Do not remove this Owner’s Manual from the vehicle. Read this manual carefully before operating the vehicle as it contains important safety information.
Read this manual carefully. This Owner’s Manual contains important information on safety, operation and maintenance of your KYMCO scooter. Any one who operates your scooter should carefully read and understand the contents of this manual before riding the scooter. For your safety, understand and follow all of the warnings contained in this Owner’s Manual and the labels applied to your scooter. This Owner’s Manual should be considered a permanent part of the vehicle, keep it with your scooter at all times.
TABLE OF CONTENTS Manual Icon Legend .................................................... (inside of front-cover) CA Prop 65 Warning .................................................... (inside of front-cover) Table of Contents .......................................................................................... 1 SECTION 1 - SAFETY ................................................................. 2 - 6 Foreword .........................................................................................
SECTION 1 FOREWORD & SAFETY INTRODUCTION Thank you for purchasing this KYMCO Agility scooter, and welcome to the KYMCO riding family. Please read this owner's manual carefully before riding so that you will be thoroughly familiar with the proper operation of your scooter’s controls, its features, its capabilities, and its limitations. To ensure a long, trouble-free life for your scooter, provide it with the proper care and maintenance as described in this manual.
SCOOTER SAFETY IMPORTANT SAFETY INFORMATION Your scooter can provide you many years of service and pleasure if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You will find many helpful recommendations throughout this manual. Here are some very important safety tips: Wear a helmet Scooter safety equipment starts with a quality helmet.
SCOOTER SAFETY PROTECTIVE APPAREL For your safety, always wear an approved motorcycle or scooter helmet, eye protection, boots, gloves, long pants, and a longsleeved shirt or jacket whenever you ride your scooter. Helmets and protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. Your helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and to aid your vision.
LOAD LIMITS & LOADING GUIDELINES These general guidelines may help you decide how to add accessories to your scooter and how to load it properly. Load limits These specifications are the load limits for your Agility scooter. Overloading the scooter will affect its stability and handling. Be sure to stay within the limits given below: Maximum weight capacity (Includes the weight of the rider, passenger, cargo and accessories): Agility 50 .....................................................
ACCESSORIES & MODIFICATION There is a large variety of accessories available to KYMCO scooter owners. KYMCO cannot have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories to your scooter can lead to unsafe operating conditions.
SECTION 2 CONTROLS & FEATURES Location of parts & controls 1 Left front turn signal 2 Rear brake lever 3 Turn signal switch, headlight dimmer switch, passing light button, horn button 3 2 4 Under-seat storage compartment 5 Fuel filler 6 Tail/Brake Light 1 4 5 6 7 7 Left rear turn signal 8 Kick start lever 9 ESN (Engine Serial Number) AT Main stand 8 9 AT NOTE: Write your scooter’s VIN and ESN in the boxes provided in the inside, rear cover of this Owner's Manual.
CONTROLS & FEATURES Location of parts & controls 1 Battery 5 6 7 2 Exhaust muffler 3 Right rear turn signal 4 Rear carrier 5 Ignition switch 4 6 Engine stop switch, starter motor button 3 7 Instruments (Speedometer) 2 8 9 AT 8 Center console 9 Right, front turn signal AT VIN (Vehicle Identification Number) 1 NOTE: Write your scooter’s VIN and ESN in the boxes provided in the inside, rear cover of this Owner's Manual.
CONTROLS & FEATURES Ignition switch & Steering lock Keys Your Agility scooter is supplied with two identical ignition switch 1 keys. The ignition key operates the ignition switch, the steering lock, and is used to open the seat to gain access to the center compartment and the fuel filler cap. Key code tab 1 ON: In this position, electrical power is connected to start and operate the engine (the key cannot be removed). The keys have a unique code that is stamped on the tab supplied with the keys.
CONTROLS & FEATURES Do not turn the ignition switch to the lock position when riding, as this could cause the steering to lock and you could lose control of your scooter. 3 3 LOCK: In this position, the steering is locked, electrical power is disconnected and the engine cannot start or operate (the key can be removed). Locking the steering Turn the handlebar fully to the left. Press in and rotate the ignition switch key counterclockwise to the “LOCK” position. The steering will now be locked.
CONTROLS & FEATURES Right handlebar switch Left handlebar switch 3 1 4 5 2 Engine stop switch 1: Headlamp switch -- UP 3: The engine stop switch turns off the ignition, stopping the en- The upper switch position turns the headlight high beam on. gine, but the scooter’s lights and horn will still function. The high beam indicator light on the dash is activated as well. 2 Electric starter button : Headlamp switch -- DOWN 4: Press the electric starter button to activate the starter motor.
CONTROLS & FEATURES Under-seat storage compartment Your scooter is equipped with an under-seat storage compartment that permits you to secure your helmet or other items. 8 6 7 9 Turn signal switch: Use the turn signal indicator to signal to other traffic that you intend to turn or change lanes. The turn signal light on the dash will flash to indicate that the switch is engaged. 6 Slide the turn switch to the left to activate the left turn signal.
CONTROLS & FEATURES Helmet posts Your scooter has two helmet posts AK so you can secure your helmet(s) outside of the under-seat storage compartment. AK Main stand (center stand) Your Agility scooter is equipped with a main (center) stand. AK To park your scooter on the main stand, stand on the left side With the seat up, put the helmet’s retaining ring onto the helmet of the scooter and grasp the handlebar with your left hand, post.
CONTROLS & FEATURES Instruments Digital clock 5 8 4 3 6 7 2 1 1 Odometer: Indicates the total riding mileage of the scooter. 2 High Beam Indicator Light: This light is illuminated when the headlight high beam is on. 3 Clock: Indicates the time (24-hour format). 4 Turn Signal Indicator Light: Flashes when either turn signal is being used. 5 Speedometer: Indicates the road speed in MPH (miles per our) and K/PH (kilometers per hour).
CONTROLS & FEATURES Passenger foot rest The floorboard of your Agility scooter is equipped with a raised section AT and floorboard area for use when you are carrying a passenger. AT Riding with a passenger will change the handling characteristics of your scooter. Allow for extra braking distance and use extra care when riding in traffic. Be sure you and your passenger always wear an approved motorcycle helmet that fits properly.
SECTION 3 OPERATION Break-in recommendations The first 600 miles (1,000 km) of riding are the most important in the life of your scooter. Following proper break-in procedures during this time will help ensure maximum life and performance from your new scooter. Proper break-in operation allows the machined surfaces to polish each other and mate smoothly. Your scooter’s reliability and performance depend on your exercise of special care and restraint during the break-in period.
OPERATION The 200 mile (300 km) service should be performed as outlined in the maintenance schedule section of this owner's manual. Pay particular attention to the cautions and warnings in the Maintenance Schedule section. Unless you have formal training as a service technician and have access to KYMCO technical reference materials, it is strongly suggested that you have the initial service performed by a KYMCO dealer.
OPERATION Pre-ride inspection (PRI) For your safety, it is very important to take a few moments 6. Steering: Check for smooth operation in all steering posibefore each ride to walk around your scooter and check its tions (page 23). condition. If you detect any problem, be sure to address it im7. Instruments: Make sure the speedometer, fuel level gauge mediately, or have it corrected by your KYMCO dealer. and indicator lights function (page 23).
OPERATION PRI - Engine oil level inspection NOTE: Park your scooter on the main stand, on level ground. 1 F L Use extreme caution when performing the oil level inspection or any other checks if the scooter’s engine has been recently run. The engine oil, engine case and muffler can become very hot creating a burn hazard.
OPERATION PRI - Front brake lever & fluid inspection (right lever) PRI - Tire inspection The condition of your scooter’s tires is vital for operational efficiency and your safety. Check the tires’ inflation pressure, The right brake lever on your Agility scooter controls the front the tread depth, and for damage before each ride. hydraulic brake. Check the free-play at the end of the lever so the brake will be responsive and will not drag, which could cause premature wear to the brake pads or brake rotor.
OPERATION 6 67 3 2. Inspect the tires for nails, screws and other objects 3 that 4. Check for damage 6 (blisters or cuts) in the side wall, or for significant flat spots 7 on the tires’ tread. Replace the may be imbedded into the rubber. tire immediately if any damage of this type is present. 5 The tires on your scooter must be replaced if they: 4 5 3. Check the tread depth 4 at the wear indicator points 5. If the tread is worn smooth at these points, the tire must be replaced.
OPERATION PRI - Fuel level inspection / Refilling When the fuel level gauge needle approaches “E” (indicating the tank is nearly empty) refill the tank with unleaded gasoline. To open the fuel filler cap: 1. With the engine “OFF”, place the scooter on its main stand and open the seat (see page 12 of this manual). 1 Do not overfill the tank. There should be no fuel in the fuel filler neck. Excess fuel can contaminate the evaporative emission canister, resulting in poor drivability.
OPERATION PRI - Steering & handlebar inspection Before riding, inspect your scooter’s handlebars for damage, and make sure the steering’s side-to-side and up-and-down movement is smooth. If you detect any looseness or abnormal sounds during your steering inspection, do not ride your scooter. Consult your KYMCO dealer for chassis service. PRI - Instrument inspection Before your ride, and as you begin your ride, make sure the instruments are functioning. 2 1 3 1.
OPERATION PRI - Horn & lights inspection 1. Turn the ignition switch to “ ON“ and press the horn button on the left handlebar switch to check if it sounds. 1 2 3 2. Turn on the headlight switch to see if the headlight 1 and the tail light 3 are illuminated. Check the lenses for dirt or damage. 3. Operate the turn signal switch to make sure the turn signals 2 flash. Make sure each of the four signals flash and the lenses are free of dirt and are not broken. 4.
OPERATION PRI - Chassis inspection Complete the pre-ride inspection of your scooter by checking Front suspension & rear shock absorber: Check the operation of the suspension by pressing down on the handlebars items on its chassis. and seat. Make sure the suspension returns in a smooth fashion. Brake lever operation: Check that the rear brake (left lever) and the front brake (right lever) have pressure and lock the wheels when you squeeze the levers.
OPERATION Starting the engine (electric start) To start your scooter using the electric starting motor, follow this procedure: NOTE: Before starting, check the engine oil and fuel levels. Take the scooter off of the main stand. The brake must be adjusted and functioning properly to lock the rear wheel during starting or the scooter could accelerate away when the engine starts. NOTE: The rear brake must be held for the starter motor to engage the engine.
OPERATION NOTE: If the scooter has not been ridden for a long period of time it may be hard to start. Add fresh fuel and press the starter button several times in succession to try to start the engine. If the scooter does not start, contact your KYMCO dealer as your scooter may need to have its fuel system cleaned and adjusted.
OPERATION Riding your scooter NOTE: After starting, allow the engine oil to circulate before riding your scooter. Allow sufficient idling time after warm or cold engine start-up before applying load or revving the engine. This allows time for the lubricating oil to reach all the critical engine components. NOTE: Review the scooter safety recommendations on pages 2 through 6 before you ride.
OPERATION 2 5. Limit the maximum speed of your scooter during the first 600 miles (1,000 km) of operation. Keep the road speed below 25 MPH (40 KPH) during this break-in period. 4. Control the scooter’s speed with the throttle grip. Rotating the grip towards you 2 will increase the scooter’s 6. Use both brake levers when slowing and stopping the speed. scooter. Release the throttle when braking.
OPERATION 7. When riding and turning the scooter, use smooth movements. NOTE: At certain speeds your scooter will turn more effectively by leaning your body, than by applying pressure on the handlebars. Practice steering in an open, trafficfree area until you are familiar with the handling characteristics of your scooter. Reduce your speed when riding on uneven or loose road surfaces. When riding downhill, use less throttle and intermittently brake to control the vehicle’s speed.
OPERATION Parking your scooter Use the following procedure and suggestions when parking your scooter. 1. Place the scooter on level ground. 9. When you stop the scooter, press the center of the turn signal indicator switch to cancel the signal flashing. Turn the ignition switch to the “OFF“ position to stop the engine and turn off the scooter’s electrical system. Never operate the ignition switch while riding your scooter.
OPERATION The scooter may fall over if it is not parked on level ground. Make sure flammable materials such as dry grass or leaves do not come into contact with the exhaust system when parking your scooter. Lock the steering of your scooter (see pages 9 & 10) to reduce the risk of theft. 32 Do not park your scooter in a place that hinders traffic, or that is unsafe to you or others.
SECTION 4 MAINTENANCE The importance of maintenance Maintaining your scooter properly is essential for safe, economical and trouble-free riding. It will also help reduce air pollution and maximize fuel economy. To help you properly care for your scooter, the following pages in this Owner's Manual include a maintenance schedule to help you make sure your scooter is serviced at the appropriate intervals.
MAINTENANCE Maintenance Schedule Perform the pre-ride inspection (see pages 18 - 25) at each scheduled maintenance period. This interval should be judged by odometer reading or months, whichever comes first. Maintenance Schedule Legend (see page 35): I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE T: TIGHTEN The maintenance schedule on page 35 specifies the maintenance required to keep your Agility scooter in peak operating condition.
MAINTENANCE Maintenance Schedule - Agility 50 & 125 MILEAGE 200 mi 600 mi 3000 km 5000 km 7000 km 9000 km 11000 km Pre-ride inspection See page R R R R R R PRI 19, 40 C - C - C - C - 40 Gear oil * R - R - R - R - 42 Spark plug * C I C R C I R - 43 Valve clearance ** A - A - A - A - Dealer Carburetor ** I - I - I - I - Dealer Drive belt ** - - - - I - - - Dealer Air cleaner * C I R I R I R - 37 Battery * I I I I I I
MAINTENANCE Tires Failure to follow these warnings may result in an accident due to tire failure. The tires on your scooter are a crucial link between your scooter and the road. You and your passenger's personal safety are dependant upon the condition of your scooter's tires. Follow these instructions: Check tire condition and pressure, and adjust the inflation pressure before each ride. Avoid overloading your scooter.
MAINTENANCE Air cleaner filter element The air cleaner filter element should be serviced at regular intervals. Service the element more often when riding in unusually wet or dusty areas. 1. Open seat (see page 12). 3 1 2 7. Complete the installation by reinstalling the air cleaner parts in the reverse order of removal. 2. 3. 4. 5. Remove air cleaner cover screws 1. Remove the air cleaner case cover 2. Remove the air cleaner element If lightly soiled, clean the filter 3 with compressed air.
MAINTENANCE Fuel system & hoses Check the fuel hoses and fittings for any signs of leakage. 1 3 4 2 1. 2. 3. 4. Check for leakage at the carburetor 1. Check for leakage from the fuel hoses, clamps and joints 2. Check for leakage at the fuel filter 3. Check for leakage at the fuel tank 4. Replace any fuel system components that are leaking fuel. Contact your KYMCO dealer for fuel system service and repairs. 38 Battery Your KYMCO scooter is equipped with a maintenance-free (sealed) battery.
MAINTENANCE Battery removal & installation The battery 5 is in the battery box below seat. Fuse replacement FUSE SIZE: 7A (One MAIN fuse & one SPARE) 1. Open the fuse holder 6. Pull the fuse holder clips 7 out of the holder. 5 2. Slide the fuse 8 out of the holder clips. 3. Install a new fuse 8 of the proper specification into the holder clips. NOTE: Always keep ignition switch OFF when servicing the battery. 1.
MAINTENANCE Engine oil Engine oil recommendation Use a premium quality 4-stroke engine oil to ensure longer service life of your scooter. Only use oils that have a SJ rating per the API service classification. The engine and related components can become very hot. Use care when inspecting or adjusting the oil level to avoid injury. If needed, let the engine and exhaust system cool before working in those areas. Engine oil capacity: 0.95 qt (0.
MAINTENANCE 3. Replace the drain bolt 1. Tighten it to the specified torque. Oil drain plug torque: 18 lb-ft (25 N-m) 4. Add engine oil through the oil filler/dipstick hole. Engine oil capacity: Engine oil viscosity: 1 1. Place a suitable container (drain pan) under the left crankcase. Remove the drain bolt 1 to drain the oil. 2 0.95 qt (0.9 L) SAE 15W-40 Do not overfill the engine with oil. Overfilling the engine can cause oil leaks and/or oil contamination of the air filter element.
MAINTENANCE Transmission fluid change 1. Place the scooter on its main stand. 3. After the fluid has drained out, reinstall the drain bolt with a new sealing washer and tighten it to the specified torque. Transmission fluid drain bolt torque: 15 lb-ft (20 N-m) 4. Remove the transmission fluid filler bolt 2. 5. Add the exact specified fluid through the fluid filler hole 3. Transmission fluid type: 2 SAE 90 Transmission fluid capacity (Agility 50): 0.12 qt (0.
MAINTENANCE Spark plug Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine. After cleaning (or when installing a new spark plug) readjust the spark plug gap to specified limit by using a spark plug gap thickness gauge. The spark plug should be replaced periodically. Under normal usage, a spark plug's porcelain tip should appear light brown or tan in color.
