KYMCO Agility 125 Service Manual
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KYMCO Agility 125 Service Manual

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See also: Driver Manual , Service Manual
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
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.
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

AGILITY 125
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  • Page 1: Table Of Contents

    PREFACE TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the FRAME COVERS/EXHAUST MUFFLER technical features and servicing procedures for the KYMCO AGILITY 125 INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all FUEL SYSTEM operations stated in this manual. Read...

  • Page 2: Agility 125

    . GENERAL INFORMATION AGILITY 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 SPECIAL TOOLS ........1-12...

  • Page 3: Specifications

    . GENERAL INFORMATION AGILITY 125 SPECIFICATIONS Air cleaner type & No Paper element, wet Motorcycle Name & Type AGILITY 125 Fuel capacity 5 liter Name & Model No. LDF7 Type Overall length (mm) 1830 φ22 Piston dia. (mm) Overall width (mm) φ37equivalent...

  • Page 4: Service Precautions

    . GENERAL INFORMATION AGILITY 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 . GENERAL INFORMATION AGILITY 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. Disconnect the battery negative (-) terminal before operation.
  • Page 6 . GENERAL INFORMATION AGILITY 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. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 7 . GENERAL INFORMATION AGILITY 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 . GENERAL INFORMATION AGILITY 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 . GENERAL INFORMATION AGILITY 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 corner When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 10 . GENERAL INFORMATION AGILITY 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 . GENERAL INFORMATION AGILITY 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.) : Apply grease for lubrication.

  • Page 12: Torque Values

    . GENERAL INFORMATION AGILITY 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 6mm flange bolt, nut 1.0-1.4...

  • Page 13: Special Tools

    . GENERAL INFORMATION AGILITY 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 Bushing remover S EO19 11203 bush rear cushion under rubber...

  • Page 14: Lubrication Points

    . GENERAL INFORMATION AGILITY 125 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API−SG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 15 . GENERAL INFORMATION AGILITY 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. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 16: Cable & Harness Routing

    . GENERAL INFORMATION AGILITY 125 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 17 . GENERAL INFORMATION AGILITY 125 Throttle Grip Regulator/Rectifier Ignition Switch Speedometer Cable Headlight Resistor Rear Brake Lever Horn Front Brake Fluid Tube 1-16...
  • Page 18 . GENERAL INFORMATION AGILITY 125 CDI Unit Fuse Battery (+) Cable Battery (-) Cable Starter Relay Fuel Tank Battery (-) Cable Battery (+) Cable Ignition Coil 1-17...
  • Page 19 . GENERAL INFORMATION AGILITY 125 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 20 . GENERAL INFORMATION AGILITY 125 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 21: Wiring Diagram

    . GENERAL INFORMATION AGILITY 125 WIRING DIAGRAM 1-20...
  • Page 22 . GENERAL INFORMATION AGILITY 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 tank and carburetor Clogged float oil passage...
  • Page 23 . GENERAL INFORMATION AGILITY 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 Engine speed does not Engine speed...
  • Page 24 . GENERAL INFORMATION AGILITY 125 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...
  • Page 25 . GENERAL INFORMATION AGILITY 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 Correctly adjusted Incorrectly adjusted Worn camshaft...
  • Page 26 . GENERAL INFORMATION AGILITY 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 increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 27 . GENERAL INFORMATION AGILITY 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 Check spark plug cap and high-tension wire...

  • Page 28: Frame Covers/Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER AGILITY 125 SCHEMATIC DRAWING...

  • Page 29: Frame Covers/Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER AGILITY 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 . FRAME COVERS/EXHAUST MUFFLER AGILITY 125 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 31 . FRAME COVERS/EXHAUST MUFFLER AGILITY 125 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.
  • Page 32 . FRAME COVERS/EXHAUST MUFFLER AGILITY 125 Discornnect the seat lock wire. Seat Lock Wire Frame Body Remove the frame body cover. Cover The installation sequence is the reverse of remove Remove the three bolts attaching each of the right and left side covers.
  • Page 33 . FRAME COVERS/EXHAUST MUFFLER AGILITY 125 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 34: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT AGILITY 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 CLUTCH SHOE WEAR.......3- 9 VALVE CLEARANCE......3-5...
  • Page 35 . INSPECTION/ADJUSTMENT AGILITY 125 Cylinder compression : 13 kg/cm Ignition timing: BTDC 27°±2°/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...

  • Page 36: Maintenance Schedule

    . INSPECTION/ADJUSTMENT AGILITY 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 Regular Service Mileage (km) Whichever Frequency...

  • Page 37: Fuel Filter

    . INSPECTION/ADJUSTMENT AGILITY 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 38: Air Cleaner

    . INSPECTION/ADJUSTMENT FILLY LX 125 AIR CLEANER Screws AIR CLEANER REPLACEMENT Remove the air cleaner case cover screws and the cover by removing the six 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 39: Valve Clearance

    . INSPECTION/ADJUSTMENT AGILITY 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. Remove the cylinder head cover. ( 7-3) Remove the cylinder head cover..

  • Page 40: Ignition Timing

    . INSPECTION/ADJUSTMENT FILLY LX 125 IGNITION TIMING Remove the right of the fan cover. Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase.

  • Page 41: Agility

    . INSPECTION/ADJUSTMENT AGILITY 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. The oil level shall be at the oil check bolt hole.

  • Page 42: Brake Shoe

    . INSPECTION/ADJUSTMENT FILLY LX 125 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 43: Headlight Aim

    . INSPECTION/ADJUSTMENT AGILITY 125 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.

  • Page 44: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT FILLY LX 125 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 45 . INSPECTION/ADJUSTMENT AGILITY 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 46: Lubrication System

    . LUBRICATION SYSTEM AGILITY 125 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 47: Lubrication System

    . LUBRICATION SYSTEM AGILITY 125 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 48 . LUBRICATION SYSTEM AGILITY 125 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 49 . LUBRICATION SYSTEM AGILITY 125 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 50 . LUBRICATION SYSTEM AGILITY 125 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 51 . LUBRICATION SYSTEM AGILITY 125 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 52 . LUBRICATION SYSTEM AGILITY 125 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 53 . FUEL SYSTEM AGILITY 125...

  • Page 54: Fuel System

    . FUEL SYSTEM AGILITY 125 Ignition Switch Regulator /Rectifier Fuse 12V Battery Lighting System 5Ω Auto Bystarter...

  • Page 55: Service Information

    . FUEL SYSTEM AGILITY 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 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous.

  • Page 56: Troubleshooting

    . FUEL SYSTEM AGILITY 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 • Faulty accelerating pump −Clogged fuel filter...

  • Page 57: Carburetor Removal

    . FUEL SYSTEM AGILITY 125 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 58 . FUEL SYSTEM AGILITY 125 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 59: Air Cut-Off Valve

    . FUEL SYSTEM AGILITY 125 Screws AIR CUT-OFF VALVE 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. Air Cut-off Valve Cover...
  • Page 60 . FUEL SYSTEM AGILITY 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. Inspect the diaphragm for deterioration and tears.

  • Page 61: Float Chamber

    . FUEL SYSTEM AGILITY 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. Float Pin Needle Jet Holder...
  • Page 62 . FUEL SYSTEM AGILITY 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. ＊ Worn or contaminated float valve and...

  • Page 63: Carburetor Installation

    . FUEL SYSTEM AGILITY 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 64: Pilot Screw Adjustment

    . FUEL SYSTEM AGILITY 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 65: Fuel Tank

    . FUEL SYSTEM AGILITY 125 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.

  • Page 66: Fuel Unit

    . FUEL SYSTEM AGILITY 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. ＊ Do not bend the float arm on the fuel unit,otherwise the figure on the fuel meter will not correct.
  • Page 67 . FUEL SYSTEM AGILITY 125 The installation sequence is the reverse of removal. 5-14...
  • Page 68 . ENGINE REMOVAL/INSTALLATION AGILITY 125...
  • Page 69 6. ENGINE REMOVAL/INSTALLATION AGILITY 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 70: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION AGILITY 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. Auto Bystarter Wire Connector Starter Relay Disconnect the starter motor cable from the starter relay.
  • Page 71 6. ENGINE REMOVAL/INSTALLATION AGILITY 125 Brake Adjusting Nut Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable. Rear Shock Absorber Lower Mount Bolt Remove the rear shock absorber lower mount bolt. Engine Mounting Bolt Remove the four A.C.
  • Page 72 . ENGINE REMOVAL/INSTALLATION AGILITY 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. Install the engine hanger bracket bolt and tighten the nut.
  • Page 73 . CYLINDER HEAD/VALVES AGILITY 125...
  • Page 74 7. CYLINDER HEAD/VALVES AGILITY 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 75: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES AGILITY 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 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.
  • Page 76 7. CYLINDER HEAD/VALVES AGILITY 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. O-ring Remove the cam chain tensioner cap screw and the O-ring.
  • Page 77 . CYLINDER HEAD/VALVES AGILITY 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 78 7. CYLINDER HEAD/VALVES AGILITY 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 79 . CYLINDER HEAD/VALVES AGILITY 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. Separate the engine cover joint claws.
  • Page 80 7. CYLINDER HEAD/VALVES AGILITY 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 81 . CYLINDER HEAD/VALVES AGILITY 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 Measure each valve guide I.D.
  • Page 82 7. CYLINDER HEAD/VALVES AGILITY 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 83: Camshaft Installation

    . CYLINDER HEAD/VALVES AGILITY 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 facing up and align the punch marks on the...
  • Page 84 7. CYLINDER HEAD/VALVES AGILITY 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 85: Cylinder/Piston

    . CYLINDER/PISTON AGILITY 125 1.0kg-m Do not bend...

  • Page 86: Cylinder/Piston

    . CYLINDER/PISTON AGILITY 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. • After disassembly, clean the removed parts and dry them with compressed air before inspection.
  • Page 87 . CYLINDER/PISTON AGILITY 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 88 . CYLINDER/PISTON AGILITY 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. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 89 . CYLINDER/PISTON AGILITY 125 Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 52.3mm replace if below Measure the piston-to-piston pin clearance.
  • Page 90 . CYLINDER/PISTON AGILITY 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 91 . CYLINDER/PISTON AGILITY 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. ＊ • Position the piston “IN” mark on the intake valve side.
  • Page 92 . CYLINDER/PISTON AGILITY 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. Tighten the cylinder base bolts.

  • Page 93: Drive And Driven Pulleys/Kick Starter

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 125 5.0～6.0kg-m 3.5-4.5g-m 3.5-4.0g-m...

  • Page 94: Kick Starter

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 95 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 Cable Clamp cable clamp Remove the seal rubber and dowel pins.
  • Page 96 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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. Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet.
  • Page 97 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 125 Remove the movable drive face assembly. Drive Pulley Collar Remove the drive pulley collar. Movable Drive Face Assembly DISASSEMBLY Ramp Plate Remove the ramp plate. Remove the weight rollers. Weight Roller...
  • Page 98 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 99 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 Drive Pulley Collar Driven Pulley Lay the drive belt on the driven pulley.
  • Page 100 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 101 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 125 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 1.5mm replace if below CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley DISASSEMBLY Hold the clutch/driven pulley assembly with Clutch Spring Compressor the clutch spring compressor.
  • Page 102 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 125 Pull out the guide roller pins and guide Guide Roller Guide Roller Pin rollers. Remove the movable driven face from the driven face. Movable Driven Face O-ring Remove the oil seal from the movable Oil Seal driven face.
  • Page 103 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 REPLACEMENT Drive the inner needle bearing out of the driven pulley face.
  • Page 104 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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. Clutch Lining...
  • Page 105 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 106 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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. Install the left crankcase cover.
  • Page 107 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 Spindle Return Spring INSPECTION Inspect the kick starter spindle and gear for wear or damage.
  • Page 108 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 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 109 . FINAL REDUCTION AGILITY 50 10-0...
  • Page 110 . 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 111 . 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 112: Final Reduction

    . 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 113 . 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 114 . 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 115 . CRANKCASE/CRANKSHAFT AGILITY 125 11-0...
  • Page 116 . CRANKCASE/CRANKSHAFT AGILITY 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. • The following parts must be removed before separating the crankcase.

  • Page 117: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT AGILITY 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. Dowel Pins Remove the crankshaft and cam chain from the left crankcase.
  • Page 118 . CRANKCASE/CRANKSHAFT AGILITY 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. Service Limit: 0.55mm replace if over...
  • Page 119 . CRANKCASE/CRANKSHAFT AGILITY 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. CRANKCASE ASSEMBLY Install the cam chain into the left crankcase.
  • Page 120 . CRANKCASE/CRANKSHAFT AGILITY 125 Crankcase Bolts Tighten the two crankcase attaching bolts. Torque: 0.9kg-m 11-5...
  • Page 121 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 12-0...

