KYMCO Agility Carry 50i User manual

Agility Carry / Delivery 50i
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Agility
Carry / Delivery 50i SCOOTER.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 to 17 give instructions for
disassembly, assembly and inspection of
engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAME COVERS/EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
CHASSIS
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
ELECTRICAL EQUIPMENT
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM
15
STARTING SYSTEM
16
LIGHTS/INSTRUMENTS/SWITCHES
17
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.

1. GENERAL INFORMATION
1-1
Agility Carry / Delivery 50i
Location of Engine Serial Number
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER ...................1- 1 LUBRICATION POINTS........................1-13
SPECIFICATIONS....................................1- 2 CABLE &HARNESS ROUTING.............1-15
SERVICE PRECAUTIONS......................1- 3 WIRINGDIAGRAM................................1-20
TORQUE VALUES ..................................1-11 TROUBLESHOOTUNG...........................1-21
SPECIAL TOOLS .....................................1-12
Delivery 50i
Agility Carry 50i

1. GENERAL INFORMATION
1-2
Agility Carry / Delivery 50i
SCOOTER
SPECIFICATIONS
Motorcycle Name & Type
Agility Carry 50i
Name & Model No.
AAF1
Overall length (mm)
1950
Overall width (mm)
685
Overall height (mm)
1145
Wheel base (mm)
1315
Engine type
O.H.C.
Displacement
50cc
Fuel Used
92# nonleaded gasoline
Front wheel
45
Net weight (kg)
Rear wheel
60
Total
105
Front wheel
96
Gross weight(kg)
Rear wheel
124
Total
220
Tires
Front wheel
120/70-12
Rear wheel
130/70-12
Ground clearance (mm)
112
Perform-
Braking distance (m)
4 (Initial speed
20km/h)
ance
Min. turning radius
(mm)
1955/1885
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
39.0 x 41.4
Compression ratio
10.5±0.2
Compression pressure
(kg/cm²-rpm)
15±2
Max. output
2.4/8000 kw/(r/min)
Engine
Max. torque
3.0/7000N. m/rpm
Intake
Open
-4
Port
Close
12
timing
Exhaust
Open
20
Close
-8
Valve clearance
Intake
0.04
(cold) (mm)
Exhaust
0.04
Idle speed (rpm)
2000±100rpm
Lubrication System
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor type
Oil filter type
Full-flow filtration
Oil capacity
0.8 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
5 liter
Type
ECU
Ignition timing
20---29
Contact breaker
Ignition coil
Spark plug
NGK CR6HSA
Spark plug gap
0.6～0.7mm.
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
CVT
Operation
Automatic centrifugal
type
Type
Two-stage reduction
Reduction
1st
0.75-2.47
ratio
2nd
13.61
Front
Caster angle
-----
Axle
Trail length

Tire pressure
Front
1.75/1.75
(kg/cm²)
Rear
2.0/2.25
Turning
Left
45
angle
Right
45
Brake system
type
Front
Disk
Rear
Drum
Suspension type
Front
TELESCOPE
Rear
Unit Swing
Shock absorber
distance
Front
--
Rear
--
Frame type
Under Bone
Fuel System
Electrical Equipment
Ignition System
Power Drive System
Transmis- sion Gear
Reduction Gear
Moving Device
Damping Device
Agility carry 50 45km/h

1. GENERAL INFORMATION
1-2
Agility Carry / Delivery 50i
SCOOTER
SPECIFICATIONS
Motorcycle Name & Type
Agility Carry 50i
Name & Model No.
AAF1
Overall length (mm)
1950
Overall width (mm)
685
Overall height (mm)
1145
Wheel base (mm)
1315
Engine type
O.H.C.
Displacement
50cc
Fuel Used
92# nonleaded gasoline
Front wheel
Net weight (kg)
Rear wheel
Total
Front wheel
Gross weight(kg)
Rear wheel
Total
Tires
Front wheel
Rear wheel
Ground clearance (mm)
Perform-
Braking distance (m)
ance
Min. turning radius
(mm)
Starting system
Type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Bore x stroke (mm)
Compression ratio
Compression pressure
(kg/cm²-rpm)
Max. output
Engine
Max. torque
Intake
Open
Port
Close
timing
Exhaust
Open
Close
Valve clearance
Intake
(cold) (mm)
Exhaust
Idle speed (rpm)
Lubrication System
Lubrication type
Oil pump type
Oil filter type
Oil capacity
Cooling Type
Air cleaner type & No
Paper element, wet
Fuel capacity
5 liter
Type
ECU
Ignition timing
20---29
Contact breaker
Ignition coil
Spark plug
NGK CR6HSA
Spark plug gap
0.6～0.7mm.
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
CVT
Operation
Automatic centrifugal
type
Type
Two-stage reduction
Reduction
1st
1.25-2.47
ratio
2nd
18.72
Front
Caster angle
-----
Axle
Trail length

Tire pressure
Front
1.75/2.0
(kg/cm²)
Rear
2.0/2.25
Turning
Left
45
angle
Right
45
Brake system
type
Front
Disk
Rear
Drum
Suspension type
Front
TELESCOPE
Rear
Unit Swing
Shock absorber
distance
Front
--
Rear
--
Frame type
Under Bone
Fuel System
Electrical Equipment
Ignition System
Power Drive System
Transmis- sion Gear
Reduction Gear
Moving Device
Damping Device
Agility carry 50 25km/h
45
60
105
96
124
220
120/70-12
130/70-12
112
4 (Initial speed
20km/h)
1955/1885
Starting motor
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C.
39.0 x 41.4
10.5±0.2
15±2
kw/(r/min)
2.3/70004500N. m/rpm
-4
12
20
-8
0.04
0.04
2000±100rpm
Forced pressure &
wet sump
Full-flow filtration
0.8 liter
Forced air cooling
1.1/4750
1
-

1. GENERAL INFORMATION
1-3
Agility Carry / Delivery 50i
SPECIFICATIONS
Motorcycle Name & Type
Delivery 50i
Name & Model No.
ALC9
Overall length (mm)
1950
Overall width (mm)
685
Overall height (mm)
1130
Wheel base (mm)
1315
Engine type
O.H.C.
Displacement
50cc
Fuel Used
92# nonleaded gasoline
Front wheel
39
Net weight (kg)
Rear wheel
61
Total
100
Front wheel
70
Gross weight(kg)
Rear wheel
125
Total
195
Tires
Front wheel
120/70-12
Rear wheel
130/70-12
Ground clearance (mm)
115
Perform-
Braking distance (m)
4 (Initial speed
20km/h)
ance
Min. turning radius
(mm)
2100/1810
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
39.0 x 41.4
Compression ratio
10.5±0.2
Compression pressure
(kg/cm²-rpm)
15±2
Max. output
2.37/8000kw/(r/min)
Engine
Max. torque
3.0/7000N. m/rpm
Intake
Open
-4
Port
Close
12
timing
Exhaust
Open
20
Close
-8
Valve clearance
Intake
0.04
(cold) (mm)
Exhaust
0.04
Idle speed (rpm)
2000±100rpm
Lubrication System
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor type
Oil filter type
Full-flow filtration
Oil capacity
0.8 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
5 liter
Type
ECU
Ignition timing
20---29
Contact breaker
Ignition coil
Spark plug
NGK CR6HSA
Spark plug gap
0.6～0.7mm.
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
CVT
Operation
Automatic centrifugal
type
Type
Two-stage reduction
Reduction
1st
0.75-2.47
ratio
2nd
13.61
Front
Caster angle
-----
Axle
Trail length

Tire pressure
Front
1.75/2.0
(kg/cm²)
Rear
2.0/2.25
Turning
Left
45
angle
Right
45
Brake system
type
Front
Disk
Rear
Drum
Suspension type
Front
TELESCOPE
Rear
Unit Swing
Shock absorber
distance
Front
--
Rear
--
Frame type
Under Bone
Fuel System
Electrical Equipment
Ignition System
Power Drive System
Transmis- sion Gear
Reduction Gear
Moving Device
Damping Device
Agility Delivery 50i 45km/h

1. GENERAL INFORMATION
1-3
Agility Carry / Delivery 50i
SPECIFICATIONS
Motorcycle Name & Type
Delivery 50i
Name & Model No.
ALC9
Overall length (mm)
1950
Overall width (mm)
685
Overall height (mm)
1130
Wheel base (mm)
1315
Engine type
O.H.C.
Displacement
50cc
Fuel Used
92# nonleaded gasoline
Front wheel
39
Net weight (kg)
Rear wheel
61
Total
100
Front wheel
70
Gross weight(kg)
Rear wheel
125
Total
195
Tires
Front wheel
120/70-12
Rear wheel
130/70-12
Ground clearance (mm)
115
Perform-
Braking distance (m)
4 (Initial speed
20km/h)
ance
Min. turning radius
(mm)
2100/1810
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
39.0 x 41.4
Compression ratio
10.5±0.2
Compression pressure
(kg/cm²-rpm)
15±2
Max. output
1.12/4750kw/(r/min)
Engine
Max. torque
2.3/4500N. m/rpm
Intake
Open
-4
Port
Close
12
timing
Exhaust
Open
20
Close
-8
Valve clearance
Intake
0.04
(cold) (mm)
Exhaust
0.04
Idle speed (rpm)
2000±100rpm
Lubrication System
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor type
Oil filter type
Full-flow filtration
Oil capacity
0.8 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
5 liter
Type
ECU
Ignition timing
20---29
Contact breaker
Ignition coil
Spark plug
NGK CR6HSA
Spark plug gap
0.6～0.7mm.
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
CVT
Operation
Automatic centrifugal
type
Type
Two-stage reduction
Reduction
1st
1.25-2.47
ratio
2nd
18.72
Front
Caster angle
-----
Axle
Trail length

Tire pressure
Front
1.75/1.75
(kg/cm²)
Rear
2.0/2.25
Turning
Left
45
angle
Right
45
Brake system
type
Front
Disk
Rear
Drum
Suspension type
Front
TELESCOPE
Rear
Unit Swing
Shock absorber
distance
Front
--
Rear
--
Frame type
Under Bone
Fuel System
Electrical Equipment
Ignition System
Power Drive System
Transmis- sion Gear
Reduction Gear
Moving Device
Damping Device
Agility Delivery 50i 25km/h

1. GENERAL INFORMATION
1-4
Agility Carry / Delivery 50i
SCOOTER
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.
Use genuine parts and lubricants
.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-5
Agility Carry / Delivery 50i
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.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-6
Agility Carry / Delivery 50i
SCOOTER
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
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.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confirm
Capacity

1. GENERAL INFORMATION
1-7
Agility Carry / Delivery 50i
The connector shall be inserted
completely.
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 or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!

1. GENERAL INFORMATION
1-8
Agility Carry / Delivery 50i
SCOOTER
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.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !

1. GENERAL INFORMATION
1-9
Agility Carry / Delivery 50i
Route harnesses so they are neither
pulled tight nor have excessive slack.
.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-10
Agility Carry / Delivery 50i
SCOOTER
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.
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !

1. GENERAL INFORMATION
1-11
Agility Carry / Delivery 50i
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
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
(12-3) :Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
＊

1. GENERAL INFORMATION
1-12
Agility Carry / Delivery 50i
SCOOTER
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45-0.6
0.6-1.2
1.8-2.5
3.0-4.0
5.0-6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35-0.5
0.7-1.1
1.0-1.4
2.4-3.0
3.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty Thread dia.(mm)
Torque (kg-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
6
6
30
6
7
3
8
8
10
28
6
4
10
10
6
6
0.7-1.1
0.7-1.1
1.0-2.0
0.7-1.1
1.2-1.6
0.07-0.09
0.4-0.7
1.1-1.5
3.5-4.5
5.0-6.0
0.8-1.2
0.1-0.3
5.5-6.5
1.0-1.4
0.8-1.2
0.8-1.2
Double end bolt
Double end bolt
Apply oil to
threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shockabsorberlowerbolt
Speedometer cable set screw
Rear shock absorber lock nut
1
1
1
1
1
1
1
25.4
10
14
10
8
5
8
8.0-12.0
5.0-7.0
11.0-13.0
4.0-5.0
2.0-3.0
0.45-0.6
3.0-3.6
U-nut
U-nut
U-nut
Applylockingagent

1. GENERAL INFORMATION
1-13
Agility Carry / Delivery 50i
SPECIAL TOOLS
Description
Tool No.
Photo
Flywheel puller
A120E00002
Oil seal and bearing installer
A120E00014
Universal holder
A120E00017
Flywheel holder
A120E00021
Clutch spring compressor
A120E00034
Valve adjuster
A120E00036
Bearing puller
A120E00037
Cylinder Compression Gauage
A120E00039

1. GENERAL INFORMATION
1-14
Agility Carry / Delivery 50i
SCOOTER
Description
Tool No.
Photo
Valve spring compressor
A120E00040
Fuel Pressure Gauage
A120E00048
INJECTOR CLEANER for
Synerjet
A120E00075
Wires Injector Connector
A120E00090
Lock nut wrench
A120F00002
Lower/Upper Race Remover &
Installer
A120F00008
Steering Stem Top Thread
Wrench (shoter type)
A120F00024
Steering Stem Top Thread
Wrench
A120F00029
Band Remover/Installer
A120F00030

1. GENERAL INFORMATION
1-15
Agility Carry / Delivery 50i
Description
Tool No.
Photo
Pliers Fuel Pipe
A120F00031
Electric Repair Kit
A120F00032

1. GENERAL INFORMATION
1-16
Agility Carry / Delivery 50i
SCOOTER
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE15W-40)
APISG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube
Adhesive

1. GENERAL INFORMATION
1-17
Agility Carry / Delivery 50i
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.
Rear Wheel Bearings
Main Stand Pivot
Grease
Grease
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease
Grease
Front Brake Lever
Pivot
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Engine/ Oil