Agility 50 - 125
Agility 50 - 125
CICLOMOTORI 4T |
SCOOTER TARGATI |
2 ANNI DI GARANZIA |
1 ANNO DI ASSISTENZA |
CREDITO PERSONALIZZATO |
KYMCO RACCOMANDA |
S e r v i z i F i n a n z i a r i
|
50 4T R10 |
50 4T R12 |
125 |
||
MOTORE |
|
MONOCILINDRICO ORIZZONTALE 4 TEMPI |
|||
RAFFREDDAMENTO |
|
|
ARIA FORZATA |
|
|
CILINDRATA |
|
|
49cc |
|
125cc |
POTENZA |
2,4kW (3,3CV) a 8.500 giri/min 2,4kW (3,3CV) a 7.500 giri/min 6,9kW (9,4CV) a 7.500 |
||||
COPPIA |
|
3,2 Nm a 7.000 giri |
|
9,6 Nm a 6.500 giri |
|
EMISSIONI |
|
|
EURO 2 |
|
EURO 3 |
AVVIAMENTO |
|
|
ELETTRICO E KICK STARTER |
|
|
FRIZIONE |
|
|
CENTRIFUGA AUTOMATICA A SECCO |
|
|
TRASMISSIONE |
|
|
CINGHIA TRAPEZOIDALE - INGRANAGGI |
|
|
SOSPENSIONI |
|
ANT. FORCELLA TELESCOPICA IDRAULICA ø 31 |
|||
|
POST. MONOBRACCIO OSCILLANTE AMMORTIZZATORE IDRAULICO REGOL |
||||
FRENI |
|
|
ANT. DISCO ø 180mm |
|
|
|
|
|
POST. TAMBURO ø 110mm |
|
|
PNEUMATICI |
ANT. - POST. 90/90-10 |
|
ANT. 120/70-12 |
||
|
|
POST. 130/70-12 |
|||
|
|
|
|
||
DIMENSIONE |
1.830 x 690 x 1.070mm |
1.830 x 690 x 1.130mm |
1.835 x 690 |
||
MASSA |
|
84kg |
|
92kg |
1 |
COLORI |
argento |
nero |
argento |
nero |
rosso |
KYMCO SI RISERVA DI APPORTARE VARIAZIONI TECNICHE, ESTETICHE O DI ALTRA NATURA SENZA L’OBBLIGO DI ALCUN PREAVVISO. |
2616-040407 |
PREFACE
This Service Manual describes the technical features and servicing procedures for the KYMCO AGILITY
50
Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation.
Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations.
Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.
Sections 6 through 17 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment.
Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section.
Our company reserves the right to
make any alteration in the design.
The information and contents included in this manual may be different from the motorcycle in case specifications are changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION
AGILITY 50
TABLE OF CONTENTS
|
GENERAL INFORMATION |
1 |
|
|
|
|
|
|
FRAME COVERS/EXHAUST MUFFLER |
2 |
|
|
|
|
|
|
INSPECTION/ADJUSTMENT |
3 |
|
|
|
|
|
|
LUBRICATION SYSTEM |
4 |
|
|
|
|
|
ENGINE |
FUEL SYSTEM |
5 |
|
|
|
||
ENGINE REMOVAL/INSTALLATION |
6 |
||
|
|||
|
|
|
|
|
CYLINDER HEAD/VALVES |
7 |
|
|
|
|
|
|
CYLINDER/PISTON |
8 |
|
|
|
|
|
|
DRIVE AND DRIVEN PULLEYS/KICK |
9 |
|
|
STARTER |
|
|
|
FINAL REDUCTION |
10 |
|
|
|
|
|
|
CRANKCASE/CRANKSHAFT |
11 |
|
|
|
|
|
CHASSIS |
FRONT WHEEL/FRONT BRAKE/ |
13 |
|
SUSPENSION |
|||
|
FRONT SUSPENSION |
12 |
|
|
REAR WHEEL /REAR BRAKE /REAR |
|
|
|
|
|
|
EQUIPMENT |
BATTERY/CHARGING SYSTEM/A.C. |
14 |
|
|
|
||
|
|
||
|
|
||
|
|
||
ELECTRICAL |
GENERATOR |
15 |
|
|
IGNITION SYSTEM |
||
|
STARTING SYSTEM |
16 |
|
|
LIGHTS/INSTRUMENTS/SWITCHES |
17 |
|
|
|
|
1. GENERAL INFORMATION
AGILITY 50
ENGINE SERIAL NUMBER ...................1- 1 |
1 |
SPECIFICATIONS ................................... |
1- 2 |
SERVICE PRECAUTIONS ...................... |
1- 3 |
TORQUE VALUES .................................. |
1-11 |
SPECIAL TOOLS ..................................... |
1-12 |
LUBRICATION POINTS |
1-13 |
|
1 |
|
|||
|
|
||
CABLE & HARNESS ROUTING |
1-15 |
|
|
|
|||
WIRING DIAGRAM................................ |
1-20 |
|
|
TROUBLESHOOTUNG .......................... |
1-21 |
|
|
|
|
|
|
ENGINE SERIAL NUMBER
AGILITY 50
Location of Engine Serial Number
1-1
1. GENERAL INFORMATION
SPECIFICATIONS
AGILITY 50
Motorcycle Name & Type
Name & Model No.
Overall length (mm)
Overall width (mm)
Overall height (mm)
Wheel base (mm)
Engine type
Displacement
Fuel Used
|
Front wheel |
|
Net weight (kg) |
Rear wheel |
|
|
Total |
|
|
Front wheel |
|
Gross weight(kg) |
Rear wheel |
|
|
Total |
|
Tires |
Front wheel |
|
Rear wheel |
||
|
||
Ground clearance (mm) |
||
Perform- |
Braking distance (m) |
|||||
ance |
|
|
Min. turning radius (m) |
|||
|
Starting system |
|
|
|||
|
Type |
|
|
|
||
|
Cylinder arrangement |
|||||
|
Combustion chamber type |
|||||
|
Valve arrangement |
|||||
|
Bore x stroke (mm) |
|||||
|
Compression ratio |
|||||
|
Compression pressure |
|||||
|
(kg/cm²-rpm) |
|
|
|||
|
Max. output |
|
|
|||
Engine |
Max. torque |
|
|
|||
|
|
|
Intake |
|
Open |
|
Port |
|
Close |
||||
|
|
|
||||
|
timing |
Exhaust |
|
Open |
||
|
|
|
|
|
Close |
|
|
|
|
|
|
|
|
|
Valve clearance |
Intake |
||||
|
(cold) (mm) |
Exhaust |
||||
|
Idle speed (rpm) |
|
||||
|
System |
Lubrication |
Lubrication type |
|||
|
Oil pump type |
|||||
|
Oil filter type |
|||||
|
Oil capacity |
|||||
|
|
|
|
|||
|
Cooling |
Type |
|
|
||
AGILITY 50
KG10SA
1830
690
1130
1325
O.H.C.
49.5cc
92# nonleaded gasoline
37.5
55
92.5
38
59
97
120/70 -12 56J
130/70 -12 56J
112
4 (Initial speed 20km/h)
1.99
Starting motor & kick starter
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C.
39.0 x 41.4
11
18
3.5/7500kw/(r/min)
0.35/7000kg m/rpm
3
7
9
1
0.04
0.04
1700 100rpm
Forced pressure & wet sump
Inner/outer rotor type
Full-flow filtration
0.8 liter
Forced air cooling
|
Air cleaner type & No |
||||||
stemSyFuel |
Fuel capacity |
|
|
||||
Carburetor |
Type |
|
|
||||
|
|
|
|
||||
|
|
Piston dia. (mm) |
|||||
|
|
Venturi dia.(mm) |
|||||
|
|
Throttle type |
|||||
mentuiEElectricalpq |
stemSnitionygI |
Type |
|
|
|||
Ignition timing |
|||||||
|
|
||||||
|
|
Contact breaker |
|||||
|
|
|
|
Spark plug |
|||
|
|
Spark plug gap |
|||||
|
Battery |
|
|
Capacity |
|||
DrivePower |
Clutch |
|
Type |
|
|
||
-Transmis Gearsion |
Type |
|
|
||||
|
|
|
|
|
|||
|
|
|
Operation |
||||
System |
Reduction Gear |
|
Type |
|
|
||
|
ratio |
|
2nd |
||||
|
|
|
Reduction |
1st |
|||
|
|
|
|
|
|
||
Moving |
Front |
Caster angle |
|||||
Tire |
pressure |
Front |
|||||
|
Axle |
Trail length |
|||||
Device |
(kg/cm²) |
Rear |
|||||
Turning |
|
|
Left |
||||
|
|
|
|||||
|
angle |
|
|
|
Right |
||
Brake system |
|
|
Front |
||||
type |
|
|
|
|
Rear |
||
|
|
|
|
|
|
||
Damping Device |
Suspension type |
Front |
|||||
|
|
|
|
Rear |
|||
|
|
|
|
|
|||
|
Shock absorber |
Front |
|||||
|
distance |
Rear |
|||||
|
|
|
|
|
|||
Frame type |
|
|
|
|
|
||
|
|
|
|
|
|
|
|
Paper element, wet
5.0 liter
CVK
17equivalent
Butterfly type
CDI
BTDC28 /4000rpm
Non-contact point type
NGK
C7HSA
0.6 0.7mm
12V4AH
Dry multi-disc clutch
Non-stage transmission
Automatic centrifugal type
Two-stage reduction
0.8-3.1
11.05
27
1.75
2.25
45
45
DISK (180mm) brake
Drum (110mm) brake
TELESCOPE
Unit Swing
80
82
Under Bone
1-2
1. GENERAL INFORMATION
AGILITY 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.
When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Use genuine parts and lubricants
.
When servicing the motorcycle, be sure to use special tools for removal and installation.
After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.
1-3
1. GENERAL INFORMATION
AGILITY 50
Apply or add designated greases and lubricants to the specified lubrication points.
After reassembly, check all parts for proper tightening and operation.
When two persons work together, pay attention to the mutual working safety.
Disconnect the battery negative (-) terminal before operation.
When using a spanner or other tools, make sure not to damage the motorcycle surface.
After operation, check all connecting points, fasteners, and lines for proper connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the battery terminals.
Terminal caps shall be installed securely.
1-4
1. GENERAL INFORMATION
If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.
After operation, terminal caps shall be installed securely.
When taking out the connector, the lock on the connector shall be released before operation.
Hold the connector body when connecting or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending, protruding or loose.
AGILITY 50
Confirm
Capacity
1-5
1. GENERAL INFORMATION
The connector shall be inserted completely.
If the double connector has a lock, lock it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Check the double connector cover for proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper coverage.
Do not make the terminal cover opening face up.
Secure wire harnesses to the frame with their respective wire bands at the designated locations.
Tighten the bands so that only the insulated surfaces contact the wire harnesses.
AGILITY 50
Snapping!
1-6
1. GENERAL INFORMATION
After clamping, check each wire to make sure it is secure.
.
Do not squeeze wires against the weld or its clamp
After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
When fixing the wire harnesses, do not make it contact the parts which will generate high heat.
Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws.
Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws.
AGILITY 50
No Contact !
1-7
1. GENERAL INFORMATION
Route harnesses so they are neither pulled tight nor have excessive slack.
.
Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner
When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it.
When installing other parts, do not press or squeeze the wires.
AGILITY 50
Do not pull too tight!
Do not press or squeeze the wire.
1-8
1. GENERAL INFORMATION
AGILITY 50
After routing, check that the wire harnesses are not twisted or kinked.
Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting.
Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
Do you understand the instrument? Is the instrument set correctly?
Remove Rust !
1-9
1. GENERAL INFORMATION
AGILITY 50
Symbols:
The following symbols represent the servicing methods and cautions included in this service manual.
Engine Oil
Grease
Gear Oil
:Apply engine oil to the specified points. (Use designated engine oil for lubrication.)
:Apply grease for lubrication.
:Transmission Gear Oil (90#)
Special |
: Use special tool. |
: Caution
|
: Warning |
( 12-3) |
: Refer to page 12-3. |
1-10
1. GENERAL INFORMATION
AGILITY 50
TORQUE VALUES
STANDARD TORQUE VALUES
Item |
Torque (kg-m) |
Item |
Torque (kg-m) |
5mm bolt, nut |
0.45-0.6 |
5mm screw |
0.35-0.5 |
6mm bolt, nut |
0.6-1.2 |
6mm screw, SH bolt |
0.7-1.1 |
8mm bolt, nut |
1.8-2.5 |
6mm flange bolt, nut |
1.0-1.4 |
10mm bolt, nut |
3.0-4.0 |
8mm flange bolt, nut |
2.4-3.0 |
12mm bolt, nut |
5.0-6.0 |
10mm flange bolt, nut |
3.5-4.5 |
|
|
|
|
Torque specifications listed below are for important fasteners.
ENGINE
Item |
Q‘ty |
Thread dia.(mm) |
Torque (kg-m) |
Remarks |
|
|
|
|
|
Cylinder head bolt A |
2 |
6 |
0.7-1.1 |
Double end bolt |
Cylinder head bolt B |
4 |
6 |
0.7-1.1 |
|
Oil filter screen cap |
1 |
30 |
1.0-2.0 |
|
Exhaust muffler lock bolt |
2 |
6 |
0.7-1.1 |
Double end bolt |
Cylinder head flange nut |
4 |
7 |
1.2-1.6 |
Apply oil to |
Valve adjusting lock nut |
2 |
3 |
0.07-0.09 |
threads |
Cam chain tensioner slipper bolt |
1 |
8 |
0.4-0.7 |
|
Oil bolt |
1 |
8 |
1.1-1.5 |
|
Clutch outer nut |
1 |
10 |
3.5-4.5 |
|
Clutch drive plate nut |
1 |
28 |
5.0-6.0 |
|
Starter motor mounting bolt |
2 |
6 |
0.8-1.2 |
|
Oil pump bolt |
3 |
4 |
0.1-0.3 |
|
Drive face nut |
1 |
10 |
5.5-6.5 |
|
Spark plug |
1 |
10 |
1.0-1.4 |
|
A.C. generator stator bolt |
2 |
6 |
0.8-1.2 |
|
Cam chain tensioner bolt |
1 |
6 |
0.8-1.2 |
|
|
|
|
|
|
FRAME |
|
|
|
|
|
|
|
|
|
Item |
Q‘ty |
Thread dia.(mm) |
Torque (kg-m) |
Remarks |
|
|
|
|
|
Steering stem lock nut |
1 |
25.4 |
8.0-12.0 |
U-nut |
Front axle nut |
1 |
10 |
5.0-7.0 |
U-nut |
Rear axle nut |
1 |
14 |
11.0-13.0 |
U-nut |
Rear shock absorber upper bolt |
1 |
10 |
4.0-5.0 |
|
Rear shock absorber lower bolt |
1 |
8 |
2.0-3.0 |
|
Speedometer cable set screw |
1 |
5 |
0.45-0.6 |
|
Rear shock absorber lock nut |
1 |
8 |
3.0-3.6 |
Apply locking agent |
|
|
|
|
|
1-11
1. GENERAL INFORMATION
AGILITY 50
SPECIAL TOOLS
Tool Name |
Tool No. |
Remarks |
Ref. Page |
|
|
|
|
|
|
Bearing puller 10.12.15.18 mm |
E037 |
10.12.15.18mm bearing |
10-3 |
|
10-4 |
||||
|
|
|
12-6 |
|
Bushing remover L |
E032 |
11102 bush engine hanger rubber |
|
|
|
|
|
|
|
Bushing remover S |
EO19 |
11203 bush rear cushion under rubber |
|
|
|
|
|
|
|
Crankshaft bearing puller |
E030 |
91005 radial bearing |
|
|
|
|
|
|
|
Crankshaft protector |
E029 |
13000 crankshaft comp 12mm.14mm |
|
|
|
|
|
|
|
|
|
|
9-9 |
|
Clutch spring compressor |
E027 |
2301a driven pully assy |
9-12 |
|
|
|
|
|
|
Cushion assemble & disassemble |
F004 |
52400 cushion assy |
13-4 |
|
tool |
||||
|
|
|
||
|
|
|
9-5 |
|
|
|
31110 flywheel comp.2310a pully assy |
9-9 |
|
Flywheel holder |
E017 |
9-13 |
||
|
|
driven |
14-7 |
|
|
|
|
14-9 |
|
Flywheel puller |
E002 |
Left hand thread 27mm |
14-7 |
|
|
||||
|
|
|
|
|
Long socket wrench 32mm 8angle |
F002 |
50306 steering stem |
12-21 |
|
12-22 |
||||
|
|
|
||
Oil seal & bearing installer |
E014 |
Oil seal & bearing install |
|
|
|
|
|
|
|
Tool boox |
E033 |
Special tools storage |
|
|
|
|
|
|
|
Tappet adjuster |
E036 |
90012 screw tappet |
3-5 |
|
|
|
|
|
|
Valve spring compressor |
E038 |
Valve spring |
7-7 |
|
7-8 |
||||
|
|
|
1-12
1. GENERAL INFORMATION
AGILITY 50
LUBRICATION POINTS
ENGINE
Lubrication Points |
Lubricant |
Valve guide/valve stem movable part |
Genuine KYMCO Engine Oil (SAE15W-40) |
Cam lobes |
API SG Engine Oil |
Valve rocker arm friction surface |
|
Cam chain |
|
Cylinder lock bolt and nut |
|
Piston surroundings and piston ring grooves |
|
Piston pin surroundings |
|
Cylinder inside wall |
|
Connecting rod/piston pin hole |
|
Connecting rod big end |
|
Crankshaft R/L side oil seal |
|
Starter reduction gear engaging part |
|
Countershaft gear engaging part |
|
Final gear engaging part |
|
Bearing movable part |
|
O-ring face |
|
Oil seal lip |
|
Starter idle gear |
|
|
Friction spring movable part/shaft movable part High-temperature resistant grease |
||
Shaft movable grooved part |
|
|
Kick starter spindle movable part |
|
|
A.C. generator connector |
Adhesive |
|
Transmission case breather tube |
||
|
||
1-13
1. GENERAL INFORMATION
AGILITY 50
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.
Grease
Front Brake Lever
Pivot
Engine/ Oil
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Grease
Rear Wheel Bearings
Grease |
|
|
|
Speedometer Gear/ Front Wheel |
|
|
Grease |
|
|
Brake Cam/ |
|
Bearings/ Brake Cam/ Anchor Pin |
Grease |
Anchor Pin |
|
/Front Shock Absorber Lower |
|
Engine Oil |
|
Mount Bushings/Pivot |
Main Stand Pivot |
Rear Brake Cable |
|
|
|
|
|
1-14
1. GENERAL INFORMATION
AGILITY 50
CABLE & HARNESS ROUTING
Winker
Brake Master Cylinder
Rear Stop Switch Wire
Front Stop Switch Wire
Throttle Cable
Rear Brake Cable
Ignition Switch
Speedometer Cable
Front Brake Fluid Tube
Horn
Regulator/Rectifier
1-15
1. GENERAL INFORMATION
AGILITY 50
Rear Brake Lever
Horn
Front Brake Fluid Tube
Throttle Grip
Regulator/Rectifier
Ignition Switch
Speedometer Cable
Headlight Resistor
1-16
1. GENERAL INFORMATION
AGILITY 50
CDI Unit
Fuse
Battery (+) Cable
Battery (-) Cable
Starter Relay
Fuel Tank
Battery (-) Cable
Battery (+) Cable
Ignition Coil
1-17
1. GENERAL INFORMATION
AGILITY 50
Auto Cock Assy Fuel
Fuel Filter
Fuel Tube
Ignition Coil
Primary Wire
Ignition Wire
Throttle Cable
Vacuum Tee
Carburetor
Overflow Tube
Crankcase Breather
Tube
1-18
1. GENERAL INFORMATION
AGILITY 50
Fuel Unit
Crankcase Breather
Tube
Throttle Cable
Wire
Vacuum Tube
Vacuum Tube
Ignition Coil
Crankcase Breather
Tube
Secondary Air
Inlet Tube
Reed Valve
Air Injection
Cut-off
Valve
Fuel Tube
Auto Bystarter
1-19
1. GENERAL INFORMATION
AGILITY 50
WIRING DIAGRAM
1-20
1. GENERAL INFORMATION
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment |
|
|
|
Symptom |
|
|
|
|
|
|
|
Check if fuel reaches carburetor by loosening drain screw
Fuel reaches |
|
Fuel does not |
carburetor |
|
reach carburetor |
Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground
Test cylinder compression
Spark jumps
Weak or no spark
Normal |
|
Low or no |
compression |
|
compression |
Start engine by following normal starting procedure
Engine does not |
|
Engine fires but |
fire |
|
does not start |
Remove spark plug and inspect again
Dry spark plug |
|
Wet spark plug |
|
|
|
AGILITY 50
Probable Cause
Empty fuel tank
Clogged fuel line between fuel tank and carburetor
Clogged float oil passage Clogged fuel tank cap breather hole
Clogged fuel filter Clogged fuel strainer Faulty auto fuel valve
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil Broken or shorted high-tension wire
Faulty ignition switch
Faulty starter clutch Valve clearance too small
Improper valve and seat contact Worn cylinder, piston and piston rings
Leaking cylinder head gasket Seized valve
Improper valve timing
Faulty auto bystarter
Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw
Flooded carburetor Faulty auto bystarter
Throttle valve excessively open
1-21
1. GENERAL INFORMATION
ENGINE LACKS POWER
Inspection/Adjustment |
|
|
Symptom |
|
||
|
|
|
|
|
|
|
Start engine and accelerate |
|
|
|
|
||
lightly for observation |
|
|
|
|
||
|
|
|
|
|
||
|
Engine speed |
|
|
Engine speed does not |
||
|
increases |
|
|
increase sufficiently |
||
Check ignition timing |
|
|
|
|
||
using a timing light |
|
|
|
|
||
|
|
|
|
|
||
|
Correct timing |
|
|
Incorrect timing |
||
|
|
|
|
|
|
|
Check valve clearance |
|
|
|
|
||
Correct
Test cylinder compression
Normal compression
Check carburetor for clogging
Not clogged
Remove spark plug and inspect
Plug not fouled or discolored
Remove oil dipstick and check oil level and condition
Correct and not contaminated
Remove cylinder head oil pipe bolt and inspect
Valve train lubricated properly
Check if engine overheats
Engine does not overheats
Rapidly accelerate or run at high speed
Incorrect
Abnormal compression
Clogged
Plug fouled or discolored
Incorrect or contaminated
Valve train not lubricated properly
Engine overheats
Engine does not knock |
|
Engine knocks |
|
|
|
AGILITY 50
Probable Cause
Clogged air cleaner
Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston diaphragm
Faulty auto fuel valve
Faulty CDI unit
Faulty pulser coil
Improper valve clearance adjustment
Worn valve seat (valve stem too protruding
Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing
Clogged carburetor jets
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston rings Mixture too lean
Poor quality fuel
Excessive carbon buildup in combustion chamber Ignition timing too early
Excessive carbon build-up in combustion chamber
Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early
1-22
1. GENERAL INFORMATION
AGILITY 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment |
|
Symptom |
|
|
|
Check ignition timing
Correct timing |
|
Incorrect timing |
|
|
|
Check carburetor pilot screw adjustment
Correctly adjusted |
Incorrectly adjusted |
Check carburetor gasket for air leaks
No air leak |
|
Air leaks |
|
|
|
Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground
Good spark
Weak or intermittent spark
Check air cut-off valve
Good |
|
Faulty |
|
|
|
Probable Cause
Faulty CDI unit
Faulty pulser coil
Mixture too rich (turn screw out)
Mixture too lean (turn screw in)
Deteriorated O-ring Carburetor not securely tightened
Damaged insulator rubber Broken vacuum tube
Faulty or fouled spark plug Faulty CDI unit
Faulty A.C. generator Faulty ignition coil
Broken or shorted spark plug wire
Faulty ignition switch
Faulty air cut-off valve Damaged vacuum tube Clogged or damaged air vent hole
1-23
1. GENERAL INFORMATION
AGILITY 50
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment |
|
Symptom |
|
Probable Cause |
|
|
|
|
|
Check ignition timing
Correct timing |
|
Incorrect timing |
|
|
|
Check valve clearance
Correctly adjusted |
|
Incorrectly adjusted |
|
|
|
Check fuel pump for fuel supply
Fuel flows freely |
|
Fuel flow restricted |
|
|
|
Check carburetor jets for clogging
Not clogged |
|
Clogged |
|
|
|
Check valve timing
Faulty CDI unit
Faulty pulser coil
Improperly adjusted valve clearance Worn camshaft
Worn valve seat
Empty fuel tank
Clogged fuel tube or filter Faulty charcoal canister Faulty auto fuel valve
Clean and unclog
Correct |
|
Incorrect |
Cam timing gear aligning marks |
|
|
|
not aligned |
|
|
|
Check valve spring tension
Not weakened |
|
Weak spring |
Faulty spring |
|
|
|
|
1-24
1. GENERAL INFORMATION
AGILITY 50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Inspection/Adjustment |
|
Symptom |
|
Probable Cause |
|
|
|
|
|
Start engine and test limit voltage between battery terminals
Measure resistance between AC generator coil terminals
Normal voltage
Voltage does not increase
Normal |
Resistance too high |
Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage
Normal voltage |
No voltage |
Check regulator/rectifier coupler for loose connection
Normal Abnormal
Overcharging
Inspection/Adjustment |
Symptom |
Connect battery (+) wire to regulator/rectifier coupler green wire and battery (-) wire to engine ground and test voltage
Check regulator/rectifier coupler for loose connection
Battery has voltage with ignition switch “ON”
Battery has no voltage with ignition switch “ON”
Normal |
|
Abnormal |
|
|
|
Dead battery
Faulty battery
Faulty A.C. generator coil Broken yellow wire Loose connector
Broken red wire
Faulty regulator/rectifier Poorly connected coupler
Faulty A.C. generator
Probable Cause
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
1-25
1. GENERAL INFORMATION
AGILITY 50
NO SPARK AT SPARK PLUG
Inspection/Adjustment |
|
Symptom |
|
Probable Cause |
|
|
|
|
|
Replace with a new spark plug and inspect again
Weak or no spark |
|
Good spark |
Faulty old spark plug |
|
|
|
|
Check spark plug cap and high-tension wire for looseness
Not loose |
|
Loose |
Loose spark plug cap |
|
|
|
|
Check CDI unit coupler for looseness
Good |
|
Good |
Poorly connected coupler |
|
|
|
|
Measure resistance between CDI unit coupler wire terminals
Normal Abnormal
Check related parts
Normal Abnormal
Check CDI unit with a
CDI unit tester
Normal Abnormal
Check ignition coil with a CDI unit tester
Abnormal
Faulty ignition switch
Faulty pulser coil
Faulty ignition coil
Broken wire harness Poorly connected coupler
Faulty CDI unit
Faulty ignition coil
1-26
2. FRAME COVERS/EXHAUST MUFFLER |
AGILITY 50 |
|
2 SCHEMATIC DRAWING |
|
|
|
|
2 |
2-0
Loading...