KYMCO AGILITY 50 User Manual

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 CABLE & H A R NESS ROUT I 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) φ39.0 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) 1700±100rpm

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 3° Close 7° Open 9°

Close 1° 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) φ17equivalent Throttle type Butterfly type Type CDI

I nition S

Ignition timing BTDC28°/4000rpm Contact breaker Non-contact point type

stem

Battery Capacity 12V4AH Clutch Type Dry multi-disc clutch

sion Gear

Gear

Front Caster angle 27° Axle

Tire pressure (kg/cm²)

Turning Left 45° angle

Suspension type Shock absorber

distance

Spark plug

Spark plug gap 0.6～0.7mm

Transmis-

Type Non-stage transmission Operation

Reduction

Type Two-stage reduction Reduction 1st

ratio

Trail length ⎯

Fron Rear 2.25

Right 45° 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

•Genuine KYMCO Engine Oil (SAE15W-40)

•API−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

2. FRAME COVERS/EXHAUST MUFFLER

SERVICE INFORMATION......................2-1 EXHAUST MUFFLER REMOVAL.........2-5

FRAME COVERS ..................................... 2-2

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• When removing frame covers, use special 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

Headlight wire connector

• Handlebar rear cover Speedometer cable and instrument light

wire connectors, etc.

• Frame body cover Met-in box, rear grip, rear turn signal

lights, floor board

• Floor board Frame body cover

Battery and wire connectors

• Front tool box Front cover, floor board

TORQUE VALUES

Exhaust muffler joint lock nut 1.0~1.4kgf-m Exhaust muffler lock bolt 3.0~3.6kgf-m

2-1

2. FRAME COVERS/EXHAUST MUFFLER

Screw

FRAME COVERS

FRONT COVER REMOVAL

Remove the screw on the front of the front cover. Remove the six screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.

AGILITY 50

HANDLEBAR FRONT/REAR COVER REMOVAL

HANDLEBAR FRONT COVER REMOVAL Remove the handlebar front cover screw.

Remove the two screws attaching the handlebar front cover. Disconnect the headlight wire connector and remove the handlebar front cover.

Front Cove

Handlebar Front Cove

Screws

Handlebar Rear Cove

HANDLEBAR REAR COVER REMOVAL Disconnect the speedometer cable, right and

left handlebar switch couplers, and the stop switch wire connectors. Remove the bolt attaching the handlebar rear cover. Remove two screws inside the handlebar rear cover and remove the handlebar rear cover. The installation sequence is the reverse of removal.

Screw

Bol

Screws

Handlebar Front Cove

2-2

2. FRAME COVERS/EXHAUST MUFFLER

Bol

MET-IN BOX REMOVAL

Open the seat and remove the two nuts and three bolt attaching the met-in box. Remove the met-in box .

Bolts

Center Cove

FRAME BODY COVER REMOVAL

Remove the center cover.

AGILITY 50

Remove the three bolts attaching the rear carrier. Remove the rear carrier. Remove the four bolts on the rear seat.

Remove the rear seat

Remove the six screws on the rear part of the frame body cover. Remove the two screws on the front of the frame body cover.

Bolts

Rear Carrie

Bolts

Screws

2-3

2. FRAME COVERS/EXHAUST MUFFLER

AGILITY 50

Discornnect the seat lock wire. Remove the frame body cover.

The installation sequence is the reverse of remove

Remove the three bolts attaching each of the right and left side covers. Remove the right and left side covers.

＊

During removal, do not pull the joint claws forcedly to avoid damage.

When installing, be sure to connect the seat lock wire.

FLOOR BOARD REMOVAL

Remove the rear carrier and rear seat. (Ö2-3) Remove the met-in box. (Ö2-3) Remove the frame body cover. (Ö2-4) Remove the eight bolts attaching the floor board. Remove the floor board.

Seat Lock Wire

Frame Body

Bolts

BOTTOM PROTECTOR COVER REMOVAL

Remove the sixbolts on the bottom protector cover. Remove the bottom protector cover.

Floor Board.

Bottom Protector Cove

Bolts

2-4

2. FRAME COVERS/EXHAUST MUFFLER

Leg shield

LEG SHIELD REMOVAL

Remove the bolt leg shield. Remove the ignition switch decorative ring Remove the leg shield.

F RONT FENDER REMOVAL

Remove the two bolts attaching the front fender bracket.

Remove the front fender.

AGILITY 50

Decorative Ring

Bol

Bolts

EXHAUST MUFFLER REMOVAL

Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the exhaust muffler joint packing collar.

When installing, first install the exhaust muffler packing collar and then install the exhaust muffler. First install and tighten the exhaust muffler joint lock nuts. Then, install and tighten the exhaust muffler lock bolts.

Torques:

Exhaust muffler lock bolt: 3.0~3.6kgf-m Exhaust muffler joint lock nut: 1.0~1.4kgf-m

＊

Be sure to install a new exhaust muffle packing collar.

Front Fende

Bolts

Lock Nu

2-5

3. INSPECTION/ADJUSTMENT

SERVICE INFORMATION....................3-0 FINAL REDUCTION GEAR OIL.......3- 7

MAINTENANCE SCHEDULE...............3-2 DRIVE BELT.........................................3- 7

FUEL FILTER..........................................3-3 BRAKE SHOE.......................................3- 8

THROTTLE OPERATION.....................3-3 BRAKE ADJUSTING NUT..................3- 8

AGILITY 50

AIR CLEANER ........................................3-4 HEADLIGHT AIM ...............................3- 9

SPARK PLUG ..........................................3-4 CLUTCH SHOE WEAR.......................3- 9

VALVE CLEARANCE............................3-5 SUSPENSION ........................................3- 9

CARBURETOR IDLE SPEED...............3-5 NUTS/BOLTS/FASTENERS................3-10

IGNITION TIMING................................3-6 WHEELS/TIRES...................................3-10

CYLINDER COMPRESSION................3-6 STEERING HANDLEBAR..................3-11

SERVICE INFORMATION

GENERAL

！ WARNING

•Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.

SPECIFICATIONS

ENGINE Throttle grip free play : 2～6mm Spark plug gap : 0.6～0.7mm

Spark plug : NGK C7HSA

Valve clearance : IN: 0.04mm :EX: 0.04mm Idle speed : 1900 ±100rpm Engine oil capacity: At disassembly : 0.85 liter At change : 0.7 liter Gear oil capacity : At disassembly : 0.11 liter At change : 0.10 liter

3-0

3. INSPECTION/ADJUSTMENT

AGILITY 50

Cylinder compression : 16 kg/cm Ignition timing: BTDC 28°/4000rpm

CHASSIS Front brake free play: 10～20mm Rear brake free play : 10～20mm

TIRE PRESSURE

Front 1.5kg/cm

Rear 2.0kg/cm

TIRE SIZE: Front : 120/70-12 Rear : 130/70-12

TORQUE VALUES

Front axle nut 5.0～7.0kgf-m Rear axle nut 11～13kgf-m

1 Rider 2 Riders

2 2

1.75kg/cm

2.25kg/cm

2 2

3-1

3. INSPECTION/ADJUSTMENT

RRR

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten

AGILITY 50

Frequenc

Item

Engine oil Engine oil filter

Whicheve comes

first

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

New

Motorcycle

300k

Regular Service Mileage (km)

screen Fuel filter screen R

New

Gear oil Note 3

motorcycle

300k

Valve clearance A A A A Carburetor I I C Air Cleaner Note 2,3 Replace at every2000km Spark plug Clean at every 3000km and replace if necessary Brake system I IIIIIIIII I I Drive belt I Suspension I I I Nut, bolt, fastener I Tire I I I Steering head bearing I I I

• In the interest of safety, we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer.

Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding in rain or at full throttle.

3-2

3. INSPECTION/ADJUSTMENT

FUEL FILTER

Remove the met-in box. (Ö2-3) Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage.

＊

Do not smoke or allow flames or sparks in your working area.

THROTTLE OPERATION

Check the throttle grip for smooth movement. Measure the throttle grip free play.

Free Play: 2～6mm

AGILITY 50

Fuel Filte

Fuel Line

2～6m

Major adjustment of the throttle grip free play is made at the carburetor side. Adjust by loosening the lock nut and turning the adjusting nut.

Minor adjustment is made with the adjusting nut at the throttle grip side. Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut.

Lock Nu

Adjusting Nu

3-3

Adjusting Nu

Lock Nu

3. INSPECTION/ADJUSTMENT

AIR CLEANER

AIR CLEANER REPLACEMENT

Remove the air cleaner case cover screws and the cover by removing the seven screws.

Remove the air cleaner element by removing the four screws. Check the element and replace it if it is excessively dirty or damaged.

CHANGE INTERVAL

More frequent replacement is required when riding in unusually dusty or rainy areas.

＊

• The air cleaner element has a viscous type paper element. Do not clean it with any fluid.

• Be sure to install the air cleaner element and cover securely.

FILLY LX 50

Screws

Air Cleaner Case Cove

Air Cleaner Elemen

SPARK PLUG

Remove the spark plug. Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush.

Specified Spark Plug: CHAMPION-P-RZ9HC

Measure the spark plug gap. Spark Plug Gap: 0.6～0.7mm

＊

When installing, first screw in the spar plug by hand and then tighten it with a spark plug wrench.

Gap, Wear, and Fouling Deposits

Washe Deformation

Cracks Damage

3-4

3. INSPECTION/ADJUSTMENT

AGILITY 50

VALVE CLEARANCE

＊

Inspect and adjust valve clearance while the engine is cold (below 35℃).

Remove the frame cover. (Ö2-3) Remove the six bolts on the cylinder head cover. Remove the cylinder head cover. (Ö7-3)

Remove the cylinder head cover..

Turn the flywheel counterclockwise so that the “T” mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke.

Cylinder Head Cove

Bolts

Inspect and adjust the valve clearance. Valve Clearance: IN : 0.04mm

EX: 0.04mm

Loosen the lock nut and adjust by turning the adjusting nut

Special

Tappet Adjuster

＊

• Check the valve clearance again afte

the lock nut is tightened.

CARBURETOR IDLE SPEED

＊

• The engine must be warm for accurate

idle speed inspection and adjustment.

Remove the inspection cover. Warm up the engine before this operation. Start the engine and connect a tachometer. Turn the throttle stop screw to obtain the specified idle speed.

Idle Speed: 1900±100rpm When the engine misses or run erratic, adjust

the pilot screw.

Round Hole

Tappet Adjuste

Feeler Gauge

Throttle Stop Screw

3-5

3. INSPECTION/ADJUSTMENT

IGNITION TIMING

＊

The CDI unit is not adjustable. If the ignition timing is incorrect, check the ignition system. (Ö15-5)

Remove the right of the fan cover.

Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase.

FILLY LX 50

Timing Hole Cap

Timing Ligh

Also use a timing light to check the advance. Raise the engine speed to 4,000rpm and the index mark on the crankcase cover should be aligned with the advance mark on the flywheel.

CYLINDER COMPRESSION

Warm up the engine before compression test. Remove the met-in box and center cover. (Ö2-3) Remove the spark plug. Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression.

Compression: 16kg/cm2rpm If the compression is low, check for the

following:

‧Leaky valves ‧Valve clearance to small ‧Leaking cylinder head gasket ‧Worn piston rings ‧Worn piston/cylinder

If the compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and the piston head.

“F” Mark

Advance Mark

Compression Gauge

3-6

3. INSPECTION/ADJUSTMENT

FINAL REDUCTION GEAR OIL

OIL LEVEL CHECK

＊

Place the motorcycle on its main stan on level ground for oil level check.

Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole. If the oil level is low, add the recommended oil to the proper level.

Recommended Oil: SAE90#

Install the oil check bolt.

＊

Make sure that the sealing washer is in good condition.

AGILITY 50

Oil Check Bolt/Sealing Washe

OIL CHANGE

Remove the oil check bolt. Remove the oil drain bolt and drain the oil thoroughly. Install the oil drain bolt. Torque: 0.8~1.2kgf-m

＊

Make sure that the sealing washer is in good condition.

Fill with the recommended oil. Oil Capacity: At disassembly : 0.11 liter

At change : 0.10 liter

Reinstall the oil check bolt and check for oil leaks.

Torque:0.8~1.2kgf-m

DRIVE BELT

Remove the left crankcase cover. (Ö9-2) Inspect the drive belt for cracks or excessive wear. Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule.

Oil Check Bolt Hole

Oil Drain Bolt/ Sealing Washe

3-7

Drive Bel

3. INSPECTION/ADJUSTMENT

FILLY LX 50

BRAKE SHOE

Replace the brake shoes if the arrow on the wear indicator plate aligns with the punch mark on the brake panel when the brake is fully applied. Refer to page 12-7 and 13-3 for brake shoe replacement.

REAR BRAKE

Measure the rear brake lever free play. Free Play: 10～20mm

Arrows

Punch Mark

BRAKE ADJUSTING NUT

If the free play do not fall within the limit, adjust by turning the adjusting nut.

BRAKE FLUID

Turn the steering handlebar upright and check if the rear brake fluid level should be between the upper and lower level lines.

Specified Brake Fluid: DOT-4。

Adjusting Nu

Upper Line

Lower Line

3-8

3. INSPECTION/ADJUSTMENT

If the free play do not fall within the limit, adjust by turning the adjusting nut.

HEADLIGHT AIM

Turn the ignition switch ON and start the engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw.

AGILITY 50

Adjusting Nu

Front Cove

CLUTCH SHOE WEAR

Start the engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary. (Ö9-11)

SUSPENSION

FRONT

Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage.

Adjusting Screw

clutc

3-9

3. INSPECTION/ADJUSTMENT

REAR

Check the action of the rear shock absorber by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.

NUTS/BOLTS/FASTENERS

Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. (Ö1-11)

FILLY LX 50

WHEELS/TIRES

Check the tires for cuts, imbedded nails or other damages.

Check the tire pressure.

＊

Tire pressure should be checked when tires are cold.

TIRE PRESSURE

1 Rider 2 Riders Front 1.5kg/cm Rear 2.00kg/cm

TIRE SIZE

Front: 120/70-12 Rear : 130/70-12

1.75kg/cm

2.25kg/cm

Check the front axle nut for looseness. Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torques.

Torques: Front : 5.0～7.0kgf-m

Rear : 11～13kgf-m

Front Axle Nu

3-10

3. INSPECTION/ADJUSTMENT

STEERING HANDLEBAR

Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.

AGILITY 50

3-11

4. LUBRICATION SYSTEM

4 LUBRICATION SYSTEM

Rocker Arm Shaft

AGILITY 50

Crankshaft

Oil PumpOil Filter Screen

4-0

4. LUBRICATION SYSTEM

SERVICE INFORMATION.......................4-1 ENGINE OIL/OIL FILTER ...................... 4-2

TROUBLESHOOTING .............................4-1 OIL PUMP.................................................4-3

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The maintenance of lubrication system can be performed with the engine installed in the frame.

• Use care when removing and installing the oil pump not to allow dust and foreign matters to

enter the engine and oil line.

• Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it

reaches its service limit.

• After the oil pump is installed, check each part for oil leaks.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm)

Inner rotor-to-outer rotor clearance ⎯ 0.12

Oil pump Outer rotor-to-pump body clearance ⎯ 0.12

Rotor end-to-pump body clearance 0.05～0.10 0.2

TROUBLESHOOTING

Oil level too low Poor lubrication pressure

• Natural oil consumption • Oil level too low

• Oil leaks • Clogged oil filter or oil passages

• Worn or poorly installed piston rings • Not use the specified oil

• Worn valve guide or seal

4-1

4. LUBRICATION SYSTEM

ENGINE OIL/OIL FILTER

OIL LEVEL

＊

• Place the motorcycle upright on level ground for engine oil level check.

• Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.

Remove the oil dipstick and check the oil level with the oil dipstick. If the level is near the lower level, fill to the upper level with the specified engine oil.

OIL CHANGE

＊

The engine oil will drain more easily while the engine is warm.

Remove the drain bolt to drain the engine oil thoroughly. Remove the oil filter screen cap and clean the oil filter screen with compressed air.

AGILITY 50

Oil Dipstick

Check the filter screen O-ring for damage and replace if necessary. Install the oil filter screen, spring and filter screen cap. Torque: 1.0~2.0kgf-m

Fill the crankcase with the specified engine oil to the proper level.

Oil Capacity: At disassembly : 0.85 liter

At change : 0.70 liter

Check for oil leaks and then start the engine and let it idle for few minutes. Recheck the oil level.

Oil Filter Screen Cap

O-ring

4-2

4. LUBRICATION SYSTEM

OIL PUMP

REMOVAL

Remove the A.C. generator flywheel. (Ö14-7) Remove the A.C. generator stator and pulsar coil. (Ö14-6) Remove the eight right crankcase cover bolts and the right crankcase cover.

Remove the gasket and dowel pins. Remove the oil pump drive gear circlip. Remove the oil pump gear.

AGILITY 50

Bol

Right Crankcase Cove

Oil Pump Drive Gear

Remove the oil pump mounting bolts. Remove the oil pump.

Remove the two O-rings. Inspect the two O-rings for damage or deterioration.

Oil Pump Gear

Circlip

Oil Pump

Bolts

O-rings

4-3

4. LUBRICATION SYSTEM

DISASSEMBLY

Remove the three oil pump boby screws. Disassembly the oil pump.

INSPECTION

Measure the pump boby-to-outer rotor clearance.

Service Limit: 0.12mm

AGILITY 50

Oil Pump Boby

Screws

Outer Rotor

Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm

Measure the rotor end-to- pump boby clearance. Service Limit: 0.2mm

Oil Pump Boby

Outer Rotor

Inner Rotor

4-4

4. LUBRICATION SYSTEM

AGILITY 50

ASSEMBLY

Install the outer rotor, inner rotor and pump shaft into the pump boby.

＊

Install the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.

Install the pump cover and tighten the screws to secure the pump cover.

Inner Rotor

Pum

Shaf

Outer Rotor

Screws

INSTALLATION

First install the two O-rings onto the oil pump base.

Install the oil pump into the crankcase.

＊

Fill the oil pump with engine oil before installation.

After the oil pump is installed, tighten the three mounting bolts.

Pump Cove

O-rings

Oil pump

Bolts

4-5

4. LUBRICATION SYSTEM

AGILITY 50

Install the pump driven gear and secure it with the circlip.

Torque: 0.8～1.2kg-m

Install the right crankcase cover and tighten the eight bolts.

Torque: 0.8~1.2kgf-m

＊

Diagonally tighten the bolts in 2～3 times.

Pump Driven Gear

Circlip

Right Crankcase Cove

Bolts

4-6

5. FUEL SYSTEM

AGILITY 50

5-0

5. FUEL SYSTEM

Ω

AGILITY 50

Ignition Switch

CDI Unit

L/Y

Regulato

/Rectifier

Lighting System

Fuse

12V Battery

G/B

5 5W

Resistor

Auto Bystarte

5-1

5. FUEL SYSTEM

SERVICE INFORMATION.......................5-2 ACCELERATING PUMP .......................5-10

TROUBLESHOOTING..............................5-3 CARBURETOR INSTALLATION.........5-11

CARBURETOR REMOVAL.....................5-4 PILOT SCREW ADJUSTMENT ............5-12

AUTO BYSTARTER.................................5-4 FUEL TANK............................................5-13

AIR CUT-OFF VALVE .............................5-6 FUEL UNIT.............................................5-14

VACUUM CHAMBER..............................5-6 AIR CLEANER .......................................5-14

FLOAT CHAMBER...................................5-8

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

• When disassembling the carburetor, be sure to service the vacuum piston and float chamber.

• Do not bend or twist control cables. Damaged control cables will not operate smoothly.

• When disassembling fuel system parts, note the locations of O-rings. Replace them with new

ones during assembly.

• Before float chamber disassembly, loosen the drain screw to drain the residual gasoline into a clean container.

• After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent foreign matters from entering.

• Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm.

• When the motorcycle is not used for over one month, drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel.

SPECIFICATIONS

Item

Venturi dia. (mm) 20 Type CVK Float level (mm) 17 Main jet #85 Slow jet #35 Idle speed 1900rpm Throttle grip free play 2～6mm Pilot screw opening 2±

Standard

5-2

5. FUEL SYSTEM

AGILITY 50

TROUBLESHOOTING

Engine is hard to start Misfiring during acceleration

• No spark at plug (ÖSection 15) • Faulty ignition system

• Compression too low • Lean mixture

• No fuel to carburetor • Faulty accelerating pump

−Clogged fuel filter Engine idles roughly, stalls or runs poorly

−Restricted fuel line • Clogged fuel system

−Faulty float valve • Ignition malfunction

−Incorrectly adjusted float level • Rich or lean mixture

• Engine flooded with fuel • Contaminated fuel

−Clogged air cleaner • Intake air leak

−Fuel overflowing • Incorrect idle speed

• Intake air leak • Incorrectly adjusted pilot screw

• Contaminated fuel • Clogged idle system or auto bystarter passages

• Faulty auto bystarter • Incorrectly adjusted float level

• Clogged idle system or auto bystarter passages Lean mixture

Rich mixture • Clogged fuel jets

• Faulty auto bystarter • Faulty float valve

• Faulty float valve • Float level too low

• Float level too high • Clogged fuel system

• Clogged air jets • Intake air leak

• Dirty air cleaner • Improper vacuum piston operation

• Flooded carburetor • Improper throttle operation

Backfiring at deceleration

• Lean mixture in idle system

• Improper air cut-off valve operation

5-3

5. FUEL SYSTEM

CARBURETOR REMOVAL

Remove the frame right side cover. (Ö2-4) Disconnect the auto bystarter wire connector. Remove the met-in box. (Ö2-3)

AGILITY 50

Loosen the drain screw and drain the fuel from the float chamber. Disconnect the fuel tube and vacuum tube at the carburetor.

Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor. Loosen the carburetor intake manifold band and air cleaner connecting tube band screws and then remove the carburetor.

uto Bystarter Wire

Air Cleaner Connectin Tube Band

uto Bystarte

Fuel Tube

Intake Manifold Band

Throttle Cable

Adjusting Nu

Lock Nu

AUTO BYSTARTER

OPERATION INSPECTION

Measure the resistance between the auto bystarter wire terminals.

Resistance:10Ω max. (10 minutes minimum after stopping the engine)

If the reading is not within the limit, replace the auto bystarter with a new one.

5-4

5. FUEL SYSTEM

AGILITY 50

Connect a hose to the fuel enriching circuit of the carburetor. Connect the auto bystarter yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal. Wait 5 minutes and blow the hose with mouth or vacuum pump. If the passage is blocked, the auto bystarter is normal.

Disconnect the auto bystarter from the battery. Wait 30 minutes and blow the hose with mouth or vacuum pump. If air can be blown into the hose, the auto bystarter is normal.

REMOVAL

Remove the set plate screws and set plate. Remove the auto bystarter from the carburetor.

Vacuum Pump

Adopte

Auto Bystarte

AUTO BYSTARTER INSPECTION

Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter as a set.

INSTALLATION

Insert the auto bystarter into the carburetor body until it bottoms. Position the set plate into the groove in the auto bystarter and tighten the screws.

＊

• Be sure to install the auto bystarter an set plate properly.

• Install the set plate with its bottom face facing down.

Set Plate

Auto Bystarte

Screws

Bystarter Valve

Bystarter Needle

5-5

Set Plate

Screws

5. FUEL SYSTEM

AGILITY 50

AIR CUT-OFF VALVE

DISASSEMBLY

Remove the two screws attaching the throttle cable set plate and the set plate. Remove the two screws attaching the air cut-off valve. Remove the spring and vacuum diaphragm. Check the vacuum diaphragm for cracks or damage and check each passage for clogging.

ASSEMBLY

Install the vacuum diaphragm onto the carburetor. Install the spring and air cut-off valve cover. Install the throttle cable set plate and tighten the two screws.

＊

• Be sure to set the vacuum diaphrag lip into the groove on the carburetor.

• When installing the air cut-off valve cover, make sure that the vacuum diaphragm is properly installed.

Screws

Throttle Cable Set Plate

Diaphrag

Spring

Screws

Air Cut-off Valve Cove

Cove

O-rin

VACUUM CHAMBER

DISASSEMBLY

Remove the two vacuum chamber cover screws and the cover.

Remove the spring and vacuum diaphragm/ piston.

Vacuum Chamber Cove

Spring

Screws

Vacuum Diaphragm/Piston

Spring

5-6

5. FUEL SYSTEM

Remove the needle holder and jet needle.

＊

Be careful not to damage the vacuu diaphragm.

INSPECTION

Inspect the needle for stepped wear. Inspect the vacuum piston for wear or damage. Inspect the diaphragm for deterioration and tears.

AGILITY 50

Jet Needle

ASSEMBLY

Install the vacuum piston/diaphragm in the carburetor body. Install the spring and then install the vacuum chamber cover. Tighten the two screws.

＊

• Be careful not to damage the diaphragm.

• Hold the vacuum piston while

tightening the vacuum chamber cover.

Vacuum Diaphrag

Vacuum Chamber Cove

5-7

5. FUEL SYSTEM

AGILITY 50

FLOAT CHAMBER

DISASSEMBLY

Remove the three float chamber screws and the float chamber.

Loosen the float pin screw. Remove the float pin, float and float valve.

Screws

Float Chambe

Float ValveFloa

Remove the main jet, needle jet holder, needle jet, slow jet and pilot screw.

＊

• Be careful not to damage the fuel jets and pilot screw.

• Before removing, turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this.

• Do not force the pilot screw against its seat to avoid seat damage.

Clean the removed fuel jets with detergent oil and blow them open with compressed air. Blow compressed air through all passages of the carburetor body.

Float Pin

Pilot Screw

eedle Jet Holde

eedle Je

Slow Je

Main Je

5-8

5. FUEL SYSTEM

INSPECTION

Inspect the float valve and valve seat for damage or clogging. Inspect the float valve and valve seat contact area for stepped wear or contamination.

＊

Worn or contaminated float valve an valve seat must be replaced because it will result in float level too high due to incomplete airtightness.

AGILITY 50

Valve Sea

ASSEMBLY

Install the slow jet, needle jet, needle jet holder, main jet and pilot screw.

＊

Return the pilot screw to the original position as noted during removal.

Standard Opening: 2±

Install the float valve, float and float pin. Secure the float pin with the screw.

turns

Pilot Screw

Floa

eedle Jet Holde

eedle Je

Slow Je

Main Je

Float Valve

FLOAT LEVEL INSPECTION

＊

• Check the operation of the float valve and float before this inspection.

• Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet.

Measure the float level. Float Level: 17.0mm

This installation sequence is the reverse of removal.

5-9

Float Pin

Float Level Gauge

Screw

5. FUEL SYSTEM

AGILITY 50

ACCELERATING PUMP

DISASSEMBLY

Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm.

INSPECTION

Inspect the accelerating pump diaphragm for cracks, damage or deterioration. Replace if necessary.

Screws

Diaphrag

Check each accelerating pump fuel passage for clogging Clean and blow them open with compressed air.

Install the accelerating pump in the reverse order of removal.

＊

Be careful not to damage the diaphragm during installation.

Compressed Ai

Diaphrag

Compressed Ai

5-10

5. FUEL SYSTEM

Adj

AGILITY 50

CARBURETOR INSTALLATION

Tighten the drain screw. Install the carburetor onto the intake manifold, aligning the tab on the carburetor with the cutout in the intake manifold. Tighten the intake manifold band screw. Install the air cleaner connecting tube and tighten the band screw. Connect the throttle cable to the throttle wheel on the carburetor. Tighten the lock nut.

Connect the fuel tube and vacuum tube to the carburetor.

Throttle Cable

Connecting Tube Band

Lock Nut

usting Nut

Connect the auto bystarter wire connector. Perform the following inspections and adjustments:

-Throttle grip free play (Ö3-3)

-Carburetor idle speed (Ö3-5)

Fuel Tube

Auto Bystarter Wire Connecto

5-11

5. FUEL SYSTEM

PILOT SCREW ADJUSTMENT

ADJUSTMENT

＊

• The pilot screw is factory pre-set an no adjustment is necessary. During carburetor disassembly, note the number of turns of the pilot screw and use as a reference when reinstalling it.

• Place the motorcycle on its main stand on level ground for this operation.

A tachometer must be used when adjusting the engine speed. Turn the pilot screw clockwise until it seats lightly and back it out to the specification given.

Standard Opening: 2±

＊

• The carburetor must be adjusted when

the engine is warm and the auto bystarter is closed.

• Do not force the pilot screw against its

seat to prevent damage.

turns

AGILITY 50

Pilot Screw

Warm up the engine and adjust the throttle stop screw to obtain the specified idle speed.

Idle Speed: 1900±100rpm Turn the pilot screw in or out slowly to

obtain the highest engine speed. Slightly accelerate several times to make sure that the idle speed is within the specified range. If the engine misses or runs erratic, repeat the above steps.

Throttle Stop Screw

5-12

5. FUEL SYSTEM

FUEL TANK REMOVE

Remove the net-in box. (Ö2-3) Remove the frame center cover. Remove the frame body cover. (Ö2-3)

Remove the four bolts on the fuel tank, take the upper seat lock off. Disconnect the fuel unit wire connector. Remove the fuel tank. The installation sequence is the reverse of removal.

AGILITY 50

Fuel Tank

FUEL STRAINER REMOVAL

Remove the fuel strainer from the fuel tank.

INSPECTION

Inspect if the fuel strainer is clogged and clean it with compressed air.

＊

• When removing the fuel strainer, do not allow flames or sparks near the working area and drain the residual gasoline into a container.

Bolts

Fuel Unit Wite Connector

Seat Loc

INSTALLATION

Install the fuel strainer with its arrow mark toward the fuel pump.

5-13

Fuel Straine

Arrow Mar

5. FUEL SYSTEM

FUEL UNIT

REMOVAL

Remove the related parts. Disconnect the fuel unit wire connector. Turn the fixed plate on the fuel unit,take the fuel unit off.

＊

Do not bend the float arm on the fuel unit,otherwise the figure on the fuel meter will not correct.

AGILITY 50

Fuel Unit Wire

INSTALLATION

Inspet if the fuel unit is damaged,or harden. Assemble the fuel unit in the reverse order of disassembly.

＊

• Align the groove on the fuel unit with

the angle on the fuel tank.

• Inspect if the fuel tank leaked after

installing and filling the gasoling.

AIR CLEANER

Loosen the air cleaner connecting tube band screw. Disconnect the clinhead cover breather tube from the air cleaner. Remove the two bolts and air cleaner case.

Fuel Tank

Fuel Unit

Align Mark

air cleane

olts

5-14

5. FUEL SYSTEM

The installation sequence is the reverse of removal.

AGILITY 50

5-15

6. ENGINE REMOVAL/INSTALLATION

FILLY LX 50

6-0

6. ENGINE REMOVAL/INSTALLATION

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

ENGINE REMOVAL................................ 6-2

FILLY LX 50

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

ENGINE REMOVAL

Disconnect the battery negative cable. Remove the frame body cover. (Ö2-3) Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Disconnect the A.C. generator wire connector.

FILLY LX 50

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

Remove the spark plug cap.

egative Cable

Earthr Cable

Auto Bystarter Wire Connecto

tarter Motor Cable

Spark Plug High Tension Wire

Disconnect the vacuum tube. Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor.

Band

Lock Nut

Vacuum Tube

Adjusting Nut

6-2

6. ENGINE REMOVAL/INSTALLATION

FILLY LX 50

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

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

Air Tube Band

connecting tube

Remove the rear shock absorber upper mount bolt.

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

Adjusting Nut

Rear Shock Absorber Upper Mount Bol

6-3

Engine Hange Bracket Bolt

Engine Mounting Bol

6. ENGINE REMOVAL/INSTALLATION

ENGINE HANGER BRACKET REMOVAL

Remove the return spring from the main stand. Remove the main stand.

FILLY LX 50

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

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

Stopper Spring

Return Sprin

Bushing

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

Main Stand

Engine Mounting Bol

Engine Hanger Bracket Bol

Return Sprin

6-4

6. ENGINE REMOVAL/INSTALLATION

FILLY LX 50

Install the removed parts in the reverse order of removal.

＊

Route the wires and cables properly.

After installation, inspect and adjust the following:

• Throttle grip free play (

• Rear brake adjustment (

3-3)

3-8)

Rear Shock Absorber Upper Mount Bol

6-5

7. CYLINDER HEAD/VALVES

AGILITY 50

7-0

7. CYLINDER HEAD/VALVES

SERVICE INFORMATION......................7-1 CYLINDER HEAD DISASSEMBLY.......7-7

TROUBLESHOOTING ............................7-2 CYLINDER HEAD ASSEMBLY.............7-8

CAMSHAFT REMOVAL.........................7-3 CYLINDER HEAD INSTALLATION .....7-8

CYLINDER HEAD REMOVAL..............7-5 CAMSHAFT INSTALLATION................7-9

FILLY LX 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder head can be serviced with the engine installed in the frame.

• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable

parts, valve arm and camshaft sliding surfaces for initial lubrication.

• The camshaft is lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

• After removal, mark and arrange the removed parts in order. When assembling, install them in

the reverse order of removal.

SPECIFICATIONS

Item

Valve clearance (cold) Cylinder head compression 14kg/cm

Cylinder head warpage ⎯ 0.05 Camshaft cam height

Valve rocker arm I.D. Valve rocker arm shaft IN 9.972-9.987 9.91

O.D. Valve seat width

Valve stem O.D.

Valve guide I.D.

Valve stem-to-guide IN 0.010-0.037 0.08 clearance

Valve spring free

IN 0.04 ⎯

EX 0.04 ⎯

IN 26.438 26.038

EX 25.807 25.407

IN 10.000-10.015 10.10

EX 10.000-10.015 10.10

EX 9.972-9.987 9.91

IN 1.0 1.8

EX 1.0 1.8

IN 4.975-4.990 4.9

EX 4.955-4.970 4.9

IN 5.000-5.012 5.03

EX 5.000-5.012 5.03

EX 0.030-0.057 0.1

Inne

Oute

Standard (mm) Service Limit (mm)

31.1 30.1

34.35 33.3

⎯

7-1

7. CYLINDER HEAD/VALVES

TORQUE VALUES

Cylinder head nut 1.8~2.2kgf-m Apply engine oil to threads Valve clearance adjusting nut 0.7~1.1kgf-m Apply engine oil to threads

SPECIAL TOOLS

Valve spring compressor

AGILITY 50

TROUBLESHOOTING

• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.

Poor performance at idle speed White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide

• Damaged valve stem seal

Compression too low

• Incorrect valve clearance adjustment Abnormal noise

• Burned or bend valves • Incorrect valve clearance adjustment

• Incorrect valve timing • Sticking valve or broken valve spring

• Broken valve spring • Damaged or worn camshaft

• Poor valve and seat contact • Worn cam chain guide

• Leaking cylinder head gasket • Worn camshaft and rocker arm

• Warped or cracked cylinder head

• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion chamber

7-2

7. CYLINDER HEAD/VALVES

Nut

CAMSHAFT REMOVAL

Remove the center cover. (Ö2-3) Remove the frame center. Remove the four cylinder head cover bolts to remove the cylinder head cover.

FILLY LX 50

Cylinder Head Cove

Remove the cam chain tensioner sealing bolt and spring. Remove the two bolts attaching the cam chain tensioner and the tensioner.

Sealing Bol

Camshaft Gea

Bolts

Remove the two cylinder head bolts. Remove the four cylinder head nuts and washers. Remove the camshaft holder.

＊

Diagonally loosen the cylinder head nuts in 2 or 3 times.

7-3

Round Hole

Washe

Punch Marks

7. CYLINDER HEAD/VALVES

Remove the camshaft holder and dowel pins.

AGILITY 50

Camshaft Holde

Remove the camshaft gear from the cam chain and remove the camshaft.

CAMSHAFT INSPECTION

Check each cam lobe for wear or damage. Measure the cam lobe height.

Service Limits:

IN : 26.038mm replace if below EX: 25.407mm replace if below

Camshaf

Cam Chain Camshaft Gea

Dowel Pins

Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.

Camshaft Bearings

7-4

7. CYLINDER HEAD/VALVES

CAMSHAFT HOLDER DISASSEMBLY

Take out the valve rocker arm shafts using a 5mm bolt. Remove the valve rocker arms.

FILLY LX 50

Rocker Arm Shaf

CAMSHAFT HOLDER INSPECTION

Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.

＊

If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

Measure the I.D. of each valve rocker arm. Service Limits: IN:10.10mm replace if over

EX:10.10mm replace if over

Measure each rocker arm shaft O.D. Service Limits: IN: 9.91mm replace if over

EX: 9.91mm replace if over

5mm Bol

Camshaft Holde

Rocker Ar

Rocker Arm Shafts

CYLINDER HEAD REMOVAL

Remove the camshaft. (Ö7-3) Remove the carburetor. (Ö5-5) Remove the exhaust muffler. (Ö2-5) Remove the carburetor intake manifold.

7-5

Intake Manifold

7. CYLINDER HEAD/VALVES

Remove the cooling fan cover. (Ö14-6) Remove the engine cover bolts and screws. Separate the engine cover joint claws.

AGILITY 50

Remove the cylinder head.

Remove the dowel pins and cylinder head gasket. Remove the cam chain guide.

Cylinder Head

Bolts

Dowel Pins

linder Head Gaske

Cam Chain Guide

7-6

7. CYLINDER HEAD/VALVES

FILLY LX 50

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor.

＊

• Be sure to compress the valve springs with a valve spring compressor.

• Mark all disassembled parts to ensure correct reassembly.

