KYMCO AK 550 Service Manual
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KYMCO AK 550 Service Manual

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Table of Contents

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KYMCO Repair Manual
AK 550
KYMCO AK 550 Service Manual
Using this manual
This manual has been designed to assist trained mechanics in servicing the
models listed above. If you do not have the proper training or tools to perform a
particular task it is best if you seek out a service professional.
This manual was written using the latest information 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
vehicle you're working on, however the procedures will be similar.
Inexperienced technicians without the correct tools and knowledge may not be
able to perform these jobs as intended. Caution needs to be taken for the vehicle
and its operator as serious injury can occur. Always read a procedure in its
entirety before attempting any repairs.
1

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Summary of Contents for KYMCO AK 550

  • Page 1 KYMCO Repair Manual AK 550 KYMCO AK 550 Service Manual Using this manual This manual has been designed to assist trained mechanics in servicing the models listed above. If you do not have the proper training or tools to perform a particular task it is best if you seek out a service professional.
  • Page 2 KYMCO Repair Manual AK 550 KYMCO reserves all rights to this publication and does not permit the reproduction or use of this publication, in full or in part, in any manner without our express written permission. No trademark or patent liability is assumed with respect to the use of the information contained in this manual.

  • Page 3: Table Of Contents

    KYMCO Repair Manual AK 550 1. Quick Reference Component Location ............1-2 Special Tools ...............1-5 Specifications ..............1-7 Fuel Injection System ............1-12 Fuel Injection System Failure Code ........1-13 Torque Specifications ............1-15 Troubleshooting ..............1-18 VIN and Engine Number Location ........1-23 2.Periodic Maintenance Maintenance Schedule ............2-2 Air Filter Servicing ..............2-4...
  • Page 4 KYMCO Repair Manual AK 550 3.External Components General Instructions ................3-2 Dismantled and assembly order .............3-3 Windscreen Cover/Windscreen/ Windscreen Holder ....3-4 Front Meter Cover/Back Mirror/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...
  • Page 5 KYMCO Repair Manual AK 550 4.Engine General Instructions ..............4-1 Troubleshooting ................4-2 Engine Torque Specifications ............4-5 Cylinder Head Cover ..............4-7 Camshaft ..................4-11 Cylinder 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...
  • Page 6 KYMCO Repair Manual AK 550 6.Fuel Injection System GENERAL INSTRUCTIONS ............6-2 TROUBLESHOOTING ..............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 ................6-32...
  • Page 7 KYMCO Repair Manual AK 550 8.Final Drive SCHEMATIC DRAWING ..............8-1 TROUBLESHOOTING ..............8-2 FINAL REDUCTION ................8-3 9.Electrical Systems General Instructions ................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...
  • Page 8 KYMCO Repair Manual AK 550 10.Brakes GENERAL INSTRUCTIONS ............10-1 TROUBLESHOOTING ..............10-2 DIAGRAM ..................10-3 Brake Pad Replacement ..............10-4 MASTER CYLINDERS ..............10-11 BLEED THE 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...
  • Page 9 Rear Wheel Removal ...............13-3 Drive Belt Inspection ...............13-13 Drive Belt Installation ..............13-14 Rear Fork ..................13-19 14.Wheels This chapter covers the location and servicing of the 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...
  • Page 10 1.Quick Reference AK 550 1. Quick Reference This chapter provides a quick 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 Specifications ............1-14 Troubleshooting ..............1-17...

  • Page 11: Quick Reference

    1.Quick Reference AK 550 Component Location Hazard Controller Regulator/Rectifier Canister Tire Pressure Controller Horn Ignition Coil/Spark Plug Coolant Reserve Tank Side Standard Switch Radiator Meter Instrument Couplers Diagnostic Tool Connector FUSE BOX Ignition Switch Seat Open Motor Air Cleaner/Element Fuel Tank Keyless &...
  • Page 12 1.Quick Reference AK 550 Component Location Fuel Cap Fuel Pump Fuel Injector T-MAP Sensor Throttle Body Thermostat T-MAP Sensor (Air Cleaner)
  • Page 13 1.Quick Reference AK 550 Component Location Battery Winker Relay (Turn Signal) Tilt Switch ABS ECU Starter Relay Heater Grip Controller Fuel Pump Relay Fan Relay Seat Relay Main Relay Radiator Cap...

  • Page 14: Special Tools

    1.Quick Reference AK 550 Special Tools CODE NAME Illustration E039 A120 E00039 CYLINDER COMPRESSION GAUAGE E048 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 &...
  • Page 15 1.Quick Reference AK 550 CODE NAME Illustration E093 A120 E00093 BEARING PULLER F002 A120 F00002 STEERING STEM LOCK NUT WRENCH F023 A120 F00023 STEERING STEM TOP THREAD WRENCH F030 A120 F00030 BAND REMOVER/INSTALLER F031 A120 F00031 PLIERS FUEL PIPE F032...

  • Page 16: Specifications

    1.Quick Reference AK 550 KYMCO AK 550 Specifications General Information Name (Model Code) AK 550 (LGC6) 2165±20 Overall length (mm) Overall width (mm) 795±20 1400±20 Overall height (mm) 1580±10 Wheel base (mm) Engine type 4 stroke DOHC Displacement (cc) Fuel recommended 90 # nonleaded gasoline 110±4...
  • Page 17 1.Quick Reference AK 550 Starting system Starting motor Type Gasoline, 4-stroke Cylinder arrangement TWIN CYLINDER Combustion chamber type Semi-sphere Valve arrangement D.O.H.C. Chain drive Bore x stroke (mm) 69 x 73.6 Compression ratio Compression pressure 19 (kg/cm M1:53/7500 PS/rpm Max. Horsepower M2:46/7000 PS/rpm Max.
  • Page 18 1.Quick Reference AK 550 Air cleaner type & No Paper element, wet Fuel capacity 14.5 liter Brand Synerjet Fuel System Type Throttle body Injection Venturi dia.(mm) Fuel pump pressure 3 Bar Type Ignition System Spec. CR7E (NGK) Electrical Spark plug Equipment Gap 0.7~0.8 mm...
  • Page 19 1.Quick Reference AK 550 ENGINE Throttle grip free play 2 ~ 6 mm Spark plug NGK: CR7E Spark 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 ±...
  • Page 20 1.Quick Reference AK 550 Cooling System Radiator cap relief pressure 0.9 ± 0.15 kg/cm (12.8 ± 2.1 psi) Begins to open 80-84 °C Thermostat temperature Full-open 95 °C Valve lift 5 mm COOLANT GRAVITY CHART Temp.℃ Concentration 1.009 1.009 1.008 1.008 1.007 1.006 1.005...
  • Page 21 1.Quick Reference AK 550 Fuel Injection System Failure Code Failure Code Contents Causes C0064 Tilt Sensor Voltage Abnormal P0031 Circuit Voltage Too High O2 Sensor Heater P0032 Circuit Voltage Too Low Or Broken Circuit O2 Sensor Heater P0107 Circuit Voltage Too Low Or Broken Circuit...
  • Page 22 1.Quick Reference AK 550 Electrical Item Standard Capacity 12V 11AH Fully charged 13.2V Battery Voltage (20°C) Insufficient charged < 12.3V Charging current 1.1A* 5 - 10H Item Standard Spark plug Standard type NGKCR7E Spark plug gap 0.7 - 0.8 mm Throttle Position Sensor 3000 - 7000 Ω...

  • Page 23: Torque Specifications

    1.Quick Reference AK 550 Engine Torque Specifications 1-14...
  • Page 24 1.Quick Reference AK 550 Frame Torque Specifications 1-15...
  • Page 25 1.Quick Reference AK 550 General Torque Specifications Torque Item kgf-m lb-ft 5 mm bolt, nut 0.45 - 0.6 3.25 - 4.34 6 mm 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...

  • Page 26: Troubleshooting

    1.Quick Reference AK 550 Troubleshooting Vehicle can not be started Preliminary 6 Step Inspection 1. Is the battery fully charged (12 V or higher). See the Battery topic for more information. 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
  • Page 27 1.Quick Reference AK 550 General Troubleshooting 1-18...
  • 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: Vin And Engine Number Location

    1.Quick Reference AK 550 VIN and Engine Number Location VIN Number Engine Number 1-22...

  • Page 32: Periodic Maintenance

    2.Periodic Maintenance AK 550 2.Periodic Maintenance This chapter covers the periodic maintenance for the KYMCO AK 550. 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...

  • Page 33: Maintenance Schedule

    KYMCO standards and specifications by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. * Should be serviced by your KYMCO dealer, unless you have the proper tools, service data and are technically qualified.
  • Page 34 2.Periodic Maintenance AK 550 FREQUENCY WHICHEVER ODOMETER READING COMES FIRST X 1000 km 0.3 ITEM X 1000 mi 0.18 MONTH ＊ Air Filter Servicing Spark Plug ＊ Throttle Free Play ＊ Valve Clearance Check/Adjust. Every 40000 km (24000 mi) ＊ Hose Inspection ＊...

