sm - kymco vitality 50 - chapter 09 (drive pulley - clutch - kick starter)

9. KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY

9-0

VITALITY 50

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KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY

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SERVICE INFORMATION........................................................ 9- 2

TROUBLESHOOTING.............................................................. 9- 2

KICK STARTER....................................................................... 9- 3

DRIVE BELT ........................................................................... 9- 7

DRIVE PULLEY....................................................................... 9- 9

STARTER PINION ................................................................... 9-11

CLUTCH/DRIVEN PULLEY ..................................................... 9-12

9


9-1

VITALITY 50

Torque:3.5_ 4.5kg-m

Torque:5.0_ 6.0kg-m

Torque:3.5_ 4.0kg-m


9-2

VITALITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• Avoid getting grease and oil on the drive belt and pulley faces.

SPECIFICATIONS VITALITY 50

Item Standard (mm) Service Limit (mm)

Drive pulley collar O.D. 19.96_ 19.974 19.94

Movable drive face I.D. 20.011_ 20.052 20.6

Weight roller O.D. 15.92_ 16.08 15.4

Clutch outer I.D. 107_ 107.2 107.5

Driven face spring free length 87.9 (2-stroke) 82.6 (2-stroke)

Driven face spring free length 95 (4-stroke) 90 (4-stroke)

Driven face O.D. 33.965_ 33.985 33.94

Movable driven face I.D. 34.0_ 34.25 34.06

Drive belt width 18 17

TORQUE VALUES

Drive face nut 3.5_ 4.0kg-mClutch outer nut 3.5_ 4.5kg-mClutch drive plate nut 5.0_ 6.0kg-m

SPECIAL TOOLS

Universal holder E017Clutch spring compressor E034

TROUBLESHOOTINGPoor performance at high speed or

Engine starts but motorcycle won‘t move lack of power• Worn drive belt • Worn drive belt• Broken ramp plate • Weak driven face spring• Worn or damaged clutch lining • Worn weight roller

• Faulty driven face

Engine stalls or motorcycle creeps• Broken clutch weight spring


9-3

VITALITY 50

KICK STARTERLEFT CRANKCASE COVER REMOVALRemove left side cover. (13-4)Remove the drive belt cooling air tubeconnector circlip. (5-3)Remove air cleaner housing. (5-2)

Remove the nine left crankcase cover bolts,left crankcase cover and dowel pins.Inspect the left crankcase cover seal rubberfor damage or deterioration.

KICK STARTER SPINDLE REMOVALRemove the kick lever from the kick starterspindle.Remove the circlip and washer from thekick starter spindle.

Slightly rotate the kick starter spindle toremove the kick starter driven gear togetherwith the friction spring.

Left Crankcase Cover

Bolt

Friction Spring

Kick Starter Driven Gear

Kick Starter Spindle


9-4

VITALITY 50

Remove the kick starter spindle and returnspring from the left crankcase cover.Remove the kick starter spindle bushing.

KICK STARTER SPINDLE INSPECTIONInspect the kick starter spindle and gear forwear or damage.Inspect the return spring for weakness ordamage.Inspect the kick starter spindle bushing forwear or damage.

Check the kick starter driven gear for wearor damage.Check the friction spring for wear ordamage.


Return Spring

Spindle

Plastic Bushing Spindle Bushing

Return Spring

Friction Spring



9-5

VITALITY 50

Inspect the kick starter spindle and drivengear forcing parts for wear or damage.

KICK STARTER INSTALLATIONInstall the kick starter spindle bushing andreturn spring onto the left crankcase cover.

Properly install the kick starter driven gearand friction spring as the figure shown.

If the hooks of the return spring can notbe installed properly, use a screw driverto press them into their locationsrespectively.

°Ø

Kick Starter Spindle Forcing Part

Kick Starter Driven Gear Forcing Part

Friction Spring


Friction Spring



9-6

VITALITY 50

First install the washer and then the circliponto the kick starter spindle.Install the kick lever.

LEFT CRANKCASE COVERINSTALLATIONFirst install the dowel pins and then the sealgasket.

Install the left crankcase cover and tightenthe ten bolts diagonally.Connect the drive belt cooling air tube andinstall the circlip.

Left Crankcase Cover

Rear Brake Cable Clamp

Seal Gasket

Dowel Pins

Washer Circlip

For drum brake, note the location of thebrake cable clamp and install the rearbrake cable in place with the clamp.

°Ø


9-7

VITALITY 50

DRIVE BELTRemove the left crankcase cover. (9-3)

INSPECTIONCheck the drive belt for cracks, separationor abnormal or excessive wear.Measure the drive belt width.Service Limit: 17mm replace if below

REPLACEMENTRemove the ten left crankcase cover boltsand left crankcase cover. (9-3)

Hold the clutch outer with the universalholder and remove the 10mm clutch outernut and clutch outer.

Universal holder E017

Hold the drive pulley with the holder andremove the 12mm drive face nut.Remove the starting ratchet.Remove the drive pulley face.

Use specified genuine parts forreplacement.

°Ø

Clutch Outer

Drive Face Nut

Drive Face

Universal Holder

Clutch Outer Nut

Ratchet

Special


9-8

VITALITY 50

Remove the drive belt from the clutch/driven pulley.

DRIVE BELT INSTALLATIONTurn the driven pulley clockwise and lift itup to expand the drive belt groove and theninstall a new drive belt.

Set the drive belt on the drive pulley.Install the drive pulley face, starting ratchetand 12mm drive face nut, then tighten thedrive face nut.Torque: 3.5_ 4.0kg-m

Clutch/Driven Pulley

Drive Belt

Drive Belt

Drive Pulley Face

Drive BeltStarting Ratchet

Drive Face Nut

When installing the drive face nut, makesure that the tooth spaces of the drivepulley face and starting ratchet alignwith the teeth of the crankshaft.

°Ø


9-9

VITALITY 50

DRIVE PULLEYREMOVALHold the drive pulley with the holder andremove the 12mm drive face nut.Remove the starting ratchet and drivepulley face.

MOVABLE DRIVE FACEDISASSEMBLYRemove the movable drive face and drivepulley collar from the crankshaft.

Remove the ramp plate.

Movable Drive Face

Ramp Plate

Drive Pulley Collar

12mm Drive Face Nut

Starting RatchetDrive Pulley Face


9-10

VITALITY 50

Remove the weight rollers.

MOVABLE DRIVE FACE INSPECTIONCheck each weight roller for wear ordamage.Measure each roller O.D.Service Limit: 15.4mm replace if below

DRIVE PULLEY INSTALLATIONInstall the drive pulley collar and movabledrive face onto the crankshaft.

Weight Roller

Movable Drive Face

Drive Pulley Collar


9-11

VITALITY 50

Install the drive belt on the crankshaft.Install the drive face, starting ratchet andwasher, then tighten the 12mm drive facenut.Torque: 3.5_ 4.0kg-m

STARTER PINIONREMOVALRemove the left crankcase cover. (9-3)Remove the drive pulley. (9-9)Remove the starter pinion.

INSPECTIONInspect the starter pinion seat for wear.Inspect the starter pinion for smoothoperation.Inspect the starter pinion shaft forcingparts for wear and damage.

INSTALLATIONApply a small amount of grease to thestarter pinion teeth.Install the starter pinion in the reverse orderof removal.

Keep grease or oil off the drive belt anddrive pulley faces.

°Ø

Drive Face Nut Starting Ratchet

Drive Pulley Face

Starter Pinion

Shaft Forcing Parts

Starter Pinion


9-12

VITALITY 50

CLUTCH/DRIVEN PULLEYCLUTCH/DRIVEN PULLEY REMOVALRemove the drive pulley. (9-9)

Hold the clutch outer with the universalholder and remove the 10mm clutch outernut.Remove the clutch outer.


Remove the clutch/driven pulley.Remove the drive belt from theclutch/driven pulley.

CLUTCH/DRIVEN PULLEY DIS-ASSEMBLYCompress the clutch/driven pulley springwith the clutch spring compressor andremove the 39mm drive plate nut.Remove the driven face spring.



Universal Holder Clutch Outer

14mm Clutch Outer Nut

Special

Special

Clutch spring compressor


9-13

VITALITY 50

Remove the seal collar.

Pull out the guide roller pins from thedriven pulley and then remove the O-ringsand oil seal from the driven pulley.

CLUTCH/DRIVEN PULLEYINSPECTIONInspect the clutch outer for wear or damage.Measure the clutch outer I.D.Service Limit: 107.5mm replace if below

Seal Collar

O-rings Guide Roller Pin

Driven Pulley


9-14

VITALITY 50

Check the clutch shoes for wear or damage.Measure the clutch lining thickness.Service Limit: 2.0mm replace if below

Measure the driven face spring free length.Service Limit: 82.6mm replace if below

Check the driven face assembly for wear ordamage.

Measure the driven face O.D.Service Limit: 33.94mm replace if below

Check the movable driven face for wear ordamage.

Measure the movable driven face I.D.Service Limit: 34.06mm replace if below

Check the guide roller pins for steppedwear.


9-15

VITALITY 50

DRIVEN PULLEY FACE BEARINGREPLACEMENTCheck the needle bearings in the driven faceand replace them if they have excessiveplay, damage or abnormal noise.Drive the inner bearing out of the drivenpulley face.

Remove the snap ring and drive the outerbearing out of the driven face.

Drive a new outer bearing into the drivenface with the sealed end facing up.Seat the snap ring in its groove.

Bearing Outer Driver

Inner Bearing

Outer Bearing

Pack all bearing cavities with 5.0_ 5.6ggrease.Specified grease: 230¢JHeat-resistant

grease

°Ø


9-16

VITALITY 50

Drive in a new needle bearing into thedriven face with the mark facing up.

CLUTCH/DRIVEN PULLEY ASSEMBLYFirst install the movable driven face ontothe driven face. Then, install the guide rollerpins, O-rings and a new oil seal.

Install the seal collar.

Seal Collar

O-rings Guide Roller Pin

Driven Pulley

Bearing Driver Pilot


9-17

VITALITY 50

Set the driven pulley, driven face spring andclutch assembly onto the clutch springcompressor. Compress the tool and installthe 39mm drive plate nut.Tighten the 39mm nut to the specifiedtorque.Torque: 5.0_ 6.0kg-m


CLUTCH/DRIVEN PULLEYINSTALLATIONInstall the drive belt on the clutch/drivenpulley and then install the clutch/drivenpulley onto the drive shaft.

Install the clutch outer.Hold the clutch outer with the universalholder.Install and tighten the 14mm clutch outernut.Torque: 3.5_ 4.5kg-m


Universal Holder

Clutch Outer


Clutch spring compressor

Special

Special

sm - kymco vitality 50 - chapter 09 (drive pulley - clutch - kick starter)

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