Text preview for : Kymco Agility 125 R16 - Service Manual [04] [Lubrication System] by salvacolnome.pdf part of KYMCO Agility 125 cc Service Manual (part 4) Lubrication/System [pag. 10]
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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
4. LUBRICATION SYSTEM AGILITY CITY 125
4
__________________________________________________________________________________
4
LUBRICATION SYSTEM
SERVICE INFORMATION------------------------------------------------ 4- 1
TROUBLESHOOTING----------------------------------------------------- 4- 1
ENGINE OIL/OIL FILTER ------------------------------------------------ 4- 2
OIL PUMP -------------------------------------------------------------------- 4- 2
4-0
4. LUBRICATION SYSTEM AGILITY CITY 125
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The maintenance of lubrication system can be performed with the engine installed in the frame.
Use care when removing and installing the oil pump not to allow dust and foreign matters to
enter the engine and oil line.
Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it
reaches its service limit.
After the oil pump is installed, check each part for oil leaks.
SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Inner rotor-to-outer rotor clearance 0.12
Oil pump Outer rotor-to-pump body clearance 0.12
Rotor end-to-pump body clearance 0.05 0.10 0.2
TROUBLESHOOTING
Oil level too low Poor lubrication pressure
Natural oil consumption Oil level too low
Oil leaks Clogged oil filter or oil passages
Worn or poorly installed piston rings Not use the specified oil
Worn valve guide or seal
4-1
4. LUBRICATION SYSTEM AGILITY CITY 125
Lower Level
ENGINE OIL/OIL FILTER
OIL LEVEL
Place the motorcycle upright on level
ground for engine oil level check.
Run the engine for 2 3 minutes and
check the oil level after the engine is
stopped for 2 3 minutes.
Remove the oil dipstick and check the oil
level with the oil dipstick.
If the level is near the lower level, fill to the
upper level with the specified engine oil. Oil Dipstick Upper Level
OIL CHANGE
The engine oil will drain more easily
while the engine is warm.
Remove the oil filter screen cap located on
the bottom of the engine to drain the engine
oil thoroughly.
After the oil has been completely drained, Oil Filter Screen Cap
check the filter screen O-ring for damage
and replace if necessary.
Install the oil filter screen, spring and filter
screen cap.
Torque: 1.5kg-m
Fill with the specified SAE15W40#, API: SG
engine oil to the proper level.
Oil Capacity: At disassembly : 0.90 liter
At change : 0.80 liter
Check for oil leaks and then start the engine
and let it idle for few minutes.
Recheck the oil level. O-ring
Bolts Pulser Coil
OIL PUMP
REMOVAL
Remove the A.C. generator flywheel.
Remove the nine right crankcase cover bolts
and the right crankcase cover.
Stator Right Crankcase Cover
4-2
4. LUBRICATION SYSTEM AGILITY CITY 125
Remove the gasket and dowel pins.
Remove the starter idle gear and starter
clutch.
Gasket
Remove the two bolts and oil separator Bolts
cover.
Oil Separator Cover
Remove the oil pump driven gear nut to Nut
remove the oil pump driven gear and drive
chain.
Oil Pump Driven Gear
Remove the two oil pump mounting bolts Bolts
and the oil pump.
Oil Pump
4-3
4. LUBRICATION SYSTEM AGILITY CITY 125
Screw
DISASSEMBLY
Remove the screw and disassemble the oil
pump.
Pump Body
Outer Rotor
INSPECTION
Measure the pump body-to-outer rotor
clearance.
Service Limit: 0.12mm
Pump Body
Outer Rotor
Measure the inner rotor-to-outer rotor
clearance.
Service Limit: 0.12mm
Inner Rotor
Measure the rotor end-to-pump body
clearance.
Service Limit: 0.2mm
4-4
4. LUBRICATION SYSTEM AGILITY CITY 125
Outer Rotor Inner Rotor
ASSEMBLY
Install the outer rotor, inner rotor and pump
shaft into the pump body.
Insert the pump shaft by aligning the flat
on the shaft with the flat in the inner
rotor.
Install the dowel pin.
Install the pump cover by aligning the hole
in the cover with the dowel pin.
Dowel Pin Pump Cover
Screw
Tighten the screw to secure the pump cover.
Make sure that the pump shaft rotates freely
without binding.
Arrow Oil Pump
INSTALLATION
Install the oil pump into the crankcase.
Install the oil pump with the arrow on
the pump body facing up and fill the oil
pump with engine oil before installation.
After the oil pump is installed, tighten the
two mounting bolts.
Bolts
Nut
Install the pump driven gear and drive chain
by aligning the pump driven gear with the
cutout in the pump shaft.
Install and tighten the pump driven gear nut.
Torque: 1.0kg-m
Pump Driven Gear
4-5
4. LUBRICATION SYSTEM AGILITY CITY 125
Bolts
Install the oil separator cover and tighten
the bolts.
Oil Separator Cover
Install the starter idle gear and starter Starter Idle Gear Dowel Pin
clutch.
Install the gasket and dowel pins.
Starter Clutch Gasket
Right Crankcase Cover
Install the right crankcase cover and tighten
the nine bolts.
Torque: 0.9kg-m
Diagonally tighten the bolts in 2 3
times.
Stator Bolts Pulser Coil
4-6
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