Text preview for : AGILITY50_cap_09_(trasmissione)2.pdf part of Kymco Agility 50 Kymco Agility service manual
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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 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. Seat the snap ring in its groove. 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