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AGILITY CITY 125
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
CITY 125 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 EXHAUST EMISSION CONTROL
18
system illustration and troubleshooting SYSTEM
for the section. The subsequent pages
give detailed procedures for the section.
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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
1. GENERAL INFORMATION AGILITY CITY 125
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
Frame Serial Number
Location of Engine Serial Number
1-1
1. GENERAL INFORMATION AGILITY CITY 125
SPECIFICATIONS
Motorcycle Name & Type AGILITY CITY 125 Air cleaner type & No Paper element, wet
Name & Model No. LFC3 Fuel capacity 6.0 liter
Fuel System
Overall length (mm) 2040 Type CVK
Carburetor
Overall width (mm) 740 Piston dia. (mm) 22
Overall height (mm) 1240 Venturi dia.(mm) 26equivalent
Wheel base (mm) 1340 Throttle type Butterfly type
Engine type O.H.C. Type CDI
Electrical Equipment
Ignition System
Displacement 125cc Ignition timing BTDC27 2 /4000rpm
Fuel Used 92# nonleaded gasoline Contact breaker Non-contact point type
Front wheel 44 CHAMP ION-P-
Net weight (kg) Rear wheel 56 Spark plug RZ9HC
Total 110 NGK CR7HSA
Front wheel 45
Gross weight(kg) Rear wheel 67 Spark plug gap 0.6 0.7mm
Total 144 Battery Capacity 12V7AH
Clutch Type Dry multi-disc clutch
Power Drive System
Front wheel 100/80 -16 56J
Tires sion Gear Gear
Rear wheel 120/80 -16 56J Transmis- Reduction Type Non-stage transmission
Ground clearance (mm) 112 Automatic centrifugal
Operation
7 (Initial speed type
Perform- Braking distance (m) 30km/h)
ance Type Two-stage reduction
Min. turning radius (m) 1.99
Starting motor & Reduction 1st 1.0-2.8
Starting system kick starter ratio 2nd 46/16*46/15
Type Gasoline, 4-stroke
Front Caster angle 27
Moving Device
Cylinder arrangement Single cylinder Axle Trail length
Combustion chamber type Semi-sphere
Tire pressure Front 1.75
Valve arrangement O.H.C.
(kg/cm²) Rear 2.25
Bore x stroke (mm) 52.4 x 57.8
Compression ratio 9.6 0.2 Turning Left 45
Compression pressure angle Right 45
(kg/cm²-rpm) 13 2
Brake system Front DISK (180mm) brake
Max. output 6.9/7500kw/(r/min) Rear Drum (110mm) brake
type
Engine
Max. torque 9.1/6500N.m/rpm
Open -2.5 Front TELESCOPE
Device
Damping
Intake Suspension type
Port Close 32 Rear Unit Swing
timing Open -3 Shock absorber Front 80
Exhaust distance 82
Close 33 Rear
Valve clearance Intake 0.12 Frame type Under Bone
(cold) (mm) Exhaust 0.12
Idle speed (rpm) 1700 100rpm
Lubrication type Forced pressure &
System
Lubrication
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.9 liter
Cooling Type Forced air cooling
1-2
1. GENERAL INFORMATION AGILITY CITY 125
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5
6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1
8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4
10mm bolt, nut 3.0-4.0 8mm flange bolt, nut 2.4-3.0
12mm bolt, nut 5.0-6.0 10mm flange bolt, nut 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 2 6 0.7-1.1 Double end bolt
Cylinder head bolt B 4 6 0.7-1.1
Oil filter screen cap 1 30 1.0-2.0
Exhaust muffler lock bolt 2 6 0.7-1.1 Double end bolt
Cylinder head flange nut 4 7 1.2-1.6 Apply oil to
Valve adjusting lock nut 2 3 0.07-0.09 threads
Cam chain tensioner slipper bolt 1 8 0.4-0.7
Oil bolt 1 8 1.1-1.5
Clutch outer nut 1 10 3.5-4.5
Clutch drive plate nut 1 28 5.0-6.0
Starter motor mounting bolt 2 6 0.8-1.2
Oil pump bolt 3 4 0.1-0.3
Drive face nut 1 10 5.5-6.5
Spark plug 1 10 1.0-1.4
A.C. generator stator bolt 2 6 0.8-1.2
Cam chain tensioner bolt 1 6 0.8-1.2
FRAME
Item Q`ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut 1 25.4 8.0-12.0 U-nut
Front axle nut 1 10 5.0-7.0 U-nut
Rear axle nut 1 14 11.0-13.0 U-nut
Rear shock absorber upper bolt 1 10 4.0-5.0
Rear shock absorber lower bolt 1 8 2.0-3.0
Speedometer cable set screw 1 5 0.45-0.6
Rear shock absorber lock nut 1 8 3.0-3.6 Apply locking agent
1-11
1. GENERAL INFORMATION AGILITY CITY 125
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
10-3
Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 10-4
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
9-9
Clutch spring compressor E027 2301a driven pully assy 9-12
Cushion assemble & disassemble F004 52400 cushion assy 13-4
tool
9-5
9-9
31110 flywheel comp.2310a pully assy 9-13
Flywheel holder E017 driven 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
1-12
1. GENERAL INFORMATION AGILITY CITY 125
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE15W-40)
Cam lobes 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 Adhesive
Transmission case breather tube
1-13
1. GENERAL INFORMATION AGILITY CITY 125
FRAME
The following 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.
Grease
Front Brake Lever
Pivot
Engine/ Oil
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Grease
Rear Wheel Bearings
Grease
Grease
Speedometer Gear/ Front Wheel Brake Cam/
Bearings/ Brake Cam/ Anchor Pin Grease Anchor Pin
/Front Shock Absorber Lower Engine Oil
Mount Bushings/Pivot Main Stand Pivot
Rear Brake Cable
1-14
1. GENERAL INFORMATION AGILITY CITY 125
CABLE & HARNESS ROUTING
Brake Master Cylinder
Front Stop Switch Wire Rear Stop Switch Wire
Throttle Cable
Rear Brake Cable
Ignition Switch
Speedometer Cable
Front Brake Fluid Tube Horn
Speedometer Winker
1-15
1. GENERAL INFORMATION AGILITY CITY 125
Throttle Grip
Headlight Resistor
Ignition Switch
Speedometer Cable
Regulator/Rectifier
Rear Brake Lever
Horn
Front Brake Fluid Tube
1-16
1. GENERAL INFORMATION AGILITY CITY 125
Fuse
Battery (-) Cable
CDI Unit
Battery (+) Cable
Starter Relay
Fuel Tank
Ignition Coil
1-17
1. GENERAL INFORMATION AGILITY CITY 125
Fuel Tube
Auto Cock Assy Fuel
Fuel Filter
Throttle Cable
Carburetor
Overflow Tube
Crankcase Breather
Tube
Ignition Coil
Primary Wire
1-18
1. GENERAL INFORMATION AGILITY CITY 125
Fuel Unit
Crankcase Breather
Tube
Throttle Cable
Wire
Vacuum Tube
Crankcase Breather
Tube
Secondary Air
Inlet Tube
Ignition Coil
Reed Valve
Air Injection
Cut-off
Valve
Vacuum Tube
Fuel Tube
Auto Bystarter
1-19
1. GENERAL INFORMATION AGILITY CITY 125
WIRING DIAGRAM
1-20
1. GENERAL INFORMATION AGILITY CITY 125
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment Symptom Probable Cause
Check if fuel reaches
carburetor by loosening
drain screw Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Fuel does not Clogged float oil passage
Fuel reaches Clogged fuel tank cap breather
carburetor reach carburetor hole
Clogged fuel filter
Clogged fuel strainer
Remove spark plug and Faulty auto fuel valve
install it into spark plug
cap to test spark by
connecting it to engine Faulty spark plug
ground Fouled spark plug
Faulty CDI unit
Spark jumps Weak or no spark Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted high-tension
wire
Faulty ignition switch
Test cylinder
compression
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Normal Low or no Worn cylinder, piston and piston
compression compression rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Start engine by follow-
ing normal starting
procedure
Faulty auto bystarter
Engine does not Engine fires but Air leaking through intake pipe
fire does not start Incorrect ignition timing
Incorrectly adjusted pilot screw
Remove spark plug and
inspect again
Flooded carburetor
Dry spark plug Wet spark plug Faulty auto bystarter
Throttle valve excessively open
1-21
1. GENERAL INFORMATION AGILITY CITY 125
ENGINE LACKS POWER
Inspection/Adjustment Symptom Probable Cause
Start engine and accelerate
lightly for observation Clogged air cleaner
Poor quality fuel (Restricted)
Clogged fuel tank cap breather hole
Engine speed Engine speed does not Clogged exhaust muffler
increases increase sufficiently Faulty auto bystarter
Split carburetor vacuum piston
Check ignition timing diaphragm
using a timing light Faulty auto fuel valve
Faulty CDI unit
Correct timing Incorrect timing Faulty pulser coil
Check valve clearance
Improper valve clearance
Correct Incorrect adjustment
Worn valve seat (valve stem too
protruding
Test cylinder compression
Improper valve and seat contact
Normal Abnormal Worn cylinder and piston rings
compression compression Leaking cylinder head gasket
Improper valve timing
Check carburetor for
clogging
Not clogged Clogged Clogged carburetor jets
Remove spark plug and
inspect
Plug not fouled or Plug fouled or Fouled spark plug
discolored discolored Incorrect heat range plug
Remove oil dipstick and
check oil level and condition
Incorrect or Oil level too high
Correct and not Oil level too low
contaminated contaminated
Oil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train not Clogged oil pipe
Valve train lubricated
properly lubricated properly Faulty oil pump
Check if engine overheats
Worn cylinder and piston rings
Mixture too lean
Engine does not Engine overheats Poor quality fuel
overheats Excessive carbon buildup in
combustion chamber
Ignition timing too early
Rapidly accelerate or run
at high speed
Excessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early
1-22
1. GENERAL INFORMATION AGILITY CITY 125
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Faulty CDI unit
Correct timing Incorrect timing
Faulty pulser coil
Check carburetor pilot
screw adjustment
Mixture too rich (turn screw
Correctly adjusted Incorrectly adjusted out)
Mixture too lean (turn screw in)
Check carburetor gasket
for air leaks
Deteriorated O-ring
Carburetor not securely
No air leak Air leaks tightened
Damaged insulator rubber
Broken vacuum tube
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Faulty or fouled spark plug
Faulty CDI unit
Weak or inter- Faulty A.C. generator
Good spark mittent spark Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Check air cut-off valve
Faulty air cut-off valve
Good Faulty Damaged vacuum tube
Clogged or damaged air vent
hole
1-23
1. GENERAL INFORMATION AGILITY CITY 125
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Faulty CDI unit
Correct timing Incorrect timing
Faulty pulser coil
Check valve clearance
Improperly adjusted valve clearance
Correctly adjusted Incorrectly adjusted Worn camshaft
Worn valve seat
Check fuel pump for
fuel supply
Empty fuel tank
Fuel flows freely Fuel flow restricted Clogged fuel tube or filter
Faulty charcoal canister
Faulty auto fuel valve
Check carburetor jets
for clogging
Not clogged Clogged Clean and unclog
Check valve timing
Correct Incorrect Cam timing gear aligning marks
not aligned
Check valve spring
tension
Not weakened Weak spring Faulty spring
1-24
1. GENERAL INFORMATION AGILITY CITY 125
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Inspection/Adjustment Symptom Probable Cause
Start engine and test
limit voltage between
battery terminals
Voltage does not Dead battery
Normal voltage
increase Faulty battery
Measure resistance
between AC generator
coil terminals
Faulty A.C. generator coil
Normal Resistance too high Broken yellow wire
Loose connector
Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage
Normal voltage No voltage Broken red wire
Check regulator/rectifier
coupler for loose
connection
Faulty regulator/rectifier
Normal Abnormal
Poorly connected coupler
Faulty A.C. generator
Overcharging
Inspection/Adjustment Symptom Probable Cause
Connect battery (+) wire
to regulator/rectifier
coupler green wire and
battery (-) wire to engine
ground and test voltage
Battery has voltage Battery has no
with ignition voltage with ignition Broken green wire
switch "ON" switch "ON"
Check regulator/rectifier
coupler for loose
connection
Normal Abnormal Poorly connected coupler
Faulty regulator/rectifier
1-25
1. GENERAL INFORMATION AGILITY CITY 125
NO SPARK AT SPARK PLUG
Inspection/Adjustment Symptom Probable Cause
Replace with a new
spark plug and inspect
again
Weak or no spark Good spark Faulty old spark plug
Check spark plug cap
and high-tension wire
for looseness
Not loose Loose Loose spark plug cap
Check CDI unit coupler
for looseness
Good Good Poorly connected coupler
Measure resistance
between CDI unit
coupler wire terminals
Normal Abnormal
Check related parts
Faulty ignition switch
Normal Abnormal Faulty pulser coil
Faulty ignition coil
Broken wire harness
Poorly connected coupler
Check CDI unit with a
CDI unit tester
Normal Abnormal Faulty CDI unit
Check ignition coil with
a CDI unit tester
Abnormal Faulty ignition coil
1-26