KYMCO AGILITY 125 Service Manual

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Service manual (252 pages)

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Table Of Contents

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Table of Contents

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See also: Driver Manual , Owner's Manual

Agility 50 - 125

Table of Contents

Troubleshooting

Summary of Contents for KYMCO AGILITY 125

Page 1 Agility 50 - 125...
Page 2: Product Overview
1.835 x 690 x 1.125mm 1.835 x 690 x 1.125mm MASSA 84kg 92kg 105kg 105kg COLORI argento nero argento nero rosso giallo giallo 2616-040407 KYMCO SI RISERVA DI APPORTARE VARIAZIONI TECNICHE, ESTETICHE O DI ALTRA NATURA SENZA L’OBBLIGO DI ALCUN PREAVVISO.
Page 3: Table Of Contents
TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing FRAME COVERS/EXHAUST MUFFLER procedures for the KYMCO AGILITY INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual. Read FUEL SYSTEM...
Page 4: Engine Serial Number
. GENERAL INFORMATION AGILITY 50 ENGINE SERIAL NUMBER ....1- 1 LUBRICATION POINTS .......1-13 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 AGILITY 50 Location of Engine Serial Number...
Page 5: Specifications
. GENERAL INFORMATION AGILITY 50 SPECIFICATIONS Air cleaner type & No Paper element, wet Motorcycle Name & Type AGILITY 50 Fuel capacity 5.0 liter Name & Model No. KG10SA Type Overall length (mm) 1830 Piston dia. (mm) Overall width (mm) Venturi dia.(mm) 17equivalent Overall height (mm)
Page 6: Service Precautions ...................... 1
. GENERAL INFORMATION AGILITY 50 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 7 . GENERAL INFORMATION AGILITY 50 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
Page 8 . GENERAL INFORMATION AGILITY 50 If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
Page 9 . GENERAL INFORMATION AGILITY 50 The connector shall be inserted completely. Snapping! 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.
Page 10 . GENERAL INFORMATION AGILITY 50 After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 11 . GENERAL INFORMATION AGILITY 50 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 When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 12 . GENERAL INFORMATION AGILITY 50 After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 13 . GENERAL INFORMATION AGILITY 50 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication. Grease : Transmission Gear Oil (90#) Gear Oil...
Page 14 . GENERAL INFORMATION AGILITY 50 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 3.0-4.0...
Page 15 . GENERAL INFORMATION AGILITY 50 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page 10-3 Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 10-4 12-6 Bushing remover L E032 11102 bush engine hanger rubber Bushing remover S EO19 11203 bush rear cushion under rubber Crankshaft bearing puller E030 91005 radial bearing...
Page 16: Lubrication Points
AGILITY 50 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE15W-40) Cam lobes API SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
Page 17 . GENERAL INFORMATION AGILITY 50 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle. Grease Front Brake Lever Pivot...
Page 18 . GENERAL INFORMATION AGILITY 50 CABLE & HARNESS ROUTING Winker Brake Master Cylinder Rear Stop Switch Wire Front Stop Switch Wire Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Front Brake Fluid Tube Horn Regulator/Rectifier 1-15...
Page 19 . GENERAL INFORMATION AGILITY 50 Throttle Grip Regulator/Rectifier Ignition Switch Speedometer Cable Headlight Resistor Rear Brake Lever Horn Front Brake Fluid Tube 1-16...
Page 20 . GENERAL INFORMATION AGILITY 50 CDI Unit Fuse Battery (+) Cable Battery (-) Cable Starter Relay Fuel Tank Battery (-) Cable Battery (+) Cable Ignition Coil 1-17...
Page 21 . GENERAL INFORMATION AGILITY 50 Auto Cock Assy Fuel Fuel Filter Fuel Tube Ignition Coil Primary Wire Ignition Wire Throttle Cable Vacuum Tee Carburetor Overflow Tube Crankcase Breather Tube 1-18...
Page 22 . GENERAL INFORMATION AGILITY 50 Fuel Unit Crankcase Breather Tube Throttle Cable Wire Throttle Cable Vacuum Tube Vacuum Tube Ignition Coil Crankcase Breather Tube Secondary Air Inlet Tube Reed Valve Air Injection Cut-off Valve Fuel Tube Auto Bystarter 1-19...
Page 23 . GENERAL INFORMATION AGILITY 50 WIRING DIAGRAM 1-20...
Page 24 . GENERAL INFORMATION AGILITY 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel reaches Fuel does not Clogged fuel tank cap breather...
Page 25 . GENERAL INFORMATION AGILITY 50 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate Clogged air cleaner lightly for observation Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed does not Engine speed Faulty auto bystarter increase sufficiently increases...
Page 26 . GENERAL INFORMATION AGILITY 50 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Incorrect timing Correct timing Faulty pulser coil Check carburetor pilot screw adjustment Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out)
Page 27 . GENERAL INFORMATION AGILITY 50 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Correctly adjusted Incorrectly adjusted Worn camshaft Worn valve seat Check fuel pump for fuel supply...
