Table Of Contents - KYMCO AGILITY 125 Service Manual

Table of Contents

Product Overview2
Table Of Contents3
General Information4
Engine Serial Number4
Specifications5
Service Precautions6
Symbols13
Torque Values14
Standard Torque Values14
Engine14
Frame14
Special Tools15
Lubrication Points16
Cable & Harness Routing18
Wiring Diagram23
Troubleshooting24
Engine Will Not Start Or Is Hard To Start24
Engine Lacks Power25
Poor Performance (Especially At Idle And Low Speeds)26
Poor Performance (At High Speed)27
Poor Charging (Battery Over Discharging Or Overcharging)28
Undercharging28
Overcharging28
No Spark At Spark Plug29
Schematic Drawing30
Frame Covers/Exhaust Muffler31
Frame Covers32
Handlebar Front/Rear Cover Removal32
Met-In Box Removal33
Frame Body Cover Removal33
Floor Board Removal34
Bottom Protector Cover Removal34
Leg Shield Removal35
Front Fender Removal35
Exhaust Muffler Removal35
Inspection/Adjustment36
Maintenance Schedule38
Fuel Filter39
Throttle Operation39
Air Cleaner Replacement40
Change Interval40
Spark Plug40
Valve Clearance41
Carburetor Idle Speed41
Ignition Timing42
Cylinder Compression42
Final Reduction Gear Oil43
Oil Level Check43
Oil Change43
Drive Belt43
Agility43
Brake Shoe44
Rear Brake44
Brake Fluid44
Brake Adjusting Nut44
Headlight Aim45
Clutch Shoe Wear45
Suspension45
Nuts/Bolts/Fasteners46
Wheels/Tires46
Steering Handlebar47
Lubrication System48
Engine Oil/Oil Filter50
Oil Pump51
Fuel System55
Carburetor Removal59
Auto Bystarter59
Auto Bystarter Inspection60
Air Cut-Off Valve61
Vacuum Chamber61
Float Chamber63
Float Level Inspection64
Accelerating Pump65
Carburetor Installation66
Pilot Screw Adjustment67
Fuel Tank Remove68
Fuel Strainer Removal68
Fuel Unit69
Air Cleaner69
Fuel Tank69
Engine Removal/Installation71
Engine Hanger Bracket75
Engine Installation75
Cylinder Head/Valves77
Camshaft Removal80
Camshaft Inspection81
Camshaft Holder Disassembly82
Camshaft Holder Inspection82
Cylinder Head Removal82
Cylinder Head Disassembly84
Cylinder Head84
Valve Spring Free Length84
Valve/Valve Guide85
Cylinder Head Assembly85
Cylinder Head Installation85
Camshaft Holder Assembly86
Camshaft Installation86
Cam Chain Tensioner Installation87
Cylinder/Piston88
Cylinder Removal90
Piston Removal90
Cylinder Inspection92
Piston Ring Installation93
Piston Installation94
Cylinder Installation94
Drive And Driven Pulleys/Kick Starter96
Left Crankcase Cover98
Kick Starter98
Left Crankcase Cover Installation100
Drive Pulley102
Starter Pinion104
Clutch/Driven Pulley105
Driven Pulley Face Bearing Replacement107
Final Reduction110
Final Reduction Disassembly112
Final Reduction Inspection112
Bearing Replacement (Transmission Case Cover)113
Bearing Replacement (Left Crankcase)114
Final Reduction Assembly114
Crankcase/Crankshaft116
Crankcase Separation118
Crankshaft119
Crankcase Assembly120
Front Wheel/Front Brake/ Front Suspension123
Front Wheel127
Axle Runout127
Wheel Rim128
Bearing Puller129
Front Brake130
Hydraulic Brake (Front Brake)133
Brake Fluid Bleeding133
Brake Fluid Refilling133
Brake Pad/Disk Replacement134
Brake Disk134
Brake Master Cylinder135
Brake Caliper (Front)138
Front Shock Absorber141
Front Fork144
Bottom Race Replacement144
Rear Wheel /Rear Brake /Rear Suspension146
Rear Wheel148
Brake Lining Inspection149
Rear Brake Disassembly149
Rear Brake Assembly149
Rear Shock Absorber150
Battery/Charging System/A.c. Generator153
Battery156
Battery Voltage (Open Circuit Voltage) Inspection156
Charging156
Charging System157
Short Circuit Test157
Current Test157
Lighting System Limit Voltage Inspection157
Regulator/Rectifier158
Main Harness Circuit Inspection158
Regulator/Rectifier Inspection158
A.c. Generator Charging Coil159
A.c. Generator Lighting Coil159
Resistor Inspection159
A.c. Generator159
A.c. Generator Installation161
Ignition System164
Cdi Unit Inspection167
Ignition Coil168
Continuity Test168
Pulser Coil169
Ignition Timing Inspection169
Starting System170
Starter Motor172
Starter Motor Case Continuity Check173
Starter Relay174
Starter Relay Voltage Inspection174
Starter Relay Test175
Starter Motor Installation175
Lights/Instruments/Switches176
Fuel Gauge Inspection177
Handlebar Switches178
Headlight Switch178
Starter Switch178
Dimmer Switch178
Horn Switch179
Switch Replacement179
Ignition Switch179
Ignition Switch Replacement179
Stop Switch180
Horn180
Instruments180
Headlight181
Bulb Replacement181
Taillight/Stoplight/Rear Turn Signal Light/License Light181
Evaporative/Exhaust Emission Control System182
Exhaust Emission Control System Diagram182
Exhaust Emission Control System183
Function183
Service Information183
Secondary Air Cleaner183
Air Injection Cut-Off Valve (A.i.c.v.)183
Reed Valve183
Exhaust Muffler183
Periodic Maintenance184
Irregular Maintenance184
Schematic Diagram186