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VITALITY 50

PREFACE
This Service Manual describes the technical features and servicing
procedures for the KYMCO VITALITY 50.
In this manual, many illustrations and drawings are used to help
servicemen have better understanding.
Section 2 contains the service precautions for all operations and
troubleshooting stated in this manual. Read them carefully before starting
any operation.
Section 3 describes the inspection/adjustment procedures, safety rules and
service information for each part, starting from periodic maintenance.
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. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4121-LBD5/6-S00

1. SPECIFICATIONS

VITALITY 50

1

1
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
CRANKCASE/CRANKSHAFT.....................................................................11
CARBURETOR...............................................................................................12
FRAME COVERS/EXHAUST MUFFLER..................................................13
STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/FRONT FORK ...........................................14
REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER .................15
ELECTRICAL EQUIPMENT .......................................................................16
INSTRUMENT/SWITCHES/LIGHTS .........................................................17
KCAS (FOR EURO 2) ....................................................................................18

1-0

1. SPECIFICATIONS

VITALITY 50

SPECIFICATIONS
(2-Stroke)
Name & Model
Overall length (mm)
Overall width (mm)
Overall height (mm)
Wheel base (mm)
Engine type
Displacement (cc)
Net weight (kg)
Seating capacity
Gross weight(kg)
Front wheel
Rear wheel
Ground clearance (mm)
Braking distance (m)
(Initial speed Km/h)
Min. turning radius (mm)
Starting system
Tires

Fuel type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Bore x stroke (mm)
Compression ratio
Compression pressure
(kg/cm² rpm)
Max. horsepower (ps/rpm)
Max. torque (kg-m/rpm)
Open
Close
Port
Open
Exhaust
timing
Close
Open
Scavenge
Close
Idle speed (rpm)
Lubrication type
Oil pump type
Oil filter type
Intake

1-1

SF10FA
1870
700
1120
1296
Air cooled 2-stroke
49.4 cc
97
1 riders (75kg)
173 (1 rider)
120/70-12
130/70-12
150
4.4m (30km/h)
1920
Starting motor &
Kick starter
#92 or higher
unleaded gosoline
Single cylinder, flat
Semi-sphere
Reed valve & piston
39 x 41.4
7.2 : 1
11.8kg/cm²
4.5/6000
(Speed limited
type:3.9/6000)
0.5/6000
(Speed limited
type:0.48/6000)
Automatic controlled
Automatic controlled




2000±100
Separate type
Plunger type
Full-flow filtration

Lubrication oil capacity (liter)
1.3
Air cleaner type & No.
Wet, single
Fuel capacity (liter)
5.0
Type
PB
Carburetor Piston dia. (mm)

Venturi dia. (mm)
14
Ignition system type
CDI electromagnetic
Ignition
Ignition timing F mark
13.5°±2°/3000rpm
NGK
BR8HSA
Spark plug
ND

Spark plug gap (mm)
0.6~0.7
Battery capacity
12V3AH
Power to transmission gear
Power-transmission
gear-clutch
Reduction ratio of power to

transmission
Clutch type
Dry multi-disc clutch
Transmission gear operation Automatic centrifugal
type
type
Transmission ratio 1 speed

Reduction Type
Two-stage reduction
gear
1st reduction ratio

2nd reduction ratio

Transmission gear type
Non-stage transmission
Tire pressure
1.50/2.0 (1 rider)
Front/Rear
1 (2 rider)
(kg/cm²)
1.75/2.25
wheel
Turning angle
Brake system
type
Suspension
type
Shock absorber
type
Frame type
Exhaust
emission
concentration

Front wheel
Rear wheel
Front wheel
Rear wheel
Front wheel
Rear wheel

Right & left 45°
hydraulic
Expanding
Telescope
Unit swing
Telescope
Unit swing
Pipe under bone

MASS CO

1.0 g/km

MASS
HC+NOX

1.2 g/km

VITALITY 50

1. SPECIFICATIONS
SPECIFICATIONS
(4-Stroke)

Ignition System

Spark plug

NGK C7HSA

Spark plug gap
Battery Capacity
Clutch Type

0.6~0.7mm
12V4AH
CVT

Transmission Gear

Type

Helical gear

Operation

Moving Device

Type
Primary
reduction
Final
reduction
FR/RR tire rolling
circumference(mm)
Reduction
Gear

Electrical EquipmentPower Drive System

Air cleaner type & No
Wet paper
Fuel capacity
5.0 liters
Type
CVK
Main jet No.
#82 (speed limited: #80)
Venturi dia.(mm)
φ17
Throttle type
PISTON
Type
CDI
Ignition timing
28°BTDC/4000rpm
Contact breaker
Non-contact point type
Carburetor

Fuel System

Engine

Tire pressure
(kgf/cm²)
Turning
angle

Brake system
type

Lubrication
System

Damping
Device

Name & Model No.
SG10AA
Overall length (mm)
1870
Overall width (mm)
700
Overall height (mm)
1120
Wheel base (mm)
1296
Engine type
O.H.C.
Displacement (cc)
49.5
Fuel Used
92# nonleaded gasoline
Dry weight (kg)
91
Seating capacity
1 riders (75kg)
Net weight(kg)
97
Front
wheel
120/70-12
56J
Tires
Rear wheel
130/70-12 59J
Ground clearance (mm)
150
Breaking distance
4.4 below
(m)(30KPH)
Motor & Kick starter
Starting system
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
39X41.4
Compression ratio
10.5:1
Compression pressure
14.0
Max. horsepower
3.8/8000 (ps/rpm)
Max. torque (kg m/rpm)
0.35/7000
Open

Intake
Close
11°
Port
timing
Open
-9°
Exhaust
Close
19°
Valve clearance Intake
0.04
Exhaust
0.04
(cold) (mm)
Idle speed (rpm)
1800rpm
Forced pressure &
Lubrication type
Wet sump
Oil pump type
Inner/outer rotor type
Oil filter type
Full-flow filtration
Oil capacity
0.85 liter
Oil exchanging
0.7 liter
capacity
Cooling Type
Air cooling

Suspension
type

Frame type

Automatic centrifugal
Type
V-Belt
0.75~2.47
13.61
1485/1515

Front
Rear
Left
Right
Front
Rear

1.5
2.0
45°
45°
Disk brake
Drum brake

Front

Telescope

Rear

Under-swing
Under bone

1-2

2. GENERAL INFORMATION

VITALITY 50

1

2

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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) ......................................................... 2-12
SPECIAL TOOLS (4-STROKE) ......................................................... 2-12
LUBRICATION POINTS .................................................................... 2-13
WIRING DIAGRAM ........................................................................... 2-15
CABLE & HARNESS ROUTING (2-STROKE) ................................ 2-17
CABLE & HARNESS ROUTING (4-STROKE) ................................ 2-21
TROUBLESHOOTING (2-STROKE)................................................. 2-25
TROUBLESHOOTING (2-STROKE) ------------------------------------ 2-36

2-0

2. GENERAL INFORMATION
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.

2-1

VITALITY 50

2. 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.

VITALITY 50
„ Apply or add designated greases and
lubricants to 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.

2-2

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

VITALITY 50
„ The connector shall be inserted
completely.
„ If the double connector has a lock, lock
it at the correct position.
„ Check if there is any loose wire.

Easy confirm

„ After operation, terminal caps shall be
installed securely.

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

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

2-3

„ 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.

2. GENERAL INFORMATION
„ After clamping, check each wire to make
sure it is secure.

„ 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.
Don’t touch

„ 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.

VITALITY 50
„ Route harnesses so they are neither
pulled tight nor have excessive slack.

„ 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.

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

2-4

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

„ 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.

VITALITY 50

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

Oil

Grease

„ When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.

Special



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

Apply grease for lubrication.

Use special tool.

Caution

„ Be careful not to drop any parts.

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

2-5

(Ö12-3)

Refer to page 12-3.

2. GENERAL INFORMATION

VITALITY 50

SERVICE INFORMATION (2-STROKE)
ENGINE
Item
Cylinder head warpage
Piston O.D.(5mm from bottom of piston skirt)
Cylinder-to- piston clearance
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end gap (top/second)
Connecting rod small end I.D.
Cylinder bore
Drive belt width
Drive pulley collar O.D.
Movable drive face ID.
Weight roller O.D.
Clutch outer I.D.
Driven face spring free length
Driven face O.D.
Movable driven face I.D.
Connecting rod big end side clearance
Connecting rod big end radial clearance
Crankshaft runout A/B

CARBURETOR
Setting mark
Type
Float level
Main jet
Slow jet
Air screw opening
Idle speed
Throttle grip free play
Jet needle clip notch

Standard (mm)

Service Limit (mm)

VITALITY 50


0.10

38.955~38.970

38.90
0.10

12.002~12.008

12.03

11.994~12.0

11.98





0.10~0.25

0.40

17.005~17.017

17.03

39.0~39.025

39.05

18

17

19.96~19.974

19.94

20.011~20.052

20.6

15.92~16.08

15.4

107~107.2

107.5

87.9

82.6

33.965~33.985

33.94

34.000~34.025

34.06













VITALITY
PB168A
PB 14
8.6mm
#85 (Speed limit type: #72)
#35
2 1/2±1/2
1850±100rpm
2~6mm
1st notch

2-6

2. GENERAL INFORMATION
FRAME

VITALITY 50

Standard (mm)
Item

VITALITY 50


Axle shaft runout
Front wheel rim runout

Service Limit (mm)
0.2

Radial
Axial

Front shock absorber spring free length

214.7

Rear wheel rim runout

2.0

Brake drum I.D.

Front/rear

110

111

Brake lining thickness

Front/rear

6.4/4.0

2.0/2.0

Brake disk runout

Front/rear



0.30

Rear shock absorber spring free length

209

ELECTRICAL EQUIPMENT

VITALITY 50

Capacity
Voltage
Battery
Charging Standard
current
Quick
Spark plug
(NGK)
Spark plug gap
Primary coil
Secondary coil
Ignition coil resistance (with plug cap)
Secondary coil
(without plug cap)
Pulser coil resistance (20℃)
Ignition timing

12V3AH
13.0~13.2V
0.4A/5H~10H
4A/0.5H
BR8HAS
0.6~0.7mm
0.153~0.187Ω

2-7

6.99K~10.21KΩ
3.24K~3.96KΩ
80~160Ω
13.5°±2°BTDC/3000 rpm

2. GENERAL INFORMATION

VITALITY 50

SERVICE INFORMATION (4-STROKE)
ENGINE
Item
Cylinder head warpage

Standard (mm)

Service Limit (mm)

VITALITY 50 (4-Stroke)

0.10

Piston O.D.(4.55mm from bottom of piston skirt)

38.975~38.99

38.90

Cylinder-to- piston clearance
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Ring-to-groove (top/second)
Connecting rod small end I.D.
Cylinder bore
Drive belt width
Drive pulley collar O.D.
Movable drive face ID.
Weight roller O.D.
Clutch outer I.D.
Driven face spring free length
Driven face O.D.
Movable driven face I.D.
Connecting rod small end free play
Connecting rod big end radial clearance
Run out

0.010~0.040

0.10

13.002~13.008

13.04

12.994~13.0

12.96

0.002~0.014

0.02

0.15~0.55

0.09

13.016~13.034

13.06

39.0~39.01

39.1

18

17

19.96~19.974

19.94

20.011~20.052

20.6

15.92~16.08

15.4

107~107.2

107.5

95

90

33.965~33.985

33.94

34.000~34.025

34.06

0.05~0.4

0.6

0~0.008

0.05



0.10

CARBURETOR
Setting mark
Type
Float level
Main jet
Slow jet
Pilot screw opening
Idle speed
Throttle grip free play

Standard
CVK104A
CVK 18
20.5
#82 (speed limited: #80)
#35
2±1/2
1800±100rpm
2~6mm

2-8

2. GENERAL INFORMATION
FRAME

VITALITY 50
Standard (mm)

Item

VITALITY 50 4-stdroke


Axle shaft runout
Front wheel rim runout

Service Limit (mm)
0.2

Radial
Axial

Front shock absorber spring free length

214.7

Rear wheel rim runout

2.0

Brake drum I.D.

Front/rear

110

111

Brake lining thickness

Front/rear

6.4/4.0

2.0/2.0

Brake disk runout

Front/rear



0.30

Rear shock absorber spring free length

209

ELECTRICAL EQUIPMENT

Battery

Capacity
Voltage
Charging Standard
current
Quick

Spark plug
(NGK)
Spark plug gap
Primary coil
Secondary coil
Ignition coil resistance (with plug cap)
Secondary coil
(without plug cap)
Pulser coil resistance (20℃)
Ignition timing

2-9

VITALITY 50 (4-stroke)
12V4AH
13.0~13.2V
0.5A/5H~10H
4A/0.5H
C7HAS
0.6~0.7mm
0.5Ω
8.12KΩ
3KΩ
118.1~118.2Ω
28°±2°BTDC/4000 rpm

2. GENERAL INFORMATION

VITALITY 50

TORQUE VALUES
ENGINE (2-STROKE)
Item
Thread dia. (mm)
Cylinder head bolt
BF7x115
Clutch drive plate nut
10
Clutch outer nut
NH10
NH12
Drive face nut
Oil check bolt
10
Engine mounting bolt
BF10x95
Engine hanger bracket bolt
BF10x50
Exhaust muffler joint lock nut
NC6mm
BF8x35
Exhaust muffler lock bolt
Spark plug

Torque (kgf-m)
1.0~1.2
3.5~4.0
3.5~4.5
5.0~6.0
1.0~1.5
4.5~5.5
3.5~4.5
1.0~1.4
3.0~3.6
1.1~1.7

Remarks
(cold)

(cold)

ENGINE (4-STROKE)
Item
Stud bolt
Oil filter screen cap
L cover
Cam shaft holder
Tappet ADJ nut
Pivot tensioner bolt
Lifter tensioner bolt
Cam chain adjust bolt
Mission case bolt
Mission fill bolt
Driver face nut
Clutch outer nut
Drive plate nut
ACG flywheel nut
Spark plug
Mission drain plug
Oil pump screw
Head CYL stud bolt (IN pipe)
Head CYL stud bolt (EX pipe)
A.C.G Startor
Fan