  • Page 35: Air Filter Servicing

    2.Periodic Maintenance AK 550 Air Filter Servicing Replace Air Filter as specified in Regular Maintenance Schedule. Check and replace Air Filter Cartridge more frequently if vehicle is often used in dusty environments or damp areas. Replace Air Filter Cartridge 1. Remove outer casing of vehicle.
  • Page 36 2.Periodic Maintenance AK 550 Check CVT Transmission System Filter Wool CVT Transmission System Filter Wool Excessive dust accumulation in CVT Transmission System may result in unsmooth engine operation; clean and replace Filter Wool regularly. Clean Filter Wool regularly as specified in Maintenance Schedule; replace or...

  • Page 37: Brake Fluid

    AK 550 Brake Fluid The KYMCO AK 550 uses DOT 4 brake fluid that should be inspected after 3,000 mi (5,000 km) of use. It should be flushed and bled every 12 months, 6,000 mi (10,000 km), whenever the brakes feel spongy, or if the brake system has been taken apart and rebuilt.
  • Page 38 2.Periodic Maintenance AK 550 Replenishing Brake Fluid 1. Straighten the Handlebar, remove 2 fixing screws of Reservoir and remove Reservoir Cover. 2. Replenish Reservoir with recommended DOT-4 Brake Fluid to the Upper Scale. Replace Reservoir Cover and tighten 2 fixing screws.
  • Page 39 2.Periodic Maintenance AK 550 Draining The brake bleeding process is the same for the front and rear brakes. Remove the two master cylinder cover screws with a #2 Phillips head screwdriver. Remove the master cylinder cover, plastic piece and rubber accordion diaphragm.
  • Page 40 2.Periodic Maintenance AK 550 Pump the brake lever several times and hold the lever in. While holding the lever in, crack open the bleeder valve. The front brake lever will travel all the way to the grip and brake fluid and/or air will come out of the bleeder valve into the 6 mm hose.

  • Page 41: Brake Inspection

    2.Periodic Maintenance AK 550 Brake Inspection Brake Lever Adjuster There is adjuster on each brake lever. Each adjuster has four positions so that the released lever position can be adjusted to suit the rider’s hands.To adjust the distance of the lever from the handlebar grip, push the lever forward and turn the adjuster knob to align the number with the arrow mark on the lever holder.
  • Page 42 2.Periodic Maintenance AK 550 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 brake pad. 2-11...
  • Page 43 2.Periodic Maintenance AK 550 Remove the spring of the brake pad. Remove the right and left brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Insert new brake pads as needed.
  • Page 44 2.Periodic Maintenance AK 550 When installation: Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.

  • Page 45: Coolant

    2.Periodic Maintenance AK 550 Coolant For the sake of safety, check level of cooling water before riding the vehicle. Replace the cooling liquid as specified in Regular Maintenance Schedule. Check Level of Cooling Water 1. Park the vehicle on level ground and brace it up with Main Stand.
  • Page 46 In case of fault of vehicle: Go to a KYMCO dealer for check and repair if any fault occurs when riding the vehicle. Use only original parts for replacement. Check following items if engine does not start or engine stops when riding the vehicle: ◆...
  • Page 47 Tighten the drain bolt securely with an 8 mm socket. Fill the cooling system with a mix of distilled water and KYMCO SIGMA Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown.
  • Page 48 2.Periodic Maintenance AK 550 Add coolant to the reserve tank until it reaches the upper level mark. Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes.

  • Page 49: Engine Oil

    2.Periodic Maintenance AK 550 Engine Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Caution: Hot engine oil can burn. Avoid letting used motor oil contact exposed skin. TROUBLESHOOTING Oil level too low 1. Natural oil consumption 2.
  • Page 50 2.Periodic Maintenance AK 550 Oil Level Inspection Check the engine oil level each day before operating the scooter. Place the motorcycle upright on level ground for engine oil level check. Run the engine for 2 ~ 3 minutes and check the oil level after the engine is stopped for 2 ~ 3 minutes.
  • Page 51 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. Remove Drain Cock. Drain all the oil. Warming up the engine before changing oil facilitates oil draining.
  • Page 52 2.Periodic Maintenance AK 550 3. Fill in new oil. Filling capacity is 3.0L. (If Oil filter cartridge is replaced, oil change shall be 2.7L). Oil Capacity: Dismantle: 3.0L (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.
  • Page 53 ◆ Do not mix-use oils of different brand, class or low quality ones; they may cause engine faults. ◆ Kymco Emissary Engine Oil contains additives (e.g., spirits, etc.) during the manufacturing process. ◆ Arbitrarily mixing additives bought from the market may deteriorate the oil, affect lubricating properties and shorten the service life of engine.

  • Page 54: General Lubrication

    2.Periodic Maintenance AK 550 General Lubrication SAFETY FIRST: Protective gloves and eyewear are recommended at 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 increase the durability of the motorcycle.

  • Page 55: Side Stand

    2.Periodic Maintenance AK 550 Side Stand Interlock Function Check Your scooter's side stand is not only necessary when you park, but it contains an important safety feature. This feature cuts-off the ignition if you try to ride the scooter when the side stand is down. Perform the following side stand inspection.

  • Page 56: Spark Plug

    2.Periodic Maintenance AK 550 Spark Plug remove the spark plug wire off of the spark plug. Remove the connectors of the ignition coil. Remove the two ignition coil mounting bolts and remove the ignition 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.
  • Page 57 2.Periodic Maintenance AK 550 Check the spark plug to see if it is the correct type and gapped properly. If the spark plug is black and fouled, replace it. If the spark plug center electrode or side electrode are corroded or damaged, or if the insulator is cracked, replace the plug.

  • Page 58: Engine Compression Test

    2.Periodic Maintenance AK 550 Engine Compression Test SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the under cowl set. See the external topic for more information. Before testing the compression make sure the cylinder head bolts are tightened securely and the valve clearance is specification.

  • Page 59: Steering Inspection

    2.Periodic Maintenance AK 550 Steering Inspection Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. See the Steering Stem Removal topic for more information.

  • Page 60: Throttle Free Play

    2.Periodic Maintenance AK 550 Throttle Free Play Inspection Closed Resistance First Felt Check the throttle cable free play by gently rotating the throttle grip back until resistance is felt. Throttle grip free play 2 ~ 6 mm Make sure the throttle moves smoothly and returns on its own. Start the engine and let it warm up.

  • Page 61: Parking Brake

    2.Periodic Maintenance AK 550 Parking Brake Adjustment Release the fixed nut, and rotate the adjust nut to adjust the parking brake. Fixed nut Adjust nut Note: Do not use the rear brake lock lever while driving. 2-30...

  • Page 62: Light Inspection

    2.Periodic Maintenance AK 550 Light Inspection Check Brake Light ◆ Turn KEYLESS Main Switch to position. Respectively pull the Front and Rear 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.

  • Page 63: Tires

    Kymco dealer for replacing with new one. Excessive wear of tire tread pattern will result in widened tread which is more prone to be punctured.

  • Page 64: Tpms Tire Pressure Management System

    4. No re-adjustment of TPMS is required when a new tire or rim is replaced. 5. Re-adjustment of TPMS is required when replacing a new wireless tire pressure sensor and controller; please consult a KYMCO dealer. 6. When replacing a tire rim, the Tire Pressure Sensor shall be kept in a correct order to distinguish the front one and the rear one.
  • Page 65 2.Periodic Maintenance AK 550 Owner Learn Code Operation: ◆ Applicable to owner and dealer service personnel. ◆ Re-adjustment 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-triggering.
  • Page 66 2.Periodic Maintenance AK 550 Learn Code Activation Procedure: 1. Press and hold Operation Button (︿ button on the Handlebar), but it is necessary to switch over to Dashboard position “m” in advance. 2. KEY ON the KEYLESS Main Switch. 3. Release the Operation Button (︿) when the front tire of the Model Symbol flashes and tire pressure unit disappears.
  • Page 67 2.Periodic Maintenance AK 550 Tire Pressure Unit Change Display Remarks: 1. The dealer and owner are requested to inflate the tires to 20psi or more, so that TPMS computer can automatically learn the initial values and facilitate the subsequent normal operation.
  • Page 68 2.Periodic Maintenance AK 550 Change Pressure Unit Turn KEYLESS Main Switch ON, the Model Symbol will light up. Push the Dashboard and noodoe Switch to “m” position and press the UP button to change over to TPMS Mode. Pressing “O” button on the Right Handlebar Switch to change units in the sequence of [kgf/cm →...

  • Page 69: Drive Belt Inspection

    2.Periodic Maintenance AK 550 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. 2-38...
  • Page 70 2.Periodic Maintenance AK 550 Abnor m al Pos s i bl y Reas on/ Sol ut i on CRACK 1) Check bel t s t or age condi t i on Avoi d t he s un l i ght...

