KYMCO AGILITY CITY 125 Full Service & Repair Manual

AGILITY 125 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO AGILITY 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/KICK 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 ELECTRICAL EQUIPMENT LIGHTS/INSTRUMENTS/SWITCHES 17 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.

1. GENERAL INFORMATION 1-1 AGILITY 125 Location of Engine Serial Number ENGINE SERIAL NUMBER 1 ENGINE SERIAL NUMBER ................... 1- 1 LUBRICATION POINTS ....................... 1-13 SPECIFICATIONS ................................... 1- 2 CABLE & HARNESS ROUTING ............ 1-15 SERVICE PRECAUTIONS ...................... 1- 3 WIRING DIAGRAM................................ 1-20 TORQUE VALUES .................................. 1-11 TROUBLESHOOTUNG .......................... 1-21 SPECIAL TOOLS ..................................... 1-12 AGILITY 125

1. GENERAL INFORMATION 1-2 AGILITY 125 SPECIFICATIONS Motorcycle Name & Type AGILITY 125 Name & Model No. LDF7 Overall length (mm) 1830 Overall width (mm) 690 Overall height (mm) 1130 Wheel base (mm) 1300 Engine type O.H.C. Displacement 124.6cc Fuel Used 92# nonleaded gasoline Front wheel 40 Net weight (kg) Rear wheel 65.5 Total 105.5 Front wheel 40 Gross weight(kg) Rear wheel 69.5 Total 109.5 Front wheel 120/70 -12 56J Tires Rear wheel 130/70 -12 56J Ground clearance (mm) 127 Perform- Braking distance (m) 7 (Initial speed 30km/h) ance Min. turning radius (m) 1.99 Starting system Starting motor & kick starter Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C. Bore x stroke (mm) φ52.4 x 57.8 Compression ratio 9.6±0.2 Compression pressure (kg/cm²-rpm) 13±2 Max. output 6.9/7500kw/(r/min) Max. torque 9.1/6500N.m/rpm Open -2.5° Port Intake Close 32° Engine timing Open -3° Exhaust Close 3° Valve clearance Intake 0.12 (cold) (mm) Exhaust 0.12 Idle speed (rpm) 1700±100rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Lubrication System Oil capacity 0.8 liter Cooling Type Forced air cooling Air cleaner type & No Paper element, wet Fuel capacity 5 liter Type CVK Piston dia. (mm) φ22 Venturi dia.(mm) φ37equivalent Carburetor Throttle type Butterfly type Type CDI Ignition timing BTDC27°±2°/4000rpm Contact breaker Non-contact point type Spark plug CHAMPION P- RZ9 HC Spark plug gap 0.6～0.7mm Battery Capacity 12V7AH Clutch Type Dry multi-disc clutch Type Non-stage transmission Operation Automatic centrifugal type Type Two-stage reduction Reduction 1st 0.95-2.8 ratio 2nd 2.94 Front Caster angle 27° Axle Trail length ⎯ Tire pressure Front 1.75 (kg/cm²) Rear 2.25 Turning Left 45° angle Right 45° Front DISK (160mm) brake Brake system type Rear Drum (140mm) brake Front TELESCOPE Suspension type Rear Unit Swing Front 410.1±2.5mm Shock absorber distance Rear 351.6±2mm Frame type Steel Pipel Fuel System Electrical Equipment Ignition System Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device

1. GENERAL INFORMATION 1-3 AGILITY 125 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. Use genuine parts and lubricants . When servicing the motorcycle, be sure to use special tools for removal and installation. After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.

1. GENERAL INFORMATION 1-4 AGILITY 125 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface. After operation, check all connecting points, fasteners, and lines for proper connection and installation. When connecting the battery, the positive (+) terminal must be connected first. After connection, apply grease to the battery terminals. Terminal caps shall be installed securely.

1. GENERAL INFORMATION 1-5 AGILITY 125 If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. Check if any connector terminal is bending, protruding or loose. Confirm Capacity

1. GENERAL INFORMATION 1-6 AGILITY 125 The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal. Check the double connector cover for proper coverage and installation. Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up. Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. Snapping!

1. GENERAL INFORMATION 1-7 AGILITY 125 After clamping, check each wire to make sure it is secure. . Do not squeeze wires against the weld or its clamp After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. When fixing the wire harnesses, do not make it contact the parts which will generate high heat. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws. No Contact !

1. GENERAL INFORMATION 1-8 AGILITY 125 Route harnesses so they are neither pulled tight nor have excessive slack. . Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. Do not break the sheath of wire. If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it. When installing other parts, do not press or squeeze the wires. Do not pull too tight! Do not press or squeeze the wire.

1. GENERAL INFORMATION 1-9 AGILITY 125 After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. Be careful not to drop any parts. When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. Do you understand the instrument? Is the instrument set correctly? Remove Rust !

KYMCO AGILITY CITY 125 Full Service & Repair Manual

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