KYMCO ADG5 Manuals

Manuals and User Guides for KYMCO ADG5. We have 1 KYMCO ADG5 manual available for free PDF download: Manual

KYMCO ADG5 Manual

KYMCO ADG5 Manual (427 pages)

Brand: KYMCO | Category: Motorcycle | Size: 19.04 MB

Table of Contents

Table of Contents
1
Quick Reference
1
Component Location
2
Special Tools
5
Specifications
10
- Axle/Brakes/Wheels
  11
- Torque Engine Specifications
  12
- Torque Frame Specifications
  13
- General Torque Specifications
  14
- Preliminary 6 Step Inspection
  15
- Vehicle Can Not be Started
  15
Troubleshooting
15
- General Troubleshooting
  16
- Engine will Not Start or Is Hard to Start
  16
- Engine Lacks Power
  17
- Poor Performance at Low and Idle Speed
  18
- Poor Performance at High Speed
  19
- Poor Handling
  19
- ID Number Record Field
  20
- Owner Information
  20
VIN and Engine Number Location
20
- Periodic Maintenance
  21
- Maintenance Schedule
  22
- Periodic Maintenance
  22
- Air Filter Servicing
  24
  - Precautions on Replacing Filter Element
    24
  - Replace Air Filter Cartridge
    24
- Brake Fluid
  25
  - Checking Front Brake Fluid
    25
  - Viewing Window of Front Brake Fluid
    25
  - Replenishing Brake Fluid
    26
  - Draining
    27
- Brake Inspection
  29
  - Brake Lever Adjuster
    29
  - Check and Adjust Brakes
    29
  - Brake Pad
    30
  - Brake Pads
    30
  - Caliper
    30
  - Check Level of Cooling Water
    35
- Coolant
  35
- Engine Oil
  39
  - Oil Level too Low
    39
  - Poor Lubrication Pressure
    39
  - Oil Capacity
    40
  - Oil Change Period
    40
  - Oil Level Inspection
    40
  - Applicable Temperature of Engine Oil
    41
  - Engine Oil Viscosities
    41
  - Oil Change Method
    41
  - Precautions on Oil Change
    42
- General Lubrication
  43
- Interlock Function Check
  44
- Side Stand
  44
- Spark Plug
  45
- Cylinder Compression
  47
- Engine Compression Test
  47
- Front Suspension Inspection
  48
- Steering Inspection
  48
- Throttle Free Play
  49
  - Parking Brake Adjustment
    50
  - Check Tread Pattern for Wear
    51
  - Service Limits
    51
  - Tire Dimensions
    51
- Tires
  51
- Valve Clearance Adjustment
  52
  - Adjustment
    54
  - External Components
    57
  - General Instructions
    58
  - Dismantled and Assembly Order
    59
  - Front Meter Cover Removal
    60
  - Windscreen Cover Removal
    60
  - Windscreen Removal
    60
  - Front Cover Set Removal
    61
  - Leg Shield Lid Removal
    61
  - Back Mirror Removal
    62
  - Mats of Floor Removal
    62
  - Side Cover Set Removal
    62
  - Panel Floor Removal
    63
  - Under Cover Removal
    63
  - Under Cowl Removal
    63
  - Center Cover Set Removal
    64
  - Meter Cover Set Removal
    64
  - Side Board Set Removal
    64
  - Leg Shield Assy. Removal
    65
  - Up and Low Handle Cover Removal
    66
  - Front Fender Assy. Removal
    67
  - Front Inner Fender Removal
    67
  - Seat Removal
    68
  - Back Carriers Removal
    69
  - Battery Cover Removal
    69
  - Rear Seat Removal
    69
  - Luggage Box Removal
    70
  - Rear Center Cover Removal
    70
  - Body Cover Set Removal
    71
  - Heat Shield Removal
    72
  - Exhaust System
    73
  - Lack of Power
    73
  - Noisy Exhaust Muffler
    73
  - Muffler Removal
    74
  - Exhaust Pipe Removal
    75
  - O2 Sensor Removal
    76
  - Side Stand Removal
    77
  - Center Stand Removal
    78
  - Engine
    79
  - Lubrication System
    79
  - Compression too Low
    80
  - Cylinder Head, Camshaft, and Valves
    80
  - Abnormal Noise
    81
  - Compression too Low or Uneven Compression
    81
  - Cylinder and Piston
    81
  - White Smoke from Exhaust Muffler
    81
- Engine Removal
  82
- Cylinder Head Cover
  91
- Installation
  93
- Camshaft
  96
  - Inspection
    101
  - Camshaft Installation
    104
- Valves
  111
  - Cylinder Block Removal
    123
  - Cylinders and Pistons
    123
  - A.C. Generator and Starter Clutch
    140
  - Starter Clutch
    151
  - Oil Pump
    161
  - Oil Pump Removal
    162
  - Oil Pump Installation
    165
  - Crankcase
    168
  - Splitting
    168
  - Crankshaft
    181
  - Crankshaft Inspection
    182
  - Crankshaft Bearings
    183
  - Engine Installation
    185
  - Pressure Testing
    204
  - Radiator
    204
  - Water Temperature Sensor and Thermostat
    209
  - Water Temperature Sensor
    212
  - Thermostat
    213
- General Instructions
  215
- Troubleshooting
  216
- Component Location
  217
- Ecu
  220
- Ignition Coil
  222
  - Ignition System
    222
  - Ignition Coil Resistance
    223
  - Secondary with Plug Cap
    223
  - Secondary Without Plug Cap
    224
- Spark Plug
  225
  - Spark Plug Gap
    226
  - AC Generator Inspection
    227
  - Crank Position Sensor Inspection
    227
  - Relays
    229
  - Relays Inspection
    229
- Fuel Tank
  230
  - Fuel Tank Removal
    231
  - Remove the Radiator
    233
  - Fuel Pump
    234
  - Input Voltage Inspection
    234
  - Fuel Level Gauge Inspection
    236
  - Fuel Pump Output Pressure
    238
  - MAP Inspection
    240
  - Throttle Body /MAP/ISC/TPS
    240
  - Throttle Body Removal
    240
  - TPS Inspection
    241
  - Throttle Cables
    243
  - Fuel Injector Removal
    244
  - When Installation
    247
- Throttle Body
  249
- Tilt Switch
  250
- Self-Diagnosis
  252
  - Fuel Injection Diagnostic Tool
    253
  - Operation Instructions
    253
- Diagnostic Tool
  255
  - DTC (Diagnostic Trouble Code) INSPECTION PROCEDURE
    257
  - Fuel Injection System Failure Code
    259
  - DTC Clear Procedure
    261
  - CVT Continuously Variable Transmission
    264
  - Engine Stalls or Motorcycle Creeps
    264
  - Engine Starts but Motorcycle Won't Move
    264
  - Belt Case
    265
  - CVT Removal
    275
  - Pulleys and Belt
    275
  - Drive Pulley Disassembly
    277
  - Clutch Disassembly
    279
  - Driven Pulley Disassembly
    286
  - CVT Installation
    292
  - Driven Pulley
    292
  - Final Drive
    293
  - Final Reduction
    294
  - Final Drive Oil
    295
  - Electrical Systems
    301
  - Charging System Failure
    303
- Electrical Systems
  303
  - Intermittent Power
    303
  - Low Power
    303
  - No Power
    303
- General Instructions
  304
  - No Peak Voltage
    305
  - Peak Voltage Is Normal, but no Spark Jumps at the Plug
    305
- Troubleshooting
  305
- Component Location
  308
- Fuse Box
  311
- Fuses
  311
- Ecu
  312
- Ignition System
  314
- Spark Plug
  317
- Charging System
  320
  - Charging Voltage Inspection
    320
  - Charging Coil Wire
    321
- Battery
  322
  - Battery Charging
    323
  - Battery Testing
    323
  - Starter Relay Inspection
    324
- Starting System
  324
- Starter Motor
  325
- Relays
  326
- Ignition Switch
  327
- Switches
  327
- Luggage Box Light
  328
- Tilt Switch
  330
- Handlebar Switch
  332
- Handlebar Switches
  333
- Side Stand Switch
  334
- Horn
  335
- Meter Instrument
  336
- USB Power Socket
  337
  - Brakes
    338
  - Brake Drag
    339
  - Brake Lever Hard
    339
  - Brake Lever Soft or Spongy
    339
- Troubleshooting
  339
- Diagram
  340
- Disc Brake
  341
- Front Caliper
  345
- Rear Brake Pad Removal
  350
- Master Cylinders
  352
- Parking Brake
  355
  - ABS Component Location
    356
  - Introduction to KYMCO Anti-Lock Brake
    357
  - ABS Servicing Precautions
    359
- Abs System
  359
- Caution
  360
- ABS Troubleshooting Outline
  361
  - Pre-Diagnosis Inspection Chart 1
    362
  - Pre-Diagnosis Inspection Chart 2
    363
  - Meter Instruments
    364
  - ABS Indicator Light Is Unlit
    365
  - Terminal Voltage
    365
  - ABS Indicator Light Lights
    366
  - ABS Solenoid Valve Relay Inspection (Service Code 19)
    366
  - Solenoid Valve Inspection (Service Code 13,14,17,18)
    366
  - Front, Rear Wheel Rotation Difference Abnormal
    367
  - ABS Motor Relay Inspection (Service Code 35)
    368
  - Front Wheel Rotation Sensor Signal Abnormal
    368
  - Front Wheel Rotation Sensor Wiring Inspection
    369
  - Rear Wheel Rotation Sensor Wiring Inspection
    369
  - Power Supply Voltage Abnormal (Under-Voltage)
    371
  - Power Supply Voltage Abnormal (Over-Voltage)
    372
  - ABS Diagnostic Tool
    373
  - ECU Inspection (Service Code 55)
    373
  - ABS Unit
    376
  - Hard Steering (Heavy)
    377
  - Steering
    377
  - Steers to One Side or Does Not Track Straight
    377
  - Bar Ends
    378
  - Handlebar
    378
  - Switch Housings
    378
  - Switch Housings and Throttle
    379
  - Steering Stem Removal
    383
  - Front Shock Absorber Noise
    388
  - Front Suspension
    388
  - Soft Front Shock Absorber
    388
  - Front Fork Removal
    390
  - Front Fork Removal and Installation
    392
  - Rear Suspension
    396
  - Soft Rear Cushion
    396
  - Rear Fork
    397
  - Pre-Load Setting
    403
  - Shock Absorbers
    403
  - Front Wheel Wobbling
    407
  - Rear Wheel Noise
    407
  - Rear Wheel Wobbling
    407
  - Wheels
    407
  - Front Wheel
    408
  - Wheel Bearing Replacement
    408
  - Wheel Inspection
    417
  - Eec System
    418
  - Crankcase Emission Control System
    419
- E.E.C System Introduction
  419
- Function
  420
- Low Engine Power, Instable Engine Idle Speed
  420
- Trouble Shooting
  420
- Air Cleaner Element Replacement
  421
- Air Filter Servicing
  421
- Maintenance Information
  422
  - Note of Maintenance
    422
  - Tool
    422
- Dismantle of Canister
  423
- Oxygen Sensor
  426
Inspection and Adjustment of Emission
426

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