User manual KYMCO AGILITY 50 SERVICE MANUAL

[. . . ] Agility 50 - 125 Agility 50 - 125 CICLOMOTORI 4T SCOOTER TARGATI 2 ANNI DI GARANZIA 1 ANNO DI ASSISTENZA CREDITO PERSONALIZZATO KYMCO RACCOMANDA Servizi Finanziari 50 4T R10 MOTORE RAFFREDDAMENTO CILINDRATA POTENZA COPPIA EMISSIONI AVVIAMENTO FRIZIONE TRASMISSIONE SOSPENSIONI FRENI PNEUMATICI DIMENSIONE MASSA COLORI argento ANT. 90/90-10 1. 830 x 690 x 1. 070mm 84kg nero 49cc 50 4T R12 MONOCILINDRICO ORIZZONTALE 4 TEMPI ARIA FORZATA 125 125cc 2, 4kW (3, 3CV) a 8. 500 giri/min 2, 4kW (3, 3CV) a 7. 500 giri/min 6, 9kW (9, 4CV) a 7. 500 giri/min 3, 2 Nm a 7. 000 giri EURO 2 ELETTRICO E KICK STARTER CENTRIFUGA AUTOMATICA A SECCO CINGHIA TRAPEZOIDALE - INGRANAGGI ANT. 130/70-12 1. 830 x 690 x 1. 130mm 92kg argento nero rosso 1. 835 x 690 x 1. 125mm 105kg giallo 9, 6 Nm a 6. 500 giri EURO 3 KYMCO SI RISERVA DI APPORTARE VARIAZIONI TECNICHE, ESTETICHE O DI ALTRA NATURA SENZA L'OBBLIGO DI ALCUN PREAVVISO. 2616-040407 AGILITY 50 PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing procedures for the KYMCO AGILITY 50 Section 1 contains the precautions for all operations stated in this manual. Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations. CHASSIS GENERAL INFORMATION FRAME COVERS/EXHAUST MUFFLER INSPECTION/ADJUSTMENT LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON DRIVE AND DRIVEN PULLEYS/KICK STARTER FINAL REDUCTION CRANKCASE/CRANKSHAFT FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION REAR WHEEL /REAR BRAKE /REAR SUSPENSION BATTERY/CHARGING SYSTEM/A. C. [. . . ] Remove the drive pulley face. Drive Face Nut (10mm) Movable Drive Face Assembly DISASSEMBLY Remove the movable drive face assembly and drive pulley collar from the crankshaft. Drive Pulley Collar 9-6 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Remove the ramp plate. AGILITY 50 Ramp Plate Weight Roller Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. Service Limit: 12. 4mm replace if below Check the drive pulley collar for wear or damage. DRIVE AND DRIVEN PULLEYS/ KICK STARTER INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft. AGILITY 50 Movable Drive Face Drive Pulley Collar Set the drive belt on the drive pulley collar. ( 9-6) Torque: 5. 5~6. 5kgf-m Do not get oil or grease on the drive belt or pulley faces. STARTER PINION REMOVAL Remove the left crankcase cover. INSPECTION Inspect the starter pinion shaft forcing part for wear or damage. INSTALLATION Apply a small amount of grease to the starter pinion shaft and install it in the reverse order of removal. Starter Pinion Starter Pinion Shaft 9-8 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Clutch Outer AGILITY 50 Nut CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9-6) Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch outer. Special Universal Holder Universal Holder Remove the clutch/driven pulley assembly Remove the drive belt from the clutch/driven pulley assembly. Clutch/Driven Pulley DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Set the clutch spring compressor in a vise and remove the 39mm clutch drive plate nut. Loosen the clutch spring compressor and disassemble the driven pulley assembly. Special Lock Nut Wrench, 39mm Clutch Spring Compressor Clutch Spring Compressor Remove the seal collar. 9-9 Seal Collar 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Pull out the guide roller pins and guide rollers. Remove the O-rings and oil seal from the movable driven face. Movable Driven Face AGILITY 50 Oil Seal O-rings Guide Roller Pin INSPECTION Inspect the clutch outer for wear or damage. Service Limit: 107. 5mm replace if over Check the clutch shoes for wear or damage. Service Limit: 2. 0mm replace if below Measure the driven face spring free length. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Check the driven face for wear or damage. Service Limit: 33. 94mm replace if below Check the movable driven face for wear or damage. Service Limit: 34. 06mm replace if over AGILITY 50 DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. Discard the removed bearing and replace with a new one. Inner Bearing Remove the snap ring and drive the outer bearing out of the driven face. Snap Ring Apply grease to the outer bearing. Drive a new outer bearing into the driven face with the sealed end facing up. Specified grease: Heat resistance 230 C Outer Bearing Bearing Remover 9-11 9. [. . . ] Install a new horn in the reverse order of removal. Screws 17-4 17. LIGHTS/INSTRUMENTS/SWITCHES HEADLIGHT REMOVAL Remove the screw on the front of the front cover. Align the tab on the headlight with the groove on the handlebar cover. ( 3-9) Screw FILLY LX 50 Front Cover Screws BULB REPLACEMENT Remove the headlight bulb Coupler. [. . . ]