Q‘ty Thread dia.(mm) Torque (kgf-m)
4
1
8
4
2
1
2
1
7
1
1
1
1
1
1
1
1
2
2
3
4

8
30
6
8
5
6
6
8
8
8
12
10
28
10
10
10
3
6
8
5
6

0.7~1.1
1.0~2.0
1.0~1.4
1.2~1.6
0.7~1.1
0.8~1.2
1.0~1.4
0.4~0.7
2.4~3.0
0.8~1.2
5.5~6.5
3.5~4.5
5.0~6.0
3.5~4.5
1.0~1.4
2.0~3.0
0.1~0.3
0.7~1.1
0.7~1.1
0.8~1.0
0.6~1.0

Remarks

Apply oil
Apply oil

Apply oil

2-10

2. GENERAL INFORMATION

VITALITY 50

FRAME
Item
Thread dia. (mm)
Torque (kgf-m)
Remarks
Handlebar lock nut
10
5.0~6.0
Flange bolt/U-nut
25.4
6.0~8.0
Steering stem lock nut
25.4
0.5~1.3
Steering top cone race
12
5.0~7.0
Flange U-nut
Front axle nut
Rear axle nut
16
11.0~13.0
Flange U-nut
Rear brake arm bolt
6
1.0~1.4
Front fork
8
3.0~3.6
upper mount bolt
8
3.0~3.6
lower mount bolt
Front brake caliper bolt
8
2.9~3.5
Apply locking agent
Brake fluid bolt
10
3.0~4.0
Front pivot arm bolt
5
0.3~0.5
Rear shock absorber:
10
3.5~4.5
upper mount bolt
lower mount bolt
8
2.4~3.0
Flange bolt/U-nut
Engine hanger bolt
10
4.5~5.5
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES
Item
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut

2-11

Torque (kgf-m)
0.45~0.6
0.8~1.2
1.8~2.5
3.0~4.0
5.0~6.0

SH bolt: 8mm
Item
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut

Flange 6mm bolt
Torque (kg-m)
0.35~0.5
0.7~1.1
1.0~1.4
2.4~3.0
3.5~4.5

2. GENERAL INFORMATION

VITALITY 50

SPECIAL TOOLS (2-STROKE)
Tool Name

Tool No.

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

E014

Clutch spring compressor

E034

Crankcase assembly collar

E023

Crankcase assembly tool

E024

Universal holder

E017

Flywheel puller

E001

Remarks

SPECIAL TOOLS (4-STROKE)
Tool Name

Tool No.

Universal bearing puller

E037

Lock nut socket wrench

F001

Lock nut wrench,

F007

Race cone install

F005

Oil seal & bearing install

E014

Clutch spring compressor

E034

Universal holder

E017

Flywheel puller

E001

Valve adjuster

E036

Remarks

2-12

2. GENERAL INFORMATION

VITALITY 50

LUBRICATION POINTS
ENGINE (2-STROKE)
NO.
1
2
3
4
5
6

Lubrication Points
Crankcase sliding & movable
Cylinder movable parts
Transmission gear (final gear)
Kick starter spindle bushing
Drive pulley movable parts
Starter pinion movable parts

Lubricant
KYMCO 2-STROKE OIL or QUIVALENT
KYMCO 2-STROKE OIL or QUIVALENT
SAE-90#
Grease
Grease
Grease

LUBRICATION POINTS
ENGINE (4-STROKE)
Lubrication Points

Lubricant

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 right side oil seal
Crankshaft one-way clutch movable part
Oil pump drive chain
Balance gear
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip

•Genuine KYMCO Engine Oil (SAE15W-40)
•API SG Engine Oil

Transmission gear and movable parts

2-13

Gear oil: SAE90#

2. GENERAL INFORMATION
FRAME
Apply clean engine oil or grease to cables and movable parts not specified.
abnormal noise and rise the durability of the motorcycle.
(1) Front/Rear Brake Lever
(2) Throttle Cable
(3) Seat Lock
(4) Rear Wheel Splines
(5) Brake Cam/Anchor Pin
(6) Rear Brake Cable
(7) Main Stand Pivot
(8) Side Stand Pivot
(9) Speedometer Gear /Lower
Mount Bushings/Pivot

VITALITY 50
This will avoid

2-14

2. GENERAL INFORMATION
WIRING DIAGRAM (2-STROKE)

2-15

VITALITY 50

2. GENERAL INFORMATION

VITALITY 50

WIRING DIAGRAM (4-STROKE)

2-16

2. GENERAL INFORMATION

VITALITY 50

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

Ignition Switch
Instrument connectors
Speedometer Cable

Throttle Cable

Headlight Connector

Regulator/Rectifier
Rear Brake Cable
Main Wire Harness
Resistor

2-17

Horn

2. GENERAL INFORMATION

VITALITY 50

Ignition Coil Wire

Spark Plug Wire

C.D.I Unit

Oil Level Switch
Oil Tank

Ignition Coil
Auto By Start Wire

Secondary Air Cleaner

Start Relay

Oil Throttle Cable
Wire Harness

Fuel Vacuum
Tube

Throttle Cable

Rear Brake Cable

Air Inlet Hose
(V—belt Chamber)

