2005–2012 KYMCO Agility 125 Scooter Service & Repair Manual

This OEM service manual from Kwang Yang Motor Co., Ltd. covers the 2005–2012 KYMCO Agility 125 (LDF7), with its carbureted, forced-air-cooled OHC four-stroke engine and automatic belt transmission.

Text search and wiring detail: Service text is searchable, but labels in the main wiring diagram are not. There are no embedded PDF bookmarks. Small wiring labels are legible when enlarged.

• Engine repair: Engine removal, cylinder-head and valve inspection, camshaft timing, piston and ring service, and crankcase separation for crankshaft inspection.

• CVT and starting: Drive-belt replacement, drive and driven pulley overhaul, clutch-shoe inspection, kick starter service, and starter-clutch repair.

• Fuel and emissions: CVK carburetor overhaul, auto bystarter testing, pilot-screw adjustment, and secondary-air system inspection.

• Brakes and chassis: Hydraulic front brake bleeding, master cylinder and caliper repair, drum-brake service, front fork overhaul, and steering-stem service.

• Electrical diagnosis: Charging-system tests, CDI and pulser-coil inspection, starter-relay checks, wiring diagrams, and wire-color continuity tables.

• Service references: Maintenance schedules, lubrication points, component-specific torque tables, fluid capacities, wear limits, and special-tool references.

The procedures are suited to mechanics familiar with engine measurement and electrical testing, with access to the pullers, spring compressors, and test equipment specified in the manual.

Model References and Service-Data Differences

Some maintenance pages carry FILLY LX 125 headers; the final-reduction chapter and several rear-chassis pages carry AGILITY 50 headers.

The publication contains conflicting figures for valve clearance, idle speed, final-drive oil capacity, and other service specifications between tables and procedure pages. Those differences require model-specific verification before the affected data is used for repair.

Engine Repair and Lubrication

The engine chapters cover oil-pump inspection, cylinder-head warpage, valve-stem and guide wear, cylinder-bore measurements, piston clearances, and crankshaft runout. Lubrication-system drawings and exploded assembly views accompany the procedures.

Cylinder-head, cylinder, and piston service can be performed with the engine installed; crankcase separation requires engine removal. Camshaft installation covers timing-mark alignment and cam-chain tensioner handling. The tool list identifies valve spring compressor E038 and tappet adjuster E036.

CVT, Final Reduction, and Starter Clutch

Pulley service extends to weight rollers, driven-face seals and bearings, clutch shoes, and spring inspection. The final-reduction chapter covers gear, shaft, bearing, and oil-seal replacement, subject to the model-reference issue noted above.

Clutch spring compressor E027 is specified for driven-pulley disassembly; the manual warns that dismantling the assembly without the compressor can damage the spring. Starter-clutch repair covers rollers, plungers, springs, and the left-hand-thread locknut.

CVK Carburetor and Emission Controls

Carburetor procedures cover the vacuum piston and diaphragm, float valve, jets, air cut-off valve, and pilot-screw adjustment. The CVK section warns that compressed-air cleaning with the vacuum diaphragm in place can damage the diaphragm.

Auto bystarter coverage consists of electrical and operating checks, removal, and replacement. Exhaust-emission procedures include air injection cut-off valve vacuum-flow tests, reed-valve inspection, secondary air cleaner service, and CO/HC testing.

The exhaust emission control system diagram shows the secondary-air and vacuum connections. Evaporative-emission coverage is limited to maintenance references for the charcoal canister, purge control valve, and associated lines.

Brakes, Suspension, and Frame Access

Frame-cover and exhaust-muffler removal procedures provide access for service. Chassis coverage includes front drum and hydraulic disc brake procedures, rear drum-brake repair, shock-absorber disassembly, and steering-stem bearing service.

The hydraulic brake section covers master-cylinder cups, caliper pistons and seals, disc inspection, and fluid replacement. Brake, fuel-system, and electrical work require the contamination, fire, and short-circuit precautions described in the relevant chapters.

Electrical Testing and Fault Isolation

The A.C. generator section covers stator and flywheel removal, charging and lighting coil tests, and regulator/rectifier checks. CDI and pulser-coil coverage consists of electrical tests and component replacement.

Starter-motor brush and commutator inspection, fuel-gauge testing, and switch continuity checks are also covered.

The hard-starting and no-spark troubleshooting charts connect symptoms with fuel, compression, and ignition checks, helping narrow the fault before parts are replaced. Cable and harness routing drawings support connector identification.

The CDI resistance table specifies Kowa or Sanwa testers because unsuitable instruments or ranges can give misleading readings.

English PDF and Included Pages

One printable English PDF contains 189 pages total: 180 pages covering Sections 1–17, eight pages of evaporative/exhaust-emission material in Section 18, and one unnumbered preface/table-of-contents page already included in that total.