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KYMCO agility R16 150 Service Manual

KYMCO agility R16 150
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 150 Specifications

General IconGeneral
Displacement149.5 cc
Bore x Stroke57.4 mm x 57.8 mm
Compression Ratio10.0:1
Fuel SystemCarburetor
IgnitionCDI
TransmissionCVT
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Front Tire100/80-16
Rear Tire120/80-16
Wheelbase1340 mm
Seat Height780 mm
Engine Type4-stroke
Starting SystemElectric & Kick

Summary

General Information

Engine Serial Number

Identifies the engine's unique serial number for tracking.

Specifications

Provides detailed technical specifications for the motorcycle.

Service Precautions

Outlines essential safety and procedural precautions for servicing.

Torque Values

Lists critical torque specifications for fasteners during assembly.

Special Tools

Identifies specialized tools required for specific maintenance tasks.

Lubrication Points

Details specific points requiring lubrication for engine and frame.

Cable & Harness Routing

Illustrates the routing paths for cables and wire harnesses.

Wiring Diagram

Presents the complete electrical system wiring diagram.

Troubleshooting

Guides users through diagnosing and resolving common engine starting issues.

Frame Covers and Exhaust Muffler

Schematic Drawing

Provides an exploded view of frame cover and exhaust components.

Service Information

Offers general instructions and warnings for servicing frame covers.

Frame Covers Removal

Details the procedure for removing front, handlebar, and met-in box covers.

Floor Board, Front Fender, and Leg Shield Removal

Outlines the steps for removing floor board, front fender, and leg shield.

Exhaust Muffler Removal

Provides instructions for removing the exhaust muffler and its components.

Inspection and Adjustment

General Inspection and Precautions

Provides general guidance and safety warnings for inspections.

Specifications

Lists key specifications for engine and chassis components.

Maintenance Schedule

Details the recommended periodic maintenance intervals and tasks.

Fuel Filter and Throttle Operation

Covers inspection of the fuel filter and adjustment of throttle operation.

Air Cleaner and Spark Plug

Provides service procedures for the air cleaner and spark plug.

Valve Clearance and Carburetor Idle Speed

Guides adjustment of valve clearance and carburetor idle speed.

Ignition Timing and Cylinder Compression

Covers inspection of ignition timing and cylinder compression.

Final Reduction Gear Oil and Drive Belt

Details service procedures for final reduction gear oil and drive belt.

Brake System Checks

Outlines checks and adjustments for the front and rear brake systems.

Headlight Aim, Clutch Shoe Wear, and Suspension

Covers headlight aiming, clutch shoe wear inspection, and suspension checks.

Rear Suspension, Fasteners, and Wheels/Tires

Details inspection of rear suspension, critical fasteners, and wheels/tires.

Steering Handlebar

Describes inspection of the steering handlebar for smooth operation.

Lubrication System

Service Information and Specifications

Provides general instructions and specifications for the lubrication system.

Troubleshooting

Guides diagnosis of lubrication system issues like low oil level.

Engine Oil, Oil Filter, and Oil Pump

Covers engine oil level check, filter, and oil pump removal procedures.

Oil Pump Disassembly and Inspection

Details disassembly and measurement of oil pump components.

Fuel System

Schematic Diagram

Illustrates the main components of the fuel system.

Wiring Diagram

Shows the electrical connections related to the fuel system.

Service Information and Specifications

Provides general instructions and technical specifications for the fuel system.

Troubleshooting

Guides diagnosis of fuel system issues like hard starting or misfiring.

Carburetor Removal and Auto Bystarter

Details carburetor removal and auto bystarter inspection steps.

Air Cut-off Valve and Vacuum Chamber

Covers disassembly and assembly procedures for these carburetor components.

Float Chamber Disassembly

Provides instructions for disassembling the carburetor float chamber.

Carburetor Installation

Outlines the steps for correctly installing the carburetor.

Pilot Screw Adjustment

Explains how to adjust the pilot screw for idle speed tuning.

Engine Removal and Installation

Schematic Diagram

Illustrates the overall engine removal process.

Service Information

Provides general instructions and safety guidelines for engine removal.

Engine Removal (Cables and Hoses)

Details disconnecting electrical, fuel, and vacuum lines before engine removal.

Engine Removal (Bolts and Hanger Bracket)

Outlines the process of removing engine mounting bolts and the hanger bracket.

Engine Hanger Bracket and Engine Installation

Guides the installation of the engine hanger bracket and the engine itself.

Cylinder Head and Valves

Schematic Diagram

Provides an exploded view of cylinder head and valve components.

Service Information and Specifications

Lists general instructions and technical specifications for cylinder head service.

Torque Values and Troubleshooting

Details critical torque values and troubleshooting for cylinder head issues.

Camshaft Removal

Guides the user through the process of removing the camshaft.

Camshaft Inspection

Covers inspection procedures for the camshaft and its lobe height.

Cylinder Head Removal

Outlines the steps required to remove the cylinder head.

Cylinder Head Disassembly

Details the process of disassembling the cylinder head, including valve springs.

Valve/Valve Guide and Cylinder Head Assembly

Covers valve inspection and the assembly of the cylinder head.

Camshaft Installation

Details the process of installing the camshaft and related components.

Cylinder and Piston

Schematic Diagram

Shows an exploded view of cylinder and piston components.

Service Information, Specifications, and Troubleshooting

Provides core technical data and troubleshooting for cylinder/piston.

Cylinder Removal and Piston Removal

Details the removal of the cylinder and piston assembly.

Piston Inspection and Ring Installation

Covers piston inspection and the correct installation of piston rings.

Piston Measurements and Cylinder Inspection

Details critical measurements for piston and cylinder inspection.

Cylinder Warpage, Connecting Rod, and Piston Ring Installation

Covers cylinder warpage checks and piston ring installation procedures.

Piston Installation and Cylinder Installation

Provides procedural steps for installing the piston and cylinder.

Drive and Driven Pulleys/Kick Starter

Schematic Diagram

Shows an exploded view of pulley and kick starter components.

Service Information, Specifications, and Troubleshooting

Provides core technical data and troubleshooting for pulleys and kick starter.

Left Crankcase Cover Removal and Installation

Details the service procedures for the left crankcase cover.

Drive Pulley Removal and Inspection

Covers drive pulley removal and drive belt inspection procedures.

Clutch/Driven Pulley Disassembly

Details the disassembly process for the clutch/driven pulley assembly.

Kick Starter Inspection

Provides inspection procedures for kick starter components.

Kick Starter Installation

Guides the installation process for the kick starter assembly.

Final Reduction

Schematic Diagram

Shows an exploded view of the final reduction gear components.

Service Information and Troubleshooting

Provides system overview and troubleshooting for the final reduction.

Final Reduction Disassembly and Inspection

Covers disassembly and inspection of final reduction gears and shafts.

Bearing Replacement (Left Crankcase) and Final Reduction Assembly

Details bearing replacement and the assembly of the final reduction system.

Crankcase and Crankshaft

Schematic Diagram

Shows an exploded view of crankcase and crankshaft components.

Service Information and Troubleshooting

Provides core technical data and troubleshooting for the crankcase/crankshaft.

Crankcase Separation

Details the procedure for separating the crankcase halves.

Crankshaft Inspection

Covers critical inspection of connecting rod clearance and crankshaft runout.

Crankcase Assembly

Details the steps involved in assembling the crankcase.

Front Wheel, Front Brake, and Front Suspension

Schematic Diagram

Shows an exploded view of front wheel, brake, and suspension components.

Service Information, Specifications, Torque Values, and Special Tools

Provides overview, critical data, and required tools for front end service.

Troubleshooting

Guides diagnosis of common steering, wheel, and suspension problems.

Steering Handlebar Removal and Installation

Details the procedure for removing and installing the steering handlebar.

Front Wheel Removal and Axle Runout Inspection

Covers front wheel removal and axle runout measurement.

Wheel Rim, Wheel Bearings, and Disassembly

Details inspection of wheel rim runout, bearings, and dust seal removal.

Wheel Bearings Assembly

Guides the process of assembling the wheel bearings correctly.

Hydraulic Brake (Front Brake)

Covers front brake fluid replacement, bleeding, and refilling procedures.

Brake Caliper Disassembly

Details the steps involved in disassembling the brake caliper.

Front Shock Absorber Removal and Disassembly

Covers the removal and disassembly procedures for the front shock absorber.

Shock Absorber Spring Measurement and Assembly

Guides measurement of the shock absorber spring and its assembly.

Front Fork Removal and Race Replacement

Details front fork removal and replacement of steering races.

Rear Wheel, Rear Brake, and Rear Suspension

Schematic Diagram

Shows an exploded view of rear wheel, brake, and suspension components.

Service Information and Troubleshooting

Provides system overview and troubleshooting for rear wheel, brake, and suspension.

Rear Wheel Removal, Inspection, and Installation

Covers the procedures for removing, inspecting, and installing the rear wheel.

Rear Brake Inspection, Disassembly, and Assembly

Details the inspection, disassembly, and assembly of the rear brake.

Rear Shock Absorber Removal and Disassembly

Covers the removal and disassembly procedures for the rear shock absorber.

Rear Shock Absorber Installation

Guides the installation process for the rear shock absorber.

Battery, Charging System, and A.C. Generator

Schematic Diagram

Shows the electrical diagram for the battery, charging system, and AC generator.

Service Information and General Instructions

Provides general information and safety instructions for battery and charging system.

Specifications and Troubleshooting

Lists technical specifications and troubleshooting for the system.

Battery Service

Covers battery removal, voltage inspection, and charging procedures.

Charging System and Current Test

Details charging system short circuit test and current testing procedures.

Regulator/Rectifier Inspection and Removal

Covers inspection and removal procedures for the regulator/rectifier.

A.C. Generator Charging Coil Inspection and Removal

Details inspection and removal of the AC generator charging coil.

A.C. Generator Installation

Provides instructions for the installation of the AC generator.

Ignition System

Schematic Diagram

Shows the electrical diagram for the ignition system.

Service Information and Specifications

Provides general information and technical specifications for the ignition system.

Troubleshooting

Lists common problems and solutions for the ignition system.

CDI Unit Inspection

Details the procedure for inspecting the CDI unit.

Ignition Coil Inspection

Covers the inspection procedures for the ignition coil.

Pulser Coil and Ignition Timing Inspection

Guides inspection of the pulser coil and ignition timing.

Starting System

Schematic Diagram

Shows the electrical diagram for the starting system.

Service Information and Troubleshooting

Provides general information and troubleshooting for the starting system.

Starter Motor Service

Covers starter motor removal, disassembly, and inspection procedures.

Starter Relay Inspection and Voltage Check

Details starter relay inspection and voltage checking procedures.

Starter Clutch Service

Covers starter clutch removal, inspection, and disassembly.

Lights, Instruments, and Switches

Troubleshooting and General Instructions

Provides general instructions and troubleshooting for lights and instruments.

Fuel Unit Service

Covers fuel unit removal, installation, and inspection procedures.

Handlebar Switches Inspection

Details the inspection procedures for various handlebar switches.

Horn Switch and Ignition Switch Service

Covers service procedures for the horn switch and ignition switch.

Stop Switch, Horn, and Instruments Service

Covers service for stop switches, horn, and instrument cluster.

Headlight and Rear Lights Service

Details replacement procedures for headlight and rear light bulbs.

Evaporative/Exhaust Emission Control System

Exhaust Emission Control System Diagram

Illustrates the components and flow of the exhaust emission control system.

Exhaust Emission Control System and Troubleshooting

Provides system overview and troubleshooting for emission control issues.

Maintenance Schedule

Details the recommended periodic maintenance schedule for the emission system.

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