KYMCO 125 AGILITY CITY - User manual

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-5
AGILITY 125
WHEEL RIM
Check the wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over
Turn the wheel bearings and replace the
bearings if they are noisy or have excessive
play.
DISASSEMBLY
Remove the dust seal.
Radial
Dust Seal
Play
Pla
y
Axial

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-6
AGILITY 125
Remove the front wheel bearings and
distance collar.
Bearing Puller
ASSEMBLY
Pack all bearing cavities with grease.
Drive in the left bearing.
Install the distance collar.
Drive in the right bearing.
Bearing Pulle
r
Pilo
t
Grease
Grease
Outer Drive
r
Pilo
t
Drive in the bearing squarely with the
sealed end facing out.
＊
Special

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-7
AGILITY 125
Apply grease to a new dust seal lip and install
the dust seal.
Install the side collar.
INSTALLATION
Install the front wheel by aligning the brake
panel groove with the front fork tab.
Insert the axle shaft and tighten the axle nut.
Torque: 4.5kg-m
Connect the speedometer cable and secure it
with the screw.
Install the front brake cable and adjust the
front brake lever free play.
FRONT BRAKE
Remove the front wheel. (Ö12-4)
Remove the front brake panel.
INSPECTION
Measure the brake drum I.D.
Service Limit: 111mm replace if over
Measure each brake lining thickness.
Service Limit: 2.00mmmm replace if below
Groove
Keep oil or grease off the brake linings.
＊
Tab
Dust Seal
Side Colla
r
Brake Linings
Brake Shoe S
p
rin
g
s Brake Ca
m

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-8
AGILITY 125
DISASSEMBLY
Do not swing the brake arm to expand the
brake shoes.
Remove the brake shoes by removing the
brake shoe springs using a screw driver.
Remove the brake arm and return spring.
Remove the wear indicator plate and felt seal.
Remove the brake cam.
Remove the dust seal and speedometer drive
gear.
ASSEMBLY
Apply grease to the speedometer drive gear
and then install it into the brake panel.
Apply grease to the dust seal lip and install it
into the brake panel.
Apply grease to the anchor pin and brake
cam.
Install the brake cam.
Brake Shoe
Speedometer Drive Gea
r
Dust Seal
Brake Ar
m
Brake Ca
m
Anchor Pin
Felt Seal
Return Spring
Brake Ca
m
1.0kg-
m
Wear Indicator Plate
S
p
eedometer Drive Gea
r
Dust Seal
Grease
Grease

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-9
AGILITY 125
Install the return spring by aligning the spring
hook end with the hole in the brake panel.
Apply a small amount of engine oil to the felt
seal and install it to the brake panel.
Install the wear indicator plate on the brake
cam by aligning the tooth on the plate with
the groove on the brake cam.
Install the brake arm on the brake cam by
aligning the punch mark on the brake arm and
the scribed line on the brake cam.
Install and tighten the brake arm bolt.
Torque:0.8~1.2kgf-m
Install the brake shoe springs to the brake
shoes and then install the brake shoes into the
brake panel.
INSTALLATION
Install the brake panel onto the front wheel.
Install the front wheel. (Ö12-7)
Adjust the front brake lever free play.
Brake Ar
m
Wear Indicator Plate
Return S
p
rin
g
Brake Shoe Springs
Brake Ca
m
Bol
t
Brake Shoes

