KYMCO Active 50 Manuals

Manuals and User Guides for KYMCO Active 50. We have 1 KYMCO Active 50 manual available for free PDF download: Service Manual

KYMCO Active 50 Service Manual

KYMCO Active 50 Service Manual (193 pages)

Kymco Active 50 Motorcycle Service manual

Brand: KYMCO | Category: Motorcycle | Size: 7.13 MB

Table of Contents

Preface

1
- Table of Contents
  1
- General Information
  2
- Engine Serial Number
  3
- General Information
  3
- Specifications
  4
- Service Precautions
  5
- Torque Values
  13
- Special Tools
  14
- Lubrication Points
  15
- Cable & Harness Routing
  16
- Wiring Diagram
  18
- Inspection/Adjustment
  19
- Troubleshooting
  19
2. Inspection/Adjustment

25
- Inspection/Adjustment
  26
- Service Information
  26
- Maintenance Schedule
  27
- Fuel Line/Filter
  28
- Throttle Operation/Choke
  28
- Air Cleaner
  29
- Spark Plug
  29
- Carburetor Idle Speed
  30
- Valve Clearance
  30
- Cylinder Compression
  31
- Ignition Timing
  31
- Drive Chain
  32
- Engine Oil
  32
- Brake Fluid
  33
- Brake Shoe
  33
- Clutch
  33
- Nuts/Bolts/Fasteners
  34
- Suspension
  34
- Wheels/Tires
  34
- Steering Handlebar
  35
3. Lubrication System

36
- Lubrication System
  36
  - Lubrication System
    38
  - Service Information
    38
  - Troubleshooting
    38
  - Engine Oil/Oil Filter
    39
  - Oil Pump/Oil Filter Rotor
    40
4. Fuel System

43
- Fuel System
  43
  - Fuel System
    45
  - Service Information
    45
  - Troubleshooting
    46
  - Air Cleaner Removal
    47
  - Throttle Valve Disassembly
    48
  - Throttle Valve Installation
    49
  - Carburetor Removal
    50
    
    Carburetor Installation
    53
    
    Fuel Tank Installation
    54
- Engine Removal/Installation
  55
  - Engine Installation
    58
6 Cylinder Head/Valves

59
- Schematic Drawing
  60
- Service Information
  61
- Troubleshooting
  62
- Cylinder Head Removal
  63
- Cylinder Head Disassembly
  64
- Cylinder Head Assembly
  67
- Cylinder Head Installation
  68
- Cylinder Head/Valves
  69
7. Cylinder/Piston

71
- Cylinder/Piston
  71
  - Schematic Drawing
    72
  - Service Information
    73
  - Troubleshooting
    73
  - Cylinder Removal
    74
  - Piston Removal
    75
  - Piston Installation
    77
  - Cylinder Installation
    77
Alternator/Starter Clutch/ Cam Chain Tensioner

79
- Service Information
  81
- Troubleshooting
  81
  - Cam Chain Tensioner
    81
- Alternator Removal
  82
- Cam Chain Trnsioner
  83
- Starter Clutch Removal
  83
- Tensioner Spring and Push Rod
  84
- Starter Clutch Installation
  85
9. Clutch/Gear Shift Mechanism

88
Starter/Transmission 10

101
- Service Information
  103
- Troubleshooting
  104
- Alterantor/Cam Chain Tensioner
  105
- Clutch/Gear Shift Mechanism
  105
  - Crankcase Removal
    105
  - Crankshaft/Kick Starter
    106
- Crankcase/Crankshaft/Kick Starter/Transmission
  107
  - Transmission
    108
  - Crankcase Bearing Replacement
    111
  - Crankcase Installation
    112
Front Wheel/Suspension/Steering

114
- Front Wheel/Suspension/Steering
  116
- Troubleshooting
  117
- Handlebar
  118
- Front Wheel
  120
- Front Shock Absorber
  124
- Steering Stem
  129
- Front Wheel/Suspension/ Steering
  130
- Rear Wheel/Brake/Suspension
  133
  - Rear Brake
    140
13. Hydraulic Brake

146
- Hydraulic Brake
  146
  - Hydraulic Brake
    148
  - Service Information
    148
  - Troubleshooting
    149
  - Brake Fluid Change/Air Bleed
    150
  - Brake Pad/Disk
    151
  - Brake Master Cylinder
    152
  - Brake Caliper
    155
- Frame Cover
  160
15. Ignition System

165
- Ignition System
  165
  - Ignition System
    167
  - Service Information
    167
  - Troubleshooting
    168
  - Ignition Coil
    169
  - CDI Unit
    170
16. Charging System

172
- Charging System
  172
- Charging System
  174
- Service Information
  174
- Troubleshooting
  175
- Battery
  176
- A.C. Generator
  177
- Performance Test
  177
- Regulator/Rectifier
  178
- Starting System
  179
  - Starting System
    181
  - Service Information
    181
  - Troubleshooting
    181
  - Starter Motor
    182
  - Starter Relay
    184
- Lights/Instruments/Switches/ Horn/Fuel Unit
  185
  - Service Information
    186
  - Troubleshooting
    186
  - Turn Signal Light
    186
  - Stop Light/Tail Light
    186
  - Fuel Unit
    186
  - Ignition Switch
    188
  - Handlebar Switches
    190

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