1.

GENERAL INFORMATION

F ILLY LX 50

1 ENGINE SERIAL NUMBER...................1- 1

SPECIFICATIONS ...................................1- 2 SERVICE PRECAUTIONS ......................1- 3 TORQUE VALUES ..................................1-11 SPECIAL TOOLS .....................................1-12

LUBRICATION POINTS.......................1-13 CABLE & HARNESS ROUTING ............1-15 WIRING DIAGRAM ...............................1-20 TROUBLESHOOTUNG..........................1-21

ENGINE SERIAL NUMBER

Filly LX 50

Location of Engine Serial Number

1-1

1. GENERAL INFORMATION
SPECIFICATIONS
Motorcycle Name & Type Filly LX 50 Name & Model No. SD10BB Overall length (mm) 1720 Overall width (mm) 625 Overall height (mm) 1035 Wheel base (mm) 1200 Engine type O.H.C. Displacement 49.5cc Fuel Used 92# nonleaded gasoline Front wheel 34 Net weight (kg) Rear wheel 48 Total 82 Front wheel 35 Gross weight(kg) Rear wheel 50 Total 85 Front wheel 90/90-10 50J Tires Rear wheel 100/80-10 53J Ground clearance (mm) 110 7.9 (Initial speed Perform Braking distance (m) 40km/h) ance
Min. turning radius (m)

F ILLY LX 50
Oil capacity Cooling Type 0.85 liter Forced air cooling

Air cleaner type & No Paper element, wet Fuel capacity 6.1 liter Type CVK Piston dia. (mm) Venturi f17equivalent dia.(mm) Throttle type Butterfly type Type CDI Ignition timing BT DC28/4000rpm Contact breaker Non-contact point type Carburetor Ignition System Spark plug NGK C7HSA 0.6_ 0.7mm 12V4AH Dry multi-disc clutch
Non-stage transmission

Fuel System Electrical Power Drive System

Spark plug gap Battery Capacity Clutch Type

Transmission Gear

Starting system

Type Cylinder arrangement Type Two-stage reduction Combustion chamber type Reduction 1st 0.8-3.1 Valve arrangement ratio 2nd 11.05 Bore x stroke (mm) Front Caster angle 27 Compression ratio Axle Trail length Compression pressure 14 (kg/cm_-rpm) Front 1.75 Tire pressure Max. output 2.208/8000kw/(r/min (kg/cm_) Rear 2.25 ) Turning Left 45 Max. torque 0.3/6500kg m/rpm angle Right 45 Open 3 Intake Front DISK (160mm) Brake system Port Close 7 timin Rear Drum (110mm) brake Open 9 type g Exhaust brake Close 1 TELESCOPE Suspension type Front 0.04 Valve clearance Intake Rear Unit Swing (cold) (mm) Exhaust 0.04 Shock absorber Front 70 distance Idle speed (rpm) 1900 100rpm Rear 66 Forced pressure & Lubrication type Frame type Under Bone wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration
Reduction Gear

1.8 Starting motor & kick starter Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C. f39.0 x 41.4 10.5

Type Operation

Automatic centrifugal type

Moving Device

1-2

Engine

Device

Lubrication System

1. GENERAL INFORMATION
SERVICE PRECAUTIONS
n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.

F ILLY LX 50

n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

n Use genuine parts and lubricants .

n When servicing the motorcycle, be sure to use special tools for removal and installation.

n After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.

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1. GENERAL INFORMATION
n Apply or add designated greases and lubricants to the specified lubrication points.

F ILLY LX 50

n After reassembly, check all parts for proper tightening and operation.

n When two persons work together, pay attention to the mutual working safety.

n Disconnect the battery negative (-) terminal before operation. n When using a spanner or other tools, make sure not to damage the motorcycle surface.

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

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1. GENERAL INFORMATION
n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.

F ILLY LX 50

Confirm Capacity

n After operation, terminal caps shall be installed securely.

n When taking out the connector, the lock on the connector shall be released before operation.

n Hold the connector body when connecting or disconnecting it. n Do not pull the connector wire.

n Check if any connector terminal is bending, protruding or loose.

1-5

1. GENERAL INFORMATION
n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire.

F ILLY LX 50

Snapping!

n Before connecting a terminal, check for damaged terminal cover or loose negative terminal.

n Check the double connector cover for proper coverage and installation.

n Insert the terminal completely. n Check the terminal cover for proper coverage. n Do not make the terminal cover opening face up.

n 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.

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1. GENERAL INFORMATION
n After clamping, check each wire to make sure it is secure.

F ILLY LX 50

. n Do not squeeze wires against the weld or its clamp

n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.

n When fixing the wire harnesses, do not make it contact the parts which will generate high heat.

No Contact !

n Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. n Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws.

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1. GENERAL INFORMATION
n Route harnesses so they are neither pulled tight nor have excessive slack.

F ILLY LX 50

Do not pull too tight!

. n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner

n When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.

n Do not break the sheath of wire. n If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it.

n When installing other parts, do not press or squeeze the wires.

Do not press or squeeze the wire.

1-8

1. GENERAL INFORMATION
n After routing, check that the wire harnesses are not twisted or kinked.

F ILLY LX 50

n 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.

n When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. n Be careful not to drop any parts.

Do you understand the instrument? Is the instrument set correctly?

n When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting.

Remove Rust !

n Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

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1. GENERAL INFORMATION
n Symbols: The following symbols represent the servicing methods and cautions included in this service manual.

F ILLY LX 50

Engine Oil

: Apply engine oil to the specified points. (Use designated engine oil for lubrication.)

Grease

: Apply grease for lubrication.

Gear Oil

: Transmission Gear Oil (90#)

Special

: Use special tool.

: Caution

: Warning

( 12-3)

: Refer to page 12-3.

1-10

1. GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut Torque (kg-m) 0.45-0.6 0.6-1.2 1.8-2.5 3.0-4.0 5.0-6.0 Item 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut

F ILLY LX 50

Torque (kg-m) 0.35-0.5 0.7-1.1 1.0-1.4 2.4-3.0 3.5-4.5

Torque specifications listed below are for important fasteners. ENGINE Item Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler lock bolt Cylinder head flange nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Starter motor mounting bolt Oil pump bolt Drive face nut Spark plug A.C. generator stator bolt Cam chain tensioner bolt FRAME Item Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Speedometer cable set screw Rear shock absorber lock nut Qty Thread dia.(mm) 1 1 1 1 1 1 1 25.4 10 14 10 8 5 8 Torque (kg-m) 8.0-12.0 5.0-7.0 11.0-13.0 4.0-5.0 2.0-3.0 0.45-0.6 3.0-3.6 Remarks U-nut U-nut U-nut Qty Thread dia.(mm) 2 4 1 2 4 2 1 1 1 1 2 3 1 1 2 1 6 6 30 6 7 3 8 8 10 28 6 4 10 10 6 6 Torque (kg-m) 0.7-1.1 0.7-1.1 1.0-2.0 0.7-1.1 1.2-1.6 0.07-0.09 0.4-0.7 1.1-1.5 3.5-4.5 5.0-6.0 0.8-1.2 0.1-0.3 5.5-6.5 1.0-1.4 0.8-1.2 0.8-1.2 Remarks Double end bolt

Double end bolt Apply oil to threads

Apply locking agent

1-11

1. GENERAL INFORMATION
SPECIAL TOOLS
Tool Name Tool No. Remarks
Bearing puller 10.12.15.1 8 mm Bushing remover L Bushing remover S Crankshaft bearing puller Crankshaft protector Clutch spring compressor Cushion assemble & disassemble tool Flywheel holder

F ILLY LX 50

Ref. Page

E037 E032 EO19 E030 E029 E027 F004

10.12.15.1 10-3 10-4 8mm bearing 12-6 11102 bush engine 11203 hanger rear bush rubber cushion 91005 under radial rubber bearing 13000 crankshaft comp 9-9 2301a 12mm.14 9-12 driven mm pully assy 52400 13-4 cushion assy 9-5 31110 flywheel 9-9 comp.231 9-13 0a pully 14-7 assy driven 14-9 Left hand 14-7 thread 27mm 50306 12-21 steering 12-22 stemseal & Oil bearing install Special tools storage 90012 3-5 screw tappet 7-7 Valve spring 7-8

E017

Flywheel E002 puller Long F002 socket wrench & Oil seal 32mm E014 bearing 8angle installer Tool boox E033 Tappet adjuster Valve spring compressor E036 E038

1-12

1. GENERAL INFORMATION

F ILLY LX 50

LUBRICATION POINTS
ENGINE Lubrication Points Valve guide/valve stem movable part Cam lobes 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 Lubricant Genuine KYM CO Engine Oil (SAE15W-40) API-SG Engine Oil

Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Kick starter spindle movable part A.C. generator connector Transmission case breather tube

High-temperature resistant grease

Adhesive

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1. GENERAL INFORMATION

F ILLY LX 50

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.

Grease Front Brake Lever Pivot

Engine/ Oil Front Brake Cable/ Speedometer Cable/ Throttle Cable

Engine Oil Grease Speedometer Gear/ Front Wheel Bearings/ Brake Cam/ Anchor Pin Grease /Front Shock Absorber Lower Main Stand Pivot Mount Bushings/Pivot Rear Brake Cable Grease Brake Cam/ Anchor Pin

Grease Rear Wheel Bearings

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1. GENERAL INFORMATION

F ILLY LX 50

CABLE & HARNESS ROUTING

Rear Stop Switch Wire Brake Master Cylinder

Front Stop Switch Wire Throttle Cable Front Brake Fluid Tube Ignition Switch Horn Regulator/Rectifier Rear Brake Cable Speedometer Cable

Winker Headlight Resistor

1-15

1. GENERAL INFORMATION

F ILLY LX 50

Throttle Grip Ignition Switch Fuel Filler

Speedometer Cable

Rear Brake Lever Regulator/Rectifier Fuel Tank Inlet Tube Fuel Tank Breather Tube Front Brake Fluid Tube

Fuel Tank

1-16

1. GENERAL INFORMATION

F ILLY LX 50

Battery (+) Cable Battery (-) Cable

CDI Unit Ignition Coil

Fuse

Battery (-) Cable Battery (+) Cable Starter Relay

CDI Unit

1-17

1. GENERAL INFORMATION

F ILLY LX 50

Ignition Coil Primary Wire

Throttle Cable

Vacuum Tee Carburetor Overflow Tube Fuel Tube

Ignition Wire

Crankcase Breather Tube Fuel Pump Fuel Vapor Recovery Tube

1-18

1. GENERAL INFORMATION

F ILLY LX 50

Fuel Vapor Recovery Tube

Crankcase Breather Tube Fuel Unit

Wire Harness Throttle Cable Throttle Cable Ignition Coil Crankcase Breather Tube Fuel Filter Vacuum Tube Vacuum Tube

Fuel Pump Auto Bystarter

Fuel Tube

1-19

1. GENERAL INFORMATION
WIRING DIAGRAM

F ILLY LX 50

1-20

1. GENERAL INFORMATION
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment
Check if fuel reaches carburetor by loosening drain screw Fuel reaches carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps Weak or no spark Fuel does not reach carburetor

F ILLY LX 50

Symptom

Probable Cause

Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Clogged fuel tank cap breather hole Clogged fuel filter Clogged fuel strainer Faulty auto fuel valve

Test cylinder compression Normal compression Low or no compression

Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted hightension wire Faulty ignition switch Faulty starter clutch Valve clearance too small Improper valve and seat contact Worn cylinder, piston and piston rings Leaking cylinder head gasket Seized valve Improper valve timing

Start engine by following normal starting procedure Engine does not fire Engine fires but does not start

Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw

Remove spark plug and inspect again Dry spark plug Wet spark plug Flooded carburetor Faulty auto bystarter Throttle valve excessively open

1-21

1. GENERAL INFORMATION
ENGINE LACKS POWER Inspection/Adjustment
Start engine and accelerate lightly for observation Engine speed increases Check ignition timing using a timing light Correct timing Check valve clearance Correct Test cylinder compression Normal compression Check carburetor for clogging Abnormal compression Incorrect Incorrect timing Engine speed does not increase sufficiently

