KYMCO Agility City 125, 150 agility, agility R16 50, agility R16 125, agility R16 150 Service Manual

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PREFACE

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AGILITY CITY 125

TABLE OF CONTENTS

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

CITY 125

Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation.

Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations.

Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.

Sections 6 through 17 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment.

GENERAL INFORMATION 1 FRAME COVERS/EXHAUST MUFFLER 2 INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4

ENGINE

FUEL SYSTEM 5 ENGINE REMOVAL/INSTALLATION 6 CYLINDER HEAD/VALVES 7 CYLINDER/PISTON 8 DRIVE AND DRIVEN PULLEYS/KIC

STARTER FINAL REDUCTION 10

CRANKCASE/CRANKSHAFT 11

CHASSIS

FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION

REAR WHEEL /REAR BRAKE /REAR SUSPENSION

ELECTRICAL

EQUIPMEN

BATTERY/CHARGING SYSTEM/A.C. GENERATOR

IGNITION SYSTEM 15 STARTING SYSTEM 16

LIGHTS/INSTRUMENTS/SWITCHES 17

Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section.

Our company reserves the right to make any alteration in the design.The

information and contents included in this manual may be different from the motorcycle in case specifications are changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

EXHAUST EMISSION CONTROL SYSTEM

1. GENERAL INFORMATION

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

SPECIFICATIONS ...................................1- 2 CABL E & H A R N E S S R O U T I N G............1-15

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

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

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

ENGINE SERIAL NUMBER

AGILITY CITY 125

Frame Serial Numbe

Location of Engine Serial Numbe

1-1

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SPECIFICATIONS

AGILITY CITY 125

Motorcycle Name & Type AGILITY CITY 125 Name & Model No. LFC3 Overall length (mm) 2040 Overall width (mm) 740 Overall height (mm) 1240 Wheel base (mm) 1340 Engine type O.H.C. Displacement 125cc Fuel Used 92# nonleaded gasoline

Front wheel 44

Net weight (kg) Rear wheel 56

Total 110

Front wheel 45

Gross weight(kg) Rear wheel 67

Total 144 Tires Ground clearance (mm) 112 Perform-

ance

Engine

Braking distance (m)

Min. turning radius (m) 1.99 Starting system Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C. Bore x stroke (mm) I52.4 x 57.8 Compression ratio 9.6±0.2

Compression pressure (kg/cm²-rpm)

Max. output 6.9/7500kw/(r/min) Max. torque 9.1/6500N.m/rpm

Port timin

Valve clearance (cold) (mm)

Idle speed (rpm) 1700Ô100rpm

Lubrication

System

Cooling Type Forced air cooling

Front wheel 100/80 -16 56J

Rear wheel 120/80 -16 56J

7 (Initial speed

30km/h)

Starting motor &

kick starter

13±2

Intake

Exhaust

Lubrication type Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration Oil capacity 0.9 liter

Open -2.5q Close Open -3q

Close Intake 0.12 Exhaust 0.12

32q

33q

Forced pressure &

wet sump

Air cleaner type & No Paper element, wet

Fuel S

Fuel capacity 6.0 liter

Carburetor

Type CVK

stem

Electrical Equipment

Power Drive System

Moving Device

Brake system type

Damping

Device

Frame type Under Bone

Piston dia. (mm) I22 Venturi dia.(mm) I26equivalent Throttle type Butterfly type Type CDI

I nition S

Ignition timing BTDC27q±2°/4000rpm Contact breaker Non-contact point type

CHAMP ION-P-

stem

Battery Capacity 12V7AH Clutch Type Dry multi-disc clutch

sion Gear

Gear

Front Caster angle 27q Axle

Tire pressure (kg/cm²)

Turning Left 45q angle

Suspension type

Shock absorber distance

Spark plug

Spark plug gap 0.6Д0.7mm

Transmis-

Type Non-stage transmission Operation

Reduction

Type Two-stage reduction Reduction 1st

ratio

Trail length 

Fron Rear 2.25

Right 45q FrontDISK (180mm) brake

Rear Drum (110mm) brake Fron

Rear Unit Swing Front 80 Rear

Automatic centrifugal

2nd

RZ9HC

NGK CR7HSA

type

1.0-2.8

46/16*46/15

1.75

TELESCOPE

1-2

1. GENERAL INFORMATION

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SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

Use genuine parts and lubricants

AGILITY CITY 125

When servicing the motorcycle, be sure to

use special tools for removal and installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil before reassembly.

1-3

1. GENERAL INFORMATION

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Apply or add designated greases and

lubricants to the specified lubrication points.

After reassembly, check all parts for proper

tightening and operation.

AGILITY CITY 125

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting

points, fasteners, and lines for proper connection and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1-4

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If the fuse is burned out, find the cause and

repair it. Replace it with a new one according to the specified capacity.

After operation, terminal caps shall be

installed securely.

AGILITY CITY 125

Confir Capacity

When taking out the connector, the lock on

the connector shall be released before operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

1-5

1. GENERAL INFORMATION

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The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative terminal.

AGILITY CITY 125

Snapping!

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely. Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses.

1-6

1. GENERAL INFORMATION

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After clamping, check each wire to make

sure it is secure.

. Do not squeeze wires against the weld or

its clamp

AGILITY CITY 125

After clamping, check each harness to

make sure that it is not interfering with any moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the projected ends of bolts and screws.

o Contact !

1-7

1. GENERAL INFORMATION

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Route harnesses so they are neither

pulled tight nor have excessive slack.

. Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or corner

When rubber protecting cover is used to

protect the wire harnesses, it shall be installed securely.

AGILITY CITY 125

Do not pull

ht!

too ti

Do not break the sheath of wire. If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or replace it.

When installing other parts, do not press or

squeeze the wires.

Do not press o squeeze the wire.

1-8

1. GENERAL INFORMATION

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After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with

handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.

AGILITY CITY 125

When a testing device is used, make sure to

understand the operating methods thoroughly and operate according to the operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent before connecting.

Do not bend or twist control cables.

Damaged control cables will not operate smoothly and may stick or bind.

Do you understand the instrument? Is the instrument set correctly?

Remove Rust !

1-9

1. GENERAL INFORMATION

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Symbols:

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

: Apply engine oil to the

specified points. (Use

Engine Oil

designated engine oil for lubrication.)

AGILITY CITY 125

Grease

Gear Oil

Special

＊

(Ö12-3) :Refer to page 12-3.

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

1-10

1. GENERAL INFORMATION

)

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TORQUE VALUES

STANDARD TORQUE VALUES

AGILITY CITY 125

Ite

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

Torque specifications listed below are for important fasteners.

ENGINE

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

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

Torque (kg-m

0.45-0.6

0.6-1.2

1.8-2.5

3.0-4.0

5.0-6.0

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

Ite

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

6 6

6 7 3 8

8 10 28

4 10 10

0.7-1.1

1.0-2.0

0.7-1.1

1.2-1.6

0.07-0.09

0.4-0.7

1.1-1.5

3.5-4.5

5.0-6.0

0.8-1.2

0.1-0.3

5.5-6.5

1.0-1.4

0.8-1.2

Torque (kg-m

0.35-0.5

0.7-1.1

1.0-1.4

2.4-3.0

3.5-4.5

Double end bolt

Double end bolt Apply oil to threads

FRAME

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

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

1 1 1 1 1 1 1

25.4 10 14 10

8 5 8

8.0-12.0

5.0-7.0

11.0-13.0

4.0-5.0

2.0-3.0

0.45-0.6

3.0-3.6

U-nut U-nut U-nut

Apply locking agent

1-11

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AGILITY CITY 125

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

Bushing remover L E032 11102 bush engine hanger rubber

Bushing remover S EO19 11203 bush rear cushion under rubber

Crankshaft bearing puller E030 91005 radial bearing

Crankshaft protector E029 13000 crankshaft comp 12mm.14mm

Clutch spring compressor E027 2301a driven pully assy

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

9-9 9-12

Cushion assemble & disassemble tool

Flywheel holder E017

Flywheel puller E002 Left hand thread 27mm

Long socket wrench 32mm 8angle F002 50306 steering stem

Oil seal & bearing installer E014 Oil seal & bearing install

Tool boox E033 Special tools storage

Tappet adjuster E036 90012 screw tappet 3-5

Valve spring compressor E038 Valve spring

F004 52400 cushion assy 13-4

9-5

31110 fl driven

wheel comp.2310a pully ass

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

14-7

12-21 12-22

7-7 7-8

1-12

1. GENERAL INFORMATION

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LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

AGILITY CITY 125

Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft R/L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O-ring face Oil seal lip

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

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

A.C. generator connector Transmission case breather tube

High-temperature resistant grease

Adhesive

1-13

1. GENERAL INFORMATION

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FRAME

The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

Grease

Front Brake Leve Pivot

Engine/ Oil Front Brake Cable

Speedometer Cable/ Throttle Cable

AGILITY CITY 125

Grease

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

Grease

Main Stand Pivot

Grease

Rear Wheel Bearings

Grease

Brake Cam Anchor Pin

Engine Oil

Rear Brake Cable

1-14

1. GENERAL INFORMATION

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CABLE & HARNESS ROUTING

Brake Master Cylinde

AGILITY CITY 125

Front Stop Switch Wire

Throttle Cable

Ignition Switch

Front Brake Fluid Tube

Rear Stop Switch Wire

Rear Brake Cable

Speedometer Cable

Horn

Speedomete

Winke

1-15

1. GENERAL INFORMATION

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AGILITY CITY 125

Throttle Grip

Headlight Resisto

Ignition Switch

Regulator/Rectifie

Rear Brake Leve

Horn

Front Brake Fluid Tube

Speedometer Cable

1-16

1. GENERAL INFORMATION

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Battery (-) Cable

AGILITY CITY 125

Fuse

CDI Unit

Starter Relay

Battery (+) Cable

Fuel Tan

Ignition Coil

1-17

1. GENERAL INFORMATION

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AGILITY CITY 125

Fuel Tube

Auto Cock Assy Fuel

Throttle Cable

Fuel Filte

Carbureto Overflow Tube

Crankcase Breathe Tube

Ignition Coil Primary Wire

1-18

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Fuel Unit

Throttle Cable

AGILITY CITY 125

Crankcase Breathe Tube

Wire

Secondary Ai Inlet Tube

Ignition Coil

Reed Valve

Air Injection Cut-off Valve

Vacuum Tube

Crankcase Breathe Tube

Vacuum Tube

Fuel Tube

Auto Bystarte

1-19

1. GENERAL INFORMATION

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WIRING DIAGRAM

AGILITY CITY 125

1-20

1. GENERAL INFORMATION

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TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

AGILITY CITY 125

Inspection/Adjustment

Check if fuel reaches carburetor by loosening drain screw

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

Test cylinde compression

Start engine by following normal starting

rocedure

Fuel reaches

carburetor

Spark jumps

Normal

compression

Symptom

Fuel does no

reach carburetor

Weak or no spark

Low or no

compression

Probable Cause

Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Clogged fuel tank cap breather hole Clogged fuel filter Clogged fuel strainer Faulty auto fuel

Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted high-tension wire Faulty ignition switch

Faulty starter clutch Valve clearance too small Improper valve and seat contact Worn cylinder, piston and piston rings Leaking cylinder head gasket Seized valve Improper valve timing

valve

Remove spark plug and inspect again

Engine does no

fire

Dry spark plug

Engine fires bu

does not start

Wet spark plug

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

Flooded carburetor Faulty auto bystarter Throttle valve excessively open

1-21

1. GENERAL INFORMATION

pip

prop

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ENGINE LACKS POWER

AGILITY CITY 125

Inspection/Adjustment

Start engine and accelerate lightly for observation

Check ignition timing using a timing light

Check valve clearance

Test cylinder compression

Check carburetor fo clogging

Engine speed

Correct timin

Correc

ormal

com

ression

Symptom

Engine speed does no increase sufficientl

Abnormal

compression

Incorrect timin

Incorrec

Probable Cause

Clogged air cleaner Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve

Faulty CDI unit Faulty pulser coil

Improper valve clearance adjustment Worn valve seat (valve stem too protruding

Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing

Remove spark plug and inspec

Remove oil dipstick and check oil level and condition

Remove cylinder head oil

e bolt and inspec

Check if engine overheats

Rapidly accelerate or run

h speed

at hi

Not clogged

Plug not fouled o discolored

Correct and no contaminated

Valve train lubricated

erl

Engine does no overheats

Engine does not knock

Clogged

Plug fouled o discolored

Incorrect o

contaminated

Valve train no lubricated properl

Engine overheats

Engine knocks

Clogged carburetor jets

Fouled spark plug Incorrect heat range plug

Oil level too high Oil level too low Oil not changed

Clogged oil pipe Faulty oil pump

Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early

Excessive carbon build-up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early

1-22

1. GENERAL INFORMATION

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AGILITY CITY 125

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Check carburetor pilo screw adjustment

Check carburetor gaske for air leaks

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

round

Correct timing

Correctly adjusted

No air leak

Good spark

Incorrect timing

Incorrectly adjusted

Air leaks

Weak or inter-

mittent spark

Faulty CDI unit Faulty pulser coil

Mixture too rich (turn screw out) Mixture too lean (turn screw in)

Deteriorated O-ring Carburetor not securely tightened Damaged insulator rubber Broken vacuum tube

Faulty or fouled spark plug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch

Check air cut-off valve

Good

Faulty

Faulty air cut-off valve Damaged vacuum tube Clogged or damaged air vent hole

1-23

1. GENERAL INFORMATION

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AGILITY CITY 125

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Check valve clearance

Check fuel pump fo fuel supply

Check carburetor jets for clogging

Correct timing

Correctly adjusted

Fuel flows freely

Not clogged

Incorrect timing

Incorrectly adjusted

Fuel flow restricted

Clogged

Faulty CDI unit Faulty pulser coil

Improperly adjusted valve clearance Worn camshaft Worn valve seat

Empty fuel tank Clogged fuel tube or filter Faulty charcoal canister Faulty auto fuel valve

Clean and unclog

Check valve timing

Check valve spring tension

1-24

Correc

Not weakened

Incorrec

Weak spring

Cam timing gear aligning marks not aligned

Faulty spring

1. GENERAL INFORMATION

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AGILITY CITY 125

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

Inspection/Adjustment

Start engine and tes limit voltage between

attery terminals

Measure resistance between AC generator coil terminals

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

round and test voltage

Check regulator/rectifier coupler for loose connection

Normal voltage

Normal

Normal voltage

Normal

Symptom

Voltage does no

Resistance too high

No voltage

Abnormal

Probable Cause

Dead battery Faulty battery

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

Broken red wire

Faulty regulator/rectifier Poorly connected coupler

Overcharging

Inspection/Adjustment

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

round and test voltage

Check regulator/rectifier coupler for loose connection

attery has voltage with ignition switch “ON”

Normal

Symptom

voltage with ignition switc

attery has no

“ON”

Abnormal

Faulty A.C. generator

Probable Cause

Broken green wire

Poorly connected coupler

Faulty regulator/rectifier

1-25

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NO SPARK AT SPARK PLUG

AGILITY CITY 125

Inspection/Adjustment Symptom

Replace with a new spark plug and inspect

ain

Weak or no spark

Check spark plug cap and high-tension wire for looseness

Not loose

Check CDI unit coupler for looseness

Good

Measure resistance between CDI unit

ler wire terminals

cou

Good spark

Loose

Good

Probable Cause

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Check related parts

Check CDI unit with a CDI unit tester

Check ignition coil with a CDI unit tester

Normal

Abnormal

Faulty ignition switch Faulty pulser coil Faulty ignition coil

Broken wire harness Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

1-26

2. FRAME COVERS/EXHAUST MUFFLER

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2 SCHEMATIC DRAWING

AGILITY CITY 125

2-0

2. FRAME COVERS/EXHAUST MUFFLER

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

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

AGILITY CITY 125

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

xLeg Shield Front cover, floor board

TORQUE VALUES

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

2-1

2. FRAME COVERS/EXHAUST MUFFLER

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AGILITY CITY 125

FRAME COVERS

FRONT COVER REMOVAL

Remove the screw on the front cover and remove the front cover.. Remove the screws on the back of the mole

assy front. Remove the front brake fluid tube and speedometer cable

Remove the four bolt attaching the R/L front

fork and remove the front fork.

Remove the mole assy

The installation sequence is the reverse of

removal.

HANDLEBAR REAR COVER

REMOVAL

Remove the handlebar rear cover screw.

Remove the clip mudguard attaching the

sponge risor and sponge risor.

Disconnect the speedometer cable, right and

left handlebar switch couplers, and the stop

switch wire connectors. Remove four screws inside the handlebar rear cover and remove the handlebar rear cover.

The installation sequence is the reverse of

removal.

Screws

Clip Mudguard

FrontCove

Front Fork Bolts

Sponge Riso

Screws

Front Brake Fluid Tube

Speedometer Cable

Handlebar Rear Cove

Screws

HANDLEBAR FRONT COVER

REMOVAL

Remove the bolt attaching the handlebar front

cover.

Remove the handlebar front cover.

MET-IN BOX REMOVAL

Open the seat and remove the six bolt and two screws attaching the met-in box.

Remove the met-in box .

Handlebar Front Cove

Screws

Bolts

2-2

2. FRAME COVERS/EXHAUST MUFFLER

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AGILITY CITY 125

FRAME BODY COVER REMOVAL

Remove the two screws on the battery cover.

Remove the battey cover

Remove the six screws on the center cover

Remove the center cover

Remove the three bolts attaching the rear

carrier.

Remove the rear carrier.

Screws

BatteryCove

Bolts

Screws

Center Cove

Remove the two bolt attaching the lefe and

right rear step.

Remove the rear step

Remove the six screws attaching the left side

and right side skirt

Remove the left side and right side skirt

＊

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

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

Rear Step

Bolts

Rear Carrie

Left Side Skir

2-3

Screws

Right Side Skir

2. FRAME COVERS/EXHAUST MUFFLER

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AGILITY CITY 125

Remove the two screws on the center rear

cover.

Remove the center rear cover.

Remove the two bolts attaching the frame

body cover.

Remove the three screws attaching the frame

body cover.

Center Rear Cover.

Screws

Bolts

Remove the six screws attaching the frame

body cover.

Remove the two bolts attaching the rear

fender.

Disconnect the taillight wire connector

Remove the erar fender.

Screws

Bol

Rear Fende

Wire

2-4

2. FRAME COVERS/EXHAUST MUFFLER

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AGILITY CITY 125

Discornnect the seat lock wire.

Discornnect the rear light wire connectors

Remove the left / right body cover and rear

light.

The installation sequence is the reverse of

remove

＊

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

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

FLOOR BOARD REMOVAL

Remove the rear carrier. (Ö2-3)

Remove the met-in box. (Ö2-3)

Remove the frame body cover. (Ö2-4)

Remove the four bolts attaching the floor

board.

Remove the floor board.

Seat Lock Wire

Lift Body Cove

Plug Floor/Bolts

Rear Light Wire Connecto

Rear Ligh

FRONT FENDER REMOVAL

Remove the L/R side bolts attaching the front

fender and front fender.

