KYMCO AK 550 Service Manual Download

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10..Brake System

AK 550

SAFETY FIRST: Protective gloves and eyewear are recommended at this
point.

NOTE: Brake fluid is a corrosive chemical and can damage paints and some

plastics. Avoid contact with skin.

Master Cylinders Removal

The master cylinders for the front and rear brakes are essentially the same way.

Bleed the brake fluid.

Place a suitable container under the banjo bolt to catch any remaining brake fluid.

Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm

socket. Discard the two sealing washers.

Replace the brake hose banjo bolt sealing washers with new items on assembly.

Remove the two master cylinder cover screws with a #2 Phillips head screwdriver.

Remove the master cylinder cover, plastic piece and rubber accordion diaphragm.

Pour out any remaining brake fluid.

10-12

Summary of Contents for AK 550

Page 1: ...formation available at the time of publication Illustrations in this manual are shown to help you with the basics of performing the jobs listed The pictures in this manual may not depict the actual ve...

Page 2: ...trations in this manual have been reviewed for accuracy it is up to the individual performing the procedures to use good judgement when performing any procedures described Every precaution has been ta...

Page 3: ...riodic Maintenance Maintenance Schedule 2 2 Air Filter Servicing 2 4 Brake Fluid 2 6 Brake Inspection 2 10 Coolant 2 14 Engine Oil 2 18 General Lubrication 2 23 Side Stand 2 24 Spark Plug 2 25 Engine...

Page 4: ...Skirt Set 3 6 Panel Floor 3 7 Seat 3 8 Luggage Box 3 9 Center Cover B Side Board A 3 10 Front Cover Set 3 11 Meter Cover Set 3 13 Leg Shield Set 3 14 Front Inner Fender Under Cowl Set 3 15 Front Fende...

Page 5: ...ylinder Head 4 16 Cylinder 4 19 Piston 4 20 CVT 4 21 Left Side Cover 4 36 Fly Wheel 4 38 Mission Box 4 42 Crankcase 4 53 Crankshaft Balancer Gear Plane Bearing 4 56 Plane Bearing Selection 4 57 Engine...

Page 6: ...4 FUEL TANK 6 15 FUEL PUMP 6 21 FUEL INJECTOR 6 27 THROTTLE BODY 6 32 T MAP SENSOR 6 36 TPS SENSOR 6 37 ISC 6 38 TILT SWITCH 6 40 WATER TEMPERATURE SENSOR 6 42 SELF DIAGNOSIS 6 43 DIAGNOSTIC TOOL 6 34...

Page 7: ...ns 9 1 Troubleshooting 9 3 Component Location 9 8 Fuses 9 12 ECU 9 13 Ignition System 9 15 Spark Plug 9 16 Charging System 9 19 Battery 9 23 Starting System 9 25 Relays 9 27 Switches 9 28 Lights 9 42...

Page 8: ...E BRAKE FLUID 10 12 PARKING BRAKE 10 18 DISC BRAKE 10 19 ABS SYSTEM 10 20 ABS TROUBLESHOOTING OUTLINE 10 25 11 Steering TROUBLESHOOTING 11 2 Up And Low Handle Cover Removal 11 2 Handlebar 11 3 Switch...

Page 9: ...e wheels for the KYMCO AK 550 model Troubleshooting 14 1 Front Wheel 14 2 Front Fender Assy Removal 14 2 Front Wheel Disassembly 14 6 Bearing Replacement 14 9 Rear Wheel 14 11 Rear Wheel Inspection 14...

Page 10: ...uick reference source of technical specifications and information for KYMCO AK 550 model Component Location 1 2 Special Tools 1 5 Specifications 1 7 Fuel Injection System Failure Code 1 12 Torque Spec...

Page 11: ...ark Plug Coolant Reserve Tank Ignition Switch Radiator Keyless Seat Open Controller Diagnostic Tool Connector Fuel Tank Air Cleaner Element Canister Muffler Rear Wheel Speed Sensor Connector Horn Tire...

Page 12: ...1 Quick Reference AK 550 1 3 Component Location Throttle Body TPS Fuel Injector Fuel Pump T MAP Sensor Fuel Cap Thermostat T MAP Sensor Air Cleaner...

Page 13: ...Quick Reference AK 550 1 4 Component Location Radiator Cap Winker Relay Turn Signal ECU Tilt Switch ABS ECU Heater Grip Controller Battery Fuel Pump Relay Fan Relay Seat Relay Main Relay Starter Rela...

Page 14: ...A120 E00048 FUEL PRESSURE GAUAGE E053 A120 E00098 CLUTCH SPRING COMPRESSOR E053 E028 E056 A120 E00017 UNIVERSAL HOLDER E058 A120 E00021 DRIVE PULLEY HOLDER E064 A120 E00014 OIL SEAL BEARING INSTALLER...

Page 15: ...NCH F023 A120 F00023 STEERING STEM TOP THREAD WRENCH F030 A120 F00030 BAND REMOVER INSTALLER F031 A120 F00031 PLIERS FUEL PIPE F032 A120 F00032 ELECTRIC REPAIR KIT F033 A120 F00033 DIGITAL ELECTRIC GA...

Page 16: ...Wheel base mm 1580 10 Engine type 4 stroke DOHC Displacement cc 550 Fuel recommended 90 nonleaded gasoline Curb weight kg Front wheel 110 4 Rear wheel 116 4 Total 226 4 Max weight capacity kg Front w...

Page 17: ...g cm2 Max Horsepower M1 53 7500 PS rpm M2 46 7000 PS rpm Max Torque 5 4 6000 Kg m rpm Valve timing Intake Open 16 BTDC Close 30 ABDC Exhaust Open 35 BBDC Close 3 ATDC Valve clearance cold mm Intake 0...

Page 18: ...System Clutch Type Wet multi disk Transmission Gear Type CVT Operation Automatic centrifugal type Reduction Gear Type Two stage reduction Reduction ratio 1st 0 8 2 4 2nd 2 659 Moving Device Tire type...

Page 19: ...plug gap 0 7 mm 0 8 mm Valve clearance IN 0 175 mm EX 0 225 mm Idle speed 1200 100 rpm Compression ratio 11 0 2 Ignition timing ECU Coolant type Liquid cooling Engine oil capacity At disassembly 3 Lit...

Page 20: ...1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1 025 30 1 053 1 051 1 051 1 049 1 047 1 045 1 04...

Page 21: ...it Voltage Too Low Or Broken Circuit P0232 Fuel Pump Relay Circuit Voltage Too High P0261 Injector Right Circuit Voltage Too Low Or Broken Circuit P0262 Injector Right Circuit Voltage Too High P0264 I...

Page 22: ...Item Standard Spark plug Standard type NGKCR7E Spark plug gap 0 7 0 8 mm Throttle Position Sensor 3000 7000 Fuel Pump 2 2 approx Fuel Injector 10 6 15 9 Oxygen Sensor engine warming condition 12 18 Cr...

Page 23: ...1 Quick Reference AK 550 1 14 Engine Torque Specifications...

Page 24: ...1 Quick Reference AK 550 1 15 Frame Torque Specifications...

Page 25: ...bolt nut 0 8 1 2 5 79 8 68 8 mm bolt nut 1 8 2 5 13 02 18 08 10 mm bolt nut 3 0 4 0 21 70 28 93 12 mm bolt nut 5 0 6 0 36 17 43 40 5 mm screw 0 45 0 6 3 25 4 34 6 mm screw SH bolt 0 7 1 1 5 06 7 96 6...

Page 26: ...uel Pump Fuel Pump Relay It will turn off automatically in 5 10 seconds 3 Key On to check for any failure lamp light up on dashboard See theSelf Diagnosis topic for more information 4 Is the Idle scre...

Page 27: ...1 Quick Reference AK 550 1 18 General Troubleshooting...

Page 28: ...1 Quick Reference AK 550 1 19...

Page 29: ...1 Quick Reference AK 550 1 20...

Page 30: ...1 Quick Reference AK 550 1 21...

Page 31: ...1 Quick Reference AK 550 1 22 VIN and Engine Number Location Engine Number VIN Number...

Page 32: ...Brake 2 30 Light Inspection 2 31 Tires 2 32 TPMS Tire Pressure Management System 2 33 Drive Belt Inspection 2 38 Drive Belt Tension Adjustment 2 40 Valve Clearance Adjustment 2 45 WARNING Before runni...

Page 33: ...pecifies the maintenance required to keep your AK 550 scooter in peak operating condition Maintenance work should be performed in accordance with KYMCO standards and specifications by properly trained...

Page 34: ...Hose Inspection I I I Engine Oil R R R R R R R Engine Oil Screen C C C C C C Engine Oil Filter R R R R R R R Fuel Injection Diagnostic Tool I I I CVT Removal I I I I I I CVT Air Filter C C C C C C CVT...

Page 35: ...lter Cartridge Precautions on replacing Filter Cartridge 1 Make sure the Air Filter Cartridge is positioned correctly in the casing 2 Do not start engine when Air Filter Cartridge is not installed or...

Page 36: ...tenance Schedule replace or clean Filter Wool every 5000km Replace Filter Wool 1 Remove side plate on the right 2 Remove Fixing Bolts of Crankcase Right Cover 3 Remove 2 Fixing Bolts of Filter Wool 4...

Page 37: ...gloves and eyewear are recommended at this point Checking Front Brake Fluid 1 Straighten the Handlebar check brake fluid in the Right Reservoir Keep the level between the Upper Mark and Lower Mark 2 I...

Page 38: ...voir with recommended DOT 4 Brake Fluid to the Upper Scale Replace Reservoir Cover and tighten 2 fixing screws 3 Replace Brake Fluid every 10000km or 1 year WARNING Mixed use of Brake Fluids of differ...

Page 39: ...ut any remaining brake fluid Clean and inspect the rubber diaphragm for tears or other damage Replace as necessary Pull off the rubber cap over the bleeder valve and crack open the bleeder valve on th...

Page 40: ...ck the master cylinder reservoir occasionally to make sure the reservoir doesn t run dry Add more brake fluid as necessary Continue this process until clean brake fluid comes out of the bleeder valve...

Page 41: ...the lever forward and turn the adjuster knob to align the number with the arrow mark on the lever holder Check and Adjust Brakes 1 Adjust brake lever clearance using adjustment knob totally 4 adjustme...

Page 42: ...dic Maintenance AK 550 2 11 Brake Pad Is braking effective Verify braking effect of front and rear brakes in low speed Brake Pad Removal Remove the snap clip of the pin Remove the screw loosen the bra...

