KYMCO AGILITY 125, Agility 50, Agility 50 4T R10, Agility 50 4T R12 Service Manual
Agility 50 - 125
50 4T R10 50 4T R12 125
MOTORE MONOCIL INDRICO ORIZZO NTALE 4 TEMPI
RAFF REDDAMENTO ARIA FOR ZATA
CILINDR ATA 49cc 125cc
POTEN ZA
2,4kW (3 ,3CV) a 8.50 0 giri/min 2,4kW (3 ,3CV) a 7.500 giri /min 6,9kW (9,4 CV) a 7.500 giri/ min
COPPIA 3,2 Nm a 7.000 gir i 9,6 Nm a 6.50 0 giri
EMISSIO NI EURO 2 EURO 3
AVVIA MENTO E LETTRICO E K ICK STARTER
FRIZION E CE NTRIFUGA AU TOMATICA A SECC O
TRAS MISSIONE CINGHIA T RAPEZOIDA LE - INGRANA GGI
SOSPEN SIONI
ANT. FORC ELLA TELESC OPICA IDRAULI CA ø 31
POST. MONO BRACCIO OSCIL LANTE AM MORTIZZATO RE IDRAULICO RE GOLABILE
FRENI
ANT. DISCO ø 180mm
POST. TAMBUR O ø 110mm
PNEUMAT ICI
ANT. - POST. 90 /90-10
ANT. 120/ 70-12
POST. 130/ 70-12
DIMENSIO NE 1.830 x 69 0 x 1.070mm 1.830 x 69 0 x 1.130mm 1.835 x 690 x 1.125mm
MASS A 8 4kg 92kg 105kg
COLORI argent o nero argent o nero rosso giallo
giallo
Agility 50 - 125
2616-0 40407KYMCO S I RISERVA DI APPO RTARE VARIAZ IONI TECNIC HE, ESTET ICHE O DI ALTRA N ATURA SENZ A L’OBBLIGO DI ALCU N PREAVVIS O.
KYMCO RACC OMANDA2 ANNI DI GAR ANZIA 1 ANNO DI ASS ISTENZA CREDITO PERSONA LIZZATO
S e r v i z i F i n a n z i a r i
SCOOTER TARGATICICLOMOTO RI 4T
AGILITY 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO AGILITY
50
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
ENGINE
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
9
FINAL REDUCTION 10
CRANKCASE/CRANKSHAFT 11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
CHASSIS
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM 15
STARTING SYSTEM 16
ELECTRICAL
EQUIPMEN
T
LIGHTS/INSTRUMENTS/SWITCHES 17
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.
1. GENERAL INFORMATION
1-1
AGILITY 50
Location of Engine Serial Numbe
r
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER...................1- 1 LUBRICATION POINTS .......................1-13
SPECIFICATIONS ...................................1- 2 CABL 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
AGILITY 50
1. GENERAL INFORMATION
1-2
AGILITY 50
SPECIFICATIONS
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
Front wheel 120/70 -12 56J
Tires
Rear wheel 130/70 -12 56J
Ground clearance (mm) 112
Perform-
Braking distance (m)
4 (Initial speed
20km/h)
ance
Min. turning radius (m) 1.99
Starting system
Starting motor &
kick starter
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)
18
Max. output 3.5/7500kw/(r/min)
Max. torque 0.35/7000kg m/rpm
Open 3q
Port
Intake
Close 7q
Engine
timin
g
Open 9q
Exhaust
Close 1q
Intake 0.04
(cold) (mm)
Exhaust 0.04
Idle speed (rpm) 1700Ô100rpm
Lubrication type
Forced
p
ressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Lubrication
System
Oil capacity 0.8 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 5.0 liter
Type CVK
Piston dia. (mm)
Venturi dia.(mm) I17equivalent
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing BTDC28q/4000rpm
Contact breaker Non-contact point type
Spark plug
NGK
C7HSA
Spark plug gap 0.6Д0.7mm
Battery Capacity 12V4AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation
Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st
0.8-3.1
ratio
2nd
11.05
Front Caster angle 27q
Axle
Trail length
Tire pressure
Fron
t
1.75
(kg/cm²)
Rear 2.25
Turning Left 45q
angle
Right 45q
FrontDISK (180mm) brake
Brake system
type
Rear Drum (110mm) brake
Fron
t
TELESCOPE
Suspension type
Rear Unit Swing
Front 80
Shock absorber
distance
Rear
82
Frame type Under Bone
Fuel S
y
stem
Electrical E
q
ui
p
ment
I
g
nition S
y
stem
Power Drive System
Transmis-
sion Gear
Reduction
Gear
Moving Device
Damping
Device
1. GENERAL INFORMATION
1-3
AGILITY 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants
.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
1. GENERAL INFORMATION
1-4
AGILITY 50
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
1. GENERAL INFORMATION
1-5
AGILITY 50
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confir
m
Capacity
1. GENERAL INFORMATION
1-6
AGILITY 50
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!
