Text preview for : Kymco Agility 125 R16 - Service Manual [03] [Inspection - Adjustment] by salvacolnome.pdf part of KYMCO Agility 125 cc Service manual [part 3] Inspection/Adjustment [pag. 14]
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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
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
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 : 2 6mm
Spark plug gap : 0.6 0.7mm
Spark plug : NGK C7HSA
Valve clearance : IN: 0.12mm
: EX: 0.12mm
Idle speed : 1700 100rpm
Engine oil capacity:
At disassembly : 0.9 liter
At change : 0.8 liter
Gear oil capacity :
At disassembly : 0.2 liter
At change : 0.18 liter
3-0
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
Cylinder compression : 16 kg/cm2
Ignition timing: BTDC 28 /4000rpm
CHASSIS
Front brake free play: 10 20mm
Rear brake free play : 10 20mm
TIRE PRESSURE
1 Rider 2 Riders
Front 1.5kg/cm2 1.75kg/cm2
Rear 2.0kg/cm2 2.25kg/cm2
TIRE SIZE:
Front : 100/80-14
Rear : 120/80-14
TORQUE VALUES
Front axle nut 5.0 7.0kgf-m
Rear axle nut 11 13kgf-m
3-1
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
MAINTENANCE SCHEDULE
Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T : Tighten
Regular Service Mileage (km)
Whichever
Frequency comes
first
Item
1000
R New
Engine oil Motorcycle
R R R R R R
300km
Engine oil filter C C
screen
Fuel filter screen R
R New
Gear oil Note 3 motorcycle
R R
300km
Valve clearance A A A A
Carburetor I I C
Air Cleaner Note 2,3 Replace at every2000km
Spark plug Clean at every 3000km and replace if necessary
Brake system I I I I I I I I I I I I
Drive belt I
Suspension I I I
Nut, bolt, fastener I
Tire I I I
Steering head bearing I I I
In the interest of safety, we recommend these items should be serviced only by an authorized
KYMCO motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in dusty or rainy areas.
3. Service more frequently when riding in rain or at full throttle.
3-2
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
Fuel Filter
FUEL FILTER
Remove the met-in box. ( 2-3)
Check the fuel lines and replace any parts
which show signs of deterioration, damage or
leakage.
Do not smoke or allow flames or sparks
in your working area.
Fuel Line
2 6mm
THROTTLE OPERATION
Check the throttle grip for smooth movement.
Measure the throttle grip free play.
Free Play: 2 6mm
Major adjustment of the throttle grip free play
is made at the carburetor side.
Adjust by loosening the lock nut and turning
the adjusting nut.
Lock Nut Adjusting Nut
Minor adjustment is made with the adjusting
nut at the throttle grip side.
Slide the rubber cover out and adjust by
loosening the lock nut and turning the
adjusting nut.
Adjusting Nut Lock Nut
3-3
3. INSPECTION/ADJUSTMENT SUPER8 50
Screws
AIR CLEANER
AIR CLEANER REPLACEMENT
Remove the air cleaner case cover screws and
the cover by removing the six screws.
Remove the air cleaner element by removing
the four screws.
Check the element and replace it if it is
excessively dirty or damaged.
Air Cleaner Case Cover
Air Cleaner Element
CHANGE INTERVAL
More frequent replacement is required when
riding in unusually dusty or rainy areas.
The air cleaner element has a viscous
type paper element. Do not clean it
with any fluid.
Be sure to install the air cleaner
element and cover securely.
SPARK PLUG
Remove the spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.
Specified Spark Plug:
CHAMPION-P-RZ9HC
NGK CR7HSA
Gap, Wear, and
Fouling Deposits
Measure the spark plug gap.
Spark Plug Gap: 0.6 0.7mm
Washer
Deformation
When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench. Cracks
Damage
3-4
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
Cylinder Head Cover
VALVE CLEARANCE
Inspect and adjust valve clearance while
the engine is cold (below 35 ).
Remove the frame cover. ( 2-3)
Remove the six bolts on the cylinder head
cover.
Remove the cylinder head cover. ( 7-3)
Remove the cylinder head cover..
Bolts
Turn the flywheel counterclockwise so that
the "T" mark on the flywheel aligns with the
index mark on the crankcase to bring the
round hole on the camshaft gear facing up to
the top dead center on the compression
stroke.
Round Hole
Inspect and adjust the valve clearance. Tappet Adjuster
Valve Clearance: IN : 0.04mm
EX: 0.04mm
Loosen the lock nut and adjust by turning the
adjusting nut
Special
Tappet Adjuster
Check the valve clearance again after
the lock nut is tightened.
Feeler Gauge
CARBURETOR IDLE SPEED
The engine must be warm for accurate
idle speed inspection and adjustment.
Remove the inspection cover.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed: 1900 100rpm
When the engine misses or run erratic, adjust
the pilot screw. Throttle Stop Screw
3-5
3. INSPECTION/ADJUSTMENT SUPER8 50
Timing Hole Cap
IGNITION TIMING
The CDI unit is not adjustable. If the
ignition timing is incorrect, check the
ignition system. ( 15-5)
Remove the right of the fan cover.