  • Page 71: Drive Belt Tension Adjustment

    2.Periodic Maintenance AK 550 Drive Belt 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 and R/H Adjusters are the same (18.8mm±0.5mm).
  • Page 72 2.Periodic Maintenance AK 550 Step 2-1: 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.
  • Page 73 2.Periodic Maintenance AK 550 Step 2-2: Measure the belt tension P.S. distance C vs. tension (for reference only) 18.8mm --- (1300~1700N) 19.2mm --- (1100~1500N) ~1. Probe of Sonic Tension meter should be parallel to the belt as shown above pictures.
  • Page 74 2.Periodic Maintenance AK 550 Step 3: Belt side Clearance ~1. Turn the wheel for several runs, check the belt 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±0.5mm.
  • Page 75 2.Periodic Maintenance AK 550 Valve Clearance The valve clearance specification is only relevant if the engine is cold. Inspection Remove the timing inspection cap from the left side of the engine. And rotate the crankshaft from the right side of the engine.

  • Page 76: Valve Clearance Adjustment

    2.Periodic Maintenance AK 550 Valve Clearance Adjustment Right cylinder Left cylinder Right cylinder Left cylinder 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.
  • Page 77 2.Periodic Maintenance AK 550 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. Specification of shim: 1.8~3.0mm...
  • Page 78 3.External Components AK 550 3.External Components This chapter covers the location and servicing of the external components for the KYMCO AK 550 model. General Instructions ................3-2 Dismantled and assembly order .............3-3 Windscreen Cover/Windscreen/ Windscreen Holder ....3-4 Front Meter Cover/Back Mirror/Mats Of Floor And Leg Shield ..3-5 Side Cover/Side Skirt Set ..............3-6...

  • Page 79: External Components

    3.External Components 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 & Harness...

  • Page 80: Dismantled And Assembly Order

    3.External Components AK 550 Dismantled and assembly order Follow the dismantled 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.
  • Page 81 3.External Components AK 550 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 the windscreen holders.
  • Page 82 3.External Components AK 550 Front 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 mats of floor and leg shield.
  • Page 83 3.External Components 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 skirts set.

  • Page 84: Panel Floor

    3.External 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 floor A set.
  • 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.

  • Page 86: Luggage Box

    3.External Components AK 550 Luggage Box Removal Remove 6 bolts, lamp coupler and remove the luggage box.
  • Page 87 3.External Components 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 board A.

  • Page 88: Front Cover Set

    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: Meter Cover Set

    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 3.External Components AK 550 Front 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 remove the under cowl set.
  • 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: Up And Low Handle Cover

    3.External Components AK 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 low handle cover.
  • 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: Rear Fender Set

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

  • Page 97: Body Cover Set

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

  • Page 98: Heat Shield

    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: Exhaust System

    3.External Components AK 550 Exhaust System SAFETY 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 • Clogged exhaust muffler •...
  • Page 100 3.External 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. 3-23...

  • Page 101: Exhaust Pipe

    3.External Components AK 550 Exhaust Pipe Removal Unplug the O sensor connector. Remove 4 nuts of the exhaust pipe. Remove the exhaust pipe. Replace the new exhaust pipe gasket(18291) when installation. 3-24...

  • Page 102: O2 Sensor

    3.External Components AK 550 O2 Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. Installation torque: 2~3 kgf-m (20~30 N-m) Apply anti-seize compound to the threads of the O sensor. Install the O sensor and tighten it to specification with a 17 mm wrench.

  • Page 103: Side Stand

    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: Center Stand

    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.Engine AK 550 4.Engine This chapter covers the location and servicing of the engine components for the KYMCO AK 550 model. General Instructions ..............4-1 Troubleshooting ................4-2 Engine Torque Specifications ............4-5 Cylinder Head Cover ..............4-7 Camshaft ..................4-11 Cylinder Head .................4-16 Cylinder ...................4-19 Piston ....................4-20...
  • Page 106 4.Engine AK 550 TROUBLESHOOTING Oil level too low 1. Natural oil consumption 2. Oil leaks 3. Worn or poorly installed piston rings 4. Worn valve guide or seal Poor lubrication pressure 1. Oil level too low 2. Clogged filter or oil passages 3.
  • Page 107 4.Engine AK 550 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed • Compression too low Compression too low • Incorrect valve clearance adjustment •...
  • Page 108 4.Engine AK 550 White smoke from exhaust muffler • Worn valve stem or valve guide • Damaged valve stem oil seal Cylinder and Piston • The cylinder and piston cannot be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection.
  • Page 109 4.Engine AK 550 Engine Torque Specifications...
  • Page 110 4.Engine AK 550...
  • 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.
  • Page 112 4.Engine AK 550 Remove 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 fuel supply rail.
  • Page 113 4.Engine AK 550 Remove 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 when installation.
  • Page 114 4.Engine AK 550 Installation torque: 1~1.4 kgf-m (9.8~13.7 N-m) 4-10...
  • Page 115 4.Engine AK 550 Camshaft Removal Remove the timing inspection cap from the left side of the engine. And rotate the crankshaft from the right side of the engine. When installation, inspect the O-ring on the cap and replace it as needed.
  • Page 116 4.Engine AK 550 Remove the cam chain 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 and remove the upper train guide.
  • Page 117 4.Engine AK 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 number mark. 4-13...
  • 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 4.Engine AK 550 Cam Holder Installation Rotate (clockwise) the 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.
  • Page 120 4.Engine AK 550 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 cylinder head. 4-16...
  • Page 121 4.Engine AK 550 Remove the cylinder head gasket 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 carefully, do not fall out the lifter and shim.
  • Page 122 4.Engine AK 550 Installation: The bolts mounting order and torque at 3 stages follow the below rule. 4-18...
  • Page 123 4.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. 4-19...
  • Page 124 4.Engine AK 550 Pistons Removal Place a clean 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 clips.
  • Page 125 4.Engine AK 550 CVT Removal SCHEMATIC DRAWING 4-21...
  • Page 126 4.Engine 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 element. Clean the cover element if necessary. 4-22...
  • Page 127 4.Engine 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. 4-23...
  • Page 128 4.Engine AK 550 Remove the bearing snap ring with snap ring 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 the same outside diameter as the bearing.
  • Page 129 4.Engine 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. Drive Pulley Disassembly 4-25...
  • Page 130 4.Engine AK 550 Inspect the faces of the drive pulley. Clean away any grease from the faces. Lift the ramp plate out of the back of the movable drive pulley face. Remove the rubber damper pieces from the ramp. There are eight weight rollers in the back of the movable face of the drive pulley.
  • Page 131 4.Engine AK 550 Inspect the movable drive face and bushing for wear and damage. Replace the parts as needed. Hold the drive pulley with a universal holder tool. Remove the nut of driven pulley. Lubricate the threads of the nut before installation.
  • Page 132 4.Engine AK 550 Remove the belt from the driven pulley. I nspect 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 free where they will contact the belt.
  • 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 4.Engine AK 550 Tighten 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 r emove the plate nut of driven pulley set. Loosen and remove the spring compressor tool.
  • 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 4.Engine AK 550 Remove the seal collar. 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, wipe away any grease that gets on the faces where the belt will ride.
  • 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 4.Engine AK 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 (9.8~13.7 N-m) 4-42...
  • Page 147 4.Engine AK 550 Remove the clip and check 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.
  • 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 4.Engine AK 550 Mission Box Disassembly Remove the 3 bolts and remove the 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 the left mission case.
  • 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 4.Engine AK 550 CRANKCASE INSTALLATION Note: Make sure the Upper/Lower crankcases are with the same number 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 oil passages or get in bearings.
  • Page 159 4.Engine AK 550 CRANKCASE INSTALLATION The bolts mounting order and torque follow the below rule. 21~25: 1.2 kgf-m 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 4.Engine 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. 4-58...
  • Page 163 4.Engine 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. 4-59...
  • Page 164 4.Engine AK 550 Balancer 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 the below charts. 4-60...
  • Page 165 4.Engine AK 550 Crankshaft/Balancer Gear 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 the timing mark as below illustrator.
  • Page 166 4.Engine AK 550 Engine Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal.
  • Page 167 4.Engine 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 N-m) 4-63...
  • Page 168 4.Engine AK 550 Support 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-m (9.8~13.7 N-m)
  • Page 169 5. Cooling System AK 550 5.Cooling System This chapter covers the location and servicing of the cooling system components for the KYMCO AK 550 model. General Instructions ..............5-1 Troubleshooting ................5-2 Coolant ....................5-3 Radiator ..................5-7 Water Temperature Sensor (WTS) ..........5-11 Water Pump ..................5-16 GENERAL INSTRUCTIONS •...

  • Page 170: Troubleshooting

    5. Cooling System AK 550 TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or sensor • Faulty radiator cap • Faulty thermostat • Insufficient coolant • Passages blocked in hoses or water jacket • Clogged radiator fins • Passages blocked in radiator •...

  • Page 171: Coolant

    5. Cooling System AK 550 Coolant SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. Draining SAFETY FIRST: Antifreeze is highly toxic and can kill pets and animals if drank.
  • Page 172 5. Cooling System AK 550 Loosen the coolant drain bolt with an 8 mm socket. The coolant reserve tank is under the left floorboard. Remove the left floorboard. Remove the engine coolant lid screw, and remove the engine coolant lid.
  • Page 173 Tighten the drain bolt securely with an 8 mm socket. Fill the cooling system with a mix of distilled water and KYMCO SIGMA Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown.
  • Page 174 5. Cooling System AK 550 Add coolant to the reserve tank until it reaches the upper level mark. Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes.

  • Page 175: Radiator

    5. Cooling System AK 550 Radiator SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. Pressure Testing Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it.
  • Page 176 5. Cooling System 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/cm (12.8 ± 2.1 psi)
  • Page 177 5. Cooling System AK 550 Radiator Removal Drain the coolant. Unplug the cooling 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 thermostat on the...
  • Page 178 5. Cooling System AK 550 Loosen the coolant hose clamps with a #2 Phillips screwdriver. Free the filler neck coolant hose from the stay and remove it from the radiator. Loosen the coolant hose clamps with a #2 Phillips screwdriver.
  • Page 179 5. Cooling System 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 from the frame.
  • Page 180 5. Cooling System AK 550 Coolant Reserve Tank The coolant reserve tank is mounting to the frame with two bolts. There are two hoses that connect to the reserve tank. The top hose is a dump hose that hangs over the other side. The bottom hose is the overflow hose that runs to the filler neck.
  • Page 181 5. Cooling System AK 550 Radiator Inspection Inspect the radiator fins for damage and clogging. Clean out the fins with low pressure compressed air and water. Check the radiator for any bent or damaged fins. Use a small flat blade screwdriver to straighten them out, but be careful not to puncture the radiator.
  • 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: Water Temperature Sensor (Wts)

    5. Cooling System AK 550 Inspection Water Temperature Sensor Inspect the WTS in a similar manner as the thermosensor. Measure the resistance between the WTS terminals and compare this to the specifications. At 60°C 703.8±40.9 Ω Water temperature At 90°C 260.7±15.1 Ω...

  • Page 185: Water Pump

    5. Cooling System AK 550 Water Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Mechanical Seal Inspection Inspect the telltale hole in the generator cover below the water pump for signs of coolant leaking. If there is coolant coming from this hole the mechanical seal is compromised and must be replaced.
  • Page 186 5. Cooling System AK 550 Remove the other 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 for more information.
  • 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 6.Fuel System AK 550 6.Fuel Injection System This chapter covers the location and servicing of the fuel system components for the KYMCO AK550 model. GENERAL INSTRUCTIONS ............6-2 TROUBLESHOOTING ..............6-3 COMPONENT LOCATION ..............6-4 ECU ....................6-7 IGNITION COIL ................6-9 SPARK PLUG .................6-10 CRANK POSITION SENSOR ............6-12...

  • Page 189: General Instructions

    6.Fuel System AK 550 GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.

  • Page 190: Troubleshooting

    6.Fuel System AK 550 TROUBLESHOOTING Engine fail to start • Intake manifold air leak • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Faulty fuel pump • Clogged fuel filter, throttle body • Sticking fuel injector needle • Faulty fuel pump operating system •...
  • Page 191 6.Fuel System AK 550 Component Location Hazard Controller Regulator/Rectifier Canister Tire Pressure Controller Horn Ignition Coil/Spark Plug Coolant Reserve Tank Side Standard Switch Radiator Meter Instrument Couplers Diagnostic Tool Connector FUSE BOX Ignition Switch Seat Open Motor Air Cleaner/Element Fuel Tank Keyless &...

  • Page 192: Component Location

    6.Fuel System AK 550 Component Location Fuel Cap Fuel Pump Fuel Injector T-MAP Sensor Throttle Body Thermostat T-MAP Sensor (Air Cleaner)
  • Page 193 6.Fuel System AK 550 Component Location Battery Winker Relay (Turn Signal) Tilt Switch Starter Relay Heater Grip Controller Fuel Pump Relay Fan Relay Seat Relay Main Relay Radiator Cap...

  • Page 194: Ecu

    6.Fuel System AK 550 Remove the front cover set. See the external topic for more information. 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.
  • Page 195 6.Fuel System AK 550 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 should be continuity at all times.

  • Page 196: Ignition Coil

    6.Fuel System AK 550 Ignition System The ignition timing is 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.

  • Page 197: Spark Plug

    6.Fuel System AK 550 Spark Plug Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
  • Page 198 6.Fuel System AK 550 Measure the gap with a wire-type thickness gauge. If the gap is incorrect, replace 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 burning.
  • Page 199 6.Fuel System AK 550 AC Generator Inspection Crank Position Sensor Inspection 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 –...
  • Page 200 6.Fuel System AK 550 O2 Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. Installation torque: 2~3 kgf-m (20~30 N-m) Apply anti-seize compound to the threads of the O sensor. Install the O sensor and tighten it to specification with a 17 mm wrench.

  • Page 201: Relays

    6.Fuel System AK 550 Relays Fuel Pump Relay Fan Relay Seat Relay Main Relay Relays Inspection Use a digital multimeter 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.

  • Page 202: Fuel Tank

    6.Fuel System AK 550 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. 6-15...
  • Page 203 6.Fuel System AK 550 Fuel Tank Removal In 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 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. 6-17...
  • Page 205 6.Fuel System AK 550 Clean 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 bolts.
  • Page 206 6.Fuel System AK 550 Remove the fuel pump assembly. Loosen the clip and remove the air tube. Remove the fuel tank mounting nuts. 6-19...
  • Page 207 6.Fuel System AK 550 Remove the fuel tank mounting nuts and remove the fuel tank from the frame. 6-20...
  • Page 208 6.Fuel System AK 550 Fuel Pump 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. Input Voltage Inspection Remove the seat. See the Seat topic for more information.
  • Page 209 6.Fuel System AK 550 Set the engine stop switch to the “RUN” position. Unplug the fuel pump connecter. Set the multi meter to read battery voltage. Touch the multi meter leads to the harness 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.

  • Page 210: Fuel Pump

    6.Fuel System AK 550 Fuel Pump Lift the fuel pump out of the tank. Discard the fuel pump O-ring, and when installation, replace the O-ring with new item and apply a small amount of fresh engine oil to the new O-ring.
  • Page 211 6.Fuel System AK 550 Fuel Level Float Position Resistance Full 100Ω± 3% Empty 2400Ω± 3 % Replace the fuel level float unit with a new part if the resistance is out of specification. 6-24...
  • Page 212 6.Fuel System AK 550 Fuel Pump Output Pressure Turn the key to the OFF position. 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.
  • Page 213 6.Fuel System AK 550 If the fuel output pressure 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.
  • Page 214 6.Fuel System AK 550 Fuel Injector Removal 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. In order to release fuel pressure from the fuel pipe when removing the fuel injector, unplug the fuel pump connecter.
  • Page 215 6.Fuel System AK 550 Slide back the clamp and free the injector 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.
  • Page 216 6.Fuel System AK 550 Inspection A digital multi 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 Ω Check for signs of clogging.
  • Page 217 6.Fuel System AK 550 When installation: 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 injector must securely fit into the pipe.
  • Page 218 6.Fuel System AK 550 Cleaning PROBLEM 1. Fuel Injector cannot output the fuel. 2. The Injector injection time (ms) is shorter or longer. Standard: < 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.
  • Page 219 ● Do not damage the throttle body, it may 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 throttle body.

  • Page 220: Fuel Injector

    6.Fuel System AK 550 Fuel Injector T-MAP Sensor Throttle Body Thermostat Loosen the two screws of throttle body/air cleaner clamps. Remove the bolt of T-MAP sensor. And remove the T-MAP sensor. 6-33...
  • Page 221 6.Fuel System AK 550 Remove four bolts of inlet pipe. Slide back and remove the throttle body. Remove the tubes of throttle body. 6-34...
  • Page 222 6.Fuel System AK 550 Remove the throttle body. 6-35...
  • Page 223 6.Fuel System AK 550 T-MAP Inspection Support the scooter on a level surface. 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 following terminals of the MAP connector.
  • Page 224 6.Fuel System AK 550 TPS Inspection Unplug the TPS sensor connector. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal Violet/Red (+) – Green/Pink (-) Throttle Position Sensor (TPS) 3000 - 7000 Ω...

  • Page 225: Isc

    6.Fuel System AK 550 ISC (Air Bypass Valve) Remove the ISC screw with a #2 Phillips. Remove the ISC screw with a #2 Phillips. 6-38...
  • Page 226 6.Fuel System AK 550 Remove the ISC. When installation, apply oil onto a new O-ring. And being careful not to damage the O-ring. 6-39...

  • Page 227: Tilt Switch

    6.Fuel System AK 550 Tilt Switch Remove the front cover. See the external topic for more information. Support the scooter level surface. Put the side stand up 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.
  • Page 228 6.Fuel System AK 550 Incline the tilt switch 65±10 degrees to the left or right at the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage) Black/Blue (+) ~ Green/Pink (-) 4 - 4.4 V...

  • Page 229: Water Temperature Sensor

    6.Fuel 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) 6-42...

  • Page 230: Self-Diagnosis

    6.Fuel System AK 550 Self-Diagnosis Note: No matter when the CELP illuminated while riding condition, should find out the cause of the problem as soon as possible. CELP If the ECM connectors, or battery leads are disconnected the stored malfunction codes will be lost.
  • Page 231 Fuel Injection Diagnostic Tool OPERATION INSTRUCTIONS Diagnostic tool Part Number: 3620A-LEB2-E00 This tool has been developed by KYMCO 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.
  • Page 232 6.Fuel System AK 550 The diagnostic tool is located 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 diagnostics connecter (part number:36205-LGC6-E00) and can linker .

  • Page 233: Diagnostic Tool

    6.Fuel System AK 550 Plug in the tool to the ECU connector and turn on the ignition switch to send power to the tool. Place the scooter on its main stand and put the side stand up prior to using the diagnostic tool.
  • Page 234 ECU Version The four functions will 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 version.
  • Page 235 6.Fuel System AK 550 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 the options shown above.
  • Page 236 6.Fuel System AK 550 Press the down 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.
  • Page 237 6.Fuel System AK 550 Fuel Injection System Failure Code Failure Code Contents Causes C0064 Tilt Sensor Voltage Abnormal P0031 Circuit Voltage Too High O2 Sensor Heater P0032 Circuit Voltage Too Low Or Broken Circuit O2 Sensor Heater P0107 Circuit Voltage Too Low Or Broken Circuit...
  • Page 238 6.Fuel System AK 550 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 shown above. 6-51...
  • Page 239 6.Fuel System AK 550 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 buttons will be off.
  • Page 240 6.Fuel System AK 550 Data Analysis Procedure Press the down button (right) 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 241 6.Fuel System AK 550 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. 6-54...
  • Page 242 6.Fuel System AK 550 Page 04 The 04 page shows atmospheric pressure, fuel injection interval, and ignition advance. Page 05 The 05 page shows the rollover voltage. 6-55...
  • Page 243 6.Fuel System AK 550 Page 06 The 06 page shows the ISC step and ISC learn step. Page 07 The 07 page shows the ECU counter. 6-56...
  • Page 244 6.Fuel System AK 550 AK 550 Dealer : Customer : VIN: Production Service Mileage : Date : Date : Reason of repair: □ maintenance □ breakdown Item Reference Data Memo ECU No LGC6 Hardware Ver Software Ver QK420010 Calibration Ver...
  • Page 245 7.CVT Continuously Variable Transmission AK 550 7.CVT Continuously Variable Transmission This chapter covers the location and servicing of the CVT components for the KYMCO AK 550 model. General Instructions ..............7-1 Troubleshooting ................7-1 Schematic Drawing ................7-2 Belt Case ..................7-3 CVT Removal ..................7-8 Driven Pulley Disassembly ............7-10...
  • Page 246 7.CVT Continuously Variable Transmission AK 550 SCHEMATIC DRAWING...
  • Page 247 7.CVT Continuously 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 element.
  • Page 248 7.CVT Continuously 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 rough or noisy.
  • Page 249 7.CVT Continuously Variable Transmission AK 550 Remove the bearing snap ring with snap ring 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 the same outside diameter as the bearing.
  • Page 250 7.CVT Continuously Variable 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. Drive Pulley Disassembly...
  • Page 251 7.CVT Continuously Variable Transmission AK 550 Inspect the faces of the drive pulley. Clean away any grease from the faces. Lift the ramp plate out of the back of the movable drive pulley face. Remove the rubber damper pieces from the ramp.
  • Page 252 7.CVT Continuously Variable Transmission AK 550 Inspect the movable drive face and bushing for wear and damage. Replace the parts as needed. Hold the drive pulley with a universal holder tool. Remove the nut of driven pulley. Lubricate the threads of the nut before installation.
  • Page 253 7.CVT Continuously Variable Transmission AK 550 Remove the belt from the driven pulley. I nspect 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 free where they...
  • Page 254 7.CVT Continuously 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 disassembly 7-10...
  • Page 255 7.CVT Continuously Variable Transmission AK 550 Tighten 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 r emove the plate nut of driven pulley set.
  • 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 7.CVT Continuously Variable Transmission AK 550 Remove the seal collar. 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.
  • Page 258 7.CVT Continuously 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 driven pulley. 7-14...
  • Page 259 8.Final Drive 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 DRAWING...
  • Page 260 8.Final Drive AK 550 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 damaged oil seal...
  • Page 261 8.Final Drive AK 550 Final Reduction SAFETY FIRST: Protective gloves and 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 bearing and oil seal.
  • Page 262 8.Final Drive AK 550 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 the left mission case. Installation torque: 1~1.4 kgf-m (9.8~13.7 N-m)
  • Page 263 8.Final Drive AK 550 Remove the final shaft. Inspect the final shaft for wear 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.
  • Page 264 8.Final Drive 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 plate.
  • 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.
  • Page 266 9.Electrical Systems AK 550 9.Electrical Systems This chapter covers the location and servicing of the electrical systems for the KYMCO AK 550 model. General Instructions ................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...
  • Page 267 9.Electrical Systems AK 550 • When a battery is overcharged, some symptoms can be found. If there is a short circuit inside the battery, no voltage is produced on the battery terminals. If the rectifier won‘t operate, the voltage will become too high and shorten the battery service life.
  • Page 268 9.Electrical Systems AK 550 TROUBLESHOOTING No power • Dead battery • Disconnected battery cable • Fuse burned out • Faulty ignition switch Intermittent power • Loose battery cable connection • Loose charging system connection • Loose connection or short circuit in the ignition system Low power •...

  • Page 269: General Instructions

    9.Electrical Systems AK 550 Ignition System GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page above.

  • Page 270: Troubleshooting

    9.Electrical Systems AK 550 TROUBLESHOOTING No peak voltage • Short circuit in engine stop switch or ignition switch wire. • Faulty engine stop switch or ignition switch. • Loose or poorly connected ignition control module connectors. • Open circuit or poor connection in ground wire of the ignition control module.
  • Page 271 9.Electrical Systems AK 550 TROUBLESHOOTING Starter motor will not turn • Fuse burned out • Weak battery • Faulty ignition switch • Faulty starter clutch or gear • Faulty front or rear stop switch • Faulty starter relay • Poorly connected, broken or shorted wire •...
  • Page 272 9.Electrical Systems AK 550 • Check the battery condition before performing any inspection that requires proper battery voltage. • A continuity test can be made with the switches installed on the scooter. • Route the wires and cables properly after servicing each component.

  • Page 273: Component Location

    9.Electrical Systems AK 550 Component Location...
  • Page 274 9.Electrical Systems AK 550 Component Location Hazard Controller Regulator/Rectifier Canister Tire Pressure Controller Horn Ignition Coil/Spark Plug Coolant Reserve Tank Side Standard Switch Radiator Meter Instrument Couplers Diagnostic Tool Connector FUSE BOX Ignition Switch Seat Open Motor Air Cleaner/Element Fuel Tank Keyless &...
  • Page 275 9.Electrical Systems AK 550 Component Location Fuel Cap Fuel Pump Fuel Injector T-MAP Sensor Throttle Body Thermostat T-MAP Sensor (Air Cleaner) 9-10...
  • Page 276 9.Electrical Systems AK 550 Component Location Battery Winker Relay (Turn Signal) Tilt Switch Starter Relay Heater Grip Controller Fuel Pump Relay Fan Relay Seat Relay Main Relay Radiator Cap 9-11...

  • Page 277: Fuses

    9.Electrical Systems AK 550 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 fuses. 9-12...

  • Page 278: Ecu

    9.Electrical Systems AK 550 Remove the front cover set. See the external topic for more information. 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.
  • Page 279 9.Electrical Systems AK 550 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 should be continuity at all times.

  • Page 280: Ignition System

    9.Electrical Systems AK 550 Ignition System The ignition timing is 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.

  • Page 281: Spark Plug

    9.Electrical Systems AK 550 Spark Plug Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
  • Page 282 9.Electrical Systems AK 550 Measure the gap with a wire-type thickness gauge. If the gap is incorrect, replace 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 burning.
  • Page 283 9.Electrical Systems AK 550 AC Generator Inspection Crank Position Sensor Inspection 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 –...

  • Page 284: Charging System

    9.Electrical Systems AK 550 Charging System To replace the stator/charging coil see the A.C. Generator and Starter clutch topic. Charging Voltage Inspection Remove the battery cover. See the Battery topic for more information. Note: The battery should be fully charged prior to making charging system checks.
  • Page 285 9.Electrical Systems AK 550 Regulator/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 connectors for loose contacts or corroded terminals. 9-20...
  • Page 286 9.Electrical Systems AK 550 Battery 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. There should be continuity at all times.
  • Page 287 9.Electrical Systems AK 550 Charging Coil Wire Disconnect the 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 regulator/rectifier side and ground. There should be no continuity.

  • Page 288: Battery

    9.Electrical Systems AK 550 Battery SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention.
  • Page 289 9.Electrical Systems AK 550 Battery Testing Check the battery voltage with a multi-meter. Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal. If the battery reads under 12.3 V it is undercharged.

  • Page 290: Starting System

    9.Electrical Systems AK 550 Starting System Starter Relay Inspection Disconnect the starter relay wire connector. And remove the starter relay. Check for continuity between the yellow/red wire and green/yellow wire. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 291 9.Electrical Systems AK 550 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 replace it as needed. 9-26...

  • Page 292: Relays

    9.Electrical Systems AK 550 Relays Fuel Pump Relay Fan Relay Seat Relay Main Relay Relays Inspection Use a digital multimeter 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.

  • Page 293: Switches

    9.Electrical Systems AK 550 Switches Ignition Switch Remove the fixed screw, rotate and remove the 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 from the ignition switch.
  • Page 294 9.Electrical Systems AK 550 To remove the anti-tamper 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 switches.
  • Page 295 9.Electrical Systems AK 550 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 controller. 9-30...

  • Page 296: Keyless Remote Controller

    9.Electrical Systems AK 550 Remove the luggage box. See the external 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 sticker.
  • Page 297 9.Electrical Systems AK 550 Luggage Box Light Light (Lighting angle adjustable): The lamp lights up when Seat Pad is lifted up, goes out when closed. (The Cabinet Light is 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 loss of battery.)
  • Page 298 9.Electrical Systems AK 550 Check the circuit following below wiring dirgram. 9-33...
  • Page 299 9.Electrical Systems AK 550 Tilt Switch Remove the front cover. See the external topic for more information. Support the scooter level surface. Put the side stand up 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.
  • Page 300 9.Electrical Systems AK 550 Incline the tilt switch 65±10 degrees to the left or right at the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage) Black/Blue (+) ~ Green/Pink (-) 4.0 - 4.4 V...
  • Page 301 9.Electrical Systems AK 550 Handlebar Switch Remove the front cover. See the external 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 inspect the handlebar switches.
  • Page 302 9.Electrical Systems AK 550 Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated. 9-37...
  • Page 303 9.Electrical Systems AK 550 Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated. 9-38...
  • Page 304 9.Electrical Systems AK 550 Side Stand Switch Place the vehicle on the center stand. Unplug the three-pin 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.
  • Page 305 9.Electrical Systems AK 550 9-40...
  • Page 306 9.Electrical Systems AK 550 Brake Light Switches Test the front and rear brake light switches in the same manner. Use a digital multimeter to check for continuity. Remove the nut of lever and brake light switch. Unplug the brake light switch connector.

  • Page 307: Lights

    9.Electrical Systems AK 550 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 the covers and headlight set.
  • Page 308 9.Electrical Systems AK 550 Headlight Replacement Headlight set need 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 Replacement Remove the screws, connecter and remove the position light driver.
  • Page 309 9.Electrical Systems AK 550 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. 9-44...
  • Page 310 9.Electrical Systems AK 550 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 needed. 9-45...
  • Page 311 9.Electrical Systems AK 550 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 signal lights set. 9-46...
  • Page 312 9.Electrical Systems AK 550 Rear turn signal 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 set.
  • Page 313 9.Electrical Systems AK 550 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. 9-48...
  • Page 314 9.Electrical Systems AK 550 Lights Wiring Diagram 9-49...

  • Page 315: Grip Heater

    After eliminating the fault and re-starting (Key Off → Key On) the vehicle, indicator will resume normal operation. Clicking the button when the indicator is flashing in red will stop the flashing. For the sake of your safety, please go to a KYMCO dealer for check-up. 9-50...
  • Page 316 9.Electrical Systems AK 550 NOTICE ◆ When clicking the button without eliminating the fault, the flashing of red indicator is turned off temporarily. It will still flash in red if restarting (Key Off → Key On) the vehicle. ◆ When clicking the button to stop red flashing without eliminating the fault, the heating function will remain inactive when starting the vehicle by pressing and holding the pushbutton, and the indicator will still flash in red.
  • Page 317 9.Electrical Systems AK 550 Grip Heater Controller Remove the 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.
  • Page 318 9.Electrical Systems AK 550 Check the circuit referring to the following diagram. 9-53...

  • Page 319: Horn

    9.Electrical Systems AK 550 Horn Remove 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 battery is connected across the horn terminals.

  • Page 320: Meter Instrument

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

  • Page 321: Noodoe Meter

    9.Electrical Systems AK 550 Noodoe Meter The Noodoe meter can be replaced individually if needed. To avoid the humidity getting in, following the process as following. 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.
  • Page 322 9.Electrical Systems AK 550 Remove the TFT 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 firmly and install the screws crisscross evenly.
  • Page 323 4. No re-adjustment of TPMS is required when a new tire or rim is replaced. 5. Re-adjustment of TPMS is required when replacing a new wireless tire pressure sensor and controller; please consult a KYMCO dealer. 6. When replacing a tire rim, the Tire Pressure Sensor shall be kept in a correct order to distinguish the front one and the rear one.
  • Page 324 9.Electrical Systems AK 550 Owner Learn Code Operation: ◆ Applicable to owner and dealer service personnel. ◆ Re-adjustment 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-triggering.
  • Page 325 9.Electrical Systems AK 550 Learn Code Activation Procedure: 1. Press and hold Operation Button (︿ button on the Handlebar), but it is necessary to switch over to Dashboard position “m” in advance. 2. KEY ON the KEYLESS Main Switch. 3. Release the Operation Button (︿) when the front tire of the Model Symbol flashes and tire pressure unit disappears.
  • Page 326 9.Electrical Systems AK 550 Tire Pressure Unit Change Display Remarks: 1. The dealer and owner are requested to inflate the tires to 20psi or more, so that TPMS computer can automatically learn the initial values and facilitate the subsequent normal operation.
  • Page 327 9.Electrical Systems AK 550 Change Pressure Unit Turn KEYLESS Main Switch ON, the Model Symbol will light up. Push the Dashboard and noodoe Switch to “m” position and press the UP button to change over to TPMS Mode. Pressing “O” button on the Right Handlebar Switch to change units in the sequence of [kgf/cm →...
  • Page 328 9.Electrical Systems AK 550 Tire Pressure Controller Remove 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 sensor direction and mounting torque as following instruction.
  • Page 329 Kymco dealer for replacing with new one. Excessive wear of tire tread pattern will result in widened tread which is more prone to be punctured.
  • Page 330 9.Electrical Systems AK 550 Check the wiring diagram to inspect the circuit. 9-65...
  • Page 331 9.Electrical Systems AK 550 USB Power Socket This vehicle is provided with a USB Power Socket. You may connect a low power consumption product to the Socket, for charging the product while 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.
  • Page 332 10..Brake System AK 550 10.Brakes This chapter covers the location and servicing of the brake system components for the KYMCO AK 550 model. GENERAL INSTRUCTIONS ............10-1 TROUBLESHOOTING ..............10-2 DIAGRAM ..................10-3 Brake Pad Replacement ..............10-4 MASTER CYLINDERS ..............10-11 BLEED THE BRAKE FLUID ............10-12 PARKING BRAKE ................10-18...

  • Page 333: Troubleshooting

    10..Brake System AK 550 TROUBLESHOOTING Brake lever soft or spongy • Air in the hydraulic system • Low brake fluid level • Clogged fluid passage • Contaminated brake disc pad • Warped/deformed brake disc • Worn brake disc pad • Sticking worn master cylinder piston •...

  • Page 334: Diagram

    10..Brake System AK 550 Diagram 10-3...

  • Page 335: Brake Pad Replacement

    10..Brake System AK 550 Brake Pad Replacement SAFETY FIRST: Protective gloves and 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.
  • 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 10..Brake System AK 550 Remove the spring of the brake pad. Remove the right and left brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Insert new brake pads as needed.
  • Page 338 10..Brake System AK 550 When installation: Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.
  • 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 10..Brake System AK 550 Loosen the hex bolt of the 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) Remove the hex bolt, and separate the caliper.
  • Page 341 10..Brake System AK 550 Remove the right and left brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Insert new brake pads as needed. Rotate the piston clockwise to backward it for installation.

  • Page 342: Master Cylinders

    10..Brake System AK 550 Master 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 remove the low handle cover.

  • Page 343: Bleed The Brake Fluid

    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.
  • Page 344 10..Brake System AK 550 Remove the brake hose 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.
  • Page 345 10..Brake System AK 550 Remove the two master cylinder mounting bolts with an 8 mm socket. Be sure to insert the pin on the clamp into the hole on the handlebar when installation. Remove the left master cylinder in the same way.
  • Page 346 10..Brake System AK 550 Front Wheel Disassembly Remove the collars from each side of the wheel. Inspect the bearing seals and the O-rings seals on the collars. Replace the seals if they are in poor condition. Inspect the wheels and axle.
  • Page 347 10..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. 10-16...
  • Page 348 10..Brake System AK 550 The bolts are all with 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 installation torque: 3.2~3.8 kgf-m (32~38 N-m)

  • Page 349: Parking Brake

    10..Brake System AK 550 Parking Brake Apply the parking brake lever and release, then remove 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 brake.

  • Page 350: Disc Brake

    10..Brake System AK 550 Disc Brake SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Measure the thickness of the brake rotor with a micrometer. Item Standard mm Brake disk thickness (rear) Brake disk thickness (front) Check if the brake rotor runout is within the service limit.
  • Page 351 10..Brake System AK 550 SAFETY FIRST: Protective gloves and eyewear are recommended 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.
  • Page 352 10..Brake System AK 550 Introduction to KYMCO Anti-Lock Brake System ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
  • Page 353 10..Brake System AK 550 Caution: Use of non-recommended tires may cause malfunctioning of ABS and lead to extended braking distance. The rider could have an accident as a result. Always use the standard tires for this vehicle. Notice: When the ABS is functioning, you may feel a pulsing in the brake lever.
  • Page 354 10..Brake System AK 550 ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. □ This ABS system is designed to be used with a 12V sealed battery as its power source. Do not use any other battery except for a 12V sealed battery as a power source.
  • Page 355 10..Brake System AK 550 Caution If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve are opened at any time, the air must be bled completely from the brake line. Do not ride the scooter with air in the brake line, or the ABS could malfunction.

  • Page 356: Abs Troubleshooting Outline

    10..Brake System AK 550 ABS Troubleshooting Outline The ABS indicator light lights up to alert the rider when an abnormality is detected by the system. The service codes are stored in the ABS unit memory. The codes will not be erased unless manually cleared. After the fault has been corrected erase the service codes.
  • 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 10..Brake System AK 550 Meter Instruments The ABS indicator light is on the left side of the meter. This light will comes on when 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.
  • Page 360 10..Brake System AK 550 ABS Indicator Light Is Unlit (When The Ignition Switch Turned To ON) 1st step test. Disconnect the meter connector. Check the terminal voltage between the ABS signal wire (Pink lead) terminal of the meter connector and ground. Turn the ignition switch ON.
  • Page 361 10..Brake System AK 550 3rd step test. Press the craw to release the coupler of ABS module. Press the craw to release the coupler of ABS module. Disconnect the 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 10..Brake System AK 550 ABS Indicator Light lights (When the scooter is running, - no service code) 1st step test. Disconnect the ABS hydraulic unit connector and meter 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 363 10..Brake System AK 550 Front, Rear Wheel Rotation Difference Abnormal (service code 25) 1st step test. Check the following and correct the faulty part. 1. Incorrect the tire pressure 2. Tire not recommended for the scooter were installed (incorrect tire size).
  • Page 364 10..Brake System AK 550 ABS Motor Relay Inspection (service code 35) 1st step test. Check the ABS motor relay fuse (25A). Front Wheel Rotation Sensor Signal Abnormal (service code 42) 1st step test. Measure the clearance between the front wheel rotation sensor and sensor rotor.
  • Page 365 10..Brake System AK 550 Front Wheel Rotation Sensor Wiring Inspection (service code 43) 1st step test. Disconnect the ABS hydraulic unit connector and front wheel sensor connector. Short the white/brown and red-green lead terminals of the main harness side connector with a jumper lead, and check for continuity between the white/brown and red green lead terminals of the main harness side connector.
  • Page 366 10..Brake System AK 550 Rear Wheel Rotation Sensor Wiring Inspection (service code 45) 1st step test. Disconnect the ABS hydraulic unit connector and 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 black/red lead terminals of the main harness side connector.
  • Page 367 10..Brake System AK 550 Power Supply Voltage Abnormal (under-voltage) (service code 52) 1st step test. Disconnect the ABS diagnosis connector and ABS hydraulic unit connector. Check for continuity for the black lead terminal of the main harness side connector. 2nd step test.
  • Page 368 10..Brake System AK 550 Power Supply Voltage Abnormal (over-voltage) (service code 53) 1st step test. Disconnect the ABS diagnosis connector and ABS hydraulic unit connector. Check for continuity for the black lead terminal of the main harness side connector. 2nd step test.
  • Page 369 10..Brake System AK 550 ECU Inspection (service code 55) 1st step test. Recheck the service code indication; erase the service code, perform the pre-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.
  • Page 370 10..Brake System AK 550 Check and clear the ABS DTCs in the same manner as the fuel injection DTCs. Bosch ABS9m DTC LIST Code NO (Diagnostic Tool description (PDA) 3620A-LEB2-E00) 5013 Rear Inlet Valve malfunction (EV) 5014 Rear Outlet Valve malfunction (AV)
  • Page 371 10..Brake System AK 550 When using the DATA Analyze feature of the diagnostic tool with the ABS system 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.
  • Page 372 10..Brake System AK 550 ABS Unit Note the markings on the ABS unit 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.
  • Page 373 11.Steering AK 550 11.Steering This chapter covers the location and servicing of the steering components for the KYMCO AK 550 model. TROUBLESHOOTING ..............11-2 Up And Low Handle Cover Removal ..........11-2 Handlebar ..................11-3 Switch Housings and Throttle ............11-4 Grips ....................11-9 Steering stem .................11-10...
  • Page 374 11.Steering AK 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 and remove the handle bar heater connecters. Remove throttle and brake wire and remove the low handle cover.
  • Page 375 11.Steering AK 550 Handlebar SAFETY FIRST: Protective 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 washer to prevent from the heater damage.
  • Page 376 11.Steering AK 550 Switch Housings 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 switches and heater connecter. 11-4...
  • Page 377 11.Steering AK 550 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 the same way. 11-5...
  • Page 378 11.Steering AK 550 Handlebar 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: 6~6.5 kgf-m (60~65 N-m)
  • 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 11.Steering AK 550 Grips If you plan to replace the grips you can slice them lengthwise with a razor blade and peel them off. To remove the grips without cutting them use a screwdriver to open a gap between the grip and the handlebar. Spray in contact cleaner to break up the grip cement.
  • Page 382 If the movement is to tight or loose the steering stem adjusting nut may need to be adjusted. The KYMCO AK 550 uses ball bearings in the steering. Always replace the races at the same time as the bearings.
  • Page 383 11.Steering AK 550 A special lock nut wrench is needed to loosen the steering stem lock nut. Special Tool - Lock Nut Wrench: F00002 Loosen and remove the lock nut. Installation torque: 5~6 kgf-m (50~60 N-m) Slide off the lock washer.
  • Page 384 11.Steering AK 550 Remove the dust cover. Remove the collar and remove the upper ball bearing. 11-12...
  • Page 385 11.Steering AK 550 Use a chisel and 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.
  • Page 386 12.Front Suspension AK 550 12.Front Suspension This chapter covers the location and servicing 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 •...
  • Page 387 12.Front Suspension AK 550 Front Fender Assy. Removal Remove the bolts, plates and reflectors. Remove the bolts and front fender assembly. 12-2...
  • Page 388 12.Front Suspension AK 550 Front Fork Removal Remove the bolt of speed sensor. And remove the speed 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.
  • Page 389 12.Front Suspension AK 550 Loosen the front axle pinch bolt with a 6 mm Allen. Installation 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.
  • Page 390 12.Front Suspension AK 550 Guide the front 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 dust seals. Insert the collars into the hub.
  • Page 391 12.Front Suspension AK 550 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: 2~2.6 kgf-m (20~26 N-m) 12-6...
  • Page 392 12.Front Suspension AK 550 Remove the right and left bolts of top bridge. Remove the right and left fork. Installation torque: 2~2.6 kgf-m (20~26 N-m) Note: When install the cushions, 1. Fork oil replacement quantity of fork oil Right: 375±2cc/Left: 555±2cc Use fork oil type #SS8 (10W).
  • Page 393 13.Rear Suspension AK 550 13.Rear Suspension This chapter provides information on the rear suspension 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 ............13-16 Rear Fork ..................13-20...
  • Page 394 13.Rear Suspension AK 550 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 N-m) 13-2...
  • Page 395 13.Rear Suspension AK 550 Rear Wheel Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this 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.
  • Page 396 13.Rear Suspension AK 550 Remove the bolt of rear fixed plate. Remove the bolt of front fixed plate. 13-4...
  • Page 397 13.Rear Suspension AK 550 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) Remove the rear caliper.
  • Page 398 13.Rear Suspension AK 550 Loosen 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. Installation torque: 12~14 kgf-m (120~140 N-m)
  • Page 399 13.Rear Suspension AK 550 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-m) 13-7...
  • Page 400 13.Rear Suspension AK 550 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 low cover A.
  • Page 401 13.Rear Suspension AK 550 Loosen and remove 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.
  • Page 402 13.Rear Suspension AK 550 Remove the drive sprocket collar. Replace the seal and 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.
  • Page 403 13.Rear Suspension AK 550 Slide out and remove the belt. Remove the drive sprocket. Slide out and remove the rear wheel axle. 13-11...
  • Page 404 13.Rear Suspension AK 550 Slide out the rear wheel assembly. 13-12...
  • Page 405 13.Rear Suspension AK 550 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. 13-13...
  • Page 406 13.Rear Suspension AK 550 Drive Belt 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 fixed nut. Right side is with the same way.
  • Page 407 13.Rear Suspension AK 550 Abnor m al Pos s i bl y Reas on/ Sol ut i on CRACK 1) Check bel t s t or age condi t i on Avoi d t he s un l i ght...
  • Page 408 13.Rear Suspension AK 550 Drive Belt 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 and R/H Adjusters are the same (18.8mm±0.5mm).
  • Page 409 13.Rear Suspension AK 550 Step 2-1: 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.
  • Page 410 13.Rear Suspension AK 550 Step 2-2: Measure the belt tension P.S. distance C vs. tension (for reference only) 18.8mm --- (1300~1700N) 19.2mm --- (1100~1500N) ~1. Probe of Sonic Tension meter should be parallel to the belt as shown above pictures.
  • Page 411 13.Rear Suspension AK 550 Step 3: Belt side Clearance ~1. Turn the wheel for several runs, check the belt 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±0.5mm.
  • Page 412 13.Rear Suspension AK 550 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. 13-20...
  • Page 413 13.Rear Suspension AK 550 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-m) 13-21...
  • Page 414 13.Rear Suspension AK 550 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. 13-22...
  • Page 415 13.Rear Suspension AK 550 Remove the two bolts. And remove the chain cover up B. Remove the two bolts. And remove the chain cover low B. 13-23...
  • Page 416 13.Rear Suspension AK 550 Check the seal and bearing for wear or damage. Replace them if necessary. 13-24...
  • Page 417 14.Wheels AK 550 14.Wheels This chapter covers the location and servicing of the 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 ..............14-17...
  • Page 418 14.Wheels AK 550 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 assembly. 14-2...
  • Page 419 14.Wheels AK 550 Remove the bolt of speed sensor. And remove the speed 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.
  • Page 420 14.Wheels AK 550 Loosen the front axle pinch bolt with a 6 mm Allen. Installation 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.
  • Page 421 14.Wheels AK 550 Guide the front 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 dust seals and collar O-rings.
  • Page 422 14.Wheels AK 550 Front Wheel Disassembly Remove the collars from each side of the wheel. Inspect the bearing seals and the O-rings seals on the collars. Replace the seals if they are in poor condition. Inspect the wheels and axle.
  • Page 423 14.Wheels 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. 14-7...
  • Page 424 14.Wheels AK 550 The bolts are all with 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 installation torque: 3.2~3.8 kgf-m (32~38 N-m)
  • Page 425 14.Wheels AK 550 Wheel Bearing Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace bearings as a set, and do not reuse old bearings. Place the new bearings in the freezer about an hour before you plan to install them.
  • Page 426 14.Wheels AK 550 Remove one of the bearings with a bearing puller. Special Tools- Bearing Puller: E00037 Repeat the procedure and remove the other bearing and seal. The seal should be replaced 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.
  • Page 427 14.Wheels AK 550 Rear Wheel Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this 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.
  • Page 428 14.Wheels AK 550 Remove the bolt of rear fixed plate. Remove the bolt of front fixed plate. 14-12...
  • Page 429 14.Wheels AK 550 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) Remove the rear caliper.
  • Page 430 14.Wheels AK 550 Loosen 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. Installation torque: 12~14 kgf-m (120~140 N-m)
  • Page 431 14.Wheels AK 550 Loosen 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 remove the rear wheel axle.
  • Page 432 14.Wheels AK 550 Slide out the rear wheel assembly. 14-16...
  • Page 433 14.Wheels AK 550 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. 14-17...
  • Page 434 14.Wheels AK 550 Remove the seal. Replace with a new one and grease it when installation. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. Remove one of the bearings with a bearing puller.
  • Page 435 14.Wheels AK 550 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 if necessary.
  • Page 436 14.Wheels AK 550 Remove the 5 bolts of the rear brake disk. Check the wear or damage, replace with a new one if necessary. Remove the brake disk. Installation torque: 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.
  • Page 437 14.Wheels AK 550 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 as the bearing. Make sure the bearing is fully seated and the marked side is facing out.
  • Page 438 14.Wheels AK 550 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. 14-22...
  • Page 439 14.Wheels AK 550 Drive Belt 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 fixed nut. Right side is with the same way.
  • Page 440 14.Wheels AK 550 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. 14-24...
  • Page 441 14.Wheels AK 550 Abnor m al Pos s i bl y Reas on/ Sol ut i on CRACK 1) Check bel t s t or age condi t i on Avoi d t he s un l i ght Do not pr es s t i e or Away t he oi l and heat pr es s t he bel t .
  • Page 442 14.Wheels AK 550 Drive Belt 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 and R/H Adjusters are the same (18.8mm±0.5mm).
  • Page 443 14.Wheels AK 550 Step 2-1: 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.
  • Page 444 14.Wheels AK 550 Step 2-2: Measure the belt tension P.S. distance C vs. tension (for reference only) 18.8mm --- (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.
  • Page 445 14.Wheels AK 550 Step 3: Belt side Clearance ~1. Turn the wheel for several runs, check the belt 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±0.5mm.
  • Page 446 14.Wheels AK 550 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. 14-30...
  • Page 447 Kymco dealer for replacing with new one. Excessive wear of tire tread pattern will result in widened tread which is more prone to be punctured.
  • Page 448 4. No re-adjustment of TPMS is required when a new tire or rim is replaced. 5. Re-adjustment of TPMS is required when replacing a new wireless tire pressure sensor and controller; please consult a KYMCO dealer. 6. When replacing a tire rim, the Tire Pressure Sensor shall be kept in a correct order to distinguish the front one and the rear one.
  • Page 449 14.Wheels AK 550 Owner Learn Code Operation: ◆ Applicable to owner and dealer service personnel. ◆ Re-adjustment 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-triggering.
  • Page 450 14.Wheels AK 550 Learn Code Activation Procedure: 1. Press and hold Operation Button (︿ button on the Handlebar), but it is necessary to switch over to Dashboard position “m” in advance. 2. KEY ON the KEYLESS Main Switch. 3. Release the Operation Button (︿) when the front tire of the Model Symbol flashes and tire pressure unit disappears.
  • Page 451 14.Wheels AK 550 Tire Pressure Unit Change Display Remarks: 1. The dealer and owner are requested to inflate the tires to 20psi or more, so that TPMS computer can automatically learn the initial values and facilitate the subsequent normal operation.
  • Page 452 14.Wheels AK 550 Change Pressure Unit Turn KEYLESS Main Switch ON, the Model Symbol will light up. Push the Dashboard and noodoe Switch to “m” position and press the UP button to change over to TPMS Mode. Pressing “O” button on the Right Handlebar Switch to change units in the sequence of [kgf/cm →...
  • Page 453 15.EEC System AK550 15.EEC SYSTEM This chapter covers the E.E.C system for the KYMCO AK 550. E.E.C System Introduction ..........15-2 Function ................15-3 Trouble Shooting ..............15-3 Air Filter Servicing ..............15-4 Maintenance Information ............15-5 Dismantle Of Canister ............15-6 Oxygen Sensor ..............15-9 WARNING: •...

  • Page 454: E.e.c System Introduction

    15.EEC System AK550 E.E.C System Introduction: Evaporative Emission Control System The evaporative emission control system is used to prevent gasoline vapors from escaping into the atmosphere from the fuel tank and fuel system. Crankcase Emission Control System The scooter is equipped with a closed crankcase system. Blow-by gas is recycled into the combustion chamber via the intake system.

  • Page 455: Function

    15.EEC System AK550 Function Item Function Description It is used to prevent gasoline Storage the gasoline vapors to Evaporative vapors from escaping into the canister, conduct the gasoline Emission atmosphere from the fuel tank vapors to engine by vacuum Control Valve and fuel system.

  • Page 456: Air Filter Servicing

    Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems..

  • Page 457: Maintenance Information

    15.EEC System AK550 Maintenance Information Note of maintenance: Install the tubes in correct position. If the tubes broken should be replaced with a new one. The tubes should be installed tightly. The leakage hole should be installed downward. Tool Vacuum pump Pressure pump Maintenance standard Emission vacuum standard: 45m/mHg...

  • Page 458: Dismantle Of Canister

    15.EEC System AK550 Dismantle of Canister 1.Dismantle the windshield, front cover and head light assembly. 2.Dismantle the canister tube set and canister. Canister Inspection of canister evaporative control valve Connecting a vacuum pump to the tube of canister. (Follow the illustration below.) Applying 250m/mHg pressure to the canister evaporative control valve.
  • Page 459 15.EEC System AK550 Inspection of the flow rate of the canister vacuum valve 1. Using a vacuum pump connecting to the vacuum tube of canister and apply 45m/mHg of negative pressure. 2. Apply pressure to the emission control valve of canister, if the flow rate above 9.4 litters per minute that means the valve is in good condition, otherwise the canister should be replaced.
  • Page 460 15.EEC System AK550 P.C.V. Dismantle 1.Dismantle the cover of air cleaner. 2.Dismantle the P.C.V cover. 3.P.C.V , if there is oil in the red drain tube, it should be cleaned. Inspection of emission system Clean or replace the air cleaner. Inspection of the spark plug.

  • Page 461: Oxygen Sensor

    15.EEC System AK550 Oxygen Sensor It uses DC-8-16V Battery Power with 4 pins: one power pin, one heater pin, one signal output pin and one earthing pin. The sensor is installed to the front pipe of exhaust pipe to detect the oxygen concentration of exhaust gas for determining if ECU shall instruct to increase or reduce fuel supply for meeting waste gas emission standard of environment legislation.

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