LEG SHIELD REMOVAL

Remove the two clip body on the lid leg

shield

Remove the lid leg shield.

The installation sequence is the reverse of

remove

Clip Body.

Floor Board.

Bolts

Screws

Front Fenderl

Lid Leg Shield.

2-5

2. FRAME COVERS/EXHAUST MUFFLER

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Remove the decorative ring.

Remove the leg shieid.

Remove the bolt attaching the hook luggage.

Remove the hook luggage.

Remove the leg shield.

The installation sequence is the reverse of

remove

Leg Shield

AGILITY CITY 125

Decorative Ring

EXHAUST MUFFLER REMOVAL

Remove the two exhaust muffler joint lock

nuts.

Remove the three exhaust muffler lock bolts.

Remove the exhaust muffler.

Remove the exhaust muffler joint packing

collar.

When installing, first install the exhaust

muffler packing collar and then install the

exhaust muffler.

First install and tighten the exhaust muffler

joint lock nuts. Then, install and tighten the

exhaust muffler lock bolts.

Torques:

Exhaust muffler lock bolt: 3.0~3.6kgf-m

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

＊

Be sure to install a new exhaust muffle packing collar.

Bolts

Lock Nu

2-6

3. INSPECTION/ADJUSTMENT

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Recambios KYMCO en www.batmotos.com

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

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

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

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

AGILITY CITY 125

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

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

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

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

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

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

SERVICE INFORMATION

GENERAL

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: 0.12mm

:EX: 0.12mm

Idle speed : 1700 Ô100rpm

Engine oil capacity:

At disassembly : 0.9 liter

At change : 0.8 liter

Gear oil capacity :

At disassembly : 0.2 liter

At change : 0.18 liter

3-0

3. INSPECTION/ADJUSTMENT

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AGILITY CITY 125

Cylinder compression : 16 kg/cm

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

Rear 2.0kg/cm

TIRE SIZE:

Front : 100/80-14

Rear : 120/80-14

TORQUE VALUES

Front axle nut 5.0Д7.0kgf-m

Rear axle nut 11Д13kgf-m

2 2

1.75kg/cm

2.25kg/cm

2 2

3-1

3. INSPECTION/ADJUSTMENT

RRR

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AGILITY CITY 125

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



Frequenc

Item

Engine oil

Engine oil filter

Whicheve comes

first

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

New

Motorcycle

300k

Regular Service Mileage (km)

screen

Fuel filter screen R

New

Gear oil Note 3

motorcycle

300k

Valve clearance A A A A

Carburetor I I C

Air Cleaner Note 2,3 Replace at every2000km

Spark plug Clean at every 3000km and replace if necessary

Brake system I IIIIIIIII I I

Drive belt I

Suspension I I I

Nut, bolt, fastener I

Tire I I I

Steering head bearing I I I

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.

3-2

3. INSPECTION/ADJUSTMENT

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AGILITY CITY 125

FUEL FILTER

Remove the met-in box. (Ö2-3)

Check the fuel lines and replace any parts

which show signs of deterioration, damage or

leakage.

＊

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

THROTTLE OPERATION

Check the throttle grip for smooth movement.

Measure the throttle grip free play.

Free Play: 2Д6mm

Fuel Filte

Fuel Line

2Д6m

Major adjustment of the throttle grip free play

is made at the carburetor side.

Adjust by loosening the lock nut and turning

the adjusting nut.

Minor adjustment is made with the adjusting

nut at the throttle grip side.

Slide the rubber cover out and adjust by

loosening the lock nut and turning the

adjusting nut.

Lock Nu

Adjusting Nu

3-3

Adjusting Nu

Lock Nu

3. INSPECTION/ADJUSTMENT

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AIR CLEANER

AIR CLEANER REPLACEMENT

Remove the air cleaner case cover screws and

the cover by removing the six 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.

＊

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.

SUPER8 50

Screws

Air Cleaner Case Cove

Air Cleaner Elemen

SPARK PLUG

Remove the spark plug.

Check the spark plug for wear and fouling

deposits.

Clean any fouling deposits with a spark plug

cleaner or a wire brush.

Specified Spark Plug:

CHAMPION-P-RZ9HC

NGK CR7HSA

Measure the spark plug gap.

Spark Plug Gap: 0.6Д0.7mm

＊

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

Gap, Wear, and Fouling Deposits

Washe Deformation

Cracks Damage

3-4

3. INSPECTION/ADJUSTMENT

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VALVE CLEARANCE

＊

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

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.

AGILITY CITY 125

Cylinder Head Cove

Bolts

Inspect and adjust the valve clearance.

Valve Clearance: IN : 0.04mm

EX: 0.04mm

Loosen the lock nut and adjust by turning the

adjusting nut

Special

Tappet Adjuster

＊

xCheck the valve clearance again afte

the lock nut is tightened.

CARBURETOR IDLE SPEED

＊

xThe engine must be warm for accurate

idle speed inspection and adjustment.

Remove the inspection cover.

Warm up the engine before this operation.

Start the engine and connect a tachometer.

Turn the throttle stop screw to obtain the

specified idle speed.

Idle Speed: 1900Ô100rpm

When the engine misses or run erratic, adjust

the pilot screw.

Round Hole

Tappet Adjuste

Feeler Gauge

Throttle Stop Screw

3-5

3. INSPECTION/ADJUSTMENT

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IGNITION TIMING

＊

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

Remove the right of the fan cover.

Check the ignition timing with a timing light.

When the engine is running at idle speed, the

ignition timing is correct if the “F” mark on

the flywheel aligns with the index mark on

the crankcase.

SUPER8 50

Timing Hole Cap

Timing Ligh

Also use a timing light to check the advance.

Raise the engine speed to 4,000rpm and the

index mark on the crankcase cover should be

aligned with the advance mark on the

flywheel.

CYLINDER COMPRESSION

Warm up the engine before compression test.

Remove the met-in box and center cover.

(Ö2-3)

Remove the spark plug.

Insert a compression gauge.

Open the throttle valve fully and push the

starter button to test the compression.

Compression: 16kg/cm2rpm

If the compression is low, check for the

following:

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.

“F” Mark

Advance Mark

Compression Gauge

3-6

3. INSPECTION/ADJUSTMENT

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FINAL REDUCTION GEAR OIL

OIL LEVEL CHECK

＊

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

Stop the engine and remove the oil check bolt.

The oil level shall be at the oil check bolt

hole.

If the oil level is low, add the recommended

oil to the proper level.

Recommended Oil: SAE90#

Install the oil check bolt.