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-10
AGILITY 125
HYDRAULIC BRAKE (FRONT BRAKE)
Brake Fluid Replacement/Air Bleeding
Check the brake fluid level on level ground.
Brake Fluid Bleeding
In order to avoid spill of brake fluid, connect
a transparent hose to the bleed valve.
Fully apply the brake lever and then loosen
the brake caliper bleed valve to drain the
brake fluid until there is no air bubbles in the
brake fluid. Then, tighten the bleed valve.
Repeat these steps until the brake system is
free of air.
Brake Fluid Refilling
Add DOT-4 brake fluid to the brake
reservoir.
Make sure to bleed air from the brake system.
•When operating the brake lever, the
brake reservoir cap must be tightened
securely to avoid spill of brake fluid.
•When servicing the brake system, use
shop towels to cover plastic parts and
coated surfaces to avoid damage
caused by spill of brake fluid.
＊
Brake fluid spilled on brake pads or
brake disk will reduce the braking
effect. Clean the brake pads and brake
disk with a high quality brake degreaser.
Warning
•When bleeding, be careful not to allow
air in the brake reservoir flowing into
the brake system.
•When using a brake bleeder, follow
the manufacturer‘s instructions.
•Never use dirty or unspecified brake
fluid or mix different brake fluids
be-cause it will damage the brake
＊
Upper Limi
t
Lower Limi
t
Bleed Valve
Front Brake Calipe
r

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-11
AGILITY 125
Brake Pad/Disk Replacement
Remove the two bolts attaching the brake
caliper.
Remove the brake caliper.
Remove the brake pad pins to remove the
brake pads.
Install the brake pads in the reverse order of
removal.
Tighten the brake pad pin bolts.
Torque: 1.5～2.0kgf-m
Brake Disk
Measure the brake disk thickness.
Service Limit: 3.0mm
Measure the brake disk runout.
Service Limit: 0.3mm
The brake pads must be replaced as a
set to ensure the balance of the brake
disk.
＊
‧Keep grease or oil off the brake pads
to avoid brake failure.
‧Do not reuse the brake pad pin bolts
that have been removed.
＊
Pad Pin
Front Brake Calipe
r
Brake Pads
Front Brake Calipe
r

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-12
AGILITY 125
BRAKE MASTER CYLINDER
Removal
First drain the brake fluid from the hydraulic
brake system.
Disassembly
Remove the piston rubber cover and snap
ring from the brake master cylinder.
Remove the washer, main piston and spring
from the brake master cylinder.
Clean the inside of the master cylinder and
brake reservoir with brake fluid.
•When servicing the brake system, use
shop towels to cover rubber and
plastic parts and coated surfaces to
avoid being contaminated by brake
fluid.
•When removing the brake fluid pipe
bolt, be sure to plug the pipe to avoid
bkflidlk
＊
Bolts Brake Master Cylinde
r
Snap Ring
Main Piston Spring Master Cylinde
r
Snap Ring

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-13
AGILITY 125
Inspection
Measure the brake master cylinder I.D.
Service Limit: 12.75mm
Inspect the master cylinder for scratch or
crack.
Measure the brake master cylinder piston
O.D.
Service Limit: 12.6mm
Before assembly, inspect the lst and 2nd
rubber cups for wear.
Assembly
Before assembly, apply brake fluid to all
removed parts.
Install the spring together with the 1st rubber
cup.
Install the main piston, spring and snap ring.
Install the rubber cover.
Install the brake lever.
•During assembly, the main piston and
spring must be installed as a unit
without exchange.
•When assembling the piston, soak the
cups in brake fluid for a while.
•Install the cups with the cup lips
facing the correct direction.
＊

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-14
AGILITY 125
Disassembly
Remove the brake caliper seat from the brake
caliper.
Remove the piston from the brake caliper.
If necessary, use compressed air to squeeze
out the piston through the brake fluid inlet
opening and place a shop towel under the
caliper to avoid contamination caused by the
removed piston.
Check the piston cylinder for scratch or wear
and replace if necessary.
Push the piston oil seal outward to remove it.
Clean the oil seal groove with brake fluid.
Be careful not to damage the piston
surface.
＊
Brake Caliper Sea
t
Compressed Ai
r
Piston Oil Seal

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-15
AGILITY 125
Place the brake master cylinder on the
handlebar and install the holder with “up”
mark facing up. Be sure to align the punch
mark with the holder joint.
First tighten the upper bolt and then tighten
the lower bolt.
Torque: 3.0～4.0kgf-m
Install the brake fluid pipe with the attaching
bolt and two sealing washers.
Install the handlebar covers. (Ö12-3)
Fill the brake reservoir with recommended
brake fluid to the upper limit and bleed air
according to the method stated in 12-10.
BRAKE CALIPER (FRONT)
Removal
Remove the brake caliper.
Place a clean container under the brake
caliper and disconnect the brake fluid pipe
from the caliper.
Do not spill brake fluid on any coated
surfaces.
＊
Punch Mark
Bolts
“Up” Mark
Bol
t
Bleed Valve
Bleed Valve
Brake Calipe
r

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-16
AGILITY 125
Check the piston for scratch or wear.
Measure the piston O.D. with a micrometer.
Service Limit: 26.3mm
Check the caliper cylinder for scratch or wear
and measure the cylinder bore.
Service Limit: 26.45mm
Assembly
Clean all removed parts.
Apply silicon grease to the piston and oil seal.
Lubricate the brake caliper cylinder inside
wall with brake fluid.
Install the brake caliper piston with grooved
side facing out.
Wipe off excessive brake fluid with a clean
shop towel. Apply silicon grease to the
brake caliper seat pin and caliper inside.
Install the brake caliper seat.
Install the piston with its outer end 3～
5mm protruding beyond the brake
caliper.
＊

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-17
AGILITY 125
Installation
Install the brake caliper and tighten the two
bolts.
Torque: 2.9～3.5kg-m
Connect the brake fluid pipe to the brake
caliper and tighten the fluid pipe bolt.
Torque: 2.5～3.5kg-m
Fill the brake reservoir with recommended
brake fluid and bleed air from the brake syst
em. (Ö12-10)
Bolts
Bol
t

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-18
AGILITY 125
FRONT SHOCK ABSORBER
REMOVAL
Remove the front wheel. (Ö12-4)
Remove the front lower cover. (Ö2-2)
Remove the front inner fender.
Remove the front shock absorber upper
mount bolts.
Loosen the lower mount bolts to remove the
front shock absorbers.
DISASSEMBLY
Remove the dust boot.
Remove the circlip.
Set the front shock absorber in a vise.
Remove the damper rod, hex bolt and copper
washer.
Pull out the front shock absorber tube.
Set the front shock absorber tube in a vise.
Remove the top nut, shock spring, damper,
and damper spring from the front shock
absorber tube.
Shock Absorber Tube
Washer/Bol
t
Circli
p
Shock Absorbe
r
Dust Boo
t
•When holding the shock absorber tube,
place a shop towel to protect it and do
apply too much force .
＊
Upper Mount Bolts
Front Shock Absorbe
r
Lower Mount Bolts

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-19
AGILITY 125
Measure the front shock absorber spring free
length.
Service Limits: Right: 206.4mm
Left : 206.4mm
ASSEMBLY
Front Shock
Absorber
Shock
Absorber
Tube
Top Nu
t
Dampe
r
Shock Absorber
Spring
Damper
Spring
Dust Seal
Circlip
Oil Seal

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-20
AGILITY 125
Install the damper spring onto the damper rod
and then install them into the front shock
absorber tube.
Install the shock absorber spring onto the
front shock absorber tube and tighten the top
nut.
Set the front shock absorber in a vise.
Insert the shock absorber tube into the shock
absorber and tighten the hex bolt.
(Apply locking agent to the washer and
install it together with the hex bolt.)
Torque: 3.0kgf-m
Add engine oil into the front shock absorber.
Specified Oil: SS#8
Oil Capacity: 38±1cc
Install the circlip.
Install the dust boot.
INSTALLATION
Install the front shock absorbers onto the
steering stem.
Install and tighten the front shock absorber
upper mount bolts.
Tighten the lower mount bolts.
Install the front wheel. (Ö12-7)
Circli
p
Dust Boo
t
Install the front shock absorber spring
with the closely wound coils facing down.
＊
Align the upper mount bolt hole with the
groove on the front fork.
＊
Front Shock Absorbe
r
Shock Absorber Tube
U
pp
er Mount Bolts
Lower Mount Bolts

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-21
AGILITY 125
FRONT FORK
REMOVAL
Remove the steering handlebar. (Ö12-3)
Remove the front wheel. (Ö12-4)
Disconnect the speedometer cable.
Remove the steering stem lock nut using long
socket wrench.
Long Socket Wrench,32mm 8Angle
Remove the top cone race and remove the
steering stem.
Inspect the ball races and cone races for wear
or damage and replace if necessary.
.
BOTTOM CONE RACE REPLACEMENT
Remove the bottom cone race using a chisel.
Drive a new bottom cone race into place with
a proper driver.
BALL RACE REPLACEMENT
Drive out the top and bottom ball races.
To
p
Cone Race
Long Socket Wrench
•Be careful not to lose the steel balls (26
on top race and 29 on bottom race).
＊
Be careful not to damage the steering
stem and front fork.
＊
Bottom Cone Race
Ball Race Remove
r
Lock Nut Wrench
Special

12. FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12-22
AGILITY 125
Drive new top and bottom ball races into the
steering head using the outer driver.
INSTALLATION
Apply grease to the top and bottom ball races
and install 26 steel balls on the top ball race
and 29 steel balls on the bottom ball race.
Apply grease to the ball races and install the
front fork.
Apply grease to the top cone race and install
it.
Tighten the top cone race and then turn the
steering stem right and left several times to
make steel balls contact each other closely.
Install the steering stem lock nut and tighten
it while holding the top cone race.
Torque: 6.0～8.0kgf-m
Install the front wheel. (Ö12-7)
Install the steering handlebar. (Ö12-3)
Install the speedometer cable. (Ö12-7)
Long Socket Wrench,32mm 8Angle
To
p
Cone Race
Outer Driver, 37x40m
m
Check that the steering stem rotates
freely without vertical play.
＊
Lock Nut Wrench
Driver Handle A
Be sure to completely drive in the ball
races.
＊
Steel Balls
Long Socket Wrench
Special

13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION
13-0
AGILITY 125
13
13
3.5kg-m
11.0kg-m
1.0kg-m
1.2kg-m

13. REAR WHEEL/REAR BRAKE/
REAR SUSPENSION
13-1
AGILITY 50
SERVICE INFORMATION
GENERAL INSTRUCTIONS
•During servicing, keep oil or grease off the brake drum and brake linings.
SPECIFICATIONS
Ite
m
Standard
(
mm
)
Service Limit
(
mm
)
Radial
⎯
2.0
Rear wheel Axial
⎯
2.0
Rear brake drum I.D 110 111
Rear brake linin
g
thickness 4.0 2.0
Rear shock absorber s
p
rin
g
free len
g
th 227 220
TORQUE VALUES
Rear axle nut 11~13kgf-m
Rear shock absorber upper mount bolt 3.5~4.5kgf-m
Rear shock absorber lower mount bolt 2.4~3.0kgf-m
Exhaust muffler joint lock nut 1.0~1.4kgf-m
Exhaust muffler lock bolt 3.0~3.6kgf-m
Special Tool
Cushion Assemble & Disassemble Tool
TROUBLESHOOTING
Rear wheel wobbling Poor brake performance
•Bent rim •Brake not adjusted properly
•Faulty tire •Worn brake linings
•Axle not tightened properly •Worn brake shoes at cam contacting area
Soft rear shock absorber •Worn brake cam
•Weak shock absorber spring •Worn brake drum
•Faulty damper
SERVICE INFORMATION...................... 13-1 REAR BRAKE.........................................13-3
TROUBLESHOOTING............................. 13-1 REAR SHOCK ABSORBER...................13-4
REAR WHEEL.......................................... 13-2
Rim runout