Kymco AGILITY 50 User Manual

Agility 50 - 125

50 4T R10 50 4T R12 125

MOTORE MONOCILINDRICO ORIZ ZONTALE 4 TEMPI

RAF FREDDAMENTO ARIA FORZATA

CILINDRATA 49cc 125cc

POTENZA

2,4kW (3,3CV) a 8.5 00 giri/min 2,4kW (3,3CV) a 7.500 giri/min 6,9kW (9,4CV) a 7.500 giri/min

COPPIA 3,2 Nm a 7.000 giri 9,6 Nm a 6.5 00 giri

EMISSIONI EURO 2 EURO 3

AVVIAMEN TO ELETTRICO E KICK STARTER

FRIZIONE CENTRIFUGA AUTOMATICA A SECCO

TRASMISSIONE CINGHIA TRAPEZOIDALE - INGRA NAGGI

SOSPENSIONI

ANT. FORCELL A TELESCOPICA IDRAULICA ø 31

POST. MONOBRACCIO OSCILL ANT E AMMORTIZ ZATORE IDRAULICO REGOL ABILE

FRENI

ANT. DISCO ø 180mm

POST. TAMBURO ø 110mm

PNEUM ATICI

ANT. - POS T. 90/90-10

ANT. 120/ 70-12

POST. 130/70-12

DIMENSIONE 1.830 x 69 0 x 1.070mm 1.830 x 69 0 x 1.130mm 1.835 x 690 x 1.125mm

MASSA 8 4kg 92kg 105kg

COLORI argento nero argento nero rosso giallo

giallo

Agility 50 - 125

2616- 040407KYM CO SI RISERVA DI AP PORTARE VARIA ZIONI TECN ICHE, ESTE TICHE O DI ALTR A NATURA SEN ZA L’OBBLIGO DI AL CUN PREAVV ISO.

KYMCO R ACCOMANDA2 ANNI DI G ARANZ IA 1 ANNO DI A SSISTENZA CREDITO P ERSONALIZ ZATO

S e r v i z i F i n a n z i a r i

SCOOTER TAR GATICICLOM OTORI 4T

PREFACE

AGILITY 50

TABLE OF CONTENTS

This Service Manual describes the technical features and servicing procedures for the KYMCO AGILITY

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.

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

STARTER FINAL REDUCTION 10

CRANKCASE/CRANKSHAFT 11

CHASSIS

FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION

REAR WHEEL /REAR BRAKE /REAR SUSPENSION

ELECTRICAL

EQUIPMEN

BATTERY/CHARGING SYSTEM/A.C. GENERATOR

IGNITION SYSTEM 15 STARTING SYSTEM 16

LIGHTS/INSTRUMENTS/SWITCHES 17

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

1. GENERAL INFORMATION

ENGINE SERIAL NUMBER...................1- 1 LUBRICATION POINTS .......................1-13

SPECIFICATIONS ...................................1- 2 CAB L E & H A R N E S S R O UTI N G............1-15

SERVICE PRECAUTIONS......................1- 3 WIRING DIAGRAM................................1-20

TORQUE VALUES..................................1-11 TROUBLESHOOTUNG ..........................1-21

SPECIAL TOOLS.....................................1-12

ENGINE SERIAL NUMBER

AGILITY 50

Location of Engine Serial Numbe

1-1

1. GENERAL INFORMATION

q p

SPECIFICATIONS

AGILITY 50

Motorcycle Name & Type AGILITY 50 Name & Model No. KG10SA Overall length (mm) 1830 Overall width (mm) 690 Overall height (mm) 1130 Wheel base (mm) 1325 Engine type O.H.C. Displacement 49.5cc Fuel Used 92# nonleaded gasoline

Front wheel 37.5

Net weight (kg) Rear wheel 55

Total 92.5

Front wheel 38

Gross weight(kg) Rear wheel 59

Total 97 Tires Ground clearance (mm) 112 Perform-

ance

Engine

Braking distance (m)

Min. turning radius (m) 1.99

Starting system Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C. Bore x stroke (mm) I39.0 x 41.4 Compression ratio 11

Compression pressure (kg/cm²-rpm)

Max. output 3.5/7500kw/(r/min) Max. torque 0.35/7000kg m/rpm

Port timin

(cold) (mm) Idle speed (rpm) 1700Ô100rpm

Lubrication

System

Cooling Type Forced air cooling

Front wheel 120/70 -12 56J

Rear wheel 130/70 -12 56J

4 (Initial speed

20km/h)

Starting motor &

kick starter

Intake

Exhaust

Lubrication type Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration Oil capacity 0.8 liter

Open 3q Close 7q Open 9q

Close 1q Intake 0.04 Exhaust 0.04

Forced

ressure &

wet sump

Air cleaner type & No Paper element, wet

Fuel S

Fuel capacity 5.0 liter

Carburetor

Type CVK

stem

Electrical E

ui ment

Power Drive System

Moving Device

Brake system type

Damping

Device

Frame type Under Bone

Piston dia. (mm) Venturi dia.(mm) I17equivalent Throttle type Butterfly type Type CDI

I nition S

Ignition timing BTDC28q/4000rpm Contact breaker Non-contact point type

stem

Battery Capacity 12V4AH Clutch Type Dry multi-disc clutch

sion Gear

Gear

Front Caster angle 27q Axle

Tire pressure (kg/cm²)

Turning Left 45q angle

Suspension type Shock absorber

distance

Spark plug

Spark plug gap 0.6Д0.7mm

Transmis-

Type Non-stage transmission Operation

Reduction

Type Two-stage reduction Reduction 1st

ratio

Trail length 

Fron Rear 2.25

Right 45q FrontDISK (180mm) brake

Rear Drum (110mm) brake Fron

Rear Unit Swing Front 80 Rear

Automatic centrifugal

2nd

NGK

C7HSA

type

0.8-3.1

11.05

1.75

TELESCOPE

1-2

1. GENERAL INFORMATION

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

AGILITY 50

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

Apply or add designated greases and

lubricants to the specified lubrication points.

After reassembly, check all parts for proper

tightening and operation.

AGILITY 50

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.

AGILITY 50

Confir Capacity

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.

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.

AGILITY 50

Snapping!

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.

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

AGILITY 50

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.

o 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.

AGILITY 50

Do not pull

ht!

too ti

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.

Do not press o squeeze the wire.

1-8

1. GENERAL INFORMATION

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.

AGILITY 50

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

Symbols:

The following symbols represent the servicing methods and cautions included in this service manual.

: Apply engine oil to the

specified points. (Use

Engine Oil

designated engine oil for lubrication.)

AGILITY 50

Grease

Gear Oil

Special

＊

(Ö12-3) :Refer to page 12-3.

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

1-10

1. GENERAL INFORMATION

)

TORQUE VALUES

STANDARD TORQUE VALUES

AGILITY 50

Ite

5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler lock bolt Cylinder head flange nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Starter motor mounting bolt Oil pump bolt Drive face nut Spark plug A.C. generator stator bolt Cam chain tensioner bolt

Torque (kg-m

0.45-0.6

0.6-1.2

1.8-2.5

3.0-4.0

5.0-6.0

2 4 1 2 4 2 1 1 1 1 2 3 1 1 2 1

Ite

5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut

6 6

6 7 3 8

8 10 28

4 10 10

0.7-1.1

1.0-2.0

0.7-1.1

1.2-1.6

0.07-0.09

0.4-0.7

1.1-1.5

3.5-4.5

5.0-6.0

0.8-1.2

0.1-0.3

5.5-6.5

1.0-1.4

0.8-1.2

Torque (kg-m

0.35-0.5

0.7-1.1

1.0-1.4

2.4-3.0

3.5-4.5

Double end bolt

Double end bolt Apply oil to threads

FRAME

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Speedometer cable set screw Rear shock absorber lock nut

1 1 1 1 1 1 1

25.4 10 14 10

8 5 8

8.0-12.0

5.0-7.0

11.0-13.0

4.0-5.0

2.0-3.0

0.45-0.6

3.0-3.6

U-nut U-nut U-nut

Apply locking agent

1-11

1. GENERAL INFORMATION

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

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

Clutch spring compressor E027 2301a driven pully assy

AGILITY 50

10-3 10-4Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 12-6

9-9 9-12

Cushion assemble & disassemble tool

Flywheel holder E017

Flywheel puller E002 Left hand thread 27mm

Long socket wrench 32mm 8angle F002 50306 steering stem

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

F004 52400 cushion assy 13-4

9-5

31110 fl driven

wheel comp.2310a pully ass

9-9 9-13 14-7 14-9

14-7

12-21 12-22

7-7 7-8

1-12

1. GENERAL INFORMATION

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

AGILITY 50

Valve guide/valve stem movable part Cam lobes 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

xGenuine KYMCO Engine Oil (SAE15W-40) xAPISG Engine Oil

Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Kick starter spindle movable part

A.C. generator connector Transmission case breather tube

High-temperature resistant grease

Adhesive

1-13

1. GENERAL INFORMATION

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 Leve Pivot

Engine/ Oil

Front Brake Cable Speedometer Cable/ Throttle Cable

AGILITY 50

Grease

Speedometer Gear/ Front Wheel Bearings/ Brake Cam/ Anchor Pin /Front Shock Absorber Lower Mount Bushings/Pivot

Grease

Main Stand Pivot

Grease

Rear Wheel Bearings

Grease

Brake Cam Anchor Pin

Engine Oil

Rear Brake Cable

1-14

1. GENERAL INFORMATION

CABLE & HARNESS ROUTING

Brake Master Cylinde

Front Stop Switch Wire

Throttle Cable

AGILITY 50

Winke

Rear Stop Switch Wire

Rear Brake Cable

Ignition Switch

Front Brake Fluid Tube

Speedometer Cable

Horn

Regulator/Rectifie

1-15

1. GENERAL INFORMATION

AGILITY 50

Throttle Grip

Regulator/Rectifie

Ignition Switch

Speedometer Cable

Rear Brake Leve

Horn

Front Brake Fluid Tube

Headlight Resisto

1-16

1. GENERAL INFORMATION

AGILITY 50

CDI Unit

Fuse

Battery (+) Cable

Battery (-) Cable

Starter Relay

Ignition Coil

Fuel Tan

Battery (-) Cable

Battery (+) Cable

1-17

1. GENERAL INFORMATION

Auto Cock Assy Fuel

Ignition Coil Primary Wire

Ignition Wire Throttle Cable

AGILITY 50

Fuel Filte

Fuel Tube

Vacuum Tee

Carbureto Overflow Tube

Crankcase Breathe Tube

1-18

1. GENERAL INFORMATION

Fuel Unit

Throttle Cable

AGILITY 50

Crankcase Breathe Tube

Wire

Throttle Cable

Crankcase Breathe Tube

Secondary Ai Inlet Tube

Reed Valve

Air Injection Cut-off Valve

Vacuum Tube

Ignition Coil

Fuel Tube

Auto Bystarte

1-19

1. GENERAL INFORMATION

WIRING DIAGRAM

AGILITY 50

1-20

1. GENERAL INFORMATION

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

AGILITY 50

Inspection/Adjustment

Check if fuel reaches carburetor by loosening drain screw

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Test cylinde compression

Start engine by following normal starting

rocedure

Fuel reaches

carburetor

Spark jumps

Normal

compression

Symptom

Fuel does no

reach carburetor

Weak or no spark

Low or no

compression

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

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

valve

Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw

Flooded carburetor Faulty auto bystarter Throttle valve excessively open

Remove spark plug and inspect again

Engine does no

fire

Dry spark plug

Engine fires bu

does not start

Wet spark plug

1-21

1. GENERAL INFORMATION

pip

prop

ENGINE LACKS POWER

AGILITY 50

Inspection/Adjustment

Start engine and accelerate lightly for observation

Check ignition timing using a timing light

Check valve clearance

Test cylinder compression

Check carburetor fo clogging

Engine speed

Correct timin

Correc

ormal

com

ression

Symptom

Engine speed does no increase sufficientl

Abnormal

compression

Incorrect timin

Incorrec

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

Remove spark plug and inspec

Remove oil dipstick and check oil level and condition

Remove cylinder head oil

e bolt and inspec

Check if engine overheats

Rapidly accelerate or run

h speed

at hi

Not clogged

Plug not fouled o discolored

Correct and no contaminated

Valve train lubricated

erl

Engine does no overheats

Engine does not knock

Clogged

Plug fouled o discolored

Incorrect o

contaminated

Valve train no lubricated properl

Engine overheats

Engine knocks

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 Probable Cause

Check ignition timing

Check carburetor pilo screw adjustment

Check carburetor gaske for air leaks

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine

round

Correct timing

Correctly adjusted

No air leak

Good spark

Incorrect timing

Incorrectly adjusted

Air leaks

Weak or inter-

mittent spark

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

Check air cut-off valve

Good

Faulty

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

Check valve clearance

Check fuel pump fo fuel supply

Check carburetor jets for clogging

Correct timing

Correctly adjusted

Fuel flows freely

Not clogged

Incorrect timing

Incorrectly adjusted

Fuel flow restricted

Clogged

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

Check valve timing

Check valve spring tension

1-24

Correc

Not weakened

Incorrec

Weak spring

Cam timing gear aligning marks not aligned

Faulty spring

1. GENERAL INFORMATION

AGILITY 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

Inspection/Adjustment

Start engine and tes limit voltage between

attery terminals

Measure resistance between AC generator coil terminals

Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine

round and test voltage

Check regulator/rectifier coupler for loose connection

Normal voltage

Normal

Normal voltage

Normal

Symptom

Voltage does no

Resistance too high

No voltage

Abnormal

Probable Cause

Dead battery Faulty battery

Faulty A.C. generator coil Broken yellow wire Loose connector

Broken red wire

Faulty regulator/rectifier Poorly connected coupler

Overcharging

Inspection/Adjustment

Connect battery (+) wire to regulator/rectifier coupler green wire and battery (-) wire to engine

round and test voltage

Check regulator/rectifier coupler for loose connection

attery has voltage with ignition switch “ON”

Normal

Symptom

voltage with ignition switc

attery has no

“ON”

Abnormal

Faulty A.C. generator

Probable Cause

Broken green wire

Poorly connected coupler

Faulty regulator/rectifier

1-25

1. GENERAL INFORMATION

NO SPARK AT SPARK PLUG

AGILITY 50

Inspection/Adjustment Symptom

Replace with a new spark plug and inspect

ain

Weak or no spark

Check spark plug cap and high-tension wire for looseness

Not loose

Check CDI unit coupler for looseness

Good

Measure resistance between CDI unit

ler wire terminals

cou

Good spark

Loose

Good

Probable Cause

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Check related parts

Check CDI unit with a CDI unit tester

Check ignition coil with a CDI unit tester

Normal

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

2 SCHEMATIC DRAWING

AGILITY 50

2-0

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