Special

Valve Spring Compressor Valve Spring Compressor Attachment

Remove carbon deposits from the combustion chamber. Clean off any gasket material from the cylinder head mating surface.

＊

Be careful not to damage the cylinde head mating surface.

Valve Spring Compresso

Valve Spring Compressor Attachmen

INSPECTION

CYLINDER HEAD Check the spark plug hole and valve areas for

cracks. Check the cylinder head for warpage with a straight edge and feeler gauge.

Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTH Measure the free length of the inner and outer

valve springs. Service Limits: Inner : 30.1mm replace if below Outer : 33.3mm replace if below

7-7

7. CYLINDER HEAD/VALVES

VALVE/ VALVE GUIDE Inspect each valve for bending, burning,

scratches or abnormal stem wear. Check valve movement in the guide.

Measure each valve stem O.D. Service Limits: IN : 4.9mm replace if below

EX: 4.9mm replace if below

AGILITY 50

CYLINDER HEAD ASSEMBLY

＊

• When assembling, a valve spring compressor must be used.

• Install the cotters with the pointed ends facing down from the upper side of the cylinder head.

Special

Valve Spring Compressor Val ve Spring Compressor Attachment

Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters.

＊

Be careful not to damage the valves.

Valve Spring Compresso

Valve Spring Compressor Attachmen

CYLINDER HEAD INSTALLATION

Install the dowel pins and a new cylinder head gasket. Install the cam chain guide.

Dowel Pins

Cam Chain Guide

Gaske

7-8

7. CYLINDER HEAD/VALVES

FILLY LX 50

Install the cylinder head.

CAMSHAFT HOLDER ASSEMBLY

First assemble the camshaft holder. Install the intake and exhaust valve rocker arms and rocker arm shafts.

＊

• When installing the rocker arm shaft, align the shaft front end with the bolt hole of the camshaft holder.

Cylinder Head

Camshaft Holde

CAMSHAFT INSTALLATION

Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the camshaft onto the cylinder head. Install the cam chain over the camshaft gear.

Install the dowel pins.

Cam Chain

Round Hole

Dowel Pins

Valve Rocker Ar

Camshaft Gea

Punch Marks

7-9

7. CYLINDER HEAD/VALVES

Nut

AGILITY 50

Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts and two bolts.

Torque: Cylinder head nut: 1.8~2.2kgf-m

＊

• Apply engine oil to the threads of the

cylinder head nuts.

• Diagonally tighten the cylinder head

nuts in 2～3 times.

CAM CHAIN TENSIONER INSTALLATION

First install a new cam chain tensioner gasket. Install the tensioner using the two bolts. Install the tensioner spring. Install the O-ring and sealing bolt.

＊

When installing the tensioner, release the lock pawl and push the push rod all the way in.

Washe

Cam Chain Tensione

Camshaft Holde

Sealing Bol

Torque:: 0.45~0.6kgf-m

Adjust the valve clearance. (Ö3-5) Install a new cylinder head cover O-ring and install the cylinder head cover.

＊

Be sure to install the O-ring into the groove properly.

Install and tighten the cylinder head cover bolts.

Torque:: 0.8~1.2kgf-m

O-rin

Push RodLock Pawl

Cylinder Head Cove

Sprin

7-10

8. CYLINDER/PISTON

1.0kg-

AGILITY 50

Do not ben

8-0

8. CYLINDER/PISTON

SERVICE INFORMATION.......................8-1 PISTON REMOVAL.................................8-2

TROUBLESHOOTING..............................8-1 PISTON INSTALLATION........................8-6

CYLINDER REMOVAL ...........................8-2 CYLINDER INSTALLATION .................8-6

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder and piston can be serviced with the engine installed in the frame.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

SPECIFICATIONS

Item

I.D. 50.00-50.01

Cylinde

Piston, piston rin

Piston pin O.D 12.994-13.000 12.96 Piston-to-piston pin clearance 0.002-0.014 ⎯ Connecting rod small end I.D. bore 13.016-13.034 13.06

Warpage ⎯ 0.05 Cylindricity ⎯ 0.05 True roundness ⎯ 0.05 Ring-to-

clearance

Ring end gap Second 0.05-0.20 0.45

Piston O.D. 49.97-49.990 49.9 Piston O.D. measuring 9mm from bottom of skirt ⎯ Piston-to-cylinder clearance 0.010-0.040 0.1 Piston pin hole I.D. 13.002-13.008 13.04

Top 0.015-0.050 0.09 Second 0.015-0.050 0.09 Top 0.08-0.20 0.45

Oil side rail 0.20-0.70 ⎯

Standard (mm) Service Limit (mm)

TROUBLESHOOTING

• When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven compression Excessive smoke from exhaust muffler

• Worn, stuck or broken piston rings • Worn or damaged piston rings

• Worn or damaged cylinder and piston • Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings chamber or on piston head

8-1

• Worn piston pin hole and piston pin

8. CYLINDER/PISTON

CYLINDER REMOVAL

Remove the cylinder head. (Ö7-6) Remove the cam chain guide. Remove the cylinder.

Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.

AGILITY 50

Cylinde

Dowel Pins

PISTON REMOVAL

Remove the piston pin clip.

＊

Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

Press the piston pin out of the piston and remove the piston.

Gaske

Piston Pin

Piston Rings

Piston

8-2

8. CYLINDER/PISTON

Inspect the piston, piston pin and piston rings. Remove the piston rings.

＊

Take care not to damage or break the piston rings during removal.

Clean carbon deposits from the piston ring grooves.

Install the piston rings onto the piston and measure the piston ring-to-groove clearance.

Service Limits:Top: 0.09mm replace if over

2nd: 0.09mm replace if over

AGILITY 50

Remove the piston rings and insert each piston ring into the cylinder bottom.

＊

Use the piston head to push each piston ring into the cylinder.

Measure the piston ring end gap. Service Limit: 0.45mm replace if over

Measure the piston pin hole I.D.

Service Limit: 13.04mm replace if below

8-3

8. CYLINDER/PISTON

Measure the piston pin O.D. Service Limit:12.96mm replace if below

Measure the piston O.D.

＊

Take measurement at 9mm from the bottom and 90° to the piston pin hole.

Service Limit: 38.9mm replace if below Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

AGILITY 50

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. at three levels of top, middle and bottom at 90° to the piston pin (in both X and Y directions).

Service Limit: 39.10mm repair or replace if over

Measure the cylinder-to-piston clearance. Service Limit: 0.1mm repair or replace if

over

The true roundness is the difference between the values measured in X and Y directions. The cylindricity (difference between the values measured at the three levels) is subject to the maximum value calculated.

Service Limits: True Roundness: 0.05mm repair or replace

if over

Cylindricity: 0.05mm repair or replace if over

Top

Middle

Botto

8-4

8. CYLINDER/PISTON

Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over

Measure the connecting rod small end I.D.

Service Limit: 13.06mm replace if over

AGILITY 50

PISTON RING INSTALLATION

Install the piston rings onto the piston. Apply engine oil to each piston ring.

＊

• Be careful not to damage or break the piston and piston rings.

• All rings should be installed with the markings facing up.

• After installing the rings, they should rotate freely without sticking.

Top

Second Side Rail

Expande Side Rail

Top

Second

Oil

8-5

8. CYLINDER/PISTON

PISTON INSTALLATION

Remove any gasket material from the crankcase surface.

＊

Be careful not to drop foreign matters into the crankcase.

Install the piston, piston pin and a new piston pin clip.

＊

• Position the piston “IN” mark on the intake valve side.

• Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

AGILITY 50

Piston Pin Clip

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder gasket on the crankcase.

Coat the cylinder bore, piston and piston rings with clean engine oil. Carefully lower the cylinder over the piston by compressing the piston rings.

＊

• Be careful not to damage or break the

piston rings.

• Do not align the ring end gaps with the

intake/exhaust valve and piston pin.

Piston Pin

Dowel Pins

Gaske

Piston

Cylinde

8-6

8. CYLINDER/PISTON

Install the cam chain guide.

＊

Insert the tab on the cam chain guide into the cylinder groove.

Install the cylinder head. (Ö7-8) Loosely install the cylinder base bolts.

Tighten the cylinder base bolts.

AGILITY 50

Cam Chain Guide

Cylinder Base Bolts

8-7

9. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

AGILITY 50

5.0～6.0kg-

3.5-4.5g-

3.5-4.0g-

9-0

9. DRIVE AND DRIVEN PULLEYS/

)

KICK STARTER

SERVICE INFORMATION.......................9-1 DRIVE BELT ..........................................9-5

TROUBLESHOOTING..............................9-1 DRIVE PULLEY .....................................9-6

LEFT CRANKCASE COVER ...................9-2 CLUTCH/DRIVEN PULLEY .................9-9

KICK STARTER........................................9-2

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The drive pulley, clutch and driven pulley can be serviced with the engine installed.

• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from

them to minimize the slipping of drive belt and drive pulley.

SPECIFICATIONS

AGILITY 50

Ite Movable drive face bushing I.D. 23.989~24.025 24.06 Drive face collar O.D. 23.960~23.974 23.94 Drive belt width 17.5 16.5 Clutch lining thickness ⎯ 1.5 Clutch outer I.D. 107.0-107.2 107.5 Driven face spring free length ⎯ 154.6 Driven face O.D. 33.965-33.485 33.94 Movable driven face I.D. 34.0-34.025 34.06 Weight roller O.D. 15.920~16.080 15.4

TORQUE VALUES

Drive face nut 5.5~6.5kgf-m Clutch outer nut 3.5~4.5kgf-m Clutch drive plate nut 5.0-6.0kg-m

SPECIAL TOOLS

Universal holder Clutch spring compressor

Standard (mm

Service Limit (mm

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Broken driven face spring • Fouled drive face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

9-1

9. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

AGILITY 50

LEFT CRANKCASE COVER

REMOVAL

Loosen the drive belt air tube band screw. Remove the eight left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Inspect the seal rubber for damage or deterioration.

＊

Use specified genuine parts for replacement.

KICK STARTER

REMOVAL

Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle.

Left Crankcase Cove

Air Tube Band Bolts

Kick Starter Spindle

Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring.

Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushings.

Washe

Friction Spring

Circlip

Starter Driven Gea

Kick Starter Spindle

Return Spring

9-2

9. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

AGILITY 50

INSPECTION

Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage.

Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage.

Spindle

Plastic Bushing

Friction Spring

Return Spring

Spindle Bushing

Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage.

INSTALLATION

Install the kick starter spindle bushings and return spring onto the left crankcase cover.

Starter Driven Gea

Kick Starter Spindle Forcing Par

Starter Driven Gear Shaft Forcing Par

Kick Starter Spindle

9-3

Return Sprin

9. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

AGILITY 50

Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown.

First install the washer and then install the circlip. Install the kick lever.

Friction Sprin

Starter Driven Gea

LEFT CRANKCASE COVER INSTALLATION

First install the dowel pins. Install the seal rubber.

Install the left crankcase cover and tighten the eight left crankcase cover bolts diagonally. Connect the drive belt air tube and tighten the tube band screw. Install the rear brake cable clamp.

Washe

Dowel Pins

Circlip

Seal Rubbe

Left Crankcase Cove

Rear Brake Cable Clamp

9-4

9. DRIVE AND DRIVEN PULLEYS/

Nut

KICK STARTER

DRIVE BELT

REMOVAL

Remove the left crankcase cover.

INSPECTION

Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width.

Service Limit: 16.5mm

AGILITY 50

REPLACEMENT

Remove the eight left crankcase cover bolts and left crankcase cover. (Ö9-2) Hold the clutch outer with an universal holder and remove the clutch outer nut.

Special

Universal Holder

Hold the drive pulley using a holder and remove the drive face nut, starting ratchet and washer. Remove the drive pulley face.

Clutch Oute

Universal Holde

Drive Pulley Face

Remove the drive belt from the clutch/driven pulley.

9-5

Drive Face Nu

Clutch/Driven Pulle

9. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

INSTALLATION

Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley.

AGILITY 50

Drive Bel

Set the drive belt on the drive pulley face collar. Install the drive pulley face, starting ratchet washer. Install and tighten the drive face nut.

＊

When installing, align the tooth space of the drive pulley face and starting ratchet with the crankshaft tooth and then tighten the nut.

DRIVE PULLEY

REMOVAL

Hold the drive pulley using a holder and remove the drive face nut, starting ratchet and washer. Remove the drive pulley face.

Drive Face Nu

Starting Ratche

Drive Pulley Face

10mmWashe

Starting Ratche

Drive Bel

DISASSEMBLY

Remove the movable drive face assembly and drive pulley collar from the crankshaft.

Movable Drive Face Assembl

Drive Pulley Colla

Drive Face Nu

(10mm)

9-6

KYMCO AGILITY 50 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual