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6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

6




6




6-0
6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

SERVICE INFORMATION ...................... 6-1 ENGINE INSTALLATION .......................6-4
ENGINE REMOVAL ................................ 6-2



SERVICE INFORMATION
GENERAL INSTRUCTIONS
A floor jack or other adjustable support is required to support and maneuver the engine. Be
careful not to damage the motorcycle body, cables and wires during engine removal.
Use shop towels to protect the motorcycle body during engine removal.
Parts requiring engine removal for servicing:
Crankcase
Crankshaft




6-1
6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

ENGINE REMOVAL
Disconnect the battery negative cable.
Remove the frame body cover. ( 2-3)
Disconnect the spark plug high tension wire.
Disconnect the auto bystarter wire connector.
Disconnect the A.C. generator wire
connector.




Negative Cable Auto Bystarter Wire Connector

Disconnect the starter motor cable and earth
cable from the starter motor.
Remove the fuel tube.




fuel tube Earthr Cable Starter Motor Cable

Remove the spark plug cap.




Spark Plug High Tension Wire
Disconnect the vacuum tube.
Loosen the throttle cable adjusting nut and Band Vacuum Tube
lock nut, and disconnect the throttle cable
from the carburetor.




Lock Nut Adjusting Nut


6-2
6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

Air Tube Band
Loosen the drive belt air cleaner connecting
tube band screw and remove the connecting
tube.




connecting tube

Remove the rear brake adjusting nut,
connector pin rear brake cable.




Adjusting Nut

Remove the rear shock absorber upper mount Rear Shock Absorber Upper Mount Bolt
bolt.




Remove the engine mounting bolt and move
the motorcycle forward to separate it from the
engine.
Support the motorcycle with a floor jack.




Engine Hanger Engine Mounting Bolt
Bracket Bolt

6-3
6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

ENGINE HANGER BRACKET
REMOVAL
Remove the return spring from the main
stand.
Remove the main stand.




Main Stand Return Spring
Bushing


Remove the engine hanger bracket bolts and
engine hanger bracket.
Inspect the engine hanger bushings and
stopper spring for wear or damage.




Stopper Spring

ENGINE HANGER BRACKET
INSTALLATION
Install the engine hanger bracket to the
chassis and tighten the bolt.
Install the main stand onto the engine and
install the return spring.




Main Stand Return Spring

Engine Mounting Bolt
ENGINE INSTALLATION
Install the engine and tighten the engine
mounting bolt.
Torque: 4.5~5.5kgf-m
Tighten the rear shock absorber upper mount
bolt.
Torque: 4.5~5.5kgf-m


Engine Hanger Bracket Bolt

6-4
6. ENGINE REMOVAL/INSTALLATION FILLY LX 50

Install the removed parts in the reverse order Rear Shock Absorber Upper Mount Bolt
of removal.

Route the wires and cables properly.
After installation, inspect and adjust the
following:
Throttle grip free play ( 3-3)
Rear brake adjustment ( 3-8)




6-5