Text preview for : Kymco Agility 125 R16 - Service Manual [06] [Engine Removal] by salvacolnome.pdf part of KYMCO Agility 125 cc Service Manual (part 6) Engine Removal/Installation [pag. 7]
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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
6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125
6
6
6-0
6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125
SERVICE INFORMATION ...................... 6-1 ENGINE INSTALLATION .......................6-4
ENGINE REMOVAL ................................ 6-2
SERVICE INFORMATION
GENERAL INSTRUCTIONS
A floor jack or other adjustable support is required to support and maneuver the engine. Be
careful not to damage the motorcycle body, cables and wires during engine removal.
Use shop towels to protect the motorcycle body during engine removal.
Parts requiring engine removal for servicing:
Crankcase
Crankshaft
6-1
6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125
ENGINE REMOVAL
Disconnect the battery negative cable.
Remove the frame body cover.
Disconnect the engine negative cable.
Disconnect the spark plug high tension
wire.
Disconnect the auto bystarter wire
connector.
Auto Bystarter Wire Connector
Starter Relay
Disconnect the starter motor cable from the
starter relay.
Remove the spark plug cap and disconnect
the ignition coil wire from the set plate.
Vacuum Tube Fuel Tube
Disconnect the fuel tube and vacuum tube
that go to the carburetor from the fuel pump.
Disconnect the vacuum tube from the air
cut-off valve.
Disconnect the throttle cable from the
carburetor.
Tee Tube
Connecting Tube
Loosen the drive belt air cleaner connecting
tube band screw and remove the connecting
tube.
Screw
6-2
6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125
Brake Adjusting Nut
Remove the air cleaner bolts.
Remove the rear brake adjusting nut,
connecting pin and rear brake cable.
Remove the rear shock absorber lower Rear Shock Absorber Lower Mount Bolt
mount bolt.
Engine Mounting Bolt
Remove the four A.C. generator cooling fan
cover bolts and cooling fan cover.
Remove the engine mounting bolt and pull
out the engine with the engine hanger
bracket backward.
ENGINE HANGER BRACKET Engine Hanger Bracket
REMOVAL
Remove the ignition coil from the engine
hanger.
Remove the engine hanger bracket bolt and
nut.
Remove the engine hanger bracket.
6-3
6. ENGINE REMOVAL/INSTALLATION AGILITY CITY 125
Bushings Stopper Rubbers
Inspect the engine hanger bushings and
stopper rubbers for wear or damage.
Bolt Nut
ENGINE HANGER BRACKET Engine Hanger Bracket
INSTALLATION
Install the engine hanger bracket to the
engine.
Install the engine hanger bracket bolt and
tighten the nut.
Nut
ENGINE INSTALLATION Engine Mounting Bolt
Install the engine and tighten the engine
mounting bolt.
Torque: 7.0kg-m
Tighten the rear shock absorber upper
mount bolt.
Torque: 4.0kg-m
Rear Shock Absorber Lower Mount Bolt
Install the removed parts in the reverse
order of removal.
Route the wires and cables properly.
After installation, inspect and adjust the
following:
Throttle grip free play.
Rear brake adjustment.
6-4
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