＊

Make sure that the sealing washer is in good condition.

AGILITY CITY 125

Oil Check Bolt/Sealing Washe

OIL CHANGE

Remove the oil check bolt.

Remove the oil drain bolt and drain the oil

thoroughly.

Install the oil drain bolt.

Torque: 0.8~1.2kgf-m

＊

Make sure that the sealing washer is in good condition.

Fill with the recommended oil.

Oil Capacity: At disassembly : 0.20 liter

At change : 0.18 liter

Reinstall the oil check bolt and check for oil

leaks.

Torque:0.8~1.2kgf-m

DRIVE BELT

Remove the left crankcase cover. (Ö9-2)

Inspect the drive belt for cracks or excessive

wear.

Replace the drive belt with a new one if

necessary and in accordance with the

Maintenance Schedule.

Oil Check Bolt Hole

Oil Drain Bolt/ Sealing Washe

3-7

Drive Bel

3. INSPECTION/ADJUSTMENT

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SUPER8 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

Arrows

Punch Mark

BRAKE ADJUSTING NUT

If the free play do not fall within the limit,

adjust by turning the adjusting nut.

FRONT/REAR 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

Adjusting Nu

Upper Line

Lower Line

3-8

3. INSPECTION/ADJUSTMENT

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If the free play do not fall within the limit,

adjust by turning the adjusting nut.

AGILITY CITY 125

Adjusting Nu

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)

Front Cove

Adjusting Screw

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.

3-9

clutc

3. INSPECTION/ADJUSTMENT

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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)

SUPER8 50

WHEELS/TIRES

Check the tires for cuts, imbedded nails or

other damages.

Check the tire pressure.

＊

Tire pressure should be checked when tires are cold.

TIRE PRESSURE

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

TIRE SIZE

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

1.75kg/cm

2.25kg/cm

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

Torques: Front : 5.0Д7.0kgf-m

Rear : 11Д13kgf-m

Front Axle Nu

3-10

3. INSPECTION/ADJUSTMENT

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STEERING HANDLEBAR

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

AGILITY CITY 125

3-11

4. LUBRICATION SYSTEM

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AGILITY CITY 125

__________________________________________________________________________________

@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@

LUBRICATION SYSTEM

@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@@

SERVICE INFORMATION------------------------------------------------ 4- 1 TROUBLESHOOTING----------------------------------------------------- 4- 1 ENGINE OIL/OIL FILTER ------------------------------------------------ 4- 2 OIL PUMP-------------------------------------------------------------------- 4- 2

4-0

4. LUBRICATION SYSTEM

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AGILITY CITY 125

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

4-1

4. LUBRICATION SYSTEM

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ENGINE OIL/OIL FILTER

OIL LEVEL

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.

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

OIL CHANGE

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

Remove the oil filter screen cap located on the bottom of the engine to drain the engine oil thoroughly.

AGILITY CITY 125

Oil Dipstick

Lower Level

Upper Level

After the oil has been completely drained, check the filter screen O-ring for damage and replace if necessary. Install the oil filter screen, spring and filter screen cap. Torque: 1.5kg-m

Fill with the specified SAE15W40#, API: SG engine oil to the proper level.

Oil Capacity: At disassembly : 0.90 liter

At change : 0.80 liter Check for oil leaks and then start the engine and let it idle for few minutes. Recheck the oil level.

OIL PUMP

REMOVAL

Remove the A.C. generator flywheel. Remove the nine right crankcase cover bolts and the right crankcase cover.

Oil Filter Screen Cap

O-ring

Bolts

Pulser Coil

Stato

ht Crankcase Cove

4-2

4. LUBRICATION SYSTEM

Nut

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Remove the gasket and dowel pins. Remove the starter idle gear and starter clutch.

AGILITY CITY 125

Gaske

Remove the two bolts and oil separator cover.

Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.

Bolts

Oil Separator Cove

Remove the two oil pump mounting bolts and the oil pump.

4-3

Oil Pump Driven Gea

Bolts

Oil Pump

4. LUBRICATION SYSTEM

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AGILITY CITY 125

DISASSEMBLY

Remove the screw and disassemble the oil pump.

INSPECTION

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

Screw

Pump Body Outer Roto

Measure the inner rotor-to-outer rotor clearance.

Service Limit: 0.12mm

Measure the rotor end-to-pump body clearance.

Service Limit: 0.2mm

Pump Body

Outer Roto

Inner Roto

4-4

4. LUBRICATION SYSTEM

Nut

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AGILITY CITY 125

ASSEMBLY

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

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

Install the dowel pin. Install the pump cover by aligning the hole in the cover with the dowel pin.

Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.

Outer Roto

Dowel Pin

Screw

Inner Roto

Pump Cove

INSTALLATION

Install the oil pump into the crankcase.

Install the oil pump with the arrow on the pump body facing up and fill the oil pump with engine oil before installation.

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

Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft. Install and tighten the pump driven gear nut.

Torque: 1.0kg-m

Arrow

Oil Pum

Bolts

4-5

Pump Driven Gea

4. LUBRICATION SYSTEM

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AGILITY CITY 125

Install the oil separator cover and tighten the bolts.

Install the starter idle gear and starter clutch. Install the gasket and dowel pins.

Starter Idle Gea

Bolts

Oil Separator Cove

Dowel Pin

Install the right crankcase cover and tighten the nine bolts.

Torque: 0.9kg-m

Diagonally tighten the bolts in 2Д3 times.

Starter Clutch

Stato

Gaske

Right Crankcase Cove

Bolts

Pulser Coil

4-6

5. FUEL SYSTEM

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AGILITY CITY 125

5-0

5. FUEL SYSTEM

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AGILITY CITY 125

Ignition Switch

CDI Unit

L/Y

Regulato

/Rectifier

Lighting System

Fuse

12V Battery

G/B

5 5W

Resistor

Auto Bystarte

5-1

5. FUEL SYSTEM

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SERVICE INFORMATION.......................5-2 CARBURETOR INSTALLATION.........5-10

TROUBLESHOOTING..............................5-3 PILOT SCREW ADJUSTMENT ............5-11

CARBURETOR REMOVAL.....................5-4 FUEL TANK............................................5-12

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

AIR CUT-OFF VALVE .............................5-6 AIR CLEANER .......................................5-13

VACUUM CHAMBER..............................5-6

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

AGILITY CITY 125

SERVICE INFORMATION

GENERAL INSTRUCTIONS

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

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

Venturi dia. (mm) I26 Type VE Float level (mm) 17 Main jet #104 Slow jet #35 Idle speed 1700rpm±100 Throttle grip free play 2Д6mm Pilot screw opening 3r

Standard

5-2

5. FUEL SYSTEM

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AGILITY CITY 125

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

5-3

5. FUEL SYSTEM

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AGILITY CITY 125

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. Disconnect the TPS coupler and remove the TPS unit

uto Bystarte

uto Bystarter Wire

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.

TPS Uni

Air Cleaner Connectin Tube Band

Throttle Cable

Fuel Tube

Vacuum Tube

AdjustingNu

Intake Manifold Band

Lock Nu

5-4

5. FUEL SYSTEM

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AGILITY CITY 125

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

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

REMOVAL

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

Vacuum Pump

Adopte

Auto Bystarte

AUTO BYSTARTER INSPECTION

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

INSTALLATION

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

＊

xBe sure to install the auto bystarter an

set plate properly.

xInstall the set plate with its bottom face

facing down.

Set Plate

Auto Bystarte

Set Plate

Screws

Bystarter Valve

Bystarter Needle

Screws

5-5

5. FUEL SYSTEM

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AGILITY CITY 125

AIR CUT-OFF VALVE

DISASSEMBLY

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.

＊

xBe sure to set the vacuum diaphrag

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

Spring

Screws

Air Cut-off Valve Cove

Cove

Screws

VACUUM CHAMBER

DISASSEMBLY

Remove the two vacuum chamber cover screws and the cover.

Remove the spring and vacuum diaphragm/ piston.

Vacuum Chamber Cove

Spring

Vacuum Diaphragm/Piston

5-6

5. FUEL SYSTEM

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Remove the needle holder and jet needle.

＊

Be careful not to damage the vacuu diaphragm.

INSPECTION

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

AGILITY CITY 125

Jet Needle

ASSEMBLY

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

Vacuum Diaphrag

Vacuum Chamber Cove

5-7

5. FUEL SYSTEM

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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.

Floa

AGILITY CITY 125

Screws

Float Chambe

Float Valve

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

＊

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.

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

Float Pin

Pilot Screw

eedle Jet Holde

eedle Je

Slow Je

Main Je

5-8

5. FUEL SYSTEM

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AGILITY CITY 125

INSPECTION

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

＊

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

ASSEMBLY

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

＊

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

Standard Opening:3r

turns

eedle Jet Holde

Valve Sea

Slow Je

Install the float valve, float and float pin.

FLOAT LEVEL INSPECTION

＊

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.

Measure the float level. Float Level: 17.0mm

Pilot Screw

Floa

Float Pin

eedle Je

Main Je

Float Valve

This installation sequence is the reverse of removal.

5-9

Float Level Gauge

5. FUEL SYSTEM

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AGILITY CITY 125

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.

Air Cleaner Connectin Tube Band

Throttle Cable

Vacuum Tube

Adjusting Nu

Intake Manifold Band

Lock Nu

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

-Throttle grip free play (Ö3-3)

-Carburetor idle speed (Ö3-5) Connect the auto TPS unit wire connector.

Fuel Tube

TPS Nui

Auto Bystarter Wire Connecto

5-10

5. FUEL SYSTEM

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PILOT SCREW ADJUSTMENT

ADJUSTMENT

＊

xThe pilot screw is factory pre-set an

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

xPlace the motorcycle on its main stand

on level ground for this operation.

AGILITY CITY 125

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: 3r

turns

＊

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.

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

Idle Speed: 1700Ô100rpm 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

5-11

5. FUEL SYSTEM

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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.

Bolts

AGILITY CITY 125

Fuel Tan

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.

＊

xWhen removing the fuel strainer, do

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

INSTALLATION

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

Fuel Unit Wite Connector

Fuel Straine

Arrow Mar

5-12

5. FUEL SYSTEM

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AGILITY CITY 125

FUEL UNIT

REMOVAL

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

＊

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

INSTALLATION

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

＊

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.

Fuel Unit Wire

Fuel Tank

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

air cleane

olts

5-13

5. FUEL SYSTEM

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AGILITY CITY 125

TPS REMOVE

Remove the TPS stay screw. Remove the TPS and TPS stay assembled.

＊

x While clean the carburetor, must

remove the TPS unit.

TPS UNIT INSPECTION

Measure the TPS resistance between the violet/black and green wire terminals. Measure the resistance:5K:±30％ Measure the TPS resistance between the violet/red and green wire terminals. Measure the resistance:5K:±30％

＊

x Whem measure the TPS

resistance,carburetor throttle open the max place .

Violet/Red

Tps Uni

Green

ScrewTPS Stay

Violet/Black

The installation sequence is the reverse of removal.

5-14

6. ENGINE REMOVAL/INSTALLATION

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AGILITY CITY 125

6-0

6. ENGINE REMOVAL/INSTALLATION

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

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

AGILITY CITY 125

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

6-1

6. ENGINE REMOVAL/INSTALLATION

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ENGINE REMOVAL

Disconnect the battery negative cable. Remove the frame body cover. Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector.

Auto Bystarter Wire Connecto

Disconnect the starter motor cable from the starter relay. Remove the spark plug cap and disconnect the ignition coil wire from the set plate.

AGILITY CITY 125

Starter Relay

Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump. Disconnect the vacuum tube from the air cut-off valve. Disconnect the throttle cable from the carburetor.

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

Vacuum Tube

Connecting Tube

Fuel Tube

Tee Tube

Screw

6-2

6. ENGINE REMOVAL/INSTALLATION

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AGILITY CITY 125

Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable.

Remove the rear shock absorber lower mount bolt.

Brake Adjusting Nut

Rear Shock Absorber Lower Mount Bol

Remove the four A.C. generator cooling fan cover bolts and cooling fan cover. Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward.

ENGINE HANGER BRACKET REMOVAL

Remove the ignition coil from the engine hanger. Remove the engine hanger bracket bolt and nut. Remove the engine hanger bracket.

Engine Mounting Bol

Engine Hanger Bracke

6-3

6. ENGINE REMOVAL/INSTALLATION

Nut

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AGILITY CITY 125

Inspect the engine hanger bushings and stopper rubbers for wear or damage.

ENGINE HANGER BRACKET INSTALLATION

Install the engine hanger bracket to the engine. Install the engine hanger bracket bolt and tighten the nut.

Bushings

Stopper Rubbers

Bol

Engine Hanger Bracke

ENGINE INSTALLATION

Install the engine and tighten the engine mounting bolt.

Torque: 7.0kg-m Tighten the rear shock absorber upper

mount bolt. Torque: 4.0kg-m

Install the removed parts in the reverse order of removal.

＊

Route the wires and cables properly.

After installation, inspect and adjust the following:

xThrottle grip free play. xRear brake adjustment.

Engine Mounting Bol

Rear Shock Absorber Lower Mount Bol

6-4

7. CYLINDER HEAD/VALVES

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AGILITY CITY 125

7-0

7. CYLINDER HEAD/VALVES

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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

AGILITY CITY 125

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)

Valve clearance (cold)

Cylinder head compression pressure 13kg/cm² Cylinder head warpage 

Camshaft cam height

Valve rocker arm I.D. Valve rocker arm shaft IN 9.972Д9.987 9.91

O.D. Valve seat width

Valve stem O.D.

Valve guide I.D. Valve stem-to-guide IN 0.010Д0.037 0.08

clearance

IN 0.12 

EX 0.12 

IN 29.803 29.40

EX 29.5637 29.16

IN 10.000Д10.015 10.10

EX 10.000Д10.015 10.10

EX 9.972Д9.987 9.91

IN 1.0 1.8

EX 1.0 1.8

IN 4.975Д4.990 4.90

EX 4.955Д4.970 4.90

IN 5.000Д5.012 5.03

EX 5.000Д5.012 5.03

EX 0.030Д0.057 0.10

7-1

7. CYLINDER HEAD/VALVES

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TORQUE VALUES

Cylinder head nut 2.0kg-m Apply engine oil to threads Valve clearance adjusting nut 0.9kg-m Apply engine oil to threads Stud bolt 0.9~1.1kg-m

SPECIAL TOOLS

Valve spring compressor

AGILITY CITY 125

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

7-2

7. CYLINDER HEAD/VALVES

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CAMSHAFT REMOVAL

Remove the center cover. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the two nuts attaching the secondary air inlet tube.

AGILITY CITY 125

Cylinder Head Cove

Remove the cam chain tensioner cap screw and the O-ring.

Turn the cam chain tensioner screw clockwise to tighten it.

O-ring

Screw

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.

7-3

Camshaft Gea

Round Hole

Tensioner Screw

Punch Marks

7. CYLINDER HEAD/VALVES

Nut

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

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

AGILITY CITY 125

Bol

Washe

Remove the camshaft holder and dowel pins.

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

Camshaft Holde

Dowel PinsCamshaf

CAMSHAFT INSPECTION

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

Service Limits:

IN : 29.40mm replace if below EX: 29.16mm replace if below

Cam Chain Camshaft Gea

7-4

7. CYLINDER HEAD/VALVES

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AGILITY CITY 125

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

CAMSHAFT HOLDER DISASSEMBLY

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

Camshaft Bearin

CAMSHAFT HOLDER INSPECTION

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

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

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

Rocker Ar

Camshaft Holde

Rocker Arm Shaf

Rocker Arm Shafts

5mm Bol

Service Limits: IN: 9.91mm replace if over EX: 9.91mm replace if over

7-5

7. CYLINDER HEAD/VALVES

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CYLINDER HEAD REMOVE

Remove the camshaft. Remove the carburetor. Remove the exhaust muffler. Remove the carburetor intake manifold. Remove the cooling fan cover. Remove the engine cover bolts and screws. Separate the engine cover joint claws.

AGILITY CITY 125

Intake Manifold

Remove the cylinder head.

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

Cylinder Head

Dowel Pins

Bolts

linder Head Gaske

Remove all gasket material from the cylinder mating surface.

xAvoid damaging the cylinder mating

surface.

xBe careful not to drop any gasket

material into the engine.

Cam Chain Guide

7-6

7. CYLINDER HEAD/VALVES

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CYLINDER HEAD DISASSEMBLY

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

xBe sure to compress the valve springs

with a valve spring compressor.

xMark all disassembled parts to ensure

correct reassembly.

Special

Valve Spring Compressor

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

AGILITY CITY 125

Valve Spring Compresso

Be careful not to damage the cylinde 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 : 32.3mm replace if below Outer : 35.0mm replace if below

7-7

7. CYLINDER HEAD/VALVES

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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 : 4.90mm replace if below EX: 4.90mm replace if below

Measure each valve guide I.D. Service Limits: IN : 5.03mm replace if over

EX: 5.03mm replace if over

Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stemto-guide clearance.

Service Limits: IN : 0.08mm replace if over

EX: 0.10mm replace if over

If the stem-to-guide clearance exceeds the service limits, replace the cylinder head as necessary.

AGILITY CITY 125

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and valve stem seals.

Be sure to install new valve stem seals.

Lubricate each valve stem with engine oil and insert the valves into the valve guides. Install the valve springs and retainers.

Compress the valve springs using the valve spring compressor, then install the valve cotters.

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

Valve Spring Compressor

Valve Spring Compresso

7-8

7. CYLINDER HEAD/VALVES

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

Be careful not to damage the valves.

AGILITY CITY 125

CYLINDER HEAD INSTALLATION

Tighten the four stud bolts. Install the dowel pins and a new cylinder

head gasket. Install the cam chain guide.

Torque: Stud Bolts :0.7Д1.1kg-m

Install the cylinder head.

Dowel Pins

Stud Bolts

Gaske

Cam Chain Guide

CAMSHAFT HOLDER ASSEMBLY

Install the exhaust valve rocker arm to the “EX” mark side of the camshaft holder. Install the intake valve rocker arm and the rocker arm shafts.

xAlign the cutout on the front end of the

intake valve rocker arm shaft with the bolt of the camshaft holder.

xAlign the cross cutout on the exhaust

valve rocker arm shaft with the bolt of the camshaft holder.

7-9

Camshaft Holde

Valve Rocker Ar

linder Head

7. CYLINDER HEAD/VALVES

Nut

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AGILITY CITY 125

CAMSHAFT INSTALLATION

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

Install the dowel pins.

Cam Chain

Round Hole

Camshaft Gea

Punch Marks

Dowel Pins

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

Torque: Cylinder head nut: 2.0kg-m

xApply engine oil to the threads of the

cylinder head nuts.

xDiagonally tighten the cylinder head

nuts in 2Д3 times.

Adjust the valve clearance. Turn the cam chain tensioner screw counterclockwise to release it.

Camshaft Holde

Washe

Tensioner Screw

7-10

7. CYLINDER HEAD/VALVES

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Apply engine oil to a new O-ring and install it.

Tighten the cam chain tensioner cap screw.

