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)
xAPISG 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

2. FRAME COVERS/EXHAUST MUFFLER

2-1

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xWhen removing frame covers, use special care not to pull them by force because the cover joint

claws may be damaged.

Items Related for Removal

xHandlebar front cover Handlebar rear cover

Headlight wire connector

xHandlebar rear cover Speedometer cable and instrument light

wire connectors, etc.

xFrame body cover Met-in box, rear grip, rear turn signal

lights, floor board

xFloor board Frame body cover

Battery and wire connectors

xFront 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

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

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

2. FRAME COVERS/EXHAUST MUFFLER

2-2

AGILITY 50

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.

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.

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.

Bol

t

Screw

Handlebar Front Cove

r

Screw

Front Cove

r

Screws

Handlebar Rear Cove

r

Handlebar Front Cove

r

Screws

2. FRAME COVERS/EXHAUST MUFFLER

2-3

AGILITY 50

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 .

FRAME BODY COVER REMOVAL

Remove the center cover.

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.

Bol

t

Rear Carrie

r

Screws

Bolts

Center Cove

r

Bolts

Screws

Bolts

2. FRAME COVERS/EXHAUST MUFFLER

2-4

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.

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.

BOTTOM PROTECTOR COVER
REMOVAL

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

Bolts

Frame Body

Bottom Protector Cove

r

Bolts

Floor Board.

Seat Lock Wire

During removal, do not pull the joint
claws forcedly to avoid damage.
When installing, be sure to connect the
seat lock wire.

＊

2. FRAME COVERS/EXHAUST MUFFLER

2-5

AGILITY 50

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.

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

Bolts

Lock Nu

t

Front Fende

r

Bolts

Leg shield

Be sure to install a new exhaust muffle

r

packing collar.

＊

Bol

t

Decorative Ring

3. INSPECTION/ADJUSTMENT

3-0

AGILITY 50

3

SERVICE INFORMATION

GENERAL

l WARNING

xBefore 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.

xGasoline 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 : 2Д6mm
Spark plug gap : 0.6Д0.7mm

Spark plug : NGK C7HSA

Valve clearance : IN: 0.04mm
:EX: 0.04mm
Idle speed : 1900 Ô100rpm
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

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

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

3. INSPECTION/ADJUSTMENT

3-1

AGILITY 50

Cylinder compression : 16 kg/cm

2

Ignition timing: BTDC 28Ę/4000rpm
CHASSIS

Front brake free play: 10Д20mm
Rear brake free play : 10Д20mm

TIRE PRESSURE

1 Rider 2 Riders

Front 1.5kg/cm

2

1.75kg/cm

2

Rear 2.0kg/cm

2

2.25kg/cm

2

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

TORQUE VALUES

Front axle nut 5.0Д7.0kgf-m
Rear axle nut 11Д13kgf-m

3. INSPECTION/ADJUSTMENT

3-2

AGILITY 50

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



Regular Service Mileage (km)

Frequenc

y

Item

comes
first

Ö

Ø

1000           

Engine oil

R

New

Motorcycle

300k

m

RRR

R

RR

Engine oil filter
screen

CC

Fuel filter screen R
Gear oil Note 3

R

New

motorcycle

300k

m

R

R

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

xIn 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.

Whicheve

r

3. INSPECTION/ADJUSTMENT

3-3

AGILITY 50

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.

THROTTLE OPERATION

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

Free Play: 2Д6mm

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

t

Adjusting Nu

t

Fuel Filte

r

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

＊

Fuel Line

Lock Nu

t

Adjusting Nu

t

2Д6m

m

3. INSPECTION/ADJUSTMENT

3-4

FILLY LX 50

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.

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: 0.6Д0.7mm

Cracks
Damage

Gap, Wear, and
Fouling Deposits

xThe air cleaner element has a viscous

type paper element. Do not clean it
with any fluid.

xBe sure to install the air cleaner

element and cover securely.

＊

When installing, first screw in the spar

k

plug by hand and then tighten it with a
spark plug wrench.

＊

Screws

Air Cleaner Case Cove

r

Air Cleaner Elemen

t

Washe

r

Deformation

3. INSPECTION/ADJUSTMENT

3-5

AGILITY 50

VALVE CLEARANCE

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.

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

Tappet Adjuster

CARBURETOR IDLE SPEED

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: 1900Ô100rpm
When the engine misses or run erratic, adjust

the pilot screw.

Throttle Stop Screw

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

＊

Special

xCheck the valve clearance again afte

r

the lock nut is tightened.

＊

xThe engine must be warm for accurate

idle speed inspection and adjustment.

＊

Cylinder Head Cove

r

Bolts

Round Hole

Tappet Adjuste

r

Feeler Gauge

3. INSPECTION/ADJUSTMENT

3-6

FILLY LX 50

IGNITION TIMING

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.

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:

ΘLeaky valves
ΘValve clearance to small
ΘLeaking cylinder head gasket
ΘWorn piston rings
ΘWorn piston/cylinder

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

Compression Gauge

Timing Ligh

t

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

＊

Timing Hole Cap

Advance Mark

“F” Mark

3. INSPECTION/ADJUSTMENT

3-7

AGILITY 50

FINAL REDUCTION GEAR OIL

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.

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

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.

Drive Bel

t

Oil Check Bolt/Sealing Washe

r

Place the motorcycle on its main stan

d

on level ground for oil level check.

＊

Make sure that the sealing washer is in
good condition.

＊

Oil Check Bolt Hole

Oil Drain Bolt/ Sealing Washe

r

Make sure that the sealing washer is in
good condition.

＊

3. INSPECTION/ADJUSTMENT

3-8

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: 10Д20mm

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-4f

Arrows

Adjusting Nu

t

Punch Mark

Upper Line

Lower Line

3. INSPECTION/ADJUSTMENT

3-9

AGILITY 50

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.

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

Adjusting Nu

t

clutc

h

Front Cove

r

3. INSPECTION/ADJUSTMENT

3-10

FILLY LX 50

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)

WHEELS/TIRES

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

Check the tire pressure.

TIRE PRESSURE

1 Rider 2 Riders

Front 1.5kg/cm

2

1.75kg/cm

2

Rear 2.00kg/cm

2

2.25kg/cm

2

TIRE SIZE

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

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 : 5.0Д7.0kgf-m

Rear : 11Д13kgf-m

Tire pressure should be checked when
tires are cold.

＊

Front Axle Nu

t

3. INSPECTION/ADJUSTMENT

3-11

AGILITY 50

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.

4. LUBRICATION SYSTEM

4-0

AGILITY 50

Oil PumpOil Filter Screen

Crankshaft

4 LUBRICATION SYSTEM

4

Rocker Arm Shaft

4. LUBRICATION SYSTEM

4-1

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xThe maintenance of lubrication system can be performed with the engine installed in the frame.
xUse care when removing and installing the oil pump not to allow dust and foreign matters to

enter the engine and oil line.

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

reaches its service limit.

xAfter 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 0.05Д0.10 0.2

TROUBLESHOOTING

Oil level too low Poor lubrication pressure

xNatural oil consumption x Oil level too low
xOil leaks x Clogged oil filter or oil passages
xWorn or poorly installed piston rings x Not use the specified oil
xWorn valve guide or seal

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

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

4. LUBRICATION SYSTEM

4-2

AGILITY 50

ENGINE OIL/OIL FILTER

OIL LEVEL

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

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.

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 Dipstick

O-ring

Oil Filter Screen Cap

xPlace the motorcycle upright on level

ground for engine oil level check.

xRun the engine for 2Д3 minutes and

check the oil level after the engine is
stopped for 2Д3 minutes.

＊

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

＊

4. LUBRICATION SYSTEM

4-3

AGILITY 50

Bol

t

Right Crankcase Cove

r

Oil Pump Drive Gear

Circlip

Oil Pump Gear

Oil Pump

Bolts

O-rings

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.

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

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

4. LUBRICATION SYSTEM

4-4

AGILITY 50

Screws

Outer Rotor

Oil Pump Boby

Outer Rotor

Inner Rotor

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

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

4. LUBRICATION SYSTEM

4-5

AGILITY 50

Pump Cove

r

Screws

Inner Rotor

O-rings

Bolts

Outer Rotor

Pum

p

Shaf

t

Oil pump

ASSEMBLY

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

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

INSTALLATION

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

Install the oil pump into the crankcase.

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

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

＊

Fill the oil pump with engine oil before
installation.

＊

4. LUBRICATION SYSTEM

4-6

AGILITY 50

Bolts

Right Crankcase Cove

r

Pump Driven Gear

Circlip

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

Torque: 0.8Д1.2kg-m

Install the right crankcase cover and tighten
the eight bolts.

Torque: 0.8~1.2kgf-m

Diagonally tighten the bolts in 2Д3
times.

＊

5. FUEL SYSTEM

5-0

AGILITY 50

5

5

5. FUEL SYSTEM

5-1

AGILITY 50

Fuse

12V Battery

Regulato

r

/Rectifier

L/Y

W

Auto Bystarte

r

Ignition Switch

CDI Unit

B

G

Y

Y

Lighting
System

Resistor

5

:

5W

G/B

.

5. FUEL SYSTEM

5-2

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xWhen disassembling the carburetor, be sure to service the vacuum piston and float chamber.
xDo not bend or twist control cables. Damaged control cables will not operate smoothly.
xWhen disassembling fuel system parts, note the locations of O-rings. Replace them with new

ones during assembly.

xBefore float chamber disassembly, loosen the drain screw to drain the residual gasoline into a

clean container.

xAfter the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent

foreign matters from entering.

xRemove the vacuum diaphragm before cleaning the carburetor air and fuel passages with

compressed air to avoid damaging the vacuum diaphragm.

xWhen 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

Standard

Venturi dia. (mm) 20
Type CVK
Float level (mm) 17
Main jet Commonly: #82 Speed limits vehicle: #80
Slow jet #35
Idle speed 2000rpm±100
Throttle grip free play 2Д6mm
Pilot screw opening 2r

1

/2

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.

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

5. FUEL SYSTEM

5-3

AGILITY 50

TROUBLESHOOTING

Engine is hard to start Misfiring during acceleration

xNo spark at plug (ÖSection 15) x Faulty ignition system
xCompression too low x Lean mixture
xNo fuel to carburetor x Faulty accelerating pump

Clogged fuel filter Engine idles roughly, stalls or runs poorly
Restricted fuel line x Clogged fuel system
Faulty float valve x Ignition malfunction
Incorrectly adjusted float level x Rich or lean mixture

xEngine flooded with fuel x Contaminated fuel

Clogged air cleaner x Intake air leak

Fuel overflowing x Incorrect idle speed
xIntake air leak x Incorrectly adjusted pilot screw
xContaminated fuel x Clogged idle system or auto bystarter passages
xFaulty auto bystarter x Incorrectly adjusted float level
xClogged idle system or auto bystarter passages Lean mixture
Rich mixture x Clogged fuel jets
xFaulty auto bystarter x Faulty float valve
xFaulty float valve x Float level too low
xFloat level too high x Clogged fuel system
xClogged air jets x Intake air leak
xDirty air cleaner x Improper vacuum piston operation
xFlooded carburetor x Improper throttle operation

Backfiring at deceleration

xLean mixture in idle system
xImproper air cut-off valve operation

5. FUEL SYSTEM

5-4

AGILITY 50

CARBURETOR REMOVAL

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

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.

AUTO BYSTARTER

OPERATION INSPECTION

Measure the resistance between the auto
bystarter wire terminals.

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

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

Adjusting Nu

t

Fuel Tube

Intake Manifold
Band

Air Cleaner Connectin

g

Tube Band

Throttle Cable

Lock Nu

t

A

uto Bystarter Wire

A

uto Bystarte

r

5. FUEL SYSTEM

5-5

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.

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.

Auto Bystarte

r

Screws

Bystarter Needle

Bystarter Valve

Auto Bystarte

r

Screws

Set Plate

Vacuum Pump

Adopte

r

Set Plate

xBe sure to install the auto bystarter an

d

set plate properly.

xInstall the set plate with its bottom face

facing down.

＊

5. FUEL SYSTEM

5-6

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.

VACUUM CHAMBER

DISASSEMBLY

Remove the two vacuum chamber cover
screws and the cover.

Remove the spring and vacuum diaphragm/
piston.

Spring

Spring

Throttle Cable Set Plate

Vacuum Diaphragm/Piston

Air Cut-off Valve Cove

r

Cove

r

Screws

O-rin

g

Screws

Screws

xBe sure to set the vacuum diaphrag

m

lip into the groove on the carburetor.

xWhen installing the air cut-off valve

cover, make sure that the vacuum
diaphragm is properly installed.

＊

Diaphrag

m

Vacuum Chamber Cove

r

Spring

5. FUEL SYSTEM

5-7

AGILITY 50

Remove the needle holder and jet needle.

INSPECTION

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

ASSEMBLY

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

Vacuum Chamber Cove

r

Vacuum Diaphrag

m

Jet Needle

Vacuum Diaphrag

m

Be careful not to damage the vacuu

m

diaphragm.

＊

xBe careful not to damage the diaphragm.
xHold the vacuum piston while

tightening the vacuum chamber cover.

＊

5. FUEL SYSTEM

5-8

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.

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

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.

Pilot Screw

Float ValveFloa

t

Float Pin

Float Chambe

r

Slow Je

t

Main Je

t

N

eedle Jet Holde

r

N

eedle Je

t

Screws

xBe careful not to damage the fuel jets

and pilot screw.

xBefore removing, turn the pilot screw

in and carefully count the number of
turns until it seats lightly and then
make a note of this.

xDo not force the pilot screw against its

seat to avoid seat damage.

＊

5. FUEL SYSTEM

5-9

AGILITY 50

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.

ASSEMBLY

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

Standard Opening: 2r

1

/2

turns

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

FLOAT LEVEL INSPECTION

Measure the float level.
Float Level: 17.0mm

This installation sequence is the reverse of
removal.

Float Level Gauge

Float Valve

xCheck the operation of the float valve

and float before this inspection.

xMeasure the float level by placing the

float level gauge on the float chamber
face parallel with the main jet.

＊

Float Pin

Pilot Screw

Slow Je

t

Main Je

t

N

eedle Jet Holde

r

N

eedle Je

t

Valve Sea

t

Floa

t

Screw

Worn or contaminated float valve an

d

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

＊

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

＊

5. FUEL SYSTEM

5-10

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.

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.

Compressed Ai

r

Screws

Diaphrag

m

Diaphrag

m

Compressed Ai

r

Be careful not to damage the diaphragm
during installation.

＊

5. FUEL SYSTEM

5-11

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.

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

-Throttle grip free play (Ö3-3)

-Carburetor idle speed (Ö3-5)

Auto Bystarter Wire Connecto

r

Fuel Tube

Connecting Tube Band

Throttle Cable

Throttle Cable

Lock Nut

Adj

usting Nut

5. FUEL SYSTEM

5-12

AGILITY 50

PILOT SCREW ADJUSTMENT

*

ADJUSTMENT

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: 2r

1

/2

turns

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

Idle Speed: 1900Ô100rpm
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.

Pilot Screw

Throttle Stop Screw

xThe pilot screw is factory pre-set an

d

no adjustment is necessary. During
carburetor disassembly, note the
number of turns of the pilot screw and
use as a reference when reinstalling it.

xPlace the motorcycle on its main stand

on level ground for this operation.

＊

xThe carburetor must be adjusted when

the engine is warm and the auto
bystarter is closed.

xDo not force the pilot screw against its

seat to prevent damage.

＊

5. FUEL SYSTEM

5-13

AGILITY 50

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.

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.

INSTALLATION

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

Bolts

xWhen removing the fuel strainer, do

not allow flames or sparks near the
working area and drain the residual
gasoline into a container.

＊

Seat Loc

k

Arrow Mar

k

Fuel Straine

r

Fuel
Tank

Fuel Unit Wite
Connector

5. FUEL SYSTEM

5-14

AGILITY 50

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.

INSTALLATION

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

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 Unit Wire

Align Mark

Fuel Unit

Fuel Tank

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

＊

xAlign the groove on the fuel unit with

the angle on the fuel tank.

xInspect if the fuel tank leaked after

installing and filling the gasoling.

＊

b

olts

air cleane

r

5. FUEL SYSTEM

5-15

AGILITY 50

The installation sequence is the reverse of removal.

6. ENGINE REMOVAL/INSTALLATION

6-0

FILLY LX 50

6

6

6. ENGINE REMOVAL/INSTALLATION

6-1

FILLY LX 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xA 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.

xUse shop towels to protect the motorcycle body during engine removal.
xParts requiring engine removal for servicing:

 Crankcase

 Crankshaft

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

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

6. ENGINE REMOVAL/INSTALLATION

6-2

FILLY LX 50

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.

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

Remove the spark plug cap.

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

Auto Bystarter Wire Connecto

r

Vacuum Tube

Spark Plug High Tension Wire

Band

N

egative Cable

S

tarter Motor Cable

Earthr Cable

Lock Nut

Adjusting Nut

6. ENGINE REMOVAL/INSTALLATION

6-3

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.

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.

Rear Shock Absorber Upper Mount Bol

t

connecting tube

Air Tube Band

Adjusting Nut

Engine Mounting Bol

t

Engine Hange

r

Bracket Bolt

6. ENGINE REMOVAL/INSTALLATION

6-4

FILLY LX 50

ENGINE HANGER BRACKET
REMOVAL

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

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.

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

Bushing

Engine Mounting Bol

t

Return Sprin

g

Main Stand

Return Sprin

g

Main Stand

Stopper Spring

Engine Hanger Bracket Bol

t

6. ENGINE REMOVAL/INSTALLATION

6-5

FILLY LX 50

Install the removed parts in the reverse order
of removal.

After installation, inspect and adjust the
following:

xThrottle grip free play (

Ö

3-3)

xRear brake adjustment (

Ö

3-8)

Rear Shock Absorber Upper Mount Bol

t

Route the wires and cables properly.

＊

7. CYLINDER HEAD/VALVES

7-0

AGILITY 50

7

7

7. CYLINDER HEAD/VALVES

7-1

FILLY LX 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xThe cylinder head can be serviced with the engine installed in the frame.
xWhen assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable

parts, valve arm and camshaft sliding surfaces for initial lubrication.
xThe camshaft is lubricated by engine oil through the cylinder head engine oil passages. Clean and

unclog the oil passages before assembling the cylinder head.

xAfter disassembly, clean the removed parts and dry them with compressed air before inspection.
xAfter removal, mark and arrange the removed parts in order. When assembling, install them in

the reverse order of removal.

SPECIFICATIONS

Item

Standard (mm) Service Limit (mm)

IN 0.04 

EX 0.04 

Cylinder head compression 14kg/cm

2



Cylinder head warpage  0.05

IN 26.438 26.038

EX 25.807 25.407

IN 10.000-10.015 10.10

EX 10.000-10.015 10.10
Valve rocker arm shaft IN 9.972-9.987 9.91
O.D.

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

EX 0.030-0.057 0.1

Inne

r

31.1 30.1

Oute

r

34.35 33.3

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

Valve clearance (cold)

Camshaft cam height

Valve rocker arm I.D.

Valve seat width

Valve stem O.D.

Valve guide I.D.

Valve spring free

7. CYLINDER HEAD/VALVES

7-2

AGILITY 50

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

TROUBLESHOOTING

xThe 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

xCompression too low x Worn valve stem or valve guide

x Damaged valve stem seal

Compression too low

xIncorrect valve clearance adjustment Abnormal noise
xBurned or bend valves x Incorrect valve clearance adjustment
xIncorrect valve timing x Sticking valve or broken valve spring
xBroken valve spring x Damaged or worn camshaft
xPoor valve and seat contact x Worn cam chain guide
xLeaking cylinder head gasket x Worn camshaft and rocker arm
xWarped or cracked cylinder head
x Poorly installed spark plug

Compression too high

xExcessive carbon build-up in combustion

chamber

7. CYLINDER HEAD/VALVES

7-3

FILLY LX 50

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.

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

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.

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

Cylinder Head Cove

r

Sealing Bol

t

Round Hole

Camshaft Gea

r

Bolts

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

＊

Punch Marks

Washe

r

Nut

7. CYLINDER HEAD/VALVES

7-4

AGILITY 50

Remove the camshaft holder and dowel pins.

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

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.

Cam Chain Camshaft Gea

r

Camshaft Bearings

Camshaft Holde

r

Dowel Pins

Camshaf

t

7. CYLINDER HEAD/VALVES

7-5

FILLY LX 50

CAMSHAFT HOLDER DISASSEMBLY

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

CAMSHAFT HOLDER INSPECTION

Inspect the camshaft holder, valve rocker
arms and rocker arm shafts 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

CYLINDER HEAD REMOVAL

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

Intake Manifold

Camshaft Holde

r

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

°

Rocker Arm Shafts

5mm Bol

t

Rocker Ar

m

Rocker Arm Shaf

t

7. CYLINDER HEAD/VALVES

7-6

AGILITY 50

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

Remove the cylinder head.

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

Cylinder Head

Dowel Pins

Cam Chain Guide

C

y

linder Head Gaske

t

Bolts

7. CYLINDER HEAD/VALVES

7-7

FILLY LX 50

CYLINDER HEAD DISASSEMBLY

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

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.

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

Valve Spring Compresso

r

xBe sure to compress the valve springs

with a valve spring compressor.

xMark all disassembled parts to ensure

correct reassembly.

＊

Special

Valve Spring Compressor Attachmen

t

Be careful not to damage the cylinde

r

head mating surface.

＊

7. CYLINDER HEAD/VALVES

7-8

AGILITY 50

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

CYLINDER HEAD ASSEMBLY

Valve Spring Compressor
Val ve Spring Compressor Attachment

Tap the valve stems gently with a plastic
hammer for 2Д3 times to firmly seat the
cotters.

CYLINDER HEAD INSTALLATION

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

Gaske

t

Cam Chain Guide

Valve Spring Compresso

r

Dowel Pins

Valve Spring Compressor Attachmen

t

xWhen assembling, a valve spring

compressor must be used.

xInstall the cotters with the pointed ends

facing down from the upper side of the
cylinder head.

＊

Special

Be careful not to damage the valves.

＊

7. CYLINDER HEAD/VALVES

7-9

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.

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.

Dowel Pins

Valve Rocker Ar

m

Punch Marks

Cylinder Head

Camshaft Holde

r

Cam Chain

Round Hole

Camshaft Gea

r

xWhen installing the rocker arm shaft,

align the shaft front end with the bolt
hole of the camshaft holder.

＊

7. CYLINDER HEAD/VALVES

7-10

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

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.

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.

Install and tighten the cylinder head cover
bolts.

Torque:: 0.8~1.2kgf-m

Nut

Washe

r

Cylinder Head Cove

r

O-rin

g

Cam Chain Tensione

r

Sealing Bol

t

Push RodLock Pawl

Camshaft Holde

r

Sprin

g

xApply engine oil to the threads of the

cylinder head nuts.

xDiagonally tighten the cylinder head

nuts in 2Д3 times.

＊

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

＊

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

＊

8. CYLINDER/PISTON

8-0

AGILITY 50

8

8

Do not ben

d

1.0kg-

m

8. CYLINDER/PISTON

8-1

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xThe cylinder and piston can be serviced with the engine installed in the frame.
xAfter disassembly, clean the removed parts and dry them with compressed air before inspection.

SPECIFICATIONS

Item

Standard (mm) Service Limit (mm)

I.D. 50.00-50.01
Warpage  0.05
Cylindricity  0.05
True roundness  0.05
Ring-to-

Top 0.015-0.050 0.09

clearance

Second 0.015-0.050 0.09
Top 0.08-0.20 0.45

Piston,

Ring end gap Second 0.05-0.20 0.45

piston rin

g

Oil side rail 0.20-0.70 
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

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

TROUBLESHOOTING

xWhen 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

xWorn, stuck or broken piston rings x Worn or damaged piston rings
xWorn or damaged cylinder and piston x Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

xExcessive carbon build-up in combustion x Worn cylinder, piston and piston rings

chamber or on piston head

x Worn piston pin hole and piston pin

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

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

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

Cylinde

r

8. CYLINDER/PISTON

8-2

AGILITY 50

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.

PISTON REMOVAL

Remove the piston pin clip.

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

Dowel Pins

Gaske

t

Cylinde

r

Piston

Piston Rings

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

＊

Piston Pin

8. CYLINDER/PISTON

8-3

AGILITY 50

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

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

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

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

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

＊

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

＊

8. CYLINDER/PISTON

8-4

AGILITY 50

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

Measure the piston O.D.

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

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. at three levels of
top, middle and bottom at 90q 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

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

＊

Middle

Botto

m

Top

8. CYLINDER/PISTON

8-5

AGILITY 50

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

PISTON RING INSTALLATION

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

Second
Side Rail

Top

xBe careful not to damage or break the

piston and piston rings.

xAll rings should be installed with the

markings facing up.

xAfter installing the rings, they should

rotate freely without sticking.

＊

Second

Top

Side Rail

Oil

Expande

r

8. CYLINDER/PISTON

8-6

AGILITY 50

PISTON INSTALLATION

Remove any gasket material from the
crankcase surface.

Install the piston, piston pin and a new 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.

Gaske

t

Cylinde

r

Be careful not to drop foreign matters
into the crankcase.

＊

xPosition the piston “IN” mark on the

intake valve side.

xPlace a clean shop towel in the

crankcase to keep the piston pin clip
from falling into the crankcase.

＊

xBe careful not to damage or break the

piston rings.

xDo not align the ring end gaps with the

intake/exhaust valve and piston pin.

＊

Piston Pin

Piston Pin Clip

Piston

Dowel Pins

8. CYLINDER/PISTON

8-7

AGILITY 50

Install the cam chain guide.

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

Tighten the cylinder base bolts.

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

＊

Cylinder Base Bolts

Cam Chain Guide

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-0

AGILITY 50

9

9

5.0Д6.0kg-

m

3.5-4.5g-

m

3.5-4.0g-

m

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-1

AGILITY 50

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xThe drive pulley, clutch and driven pulley can be serviced with the engine installed.
xAvoid 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

Ite

m

Standard (mm

)

Service Limit (mm

)

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

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

xWorn drive belt x Worn drive belt
xBroken ramp plate x Weak driven face spring
xWorn or damaged clutch lining x Worn weight roller
xBroken driven face spring x Fouled drive face

Engine stalls or motorcycle creeps

xBroken clutch weight spring

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

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-2

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.

KICK STARTER

REMOVAL

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

Return Spring

Kick Starter Spindle

Friction Spring

Kick Starter Spindle

Circlip

Starter Driven Gea

r

Washe

r

Use specified genuine parts for replace­ment.

＊

Air Tube Band Bolts

Left Crankcase Cove

r

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-3

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.

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 Gear Shaft Forcing Par

t

Friction Spring

Starter Driven Gea

r

Spindle

Return Spring

Plastic Bushing

Spindle Bushing

Kick Starter Spindle Forcing Par

t

Kick Starter Spindle

Return Sprin

g

9. DRIVE AND DRIVEN PULLEYS/
KICK STARTER

9-4

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.

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.

Rear Brake Cable Clamp

Washe

r

Left Crankcase Cove

r

Starter Driven Gea

r

Friction Sprin

g

Circlip

Dowel Pins

Seal Rubbe

r