KYMCO AGILITY 125 Service Manual
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KYMCO AGILITY 125 Service Manual

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12
. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
WHEEL RIM
Check the wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over
Turn the wheel bearings and replace the
bearings if they are noisy or have excessive
play.
DISASSEMBLY
Remove the dust seal.
12-5
Play
Axial
Dust Seal
AGILITY 125
Play
Radial

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  • Page 1 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Play Turn the wheel bearings and replace the bearings if they are noisy or have excessive play.
  • Page 2 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Remove the front wheel bearings and Bearing Puller distance collar. Special Bearing Puller Pilot ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar.
  • Page 3 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Side Collar Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Dust Seal Groove INSTALLATION Install the front wheel by aligning the brake panel groove with the front fork tab.
  • Page 4 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 DISASSEMBLY Do not swing the brake arm to expand the brake shoes. Remove the brake shoes by removing the brake shoe springs using a screw driver. Remove the brake arm and return spring.
  • Page 5 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Wear Indicator Plate Brake Cam Install the return spring by aligning the spring hook end with the hole in the brake panel. Apply a small amount of engine oil to the felt seal and install it to the brake panel.
  • Page 6 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 HYDRAULIC BRAKE (FRONT BRAKE) Upper Limit Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground. ＊ • When operating the brake lever, the brake reservoir cap must be tightened securely to avoid spill of brake fluid.
  • Page 7 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Pad Pin Brake Pad/Disk Replacement ＊ The brake pads must be replaced as a set to ensure the balance of the brake disk. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
  • Page 8 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 BRAKE MASTER CYLINDER Brake Master Cylinder Bolts Removal First drain the brake fluid from the hydraulic brake system. ＊ • When servicing the brake system, use shop towels to cover rubber and...
  • Page 9 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D. Service Limit: 12.6mm Before assembly, inspect the lst and 2nd rubber cups for wear.
  • Page 10 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Brake Caliper Seat Disassembly Remove the brake caliper seat from the brake caliper. Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet...
  • Page 11 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Punch Mark Bolts Place the brake master cylinder on the handlebar and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint. First tighten the upper bolt and then tighten the lower bolt.
  • Page 12 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 26.3mm Check the caliper cylinder for scratch or wear and measure the cylinder bore. Service Limit: 26.45mm Assembly Clean all removed parts.
  • Page 13 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Installation Install the brake caliper and tighten the two bolts. Torque: 2.9～3.5kg-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 2.5～3.5kg-m Fill the brake reservoir with recommended brake fluid and bleed air from the brake syst em.
  • Page 14 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. ( 12-4) Remove the front lower cover. ( 2-2) Remove the front inner fender. Remove the front shock absorber upper mount bolts.
  • Page 15 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Measure the front shock absorber spring free length. Service Limits: Right : 206.4mm Left : 206.4mm ASSEMBLY Top Nut Dust Seal Circlip Damper Oil Seal Damper Spring Shock Absorber Spring Front Shock...
  • Page 16 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube and tighten the top nut.
  • Page 17 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 FRONT FORK Long Socket Wrench REMOVAL Remove the steering handlebar. ( 12-3) Remove the front wheel. ( 12-4) Disconnect the speedometer cable. Remove the steering stem lock nut using long socket wrench.
  • Page 18 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Driver Handle A Drive new top and bottom ball races into the steering head using the outer driver. ＊ Be sure to completely drive in the ball races. Outer Driver, 37x40mm INSTALLATION...
  • Page 19 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 1.2kg-m 1.0kg-m 11.0kg-m 3.5kg-m 13-0...
  • Page 20 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 SERVICE INFORMATION ...... 13-1 REAR BRAKE.........13-3 TROUBLESHOOTING ......13-1 REAR SHOCK ABSORBER....13-4 REAR WHEEL .......... 13-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm)
  • Page 21 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Rear Axle Nut REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-5) Remove the rear axle nut to remove the rear wheel. INSPECTION Measure the rear wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over...
  • Page 22 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 REAR BRAKE BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below ＊ Keep oil or grease off the brake linings. Brake Arm Brake Shoes REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable.
  • Page 23 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Brake Arm Bolt Wear Indicator Plate Apply a small amount of engine oil to the felt seal and install it to the brake cam. Install the wear indicator plate and brake arm.
  • Page 24 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 Lock Nut Loosen the lower joint lock nut. Remove the lower joint. Remove the lock nut, rubber and damper. Spring INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage.
  • Page 25 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then the lower mount bolt. Tighten the bolts. Torque: Upper Mount Bolt: 3.5~4.5kgf-m Lower Mount Bolt: 2.4~3.0kgf-m Install the air cleaner case.
  • Page 26 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Battery Fuse Regulator/Rectifier Resistors A.C. Generator A.C. Generator Auto Regulator/ Bystarter Rectifier 5Ω Battery 12V4AH 14-0...

  • Page 27: Service Information

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 SERVICE INFORMATION...... 14-1 A.C. GENERATOR CHARGING COIL ...14-6 TROUBLESHOOTING ......14-2 RESISTOR INSPECTION......14-6 BATTERY..........14-3 A.C. GENERATOR REMOVAL .....14-6 CHARGING SYSTEM ......14-4 A.C. GENERATOR INATALLATION ...14-8 REGULATOR/RECTIFIER...... 14-5 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes.

  • Page 28: Troubleshooting

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 SPECIFICATIONS Item Standard Capacity/Model 12V−8AH Voltage Fully charged 13.1V Battery (20℃) Undercharged 12.3V Charging current STD: 0.4A Quick: 4.0A Charging time STD: 5～10hr Quick: 30min Capacity 0.144KW/5000rpm A.C. Generator Lighting coil resistance (20℃) Yellow～Green...
  • Page 29 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 Battery Cover REMOVAL Remove the battery cover screws on the floor board. Open the battery cover and remove the battery by removing the bolt and band. First disconnect the battery negative (-) cable and then the positive (+) cable.
  • Page 30 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Terminal CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative (-) terminal and the ground wire. Turn the ignition switch OFF and check for short circuit.
  • Page 31 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 REGULATOR/RECTIFIER Regulator/Rectifier MAIN HARNESS CIRCUIT INSPECTION Remove the front covers. ( 2-2) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following : Item (Wire Color) Judgment Between battery (red) Battery has...
  • Page 32 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Fan C Charging Coil Wire A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 2P connector. Measure the resistance between the A.C.
  • Page 33 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 34 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Remove the A.C. generator wire set plate. Bolts Remove the pulser coil bolts. Remove the A.C. generator wire rubber sleeve and pulser coil from the right crankcase. Remove the two bolts and A.C. generator stator.
  • Page 35 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Holder Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
  • Page 36 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Install the fan cover. Install the right side cover. ( 2-4) Fan Cover 14-10...

  • Page 37: Ignition Switch

    . IGNITION SYSTEM AGILITY 125 CDI Unit Ignition Switch A.C. Generator Spark Plug Pulser Coil Install on the carburetor 15-0...
  • Page 38 . IGNITION SYSTEM AGILITY 125 SERVICE INFORMATION ...... 15-1 IGNITION COIL ........15-4 TROUBLESHOOTING ......15-2 PULSER COIL ........15-5 CDI UNIT INSPECTION ......15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 15-2) •...
  • Page 39 . IGNITION SYSTEM AGILITY 125 TROUBLESHOOTING High voltage too low No or intermittent high voltage • Weak battery or low engine speed • Faulty ignition coil • Loose ignition system connection • Weak battery • Faulty ignition coil • Faulty charging system •...
  • Page 40 . IGNITION SYSTEM AGILITY 125 CDI UNIT INSPECTION Remove the three battery cover screws. Disconnect the CDI coupler and remove the CDI unit. CDI Unit Black/ Violet/ Black Blue Black/ Blue/ Green Violet/ Yellow Yellow 15-3...
  • Page 41 . IGNITION SYSTEM AGILITY 125 IGNITION COIL REMOVAL Remove the met-in box. ( 2-3) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. Ignition Coil INSPECTION CONTINUITY TEST ＊ The CDI unit is not adjustable. If the timing is incorrect, inspect the CDI unit, pulser coil and A.C.
  • Page 42 . IGNITION SYSTEM AGILITY 125 PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2-3) Disconnect the A.C. generator connector. Pulser Coil Coupler Measure the pulser coil resistance between the blue/yellow and green wire terminals.

