KYMCO AHG5 Service Manual Download Page 1

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Foreword

This service manual provides maintenance

guidelines for KYMCO AHG5 fuel injection

engine.

Chapter 1 contains all the operational

precautions that you should read carefully

before you start.

Chapter 3 gives inspection and fine-tuning tips

and maintenance of individual functions

beginning with regular inspection.

The remaining chapters outline assembly/

disassembly and inspection steps for the

engine, and electrical system.

Each chapter begins with an overall

explanation of the exploded diagram, system

diagram, maintenance troubleshooting, and

diagnosis description.

ALL

INFORMATION,

GRAPHICS

AND

SPECIFICATIONS

CONTAINED

THIS

DOCUMENT ARE BASED ON THE LATEST

PRODUCT INFORMATION AVAILABLE AT THE

TIME

OF MANUFACTURE.

KWANG

YANG

MOTOR CO., LTD. RESERVES THE RIGHT TO

MAKE CHANGES AT ANY TIME WITHOUT

NOTICE

AND

WITHOUT

INCURRING

ANY

OBLIGATION WHATEVER.

UNAUTHORIZED

USE

WITHOUT

THE

WRITTEN PERMISSION OF KWANG YANG

MOTOR CO., LTD.IS STRICTLY PROHIBITED.

© KWANG YANG MOTOR CO., LTD.

By the Technology Training Section

First Edition

– Jun. 2021

Quick Reference

External Components

Periodic Maintenance

En
g

Lubrication System

Engine Removal/ Installation

Cylinder Head/ Valve

Cylinder/ Piston

Drive & Driven Pulley

Final Reduction

Alternator / Start Clutch

Crankcase/ Crankshaft

Cooling System

Fi System

rame

Front Assembly

Rear Assembly

El
ec
tr

ica
l

Battery & Charging System

Ignition System

Starting System

Switches/ Lights

EEC

EEC System

ABS/TCS

Summary of Contents for AHG5

Page 1: ...T PRODUCT INFORMATION AVAILABLE AT THE TIME OF MANUFACTURE KWANG YANG MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER ALL RIGHT...

Page 2: ...General Torque Value 5 4 2 Engine 6 4 3 Frame 7 5 Special Tool 8 6 LUBRICATION POINTS FRAME 9 7 Components Location 10 8 General Troubleshooting 13 8 1 Engine lacks power 13 8 2 Engine will not stat o...

Page 3: ...1 Quick Reference 1 2 1 Engine Frame Serial Number Frame Serial Number Engine Serial Number...

Page 4: ...Valve clearance cold mm Intake 0 12 Exhaust 0 12 Idle speed rpm 1700 100 Lubricate System Lubrication type Forced pressure Wet sump Oil Pump Type Inner outer rotor type Oil Filter Type Full flow filtr...

Page 5: ...r diagonally to the specified torque We recommend that you use genuine lubricants and parts Please use dedicated or common tools when working on any assembly and disassembly of the parts during servic...

Page 6: ...screw Cut 0 05 0 15 6mm Bolt Nut 0 8 1 2 4mm Tapping screw Point 0 2 0 4 8mm Bolt Nut 1 8 2 5 5mm screw Cut 0 1 0 3 10mm Bolt Nut 3 0 4 0 5mm Tapping screw Point 0 35 0 5 12mm Bolt Nut 5 0 6 0 6mm scr...

Page 7: ...1 Quick Reference 1 6 4 2 Engine...

Page 8: ...1 Quick Reference 1 7 4 3 Frame...

Page 9: ...embly Thread Protector A120E00029 Protecting the crankshaft s thread Valve Cotter Installer A120E00051 Valve cotter installation Clutch Spring Compressor A120E00053 Clutch disassembly assembly Shaft C...

Page 10: ...me Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorcycle Grease Engine Oil Throt...

Page 11: ...ents Location Front brake fluid reservoir Rear brake fluid hose Rear brake fluid reservoir USB charger wires Right handlebar switch Front brake fluid hose Left handlebar switch Start relay Fuse box OB...

Page 12: ...Fuel pump Throttle body ISC Idle air bypass valve Fuel injector PPTS Intake air temp MAP TPS Fuel hose Spark plug cap Thermostat Throttle cables Inductive ignition coil Rectifier Regulator Canister H...

Page 13: ...1 12 USB charger controller Long distance antenna Tilt switch KEYLESS controller Ignition switch Engine oil indicator controller ECU Headlight controller Coolant reserve tank Start relay ABS controlle...

Page 14: ...1 Quick Reference 1 13 8 General Troubleshooting 8 1 Engine lacks power...

Page 15: ...1 Quick Reference 1 14...

Page 16: ...1 Quick Reference 1 15 8 2 Engine will not stat or is hard to start...

Page 17: ...1 Quick Reference 1 16 8 3 Poor handling...

Page 18: ...1 Quick Reference 1 17 8 4 Poor performance at high speed...

Page 19: ...1 Quick Reference 1 18 8 5 Poor performance at low and idle speed...

Page 20: ...2 External components Exhaust pipe 2 0 2...

Page 21: ...2 External components Exhaust pipe 2 1...

Page 22: ...4 2 1 Front cover 4 2 2 Headlight assy 4 2 3 Side covers 5 Seat 6 2 4 Luggage box 6 2 5 Rear carriers 6 2 6 Center cover 6 2 7 Tail light assy 7 2 8 Floor panel assy 7 2 9 Meter cover 8 2 10 Leg shiel...

Page 23: ...cables and harnesses according to the Cable Harness Routing Torque value 1 2 Item Torque kgf m Remarks Exhaust pipe fixing bolts tighten on the rear fork 3 5 4 5 Exhaust pipe front end nuts 1 8 2 2 O...

Page 24: ...bolts and Allen bolts Remove the wind screen and brackets Install in the reverse order of work Front cover 2 2 Remove the plastic screws Remove the screws Remove the front cover Install in the reverse...

Page 25: ...each side of cover Remove the screws Side covers Remove the plastic screws on each side of the under cowl Remove the plastic screw on rear part of the side cover Repeat the process on the other side...

Page 26: ...luggage box light connector Remove the luggage box Install in the reverse order of work Rear carriers 2 6 Remove the Allen bolts on the each rear carrier Remove the rear carriers Install in the rever...

Page 27: ...bber cover Remove the bolt Remove the plastic screws on the upper and down side of each side cover Disconnect all connectors of tail light assy Remove the tail light assy Install in the reverse order...

Page 28: ...Remove the plastic screw on each side of the leg shield Remove the floor panel assy Install in the reverse order of work Meter cover 2 10 Remove the wind screen Remove the front cover Remove the headl...

Page 29: ...se Pull out the cover but do not over pull it Disconnect the connector Remove the ignition switch cover Use a proper tool to pry out the lid Remove the key cover Lid Key cover Remove the bolts Remove...

Page 30: ...eld Install in the reverse of work Handlebar covers 2 12 Remove the bolts on each side of lower handlebar cover Disconnect the USB connector Remove the upper handlebar cover Remove the throttle cables...

Page 31: ...fender Remove the front fender Install in the reverse order of work Rear fenders 2 14 Remove the bolts on the lower rear fender Remove the lower rear fender Remove the bolts on the upper rear fender R...

Page 32: ...pipe 2 12 Undercover 2 15 Remove the bolts on each side of the undercover Remove the undercover Install in the reverse order of work Muffler cover 2 16 Remove the bolts Remove the muffler cover Instal...

Page 33: ...ector Remove the nuts on the front end of the exhaust pipe Remove the gasket Install in the reverse order of work Replace a new gasket after remove the exhaust pipe Nuts Gasket Torque value Item Torqu...

Page 34: ...Adjustment 10 8 Cylinder Compression 10 9 Engine Oil 11 9 1 Engine oil recommendation 11 9 2 Engine oil level check 11 9 3 Engine oil replacement 12 9 4 Oil strainer screen clean 13 9 5 Oil filter re...

Page 35: ...2 16 2 Brake pad wear 19 16 3 Brake levers 20 17 Nuts Bolts Fasteners 20 18 Wheels Tires 21 18 1 Tire pressure 21 19 Steering Handlebar 21 20 Suspension 22 20 1 Rear suspension adjustment 22 21 Side S...

Page 36: ...a or fuel storage area 1 2 Specifications Throttle Grip Free Play 2 6 mm Spark Plug NGK CPR7E Spark Plug Gap 0 7 0 8 mm Valve Clearance IN 0 1 mm EX 0 1 mm Idle Speed 1700 100 rpm Cylinder Compression...

Page 37: ...ements Should be serviced by your KYMCO dealer unless the owner has the proper tools and service data and is mechanically qualified In the interest of safety we recommend these items be serviced only...

Page 38: ...nkcase Breather Note3 C C C C C C C Engine Oil R R R R R R R Engine Oil Screen C R C R C R Engine Oil Filter R R R R R R R Engine Idle Speed I I I Transmission Oil Note5 R R R R R R R Drive Belt I I I...

Page 39: ...free play is made with the adjusting nut at the throttle valve Adjust by loosening the lock nut and turning the adjusting nut When the free play has been moved into specification hold the adjuster in...

Page 40: ...r element which is not of equivalent quality may cause premature engine wear or performance problems The air cleaner should be serviced at regular intervals Service more frequently when riding in unus...

Page 41: ...timing inspection cap from the right side of the engine with a large flat blade screwdriver Inspect the O ring on the cap and replace it as needed Turn the A C generator flywheel clockwise to the top...

Page 42: ...nder head surface If this is not the case rotate the crankshaft 360 clockwise until the T mark is once again aligned with the notch on the case cover Measure the valve clearance with a thickness feele...

Page 43: ...the removed parts in the reverse order of removal Make sure the O rings on the crankshaft and timing plugs are in good condition Replace them as needed Install the timing inspection and crankshaft ca...

Page 44: ...e riding the scooter The level must be maintained between the upper and lower level marks on the oil filler cap dipstick 1 Start the engine and let it idle for a few minutes 2 Stop the engine and put...

Page 45: ...ly basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Change the engine oil with the engine at normal operating temperature and t...

Page 46: ...plug is removed 4 Let the engine oil drain out 5 Clean the oil strainer screen 6 Check that the oil strainer screen sealing rubber and drain plug O ring are in good condition 7 Apply light coat engine...

Page 47: ...in out 4 Remove and discard the oil filter Do not remain the rubber seal on the oil filter in the oil filter housing Check that the O ring is in good condition 5 Install the new oil filter Cap bolt to...

Page 48: ...nsmission oil filler bolt 2 slowly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it Torque 1 0kgf m 5 Fill th...

Page 49: ...a tachometer Turn the throttle stop screw to obtain the specified idle speed When the engine misses or run erratic adjust the pilot screw Idle Speed 1750 100 rpm 12 Drive Belt Remove the left crankca...

Page 50: ...side of main switch with the scooter in an upright position on a level ground If the coolant level is below the LOWER level mark remove the reserve tank cap to add coolant mixture until it reaches the...

Page 51: ...ainer label Use only low mineral drinking water or distilled water as a part of the antifreeze solution Water that is high in mineral content or salt may be harmful to the aluminum engine Using coolan...

Page 52: ...d from a sealed container or an equivalent Other checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings Warning Brake fluid is very caustic and can damag...

Page 53: ...ush the brake lever forward and then turn the adjuster knob to align the number with the round punch mark on the lever 3 After adjustment release the Brake Lever and check if the lever position is sui...

Page 54: ...ground which can lead to skids and loss of control Be sure that the tire pressure is within the specified limits at all times Tire pressure should only be adjusted when the tires are cold Cold inflat...

Page 55: ...s if there is any looseness 20 1 Rear suspension adjustment Each shock absorb has 5 adjustment positions for different load or riding conditions Use a fitting wrench to turn the adjuster s boss Positi...

Page 56: ...f tension and the side stand assembly for freedom of movement Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower...

Page 57: ...4 LUBRICATION SYSTEM DT X360 4 1 Lubrication System...

Page 58: ...2 1 Lubrication Diagram 3 2 SERVICE INFORMATION 4 2 1 GENERAL INSTRUCTIONS 4 2 2 SPECIFICATIONS 4 2 3 TROUBLESHOOTING 5 3 Engine oil 6 4 Oil Pump 6 4 1 Removal 6 4 2 Disassembly 7 4 3 Inspection 8 4 4...

Page 59: ...4 LUBRICATION SYSTEM DT X360 4 3 1 Lubrication Diagram Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Filter Screen Oil Pump...

Page 60: ...e care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a se...

Page 61: ...oil consumption Oil leaks Worn piston rings Worn valve guide Worn valve guide seal Poor lubrication pressure Oil level too low Clogged oil filter or oil passage Faulty oil pump Oil contamination Oil...

Page 62: ...ear shaft pins and starter driven gear Remove the bolt and then oil pump cover Pry the snap ring off and remove the oil pump driven sprocket then remove the oil pump drive chain Inspect the oil pump d...

Page 63: ...or dirt to enter the engine Turn the oil pump shaft by hand and make sure it turns smoothly If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit 4 2 Disassem...

Page 64: ...mbly Install the outer rotor inner rotor and pump shaft into the pump body Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin There is one p...

Page 65: ...rotates freely and arrow mark which is on the oil pump is upside Install the pump drive chain and driven sprocket then set the snap ring securely on the pump shaft Install the oil separator cover prop...

Page 66: ...5 ENGINE DT X360 5 1 Engine 1 ENGINE REMOVAL INSTALLATION 4 1 1 Removal 4 1 2 Installation 6...

Page 67: ...he brake fluid tube Place the scooter on the center stand Remove the following external components Seat Center Cover Front Cover Front Lower Cover Foot Skirt Rear Carrier Body Cover Under Cover Discon...

Page 68: ...tank capacity 0 59 L Hot coolant hose 0 169 L Cold coolant hose 0 194 L Total capacity 1 719 L TORQUE VALUES Engine hanger bolts Engine side 5 0 kgf m Engine hanger bolts Frame side 6 5 kgf m Engine r...

Page 69: ...he starter motor lead Remove the starter motor lead nut Free the cable lead from the starter motor Thread the nut back on to keep track of it Disconnect the ground wire Loosen the water pump hose clam...

Page 70: ...scooter securely on its main stand Remove the bolts and then remove the rear brake caliper Disconnect the alternator cord including the crank position sensor cord Remove the spark plug cap Remove the...

Page 71: ...Tighten the rear suspension bolts Torque 3 5kgf m Tighten the right and left rear shock absorber lower mount bolts Torque 4 0kgf m Tighten the rear axle nut Torque 12 0kgf m Install the rear brake ca...

Page 72: ...2 1 GENERAL INSTRUCTIONS 3 2 2 SPECIFICATIONS 3 2 3 TORQUE VALUES 4 2 4 SPECIAL TOOLS 4 2 5 TROUBLESHOOTING 5 3 Cylinder Head Cover 6 3 1 Removal 6 4 Camshaft 9 4 1 Removal 9 4 2 Inspection 13 4 3 Cam...

Page 73: ...6 CYLINDER HEAD VALVE DT X360 6 2 1 SCHEMATIC DRAWING...

Page 74: ...sassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order of remo...

Page 75: ...8 1 2 kgf m Tensioner mounting bolt 1 0 1 4 kgf m Tensioner sealing bolt 0 4 kgf m Cylinder head nut 3 2 3 6 kgf m Apply engine oil to threads Cylinder head bolt 0 7 1 1 kgf m Valve clearance fixing...

Page 76: ...ve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plug Abnormal noise Incorrect valve clearance adjustment S...

Page 77: ...r are recommended at this point 3 1 Removal Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Squeeze the breather hose clam...

Page 78: ...olt with an 8 mm socket Free the fuel hose stay from the cylinder head cover Loosen the four cylinder head cover bolts with a 10 mm socket Remove the cylinder head cover bolts with washers and grommet...

Page 79: ...6 CYLINDER HEAD VALVE DT X360 6 8 Remove the cylinder head cover and gasket Discard the gasket and replace it with a new item on installation Remove the dowel pin...

Page 80: ...the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the spark plug See the Spark Plug topic for more information Remove the c...

Page 81: ...60 6 10 Remove the cam chain tensioner cap bolt with a 10 mm socket Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket Lift the cam chain tensioner our of the cylinder Remove the...

Page 82: ...X360 6 11 Use a 5 mm Allen wrench to remove the camshaft sprocket bolts Remove the camshaft sprocket as shown Support the chain so it does not fall into the cylinder head Use a 5 mm Allen wrench to r...

Page 83: ...6 CYLINDER HEAD VALVE DT X360 6 12 Remove the set plate as shown Thread a bolt into the rocker arm shafts and pull the shafts out Lift out the rocker arms as the shafts are removed...

Page 84: ...nspection Inspect the camshaft cam heights for the intake and exhaust lobes Inspect the camshaft bearings for excessive play or roughness Replace the entire camshaft assembly if the bearings are rough...

Page 85: ...outer diameter for the intake and exhaust valves Item Standard mm Valve rocker arm shaft O D IN 9 972 9 987 EX 9 972 9 987 Inspect the rocker arm inner diameter for the intake and exhaust valves Item...

Page 86: ...6 CYLINDER HEAD VALVE DT X360 6 15 Inspect the camshaft bearing journals for scoring or scratches...

Page 87: ...r head oil passages with compressed air Make sure all cylinder head oil passages are free of clogs NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or...

Page 88: ...eded The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Position the piston at top dead center as above The T mark should be aligned with the...

Page 89: ...ubricate the inside diameter of the rocker arms and the roller with fresh engine oil Position the rocker arms to accept the rocker arm shafts Wipe the rocker arm shafts clean Insert the rocker arm sha...

Page 90: ...amshaft and between the projections on the rocker arm shafts Apply a small amount of blue Loctite non permanent to the threads of the set plate bolt Thread in the bolt and tighten it to specification...

Page 91: ...over the camshaft sprocket For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the same time the T mark is lined up with the with the ind...

Page 92: ...he rod must be held in with the screwdriver until the cam chain tensioner mounting bolts have been installed Install the camchain tensioner with a new gasket Insert the mounting bolts and tighten them...

Page 93: ...the crankshaft 360 clockwise and check the engine timing one more time Make sure the cam chain tensioner cap bolt O ring is in good condition Install the O ring and cam chain tensioner cap bolt Tighte...

Page 94: ...ming inspection and crankshaft caps to the right side of the engine Tighten the caps securely but not overly with a large flat blade screwdriver Install the cylinder head cover See the Cylinder Head C...

Page 95: ...luggage box See the Luggage Box topic for more information Drain the coolant See the Coolant topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more infor...

Page 96: ...Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Allow any remaining coolant to drain into a suitable container Squeeze the air bleed hose clamp with needle nose...

Page 97: ...6 26 Remove the two right side cylinder head bolts with an 8 mm socket Also loosen the two cylinder bolts below with an 8 mm socket There are two cylinder head mounting nuts one below the intake port...

Page 98: ...holder nuts in a criss cross pattern over the course of 2 3 loosening sequences When installation Apply engine oil to the threads of the cylinder head nuts Thread on the four cylinder head nuts and ti...

Page 99: ...cylinder head off of the studs Guide the cam chain through the opening in the cylinder head but do not allow the chain to fall into the crankcase Remove the cylinder head gasket Remove the two dowel...

Page 100: ...6 CYLINDER HEAD VALVE DT X360 6 29 Remove the two intake mounting nuts with a 10 mm socket Remove the intake from the cylinder head Inspect the intake O ring and replace it as needed...

Page 101: ...om the cylinder head Use a 17 mm wrench to remove the water temperature sensor if needed Clean the combustion chamber with contact cleaner a plastic knife brush and or rag Take care to only remove car...

Page 102: ...X360 6 31 Place a straight edge across the bottom of the cylinder head and check for warp with a feeler gauge You will need to check clearance readings from several places on the bottom of the cylind...

Page 103: ...aft topic for more information Remove the cylinder head See the Cylinder Head topic for more information IMPORTANT Record the position of all parts so they can be returned to their proper place during...

Page 104: ...HEAD VALVE DT X360 6 33 Remove the spring retainer Remove the valve springs Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head Rotate the valve as it...

Page 105: ...alve guide The valve seals should be replaced if they are removed or you are going to install new valves Remove the spring seat 6 2 Inspection Inspect the valve springs for fatigue and damage Replace...

Page 106: ...6 CYLINDER HEAD VALVE DT X360 6 35...

Page 107: ...e If the measurement is below specification replace the valve Item Standard mm Valve stem O D IN 4 990 4 975 EX 4 970 4 955 Inspect the valve seat and the valve seat width The valve seat should be cen...

Page 108: ...e the guides if the measurement is out of specification Calculate the valve stem to guide clearance Replace the guide and valve if the clearance is out of specification Item Standard mm Valve guide I...

Page 109: ...TON DT X360 7 1 Cylinder Piston 1 SCHEMATIC DRAWING 2 2 SERVICE INFORMATION 3 2 1 GENERAL INSTRUCTIONS 3 2 2 SPECIFICATIONS 3 2 3 TROUBLESHOOTING 4 3 Cylinder Block 5 3 1 Removal 5 3 2 Inspection 10 3...

Page 110: ...7 CYLINDER PISTON DT X360 7 2 1 SCHEMATIC DRAWING...

Page 111: ...2 2 SPECIFICATIONS Unit mm Item Standard Cylinder Bore diameter A 75 30 75 31 B 75 31 75 32 Warpage Taper Out of round Piston piston ring Ring side Clearance Top 0 015 0 055 Second 0 015 0 055 Ring e...

Page 112: ...Compression too low or uneven compression Worn or damaged cylinder and piston rings Worn stuck or broken piston rings Compression too high Excessive carbon build up in combustion chamber or on piston...

Page 113: ...ee the Cylinder Head Cover topic for more information Remove the camshaft sprocket See the Camshaft topic for more information Remove the cylinder head See the Cylinder Head topic for more information...

Page 114: ...hose clamp with a 2 Phillips screwdriver Free the coolant hose from the cylinder Slide the cylinder off of the studs and piston Guide the cam chain through its opening and do not allow if to fall into...

Page 115: ...nd around the base of the piston to prevent any parts or debris falling into the crankcase Remove the piston pin clips with a pick or needle nose pliers Discard the piston pin clips Remove the piston...

Page 116: ...ston rings and lift them off opposite the gap Spread the rings the minimum amount during removal The rings can be easily damaged The two upper rings are each a single piece of metal The oil ring consi...

Page 117: ...lean the carbon build up off of the piston with a stiff bristled plastic brush or rag Never use a wire brush to clean a piston Also clean out the ring grooves You can use an old ring to scrape out any...

Page 118: ...The cylinder and piston must be replaced as a set There are two sets of cylinder and piston combinations Make sure to have a No A cylinder with an A piston or a No B cylinder with a B piston Inspect t...

Page 119: ...ent height levels with a dial bore gauge Replace the cylinder and piston as a set if the cylinder is out of specification Calculate the cylinder taper The taper is the maximum difference between eithe...

Page 120: ...linder to calculate the piston to cylinder clearance Replace the piston and cylinder as needed to achieve a correct piston to cylinder clearance Item Standard mm Piston to cylinder clearance 0 010 0 0...

Page 121: ...d of the connecting rod with vernier calipers Item Standard mm Connecting rod small end I D Bore 18 016 18 034 Measure the ring groove width and the ring to groove clearance with feeler gauges Item St...

Page 122: ...in the cylinder about an inch Use the piston to push in the ring to keep it square with the cylinder Measure the ring gap with a feeler gauge Repeat this procedure with second ring and the oil side ra...

Page 123: ...7 15 Check the oil jet for clogs 3 3 Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings Spread the rings the minimum amount possible to install them Do not try and...

Page 124: ...iston pin or perpendicular to the piston pin The rings should turn easily on the piston without sticking or roughness Install the oil expander ring so that the ends are not overlapping Install the ste...

Page 125: ...he piston pin into the piston and rod Install new piston pin clips securely into their grooves Turn the gap in the clips away from the access gap Make sure the cylinder head mating surface is clean In...

Page 126: ...in the two cylinder bolts on the right side of the engine Fit the coolant hose to the cylinder Tighten the cylinder coolant hose clamp to securely with a 2 Phillips screwdriver Insert the lower cam c...

Page 127: ...rque Values 3 2 4 Special Tools 3 2 5 Troubleshooting 4 3 Belt Case 5 3 1 Removal 5 3 2 Inspection 8 4 CVT Removal 10 4 1 Pulleys and Belt 10 4 2 Drive Pulley Disassembly 14 4 3 Clutch Disassembly 16...

Page 128: ...8 DRIVE DRIVEN PULLEYS DT X360 8 2 1 SCHEMATIC DRAWING...

Page 129: ...elt and drive pulley 2 2 Specifications Unit mm Item Standard Service limit Clutch lining thickness 4 0 2 0 Clutch outer I D 152 1 152 2 152 2 Driven face spring free length 103 5 Weight roller O D 19...

Page 130: ...ut motorcycle won t move Worn drive belt Broken ramp plate Worn or damaged clutch lining Broken driven face spring Engine stalls or motorcycle creeps Broken clutch weight spring Lack of power Worn dri...

Page 131: ...DRIVE DRIVEN PULLEYS DT X360 8 5 3 Belt Case SAFETY FIRST Protective gloves and eyewear are recommended at this point 3 1 Removal Remove the mounting bolts of belt case cover Remove the belt case cove...

Page 132: ...8 DRIVE DRIVEN PULLEYS DT X360 8 6 Remove the bolts of belt case and remove the belt case Remove the bolts of filter and remove the filter...

Page 133: ...8 DRIVE DRIVEN PULLEYS DT X360 8 7 Remove the belt case cover and gasket Remove the two dowel pins...

Page 134: ...360 8 8 3 2 Inspection Inspect the drive belt for cracks or excessive wear Inspect the belt case bearing by turning it with a finger Replace the bearing if it is rough or noisy Remove the bearing snap...

Page 135: ...LLEYS DT X360 8 9 Remove the bearing with a suitable bearing puller Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing Install a new snap ring with...

Page 136: ...s and eyewear are recommended at this point Remove the belt case See the Belt Case topic for more information 4 1 Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen the nut...

Page 137: ...8 DRIVE DRIVEN PULLEYS DT X360 8 11 Remove the left face of the drive pulley Loosen the driven pulley nut with a 19 mm socket Remove the driven pulley nut and bushing...

Page 138: ...8 DRIVE DRIVEN PULLEYS DT X360 8 12 Slide the driven pulley off of the shaft Remove the belt from the driven pulley Inspect the drive belt for cracks or excessive wear...

Page 139: ...8 DRIVE DRIVEN PULLEYS DT X360 8 13 Remove the right movable face of the drive pulley from the crankshaft Slide the bushing out of the movable drive face Remove the washer from the crankshaft...

Page 140: ...360 8 14 4 2 Drive Pulley Disassembly Inspect the faces of the drive pulley Clean away any grease from the faces Lift the ramp plate out of the back of the movable drive pulley face Remove the rubber...

Page 141: ...Remove the rollers and check them for excessive or uneven wear Measure the outside diameter of the rollers Replace the weight rollers as needed Item Standard mm Service Limit mm Weight roller O D Dri...

Page 142: ...the clutch outer off of the centrifugal clutch Inspect the inside of the clutch outer for excessive wear and damage Measure the inside diameter of the clutch outer and replace the part as needed Item...

Page 143: ...service limit Item Standard mm Service Limit mm Clutch lining thickness 4 0 2 0 To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch ITEM TOOL NO DESCRIPTION 41 N...

Page 144: ...ch spring compressor tool to compress the spring in the driven pulley assembly Secure the spring compressor tool in a vise Loosen the clutch drive plate nut with the special socket that comes with the...

Page 145: ...PULLEYS DT X360 8 19 Inspect the left side bearing by turning it with a finger If the bearing is rough turning or noisy it should be replaced Remove the clutch spring compressor tool Lift off the cent...

Page 146: ...8 DRIVE DRIVEN PULLEYS DT X360 8 20 Remove the collars and spring Measure the free length of the clutch spring Replace the spring if the measurement fails to meet the service limit...

Page 147: ...DRIVE DRIVEN PULLEYS DT X360 8 21 Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver Lift off the plate Slide the clutch shoes off of the pivots on the drive plat...

Page 148: ...VE DRIVEN PULLEYS DT X360 8 22 Inspect the clutch shoe bumpers and replace them as needed 4 4 Driven Pulley Disassembly Remove the clutch as shown above Remove the four guide rollers with guide roller...

Page 149: ...8 DRIVE DRIVEN PULLEYS DT X360 8 23 Separate the left and right faces of the driven pulley Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides...

Page 150: ...seals with a suitable driver with the same outside diameter as the seal Remove the O rings on the left face Clean the left face and roller pins with a high flash point solvent and compressed air NOTE...

Page 151: ...8 DRIVE DRIVEN PULLEYS DT X360 8 25 Bearing Replacement Inspect the bearings in the right face of the driven pulley Remove the needle bearing with a suitable puller...

Page 152: ...Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else Drive in the new baring so the sealed side face out towards the clutch Install the snap rin...

Page 153: ...8 DRIVE DRIVEN PULLEYS DT X360 8 27 Lubricate the bearings in the right face of the driven pulley with grease...

Page 154: ...SAFETY FIRST Protective gloves and eyewear are recommended at this point 5 1 Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease Drive in the new seals with a suit...

Page 155: ...O rings to the left face of the driven pulley Coat the O rings seals and inside of the left face where it rides on the right face with grease Fit the left face onto the right face Wipe away any grease...

Page 156: ...with grease Place the rollers on the pins and insert the pins into driven pulley as shown 5 2 Clutch Apply a light coat of grease to the brake shoe pivot pins on the drive plate Install the three rubb...

Page 157: ...8 DRIVE DRIVEN PULLEYS DT X360 8 31 Connect the clutch shoes with the springs as shown Slide the clutch shoes onto the drive plate pivots Fit the plate onto the clutch shoe pivots...

Page 158: ...DRIVEN PULLEYS DT X360 8 32 Install the three clutch shoe pivot circlips Install the seal collar and spring Install the spring collar into the spring and set the centrifugal clutch on top of the sprin...

Page 159: ...VE DRIVEN PULLEYS DT X360 8 33 Set the clutch fitting tool to onto the clutch Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Thread on the clutch drive plat...

Page 160: ...l socket that comes with the fitting tool Item Qty Torque kgf m lb ft Clutch drive plate nut 1 5 0 6 0 36 17 43 40 Wipe away any excess grease Do not allow grease to contact the clutch shoe linings or...

Page 161: ...the movable drive face of the driven pulley Position the rollers so that their colored sides are clockwise Insert the four rubber damper pieces into the ramp Fit the ramp into the back of the movable...

Page 162: ...lide the drive pulley washer onto the crankshaft Insert the bushing into movable drive face of the drive pulley Slide the movable face of the drive pulley onto the crankshaft Make sure the drive face...

Page 163: ...t the Belt in between the faces of the driven pulley Spread the faces by had if needed in get the belt to fit Slide the driven pulley and clutch assembly onto the final drive shaft Position the front...

Page 164: ...S DT X360 8 38 Install the driven pulley bushing and nut Torque the driven pulley nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft Clutch outer nut driven pulley 1 1...

Page 165: ...8 DRIVE DRIVEN PULLEYS DT X360 8 39 Slide the left face of the drive pulley onto the crankshaft Lubricate the threads of the drive pulley nut with engine oil Install the drive pulley washer and nut...

Page 166: ...ive pulley with a universal holder tool and torque the nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft Drive face nut 1 14 9 0 10 0 65 10 72 33 Install the belt cas...

Page 167: ...AWING 2 2 SERVICE INFORMATION 3 2 1 General Instructions 3 2 2 Specifications 3 2 3 Torque Values 3 2 4 Special Tools 3 2 5 Troubleshooting 3 3 Gear Oil 4 3 1 Draining 4 3 2 Filling 6 4 Final Reductio...

Page 168: ...9 FINAL REDUCTION DT X360 9 2 1 SCHEMATIC DRAWING...

Page 169: ...Oil SAE 90 Oil Capacity At disassembly 0 23 L At change 0 20 L 2 3 Torque Values ITEM TORQUE kgf m Transmission case cover bolt 1 8 2 2 L case gear oil check drain bolt 0 8 1 2 2 4 Special Tools Oil...

Page 170: ...il drain pan under the transmission oil drain plug Remove the transmission oil level filler bolt with a 12 mm socket Place a suitable container under the drain plug to capture the final drive oil Loos...

Page 171: ...T X360 9 5 Inspect the drain plug and washer Install the oil drain plug and washer with a 12 mm socket Tighten to specification Item Qty Thread size mm Torque kgf m lb ft Final drive oil drain bolt 1...

Page 172: ...60 9 6 3 2 Filling Fill the final drive with the specified quantity of oil with a syringe Gear oil type SAE 90 Gear oil capacity At disassembly 0 23 Liter At change 0 20 Liter Thread in the final driv...

Page 173: ...FINAL REDUCTION DT X360 9 7 Install the oil filler plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil filler bolt 1 8 0 8 1 2 5 79 8 68...

Page 174: ...ent If the drive shaft is replaced make sure to also replace the bearing and oil seal Remove the belt case See the Belt Case topic for more information Remove the CVT belt and pulleys See the CVT Remo...

Page 175: ...9 FINAL REDUCTION DT X360 9 9 Remove the 9 transmission case cover bolts using a 12 mm socket Utilize the reinforced pry points and remove the case cover...

Page 176: ...10 Use a press to remove the drive shaft Thread a nut onto the drive shaft to protect the threads If the drive shaft is to be replaced also replace the seal Remove the two dowel pins and the gasket R...

Page 177: ...9 FINAL REDUCTION DT X360 9 11 Remove the countershaft Remove the final shaft...

Page 178: ...untershaft gear for wear or damage Inspect the final gear and final shaft for wear damage or seizure If the final shaft snap ring is removed replace it with a new item Check the left crankcase bearing...

Page 179: ...transmission case cover bearings for excessive play Inspect the drive shaft drive shaft bearing and oil seal for wear or damage Use a bearing puller to remove the crankcase or transmission case covers...

Page 180: ...ame outside diameter as the bearings The bearings should go in square and have their markings facing out Drive in a new seals in the same manner if needed 4 3 Installation Lubricate the final drive be...

Page 181: ...Insert the final shaft through the oil seal and bearing Install the countershaft into its bearing as shown Install the final gear onto the final shaft as shown Install the dowel pins Install a new gas...

Page 182: ...ansmission case cover bolts Tighten the bolts to specification using a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Transmission case bolts 9 8 1 8 2 5 13 02 18 08 Install the rear wheel Se...

Page 183: ...Instructions 3 2 2 Specifications 3 2 3 Special Tools 3 2 4 Torque Values 3 2 5 Troubleshooting 3 3 A C GENERATOR AND STARTER CLUTCH 4 3 1 Removal 4 Stator and Pulsar Coil Crank Position Sensor 8 Fly...

Page 184: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 2 1 SCHEMATIC DRAWING...

Page 185: ...ight crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket Refer to chapter 17 for A C generator inspection 2 2 Specifications Engine Oil S...

Page 186: ...gloves and eyewear are recommended at this point 3 1 Removal Drain engine oil and remove the oil filter See the Engine Oil topic for more information Drain the coolant See the Coolant topic for more...

Page 187: ...p and free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the right crankcase coolant hose clamp with a 2 Phillips screwdriver Slide up the...

Page 188: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 6 Remove the 12 generator cover bolts with an 8 mm socket Utilize the pry points and remove the generator cover Remove the generator cover gasket...

Page 189: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 7 Remove the two dowel pins Remove the two oil filter chamber O rings Inspect the O rings and replace them as needed...

Page 190: ...see the Charging System topic For crank position sensor inspection see the Ignition System topic Free the rubber wire grommet from the right crankcase cover Remove the three stator mounting bolts and...

Page 191: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 9 Flywheel To remove the fly wheel two special tools are needed ITEM TOOL NO UNIVERSAL HOLDER E021 ITEM TOOL NO FLYWHEEL PULLER A120E00099...

Page 192: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 10 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket Remove the flywheel nut and washer...

Page 193: ...ase to the threads of the flywheel puller tool before using it Thread the puller onto the flywheel Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from...

Page 194: ...10 A C GENERATOR STARTER CLUTCH DT X360 10 12 Slide the starter driven gear off of the crankshaft Remove the woodruff key from the crankshaft...

Page 195: ...pect the starter idle gear and shaft for wear and damage Replace the idle gear and shaft as needed Inspect the starter driven gear for wear and damage Measure the inside and outside diameter of the st...

Page 196: ...lutch The starter clutch should only allow the driven gear to turn in one direction If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the...

Page 197: ...clutch mounting bolts Insert the three starter clutch mounting bolts Tighten the starter clutch mounting bolts to specification with a 6 mm Allen socket Item Qty Thread size mm Torque Remark kgf m lb...

Page 198: ...f the crankshaft Lubricate the inside of the starter driven gear with fresh engine oil Slide the starter driven gear onto the flywheel as shown Clean off the tapered end of the crankshaft where the fl...

Page 199: ...LUTCH DT X360 10 17 Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft Guide the starter driven gear into the starter clutch on the back of the flywheel Install t...

Page 200: ...60 10 18 Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft ACG flywheel nut 1 14 5 5 6 5 39 78 47...

Page 201: ...into the generator cover together as shown Insert the two crank position sensor mounting bolts and the three stator mounting bolts Tighten the bolts securely with an 8 mm socket Coat the rubber gromm...

Page 202: ...LUTCH DT X360 10 20 Generator Cover Make sure the generator cover mating surface is clean Install the two dowel pins and a new generator cover gasket Make sure the oil filter chamber O rings are in pl...

Page 203: ...TER CLUTCH DT X360 10 21 Fit the generator cover into place Make sure the water pump shaft engages correctly with the oil pump shaft Insert the 12 generator cover bolts Tighten the bolts securely in a...

Page 204: ...e cover pipe Secure the hose with the clamp and tighten the coolant hose clamp securely with a 2 Phillips screwdriver Connect the coolant hose to the water pump Move the clamp into place and tighten i...

Page 205: ...ensor wire coupler on the right side of the frame Fill the engine oil See the Engine Oil topic for more information Install the exhaust system See the Exhaust System topic for more information Fill th...

Page 206: ...WING 2 2 SERVICE INFORMATION 3 2 1 General Instructions 3 2 2 Specifications 3 2 3 Torque Values 3 2 4 Troubleshooting 3 3 Crankcase 4 3 1 Splitting 4 3 2 Assembly 10 4 Crankshaft 14 4 1 Removal 14 4...

Page 207: ...11 CRANK CASE DT X360 11 2 1 SCHEMATIC DRAWING...

Page 208: ...lowing parts must be removed before separating the crankcase Cylinder head Cylinder piston Drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pump 2...

Page 209: ...the Camshaft topic for more information Remove the cylinder head See the Cylinder Head topic for more information Remove the cylinder and piston See the Cylinder and Piston topic for more information...

Page 210: ...CRANK CASE DT X360 11 5 Remove the upper cam chain guide bolt with an 8 mm Allen Remove the upper cam chain guide Inspect the cam chain guides for damage and excessive wear Replace the guides as need...

Page 211: ...ankshaft and crankcase Inspect the cam chain for wear and damage Replace the cam chain as needed There are 11 crankcase bolts Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm socket...

Page 212: ...with the bottom two crankcase bolts Set the crankcases on the right side Separate the halves of the crankcase If needed gently tap the reinforced areas of the right crankcase half with a rubber malle...

Page 213: ...DT X360 11 8 Remove the dowel pins from the crankcase Inspect the O ring and replace it as needed To remove the crankshaft see the Crankshaft topic Replace the left crankshaft seal if the crankcases...

Page 214: ...e the seal with a seal pick Drive the new seal into the left crankcase from the outside with a suitable driver The driver should have the same outside diameter as the seal Lubricate the new crankshaft...

Page 215: ...urface Apply sealant uniformly to the crankcase mating surface as indicated Do not allow sealant to enter oil passages or get in bearings Set the right case half down on top of the left Install the en...

Page 216: ...Insert the 11 crankcase bolts The plate goes on with the bottom two bolts Tighten the bolts securely and evenly in a crisscross pattern with an 8 mm socket Install the cam chain around the timing spro...

Page 217: ...gf m lb ft Cam chain tensioner pivot 1 8 0 8 1 2 5 79 8 68 Install the oil pump See the Oil Pump topic for more information Install the starter idle gear driven gear flywheel and the generator cover S...

Page 218: ...d See the Cylinder Head topic Install the camshaft See the Camshaft topic for more information Install the cylinder head cover See the Cylinder Head Cover topic for more information Install the rear w...

Page 219: ...11 14 4 Crankshaft SAFETY FIRST Protective gloves and eyewear are recommended at this point 4 1 Removal Split the crankcases See the Crankcase topic for more information Lift the crankshaft out of th...

Page 220: ...l end of the connecting rod and try and push the rod down towards the crank weights If there is definite play between the connecting rod and crank the crankshaft should be replaced Measure the connect...

Page 221: ...ts are also marked with a size code When the crankshaft and or crankcases must be replaced also replace both crank bearings according to the chart below A A A and A all means A for both sides CVT and...

Page 222: ...ECTION 5 4 COOLANT REPLACEMENT 6 4 1 Preparation 6 4 2 Replacement 6 4 3 Air Bleeding 7 5 RADIATOR 8 5 1 Removal 8 5 2 Inspection 9 5 3 Installation 9 6 WATER PUMP 10 6 1 Mechanical Seal Water Seal In...

Page 223: ...coolant temperature is over 100 never remove the radiator cap to release the pressure because the boiling coolant may cause danger Avoid spilling coolant on painted surfaces because the coolant will...

Page 224: ...rect coolant temperature Faulty temperature gauge or thermo sensor Faulty thermostat Coolant leaks Faulty pump mechanical water seal Deteriorated O rings Damaged or deteriorated water hoses 2 5 Specif...

Page 225: ...070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1...

Page 226: ...remove it After remove the radiator cap wet the tester seal and install the end of the pressure tester onto the filler neck Pump the tester up until the gauge reads 0 84 kg cm2 or 12 psi The cooling...

Page 227: ...sage Therefore for best performance change the coolant regularly as specified in the maintenance schedule Mix only distilled low mineral water with the antifreeze Recommended mixture 1 1 Distilled wat...

Page 228: ...k to the upper level line Fill the system with the recommended coolant through the filler opening up to the filler neck Gently rock the vehicle side to side to release any air bubbles trapped in the c...

Page 229: ...and air bleed hose 2 Remove the nut 3 Loosen the hose bands and then disconnect the output hose 4 to the water pump coolant filling hose 5 and input hose 6 from the engine from the radiator Disconnect...

Page 230: ...air and water Check the radiator for any bent or damaged fins Use a small flat blade screwdriver to straighten them out but be careful not to puncture the radiator Always wear safety glasses when usi...

Page 231: ...le hole for signs of mechanical seal coolant leakage If the mechanical seal is leaking remove the right crankcase cover and replace the mechanical seal 6 2 Water Pump Impeller Removal Drain the coolan...

Page 232: ...pins Remove the water pump impeller The impeller has left hand threads Inspect the mechanical water seal and seal washer for wear or damage The mechanical seal and seal washer must be replaced as a se...

Page 233: ...water pump shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly Install the dowel pins and a new gasket...

Page 234: ...impeller Install the impeller onto the water pump shaft Torque 1 2 kgf m 12 N m 9 lbf ft The impeller has left hand threads Install the two dowel pins and a new gasket Install the water pump cover an...

Page 235: ...in a pan which is placed on an electric heater Gradually raise oil temperature while reading the thermometer in the pan and the ohmmeter connected If the resistance measured is out of specification r...

Page 236: ...tion With thread lock applied to the threaded part tighten the water temperature sensor Torque 0 8 kgf m 8 N m 5 8 lbf ft Connect the sensor connectors After the water temperature sensor has been inst...

Page 237: ...mounting bolts 2 and the thermostat housing from the cylinder head 8 2 Installation The installation sequence is the reverse of removal After the water thermostat has been installed fill coolant and...

Page 238: ...80 82 C 176 180 F Full open 90 C 198 F Valve lift 3 5 mm 0 14 in minimum Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room...

Page 239: ...ture Sensor 6 3 7 PPTS MAP Sensor Manifold Absolute Pressure TPS Throttle Position Sensor Inlet air temp sensor 7 3 8 CPS Crank Position Sensor 7 3 9 Oxygen Sensor 8 3 10 Rollover Sensor 8 4 ENGINE CO...

Page 240: ...13 Fi DIAGNOSTIC TOOL DT X360 2 1 SYSTEM DIAGRAM...

Page 241: ...13 Fi DIAGNOSTIC TOOL DT X360 3 2 EMS COMPONENTS LOCATION Rollover sensor KEYLESS controller Ignition switch OBD connector ECU Fuse box Start relay ABS controller...

Page 242: ...13 Fi DIAGNOSTIC TOOL DT X360 4 Fuel pump Throttle body Idle air bypass valve Fuel injector TTPS Intake air temperature sensor MAP TPS Ignition coil Rectifier Regulator Alternator Oxygen sensor...

Page 243: ...tage Standard Resistance 9 97 11 03 Fuel injector is a voltage driven electromagnetic needle valve It located on the front part of engine and there is an O ring on each connecting side The ECU control...

Page 244: ...e ECU controls the operation of the ignition coil through the ground terminal After the primary circuit forms a magnetic field by power pass through the power will be cut off by the ECU The secondary...

Page 245: ...ble resistor The ECU controls fuel injecting and ignition based on the voltage signal of the PPTS data 3 8 CPS Crank Position Sensor 2 Pins Grounded Pulse Signal Output When the flywheel rotates the i...

Page 246: ...sensor is 6 7 9 5 Voltage output after engine warm A F 14 7 Reach Mixture 0 7V A F 14 7 Lean Mixture 0 18V 3 10 Rollover Sensor 3 Pins Power Input Grounded Signal output Input DC 5V from ECU Once the...

Page 247: ...the time 4 2 Fuel Pressure Regulator This is a mechanical pressure regulator valve in the fuel pump The main function of the fuel pressure regulator is that maintains absolute pressure of fuel hose Th...

Page 248: ...vehicle This will cause the diagnostic tool crash 4 The diagnostic tool needs to reconnect again and reboot when the diagnostic tool crashes If the diagnostic tool does not recover still turn the ign...

Page 249: ...onnection or oxidation terminals 1 Poor Connection Check the connection between the harness wires and battery terminals fuse installation connection of each connector of Fi electronic components and s...

Page 250: ...and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed...

Page 251: ...of the rod seized Crankshaft seized Drive gear or bearing seized Camshaft seized Balance shaft bearing seized No fuel pass through Insufficient fuel Fuel tank breathe hole clogged Fuel filter clogged...

Page 252: ...lve spring broken fatigue Valve is bent worn carbon deposits on the seat Pressure release cam rod is not placed properly 2 Poor performance at low speed Weak spark Battery low Spark plug contaminated...

Page 253: ...too lean or too rich Air cleaner clogged no sealed no installed Throttle body loose Fuel pump malfunction Fuel contains water or foreign matters Fuel tank breathe hole clogged Fuel hose clogged Insuff...

Page 254: ...le Cause Exhaust pipe clogged 4 Excessive smoke White smoke Cylinder worn Valve oil seal worn Piston oil ring worn Valve guides or valve stem seals worn Too much engine oil Black smoke Air cleaner clo...

Page 255: ...emperature intermittent failure AF P0120 Throttle Position Sensor malfunction or Voltage Low B0 P0121 Throttle position sensor adaptation is out of range B1 P0122 Throttle Position Sensor Voltage Low...

Page 256: ...4 P2300 Ignition malfunction or Voltage Low D5 P2301 Ignition malfunction or Voltage High D7 P0171 System over lean or over rich Too Lean D8 P0172 System over lean or over rich Too Rich D9 P0501 Vehic...

Page 257: ...ion D4 P2303 Ignition malfunction or Voltage Low D5 P2304 Ignition malfunction or Voltage High F5 P0642 Sensor Power Voltage Low F6 P0643 Sensor Power Voltage High F7 P0615 Starter Relay malfunction F...

Page 258: ...3 10 5 0 53 3 Fuel pump V V Resistance of the fuel pump 1 9 4 ISC Idle air bypass valve V X On board testing with the diagnostic tool 5 Inductive ignition coil V V Primary 3 57 4 83 Secondary 10 42 14...

Page 259: ...13 Fi DIAGNOSTIC TOOL DT X360 21 8 ECU WIRING...

Page 260: ...e Occurred The occurred fault after starting the engine History Faults that have occurred in the past but have not been cleared Cool Engine Engine Stop Engine Temp C Eviron temp 2 C Atm Press kPa 101...

Page 261: ...0 1 2V O2 correction 10 ISC step Below 45 Factory standard value Below 46 1 When the angle exceeds 46 clean the throttle body when exchange the engine oil 2 When the angle exceeds 500 clean the thrott...

Page 262: ...ion 10 ISC step Below 45 Factory standard value Below 46 3 When the angle exceeds 46 clean the throttle body when exchange the engine oil 4 When the angle exceeds 500 clean the throttle body for optim...

Page 263: ...sembly 7 3 4 Assembly 8 4 Front Brake Fluid 9 4 1 Check 9 4 2 Fluid Replacement Air Bleeding 9 4 3 Brake Fluid Draining 9 4 4 Brake Fluid Filling Air Bleeding 10 5 Front Brake Pad 11 5 1 Brake Pad Rep...

Page 264: ...14 FRONT ASSEMBLY DT X360 14 2 1 SCHEMATIC DRAWING...

Page 265: ...14 FRONT ASSEMBLY DT X360 14 3...

Page 266: ...3 0 Brake Disk Runout 0 3 Brake Master Cylinder I D 12 7 12 74 Brake Master Cylinder Piston O D 12 65 12 68 Brake Caliper Piston O D 25 33 25 36 Brake Caliper Cylinder I D 25 4 25 45 TORQUE VALUES 2...

Page 267: ...e or does not track straight Uneven front shock absorbers Bent front fork Bent front axle or uneven tire Poor brake performance Worn brake pads Contaminated brake pad surface Deformed brake disk Air i...

Page 268: ...all in the reverse order of work Inspection 3 2 Remove the collars from each side of the wheel Inspect the bearing seals and the O rings seals on the collars Replace the seals if they are in poor cond...

Page 269: ...e to the collar and then install the collar onto the wheel Disassembly 3 3 Replace bearings as a set and do not reuse old bearings Place the new bearings in the freezer about an hour before you plan t...

Page 270: ...a bearing installer tool or a socket with the same outside diameter as the bearing Make sure the bearing is fully seated and the marked side is facing out Special tool Bearing installer A120E00014 In...

Page 271: ...ing instructions A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Do not allow foreign materia...

Page 272: ...bleed valve and operate the front brake lever If it still spongy bleed the system again If the brake bleeder is not available perform the following procedure Pump up the system pressure with the brake...

Page 273: ...rs to ensure even disc pressure Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring and insert the brake pad pin It may be necessary to spread the pads an...

Page 274: ...vice limits 4 mm Replace the brake disc if the smallest measurement is less than the service limit Measure the brake disc warpage Service limits 0 3 mm Removal 6 2 Remove the front wheel Remove the fi...

Page 275: ...from the handlebar cable guide Remove the handlebar lock nut and take out the bolt Remove the handlebar and collar Installation 7 2 Install the handlebar onto the steering stem and install the handle...

Page 276: ...the right switch housing from the handlebar Remove the two screws and then remove the left handlebar switch Disconnect the switch Separate the left switch housing from the handlebar Bar ends Remove th...

Page 277: ...area with a brake or parts cleaner that will dry without leaving a residue When you are sure the area is dry apply grip cement to the bar or tube Install the left grip at an angle of your preference...

Page 278: ...lamp Loosen the fork clamp pinch bolts with a 12 mm socket The top bolts must be removed Slide the forks legs down and out of the fork clamp using a twisting motion Installation is in the reverse orde...

Page 279: ...adjusting nut may need to be adjusted Always replace the races at the same time as the bearings Remove the handlebar covers Remove the front cover Remove the handlebar Remove the front fender Remove...

Page 280: ...se the special tools or a drift and hammer to drive out the bearing races in the steering head Have the drift set against the lip of the race and work around the race evenly to drive it out Repeat the...

Page 281: ...tall the steering stem Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other cl...

Page 282: ...14 FRONT ASSEMBLY DT X360 14 20 Bottom Ball Race Remove Special Tool Bottom Ball Race Install special tool Top Ball Cone Race Install special tool...

Page 283: ...3 2 3 TORQUE VALUES 3 2 4 TROUBLESHOOTING 4 3 Rear Brake 5 3 1 Rear Brake Caliper Removal 5 3 2 Inspection 5 3 3 Disassembly 6 3 4 Assembly 7 3 5 Installation 8 4 Rear Fork 9 4 1 Removal 9 4 2 Inspec...

Page 284: ...15 REAR ASSEMBLY DT X360 15 2 1 SCHEMATIC DRAWING...

Page 285: ...rd mm Service Limit mm Rear wheel rim runout 2 0 Rear brake disk thickness 5 0 4 0 Rear brake disk runout 0 3 Rear brake master cylinder I D 27 00 Rear brake master cylinder piston O D 26 95 TORQUE VA...

Page 286: ...rectly mounted suspension components Incorrect damper adjustment Bent swing arm pivot Bent damper rod Damaged swing arm pivot bearing s Faulty suspension linkage Damaged linkage pivot bearings Rear wh...

Page 287: ...ake hose banjo bolt sealing washers with new items on assembly Remove the exhaust muffler Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove two bolts attaching the rear...

Page 288: ...g and place a towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to r...

Page 289: ...inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3 5mm beyond the brake caliper Install the two spring plate...

Page 290: ...orque 27 N m Connect the brake fluid tube to the brake caliper and install fluid tube bolt copper washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bl...

Page 291: ...to protect the rear fork and covers from being scratched Install in the reverse order of work Inspection 4 2 Remove the clip Turn the inner race of each bearing with your finger to see if they turn sm...

Page 292: ...the rear fork Remove the rear axle collar Remove the rear wheel Inspection 5 2 Measure the rear wheel rim runout Installation 5 3 Apply a proper amount of grease on the rear axle before installation I...

Page 293: ...the body cover center cover and rear fender together Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers Installation 6 2 Install the r...

Page 294: ...INFORMATION 3 2 1 GENERAL INSTRUCTIONS 3 2 2 SPECIFICATIONS 4 2 3 TROUBLESHOOTING 4 3 Battery 5 3 1 Removal 5 3 2 Installation 5 3 3 Voltage Inspection 5 3 4 Battery Charging 6 4 Charging System Insp...

Page 295: ...16 BATTERY CHARGING SYSTEM DT X360 16 2 1 CHARGING SYSTEM LAYOUT Positive cord Negative cord OBD connector ACG REGULATOR RECTIFIER...

Page 296: ...with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging sy...

Page 297: ...performance 18A 5000rpm Regulator Rectifier Regulated voltage 14 5 0 5V TROUBLESHOOTING 2 3 No power Dead battery Disconnected battery cable Fuse burned out Faulty ignition switch Low power Weak batte...

Page 298: ...n disconnect the positive cable 5 Remove the battery from the battery box Installation 3 2 Install in the reverse order of the removal When install the battery first connect the positive cable and the...

Page 299: ...he leads will permit Always keep flammable material or spark from battery Turn off the charger after charging Charging the battery under 45 Quick charging should only be done in an emergency slow char...

Page 300: ...which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000...

Page 301: ...ground There should be continuity at all times and the value should be very small The inspection value should be minus the resistance value between the probes Check the continuity between the each ye...

Page 302: ...TEM DT X360 16 9 Removal Installation 5 2 Remove the side body cover Disconnect the regulator rectifier connectors Remove the two bolts regulator rectifier Installation is in the reverse order of remo...

Page 303: ...rmation 3 2 1 General instructions 3 2 2 Specifications 3 2 3 Troubleshooting 4 3 Spark Plug 5 3 1 Inspection 5 4 Ignition Coil 5 4 1 Removal 5 4 2 Inspection 6 5 Crank Position Sensor 6 5 1 Inspectio...

Page 304: ...17 IGNITION SYSTEM DT X360 17 2 1 Ignition System Layout Rollover sensor ECU Ignition switch Ignition coil CPS...

Page 305: ...urn off the ignition switch before servicing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using t...

Page 306: ...dule connectors Open circuit or poor connection in ground wire of the ignition control module Faulty ignition pulse generator Faulty ignition control module PEAK VOLTAGE IS NORMAL BUT NO SPARK JUMPS A...

Page 307: ...c for more information If the spark plug center electrode or side electrode are corroded or damaged or if the insulator is cracked replace the plug Measure the gap with a wire type thickness gauge If...

Page 308: ...terminal and the spark plug cap Secondary resistance with spark plug cap 12 5 15 8 Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap Secondary...

Page 309: ...stance Terminal Value V R G P 5V ECU voltage B L G P 0 4 1 4V Fall down resistance Incline the tilt switch 65 10 degrees to the left or right at the ignition switch ON Measure the voltage as below Ter...

Page 310: ...connect the harness cable Remove the mounting nuts Remove the ECU The ignition control module or ECU may be damaged if dropped soak in water or the connector is disconnected when the key is ON The exc...

Page 311: ...tarting System Layout 2 2 Service Information 3 2 1 General Instructions 3 2 2 Torque Values 3 2 3 Troubleshooting 3 3 Start Motor 4 3 1 Inspection 4 3 2 Removal 4 3 3 Installation 4 4 Starter Relay 5...

Page 312: ...18 STARTING SYSTEM DT X360 18 2 1 Starting System Layout Battery Start MAG switch Start Motor...

Page 313: ...Item Unit kgf m N m Starter motor mounting bolt 0 7 1 1 7 11 ACG flywheel mounting bolt 5 5 6 5 55 65 2 3 Troubleshooting Starter motor won t turn Fuse burned out Weak battery Faulty ignition switch...

Page 314: ...he rubber cap and remove the terminal screw to disconnect the cable from the start motor Remove the two mounting bolts then remove the start motor Rubber cap Cable 3 3 Installation Coat a new O ring 9...

Page 315: ...relay may be damaged and fail starting 4 3 Inspection Continuity Test Disconnect the starter relay wire connector Check for continuity between the yellow red wire and green yellow wire There should b...

Page 316: ...and the frame There should be continuity always Operation Test Removed Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable...

Page 317: ...ate Light 6 4 Speed Sensors 6 4 1 Front Speed Sensor 6 4 2 Inspection 7 5 Switches 8 5 1 Brake Light Switch 8 5 2 Ignition Switch 8 5 3 Right handlebar switch 9 5 4 Left Handlebar Switch 10 6 Luggage...

Page 318: ...19 ELECTRICAL SYSTEM DT X360 19 2 10 1 Inspection 18 10 2 Removal Installation 18 11 Rollover sensor 19 11 1 Inspection 19 11 2 Removal Installation 19...

Page 319: ...o prevent its early failure Be sure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that requires proper battery voltage A continuity te...

Page 320: ...r removal to prevent scratches Remove the headlight assy Remove screws Remove the headlight Install in the reverse order of work 2 2 Front turn signal lights Remove the headlight assy Remove the screw...

Page 321: ...ights assy 3 1 Tail light assy Remove the rear light assy Remove screws on the each side of cover Remove the side covers Remove the rear center cover Remove the screws Remove the tail light assy Insta...

Page 322: ...e screws Push and turn the bulb counterclockwise to remove it and then replace with a new one Specification 12V 5W Installation is in the reverse order of removal 4 Speed Sensors 4 1 Front Speed Senso...

Page 323: ...Remove the rear speed sensor Install in the reverse order of removal 4 2 Inspection After remove the speed sensor rotate the wheel to check the speed sensor ring If the speed sensor ring is deformed o...

Page 324: ...and check for continuity between the switch terminals 1 There should be continuity with the front or rear brake lever squeezed and there should be no continuity when the front or rear brake lever 2 is...

Page 325: ...lebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Engine Stop SW...

Page 326: ...ebar Switch Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Turn Signal Light...

Page 327: ...box light sensor being covered up and there should be continuity with the luggage box light sensor being not covered up To inspect the lamp and sensor of luggage box Sensor Voltage supply range 8 16V...

Page 328: ...does not come up perform the following inspection process 1 Remove the protective cap to disconnect the wire 2 Connect the wire to ground directly to check if the indicator comes up automatically 3 If...

Page 329: ...cap and disconnect the wire Remove the engine oil pressure sensor 7 3 Installation Apply suitable sealant as shown and do not seize the sensor Tighten the oil pressure sensor to specified torque TORQU...

Page 330: ...the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose Remove the 6 nuts 1 and fuel unit connectors 2 then remove the fuel hose 3...

Page 331: ...normal Use a good condition and fully charged battery to perform the inspection Check the fuel meter for correct indication by moving the fuel unit float up and down Float Position Display Upper Much...

Page 332: ...minals of the fuel unit connector Standard at 20 C 68 F Float at full position About1100 Float at empty position About100 8 3 Installation Installation is in the reverse order of removal Check the fue...

Page 333: ...should be continuity between the Yellow Black and Green with the side stand applied 9 2 Removal Disconnect the side stand switch connector Remove the bolt and side stand switch from the side stand 9...

Page 334: ...tors 1 from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is connected across the horn terminals 10 2 Removal Installation Disconnect the...

Page 335: ...voltage of the rollover sensor Termials Standard V R G P 5V ECU voltage B L G P 0 4 1 4V If the vehicle tipping angle exceeds 65 the engine will stop 11 2 Removal Installation Disconnect the connector...

Page 336: ...4 1 4 Removal 7 1 5 Installation 7 2 Diagnostic Tool 8 2 1 PC version 8 3 Diagnostic Tool Operation 9 3 1 Operation Instructions 9 3 2 Connection 10 3 3 DTC Inspect 11 3 4 DTC Displayed 11 3 5 DTC Cle...

Page 337: ...BS automatically regulates brake force Intermittently gaining gripping force and braking force helps prevent wheel lock up and allows stable steering control while stopping Brake control function is i...

Page 338: ...hicle speed with wheel speed Since non recommended tires can affect wheel speed they may confuse which can extend distance Use of non recommended tires may cause malfunctioning of ABS and lead to exte...

Page 339: ...a tire different in size from the standard size is being used Replace with standard size When the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of confirming contin...

Page 340: ...21 ANTI LOCK BRAKE SYSTEM ABS DT X360 21 5 Pre diagnosis Inspection Chart 1...

Page 341: ...21 ANTI LOCK BRAKE SYSTEM ABS DT X360 21 6 Pre diagnosis Inspection Chart 2...

Page 342: ...damage the joint claw Remove the bolts Remove the ABS module Installation 1 5 Install in the reverse order of removal TORQUE 3 4 kgf m Install the brake fluuid hoses in the correct positions Wipe off...

Page 343: ...l software Remove the front cover Connect the integrated linker to the OBD connector Turn on the ignition switch Chose the ABS brake system Check the ECU version which should be ACD5 If any of compone...

Page 344: ...Model No UP Button Down Button Adjust TPI and ABV reset function DTC indicator Failure codes DATA Analyze Enter or Exit DTC Inspect Power indicator ECU Version Note For EURO models Use the Sub cord O...

Page 345: ...i Diagnostic tool Power comes from vehicle s Battery 2 Put the side stand upward and ENG stop switch is at RUN position 3 Choose Fi ECU Version and press the enter button 4 Press the down button 2 tim...

Page 346: ...LOCK BRAKE SYSTEM ABS DT X360 21 11 DTC Inspect 3 3 1 Choose DTC Inspect 2 Load DTC Active Occurred History DTC Displayed 3 4 1 Rear wheel speed sensor disconnect 2 Front wheel speed sensor disconnec...

Page 347: ...ed lamp is off Data Analyze 3 6 1 Choose DATA Analyze and then push Enter button 2 Front wheel speed Rear wheel speed Battery volt Battery volt Standard 9 6 16 7 V You can turn the front or rear wheel...

Page 348: ...10 5044 Rear wheel speed sensor malfunction Plausibility 11 5045 Rear wheel speed sensor Disconnection gnd Short Battery Voltage Short 12 5052 Power Supply Malfunction Under Voltage 13 5053 Power Sup...

Page 349: ...21 ANTI LOCK BRAKE SYSTEM ABS DT X360 21 14 5 Introduction to KYMCO TCS System...

Page 350: ...21 ANTI LOCK BRAKE SYSTEM ABS DT X360 21 15...

Page 351: ...21 ANTI LOCK BRAKE SYSTEM ABS DT X360 21 16...

Page 352: ...ankcase Emission Control System 3 2 3 Exhaust Emission Control System 3 2 4 Noise Exhaust Emission Control System 3 3 Function 4 3 1 Trouble Shooting 4 4 Maintenance Schedule 5 4 1 Maintenance schedul...

Page 353: ...Emission System Diagram Fuel tank Fuel pump Fuel Fuel injector Canister Air cleaner Negative pressure Negative pressure Fuel Fuel vapors Water bleed hole Fuel vapors To atmosphere Crankcase blow by I...

Page 354: ...2 2 Crankcase Emission Control System The scooter is equipped with a closed crankcase system Blow by gas is recycled into the combustion chamber via the intake system This arrangement is to prevent bl...

Page 355: ...condition Sending the mixture condition info to ECU by voltage signal ECU controls the fuel injection to meet the emission regulation Catalyst To reduce the emission of HC CO and NOx produced from the...

Page 356: ...by properly trained and equipped technicians Your KYMCO dealer meets all of these requirements Should be serviced by your KYMCO dealer unless the owner has the proper tools and service data and is mec...

Page 357: ...se Breather Note3 C C C C C C C Engine Oil R R R R R R R Engine Oil Screen C R C R C R Engine Oil Filter R R R R R R R Engine Idle Speed I I I Transmission Oil Note5 R R R R R R R Drive Belt I I I R I...

Page 358: ...replaced with a new one The tubes should be installed tightly The leakage hole should be installed downward Tool Vacuum pump Pressure pump Maintenance standard Emission Vacuum Standard 45m mHg Capacit...

Page 359: ...ve control valve If the pressure will be kept without change obviously in one minute that means the valve are with good condition otherwise the valve malfunction a new canister should be replaced Conn...

Page 360: ...flow rate above 9 4 liters per minute that means the valve is in good condition otherwise the canister should be replaced Always using the pump by manual do not apply high pressure for testing to prev...

Page 361: ...eaner element The new air cleaner element installation is in the reverse order of removal Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using...

Page 362: ...educe the pollution emission Inspect Catalyst Converter Inspect catalyst converter efficiency at idle speed Warm up the engine 8 10 minutes connect to emission machine To check the CO value before cat...

Page 363: ...ygen Sensor to work normally In normal hours the impedance of heater is 7 7 1 2 ohm and can be told with multimeter Output of sensor after the engine is warmed up is A F 14 7 mixing ratio too thick 0...

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KYMCO AHG5, Service Manual

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