  • Page 122: Front Wheel/Front Brake/ Front Suspension

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 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 123 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Excessive wheel bearing play cone race • Broken steering balls • Bent spoke plate • Insufficient tire pressure •...
  • Page 124 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 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. Remove the front and rear brake levers.
  • Page 125 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Throttle Cable Apply grease to the tip of the throttle pipe. 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 126 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Play Turn the wheel bearings and replace the bearings if they are noisy or have excessive play.
  • Page 127 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 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. Install the distance collar.
  • Page 128 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Side Collar Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Dust Seal Groove INSTALLATION Install the front wheel by aligning the brake panel groove with the front fork tab.
  • Page 129 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 DISASSEMBLY Do not swing the brake arm to expand the brake shoes. Remove the brake shoes by removing the brake shoe springs using a screw driver. Remove the brake arm and return spring.
  • Page 130 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Wear Indicator Plate Brake Cam Install the return spring by aligning the spring hook end with the hole in the brake panel. Apply a small amount of engine oil to the felt seal and install it to the brake panel.
  • Page 131 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 HYDRAULIC BRAKE (FRONT BRAKE) Upper Limit Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground. ＊ • When operating the brake lever, the brake reservoir cap must be tightened securely to avoid spill of brake fluid.
  • Page 132 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Pad Pin Brake Pad/Disk Replacement ＊ The brake pads must be replaced as a set to ensure the balance of the brake disk. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
  • Page 133 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 BRAKE MASTER CYLINDER Brake Master Cylinder Bolts Removal First drain the brake fluid from the hydraulic brake system. ＊ • When servicing the brake system, use shop towels to cover rubber and...
  • Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D. Service Limit: 12.6mm Before assembly, inspect the lst and 2nd rubber cups for wear.
  • Page 135 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 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 out the piston through the brake fluid inlet...
  • Page 136 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Punch Mark Bolts Place the brake master cylinder on the handlebar and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint. First tighten the upper bolt and then tighten the lower bolt.
  • Page 137 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 26.3mm Check the caliper cylinder for scratch or wear and measure the cylinder bore. Service Limit: 26.45mm Assembly Clean all removed parts.
  • Page 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Installation Install the brake caliper and tighten the two bolts. Torque: 2.9～3.5kg-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 2.5～3.5kg-m Fill the brake reservoir with recommended brake fluid and bleed air from the brake syst em.
  • Page 139 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. ( 12-4) Remove the front lower cover. ( 2-2) Remove the front inner fender. Remove the front shock absorber upper mount bolts.
  • Page 140 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Measure the front shock absorber spring free length. Service Limits: Right : 206.4mm Left : 206.4mm ASSEMBLY Top Nut Dust Seal Circlip Damper Oil Seal Damper Spring Shock Absorber Spring Front Shock...
  • Page 141 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube and tighten the top nut.
  • Page 142 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 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 143 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 125 Driver Handle A Drive new top and bottom ball races into the steering head using the outer driver. ＊ Be sure to completely drive in the ball races. Outer Driver, 37x40mm INSTALLATION...

  • Page 144: Rear Wheel /Rear Brake /Rear Suspension

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 1.2kg-m 1.0kg-m 11.0kg-m 3.5kg-m 13-0...

  • Page 145: Rear Suspension

    . 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 146 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Rear Axle Nut REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-5) Remove the rear axle nut to remove the rear wheel. INSPECTION Measure the rear wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over...
  • Page 147 . 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 148: Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Brake Arm Bolt Wear Indicator Plate Apply a small amount of engine oil to the felt seal and install it to the brake cam. Install the wear indicator plate and brake arm.
  • Page 149 . 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 150 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 125 Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then the lower mount bolt. Tighten the bolts. Torque: Upper Mount Bolt: 3.5~4.5kgf-m Lower Mount Bolt: 2.4~3.0kgf-m Install the air cleaner case.

  • Page 151: Battery/Charging System/A.c

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Battery Fuse Regulator/Rectifier Resistors A.C. Generator A.C. Generator Auto Regulator/ Bystarter Rectifier 5Ω Battery 12V4AH 14-0...
  • Page 152 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 SERVICE INFORMATION...... 14-1 A.C. GENERATOR CHARGING COIL ...14-6 TROUBLESHOOTING ......14-2 RESISTOR INSPECTION......14-6 BATTERY..........14-3 A.C. GENERATOR REMOVAL .....14-6 CHARGING SYSTEM ......14-4 A.C. GENERATOR INATALLATION ...14-8 REGULATOR/RECTIFIER...... 14-5 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes.
  • Page 153 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 SPECIFICATIONS Item Standard Capacity/Model 12V−7AH Voltage Fully charged 13.1V Battery (20℃) Undercharged 12.3V Charging current STD: 0.4A Quick: 4.0A Charging time STD: 5～10hr Quick: 30min Capacity 0.144KW/5000rpm A.C. Generator Lighting coil resistance (20℃) Yellow～Green...
  • Page 154 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 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. First disconnect the battery negative (-) cable and then the positive (+) cable.
  • Page 155 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 CHARGING SYSTEM Terminal 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 156 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 Regulator/Rectifier REGULATOR/RECTIFIER MAIN HARNESS CIRCUIT INSPECTION Remove the front covers. ( 2-2) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following : Item (Wire Color) Judgment Between battery (red) Battery has...
  • Page 157 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Charging Coil Wire A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 2P connector. Measure the resistance between the A.C.
  • Page 158 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 159 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 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 160 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 125 A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Holder Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
  • Page 161 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 125 Install the fan cover. Install the right side cover. ( 2-4) Fan Cover 14-10...

  • Page 162: Ignition System

    . IGNITION SYSTEM AGILITY 125 CDI Unit Ignition Switch A.C. Generator Spark Plug Pulser Coil Ignition Switch CDI Unit Battery 15-0...
  • Page 163 . IGNITION SYSTEM AGILITY 125 SERVICE INFORMATION ...... 15-1 IGNITION COIL ........15-4 TROUBLESHOOTING ......15-2 PULSER COIL ........15-5 CDI UNIT INSPECTION ......15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 15-2) •...
  • Page 164 . IGNITION SYSTEM AGILITY 125 TROUBLESHOOTING High voltage too low No or intermittent high voltage • Weak battery or low engine speed • Faulty ignition coil • Loose ignition system connection • Weak battery • Faulty ignition coil • Faulty charging system •...
  • Page 165 . IGNITION SYSTEM AGILITY 125 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 166 . IGNITION SYSTEM AGILITY 125 IGNITION COIL REMOVAL Remove the met-in box. ( 2-3) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. Ignition Coil INSPECTION CONTINUITY TEST ＊ The CDI unit is not adjustable. If the timing is incorrect, inspect the CDI unit, pulser coil and A.C.
  • Page 167 . IGNITION SYSTEM AGILITY 125 PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2-3) Disconnect the A.C. generator connector. Pulser Coil Coupler Measure the pulser coil resistance between the blue/yellow and green wire terminals.
  • Page 168 . STARTING SYSTEM AGILITY 125 Stop Switches Starter Relay Starter Button Starter Motor 16-0...

  • Page 169: Starting System

    . STARTING SYSTEM AGILITY 125 SERVICE INFORMATION.......16-1 STARTER MOTOR ........ 16-2 TROUBLESHOOTING......16-1 STARTER RELAY........16-4 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5...

  • Page 170: Starter Motor

    . STARTING SYSTEM AGILITY 125 Bolts STARTER MOTOR REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 171 . STARTING SYSTEM AGILITY 125 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.

  • Page 172: Starter Relay

    . STARTING SYSTEM AGILITY 125 Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.

  • Page 173: Starter Clutch

    . STARTING SYSTEM AGILITY 125 Yellow/Red Wire STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 174 . STARTING SYSTEM AGILITY 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. Flywheel Holder INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch.
  • Page 175 . STARTING SYSTEM AGILITY 125 Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Clutch Cover Measure the starter idle gear I.D. Starter Idle Gear Service Limit: 10.05mm replace if over Measure the starter idle gear shaft O.D.

  • Page 176: Lights/Instruments/Switches

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

  • Page 181: Headlight

    . LIGHTS/INSTRUMENTS/SWITCHES AGILITY 125 Screw HEADLIGHT REMOVAL Remove the screw on the front of the front cover. Remove the six screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.

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