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Cortesia de / Courtesy of: www.batmotos.com
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO AGILITY
CITY 125
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
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
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
Recambios KYMCO en www.batmotos.com
The
AGILITY CITY 125

TABLE OF CONTENTS

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Chapters

Table of Contents

   Also See for KYMCO Agility City 125

   Summary of Contents for KYMCO Agility City 125

  • Page 1: 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 CITY 125 INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual. Read...
  • Page 2: General Information

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 3: Specifications

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 SPECIFICATIONS Air cleaner type & No Paper element, wet Motorcycle Name & Type AGILITY CITY 125 Fuel capacity 6.0 liter Name & Model No. LFC3 Type Overall length (mm) 2040 Piston dia.
  • Page 4: Service Precautions

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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 5 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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 6 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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.
  • Page 7 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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 8 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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 9 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 10 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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 11 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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.)
  • Page 12: Torque Values

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 13: Special Tools

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 14: Lubrication Points

    AGILITY CITY 125 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 15 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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.
  • Page 16: Cable & Harness Routing

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 CABLE & HARNESS ROUTING Brake Master Cylinder Rear Stop Switch Wire Front Stop Switch Wire Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Horn Front Brake Fluid Tube...
  • Page 17 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 Throttle Grip Headlight Resistor Ignition Switch Speedometer Cable Regulator/Rectifier Rear Brake Lever Horn Front Brake Fluid Tube 1-16 Recambios KYMCO en www.batmotos.com...
  • Page 18 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 Fuse Battery (-) Cable CDI Unit Battery (+) Cable Starter Relay Fuel Tank Ignition Coil 1-17 Recambios KYMCO en www.batmotos.com...
  • Page 19 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 Fuel Tube Auto Cock Assy Fuel Fuel Filter Throttle Cable Carburetor Overflow Tube Crankcase Breather Tube Ignition Coil Primary Wire 1-18 Recambios KYMCO en www.batmotos.com...
  • Page 20 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 Fuel Unit Crankcase Breather Tube Throttle Cable Wire Vacuum Tube Crankcase Breather Tube Secondary Air Inlet Tube Ignition Coil Reed Valve Air Injection Cut-off Valve Vacuum Tube Fuel Tube...
  • Page 21: Wiring Diagram

    Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 WIRING DIAGRAM 1-20 Recambios KYMCO en www.batmotos.com...
  • Page 22 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 23 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 24 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check carburetor pilot...
  • Page 25 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 26 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 27 Cortesia de / Courtesy of: www.batmotos.com . GENERAL INFORMATION AGILITY CITY 125 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...
  • Page 28 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 SCHEMATIC DRAWING Recambios KYMCO en www.batmotos.com...
  • Page 29: Frame Covers/exhaust Muffler

    Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 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 30 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 Front Brake Fluid Tube Front Cover Front Cover Screw FRAME COVERS FRONT COVER REMOVAL Remove the screw on the front cover and remove the front cover.. Remove the screws on the back of the mole assy front.
  • Page 31 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 FRAME BODY COVER REMOVAL Battery Cover Screws Screws Remove the two screws on the battery cover. Remove the battey cover Remove the six screws on the center cover...
  • Page 32 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 Remove the two screws on the center rear Center Rear Cover. cover. Remove the center rear cover. Screws Bolts Remove the two bolts attaching the frame body cover.
  • Page 33 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 Connector Rear Light Wire Discornnect the seat lock wire. Seat Lock Wire Discornnect the rear light wire connectors Remove the left / right body cover and rear light.
  • Page 34 Cortesia de / Courtesy of: www.batmotos.com . FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125 Remove the decorative ring. Remove the leg shieid. Leg Shield Remove the bolt attaching the hook luggage. Remove the hook luggage. Remove the leg shield. The installation sequence is the reverse of...
  • Page 35: Inspection/adjustment

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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...
  • Page 36 Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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...
  • Page 37: Maintenance Schedule

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten...
  • Page 38: Fuel Filter

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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.
  • Page 39: Air Cleaner

    Gap, Wear, and Fouling Deposits Measure the spark plug gap. Spark Plug Gap: 0.6 0.7mm Washer Deformation When installing, first screw in the spark plug by hand and then tighten it with a spark plug wrench. Cracks Damage Recambios KYMCO en www.batmotos.com...
  • Page 40: Valve Clearance

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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.
  • Page 41: Ignition Timing

    Leaky valves Valve clearance to small Leaking cylinder head gasket Worn piston rings Worn piston/cylinder If the compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and the piston head. Recambios KYMCO en www.batmotos.com...
  • Page 42: Agility City

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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.
  • Page 43: Brake Shoe

    Adjusting Nut Upper Line FRONT/REAR BRAKE FLUID Turn the steering handlebar upright and check if the rear brake fluid level should be between the upper and lower level lines. Specified Brake Fluid: DOT-4 Lower Line Recambios KYMCO en www.batmotos.com...
  • Page 44: Headlight Aim

    Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 If the free play do not fall within the limit, adjust by turning the adjusting nut. Adjusting Nut HEADLIGHT AIM Front Cover Turn the ignition switch ON and start the engine.
  • Page 45: Nuts/bolts/fasteners

    Check the front axle nut for looseness. Check the rear axle nut for looseness. If the axle nuts are loose, tighten them to the specified torques. Torques: Front : 5.0 7.0kgf-m Rear : 11 13kgf-m Front Axle Nut 3-10 Recambios KYMCO en www.batmotos.com...
  • Page 46 Cortesia de / Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT AGILITY CITY 125 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 47 Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 __________________________________________________________________________________ LUBRICATION SYSTEM SERVICE INFORMATION------------------------------------------------ 4- 1 TROUBLESHOOTING----------------------------------------------------- 4- 1 ENGINE OIL/OIL FILTER ------------------------------------------------ 4- 2 OIL PUMP -------------------------------------------------------------------- 4- 2 Recambios KYMCO en www.batmotos.com...
  • Page 48: Lubrication System

    Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 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 49: Engine Oil/oil Filter

    Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 Lower Level 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 50 Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 Remove the gasket and dowel pins. Remove the starter idle gear and starter clutch. Gasket Remove the two bolts and oil separator Bolts cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
  • Page 51 Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 Screw DISASSEMBLY Remove the screw and disassemble the oil pump. Pump Body Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance.
  • Page 52 Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 Inner Rotor Outer Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 53 Cortesia de / Courtesy of: www.batmotos.com . LUBRICATION SYSTEM AGILITY CITY 125 Bolts Install the oil separator cover and tighten the bolts. Oil Separator Cover Install the starter idle gear and starter Dowel Pin Starter Idle Gear clutch. Install the gasket and dowel pins.
  • Page 54 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 Recambios KYMCO en www.batmotos.com...
  • Page 55: Fuel System

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 Ignition Switch Regulator /Rectifier Fuse 12V Battery Lighting System Auto Bystarter Recambios KYMCO en www.batmotos.com...
  • Page 56 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 SERVICE INFORMATION.......5-2 CARBURETOR INSTALLATION..5-10 TROUBLESHOOTING......5-3 PILOT SCREW ADJUSTMENT ....5-11 CARBURETOR REMOVAL.....5-4 FUEL TANK..........5-12 AUTO BYSTARTER .........5-4 FUEL UNIT ..........5-13 AIR CUT-OFF VALVE ......5-6 AIR CLEANER ........5-13 VACUUM CHAMBER ......5-6 FLOAT CHAMBER........5-8...
  • Page 57: Troubleshooting

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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...
  • Page 58: Carburetor Removal

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 CARBURETOR REMOVAL Auto Bystarter Remove the frame right side cover. ( 2-4) Disconnect the auto bystarter wire connector. Remove the met-in box. ( 2-3) Auto Bystarter Wire Loosen the drain screw and drain the fuel from the float chamber.
  • Page 59 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 Connect a hose to the fuel enriching circuit Vacuum Pump of the carburetor. Connect the auto bystarter yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal.
  • Page 60: Air Cut-off Valve

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 AIR CUT-OFF VALVE Screws DISASSEMBLY Remove the two screws attaching the air cut-off valve. Remove the spring and vacuum diaphragm. Check the vacuum diaphragm for cracks or damage and check each passage for clogging.
  • Page 61 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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.
  • Page 62: Float Chamber

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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.
  • Page 63 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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.
  • Page 64: Carburetor Installation

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 Air Cleaner Connecting Vacuum Tube Intake Manifold Tube Band Band CARBURETOR INSTALLATION Tighten the drain screw. Install the carburetor onto the intake manifold, aligning the tab on the carburetor with the cutout in the intake manifold.
  • Page 65: Pilot Screw Adjustment

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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.
  • Page 66 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 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.
  • Page 67: Fuel Tank

    Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 FUEL UNIT Fuel Unit Wire REMOVAL Remove the related parts. Disconnect the fuel unit wire connector. Turn the fixed plate on the fuel unit,take the fuel unit off.
  • Page 68 Cortesia de / Courtesy of: www.batmotos.com . FUEL SYSTEM AGILITY CITY 125 Tps Unit TPS REMOVE Remove the TPS stay screw. Remove the TPS and TPS stay assembled. While clean the carburetor, must remove the TPS unit. TPS Stay Screw...
  • Page 69 Cortesia de / Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION AGILITY CITY 125 Recambios KYMCO en www.batmotos.com...
  • Page 70 Cortesia de / Courtesy of: www.batmotos.com 6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125 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.
  • Page 71: Engine Removal/installation

    Cortesia de / Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION AGILITY CITY 125 ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector.
  • Page 72 Cortesia de / Courtesy of: www.batmotos.com 6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125 Brake Adjusting Nut Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable. Remove the rear shock absorber lower Rear Shock Absorber Lower Mount Bolt mount bolt.
  • Page 73: Engine Installation

    Cortesia de / Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION AGILITY CITY 125 Bushings Stopper Rubbers Inspect the engine hanger bushings and stopper rubbers for wear or damage. Bolt Engine Hanger Bracket ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine.
  • Page 74 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 Recambios KYMCO en www.batmotos.com...
  • Page 75: Cylinder Head/valves

    Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 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.
  • Page 76: Troubleshooting

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 TORQUE VALUES Cylinder head nut 2.0kg-m Apply engine oil to threads Valve clearance adjusting nut 0.9kg-m Apply engine oil to threads Stud bolt 0.9~1.1kg-m SPECIAL TOOLS Valve spring compressor...
  • Page 77: Camshaft Removal

    Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the two nuts attaching the secondary air inlet tube.
  • Page 78 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 Bolt Remove the two cylinder head bolts. Remove the four cylinder head nuts and washers. Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins.
  • Page 79 Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 Camshaft Bearings Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt.
  • Page 80 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 Intake Manifold CYLINDER HEAD REMOVE Remove the camshaft. Remove the carburetor. Remove the exhaust muffler. Remove the carburetor intake manifold. Remove the cooling fan cover. Remove the engine cover bolts and screws.
  • Page 81: Cylinder Head Disassembly

    Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 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 82: Cylinder Head Assembly

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 VALVE /VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: IN : 4.90mm replace if below EX: 4.90mm replace if below...
  • Page 83 Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 Tap the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters. Be careful not to damage the valves. Dowel Pins Gasket CYLINDER HEAD INSTALLATION Tighten the four stud bolts.
  • Page 84: Camshaft Installation

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER HEAD/VALVES AGILITY CITY 125 Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear...
  • Page 85 Cortesia de / Courtesy of: www.batmotos.com 7. CYLINDER HEAD/VALVES AGILITY CITY 125 Apply engine oil to a new O-ring and install Tighten the cam chain tensioner cap screw. Be sure to install the O-ring into the groove properly. O-ring Install a new cylinder head cover O-ring and install the cylinder head cover.
  • Page 86 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 1.0kg-m Do not bend Recambios KYMCO en www.batmotos.com...
  • Page 87: Cylinder/piston

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 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 88: Cylinder Removal

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 Cylinder CYLINDER REMOVAL Remove the cylinder head. Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder. Remove the cylinder gasket and dowel pins. Gasket Dowel Pins Clean any gasket material from the cylinder surface.
  • Page 89 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 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.
  • Page 90 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 Measure the piston pin O.D. Service Limit: 14.996mm replace if below Measure the piston O.D. Take measurement at 9mm from the bottom and 90 to the piston pin hole.
  • Page 91 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.
  • Page 92: Piston Installation

    Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 PISTON INSTALLATION Remove any gasket material from the crankcase surface. Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip.
  • Page 93 Cortesia de / Courtesy of: www.batmotos.com . CYLINDER/PISTON AGILITY CITY 125 Loosely install the cylinder base bolts. Cam Chain Guide Install the cam chain guide. Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head.
  • Page 94 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 5.0 6.0kg-m 3.5-4.5g-m 3.5-4.0g-m Recambios KYMCO en www.batmotos.com...
  • Page 95: Drive And Driven Pulleys/kick Starter

    Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 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.
  • Page 96 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Screw Remove the left crankcase cover bolts and Left Crankcase Cover...
  • Page 97 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Intake Cover Install the drive belt air tube and tighten the tube band screw. Tube Band Screw Starting Ratchet Drive Pulley Face DRIVE PULLEY REMOVAL Remove the left crankcase cover.
  • Page 98 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly DISASSEMBLY Ramp Plate Remove the ramp plate.
  • Page 99 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Measure the movable drive face bushing I.D. Service Limit: 24.06mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
  • Page 100 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly...
  • Page 101 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Drive Pulley Face Install the drive pulley face, starting ratchet and drive face nut. When installing the drive pulley face, compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened.
  • Page 102 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 1.5mm replace if below CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch/Driven Pulley Hold the clutch/driven pulley assembly with the clutch spring compressor.
  • Page 103 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Guide Roller Guide Roller Pin Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face...
  • Page 104 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING...
  • Page 105 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Press a new needle bearing into the driven face. Circlip CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch linings.
  • Page 106 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
  • Page 107 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 5.5kg-m Special Flywheel Holder Install the drive belt.
  • Page 108 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Return Spring...
  • Page 109 Cortesia de / Courtesy of: www.batmotos.com 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY CITY 125 INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover. When installing the return spring, use a screw driver to press the inward and outward return spring hooks into their original positions respectively.
  • Page 110 Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 10-0 Recambios KYMCO en www.batmotos.com...
  • Page 111: Final Reduction

    Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 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 : 0.2 liter...
  • Page 112: Final Reduction

    Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 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: Bearing Replacement

    Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 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.
  • Page 114 Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 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.
  • Page 115 Cortesia de / Courtesy of: www.batmotos.com . FINAL REDUCTION AGILITY CITY 125 Countershaft Install the countershaft and gear into the left crankcase. Install the dowel pins and a new gasket. Gasket Dowel Pins Install the transmission case cover. Transmission Case Cover...
  • Page 116 Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 11-0 Recambios KYMCO en www.batmotos.com...
  • Page 117 Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 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 118: Crankcase/crankshaft

    Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 Crankcase Bolts CRANKCASE SEPARATION Remove the two crankcase attaching bolts. Separate the left and right crankcase halves. Do not damage the crankcase gasket surface. Gasket Remove the gasket and dowel pins.
  • Page 119 Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration. The installation sequence is the reverse of removal. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
  • Page 120 Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 Turn the crankshaft bearings and check for excessive play. If they do not turn smoothly, quietly or if they fit loosely in the crankshaft, replace the crankshaft as a set.
  • Page 121 Cortesia de / Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT AGILITY CITY 125 Crankcase Bolts Tighten the two crankcase attaching bolts. Torque: 0.9kg-m 11-5 Recambios KYMCO en www.batmotos.com...
  • Page 122: Front Wheel/front Brake/ Front Suspension

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 12-0 Recambios KYMCO en www.batmotos.com...
  • Page 123: Front Suspension

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 SERVICE INFORMATION ....12-1 FRONT SHOCK ABSORBER....12-18 TROUBLESHOOTING ......12-2 FRONT FORK......... 12-21 STEERING HANDLEBAR..... 12-3 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 124: Troubleshooting

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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...
  • Page 125: Steering Handlebar

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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.
  • Page 126: Front Wheel

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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.
  • Page 127 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Turn the wheel bearings and replace the...
  • Page 128: Agility City 125

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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.
  • Page 129 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Apply grease to a new dust seal lip and install Side Collar the dust seal. Install the side collar. Dust Seal 12-7 Recambios KYMCO en www.batmotos.com...
  • Page 130 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Upper Limit HYDRAULIC BRAKE (FRONT BRAKE) Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground. When operating the brake lever, the brake reservoir cap must be tightened securely to avoid spill of brake fluid.
  • Page 131 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Reed Brake pads 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.
  • Page 132 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 BRAKE MASTER CYLINDER Brake Master Cylinder Bolts Removal First drain the brake fluid from the hydraulic brake system. When servicing the brake system, use shop towels to cover rubber and...
  • Page 133 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D.
  • Page 134 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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...
  • Page 135 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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.
  • Page 136 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 34mm Check the caliper cylinder for scratch or wear and measure the cylinder bore.
  • Page 137 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Installation Install the brake caliper and tighten the two bolts. Torque: 2.9 3.5kg-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt.
  • Page 138: Front Shock Absorber

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. ( 12-4) Remove the front lower cover. ( 2-2) Remove the front inner fender.
  • Page 139 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Measure the front shock absorber spring free length. Service Limits: Right : 226.5mm Left : 226.5mm ASSEMBLY Top Nut Dust Seal Circlip Damper Oil Seal...
  • Page 140 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube and tighten the top nut.
  • Page 141: Front Fork

    Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 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.
  • Page 142 Cortesia de / Courtesy of: www.batmotos.com . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY CITY 125 Driver Handle A Drive new top and bottom ball races into the steering head using the outer driver. Be sure to completely drive in the ball races.
  • Page 143: Rear Wheel /rear Brake /rear Suspension

    Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 13-0 Recambios KYMCO en www.batmotos.com...
  • Page 144: Rear Suspension

    Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 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.
  • Page 145 Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 Rear Shock Absorber Bolt REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-5) Remove the rear axle nut and rear shock absorber bolt. Remove the rear axle side collar and rear fork.
  • Page 146 Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 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...
  • Page 147 Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 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 148 Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 Lock Nut INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage.
  • Page 149 Cortesia de / Courtesy of: www.batmotos.com . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY CITY 125 Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then the lower mount bolt. Tighten the bolts.
  • Page 150: Battery/charging System/a.c

    Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 A.C. GENERATOR Regulator/Rectifier Battery Fuse A.C. Generator Fuse A.C. Generator Regulator/Rectifier Battery 14-0 Recambios KYMCO en www.batmotos.com...
  • Page 151 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY CITY 125 SERVICE INFORMATION...... 14-1 A.C. GENERATOR CHARGING COIL ...14-6 TROUBLESHOOTING ......14-2 RESISTOR INSPECTION......14-6 BATTERY..........14-3 A.C. GENERATOR REMOVAL .....14-6 CHARGING SYSTEM ......14-4 A.C. GENERATOR INATALLATION ...14-8 REGULATOR/RECTIFIER......
  • Page 152 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 A.C. GENERATOR 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...
  • Page 153 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY CITY 125 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.
  • Page 154: Charging System

    Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 A.C. GENERATOR 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.
  • Page 155 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY CITY 125 Regulator/Rectifier REGULATOR/RECTIFIER MAIN HARNESS CIRCUIT INSPECTION Remove the front covers. ( 2-2) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following :...
  • Page 156 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 A.C. GENERATOR 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.
  • Page 157 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY CITY 125 Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut.
  • Page 158 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 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.
  • Page 159 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY CITY 125 A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway.
  • Page 160 Cortesia de / Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM/ AGILITY CITY 125 A.C. GENERATOR Install the fan cover. Install the right side cover. ( 2-4) Fan Cover 14-10 Recambios KYMCO en www.batmotos.com...
  • Page 161: Ignition System

    Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 Ignition Switch A.C. Generator Spark Plug Pulser Coil Headlight controller 15-0 Recambios KYMCO en www.batmotos.com...
  • Page 162 Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 SERVICE INFORMATION ...... 15-1 IGNITION COIL ........15-4 TROUBLESHOOTING ......15-2 PULSER COIL ........15-5 CDI UNIT INSPECTION ......15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS Check the ignition system according to the sequence specified in the Troubleshooting. ( 15-2) The ignition system adopts CDI unit and the ignition timing cannot be adjusted.
  • Page 163 Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 TROUBLESHOOTING High voltage too low No or intermittent high voltage Weak battery or low engine speed Faulty ignition coil Loose ignition system connection Weak battery Faulty ignition coil...
  • Page 164 Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 CDI UNIT INSPECTION Remove the two battery cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester.
  • Page 165 Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 IGNITION COIL REMOVAL Remove the met-in box. ( 2-3) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil.
  • Page 166 Cortesia de / Courtesy of: www.batmotos.com . IGNITION SYSTEM AGILITY CITY 125 PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2-3) Disconnect the A.C. generator connector. Pulser Coil Coupler Measure the pulser coil resistance between the blue/yellow and green wire terminals.
  • Page 167: Starting System

    Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Stop Switches Starter Button Starter Relay Starter Motor 16-0 Recambios KYMCO en www.batmotos.com...
  • Page 168: Starting System

    Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 SERVICE INFORMATION.......16-1 STARTER MOTOR ........ 16-2 TROUBLESHOOTING......16-1 STARTER RELAY........16-4 SERVICE INFORMATION GENERAL INSTRUCTIONS The removal of starter motor can be accomplished with the engine installed. SPECIFICATIONS Item...
  • Page 169: Starter Motor

    Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Bolts STARTER MOTOR REMOVAL Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 170 Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.
  • Page 171: Starter Relay

    Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft.
  • Page 172: Starter Clutch

    Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Yellow/Red Wire STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed.
  • Page 173 Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Lock Nut Remove the starter clutch lock nut. Special Flywheel Holder Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft.
  • Page 174 Cortesia de / Courtesy of: www.batmotos.com . STARTING SYSTEM AGILITY CITY 125 Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Measure the starter idle gear I.D. Clutch Cover Service Limit: 10.05mm replace if over Starter Idle Gear Measure the starter idle gear shaft O.D.
  • Page 175: Lights/instruments/switches

    Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 SERVICE INFORMATION ....17-0 IGNITION SWITCH ......17-3 TROUBLESHOOTING ......17-0 STOP SWITCHES/HORN ....17-4 FUEL UNIT ..........17-1 INSTRUMENTS........17-4 HANDLEBAR SWITCHES....17-2 HEADLIGHT/LIGHTS......17-5 SERVICE INFORMATION GENERAL INSTRUCTIONS An electric tester is needed to measure or test the electric equipment.
  • Page 176 Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 Fuel Unit FUEL UNIT No Smoking! REMOVAL Remove the met-in box. ( 2-3) Remove the frame right side cover. ( 2-4) Disconnect the fuel unit wire connector. Turn the fuel unit retainer counterclockwise to remove it.
  • Page 177 Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 HANDLEBAR SWITCHES INSPECTION Remove the handlebar front cover. ( 2-2) Disconnect the handlebar switch couplers and check for continuity between wire terminals. If there is any abnormality found, check each switch.
  • Page 178 Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 HORN SWITCH Color Light Green Black FREE PUSH SWITCH REPLACEMENT Remove the front covers. ( 2-2) Remove the handlebar front cover. ( 2-2) The installation sequence is the reverse of removal.
  • Page 179 Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 STOP SWITCH INSPECTION Remove the handlebar front cover. ( 2-2) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied.
  • Page 180: Headlight

    Cortesia de / Courtesy of: www.batmotos.com . LIGHTS/INSTRUMENTS/SWITCHES AGILITY CITY 125 HEADLIGHT Screw REMOVAL Front Cover Remove the screw on the front cover. Remove the two screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.
  • Page 181: Exhaust Emission Control System Diagram

    EXHAUST EMISSION CONTROL SYSTEM DIAGRAM Air Injection Carburetor Fresh Air Cut-off Valve Vacuum Tube Intake Manifold Secondary Air Crankshaft Inlet Tube Reed Valve Engine Oil Valve Secondary Piston Secondary Air Air Cleaner Fresh Air Catalytic Exhaust Convertre 18-0 Recambios KYMCO en www.batmotos.com...
  • Page 182: Exhaust Emission Control System

    Broken vacuum tube Clogged air cleaner Faulty reed valve Backfiring at sudden deceleration Damaged reed valve (malfunction) Faulty air injection cut-off valve (unable to close) Carburetor incorrectly adjusted Faulty air cut-off valve Leaking vacuum tube 18-1 Recambios KYMCO en www.batmotos.com...
  • Page 183 It must be reported and approved if the exhaust emission control system is seriously affected. (2) IRREGULAR MAINTENANCE: Item Contents Inspect and repair when obvious symptoms of ignition Ignition system 18-2 Recambios KYMCO en www.batmotos.com...
  • Page 184 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 185 Cortesia de / Courtesy of: www.batmotos.com uso & manutenzione Agility 50-125-150 ruota 16" Recambios KYMCO en www.batmotos.com...
  • Page 186 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 187 Affinché non decadano le condizioni di garanzia, La invitiamo a rivolgersi esclusivamente alle Officine Autorizzate KYMCO e ad esigere sempre ricambi originali KYMCO. Per tutte le informazioni in merito alla garanzia del suo Agility R16 La invitiamo a leggere con cura il libretto di garanzia.
  • Page 188 Avvisatore acustico (clacson) ............. 13 1.6 DOTAZIONI Gancio portacasco ..............14 Gancio portaborse ..............14 Vano sottosella ................15 Cavalletto laterale ..............15 Regolazione ammortizzatori posteriori ........16 Accessori e modifiche ..............17 1.7 SCHEDE TECNICHE Recambios KYMCO en www.batmotos.com...
  • Page 189 Sostituzione olio motore ............48 Ispezione filtro aria ..............49 Sostituzione olio trasmissione ........... 50 Ispezione candela ..............51 Ispezione batteria ............... 52 Sostituzione fusibili ..............54 3.3 IN CASO DI GUASTO TAVOLA DI MANUTENZIONE Indice analitico Recambios KYMCO en www.batmotos.com...
  • Page 190 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 191 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 192: 1.1 Identificazione Del Veicolo

    Cortesia de / Courtesy of: www.batmotos.com 1.1 IDENTIFICAZIONE DEL VEICOLO Numero di telaio Numero di motore Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 193: Numero Di Telaio

    Riportare qui di seguito il numero di motore del proprio Riportare qui di seguito il numero di telaio del proprio veicolo. veicolo. Numero di motore Numero di telaio Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 194: 1.2 Particolari

    1.2 PARTICOLARI Vano sottosella Tappo serbatoio carburante (sotto la sella) Leva freno posteriore Portapacchi Gancio portaborse Serratura sella Filtro aria Pedale avviamento Freno posteriore Freno anteriore a disco Cavalletto centrale Cavalletto laterale Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 195 Cortesia de / Courtesy of: www.batmotos.com Gancio portacasco (all'interno del vano sottosella) Leva freno anteriore Interruttore avviamento/Bloccasterzo Proiettore anteriore Marmitta Astina controllo olio Targhetta del costruttore Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 196: 1.3 Chiavi

    Il veicolo viene dotato di una chiave (e di un suo duplicato) che serve per: interruttore avviamento / bloccasterzo / apertura vano sottosella. Attenzione Conservare il duplicato della chiave separatamente dal veicolo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 197: 1.4 Gruppo Strumentazione

    Quando l'ago è al limite della zona rossa, rifornirsi al più presto di carburante. Contachilometri (3) Indica i chilometri totali percorsi. La cifra nera su fondo bianco a destra indica le centinaia di metri. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 198 Premere il pulsante "Set" finché non lampeggia il valore "Set" "Adjust" da regolare (mese, giorno, ora, minuti). c Utilizzare il pulsante "Adjust" per regolare il valore. d Aspettare 10 secondi circa affinché la modifica venga memorizzata. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 199: Funzioni Di Controllo

    LOCK (3) Il motore e le luci non possono funzionare. La chiave può essere tolta. Attenzione Bloccare sempre lo sterzo quando lo scooter viene parcheg- giato per evitare l'uso non autorizzato del veicolo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 200: Bloccasterzo

    • Sbloccare sempre lo sterzo prima di fare scendere dal cavalletto il veicolo. • Non girare mai la chiave sulla posizione " " durante LOCK la guida. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 201: Pulsante Avviamento

    Le luci di posizione, le luci della strumentazione e le luci posteriori si accendono contemporaneamente. La luce anabbagliante, le luci della strumentazione e le luci posteriori si accendono contemporaneamente. Attenzione Le luci funzionano solo con il motore acceso. Interruttore luci Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 202: Deviatore Luci

    Luce anabbagliante (2): illumina la strada di fronte allo scooter. Attenzione Non utilizzare la luce abbagliante incrociando altri vei- coli. Lampeggio Lampeggio diurno: premere l'interruttore (3) per PASSING il lampeggio. Lampeggio Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 203: Comando Indicatori Di Direzione (frecce)

    Il comando indicatori di direzione non funziona quando l'interruttore di avviamento è su " ". Comando indicatori di direzione Avvisatore acustico Avvisatore acustico (clacson) Premere (4) il pulsante per far suonare l'avvisatore acustico. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 204: Dotazioni Gancio Portacasco

    Attenzione Vano sottosella Non tenere il casco sullo scooter durante la guida: potrebbe pregiudicare la sicurezza e graffiare la carrozzeria. Gancio portaborse Infilare la maniglia della borsa nell'apposito gancio. Gancio portaborse Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 205: Vano Sottosella

    Attenzione Non lasciare lo scooter sul cavalletto laterale in zone di passaggio o con il motore acceso, in entrambi i casi lo scooter potrebbe cadere. Cavalletto laterale Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 206: Regolazione Ammortizzatori Posteriori

    Assicurarsi che il fermo della regolazione sia correttamente inserito nella cava presente sulla ghiera di regolazione. • Assicurarsi di utilizzare sempre la stessa posizione di regolazione per gli ammortizzatori destro e sinistro (solo per Agility R16 125/150). Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 207: Accessori E Modifiche

    In particolare, guidare con molta cautela nel caso in cui sul vostro scooter sia montato il parabrezza: quest'ultimo genera delle forze aerodinamiche che possono influire sulla stabilità del veicolo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 informazioni...
  • Page 208: 1.7 Schede Tecniche

    KL10 NGK CR7HSA o CHAMPION P-RZ9HC disposizione e ciclo carburatore monocilindrico orizzontale, 4 tempi KYMCO LEJ2 Ø 17 mm distribuzione carburante camme in testa, 2 valvole benzina verde raffreddamento ad aria serbatoio carburante 6 lt alesaggio x corsa 39 x 41,4 mm lubrificazione...
  • Page 209 KL25B candela NGK CR7HSA o CHAMPION P-RZ9HC disposizione e ciclo monocilindrico orizzontale, 4 tempi carburatore KYMCO LEJ3 III Ø 22 mm distribuzione carburante camme in testa, 2 valvole benzina verde raffreddamento serbatoio carburante ad aria 6 lt alesaggio x corsa lubrificazione...
  • Page 210 KL30 candela NGK CR7HSA o CHAMPION P-RZ9HC disposizione e ciclo monocilindrico orizzontale, 4 tempi carburatore KYMCO LFC4 Ø 22 mm distribuzione carburante camme in testa, 2 valvole benzina verde raffreddamento serbatoio carburante ad aria 6 lt alesaggio x corsa lubrificazione...
  • Page 211 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 212: 2.1 Sicurezza Di Guida

