Kymco Agility 50 - Service manual > Crankcase/Crankshaft

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.
• The following parts must be removed before separating the crankcase.
• Cylinder head
• Cylinder/piston
• Drive and driven pulleys
• A.C. generator
• Carburetor/air cleaner
• Rear wheel/rear shock absorber
• Starter motor
• Oil pump

SPECIFICATIONS

TORQUE VALUES

Crankcase bolt 0.8~1.2kgf-m
Cam chain tensioner slipper bolt 0.8~1.2kgf-m

TROUBLESHOOTING

Excessive engine noise

• Excessive bearing play
• Excessive crankpin bearing play

CRANKCASE SEPARATION

Remove the cam chain tensioner slipper bolt and cam chain tensioner slipper.

Remove the crankcase attaching bolt.

Separate the left and right crankcase halves.

• Do not damage the crankcase gasket surface.
• Never use a driver to pry the crankcase mating surfaces apart.

Remove the gasket and dowel pins.

Remove the crankshaft from the left crankcase.

Remove the cam chain.

Clean off all gasket material from the crankcase mating surfaces.

Avoid damaging the crankcase mating surfaces.

Remove the oil seal from the left crankcase.

Remove the oil seal from the left crankcase.

CRANKSHAFT

Measure the connecting rod big end side clearance.

Service Limit: 0.55mm replace if over

Measure the connecting rod big end radial clearance at two points at right angels to the shaft.

Service Limit: 0.05mm replace if over

Measure the crankshaft runout.

Service Limit: 0.10mm replace if over

Turn the crankshaft bearings and check for excessive play.

If they do not turn smoothly, quietly or if they fit loosely in the crankshaft, replace the crankshaft as a set.

CRANKCASE ASSEMBLY

Install new oil seals into the right and left crankcase.

Install the cam chain into the left crankcase.

Install the crankshaft into the left crankcase.

When installing the cam chain, be careful not to damage the oil seal.

Install the dowel pins and a new gasket onto the left crankcase.

Place the right crankcase over the crankshaft and onto the left crankcase.

Tighten the crankcase attaching bolt.

Torque: 0.8~1.2kgf-m

Install the cam chain tensioner slipper.

Install a new O-ring onto the cam chain tensioner slipper bolt.

Apply engine oil to the O-ring and tighten the bolt.

Torque: 0.8~1.2kgf-m

Be sure to install the O-ring into the groove.

See also: