Text preview for : Kymco Agility 125 R16 - Service Manual [05] [Fuel System] by salvacolnome.pdf part of KYMCO Agility 125 cc Service Manual (part 5) Fuel System [pag. 17]
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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
5. FUEL SYSTEM AGILITY CITY 125
5
5
5-0
5. FUEL SYSTEM AGILITY CITY 125
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 CITY 125
SERVICE INFORMATION.......................5-2 CARBURETOR INSTALLATION.........5-10
TROUBLESHOOTING..............................5-3 PILOT SCREW ADJUSTMENT ............5-11
CARBURETOR REMOVAL.....................5-4 FUEL TANK............................................5-12
AUTO BYSTARTER .................................5-4 FUEL UNIT .............................................5-13
AIR CUT-OFF VALVE .............................5-6 AIR CLEANER .......................................5-13
VACUUM CHAMBER ..............................5-6
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.
SPECIFICATIONS
Item Standard
Venturi dia. (mm) 26
Type VE
Float level (mm) 17
Main jet #104
Slow jet #35
Idle speed 1700rpm 100
Throttle grip free play 2 6mm
Pilot screw opening 3 1/2
5-2
5. FUEL SYSTEM AGILITY CITY 125
TROUBLESHOOTING
Engine is hard to start Misfiring during acceleration
No spark at plug ( Section 15) Faulty ignition system
Compression too low Lean mixture
No fuel to carburetor Faulty accelerating pump
Clogged fuel filter Engine idles roughly, stalls or runs poorly
Restricted fuel line Clogged fuel system
Faulty float valve Ignition malfunction
Incorrectly adjusted float level Rich or lean mixture
Engine flooded with fuel Contaminated fuel
Clogged air cleaner Intake air leak
Fuel overflowing Incorrect idle speed
Intake air leak Incorrectly adjusted pilot screw
Contaminated fuel Clogged idle system or auto bystarter passages
Faulty auto bystarter Incorrectly adjusted float level
Clogged idle system or auto bystarter passages Lean mixture
Rich mixture Clogged fuel jets
Faulty auto bystarter Faulty float valve
Faulty float valve Float level too low
Float level too high Clogged fuel system
Clogged air jets Intake air leak
Dirty air cleaner Improper vacuum piston operation
Flooded carburetor Improper throttle operation
Backfiring at deceleration
Lean mixture in idle system
Improper air cut-off valve operation
5-3
5. FUEL SYSTEM AGILITY CITY 125
CARBURETOR REMOVAL Auto Bystarter
Remove the frame right side cover. ( 2-4)
Disconnect the auto bystarter wire
connector.
Remove the met-in box. ( 2-3)
Auto Bystarter Wire
Loosen the drain screw and drain the fuel
from the float chamber.
Disconnect the fuel tube and vacuum tube at
the carburetor.
Disconnect the TPS coupler and remove the
TPS unit
TPS Unit Fuel Tube
Loosen the throttle cable adjusting nut and
lock nut, and disconnect the throttle cable
from the carburetor. Air Cleaner Connecting Vacuum Tube Intake Manifold
Tube Band Band
Loosen the carburetor intake manifold band
and air cleaner connecting tube band screws
and then remove the carburetor.
AUTO BYSTARTER
Throttle Cable Adjusting Nut Lock Nut
OPERATION INSPECTION
Measure the resistance between the auto
bystarter wire terminals.
Resistance: 10 max. (10 minutes
minimum after stopping the engine)
If the reading is not within the limit, replace
the auto bystarter with a new one.
5-4
5. FUEL SYSTEM AGILITY CITY 125
Connect a hose to the fuel enriching circuit
of the carburetor. Connect the auto Vacuum Pump
bystarter yellow wire to the positive (+)
terminal of a battery and green wire to the
negative (-) terminal. Wait 5 minutes and
blow the hose with mouth or vacuum
pump. If the passage is blocked, the
auto bystarter is normal.
Disconnect the auto bystarter from the
battery. Wait 30 minutes and blow the hose
with mouth or vacuum pump. If air can be Adopter
blown into the hose, the auto bystarter is
normal.
Auto Bystarter
REMOVAL
Remove the set plate screws and set plate.
Remove the auto bystarter from the
carburetor.
Set Plate Screws
Bystarter Valve
AUTO BYSTARTER INSPECTION
Check the auto bystarter valve and needle
for nicks, wear or damage.
If any faulty part is found, replace the auto
bystarter as a set.
Bystarter Needle
Auto Bystarter
INSTALLATION
Insert the auto bystarter into the carburetor
body until it bottoms.
Position the set plate into the groove in the
auto bystarter and tighten the screws.
Be sure to install the auto bystarter and
set plate properly.
Install the set plate with its bottom face
facing down. Set Plate Screws
5-5
5. FUEL SYSTEM AGILITY CITY 125
AIR CUT-OFF VALVE Screws
DISASSEMBLY
Remove the two screws attaching the air
cut-off valve.
Remove the spring and vacuum diaphragm.
Check the vacuum diaphragm for cracks or
damage and check each passage for
clogging.
Air Cut-off Valve Cover
ASSEMBLY
Install the vacuum diaphragm onto the
carburetor.
Install the spring and air cut-off valve cover.
Install the throttle cable set plate and tighten
the two screws.
Be sure to set the vacuum diaphragm
lip into the groove on the carburetor.
When installing the air cut-off valve
cover, make sure that the vacuum
diaphragm is properly installed. Diaphragm Spring Cover
Screws
VACUUM CHAMBER
DISASSEMBLY
Remove the two vacuum chamber cover
screws and the cover.
Vacuum Chamber Cover
Spring Vacuum Diaphragm/Piston
Remove the spring and vacuum diaphragm/
piston.
5-6
5. FUEL SYSTEM AGILITY CITY 125
Remove the needle holder and jet needle.
Be careful not to damage the vacuum
diaphragm.
Jet Needle
INSPECTION
Inspect the needle for stepped wear.
Inspect the vacuum piston for wear or
damage.
Inspect the diaphragm for deterioration and
tears.
Vacuum Diaphragm
Vacuum Diaphragm Vacuum Chamber Cover
ASSEMBLY
Install the vacuum piston/diaphragm in the
carburetor body.
Install the spring and then install the
vacuum chamber cover.
Tighten the two screws.
5-7
5. FUEL SYSTEM AGILITY CITY 125
Screws
FLOAT CHAMBER
DISASSEMBLY
Remove the three float chamber screws and
the float chamber.
Float Chamber
Float Float Valve
Loosen the float pin screw.
Remove the float pin, float and float valve.
Float Pin
Needle Jet Holder Slow Jet
Remove the main jet, needle jet holder,
needle jet, slow jet and pilot screw.
Be careful not to damage the fuel jets
and pilot screw.
Before removing, turn the pilot screw
in and carefully count the number of
turns until it seats lightly and then
make a note of this.
Do not force the pilot screw against its
seat to avoid seat damage. Pilot Screw Needle Jet Main Jet
Clean the removed fuel jets with detergent
oil and blow them open with compressed
air.
Blow compressed air through all passages
of the carburetor body.
5-8
5. FUEL SYSTEM AGILITY CITY 125
Valve Seat
INSPECTION
Inspect the float valve and valve seat for
damage or clogging.
Inspect the float valve and valve seat
contact area for stepped wear or
contamination.
Worn or contaminated float valve and
valve seat must be replaced because it
will result in float level too high due to
incomplete airtightness.
Needle Jet Holder Slow Jet
ASSEMBLY
Install the slow jet, needle jet, needle jet
holder, main jet and pilot screw.
Return the pilot screw to the original
position as noted during removal.
Standard Opening:3 1
/2 turns
Pilot Screw Needle Jet Main Jet
Float Float Valve
Install the float valve, float and float pin.
Float Pin
FLOAT LEVEL INSPECTION
Check the operation of the float valve
and float before this inspection.
Measure the float level by placing the
float level gauge on the float chamber
face parallel with the main jet.
Measure the float level.
Float Level: 17.0mm
This installation sequence is the reverse of Float Level Gauge
removal.
5-9
5. FUEL SYSTEM AGILITY CITY 125
Air Cleaner Connecting Vacuum Tube Intake Manifold
Tube Band Band
CARBURETOR INSTALLATION
Tighten the drain screw.
Install the carburetor onto the intake
manifold, aligning the tab on the carburetor
with the cutout in the intake manifold.
Tighten the intake manifold band screw.
Install the air cleaner connecting tube and
tighten the band screw.
Connect the throttle cable to the throttle
wheel on the carburetor.
Tighten the lock nut.
Throttle Cable Adjusting Nut Lock Nut
Connect the fuel tube and vacuum tube to
the carburetor.
Fuel Tube
Connect the auto bystarter wire connector. TPS Nuit
Perform the following inspections and
adjustments:
-Throttle grip free play ( 3-3)
-Carburetor idle speed ( 3-5)
Connect the auto TPS unit wire connector.
Auto Bystarter Wire Connector
5-10
5. FUEL SYSTEM AGILITY CITY 125
PILOT SCREW ADJUSTMENT
* ADJUSTMENT
The pilot screw is factory pre-set and
no adjustment is necessary. During
carburetor disassembly, note the
number of turns of the pilot screw and
use as a reference when reinstalling it.
Place the motorcycle on its main stand
on level ground for this operation.
A tachometer must be used when adjusting Pilot Screw
the engine speed.
Turn the pilot screw clockwise until it seats
lightly and back it out to the specification
given.
Standard Opening: 3 1/2 turns
The carburetor must be adjusted when
the engine is warm and the auto
bystarter is closed.
Do not force the pilot screw against its
seat to prevent damage.
Warm up the engine and adjust the throttle Throttle Stop Screw
stop screw to obtain the specified idle
speed.
Idle Speed: 1700 100rpm
Turn the pilot screw in or out slowly to
obtain the highest engine speed.
Slightly accelerate several times to make
sure that the idle speed is within the
specified range.
If the engine misses or runs erratic, repeat
the above steps.
5-11
5. FUEL SYSTEM AGILITY CITY 125
FUEL TANK REMOVE
Remove the net-in box. ( 2-3)
Remove the frame center cover.
Remove the frame body cover. ( 2-3)
Remove the four bolts on the fuel tank, take
the upper seat lock off.
Disconnect the fuel unit wire connector.
Remove the fuel tank.
The installation sequence is the reverse of
removal.
Bolts Fuel Tank
FUEL STRAINER REMOVAL
Remove the fuel strainer from the fuel tank.
INSPECTION Fuel Unit Wite
Inspect if the fuel strainer is clogged and Connector
clean it with compressed air.
When removing the fuel strainer, do
not allow flames or sparks near the
working area and drain the residual
gasoline into a container.
INSTALLATION
Install the fuel strainer with its arrow mark
toward the fuel pump.
Fuel Strainer
Arrow Mark
5-12
5. FUEL SYSTEM AGILITY CITY 125
FUEL UNIT Fuel Unit Wire
REMOVAL
Remove the related parts.
Disconnect the fuel unit wire connector.
Turn the fixed plate on the fuel unit,take the
fuel unit off.
Do not bend the float arm on the fuel
unit,otherwise the figure on the fuel
meter will not correct.
INSTALLATION Fuel Tank
Inspet if the fuel unit is damaged,or harden.
Assemble the fuel unit in the reverse order
of disassembly.
Align the groove on the fuel unit with
the angle on the fuel tank.
Inspect if the fuel tank leaked after
installing and filling the gasoling.
Fuel Unit
AIR CLEANER air cleaner
Loosen the air cleaner connecting tube band
screw.
Disconnect the clinhead cover breather tube
from the air cleaner.
Remove the two bolts and air cleaner case.
bolts
5-13
5. FUEL SYSTEM AGILITY CITY 125
Tps Unit
TPS REMOVE
Remove the TPS stay screw.
Remove the TPS and TPS stay assembled.
While clean the carburetor, must
remove the TPS unit.
TPS Stay Screw
TPS UNIT INSPECTION
Measure the TPS resistance between
the violet/black and green wire terminals.
Measure the resistance:5K 30
Measure the TPS resistance between
the violet/red and green wire terminals.
Measure the resistance:5K 30
Whem measure the TPS
resistance carburetor throttle open the
max place . Violet/Red Green Violet/Black
The installation sequence is the reverse of removal.
5-14
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44040176