Text preview for : Kymco Agility 125 R16 - Service Manual [02] [Frame Covers - Exhaust Muffler] by salvacolnome.pdf part of KYMCO Agility 125 cc Service manual [part 2] Frame Covers/Exhaust Muffler [pag. 9]
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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
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
2 SCHEMATIC DRAWING
2
2-0
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
SERVICE INFORMATION ...................... 2-1 EXHAUST MUFFLER REMOVAL .........2-5
FRAME COVERS ..................................... 2-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
When removing frame covers, use special care not to pull them by force because the cover joint
claws may be damaged.
Items Related for Removal
Handlebar front cover Handlebar rear cover
Headlight wire connector
Handlebar rear cover Speedometer cable and instrument light
wire connectors, etc.
Frame body cover Met-in box, rear grip, rear turn signal
lights, floor board
Floor board Frame body cover
Battery and wire connectors
Leg Shield Front cover, floor board
TORQUE VALUES
Exhaust muffler joint lock nut 1.0~1.4kgf-m
Exhaust muffler lock bolt 3.0~3.6kgf-m
2-1
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
Front Cover Screw Front Cover Front Brake Fluid Tube
FRAME COVERS
FRONT COVER REMOVAL
Remove the screw on the front cover and
remove the front cover..
Remove the screws on the back of the mole
assy front.
Remove the front brake fluid tube and
speedometer cable
Remove the four bolt attaching the R/L front
fork and remove the front fork.
Remove the mole assy
The installation sequence is the reverse of Screws
removal. Front Fork Bolts Speedometer Cable
Clip Mudguard Sponge Risor Handlebar Rear Cover
HANDLEBAR REAR COVER
REMOVAL
Remove the handlebar rear cover screw.
Remove the clip mudguard attaching the
sponge risor and sponge risor.
Disconnect the speedometer cable, right and
left handlebar switch couplers, and the stop
switch wire connectors.
Remove four screws inside the handlebar rear
cover and remove the handlebar rear cover.
The installation sequence is the reverse of
removal. Screws Screws
Handlebar Front Cover
HANDLEBAR FRONT COVER
REMOVAL
Remove the bolt attaching the handlebar front
cover.
Remove the handlebar front cover.
Screws
Screws
MET-IN BOX REMOVAL
Open the seat and remove the six bolt and two
screws attaching the met-in box.
Remove the met-in box .
Bolts
2-2
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
FRAME BODY COVER REMOVAL Screws Battery Cover Screws
Remove the two screws on the battery cover.
Remove the battey cover
Remove the six screws on the center cover
Remove the center cover
Center Cover
Bolts
Remove the three bolts attaching the rear
carrier.
Remove the rear carrier.
Rear Carrier
Rear Step
Remove the two bolt attaching the lefe and
right rear step.
Remove the rear step
Bolts
Left Side Skirt
Remove the six screws attaching the left side
and right side skirt
Remove the left side and right side skirt
During removal, do not pull the joint
claws forcedly to avoid damage.
When installing, be sure to connect the
seat lock wire.
Screws Right Side Skirt
2-3
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
Remove the two screws on the center rear Center Rear Cover.
cover.
Remove the center rear cover.
.
Screws
Bolts
Remove the two bolts attaching the frame
body cover.
Remove the three screws attaching the frame
body cover.
Screws
Remove the six screws attaching the frame
body cover.
Screws
Remove the two bolts attaching the rear Bolts
fender.
Disconnect the taillight wire connector
Remove the erar fender.
Rear Fender Wire
2-4
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
Discornnect the seat lock wire. Seat Lock Wire Rear Light Wire Connector
Discornnect the rear light wire connectors
Remove the left / right body cover and rear
light.
The installation sequence is the reverse of
remove
During removal, do not pull the joint
claws forcedly to avoid damage.
When installing, be sure to connect the
seat lock wire. Lift Body Cover Rear Light
Plug Floor/Bolts
FLOOR BOARD REMOVAL
Remove the rear carrier. ( 2-3)
Remove the met-in box. ( 2-3)
Remove the frame body cover. ( 2-4)
Remove the four bolts attaching the floor
board.
Remove the floor board.
Floor Board.
Screws
FRONT FENDER REMOVAL
Remove the L/R side bolts attaching the front
fender and front fender.
Bolts Front Fenderl
Clip Body. Lid Leg Shield.
LEG SHIELD REMOVAL
Remove the two clip body on the lid leg
shield
Remove the lid leg shield.
The installation sequence is the reverse of
remove
2-5
2. FRAME COVERS/EXHAUST MUFFLER AGILITY CITY 125
Remove the decorative ring.
Remove the leg shieid. Leg Shield
Remove the bolt attaching the hook luggage.
Remove the hook luggage.
Remove the leg shield.
The installation sequence is the reverse of
remove
Decorative Ring
EXHAUST MUFFLER REMOVAL
Remove the two exhaust muffler joint lock
nuts.
Remove the three exhaust muffler lock bolts.
Remove the exhaust muffler.
Remove the exhaust muffler joint packing
collar.
When installing, first install the exhaust
muffler packing collar and then install the
exhaust muffler.
First install and tighten the exhaust muffler
joint lock nuts. Then, install and tighten the
exhaust muffler lock bolts. Bolts
Torques:
Exhaust muffler lock bolt: 3.0~3.6kgf-m
Exhaust muffler joint lock nut: 1.0~1.4kgf-m
Be sure to install a new exhaust muffler
packing collar.
Lock Nut
2-6
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