SM - Kymco Vitality 50 - Chapter 04 (Lubrication System)
15
4. LUBRICATION SYSTEM 4-0 VITALITY 50 4 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION (2-STROKE).................................... 4-3 SERVICE INFORMATION (4-STROKE).................................... 4-4 OIL PUMP (2-STROKE) ........................................................... 4-5 OIL TANK (2-STROKE) ........................................................... 4-8 ENGINE OIL/OIL FILTER (4-STROKE) ................................... 4-9 OIL PUMP (4-STROKE) ........................................................... 4-9 4
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Transcript of SM - Kymco Vitality 50 - Chapter 04 (Lubrication System)
4. LUBRICATION SYSTEM
4-0
VITALITY 50
4 __________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
LUBRICATION SYSTEM__________________________________________________________________________________
SERVICE INFORMATION (2-STROKE).................................... 4-3
SERVICE INFORMATION (4-STROKE).................................... 4-4
OIL PUMP (2-STROKE) ........................................................... 4-5
OIL TANK (2-STROKE) ........................................................... 4-8
ENGINE OIL/OIL FILTER (4-STROKE) ................................... 4-9
OIL PUMP (4-STROKE) ........................................................... 4-9
4
4. LUBRICATION SYSTEM
4-1
VITALITY 50
LUBRICATION SYSTEM(2-STROKE)
4. LUBRICATION SYSTEM
4-2
VITALITY 50
(4-STROKE)
Oil PumpOil Filter Screen
Crankshaft
Rocker Arm Shaft
4. LUBRICATION SYSTEM
4-3
VITALITY 50
SERVICE INFORMATION (2-STROKE)
GENERAL INSTRUCTIONS
• Use care when removing and installing the oil pump not to allow dust and dirt to enter the engineand oil line.
• Do not attempt to disassemble the oil pump.• Bleed air from the oil pump if there is air between the oil pump and oil line.• If the oil is disconnected, refill the oil line with motor oil before connecting it.
SPECIFICATIONS
• Recommended Motor Oil: SAE20W20# 2-stroke Motor Oil• Oil Capacity : 1.3 liter
Light comes on : 0.5 liter
TROUBLESHOOTING
Excessive white smoke or carbon deposits on spark plug• Oil pump not properly synchronized (excessive oil)• Poor quality oil
Engine overheating• Oil pump not properly adjusted (insufficient oiling)• Poor quality oil
Seized piston• No oil in tank or clogged oil line• Oil pump not properly adjusted (insufficient oiling)• Air in oil line• Faulty oil pump
Oil not flowing out of tank to engine• Clogged oil tank cap breather hole• Clogged oil filter
4. LUBRICATION SYSTEM
4-4
VITALITY 50
SERVICE INFORMATION (4-STROKE)
GENERAL INSTRUCTIONS
• The maintenance of lubrication system can be performed with the engine installed in the frame.• Use care when removing and installing the oil pump not to allow dust and foreign matters to enter
the engine and oil line.• Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it
reaches its service limit.• After the oil pump is installed, check each part for oil leaks.
SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Inner rotor-to-outer rotor clearance 0.15 0.20
Oil pump Outer rotor-to-pump body clearance 0.15_ 0.20 0.25
Rotor end-to-pump body clearance 0.04_ 0.09 0.12
TROUBLESHOOTING
Oil level too low Poor lubrication pressure• Natural oil consumption • Oil level too low• Oil leaks • Clogged oil filter or oil passages• Worn or poorly installed piston rings • Not use the specified oil• Worn valve guide or seal
4. LUBRICATION SYSTEM
4-5
VITALITY 50
OIL PUMP (2-STROKE)REMOVAL
Remove the met-in box (13-5), spark plugcover (13-5), center cover (13-6).
Disconnect the oil pump control cable (3)from the pump body.Disconnect the oil inlet line (1) from the oilpump.Then, disconnect the oil outlet line (2).
Remove the two bolts and oil pump controlcable plate (1).
Pull up and remove the oil pump (2) fromthe crankcase.
INSPECTION
Remove the oil pump and inspect thefollowing items:• Weakened O-ring (1)• Damage to crankcase mating surface• Damage to pump body• Control lever operation (2)• Oil leaks through oil seals• Worn or damaged pump pinion (3)
Do not allow foreign matters to enter thecrankcase. Before removing the oilpump, clean the oil pump and crankcasesurfaces.
°Ø
Do not disassemble the oil pump whichcannot be used after disassembly.
°Ø
Before disconnecting the oil line, clipthe oil line to avoid oil flowing out andthen plug the oil line after it isdisconnected.
°Ø
4. LUBRICATION SYSTEM
4-6
VITALITY 50
INSTALLATION
Install the oil pump into the crankcase.Install the oil pump control cable plate (1)and tighten the two bolts.
Connect the oil inlet line (1) and oil outletline (2) properly.Connect the oil pump control cable (3).Bleed air from the oil pump.
• Lubricate the O-ring (1) with grease orengine oil before installation.
•Make sure that the oil pump isinserted into the crankcase.
•Apply molybdenum disulfide or greaseto the pump pinion.
°Ø
4. LUBRICATION SYSTEM
4-7
VITALITY 50
BLEEDING
OIL INLET LINE/OIL PUMP BLEEDINGFill the oil tank with recommended oil.Place a shop towel around the oil pump.Disconnect the oil inlet line from the oilpump and clip it.Fill the oil pump with oil by squirting cleanoil through the joint. (About 3cc)Fill the oil line with oil and connect it to theoil pump.
OIL OUTLET LINE BLEEDING1. Disconnect the oil outlet line and bend it
into U shape. Force air out of the tube byfilling it with oil.
2. Start the engine and allow it to idle withthe oil control lever in the fully openposition. Visually check the oil flow.
3. If there is no oil flowing out within 1minute, bleed air from the oil inlet lineand oil pump.
•Air in the oil lines will block oil flowand result in severe engine damage.
• Bleed air from the oil lines and oilpump whenever the oil lines or pumphave been removed or there is air in theoil lines.
°Ø
Bleed air from the oil inlet line first,then bleed air from the oil outlet line.
°Ø
•Never run the engine in a closed area.•Do not increase the engine speed at
will.
°Ø Oil Outlet Line
4. LUBRICATION SYSTEM
4-8
VITALITY 50
OIL TANK (2-STROKE)
OIL TANK REMOVALRemove the rear body cover. (13-6)
Disconnect the oil meter connector (1).Remove the two bolts from the oil tank.Disconnect the oil inlet line (2).Drain the oil inside the oil tank into a cleancontainer.Remove the oil tank.The installation sequence is the reverse ofremoval.
• Connect the oil line properly.• Bleed air from the oil pump after
installation.• The oil tube clip (at the oil tank side)
must be locked from inside of the oiltube joint.
°Ø
4. LUBRICATION SYSTEM
4-9
VITALITY 50
Bolts
Nut
Bolts
ENGINE OIL/OIL FILTER
(4-STROKE)OIL LEVEL AND OIL CHANGE
Refer to the “ENGINE OIL” section in thechapter 3 to check the oil level andreplacement and oil filter cleaning.
OIL PUMP (4-STROKE)REMOVALPlace a container under the engine.Remove the drain plug to drain the oil. (3-8)Remove the A.C. generator flywheel. (8-3)Remove the A.C. generator stator andpulsar coil. (8-3)Remove the eight right crankcase coverbolts and the right crankcase cover.
Remove the oil pump gear nut and oil pumpgear.
Oil Pump Gear
Nut
Bolts
Right Crankcase Cover
4. LUBRICATION SYSTEM
4-10
VITALITY 50
Remove three oil pump mounting bolts andthe oil pump.
Remove O-rings and dowel pin.
Bolts
Oil Pump
O-rings Dowel Pin
4. LUBRICATION SYSTEM
4-11
VITALITY 50
Bolts
Outer Rotor Pump Body
Outer Rotor
Inner Rotor
DISASSEMBLYRemove the screws and disassemble the oilpump.
INSPECTIONMeasure the pump body-to-outer rotor clearance.Service Limit: 0.25mm
Measure the inner rotor-to-outer rotorclearance.Service Limit: 0.2mm
Screws
4. LUBRICATION SYSTEM
4-12
VITALITY 50
Inner Rotor
Screws
Dowel Pin
Measure the rotor end-to-pump bodyclearance.Service Limit: 0.12mm
ASSEMBLYInstall the outer rotor, inner rotor and pumpshaft into the pump body.
Install the dowel pin.Install the pump cover by aligning the holein the cover with the dowel pin.
Tighten the screw to secure the pumpcover.Make sure that the pump shaft rotatesfreely without binding.
Insert the pump shaft by aligning the flaton the shaft with the flat in the innerrotor.
°Ø
4. LUBRICATION SYSTEM
4-13
VITALITY 50
INSTALLATIONInstall the O-rings and dowel pin.
Install the oil pump and tighten the bolts.Make sure that the pump shaft rotatesfreely without binding.
Install the oil pump gear and tighten thenut.
Bolts
Oil Pump
O-rings Dowel Pin
Inspect the O-rings and replace ifdamaged.
°Ø
Oil Pump Gear
Nut
4. LUBRICATION SYSTEM
4-14
VITALITY 50
Install the right crankcase cover and tightenthe bolts.
Right Crankcase Cover
Bolts