1. GENERAL INFORMATION
1-7
AGILITY 50
After clamping, check each wire to make
sure it is secure.
.
Do not squeeze wires against the weld or
its clamp
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !
1. GENERAL INFORMATION
1-8
AGILITY 50
Route harnesses so they are neither
pulled tight nor have excessive slack.
.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too ti
g
ht!
Do not press o
r
squeeze the wire.
1. GENERAL INFORMATION
1-9
AGILITY 50
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !
1. GENERAL INFORMATION
1-10
AGILITY 50
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
(Ö12-3) :Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
＊
1. GENERAL INFORMATION
1-11
AGILITY 50
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Torque (kg-m
)
Ite
m
Torque (kg-m
)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45-0.6
0.6-1.2
1.8-2.5
3.0-4.0
5.0-6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35-0.5
0.7-1.1
1.0-1.4
2.4-3.0
3.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A
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
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
6
6
30
6
7
3
8
8
10
28
6
4
10
10
6
6
0.7-1.1
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
0.8-1.2
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. GENERAL INFORMATION
1-12
AGILITY 50
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
10-3
10-4Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing
12-6
Bushing remover L E032 11102 bush engine hanger rubber
Bushing remover S EO19 11203 bush rear cushion under rubber
Crankshaft bearing puller E030 91005 radial bearing
Crankshaft protector E029 13000 crankshaft comp 12mm.14mm
Clutch spring compressor E027 2301a driven pully assy
9-9
9-12
Cushion assemble & disassemble
tool
F004 52400 cushion assy 13-4
Flywheel holder E017
31110 fl
y
wheel comp.2310a pully ass
y
driven
9-5
9-9
9-13
14-7
14-9
Flywheel puller E002 Left hand thread 27mm
14-7
Long socket wrench 32mm 8angle F002 50306 steering stem
12-21
12-22
Oil seal & bearing installer E014 Oil seal & bearing install
Tool boox E033 Special tools storage
Tappet adjuster E036 90012 screw tappet 3-5
7-7
Valve spring compressor E038 Valve spring
7-8
1. GENERAL INFORMATION
1-13
AGILITY 50
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
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)
xAPISG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube
Adhesive
1. GENERAL INFORMATION
1-14
AGILITY 50
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.
Rear Wheel Bearings
Main Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot
Grease
Grease
Grease
Engine Oil
Rear Brake Cable
Brake Cam
/
Anchor Pin
Grease
Grease
Front Brake Leve
r
Pivot
Front Brake Cable
/
Speedometer Cable/
Throttle Cable
Engine/ Oil
1. GENERAL INFORMATION
1-15
AGILITY 50
CABLE & HARNESS ROUTING
Front Stop Switch Wire
Rear Stop Switch Wire
Throttle Cable
Regulator/Rectifie
r
Rear Brake Cable
Speedometer Cable
Horn
Ignition Switch
Winke
r
Front Brake Fluid Tube
Brake Master Cylinde
r
1. GENERAL INFORMATION
1-16
AGILITY 50
Regulator/Rectifie
r
Speedometer Cable
Ignition Switch
Throttle Grip
Rear Brake Leve
r
Front Brake Fluid Tube
Headlight Resisto
r
Horn
1. GENERAL INFORMATION
1-17
AGILITY 50
Starter Relay
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Battery (+) Cable
Battery (-) Cable
Fuel Tan
k
Ignition Coil
1. GENERAL INFORMATION
1-18
AGILITY 50
Throttle Cable
Vacuum Tee
Carbureto
r
Overflow Tube
Fuel Tube
Crankcase Breathe
r
Tube
Ignition Coil
Primary Wire
Ignition Wire
Fuel Filte
r
Auto Cock Assy Fuel
1. GENERAL INFORMATION
1-19
AGILITY 50
Throttle Cable
Fuel Tube
Vacuum Tube
Auto Bystarte
r
Crankcase Breathe
r
Tube
Ignition Coil
Wire
Crankcase Breathe
r
Tube
Throttle Cable
Vacuum Tube
Fuel Unit
Reed Valve
Secondary Ai
r
Inlet Tube
Air Injection
Cut-off
Valve
1. GENERAL INFORMATION
1-20
AGILITY 50
WIRING DIAGRAM
1. GENERAL INFORMATION
1-21
AGILITY 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel strainer
Faulty auto fuel
valve
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted high-tension
wire
Faulty ignition switch
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Faulty auto bystarter
Air leaking through intake pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw
Flooded carburetor
Faulty auto bystarter
Throttle valve excessively open
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
Inspection/Adjustment
Probable Cause
Spark jumps
Normal
compression
Engine does no
t
fire
Weak or no spark
Low or no
compression
Engine fires bu
t
does not start
Test cylinde
r
compression
Start engine by following normal starting
p
rocedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does no
t
reach carburetor
Wet spark plug
Dry spark plug
1. GENERAL INFORMATION
1-22
AGILITY 50
ENGINE LACKS POWER
Clogged air cleaner
Poor quality fuel (Restricted)
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
diaphragm
Faulty auto fuel valve
Faulty CDI unit
Faulty pulser coil
Improper valve clearance
adjustment
Worn valve seat (valve stem too
protruding
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing
Clogged carburetor jets
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too early
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early
Start engine and accelerate
lightly for observation
Inspection/Adjustment
Symptom
Probable Cause
Engine speed
Correct timin
g
Engine speed does no
t
increase sufficientl
y
Incorrect timin
g
Check ignition timing
using a timing light
Test cylinder compression
Check carburetor fo
r
clogging
Rapidly accelerate or run
at hi
g
h speed
Remove spark plug and
inspec
t
Check if engine overheats
Check valve clearance
Correc
t
Incorrec
t
N
ormal
com
p
ression
Abnormal
compression
Remove oil dipstick and
check oil level and condition
Remove cylinder head oil
pip
e bolt and inspec
t
Engine overheats
Engine does no
t
overheats
Plug not fouled o
r
discolored
Plug fouled o
r
discolored
Correct and no
t
contaminated
Incorrect o
r
contaminated
Valve train lubricated
prop
erl
y
Valve train no
t
lubricated properl
y
Engine does not knock
Engine knocks
Not clogged
Clogged
1. GENERAL INFORMATION
1-23
AGILITY 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
Mixture too rich (turn screw
out)
Mixture too lean (turn screw in)
Deteriorated O-ring
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Faulty air cut-off valve
Damaged vacuum tube
Clogged or damaged air vent
hole
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
g
round
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check air cut-off valve
Check carburetor gaske
t
for air leaks
Check carburetor pilo
t
screw adjustment
Correct timing
Incorrect timing
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter-
mittent spark
Good
Faulty
Incorrectly adjusted
1. GENERAL INFORMATION
1-24
AGILITY 50
POOR PERFORMANCE (AT HIGH SPEED)
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
Cam timing gear aligning marks
not aligned
Faulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jets
for clogging
Check fuel pump fo
r
fuel supply
Correct timing
Incorrect timing
Check valve spring
tension
Check valve clearance
Fuel flows freely
Fuel flow restricted
Correc
t
Incorrec
t
Not clogged
Clogged
Correctly adjusted
Incorrectly adjusted
Not weakened
Weak spring
Check valve timing
1. GENERAL INFORMATION
1-25
AGILITY 50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead battery
Faulty battery
Faulty A.C. generator coil
Broken yellow wire
Loose connector
Broken red wire
Faulty regulator/rectifier
Poorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and tes
t
limit voltage between
b
attery terminals
Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
g
round and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
B
attery has voltage
with ignition
switch “ON”
Normal
Voltage does no
t
B
attery has no
voltage with ignition
switc
h
“ON”
Resistance too high
Normal voltage
No voltage
Measure resistance
between AC generator
coil terminals
Normal
Abnormal
Check regulator/rectifier
coupler for loose
connection
Normal
Abnormal
Connect battery (+) wire
to regulator/rectifier
coupler green wire and
battery (-) wire to engine
g
round and test voltage
Check regulator/rectifier
coupler for loose
connection
1. GENERAL INFORMATION
1-26
AGILITY 50
NO SPARK AT SPARK PLUG
Faulty old spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switch
Faulty pulser coil
Faulty ignition coil
Broken wire harness
Poorly connected coupler
Faulty CDI unit
Faulty ignition coil
Replace with a new
spark plug and inspect
a
g
ain
Check CDI unit coupler
for looseness
Inspection/Adjustment Symptom
Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal
Abnormal
Abnormal
Measure resistance
between CDI unit
cou
p
ler wire terminals
Check related parts
Check ignition coil with
a CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Good
Good
Check spark plug cap
and high-tension wire
for looseness
Check CDI unit with a
CDI unit tester
2. FRAME COVERS/EXHAUST MUFFLER
2-0
AGILITY 50
2 SCHEMATIC DRAWING
2
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