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KYMCO agility R16 125 User Manual

KYMCO agility R16 125
252 pages
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AGILITY CITY 125
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO AGILITY
CITY 125
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
FRAME COVERS/EXHAUST MUFFLER 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL SYSTEM 5
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
ENGINE
DRIVE AND DRIVEN PULLEYS/KIC
K
STARTER
9
FINAL REDUCTION 10
CRANKCASE/CRANKSHAFT 11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
CHASSIS
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM 15
STARTING SYSTEM 16
LIGHTS/INSTRUMENTS/SWITCHES 17
ELECTRICAL
EQUIPMEN
T
EXHAUST EMISSION CONTROL
SYSTEM
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.
18
Cortesia de / Courtesy of: www.batmotos.com
Recambios KYMCO en www.batmotos.com

Table of Contents

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KYMCO agility R16 125 Specifications

General IconGeneral
Displacement124.6 cc
TransmissionCVT
Fuel SystemCarburetor
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Front Tire100/80-16
Rear Tire120/80-16
Fuel Tank Capacity6.5 liters
Seat Height780 mm
Bore x Stroke52.4 mm x 57.8 mm
Compression Ratio9.6:1
Wheelbase1340 mm
Engine Type4-Stroke
Starting SystemElectric
Length x Width x Height2050 mm x 735 mm x 1210 mm
Weight120 kg (Dry)

Summary

Preface

Service Precautions

Precautions for all operations stated in this manual.

Frame Covers Removal/Installation

Procedures for frame covers subject to frequent removal/installation.

Inspection/Adjustment Procedures

Inspection/adjustment, safety rules, service info for each part.

Disassembly/Assembly of Engine, Chassis, Electrical Equipment

Instructions for disassembly/assembly of engine, chassis, electrical equipment.

1. General Information

Specifications

Technical specifications for the KYMCO AGILITY CITY 125.

Service Precautions

Precautions to follow when servicing the motorcycle.

Torque Values

Specified torque values for important fasteners.

Special Tools

List of special tools required for servicing.

Lubrication Points

Points requiring lubrication on the engine.

Cable & Harness Routing

Routing diagram for cables and harnesses.

Wiring Diagram

Electrical wiring diagram of the motorcycle.

Troubleshooting

Common issues and troubleshooting steps.

2. Frame Covers/Exhaust Muffler

Schematic Drawing

Exploded view drawing of frame covers and exhaust muffler.

Service Information

General service information for frame covers.

Torque Values

Torque values for exhaust muffler components.

Front Cover Removal

Steps to remove the front cover.

Handlebar Rear Cover Removal

Steps to remove the handlebar rear cover.

Met-in Box Removal

Steps for removing the met-in box.

Frame Body Cover Removal

Procedures for removing the frame body cover components.

Floor Board Removal

Steps for removing the floor board.

Front Fender Removal

Steps for removing the front fender.

Leg Shield Removal

Steps for removing the leg shield.

Exhaust Muffler Removal

Procedure for removing the exhaust muffler.

3. Inspection/Adjustment

Service Information

General service information, warnings, and engine specifications.

Specifications

Detailed specifications for engine, chassis, tires, and torques.

Maintenance Schedule

Periodic maintenance schedule based on mileage.

Fuel Filter

Fuel filter inspection and replacement procedures.

Throttle Operation

Throttle grip operation and free play adjustment.

Air Cleaner

Air cleaner replacement and change interval.

Spark Plug

Spark plug inspection, gap measurement, and replacement.

Valve Clearance

Valve clearance inspection and adjustment procedure.

Carburetor Idle Speed

Carburetor idle speed inspection and adjustment.

Ignition Timing

Ignition timing inspection procedure.

Cylinder Compression

Procedure for testing cylinder compression.

Final Reduction Gear Oil

Gear oil level check and change procedure.

Drive Belt

Drive belt inspection and replacement.

Brake Shoe

Brake shoe wear inspection procedure.

Rear Brake

Rear brake lever free play measurement.

Brake Adjusting Nut

Procedure for adjusting rear brake free play.

Front/Rear Brake Fluid

Brake fluid level check procedure.

Headlight Aim

Procedure for adjusting headlight aim.

Clutch Shoe Wear

Inspection of clutch shoe wear.

Suspension

Inspection of front suspension components.

Rear Suspension

Inspection of rear suspension components.

Nuts/Bolts/Fasteners

Checking chassis nuts and bolts for looseness.

Wheels/Tires

Inspection of tires and checking tire pressure.

Steering Handlebar

Checking steering handlebar rotation.

4. Lubrication System

Service Information

General instructions and specifications for the lubrication system.

Troubleshooting

Common lubrication system problems and solutions.

Engine Oil/Oil Filter

Engine oil level check and oil change procedures.

Oil Pump

Procedures for oil pump removal, disassembly, and installation.

5. Fuel System

Service Information

General instructions and specifications for the fuel system.

Troubleshooting

Troubleshooting common fuel system issues.

Carburetor Removal

Steps for removing the carburetor.

Auto Bystarter

Inspection and installation of the auto bystarter.

Air Cut-off Valve

Disassembly and assembly of the air cut-off valve.

Vacuum Chamber

Disassembly of the vacuum chamber.

Float Chamber

Float chamber disassembly, inspection, and assembly.

Carburetor Installation

Procedure for installing the carburetor.

Pilot Screw Adjustment

Adjustment procedure for the pilot screw.

Fuel Tank Remove

Procedure for removing the fuel tank.

Fuel Strainer Removal

Fuel strainer removal and inspection.

Fuel Unit

Fuel unit removal and installation.

Air Cleaner

Air cleaner inspection and removal.

TPS Remove

TPS unit removal and inspection.

6. Engine Removal/Installation

Service Information

General instructions for engine removal and installation.

Engine Removal

Step-by-step procedure for removing the engine.

Engine Hanger Bracket Removal

Procedure to remove the engine hanger bracket.

Engine Hanger Bracket Installation

Procedure to install the engine hanger bracket.

Engine Installation

Step-by-step procedure for installing the engine.

7. Cylinder Head/Valves

Service Information

General instructions and specifications for cylinder head/valves.

Troubleshooting

Troubleshooting cylinder head and valve issues.

Camshaft Removal

Procedure for removing the camshaft.

Cylinder Head Removal

Procedure for removing the cylinder head.

Cylinder Head Disassembly

Steps for disassembling the cylinder head.

Cylinder Head Assembly

Steps for assembling the cylinder head.

Cylinder Head Installation

Procedure for installing the cylinder head.

Camshaft Installation

Procedure for installing the camshaft.

8. Cylinder/Piston

Service Information

General instructions and specifications for cylinder/piston.

Troubleshooting

Troubleshooting cylinder and piston issues.

Cylinder Removal

Procedure for removing the cylinder.

Piston Removal

Procedure for removing the piston.

Piston Ring Installation

Piston ring installation and clearance measurement.

Cylinder Inspection

Cylinder bore inspection and measurement.

Piston Installation

Procedure for installing the piston.

Cylinder Installation

Procedure for installing the cylinder.

9. Drive and Driven Pulleys/Kick Starter

Service Information

General instructions, specifications, torque values, and tools.

Troubleshooting

Troubleshooting drive/driven pulleys and kick starter issues.

Left Crankcase Cover

Removal and installation of the left crankcase cover.

Drive Pulley

Drive pulley removal, inspection, and disassembly.

Clutch/Driven Pulley

Clutch/driven pulley inspection and disassembly.

Kick Starter

Kick starter removal, inspection, and installation.

10. Final Reduction

Service Information

Specifications for final reduction gear oil and special tools.

Troubleshooting

Troubleshooting final reduction issues.

Final Reduction Disassembly

Procedure for disassembling the final reduction unit.

Final Reduction Inspection

Inspection of final reduction components.

Bearing Replacement (Transmission Case Cover)

Replacing bearings in the transmission case cover.

Bearing Replacement (Left Crankcase)

Replacing bearings in the left crankcase.

Final Reduction Assembly

Procedure for assembling the final reduction unit.

11. Crankcase/Crankshaft

Service Information

General instructions, specifications, and troubleshooting.

Crankcase Separation

Procedure for separating the crankcase halves.

Crankshaft Inspection

Inspection and measurement of crankshaft components.

Crankcase Assembly

Procedure for assembling the crankcase.

12. Front Wheel/Front Brake/Front Suspension

Service Information

General instructions, specifications, torque values, and tools.

Troubleshooting

Troubleshooting front wheel, brake, and suspension issues.

Steering Handlebar

Removal and installation of the handlebar.

Front Wheel

Front wheel removal and inspection.

Wheel Rim

Wheel rim runout inspection.

Hydraulic Brake (Front Brake)

Front brake fluid replacement and bleeding.

Brake Pad/Disk Replacement

Procedures for replacing brake pads and disks.

Brake Master Cylinder

Removal and disassembly of the brake master cylinder.

Brake Caliper (Front)

Removal and disassembly of the front brake caliper.

Front Shock Absorber

Removal and disassembly of the front shock absorber.

Front Fork

Front fork removal and component inspection.

13. Rear Wheel/Rear Brake/Rear Suspension

Service Information

General instructions and specifications for rear components.

Troubleshooting

Troubleshooting rear wheel, brake, and suspension issues.

Rear Wheel

Rear wheel removal, inspection, and installation.

Rear Brake

Rear brake lining inspection and disassembly.

Left Rear Shock Absorber

Rear shock absorber removal and disassembly.

14. Battery/Charging System/A.C. Generator

Service Information

General instructions for battery and charging system servicing.

Troubleshooting

Troubleshooting battery and charging system issues.

Battery

Battery removal, voltage inspection, and charging procedures.

Charging System

Charging system short circuit and current tests.

Regulator/Rectifier

Regulator/rectifier inspection and removal procedures.

A.C. Generator Charging Coil

Inspection of the A.C. generator charging coil.

A.C. Generator

Procedures for A.C. generator removal and installation.

15. Ignition System

Service Information

General instructions and specifications for the ignition system.

Troubleshooting

Troubleshooting ignition system problems.

CDI Unit Inspection

Procedure for inspecting the CDI unit.

Ignition Coil

Inspection procedures for the ignition coil.

Pulser Coil

Pulser coil inspection and ignition timing check.

16. Starting System

Service Information

General instructions, specifications, torque, tools, and troubleshooting.

Starter Motor

Starter motor removal, disassembly, and inspection.

Starter Relay

Inspection and testing of the starter relay.

Starter Clutch

Starter clutch removal, inspection, and disassembly.

17. Lights/Instruments/Switches

Service Information

General instructions for electrical system checks.

Troubleshooting

Troubleshooting lights, instruments, and switches.

Fuel Unit

Fuel unit removal, installation, and inspection.

Handlebar Switches

Inspection of various handlebar switches.

Headlight

Headlight removal and bulb replacement procedures.

Taillight/Stoplight/Rear Turn Signal Light/License Light

Replacement of rear lights and turn signal bulbs.

18. Evaporative/Exhaust Emission Control System

Exhaust Emission Control System Diagram

Diagram illustrating the exhaust emission control system.

Exhaust Emission Control System

Explanation of the exhaust emission control system's function.

Service Information

General instructions and tools for emission control system servicing.

Troubleshooting

Troubleshooting common exhaust emission control problems.

Maintenance Schedule

Periodic maintenance schedule for emission control components.

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