Fuel Tube

Fuel Throttle Cable

Rear Brake Cable

Overflow Tube

2-18

2. GENERAL INFORMATION

VITALITY 50

Instrument Connectors

Fuel Unit
Fuel Tank

Oil Level
Switch
Connector

Regulator/Rectifier

Headlight Connector
Ignition Switch Connector
Start Relay
Fuel Strainer
Auto By Start

Resistor

Ignition Coil
Fuel Throttle Cable
Oil Throttle Cable
Fuse Box

Taillight
Connector
Oil Throttle Cable
Fuel Unit
Connector
Oil Tank
Reed Valve

2-19

Wire Harness

Oil Tube

Battery (+) Cable
Battery (-) Cable

Speedometer Cable

2. GENERAL INFORMATION

VITALITY 50

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

Wire Harness

Battery (+) Cable

A.C.G Connector

Fuel Throttle Cable

Battery (-) Cable

Battery
Fuse Box

2-20

2. GENERAL INFORMATION

VITALITY 50

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

Ignition Switch
Instrument connectors
Speedometer Cable

Throttle Cable

Headlight Connector

Regulator/Rectifier
Rear Brake Cable
Main Wire Harness
Resistor

2-21

Horn

2. GENERAL INFORMATION

VITALITY 50

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)
Rear Brake Cable

2-22

2. GENERAL INFORMATION

VITALITY 50

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/
A.C.G./
Start Motor
Connectors

Ignition Coil

Wire Harness

Battery (-) Cable
Starter Relay

Speedometer Cable
Battery (+) Cable

Spark Plug Cap
Taillight Connector
Secondary Air Cleaner

2-23

2. GENERAL INFORMATION

VITALITY 50

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
Vacuum Tube C

Crankcase Breather Tube

Spark Plug Cap
Air Inlet Hose
(V-belt Chamber)
Secondary Air Cleaner
Throttle Cable

Harness Wire
Battery (-) Cable
Battery (+) Cable

Battery

Fuse Box
Throttle Cable

Rear Brake Cable

2-24

2. GENERAL INFORMATION

VITALITY 50

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.
Fuel reaches
carburetor

Fuel does not
reach 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

Test cylinder
compression.
Normal
compression

Low or no
compression

Start engine by following normal starting
procedure.
Engine does not
fire

Engine fires but
does not start

Dry spark plug

Wet spark plug

Not clogged

Clogged

c Empty fuel tank
d Clogged float valve
e Clogged fuel filter
f Faulty auto fuel valve

c Faulty spark plug
d Fouled spark plug
e Faulty CDI unit
f Faulty A.C. generator
g Broken or shorted ignition coil
h Broken or shorted exciter coil
iFaulty ignition switch
c Burned or worn cylinder
piston
d Faulty reed valve
e Blown cylinder head gasket
f Leaking crankcase
g Faulty crankcase oil seal

c Incorrectly adjusted idle speed
d Air leaking through intake
pipe
e Incorrect ignition timing

Remove spark plug and
inspect again.

Wait for 30 minutes and
then remove the carburetor auto choke circuit
hose and blow the hose
with mouth.

2-25

c Flooded carburetor
d Throttle valve excessively
open

c Faulty auto bystarter

2. GENERAL INFORMATION

VITALITY 50

ENGINE STOPS IMMEDIATELY AFTER IT STARTS
Inspection/Adjustment

Symptom

Probable Cause

Check if fuel reaches
carburetor by loosening
drain screw.
Fuel reaches
carburetor

Fuel does not
reach carburetor

c Empty fuel tank
d Clogged float valve
e Clogged fuel filter
f Faulty auto fuel valve

Plug fouled or
discolored

c Fouled spark plug
d Incorrect heat range plug

Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Plug not fouled or
discolored
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Good spark

Weak or intermittent spark

Test cylinder
compression (using a
compression gauge).

c Fouled spark plug
d Faulty CDI unit
e Faulty A.C. generator
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Flaws in cylinder head
f Faulty reed valve
g Seized piston

Normal
compression

Abnormal
compression

Not Clogged

Clogged

Correct timing

Incorrect timing

c Faulty CDI unit or A.C.
generator
d A.C.G. flywheel not aligned

Correctly adjusted

Incorrectly adjusted

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

Check carburetor for
clogging.
c Clogged carburetor jets

Check ignition timing.

Check carburetor air
screw adjustment.

2-26

2. GENERAL INFORMATION
Inspection/Adjustment

VITALITY 50

Probable Cause

Symptom

Check carburetor gasket
for air leaks.

No air leak

Air leaks

c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed or broken
carburetor O-ring

Not clogged

Clogged

c Broken cable
d Dirty auto bystarter
e Faulty auto bystarter

Clogged

Not Clogged

c Faulty auto bystarter

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.

2-27

2. GENERAL INFORMATION

VITALITY 50

ENGINE LACKS POWER
Inspection/Adjustment

Symptom

Probable Cause

Start engine and
accelerate lightly for
observation.
Engine speed
increases

Engine speed does
not increase
sufficiently

Correct timing

Incorrect timing

Normal
compression

Abnormal
compression

Not Clogged

Clogged

c Clogged air cleaner
d Clogged fuel filter
e Clogged exhaust muffler
f Faulty auto bystarter

Check ignition timing
(using a timing light).
c Faulty CDI unit
d Faulty A.C. generator

Test cylinder
compression (using a
compression gauge)
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Faulty reed valve

Check carburetor for
clogging
c Clogged carburetor jets

Remove spark plug and
inspect
Plug not fouled or
discolored

Plug fouled or
discolored

c Fouled spark plug
d Incorrect heat range plug

Engine overheats

c Mixture too lean
d Poor quality fuel
e Excessive carbon build-up in
combustion chamber
f Ignition timing too early

Engine knocks

c Excessive carbon build-up in
combustion chamber
d Poor quality fuel
e Clutch slipping
f Mixture too lean

Check if engine
overheats
Engine does not
overheats
Rapidly accelerate or
run at high speed
Engine does not
knock

2-28

2. GENERAL INFORMATION

VITALITY 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing.

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

c Faulty CDI unit
d Faulty A.C. generator

Check carburetor air
screw adjustment.
c Mixture too rich (turn screw
out)
d Mixture too lean (turn screw
in)

Check carburetor gasket
for air leaks.
Air leaks

c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed carburetor O-ring

Good spark

Weak or intermittent spark

c Faulty or fouled spark plug
d Faulty CDI unit
e Faulty A.C. generator
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch

Not clogged

Clogged

Clogged

Not clogged

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

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.

2-29

c Broken auto bystarter wire
d Faulty auto bystarter

2. GENERAL INFORMATION

VITALITY 50

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing.
c Faulty CDI unit
d Loose A.C.G. stator
e Faulty A.C. generator

Correct timing

Incorrect timing

Fuel flows freely

Fuel flow restricted

Not clogged

Clogged

c Clean and unclog

Not clogged

Clogged

c Broken auto bystarter wire
d Faulty auto bystarter

Clogged

Not clogged

Check auto fuel valve
for fuel supply.
c Empty fuel tank
d Clogged fuel tube or filter
e Clogged charcoal canister

Check carburetor jets
for clogging.

Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.

Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.
c Faulty auto bystarter

2-30

2. GENERAL INFORMATION

VITALITY 50

CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom

Probable Cause

Engine starts but motorcycle does not move

c Worn or slipping drive belt
d Broken ramp plate
e Broken driven face spring
f Separated clutch lining
g Damaged driven pulley shaft splines
h Damaged final gear
i Seized final gear

Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)

c Broken shoe spring
d Clutch outer and clutch weight stuck
eSeized pivot

Engine lacks power at
start of a grade (poor
slope performance)

c Worn or slipping drive belt
d Worn weight rollers
e Seized drive pulley bearings
f Weak driven face spring
g Worn or seized driven pulley bearings

Engine lacks power at
high speed

c Worn or slipping drive belt
d Worn weight rollers
e Worn or seized driven pulley bearings

There is abnormal noise
or smell while running

c Oil or grease fouled drive belt
d Worn drive belt
e Weak driven face spring
f Worn or seized driven pulley bearings

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
Symptom

Probable Cause
(Front and rear tire pressures are normal)

2-31

Steering is heavy

c Steering stem nut too tight
d Broken steering steel balls

Front or rear wheel is
wobbling

c Excessive wheel bearing play
d Bent rim
e Loose axle nut

Steering handlebar pulls
to one side

c Misaligned front and rear wheels
d Bent front fork

2. GENERAL INFORMATION

VITALITY 50

POOR SUSPENSION PERFORMANCE
Symptom

Probable Cause
(Front and rear tire pressures are normal)

Suspension is too soft

c Weak shock spring
d Excessive load
e Shock damper oil leaking

Suspension is too hard

c Bent fork tube or shock rod
d Fork slider and tube binding

Suspension is noisy

c Fork tube and spring binding
d Fork slider and tube binding

POOR BRAKE PERFORMANCE

Symptom

Probable Cause
(Adjust brake according to standards)

Index mark on brake
panel aligns with wear
indicator arrow

c Worn brake linings
d Worn brake cam contacting area on
brake shoes
e Worn brake cam
f Worn brake drum

Brake squeaks

c Worn brake linings
d Foreign matter on brake linings
e Rough brake drum contacting area

Brake performance is
poor

c Sluggish or elongated brake cables
d Brake shoes improperly contact
brake drum
e Water and mud in brake system
f Oil or grease on brake linings

Expanding
Brake

Hydraulic
Brake

c Faulty brake master cylinder
d Faulty brake caliper
e Oil or grease on brake disk
f Deformed brake disk
g Leaking brake fluid tube

2-32

2. GENERAL INFORMATION

VITALITY 50

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.
Signals operate
properly

Signals dim, remain
on or don‘t operate

c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness

Bulb lights

Bulb does not light

cBurned out bulb

Good

Faulty

c Loose wire connector
d Broken wire harness
e Incorrectly connected wire

Good

Faulty

c Faulty float
d Broken or shorted wire in
meter

Connect indicator light
bulb to battery for bulb
inspection.

Check connectors for
proper operation.

Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on

2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)
Inspection/Adjustment

Probable Cause

Symptom

Check connectors for
proper connection.

Good

Faulty

Good

Faulty

Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on

c Loose or disconnected
connector
d Broken wire harness
e Incorrectly connected wire

c Faulty float
d Broken or shorted wire in
meter
c Damaged oil tank
d Foreign matters in oil tank

2-33

2. GENERAL INFORMATION

VITALITY 50

FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Inspection/Adjustment

Probable Cause

Symptom

Check battery circuit by
operating turn signals.

Remove fuel unit and
check operation of
pointer by moving float
up and down.
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire
harness side.

Signals operate
properly

Signals dim, remain
on or don‘t operate

Pointer does not
move

Pointer does not
move

c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness

Pointer moves

c Faulty float

Pointer moves

c Broken or shorted fuel unit
wire

Check connectors for
proper connection.
c Loose or disconnected
Faulty

Good

connector

d Incorrectly connected
connector
c Broken or shorted wire in
fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)
Probable Cause

Symptom

Inspection/Adjustment
Check battery circuit by
operating turn signals
and horn.

Remove fuel unit and
check operation of
pointer by moving float
up and down.

Signals operate
properly

Pointer moves
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer.

Pointer moves in
accordance with
float

Signals dim, remain
on or don‘t operate

Pointer does not
move

Pointer does not
move in accordance with float

c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness
c Poor contact in fuel unit

c Insufficient damping oil in
fuel gauge

Check connectors for
proper connection.
Good

Faulty

c Loose or disconnected
connector
c Broken or shorted wire in
fuel gauge

2-34

2. GENERAL INFORMATION

VITALITY 50

STARTER MOTOR
1. Starter motor won‘t turn
Symptom

Inspection/Adjustment

Probable Cause

Check operation of
stop switch by
applying brake.
Stoplight does not
come on

c Burned out fuse
d Weak or dead battery
e Faulty stop switch
f Loose or disconnected
connector
g Broken or shorted ignition
switch wire

Signals operate
properly

Signals dim, remain
on or don‘t operate

c Faulty or weak battery

Relay operates
properly

Relay does not
operate

Starter motor turns

Starter does not turn

Stoplight comes on
Check battery circuit
by operating turn
signals.
Check operation of
starter relay by
depressing starter
button.
Connect starter
motor directly to
battery.

c Poor starter button connection
d Faulty starter relay
e Loose or disconnected
connector

c Faulty starter motor
c Faulty wire harness

2. Starter motor turns slowly or idles
Symptom

Inspection/Adjustment

Probable Cause

Check battery circuit
by operating turn
signals.
Signals operate
properly

Signals dim, remain
on or don‘t operate

c Weak or dead battery

Starter motor
turns slowly

Starter motor
turns normally

c Loose or disconnected
connector
d Faulty starter relay

Connect starter
motor directly to
battery.

Rotate crankshaft.
Hard to turn

Turns easily

c Seized cylinder
c Broken or shorted starter
motor cable
d Faulty starter pinion

3. Starter motor does not stop turning
Symptom

Inspection/Adjustment

Probable Cause

Turn ignition switch
OFF.
Not stopped

Stopped

c Faulty starter pinion
c Starter relay shorted or stuck
closed

2-35

2. GENERAL INFORMATION

VITALITY 50

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
Fuel reaches
carburetor

Fuel does not
reach carburetor

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

Weak or no spark

Faulty charging system
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery

Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Spark jumps

Test cylinder
compression
Normal
compression

Low or no
compression

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

Dry spark plug

Wet spark plug

Flooded carburetor
Faulty auto bystarter
Throttle valve excessively open

Remove spark plug and
inspect again

2-36

2. GENERAL INFORMATION

VITALITY 50

ENGINE LACKS POWER
Inspection/Adjustment

Probable Cause

Symptom

Start engine and
accelerate lightly for
observation
Engine speed
increases

Engine speed does not
increase sufficiently

Check ignition timing
(using a timing light)

Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
diaphragm
Faulty auto fuel valve
Faulty CDI unit

Correct timing

Incorrect timing

Correct

Incorrect

Faulty pulser coil

Check valve clearance
Improper valve clearance
adjustment
Worn valve seat (valve stem too
protruding

Test cylinder compression
Normal
compression

Abnormal
compression

Improper valve and seat contact
Worn cylinder and piston rings
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
discolored

Plug fouled or
discolored

Correct and not
contaminated

Incorrect or
contaminated

Fouled spark plug
Incorrect heat range plug

Remove oil dipstick and
check oil level and condition
Oil level too high
Oil level too low
Oil not changed

Remove cylinder head oil
pipe bolt and inspect
Valve train lubricated
properly

Valve train not
lubricated properly

Clogged oil pipe
Faulty oil pump

Check if engine overheats
Engine does not
overheats

Engine overheats

Rapidly accelerate or run
at high speed
Engine does not knock

2-37

Engine knocks

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

2. GENERAL INFORMATION

VITALITY 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

Check carburetor pilot
screw adjustment

Faulty CDI unit
Faulty pulser coil
The woodruff key in the
crankshaft is not fixed position.

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

Check carburetor gasket
for air leaks

No air leak

Air leaks

Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground

Deteriorated O-ring
Carburetor is not securely
tightened
Damaged insulator rubber
Broken vacuum tube

Good spark

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

Good

Faulty

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

Check air cut-off valve

2-38

2. GENERAL INFORMATION

VITALITY 50

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Faulty CDI unit
Faulty pulser coil
The woodruff key in the
crankshaft is not fix position.

Correct timing

Incorrect timing

Correctly adjusted

Incorrectly adjusted

Improperly adjusted valve
clearance
Worn valve seat

Fuel flows freely

Fuel flow restricted

Empty fuel tank
Clogged fuel tube or filter
Clogged Fuel tank cap breather
hole
Faulty auto fuel valve

Not clogged

Clogged

Clean and unclog

Correct

Incorrect

Cam timing gear aligning marks
not aligned

Not weakened

Weak spring

Check carburetor pilot
screw adjustment

Check fuel pump for
fuel supply

Check carburetor jets
for clogging

Check valve timing

Check valve spring
tension

2-39

Faulty spring

2. GENERAL INFORMATION

VITALITY 50

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

Symptom

Probable Cause

Start engine and test
limit voltage of battery
terminals
Voltage does not
increase

Dead battery
Faulty battery

Normal

Resistance too high

Faulty A.C. generator coil
Broken yellow wire
Loose connector

Normal voltage

No voltage

Broken red wire

Normal

Abnormal

Faulty regulator/rectifier
Poorly connected coupler

Normal voltage
Measure resistance
between AC generator
coil terminals

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

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”

Normal

Abnormal

Broken green wire

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

2-40

2. GENERAL INFORMATION

VITALITY 50

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
Not loose

Loose spark plug cap

Normal

Abnormal

Poorly connected coupler

Normal

Abnormal

Loose
Check CDI unit coupler
for looseness

Measure resistance
between terminals of
CDI unit coupler

Check related parts

Normal

Abnormal

Faulty ignition switch
Weak battery
Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler

Check CDI unit with
the CDI unit tester
Normal

Abnormal

cFaulty CDI unit

Check ignition coil with
the CDI unit tester
Normal

2-41

cFaulty ignition coil

3. INSPECTION/ADJUSTMENT

VITALITY 50

3
__________________________________________________________________________________

3

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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........................................................................ 3-10
AIR CLEANER.................................................................................... 3-10
CYLINDER COMPRESSION............................................................. 3-13
VALVE CLEARANCE (4-STROKE) ................................................. 3-14
IGNITION APPARATUS.................................................................... 3-15
THROTTLE GRIP PLAY.................................................................... 3-16
OTHERS............................................................................................... 3-16

3-0

3. INSPECTION/ADJUSTMENT

VITALITY 50

MAINTENANCE SCHEDULE
Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T: Tighten
Regular Service Mileage (km)

Whichever

Frequency comes
Item
*Engine oil

first Ö
Ø

Note 4

New
scooter

300km
C

Engine oil filter
screen
Fuel filter
Gear oil

300

1000

3000

5000

7000

9000

R

R

R

R

R

R

C

C

Replace at every 6000km
Note 3

R New
scooter
300km
A

*Valve clearance
Note 4
Carburetor
Air Cleaner
Note 2,3
Spark plug
Brake system
I
Drive belt
Suspension
Nut, bolt, fastener
T
Tire
Steering head bearing
I
Brake fluid
Brake lever
Brake shoe wear
Shock absorber

R

R

A
A
I
I
I
R
I
R
Clean at every 2000km and replace if necessary
I
I
I
I
I
I
I
T
I
I
I
I
I
Perform pre-ride inspection daily
I
I
I

I
I

I
I
I

• 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.
3. Service more frequently when riding in rain or at full throttle.
4. 4-stroke engine only.

3-1

3. INSPECTION/ADJUSTMENT

VITALITY 50

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.
Turn the adjusting nut in direction (A) to
decrease play, and in direction (B) to
increase play.
Turn the adjusting nut on the brake hub in
direction (A) to decrease play, and in
direction (B) to increase play.



Make sure the cut-out on the adjusting
nut (2) is seated on the brake arm pin
(1) after making final free play
adjustment.

3-2


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