2014 Kymco Agility 50 Upgrade Report

[adkbiker]

I bought a used, restricted, 2014 Kymco Agility 50 and would like to share my progress so far at performance upgrades and welcome any helpful comments:


1. Replaced variator boss that has the shoulder with a smooth boss obtained from scooter assassins on ebay; absolutely need to do this to achieve a few more mph.


2. CDI: Did not need to “cut wire” as described in earlier models. Kymco must have changed CDI design as once boss changed and carb change below no problem getting faster speed and did not notice any restriction. I tried two replacement CDIs. The orange DC one from scrappydog did not work, engine would not start. They said must be something in Kymco wiring. I bought one off ebay advertised as non rev-limiting and the scoot ran but hill climbing performance was much worse.


3. Obtained a CVK 20 Carb and performance air filter with splash guard from scrappydog. This was simple to install but two issues to be aware of.


a. First there is a rubber tube out of the front of the bowl that goes somewhere, I don’t know. I plugged it and it ran OK. Any thoughts on this let me know. There was no documentation with the carb and I couldn’t find anything online.


b. Second, the crankcase breather tube out of the valve cover to the old air filter box was simply routed under the seat and left open.


4. At the same time I installed the carb I installed a scrappydog orange performance coil/spark plug lead. I’m not sure how much that may have helped.


Performance is markedly improved; particularly throttle response. Still slows up steep hills but it is only 50cc and I weigh 190.



Since I ride often on gravel roads I swapped tires out for knobby Maxxis M6024 tires and they work great.



Next I plan to replace complete engine/trans with scrappydog 80cc engine/trans as I think this will do better on the hills, not looking for a lot more top speed. However, I think I will need to swap stator as I notice wiring out of the 80cc engine has an extra wire.



BTW, an electric impact wrench works great to remove variator and flywheel nuts. Before removing nut I mark location of nut/bolt alignment with permanent marker and carefully re-tighten to that mark. I have a Makita XWT02Z that has 3 settings, the lower setting providing a bit more control when re-tightening.

Any comments or ideas please respond.


Thanks,
 Michael

[spaz12]

Welcome to forum

Great intro with a well written report. No doubt it will be useful

[arkie]

The rubber tube you say you pluged is a breather/overflow I believe. Its there to equalize pressure. I think it should be left open. As for the crankcase breather tube its probably just fine as is. It went to a pair system that most of us lovingly toss in the trash. The important thing is that it be routed above the rocker cover so that any oil that gets in will drain back.

[90GTVert]

3a : Leave that open.

3b : If you mean it's under the seat in the storage area, that's not a good idea. It would be best to run it up the frame, not where it can potentially get oil on your stuff. More info HERE.

[gsx600racer]

Item B

If this is the hose that went either between the stock air box and carb or into the airbox, my suggestion would to mount it the open of hose close to or on your open air filter. This way anything(fumes/vapers/mist/smoke)can be drawn back though the intake a burned off vs that stuff collecting on where you relocated it.

[adkbiker]

Thanks all for your feedback, will make a couple changes. Also I forgot to mention there was a large aluminum washer restrictor in the intake I removed when I swapped carbs.
Michael

[adkbiker]

3a. Pic show tube out of lower left of carb, provided tube goes up under my hand.  With engine running and unplugged there is a vacuum so I'm guessing it's a manifold vacuum line for some purpose not applicable to my soot.

3b. For breather tube you got me to thinking and I put a chain saw fuel filter on the end of the tube.

[adkbiker]

OK, so I’m going to go for it in the next few days and swap out the 50cc motor for the GY6-80cc motor I bought from scrappydog. I keep procrastinating because the GY6-80 has an extra red/black wire coming out of the stator that I don’t have on my engine. I know a lot about engines, carbs, and gears but electrical shit is a mystery. I read that there are 8 pole and 6 pole stators, DC fired stators, not to mention 6, 8, and 11 pole magneto flywheels. I’m not sure what to do about this. So, I think I’ll just remove the flywheel and stator from the stock engine and see if I can install it on the GY6-80 motor.

[arkie]

Yeah, swap the stator and mystery gone.

[aeroxbud]

Good luck with the swap. Let us know how it goes.

[adkbiker]

Now that I have the old engine out and trying to install the new ScrappyDog GY6-80 I ran into a major problem with the rear spindle. On the new engine it is much longer than on the old engine (see pics) and not sure what to do at this point. The spindle can probably be swapped out, any advice please let me know!

[Deleted]

Stupid question time. Kymco is made in Taiwan right? Our local Honda dealer sells them and I believe it says that in their ads. If an engine swap is possible like this, does this means we can buy a Kymco engine and just drop that into our Chinese 49cc scoots? What I am asking is can we obtain Taiwan quality engines that will drop in, so to speak?

If this is possible, I wonder why I have not heard of this?

Thanks,

Bill

[RnDmoto]

yes, the long axle is for twin shock setup. You can either swap out your short shaft and retain the single shock, buy a new short shaft and might as well do the bearings and maybe some taller gears (keeping the single shock), or upgrade to a twin shock setup which would require getting a right side swingarm, and hopefully you have the upper shock mount already on your existing frame.
several options.

[adkbiker]

Looking at the Kymco Agility 50 maintenance manual I got from the "Manuals" link to the left of this page I can see how to pull the short shaft from the original engine and install in the new engine. I'll try that first and see if I can get the scoot back together and running.

As to Bill's question above I got the "GY6-80 engine assembly" from ScrappyDog, link below if you scroll down a ways:
www.scrappydogscooters.com/139QMB_50cc_Performance.html

Other issues to make the swap:
1. Swap out Kymco stator as wiring is different and I think it's a different type of some kind, it certainly looks different, and don't want to mess around with existing electrical stuff.
2. Swap out starter because wire connectors are a bit different, although I could have made the one in the new engine work.
3. There is no bolt provision for the rear fender on the left side but I think I can fabricate something.
4. I had a bit of trouble getting the center stand reinstalled as the bolt holes are just a bit wider but I got it to work with a bit of bending to the stand mount bracket and some persuasion.
5. I don't know how I would have gotten some of the bolts off without my electric impact driver and a flywheel puller.

As mentioned in my first post above I've already been running a CVK 20 carb I got from scrappydog on the stock engine that should work well on the bigger engine.

I also have a ScrappyDog stainless steel exhaust system I thought would bolt right on but the rear bottom bracket doesn't lineup with the mounting point. I think maybe the top bracket might fit OK. I'll have to work out something for that latter.

[paceneedsstides]

my friend had same problem you did with the GY80 swap he forgot to mention had the short shaft and he sent it back then they sent him long shaft but it's not hard to do yourself.