KYMCO 125 AGILITY CITY - Service Manual Download

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. FRONT WHEEL/FRONT BRAKE/

FRONT

SUSPENSION

12-5

AGILITY 125

WHEEL RIM

Check the wheel rim runout.

Service Limits

Radial

: 2.0mm replace if over

Axial

: 2.0mm replace if over

Turn the wheel bearings and replace the
bearings if they are noisy or have excessive
play.

DISASSEMBLY

Remove the dust seal.

Radial

Dust Seal

Play

Axial

Summary of Contents for 125 AGILITY CITY -

Page 1: ...EEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Turn the wheel bearings and replace the bearings if they are noisy or have excessive play DIS...

Page 2: ...ngs and distance collar Bearing Puller ASSEMBLY Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Bearing Puller Pilot Grease Greas...

Page 3: ...nut Torque 4 5kg m Connect the speedometer cable and secure it with the screw Install the front brake cable and adjust the front brake lever free play FRONT BRAKE Remove the front wheel 12 4 Remove th...

Page 4: ...al Remove the brake cam Remove the dust seal and speedometer drive gear ASSEMBLY Apply grease to the speedometer drive gear and then install it into the brake panel Apply grease to the dust seal lip a...

Page 5: ...the groove on the brake cam Install the brake arm on the brake cam by aligning the punch mark on the brake arm and the scribed line on the brake cam Install and tighten the brake arm bolt Torque 0 8 1...

Page 6: ...Make sure to bleed air from the brake system When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid When servicing the brake system use shop to...

Page 7: ...rse order of removal Tighten the brake pad pin bolts Torque 1 5 2 0kgf m Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm The brake pad...

Page 8: ...asher main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid When servicing the brake system use shop towels to cover rubber...

Page 9: ...ct the lst and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and snap ring...

Page 10: ...ueeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear an...

Page 11: ...the brake fluid pipe with the attaching bolt and two sealing washers Install the handlebar covers 12 3 Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according...

Page 12: ...26 45mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved...

Page 13: ...stall the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 2 5 3 5kg m Fill the brake reservoir with...

Page 14: ...the dust boot Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a v...

Page 15: ...N 12 19 AGILITY 125 Measure the front shock absorber spring free length Service Limits Right 206 4mm Left 206 4mm ASSEMBLY Front Shock Absorber Shock Absorber Tube Top Nut Damper Shock Absorber Spring...

Page 16: ...install it together with the hex bolt Torque 3 0kgf m Add engine oil into the front shock absorber Specified Oil SS 8 Oil Capacity 38 1cc Install the circlip Install the dust boot INSTALLATION Instal...

Page 17: ...ing stem Inspect the ball races and cone races for wear or damage and replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into pla...

Page 18: ...tall it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while ho...

Page 19: ...13 REAR WHEEL REAR BRAKE REAR SUSPENSION 13 0 AGILITY 125 13 13 3 5kg m 11 0kg m 1 0kg m 1 2kg m...

Page 20: ...er 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 Disa...

Page 21: ...bearing for excessive play and the final shaft for bending Inspect the rear wheel and wheel rim for runout Inspect the rear brake drum Measure the rear brake drum I D Service Limits 111mm replace if o...

Page 22: ...t the rear brake cable Remove the rear brake shoes Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Remove the brake cam REAR BRAKE ASSEMBLY Apply grease to the anc...

Page 23: ...rear shock absorber upper and lower mount bolts Remove the rear shock absorber DISASSEMBLY Install the rear shock absorber compressor as the figure shown Compress the rear shock absorber spring Cushio...

Page 24: ...mper for oil leaks Inspect the damper rubber for deterioration or damage Measure the rear shock absorber spring free length Service Limit 198mm replace if over ASSEMBLY Assemble the rear shock absorbe...

Page 25: ...ear shock absorber Install the rear shock absorber upper mount bolt and then the lower mount bolt Tighten the bolts Torque Upper Mount Bolt 3 5 4 5kgf m Lower Mount Bolt 2 4 3 0kgf m Install the air c...

Page 26: ...G SYSTEM A C GENERATOR 14 0 AGILITY 125 14 Fuse Regulator Rectifier A C Generator Battery Regulator Rectifier A C Generator Headlight Switch Y R G Battery 12V4AH Resistors 14 Y Auto Bystarter G B W G...

Page 27: ...ity is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect t...

Page 28: ...tance 20 5W12 Resistor Resistance 20 30W7 5 TORQUE VALUES Pulser coil bolt 0 45 0 6kgf m Stator bolt 0 8 1 2kgf m Flywheel nut 3 5 4 5kgf m Cooling fan bolt 0 8 1 2kgf m SPECIAL TOOLS Universal holder...

Page 29: ...Standard 0 8A Quick 8A Charging time Standard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min Note The battery temperature should not exceed 45 during charging Battery Cover...

Page 30: ...r between the fuse terminals Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 14 15V 0 8A max 5...

Page 31: ...terminals are normal check the regulator rectifier coupler for loose connection and measure the resistances between the regulator rectifier terminals Replace the regulator rectifier if the readings a...

Page 32: ...enerator yellow wire and engine ground with an electric tester Standard 0 1 1 0 20 Replace the A C generator lighting coil if the reading is not within the specifications RESISTOR INSPECTION Remove th...

