Manual de Taller KYMCO AGLITY 50 MANUAL TALLER

Vista Previa del Manual

Agility 50 - 125

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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 ø 31

POST. MONOBRACCIO OSCILLANTE AMMORTIZZATORE IDRAULICO REGOLABILE

FRENI

ANT. DISCO ø 180mm

POST. TAMBURO ø 110mm

PNEUMATICI

ANT. - POST. 90/90-10

ANT. 120/70-12

POST. 130/70-12

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

i/min

ABILE

0 x 1.125mm

05kg

giallo

Agility 50 - 125

2616-040407

KYMCO SI RISERVA DI APPORTARE VARIAZIONI TECNICHE, ESTETICHE O DI ALTRA NATURA SENZA L’OBBLIGO DI ALCUN PREAVVISO.

KYMCO RACCOMANDA

2 ANNI DI GARANZIA

1 ANNO DI ASSISTENZA

CREDITO PERSONALIZZATO

S e r v i z i F i n a n z i a r i

SCOOTER TARGATI

CICLOMOTORI 4T

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AGILITY 50

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO AGILITY

Section 1 contains the precautions for all

operations stated in this manual. Read

them carefully before starting any

operation.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 6 through 17 give instructions

for disassembly, assembly and inspection

of engine, chassis frame and electrical

equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

ENGINE

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

FINAL REDUCTION

CRANKCASE/CRANKSHAFT

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

CHASSIS

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

ELECTRICAL

EQUIPMENT

LIGHTS/INSTRUMENTS/SWITCHES

Our company reserves the right to

make any alteration in the design.

The information and contents included

in this manual may be different from

the motorcycle in case specifications

are changed.

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1. GENERAL INFORMATION

1-1

AGILITY 50

Location of Engine Serial Number

ENGINE SERIAL NUMBER

ENGINE SERIAL NUMBER ...................1- 1

LUBRICATION POINTS .......................1-13

SPECIFICATIONS ...................................1- 2

CABLE & HARNESS ROUTING ............1-15

SERVICE PRECAUTIONS......................1- 3

WIRING DIAGRAM................................1-20

TORQUE VALUES ..................................1-11

TROUBLESHOOTUNG ..........................1-21

SPECIAL TOOLS.....................................1-12

AGILITY 50

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1. GENERAL INFORMATION

1-2

AGILITY 50

SPECIFICATIONS

Motorcycle Name & Type

AGILITY 50

Name & Model No.

KG10SA

Overall length (mm)

1830

Overall width (mm)

690

Overall height (mm)

1130

Wheel base (mm)

1325

Engine type

O.H.C.

Displacement

49.5cc

Fuel Used

92# nonleaded gasoline

Front wheel

37.5

Net weight (kg)

Rear wheel

Total

92.5

Front wheel

Gross weight(kg) Rear wheel

Total

Front wheel

120/70 -12 56J

Tires

Rear wheel

130/70 -12 56J

Ground clearance (mm)

112

Perform- ^{Braking distance (m)}

4 (Initial speed

20km/h)

ance

Min. turning radius (m)

1.99

Starting system

Starting motor &

kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

I39.0 x 41.4

Compression ratio

Compression pressure

(kg/cm²-rpm)

Max. output

3.5/7500kw/(r/min)

Max. torque

0.35/7000kg m/rpm

Open

Port

Intake

Engine

timing

Open

Exhaust

Valve clearance ^Intake

0.04

(cold) (mm)

Exhaust

0.04

Idle speed (rpm)

1700Ô100rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor type

Oil filter type

Full-flow filtration

Lubrication

System

Oil capacity

0.8 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

5.0 liter

Type

CVK

Piston dia. (mm)

Venturi dia.(mm)

I17equivalent

Carburetor

Throttle type

Butterfly type

Type

CDI

Ignition timing

BTDC28q/4000rpm

Contact breaker

Non-contact point type

Spark plug

NGK

C7HSA

Spark plug gap

0.6Д0.7mm

Battery

Capacity

12V4AH

Clutch Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic centrifugal

type

Type

Two-stage reduction

Reduction 1st

0.8-3.1

ratio

2nd

11.05

Front Caster angle

27q

Axle Trail length

Tire pressure

Front

1.75

(kg/cm²)

Rear

2.25

Turning

Left

45q

angle

Right

45q

Front DISK (180mm) brake

Brake system

type

Rear

Drum (110mm) brake

Front

TELESCOPE

Suspension type Rear

Unit Swing

Front

Shock absorber

distance

Rear

Frame type

Under Bone

Fuel System

Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

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1. GENERAL INFORMATION

1-3

AGILITY 50

SERVICE PRECAUTIONS

„Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

„When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

„Use genuine parts and lubricants

„When servicing the motorcycle, be sure to

use special tools for removal and

installation.

„After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

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1. GENERAL INFORMATION

1-4

AGILITY 50

„Apply or add designated greases and

lubricants to the specified lubrication

points.

„After reassembly, check all parts for proper

tightening and operation.

„When two persons work together, pay

attention to the mutual working safety.

„Disconnect the battery negative (-) terminal

before operation.

„When using a spanner or other tools, make

sure not to damage the motorcycle surface.

„After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

„When connecting the battery, the positive

(+) terminal must be connected first.

„After connection, apply grease to the

battery terminals.

„Terminal caps shall be installed securely.

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1. GENERAL INFORMATION

1-5

AGILITY 50

„If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

„After operation, terminal caps shall be

installed securely.

„When taking out the connector, the lock on

the connector shall be released before

operation.

„Hold the connector body when connecting

or disconnecting it.

„Do not pull the connector wire.

„Check if any connector terminal is bending,

protruding or loose.

Confirm

Capacity

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1. GENERAL INFORMATION

1-6

AGILITY 50

„The connector shall be inserted

completely.

„If the double connector has a lock, lock

it at the correct position.

„Check if there is any loose wire.

„Before connecting a terminal, check for

damaged terminal cover or loose

negative terminal.

„Check the double connector cover for

proper coverage and installation.

„Insert the terminal completely.

„Check the terminal cover for proper

coverage.

„Do not make the terminal cover opening

face up.

„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.

Snapping!

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1. GENERAL INFORMATION

1-7

AGILITY 50

„After clamping, check each wire to make

sure it is secure.

„Do not squeeze wires against the weld or

its clamp

„After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

„When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

„Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

„Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

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1. GENERAL INFORMATION

1-8

AGILITY 50

„Route harnesses so they are neither

pulled tight nor have excessive slack.

„Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner

„When rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

„Do not break the sheath of wire.

„If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

„When installing other parts, do not press or

squeeze the wires.

Do not pull

too tight!

Do not press or

squeeze the wire.

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1. GENERAL INFORMATION

1-9

AGILITY 50

„After routing, check that the wire harnesses

are not twisted or kinked.

„Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or surrounding parts in all steering

positions.

„When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

„Be careful not to drop any parts.

„When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

„Do not bend or twist control cables.

Damaged control cables will not operate

smoothly and may stick or bind.

Do you understand

the instrument? Is

the instrument set

correctly?

Remove Rust !

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1. GENERAL INFORMATION

1-10

AGILITY 50

„Symbols:

The following symbols represent the

servicing methods and cautions included in

this service manual.

: Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

(Ö12-3)

:Refer to page 12-3.

Engine Oil

Grease

Gear Oil

Special

＊

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1. GENERAL INFORMATION

1-11

AGILITY 50

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kg-m)

Item

Torque (kg-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

0.45-0.6

0.6-1.2

1.8-2.5

3.0-4.0

5.0-6.0

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut

8mm flange bolt, nut

10mm flange bolt, nut

0.35-0.5

0.7-1.1

1.0-1.4

2.4-3.0

3.5-4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

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

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

Double end bolt

Apply oil to

threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

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

25.4

8.0-12.0

5.0-7.0

11.0-13.0

4.0-5.0

2.0-3.0

0.45-0.6

3.0-3.6

U-nut

Apply locking agent

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1. GENERAL INFORMATION

1-12

AGILITY 50

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref. Page

10-3

10-4

Bearing puller 10.12.15.18 mm

E037

10.12.15.18mm bearing

12-6

Bushing remover L

E032

11102 bush engine hanger rubber

Bushing remover S

EO19

11203 bush rear cushion under rubber

Crankshaft bearing puller

E030

91005 radial bearing

Crankshaft protector

E029

13000 crankshaft comp 12mm.14mm

Clutch spring compressor

E027

2301a driven pully assy

9-9

9-12

Cushion assemble & disassemble

tool

F004

52400 cushion assy

13-4

Flywheel holder

E017

31110 flywheel comp.2310a pully assy

driven

9-5

9-9

9-13

14-7

14-9

Flywheel puller

E002

Left hand thread 27mm

14-7

Long socket wrench 32mm 8angle

F002

50306 steering stem

12-21

12-22

Oil seal & bearing installer

E014

Oil seal & bearing install

Tool boox

E033

Special tools storage

Tappet adjuster

E036

90012 screw tappet

3-5

7-7

Valve spring compressor

E038

Valve spring

7-8

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