Kymco Agility 50 - Service manual > Rear Wheel /Rear Brake /Rear Suspension

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• During servicing, keep oil or grease off the brake drum and brake linings.

SPECIFICATIONS

TORQUE VALUES

Rear axle nut 11~13kgf-m
Rear shock absorber upper mount bolt 3.5~4.5kgf-m
Rear shock absorber lower mount bolt 2.4~3.0kgf-m
Exhaust muffler joint lock nut 1.0~1.4kgf-m
Exhaust muffler lock bolt 3.0~3.6kgf-m

Special Tool

Cushion Assemble & Disassemble Tool

TROUBLESHOOTING

Rear wheel wobbling

• Bent rim
• Faulty tire
• Axle not tightened properly

Soft rear shock absorber

• Weak shock absorber spring
• Faulty damper

Poor brake performance

• Brake not adjusted properly
• Worn brake linings
• Worn brake shoes at cam contacting area
• Worn brake cam
• Worn brake drum

REAR WHEEL

REMOVAL

Remove the exhaust muffler.

Remove the rear axle nut to remove the rear wheel.

INSPECTION

Measure the rear wheel rim runout.

Service Limits:

Radial:2.0mm replace if over
Axial: 2.0mm replace if over

Inspect the rear brake drum.

Measure the rear brake drum I.D.

Service Limits: 111mm replace if over

INSTALLATION

Install the rear wheel in the reverse order of removal.

Tighten the rear axle nut.

Torque: 11.0-13.0kg-m

Install the exhaust muffler.

Torque:

Exhaust muffler joint lock nut: 1.0~1.4kgf-m
Exhaust muffler lock bolt: 3.0~3.6kgf-m

First install and tighten the exhaust muffler joint lock nuts and then the exhaust muffler lock bolts.

REAR BRAKE

BRAKE LINING INSPECTION

Measure the brake lining thickness.

Service Limit: 2.0mm replace if below

Keep oil or grease off the brake linings.

REAR BRAKE DISASSEMBLY

Remove the rear brake adjusting nut and disconnect the rear brake cable.

Remove the rear brake shoes.

Remove the brake arm bolt to remove the brake arm, wear indicator plate and felt seal.

Remove the brake cam.

REAR BRAKE ASSEMBLY

Apply grease to the anchor pin.

Apply grease to the brake cam and install it.

Install the brake shoes.

Apply a small amount of engine oil to the felt seal and install it to the brake cam.

Install the wear indicator plate and brake arm.

Align the wide groove on the wear indicator plate with the wide tooth of the brake cam.

Install and tighten the brake arm bolt.

Align the scribed line on the brake arm with the punch mark on the brake cam.

Install the brake arm return spring.

Install the brake arm pin.

Connect the brake cable and install the adjusting nut.

Install the rear wheel.

Adjust the rear brake lever free play.

REAR SHOCK ABSORBER

REMOVAL

Remove the frame body cover.

Remove the air cleaner case. Remove the rear shock absorber upper and lower mount bolts.

Remove the rear shock absorber.

DISASSEMBLY

Install the rear shock absorber compressor as the figure shown.

Install the rear shock absorber lower joint into the rear shock absorber compressor.

Compress the rear shock absorber spring.

Cushion Assemble & Disassemble Tool

Loosen the lower joint lock nut.

Remove the lower joint.

Remove the lock nut, rubber and damper.

INSPECTION

Inspect the damper rod for bending or damage.

Inspect the damper for oil leaks.

Inspect the damper rubber for deterioration or damage.

Measure the rear shock absorber spring free length.

Service Limit: 198mm replace if over

ASSEMBLY

Assemble the rear shock absorbers in the reverse order of disassembly.

• Install the shock absorber spring with loosely wound coils facing down.
• Apply locking agent to the lock nut threads and tighten the lock nut.

INSTALLATION

Install the rear shock absorber.

Install the rear shock absorber upper mount bolt and then the lower mount bolt.

Tighten the bolts.

Torque:

Upper Mount Bolt: 3.5~4.5kgf-m
Lower Mount Bolt: 2.4~3.0kgf-m

Install the air cleaner case.

Install the frame body cover.

See also: