KYMCO Agility Carry 50i Manual
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KYMCO Agility Carry 50i Manual

KYMCO Agility Carry 50i Manual

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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Agility
Carry / Delivery 50i SCOOTER.
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 to 17 give instructions for
disassembly, assembly and inspection of
engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
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
Agility Carry / Delivery 50i

TABLE OF CONTENTS

FUEL SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

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  • Page 1: Table Of Contents

    Agility Carry / Delivery 50i PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing procedures for the KYMCO Agility FRAME COVERS/EXHAUST MUFFLER Carry / Delivery 50i SCOOTER. INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual.

  • Page 2: General Information

    SPECIFICATIONS ........1- 2 CABLE & HARNESS ROUTING ..... 1-15 SERVICE PRECAUTIONS ...... 1- 3 WIRING DIAGRAM ........ 1-20 TORQUE VALUES ........1-11 TROUBLESHOOTUNG ......1-21 SPECIAL TOOLS ........1-12 ENGINE SERIAL NUMBER Delivery 50i Agility Carry 50i Location of Engine Serial Number...

  • Page 3: Specifications

    . GENERAL INFORMATION SCOOTER SPECIFICATIONS Agility carry 50 45km/h Motorcycle Name & Type Air cleaner type & No Paper element, wet Agility Carry 50i Fuel capacity 5 liter Name & Model No. AAF1 Overall length (mm) 1950 Overall width (mm)
  • Page 4 . GENERAL INFORMATION SCOOTER SPECIFICATIONS Agility carry 50 25km/h Motorcycle Name & Type Air cleaner type & No Paper element, wet Agility Carry 50i Fuel capacity 5 liter Name & Model No. AAF1 Overall length (mm) 1950 Overall width (mm)
  • Page 5 . GENERAL INFORMATION Agility Carry / Delivery 50i SPECIFICATIONS Agility Delivery 50i 45km/h Motorcycle Name & Type Air cleaner type & No Paper element, wet Delivery 50i Fuel capacity 5 liter Name & Model No. ALC9 Overall length (mm) 1950 Overall width (mm) Overall height (mm) 1130...
  • Page 6 . GENERAL INFORMATION Agility Carry / Delivery 50i SPECIFICATIONS Agility Delivery 50i 25km/h Motorcycle Name & Type Air cleaner type & No Paper element, wet Delivery 50i Fuel capacity 5 liter Name & Model No. ALC9 Overall length (mm) 1950 Overall width (mm) Overall height (mm) 1130...

  • Page 7: Service Precautions

    Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER 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.
  • Page 8 . GENERAL INFORMATION Agility Carry / Delivery 50i  Apply or add designated greases and lubricants to the specified lubrication points.  After reassembly, check all parts for proper tightening and operation.  When two persons work together, pay attention to the mutual working safety. ...
  • Page 9 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER  If the fuse is burned out, find the cause and Confirm repair it. Replace it with a new one Capacity according to the specified capacity.  After operation, terminal caps shall be installed securely.
  • Page 10 . GENERAL INFORMATION Agility Carry / Delivery 50i  The connector shall be inserted completely.  If the double connector has a lock, lock Snapping! 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.
  • Page 11 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER  After clamping, check each wire to make sure it is secure.  Do not squeeze wires against the weld or its clamp  After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
  • Page 12 . GENERAL INFORMATION Agility Carry / Delivery 50i  Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight!  Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner ...
  • Page 13 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER  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.
  • Page 14 . GENERAL INFORMATION Agility Carry / Delivery 50i  Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication.

  • Page 15: Torque Values

    Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5 6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1 8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4 10mm bolt, nut...

  • Page 16: Special Tools

    . GENERAL INFORMATION Agility Carry / Delivery 50i SPECIAL TOOLS Description Tool No. Photo Flywheel puller A120E00002 Oil seal and bearing installer A120E00014 Universal holder A120E00017 Flywheel holder A120E00021 Clutch spring compressor A120E00034 Valve adjuster A120E00036 Bearing puller A120E00037 Cylinder Compression Gauage A120E00039 1-13...
  • Page 17 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER Description Tool No. Photo Valve spring compressor A120E00040 Fuel Pressure Gauage A120E00048 INJECTOR CLEANER for A120E00075 Synerjet Wires Injector Connector A120E00090 Lock nut wrench A120F00002 Lower/Upper Race Remover & A120F00008 Installer Steering Stem Top Thread A120F00024 Wrench (shoter type)
  • Page 18 . GENERAL INFORMATION Agility Carry / Delivery 50i Description Tool No. Photo Pliers Fuel Pipe A120F00031 Electric Repair Kit A120F00032 1-15...

  • Page 19: Lubrication Points

    Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER LUBRICATION POINTS ENGINE Lubrication Points Lubricant Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part APISG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut...
  • Page 20 . GENERAL INFORMATION Agility Carry / Delivery 50i 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 Lever Pivot...

  • Page 21: Cable & Harness Routing

    Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER CABLE & HARNESS ROUTING Winker Brake Master Cylinder Throttle Cable Rear Brake Cable Ignition Switch Fuel pump relay Horn Roll Sensor Speedometer Cable Front Brake Fluid Tube Agility Carry 50i 1-18...
  • Page 22 . GENERAL INFORMATION Agility Carry / Delivery 50i CABLE & HARNESS ROUTING Winker Brake Master Cylinder Throttle Cable Rear Brake Cable Ignition Switch Roll Sensor Horn Fuel pump relay Speedometer Cable Delivery 50i 1-19...
  • Page 23 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER Fuel Pump Relay Fuel level indicator Fuel Tank Fuel Pump Fuel injector Diaglostic tool connector Starter Relay Regulator/Rectifier ACG/CPS Ignition Coil 1-20...
  • Page 24 . GENERAL INFORMATION Agility Carry / Delivery 50i Starter Motor Battery (+) Cable Throttle body/ECU Ignition Coil Battery (-) Cable Fuel Tube Fuse E T S Throttle Cable Crankcase Breather Tube 1-21...

  • Page 25: Wiring Diagram

    Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER WIRING DIAGRAM 1-22...
  • Page 26 . GENERAL INFORMATION Agility Carry / Delivery 50i Troubleshooting Vehicle can not be started Preliminary 6 Step Inspection 1. Is the battery fully charged (12 V or higher). See the Battery topic for more information. 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
  • Page 27 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER General Troubleshooting ENGINE WILL NOT START OR IS HARD TO START Possible cause  Faulty fuel pump 1. Check for operation of the fuel pump Abnormal Normal  Faulty pressure regulator 2.
  • Page 28 . GENERAL INFORMATION Agility Carry / Delivery 50i ENGINE LACKS POWER Possible cause  Brake dragging 1. Raise wheel off the ground Wheels do not  Worn or damaged wheel bearing and spin by hand spin freely Wheel spins freely ...
  • Page 29 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER Possible cause  Oil level too high 9. Check oil level and condition Incorrect  Oil level too low  Contaminated oil Correct  Clogged oil 10. Remove cylinder head cover Valve train not ...
  • Page 30 . GENERAL INFORMATION Agility Carry / Delivery 50i POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause  Improper ignition timing 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3.
  • Page 31 Agility Carry / Delivery 50i . GENERAL INFORMATION SCOOTER POOR PERFORMANCE AT HIGH SPEED Possible cause  Faulty ECU 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector Abnormal Normal ...

  • Page 32: Frame Covers/Exhaust Muffler

    2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i COVERS DISASSEMBLY...
  • Page 33 2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i SERVICE INFORMATION ...... 2-1 EXHAUST MUFFLER REMOVAL ..2-5 FRAME COVERS ........2-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged.
  • Page 34 2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i Front Panel Removal Remove the 3 bolts from the hook. Blots Disconnect the headlight connector. Remove the 4 bolts attaching to the frame. Remove the front luggage carrier. Connector Blots Remove the 1 screw on the front panel. Remove the 4 screws from the back side on the front panel.
  • Page 35 2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i MET-IN BOX REMOVAL Open the seat Remove the 5 bolts attaching the met-in box. Remove the met-in box . Bolts FLOOR BOARD REMOVAL Remove the 7 bolts attaching the rear carrier. Remove the rear carrier.
  • Page 36 2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i LEG SHIELD REMOVAL Remove the floor board.(2-3) Remove the front panel.(2-2) Remove the 4 screws from the back of the leg shield. Remove the leg shield. Screws Rear Fender Remove the 2 bolts and 2 clips. Remove the rear fender.
  • Page 37 2. FRAME COVERS/EXHAUST MUFFLER Agility Carry / Delivery 50i Handlebar Cover Removal Remove the 4 screws and 1 bolt attaching to the front handlebar cover. Remove the front handlebar cover Screws Bolt Remove the 2 screws and 1 bolt attaching to the rear handlebar cover.

  • Page 38: Inspection/Adjustment

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT SERVICE INFORMATION ....3-0 FINAL REDUCTION GEAR OIL..3- 7 MAINTENANCE SCHEDULE ....3-2 DRIVE BELT ......... 3- 7 FUEL FILTER .......... 3-3 BRAKE SHOE ........3- 8 THROTTLE OPERATION ....3-3 BRAKE ADJUSTING NUT....3- 8 AIR CLEANER ........
  • Page 39 Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT Cylinder compression : 15±2 kg/cm Ignition timing: 20º～29º CHASSIS Front brake free play : 10～20mm Rear brake free play : 10～20mm TIRE PRESSURE 1 Rider 2 Riders Front 1.75kg/cm 1. 75kg/cm Rear 2.0kg/cm 2.25kg/cm TIRE SIZE: Front : 120/70-12...

  • Page 40: Maintenance Schedule

    Your KYMCO dealer meets all of these requirements. * Should be serviced by your KYMCO dealer, unless you have the proper tools, service data and are technically qualified * In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
  • Page 41 Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT...

  • Page 42: Throttle Operation

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT THROTTLE OPERATION 2～6mm Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6mm Major adjustment of the throttle grip free play is made at the throttle body.. Adjust by loosening the lock nut and turning the adjusting nut.

  • Page 43: Air Cleaner

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT AIR CLEANER AIR CLEANER REPLACEMENT Screws Remove the air cleaner case cover screws and the cover by removing the five screws. Remove the air cleaner element by removing the four screws. Check the element and replace it if it is excessively dirty or damaged.

  • Page 44: Valve Clearance

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT Cylinder Head Cover VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the frame cover. (  2-3) Remove the four bolts on the cylinder head cover.

  • Page 45: Ignition Timing

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT IGNITION TIMING Timing Hole Cap Remove the right of the fan cover. Check the ignition timing with a timing light. 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.

  • Page 46: Final Reduction Gear Oil

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT FINAL REDUCTION GEAR OIL OIL LEVEL CHECK ＊ Place the motorcycle on its main stand 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.

  • Page 47: Brake Shoe

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT BRAKE SHOE Punch Mark Arrows 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.

  • Page 48: Headlight Aim

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT If the free play do not fall within the limit, adjust by turning the adjusting nut. Adjusting Nut HEADLIGHT AIM Turn the ignition switch ON and start the engine. Adjust the headlight aim by turning the headlight aim adjusting screw.

  • Page 49: Nuts/Bolts/Fasteners

    Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT REAR Check the action of the rear shock absorber by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
  • Page 50 Agility Carry / Delivery 50i . INSPECTION/ADJUSTMENT STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.

  • Page 51: Lubrication System

    Agility Carry / Delivery 50i . LUBRICATION SYSTEM LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
  • Page 52 Agility Carry / Delivery 50i . LUBRICATION SYSTEM SERVICE INFORMATION ....... 4-1 ENGINE OIL/OIL FILTER ....... 4-2 TROUBLESHOOTING ......4-1 OIL PUMP ..........4-3 SERVICE INFORMATION GENERAL INSTRUCTIONS  The maintenance of lubrication system can be performed with the engine installed in the frame. ...
  • Page 53 Agility Carry / Delivery 50i . LUBRICATION SYSTEM ENGINE OIL/OIL FILTER OIL LEVEL ＊  Place the motorcycle upright on level ground for engine oil level check.  Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
  • Page 54 Agility Carry / Delivery 50i . LUBRICATION SYSTEM Bolts OIL PUMP REMOVAL Remove the A.C. generator flywheel. (  14-7) Remove the A.C. generator stator and pulsar coil. (  14-6) Remove the eight right crankcase cover bolts and the right crankcase cover. Right Crankcase Cover Oil Pump Drive Gear Remove the gasket and dowel pins.
  • Page 55 Agility Carry / Delivery 50i . LUBRICATION SYSTEM Oil Pump Boby DISASSEMBLY Remove the three oil pump boby screws. Disassembly the oil pump. Screws INSPECTION Outer Rotor Measure the pump boby-to-outer rotor clearance. Service Limit: 0.12mm Oil Pump Boby Measure the inner rotor-to-outer rotor Outer Rotor clearance.
  • Page 56 Agility Carry / Delivery 50i . LUBRICATION SYSTEM Outer Rotor Inner Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump boby. ＊ Install the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 57 Agility Carry / Delivery 50i . LUBRICATION SYSTEM Pump Driven Gear Install the pump driven gear and secure it with the circlip. Torque: 0.8～1.2kg-m Circlip Right Crankcase Cover Install the right crankcase cover and tighten the eight bolts. Torque: 0.8~1.2kgf-m ＊...
  • Page 58 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i FUEL INJECTION SYSTEM SYSTEM DIAGRAM ................5 - 1 SYSTEM LOCATION ................5 - 2 SERVICE INFORMATION ..............5 - 3 TROUBLESHOOTING ................. 5 - 4 CHECK ENGINE LAMP (CELP) ............5 - 5 HOW TO SHOW THE FAILURE CODE ..........

  • Page 59: System Diagram

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i KEY ON FUEL PUMP ROLL T-MAP Voltage 曲軸感知器 曲軸感知器 進氣壓力及 感知器 含氧(O2) 大氣壓力感 感知器 知器 INDUCTIVE INJECTOR 進氣壓力及大氣壓力 感知器 IGNITION COIL 感知器 KEY OFF SYSTEM DIAGRAM...
  • Page 60 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Parts Location 01: Inductive ignition coil 02: Fuel pump 03: ECU 04: Fuel injector 05: WTS sensor 06: T-MAP sensor 07: ABV 08: TPS 09: Roll sensor(Angle detect sensor) 10: CPS 11: O2/O2 HT sensor...

  • Page 61: Service Information

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i 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.

  • Page 62: Troubleshooting

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration  Battery voltage too low  Ignition system malfunction  Fuel level too low  Pinched or clogged fuel hose Poor performance (drive ability) and poor ...

  • Page 63: Check Engine Lamp (Celp)

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i CHECK ENGINE LAMP (CELP)  When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU. ...

  • Page 64: How To Show The Failure Code

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i How To Show Failure Code  You can read the failure code by as below :  Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes ...

  • Page 65: Failure Codes Chart

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Failure Code Chart Blink Failure Fault Priority Fault management Codes description P0217 Engine 1.Slow down the vehicle and go to workshop for temperature checking immediately. overheat 2.Confirm if the engine temperature sensor or electric circuit is abnormality.
  • Page 66 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Failure Code Blink Failure Fault description Priority Fault management Codes 1.Make sure if the connector of Throttle position sensor is P1122 Throttle position sensor connected correctly. movement speed 2.Check if theThrottle position sensor is adjusted. problem 1.
  • Page 67 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Failure Code Blink Failure Fault description Priority Fault management Codes 1. Check if the connector of ignition coil is loosen. P0350 Ignition coil or electric 2. Check if the ECU send signal to Ignition coil. circuit malfunction 3.
  • Page 68 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Failure Code Blink Failure Fault description Priority Fault management Codes 1. Check if the lamp of CELP is broken. P0650 CELP electric circuit 2. Check if wires of CELP is broken. malfunction 1.

  • Page 69: Ecu

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i There are 36 pins attaching the ECU. Part number: 3920A-LHB6-900 Voltage inspection Connect the meter (+) probe to the F4(R/W)wire and the meter (-) probe to the H4(G/B) wire to measure the voltage. MAP content (edition issue no.) ALC9 E4ALC9E4TB...

  • Page 70: Fuel Pump

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i FUEL PUMP Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit. Standard : 8~16 V (Battery volt) To measure the resistance of the fuel pump to see if it is short circuit or not.
  • Page 71 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i T-MAP(Manifold Temperature Pressure) Sensor ALC9 Connect the PDA or Fi diagnostic tool. Enter the Data Analyze Check if the manifold pressure data is malfunction. Turn the ignition switch to the “ON” position. If data is incorrect, and the T-map sensor is problem.

  • Page 72: Ets

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i ETS (Engine Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5± 0.25 V Measure the resistance of the WTS Standard (25°...

  • Page 73: O ₂ Sensor

    Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20°C/68°F ): 6.7 ~9.5Ω Connect the PDA or KYMCO Fi diagnostic tool. Enter the Data Analyze Check Page 05 Turn the ignition switch to the “ON” position.

  • Page 74: Roll Sensor

    5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i ROLL SENSOR The engine should be stop when the vehicle incline over 65° for safety. When you place the vehicle back to normal position, you have to key-off and key-on the switch again, then it can be restarted.
  • Page 75 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i 5-17...
  • Page 76 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 ALC9 1 Model No. 8 D ATA Analyze 2 Down Button 9 DTC Inspect 3 DTC indicator (Failure codes) 10 ECU Version 4 Enter or Exit 5 Power indicator 6 UP Button Adjust (TPI and ABV reset function)
  • Page 77 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i DTC INSPECTION Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. Press the " Enter " button ALC9 Check the software version ALC9 Press the " Enter " button and then turn to the first page.
  • Page 78 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Press the " Enter " button to check the DTC number ALC9 Press the " Enter " button Press the " Enter " button Display the DTC number of the DTC-List. Refer to DTC summary list.
  • Page 79 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i Press the " UP " button Press the " Enter " button and then turn to thee previous page. Press the " UP " button ALC9 Press the " Enter " button and then turn to the first page.
  • Page 80 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i DTC CLEAR PROCEDURE Choose " Load DTC " Press the " Down " button Press the " Enter " button The DTC indicator is lighting at that time. Clearing DTC until the DTC indicator is off. 5-23...
  • Page 81 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i DATA ANALYSIS Choose " Data Analyze " ALC9 Press the " Enter " button to enter page 01. The figure includes the engine speed, idle speed and the battery voltage. Refer to standard specification. Press the "...
  • Page 82 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i The figure includes fuel injector interval, ignition advance angle and ABV angle. Refer to standard specification. Press the "Down" button to enter page 05. The figure includes O2 sensor voltage,O2 heater working condition and O2 correction. Refer to standard specification.
  • Page 83 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i ADJUST Need to process the TPI/ABV reset after ALC9 replacing a new ECU or clean Throttle Body. To make ECU set up and set up initially Choose " Adjust " Press the " Enter " button to TPI/ABV Reset Press the "...
  • Page 84 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i DIAGNOSTIC REPORT --- AAF1/ALC9 45km/h Reason of repair: □Maintenance □Breakdown Item Data Reference Memo ECU No Hardware Ver Software Ver QK0A00 Calibration Ver E4AAF 1E4AA Model Name AAF 1 Active Occurred History Air Temp.(°...
  • Page 85 5. FUEL INJECTION SYSTEM Agility Carry / Delivery 50i DIAGNOSTIC REPORT --- AAF1/ALC9 25km/h Reason of repair: □Maintenance □Breakdown Item Data Reference Memo ECU No Hardware Ver Software Ver QK0A00 Calibration Ver E4AAF 125AA Model Name AAF 1 Active Occurred History Air Temp.(°...

  • Page 86: Engine Removal/Installation

    6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION .................. 6-2 ENGINE REMOVAL.................... 6-3 ENGINE INSTALLATION ..................6-6...
  • Page 87 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i...
  • Page 88 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i SERVICE INFORMATION GENERALINSTRUCTIONS • A 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. •...
  • Page 89 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i ENGINE REMOVAL Remove the frame body cover(2-4/5). Disconnect the battery negative cable. Disconnect the engine negative cable. Disconnect the A.C. Generator wire connector. Disconnect the starter motor cable from the starter relay. Starter Relay A.C.G wire connector Spark plug cap...
  • Page 90 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i Remove the air cleaner Remove the exhaust muffler(2-6) Air cleaner Remove the rear brake caliper. Remove one bolt attaching to rear brake hose clamps. Remove the rear shock absorbers mounting bolts. Rear Shock Absorber Bolt...
  • Page 91 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward. Engine Hanger Engine Mounting Bolt Bracket Bolt ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket bolt and nut. Remove the engine.
  • Page 92 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine. Install and tighten the engine hanger bracket bolts. Engine Hanger Engine Mounting Bolt Bracket Bolt ENGINE INSTALLATION Install the engine and tighten the engine mounting bolts.
  • Page 93 6. ENGINE REMOVAL/INSTALLATION Agility Carry / Delivery 50i...

  • Page 94: Cylinder Head/Valves

    Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES...
  • Page 95 Agility Carry / Delivery 50i 7. CYLINDER HEAD/VALVES SERVICE INFORMATION ...... 7-1 CYLINDER HEAD DISASSEMBLY ..7-7 TROUBLESHOOTING ......7-2 CYLINDER HEAD ASSEMBLY ..... 7-8 CAMSHAFT REMOVAL ......7-3 CYLINDER HEAD INSTALLATION ..7-8 CYLINDER HEAD REMOVAL ....7-5 CAMSHAFT INSTALLATION ....7-9 SERVICE INFORMATION GENERAL INSTRUCTIONS ...
  • Page 96 Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head nut 1.8~2.2kgf-m Apply engine oil to threads Valve clearance adjusting nut 0.7~1.1kgf-m Apply engine oil to threads SPECIAL TOOLS Valve spring compressor TROUBLESHOOTING  The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.
  • Page 97 Agility Carry / Delivery 50i 7. CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove the center cover. (  2-3) Cylinder Head Cover Remove the frame center. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the cam chain tensioner sealing bolt and spring.
  • Page 98 Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES Remove the camshaft holder and dowel pins. Camshaft Holder Remove the camshaft gear from the cam Camshaft Dowel Pins chain and remove the camshaft. Cam Chain Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height.
  • Page 99 Agility Carry / Delivery 50i 7. CYLINDER HEAD/VALVES Rocker Arm Shaft CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt. Remove the valve rocker arms. 5mm Bolt Rocker Arm Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
  • Page 100 Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES Remove the cooling fan cover. (  14-6) Remove the engine cover bolts and screws. Separate the engine cover joint claws. Cylinder Head Remove the cylinder head. Bolts Dowel Pins Cylinder Head Gasket Remove the dowel pins and cylinder head gasket.
  • Page 101 Agility Carry / Delivery 50i 7. CYLINDER HEAD/VALVES Valve Spring Compressor CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. ＊  Be sure to compress the valve springs with a valve spring compressor.
  • Page 102 Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES VALVE/ VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: IN : 4.9mm replace if below EX: 4.9mm replace if below Valve Spring Compressor CYLINDER HEAD ASSEMBLY...
  • Page 103 Agility Carry / Delivery 50i 7. CYLINDER HEAD/VALVES Cylinder Head Install the cylinder head. Camshaft Holder CAMSHAFT HOLDER ASSEMBLY First assemble the camshaft holder. Install the intake and exhaust valve rocker arms and rocker arm shafts. ＊  When installing the rocker arm shaft, align the shaft front end with the bolt hole of the camshaft holder.
  • Page 104 Agility Carry / Delivery 50i . CYLINDER HEAD/VALVES Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts and two Washer bolts. Torque: Cylinder head nut: 1.8~2.2kgf-m ＊  Apply engine oil to the threads of the cylinder head nuts.

