1. GENERAL INFORMATION
Contents
1. Fuel reaches Fuel does not carburetor reach carburetor Remove spark plug and install it into spark plug i cap to test spark by connecting it to engine ground Spark jumps Weak or no spark Broken or shorted ignition coil Broken or shorted high tension wire Faulty ignition switch Test cylinder j compression aulty starter clutch Valve clearance too small proper valve and seat contact compression compression rings eaking cylinder head gasket Seized valve Improper valve timing i Start engine by follow ting normal starting procedure Engine does not Engine fires but fire does not start Incorrect ignition timing Incorrectly adjusted pilot screw Remove spark plug and inspect again Dry spark plug Wet spark plug Faulty auto bystarter Throttle valve excessively open 1 21 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 ENGINE LACKS POWER Inspection Adjustment tart engine and accelerat Tightly for observation Engine speed increases Correct timing Check valve clearance peeeeeeeeeeeeee gt Probable Cause Clogged air cleaner Poor quality fuel Restricted Clogged fuel tank cap breather hole Clogged exhaust muffler Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Engine speed does not increase sufficiently Incorrect timing Check ignition timi2. Check carburetor gasket i for air leaks Deteriorated O ring arburetor not securely tightened Damaged insulator rubber Broken vacuum tube Remove spark plug and install it into spark plug i cap to test spark by connecting it to engine ground Faulty or fouled spark plug Faulty CDI unit aulty A C generator aulty ignition coil Broken or shorted spark plug wire aulty ignition switch Weak or inter mittent spark Good spark Check air cut off valve aulty air cut off valve Damaged vacuum tube logged or damaged air vent hole 1 23 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing Probable Cause aulty CDI unit aulty pulser coil Correct timing Incorrect timing Check valve clearance Improperly adjusted valve clearance Worn camshaft Worn valve seat Check fuel pump for fuel supply Empty fuel tank logged fuel tube or filter Faulty charcoal canister Faulty auto fuel valve Check carburetor jets for clogging Not clogged Clogged Clean and unclog Check valve timing not aligne Check valve spring tension P Weak spring Faulty spring 1 24 1 GENERAL INFORMATION C KYMCO AGILITY RS 50 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Start engine and test
3. AGILITY RS 50 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 E If the fuse is burned out find the cause and JC repair it Replace it with a new one Confirm according to the specified capacity ad Capacity es E After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before l operation DD E Hold the connector body when connecting f r or disconnecting it Be bu E Do not pull the connector wire B Check if any connector terminal is bending protruding or loose 1 5 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 B The connector shall be inserted completely p X aa Snapping E If the double connector has a lock lock it at the correct position B Check if there is any loose wire E Before connecting a terminal check for damaged terminal cover or loose negative terminal B Check the double connector cover for proper coverage and installation B Insert the terminal completely M Check the terminal cover for proper coverage B Do not make the terminal cover opening face up BM 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 1 6 1 GENERAL INFORMATION C KYMCO AGILITY RS 50 B After clamping check each wire to make sure it is secure E D
4. 0 4 0 7 1 1 1 5 3 5 4 5 5 0 6 0 0 8 1 2 0 1 0 3 5 5 6 5 1 0 1 4 0 8 1 2 0 8 1 2 Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler lock bolt Cylinder head flange nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Starter motor mounting bolt Oil pump bolt Drive face nut Spark plug A C generator stator bolt Re Nee WN RR RK kK NBN K AN Cam chain tensioner bolt Steering stem lock nut 8 0 12 0 Front azle nut 5 0 7 0 Rear axle nut 11 0 13 0 Rear shock absorber upper bolt 4 0 5 0 Rear shock absorber lower bolt 2 0 3 0 Speedometer cable set screw 0 45 0 6 Rear shock absorber lock nut C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 SPECIAL TOOLS fara ka E O poremos ron freonen emnene e posee NN 9 9 Clutch spring compressor E027 2301adriven pully assy Min assemble amp disassemble F004 52400 cushion assy 9 9 9 3 5 31110 flywheel comp 2310a pully assy o 13 driven 1 12 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAE15W 40 Cam lobes eAPI SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big
5. CO KYMCO 1 GENERAL INFORMATION AGILITY RS 50 ENGINE SERIAL NUMBER LUBRICATION POINTS SPECIFICATIONS CABLE amp HARNESS ROUTING SERVICE PRECAUTIONS WIRING DIAGRAM TORQUE VALUES TROUBLESHOOTUNG SPECIAL TOOLS ENGINE SERIAL NUMBER Location of Engine Serial Number 1 1 1 GENERAL INFORMATION C KYMCO AGILITY RS 50 SPECIFICATIONS Engine type 97 Front wheel Se Starting motor amp tarting system kick starter Fuel Used Tires Compression ratio o o o Compression pressure kg cm rpm 2 7 8500kw r min Open 33 Port eR 3 Gming Exhaust BIS 5 Ee gsed m cold mm T Oil pump type Inner outer rotor type Oil filter type Full flow filtration S Oil capacity Cooling Type Forced air cooling 1 1 3 7 1 wWia sAg ony UloJs S Jang I9M0d waudinby eounoo q w ononpey IMAI SUMON Brake system type Jg 2 Shock absorber Air cleaner type amp No Fuel capacity 5 0 liter Piston dia mm NGK CR7HSA Spark plug CHAMPION P RZ9HC Spark plug gap 0 6 0 7mm 12V4AH Type Dry multi disc clutch Non stage transmission Operation Automatic centrifugal type Reduction 1st Taa Front Caster angle Axle Trilengh ront l0jomnque UlIo s S uonius STUISUBI Tire pressure kg cm zm oO EE eu Hd ga 3 Z c B p c B 2 oO o oO ront Drum 11
6. 0mm brake car Dr ak ront TELESCOPE Unit Swing 2 mz J x e B S 3 3 ion z B Cc Suspension type ront Zu 5 5 distance C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 SERVICE PRECAUTIONS B Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally B Use genuine parts and lubricants B When servicing the motorcycle be sure to use special tools for removal and installation E After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly 1 3 1 GENERAL INFORMATION E Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety B Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface E After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first E After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 4 C KYMCO
7. E mo m H a jis S or WH LIBRE uve 3 9 uve NS NUOH NS ONGSVd Msnvis N MS wanya MS BBN MS ano i a0 Od ju m 19 MS ONUHON Kava 3nvii s MS NOH MSNUOH TUDNI NS i ONISS d u ETSI 99v aasma ror INN l ra B 5 6 H ona aves vans ouv v yA n HH 9 cmg i Sass E l Zima o TT Bo r wed NGATI S8062 972 n 4 AHON NOLLUISOd 100 N9I lt 8 VA TIT 2 oss es 5 Hie T 38505 E ann ra d g283303 E sw UI s le Ta iS guise NZI MT TI ss 8 vya HOIH AHON avaH 980 gorf i v lt 3 2 oss og 8 sd 2 M TI MSUSE NZI vya O38 HiHILHoN OV3H e 9 I M 4 MBAZI LON NOUISOd 9 9 eS HH H eke WA MA 9 Hi A9 Jz NO 1 m 0 E 0 1 B PI i wg 9 a T Mig A ms wa wa t SEPT L 2 S e Z 1 gt L e 35 9 ee A9 8 M t e 1 B f Wi Li wi WA A wa 9 a 8 38 ee a E as Li j lt 5 ogee i a Bwa Th D a 9 3 amp ann omia T OULNOD jii LH DN VIDOAO orm r4 MS AHOM VIS M dolsui MOL AZ M3NIM Yd HY 1 20 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Empty fuel tank logged fuel line between fuel tank and carburetor logged float oil passage logged fuel tank cap breather hole Check if fuel reaches carburetor by loosening KWAA ananassae gt i drain screw
8. end Crankshaft R L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip Starter idle gear Friction spring movable part shaft movable part High temperature resistant grease Shaft movable grooved part Kick starter spindle movable part A C generator connector Adhesive Transmission case breather tube 1 13 dC KYMCO 1 GENERAL INFORMATION AGILITY RS 50 FRAME The following is the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Am Grease Front Brake Lever Pivot Engine Oil Front Brake Cable Speedometer Cable Throttle Cable Grease Brake Cam Anchor Pin E Pieds Engine Oil D Main Stand Pivot Rear Brake Cable 1 14 dC KYMCO 1 GENERAL INFORMATION AGILITY RS 50 CABLE amp HARNESS ROUTING Winker Brake Master Cylinder Rear Stop Switch Wire Front Stop Switch Wire Rear Brake Cable Throttle Cable Ignition Switch Speedometer Cable Front Brake Fluid Tube Horn Regulator Rectifier 1 15 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 Throttle Grip Regulator Rectifier Ignition Switch Speedometer Cable Headlight Resistor Rear Brake Lev
9. er Horn Front Brake Fluid Tube 1 16 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 CDI Unit Battery 4 Cable Battery Cable Starter Relay Fuel Tank Battery Cable Battery 4 Cable 1 17 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 Auto Cock Assy Fuel Fuel Filter gl rd gl gg Fuel Tube Ignition Coil Primary Wire Ignition Wire Throttle Cable Vacuum Tee Carburetor Overflow Tube pom Crankcase Breather ars Tube Aa 1 18 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 Fuel Unit Crankcase Breather Tube Throttle Cable Wire Harness Vacuum Tube Vacuum Tube Ignition Coil Crankcase Breather Tube Secondary Air Inlet Tube Reed Valve Air Injection Cut off Valve Auto Bystarter 1 19 AGILITY RS 50 dC KYMCO 1 GENERAL INFORMATION WIRING DIAGRAM MS AZ AH9r135N39n1 MOL AZL W3XNIM HT MING NZI AHon ivudo1s MOL AZE M3DINIM YY Y of m 8 ovo aa o ss wono 89 wa 4 Hows 87517 Wowo a 1 ovo 9 Jwa ovo wes MI wa 8 kunoa Let LC wo HSN OS M o Hsna T lola N 4 334 T EET ic w LI ar 1 i
10. g device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions E Be careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting B Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind the instrument the instrument set orrect y Remove Rust C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 B Symbols The following symbols represent the servicing methods and cautions included in this service manual b Apply engine oil to the specified points Use Engine Oil designated engine oil for lubrication Grease Apply grease for lubrication Transmission Gear Oil 90 Gear Oil Use special tool Caution V Warning 212 3 Refer to page 12 3 1 10 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 TORQUE VALUES STANDARD TORQUE VALUES Torque kg m Torque kg m 5mm bolt nut 45 0 5mm screw 6mm bolt nut 6 1 6mm screw SH bolt 8mm bolt nut 8 2 6mm flange bolt nut 10mm bolt nut 0 4 8mm flange bolt nut 12mm bolt nut 0 6 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Thread dia mm Torque kg m 0 7 1 1 Double end bolt 0 7 1 1 1 0 2 0 0 7 1 1 Double end bolt 1 2 1 6 Apply oil to 0 07 0 09 threads
11. limit voltage between gt battery terminals Normal voltage Voltage does not increase Measure resistance between AC generator gt coil terminals Resistance too high Connect battery 4 wire to regulator rectifier coupler red wire and gt battery wire to T ground and test voltage frhducud e WA a ATE Hamani Nona voltage Check regulator rectifier coupler for loose i connection Probable Cause Dead battery Faulty battery Faulty A C generator coil Broken yellow wire Loose connector Broken red wire Faulty regulator rectifier L Poor connected coupler Overcharging Inspection Adjustment dt battery wire tto regulator rectifier icoupler green wire and ibattery wire to engine ground and test voltag Q Battery has voltage with ignition switch ON Battery has no voles with ignition switch ON j Check regulator rectifier coupler for loose connection Faulty A C generator Probable Cause Broken green wire Poorly connected coupler Faulty regulator rectifier 1 25 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause OQ Replace with a new spark plug and inspect again Weak or no spark or no Weak or no spark Good spark Faulty old spark plug Check spark plug cap and high tension wire a for looseness Loose s
12. ng _using a timing light Faulty CDI unit Faulty pulser coil apron valve clearance orn valve seat valve stem too protruding Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Check carburetor for clogging Not clogged Clogged carburetor jets Remove spark plug and ouled spark plug Incorrect heat range plug Remove oil dipstick and check oil level and conditio Oil level too high Oil level too low Oil not changed j Remove cylinder head oil i pipe bolt and inspect logged oil pipe Faulty oil pump Check if engine overheats j Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Rapidly accelerate or run at high speed Excessive carbon build up in combustion chamber Poor quality fuel lutch slipping Engine does not knock Engine knocks Mixture too lean Ignition timing too early 1 22 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause aulty CDI unit Faulty pulser coil Correct timing Incorrect timing Check carburetor pilot i screw adjustment ixture too rich turn screw out ixture too lean turn screw in Correctly adjusted Incorrectly adjusted
13. o not squeeze wires against the weld or its clamp E After clamping check each harness to make sure that it is not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat B Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws E Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws OQ X 3 OO P a eO m O T No Contact 1 7 C KYMCO 1 GENERAL INFORMATION AGILITY RS 50 E Route harnesses so they are neither pulled tight nor have excessive slack B Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Bi Do not break the sheath of wire B If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it Do not press or B When installing other parts do not press or Aa d squeeze the wires 1 8 1 GENERAL INFORMATION C KYMCO AGILITY RS 50 B After routing check that the wire harnesses are not twisted or kinked B 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 B When a testin
14. park plug cap Check CDI unit Gop for looseness gt Measure resistance i between CDI unit coupler wire terminals Check related parts gt Faulty ignition switch Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler Check CDI unit with a CDI unit tester d Check ignition coil wit R j a CDI unit tester Faulty ignition coil
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