Kymco Agility 50 free download

File name AGILITY 50 cap 00 (prefazione).pdf

AGILITY 50 PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION 1 technical features and servicing procedures for the KYMCO AGILITY FRAME COVERS/EXHAUST MUFFLER 2 50 INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4 Section 1 contains the precautions for all operations stated in this manual. Read FUEL SYSTEM 5 ENGINE them carefully before starting any ENGINE REMOVAL/INSTALLATION 6 operation. CYLINDER HEAD/VALVES 7 Section 2 is the removal/installation CYLINDER/PISTON 8 procedures for the frame covers which DRIVE AND DRIVEN PULLEYS/KICK are subject to higher removal/installation STARTER 9 frequency during maintenance and FINAL REDUCTION 10 servicing operations. CRANKCASE/CRANKSHAFT 11 CHASSIS Section 3 describes the inspection/ FRONT WHEEL/FRONT BRAKE/ 12 adjustment procedures, safety rules and FRONT SUSPENSION service information for each part, starting REAR WHEEL /REAR BRAKE /REAR 13 from periodic maintenance. SUSPENSION BATTERY/CHARGING SYSTEM/A.C. 14 EQUIPMENT ELECTRICAL GENERATOR Sections 6 through 17 give instructions for disassembly, assembly and inspection IGNITION SYSTEM 15 of engine, chassis frame and electrical STARTING SYSTEM 16 equipment. LIGHTS/INSTRUMENTS/SWITCHES 17 Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section. 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

File name AGILITY 50 cap 01 (info generali).pdf

1. GENERAL INFORMATION AGILITY 50 1 ENGINE SERIAL NUMBER ... 1- 1 SPECIFICATIONS ... 1- 2 LUBRICATION POINTS ...1-13 CABLE & HARNESS ROUTING ...1-15 1 SERVICE PRECAUTIONS ... 1- 3 WIRING DIAGRAM...1-20 TORQUE VALUES ... 1-11 TROUBLESHOOTUNG ...1-21 SPECIAL TOOLS ... 1-12 ENGINE SERIAL NUMBER AGILITY 50 Location of Engine Serial Number 1-1 1. GENERAL INFORMATION AGILITY 50 SPECIFICATIONS Motorcycle Name & Type AGILITY 50 Air cleaner type & No Paper element, wet Name & Model No. KG10SA Fuel capacity 5.0 liter Fuel System Overall length (mm) 1830 Type CVK Carburetor Overall width (mm) 690 Piston dia. (mm) Overall height (mm) 1130 Venturi dia.(mm) 17equivalent Wheel base (mm) 1325 Throttle type Butterfly type Engine type O.H.C. Type CDI Electrical Equipment Ignition System Displacement 49.5cc Ignition timing BTDC28°/4000rpm Fuel Used 92# nonleaded gasoline Contact breaker Non-contact point type Front wheel 37.5 Net weight (kg) Rear wheel 55 Spark plug NGK Total 92.5

File name AGILITY 50 cap 02 (plastiche marmitta).pdf

2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50 2 SCHEMATIC DRAWING 2 2-0 2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50 SERVICE INFORMATION ... 2-1 EXHAUST MUFFLER REMOVAL ...2-5 FRAME COVERS ... 2-2 SERVICE INFORMATION GENERAL INSTRUCTIONS · When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. Items Related for Removal · Handlebar front cover Handlebar rear cover Headlight wire connector · Handlebar rear cover Speedometer cable and instrument light wire connectors, etc. · Frame body cover Met-in box, rear grip, rear turn signal lights, floor board · Floor board Frame body cover Battery and wire connectors · Front tool box Front cover, floor board TORQUE VALUES Exhaust muffler joint lock nut 1.0~1.4kgf-m Exhaust muffler lock bolt 3.0~3.6kgf-m 2-1 2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50 Screw FRAME COVERS FRONT COVER REMOVAL Remove the screw on the front of the front cover. Remove the six screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal. 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. Screw Screws HANDLEBAR REAR COVER REMOVAL 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. Bolt 2-2 2. FRAME COVERS/EXHAUST MUFFLER AGILITY 50 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 .

