KYMCO Agility RS 50 Service Manual
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KYMCO Agility RS 50 Service Manual

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Table of Contents

1
. GENERAL INFORMATION
1
ENGINE SERIAL NUMBER ................... 1- 1
SPECIFICATIONS ................................... 1- 2
SERVICE PRECAUTIONS ...................... 1- 3
TORQUE VALUES .................................. 1-11
SPECIAL TOOLS ..................................... 1-12
ENGINE SERIAL NUMBER
LUBRICATION POINTS .......................1-13
CABLE & HARNESS ROUTING ............1-15
WIRING DIAGRAM................................1-20
TROUBLESHOOTUNG ..........................1-21
AGILITY RS 50
Location of Engine Serial Number
1
1-1

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Summary of Contents for KYMCO Agility RS 50

  • Page 1: Table Of Contents

    . GENERAL INFORMATION AGILITY RS 50 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...

  • Page 2: Specifications

    . GENERAL INFORMATION AGILITY RS 50 SPECIFICATIONS Air cleaner type & No Paper element, wet Motorcycle Name & Type AGILITY RS 50 Fuel capacity 5.0 liter Name & Model No. KG10SA Type Overall length (mm) 1940 Piston dia. (mm) Overall width (mm) φ17equivalent...

  • Page 3: Service Precautions

    . GENERAL INFORMATION AGILITY RS 50 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.
  • Page 4 . GENERAL INFORMATION AGILITY RS 50 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.
  • Page 5 . GENERAL INFORMATION AGILITY RS 50 If the fuse is burned out, find the cause and Confirm repair it. Replace it with a new one Capacity 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.
  • Page 6 . GENERAL INFORMATION AGILITY RS 50 connector shall inserted completely. Snapping! 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 loose negative terminal.
  • Page 7 . GENERAL INFORMATION AGILITY RS 50 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.
  • Page 8 . GENERAL INFORMATION AGILITY RS 50 Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner...
  • Page 9 . GENERAL INFORMATION AGILITY RS 50 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.
  • Page 10 . GENERAL INFORMATION AGILITY RS 50 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication.

  • Page 11: Torque Values

    . GENERAL INFORMATION AGILITY RS 50 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5 6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1 8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4...

  • Page 12: Special Tools

    . GENERAL INFORMATION AGILITY RS 50 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page 10-3 Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 10-4 12-6 Bushing remover L E032 11102 bush engine hanger rubber Bushing remover S EO19 11203 bush rear cushion under rubber...

  • Page 13: Lubrication Points

    . GENERAL INFORMATION AGILITY RS 50 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API−SG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 14 . GENERAL INFORMATION AGILITY RS 50 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 15: Cable & Harness Routing

    . GENERAL INFORMATION AGILITY RS 50 CABLE & HARNESS ROUTING Winker Brake Master Cylinder Rear Stop Switch Wire Front Stop Switch Wire Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Front Brake Fluid Tube Horn Regulator/Rectifier 1-15...
  • Page 16 . GENERAL INFORMATION AGILITY RS 50 Throttle Grip Regulator/Rectifier Ignition Switch Speedometer Cable Headlight Resistor Rear Brake Lever Horn Front Brake Fluid Tube 1-16...
  • Page 17 . GENERAL INFORMATION AGILITY RS 50 CDI Unit Fuse Battery (+) Cable Battery (-) Cable Starter Relay Fuel Tank Battery (-) Cable Battery (+) Cable Ignition Coil 1-17...
  • Page 18 . GENERAL INFORMATION AGILITY RS 50 Auto Cock Assy Fuel Fuel Filter Fuel Tube Ignition Coil Primary Wire Ignition Wire Throttle Cable Vacuum Tee Carburetor Overflow Tube Crankcase Breather Tube 1-18...
  • Page 19 . GENERAL INFORMATION AGILITY RS 50 Fuel Unit Crankcase Breather Tube Throttle Cable Wire Harness Vacuum Tube Vacuum Tube Ignition Coil Crankcase Breather Tube Secondary Air Inlet Tube Reed Valve Air Injection Cut-off Valve Fuel Tube Auto Bystarter 1-19...

  • Page 20: Wiring Diagram

    . GENERAL INFORMATION AGILITY RS 50 WIRING DIAGRAM 1-20...

  • Page 21: Troubleshooting

    . GENERAL INFORMATION AGILITY RS 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor...
  • Page 22 . GENERAL INFORMATION AGILITY RS 50 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate Clogged air cleaner lightly for observation Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed does not...
  • Page 23 . GENERAL INFORMATION AGILITY RS 50 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Incorrect timing Correct timing Faulty pulser coil Check carburetor pilot screw adjustment Mixture too rich (turn screw...
  • Page 24 . GENERAL INFORMATION AGILITY RS 50 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Correctly adjusted Incorrectly adjusted Worn camshaft...
  • Page 25 . GENERAL INFORMATION AGILITY RS 50 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 26 . GENERAL INFORMATION AGILITY RS 50 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty old spark plug Check spark plug cap and high-tension wire...

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