Page 43: ...Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Insert new brake pads as needed Remove the two bolts of caliper and remove the caliper Installation torque...

Page 44: ...ake pad pin It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads Install the front caliper Guide the...

Page 45: ...Check water level after the engine cools down Inclined vehicle may cause false reading of Cooling Water level 3 Check level of Cooling Water via viewing window on the water preserving tank Make sure...

Page 46: ...ality cooling water may shorten the service life of water tank Please be careful Replace cooling water in the tank every 10000km Add proper amount of water tank additives to ensure performance of the...

Page 47: ...Coolant Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Coolant capacity Total 1500 cc Radiator 1200 cc Reserve tank 300 cc Use coolant of speci...

Page 48: ...cooling system Place the vehicle on its center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles...

Page 49: ...ion Hot engine oil can burn Avoid letting used motor oil contact exposed skin TROUBLESHOOTING Oil level too low 1 Natural oil consumption 2 Oil leaks 3 Worn or poorly installed piston rings 4 Worn val...

Page 50: ...thout threading it in Remove the dipstick and check the oil level The level must be maintained between the upper and lower level marks on the oil filler cap dipstick If the oil level is at or below th...

Page 51: ...ong with time and cause damage to the engine Applicable Temperature of Engine Oil NOTICE To avoid using poor quality oil please go to a KYMCO dealer for oil change Oil Change Method 1 Remove Oil Scale...

Page 52: ...L full capacity Change oil 2 6L excluding oil filter 2 7L including oil filter Make sure the O ring is positioned correctly in the groove of the oil filter cartridge Oil filter cartridge installation...

Page 53: ...ock Tightening Torque 9 Nm 90 kgf cm Magnet Screw Tightening Torque 28 Nm 280 kgf cm Precautions on Oil Change Excessive and insufficient oil amount can both affect engine performance Excessive Oil In...

Page 54: ...t this point The frame lubrication points are listed below Use general purpose grease Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and incr...

Page 55: ...r when the side stand is down Perform the following side stand inspection Place the vehicle on the center stand Unplug the three pin side stand switch connector Use a digital multimeter to check for c...

Page 56: ...nition coil Clean off the area surrounding the spark plug with compressed air or a shop towel to make sure debris doesn t get into the combustion chamber when the spark plug is removed NOTE Always wea...

Page 57: ...ce the spark plug Always check the gap of the spark plug before installation Inspect the color of the porcelain nose of the spark plug The color of the spark plug can indicate how the mixture is burni...

Page 58: ...Remove the spark plug See the Spark Plug topic for more information Thread a compression tester into the spark plug hole hand tight Hold the throttle all the way open Crank the engine with the starter...

Page 59: ...eely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing See the Steering Stem Removal topic for more information Front Suspension Inspection Check the acti...

Page 60: ...m side to side if the engine rpm changes either the free play is too small or the throttle cables are not routed properly Check and correct the cause Adjustments of the throttle free play can be made...

Page 61: ...odic Maintenance AK 550 2 30 Parking Brake Adjustment Release the fixed nut and rotate the adjust nut to adjust the parking brake Note Do not use the rear brake lock lever while driving Fixed nut Adju...

Page 62: ...Brake Levers verify if Brake Light goes on Check Brake Light for stain or fracture NOTICE Turn KEYLESS Main Switch to position but Engine Stop Switch to position Check Direction Lights Turn KEYLESS M...

Page 63: ...ts due to uneven wear Replace the tire if any of the measurements is lower than the service limit Make sure the wheel is properly balanced when a new tire is replaced Service Limits Front Wheel 0 8 mm...

Page 64: ...related pressure symbol on the left side of Dashboard will light up if this symbol stays on constantly the tire pressure is not normal as shown in the Figure Front Tire Pressure 3 2kgf cm2 or 1 6kgf...

Page 65: ...ment of TPMS is required when replacing a new wireless tire pressure sensor and controller When performing code learning keep the vicinity clear of other vehicle or transmitter to prevent miss trigger...

Page 66: ...nt wheel is complete when the pressure value appears If a Code Learn is not performed when the Front Tire flashes press the UP button to jump to Rear Tire Code Learn If a Code Learn is not accomplishe...

Page 67: ...de Learning after replacing parts 3 When replacing a tire care must be taken to avoid inserting a tool onto the nozzle 4 Make sure the direction is correct when replacing a part 5 Tire Pressure values...

Page 68: ...ange over to TPMS Mode by pressing the Mode button the tire pressure value will be flashing 2 Tire Pressure Indicator will light up continuously if controller is faulty Change over to TPMS Mode by pre...

Page 69: ...2 Periodic Maintenance AK 550 2 38 Drive Belt Inspection Check the drive belt If the drive belt crack missing teeth hook wear or damage replace the drive belt with a new one...

Page 70: ...The bel t t ensi on t oo hi gh or t oo l ow Adj ust t he t ensi on 2 Rugged gear Repl ace a new gear W EAR BELT TEETH 1 The bel t t ensi on t oo hi gh Adj ust t he t ensi on 2 Rugged gear Repl ace a...

Page 71: ...lt Tension Adjustment Step 1 Adjusting the Adjusters 1 Adjust L H Adjuster place to the Mark on Rear Fork 2 Adjust R H Adjuster place to be aligned the L H Adjuster 3 Check the distance C of both L H...

Page 72: ...Sonic Tension Meter setting and use Recommended Gates Unitta U 508 1 Setting mass constant M width W span S M 008 3 g m W 040 0 mm R S 0381 mm 2 Align the meter probe and press MEASURE button 3 Knock...

Page 73: ...mm 1300 1700N 19 2mm 1100 1500N 1 Probe of Sonic Tension meter should be parallel to the belt as shown above pictures 2 Distance between probe and belt is approx 1cm location as shown above pictures 3...

Page 74: ...elt is located at the center of driven pulley both sides clearance should be more than 1mm if not slightly adjust R H Adjuster and distance C of R H and L H Adjuster must remained within the range 18...

Page 75: ...kshaft to TDC mark And align the TDC mark at 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 ma...

Page 76: ...e Adjustment Measure the valve clearance with a thickness feeler gauge Valve clearance IN 0 175 mm EX 0 225 mm If the clearance is out of specification replace the shim to fit in the standard Left cyl...

Page 77: ...IN 0 175 mm EX 0 225 mm If the clearance is out of specification replace the shim to fit in the standard Specification of shim 1 8 3 0mm Note Valve clearance measuring sequence First to adjust the le...

Page 78: ...r Mats Of Floor And Leg Shield 3 5 Side Cover Side Skirt Set 3 6 Panel Floor 3 7 Seat 3 8 Luggage Box 3 9 Center Cover B Side Board A 3 10 Front Cover Set 3 11 Meter Cover Set 3 13 Leg Shield Set 3 14...

Page 79: ...s AK 550 General Instructions When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to the Cable...

Page 80: ...smantled order as below illustration Assembly is reverse of dismantled order Note When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure t...

Page 81: ...0 Windscreen Cover Removal Remove four fasteners and remove the windscreen covers Windscreen Removal Remove four bolts and remove the windscreen Windscreen Holder Removal Remove four bolts and remove...

Page 82: ...Meter Cover Removal Remove two screws and two fasteners Remove the front meter cover Back Mirror Removal Remove four bolts and remove the back mirrors Mats Of Floor And Leg Shield Removal Remove four...

Page 83: ...omponents AK 550 Side Cover Removal Remove 6 screws 4 fasteners and remove the left and right side covers Side Skirt Set Removal Remove 4 screws 6 small fasteners and remove the left and right side sk...

Page 84: ...Components AK 550 Panel Floor B Removal Remove screws two bolts and fasteners remove the right and left panel floor B Panel Floor A Set Removal Remove screws bolts remove the right and left panel floo...

Page 85: ...3 External Components AK 550 Seat Removal Turn the ignition switch counter clockwise to open the seat Lift up the seat and remove 3 nuts and remove the seat 3 8...

Page 86: ...3 External Components AK 550 Luggage Box Removal Remove 6 bolts lamp coupler and remove the luggage box 3 9...

Page 87: ...omponents AK 550 Center Cover B Removal Open the fuel cap lid and open the fuel cap Remove a screw and remove the center cover B Side Board A Removal Remove two fasteners four screws remove the side b...

Page 88: ...3 External Components AK 550 Front Cover Set Removal Remove nuts and coupler remove the front cover set Remove the screws and remove the front cover set 3 11...

Page 89: ...3 External Components AK 550 3 12...

Page 90: ...3 External Components AK 550 Meter Cover Set Removal Remove couplers Remove fasteners screws bolts and remove the meter cover set 3 13...

Page 91: ...3 External Components AK 550 Leg Shield Assy Removal Remove the screw rotate and remove the main switch plate Remove bolts screws couplers and remove the leg shield assembly 3 14...

Page 92: ...ont Inner Fender Removal Remove fasteners temperature sensor couplers and remove the front fender Remove the connecter of the air temperature sensor Under Cowl Set Removal Remove the bolts screws and...

Page 93: ...3 External Components AK 550 Front Fender Assy Removal Remove the bolts plates and reflectors Remove the front fender assembly 3 16...

Page 94: ...K 550 Up And Low Handle Cover Removal Remove the top handle cover Remove the bolts screws and remove the up handle cover Remove the bolts screws Remove throttle and parking brake cables and remove the...

Page 95: ...3 External Components AK 550 Rear carriers Removal Remove four bolts and remove the right and left rear carriers Rear Center Cover Removal Remove fasteners and remove the rear center cover 3 18...

Page 96: ...3 External Components AK 550 Rear Fender Set Removal Remove the 3 bolts coupler and remove the rear fender set 3 19...

Page 97: ...3 External Components AK 550 Body Cover Set Removal Remove fasteners bolts screws coupler and remove the body cover set 3 20...

Page 98: ...3 External Components AK 550 Heat Shield Removal Remove bolts washers rubbers and remove the heat shields Remove bolts washers rubbers and remove the heat shields 3 21...

Page 99: ...FIRST Protective gloves and eyewear are recommended at this point Troubleshooting Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clog...

Page 100: ...ernal Components AK 550 Muffler Removal Remove bolts of the muffler Fix bolts installation torque 2 7 3 2 kgf m 27 32 N m Remove the muffler Replace the new exhaust pipe gasket 18391 when installation...

Page 101: ...External Components AK 550 Exhaust Pipe Removal Unplug the O2 sensor connector Remove 4 nuts of the exhaust pipe Remove the exhaust pipe Replace the new exhaust pipe gasket 18291 when installation 3 2...

Page 102: ...ch Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperature Use a digital multimeter set...

Page 103: ...3 External Components AK 550 Side Stand Removal Unplug the three pin side stand switch connector Remove the spring side stand bolt switch and side stand 3 26...

Page 104: ...3 External Components AK 550 Center Stand Removal Lift up the vehicle by a jack carefully Remove the center stand spring with a spring puller Remove the nuts and bolts Remove the center stand 3 27...

Page 105: ...4 36 Fly Wheel 4 38 Mission Box 4 42 Crankcase 4 53 Crankshaft Balancer Gear Plane Bearing 4 56 Plane Bearing Selection 4 57 Engine Removal 4 62 GENERAL INSTRUCTIONS Lubrication System The maintenance...

Page 106: ...ant in the radiator and water hoses must be drained When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubricat...

Page 107: ...adjustment Burned or bent valves Incorrect valve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plug Compre...

Page 108: ...nspection If replacing the piston or cylinder they must be changed as a pair TROUBLESHOOTING Compression too low or uneven compression Worn stuck or broken piston rings Worn or damaged cylinder and pi...

Page 109: ...4 Engine AK 550 Engine Torque Specifications 4 5...

Page 110: ...4 Engine AK 550 4 6...

Page 111: ...4 Engine AK 550 CYLINDER HEAD VALVES SCHEMATIC DRAWING Cylinder Head Cover Removal Cylinder head cover can be removed when engine is installed on the vehicle 4 7...

Page 112: ...emove the bolts and remove the thermostat cover The seal need to be replace when remove the thermostat cover Note Replace a new seal when installing Remove the thermostat Remove four bolts and the fue...

Page 113: ...ove injectors Remove 4 bolts and inlet pipes Remove two bolts and two ignition coils Remove bolts and mounting rubbers of the cylinder head cover Remove the cylinder head cover Replace the rubbers whe...

Page 114: ...4 Engine AK 550 Installation torque 1 1 4 kgf m 9 8 13 7 N m 4 10...

Page 115: ...ed Rotate the crankshaft to TDC mark And align the TDC mark at camshaft sprocket For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the...

Page 116: ...n tensioner cap bolt Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket Lift the cam chain tensioner out of the cylinder Remove the cam chain tensioner gasket Remove two bolts an...

Page 117: ...550 Loosen and remove the camshaft holder bolts in a crisscross pattern in several steps then remove the camshaft holder And remove camshafts The camshaft holder and cylinder need with the same numbe...

Page 118: ...4 Engine AK 550 Install the cam holder The bolts mounting order and torque should follow the below rule Install the upper train guide 4 14...

Page 119: ...crankshaft until the piston is at top dead center TDC on the compression stroke And align the TDC mark at camshaft sprocket Install the tensioner Note Replace a new gasket when installing Tensioner c...

Page 120: ...Cylinder Head Removal Remove bolts of cylinder head Installation torque 1 1 4 kgf m 9 8 13 7 N m Loosen and remove the cylinder head bolts in a crisscross pattern in several steps then remove the cyl...

Page 121: ...and dowel pins Replace a new gasket when installation After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal Place this cylinder head ca...

Page 122: ...4 Engine AK 550 Installation The bolts mounting order and torque at 3 stages follow the below rule 4 18...

Page 123: ...Engine AK 550 Cylinder Removal Remove the cylinder head gasket and dowel pins Replace a new gasket when installation Remove the cylinder gasket and dowel pins Replace a new gasket when installation 4...

Page 124: ...n shop towel under and 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 clip...

Page 125: ...4 Engine AK 550 CVT Removal SCHEMATIC DRAWING 4 21...

Page 126: ...50 Belt Case Removal Remove three bolts And remove the pillion step set Remove five bolts and remove the CVT right cover Remove two bolts and remove the CVT cover element Clean the cover element if ne...

Page 127: ...ngine AK 550 Remove the bolts nut and remove the CVT cover Remove the gasket and two dowel pins Inspect the belt case bearing by turning it with a finger Replace the bearing if it is rough or noisy 4...

Page 128: ...he bearing with a suitable bearing puller Remove two screws and plates Remove the bearing with a suitable bearing puller Drive in a new bearing with a suitable bearing driver that has the same outside...

Page 129: ...550 CVT Removal Remove the nut and boss of drive pulley Installation torque 7 6 9 3 kgf m 75 91 3 N m Lubricate the threads of the nut before installation Remove the movable face set Drive Pulley Disa...

Page 130: ...he back of the movable face of the drive pulley Remove the rollers and check them for excessive or uneven wear Replace the weight rollers as needed Installation Install the rollers into the back of th...

Page 131: ...drive pulley with a universal holder tool Remove the nut of driven pulley Lubricate the threads of the nut before installation Installation torque 8 3 10 kgf m 81 99 N m When installation make sure th...

Page 132: ...driven pulley Inspect the drive belt for cracks or excessive wear Replace it if needed Remove the driven pulley Remove the drive face When installation make sure the drive face are clean and grease fr...

Page 133: ...4 Engine AK 550 Remove the three bolts Remove the air intake plate Remove the five bolts of the CVT case Installation torque 1 8 2 2 kgf m 17 7 21 6 N m Remove the CVT case 4 29...

Page 134: ...4 Engine AK 550 Remove the gaskets of CVT case Replace with new gaskets when installation 4 30...

Page 135: ...4 Engine AK 550 Driven Pulley Disassembly Set the compressor tool to disassemble the driven pulley ITEM TOOL NO DESCRIPTION Compressor Tool A120E00053 Driven Pulley disassembly 4 31...

Page 136: ...fitting tool to compress the spring Secure the spring compressor tool in a vise Loosen the plate nut with the socket And remove the plate nut of driven pulley set Loosen and remove the spring compress...

Page 137: ...4 Engine AK 550 Remove the spring Measure the free length of the clutch spring Replace the spring if needed 4 33...

Page 138: ...uide rollers with guide roller pins Note When installation lubricate the guide pins and rollers with grease Separate the left and right faces of the driven pulley When installation wipe away any greas...

Page 139: ...4 Engine AK 550 Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides Replace the seals from the driven pulley Replace the O rings of the driven pulley 4 35...

Page 140: ...4 Engine AK 550 Left Side Cover Removal Remove the clamp and water hose Remove the bolts water pump cover 4 36...

Page 141: ...4 Engine AK 550 Remove the bolts and left side cover Installation torque 1 1 4 kgf m 9 8 13 7 N m 4 37...

Page 142: ...4 Engine AK 550 Flywheel Removal Remove the starter reduction gear and shaft Remove the nut of flywheel and remove the washer Installation torque 5 5 6 5 kgf m 53 9 63 7 N m 4 38...

Page 143: ...4 Engine AK 550 Mount the shaft protector Use the special tool and remove the flywheel Special tool A120 E00084 Inspect the one way bearing replace if necessary 4 39...

Page 144: ...4 Engine AK 550 Remove the starting clutch gear Remove the cam chain Remove the c clip of the sprocket Remove the chain of the oil pump and remove the sprocket 4 40...

Page 145: ...4 Engine AK 550 Remove the three bolts and remove the oil pump Installation torque 0 8 1 2 kgf m 7 8 11 8 N m 4 41...

Page 146: ...550 Mission Box Removal Remove the filter plug bolt and remove the filter Replace with new filter when installation Remove the bolts and remove the mission cover Installation torque 1 1 4 kgf m 9 8 13...

Page 147: ...eck the bearing for wear or damage Replace a new bearing if needed Remove the gasket of the mission case Replace a new gasket when installation Remove the nut and remove the wet clutch Installation to...

Page 148: ...4 Engine AK 550 Remove the washer Wet Clutch Disassembly Remove the C clip 4 44...

Page 149: ...4 Engine AK 550 Remove the C clip Remove the retainer and spring Remove the retainer and brake shoes set 4 45...

Page 150: ...4 Engine AK 550 Remove the washer and collar Remove the spring and lower retainer set Remove the rollers 4 46...

Page 151: ...4 Engine AK 550 Remove the left side three nuts and right side two nuts Remove the mission case set Remove the mission box 4 47...

Page 152: ...4 Engine AK 550 Installation The nuts tighten order and torque should follow the below rule 4 48...

Page 153: ...he swim arm pivot The bolts are all with blue Loctite non permanent to the threads Using this type of bolts when installation Installation torque 1 1 4 kgf m 9 8 13 7 N m Remove the bolts and remove t...

Page 154: ...4 Engine AK 550 Remove the final shaft Remove the counter A gear and remove the final gear Remove the counter B gear and remove the counter gear 4 50...

Page 155: ...4 Engine AK 550 Remove the washer and remove the drive shaft Remove the two screws of the bearing fixed plate Remove the two bearing fixed plate 4 51...

Page 156: ...4 Engine AK 550 Remove the bearing by bearing puller tool Tap the new bearing in when installation 4 52...

Page 157: ...4 Engine AK 550 Crankcase Removal Remove the bolts washers and rubber seals Replace the washers and rubber seals when installation Remove the upper crankcase 4 53...

Page 158: ...mber mark Both are pairing of parts assembly machining Thoroughly clean the crankcase mating surface Apply sealant uniformly to the crankcase mating surface as indicated Do not allow sealant to enter...

Page 159: ...4 Engine AK 550 CRANKCASE INSTALLATION The bolts mounting order and torque follow the below rule 21 25 1 2 kgf m 1 2 3 4 5 6 7 8 9 1 11 12 13 14 15 16 17 18 19 22 6 2 3 4 5 7 20 21 23 24 25 8 4 55...

Page 160: ...4 Engine AK 550 Crankshaft Balancer Gear Plane Bearing Removal Remove the crankshaft balancer gears and plane bearing Check the balancers for worn or damage replace if necessary 4 56...

Page 161: ...4 Engine AK 550 Plane Bearing Selection Inspect the bearings for signs of damage and wear Replace the bearings if they show any kind of imperfection Plane bearing color For example Red 4 57...

Page 162: ...gine AK 550 Crankshaft And Crankcase Plane Bearing Selection Crankshaft main journal grade marks A or B Crankcase grade marks A or B Crankshaft plane bearing color selection follows the below charts 4...

Page 163: ...gine AK 550 Crankshaft And Connecting Rod Plane Bearing Selection Crankshaft grade marks A or B Connecting rod grade marks 1 or 2 Connecting rod plane bearing color selection follows the below charts...

Page 164: ...er Gear Shaft And Crankcase Plane Bearing Selection Balancer gear shaft grade marks A or B Crankcase grade journal marks 1 or 2 Balancer gear shaft and crankcase plane bearing color selection follows...

Page 165: ...Installation Install the crankshaft balancer gears in the correct timing Check the balancers for worn or damage replace if necessary Install the crankshaft balancer gears in the correct timing Align t...

Page 166: ...ect the scooter body during engine removal Place the scooter on the center stand Drain the coolant Drain the engine oil Remove the external components See the external topic for more information Remov...

Page 167: ...AK 550 Remove the bolt nut and collar of rear frame body Installation torque 1 1 4 kgf m 9 8 13 7 N m Remove the bolts and nuts and remove the rear frame body Installation torque 8 6 9 1 kgf m 86 91...

Page 168: ...port the engine with a suitable jack or stand Remove the bolt collar and nut Remove the four bolts Carefully move the front frame forward and separate it from the engine Installation torque 1 1 4 kgf...

Page 169: ...ng the engine Other cooling system service can be done with the engine installed in the frame The engine must be cool before servicing the cooling system When the coolant temperature is over 100 never...

Page 170: ...Insufficient coolant Passages blocked in hoses or water jacket Clogged radiator fins Passages blocked in radiator Faulty water pump Temperature gauge shows the wrong temperature Faulty temperature ga...

Page 171: ...ets and animals if drank Do not leave coolant where animals including children can get to it Remove the right side cover and right side skirt set Remove the radiator cap in two stages Allow any built...

Page 172: ...the left floorboard Remove the left floorboard Remove the engine coolant lid screw and remove the engine coolant lid Open the coolant reserve tank lid Siphon the coolant out of the reserve tank with a...

Page 173: ...Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Coolant capacity Radiator with cool coolant 1200 cc Reserve tank 300 cc Use coolant of specified...

Page 174: ...system Place the vehicle on its center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles stop co...

Page 175: ...way and remove it When checking the cooling system for leaks you will need a pressure tester Remove the radiator cap wet the tester seal and install the end of the pressure tester onto the filler neck...

Page 176: ...ystem AK 550 Wet the seal on the radiator cap and install it to the pressure tester Replace the cap if it does not relieve the pressure as specified Radiator cap relief pressure 0 9 0 15 kg cm2 12 8 2...

Page 177: ...fan motor connector blue and black color of wires There are three coolant hoses that connect to the radiator The top left hose runs to the filler neck and cap The top back of left hose runs to the the...

Page 178: ...he stay and remove it from the radiator Loosen the coolant hose clamps with a 2 Phillips screwdriver Free the thermostat coolant hose from the stay and remove it from the radiator Loosen the coolant h...

Page 179: ...AK 550 Remove the radiator mounting bolts with a 10 mm socket Remove the radiator and free the grommet from the radiator And remove the tube and remove bolts of the fixed plate Remove the radiator fro...

Page 180: ...ngs over the other side The bottom hose is the overflow hose that runs to the filler neck Position a suitable container below the reserve tank Pull back the clamp and free the overflow hose from the b...

Page 181: ...or for any bent or damaged fins Use a small flat blade screwdriver to straighten them out but be careful not to puncture the radiator Check the radiator for any bent or damaged fins Use a small flat b...

Page 182: ...5 Cooling System AK 550 Water Temperature Sensor WTS Unplug the water temperature sensor Use a 17 mm wrench to remove the water temperature sensor Installation torque 1 8 2 2 kgf m 18 22 N m 5 14...

Page 183: ...5 Cooling System AK 550 Thermostat Remove the bolts and remove the coolant pipe And remove the Cir clip and tube Loosen the two bolts of thermostat cover Lift out and remove the thermostat 5 15...

Page 184: ...sed at room temperature Suspend the thermostat and a thermometer in a pot of water with string Make sure the thermostat and the thermometer are not touching the pot Bring the temperature up to the spe...

Page 185: ...r signs of coolant leaking If there is coolant coming from this hole the mechanical seal is compromised and must be replaced Removal Water Pump Cover Drain the coolant See the Coolant topic for more i...

Page 186: ...coolant hose and tube And remove the bolts of coolant pump cover Remove the water pump cover bolts Remove the water pump cover Remove the generator cover See the A C Generator and Starter clutchtopic...

Page 187: ...5 Cooling System AK 550 Remove the washer Remove the water pump shaft and impeller Remove the two dowel pins and the water pump cover gasket 5 19...

Page 188: ...ROUBLESHOOTING 6 3 COMPONENT LOCATION 6 4 ECU 6 7 IGNITION COIL 6 9 SPARK PLUG 6 10 CRANK POSITION SENSOR 6 12 O2 SENSOR 6 13 RELAYS 6 14 FUEL TANK 6 15 FUEL PUMP 6 21 FUEL INJECTOR 6 27 THROTTLE BODY...

Page 189: ...le 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 Do no...

Page 190: ...operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Backfiring or misfiring during acceleration Ignition system malfunction Engine stall hard to start...

Page 191: ...k Plug Coolant Reserve Tank Ignition Switch Radiator Keyless Seat Open Controller Diagnostic Tool Connector Fuel Tank Air Cleaner Element Canister Muffler Rear Wheel Speed Sensor Connector Horn Tire P...

Page 192: ...6 Fuel System AK 550 6 5 Component Location Throttle Body Fuel Injector T MAP Sensor Thermostat T MAP Sensor Air Cleaner TPS Fuel Pump Fuel Cap...

Page 193: ...6 Fuel System AK 550 6 6 Component Location Winker Relay Turn Signal Tilt Switch Battery Starter Relay Radiator Cap ECU Heater Grip Controller Fuel Pump Relay Fan Relay Seat Relay Main Relay...

Page 194: ...n Note The ECU could be damaged if dropped or the connector is disconnected when the key is on The excessive voltage may damage the ECU Always turn off the ignition switch before servicing Press the t...

Page 195: ...pection Check for continuity between pin M3 and M4 of the ECU side connector There should be continuity at all times Check for continuity between each pins C3 D1 of the ECU side connector There should...

Page 196: ...at the factory and is not adjustable Perform the following checks Before performing any tests make sure the electrical connections are not loose or corroded Ignition Coil Remove the connectors Remove...

Page 197: ...ark plug wire while cranking or running the engine as this can result in a severe shock Remove the spark plug with a spark plug with a 5 8 in socket Spark plug NGKCR7E Check the spark plug to see if i...

Page 198: ...spark plug The color of the spark plug can indicate how the mixture is burning A white colored plug shows a lean mixture where a dark plug shows a rich mixture Do not hesitate to replace a spark plug...

Page 199: ...te This test is performed with the stator installed in the engine Disconnect the crank position sensor wire coupler Measure the resistance between L Y and G GR wire terminals Resistance L Y G GR 120 2...

Page 200: ...nch Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperature Use a digital multimeter se...

Page 201: ...to inspect the relay Relay Connect 12 V battery with the fuel cut off relay connector There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is c...

Page 202: ...6 Fuel System AK 550 6 15 Fuel Tank SAFETY FIRST Protective gloves and eyewear are recommended at this point Warning Gas is extremely flammable Do not work around an open flame or a source of sparks...

Page 203: ...n order to drain the fuel from the fuel pipe and release the fuel pressure unplug the fuel pump connecter Start the engine and let it run until it dies of fuel starvation Turn the ignition switch off...

Page 204: ...6 Fuel System AK 550 6 17 Disconnect the coupler Clamp the fuel hose for safety And loosen the fuel hose clamp To separate the fuel hose from the fuel pump pipe...

Page 205: ...an up any remaining fuel immediately Note When slide back the fuel hose carefully not to damage the fuel pump pipe and replace the clamp with a new one when installation Remove the fuel pump mounting...

Page 206: ...6 Fuel System AK 550 6 19 Remove the fuel pump assembly Loosen the clip and remove the air tube Remove the fuel tank mounting nuts...

Page 207: ...6 Fuel System AK 550 6 20 Remove the fuel tank mounting nuts and remove the fuel tank from the frame...

Page 208: ...rk around an open flame or a source of sparks Input Voltage Inspection Remove the seat See the Seat topic for more information Remove the luggage box See the Seat topic for more information Remove the...

Page 209: ...side of the fuel pump connector with the positive lead touching the red black wire terminal and the negative lead touching the green wire terminal Turn the ignition switch on The battery voltage shoul...

Page 210: ...ce the O ring with new item and apply a small amount of fresh engine oil to the new O ring Fuel Level Gauge Inspection Using a digital multi meter set to ohms of resistance measure the resistance betw...

Page 211: ...6 Fuel System AK 550 6 24 Fuel Level Float Position Resistance Full 100 3 Empty 2400 3 Replace the fuel level float unit with a new part if the resistance is out of specification...

Page 212: ...Use a fuel hose clamp as shown To separate the fuel hose from the fuel pump pipe Clean up any remaining fuel immediately Disconnect the fuel hose from the fuel injector Connect the fuel pressure gaug...

Page 213: ...is less than 3 0 bar may fail to start the engine or in trouble in case of riding Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose Return the fuel line to the inject...

Page 214: ...k around an open flame or a source of sparks In order to release fuel pressure from the fuel pipe when removing the fuel injector unplug the fuel pump connecter Start the engine and let it run until i...

Page 215: ...njector fuel pipe from the fuel hose Inspect the fuel hose for signs of deterioration or damaged Replace the fuel hose as needed Remove the two fuel injector mounting bolt with a socket Remove two spr...

Page 216: ...ulti meter is needed to test the fuel injector Measure the resistance between the fuel injector terminals ITEM SPECIFICATIONS Fuel injector resistance at 20 C 68 F 10 6 15 9 Check for signs of cloggin...

Page 217: ...on Apply a light coat of fresh engine oil to a new fuel injector O ring Install the O ring to injector before install injector to inlet pipe Fit the fuel injector pipe onto the top of the injector The...

Page 218: ...d 1 6ms ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container 3 Connect the battery as picture...

Page 219: ...y cause the throttle and idle valve to fail synchronization The throttle body is preset in KYMCO factory do not disassemble it incorrectly Do not loosen or tighten the painted bolts and screws for the...

Page 220: ...6 Fuel System AK 550 6 33 Loosen the two screws of throttle body air cleaner clamps Remove the bolt of T MAP sensor And remove the T MAP sensor Throttle Body Fuel Injector T MAP Sensor Thermostat...

Page 221: ...6 Fuel System AK 550 6 34 Remove four bolts of inlet pipe Slide back and remove the throttle body Remove the tubes of throttle body...

Page 222: ...6 Fuel System AK 550 6 35 Remove the throttle body...

Page 223: ...urface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON position Unplug the MAP sensor connector Measure if the ECU voltage outputs to the MAP between the followin...

Page 224: ...ween the following terminals of the TPS connector Terminal Normal Violet Red Green Pink 5 V Throttle Position Sensor TPS resistance at 20 C 68 F 3000 7000 When installation apply oil onto a new O ring...

Page 225: ...6 Fuel System AK 550 6 38 ISC Air Bypass Valve Remove the ISC screw with a 2 Phillips Remove the ISC screw with a 2 Phillips...

Page 226: ...6 Fuel System AK 550 6 39 Remove the ISC When installation apply oil onto a new O ring And being careful not to damage the O ring...

Page 227: ...nd engine stop switch on RUN Turn the ignition switch to OFF Note Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged Place the tilt switch vert...

Page 228: ...s below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 4 4 4 V Note Repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON Disconnect...

Page 229: ...6 Fuel System AK 550 6 42 Water Temperature Sensor WTS Unplug the water temperature sensor Use a 17 mm wrench to remove the water temperature sensor Installation torque 1 8 2 2 kgf m 18 22 N m...

Page 230: ...gnosis Note No matter when the CELP illuminated while riding condition should find out the cause of the problem as soon as possible If the ECM connectors or battery leads are disconnected the stored m...

Page 231: ...and for KYMCO vehicles only The tool software can be updated for new models with a computer via the USB cable Please refer to the specifications when serving this vehicle This tool does not have an i...

Page 232: ...ted under the seat Remove the protective rubber cover Use the Sub cord OBD diagnostics connecter part number 36205 LGC6 E00 and can linker to connect between vehicle and diagnostic tool OBD diagnostic...

Page 233: ...ide stand up prior to using the diagnostic tool The functions of the diagnostic tool include ECU version model name data analysis and reset ECU version includes model name ECU number identifications n...

Page 234: ...l display when the tool is powered on The model name will show LGC6 for the AK 550 Pressing the enter button on the ECU version will show model name ECU number identifications number and software vers...

Page 235: ...48 DTC Diagnostic Trouble Code INSPECTION PROCEDURE Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring up t...

Page 236: ...wn button to select the load DTC option Press the enter button on the Load DTC item to display the DTC options Move the selector to the Current option and press enter to display current DTC The diagno...

Page 237: ...Voltage Too Low Or Broken Circuit P0232 Fuel Pump Relay Circuit Voltage Too High P0261 Injector Right Circuit Voltage Too Low Or Broken Circuit P0262 Injector Right Circuit Voltage Too High P0264 Inj...

Page 238: ...ystem AK 550 6 51 DTC Clear Procedure Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring up the options sho...

Page 239: ...550 6 52 Move the selector down to the Clear DTC option and press enter The diagnostic tool will show when the DTC in memory are cleared Also the DTC indicator light between the center and right butt...

Page 240: ...ight to move the item selector down to the DATA Analyze item Press enter to bring up the DATA Analyze page 01 shown below Press the down button to continue through the seven DATA Analyze pages Page 01...

Page 241: ...6 Fuel System AK 550 6 54 Page 02 The 02 page shows TPS position and TPI idle adapted Page 03 The 03 page shows engine temperature air temperature and intake pressure...

Page 242: ...6 Fuel System AK 550 6 55 Page 04 The 04 page shows atmospheric pressure fuel injection interval and ignition advance Page 05 The 05 page shows the rollover voltage...

Page 243: ...6 Fuel System AK 550 6 56 Page 06 The 06 page shows the ISC step and ISC learn step Page 07 The 07 page shows the ECU counter...

Page 244: ...ration Atom Temp C 30 40 C Atom Pressure Kpa 50 65 kPa Fuel Inject Interval ms 1 0 2 0 ms Ignition Timing 2 7 BTDC O2 Sensor Voltage V 0 1 V O2 Correction 15 ISC Learn Step 20 15 IDLE CO 0 3 1 3 Befor...

Page 245: ...Pulley Disassembly 7 10 GENERAL INSTRUCTIONS The drive pulley and driven pulley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil...

Page 246: ...7 CVT Continuously Variable Transmission AK 550 SCHEMATIC DRAWING 7 2...

Page 247: ...inuously Variable Transmission AK 550 Belt Case Removal Remove three bolts And remove the pillion step set Remove five bolts and remove the CVT right cover Remove two bolts and remove the CVT cover el...

Page 248: ...Variable Transmission AK 550 Remove the bolts nut and remove the CVT cover Remove the gasket and two dowel pins Inspect the belt case bearing by turning it with a finger Replace the bearing if it is...

Page 249: ...pliers Remove the bearing with a suitable bearing puller Remove two screws and plates Remove the bearing with a suitable bearing puller Drive in a new bearing with a suitable bearing driver that has...

Page 250: ...Transmission AK 550 CVT Removal Remove the nut and boss of drive pulley Installation torque 7 6 9 3 kgf m 75 91 3 N m Lubricate the threads of the nut before installation Remove the movable face set D...

Page 251: ...ight rollers in the back of the movable face of the drive pulley Remove the rollers and check them for excessive or uneven wear Replace the weight rollers as needed Installation Install the rollers in...

Page 252: ...needed Hold the drive pulley with a universal holder tool Remove the nut of driven pulley Lubricate the threads of the nut before installation Installation torque 8 3 10 kgf m 81 99 N m When installa...

Page 253: ...he belt from the driven pulley Inspect the drive belt for cracks or excessive wear Replace it if needed Remove the driven pulley Remove the drive face When installation make sure the drive face are cl...

Page 254: ...ontinuously Variable Transmission AK 550 Driven Pulley Disassembly Set the compressor tool to disassemble the driven pulley ITEM TOOL NO DESCRIPTION Compressor Tool A120E00053 Driven Pulley disassembl...

Page 255: ...the bolt of the fitting tool to compress the spring Secure the spring compressor tool in a vise Loosen the plate nut with the socket And remove the plate nut of driven pulley set Loosen and remove the...

Page 256: ...7 CVT Continuously Variable Transmission AK 550 Remove the spring Measure the free length of the clutch spring Replace the spring if needed 7 12...

Page 257: ...Remove the six guide rollers with guide roller pins Note When installation lubricate the guide pins and rollers with grease Separate the left and right faces of the driven pulley When installation wip...

Page 258: ...ly Variable Transmission AK 550 Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides Replace the seals from the driven pulley Replace the O rings of the dri...

Page 259: ...ve AK 550 8 Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO AK550 model SCHEMATIC DRAWING 8 1 TROUBLESHOOTING 8 2 FINAL REDUCTION 8 3 SCHEMATIC D...

Page 260: ...TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or...

Page 261: ...eyewear are recommended at this point Disassembly Note Do not remove the transmission case cover except for necessary part replacement If the drive shaft is replaced make sure to also replace the bea...

Page 262: ...ll with blue Loctite non permanent to the threads Using this type of bolts when installation Installation torque 1 1 4 kgf m 9 8 13 7 N m Remove the bolts and remove the left mission case Installation...

Page 263: ...or damage Replace it if necessary Remove the counter A gear and remove the final gear Inspect the gears for wear or damage Replace the gear if necessary Remove the counter B gear and remove the counte...

Page 264: ...ive AK 550 Remove the washer and remove the drive shaft Inspect the drive shaft for wear or damage Replace it if necessary Remove the two screws of the bearing fixed plate Remove the two bearing fixed...

Page 265: ...8 Final Drive AK 550 Remove the bearing by bearing puller tool Inspect the bearing for wear or damage Replace it if necessary Tap the new bearing in when installation 8 7...

Page 266: ...yless remote controller 9 31 Lights 9 42 Grip Heater 9 50 Horn 9 54 Meter Instrument 9 55 noodoe Meter 9 56 Tire Pressure Management System 9 58 Tire Pressure Management System 9 58 GENERAL INSTRUCTIO...

Page 267: ...sufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power...

Page 268: ...tent power Loose battery cable connection Loose charging system connection Loose connection or short circuit in the ignition system Low power Weak battery Loose battery connection Charging system fail...

Page 269: ...tory The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn off...

Page 270: ...nd wire of the ignition control module Faulty crank position sensor Faulty ignition control module Peak voltage is normal but no spark jumps at the plug Faulty spark plug or leaking ignition coil seco...

Page 271: ...Starter motor rotates but engine does not start Faulty starter pinion Starter motor rotates in reverse Weak battery Lights Switches AND Fuel Pump GENERAL INSTRUCTIONS Note the following when replacin...

Page 272: ...h component TROUBLESHOOTING Lights do not come on when ignition switch is ON Burned bulb Faulty switch Poorly connected broken or shorted wire Temperature gauge does not register correctly Faulty temp...

Page 273: ...9 Electrical Systems AK 550 9 8 Component Location...

Page 274: ...park Plug Coolant Reserve Tank Ignition Switch Radiator Keyless Seat Open Controller Diagnostic Tool Connector Fuel Tank Air Cleaner Element Canister Muffler Rear Wheel Speed Sensor Connector Horn Tir...

Page 275: ...9 Electrical Systems AK 550 9 10 Component Location Throttle Body Fuel Injector T MAP Sensor Thermostat T MAP Sensor Air Cleaner TPS Fuel Pump Fuel Cap...

Page 276: ...9 Electrical Systems AK 550 9 11 Component Location Winker Relay Turn Signal Tilt Switch Battery Starter Relay Radiator Cap ECU Heater Grip Controller Fuel Pump Relay Fan Relay Seat Relay Main Relay...

Page 277: ...trical Systems AK 550 9 12 Fuses Fuse Box Remove the windscreen and meter cover See the external topic for more information The fuse box is located on top of the battery Open the covers to access the...

Page 278: ...ation Note The ECU could be damaged if dropped or the connector is disconnected when the key is on The excessive voltage may damage the ECU Always turn off the ignition switch before servicing Press t...

Page 279: ...Inspection Check for continuity between pin M3 and M4 of the ECU side connector There should be continuity at all times Check for continuity between each pins C3 D1 of the ECU side connector There sh...

Page 280: ...set at the factory and is not adjustable Perform the following checks Before performing any tests make sure the electrical connections are not loose or corroded Ignition Coil Remove the connectors Re...

Page 281: ...r spark plug wire while cranking or running the engine as this can result in a severe shock Remove the spark plug with a spark plug with a 5 8 in socket Spark plug NGKCR7E Check the spark plug to see...

Page 282: ...park plug The color of the spark plug can indicate how the mixture is burning A white colored plug shows a lean mixture where a dark plug shows a rich mixture Do not hesitate to replace a spark plug A...

Page 283: ...Note This test is performed with the stator installed in the engine Disconnect the crank position sensor wire coupler Measure the resistance between L Y and G GR wire terminals Resistance L Y G GR 12...

Page 284: ...aking charging system checks Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent s...

Page 285: ...Rectifier Remove the front cover set See the front cover topic for more information Remove two nuts and remove the regulator rectifier Disconnect the regulator rectifier connector Check the connector...

Page 286: ...ery Wire Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all times Ground Wire Check the continuity between the Green wire terminal and ground The...

Page 287: ...generator 3 pin connector Check the connectors for loose contacts or corroded terminals Measure the resistance between each Yellow wire terminals Check for continuity between each yellow wire terminal...

Page 288: ...ing In case of contact flush with water and get prompt medical attention Removal The battery is located in the front of the vehicle Remove the windscreen and meter cover See the external topic for mor...

Page 289: ...ry Voltage 20 C 68 F Fully Charged 13 0 13 2 V Battery Charging Charge the battery with a motorcycle specific battery charger at the specified rate Connect the charger leads to their appropriate batte...

Page 290: ...ontinuity and inspect the wire Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across t...

Page 291: ...s AK 550 9 26 Starter Motor Pull back the rubber starter motor lead cover and remove the nut Remove two starter motor mounting bolts and remove the starter motor Inspect the starter motor O ring and r...

Page 292: ...eter to inspect the relay Relay Connect 12 V battery with the fuel cut off relay connector There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery...

Page 293: ...he keyless main panel and leg shield See the external topic for the details Unplug the two connectors which connect to keyless controller Remove the screws remove the seat and fuel cap latch cables fr...

Page 294: ...er bolts use a punch and a hammer to strike the bolts so that they rotate loose Turn the bolts clockwise to loosen them Use a digital multimeter to check for continuity to inspect the ignition switche...

Page 295: ...ectrical Systems AK 550 9 30 Keyless And Seat Open Controller Remove the front cover set See the external topic for more information Remove the keyless control connecters and remove the keyless contro...

Page 296: ...ternal topic for more information Remove the bolt screws and remove the seat open motor Keyless remote controller Note There is an antenna attached inside the remote controller which looks like a stic...

Page 297: ...s provided with light sensing switch in case the user forgets to close the Seat Pad or the Pad fails to fully close up system will cut the power automatically after a set time preventing any power los...

Page 298: ...9 Electrical Systems AK 550 9 33 Check the circuit following below wiring dirgram...

Page 299: ...p and engine stop switch on RUN Turn the ignition switch to OFF Note Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged Place the tilt switch v...

Page 300: ...as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 4 0 4 4 V Note Repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON Discon...

Page 301: ...al topic for more information Unplug the black connector for the left handlebar switches Unplug the green connector for the right handlebar switches Use a digital multimeter to check for continuity to...

Page 302: ...9 Electrical Systems AK 550 9 37 Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indicated...

Page 303: ...9 Electrical Systems AK 550 9 38 Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indicated...

Page 304: ...side stand switch connector Use a digital multimeter to check for continuity With the side stand retracted there should be continuity between the yellow green wire and the green wire terminals With t...

Page 305: ...9 Electrical Systems AK 550 9 40...

Page 306: ...r Use a digital multimeter to check for continuity Remove the nut of lever and brake light switch Unplug the brake light switch connector Remove the lever and brake light switch Check for continuity b...

Page 307: ...42 Lights Headlight Make sure the machine has been off for several minutes before removing the headlight bulb Remove the front cover set see the external topic Remove the screws fasteners and separate...

Page 308: ...to be replaced as a set And the headlight and position light drivers can be replaced if needed Headlight Driver Replacement Remove the screws and remove the headlight driver Position light Driver Rep...

Page 309: ...9 Electrical Systems AK 550 9 44 Aim Adjustment Use a long screw driver to adjust the aim Turn the screws to adjust the right and left head lights aim as needed...

Page 310: ...ctrical Systems AK 550 9 45 Front Turn Signals Remove 3 screws to separate the cover and front turn signal light set Remove the front turn signal light set Replace the front turn signal light set if n...

Page 311: ...Systems AK 550 9 46 Tail Stop Rear turn signal lights Remove the body cover set See the external topic for more information Remove the screws fasteners and separate the covers tail stop rear turn sign...

Page 312: ...al lights Rear turn signal lights need to be replaced as a set And the tail stop light set can be replaced if needed Tail Stop lights set Replacement Remove the screws and remove the tail stop lights...

Page 313: ...9 Electrical Systems AK 550 9 48 License Tag Light Remove the 3 bolts coupler and remove the rear fender set Remove the screws Remove the license tag light from the rear fender...

Page 314: ...9 Electrical Systems AK 550 9 49 Lights Wiring Diagram...

Page 315: ...ch ON press and hold the button to activate Handlebar Heater Indicator lights in white constantly for normal operation 4 Turn KEYLESS Main Switch OFF or press and hold the button to deactivate Handleb...

Page 316: ...ill remain inactive when starting the vehicle by pressing and holding the pushbutton and the indicator will still flash in red Dashboard Level Indication 1 On activation of heating function Dashboard...

Page 317: ...he covers see the external topic Unplug the grip heater controller connectors Remove two bolts and remove the grip heater controller Open the fuse box Inspect the fuse and replace it if needed Remove...

Page 318: ...9 Electrical Systems AK 550 9 53 Check the circuit referring to the following diagram...

Page 319: ...the front cover See the external topic for more information Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V bat...

Page 320: ...9 Electrical Systems AK 550 9 55 Meter Instrument Remove couplers Check the wiring diagram to inspect circuit...

Page 321: ...ollowing Remove the screw and loosen the claw as below pictures Remove the cover of meter There is anti fogging agent applied on the surface of inside cover Warning Never to touch the surface of botto...

Page 322: ...module and replace with a new one The boss need to be matched firmly and fasten four screws crisscross evenly Install the meter board and remove dust by air tool tenderly Install the cover of meter f...

Page 323: ...related pressure symbol on the left side of Dashboard will light up if this symbol stays on constantly the tire pressure is not normal as shown in the Figure Front Tire Pressure 3 2kgf cm2 or 1 6kgf c...

Page 324: ...ent of TPMS is required when replacing a new wireless tire pressure sensor and controller When performing code learning keep the vicinity clear of other vehicle or transmitter to prevent miss triggeri...

Page 325: ...t wheel is complete when the pressure value appears If a Code Learn is not performed when the Front Tire flashes press the UP button to jump to Rear Tire Code Learn If a Code Learn is not accomplished...

Page 326: ...e Learning after replacing parts 3 When replacing a tire care must be taken to avoid inserting a tool onto the nozzle 4 Make sure the direction is correct when replacing a part 5 Tire Pressure values...

Page 327: ...nge over to TPMS Mode by pressing the Mode button the tire pressure value will be flashing 2 Tire Pressure Indicator will light up continuously if controller is faulty Change over to TPMS Mode by pres...

Page 328: ...move the two nuts of tire pressure controller Remove the tire pressure controller Tire Pressure Sensor Remove the tire Loosen the nut and remove the tire pressure sensor When installation notice the s...

Page 329: ...s due to uneven wear Replace the tire if any of the measurements is lower than the service limit Make sure the wheel is properly balanced when a new tire is replaced Service Limits Front Wheel 0 8 mm...

Page 330: ...9 Electrical Systems AK 550 9 65 Check the wiring diagram to inspect the circuit...

Page 331: ...le the engine is running WARNING To avoid electrocution or short circuit make sure to cover up the protection cap after using the USB Power Socket To prevent any accident from occurring park your Moto...

Page 332: ...sc with high quality brake degreasing agent Avoid spilling brake fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Never allow contamination dirt wa...

Page 333: ...minated caliper Caliper not sliding properly Leaking hydraulic system Worn caliper piston seal Worn master cylinder piston cups Bent brake lever Brake lever hard Clogged restricted brake system Sticki...

Page 334: ...10 Brake System AK 550 Diagram 10 3...

Page 335: ...nd eyewear are recommended at this point Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Remove the bolt of speed sensor And remove the speed sensor Remove...

Page 336: ...10 Brake System AK 550 Front Brake Pad Removal Remove the snap clip of the pin Remove the screw loosen the brake pad 10 5...

Page 337: ...the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Insert new brake pads as needed Remove the two bolts of caliper and remove the caliper Installation torque 3 4 kgf...

Page 338: ...in It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads Install the front caliper Guide the brake di...

Page 339: ...10 Brake System AK 550 Rear Brake Pad Removal Release the cable of speed sensor And release the cable of rear brake Remove the bolt of rear fixed plate 10 8...

Page 340: ...caliper Loosen and remove the two bolts of rear caliper The bolts are with blue Loctite non permanent to the threads Using this type of bolts when installation Installation torque 3 4 kgf m 30 40 N m...

Page 341: ...lation When installation Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring It may be necessary to rotate the piston and force the pistons back into the...

Page 342: ...Cylinders Up And Low Handle Cover Removal Remove the top handle cover Remove the bolts screws and remove the up handle cover Remove the bolts screws Remove throttle and parking brake cables and remov...

Page 343: ...way Bleed the brake fluid Place a suitable container under the banjo bolt to catch any remaining brake fluid Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket Discar...

Page 344: ...banjo bolt from the master cylinder using a 12 mm socket Discard the sealing washers and replace with new ones Remove the nut of lever and brake light switch Unplug the brake light switch connector R...

Page 345: ...to the hole on the handlebar when installation Remove the left master cylinder in the same way When installation fill the rear brake system with fresh brake fluid and bleed out the air Pump the brake...

Page 346: ...e play in them or are rough replace all the bearings for that wheel When installation Make sure the tire direction of rotation marker is correct Slide the front wheel into the fork Fit the brake disc...

Page 347: ...Brake System AK 550 Loosen the front axle pinch bolt with a 6 mm Allen Inspect the wheel speed sensor and brake disc for wear and damage Replace the parts as needed Remove the bolts of brake disk 10...

Page 348: ...ue Loctite non permanent to the threads Using this type of bolts when installation When installation follow the order below first time tighten the bolts with torque 1 5 kgf m 15 N m And second time in...

Page 349: ...ve the spring Remove the screws of handle bar switch parking brake wire and remove the parking brake set Parking Brake Adjustment Release the fixed nut and rotate the adjust nut to adjust the parking...

Page 350: ...ith a micrometer Item Standard mm Brake disk thickness rear 5 Brake disk thickness front 4 5 Check if the brake rotor runout is within the service limit Measure the runout of the brake disc with a dia...

Page 351: ...mmended at this point ABS Component Location 1 Front Wheel speed Sensor 2 Front Wheel speed Sensor Rotor 3 Rear Wheel speed Sensor 4 Rear Wheel speed Sensor Rotor 5 ABS Indicator Light 6 ABS Hydraulic...

Page 352: ...ns misjudgment or improper application of brakes You must take the same care as with vehicle not equipped with ABS o ABS isn t designed to shorten the braking distance On loose uneven or downhill surf...

Page 353: ...lways use the standard tires for this vehicle Notice o When the ABS is functioning you may feel a pulsing in the brake lever This is normal you need not suspend applying the brakes o ABS does not func...

Page 354: ...are disconnected The ABS hydraulic unit memorizes service codes Do not spray water on the electrical parts ABS parts connectors leads and wiring Whenever the ABS electrical connections are to be disco...

Page 355: ...ice codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the service c...

Page 356: ...ent 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 continuity of the w...

Page 357: ...10 Brake System AK 550 Pre diagnosis Inspection Chart 1 10 26...

Page 358: ...10 Brake System AK 550 Pre diagnosis Inspection Chart 2 10 27...

Page 359: ...the ignition switch is turned on and goes off shortly after the vehicle starts moving The light stays off as long as the system is ok If something is wrong with the ABS the indicator comes on and rema...

Page 360: ...rminal of the meter connector and ground Turn the ignition switch ON Terminal Voltage Standard About 8V If the terminal voltage correct replace the meter assembly 2nd step test Disconnect the meter co...

Page 361: ...e ABS hydraulic unit connector Check for continuity between the ABS signal wire Pink lead terminal of the meter side connector and the ABS signal wire Pink lead terminal of the ABS unit side connector...

Page 362: ...lace the ABS hydraulic unit If there is not the continuity in the lead replace or repair the main harness Solenoid Valve Inspection Service Code 13 14 17 18 1st step test Recheck the service code indi...

Page 363: ...ormation of the wheel or tire 4 Sensor rotor for missing teeth and clogging with foreign matter If the all parts are correct move on to the 2nd step 2nd step test Recheck the service code indication e...

Page 364: ...sor rotor Standard 1 mm 0 04 in If the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the clearance Check that there is iron or other magnet...

Page 365: ...eplace the rear wheel rotation sensor Rear Wheel Rotation Sensor Wiring Inspection service code 44 1st step test Measure the clearance between the rear wheel rotation sensor and sensor rotor Standard...

Page 366: ...rear wheel sensor connector Short the light blue brown and black red lead terminals of the main harness side connector with a jumper lead and check for continuity between the light blue brown and bla...

Page 367: ...terminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 9 6V or more 3rd step test Inspect the following parts Battery...

Page 368: ...erminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 16 6V or less 3rd step test Inspect the following parts Battery...

Page 369: ...diagnosis inspection 1 and 2 and retrieve the service code If the ABS indicator light lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit If the ABS indicator light unlit ABS syste...

Page 370: ...ction AV 05 5019 Valve Relay malfunction Failsafe relay 06 5025 Deviation between Wheel speeds WSS_GENERIC 07 5035 Pump Motor Malfunction 08 5042 Front wheel speed sensor malfunction Plausibility 09 5...

Page 371: ...the front and rear wheel speed sensors should show speed when the wheels are rotated Inspect the wheel speed sensors rotors wires and connectors if the speed doesn t show correctly Check the speed se...

Page 372: ...for the brake Front F and Rear R brake hose positions Do not attempt to disassemble the ABS unit If the ABS unit must be replaced the new unit should come filled with brake fluid Install the new comp...

Page 373: ...ndle Cover Removal 11 2 Handlebar 11 3 Switch Housings and Throttle 11 4 Grips 11 9 Steering stem 11 10 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken ste...

Page 374: ...e Cover Removal Remove the top handle cover Remove the bolts screws and remove the up handle cover Remove the bolts screws and remove the handle bar heater connecters Remove throttle and brake wire an...

Page 375: ...tective gloves and eyewear are recommended at this point Bar Ends Removal Remove the left and right bar ends with a 6 mm Allen Note When installation the left side bar end need to be combined with a w...

Page 376: ...gs and Throttle Remove the bolt of right switch throttle cable fixed state Remove the front right switch housing mounting screws with a 2 Phillips screwdriver Disconnect the switches Disconnect the sw...

Page 377: ...Disconnect the throttle cables and free the right switch housing from the handlebar Separate the switch housing from the handlebar Remove the parking brake cable And remove the left switch housing as...

Page 378: ...bar Removal Release the cables and lines from the handlebar cable bind Disconnect the connecters and couplers of the switches Remove the nut of bottom bridge with a 29 mm socket Installation torque 6...

Page 379: ...11 Steering AK 550 Remove the washer of bottom bridge 11 7...

Page 380: ...11 Steering AK 550 Remove the handle bar assembly Remove the nuts and washer to separate the handle bar assembly Installation torque 3 4 kgf m 30 40 N m 11 8...

Page 381: ...between the angle of the grip and the throttle tube so that the new grip can be installed with the correct angle NOTE Always wear safety glasses when using compressed air and never point it directly...

Page 382: ...front wheel is off the ground Grip the bottom of the fork legs and turn the front end side to side If the movement is rough the bearings should be greased or replaced If the movement is to tight or lo...

Page 383: ...osen and remove the lock nut Installation torque 5 6 kgf m 50 60 N m Slide off the lock washer A special race nut wrench is needed to loosen the steering stem lock nut Special Tool race Nut Wrench F00...

Page 384: ...11 Steering AK 550 Remove the dust cover Remove the collar and remove the upper ball bearing 11 12...

Page 385: ...hammer to drive out the bearing races Do not damage the frame pipe and steering stem Have the drift set against the lip of the race and work around the race evenly to drive it out Repeat the process w...

Page 386: ...of the front fork components for the KYMCO AK 550 model TROUBLESHOOTING 12 1 Front Fender Assy Removal 12 2 Front Fork Removal 12 3 TROUBLESHOOTING Soft front shock absorber Weak shock springs Insuffi...

Page 387: ...12 Front Suspension AK 550 12 2 Front Fender Assy Removal Remove the bolts plates and reflectors Remove the bolts and front fender assembly...

Page 388: ...sensor Remove two bolts and remove the front caliper And remove the left of caliper Installation torque 3 4 kgf m 30 40 N m Remove the bolt of front axle Installation torque 7 7 5 kgf m 70 75 N m The...

Page 389: ...allation torque 2 2 6 kgf m 20 26 N m Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground Support the front wheel and slide the front axle o...

Page 390: ...ont wheel out from the fork and the brake disc out from between the pads Do not squeeze the brake lever while the disc is not present between the pads When installation Apply grease to the lips of the...

Page 391: ...AK 550 12 6 Remove the front wheel assembly Remove the right and left bolts of top bridge Installation torque 2 2 6 kgf m 20 26 N m Remove the right and left bolts of top bridge Installation torque 2...

Page 392: ...ork oil replacement quantity of fork oil Right 375 2cc Left 555 2cc Use fork oil type SS8 10W 2 The cushions need to be kept upward when storage 3 Assembly process of the product must be kept upward 4...

Page 393: ...uspension components of the KYMCO AK 550 model TROUBLESHOOTING 13 1 Rear CUSHION 13 2 Rear Wheel Removal 13 3 Drive Belt Inspection 13 13 Drive Belt Installation 13 14 Drive Belt Tension Adjustment 13...

Page 394: ...ar Suspension AK 550 13 2 Rear Cushion SAFETY FIRST Protective gloves and eyewear are recommended at this point Remove the two bolts and remove the rear cushion Installation torque 3 5 4 5 kgf m 35 45...

Page 395: ...is point When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk Removal...

Page 396: ...13 Rear Suspension AK 550 13 4 Remove the bolt of rear fixed plate Remove the bolt of front fixed plate...

Page 397: ...13 5 Loosen and remove the two bolts of rear caliper The bolts are all with blue Loctite non permanent to the threads Using this type of bolts when installation Installation torque 3 4 kgf m 30 40 N...

Page 398: ...en the fixed nut front rotate the adjust bolt rear counter clockwise and move wheel forward to loosen the belt Loosen and remove the rear wheel axle nut move wheel forward to loosen the belt Installat...

Page 399: ...3 Rear Suspension AK 550 13 7 Loosen and remove the rear swing axle nut and washer Installation torque 9 5 10 5 kgf m 95 105 N m Loosen the rear swing axle bolt Installation torque 0 6 1 kgf m 6 10 N...

Page 400: ...pension AK 550 13 8 Loosen the fixed nut left and rotate the adjust bolt right counter clockwise to loosen belt Remove two bolts and remove the chain up cover A Remove two bolts and remove the chain l...

Page 401: ...ove the three bolts Remove the final shaft holder cap Loosen and remove the five bolts of the drive sprocket stopper Remove the drive sprocket nut and washer Remove the drive sprocket stopper cover In...

Page 402: ...grease the collar when installation Remove the two bolts and remove the rear cushion Installation torque 3 5 4 5 kgf m 35 45 N m Remove the three bolts and remove the stop plate The bolts are all with...

Page 403: ...13 Rear Suspension AK 550 13 11 Slide out and remove the belt Remove the drive sprocket Slide out and remove the rear wheel axle...

Page 404: ...13 Rear Suspension AK 550 13 12 Slide out the rear wheel assembly...

Page 405: ...13 Rear Suspension AK 550 13 13 Drive Belt Inspection Check the drive belt If the drive belt crack missing teeth hook wear or damage replace the drive belt with a new one...

Page 406: ...elt Installation When installation Make sure the belt direction of rotation marker is correct Rotate the adjust bolt clockwise until the plate edge align the mark to tense the belt then tighten the fi...

Page 407: ...The bel t t ensi on t oo hi gh or t oo l ow Adj ust t he t ensi on 2 Rugged gear Repl ace a new gear W EAR BELT TEETH 1 The bel t t ensi on t oo hi gh Adj ust t he t ensi on 2 Rugged gear Repl ace a n...

Page 408: ...Tension Adjustment Step 1 Adjusting the Adjusters 1 Adjust L H Adjuster place to the Mark on Rear Fork 2 Adjust R H Adjuster place to be aligned the L H Adjuster 3 Check the distance C of both L H an...

Page 409: ...onic Tension Meter setting and use Recommended Gates Unitta U 508 1 Setting mass constant M width W span S M 008 3 g m W 040 0 mm R S 0381 mm 2 Align the meter probe and press MEASURE button 3 Knock t...

Page 410: ...m 1300 1700N 19 2mm 1100 1500N 1 Probe of Sonic Tension meter should be parallel to the belt as shown above pictures 2 Distance between probe and belt is approx 1cm location as shown above pictures 3...

Page 411: ...lt is located at the center of driven pulley both sides clearance should be more than 1mm if not slightly adjust R H Adjuster and distance C of R H and L H Adjuster must remained within the range 18 8...

Page 412: ...13 Rear Suspension AK 550 13 20 Rear Fork Removal Slide backward and remove the rear axle holder Remove the two bolts nuts And remove the main stand plate Remove the bolt nut and upper plate...

Page 413: ...Rear Suspension AK 550 13 21 Loosen the two bolts of left rear fork Remove the two bolts and nuts of left rear fork And Slide out and remove the left rear fork Installation torque 3 3 5 kgf m 30 35 N...

Page 414: ...13 Rear Suspension AK 550 13 22 Remove the two dowl pin of the rear fork Slide out and remove the right rear fork Loosen and slide out the rear swing axle bolt...

Page 415: ...13 Rear Suspension AK 550 13 23 Remove the two bolts And remove the chain cover up B Remove the two bolts And remove the chain cover low B...

Page 416: ...13 Rear Suspension AK 550 13 24 Check the seal and bearing for wear or damage Replace them if necessary...

Page 417: ...ing Replacement 14 9 Rear Wheel 14 11 Rear Wheel Inspection 14 17 Rear Wheel Installation 14 22 Drive Belt Tension Adjustment 14 26 Tire Pressure Sensor 14 28 Troubleshooting Front wheel wobbling Bent...

Page 418: ...ls AK 550 14 2 Front Wheel SAFETY FIRST Protective gloves and eyewear are recommended at this point Front Fender Assy Removal Remove the bolts plates and reflectors Remove the bolts and front fender a...

Page 419: ...two bolts and remove the front caliper And remove the left of caliper Installation torque 3 4 kgf m 30 40 N m Remove the bolt of front axle Installation torque 7 7 5 kgf m 70 75 N m The bolts are all...

Page 420: ...ion torque 2 2 6 kgf m 20 26 N m Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground Support the front wheel and slide the front axle out fr...

Page 421: ...from the fork and the brake disc out from between the pads Do not squeeze the brake lever while the disc is not present between the pads When installation Apply grease to the lips of the dust seals an...

Page 422: ...ave play in them or are rough replace all the bearings for that wheel When installation Make sure the tire direction of rotation marker is correct Slide the front wheel into the fork Fit the brake dis...

Page 423: ...14 Wheels AK 550 14 7 Loosen the front axle pinch bolt with a 6 mm Allen Inspect the wheel speed sensor and brake disc for wear and damage Replace the parts as needed Remove the bolts of brake disk...

Page 424: ...blue Loctite non permanent to the threads Using this type of bolts when installation When installation follow the order below first time tighten the bolts with torque 1 5 kgf m 15 N m And second time...

Page 425: ...bearings in the freezer about an hour before you plan to install them Remove the dust seal from the right side of the front wheel using a seal pick or large flat blade screwdriver Discard the dust se...

Page 426: ...d with a new item Heat the bearing area of the wheel with a heat gun take the bearing out of the freezer and install it You can use a bearing installer tool or a socket with the same outside diameter...

Page 427: ...oint When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk Removal Rem...

Page 428: ...14 Wheels AK 550 14 12 Remove the bolt of rear fixed plate Remove the bolt of front fixed plate...

Page 429: ...3 Loosen and remove the two bolts of rear caliper The bolts are all with blue Loctite non permanent to the threads Using this type of bolts when installation Installation torque 3 4 kgf m 30 40 N m Re...

Page 430: ...he fixed nut front rotate the adjust bolt rear counter clockwise and move wheel forward to loosen the belt Loosen and remove the rear wheel axle nut move wheel forward to loosen the belt Installation...

Page 431: ...oosen the fixed nut left and rotate the adjust bolt right counter clockwise to loosen belt Remove the two bolts and remove the rear cushion Installation torque 3 5 4 5 kgf m 35 45 N m Slide out and re...

Page 432: ...14 Wheels AK 550 14 16 Slide out the rear wheel assembly...

Page 433: ...4 Wheels AK 550 14 17 Rear Wheel Inspection Remove the collar of the rear axle Remove the five bolts of the driven belt sprocket Installation torque 3 4 kgf m 30 40 N m Remove the driven belt sprocket...

Page 434: ...bearing puller Special Tools Bearing Puller E00037 Heat the bearing area of the wheel with a heat gun take the bearing out of the freezer and install it You can use a bearing installer tool or a socke...

Page 435: ...550 14 19 Check the right side of the rear wheel Remove the collar And remove the 5 bolts of the rear ABS toothed ring Remove the rear ABS toothed ring Check the wear or damage replace with a new one...

Page 436: ...orque 3 2 3 8 kgf m 32 38 N m The bolts are all with blue Loctite non permanent to the threads Using this type of bolts when installation Inspect the wheel bearings by turning them with a finger If th...

Page 437: ...the bearing is fully seated and the marked side is facing out Special Tools Bearing Installer E00014 Apply grease to the lips of the dust seals Drive in new dust seals Wheel Inspection Turn the inner...

Page 438: ...14 Wheels AK 550 14 22 Rear Wheel Installation Drive Belt Inspection Check the drive belt If the drive belt crack missing teeth hook wear or damage replace the drive belt with a new one...

Page 439: ...nstallation When installation Make sure the belt direction of rotation marker is correct Rotate the adjust bolt clockwise until the plate edge align the mark to tense the belt then tighten the fixed n...

Page 440: ...14 Wheels AK 550 14 24 Drive Belt Inspection Check the drive belt If the drive belt crack missing teeth hook wear or damage replace the drive belt with a new one...

Page 441: ...el t t ensi on t oo hi gh or t oo l ow Adj ust t he t ensi on 2 Rugged gear Repl ace a new gear W EAR BELT TEETH 1 The bel t t ensi on t oo hi gh Adj ust t he t ensi on 2 Rugged gear Repl ace a new ge...

Page 442: ...sion Adjustment Step 1 Adjusting the Adjusters 1 Adjust L H Adjuster place to the Mark on Rear Fork 2 Adjust R H Adjuster place to be aligned the L H Adjuster 3 Check the distance C of both L H and R...

Page 443: ...Tension Meter setting and use Recommended Gates Unitta U 508 1 Setting mass constant M width W span S M 008 3 g m W 040 0 mm R S 0381 mm 2 Align the meter probe and press MEASURE button 3 Knock the b...

Page 444: ...0 1700N 19 2mm 1100 1500N 1 Probe of Sonic Tension meter should be parallel to the belt as shown above pictures 2 Distance between probe and belt is approx 1cm location as shown above pictures 3 Appro...

Page 445: ...located at the center of driven pulley both sides clearance should be more than 1mm if not slightly adjust R H Adjuster and distance C of R H and L H Adjuster must remained within the range 18 8 0 5m...

Page 446: ...4 Wheels AK 550 14 30 Tire Pressure Sensor Remove the tire Loosen the nut and remove the tire pressure sensor When installation notice the sensor direction and mounting torque as following instruction...

Page 447: ...to uneven wear Replace the tire if any of the measurements is lower than the service limit Make sure the wheel is properly balanced when a new tire is replaced Service Limits Front Wheel 0 8 mm Rear...

Page 448: ...ed pressure symbol on the left side of Dashboard will light up if this symbol stays on constantly the tire pressure is not normal as shown in the Figure Front Tire Pressure 3 2kgf cm2 or 1 6kgf cm2 Re...

Page 449: ...f TPMS is required when replacing a new wireless tire pressure sensor and controller When performing code learning keep the vicinity clear of other vehicle or transmitter to prevent miss triggering Af...

Page 450: ...el is complete when the pressure value appears If a Code Learn is not performed when the Front Tire flashes press the UP button to jump to Rear Tire Code Learn If a Code Learn is not accomplished with...

Page 451: ...rning after replacing parts 3 When replacing a tire care must be taken to avoid inserting a tool onto the nozzle 4 Make sure the direction is correct when replacing a part 5 Tire Pressure values are f...

Page 452: ...ver to TPMS Mode by pressing the Mode button the tire pressure value will be flashing 2 Tire Pressure Indicator will light up continuously if controller is faulty Change over to TPMS Mode by pressing...

Page 453: ...r 15 6 Oxygen Sensor 15 9 WARNING Before running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas...

Page 454: ...from spreading to the atmosphere Exhaust Emission Control System The exhaust emission from the scooter is controlled by combustion management fuel delivery ignition setting and exhaust system The exh...

Page 455: ...ndition Sending the mixture condition info to ECU by voltage signal ECU control the fuel injection to meet the emission regulation Catalyst To reduce the emission of HC CO and NOx produced from the ex...

Page 456: ...ent set 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 the wrong KYMCO air cleaner elemen...

Page 457: ...uld be installed tightly The leakage hole should be installed downward Tool Vacuum pump Pressure pump Maintenance standard Emission vacuum standard 45m mHg Capacity of canister 90cc Install angle incl...

Page 458: ...ontrol 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 Connecti...

Page 459: ...the flow rate above 9 4 litters per minute that means the valve is in good condition otherwise the canister should be replaced NOTE Always using the pump by manual do not apply high pressure for testi...

Page 460: ...reach above 80 C This model equipped the catalyst in the muffler to reduce the pollution emission Inspection Of Catalyst Converter Inspection of catalyst converter efficiency at idle speed Warm up th...

Page 461: ...nsor 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 7V A F...

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KYMCO AK 550, Service Manual

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