MAINTENANCE Brake shoe adjustment (rear brake) Your scooter requires the proper lever free-play and brake shoe adjustment so the rear brake will be responsive and will not drag, causing premature wear to the brake shoes. 2 3 4 5 1 4. Use the cable end adjuster 4 to set the free play Note: The free-play is the measured distance between the brake lever at rest and a fully applied brake. 1. Measure the free-play at the left brake lever end 1: 0.4 - 0.6 in (10 - 20 mm).
MAINTENANCE Cleaning Clean your scooter regularly to protect the surface finishes and inspect for damage, wear, and oil, coolant or brake fluid leakage. Avoid cleaning products that are not specifically designed for scooter, motorcycle, or automobile surfaces. Nonspecific cleaners may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your scooter.
MAINTENANCE 6. Test the brakes before riding the scooter. Several applica- Removing road salt tions of the brakes may be necessary to restore normal brak- The salt used in some communities to prevent road icing can become very corrosive to your scooter. Wash your scooter as ing performance. soon as possible if it comes in contact with road salt (or sea water). 1. Clean the scooter using cool water (see page 45). Do not use warm water; as this will increase the corrosive effect of the salt. 2.
MAINTENANCE STORAGE GUIDE 3. To prevent rusting in the cylinder, perform the following: Extended storage, such as for the winter months, requires that Remove the spark plug cap from the spark plug, and use tape you take certain steps to reduce the effects of deterioration or string to secure the cap to any convenient plastic body part from the non-use of your scooter. Whenever possible, perform so that it is positioned away from the spark plugs.
Removal from storage 1. Uncover and clean the scooter. 2. Change the engine oil if more than 1 month has passed since the start of storage. 3. Charge the battery as required (use a quality charger designed for use on a maintenance-free type battery). Install the battery. 4. Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh gasoline. 5. Perform all the pre-ride inspection checks (see pages 18 25).
MAINTENANCE RECORD DATE MILEAGE SERVICE PERFORMED & NOTES 49
MAINTENANCE RECORD DATE 50 MILEAGE SERVICE PERFORMED & NOTES
SPECIFICATIONS - AGILITY 50 Dimensions Overall length .......................................... 72.0 in (1830 mm) Overall width .............................................. 27.1 in (690 mm) Overall height .......................................... 44.5 in (1130 mm) Wheel base ............................................... 52.1 in (1325mm) Seat height ................................................ 29.0 in (790 mm) Dry weight ............................................... 202.8 lbs (92.
SPECIFICATIONS - AGILITY 125 Dimensions Overall length .......................................... 72.0 in (1830 mm) Overall width .............................................. 27.1 in (690 mm) Overall height .......................................... 44.3 in (1125 mm) Wheel base.............................................. 51.7 in (1315 mm) Seat height ................................................ 30.9 in (785 mm) Dry weight ................................................ 233.
EXHAUST EMISSION CONTROL SYSTEM KYMCO Clean-Air System The KYMCO Clean-Air System is a secondary air suction system that helps the exhaust gases to burn more completely. When the engine's exhaust is sent into the exhaust system, it contains some unused fuel. This exhaust is still hot enough to burn the unused fuel. The Clean-Air system introduces more air so the oxygen will then permit the unused fuel to burn in the exhaust system.
EMISSION CONTROL & WARRANTY INFORMATION Crankcase Emission Control System Your Agility scooter’s engine is equipped with a closed crankcase system. Blow-by gases are routed back in to the combustion chamber via the intake system. This system does not allow the blow-by gases to enter the atmosphere. Exhaust Emission Control System The exhaust emissions from your scooter are controlled by engine design, factory-set fuel delivery, ignition settings, and exhaust system design.
KYMCO LIMITED WARRANTY 55
INDEX Accessories & Modifications .................................. 6 Headlight Dimmer Switch ..................................... 11 Right-hand Handlebar Switch .............................. 11 Air Filter Maintenance .......................................... 37 Helmet Posts ......................................................... 13 Scooter Safety .................................................. 3 - 4 Battery ...........................................................
Identification Numbers Record 1 2 3 1. IGNITION SWITCH KEY IDENTIFICATION NUMBER The ignition switch key identification code is stamped on tab 1 supplied with the key. If you require a replacement key, you will need this code to obtain a new key from your authorized KYMCO dealer. Record the key number in the box above. 2. VEHICLE IDENTIFICATION NUMBER (VIN) 3.
5 Stan Perkins Road Spartanburg, SC 29307 Telephone: (888) 235-3417 FAX: (864) 327-4745 Prepared: February 2009 T300-KG10SA/KN25SA-US-A5
