SM - Kymco Vitality 50 - Chapter 05 (Engine Installation)

8/3/2019 SM - Kymco Vitality 50 - Chapter 05 (Engine Installation)

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5. ENGINE REMOVAL/INSTALLATION

5-0

VITALITY 50

5

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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

5


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5-1

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


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5-2

VITALITY 50

ENGINE REMOVAL

(2-STROKE)

Remove the frame body cover. (13-6)Disconnect the oil pump control cable fromthe pump body. (4-5)Disconnect the oil inlet line from the oil

pump. (4-5)

Remove the spark plug cap (1).

Disconnect the auto bystarter, A.C.generator and starter motor wire connector(2).

Loosen the band screw (1) and remove thetwo mounting bolts (2), then remove aircleaner housing.

Slide the rubber sleeve up to expose thecarburetor.

Disconnect the fuel tube (2) from thecarburetor.

Disconnect the fuel vacuum tube from theintake manifold (3).

Loosen the carburetor top (1).

Remove the carburetor top and throttlevalve from the carburetor. (12-3)

After the oil inlet line is disconnected,plug the oil line opening to prevent oilfrom flowing out.


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5-3

VITALITY 50

Remove the rear brake adjusting nut (1),brake arm pin (2) and retainer bolt (4) anddisconnect the brake cable (3) from thecrankcase.Remove the cooling air tube band (6) fromthe left crankcase cover and disconnect thecooling air tube.Remove the rear shock absorber lowermounting bolt (5).

Remove the secondary air hose band (1)from the exhaust muffler and disconnect thesecondary air hose.

Remove the right and left engine mountingnuts (1).Take out the right and left engine mounting

bolts.


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5-4

VITALITY 50

Lift the frame rear upward and move theframe forward to separate it from the engineand be careful not to damage the rear fender.

ENGINE HANGER BRACKET REMOVAL

Remove the engine hanger bracket bolts andengine hanger bracket.The installation sequence is the reserve ofremoval.Torque: 4.5_ 5.5kg-m

Engine Hanger Bracket Bolt


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5-5

VITALITY 50

ENGINE HANGER BRACKET

INSPECTION

Inspect the stopper rubbers and bushingsfor damage and replace with new ones ifnecessary.

ENGINE INSTALLATION

Install the engine in the reverse order ofremoval.

Torque Values:

Engine mounting bolt : 4.5_ 5.5kg-m

Rear shock absorber lower mount bolt:2.4_ 3.0kg-m

Perform the following inspections andadjustments after installation.

Throttle cable

Oil pump control cable (3-7)

Rear brake cable (3-2)

Oil pump bleeding (4-7)

Bushings

Engine HangerStopper Rubbers

Cables and wires should be routedproperly.


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5-6

VITALITY 50

ENGINE REMOVAL

(4-STROKE)

Remove the frame body cover. (13-6)

Disconnect the auto bystarter, A.C.generator and starter motor wire connector

.

Remove the spark plug cap.

Disconnect the secondary air apply hoseand crankcase breather hose.

Disconnect vacuum tube.

Loosen the air cleaner connecting tube bandscrew and intake manifold band screw.

A.C. Generator Wire

Starter Motor Wire Auto Bystarter Wire

Spark Plug Cap

Crankcase Breather Hose

Secondary Air Apply Hose

Vacuum Tube

Band Screw Band Screw


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5-7

VITALITY 50

Remove the bolts from air cleaner housing.

Release the wire band (auto bystarter/A.C.generator/starter motor wire).

Remove the carburetor.

Remove rear brake adjusting nut, arm pinand spring.

Bolts

Wire Band

Spring Arm Pin Arm Pin


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VITALITY 50

Disconnect the rear brake cable from thetransmission cover.

Remove the rear shock absorber lowermount bolt.

Disconnect the inlet hose.

Remove the right and left engine mountingnuts..

Take out the right and left engine mounting

bolts.

Rear Brake Cable

BoltInlet Hose

Bolts/Nuts


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VITALITY 50

Lift the frame rear upward and move theframe forward to separate it from the engineand be careful not to damage the rear fender.

ENGINE HANGER BRACKET REMOVAL

Remove the engine hanger bracket nuts.

Remove the engine hanger bracket bolts andengine hanger bracket.

The installation sequence is the reserve ofremoval.Torque: 4.5_ 5.5kg-m

Nut

Bolts


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5-10

VITALITY 50

ENGINE HANGER BRACKET

INSPECTION

Inspect the stopper rubbers and bushingsfor damage and replace with new ones ifnecessary.

ENGINE INSTALLATION

Install the engine in the reverse order ofremoval.

Torque Values:

Engine mounting bolt : 4.5_ 5.5kg-m

Rear shock absorber lower mount bolt:2.4_ 3.0kg-m

Perform the following inspections andadjustments after installation.

Rear brake cable (3-2)

Cables and wires should be routedproperly.

Bushings Bushings

Documents

SM - Kymco Vitality 50 - Chapter 05 (Engine Installation)