Kymco Sento 50 / Kiwi 50 / Kiwi 100 Scooter Service Manual, 2009–2012

This KYMCO service manual covers the 2009–2012 Sento 50, Kiwi 50, and Kiwi 100 carbureted models. It was published by KYMCO’s Quality Technology Division, Overseas Service Department.

PDF Search, Bookmarks, and Circuit Detail

Text search and navigation: The main service procedures contain searchable text, but some table content and diagram labels are not searchable. Chapter bookmarks are present; some individual page bookmarks lead to unrelated pages. Small circuit labels require zooming for comfortable reading.

The ZIP contains one printable, 164-page English PDF, including one combined preface and contents page and 17 service sections.

Engine, CVT, Chassis, and Electrical Service

These selected content highlights outline the repair coverage. Other topics include body-panel removal and headlight-aim adjustment.

• Engine repair: Engine removal and installation, engine-hanger inspection, oil-pump service, camshaft and valve work, cylinder and piston inspection, crankcase separation, crankshaft checks, and reassembly.

• Fuel-system service: CVK carburetor removal, auto-bystarter testing, air cut-off valve and vacuum-chamber work, float and accelerator-pump inspection, float-level measurement, and pilot-screw and idle adjustment.

• CVT and final drive: Drive-belt replacement, drive-pulley and weight-roller inspection, clutch/driven-pulley disassembly, kick-starter service, driven-face bearing replacement, and final-reduction gear, bearing, and oil-seal repair.

• Brakes, steering, and suspension: Hydraulic front-brake bleeding, master-cylinder and caliper repair, front-fork overhaul, steering-head race replacement, rear drum-brake service, and rear shock-absorber disassembly and inspection.

• Electrical diagnosis: Battery and charging tests, regulator/rectifier inspection, A.C. generator removal, CDI, ignition-coil and pulser-coil checks, starter-motor repair, starter-relay testing, switch continuity checks, and fuel-gauge diagnosis.

• Diagrams and fault isolation: Charging System Diagram, Ignition System and Starting System circuits, a lubrication-system schematic, cable-and-harness routing views, and exploded assemblies, supported by troubleshooting charts for starting, power, carburetion, charging, and no-spark faults.

Because the deeper procedures call for dedicated pullers, holders, compressors, precision measuring equipment, and electrical testers, this service manual is suited to professional technicians and experienced owners already comfortable with engine, brake, and electrical repair.

Engine Access and Internal Inspection

The cylinder head, cylinder and piston, and CVT assemblies can be serviced with the engine installed. Crankcase separation and crankshaft service require engine removal. These access notes help determine the extent of disassembly before a repair begins.

Inspection depth: Component sections cover oil-pump rotor clearances; camshaft, rocker-arm, valve-spring, and cylinder-head checks; piston-ring, bore, and connecting-rod measurements; and crankshaft big-end clearance and runout. Step-by-step procedures address camshaft installation, cam-chain tensioner installation, and crankcase reassembly.

Variant reference data: Factory tables distinguish spark-plug application, valve clearance, idle speed, compression, rear-tire specification, and reduction ratio. Component sections add fastener torque tables, wear limits, fit and clearance data, electrical test values, and suspension specifications.

Brake Configurations and Electrical Fault Tracing

The adjustment section specifically identifies front-brake lever free-play coverage for SD10RB and SG20TB. The hydraulic front-disc subsection covers fluid replacement and bleeding, pad and disc service, master-cylinder inspection and assembly, and caliper disassembly and assembly.

Chassis procedures also address wheel runout, steering-stem bearings, fork oil filling, rear brake shoes, and wear-indicator indexing. During brake repair, fluid must be kept off coated and plastic surfaces, and oil or grease must not contaminate pads, discs, drums, or linings because braking performance can be reduced.

Circuit checks: Connector views and continuity tables support checks of the regulator/rectifier, handlebar switches, ignition switch, horn, stop switches, and fuel unit. The ignition section explains the specified-tester requirements for CDI resistance checks and identifies the CDI timing as nonadjustable.

Workshop Tools and Carburetor Cautions

The special-tool chart identifies the oil-seal and bearing installer A120E00014, valve adjuster A120E00036, clutch spring compressor A120E00034, universal holder A120E00017, and flywheel puller A120E00001.

The carburetor procedures warn that forcing the pilot screw against its seat can damage the seat. They also identify the vacuum diaphragm as vulnerable to compressed-air cleaning damage.

Preview of Valve and Carburetor Test Data

For cold-engine valve inspection below 35°C, the manual lists intake and exhaust clearances of 0.04 mm for SD10RA/RB/RC and 0.10 mm for SG20TA/TB.

The carburetor section specifies a 17.0 mm float level and an auto-bystarter resistance limit of 10 Ω maximum, measured at least 10 minutes after stopping the engine. These examples show the adjustment and component-test detail included alongside the illustrated procedures.