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