File name AGILITY 50 cap 03 (manutenzione).pdf

3. INSPECTION/ADJUSTMENT AGILITY 50 3 SERVICE INFORMATION...3-0 FINAL REDUCTION GEAR OIL...3- 7 MAINTENANCE SCHEDULE...3-2 DRIVE BELT...3- 7 FUEL FILTER...3-3 BRAKE SHOE ...3- 8 THROTTLE OPERATION...3-3 BRAKE ADJUSTING NUT...3- 8 AIR CLEANER ...3-4 SPARK PLUG ...3-4 HEADLIGHT AIM ...3- 9 CLUTCH SHOE WEAR...3- 9 3 VALVE CLEARANCE...3-5 SUSPENSION ...3- 9 CARBURETOR IDLE SPEED ...3-5 NUTS/BOLTS/FASTENERS...3-10 IGNITION TIMING ...3-6 WHEELS/TIRES...3-10 CYLINDER COMPRESSION ...3-6 STEERING HANDLEBAR ...3-11 SERVICE INFORMATION GENERAL WARNING ·Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. ·Gasoline 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 : 26mm Spark plug gap : 0.60.7mm 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 3. INSPECTION/ADJUSTMENT AGILITY 50 Cylinder compression : 16 kg/cm2 Ignition timing: BTDC 28 /4000rpm CHASSIS Front brake free play: 1020mm Rear brake free play : 1020mm TIRE PRESSURE 1 Rider 2 Riders Front 1.5kg/cm2 1.75kg/cm2 Rear 2.0kg/cm2 2.25kg/cm2 TIRE SIZE: Front : 120/70-12 Rear : 130/70-12 TORQUE VALUES Front axle nut 5.07.0kgf-m Rear axle nut 1113kgf-m 3-

File name AGILITY 50 cap 04 (lubrificazione).pdf

4. LUBRICATION SYSTEM AGILITY 50 4 LUBRICATION SYSTEM Rocker Arm Shaft 4 Crankshaft Oil Filter Screen Oil Pump 4-0 4. LUBRICATION SYSTEM AGILITY 50 SERVICE INFORMATION...4-1 ENGINE OIL/OIL FILTER ... 4-2 TROUBLESHOOTING ...4-1 OIL PUMP... 4-3 SERVICE INFORMATION GENERAL INSTRUCTIONS · The maintenance of lubrication system can be performed with the engine installed in the frame. · Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line. · Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it reaches its service limit. · After the oil pump is installed, check each part for oil leaks. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Inner rotor-to-outer rotor clearance 0.12 Oil pump Outer rotor-to-pump body clearance 0.12 Rotor end-to-pump body clearance 0.050.10 0.2 TROUBLESHOOTING Oil level too low Poor lubrication pressure · Natural oil consumption · Oil level too low · Oil leaks · Clogged oil filter or oil passages · Worn or poorly installed piston rings · Not use the specified oil · Worn valve guide or seal 4-1 4. LUBRICATION SYSTEM AGILITY 50 ENGINE OIL/OIL FILTER OIL LEVEL · Place the motorcycle upright on level ground for engine oil level check. · Run the engine for 23 minutes and check the oil level after the engine is stopped for 23 minutes. Remove the oil dipstick and check the oil level with the oil dipstick. If the level is near the lower level, fill to the upper level with the specified engine oil. Oil Dipstick OIL CHANGE The engine oil will drain more easily while the engine is warm. Remove the drain bolt to drain the engine oil thoroughly. Remove the oil filter screen cap and clean the oil filter screen with compressed air. Oil Filter Screen Cap 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 O-ring Fill the

File name AGILITY50 cap 05 (alimentazione).pdf

5. FUEL SYSTEM AGILITY 50 5 5 5-0 5. FUEL SYSTEM AGILITY 50 Ignition Switch B Regulator /Rectifier W Fuse CDI Unit L/Y Y 12V Battery Y Resistor G/B G Lighting System 5 5W Auto Bystarter 5-1 5. FUEL SYSTEM AGILITY 50 SERVICE INFORMATION...5-2 ACCELERATING PUMP ...5-10 TROUBLESHOOTING...5-3 CARBURETOR INSTALLATION...5-11 CARBURETOR REMOVAL...5-4 PILOT SCREW ADJUSTMENT ...5-12 AUTO BYSTARTER ...5-4 FUEL TANK...5-13 AIR CUT-OFF VALVE ...5-6 FUEL UNIT ...5-14 VACUUM CHAMBER ...5-6 AIR CLEANER ...5-14 FLOAT CHAMBER...5-8 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. · When disassembling the carburetor, be sure to service the vacuum piston and float chamber. · Do not bend or twist control cables. Damaged control cables will not operate smoothly. · When disassembling fuel system parts, note the locations of O-rings. Replace them with new ones during assembly. · Before float chamber disassembly, loosen the drain screw to drain the residual gasoline into a clean container. · After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent foreign matters from entering. · Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm. · 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

File name AGILITY50 cap 06 (rimozione motore).pdf

6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 6 6 6-0 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 SERVICE INFORMATION ... 6-1 ENGINE INSTALLATION ...6-4 ENGINE REMOVAL ... 6-2 SERVICE INFORMATION GENERAL INSTRUCTIONS · A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. · Use shop towels to protect the motorcycle body during engine removal. · Parts requiring engine removal for servicing: Crankcase Crankshaft 6-1 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. Negative Cable Auto Bystarter Wire Connector Disconnect the starter motor cable and earth cable from the starter motor. Remove the fuel tube. fuel tube Earthr Cable Starter Motor Cable Remove the spark plug cap. 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. Lock Nut Adjusting Nut 6-2 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 Air Tube Band Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube. connecting tube Remove the rear brake adjusting nut, connector pin rear brake cable. Adjusting Nut Remove the rear shock absorber upper mount Rear Shock Absorber Upper Mount Bolt bolt. Remove the engine mounting bolt and move the motorcycle forward to separate it from the engine. Support the motorcycle with a floor jack. Engine Hanger Engine Mounting Bolt Bracket Bolt 6-3 6. ENGINE REMOVAL/INSTALLATION FILLY LX 50 ENGINE HANGER BRACKET REMOVAL Remove the return spring from the main stand. Remove the main stand.

File name AGILITY50 cap 07 (testa valvole).pdf

7. CYLINDER HEAD/VALVES AGILITY 50 7 7 7-0 7. CYLINDER HEAD/VALVES FILLY LX 50 SERVICE INFORMATION... 7-1 CYLINDER HEAD DISASSEMBLY...7-7 TROUBLESHOOTING ... 7-2 CYLINDER HEAD ASSEMBLY ...7-8 CAMSHAFT REMOVAL... 7-3 CYLINDER HEAD INSTALLATION ...7-8 CYLINDER HEAD REMOVAL ... 7-5 CAMSHAFT INSTALLATION...7-9 SERVICE INFORMATION GENERAL INSTRUCTIONS · The cylinder head can be serviced with the engine installed in the frame. · When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. · The camshaft is lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head. · After disassembly, clean the removed parts and dry them with compressed air before inspection. · After removal, mark and arrange the removed parts in order. When assembling, install them in the reverse order of removal. SPECIFICATIONS Item Standard (mm) Service Limit (mm) IN 0.04 Valve clearance (cold) EX 0.04 Cylinder head compression 14kg/cm2 Cylinder head warpage 0.05 IN 26.438 26.038 Camshaft cam height EX 25.807 25.407 Valve rocker arm I.D. IN 10.000-10.015 10.10 EX 10.000-10.015 10.10 Valve rocker arm shaft IN 9.972-9.987 9.91 O.D. EX 9.972-9.987 9.91 Valve seat width IN 1.0 1.8 EX 1.0 1.8 Valve stem O.D. IN 4.975-4.990 4.9 EX 4.955-4.970 4.9 IN 5.000-5.012 5.03 Valve guide I.D. EX 5.000-5.012 5.03 Valve stem-to-guide IN 0.010-0.037 0.08 clearance EX 0.030-0.057 0.1 Inner 31.1 30.1 Valve

File name AGILITY50 cap 08 (cilindro pistone).pdf

8. CYLINDER/PISTON AGILITY 50 8 1.0kg-m 8 Do not bend 8-0 8. CYLINDER/PISTON AGILITY 50 SERVICE INFORMATION...8-1 PISTON REMOVAL... 8-2 TROUBLESHOOTING...8-1 PISTON INSTALLATION... 8-6 CYLINDER REMOVAL ...8-2 CYLINDER INSTALLATION ... 8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS · The cylinder and piston can be serviced with the engine installed in the frame. · After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Item Standard (mm) Service Limit (mm) I.D. 50.00-50.01 Warpage 0.05 Cylinder Cylindricity 0.05 True roundness 0.05 Ring-to- Top 0.015-0.050 0.09 clearance Second 0.015-0.050 0.09 Top 0.08-0.20 0.45 Piston, Ring end gap Second 0.05-0.20 0.45 piston ring Oil side rail 0.20-0.70 Piston O.D. 49.97-49.990 49.9 Piston O.D. measuring 9mm from bottom of skirt Piston-to-cylinder clearance 0.010-0.040 0.1 Piston pin hole I.D. 13.002-13.008 13.04 Piston pin O.D 12.994-13.000 12.96 Piston-to-piston pin clearance 0.002-0.014 Connecting rod small end I.D. bore 13.016-13.034 13.06 TROUBLESHOOTING · 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 from exhaust muffler · Worn, stuck or broken piston rings · Worn or damaged piston rings · Worn or damaged cylinder and piston · Worn or damaged cylinder and piston Compression too high Abnormal noisy piston · Excessive carbon buil

File name AGILITY50 cap 10 (riduzione finale).pdf

10. FINAL REDUCTION AGILITY 50 10 10 10-0 10. FINAL REDUCTION AGILITY 50 SERVICE INFORMATION...10-1 FINAL REDUCTION INSPECTION... 10-2 TROUBLESHOOTING...10-1 BEARING REPLACEMENT... 10-3 FINAL REDUCTION DISASSEMBLY...10-2 FINAL REDUCTION ASSEMBLY... 10-4 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0.11 liter At change : 0.10 liter SPECIAL TOOLS Bearing puller, 10,12,15,18mm 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 AGILITY 50 Bolt FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. ( 13-3) Remove the rear wheel. ( 13-2) Remove the left crankcase cover. ( 9-2) Remove the clutch/driven pulley. ( 9-10) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts. Remove the transmission case cover. Remove the gasket and dowel pins. Drive Shaft Remove the final gear and countershaft. Final Gear Countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Countershaft Inspect the final gear and final shaft for wear, damage or seizure. Final Shaft 10-2 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

File name AGILITY50 cap 11 (albero motore).pdf

11. CRANKCASE/CRANKSHAFT AGILITY 50 11 11 11-0 11. CRANKCASE/CRANKSHAFT AGILITY 50 SERVICE INFORMATION...11-1 CRANKSHAFT... 11-3 TROUBLESHOOTING ...11-1 CRANKCASE ASSEMBLY... 11-4 CRANKCASE SEPARATION ...11-2 SERVICE INFORMATION GENERAL INSTRUCTIONS · This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. · The following parts must be removed before separating the crankcase. -Cylinder head ( Section 7) -Cylinder/piston ( Section 8) -Drive and driven pulleys ( Section 9) -A.C. generator ( Section 14) -Carburetor/air cleaner ( Section 5) -Rear wheel/rear shock absorber ( Section 13) -Starter motor ( Section 16) -Oil pump ( Section 4) SPECIFICATIONS Item Standard (mm) Service Limit (mm) Connecting rod big end side clearance 0.100.35 0.55 Crankshaft Connecting rod big end radial clearance 0-0.008 0.05 Runout 0.10 TORQUE VALUES Crankcase bolt 0.8~1.2kgf-m Cam chain tensioner slipper bolt 0.8~1.2kgf-m TROUBLESHOOTING Excessive engine noise · Excessive bearing play · Excessive crankpin bearing play 11-1 11. CRANKCASE/CRANKSHAFT AGILITY 50 CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt and cam chain tensioner slipper. Cam Chain Tensioner Slipper Bolt Crankcase Bolt Remove the crankcase attaching bolt. Separate the left and right crankcase halves. · Do not damage the crankcase gasket surface. · Never use a driver to pry the crankcase mating surfaces apart. Remove the gasket and dowel pins. Dowel Pins Cam Chain Remove the crankshaft from the left crankcase. Remove the cam chain. 11-2 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. Oil Sea

File name AGILITY50 cap 12 (ruota freno sospens ant).pdf

12. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 12 12 12-0 12. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION AGILITY 50 SERVICE INFORMATION ... 12-1 FRONT BRAKE... 12- 7 TROUBLESHOOTING ... 12-2 FRONT SHOCK ABSORBER... 12-18 STEERING HANDLEBAR... 12-3 FRONT FORK... 12-21 FRONT WHEEL... 12-4 SERVICE INFORMATION GENERAL INSTRUCTIONS · Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. · During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Axle shaft runout 0.2 Radial 2.0 Front wheel rim runout Axial 2.0 Front brake drum I.D 110(SG20AB) 111(SG20AB) Front brake lining thickness 4.0(SG20AB) 2.0(SG20AB) 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 AGILITY 50 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling · Excessively tightened steering stem top · Bent rim cone race · Excessive wheel bearing play · Broken steering balls · Bent spoke plate · Insufficient tire pressure · Faulty tire Steers to one side or does not track straight · Improperly tightened axle nut · Uneven front shock absorbers Soft front shock absorber · Bent front fork · Weak shock springs · Bent front axle or uneven tire · Insufficient damper oil Poor brake performance Front shock absorber noise · Incorrectly adjusted brake

File name AGILITY50 cap 13 (ruota freno sospens post).pdf

13. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 13 13 13-0 13. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 SERVICE INFORMATION ... 13-1 REAR BRAKE...13-3 TROUBLESHOOTING ... 13-1 REAR SHOCK ABSORBER...13-4 REAR WHEEL ... 13-2 SERVICE INFORMATION GENERAL INSTRUCTIONS · During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Radial 2.0 Rim runout Rear wheel Axial 2.0 Rear brake drum I.D 110 111 Rear brake lining thickness 4.0 2.0 Rear shock absorber spring free length 202.5 198 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 & Disassemble Tool TROUBLESHOOTING Rear wheel wobbling Poor brake performance · Bent rim · Brake not adjusted properly · Faulty tire · Worn brake linings · Axle not tightened properly · Worn brake shoes at cam contacting area Soft rear shock absorber · Worn brake cam · Weak shock absorber spring · Worn brake drum · Faulty damper 13-1 13. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION AGILITY 50 REAR WHEEL Rear Axle Nut REMOVAL Remove the exhaust muffler. ( 2-5) Remove the rear axle nut to remove the rear wheel. INSPECTION Measure the rear wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over 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. Torqu

File name AGILITY50 cap 14 (imp ricarica).pdf

14. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGILITY 50 14 Battery Fuse Regulator/Rectifier CDI Resistors A.C. Generator G Y W R G/B Y G Resistor A.C. Generator Auto Bystarter Regulator/ 14 Headlight Switch Rectifier 5 5W Battery 12V4AH 14-0 14. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR AGIKITY 50 SERVICE INFORMATION... 14-1 A.C. GENERATOR CHARGING COIL ...14-6 TROUBLESHOOTING ... 14-2 RESISTOR INSPECTION...14-6 BATTERY... 14-3 A.C. GENERATOR REMOVAL ...14-6 CHARGING SYSTEM ... 14-4 A.C. GENERATOR INATALLATION ...14-8 REGULATOR/RECTIFIER... 14-5 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention · 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 it is used for 23 years. A capacity-decreased battery will resume its voltage after it is recharged but its voltage decreases suddenly and then increases when a load is added. · When a battery is overcharged, some symptoms can

File name AGILITY50 cap 15 (imp accensione).pdf

15. IGNITION SYSTEM AGILITY 50 15 CDI Unit Ignition Switch A.C. Generator Spark Plug Pulser Coil Ignition Switch B/Y L/Y Y W B G Ignition Coil Spark Plug Fuse Pulser Coil CDI Unit G Battery 15 15-0 15. IGNITION SYSTEM AGILITY 50 SERVICE INFORMATION ... 15-1 IGNITION COIL ... 15-4 TROUBLESHOOTING ... 15-2 PULSER COIL ... 15-5 CDI UNIT INSPECTION ... 15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS · Check the ignition system according to the sequence specified in the Troubleshooting. ( 15-2) · The ignition system adopts CDI unit and the ignition timing cannot be adjusted. · If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts. Inspect the CDI unit with a CDI tester · Loose connector and poor wire connection are the main causes of faulty ignition system. Check each connector before operation. · Use of spark plug with improper heat range is the main cause of poor engine performance. · The inspections in this section are focused on maximum voltage. The inspection of ignition coil resistance is also described in this section. · Inspect the ignition switch according to the continuity table specified in page 17-3. · Inspect the spark plug referring to Section 3. · Remove the A.C. generator and pulser coil referring to Section 14. SPECIFICATIONS Item Standard Standard type (NGK) C7HSA Spark plug Hot type (NGK) C6HSA Cold type (NGK) C8HSA Spark plug gap 0.60.7mm "F" mark 13° BTDC /1,700rpm±100RPM Ignition timing

File name AGILITY50 cap 16 (imp avviamento).pdf

16. STARTING SYSTEM AGILITY 50 16 Stop Switches Starter Relay Starter Button Starter Motor Starter Relay Ignition Switch Fuse G/Y R/W R Y/R G Stoplight G/Y Battery G Front Rear Starter Motor Stop Switches 16 16-0 16. STARTING SYSTEM AGILITY 50 SERVICE INFORMATION...16-1 STARTER MOTOR ... 16-2 TROUBLESHOOTING...16-1 STARTER RELAY... 16-4 SERVICE INFORMATION GENERAL INSTRUCTIONS · The removal of starter motor can be accomplished with the engine installed. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5 8.5 TROUBLESHOOTING Starter motor won`t turn Lack of power · Fuse burned out · Weak battery · Weak battery · Loose wire or connection · Faulty ignition switch · Foreign matter stuck in starter motor · Faulty starter clutch or gear · Faulty front or rear stop switch · Faulty starter relay Starter motor rotates but engine does · Poorly connected, broken or shorted wire not start · Faulty starter motor · Faulty starter clutch · Starter motor rotates reversely · Weak battery 16-1 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. Remov

File name AGILITY50 cap 17 (imp elettrico).pdf

17. LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 17 INFORMATION ... 17-0 SERVICE IGNITION SWITCH ... 17-3 17 TROUBLESHOOTING ... 17-0 STOP SWITCHES/HORN ... 17-4 FUEL UNIT ... 17-1 INSTRUMENTS... 17-4 HANDLEBAR SWITCHES... 17-2 HEADLIGHT/LIGHTS... 17-5 SERVICE INFORMATION GENERAL INSTRUCTIONS · An electric tester is needed to measure or test the electric equipment. · Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment. · 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 is "ON" correctly · Burned bulb · Disconnected wire or connector · Faulty switch · Broken wire · Broken wire · Faulty float · Fuse burned out · Faulty fuel unit · Weak battery · Faulty instrument · Poorly connected or shorted wire · Faulty winker Fuel gauge pointer fluctuates or swings · Loose wire connection Light dims · Faulty fuel unit · Faulty ignition coil · Faulty instrument · Wire or switch resistance too high · Faulty regulator/rectifier Headlight does not change when dimmer switch is turn to Hi or Lo · Faulty or burned bulb · Faulty dimmer switch 17-0 17. LIGHTS/INSTRUMENTS/SWITCHES FILLY LX 50 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. Tab Groove Remove the fuel unit. Be

File name AGILITY50 cap 18 (imp scarico).pdf

18. EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM 18 EMISSION CONTROL SYSTEM ...18-1 EXHAUST EXHAUST EMISSION CONTROL SYSTEM DIAGRAM ...18-0 SERVICE INFORMATION...18-1 TROUBLESHOOTING ...18-1 MAINTENANCE SCHEDULE ...18-2 SECONDARY AIR CLEANER...18-3 18 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 EXHAUST EMISSION CONTROL SYSTEM DIAGRAM Fresh Air Carburetor Air Injection Intake Manifold Vacuum Tube Cut-off Valve Secondary Air Inlet Tube Crankshaft Reed Valve Valve Secondary Piston Secondary Air Air Cleaner Fresh Air 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 Item Purpose Function It

File name AGILITY50_cap_09_(trasmissione)1.pdf

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER AGILITY 50 9 5.0 6.0kg-m 3.5-4.5g-m 9 3.5-4.0g-m 9-0 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SERVICE INFORMATION...9-1 TROUBLESHOOTING...9-1 LEFT CRANKCASE COVER ...9-2 KICK STARTER ...9-2 AGILITY 50 DRIVE BELT ... 9-5 DRIVE PULLEY ... 9-6 CLUTCH/DRIVEN PULLEY ... 9-9 SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed. 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 Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D. Weight roller O.D. TORQUE VALUES Drive face nut Clutch outer nut Clutch drive plate nut SPECIAL TOOLS Universal holder Standard (mm) 23.989~24.025 23.960~23.974 17.5 107.0-107.2 33.965-33.485 34.0-34.025 15.920~16.080 Service Limit (mm) 24.06 23.94 16.5 1.5 107.5 154.6 33.94 34.06 15.4 5.5~6.5kgf-m 3.5~4.5kgf-m 5.0-6.0kg-m Clutch spring compressor TROUBLESHOOTING Engine starts but motorcycle won`t move Worn drive belt Broken ramp plate Worn or damaged clutch lining Broken driven face spring Engine stalls or motorcycle creeps Broken clutch weight spring Lack of power Worn drive belt Weak driven face spring Worn weight roller Fouled drive face 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 specified genuine parts for replacement. AGILITY 50 Left Crankcase Cover Air Tube Band Bolts Kick Starter Spindle KICK STARTER REMOVAL Remove the kick lever from the kick starter spindle. Remove the circlip and washer from the kick starter spindle. Washer Circlip 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. Friction Spring Starter Driven Gear Kick Starter Spindle Return Spring 9-2 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Spindle AGILITY 50 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 Part Inspect the

File name AGILITY50_cap_09_(trasmissione)2.pdf

9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Remove the ramp plate. AGILITY 50 Ramp Plate Weight Roller Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. 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 9-7 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft. AGILITY 50 Movable Drive Face Drive Pulley Collar Set the drive belt on the drive pulley collar. Install the drive pulley face and tighten the drive face nut. ( 9-6) Torque: 5.5~6.5kgf-m Do not get oil or grease on the drive belt or pulley faces. STARTER PINION REMOVAL Remove the left crankcase cover. 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. Inspect the starter pinion for smooth operation. Inspect the starter pinion and shaft for wear or damage. INSTALLATION Apply a small amount of grease to the starter pinion shaft and install it in the reverse order of removal. Starter Pinion Starter Pinion Shaft 9-8 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Clutch Outer AGILITY 50 Nut CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9-6) Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch outer. Special Universal Holder Universal Holder Remove the clutch/driven pulley assembly Remove the drive belt from the clutch/driven pulley assembly. Clutch/Driven Pulley DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Set the clutch spring compressor in a vise and remove the 39mm clutch drive plate nut. Loosen the clutch spring compressor and disassemble the driven pulley assembly. Special Lock Nut Wrench, 39mm Clutch Spring Compressor Clutch Spring Compressor Remove the seal collar. 9-9 Seal Collar 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Remove the O-rings and oil seal from the movable driven face. Movable Driven Face AGILITY 50 Oil Seal O-rings Guide Roller Pin INSPECTION Inspect the clutch outer for wear or damage. 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/ KICK STARTER 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 AGILITY 50 DRIVEN PULLEY FACE BE