KYMCO Agility Carry 50i Manual de usuario

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

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS

FINAL REDUCTION

CRANKCASE/CRANKSHAFT

CHASSIS

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

ELECTRICAL

EQUIPMENT

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/INSTRUMENTS/SWITCHES

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

ENGINE SERIAL NUMBER

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

Net weight (kg)

Rear wheel

Total

105

Front wheel

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

timing

Exhaust

Open

-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

timing

Exhaust

Open

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

105

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

-8

0.04

2000±100rpm

Forced pressure &

wet sump

Full-flow filtration

0.8 liter

Forced air cooling

1.1/4750

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

Net weight (kg)

Rear wheel

Total

100

Front wheel

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

timing

Exhaust

Open

-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

Net weight (kg)

Rear wheel

Total

100

Front wheel

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

timing

Exhaust

Open

-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!

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