User manual KYMCO AGILITY 125 SERVICE MANUAL

[. . . ] Agility 50 - 125 Agility 50 - 125 CICLOMOTORI 4T SCOOTER TARGATI 2 ANNI DI GARANZIA 1 ANNO DI ASSISTENZA CREDITO PERSONALIZZATO KYMCO RACCOMANDA Servizi Finanziari 50 4T R10 MOTORE RAFFREDDAMENTO CILINDRATA POTENZA COPPIA EMISSIONI AVVIAMENTO FRIZIONE TRASMISSIONE SOSPENSIONI FRENI PNEUMATICI DIMENSIONE MASSA COLORI argento ANT. 90/90-10 1. 830 x 690 x 1. 070mm 84kg nero 49cc 50 4T R12 MONOCILINDRICO ORIZZONTALE 4 TEMPI ARIA FORZATA 125 125cc 2, 4kW (3, 3CV) a 8. 500 giri/min 2, 4kW (3, 3CV) a 7. 500 giri/min 6, 9kW (9, 4CV) a 7. 500 giri/min 3, 2 Nm a 7. 000 giri EURO 2 ELETTRICO E KICK STARTER CENTRIFUGA AUTOMATICA A SECCO CINGHIA TRAPEZOIDALE - INGRANAGGI ANT. FORCELLA TELESCOPICA IDRAULICA ø 31 POST. MONOBRACCIO OSCILLANTE AMMORTIZZATORE IDRAULICO REGOLABILE ANT. [. . . ] Service Limit: 33. 94mm replace if below Check the movable driven face for wear or damage. Service Limit: 34. 06mm replace if over AGILITY 50 DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. Discard the removed bearing and replace with a new one. Inner Bearing Remove the snap ring and drive the outer bearing out of the driven face. Snap Ring Apply grease to the outer bearing. Drive a new outer bearing into the driven face with the sealed end facing up. Pack all bearing cavities with 5. 0 5. 6g grease. Specified grease: Heat resistance 230 C Outer Bearing Bearing Remover 9-11 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Press a new needle bearing into the driven face. AGILITY 50 Driver Handle Outer Driver, 24x26mm Movable Driven Face Pilot, 17mm 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. O-rings Guide Roller Pin Install the seal collar. 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 Special Seal Collar Lock Nut Wrench, 39mm Clutch Spring Compressor Clutch Spring Compressor 9-12 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER INSTALLATION Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft. AGILITY 50 Clutch/Driven Pulley Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the 10mm clutch outer nut. Torque: 3. 5~4. 5kgf-m Install the left crankcase cover. ( 9-4) Clutch Outer Nut Universal Holder 9-13 10. FINAL REDUCTION AGILITY 50 10 10 10-0 10. FINAL REDUCTION SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . 10-1 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 FINAL REDUCTION DISASSEMBLY. . . . 10-2 AGILITY 50 FINAL REDUCTION INSPECTION. . . . . . 10-2 BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . 10-4 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0. 11 liter At change : 0. 10 liter SPECIAL TOOLS Bearing puller, 10, 12, 15, 18mm TROUBLESHOOTING Engine starts but motorcycle won`t move Damaged transmission Seized or burnt transmission Faulty drive belt Faulty clutch Abnormal noise Worn, seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged oil seal 10-1 10. FINAL REDUCTION FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. [. . . ] The installation sequence is the reverse of removal. Nuts 17-5 18. EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM EXHAUST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-0 18 EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 EXHAUST EMISSION CONTROL SYSTEM SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2 SECONDARY AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3 AIR INJECTION CUT-OFF VALVE (A. I. C. V. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4 REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5 EXHAUST MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-6 EXHAUST EMISSION RELATED SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7 18 EXHAUST EMISSION CONTROL SYSTEM DIAGRAM Fresh Air Carburetor Intake Manifold Vacuum Tube Secondary Air Inlet Tube Air Injection Cut-off Valve Crankshaft Reed Valve Valve Piston Engine Oil Exhaust Secondary Air Secondary Air Cleaner Fresh Air 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 Item Secondary Air Cleaner Purpose Filter secondary air. [. . . ]