instrument Bulbs Replacement Remove the handlebar rear cover. ( 13-3) Remove the front body cover. ( 13-9) Remove the bulbs and replace with new ones. Instrument Connectors Instrument INSTRUMENT REMOVAL Remove the handlebar rear cover. ( 13-3) Disconnect the speedometer cable.
Page 273 . INSTRUMENT/SWITCHES/LIGHTS VITALITY 50 HEADLIGHT BULB REPLACEMENT Remove the front body cover. ( 13-6) Pull off the socket without turning. Remove the dust cover. Bulb Socket Dust Cover Bulb Remove the bulb while pressing down on the pin. Pull out the bulb without turning.
Page 274: Kcas (For Euro 2)
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.
Page 275 SPECIFICATIONS 4-STROKE 18-1...

KYMCO VITALITY 50 Manual

1. Specifications 1 1

. Inspection/Adjustment 3

. Lubrication System 4

. Engine Removal/Installation 5

6 4-Stroke: Cylinder Head/Valves

Cylinder/Piston 7 7

Kick Starter/Drive Pulley/ Clutch/Driven Pulley

. Final Reduction 10

. Carburetor 12

Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

Rear Wheel/Rear Brake/Rear Shock Absorber

16. Electrical Equipment

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Chapters

Troubleshooting

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Summary of Contents for KYMCO VITALITY 50

Table of Contents