03/12/2002
Installing a Kickstart on Your Kymco Agility City 125
The Kymco Agility City 125 is a popular scooter known for its reliability and practicality. While it's primarily designed for electric start, understanding how to install or troubleshoot the kickstart mechanism can be invaluable for any owner. This guide, drawing on the principles of service manuals, will walk you through the process, highlighting key components and considerations. Whether you're a seasoned mechanic or a budding enthusiast, this article aims to provide a clear and comprehensive approach to getting your kickstart operational.
Understanding the Kickstart Mechanism
The kickstart system on a scooter like the Agility City 125 is a mechanical linkage designed to manually engage the engine's starting system. It typically involves a lever, a shaft, a return spring, and a gear or spline mechanism that connects to the engine's crankshaft or a related component. When the kickstart lever is depressed, it rotates the shaft, which in turn drives the starting gears, initiating the combustion cycle. The return spring is crucial for bringing the lever back to its resting position after use.
Essential Tools and Preparation
Before embarking on the installation, it's vital to gather the necessary tools and prepare your workspace. Safety is paramount, so ensure you're working in a well-lit, ventilated area. Here's a list of common tools you might need:
- Socket Set: Various metric sockets will be required for removing body panels and internal engine components.
- Wrenches: Both open-ended and ring wrenches, again in metric sizes.
- Screwdrivers: Phillips and flathead screwdrivers for different types of fasteners.
- Pliers: For gripping and manipulating small parts, especially springs.
- Torque Wrench: Essential for ensuring fasteners are tightened to the correct specifications, preventing damage.
- Grease: A good quality multi-purpose grease for lubricating moving parts.
- Service Manual: While this guide provides general information, the specific Kymco Agility City 125 service manual is the ultimate reference for exact procedures and torque values.
- Gloves and Eye Protection: To ensure your safety during the process.
Step-by-Step Installation Procedure
The installation of a kickstart system typically involves accessing the engine's crankcase. This often means removing several body panels to gain clear access to the engine. Always refer to your service manual for the exact panel removal sequence to avoid damaging clips or mounting points.
1. Panel Removal
Begin by carefully removing the necessary body panels. This usually includes the floorboard, side panels, and potentially some under-seat panels. Keep track of all fasteners and their locations; using a labelled tray or a piece of cardboard with holes can be very helpful.
2. Accessing the Crankcase Cover
Once the body panels are off, you'll need to locate and remove the crankcase cover that houses the kickstart mechanism. This cover is typically secured with several bolts. Loosen these bolts evenly in a crosswise pattern to prevent warping the cover. Be aware that there might be residual oil in the crankcase, so have a drain pan ready.
3. Removing the Old Kickstart (if applicable)
If you are replacing an existing kickstart, you'll need to remove the old one first. This usually involves removing a retaining clip or nut that holds the kickstart lever and shaft in place. Pay close attention to the orientation of any washers or spacers.
4. Installing the New Kickstart Shaft and Lever
Slide the new kickstart shaft into its designated bore in the crankcase. Ensure it moves freely. If your kit includes a new return spring, carefully install it according to the service manual's diagram. This can sometimes be the trickiest part, as springs can be under tension. Apply a light coat of grease to the shaft and any engaging splines.
5. Engaging the Starting Mechanism
The kickstart shaft will have an engagement mechanism, often a gear or a dog clutch, that meshes with the engine's starting gears. Ensure this mechanism is properly aligned and engaged. This is critical for the kickstart to actually turn the engine over.
6. Securing the Kickstart Assembly
Once the shaft and lever are in place and the engagement mechanism is set, you'll need to secure it. This usually involves re-installing the retaining clip, nut, or bolt that was removed earlier. Tighten any fasteners to the manufacturer's specified torque using a torque wrench.
7. Refitting the Crankcase Cover
Before refitting the crankcase cover, inspect the gasket for any damage. If it's damaged or brittle, it's advisable to replace it to ensure a proper seal and prevent oil leaks. Clean both the cover and the crankcase mating surfaces. Reinstall the cover, tightening the bolts evenly in a crosswise pattern to the specified torque. Ensure no wires or components are pinched under the cover.
8. Reinstalling Body Panels
Carefully re-install all the body panels you removed earlier. Make sure all fasteners are correctly installed and that the panels fit snugly without any gaps or stress points. Double-check that all clips are secured and that no electrical connectors have been dislodged.
Testing the Kickstart
With everything reassembled, it's time to test the kickstart. Ensure the scooter is on its centre stand. Gently push the kickstart lever down. It should move smoothly, engage the engine, and return to its resting position when released. If it feels stiff or doesn't engage, re-check all connections and torque settings.
Troubleshooting Common Issues
If the kickstart doesn't work as expected, here are a few common issues and their potential solutions:
| Symptom | Possible Cause | Solution |
|---|---|---|
| Kickstart lever is stiff or won't move. | Lack of lubrication, bent shaft, or obstruction. | Lubricate shaft, check for obstructions, inspect shaft for damage. |
| Kickstart lever moves but doesn't engage the engine. | Worn or damaged engagement gears, missing spring, or incorrect assembly. | Inspect engagement gears and spring, ensure correct assembly as per manual. |
| Kickstart lever doesn't return to position. | Faulty or broken return spring. | Replace the return spring. |
| Kickstart feels loose or sloppy. | Worn bushings or loose retaining nut/clip. | Check and tighten retaining nut/clip, inspect and replace bushings if necessary. |
Key Components to Inspect
When installing or troubleshooting a kickstart, pay particular attention to these key components:
- Kickstart Lever: Check for cracks or bending.
- Kickstart Shaft: Ensure it's straight and the splines are not worn.
- Return Spring: Verify its integrity and tension. A weakened spring will prevent proper return.
- Engagement Mechanism: Inspect the gears or dogs for wear or damage. This is the part that actually turns the engine over.
- Crankcase Cover Gasket: A good seal is essential to prevent oil leaks.
Frequently Asked Questions
Q1: Do I need to drain the engine oil before installing the kickstart?
A1: It is highly recommended to drain the engine oil before opening the crankcase cover. While some oil might remain, draining it significantly reduces mess and the risk of oil spills, especially if the scooter is not perfectly upright.
Q2: Can I use a generic kickstart kit for my Agility City 125?
A2: It's always best to use genuine Kymco parts or high-quality aftermarket parts specifically designed for the Agility City 125. Using generic parts may lead to poor fitment, premature wear, or even damage to your engine.
Q3: How tight should the crankcase cover bolts be?
A3: The specific torque setting is crucial and can be found in the official Kymco Agility City 125 service manual. Overtightening can strip threads or warp the cover, while undertightening can lead to oil leaks.
Q4: Is it difficult to replace the kickstart return spring?
A4: Replacing the return spring can be challenging due to the spring's tension. It's often easier with a second person to help hold components in place. Referencing diagrams in the service manual is essential for correct placement.
Conclusion
Installing a kickstart on your Kymco Agility City 125 is a manageable task with the right preparation and tools. By carefully following these steps and consulting your specific service manual, you can ensure a successful installation. Remember, proper maintenance and timely repairs are key to keeping your scooter running smoothly and reliably for years to come. If at any point you feel unsure about a step, it's always best to seek assistance from a qualified mechanic.
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