Kymco Agility 50 - Service manual > Engine Removal/Installation
SERVICE INFORMATION
GENERAL INSTRUCTIONS
- A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal.
- Use shop towels to protect the motorcycle body during engine removal.
- Parts requiring engine removal for servicing:
- Crankcase
- Crankshaft
ENGINE REMOVAL
Disconnect the battery negative cable.
Remove the frame body cover.
Disconnect the spark plug high tension wire.
Disconnect the auto bystarter wire connector.
Disconnect the A.C. generator wire connector.
Disconnect the starter motor cable and earth cable from the starter motor.
Remove the fuel tube.
Remove the spark plug cap.
Disconnect the vacuum tube.
Loosen the throttle cable adjusting nut and lock nut, and disconnect the throttle cable from the carburetor.
Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube.
Remove the rear brake adjusting nut, connector pin rear brake cable.
Remove the rear shock absorber upper mount bolt.
Remove the engine mounting bolt and move the motorcycle forward to separate it from the engine.
Support the motorcycle with a floor jack.
ENGINE HANGER BRACKET REMOVAL
Remove the return spring from the main stand.
Remove the main stand.
Remove the engine hanger bracket bolts and engine hanger bracket.
Inspect the engine hanger bushings and stopper spring for wear or damage.
ENGINE HANGER BRACKET INSTALLATION
Install the engine hanger bracket to the chassis and tighten the bolt.
Install the main stand onto the engine and install the return spring.
ENGINE INSTALLATION
Install the engine and tighten the engine mounting bolt.
Torque: 4.5~5.5kgf-m
Tighten the rear shock absorber upper mount bolt.
Torque: 4.5~5.5kgf-m
Install the removed parts in the reverse order of removal.
Route the wires and cables properly.
After installation, inspect and adjust the following:
- Throttle grip free play
- Rear brake adjustment
See also:
Kymco Agility 50 - Service manual > Fuel tank
FUEL TANK REMOVE Remove the net-in box. Remove the frame center cover. Remove the frame body cover. Remove the four bolts on the fuel tank, take the upper seat lock off.
Kymco Agility 50 - Service manual > Cylinder Head/Valves
SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame. When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surfaces for initial lubrication. The camshaft is lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head. After disassembly, clean the removed parts and dry them with compressed air before inspection. After removal, mark and arrange the removed parts in order. When assembling, install them in the reverse order of removal.
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