  • Page 43: Stop Switches/Horn

    . STARTING SYSTEM AGILITY 125 Stop Switches Starter Relay Starter Button Starter Motor 16-0...
  • Page 44 . STARTING SYSTEM AGILITY 125 SERVICE INFORMATION.......16-1 STARTER MOTOR ........ 16-2 TROUBLESHOOTING......16-1 STARTER RELAY........16-4 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5...
  • Page 45 . STARTING SYSTEM AGILITY 125 Bolts STARTER MOTOR REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 46 . STARTING SYSTEM AGILITY 125 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.
  • Page 47 . STARTING SYSTEM AGILITY 125 Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.
  • Page 48 . STARTING SYSTEM AGILITY 125 Yellow/Red Wire STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 49 . STARTING SYSTEM AGILITY 125 Remove the starter clutch lock nut. Lock Nut Special Flywheel Holder ＊ Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft. Flywheel Holder INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch.
  • Page 50 . STARTING SYSTEM AGILITY 125 Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Measure the starter idle gear I.D. Clutch Cover Service Limit: 10.05mm replace if over Starter Idle Gear Measure the starter idle gear shaft O.D.
  • Page 51 . STARTING SYSTEM AGILITY 125 16-8...

  • Page 52: Table Of Contents

    . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 SERVICE INFORMATION ....17-0 IGNITION SWITCH ......17-3 TROUBLESHOOTING ......17-0 STOP SWITCHES/HORN ....17-4 FUEL UNIT ..........17-1 INSTRUMENTS........17-4 HANDLEBAR SWITCHES....17-2 HEADLIGHT/LIGHTS......17-5 SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment.
  • Page 53 . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 Fuel Unit FUEL UNIT ＊ No Smoking! REMOVAL Remove the met-in box. ( 2-3) Remove the frame right side cover. ( 2-4) Disconnect the fuel unit wire connector. Turn the fuel unit retainer counterclockwise to remove it.
  • Page 54 . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 HANDLEBAR SWITCHES INSPECTION Remove the handlebar front cover. ( 2-2) Disconnect the handlebar switch couplers and check for continuity between wire terminals. If there is any abnormality found, check each switch. HEADLIGHT SWITCH Blue/ Color Yellow Brown Pink Yellow White ‧...
  • Page 55 . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 HORN SWITCH Color Light Green Black FREE ○ ○ PUSH SWITCH REPLACEMENT Remove the front covers. ( 2-2) Remove the handlebar front cover. ( 2-2) The installation sequence is the reverse of removal. IGNITION SWITCH INSPECTION Remove the front covers.

  • Page 56: Instruments

    . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 STOP SWITCH INSPECTION Remove the handlebar front cover. ( 2-2) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied. The switch is normal if there is continuity.
  • Page 57 . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 Screw HEADLIGHT 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.
  • Page 58 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 EXHAUST EMISSION CONTROL SYSTEM DIAGRAM ...........18-0 EXHAUST EMISSION CONTROL SYSTEM ...............18-1 SERVICE INFORMATION.....................18-1 TROUBLESHOOTING ......................18-1 MAINTENANCE SCHEDULE ....................18-2 SECONDARY AIR CLEANER....................18-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.) ..............18-4 REED VALVE .........................18-5 EXHAUST MUFFLER ......................18-6 EXHAUST EMISSION RELATED SYSTEM INSPECTION..........18-7...

  • Page 59: Exhaust Emission Control System

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
  • Page 60 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 MAINTENANCE SCHEDULE: (1) PERIODIC MAINTENANCE Service Mileage 300 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 Item Engine oil Oil filter screen Gear oil Motor oil filter...
  • Page 61 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 Met-in Box Center Coverl SECONDARY AIR CLEANER REMOVAL Remove the met-in box. ( 2-3) Remove the center cover. ( 2-3) Remove the frame body covers. ( 2-4) Remove the floor board. ( 2-4)

  • Page 62: Air Injection Cut-Off Valve (A.i.c.v.)

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 AIR INJECTION CUT-OFF VALVE Air Injection Cut-off Valve INSPECTION Inspect the air injection cut-off valve flow Vacuum Pump using a vacuum pump. If the flow is not within the specified values, replace with a new one.

  • Page 63: Reed Valve

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 REED VALVE Cylinder Head Cover Bolts REMOVAL Remove the met-in box and frame center cover. Disconnect the secondary air inlet tube connector. Remove the four cylinder head cover bolts and two secondary air outlet tube bolts.

  • Page 64: Exhaust Muffler

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 Exhaust Muffler Joint Lock Nut EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler. ＊ • The temperature of exhaust muffler is very high.

  • Page 65: Exhaust Emission Related System Inspection

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM AGILITY 125 EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner. ( 3-4) Clean and adjust the carburetor. ( 3-5) Inspect the auto bystarter system. ( 5-4) Clean and inspect the spark plug. ( 3-4) Inspect the ignition system.

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