Timing Light
Check the ignition timing with a timing light.
When the engine is running at idle speed, the
ignition timing is correct if the "F" mark on
the flywheel aligns with the index mark on
the crankcase.
Also use a timing light to check the advance.
Raise the engine speed to 4,000rpm and the
index mark on the crankcase cover should be
aligned with the advance mark on the
flywheel.
CYLINDER COMPRESSION
Warm up the engine before compression test.
Remove the met-in box and center cover.
( 2-3)
Remove the spark plug.
Insert a compression gauge.
Open the throttle valve fully and push the
starter button to test the compression. "F" Mark Advance Mark
Compression Gauge
Compression: 16kg/cm2rpm
If the compression is low, check for the
following:
Leaky valves
Valve clearance to small
Leaking cylinder head gasket
Worn piston rings
Worn piston/cylinder
If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.
3-6
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
FINAL REDUCTION GEAR OIL
OIL LEVEL CHECK
Place the motorcycle on its main stand
on level ground for oil level check.
Stop the engine and remove the oil check bolt.
The oil level shall be at the oil check bolt
hole.
If the oil level is low, add the recommended
oil to the proper level.
Recommended Oil: SAE90# Oil Check Bolt/Sealing Washer
Install the oil check bolt.
Make sure that the sealing washer is in
good condition.
Oil Check Bolt Hole
OIL CHANGE
Remove the oil check bolt.
Remove the oil drain bolt and drain the oil
thoroughly.
Install the oil drain bolt.
Torque: 0.8~1.2kgf-m
Make sure that the sealing washer is in
good condition.
Fill with the recommended oil.
Oil Capacity: At disassembly : 0.20 liter
At change : 0.18 liter
Oil Drain Bolt/ Sealing Washer
Reinstall the oil check bolt and check for oil
leaks.
Torque:0.8~1.2kgf-m
DRIVE BELT
Remove the left crankcase cover. ( 9-2)
Inspect the drive belt for cracks or excessive
wear.
Replace the drive belt with a new one if
necessary and in accordance with the
Maintenance Schedule.
Drive Belt
3-7
3. INSPECTION/ADJUSTMENT SUPER8 50
BRAKE SHOE Arrows Punch Mark
Replace the brake shoes if the arrow on the
wear indicator plate aligns with the punch
mark on the brake panel when the brake is
fully applied.
Refer to page 12-7 and 13-3 for brake shoe
replacement.
REAR BRAKE
Measure the rear brake lever free play.
Free Play: 10 20mm
BRAKE ADJUSTING NUT
If the free play do not fall within the limit,
adjust by turning the adjusting nut.
Adjusting Nut
Upper Line
FRONT/REAR BRAKE FLUID
Turn the steering handlebar upright and check
if the rear brake fluid level should be between
the upper and lower level lines.
Specified Brake Fluid: DOT-4
Lower Line
3-8
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
If the free play do not fall within the limit,
adjust by turning the adjusting nut.
Adjusting Nut
HEADLIGHT AIM Front Cover
Turn the ignition switch ON and start the
engine.
Turn on the headlight switch.
Adjust the headlight aim by turning the
headlight aim adjusting screw.
Adjusting Screw
CLUTCH SHOE WEAR
Start the engine and check the clutch
operation by increasing the engine speed
gradually.
If the motorcycle tends to creep, or the engine
stalls, check the clutch shoes for wear and
replace if necessary. ( 9-11)
clutch
SUSPENSION
FRONT
Fully apply the front brake lever and check
the action of the front shock absorbers by
compressing them several times.
Check the entire shock absorber assembly for
oil leaks, looseness or damage.
3-9
3. INSPECTION/ADJUSTMENT SUPER8 50
REAR
Check the action of the rear shock absorber
by compressing it several times.
Check the entire shock absorber assembly for
oil leaks, looseness or damage.
Jack the rear wheel off the ground and move
the rear wheel sideways with force to see if
the engine hanger bushings are worn.
NUTS/BOLTS/FASTENERS
Check all important chassis nuts and bolts for
looseness.
Tighten them to their specified torque values
if any looseness is found. ( 1-11)
WHEELS/TIRES
Check the tires for cuts, imbedded nails or
other damages.
Check the tire pressure.
Tire pressure should be checked when
tires are cold.
TIRE PRESSURE
1 Rider 2 Riders
Front 1.5kg/cm2 1.75kg/cm2
Rear 2.00kg/cm2 2.25kg/cm2
TIRE SIZE
Front : 120/70-12
Rear : 130/70-12
Check the front axle nut for looseness.
Check the rear axle nut for looseness.
If the axle nuts are loose, tighten them to the
specified torques.
Torques: Front : 5.0 7.0kgf-m
Rear : 11 13kgf-m
Front Axle Nut
3-10
3. INSPECTION/ADJUSTMENT AGILITY CITY 125
STEERING HANDLEBAR
Check that the control cables do not interfere
with handlebar rotation.
Raise the front wheel off the ground and
check that the steering handlebar rotates
freely.
If the handlebar moves unevenly, binds, or
has vertical movement, adjust the steering
head bearing.
3-11
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