Page 33: ...g bolts Hold the flywheel with an universal holder Remove the flywheel nut Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Flywheel Puller Remove t...

Page 34: ...s and A C generator stator A C GNERATOR INSTALLATION Install the A C generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 45 0 6kgf...

Page 35: ...lywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and tighten the flywheel nut Torque 3 5 4 5kgf m Universal Holde...

Page 36: ...14 BATTERY CHARGING SYSTEM A C GENERATOR 14 10 AGILITY 125 Install the fan cover Install the right side cover 2 4 Fan Cover...

Page 37: ...15 IGNITION SYSTEM 15 0 AGILITY 125 15 Pulser Coil Ignition Switch CDI Unit A C Generator 15 Spark Plug Install on the carburetor...

Page 38: ...esistance 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...

Page 39: ...lty CDI unit Faulty pulser coil Intermittent high voltage Faulty ignition switch Poorly connected CDI unit coupler Poorly connected or broken CDI ground wire Faulty pulser coil Loose high tension wire...

Page 40: ...N SYSTEM 15 3 AGILITY 125 CDI UNIT INSPECTION Remove the three battery cover screws Disconnect the CDI coupler and remove the CDI unit Blue Yellow Green CDI Unit Black Yellow Violet Black Black Blue V...

Page 41: ...he resistance between the ignition coil primary coil terminals Resistance 0 1 1 0 Measure the secondary coil resistances with and without the spark plug cap Resistances with plug cap 7 12K without plu...

Page 42: ...SPECTION Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When the engine is running at the ignition timing is correct if the F mark aligns with the inde...

Page 43: ...16 STARTING SYSTEM 16 0 AGILITY 125 16 Starter Relay Starter Button Starter Motor Stop Switches 16...

Page 44: ...ywheel Holder 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 Fau...

Page 45: ...f necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check...

Page 46: ...tinuity between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is contin...

Page 47: ...lick sound Inspect the starter relay voltage Inspect the starter relay ground circuit Inspect the starter relay operation STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand Measur...

Page 48: ...rter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal...

Page 49: ...drive gear for wear or damage and replace if necessary Measure the starter drive gear I D Service Limit 32 06mm replace if over Inspect the needle bearing for wear or damage and replace if necessary C...

Page 50: ...the threads of the clutch cover bolts and tighten them Torque 1 2kg m Apply engine oil to the needle bearing and starter drive gear and then install them to the clutch body INSTALLATION Install the s...

Page 51: ...16 STARTING SYSTEM 16 8 AGILITY 125...

Page 52: ...ter 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 connecte...

Page 53: ...L W 566 153 Y W L W 599 599 FUEL GAUGE INSPECTION Connect the fuel unit wire connector and turn the ignition switch ON Check the fuel gauge needle for correct indication by moving the fuel unit float...

Page 54: ...nuity between wire terminals If there is any abnormality found check each switch HEADLIGHT SWITCH Color Yellow Brown Pink Yellow Blue White STARTER SWITCH Color Yellow Red Green FREE PUSH DIMMER SWITC...

Page 55: ...ct the ignition switch wire coupler Check for continuity between the wire terminals Color Black Red Blue Yellow Green OFF ON LOCK IGNITION SWITCH REPLACEMENT Remove the front covers 2 2 Disconnect the...

Page 56: ...witch is normal if there is continuity HORN INSPECTION Remove the front covers 2 2 Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery is connected across the horn wire...

Page 57: ...e installation sequence is the reverse of removal TAILLIGHT STOPLIGHT REAR TURN SIGNAL LIGHT LICENSE LIGHT Remove the two screws attaching the rear protector molding Remove the rear protector molding...

Page 58: ...OUBLESHOOTING 18 1 MAINTENANCE SCHEDULE 18 2 SECONDARY AIR CLEANER 18 3 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 Se...

Page 59: ...t exhaust muffler backfiring due to air in the exhaust system Reed Valve Control the secondary air inlet to reduce CO When the motorcycle speed is less than 50km per hour the reed valve operates to dr...

Page 60: ...ts and nuts T T T T T T T T T T T T T T T Others Brake system A A A A A A A A A A A A A A A Remarks I Inspect A Adjust C Clean R Replace T Tighten During riding or inspection if any part is found to b...

Page 61: ...e Remove the air cleaner attaching the air cleaner INSTALLATION The installation sequence is the reverse of removal DISASSEMBLY Remove the two secondary air cleaner replace with new secondary air clea...

Page 62: ...a vacuum of 250mm Hg is applied The flow should be at least 1 6 liter min when a vacuum of 320mm Hg is applied Check each connecting tube for cracks or damage and replace if necessary INSTALLATION The...

Page 63: ...and the reed valve Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Check the gasket and O ring for damage or deterior...

Page 64: ...moval Exhaust Muffler Joint Lock Nut The temperature of exhaust muffler is very high Be careful to avoid burns during working Lock Bolts Catalytic Converter Exhaust Muffler A large amount of unburned...

Page 65: ...ION TEST AND ADJUSTMENT 1 Start the engine and warm up for several minutes Engine surface temperature 50 60 2 Adjust the idle speed to 1900rpm 3 Connect the emission tester sampling pipe to the exhaus...

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