F ILLY LX 50

Symptom

Probable Cause
Clogged air cleaner Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Faulty CDI unit Faulty pulser coil

Improper valve clearance adjustment Worn valve seat (valve stem too protruding Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing

Not clogged
Remove spark plug and inspect Plug not fouled or discolored Remove oil dipstick and check oil level and condition Correct and not contaminated Remove cylinder head oil pipe bolt and inspect Valve train lubricated properly Check if engine overheats Engine does not overheats Rapidly accelerate or run at high speed Engine does not knock

Clogged

Clogged carburetor jets

Plug fouled or discolored

Fouled spark plug Incorrect heat range plug

Incorrect or contaminated

Oil level too high Oil level too low Oil not changed

Valve train not lubricated properly

Clogged oil pipe Faulty oil pump Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Excessive carbon build-up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early

Engine overheats

Engine knocks

1-22

1. GENERAL INFORMATION
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

F ILLY LX 50

Inspection/Adjustment
Check ignition timing

Symptom

Probable Cause

Correct timing Check carburetor pilot screw adjustment Correctly adjusted

Incorrect timing

Faulty CDI unit Faulty pulser coil

Incorrectly adjusted

Mixture too rich (turn screw out) Mixture too lean (turn screw in)

Check carburetor gasket for air leaks Deteriorated O-ring Carburetor not securely tightened Damaged insulator rubber Broken vacuum tube

No air leak Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark

Air leaks

Weak or intermittent spark

Faulty or fouled spark plug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch

Check air cut-off valve Good Faulty Faulty air cut-off valve Damaged vacuum tube Clogged or damaged air vent hole

1-23

1. GENERAL INFORMATION
POOR PERFORMANCE (AT HIGH SPEED)

F ILLY LX 50

Inspection/Adjustment
Check ignition timing

Symptom

Probable Cause

Correct timing

Incorrect timing

Faulty CDI unit Faulty pulser coil

Check valve clearance Improperly adjusted valve clearance Worn camshaft Worn valve seat

Correctly adjusted

Incorrectly adjusted

Check fuel pump for fuel supply Empty fuel tank Clogged fuel tube or filter Faulty charcoal canister Faulty auto fuel valve

Fuel flows freely Check carburetor jets for clogging Not clogged

Fuel flow restricted

Clogged

Clean and unclog

Check valve timing

Correct Check valve spring tension

Incorrect

Cam timing gear aligning marks not aligned

Not weakened

Weak spring

Faulty spring

1-24

1. GENERAL INFORMATION

F ILLY LX 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment

Start engine and test limit voltage between battery terminals Normal voltage Measure resistance between AC generator coil terminals Normal Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage Check regulator/rectifier coupler for loose connection Normal Abnormal Resistance too high Faulty A.C. generator coil Broken yellow wire Loose connector Voltage does not increase Dead battery Faulty battery

Symptom

Probable Cause

Normal voltage

No voltage

Broken red wire

Faulty regulator/rectifier Poorly connected coupler Faulty A.C. generator

Overcharging Inspection/Adjustment
Connect battery (+) wire to regulator/rectifier coupler green wire and battery (-) wire to engine ground and test voltage

Symptom

Probable Cause

Battery has voltage with ignition switch ON

Battery has no voltage with ignition switch ON

Broken green wire

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

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1. GENERAL INFORMATION
NO SPARK AT SPARK PLUG Inspection/Adjustment
Replace with a new spark plug and inspect again Weak or no spark Check spark plug cap and high-tension wire for looseness Not loose Check CDI unit coupler for looseness Good Measure resistance between CDI unit coupler wire terminals Normal Check related parts Abnormal Good Loose Good spark

F ILLY LX 50

Symptom

Probable Cause

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Normal

Abnormal

Faulty ignition switch Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler

Check CDI unit with a CDI unit tester Normal Check ignition coil with a CDI unit tester Abnormal Faulty ignition coil Abnormal Faulty CDI unit

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