Page 28 . GENERAL INFORMATION AGILITY 50 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
Page 29 . GENERAL INFORMATION AGILITY 50 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty old spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose spark plug cap...
Page 30 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 SCHEMATIC DRAWING...
Page 31 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 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. Items Related for Removal Handlebar front cover Handlebar rear cover...
Page 32 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 Screw FRAME COVERS FRONT COVER REMOVAL Remove the screw on the front of the front cover. Remove the six screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.
Page 33 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 Bolt MET-IN BOX REMOVAL Open the seat and remove the two nuts and three bolt attaching the met-in box. Remove the met-in box . Bolts Center Cover FRAME BODY COVER REMOVAL Remove the center cover. Rear Carrier Remove the three bolts attaching the rear carrier.
Page 34 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 Seat Lock Wire Frame Body Discornnect the seat lock wire. Cover Remove the frame body cover. The installation sequence is the reverse of remove Remove the three bolts attaching each of the right and left side covers. Remove the right and left side covers.
Page 35 . FRAME COVERS/EXHAUST MUFFLER AGILITY 50 Leg shield Decorative Ring LEG SHIELD REMOVAL Remove the bolt leg shield. Remove the ignition switch decorative ring Remove the leg shield. Bolt Bolts F RONT FENDER REMOVAL Remove the two bolts attaching the front fender bracket.
Page 36 . INSPECTION/ADJUSTMENT AGILITY 50 SERVICE INFORMATION....3-0 FINAL REDUCTION GEAR OIL..3- 7 MAINTENANCE SCHEDULE....3-2 DRIVE BELT.........3- 7 FUEL FILTER..........3-3 BRAKE SHOE ........3- 8 THROTTLE OPERATION.....3-3 BRAKE ADJUSTING NUT....3- 8 AIR CLEANER ........3-4 HEADLIGHT AIM .......3- 9 SPARK PLUG ..........3-4 CLUTCH SHOE WEAR.......3- 9 VALVE CLEARANCE......3-5 SUSPENSION ........3- 9 CARBURETOR IDLE SPEED ....3-5...
Page 37 . INSPECTION/ADJUSTMENT AGILITY 50 Cylinder compression : 16 kg/cm Ignition timing: BTDC 28 /4000rpm CHASSIS Front brake free play: 10 20mm Rear brake free play : 10 20mm TIRE PRESSURE 1 Rider 2 Riders Front 1.5kg/cm 1.75kg/cm Rear 2.0kg/cm 2.25kg/cm TIRE SIZE: Front : 120 / 70 - 12 Rear : 130/70 - 12...
Page 38 Steering head bearing In 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.
Page 39 . INSPECTION/ADJUSTMENT AGILITY 50 Fuel Filter FUEL FILTER Remove the met-in box. ( 2-3) 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. Fuel Line 2 6mm THROTTLE OPERATION...
Page 40 . INSPECTION/ADJUSTMENT FILLY LX 50 Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the air cleaner case cover screws and the cover by removing the seven screws. Remove the air cleaner element by removing the four screws. Check the element and replace it if it is excessively dirty or damaged.
Page 41 . INSPECTION/ADJUSTMENT AGILITY 50 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 six bolts on the cylinder head cover. Remove the cylinder head cover. ( 7-3) Remove the cylinder head cover..
Page 42 . INSPECTION/ADJUSTMENT FILLY LX 50 Timing Hole Cap IGNITION TIMING The CDI unit is not adjustable. If the ignition timing is incorrect, check the ignition system. ( 15-5) Remove the right of the fan cover. Timing Light Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F”...
Page 43 . INSPECTION/ADJUSTMENT AGILITY 50 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 44 . INSPECTION/ADJUSTMENT FILLY LX 50 Punch Mark BRAKE SHOE 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 45 . INSPECTION/ADJUSTMENT AGILITY 50 If the free play do not fall within the limit, adjust by turning the adjusting nut. Adjusting Nut Front Cover 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.
Page 46 . INSPECTION/ADJUSTMENT FILLY LX 50 REAR Check the action of the rear shock absorber by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
Page 47 . INSPECTION/ADJUSTMENT AGILITY 50 STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.
Page 48 . LUBRICATION SYSTEM AGILITY 50 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 49 . LUBRICATION SYSTEM AGILITY 50 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. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 50: Engine Oil/Oil Filter
. LUBRICATION SYSTEM AGILITY 50 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. Remove the oil dipstick and check the oil level with the oil dipstick.
Page 51 . LUBRICATION SYSTEM AGILITY 50 Bolt 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 Remove the gasket and dowel pins.
Page 52 . LUBRICATION SYSTEM AGILITY 50 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 53: Agility
. LUBRICATION SYSTEM AGILITY 50 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 54 . LUBRICATION SYSTEM AGILITY 50 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 Diagonally tighten the bolts in 2 3 times.
Page 55 . FUEL SYSTEM AGILITY 50...
Page 56 . FUEL SYSTEM AGILITY 50 Ignition Switch Regulator /Rectifier Fuse 12V Battery Lighting System Auto Bystarter...
Page 57 . FUEL SYSTEM AGILITY 50 SERVICE INFORMATION.......5-2 ACCELERATING PUMP .......5-10 TROUBLESHOOTING......5-3 CARBURETOR INSTALLATION..5-11 CARBURETOR REMOVAL.....5-4 PILOT SCREW ADJUSTMENT ....5-12 AUTO BYSTARTER .........5-4 FUEL TANK..........5-13 AIR CUT-OFF VALVE ......5-6 FUEL UNIT ..........5-14 VACUUM CHAMBER ......5-6 AIR CLEANER ........5-14 FLOAT CHAMBER........5-8 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous.
Page 58 . FUEL SYSTEM AGILITY 50 TROUBLESHOOTING Engine is hard to start Misfiring during acceleration No spark at plug ( Section 15) Faulty ignition system Compression too low Lean mixture No fuel to carburetor Faulty accelerating pump Clogged fuel filter Engine idles roughly, stalls or runs poorly Restricted fuel line Clogged fuel system Faulty float valve...
Page 59 . FUEL SYSTEM AGILITY 50 CARBURETOR REMOVAL Remove the frame right side cover. ( 2-4) Disconnect the auto bystarter wire connector. Remove the met-in box. ( 2-3) Auto Bystarter Wire Auto Bystarter Loosen the drain screw and drain the fuel from the float chamber.
Page 60 . FUEL SYSTEM AGILITY 50 Vacuum Pump 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.
Page 61 . FUEL SYSTEM AGILITY 50 Screws Screws AIR CUT-OFF VALVE DISASSEMBLY Remove the two screws attaching the throttle cable set plate and the set plate. Remove the two screws attaching the air cut-off valve. Remove the spring and vacuum diaphragm. Check the vacuum diaphragm for cracks or damage and check each passage for clogging.
Page 62 . FUEL SYSTEM AGILITY 50 Remove the needle holder and jet needle. Be careful not to damage the vacuum diaphragm. Jet Needle INSPECTION Inspect the needle for stepped wear. Inspect the vacuum piston for wear or damage. Inspect the diaphragm for deterioration and tears.
Page 63 . FUEL SYSTEM AGILITY 50 Screws FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Float Chamber Float Float Valve Loosen the float pin screw. Remove the float pin, float and float valve. Float Pin Needle Jet Holder Slow Jet Remove the main jet, needle jet holder, needle jet, slow jet and pilot screw.
Page 64 . FUEL SYSTEM AGILITY 50 Valve Seat 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 and valve seat must be replaced because it will result in float level too high due to incomplete airtightness.
Page 65 . FUEL SYSTEM AGILITY 50 Screws Diaphragm ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration. Replace if necessary. Diaphragm Check each accelerating pump fuel passage for clogging...
Page 66 . FUEL SYSTEM AGILITY 50 Connecting Tube Band CARBURETOR INSTALLATION Throttle Cable 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.
Page 67 . FUEL SYSTEM AGILITY 50 PILOT SCREW ADJUSTMENT * ADJUSTMENT The pilot screw is factory pre-set and no adjustment is necessary. During carburetor disassembly, note the number of turns of the pilot screw and use as a reference when reinstalling it. Place the motorcycle on its main stand on level ground for this operation.
Page 68 . FUEL SYSTEM AGILITY 50 Fuel Tank FUEL TANK REMOVE Remove the net-in box. ( 2-3) Remove the frame center cover. Remove the frame body cover. ( 2-3) Remove the four bolts on the fuel tank, take the upper seat lock off. Disconnect the fuel unit wire connector.
Page 69 . FUEL SYSTEM AGILITY 50 Fuel Unit Wire 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.
Page 70 . FUEL SYSTEM AGILITY 50 The installation sequence is the reverse of removal. 5-15...
Page 71 . ENGINE REMOVAL/INSTALLATION FILLY LX 50...
Page 72 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 SERVICE INFORMATION ...... 6-1 ENGINE INSTALLATION .......6-4 ENGINE REMOVAL ........ 6-2 SERVICE INFORMATION GENERAL INSTRUCTIONS A 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. Use shop towels to protect the motorcycle body during engine removal.
Page 73 . ENGINE REMOVAL/INSTALLATION FILLY LX 50 ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. ( 2-3) Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Disconnect the A.C. generator wire connector. Negative Cable Auto Bystarter Wire Connector Disconnect the starter motor cable and earth cable from the starter motor.
Page 74 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 Air Tube Band Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube. connecting tube Remove the rear brake adjusting nut, connector pin rear brake cable. Adjusting Nut Rear Shock Absorber Upper Mount Bolt Remove the rear shock absorber upper mount bolt.
Page 75 . ENGINE REMOVAL/INSTALLATION FILLY LX 50 ENGINE HANGER BRACKET REMOVAL Remove the return spring from the main stand. Remove the main stand. Main Stand Return Spring Bushing Remove the engine hanger bracket bolts and engine hanger bracket. Inspect the engine hanger bushings and stopper spring for wear or damage.
Page 76 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 Install the removed parts in the reverse order Rear Shock Absorber Upper Mount Bolt of removal. Route the wires and cables properly. After installation, inspect and adjust the following: Throttle grip free play ( 3-3) Rear brake adjustment ( 3-8)
Page 77 . CYLINDER HEAD/VALVES AGILITY...
Page 78 7. CYLINDER HEAD/VALVES FILLY LX 50 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 The cylinder head can be serviced with the engine installed in the frame. When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication.
Page 79 . CYLINDER HEAD/VALVES AGILITY 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 80 7. CYLINDER HEAD/VALVES FILLY LX 50 Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. ( 2-3) Remove the frame center. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the cam chain tensioner sealing bolt Sealing Bolt Bolts and spring.
Page 81 . CYLINDER HEAD/VALVES AGILITY Camshaft Holder Remove the camshaft holder and dowel pins. Camshaft Dowel Pins Remove the camshaft gear from the cam 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 82 7. CYLINDER HEAD/VALVES FILLY LX 50 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 83 . CYLINDER HEAD/VALVES AGILITY 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 Cylinder Head Gasket Dowel Pins Remove the dowel pins and cylinder head gasket.
Page 84 7. CYLINDER HEAD/VALVES FILLY LX 50 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. Mark all disassembled parts to ensure correct reassembly.
Page 85 . CYLINDER HEAD/VALVES AGILITY VALVE/ VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: IN : 4.9mm replace if below EX: 4.9mm replace if below CYLINDER HEAD ASSEMBLY Valve Spring Compressor When assembling, a valve spring...
Page 86 7. CYLINDER HEAD/VALVES FILLY LX 50 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 87 . CYLINDER HEAD/VALVES AGILITY Washer Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts and two bolts. Torque: Cylinder head nut: 1.8~2.2kgf-m Apply engine oil to the threads of the cylinder head nuts. Diagonally tighten the cylinder head nuts in 2 3 times.
Page 88 . CYLINDER/PISTON AGILITY 50 1.0kg-m Do not bend...
Page 89 . CYLINDER/PISTON AGILITY 50 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. After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Item Standard (mm)
Page 90 . CYLINDER/PISTON AGILITY 50 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. Gasket Piston Pin PISTON REMOVAL Remove the piston pin clip.
Page 91 . CYLINDER/PISTON AGILITY 50 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 92 . CYLINDER/PISTON AGILITY 50 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. Service Limit: 0.02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage.
Page 93 . CYLINDER/PISTON AGILITY 50 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 13.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.
Page 94 . CYLINDER/PISTON AGILITY 50 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. Position the piston “IN” mark on the intake valve side.
Page 95 . CYLINDER/PISTON AGILITY 50 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. Cylinder Base Bolts...
Page 96 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 5.0 6.0kg-m 3.5-4.5g-m 3.5-4.0g-m...
Page 97 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 The drive pulley, clutch and driven pulley can be serviced with the engine installed. Avoid getting grease and oil on the drive belt and pulley faces.
Page 98 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 LEFT CRANKCASE COVER Left Crankcase Cover REMOVAL Loosen the drive belt air tube band screw. Remove the eight left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Inspect the seal rubber for damage or deterioration.
Page 99 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 Return Spring Spindle INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage. Plastic Bushing Spindle Bushing Friction Spring...
Page 100 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 Friction Spring Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown. Starter Driven Gear First install the washer and then install the circlip. Install the kick lever.
Page 101 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 102 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley. Drive Belt Drive Belt Drive Pulley Face Drive Face Nut Set the drive belt on the drive pulley face collar.
Page 103 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 104 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 105 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 Remove the clutch/driven pulley assembly Clutch/Driven Pulley...
Page 106 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 107 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 108 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 109 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 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 110 . FINAL REDUCTION AGILITY 50 10-0...
Page 111 . FINAL REDUCTION AGILITY 50 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 : 0.11 liter At change : 0.10 liter SPECIAL TOOLS Bearing puller, 10,12,15,18mm...
Page 112 . FINAL REDUCTION AGILITY 50 Bolt 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 113 . FINAL REDUCTION AGILITY 50 Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing 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.
Page 114 . FINAL REDUCTION AGILITY 50 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 115 . FINAL REDUCTION AGILITY 50 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 116 . CRANKCASE/CRANKSHAFT AGILITY 50 11-0...
Page 117 . CRANKCASE/CRANKSHAFT AGILITY 50 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. The following parts must be removed before separating the crankcase. Cylinder head ( Section 7) Cylinder/piston ( Section 8) Drive and driven pulleys ( Section 9)
Page 118 . CRANKCASE/CRANKSHAFT AGILITY 50 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. Do not damage the crankcase gasket surface.
Page 119 . CRANKCASE/CRANKSHAFT AGILITY 50 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 120 . CRANKCASE/CRANKSHAFT AGILITY 50 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 121 . CRANKCASE/CRANKSHAFT AGILITY 50 Driver Handle A Outer Driver 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 122 . CRANKCASE/CRANKSHAFT AGILITY 50 O-ring Install the cam chain tensioner slipper. Install a new O-ring onto the cam chain tensioner slipper bolt. Apply engine oil to the O-ring and tighten the bolt. Torque: 0.8~1.2kgf-m Be sure to install the O-ring into the groove.
Page 123 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 12-0...
Page 124 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 125 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling Excessively tightened steering stem top Bent rim cone race Excessive wheel bearing play Broken steering balls Bent spoke plate Insufficient tire pressure Faulty tire Steers to one side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber...
Page 126 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 127 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 Apply grease to the tip of the throttle pipe. Throttle Cable Install the throttle pipe and connect the throttle cable. Brake Levers Install the front and rear brake levers in the reverse order of removal. Bolts Bolts Axle Nut...
Page 128 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 129 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 Bearing Puller Remove the front wheel bearings and distance collar. Special Bearing Puller Pilot ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing.
Page 130 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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. Insert the axle shaft and tighten the axle nut.
Page 131 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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. Remove the wear indicator plate and felt seal.
Page 132 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 133 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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. When servicing the brake system, use shop towels to cover plastic parts and coated surfaces to avoid damage...
Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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. Remove the brake pad pins to remove the brake pads.
Page 135 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 136 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 137 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 Disassembly Brake Caliper Seat 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 opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.
Page 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 Place the brake master cylinder on the Punch Mark Bolts 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 139 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 140 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 141 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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. Loosen the lower mount bolts to remove the front shock absorbers.
Page 142 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 Absorber...
Page 143 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 144 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 Long Socket Wrench FRONT FORK 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. Special Long Socket Wrench,32mm 8Angle Lock Nut Wrench...
Page 145 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 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 29 steel balls on the bottom ball race.
Page 146 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 13-0...
Page 147 . 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 148 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 REAR WHEEL Rear Axle Nut 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 Inspect the rear brake drum.
Page 149 . 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 150 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 Punch Mark 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. Align the wide groove on the wear indicator plate with the wide tooth of the brake cam.
Page 151 . 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 152 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 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 153 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 Battery Fuse Regulator/Rectifier Resistors A.C. Generator A.C. Generator Auto Regulator/ Bystarter Rectifier Battery 12V4AH 14-0...
Page 154 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 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 155 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 SPECIFICATIONS Item Standard Capacity/Model 12V 4AH 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 0.1 1.0 Charging coil resistance (20 ) White Green...
Page 156 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 Battery Cover BATTERY 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 157 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 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 158 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 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 159 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 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. generator white wire and engine ground with an electric tester.
Page 160 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Hold the flywheel with an universal holder. Universal Holder Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
Page 161 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 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 162 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 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 163 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 Install the fan cover. Install the right side cover. ( 2-4) Fan Cover 14-10...
Page 164 . IGNITION SYSTEM AGILITY 50 CDI Unit Ignition Switch A.C. Generator Spark Plug Pulser Coil Ignition Switch CDI Unit Battery 15-0...
Page 165 . IGNITION SYSTEM AGILITY 50 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) The ignition system adopts CDI unit and the ignition timing cannot be adjusted.
Page 166 . IGNITION SYSTEM AGILITY 50 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 Faulty CDI unit Faulty pulser coil Intermittent high voltage Faulty ignition switch Poorly connected CDI unit coupler...
Page 167 . IGNITION SYSTEM AGILITY 50 CDI UNIT INSPECTION Remove the three battery cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester. Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.
Page 168 . IGNITION SYSTEM AGILITY 50 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 169 . IGNITION SYSTEM AGILITY 50 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 170 . STARTING SYSTEM AGILITY 50 Stop Switches Starter Relay Starter Button Starter Motor Starter Relay Ignition Switch Fuse Stoplight Battery Front Rear Starter Motor Stop Switches 16-0...
Page 171 . STARTING SYSTEM AGILITY 50 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 TROUBLESHOOTING Starter motor won‘t turn...
Page 172 . STARTING SYSTEM AGILITY 50 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 173 . STARTING SYSTEM AGILITY 50 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 174 . STARTING SYSTEM AGILITY 50 Front Cover 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 175 . STARTING SYSTEM AGILITY 50 Starter Relay STARTER RELAY TEST Remove the battery cover. Disconnect the 4P connector from the starter relay and remove the 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 176 . LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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. Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment.
Page 177 . LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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. Do not damage the fuel unit wire.
Page 178 . LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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 Color Yellow Brown Pink Yellow Blue/ White Use the X1 range for test when using an electric tester.
Page 179 . LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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. ( 2-2) Disconnect the ignition switch wire coupler.
Page 180 . LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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 181: Headlight
. LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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 182 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM 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 EXHAUST EMISSION CONTROL SYSTEM DIAGRAM Carburetor Air Injection...
Page 183 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM 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 184 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM 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 Fuel filter Fuel filter screen Carburetor Fuel line...
Page 185 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SECONDARY AIR CLEANER Center Coverl Met-in Box REMOVAL Remove the met-in box. ( 2-3) Remove the center cover. ( 2- ) Remove the rear seat and rear carrier. ( 2- ) Remove the frame body covers. ( 2- ) Remove the floor board.

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KYMCO AGILITY 125 Service Manual

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