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1 - Monster Scooter Parts

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2. e Lm NO me bech LP B NO ke A 0 7 1 1 0 7 1 1 1 0 2 0 0 7 1 1 1 2 1 6 0 07 0 09 0 4 0 7 1 1 1 5 3 5 4 5 5 0 6 0 0 8 1 2 0 1 0 3 5 5 6 5 1 0 1 4 0 8 1 2 0 8 1 2 8 0 12 0 5 0 7 0 11 0 13 0 4 0 5 0 2 0 3 0 0 45 0 6 Double end bolt Double end bolt Apply oil to threads dC KYMCO 1 GENERAL INFORMATION AGILITY 50 SPECIAL TOOLS 9 9 E027 2301a driven pully assy F004 52400 cushion assy 9 5 9 9 31110 flywheel comp 2310a pully driven 1 12 GQ KYMCO 1 GENERAL INFORMATION AGILITY 50 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAEIS5W 40 Cam lobes e API SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft R L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip Starter idle gear Friction spring movable part shaft movable part High temperature resistant grease Shaft movable grooved part Kick starter spindle movable part A C generator connector 5 Adhesive Transmission case breather tube 1 13 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 FRAME The following
3. z 1 5 pn A V 00 e THDTTdOLS ANZ C r3 AFC ATT ASE MOE AZT K 8s 8S as IOT INIA IHDIIGVHH Tle pI o Em ASUS ATI 8 lt IHOTIdOIS IIV L AVI AI CS 4 Z 5 WK WA xg ug Ng ALT ACL 25 T 1 T S A FT D INATT CS og BR D ALT ACL d d IWANTI e MALIN 45 E gt i lt Da MOL ATL z 5 SHXNIA WA HA CS Ty pes a 9 c Mi y XM lt lt DMAA Do Qo O ody EE CS mei Zi D oha pas A X 0 i gt ES IC d om Run Solo es hi L TANA om ASHLLVg INVIS Taos Get TOT La HVE AZI Y LA OdH S CS MS 97000 MOT ACI AS IHON AS INVIS ASdOLS WA AS dOLS W P DINIM W HA e 1 20 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment carburetor by loosening Check if fuel reaches drain screw Fuel reaches carburetor Probable Cause Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage logged fuel tank cap breather hole Clogged fuel filter Clogged fuel strainer Faulty auto fuel valve Fuel does not reach carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps
4. The CDI unit is not adjustable If the timing is incorrect inspect the CDI unit pulser coil and A C generator and replace any faulty parts Measure the resistance between the ignition coil primary coil terminals ur Resistance 0 1 1 0Q xix Measure the secondary coil resistances with and without the spark plug cap Resistances with plug 7 12 without plug cap 3 5 Correctly operate the tester following the manufacturer s instructions 15 4 KYMCO 15 IGNITION SYSTEM AGILITY 50 PULSER COIL INSPECTION This test 1s performed with the stator installed 1n 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 Resistance 80 1600 Refer to page 14 6 for the generator removal Timing Hole Cap IGNITION TIMING INSPECTION The CDI unit is not adjustable If the ignition timing is incorrect inspect the CDI unit pulser coil and A C generator and replace any faulty parts Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When the engine is running at the ignition timing is correct if the F mark aligns with the index mark within 2 Ignition Timing BTDC28 4000rpm Mark 15 5 KYMCO 16 STARTING SYSTEM AGILITY 50 Stop Switches 1
5. FRONT SUSPENSION HYDRAULIC BRAKE FRONT BRAKE Brake Fluid Replacement Air Bleeding Check the brake fluid level on level ground e When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by spill of brake fluid Brake Fluid Bleeding In order to avoid spill of brake fluid connect a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there 1s no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Brake Fluid Refilling Add DOT 4 brake fluid to the brake reservolr e When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e When using a brake bleeder follow the manufacturer s instructions e Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system Make sure to bleed air from the brake system KYMCO AGILITY 50 Upper Limit Lower Limit Bleed Valve Front Brake Caliper 12 10 12 FRONT WHEE
6. AGILITY 50 Location of Engine Serial Number 1 1 1 GENERAL INFORMATION dC KYMCO AGILITY 50 SPECIFICATIONS Name amp Model No Overall width mm 690 Engine type Rear wheel 130 70 12 56 Ground clearance mm 112 Perform Braking distance m 4 Initial speed ance 20km h 1 99 Gasoline 4 stroke Single cylinder Compression pressure kg cm 2 rpm 54 Semi sphere O H C 39 0 x 41 4 m oo 3 5 500kw r min 0 35 7000kg m rpm J Q2 EY 0 04 0 04 1700 100rpm Forced pressure amp Lubrication type Get DIE Inner outer rotor type Full flow filtration 0 8 liter Forced air cooling ose Valve clearance cold mm Idle speed rpm up 15 uoneonq 0191845 Jon uaurdrnb eorunoo q IMA SUMON Air cleaner type amp No Fuel capacity 5 0 liter Type CVK Piston dia mm Type Contact breaker Non contact point type Spark plug Spark plug gap 0 6 0 7mm 12V4AH Dry multi disc clutch Operation Automatic centrifugal Ionge UI9 s S uous Tear UOI SIUISUEI uononpowy Brake system DISK 180mm brake type Drum 110mm brake z TELESCOPE uspension type Shockabsorber Front 80 Rear 82 Frame type KYMCO 1 GENERAL INFORMATION AGILITY 50 SERVICE PRECAUTIONS Bi Make sure to install new gaskets O rings circlips cotter pins
7. Auto Cock Assy Fuel E Fuel Filter Fuel Tube Ignition Coil Primary Wire Ignition Wire Throttle Cable arburetor Vacuum Tee Overflow Tube rankcase Breather Tube 1 18 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 Fuel Unit Crankcase Breather Tube Throttle Cable Wire 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
8. gt Section 14 Carburetor air cleaner gt Section 5 Rear wheel rear shock absorber gt Section 13 Starter motor gt Section 16 Oil pump gt Section 4 SPECIFICATIONS Item Standard mm Service Limit mm Connecting rod big end side clearance 0 10 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 Runot Pt TORQUE VALUES Crankcase bolt 0 8 1 2kgf m Cam chain tensioner slipper bolt 0 8 1 2kgf m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bearing play 11 1 dO KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt and cam chain tensioner slipper Remove the crankcase attaching bolt Separate the left and right crankcase halves e Do not damage the crankcase gasket surface e Never use a driver to pry the crankcase mating surfaces apart Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Remove the cam chain KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces Oil Seal Remove the oil seal from the left crankcase T NZ Oil Seal Remove the oil seal from the right crankcase CRANKSHAFT Measure the connecting rod big end side clearance Service Limit 0 55mm replace if over Connecting Rod
9. pipe bolt and inspect EEE s Valve train lubricated Valve train not properly lubricated properly Check if engine overheats s RED at high speed Engine does not knock Engine knocks 1 22 dC KYMCO AGILITY 50 Probable Cause Clogged air cleaner Poor quality fuel Restricted Clogged fuel tank cap breather hole ged exhaust muffler ulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Faulty CDI unit Faulty pulser coil Improper valve clearance adjustment Worn valve seat valve stem too protruding Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Clogged carburetor jets Fouled spark plug Incorrect heat range plug Oil level too high Oil level too low Oil not changed logged oil pipe Faulty oil pump Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Excessive carbon build up in combustion chamber Poor quality fuel lutch slipping Mixture too lean Ignition timing too early dC KYMCO 1 GENERAL INFORMATION AGILITY 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing um e mU mr E L LE bein f e Faulty pulser coil Check carburetor pilot screw adjustment ixture
10. 2 Starter Relay Starter Button Starter Motor Starter Relay Ignition Switch R W R YR Us a A E Stoplight Battery Front AL Rear G Ul tarter Moto 4 um 16 E Stop Switches prn 16 0 16 STARTING SYSTEM SERVICE INFORMATION TROUBLESHOOTING C KYMCO AGILITY 50 STARTER MOTOR STARTER RELAY SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed SPECIFICATIONS Standard mm ons Lal Dun TROUBLESHOOTING Starter motor won t turn e Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter clutch e Faulty front or rear stop switch e Faulty starter relay e Poorly connected broken or shorted wire e Faulty starter motor 16 1 Lack of power e Weak battery e Loose wire or connection e Foreign matter stuck in starter motor or gear Starter motor rotates but engine does not start e Faulty starter clutch e Starter motor rotates reversely e Weak battery KYMCO 16 STARTING SYSTEM AGILITY 50 Bolts STARTER MOTOR REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly Rfmove the mrt in box Remove the starter motor cable Remove the two starter motor mo
11. It filters the fresh air drawn for re burning to Filter secondary air prevent dirt or dust from affecting the operation of the air injection cut off valve Secondary Air Cleaner The air injection cut off valve usually opens to lead air into the exhaust muffler in which air is re burned to reduce CO When the throttle valve closes suddenly the air injection cut off valve 1s actuated by vacuum to close and cut off secondary air in order to prevent exhaust muffler backfiring due to air in the exhaust system Prevent exhaust Air Injection Cut muffler noise and off Valve backfiring at sudden deceleration When the motorcycle speed 1s less than 50km per hour the reed valve operates to draw secondary air into the exhaust system for re combustion Control the secondary Reed Valve air inlet to reduce CO SERVICE INFORMATION GENERAL INSTRUCTIONS e During operation be careful to avoid scalding caused by the exhaust muffler e Note the locations of tubes for proper installation e Replace any damaged tube with a new one e Make sure to tighten the connector of each tube securely TOOLS SPECIFICATIONS e Vacuum pump Air injection cut off valve actuating pressure 250mm Hg 30 liter min Reed valve stopper clearance 6 6mm TROUBLESHOOTING High CO at idle speed Exhaust muffler noise e Damaged or clogged reed valve e Faulty air injection cut off valve e Damaged or clogged air injection cut off valve e Broken vacuum tu
12. gt Outer Bearing Bearing Remover 1 ORG B Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Pack all bearing cavities with 5 0 5 6g grease Specified grease Heat resistance 230 C 9 11 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER AGILITYSO Driver Handle Press a new needle bearing into the driven face Outer Driver 24x26mm Pilot 17mm Movable Driven Face Oil Seal ASSEMBLY Install the movable driven face onto the driven face Install the O rings guide rollers and guide roller pins Install the a new oil seal Install the seal collar Seal Collar Lock Nut Wrench 39mm Set the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor Compress the clutch spring compressor and install the 39mm drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 0 6 0kgf m Clutch Spring Compressor Clutch Spring Compressor 9 12 9 DRIVE AND DRIVEN PULLEYS dC KYMCO KICK STARTER AGILITY 50 INSTALLATION Clutch Driven Geen Lay the drive belt on the driven pulley and install the clutch driven pulley onto the drive shaft aa f F t ud Install the clutch outer Hold the clutch outer with the universal holder Install and tighten
13. Intermittent high voltage e Faulty ignition switch e Poorly connected CDI unit coupler e Poorly connected or broken CDI ground wire e Faulty pulser coil e Loose high tension wire connection e Faulty CDI unit Normal high voltage but no spark at plug e Faulty spark plug e Faulty spark plug cap No high voltage e Faulty ignition switch e Dead battery or faulty regulator rectifier e Faulty charging circuit e Faulty ignition coil e Faulty CDI unit 15 2 15 IGNITION SYSTEM 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 e Due to the semiconductor in circuit it 1s necessary to use a specified tester for accurate testing Use of an improper tester In an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester e n this table Needle swings then returns indicates that there 1s a charging current applied to a condenser The needle will then remain at unless the condenser is discharged 15 3 Black Blue Yellow Yellow Green C KYMCO AGILITY 50 KYMCO 15 IGNITION SYSTEM AGILITY 50 IGNITION COIL REMOVAL Remove the met in box 2 3 Remove the spark plug cap Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil Ignition Coil INSPECTION CONTINUITY TEST
14. lower mount bolts Remove the rear shock absorber DISASSEMBLY Install the rear shock absorber compressor as the figure shown Install the rear shock absorber lower Joint into the rear shock absorber compressor Compress the rear shock absorber spring Special Cushion Assemble amp Disassemble Tool dC KYMCO AGILITY 50 Wear Indicator Plate Punch Mark En Return Spring Brake Cable K t Brake Arm Pin Adjusting Nut Upper Mount Bolt Lower Mount Bolt L Rear Shock Absorber Rear Shock Absorber Compressor Cushion Assemble amp Disassemble Too 1 3 4 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PP Lock Nut Loosen the lower joint lock nut Remove the lower joint Remove the lock nut rubber and damper INSPECTION Inspect the damper rod for bending or damage Inspect the damper for oil leaks Inspect the damper rubber for deterioration or damage eee Damper Damper Rod Rubber Measure the rear shock absorber spring free length Service Limit 198mm replace if over ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly e nstall the shock absorber spring with loosely wound coils facing down e Apply locking agent to the lock nut threads and tighten the lock nut 13 5 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION prin Upper Mount Bo
15. 20 Yellow Green 0 1 1 00 Charging coil resistance 20 0 2 1 20 Single phase half wave SCR 13 1 13 9V 5000rpm Electric tester tachometer Lighting Limit voltage Regulator Rectifier Resistor TORQUE VALUES Pulser coil bolt 0 45 0 6kgf m Stator bolt 0 8 1 2kgf m Flywheel nut 3 5 4 5kgf m Cooling fan bolt 0 8 1 2kgf m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power e Dead battery e Loose battery cable connection e Disconnected battery cable e Loose charging system connection e Fuse burned out e Loose connection or short circuit in e Faulty ignition switch lighting system Low power Charging system failure e Weak battery e Loose broken or shorted wire or connector e Loose battery connection e Faulty regulator rectifier e Charging system failure e Faulty A C generator e Faulty regulator rectifier 14 2 14 BATTERY CHARGING SYSTEM KYMCO 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 When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence is the reverse of
16. Apply grease to the ball races and install the front fork Steel Balls Apply grease to the top cone race and install Top Cone Race it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Long Socket Wrench Install the steering stem lock nut and tighten it while holding the top cone race Torque 6 0 8 0kgf m Install the front wheel gt 12 7 Install the steering handlebar gt 12 3 Install the speedometer cable gt 12 7 Special Long Socket Wrench 32mm 8Angle 12 22 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION noci 1 0kg m 3 bkg m 13 0 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION ie SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL SERVICE INFORMATION GENERAL INSTRUCTIONS e During servicing keep oil or grease off the brake drum and brake linings SPECIFICATIONS Standard mm Service Limit mm Rear wheel Rear brake drum I D Rear brake lining thickness Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11 13kgf m Rear shock absorber upper mount bolt 3 5 4 5kgf m Rear shock absorber lower mount bolt 2 4 3 0kgf m Exhaust muffler joint lock nut 1 0 1 4kgf m Exhaust muffler lock bolt 3 0 3 6kgf m Special Tool Cushion Assemble amp Disassemble To
17. Base Bolts 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER AGILITYSO 9 0 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER etiem SERVICE INFORMATION DRIVE BELT TROUBLESHOOTING DRIVE PULLEY LEFT CRANKCASE COVER CLUTCH DRIVEN PULLEY KICK STARTER SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed e Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS Chueh ning thickness Le Driven face springfeelength isse TOROUE VALUES Drive face nut 5 5 6 5kgf m Clutch outer nut 3 5 4 5kef m Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Universal holder Clutch spring compressor TROUBLESHOOTING Engine starts but motorcycle won t move Lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Broken driven face spring e Fouled drive face Engine stalls or motorcycle creeps e Broken clutch weight spring 9 1 9 DRIVE AND DRIVEN PULLEYS KICK STARTER LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw Remove the eight left crankcase cover bolts and left crankcase cover Remove the seal rubber and dowel pins Inspect the seal rubber for damage or deterioration Use spe
18. 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 Between battery red Battery has and engine ground voltage Between ground green and engine ground Between lighting wire yellow and engine ground Remove the A C generator resistor coupler and auto stator has bystarter coupler and resistance turn the lighting switch OFF for inspection Between charging coil A C generator white and engine stator has ground resistance REGULATOR RECTIFIER INSPECTION If the main harness terminals are normal check the regulator rectifier coupler for loose connection and measure the resistances between the regulator rectifier terminals e Do not touch the tester probes with your finger because human body has resistance e Use the following specified testers for accurate testing Use of an improper tester in an improper range may give false readings Kowa Electric Tester Sanwa Electric Tester Kowa Electric Tester TH 5H e Proper range for testing Use XKQ range for Sanwa Tester Use X100Q range for Kowa Tester e If the dry battery in the tester 15 weak the readings will be incorrect In this case check the dry battery e The Kowa tester readings are 100 times the actual values Be careful during testing Replace the regulator rectifier if the read
19. KYMCO _ KICK STARTER AGILITYSO _ Friction Spring Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown Starter Driven Gear First install the washer and then install the circlip Install the kick lever Washer Circlip Dowel Pins LEFT CRANKCASE COVER AE NS INSTALLATION 4 First install the dowel pins Install the seal rubber Seal Rubber Left Crankcase Cover Install the left crankcase cover and tighten the ey eight left crankcase cover bolts diagonally Connect the drive belt air tube and tighten the tube band screw Install the rear brake cable clamp o 50 2 v Clamp Rear Brake Cable 9 4 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER KENE DRIVE BELT REMOVAL Remove the left crankcase cover INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 16 5mm REPLACEMENT Remove the eight left crankcase cover bolts and left crankcase cover 9 2 Hold the clutch outer with an universal holder and remove the clutch outer nut Special Universal Holder Universal Holder Drive Pulley Face Hold the drive pulley using a holder and remove the drive face nut starting ratchet and washer Remove the drive pulley face Drive Face Nut Clutch Driven Pulley Remove the drive belt from the clutch driven gt jm
20. REG REC UNIT EHE KEE R 2 R G G FUEL METER SB RH RR WINKER SPEED METER TEN B L R G G Ur L K FUSE 7A I A ILLUMI G 12V1 7VV BR s ILLUMI G iD BR P P Y Y SB PILOT LAMP yi y BR BR BR BR R L TURN PILOT YIR YIR 12V34W UW UW TAIL STOP LIGHT HIGH BEAM PILOT YAN YAN 12V 5 21W 12V 17W E E alE LG LG SB G RH FR WINKER 12V 10W G o LH RR WINKER 12V 10W HEAD LIGHT tegis NEN LH FR POSITION m IGN COIL lul w s AUTO ay BIS CDI SPARK PLUG UNIT 12V 3W om o mE L 9 C 25 75 122 PULSER 30W 5W EARTH BEG 12V 10W WINKER HORN START MOTOR LH FR WINKER RELAY RR STOP LIGHTING SW DIMMER PASSING sw WINKER amp HORN SW COMB SW WINKER SW START SW PASSING SW HORN SW
21. across the battery negative terminal and the ground wire Turn the ignition switch OFF and check for short circuit Connect the electric tester positive 4 terminal to ground wire and the tester negative terminal to the battery negative terminal If any abnormality 1s found check the ignition E Battery switch and wire harness for short circuit Terminal Terminal E CURRENT TEST This inspection must be performed with an electric tester when the battery is fully charged Warm up the engine for inspection Connect the electric tester across the battery terminals Disconnect the fuse and connect an ammeter between the fuse terminals Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 14 15V 0 5A max fuse 5000rpm max Headlight Wire Coupler If the limit voltage 1s not within the specified VE range check the regulator rectifier gt 14 5 LIGHTING SYSTEM LIMIT VOLTAGE INSPECTION Remove the handlebar front cover 2 2 Measure the voltage with the electric tester in the AC range Limit Voltage 12 14V 5000rpm max If the limit voltage 1s not within the specified range check the regulator rectifier gt 14 5 Perform this test with a fully charged battery 14 4 14 BATTERY CHARGING SYSTEM A C GENERATOR REGULATOR RECTIFIER MAIN HARNESS CIRCUIT
22. affected 2 IRREGULAR MAINTENANCE Inspect and repair when obvious symptoms of ignition failure engine overheating and stalling are found frequently Remove carbon deposits from the exhaust system cylinder Carbon deposit removal head and piston head when the engine horsepower decreases greatly during the service mileage of 10000 15000 km Perform CVT system maintenance and inspection when the engine performance decreases obviously Severe use in the first 1000 km may cause worn or seized Piston cylinder piston and piston rings Clean or replace with new ones if necessary 18 2 18 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM SECONDARY AIR CLEANER Center Coverl Met in Box REMOVAL Remove the met in box 2 3 Remove the center cover gt 2 Remove the rear seat and rear carrier gt 2 Remove the frame body covers gt 2 Remove the floor board gt 2 Floor Board Secondary Air Disconnect the secondary air cleaner Cleaner connecting tube Remove the air cleaner attaching the air cleaner INSTALLATION The installation sequence is the reverse of removal eh I P 1 H H J Vacuum Tube Tube to Reed Valve DISASSEMBLY Remove the two e The secondary air cleaner must be assembled and installed properly to avoid dust entering the air cleaner 18 3 START LIGHT SW FR STOP SW COMB SW BATTERY 12V3AH FUEL DETECTOR UNIT
23. air Blow compressed air through all passages of the carburetor body GQ KYMCO 5 FUEL SYSTEM AGILITY 50 _ Valve Seat INSPECTION Inspect the float valve and valve seat for damage or clogging Inspect the float valve and valve seat contact area for stepped wear or contamination Worn or contaminated float valve and valve seat must be replaced because it will result in float level too high due to incomplete airtightness Needle Jet Holder Slow Jet ASSEMBLY Install the slow jet needle jet needle jet holder main jet and pilot screw Return the pilot screw to the original position as noted during removal Standard Opening 2 1 turns Ww fe 2 NS Pilot Screw Needle Jet Main Jet Float Float Valve Install the float valve float and float pin Secure the float pin with the screw FLOAT LEVEL INSPECTION Float Pin Screw e Check the operation of the float valve and float before this inspection e Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet Measure the float level Float Level 17 0mm This installation sequence is the reverse of removal 5 9 Float Level Gauge GQ KYMCO 5 FUEL SYSTEM AGILITY 50 Screws Diaphragm ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover Remove the spring and accelerating pump
24. battery removal i First connect the positive cable and the negative cable to avoid short circuit BATTERY VOLTAGE OPEN CIRCUIT VOLTAGE INSPECTION Remove the floor board Open the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 1V Undercharged 12 3V max negative cable positive cable Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal re Keep flames and sparks away from a charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery to avoid explosion e Charge the battery according to the e Quick charging should only be done in an emergency e Measure the voltage 30 minutes after the battery is charged Red Power TLamptRed Charging Charging current Standard 0 4A Quick 4A Charging time Standard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min Note The battery temperature should not exceed 45 during charging 14 3 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR Terminal CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter
25. by removing the four cooling fan attaching bolts Cooling Fan Hold the flywheel with an universal holder Remove the flywheel nut Special Universal Holder Universal Holder ET d Leg 1 bg Z E es Dh R nn D Ve a i i z E EZ d h Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Flywheel Puller Remove the A C generator wire connector 14 7 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR AGILITY 50 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 A C GNERATOR INSTALLATION Flywheel 5 5kg m Woodruff Key Cooling Fan 0 9ke m Fan Cover A C Generator Wire Stator Rubber Sleeve Install the generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 45 0 6kgf m Stator 0 8 1 2kgf m Install the A C generator wire rubber sleeve and A C generator wire set plate 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR psit Connect the A C generator wire connector A C Generator Wire Connector Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway Install the flywheel onto the crankshaft
26. deposits with a spark plug cleaner or a wire brush Specified Spark Plug CHAMPION P RZ9HC Measure the spark plug gap Gap Wear and Spark Plug Gap 0 6 0 7mm Fouling Deposits 0 6 0 7mm When installing first screw in the spark plug by hand and then tighten it with a Washer spark plug wrench Deformation Cracks Damage dC KYMCO 3 INSPECTION ADJUSTMENT AgIUTYs0 _ VALVE CLEARANCE Oe za Inspect and adjust valve clearance while the engine is cold below 35 Remove the frame cover 22 3 Remove the six bolts on the cylinder head cover Remove the cylinder head cover 57 3 Remove the cylinder head cover Turn the flywheel counterclockwise so that the T mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Round Hole Inspect and adjust the valve clearance Tappet Adjuster Valve Clearance IN 0 04mm EX 0 04mm Loosen the lock nut and adjust by turning the adjusting nut Special Tappet Adjuster e Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED e The engine must be warm for accurate idle speed inspection and adjustment Remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Sp
27. ground for this operation Pilot Screw A tachometer must be used when adjusting the engine speed Turn the pilot screw clockwise until it seats lightly and back it out to the specification given Standard Opening 2 turns e The carburetor must be adjusted when the engine 15 warm and the auto bystarter 1s closed e Do not force the pilot screw against its seat to prevent damage Warm up the engine and adjust the throttle stop screw to obtain the specified idle speed Idle Speed 1900 100rpm Turn the pilot screw in or out slowly to obtain the highest engine speed Slightly accelerate several times to make sure that the idle speed 1s within the specified range If the engine misses or runs erratic repeat the above steps Throttle Stop Screw 5 12 KYMCO 5 FUEL SYSTEM AGILITY 50 Fuel FUEL TANK REMOVE Tank Remove the net in box 2 3 Remove the frame center cover Remove the frame body cover 2 3 Remove the four bolts on the fuel tank take the upper seat lock off Disconnect the fuel unit wire connector Remove the fuel tank The installation sequence is the reverse of removal Fuel Unit Wite Connector FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air e When removing the fuel strainer do not allow flames or sparks near the working area and drain the r
28. pulley 9 5 9 DRIVE AND DRIVEN PULLEYS KICK STARTER INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley Set the drive belt on the drive pulley face collar Install the drive pulley face starting ratchet washer Install and tighten the drive face nut When installing align the tooth space of the drive pulley face and starting ratchet with the crankshaft tooth and then tighten the nut DRIVE PULLEY REMOVAL Hold the drive pulley using a holder and remove the drive face nut starting ratchet and washer Remove the drive pulley face DISASSEMBLY Remove the movable drive face assembly and drive pulley collar from the crankshaft OK KYMCO AGILITY 50 Drive Belt Drive Face Nut Drive Pulley Face Drive Belt i i 10mmWasher Starting Ratchet Starting Ratchet Drive Pulley Face Drive Face Nut 10mm Movable Drive Face Assembly _ C gt 9 DRIVE AND DRIVEN PULLEYS KICK STARTER Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 12 4mm replace if below Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 19 97mm replace if below KYMCO AGILITY 50 Ramp Plate 9 DRIVE AND
29. rear brake cable Remove the rear brake shoes 1 Ze Adjusting Nut Brake Arm Bolt Wear Indicator Plate Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Remove the brake cam Brake Arm mm Cam Grease CES Wf REAR BRAKE ASSEMBLY Apply grease to the anchor pin Apply grease to the brake cam and install it Install the brake shoes AL E J d EI b 1 gt E 4 d d P p D r w 4 e d PN m 1 E Li P AN AR M D a 1 LM d Ay 13 3 13 REAR WHEEL REAR BRAKE REAR SUSPENSION Apply a small amount of engine oil to the felt seal and install it to the brake cam Install the wear indicator plate and brake arm Align the wide groove on the wear indicator plate with the wide tooth of the brake cam Install and tighten the brake arm bolt L Align the scribed line on the brake arm with the punch mark on the brake cam Install the brake arm return spring Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel gt 13 2 Adjust the rear brake lever free play 3 8 REAR SHOCK ABSORBER REMOVAL Remove the frame body cover 2 3 Remove the air cleaner case 255 19 Remove the rear shock absorber upper and
30. ring into the cU Cam Chain Tensioner Slipper Bolt 11 6 12 FRONT WHEEL FRONT BRAKE KYMCO __ FRONT SUSPENSION AGILITYSO 12 0 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION perm SERVICE INFORMATION FRONT BRAKE TROUBLESHOOTING FRONT SHOCK ABSORBER STEERING HANDLEBAR FRONT FORK FRONT WHEEL SERVICE INFORMATION GENERAL INSTRUCTIONS e 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 e During servicing keep oil or grease off the brake drum and brake linings SPECIFICATIONS Axle shaft runout 9 7 P Radial _ 20 Axa LL 20 Front brake drum I D 110 SG20AB 111 SG20AB Front brake lining thickness 4 0 SG20AB 2 0 8G20AB Front shock absorber spring free length 210 9 206 4 TORQUE VALUES Handlebar bolt 4 5 5 5kgf m Steering stem lock nut 6 0 8 0kgf m Steering top cone race 0 5 1 3kgf m Front shock absorber bolt 3 0kgf m Front axle nut 5 0 7 0kgf m Brake arm bolt 0 8 1 2kgf m SPECIAL TOOLS Long socket wrench 32mm _ 8angle 12 1 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e
31. too rich turn screw Incorrectly adjusted out ixture too lean turn screw in Check carburetor gasket for air leaks Deteriorated O ring Carburetor not securely tightened Damaged insulator rubber Broken vacuum tube Remove spark plug and Install it into spark plug cap to test spark by gt connecting it to engine ground Faulty or fouled spark plug Faulty CDI unit aulty A C generator aulty ignition coil Broken or shorted spark plug wire Faulty ignition switch m aulty air cut off valve Damaged vacuum tube logged or damaged air vent hole 1 23 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing SE ee Probable Cause aulty CDI unit Faulty pulser coil Improperly adjusted valve clearance Correctly adjusted Incorrectly adjusted Worn camshaft Worn valve seat Check fuel pump for fuel supply OEE P Empty fuel tank Fuel flows freely Fuel flow restricted logged fuel tube or filter Faulty charcoal canister Faulty auto fuel valve Check carburetorjets for clogging MSIE GHI EH mH INI DD MES 5 Not clogged Clogged Clean and unclog Check valve mino ar Cam timing gear aligning marks not aligned Check valve spring tension Weak spring Faulty spring 1 24 dC KYMCO 1 GENERAL INFOR
32. 6mm 5 2 5 FUEL SYSTEM TROUBLESHOOTING Engine is hard to start e No spark at plug Section 15 e Compression too low e No fuel to carburetor Clogged fuel filter Restricted fuel line Faulty float valve Incorrectly adjusted float level e Engine flooded with fuel Clogged air cleaner Fuel overflowing e Intake air leak e Contaminated fuel e Faulty auto bystarter e Clogged idle system or auto bystarter passages Rich mixture e Faulty auto bystarter e Faulty float valve e Float level too high e Clogged air jets e Dirty air cleaner e Flooded carburetor Backfiring at deceleration e Lean mixture in idle system e Improper air cut off valve operation GQ KYMCO AGILITY 50 Misfiring during acceleration e Faulty ignition system e Lean mixture e Faulty accelerating pump Engine idles roughly stalls or runs poorly e Clogged fuel system e Ignition malfunction e Rich or lean mixture e Contaminated fuel e Intake air leak e Incorrect idle speed e Incorrectly adjusted pilot screw e Clogged idle system or auto bystarter passages e Incorrectly adjusted float level Lean mixture e Clogged fuel jets e Faulty float valve e Float level too low e Clogged fuel system e Intake air leak e Improper vacuum piston operation e Improper throttle operation dC KYMCO 5 FUEL SYSTEM AGILITY 50 CARBURETOR REMOVAL Remove the frame right side cover 2 4 Disconnect the auto bystarter wir
33. AL CAMSHAFT INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts valve arm and camshaft sliding surfaces for initial lubrication e The camshaft 1s lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head e After disassembly clean the removed parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Standard mm Service Limit mm N 004 4j Eo EN MERC NR Cylinder head compression 14kg cm COo o Cylinder head warpage el 05 26 438 26 038 Camshaft cam height 25 807 25 407 Valve rocker arm I D 10 000 10 015 10 10 10 000 10 015 10 10 Valve rocker arm shaft IN 9 972 9 987 O D EX 9 972 9 987 EEE bcd dA IN 4 975 4 990 EX 4 955 4 970 IN 5 000 5 012 5 000 5 012 Valve stem to guide IN 0 010 0 037 clearance EX 0 030 0 057 Valve spring free 7 CYLINDER HEAD VALVES TORQUE VALUES Cylinder head nut 1 8 2 2kgf m Valve clearance adjusting nut 0 7 1 1kgf m SPECIAL TOOLS Valve spring compressor TROUBLESHOOTING KYMCO AGILITY 50 Apply engine oil to threads
34. Agility 50 125 Agility 50 125 O KYMCO CICLOMOTORI 4T SCOOTER TARGATI 2 ANNI DI GARANZIA 1 ANNO DI ASSISTENZA CREDITO PERSONALIZZATO KYMCO RACCOMANDA ue KYMCO J lm 50 4T R10 50 4T R12 125 MOTORE MONOCILINDRICO ORIZZONTALE 4 TEMPI RAFFREDDAMENTO ARIA FORZATA CILINDRATA 49cc 125cc POTENZA 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 COPPIA 3 2 Nm a 7 000 giri 9 6 Nm a 6 500 giri EMISSIONI EURO 2 EURO 3 AVVIAMENTO ELETTRICO E KICK STARTER FRIZIONE CENTRIFUGA AUTOMATICA A SECCO TRASMISSIONE CINGHIA TRAPEZOIDALE INGRANAGGI SOSPENSIONI ANT FORCELLA TELESCOPICA IDRAULICA 9 31 POST MONOBRACCIO OSCILLANTE AMMORTIZZATORE IDRAULICO REGOLABILE FRENI ANT DISCO 9 180mm POST TAMBURO 9 110mm PNEUMATICI 20 9070 10 s DIMENSIONE 1 830 x 690 x 1 070mm 1 830 x 690 x 1 130mm 1 835 x 690 x 1 125mm MASSA 84kg 92kg 105kg COLORI argento nero argento nero rosso giallo KYMCO SI RISERVA DI APPORTARE VARIAZIONI TECNICHE ESTETICHE O DI ALTRA NATURA SENZA L OBBLIGO DI ALCUN PREAVVISO 2616 040407 PREFACE 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 Read them carefully before starting any operation Section 2 1s the removal i
35. Apply engine oil to threads e The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed e Compression too low Compression too low e ncorrect valve clearance adjustment e Burned or bend valves e ncorrect valve timing e Broken valve spring e Poor valve and seat contact e Leaking cylinder head gasket e Warped or cracked cylinder head e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber White smoke from exhaust muffler e Worn valve stem or valve guide e Damaged valve stem seal Abnormal noise e Incorrect valve clearance adjustment e Sticking valve or broken valve spring e Damaged or worn camshaft e Worn cam chain guide e Worn camshaft and rocker arm 7 2 KYMCO EE Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover 2 3 Remove the frame center Remove the four cylinder head cover bolts to remove the cylinder head cover Remove the cam chain tensioner sealing bolt Sealing Bolt Bolts and spring Remove the two bolts attaching the cam chain tensioner and the tensioner 3 Turn the flywheel counterclockwise so that Camshaft Gear the T mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke m4 sl Round Hole Punch M
36. Bent front fork e Bent front axle or uneven tire Poor brake performance e Incorrectly adjusted brake e Worn brake linings e Contaminated brake lining surface e Worn brake shoes at cam contacting area e Worn brake drum e Poorly connected brake arm GQ KYMCO AGILITY 50 Front wheel wobbling e Bent rim e Excessive wheel bearing play e Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs e Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 12 2 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION pe RN STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers c 2 2 Remove the two bolts attaching each of the front and rear brake levers Remove the front and rear brake levers Bolts p Bolts Throttle Pipe Remove the two throttle holder screws and throttle holder Disconnect the throttle cable from the throttle pipe and then remove the throttle pipe from the handlebar Throttle Cable Remove the handlebar lock nut and bolt to remove the handlebar Nut Bolt Bolt Orifice INSTALLATION Install the handlebar onto the steering stem by aligning the tab on the handlebar with the bolt orifice on the steering stem Install and tighten the handlebar bolt and lock nut Torque 4 5 5 5kgf m 12 3 12 FRONT WHEEL FRONT BRAKE KYMCO __ F
37. Big End 11 3 KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 Measuring Location Measure the connecting rod big end radial clearance at two points at right angels to the shaft Service Limit 0 05mm replace if over Measure the crankshaft runout Service Limit 0 1 Omm replace if over Crankshaft Bearings 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 new oil seals into the right and left crankcase e Outer Driver 11 4 dC KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 Install the cam chain into the left crankcase Install the crankshaft into the left crankcase When installing the cam chain be careful not to damage the oil seal Install the dowel pins and a new gasket onto the left crankcase Place the right crankcase over the crankshaft and onto the left crankcase Tighten the crankcase attaching bolt Torque 0 8 1 2kgf m 11 5 Driver Handle A A E Outer Driver Cam Chain Dowel Pins Crankcase Bolt dO KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 O ring Install the cam chain tensioner slipper j Install a new O ring onto the cam chain tensioner slipper bolt Apply engine oil to the O ring and tighten the bolt Torque 0 8 1 2kgf m giae Ze Bet e Be sure to install the O
38. DRIVEN PULLEYS KYMCO KICK STARTER AGILITY 50 Movable Drive Face INSTALLATION x Install the drive pulley collar and movable drive face onto the crankshaft Set the drive belt on the drive pulley collar Install the drive pulley face and tighten the drive face nut 49 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 Remove the drive pulley Remove the starter pinion holder Remove the starter pinion INSPECTION Inspect the starter pinion shaft forcing part for wear or damage e Inspect the starter pinion for smooth e operation Inspect the starter pinion and shaft for wear or damage Starter Pinion Starter Pinion Shaft INSTALLATION Apply a small amount of grease to the starter pinion shaft and install it in the reverse order of removal 9 DRIVE AND DRIVEN PULLEYS KICK STARTER 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 Remove the clutch driven pulley assembly Remove the drive belt from the clutch driven pulley assembly 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 clutc
39. EMOVAL 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 Front Cover Screws Handlebar Front Cover Handlebar Rear Cover HANDLEBAR FRONT REAR COVER REMOVAL HANDLEBAR FRONT COVER REMOVAL Remove the handlebar front cover screw Remove the two screws attaching the handlebar front cover Disconnect the headlight wire connector and remove the handlebar front cover HANDLEBAR REAR COVER REMOVAL i Disconnect the speedometer cable right and Handlebar Front Cover left handlebar switch couplers and the stop switch wire connectors Remove the bolt attaching the handlebar rear cover Remove two screws inside the handlebar rear cover and remove the handlebar rear cover The installation sequence is the reverse of removal dC KYMCO 2 FRAME COVERS EXHAUST MUFFLER cu a _ 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 Remove the three bolts attaching the rear carrier Remove the rear carrier Remove the four bolts on the rear seat Remove the rear seat Remove the six screws on the rear part of the frame body cover Remove the two screws on the front of the frame body cover 2 3 KYMCO 2 FRAME COVE
40. EVEL 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 uw 2 NS If the oil level is low add the recommended E a W s iz Ja oil to the proper level a Es Ee gel P dd Ws Recommended Oil SAE90 SET o TE SS KS Y Oil Check Bolt Sealing Washer Install the oil check bolt Make sure that the sealing washer is in good condition Oil Check Bolt Hole OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt Torque 0 8 1 2kgf m Make sure that the sealing washer 1s in good condition Fill with the recommended oil Oil Capacity At disassembly 0 11 liter At change 0 10 liter Reinstall the oil check bolt and check for oil leaks Torque 0 8 1 2kgf m DRIVE BELT Remove the left crankcase cover 99 2 Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule Drive Belt 3 7 GQ KYMCO 3 INSPECTION ADJUSTMENT FILLY LX 5 BRAKE SHOE AITOWS Punch Mark 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 REAR BRAKE Measure the rear brake lever fre
41. FORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed in the frame e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line e Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After the oil pump is installed check each part for oil leaks SPECIFICATIONS Standard mm Service Limit mm Inner rotor to outer rotor clearance 02 Oil pump Outer rotor to pump body clearance 02 Rotor end to pump body clearance 0 05 0 10 TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption e Oil level too low e Oil leaks e Clogged oil filter or oil passages e Worn or poorly installed piston rings e Not use the specified oil e Worn valve guide or seal 4 1 GQ KYMCO 4 LUBRICATION SYSTEM AGILITY 50 ENGINE OIL OIL FILTER OIL LEVEL e Place the motorcycle upright on level ground for engine oil level check e Run the engine for2 3 minutes and check the oil level after the engine is stopped for 2 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level 1s near the lower level fill to the upper level with the specified engine oil OIL CHANGE The engine oil will drain more easily while the engine 1s warm Remove the dr
42. Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted high tension Wire Faulty ignition switch Weak or no spark Test cylinder UI aulty starter clutch Valve clearance too small proper valve and seat contact compression compression rings eaking cylinder head gasket Seized valve a Improper valve timing Start engine by follow ing normal starting HM procedure Engine does not Engine fires but fire does not start Remove spark plug and inspect again Dry spark plug Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open Wet spark plug 1 21 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation Engine speed Increases Correct timing Engine speed does not increase sufficiently Incorrect timing EE using a timing light Check valve clearance eesti Test cylinder compression Normal Abnormal compression compression IgE clogging 2 Remove spark plug and gt inspect Remove oil dipstick and check oil level condition Remove cylinder head oil
43. ISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring e Be careful not to damage or break the piston and piston rings e All rings should be installed with the markings facing up Sg e After installing the rings they should Ke D ser Second rotate freely without sticking 4 Side Rail Expander Side Rail 8 5 GQ KYMCO CYLINDER PISTON AGILITY 50 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 e Position the piston IN mark on the intake valve side e Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings e Be careful not to damage or break the piston rings e Do not align the ring end gaps with the intake exhaust valve and piston pin dC KYMCO 8 CYLINDER PISTON AGILITY 50 Install the cam chain guide Insert the tab on the cam chain guide into e the cylinder groove Install the cylinder head 7 8 Loosely install the cylinder base bolts Tighten the cylinder base bolts Cylinder
44. Install the brake caliper piston with grooved side facing out Install the piston with its outer end 3 5mm protruding beyond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat 12 16 12 FRONT WHEEL FRONT BRAKE C KYMCO Installation Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m 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 c 12 10 Bolt 12 17 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL Remove the front wheel 12 4 Remove the front lower cover 2 2 Remove the front inner fender Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers DISASSEMBLY Remove the dust boot Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a vise Remove the top nut shock spring damper and damper spring from the front shock absorber tube e When holding the shock absorber tube place a shop towel to protect it and do apply too much force GQ KY
45. L FRONT BRAKE O KYMCO FRONT SUSPENSION ptem Brake Pad Disk Replacement Pad Pin The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Remove the brake pad pins to remove the brake pads Front Brake Caliper Install the brake pads in the reverse order of Brake Pads removal Tighten the brake pad pin bolts Torque 1 5 2 0kg m Keep grease or oil off the brake pads to avoid brake failure Do not reuse the brake pad pin bolts that have been removed Front Brake Caliper Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm 12 11 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system e When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid pipe bolt be sure to plug the pipe to avoid Disassembly Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid KYMCO AGILITY 50 Bolts Snap Ring Main Piston S
46. MATION AGILITY 50 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause E Start engine and test limit voltage between Ste battery terminals Normal voltage Voltage does not Dead battery increase Faulty battery Measure resistance between AC generator gt coil terminals Faulty A C generator coil Resistance too high Broken yellow wire BEE Loose connector Connect battery wire to regulator rectifier coupler red Wire and RE battery wire to Diu ground and test voltage RI MMOL MEDI voltage Check regulator rectifier coupler for loose nucum s M MEME E E connection Faulty regulator rectifier 1 LPooriy connected coupler Faulty A C generator Overcharging Inspection Adjustment Probable Cause C mE battery wire to regulator rectifier 4m SM gt coupler green wire and battery wire to engine ground and test voltage with ignition vole e with ignition Broken green wire switch ON switch ON O5 Check regulator rectifier coupler for loose eM E connection Faulty regulator rectifier 1 25 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Q Replace with a new spark plug and inspect ro i
47. MCO AGILITY 50 Upper Mount Bolts AB Lower Mount Bolts Circlip MK im Washer Bolt Front Shock Absorber Shock Absorber Tube 4 12 18 12 FRONT WHEEL FRONT BRAKE KYMCO ___ FRONT SUSPENSION AGILITYSO Measure the front shock absorber spring free length Service Limits Right 206 4mm Left 206 4mm M d LUAM LAUD ASSEMBLY Top Nut Dust Seal Shock Absorber Front Shock Spring Absorber Shock Absorber Tube 12 19 12 FRONT WHEEL FRONT BRAKE KYMCO __ FRONT SUSPENSION AGILITYSO 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 Install the front shock absorber spring with the closely wound coils facing down Shock Absorber Tube _ Circlip Set the front shock absorber in a vise bs Insert the shock absorber tube into the shock absorber and tighten the hex bolt Apply locking agent to the washer and install it together with the hex bolt Torque 3 0kgf m Add engine oil into the front shock absorber Specified Oil SS S Oil Capacity 38 1 Dust Boot m Upper Mount Bolts Install the circlip m Install the dust boot Front Shock Absorber Lower Mount Bolts INSTALLATION Install the front shock absorbers onto the steering
48. RONT SUSPENSION AGILITYSO Apply grease to the tip of the throttle pipe Throttle Cable Install the throttle pipe and connect the throttle cable Install the front and rear brake levers in the reverse order of removal FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Remove the speedometer cable set screw and disconnect the speedometer cable Remove the front brake cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the front brake panel and side collar A C Wee P Adjusting Nut Brake Cable Speedometer Cable INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is of the total indicator reading Service Limit 0 2mm replace if over 12 4 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION FM 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 Play bearings if they are noisy or have excessive play Play Axial _ Radial DISASSEMBLY Remove the dust seal 12 5 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION Remove the front wheel bearings and distance collar Special Bearing Puller ASSEMBLY d d O 335 ae e ON Ran Grease Pack all bearing cavities with grease Drive in the left bearing Install the d
49. RS EXHAUST MUFFLER AGILITY 50 Seat Lock Wire Frame Body Discornnect the seat lock wire Gass Remove the frame body cover The installation sequence is the reverse of remove Remove the three bolts attaching each of the right and left side covers Remove the right and left side covers During removal do not pull the joint claws forcedly to avoid damage When installing be sure to connect the seat lock wire FLOOR BOARD REMOVAL Remove the rear carrier and rear seat 2 3 Remove the met in box 2 3 Remove the frame body cover 2 4 Remove the eight bolts attaching the floor board Remove the floor board BOTTOM PROTECTOR COVER REMOVAL Remove the sixbolts on the bottom protector COVer Remove the bottom protector cover dC KYMCO 2 FRAME COVERS EXHAUST MUFFLER AGILITY 50 Leg shield Decorative Ring LEG SHIELD REMOVAL gt Remove the bolt leg shield Remove the ignition switch decorative ring Remove the leg shield F RONT FENDER REMOVAL Remove the two bolts attaching the front fender bracket Remove the front fender EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts Remove the exhaust muffler Remove the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar and then install the exhaust muffler First install and tighten the exhaust muffler joint lock nuts The
50. Remove the six screws on the back of the front cover Remove the front cover The installation sequence is the reverse of removal e Align the tab on the headlight with the groove on the handlebar cover e After installation adjust the headlight Front Cover beam 3 9 BULB REPLACEMENT Remove the headlight bulb Coupler 52 2 Remove the headlight replace with new bulbs The installation sequence is the reverse of removal TAILLIGHT STOPLIGHT REAR TURN SIGNAL LIGHT LICENSE LIGHT Remove the two screws attaching the rear protector molding Remove the rear protector molding and remove the two nuts attaching the rear light shell Remove the rear turn signal light bulb and replace with a new one The installation sequence 15 the reverse of removal 17 5 18 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM DIAGRAM Fresh Air ES Carburetor Air Injection iv EE Intake Manifold Vacuum Tube Cut off Valve Crankshaft d 1 bag 24 Pist Secondary t Piston A De p F J Secondary Air Arlean Wo Engine Oil Exhaust 18 0 18 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re combustion by means of exhaust pulsation so as to minimize the exhaust emission FUNCTION
51. UEL SYSTEM AGILITY 50 SERVICE INFORMATION ACCELERATING PUMP TROUBLESHOOTING CARBURETOR INSTALLATION CARBURETOR REMOVAL PILOT SCREW ADJUSTMENT AUTO BYSTARTER FUEL TANK AIR CUT OFF VALVE FUEL UNIT VACUUM CHAMBER AIR CLEANER FLOAT CHAMBER SERVICE INFORMATION GENERAL INSTRUCTIONS V Gasoline 1s very dangerous When working with gasoline keep sparks and flames away from the working area Gasoline 1s extremely flammable and is explosive under certain conditions Be sure to work in a well ventilated area e When disassembling the carburetor be sure to service the vacuum piston and float chamber e Do not bend or twist control cables Damaged control cables will not operate smoothly e When disassembling fuel system parts note the locations of O rings Replace them with new ones during assembly e Before float chamber disassembly loosen the drain screw to drain the residual gasoline into a clean container e After the carburetor 1s removed plug the intake manifold side with a clean shop towel to prevent foreign matters from entering e Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm e When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel SPECIFICATIONS Venturi dia mm O D pe VK Float level mm el Slow jet 2
52. again Good spark Faulty old spark plug foe sr eap and high tension wire for looseness Check CDI unit i for looseness oM UN God Peowy connected coupler Measure resistance between coupler wire terminals Checktelated parts Eee 9 Faulty ignition switch Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler Check CDI unit with a CDI unit tester Check ignition coil with a CDI unit tester Abnormal Faulty ignition coil 2 FRAME COVERS EXHAUST MUFFLER AGILITY 50 SCHEMATIC DRAWING GQ KYMCO 2 FRAME COVERS EXHAUST MUFFLER cum a _ SERVICE INFORMATION FRAME COVERS SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use special care not to pull them by force because the cover joint claws may be damaged Items Related for Removal e Handlebar front cover Handlebar rear cover Headlight wire connector Speedometer cable and instrument light wire connectors etc e Frame body cover Met in box rear grip rear turn signal lights floor board Frame body cover Battery and wire connectors Front cover floor board e Handlebar rear cover e Floor board e Front tool box TORQUE VALUES Exhaust muffler joint lock nut 1 0 1 4kgf m Exhaust muffler lock bolt 3 0 3 6kgf m dC KYMCO 2 FRAME COVERS EXHAUST MUFFLER AGILITY 50 Screw FRAME COVERS FRONT COVER R
53. ain bolt to drain the engine oil thoroughly Remove the oil filter screen cap and clean the oil filter screen with compressed air Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring and filter screen cap Torque 1 0 2 0kgf m Fill the crankcase with the specified engine oil to the proper level Oil Capacity At disassembly 0 85 liter At change 0 70 liter Check for oil leaks and then start the engine and let it idle for few minutes Recheck the oil level KYMCO 4 LUBRICATION SYSTEM AgGILITYs0 OIL PUMP REMOVAL Remove the A C generator flywheel gt 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 Oil Pump Drive Gear Remove the oil pump drive gear circlip Remove the oil pump gear Oil Pump Gear Circlip Remove the oil pump mounting bolts _ Oil Pump Remove the oil pump Remove the two O rings Inspect the two O rings for damage or deterioration dO KYMCO 4 LUBRICATION SYSTEM AGILITY 50 Oil Pump Boby DISASSEMBLY Remove the three oil pump boby screws Disassembly the oil pump Screws INSPECTION Outer Rotor Measure the pump boby to outer rotor e clearance Service Limit 0 12mm Measure the inner rotor to outer rotor Oil Pum
54. al outward to remove it Clean the oil seal groove with brake fluid 1 Be careful not to damage the piston surface 12 14 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION seared os Place the brake master cylinder on the handlebar and install the holder with up Bolts Punch Mark 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 Torque 3 0 4 0kgf m Mark Install the brake fluid pipe with the attaching bolt and two sealing washers Install the handlebar covers gt 12 3 Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 12 10 Brake Caliper Bleed Valve BRAKE CALIPER FRONT Removal Remove the brake caliper Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces Bolt Bleed Valve 12 15 12 FRONT WHEEL FRONT BRAKE KYMCO _ FRONT SUSPENSION A AGILITYSO 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 Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid
55. arks Washer Nut Remove the two cylinder head bolts V Remove the four cylinder head nuts and washers Remove the camshaft holder Diagonally loosen the cylinder head nuts in 2 or 3 times 7 3 KYMCO 7 CYLINDER HEAD VALVES AGILITY 50 Remove the camshaft holder and dowel pins Camshaft Dowel Pins Remove the camshaft gear from the cam aT chain and remove the camshaft CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 26 038mm replace if below EX 25 407mm replace if below 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 KYMCO MNO Rocker Arm Shaft CAMSHAFT HOLDER DISASSEMBL Y Take out the valve rocker arm shafts using a 5mm bolt Remove the valve rocker arms 5mm Bolt Rocker Arm Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface 1s worn check each cam lobe for wear or damage Rocker Arm Shafts Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 91 mm replace if over EX 9 91mm replace if over Intake Manifold CYLINDER HEAD REMOVAL c Re
56. be e Clogged air cleaner e Faulty reed valve Backfiring at sudden deceleration e Damaged reed valve malfunction e Faulty air injection cut off valve unable to close e Carburetor incorrectly adjusted e Faulty air cut off valve e Leaking vacuum tube 18 1 18 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE 1 PERIODIC MAINTENANCE ppp Engine oil C C to Led E R eordT UaJSA usSAS AiddnS TV said uo Motor oil filter Eum T1113 31 14 Intake manifold screw Purge control valve I I Reims Catalytic converter De LHP Drive chan I JT JT Drivebelt I JT JT clearance _ Jaf jut oj LU LIL Spark stroke Es Th CDE e le qj NE ed Ignition system wires Un SA SALI ULr SA uous EE Bolts and nuts ITITITITITITITITITITITITITITIT Brake system AIAIAIAIAIAIAIAIAIAIA I Inspect A Adjust C Clean R Replace T Tighten eDuring riding or inspection if any part 1s found to be cleaned adjusted SIO Remarks or replaced do it directly and take a record 1f the exhaust emission control system is not seriously affected It must be reported and approved if the exhaust emission control system is seriously
57. cified genuine parts for replace ment KICK STARTER REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushings dO KYMCO AGILITY 50 Left Crankcase Cover _ Air Tube Band Bolts Kick Starter Spindle Washer Circlip Starter Driven Gear Kick Starter Spindle Friction Spring Return Spring 9 2 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER ped Spindle Return Spring INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushings for wear or damage Plastic Bushing Spindle Bushing Friction Spring Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or damage Starter Driven Gear Kick Starter Spindle Forcing Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage Starter Driven Gear Shaft Forcing Part Kick Starter Spindle INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover Return Spring 9 3 9 DRIVE AND DRIVEN PULLEYS
58. diaphragm INSPECTION Inspect the accelerating pump diaphragm for cracks damage or deterioration Replace if necessary Check each accelerating pump fuel passage for clogging Clean and blow them open with compressed air Compressed Air Compressed Air Install the accelerating pump in the reverse order of removal Be careful not to damage the diaphragm during installation 5 10 dC KYMCO S FUELSYSTEM AGILITYSO _ CARBURETOR INSTALLATION Throttle Cable OD CODE AME UD Tighten the drain screw Install the carburetor onto the intake manifold aligning the tab on the carburetor with the cutout in the intake manifold Tighten the intake manifold band screw Install the air cleaner connecting tube and tighten the band screw Connect the throttle cable to the throttle wheel on the carburetor Tighten the lock nut Connect the fuel tube and vacuum tube to the carburetor Connect the auto bystarter wire connector Perform the following inspections and adjustments Throttle grip free play 3 3 Carburetor idle speed 3 5 Auto Bystarter Wire Connector 5 11 GQ KYMCO 5 FUEL SYSTEM AGILITY 50 PILOT SCREW ADJUSTMENT ADJUSTMENT e The pilot screw 1s factory pre set and adjustment is necessary During carburetor disassembly note the number of turns of the pilot screw and use as a reference when reinstalling it e Place the motorcycle on its main stand on level
59. e connector Remove the met in box 2 3 Loosen the drain screw and drain the fuel from the float chamber Disconnect the fuel tube and vacuum tube at the carburetor by Fuel Tube Loosen the throttle cable adjusting nut and Air Cleaner Connecting Intake Manifold lock nut and disconnect the throttle cable Tube Band Band from the carburetor Loosen the carburetor intake manifold band and air cleaner connecting tube band screws and then remove the carburetor Throttle C AUTO BYSTARTER OPERATION INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 100 max 10 minutes minimum after stopping the engine If the reading 1s not within the limit replace the auto bystarter with a new one 5 FUEL SYSTEM 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 If the passage is blocked the auto bystarter 1s normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth or vacuum pump If air can be blown into the hose the auto bystarter is normal REMOVAL Remove the set plate screws and set plate Remove the auto bystarter from the carburetor AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or da
60. e When a battery 15 overcharged some symptoms can be found If there 1s a short circuit inside the battery no voltage 1s produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life e If a battery is not used for a long time it will discharge by itself and should be recharged every 3 months e A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life e Inspect the charging system according to the sequence specified in the Troubleshooting e Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation e t is not necessary to check the MF battery electrolyte or fill with distilled water e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done in an emergency e Remove the battery from the motorcycle for charging e When replacing the battery do not use a traditional battery e When charging check the voltage with an voltmeter 14 1 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR pet SPECIFICATIONS Voltage Battery 20 Charging time STD 5 10hr Quick 30min 0 144KW 5000rpm A C Generator Lighting coil resistance
61. e cylinder Measure the piston ring end gap Service Limit 0 45mm replace if over Measure the piston pin hole I D Service Limit 13 04mm replace if below 8 3 dC KYMCO AGILITY 50 GQ KYMCO 8 CYLINDER PISTON AGILITY 50 Measure the piston pin O D Service Limit 12 96mm replace if below Measure the piston O D Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 38 9mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin 1n both X and Y directions Service Limit 39 1 0mm repair or replace if OVer Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if OVer The true roundness is the difference between the values measured In X and Y directions The cylindricity difference between the values measured at the three levels 1s subject to the maximum value calculated Service Limits True Roundness 0 05mm repair or replace if over Cylindricity 0 05mm repair or replace if over Bottom dC KYMCO 8 CYLINDER PISTON AGILITY 50 Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if over Measure the connecting rod small end 1 D Service Limit 13 06mm replace if over P
62. e play Free Play 10 20mm BRAKE ADJUSTING NUT If the free play do not fall within the limit adjust by turning the adjusting nut D Adjusting Nut BRAKE FLUID Upper Line 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 3 5 dC KYMCO 3 INSPECTION ADJUSTMENT a unys _ If the free play do not fall within the limit adjust by turning the adjusting nut Adjusting Nut HEADLIGHT AIM Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting screw CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary 9 11 SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage 3 9 dO KYMCO S INSPECTION ADJUSTMENT mpILLYLXsOo 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
63. e valve clearance 3 5 Pu Install a new cylinder head cover O ring and install the cylinder head cover Be sure to install the O ring into the eroove properly Install and tighten the cylinder head cover bolts Torque 0 8 1 2kgf m 7 10 KYMCO CYLINDER PISTON AGILITY 50 Do not bend 8 0 KYMCO CYLINDER PISTON AGILITY 50 SERVICE INFORMATION PISTON REMOVAL TROUBLESHOOTING PISTON INSTALLATION CYLINDER REMOVAL CYLINDER INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder and piston can be serviced with the engine installed in the frame e After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS Item Standard mm Service Limit mm LD 8000500 1 ETC Cylindricity Lo oc 005 True roundness Lo 005 Ringto Top 0015005 009 ds 0 08 0 20 0 45 Piston Ring end gap piston ring 020070 Piston Piston O D measuring gen from bottom of skirt Piston to cylinder clearance Piston pin hole LD Piston to piston pin clearance _ 00020014 TROUBLESHOOTING e When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke f
64. eed 1900 100rpm When the engine misses or run erratic adjust the pilot screw Throttle Stop Screw 3 5 gO KYMCO 3 INSPECTION ADJUSTMENT pILLYLXso Timing Hole Cap IGNITION TIMING ee The CDI unit is not adjustable If the ignition timing is incorrect check the ignition system 5 15 5 Remove the right of the fan cover Check the ignition timing with a timing light When the engine 1s running at idle speed the ignition timing is correct if the mark on the flywheel aligns with the index mark on the crankcase Also use a timing light to check the advance Raise the engine speed to 4 000rpm and the index mark on the crankcase cover should be aligned with the advance mark on the flywheel CYLINDER COMPRESSION Warm up the engine before compression test Remove the met in box and center cover 52 3 Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Advance Mark Compression Gauge Compression 16kg cm2rpm If the compression 1s low check for the following 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 dC KYMCO 3 INSPECTION ADJUSTMENT AgIUTYs0 _ FINAL REDUCTION GEAR OIL OIL L
65. esidual gasoline into a container Fuel Strainer INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump Arrow Mark 5 13 5 FUEL SYSTEM FUEL UNIT REMOVAL Remove the related parts Disconnect the fuei 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 INSTALLATION Inspet if the fuel unit is damaged or harden Assemble the fuel unit in the reverse order of disassembly e Align the groove on the fuel unit with the angle on the fuel tank e Inspect if the fuel tank leaked after installing and filling the gasoling AIR CLEANER Loosen the air cleaner connecting tube band screw Disconnect the clinhead cover breather tube from the air cleaner Remove the two bolts and air cleaner case dO KYMCO AGILITY 50 Fuel Unit Wire air cleaner 5 14 dC KYMCO S FUELSYSTEM AGILITY 50 The installation sequence is the reverse of removal 5 15 dO KYMCO 6 ENGINE REMOVAL INSTALLATION FILLY LX 50 6 0 GQ KYMCO 6 ENGINE REMOVAL INSTALLATION FILLY LX 50 SERVICE INFORMATION ENGINE REMOVAL SERVICE INFORMATION GENERAL INSTRUCTIONS e A floor jack or other adjustable support 1s required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine rem
66. ession 16 kg cm Ignition timing BTDC 28 4000rpm CHASSIS Front brake free play 10 20mm Rear brake free play 10 20mm TIRE PRESSURE TIRE SIZE Front 120 70 12 Rear 130 70 12 TORQUE VALUES Front axle nut 5 0 7 0kgf m Rear axle nut 11 13kgf m 3 1 KYMCO 3 INSPECTION ADJUSTMENT AGILITY 50 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 Replace Tighten Whichever Regular Service Mileage km comes first gt 4 New 300km Engine oil filter screen bone New ns 300km Vade al _ 1 Replace at every2000km Spark plug Clean at every 3000km and replace if necessary Buessm 1 1 i r r r r r i r 1 bwwk L1 HI ES Suspension ILL Nus von teer HILL 1 HL IJ dL Id 1 il e n the interest of safety we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle C KYMCO 3 INSPECTION ADJUSTMENT AgIUTYs0 _ Fuel Filter FUEL FILTER Remove the
67. etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants E When servicing the motorcycle be sure to use special tools for removal and installation B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly 1 GENERAL INFORMATION E Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety B Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 4 KYMCO AGILITY 50 1 GENERAL INFORMATION dC KYMCO AGILITY 50 B f the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity B After operation terminal caps shall be installed securely B When taking out the connector the
68. g Nut Rear Shock Absorber Upper Mount Bolt Engine Hanger Bracket Bolt Engine Mounting Bolt KYMCO 6 ENGINE REMOVAL INSTALLATION FILLY LX 50 ENGINE HANGER BRACKET REMOVAL Remove the return spring from the main stand Remove the main stand Main Stand Return Spring Bushing Remove the engine hanger bracket bolts and engine hanger bracket Inspect the engine hanger bushings and stopper spring for wear or damage ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the chassis and tighten the bolt Install the main stand onto the engine and install the return spring Main Stand Return Spring Engine Mounting Bolt ENGINE INSTALLATION Install the engine and tighten the engine mounting bolt Torque 4 5 5 5kgf m Tighten the rear shock absorber upper mount bolt Torque 4 5 5 5kgf m Engine Hanger Bracket Bolt GQ KYMCO EE a Install the removed parts in the reverse order Rear Shock Absorber Upper Mount Bolt of removal F Route the wires and cables properly Ed After installation inspect and adjust the following e Throttle grip free play 3 3 e Rear brake adjustment gt 3 8 6 5 KYMCO 7 CYLINDER HEAD VALVES AGILITY 50 2 kg n 7 0 KYMCO 7 CYLINDER HEAD VALVES FILLY LX 50 SERVICE INFORMATION CYLINDER HEAD DISASSEMBLY TROUBLESHOOTING CYLINDER HEAD ASSEMBLY CAMSHAFT REMOVAL CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOV
69. gear for wear or damage Inspect the final gear and final shaft for wear damage or seizure 10 2 dC KYMCO 10 FINAL REDUCTION AGILITY 50 Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Final Shaft Bearing Countershaft 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 Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Countershaft Bearing Drive Shaft Bearing Oil Seal Final Shaft Bearing BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using a bearing puller Remove the final shaft oil seal Special Bearing Puller Drive new bearings into the transmission case cover Outer Driver 32x35mm 10 3 GQ KYMCO 10 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 Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaf
70. h spring compressor and disassemble the driven pulley assembly Special Clutch Spring Compressor Remove the seal collar 9 9 dC KYMCO AGILITY 50 Lock Nut Wrench 39mm Seal Collar 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER AGILITY 50 Movable Driven Face Oil Seal Pull out the guide roller pins and guide rollers En Remove the movable driven face from the driven face Remove the O rings and oil seal from the movable driven face O rings Guide Roller Pin INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 107 5mm replace if over Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Measure the driven face spring free length Service Limit 92 8mm replace if below 9 10 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER rcr Check the driven face for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if over DRIVEN PULLEY FACE BEARING Inner Bearing REPLACEMENT Drive the inner needle bearing out of the driven pulley face Discard the removed bearing and replace with a new one Snap Ring Remove the snap ring and drive the outer bearing out of the driven face m
71. ings are not within the specifications in the table 14 5 Regulator Rectifier Red KYMCO AGIKITY 50 Yellow 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR AGILITY 50 A C GENERATOR CHARGING Charging Coil Wire COIL The inspection of A C generator charging coil can be made with the engine installed INSPECTION Disconnect the A C generator 2P connector Measure the resistance between the A C generator white wire and engine ground with an electric tester Standard 0 2 1 20 at 20 Replace the A C generator charging coil if the reading 1s not within the specifications A C GENERATOR LIGHTING COIL The inspection of A C generator lighting coil can be made with the engine installed INSPECTION Disconnect the A C generator 2P connector Measure the resistance between the A C generator yellow wire and engine ground with an electric tester Standard 0 1 1 00 20 Replace the A C generator lighting coil if the reading 1s not within the specifications RESISTOR INSPECTION Remove the front covers 2 2 Measure the resistance between the resistor lead and engine ground Resistances 5W120 11 13 30W7 5Q 6 80 A C GENERATOR REMOVAL Remove the right side cover 52 4 Remove the four bolts attaching the cooling fan cover to remove the fan cover Fan Cover 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR Remove the cooling fan
72. 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 E Grease Front Brake Lever Pivot Engine Oil Front Brake Cable Speedometer Cable Throttle Cable mio Rear Wheel Bearings Grease dm Grease Speedometer Gear Front Wheel Brake Cam Bearings Brake Cam Anchor Pin Anchor Pin Front Shock Absorber Lower mn Case Engine Oil Mount Bushings Pivot Main Stand Pivot Rear Brake Cable 1 14 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 CABLE amp 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 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 Throttle Grip Regulator Rectifier Ignition Switch Speedometer Cable Headlight Resistor Rear Brake Lever a pem gt i N Horn e DEN Front Brake Fluid Tube 1 16 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 CDI Unit Fuse Battery Cable Battery Cable Starter Relay Fuel Tank Battery Cable Battery Cable Ignition Coil 1 17 dO KYMCO AGILITY 50 1 GENERAL INFORMATION
73. istance collar Drive in the right bearing Drive in the bearing squarely with the sealed end facing out dO KYMCO AGILITY 50 Bearing Puller dm PA Grease Outer Driver Pilot 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION Side Collar Apply grease to a new dust seal lip and install the dust seal Install the side collar Dust Seal Groove INSTALLATION Install the front wheel by aligning the brake panel groove with the front fork tab Insert the axle shaft and tighten the axle nut Torque 4 5kg m Connect the speedometer cable and secure it with the screw Install the front brake cable and adjust the front brake lever free play FRONT BRAKE Remove the front wheel 12 4 Remove the front brake panel INSPECTION Measure the brake drum I D Service Limit 111mm replace if over Brake Shoe Springs Brake Cam Measure each brake lining thickness Service Limit 2 00mmmm replace if below a 7 mu Keep oil or grease off the brake linings Z ei m b c 12 7 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION DISASSEMBLY Do not swing the brake arm to expand the brake shoes Remove the brake shoes by removing the brake shoe springs using a screw driver Remove the brake arm and return spring Remove the wear indicator plate and felt seal Remove the brake cam Remove the dust seal and speedometer drive gear Speedometer D
74. l 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 e Be careful not to damage the brush and armature shaft mating surfaces e When installing the commutator the armature shaft should not damage the dust seal lip STEE Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the tab on the front cover Tighten the starter motor case screws When assembling the front cover and motor case slightly press down the armature shaft to assemble them Motor Case Starter Relay STARTER RELAY INSPECTION Remove the met in box Remove the battery cover Remove the frame body cover 2 2 Turn the ignition switch ON and the starter relay is normal if you hear a click when the starter button is depressed If there 1s no click sound e Inspect the starter relay voltage e Inspect the starter relay ground circuit e Inspect the starter relay operation STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand Measure the voltage between the starter relay connector green yellow wire and engine ground Turn the ignition switch ON and the battery voltage should be normal when the brake lever is fully applied If the battery has no voltage inspect the stop switch continuity and cable Turn to the DCV posi
75. lock on the connector shall be released before operation Bi Hold the connector body when connecting or disconnecting it Bi Do not pull the connector wire E Check if any connector terminal is bending protruding or loose Dr ter Confirm Capacity me ES 1 5 1 GENERAL INFORMATION KYMCO AGILITY 50 B The connector shall be inserted completely B f the double connector has a lock lock it at the correct position Bi Check if there is any loose wire E Before connecting a terminal check for damaged terminal cover or loose negative terminal E Check the double connector cover for proper coverage and installation B Insert the terminal completely B Check the terminal cover for proper coverage E Do not make the terminal cover opening face up E Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses 1 6 TI Ox Snapping 1 GENERAL INFORMATION dC KYMCO AGILITY 50 B After clamping check each wire to make sure it is secure E Do not squeeze wires against the weld or its clamp B After clamping check each harness to make sure that it is not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat B Route wire harnesses t
76. lt INSTALLATION i 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 5 15 Install the frame body cover 52 3 A aw Lower Mount Bolt 13 6 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR editi Battery Fuse Regulator Rectifier Resistors A C Generator A C Generator IO SISOW Regulator Rectifier Battery I2VAAH YOUMS JUST peoH 14 BATTERY CHARGING SYSTEM O KYMCO _ A C GENERATOR AGIKITYsO SERVICE INFORMATION A C GENERATOR CHARGING COIL 14 6 TROUBLESHOOTING RESISTOR INSPECTION BATTERY A C GENERATOR REMOVAL A C GENERATOR INATALLATION 14 8 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention e The battery can be charged and discharged repeatedly If a discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after itis used for 2 3 years A capacity decreased battery will resume its voltage after it 1s recharged but its voltage decreases suddenly and then increases when a load is added
77. mage If any faulty part 1s found replace the auto bystarter as a set INSTALLATION Insert the auto bystarter into the carburetor body until it bottoms Position the set plate into the groove in the auto bystarter and tighten the screws e Be sure to install the auto bystarter and set plate properly e Install the set plate with its bottom face facing down 5 5 Vacuum Pump Set Plate Auto Bystarter KYMCO AGILITY 50 Screws Bystarter Valve Bystarter Needle Set Plate Screws 5 FUEL SYSTEM AIR CUT OFF VALVE DISASSEMBLY Remove the two screws attaching the throttle cable set plate and the set plate Remove the two screws attaching the air cut off valve Remove the spring and vacuum diaphragm Check the vacuum diaphragm for cracks or damage and check each passage for clogging ASSEMBLY Install the vacuum diaphragm onto the carburetor Install the spring and air cut off valve cover Install the throttle cable set plate and tighten the two screws e Be sure to set the vacuum diaphragm lip into the groove on the carburetor e When installing the air cut off valve cover make sure that the vacuum diaphragm is properly installed VACUUM CHAMBER DISASSEMBLY Remove the two vacuum chamber cover screws and the cover Remove the spring and vacuum diaphragm piston GQ KYMCO AGILITY 50 Diaphragm Spring Cover O ring Screws Vacuum Chamber Cover Spri
78. met in box 2 3 Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Do not smoke or allow flames or sparks in your working area Fuel Line 2 6mm THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6mm Major adjustment of the throttle grip free play is made at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment 15 made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut 3 3 GQ KYMCO 3 INSPECTION ADJUSTMENT FILLY LX 5 Screws AIR CLEANER f AIR CLEANER REPLACEMENT Remove the air cleaner case cover screws and the cover by removing the seven screws f ep 4 Ia Remove the air cleaner element by removing the four screws Check the element and replace it if it is excessively dirty or damaged Air Cleaner Case Cover CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas Air Cleaner Element e The air cleaner element has a viscous type paper element Do not clean it with any fluid e Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the spark plug Check the spark plug for wear and fouling deposits Clean any fouling
79. move the camshaft 7 3 Remove the carburetor 45 5 Remove the exhaust muffler 42 5 Remove the carburetor intake manifold 7 5 KYMCO 7 CYLINDER HEAD VALVES AGILITY 50 Remove the cooling fan cover gt 14 6 Remove the engine cover bolts and screws Separate the engine cover joint claws Remove the cylinder head Dowel Pins Cylinder Head Gasket Remove the dowel pins and cylinder head gasket M Remove the cam chain guide L7 ain w ak 2 7 R F 6 j 5 K a d 7 6 Cam Chain Guide C KYMCO MI E 110 CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor e Be sure to compress the valve springs with a valve spring compressor e Mark all disassembled parts to ensure correct reassembly Valve Spring Compressor Valve Spring Compressor Attachment Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head mating surface Be careful not to damage the cylinder head mating surface INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over VALVE SPRING FREE LENGTH Measure the free length of the inner and ou
80. n install and tighten the exhaust muffler lock bolts Torques Exhaust muffler lock bolt 3 0 3 6kgf m Exhaust muffler joint lock nut 1 0 1 4kgf m Be sure to install a new exhaust muffler packing collar Lock Nut 2 5 C KYMCO 3 INSPECTION ADJUSTMENT AGILITY 50 SERVICE INFORMATION FINAL REDUCTION GEAR OIL MAINTENANCE SCHEDULE DRIVE BELT FUEL FILTER BRAKE SHOE THROTTLE OPERATION BRAKE ADJUSTING NUT AIR CLEANER HEADLIGHT AIM SPARK PLUG CLUTCH SHOE WEAR VALVE CLEARANCE SUSPENSION CARBURETOR IDLE SPEED NUTS BOLTS FASTENERS IGNITION TIMING WHEELS TIRES CYLINDER COMPRESSION STEERING HANDLEBAR SERVICE INFORMATION GENERAL eBefore running the engine make sure that the working area 1s well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6mm Spark plug gap Up 0 7mm Spark plug NGK C7HSA Valve clearance IN 0 04mm EX 0 04mm Idle speed 1900 100rpm Engine oil capacity At disassembly 0 85 liter At change 0 7 liter Gear oil capacity At disassembly 0 11 liter At change 0 10 liter 3 0 KYMCO 3 INSPECTION ADJUSTMENT AGILITY 50 Cylinder compr
81. nd holder Remove the two screws to remove the ignition switch from the ignition switch holder for replacement The installation sequence 15 the reverse of removal Bolts 17 3 GQ KYMCO l7 LIGHTS INSTRUMENTS SWITCHES riLYLXs0 _ 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 1s applied The switch is normal if there is continuity Disconnect the rear stop switch wire coupler Check for continuity between the wire CSL terminals when the rear brake lever is applied NM um i The switch is normal if there 1s continuity Coupler HORN INSPECTION Remove the front covers 2 2 Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery 15 connected across the horn wire terminals REPLACEMENT Disconnect the horn wire coupler Remover the two bolts attaching the horn Remove the horn The installation sequence is the reverse of removal Instruments INSTRUMENTS Remove the handlebar front cover 2 2 Remove the handlebar rear cover 2 2 Disconnect the handlebar switch couplers Remove the three screws to remove the instruments Install a new horn in the reverse order of removal Screws 17 4 dC KYMCO 17 LIGHTS INSTRUMENTS SWITCHES kirLYLXs0 HEADLIGHT REMOVAL Remove the screw on the front of the front COVer
82. ng Vacuum Diaphragm Piston 5 6 KYMCO 5 FUEL SYSTEM AGILITY 50 Remove the needle holder and jet needle Be careful not to damage the vacuum diaphragm Jet Needle INSPECTION Inspect the needle for stepped wear Inspect the vacuum piston for wear or damage Inspect the diaphragm for deterioration and tears Vacuum Diaphragm ASSEMBLY Vacuum Diaphragm Vacuum Chamber Cover Install the vacuum piston diaphragm in the carburetor body Install the spring and then install the vacuum chamber cover Tighten the two screws e Be careful not to damage the diaphragm e Hold the vacuum piston while tightening the vacuum chamber cover 5 7 GQ KYMCO 5 FUEL SYSTEM AGILITY 50 Screws FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber Float Chamber Float Float Valve Loosen the float pin screw Remove the float pin float and float valve Float Pin Needle Jet Holder slow Jet Remove the main jet needle jet holder needle jet slow jet and pilot screw e Be careful not to damage the fuel jets and pilot screw e Before removing turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this e Do not force the pilot screw against its seat to avoid seat damage Pilot Screw Needle Jet Main Jet Clean the removed fuel jets with detergent oil and blow them open with compressed
83. nstallation 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 eive detailed procedures for the section Our conpany reserves the ri ght to nake any alteration i n the desi gn 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 LNHINdIQO8H IVORLLOW TA KYMCO AGILITY 50 TABLE OF CONTENTS ENGINE REMOVALINSTALLATION 6 CVLINDERPISTON DRIVE AND DRIVEN PULLEYS KICK STARTER FINAL REDUCTION E CRANKCASE CRANKSHAFT WHEEL FRONT BRAKE FRONT SUSPENSION REAR WHEEL REAR BRAKE REAR SUSPENSION GENERATOR HNIDONH dO KYMCO 1 GENERAL INFORMATION AGILITY 50 ENGINE SERIAL NUMBER LUBRICATION POINTS SPECIFICATIONS CABLE amp HARNESS ROUTING SERVICE PRECAUTIONS WIRING DIAGRAM TORQUE VALUES TROUBLESHOOTUNG SPECIAL TOOLS ENGINE SERIAL NUMBER Ld
84. o avoid sharp edges orcorners Avoid the projected ends of bolts and screws B Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 1 GENERAL INFORMATION KYMCO AGILITY 50 Bi Route harnesses so they are neither pulled tight nor have excessive slack E Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner E When rubber protecting cover is used to protect the wire harnesses it shall be installed securely B Do not break the sheath of wire B f a wire or harness 15 with a broken sheath repair by wrapping it with protective tape or replace it E When installing other parts do not press or squeeze the wires Do not press or queeze the wire dC KYMCO 1 GENERAL INFORMATION AGILITY 50 B After routing check that the wire harnesses are not twisted or kinked E 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 E When a testing device is used make sure to Es Instrument understand the operating methods the instrument set 7 thoroughly and operate according to the operating instructions E Be careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Remove Rust E Do not bend
85. ol TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Brake not adjusted properly e Faulty tire e Worn brake linings e Axle not tightened properly e Worn brake shoes at cam contacting area Soft rear shock absorber e Worn brake cam e Weak shock absorber spring e Worn brake drum e Faulty damper 13 1 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION AGILITY 50 REAR WHEEL Rear Axle Nut REMOVAL Remove the exhaust muffler 42 5 Remove the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Inspect the rear brake drum Measure the rear brake drum I D Service Limits 111mm replace if over INSTALLATION Install the rear wheel in the reverse order of removal Tighten the rear axle nut Torque 11 0 13 0kg m Install the exhaust muffler Torque Exhaust muffler joint lock nut 1 0 1 4kgf m Exhaust muffler lock bolt 3 0 3 6kgf m First install and tighten the exhaust muffler joint lock nuts and then the exhaust muffler lock bolts 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION 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 LoS Remove the rear brake adjusting nut and si disconnect the
86. or twist control cables Damaged control cables will not operate smoothly and may stick or bind 1 9 dC KYMCO 1 GENERAL INFORMATION AGILITY 50 E Symbols The following symbols represent the servicing methods and cautions included in this service manual B Apply engine oil to the specified points Use Piene Oil designated engine oil for lubrication Grease Apply grease for lubrication Iransmission Gear Oil 90 Gear Oil Use special tool Caution Warning gt 12 3 Refer to page 12 3 1 10 GQ KYMCO 1 GENERAL INFORMATION AGILITY 50 TORQUE VALUES STANDARD TORQUE VALUES Torque kg m 5mm screw 6mm screw SH bolt 6mm flange bolt nut 8mm flange bolt nut 10mm flange bolt nut 5mm bolt nut 6mm bolt nut Smm bolt nut 10mm bolt nut 2mm bolt nut Torque specifications listed below are for important fasteners ENGINE Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler lock bolt Cylinder head flange nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Starter motor mounting bolt Oil pump bolt Drive face nut Spark plug A C generator stator bolt Cam chain tensioner bolt Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Speedometer cable set screw Rear shock absorber lock nut
87. oval e Use shop towels to protect the motorcycle body during engine removal e Parts requiring engine removal for servicing Crankcase Crankshaft 6 1 dC KYMCO 6 ENGINE REMOVAL INSTALLATION FILLY LX 50 ENGINE REMOVAL Disconnect the battery negative cable Remove the frame body cover 2 3 Disconnect the spark plug high tension wire Disconnect the auto bystarter wire connector Disconnect the A C generator wire connector a NON 4 Negative Cable Auto Bystarter Wire Connector Disconnect the starter motor cable and earth cable from the starter motor Remove the fuel tube N fuel tube amp EO Earthr Cable Starter Motor Cable Remove the spark plug cap M v9 Spark Plug High Tension Wire Disconnect the vacuum tube Loosen the throttle cable adjusting nut and Band Vacuum Tube lock nut and disconnect the throttle cable from the carburetor 6 ENGINE REMOVAL INSTALLATION Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube Remove the rear brake adjusting nut connector pin rear brake cable Remove the rear shock absorber upper mount bolt Remove the engine mounting bolt and move the motorcycle forward to separate it from the engine Support the motorcycle with a floor jack dC KYMCO FILLY LX 50 Air Tube Band 4 E y v Uu AU NN uv TEC E d v AN 4 Adjustin
88. p Boby clearance Service Limit 0 12mm Outer Rotor Measure the rotor end to pump boby clearance Service Limit 0 2mm Inner Rotor 4 LUBRICATION SYSTEM 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 Install the pump cover and tighten the screws to secure the pump cover INSTALLATION First install the two O rings onto the oil pump base Install the oil pump into the crankcase Fill the oil pump with engine oil before installation After the oil pump is installed tighten the three mounting bolts 4 5 Pump Cover dC KYMCO AGILITY 50 Inner Rotor Outer Rotor Pump Shaft FE E A a 1 A Screws O rings Oil pump C KYMCO 4 LUBRICATION SYSTEM anys Install the pump driven gear and secure it Pump Driven Gear with the circlip Torque 0 8 1 2kg m Install the right crankcase cover and tighten the eight bolts Torque 0 8 1 2kgf m Diagonally tighten the bolts in 2 3 times 4 6 KYMCO AGILITY 50 5 FUEL SYSTEM 5 0 dC KYMCO AGILITY 50 5 FUEL SYSTEM Ignition Switch 12V Battery EN a i Auto Bystarter Resistor 2 Regulator Rectifier Lighting System z pers i 5 1 KYMCO 5 F
89. pring Master Cylinder di E zm A fe E ol 1 kv Snap Ring 12 12 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION pon 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 Ist and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the Ist rubber cup e During assembly the main piston and spring must be installed as a unit zu C LIES without exchange e When assembling the piston soak the cups in brake fluid for a while e Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber cover Install the brake lever 12 13 12 FRONT WHEEL FRONT BRAKE KYMCO ___ FRONT SUSPENSION AGILITYSO Disassembly Brake Caliper Seat Remove the brake caliper seat from the brake caliper Remove the piston from the brake caliper Compressed Air If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Piston Oil Seal Push the piston oil se
90. rive Gear Dust peal Return Spring Brake Shoe Brake Cam Brake Arm Felt Seal Wear Indicator Plate ASSEMBLY Apply grease to the speedometer drive gear and then install it into the brake panel Apply grease to the dust seal lip and install it into the brake panel Grease Speedometer Drive Gear Apply grease to the anchor pin and brake cam Install the brake cam Anchor Pin Brake Cam 2 8 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION STEE 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 Install the wear indicator plate on the brake cam by aligning the tooth on the plate with the groove on the brake cam IR ael Laf PE Install the brake arm on the brake cam by aligning the punch mark on the brake arm and the scribed line on the brake cam Install and tighten the brake arm bolt Torque 0 8 1 2kgf m Brake Am Brake Shoe Springs AN ig Ce v AES x INSTALLATION 2 v4 Install the brake panel onto the front wheel Install the front wheel gt 12 7 b Adjust the front brake lever free play D 4 E el Install the brake shoe springs to the brake shoes and then install the brake shoes into the brake panel m Brake Shoes 12 9 12 FRONT WHEEL FRONT BRAKE
91. rom exhaust muffler e Worn stuck or broken piston rings e Worn or damaged piston rings e Worn or damaged cylinder and piston e Worn or damaged cylinder and piston Compression too high Abnormal noisy piston e Excessive carbon build up in combustion e Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and piston pin 8 1 KYMCO 8 CYLINDERPISTON Gury so CYLINDER REMOVAL Cylinder Remove the cylinder head 7 6 Remove the cam chain guide Remove the cylinder _Dowel Pins Remove the cylinder gasket and dowel pins A eg Clean any gasket material from the cylinder Surface p c Gasket Piston Pin PISTON REMOVAL Remove the piston pin clip Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Press the piston pin out of the piston and remove the piston Piston Rings i Piston 8 2 8 CYLINDER PISTON 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 Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Use the piston head to push each piston ring into th
92. sideways with force to see 1f the engine hanger bushings are worn NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found gt 1 11 WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE 1 5kg cm2 lt 1 75kg cm Rear 2 00kg cm 2 25kg cm TIRE SIZE Front 120 70 12 Rear 130 70 12 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 dC KYMCO 3 INSPECTION ADJUSTMENT AGILITY 50 STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing 3 11 dO KYMCO 4 LUBRICATION SYSTEM ST LUBRICATION SYSTEM Rocker Arm Shaft Si d hs Oe iil HE 8 Crankshaft 4 Oil Filter Screen Oil Pump 4 0 GQ KYMCO 4 LUBRICATION SYSTEM AgGILITYs0 SERVICE INFORMATION 4 ENGINE OIL OIL FILTER TROUBLESHOOTING 4 OIL PUMP SERVICE IN
93. stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align the upper mount bolt hole with the eroove on the front fork Install the front wheel gt 12 7 12 20 12 FRONT WHEEL FRONT BRAKE O KYMCO _ _ FRONTSUSPENSION AGILITYSO Long Socket Wrench FRONT FORK REMOVAL Remove the steering handlebar gt 12 3 Remove the front wheel gt 12 4 Disconnect the speedometer cable Remove the steering stem lock nut using long socket wrench Special Long Socket Wrench 32mm SAngle Remove the top cone race and remove the steering stem e careful not to lose the steel balls 26 on top race and 29 on bottom race Inspect the ball races and cone races for wear or damage and replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Be careful not to damage the steering stem and front fork Drive a new bottom cone race into place with a proper driver BALL RACE REPLACEMENT Drive out the top and bottom ball races 12 21 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION ence is Driver Handle Drive new top and bottom ball races into the steering head using the outer driver Be sure to completely drive in the ball races INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race
94. t into the left crankcase 10 4 KYMCO 10 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 Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 9 13 After installation fill the transmission case with the specified oil 3 7 e Place the motorcycle on its main stand on level ground e Check the oil sealing washer for wear Bolt or damage Specified Gear Oil SAE90 Oil Capacity At disassembly 0 11 liter At change 0 10 liter Install and tighten the oil check bolt Torque 0 8 1 2kgt m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low 10 5 KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 dC KYMCO 11 CRANKCASE CRANKSHAFT AGILITY 50 SERVICE INFORMATION TROUBLESHOOTING CRANKCASE SEPARATION SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e The following parts must be removed before separating the crankcase Cylinder head Section 7 Cylinder piston gt Section 8 Drive and driven pulleys gt Section 9 A C generator
95. ter valve springs Service Limits Inner 30 1mm replace if below Outer 33 3mm replace if below 7 7 KYMCO 7 CYLINDER HEAD VALVES AGILITY 50 VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 9mm replace if below EX 4 9mm replace if below q bs LL CYLINDER HEAD ASSEMBLY Valve i e When assembling a valve spring compressor must be used e nstall the cotters with the pointed ends facing down from the upper side of the cylinder head Valve Spring Compressor Val ve Spring Compressor Attachment Valve Spring Compressor Attachment 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 CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket Install the cam chain guide Cam Chain Guide 7 CYLINDER HEAD VALVES Install the cylinder head CAMSHAFT HOLDER ASSEMBLY First assemble the camshaft holder Install the intake and exhaust valve rocker arms and rocker arm shafts e When installing the rocker arm shaft align the shaft front end with the bolt hole of the camshaft holder CAMSHAFT INSTALLATION Turn the flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase Keep the ro
96. the 10mm clutch outer nut Torque 3 5 4 5kgf m Install the left crankcase cover 9 4 Universal Holder 9 13 KYMCO 10 FINAL REDUCTION AGILITY 50 10 0 KYMCO 10 FINAL REDUCTION AGILITY 50 SERVICE INFORMATION FINAL REDUCTION INSPECTION TROUBLESHOOTING BEARING REPLACEMENT FINAL REDUCTION DISASSEMBLY 10 2 FINAL REDUCTION ASSEMBLY SERVICE INFORMATION SPECIFICATIONS Specified Oil GEAR OIL SAE 908 Oil Capacity At disassembly 0 11 liter At change 0 10 liter SPECIAL TOOLS Bearing puller 10 12 15 18mm TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission e Faulty drive belt e Faulty clutch Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks e Oil level too high e Worn or damaged oil seal 10 1 AA aaiaaaaiiaiaiaiaaauauauauauauauaiaiaiaiasasussussussssssssl gO KYMCO 10 FINAL REDUCTION AGILITY 50 FINAL REDUCTION DISASSEMBLY Remove the rear brake cable 4 13 3 Remove the rear wheel gt 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 Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft Final Gear Countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and
97. tion for the voltage meter then inspect the starter relay Green Yellow Wire C KYMCO 16 STARTING SYSTEM AGILITY 50 STARTER RELAY TEST 2 Remove the battery cover Disconnect the 4P connector from the starter relay and remove the starter relay Connect the starter relay D terminal to the 12V battery positive terminal and the relay C terminal to the battery negative terminal Check for continuity between the starter relay A and B terminals The relay is normal if there is continuity STARTER MOTOR INSTALLATION Apply engine oil to the starter motor O ring and install the starter motor Tighten the two mounting bolts Connect the starter motor cable connector ks Connector Startet Motor 16 5 GQ KYMCO 17 LIGHTS INSTRUMENTS SWITCHES FILLY LX 50_ SERVICE INFORMATION IGNITION SWITCH TROUBLESHOOTING STOP SWITCHES HORN FUEL UNIT INSTRUMENTS HANDLEBAR SWITCHES HEADLIGHT LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS e An electric tester is needed to measure or test the electric equipment e Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment e After installation of each switch a continuity check must be performed A continuity check can usually be made without removing the part from the motorcycle TROUBLESHOOTING Lights do not come on when ignition Fuel gauge pointer does not register switch 15 ON correctly e B
98. und hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the camshaft onto the cylinder head Install the cam chain over the camshaft gear Install the dowel pins mi 1 See T IW Va CM Lag KN F ui um dC KYMCO FILLY LX 50 Cylinder Head Valve Rocker Arm Cam Chain Camshaft Gear SS NI Round Hole Dowel Pins KYMCO 7 CYLINDER HEAD VALVES AGILITY 50 Install the camshaft holder washers and nuts Washer on the cylinder head Tighten the four cylinder head nuts and two bolts Nut dili d du EL Ae Pe Wi ei Torque Cylinder head nut 1 8 2 2kgf m e Apply engine oil to the threads of the cylinder head nuts e Diagonally tighten the cylinder head nutsin2 3 times a 891 1 Ca T Lj d 1 D D da D Le L EN ten vorn bd 7 Ze Holder Cam Chain Tensioner Sealing Bolt CAM CHAIN TENSIONER INSTALLATION First install a new cam chain tensioner gasket Install the tensioner using the two bolts Install the tensioner spring Install the O ring and sealing bolt When installing the tensioner release the lock pawl and push the push rod all the Way in Torque 0 45 0 6kgf m 1 7 A Lock Pawl Push Rod Spring O ring Cylinder Head Cover Adjust th
99. unit and A C generator and replace any faulty parts Inspect the CDI unit with a CDI tester e Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation e Use of spark plug with improper heat range is the main cause of poor engine performance e The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance 1s also described in this section e nspect the ignition switch according to the continuity table specified in page 17 3 e nspect the spark plug referring to Section 3 e Remove the generator and pulser coil referring to Section 14 SPECIFICATIONS Item Standard type NGK C7HSA Spark plug NGK C6HSA Cold type NGK C8HSA Spark plug gap 0 6 0 7mm 13 BTDC 1 700rpm 100RPM n gnition timing 28 BTDC 4 000rpm 100RPM Ignition coil resistance 20 Secondary without plug cap Pulser coil resistance 20 Ignition coil primary side max voltage Pulser coil max voltage TESTING INSTRUMENT Kowa Electric Tester or commercially available electric tester with resistance over 1 OMQ CDV 15 1 GQ KYMCO 15 IGNITION SYSTEM AGILITY 50 TROUBLESHOOTING High voltage too low No or intermittent high voltage e Weak battery or low engine speed e Faulty ignition coil e Loose ignition system connection e Weak battery e Faulty ignition coil e Faulty charging system e Faulty CDI unit e Faulty pulser coil
100. unting bolts Starter Motor Cable and the motor Front Cover Remove the waterproof rubber jacket and disconnect the starter motor cable connector DISASSEMBLY Remove the two starter motor case screws front cover motor case and other parts Motor Case Case Screws Commutator INSPECTION Inspect the removed parts for wear damage or discoloration and replace if necessary Clean the commutator if there 1s metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity KYMCO 16 STARTING SYSTEM AGILITY 50 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush and there should be continuity Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity replace with new ones Check if the needle bearing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage 16 3 dO KYMCO 16 STARTING SYSTEM AGILITY 50 Ion Cover commutator ASSEMBLY Apply grease to the dust sea
101. urned bulb e Disconnected wire or connector e Faulty switch e Broken wire e Broken wire e Faulty float e Fuse burned out e Faulty fuel unit e Weak battery e Faulty instrument e Poorly connected or shorted wire e Faulty winker Fuel gauge pointer fluctuates or swings e Loose wire connection Light dims e Faulty fuel unit e Faulty ignition coil e Faulty instrument e Wire or switch resistance too high e Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo e Faulty or burned bulb e Faulty dimmer switch 17 0 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES kirLYLXs0 Fuel Unit FUEL UNIT No Smoking REMOVAL Remove the met in box 2 3 Remove the frame right side cover 2 4 Disconnect the fuel unit wire connector Turn the fuel unit retainer counterclockwise to remove it Do not damage the fuel unit wire t Tab Groove Remove the fuel unit i Be careful not to bend or damage the fuel unit float arm INSTALLATION The installation sequence is the reverse of removal e Align the groove on the fuel unit with the tab on the fuel tank e Align the arrow on the retainer with the arrow on the fuel tank e Turn the retainer clockwise to secure it INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions 300 mei FUEL GAUGE INSPECTION Connect the fuel unit
102. wire connector and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit 1s normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Needle Position F Full E Empty 17 1 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES FILLY LX 50 HANDLEBAR SWITCHES L W Y 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 EEGEN G Use the X1Q range for test when using an electric tester STARTER SWITCH Yellow Red FREE II Y R PUSH DIMMER SWITCH TURN SIGNAL SWITCH Gr LL po qo 17 2 dC KYMCO 17 LIGHTS INSTRUMENTS SWITCHES FILLY LX 50 HORN SWITCH Light Green FREE oo SWITCH REPLACEMENT Remove the front covers 2 2 Remove the handlebar front cover 2 2 The installation sequence is the reverse of removal 2 IGNITION SWITCH INSPECTION Remove the front covers 2 2 Disconnect the ignition switch wire coupler LY B Check for continuity between the wire terminals G R LR IGNITION SWITCH REPLACEMENT Remove the front covers 52 2 Disconnect the ignition switch wire coupler Remove the two mounting bolts to remove the ignition switch decorative ring a
103. with the flywheel hole aligned with the crankshaft woodruff key The inside of the flywheel is magnetic Make sure that there 1s no bolt or nut before installation Hold the flywheel with the universal holder and tighten the flywheel nut Torque 3 5 4 5kgf m Universal Holder Install the cooling fan Torque 0 8 1 2kgf m Cooling Fan 14 9 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR dii Install the fan cover Install the right side cover 2 4 Fan Cover 14 10 dC KYMCO 15 IGNITION SYSTEM AGILITY 50 CDI Unit Ignition Switch A C Generator Spark Plug Pulser Coil Ignition 4 Switch T SE x Y W B G 09 E ele S wei EH E tu E G i iem o mm D P O m 5 A a cm CDI Unit d m E d 2 Seis G L a mm i ee we Ecg Battery md 15 0 dC KYMCO 15 IGNITION SYSTEM AGILITY 50 SERVICE INFORMATION TROUBLESHOOTING CDI UNIT INSPECTION SERVICE INFORMATION GENERAL INSTRUCTIONS e Check the ignition system according to the sequence specified in the Troubleshooting gt 15 2 e The ignition system adopts CDI unit and the ignition timing cannot be adjusted e f the timing is incorrect inspect the CDI

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