    Non toccare la marmitta durante la guida e per almeno 10 minuti dopo aver spento il motore. • Per evitare il pericolo di incendio non parcheggiare in pros- simità di sostanze infiammabili o erba secca. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 213: Metodo Di Guida

    Non mettere alcun tipo di strofinaccio tra la carrozzeria ed il motore perché farebbe surriscaldare il motore. • Non trasportare oggetti al di fuori degli spazi predisposti per evitare incidenti o danni alla carrozzeria. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 214: Trasporto Passeggero

    Il conducente, dopo aver arrestato il veicolo, tiene entrambi i piedi appoggiati a terra per mantenerlo in equilibrio. • Il passeggero scende sempre dal lato sinistro muovendosi con cautela per non sbilanciare il veicolo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 215: Avviamento Avviamento Elettrico

    Non premere il pulsante di avviamento quando il motore è in funzione, altrimenti il motore potrebbe danneggiarsi. • Perché il dispositivo di avviamento elettrico funzioni si deve tirare la leva del freno e la luce di arresto deve accen- dersi. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 216 Tirare la leva del freno posteriore per evitare che lo scooter possa sfuggire. • I gas di scarico sono altamente tossici. Non avviare mai lo scooter in locali chiusi o non ben ventilati. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 217: Avviamento A Pedale Del Motore

    Se dopo 2-3 tentativi il motore non si avvia ruotare legger- mente la manopola dell'acceleratore (1/8 ÷ 1/4 di giro). Attenzione Dopo aver avviato il motore accertarsi che il pedale sia tornato nella posizione di riposo. 1/8 ÷ 1/4 di giro Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 218: 2.3 Guida

    Salire sullo scooter dal lato sinistro e sedersi in posizione sicura e confortevole. Mantenere il piede sinistro al suolo per non perdere l'equilibrio. Attenzione Mantenere tirata la leva del freno posteriore fino al momento della partenza. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 219 Alla partenza o in prossimità di una salita ruotare la manopola gradualmente per aumentare la potenza erogata dal motore. Ritorno (2) La velocità diminuisce. • In caso di emergenza il ritorno va effettuato il più rapi- damente possibile. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 220 Quando si azionano i freni la luce di arresto si accende per avvertire i veicoli che seguono. Attenzione L'uso di un solo freno può far scivolare lo scooter. Usare sempre entrambi i freni. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 221 Moderare la velocità in discesa In discesa rilasciare l'acceleratore e ridurre la velocità con leggere frenate intermittenti. Attenzione Evitare l'uso prolungato dei freni, che possono surriscaldarsi e perdere di efficienza. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 222: 2.4 Come Fermarsi

    " " per spegnere il motore. Attenzione Non girare mai la chiave su " " quando lo scooter è in movimento. Il mancato funzionamento dell'impianto elet- trico potrebbe provocare situazioni di pericolo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 223 Non toccare la marmitta durante la guida e per 10 minuti dopo aver spento il motore onde evitare scottature. • Per evitare pericolo di incendio non parcheggiare in pros- simità di sostanze infiammabili o di erba secca. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 224 Il danneggiamento di strumentazioni, plastiche, ecc. dovuto al montaggio di parabrezza non originali non è coperto da garanzia. • Eventuali danni al veicolo dovuti ad un mancato rispetto degli accorgimenti qui specificati non sono coperti da garanzia. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 225: 2.5 Rodaggio

    • D'estate, nelle giornate più calde, non lasciare per lungo tempo il motore al minimo per evitare danneggiamenti. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 uso...
  • Page 226 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 227 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 228: 3.1 Controlli Pre-guida

    E' a cura del proprietario controllare periodicamente il livello • dell'olio motore e rabboccare se necessario. Un normale consumo di olio può comportare un livello insufficiente anche se i tagliandi sono regolarmente eseguiti. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 229 Utilizzare olio di qualità non sufficiente provoca perdite di prestazioni e nei casi più gravi danneggiamento del motore. • Avarie meccaniche provocate dall'uso di olio non adeguato non sono coperte da garanzia. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 230: Rifornimento Di Carburante

    Per chiudere il serbatoio avvitare il tappo in senso orario fino a battuta (1). Rimettere in posizione la sella. Tappo serbatoio Attenzione carburante Usare sempre benzina verde senza piombo. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 231: Controllo Acceleratore

    Controllare le condizioni degli ammortizzatori anteriori e posteriori premendo verso il basso il manubrio e la sella ripetutamente. Verificare che gli ammortizzatori non siano troppo cedevoli o poco progressivi. Controllare eventuali rumori anomali. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 232: Controllo Freni

    • Per la sostituzione delle pastiglie freno rivolgersi ad una officina autorizzata KYMCO • Dopo aver sostituito le pastiglie freno azionare più volte la leva freno allo scopo di riposizionare le pastiglie. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 233 Contattare un punto di assistenza KYMCO per la sostituzione. Controllo dell'efficienza dei freni A velocità moderata controllare l'efficienza dei freni. Verificare che l'azione sia potente e modulabile. Indice "V" Braccio del freno Dado di registro Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 234: Controllo Luce Di Arresto