  • Page 105: Cylinder/Piston

    Agility Carry / Delivery 50i . CYLINDER/PISTON 1.0kg-m Do not bend...
  • Page 106 Agility Carry / Delivery 50i . CYLINDER/PISTON SERVICE INFORMATION ....... 8-1 PISTON REMOVAL ......... 8-2 TROUBLESHOOTING ......8-1 PISTON INSTALLATION ......8-6 CYLINDER REMOVAL ......8-2 CYLINDER INSTALLATION ....8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder and piston can be serviced with the engine installed in the frame. ...
  • Page 107 Agility Carry / Delivery 50i . CYLINDER/PISTON Cylinder CYLINDER REMOVAL Remove the cylinder head. (  7-6) Remove the cam chain guide. Remove the cylinder. Dowel Pins Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.
  • Page 108 Agility Carry / Delivery 50i . CYLINDER/PISTON Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 109 Agility Carry / Delivery 50i . CYLINDER/PISTON Measure the piston pin O.D. Service Limit:12.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90 to the piston pin hole. Service Limit: 38.9mm replace if below Measure the piston-to-piston pin clearance.
  • Page 110 Agility Carry / Delivery 50i . CYLINDER/PISTON Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 13.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.
  • Page 111 Agility Carry / Delivery 50i . CYLINDER/PISTON PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Piston Pin Clip Install the piston, piston pin and a new piston pin clip.
  • Page 112 Agility Carry / Delivery 50i . CYLINDER/PISTON Install the cam chain guide. ＊ Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head. (  7-8) Loosely install the cylinder base bolts. Cam Chain Guide Tighten the cylinder base bolts.

  • Page 113: Drive And Driven Pulleys

    9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i...
  • Page 114 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i SERVICE INFORMATION ....... 9-1 DRIVE BELT ........... 9-3 TROUBLESHOOTING ......9-1 DRIVE PULLEY ........9-4 LEFT CRANKCASE COVER ....9-2 CLUTCH/DRIVEN PULLEY ....9-7 SERVICE INFORMATION GENERAL INSTRUCTIONS  The drive pulley, clutch and driven pulley can be serviced with the engine installed. ...
  • Page 115 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Anti-modification Bolt Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Remove the 7 left crankcase cover bolts and two Anti-modification Bolts . Remove the seal gasket and dowel pins. Inspect the seal gasket for damage or deterioration.
  • Page 116 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i DRIVE BELT REMOVAL Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm REPLACEMENT Clutch Outer Remove the eight left crankcase cover bolts and left crankcase cover.
  • Page 117 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley. Drive Belt Set the drive belt on the drive pulley face Drive Belt Drive Pulley Face Drive Face Nut...
  • Page 118 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Ramp Plate Remove the ramp plate. Weight Roller Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 12.4mm replace if below Check the drive pulley collar for wear or damage.
  • Page 119 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Movable Drive Face INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft. Drive Pulley Collar Set the drive belt on the drive pulley collar. Install the drive pulley face and tighten the drive face nut.
  • Page 120 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Clutch Outer CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. (  9-6) Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch outer. Special Universal Holder Universal Holder...
  • Page 121 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Oil Seal Movable Driven Face Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Remove the O-rings and oil seal from the movable driven face.
  • Page 122 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Check the driven face for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over Inner Bearing DRIVEN PULLEY FACE BEARING...
  • Page 123 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Driver Handle Press a new needle bearing into the driven face. Outer Driver, 24x26mm Pilot, 17mm Movable Driven Face Oil Seal ASSEMBLY Install the movable driven face onto the driven face. Install the O-rings, guide rollers and guide roller pins.
  • Page 124 9. DRIVE AND DRIVEN PULLEYS Agility Carry / Delivery 50i Clutch/Driven Pulley INSTALLATION Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft. Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder.

  • Page 125: Final Reduction

    Agility Carry / Delivery 50i . FINAL REDUCTION 10-0...
  • Page 126 . FINAL REDUCTION Agility Carry / Delivery 50i SERVICE INFORMATION ....... 10-1 FINAL REDUCTION INSPECTION ..10-2 TROUBLESHOOTING ......10-1 BEARING REPLACEMENT ....10-3 FINAL REDUCTION DISASSEMBLY ..10-2 FINAL REDUCTION ASSEMBLY ..10-4 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0.18 liter At change...
  • Page 127 Agility Carry / Delivery 50i . FINAL REDUCTION Drive Shaft FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. (  13-3) Remove the rear wheel. (  13-2) Remove the left crankcase cover. (  9-2) Remove the clutch/driven pulley. (  9-10) Drain the transmission gear oil into a clean container.
  • Page 128 . FINAL REDUCTION Agility Carry / Delivery 50i Inspect the drive shaft and gear for wear or damage. Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage. ＊ Do not remove the transmission case cover except for necessary part replace-ment.
  • Page 129 Agility Carry / Delivery 50i . FINAL REDUCTION BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing puller. Special Bearing Puller Bearing Puller, 12mm Drive new bearings into the left crankcase. Install a new drive shaft oil seal.
  • Page 130 . FINAL REDUCTION Agility Carry / Delivery 50i Resin Washer Countershaft Install the countershaft and gear into the left crankcase. Install the resin washer onto the countershaft. Install the dowel pins and a new gasket. Gasket Dowel Pins Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.
  • Page 131 Agility Carry / Delivery 50i . FINAL REDUCTION 10-0...
  • Page 132 . FINAL REDUCTION Agility Carry / Delivery 50i SERVICE INFORMATION ....... 10-1 FINAL REDUCTION INSPECTION ..10-2 TROUBLESHOOTING ......10-1 BEARING REPLACEMENT ....10-3 FINAL REDUCTION DISASSEMBLY ..10-2 FINAL REDUCTION ASSEMBLY ..10-4 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0.18 liter At change...
  • Page 133 Agility Carry / Delivery 50i . FINAL REDUCTION Drive Shaft FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. (  13-3) Remove the rear wheel. (  13-2) Remove the left crankcase cover. (  9-2) Remove the clutch/driven pulley. (  9-10) Drain the transmission gear oil into a clean container.
  • Page 134 . FINAL REDUCTION Agility Carry / Delivery 50i Inspect the drive shaft and gear for wear or damage. Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage. ＊ Do not remove the transmission case cover except for necessary part replace-ment.
  • Page 135 Agility Carry / Delivery 50i . FINAL REDUCTION BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing puller. Special Bearing Puller Bearing Puller, 12mm Drive new bearings into the left crankcase. Install a new drive shaft oil seal.
  • Page 136 . FINAL REDUCTION Agility Carry / Delivery 50i Resin Washer Countershaft Install the countershaft and gear into the left crankcase. Install the resin washer onto the countershaft. Install the dowel pins and a new gasket. Gasket Dowel Pins Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.

  • Page 137: Crankcase/Crankshaft

    Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT 11-0...
  • Page 138 Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT SERVICE INFORMATION ....... 11-1 CRANKSHAFT ........11-3 TROUBLESHOOTING ......11-1 CRANKCASE ASSEMBLY ....11-4 CRANKCASE SEPARATION ....11-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.
  • Page 139 Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt and cam chain tensioner slipper. Cam Chain Tensioner Slipper Bolt Crankcase Bolt Remove the crankcase attaching bolt. Separate the left and right crankcase halves. ＊...
  • Page 140 Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Oil Seal Remove the oil seal from the left crankcase. Oil Seal Remove the oil seal from the right crankcase. CRANKSHAFT Measure the connecting rod big end side clearance.
  • Page 141 Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT Measuring Location Measure the connecting rod big end radial clearance at two points at right angels to the shaft. Service Limit: 0.05mm replace if over Measure the crankshaft runout. Service Limit: 0.10mm replace if over Crankshaft Bearings Turn the crankshaft bearings and check for excessive play.
  • Page 142 Agility Carry / Delivery 50i . CRANKCASE/CRANKSHAFT Cam Chain Install the cam chain into the left crankcase. Install the crankshaft into the left crankcase. ＊ When installing the cam chain, be careful not to damage the oil seal. Gasket Install the dowel pins and a new gasket onto the left crankcase.

  • Page 143: Front Wheel/Front Brake/ Front Suspension

    . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 12-0...
  • Page 144 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION SERVICE INFORMATION ..... 12-1 FRONT BRAKE........12- 7 TROUBLESHOOTING ......12-2 FRONT SHOCK ABSORBER....12-18 STEERING HANDLEBAR ....... 12-3 FRONT FORK ......... 12-21 FRONT WHEEL........12-4 SERVICE INFORMATION GENERAL INSTRUCTIONS ...
  • Page 145 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling  Excessively tightened steering stem top  Bent rim  Excessive wheel bearing play cone race  Broken steering balls  Bent spoke plate ...
  • Page 146 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. (  2-2) Remove the two bolts attaching each of the front and rear brake levers. Remove the front and rear brake levers. Bolts Bolts Throttle Pipe...
  • Page 147 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION Throttle Cable Apply grease to the tip of the throttle pipe. Brake Levers Install the throttle pipe and connect the throttle cable. Install the front and rear brake levers in the reverse order of removal.
  • Page 148 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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. Play Axial Radial...
  • Page 149 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION Bearing Puller Remove the front wheel bearings and distance collar. Special Bearing Puller ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing.
  • Page 150 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION Side Collar Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Dust Seal INSTALLATION Apply grease to the brake panel dust seal lip. Apply grease to the speedometer gear engaging and sliding parts.
  • Page 151 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION HYDRAULIC BRAKE (FRONT BRAKE) Brake Fluid Replacement/Air Bleeding Upper Limit 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 152 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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. Remove the brake pad pins to remove the brake pads.
  • Page 153 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 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 plastic parts and coated surfaces to avoid being contaminated by brake fluid.
  • Page 154 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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 155 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION Disassembly Remove the brake caliper seat from the brake caliper. Brake Caliper Seat Remove the piston from the brake caliper. Compressed Air If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.
  • Page 156 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION Place the brake master cylinder on the handlebar Punch Mark Bolts and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint.
  • Page 157 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 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 158 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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 159 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 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 160 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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 Absorber Shock...
  • Page 161 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 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 162 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery FRONT SUSPENSION 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 163 . FRONT WHEEL/FRONT BRAKE/ Agility Carry / Delivery 50i FRONT SUSPENSION 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 Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and...

  • Page 164: Rear Wheel/Rear Brake/ Rear Suspension

    . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION 13-0...
  • Page 165 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION 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 166 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION REAR WHEEL REMOVAL Remove the exhaust muffler. (  2-5) Remove the rear axle nut. Remove the rear wheel. Rear Axle Nut INSPECTION Measure the rear wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over...
  • Page 167 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION 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 168 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION Apply a small amount of engine oil to the felt seal and install it to the brake cam. Install the brake arm. ＊ Align the wide groove on the wear indicator plate with the wide tooth of the brake cam.
  • Page 169 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION INSPECTION Lock Nut Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Measure the rear shock absorber spring free Spring length.
  • Page 170 . REAR WHEEL/REAR BRAKE/ Agility Carry / Delivery 50i REAR SUSPENSION 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 171: Battery/Charging System/A.c

    . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR Fuse Regulator/Rectifier A.C. Generator 14-0...
  • Page 172 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR SERVICE INFORMATION ...... 14-1 A.C. GENERATOR CHARGING COIL ..14-6 TROUBLESHOOTING ......14-2 A.C. GENERATOR REMOVAL ..... 14-6 BATTERY ..........14-3 A.C. GENERATOR INATALLATION ..14-8 CHARGING SYSTEM ......14-4 REGULATOR/RECTIFIER ......
  • Page 173 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR TORQUE VALUES Pulser coil bolt 0.45~0.6kgf-m Stator bolt 0.8~1.2kgf-m Flywheel nut 3.5~4.5kgf-m Cooling fan bolt 0.8~1.2kgf-m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power...
  • Page 174 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR BATTERY 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 When disconnecting the battery positive (+) cable, do not touch the frame with tool;...
  • Page 175 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR Battery 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 176 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator/rectifier connectors. Check the connectors for loose contacts of corroded terminals. Regulator/Rectifier BATTERY WIRE Measure the voltage between the Red/White wire terminal and ground.
  • Page 177 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. A.C GENERATOR INSPECTION This test can be made without removing the staor from the engine.Disconnect the yellow wire from the auto-bystarter.
  • Page 178 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR 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.
  • Page 179 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR Bolts Remove the A.C. generator wire set plate. 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 180 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR Clean the taper hole in the flywheel off any A.C. Generator Wire Connector burrs and dirt. Install the woodruff key in the crankshaft keyway. Woodruff Key Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
  • Page 181 . BATTERY/CHARGING SYSTEM/ Agility Carry / Delivery 50i A.C. GENERATOR Install the fan cover. Install the right side cover. (  2-4) Fan Cover 14-10...

  • Page 182: Ignition System

    Agility Carry / Delivery 50i . IGNITION SYSTEM Ignition Switch A.C. Generator Spark Plug 15-0...
  • Page 183 Agility Carry / Delivery 50i . IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS  Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present.  When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2. ...
  • Page 184 Agility Carry / Delivery 50i . IGNITION SYSTEM 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. SPARK PLUG Spark plug inspection and adjustment Ignition Coil IGNITION COIL CONTINUITY TEST...
  • Page 185 Agility Carry / Delivery 50i . IGNITION SYSTEM A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler.

  • Page 186: Starting System

    Agility Carry / Delivery 50i . STARTING SYSTEM Starter Relay Starter Motor Starter Button Starter Relay Ignition Switch Fuse Stoplight Battery Front Rear Starter Motor Stop Switches 16-0...
  • Page 187 Agility Carry / Delivery 50i . STARTING SYSTEM 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)
  • Page 188 Agility Carry / Delivery 50i . STARTING SYSTEM 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 189 Agility Carry / Delivery 50i . STARTING SYSTEM 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 and there should be continuity.
  • Page 190 Agility Carry / Delivery 50i . STARTING SYSTEM ASSEMBLY Front Cover Commutator 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.
  • Page 191 Agility Carry / Delivery 50i . STARTING SYSTEM STARTER RELAY TEST Remove the battery cover. Disconnect the 4P connector from the starter relay and remove the starter relay. Starter Relay Connect the starter relay (D) terminal to the 12V battery positive (+) terminal and the relay (C) terminal to the battery negative (-) terminal.

  • Page 192: Lights/Instruments/Switches

    17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i 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 ...
  • Page 193 17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i 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 194 17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i 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 STARTER SWITCH Color Yellow/Red Green...
  • Page 195 17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i 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.
  • Page 196 17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i HORN Horn INSPECTION Remove the front covers. (  2-2) Disconnect the horn wire coupler. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals. REPLACEMENT Disconnect the horn wire coupler.
  • Page 197 17. LIGHTS/INSTRUMENTS/SWITCHES Agility Carry / Delivery 50i HEADLIGHT Screw REMOVAL Remove the screw on the front of the front cover. Remove the 4 screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.

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Delivery 50i

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