sm - kymco vitality 50 - chapter 13 (exhaust - frame covers)

13. FRAME COVERS/EXHAUST MUFFLER

13-0

VITALITY 50

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FRAME COVERS/EXHAUST MUFFLER__________________________________________________________________________________

SERVICE INFORMATION........................................................ 13- 1

FRAME COVERS REMOVAL ................................................... 13- 2

EXHAUST MUFFLER .............................................................. 13- 10

13


13-1

VITALITY 50

SERVICE INFORMATION• When removing frame covers, use care not to pull them by force because the cover joint claws

may be damaged.

Items Related for Removal• Handlebar front cover Handlebar rear cover

• Front cover Headlight wire

• Handlebar rear cover Speedometer cable and instrument lightwire connectors, etc.

• Frame body cover Met-in box, rear carrier

• Floor board Rear carrier, frame body cover, right and leftside cover, battery

• Leg shield Front body cover, front right and left side covers,rear body cover, floor board


13-2

VITALITY 50

FRAME COVERS REMOVALHANDLEBAR FRONT COVERREMOVAL/INSTALLATIONRemove the screw from the handlebar frontcover.

Remove the two screws from the handlebar rearcover.Separate the handlebar front cover fromhandlebar rear cover.

Disconnect the winker relay from the handlebarfront cover and then remove handlebar frontcover.

Installation is in the reverse order of removal.

During removal, be careful not to pullthe joint claws forcibly and remove thefront cover downward.

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13. FRAME COVERS

13-3

HANDLEBAR REAR COVERREMOVAL/INSTALLATIONRemove the handlebar front cover. (13-2)

Remove the bolt from handlebar rear cover.

Remove the two mounting screws anddisconnect speedometer cable (1).Disconnect the wire connectors (2) andseparate handlebar rear cover.

Remove the three screws from the instrumentand then remove handlebar rear cover.



13-4

VITALITY 50

FRONT COVER REMOVALRemove the screw and front cover (1).


RIGHT/LEFT SIDE COVERSREMOVAL/INSTALLATIONRemove the two screws and then removeright/left side cover (1).


FRONT FENDERREMOVAL/INSTALLATIONRemove the four screws and then remove frontfender.



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13. FRAME COVERS

13-5

REAR CARRIERREMOVAL/INSTALLATIONRemove the three bolts and then remove rearcarrier (1).


MET-IN BOX REMOVAL/INSTALLATIONUnlock the seat with ignition key and open theseat.Remove the screw, two bolts and two nutsfrom met-in box.Remove the oil tank cap (1) and then removemet-in box.


SPARK PLUG COVERREMOVAL/INSTALLATIONRemove the screw and then remove spark plugcover (1).



13-6

VITALITY 50

CENTER COVERREMOVAL/INSTALLATIONRemove the met-in box. (13-5)

Remove the two screws and then remove centercover.


REAR BODY COVERREMOVAL/INSTALLATIONRemove the following: Met-in box (13-5) Center cover (13-6) Rear carrier (13-5)

Remove the two screws from the rear fender.

Remove the two screws form the rear bodycover.Disconnect the seat lock cable and then removerear body cover.


When removing the right and left siderails, pull them backward not to damagethe joint claws.

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13. FRAME COVERS

13-7

REAR UPPER FENDER & TAILLIGHTREMOVAL/INSTALLATIONRemove the following: Met-in box (13-5) Rear carrier (13-5) Center cover (13-6) Rear body cover (13-6)

Remove the two bolts from the taillight andtwo nuts from the rear upper fender.

Slide the two clips (1) for disconnect fuel hoseand vacuum hose (2).Remove the rear upper fender/taillight.


BOTTOM COVERREMOVAL/INSTALLATIONRemove the right and left side covers. (13-4)

Remove the nut from the bottom cover leftside.

(1)


13-8

VITALITY 50

Remove the two nuts from the bottom coverright side and then remove bottom cover.


FLOOR BOARDREMOVAL/INSTALLATIONRemove the following: Rear carrier (13-5) Right and left side cover (13-4) Met-in box (13-5) Center cover (13-6) Rear body cover (13-6) Battery cover (1) (16-5) Battery (2) (16-5) Fuse (3) (16-5)

Remove the four bolts and then remove floorboard.


13. FRAME COVERS

13-9

LEG SHIELD REMOVAL/INSTALLATIONRemove the following: Rear carrier (13-5) Right and left side cover (13-4) Met-in box (13-5) Center cover (13-6) Rear body cover (13-6) Battery cover (16-5) Battery (16-5) Fuse (16-5) Floor board (13-8)

Remove the ten screws and one bolt from theleg shield.Turn the ignition switch cover (1)counterclockwise and remove ignition switchcover, then remove leg shield.


FRONT BODY COVERREMOVAL/INSTALLATIONRemove the following: Front cover (13-4) Right and left side cover (13-4)

Remove the two nuts form the front bodycover.


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13-10

VITALITY 50

Remove the ten screws from the leg shield.Disconnect the headlight connector and thenremove front body cover.


EXHAUST MUFFLERREMOVAL/INSTALLATIONDisconnect the secondary air hose (2-stroke).(5-3)

Remove the two exhaust pipe joint lock nuts(1).

Remove the bolt from the rear lower fender andtwo Exhaust muffler lock bolts from theexhaust muffler.


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13. FRAME COVERS

13-11

Inspect the gasket (1).If the exhaust gas leaks, the gasket should bereplaced.


Torque:Exhaust muffler lock bolt: 3.0_ 3.6kgf-mexhaust pipe joint lock nuts: 1.0_ 1.4kgf-m

When installing the exhaust muffler,first tighten the two nuts on the frontand then tighten the two bolts.

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Be sure to install a new exhaust gasket.°Ø

sm - kymco vitality 50 - chapter 13 (exhaust - frame covers)

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