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

Install a new cylinder head cover O-ring and install the cylinder head cover. Install and tighten the cylinder head cover bolts.

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

AGILITY CITY 125

O-ring

Cylinder Head Cove

7-11

8. CYLINDER/PISTON

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1.0kg-

AGILITY CITY 125

Do not ben

8-0

8. CYLINDER/PISTON

)

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

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

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

AGILITY CITY 125

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

Ite

I.D. 52.4Д52.410 52.50

Cylinde

Piston, piston rin

. Piston-to-cylinder clearance 0.010Д0.040 0.1

Piston pin O.D 14.994Д15.000 14.96 Piston-to-piston pin clearance 0.002Д0.014 0.02 Connecting rod small end I.D. bore 15.016Д15.034 15.06

Warpage  0.05 Cylindricity  0.05 True roundness  0.05 Ring-to-groove

clearance

Ring end gap Second 0.10Д0.25 0.5

Piston O.D. 52.370Д52.390 52.3 Piston O.D. measuring position 9mm from bottom of skirt 

Piston pin hole I.D. 15.002Д15.008 15.04

Top 0.015Д0.055 0.09 Second 0.015Д0.055 0.09 Top 0.10Д0.25 0.5

Oil side rail 0.2Д0.7 

Standard (mm

Service Limit (mm

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

8-1

x Worn piston pin hole and piston pin

8. CYLINDER/PISTON

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AGILITY CITY 125

CYLINDER REMOVAL

Remove the cylinder head. Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder.

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

Gaske

Cylinde

Dowel Pins

PISTON REMOVAL

Remove the piston pin clip.

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

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

PistonPiston Rings

8-2

8. CYLINDER/PISTON

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

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

Clean carbon deposits from the piston ring grooves.

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

Service Limits:

Top: 0.09mm replace if over 2nd: 0.09mm replace if over

AGILITY CITY 125

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

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

Measure the piston ring end gap. Service Limit: 0.5mm replace if over

Measure the piston pin hole I.D. Service Limit: 15.04mm replace if over

Gap

8-3

8. CYLINDER/PISTON

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Measure the piston pin O.D. Service Limit: 14.996mm replace if below

Measure the piston O.D.

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

Service Limit: 52.3mm replace if below Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

AGILITY CITY 125

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: 52.50mm repair or replace if

over

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

over

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

Service Limits: True Roundness: 0.05mm repair or replace

if over Cylindricity: 0.05mm repair or replace if over

Top

Middle

Botto

8-4

8. CYLINDER/PISTON

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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: 15.06mm replace if over

AGILITY CITY 125

PISTON RING INSTALLATION

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

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.

Top

Second

Side Rail

Oil Ring Side Rail

8-5

8. CYLINDER/PISTON

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PISTON INSTALLATION

Remove any gasket material from the crankcase surface.

Be careful not to drop foreign matters into the crankcase.

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

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.

AGILITY CITY 125

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.

xBe careful not to damage or break the

piston rings.

xStagger the ring end gaps at 120q to the

piston pin.

Piston Pin Clip

Gaske

Piston Pin

Piston

Cylinde

8-6

8. CYLINDER/PISTON

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Loosely install the cylinder base bolts.

Install the cam chain guide.

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

Install the cylinder head. Tighten the cylinder base bolts.

AGILITY CITY 125

Cam Chain Guide

Cylinder Base Bol

8-7

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

AGILITY CITY 125

5.0Д6.0kg-

3.5-4.5g-

3.5-4.0g-

9-0

9. DRIVE AND DRIVEN PULLEYS/

)

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KICK STARTER

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

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

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

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

SERVICE INFORMATION

GENERAL INSTRUCTIONS

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

AGILITY CITY 125

Ite Movable drive face bushing I.D. 23.989~24.025 24.06 Drive face collar O.D. 23.960~23.974 23.94 Drive belt width 17.5 16.5 Clutch lining thickness  1.5 Clutch outer I.D. 125.2-125.7 125.5 Driven face spring free length  147.6 Driven face O.D. 33.965-33.485 33.94 Movable driven face I.D. 34.0-34.025 34.06 Weight roller O.D. 15.920~16.080 15.4

TORQUE VALUES

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

SPECIAL TOOLS

Universal holder Clutch spring compressor

Standard (mm

Service Limit (mm

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

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

9-1

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

LEFT CRANKCASE COVER

REMOVAL

Loosen the drive belt air tube band screw.

AGILITY CITY 125

Air Tube Band

Screw

Remove the left crankcase cover bolts and

cable clamp.

Remove the seal rubber and dowel pins.

INSTALLATION

Install the dowel pins and gasket.

Cable Clamp

Left Crankcase Cove

Bolts

Dowel Pins

Install the left crankcase cover and tighten the left crankcase cover bolts. Install the cable clamp to the specified location and tighten the bolt.

Left Crankcase Cove

Bolts

9-2

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

AGILITY CITY 125

Install the drive belt air tube and tighten the tube band screw.

DRIVE PULLEY

REMOVAL

Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet. Remove the drive pulley face.

Special

Flywheel Holder

Starting Ratche

Intake Cove

Tube Band Screw Drive Pulley Face

Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch/driven pulley and drive belt.

INSPECTION

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

Service Limit: 17.0mm replace if below

Use specified genuine parts for replacement.

Flywheel Holde

Movable Drive Face

Drive Bel

9-3

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

AGILITY CITY 125

Remove the movable drive face assembly. Remove the drive pulley collar.

DISASSEMBLY

Remove the ramp plate.

Drive Pulley Colla

Movable Drive Face Assembly

Ramp Plate

Remove the weight rollers.

INSPECTION

Check each weight roller for wear or damage. Measure each weight roller O.D.

Service Limit: 15.4mm replace if below

Weight Rolle

9-4

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

Measure the movable drive face bushing I.D.

Service Limit: 24.06mm replace if over

Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.

Service Limit: 23.94mm replace if below

AGILITY CITY 125

ASSEMBLY

Install the weight rollers into the movable drive face.

Install the ramp plate.

Weight Rolle

Ramp Plate

9-5

9. DRIVE AND DRIVEN PULLEYS/

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KICK STARTER

AGILITY CITY 125

Insert the drive pulley collar into the movable drive face.

INSTALLATION

Install the movable drive face onto the crankshaft.

Drive Pulley Colla

Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.

Drive Pulle

Drive Bel

Movable Drive Face Assembly

Colla

Driven Pulle

9-6

KYMCO Agility City 125, 150 agility, agility R16 50, agility R16 125, agility R16 150 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual