Kymco Agility 50 - Service manual > 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.

• 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.

• 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.

• 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.

• 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.

• 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.

• 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.

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.

See also: