Kymco Agility 50 - Service manual > Starter pinion

REMOVAL

Remove the left crankcase cover.

Remove the drive pulley.

Remove the starter pinion holder.

Remove the starter pinion.

INSPECTION

Inspect the starter pinion shaft forcing part for wear or damage.

Inspect the starter pinion for smooth operation.

Inspect the starter pinion and shaft for wear or damage.

INSTALLATION

Apply a small amount of grease to the starter pinion shaft and install it in the reverse order of removal.

CLUTCH/DRIVEN PULLEY

REMOVAL

Remove the drive pulley.

Hold the clutch outer with the universal holder and remove the clutch outer nut.

Remove the clutch outer.

Universal Holder

Remove the clutch/driven pulley assembly Remove the drive belt from the clutch/driven pulley assembly.

DISASSEMBLY

Hold the clutch/driven pulley assembly with the clutch spring compressor.

Set the clutch spring compressor in a vise and remove the 39mm clutch drive plate nut.

Loosen the clutch spring compressor and disassemble the driven pulley assembly.

Clutch Spring Compressor

Remove the seal collar.

Pull out the guide roller pins and guide rollers.

Remove the movable driven face from the driven face.

Remove the O-rings and oil seal from the movable driven face.

INSPECTION

Inspect the clutch outer for wear or damage.

Measure the clutch outer I.D.

Service Limit: 107.5mm replace if over

Check the clutch shoes for wear or damage.

Measure the clutch lining thickness.

Service Limit: 2.0mm replace if below

Measure the driven face spring free length.

Service Limit: 92.8mm replace if below

Check the driven face for wear or damage.

Measure the driven face O.D.

Service Limit: 33.94mm replace if below

Check the movable driven face for wear or damage.

Measure the movable driven face I.D.

Service Limit: 34.06mm replace if over

DRIVEN PULLEY FACE BEARING REPLACEMENT

Drive the inner needle bearing out of the driven pulley face.

Discard the removed bearing and replace with a new one.

Remove the snap ring and drive the outer bearing out of the driven face.

Apply grease to the outer bearing.

Drive a new outer bearing into the driven face with the sealed end facing up.

Seat the snap ring in its groove.

Pack all bearing cavities with 5.0~5.6g grease.

Specified grease: Heat resistance 230ºC

Press a new needle bearing into the driven face.

ASSEMBLY

Install the movable driven face onto the driven face.

Install the O-rings, guide rollers and guide roller pins.

Install the a new oil seal.

Install the seal collar.

Set the driven pulley assembly, driven face spring and clutch assembly onto the clutch spring compressor.

Compress the clutch spring compressor and install the 39mm drive plate nut.

Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque.

Torque: 5.0~6.0kgf-m

Clutch Spring Compressor

INSTALLATION

Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft.

Install the clutch outer.

Hold the clutch outer with the universal holder.

Install and tighten the 10mm clutch outer nut.

Torque: 3.5~4.5kgf-m

Install the left crankcase cover.

See also: