PREFACE

TABLE OF CONTENTS
This Service Manual describes the GENERAL INFORMATION 1
technical features and servicing
procedures for the KYMCO FILLY 50. FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
Section 1 contains the precautions for all
LUBRICATION SYSTEM 4
operations stated in this manual. Read
them carefully before starting any FUEL SYSTEM 5

ENGINE
operation. ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
Section 2 is the removal/installation
procedures for the frame covers which CYLINDER/PISTON 8
are subject to higher removal/installation DRIVE AND DRIVEN PULLEYS/KICK
frequency during maintenance and STARTER 9
servicing operations. FINAL REDUCTION 10

Section 3 describes the inspection/ CRANKCASE/CRANKSHAFT 11

CHASSIS

adjustment procedures, safety rules and FRONT WHEEL/FRONT BRAKE/ 12

service information for each part, starting FRONT SUSPENSION
from periodic maintenance. REAR WHEEL /REAR BRAKE /REAR 13
SUSPENSION
Sections 6 through 18 give instructions BATTERY/CHARGING SYSTEM/A.C. 14
EQUIPMENT
ELECTRICAL

for disassembly, assembly and inspection GENERATOR

of engine, chassis frame and electrical IGNITION SYSTEM 15
equipment. STARTING SYSTEM 16

Most sections start with an assembly or INSTRUMENTS/SWITCHES/LIGHTS 17

system illustration and troubleshooting
for the section. The subsequent pages EVAPORATIVE EMISSION CONTROL 18
CONTROL
EMISSION

give detailed procedures for the section. SYSTEM

EXHAUST EMISSION CONTROL 18
The information and contents included SYSTEM
in this manual may be different from
the motorcycle in case specifications
are changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
1. GENERAL INFORMATION

1
ENGINE SERIAL NUMBER ..............................1- 1
SPECIFICATION ...................................................1- 2
LUBRICATION POINTS..................................1-13
CABLE & HARNESS ROUTING..........................1-15
1
SERVICE PRECAUTIONS ...................................1- 3 WIRING DIAGRAM ...........................................1-20
TORQUE VALUES................................................1- 11 TROUBLESHOOTING........................................1-21
SPECIAL TOOLS ..................................................1-12

ENGINE SERIAL NUMBER

Location of Engine Serial Number

1-1
1. GENERAL INFORMATION
SPECIFICATIONS
Motorcycle Name & Type Air cleaner type & No Paper element, wet
Name & Model No. SD10AA Fuel capacity 6.2 liter

Fuel System
Overall length (mm) 1660 Type CVK

Carburetor
Overall width (mm) 680 Piston dia. (mm)
Overall height (mm) 1070 Venturi dia.(mm) φ18 equivalent
Wheel base (mm) 1195 Throttle type Butterfly type
Engine type O.H.C. Type CDI

Electrical Equipment

Ignition System
Displacement 49.5cc Ignition timing 15±2°BTDC/1700rpm
Fuel Used 92# nonleaded gasoline Contact breaker Non-contact point type
Front wheel 33
Net weight (kg) Rear wheel 46 Spark plug NGK ND
Total 79 C7HSA U22FS-U
Front wheel 32
Gross weight(kg) Rear wheel 52 Spark plug gap 0.6 0.7mm
Total 84 Battery Capacity 12V4AH
Front wheel 90/90-10 50J Clutch Type Dry multi-disc clutch
Power Drive System

Tires
sion Gear Gear
Transmis- Reduction
Rear wheel 90/90-10 50J Type Non-stage transmission
Ground clearance (mm) 100 Automatic centrifugal
Operation
4.4 (Initial speed type
Perform- Braking distance (m) 30km/h)
ance Min. turning radius (m) 1.6 Type Two-stage reduction
Starting motor & Reduction 1st 10.85 3.0
Starting system kick starter ratio 2nd 11.05
Type Gasoline, 4-stroke
Front Caster angle 26.5°
Cylinder arrangement Single cylinder
Moving Device

Combustion chamber type Semi-sphere

Axle Trail length ⎯
Valve arrangement O.H.C. Tire pressure Front 1.75
(kg/cm²) Rear 2.25
Bore x stroke (mm) φ39 x 41.4
Compression ratio 10.5 Turning Left 45°
Compression pressure angle Right 45°
(kg/cm²-rpm) 14−600
Brake system Front Drum (110mm) brake
Max. output (ps/rpm) 4.0/8000 type Rear Drum (110mm) brake
Engine

Max. torque (kg m/rpm) 1.04/6000

Suspension type Front Telescope
Device
Damping

Intake Open 0° BTDC

Rear Unit Swing
Port (1mm) Close 34° ABDC
timing Exhaust Open Shock absorber Front Telescope
32° BBDC type
(1mm) Rear Unit Swing
Close 0° TDC
Frame type Under bone
Valve clearance Intake 0.10
(cold) (mm) Exhaust 0.10
Idle speed (rpm) 1700rpm
Lubrication type Forced pressure &
System
Lubrication

wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.9 liter

Cooling Type Forced air cooling

1-2
1. GENERAL INFORMATION

SERVICE PRECAUTIONS
„ Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when reassembling.

„ When tightening bolts or nuts, begin with larger-

diameter to smaller ones at several times, and
tighten to the specified torque diagonally.

„ Use genuine parts and lubricants.

„ When servicing the motorcycle, be sure to use

special tools for removal and installation.

„ After disassembly, clean removed parts. Lubricate

sliding surfaces with engine oil before
reassembly.

„ Apply or add designated greases and lubricants to

1-3
1. GENERAL INFORMATION
the specified lubrication points.

„ After reassembly, check all parts for proper

tightening and operation.

„ When two persons work together, pay attention to

the mutual working safety.

„ Disconnect the battery negative (-) terminal before

operation.
„ When using a spanner or other tools, make sure
not to damage the motorcycle surface.

„ After operation, check all connecting points,

fasteners, and lines for proper connection and
installation.
„ When connecting the battery, the positive (+)
terminal must be connected first.
„ After connection, apply grease to the battery
terminals.
„ Terminal caps shall be installed securely.

„ If the fuse is burned out, find the cause and repair

it. Replace it with a new one according to the
specified capacity.

1-4
1. GENERAL INFORMATION

„ After operation, terminal caps shall be installed

securely.

„ When taking out the connector, the lock on the

connector shall be released before operation.

„ Hold the connector body when connecting or

disconnecting it.
„ Do not pull the connector wire.

„ Check if any connector terminal is bending,

protruding or loose.

Confirm „ The connector shall be inserted completely.

Capacity „ If the double connector has a lock, lock it at
the correct position.

1-5
1. GENERAL INFORMATION
„ Check if there is any loose wire.

„ Before connecting a terminal, check for

damaged terminal cover or loose negative
terminal.

„ Check the double connector cover for proper

coverage and installation.

„ Insert the terminal completely.

„ Check the terminal cover for proper coverage.
„ Do not make the terminal cover opening face up.

„ Secure wire harnesses to the frame with their

respective wire bands at the designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.

„ After clamping, check each wire to make sure it is

secure.
Snapping!

1-6
1. GENERAL INFORMATION

„ Do not squeeze wires against the weld or its

clamp.

„ After clamping, check each harness to make sure

that it is not interfering with any moving or
sliding parts.

„ When fixing the wire harnesses, do not make it

contact the parts which will generate high heat.
No Contact !

„ Route wire harnesses to avoid sharp edges or

corners. Avoid the projected ends of bolts and
screws.
„ Route wire harnesses passing through the side of
bolts and screws. Avoid the projected ends of
bolts and screws.

„ Route harnesses so they are neither pulled

tight nor have excessive slack.

1-7
1. GENERAL INFORMATION
„ Protect wires and harnesses with electrical tape or
tube if they contact a sharp edge or corner.

„ When rubber protecting cover is used to protect

the wire harnesses, it shall be installed securely.

„ Do not break the sheath of wire.

„ If a wire or harness is with a broken sheath, repair
by wrapping it with protective tape or replace it.

Do not press or
„ When installing other parts, do not press or squeeze the wire.
squeeze the wires.

Do not pull „ After routing, check that the wire harnesses are
too tight! not twisted or kinked.

1-8
1. GENERAL INFORMATION
„ Wire harnesses routed along with handlebar
should not be pulled tight, have excessive slack or
interfere with adjacent or surrounding parts in all
steering positions.

Do you understand
the instrument? Is
the instrument set
correctly?
„ When a testing device is used, make sure to
understand the operating methods thoroughly and
operate according to the operating instructions.

„ Be careful not to drop any parts.

Remove Rust !
„ When rust is found on a terminal, remove the rust
with sand paper or equivalent before connecting.

„ Do not bend or twist control cables. Damaged

control cables will not operate smoothly and may
stick or bind.

„ Symbols:
The following symbols represent the servicing
methods and cautions included in this service
manual.

: Apply engine oil to the specified

points. (Use designated engine
Engine Oil oil for lubrication.)

1-9
1. GENERAL INFORMATION

Grease : Apply grease for lubrication.

: Transmission Gear Oil (90#)

Gear Oil

Special : Use special tool.

: Caution

: Warning

(Ö12-3) : Refer to page 12-3.

TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut 0.5 5mm screw 0.4

1-10
1. GENERAL INFORMATION
6mm bolt, nut 1.0 6mm screw, SH bolt 0.9
8mm bolt, nut 2.2 6mm flange bolt, nut 1.2
10mm bolt, nut 3.5 8mm flange bolt, nut 2.7
12mm bolt, nut 5.5 10mm flange bolt, nut 4.0

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Cylinder head bolt A 2 8 0.9 Double end bolt

Cylinder head bolt B 4 8 0.9
Oil filter screen cap 1 30 1.5
Exhaust muffler lock bolt 2 6 3.5 Double end bolt
Cylinder head flange nut 4 8 2.0 Apply oil to threads
Valve adjusting lock nut 2 5 0.9
Cam chain tensioner slipper bolt 1 6 1.0
Oil bolt 1 8 1.3
Clutch outer nut 1 10 5.5
Clutch drive plate nut 1 28 5.5
Starter motor mounting bolt 2 6 1.0
Oil pump bolt 3 6 1.2
Drive face nut 1 10 3.8
Spark plug 1 10 1.2
A.C. generator stator bolt 2 6 0.9
Cam chain tensioner bolt 1 6 0.4

FRAME

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Steering stem lock nut 1 25.4 8.0 12.0 U-nut

Front axle nut 1 10 4.0 5.0 U-nut
Rear axle nut 1 14 8.0 10.0 U-nut
Rear shock absorber upper bolt 1 10 3.0 4.5
Rear shock absorber lower bolt 1 8 2.0 3.0
Speedometer cable set screw 1 5 0.45
Rear shock absorber lock nut 1 8 2.5 Apply locking agent

SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Valve adjuster
Valve guide driver
Valve guide reamer

1-11
1. GENERAL INFORMATION
Valve spring compressor
Lock nut wrench, 39mm
Bearing driver
Bearing driver
Bearing remover, 12mm
Remover set, 12mm
Remove head, 12mm
Remover shaft
Remover weight
Bearing remover, 15mm
Driver set, 15mm
Driver shaft, 15mm
Driver head, 15mm
Driver weight
Bearing driver
Driver handle
Driver weight
Outer extension
Crankshaft assembly tool
Crankshaft assembly collar
Crankshaft assembly shaft
Attachment
Lock nut wrench
Lock nut wrench
Ball race remover extension
Ball race remover
Spring compressor
Spring compressor attachment
Spring compressor attachment
Spring compressor attachment
Lock nut wrench
Driver outer extension
Float level gauge
Valve spring compressor
Valve seat cutter, 24.5mm Seat cutter 45° IN/EX
Valve seat cutter, 25mm Plane cutter 32° IN
Valve seat cutter, 22mm Plane cutter 32° EX
Valve seat cutter, 26mm Plane cutter 60° IN/EX
Cutter clip, 5mm
Universal holder
Outer driver, 32x35mm
Outer driver, 37x40mm
Outer driver, 42x47mm
Pilot, 12mm
Pilot, 15mm
Pilot, 17mm
Pilot, 20mm
Driver handle A
Bearing remover shaft
Bearing remover head, 12mm
Flywheel puller

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

1-12
1. GENERAL INFORMATION
Valve guide/valve stem movable part •Genuine KYMCO Engine Oil (SAE10W-30)
Cam lobes •API−SG Engine Oil
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip

Starter idle gear

Friction spring movable part/shaft movable part High-temperature resistant grease
Shaft movable grooved part
Kick starter spindle movable part

A.C. generator connector

Adhesive
Transmission case breather tube

FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
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.

1-13
1. GENERAL INFORMATION

Engine/ Oil
Grease
Front Brake Cable/ Front Brake Lever
Speedometer Cable/ Pivot
Throttle Cable

Grease
Seat Lock

Engine Oil

Grease Rear Brake Cable

Speedometer Gear/ Front Wheel Grease

Bearings/ Brake Cam/ Anchor Pin /Front
Grease Grease Brake Cam/
Shock Absorber Lower Mount
Main Stand Pivot Rear Wheel Bearings Anchor Pin
Bushings/Pivot

CABLE & HARNESS ROUTING

Front Stop Switch Wire
Rear Stop Switch Wire
Front Brake Cable
Rear Brake Cable

1-14
1. GENERAL INFORMATION

Throttle Cable Speedometer Cable

Headlight Wire
Ignition Switch Connector

Headlight Resistor
Regulator/Rectifier
Auto Bystarter
Resistor
Horn

Winker

1-15
1. GENERAL INFORMATION
Regulator/Rectifier

Wire Harness

Headlight Resistor

Auto Bystarter
Resistor

Throttle Cable

Rear Brake Cable

Speedometer Cable

Front Brake Cable

Starter Relay

CDI Unit
1-16
1. GENERAL INFORMATION

Battery (+) Cable Battery (-) Cable

Battery (-) Cable Battery (+) Cable

Starter Relay Fuse

1-17
1. GENERAL INFORMATION
FCV (Fuel Control
Valve

Fuel Vapor
Purge Control Valve Recovery Tube
/Charcoal Canister

Fuel Tube
Ignition Coil
Primary Wire

Throttle Cable

Ignition Wire

Carburetor
Overflow Tube

Vacuum Tee

Crankcase Breather
Tube

Fuel Unit
Fuel Vapor
Recovery Tube

Fuel Tube Carburetor

Breather Tube

1-18
1. GENERAL INFORMATION

FCV (Fuel Control

Valve

Throttle Cable
Wire Harness

Auto Bystarter Wire

Vacuum Tube

Ignition Coil FCV (Fuel Control

Spark Plug Cap Valve
Wire Harness Vacuum Tube

Purge Control Valve

/Charcoal Canister

Auto Bystarter Starter Motor Wire

Crankcase Breather
Tube

WIRING DIAGRAM
R Red O Orange
B Black P Pink
W White Br Brown
G Green LG Light green
V Violet SB Light blue

1-19
1. GENERAL INFORMATION
L Blue GR Gray
Y Yellow

TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment Probable Cause

1-20
1. GENERAL INFORMATION
Symptom

Check if fuel reaches

carburetor by loosening
drain screw Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Fuel does not Clogged float oil passage
Fuel reaches Clogged fuel tank cap breather
carburetor reach carburetor hole
Clogged fuel filter
Clogged fuel strainer
Remove spark plug and Faulty auto fuel valve
install it into spark plug
cap to test spark by
connecting it to engine Faulty spark plug
ground Fouled spark plug
Faulty CDI unit
Spark jumps Weak or no spark Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted high-tension
wire
Faulty ignition switch
Test cylinder
compression
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Normal Low or no Worn cylinder, piston and piston
compression compression rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Start engine by follow-
ing normal starting
procedure
Faulty auto bystarter
Engine does not Engine fires but Air leaking through intake pipe
fire does not start Incorrect ignition timing
Incorrectly adjusted pilot screw

Remove spark plug and

inspect again

Flooded carburetor
Dry spark plug Wet spark plug Faulty auto bystarter
Throttle valve excessively open

ENGINE LACKS POWER

Inspection/Adjustment Symptom Probable Cause

Start engine and accelerate

lightly for observation Clogged air cleaner
Poor quality fuel (Restricted)
Clogged fuel tank cap breather hole
Engine speed Engine speed does not
increases increase sufficiently 1-21
1. GENERAL INFORMATION
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
Check ignition timing diaphragm
using a timing light Faulty auto fuel valve
Faulty CDI unit
Correct timing Incorrect timing Faulty pulser coil

Check valve clearance

Improper valve clearance
Correct Incorrect adjustment
Worn valve seat (valve stem too
protruding
Test cylinder compression
Improper valve and seat contact
Normal Abnormal Worn cylinder and piston rings
compression compression Leaking cylinder head gasket
Improper valve timing
Check carburetor for
clogging

Not clogged Clogged Clogged carburetor jets

Remove spark plug and

inspect

Plug not fouled or Plug fouled or Fouled spark plug

discolored discolored Incorrect heat range plug
Remove oil dipstick and
check oil level and condition
Incorrect or Oil level too high
Correct and not Oil level too low
contaminated contaminated
Oil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train not Clogged oil pipe
Valve train lubricated
properly lubricated properly Faulty oil pump

Check if engine overheats

Worn cylinder and piston rings
Mixture too lean
Engine does not Engine overheats Poor quality fuel
overheats Excessive carbon buildup in
combustion chamber
Ignition timing too early
Rapidly accelerate or run
at high speed
Excessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks Poor quality fuel
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

1-22
1. GENERAL INFORMATION

Faulty CDI unit

Correct timing Incorrect timing
Faulty pulser coil

Check carburetor pilot

screw adjustment

Mixture too rich (turn screw

Correctly adjusted Incorrectly adjusted out)
Mixture too lean (turn screw in)

Check carburetor gasket

for air leaks
Deteriorated O-ring
Carburetor not securely
No air leak Air leaks tightened
Damaged insulator rubber
Broken vacuum tube
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Faulty or fouled spark plug
Faulty CDI unit
Weak or inter- Faulty A.C. generator
Good spark mittent spark Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Check air cut-off valve

Faulty air cut-off valve

Good Faulty Damaged vacuum tube
Clogged or damaged air vent
hole

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

1-23
1. GENERAL INFORMATION

Faulty CDI unit

Correct timing Incorrect timing
Faulty pulser coil

Check valve clearance

Improperly adjusted valve clearance

Correctly adjusted Incorrectly adjusted Worn camshaft
Worn valve seat
Check fuel pump for
fuel supply

Empty fuel tank

Fuel flows freely Fuel flow restricted Clogged fuel tube or filter
Faulty charcoal canister
Faulty auto fuel valve
Check carburetor jets
for clogging

Not clogged Clogged Clean and unclog

Check valve timing

Correct Incorrect Cam timing gear aligning marks

not aligned

Check valve spring

tension

Not weakened Weak spring Faulty spring

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Inspection/Adjustment Symptom Probable Cause

Start engine and test

limit voltage between
1-24
battery terminals
1. GENERAL INFORMATION

Voltage does not Dead battery

Normal voltage
increase Faulty battery

Measure resistance
between AC generator
coil terminals
Faulty A.C. generator coil
Normal Resistance too high Broken yellow wire
Loose connector
Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage
Normal voltage No voltage Broken red wire

Check regulator/rectifier
coupler for loose
connection
Faulty regulator/rectifier
Normal Abnormal
Poorly connected coupler

Faulty A.C. generator

Overcharging

Inspection/Adjustment Symptom Probable Cause

Connect battery (+) wire

to regulator/rectifier
coupler green wire and
battery (-) wire to engine
ground and test voltage
Battery has voltage Battery has no
with ignition voltage with ignition Broken green wire
switch “ON” switch “ON”

Check regulator/rectifier
coupler for loose
connection

Normal Abnormal Poorly connected coupler

Faulty regulator/rectifier

NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom Probable Cause

Replace with a new

spark plug and inspect
again
1-25
1. GENERAL INFORMATION
Weak or no spark Good spark Faulty old spark plug

Check spark plug cap

and high-tension wire
for looseness

Not loose Loose Loose spark plug cap

Check CDI unit coupler

for looseness

Good Good Poorly connected coupler

Measure resistance
between CDI unit
coupler wire terminals

Normal Abnormal

Check related parts

Faulty ignition switch

Normal Abnormal Faulty pulser coil
Faulty ignition coil

Broken wire harness

Poorly connected coupler

Check CDI unit with a

CDI unit tester

Normal Abnormal Faulty CDI unit

Check ignition coil with

a CDI unit tester

Abnormal Faulty ignition coil

1-26