    Controllo specchi retrovisori Sedersi sulla sella e regolare gli specchi in modo da avere una corretta visione alle spalle. Verificare che gli specchi non siano danneggiati o sporchi. Indicatori di direzione Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 235: Controllo Pneumatici

    Controllare lo stato di usura. Sostituire il pneumatico se presenta usura eccessiva od irregolare. Attenzione Pressione non corretta, usura eccessiva od irregolare del pneumatico riducono la stabilità del veicolo e danneggiano precocemente il pneumatico stesso. Tagli Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 236: Controllo Fanali

    Osservare lo scooter e verificare che non ci siano danni evidenti a parti meccaniche, che il rumore e la fumosità allo scarico non siano eccessivi e che non siano presenti rumori anormali. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 237: 3.2 Manutenzione Periodica

    Operare sempre a motore spento. • Dopo essere stato spento il motore rimane caldo per molto tempo. Fare attenzione a non scottarsi. Lubrificazione generale Provvedere periodicamente alla lubrificazione di tutte le parti in scorrimento tra loro. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 238: Sostituzione Olio Motore

    Controllare il livello come indicato a pag. 38. Serrare a mano l'astina di controllo. g Scaldare il motore. Ricontrollare il livello dell'olio almeno Vite di drenaggio 10 minuti dopo aver spento il motore Attenzione Non disperdere olii esausti nell'ambiente. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 239: Ispezione filtro Aria

    Non utilizzare benzina per la pulizia del filtro aria perché facilmente infiammabile. • Se il filtro aria non è installato propriamente il motore aspira polvere e sporcizia. Questo pregiudica la durata del motore nel tempo. Elemento filtrante Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 240: Sostituzione Olio Trasmissione

    E' necessario sostituire l'olio della trasmissione con mag- gior frequenza rispetto a quanto indicato nella tavola di manutenzione qualora si guidi spesso su strade bagnate, su lunghe distanze o con carico elevato. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 241: Ispezione Candela

    L'utilizzo di una candela differente da quella specificata Rondella può provocare gravi avarie meccaniche. • Quando si smonta la candela attenzione a non scottarsi. • Per rimontare la candela, prima avvitarla a mano, poi serrarla con la chiave candela. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 242: Ispezione Batteria

    • Quando la batteria viene smontata il terminale negativo (verde) va scollegato prima di quello positivo (rosso), quando viene rimontata va collegato prima il positivo. • Serrare propriamente i dadi dei terminali. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 243 Se la batteria viene lasciata sul veicolo scollegare l'elettrodo negativo. • Se il veicolo viene tenuto inutilizzato per lunghi periodi senza prendere adeguate precauzioni la batteria si danneggia. Tale danno non è coperto da garanzia. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 244: Sostituzione Fusibili

    Dopo aver installato il fusibile controllare che i terminali non siano laschi, causa questa di malfunzionamenti del- l'impianto elettrico. • Fusibili con caratteristiche diverse da quelle indicate possono causare danni all'impianto elettrico. Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 245: 3.3 In Caso Di Guasto

    è buona norma recarsi tempestivamente presso un punto di assistenza dove KYMCO sono disponibili i ricambi originali che assicurano KYMCO un livello di qualità adatto al veicolo (oltre alla validità della garanzia). Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 246: Tavola Di Manutenzione

    • • Pneumatici • • • • Batteria • • (•) Controllo. Inclusa anche pulizia, registrazione, riparazione o sostituzione (S) Sostituzione (*) Sostituire più spesso se il veicolo viene utilizzato fuori strada Recambios KYMCO en www.batmotos.com Agility R16 50/125/150 manutenzione...
  • Page 247 Freni: controlli e regolazione, 42-43 Fusibili, 54 Schede tecniche, 18, 19, 20 Spia abbaglianti, 8 Gancio portaborse, 14 Spia indicatori di direzione, 8 Gancio portacasco, 14 Strumentazione, 7 Indicatore livello carburante, 7 Interruttore avviamento, 9 Interruttore luci, 11 Recambios KYMCO en www.batmotos.com...
  • Page 248 Cortesia de / Courtesy of: www.batmotos.com Tachimetro, 7 Tappo serbatoio carburante: apertura, 40 Targhetta del costruttore, 5 Tavola di manutenzione, 56 Vano sottosella, 15 Recambios KYMCO en www.batmotos.com...
  • Page 249 Cortesia de / Courtesy of: www.batmotos.com Recambios KYMCO en www.batmotos.com...
  • Page 250 PADANA RICAMBI SPA Divisione Motori KYMCO (Kwang Yang Motor COmpany) Place: 35,WAN HSING ST., SANMIN DIST., KAOHSIUNG, TAIWAN, R.O.C. TEL: 886-7-3822526 FAX: 886-7-3852583 E-mail : service@mail.kymco.com...
  • Page 251 Cortesia de / Courtesy of: www.batmotos.com raccomanda LUBRIFICANTI FUCHS SILKOLENE Recambios KYMCO en www.batmotos.com...
  • Page 252 Cortesia de / Courtesy of: www.batmotos.com êL$!lTë Recambios KYMCO en www.batmotos.com 44040176...

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