KYMCO AHG5 Service Manual

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Foreword

This service manual provides maintenance

guidelines for KYMCO AHG5 fuel injection

engine.

Chapter 1 contains all the operational

precautions that you should read carefully

before you start.

Chapter 3 gives inspection and fine-tuning tips

and maintenance of individual functions

beginning with regular inspection.

The remaining chapters outline assembly/

disassembly and inspection steps for the

engine, and electrical system.

Each

chapter

begins

explanation of the exploded diagram, system

diagram, maintenance troubleshooting, and

diagnosis description.

ALL

INFORMATION,

SPECIFICATIONS

DOCUMENT ARE BASED ON THE LATEST

PRODUCT INFORMATION AVAILABLE AT THE

TIME

MANUFACTURE.

MOTOR CO., LTD. RESERVES THE RIGHT TO

MAKE CHANGES AT ANY TIME WITHOUT

NOTICE

AND

WITHOUT

OBLIGATION WHATEVER.

UNAUTHORIZED

WRITTEN

PERMISSION

MOTOR CO., LTD.IS STRICTLY PROHIBITED.

By the Technology Training Section

with

overall

GRAPHICS

CONTAINED

KWANG

INCURRING

USE

WITHOUT

KWANG

First Edition – Jun. 2021

Quick Reference

External Components

Periodic Maintenance

Lubrication System

Engine Removal/ Installation

Cylinder Head/ Valve

Cylinder/ Piston

Drive & Driven Pulley

Final Reduction

Alternator / Start Clutch

Crankcase/ Crankshaft

Cooling System

AND

Fi System

THIS

Front Assembly

Rear Assembly

YANG

Battery & Charging System

Ignition System

ANY

Starting System

Switches/ Lights

THE

YANG

EEC System

ABS/TCS

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO AHG5

Page 1 Foreword This service manual provides maintenance guidelines for KYMCO AHG5 fuel injection Quick Reference engine. External Components Chapter 1 contains all the operational Periodic Maintenance precautions that you should read carefully Lubrication System before you start. Engine Removal/ Installation Chapter 3 gives inspection and fine-tuning tips...
Page 2: Table Of Contents
1. Quick Reference Quick Reference Engine /Frame Serial Number ....................... 2 Specifications .............................. 3 Operation precautions ..........................4 Torque ................................5 4.1. General Torque Value ........................5 4.2. Engine ............................... 6 4.3. Frame ..............................7 Special Tool ..............................8 LUBRICATION POINTS-FRAME ......................9 Components Location ...........................
Page 3: Engine /Frame Serial Number
1. Quick Reference 1. Engine /Frame Serial Number Frame Serial Number Engine Serial Number...
Page 4: Specifications
1. Quick Reference Oil Filter Type Full-flow filtration 2. Specifications Disassembly 1.5L Engine Model Code SK64DA Exchange 1.3L Model Name DT X360 Disassembly 0.23L Overall Length (mm) 2165 Gear Oil Exchange 0.20L Overall Width (mm) Cooling Type Liquid Cooling Overall High (mm) 1285 Air cleaner type &...
Page 5: Operation Precautions
1. Quick Reference 3. Operation precautions If any gaskets, O-rings circlips and cotter pins are removed, they need to be replaced with new ones. Tighten the screws and nuts from the one with bigger outer diameter diagonally to the specified torque. recommend that genuine...
Page 6: Torque
1. Quick Reference 4. Torque 4.1. General Torque Value Torque (kgf∙m) Torque (kgf∙m) Item Item 5mm Bolt/ Nut 0.45~0.6 4mm Tapping screw (Cut) 0.05~0.15 6mm Bolt/ Nut 0.8~1.2 4mm Tapping screw (Point) 0.2~0.4 8mm Bolt/ Nut 1.8~2.5 5mm screw (Cut) 0.1~0.3 10mm Bolt/ Nut 3.0~4.0...
Page 7: Engine
1. Quick Reference 4.2. Engine...
Page 8: Frame
1. Quick Reference 4.3. Frame...
Page 9: Special Tool
1. Quick Reference 5. Special Tool Tool Name Tool No. Performance Photo A.C. generator flywheel Flywheel Puller A120E00003 removal Tappet Adjuster A120E00012 Tappet adjustment Oil Seal & Bearing A120E00014 Oil seal & bearing installing Installer A.C. generator flywheel Flywheel Holder A120E00021 holding Clutch disassembly &...
Page 10: Lubrication Points-Frame
1. Quick Reference 6. LUBRICATION POINTS-FRAME The following is the lubrication points for the frame. Use grease for parts not listed. Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise and damage the durability of the motorcycle. : Grease : Engine Oil Throttle...
Page 11: Components Location
1. Quick Reference 7. Components Location Right handlebar Left handlebar Rear brake Front brake switch switch fluid reservoir fluid reservoir USB charger wires Front brake fluid hose Rear brake fluid hose Start relay OBD connector Coolant filling cap Fuse box 1-10...
Page 12 1. Quick Reference Throttle body ISC (Idle air bypass valve) Fuel injector Fuel hose PPTS (Intake air temp/MAP/TPS) Throttle cables Fuel pump Thermostat Inductive ignition coil Spark plug Canister Rectifier/Regulator Hazard light controller 1-11...
Page 13 1. Quick Reference Long-distance Tilt switch Ignition antenna switch USB charger controller Engine oil indicator controller KEYLESS Headlight controller controller Start relay Coolant reserve tank 電瓶盒 ABS controller Coolant radiator 1-12...
Page 14: General Troubleshooting
1. Quick Reference 8. General Troubleshooting 8.1. Engine lacks power 1-13...
Page 15 1. Quick Reference 1-14...
Page 16: Engine Will Not Stat Or Is Hard To Start
1. Quick Reference 8.2. Engine will not stat or is hard to start 1-15...
Page 17: Poor Handling
1. Quick Reference 8.3. Poor handling 1-16...
Page 18: Poor Performance At High Speed
1. Quick Reference 8.4. Poor performance at high speed 1-17...
Page 19: Poor Performance At Low And Idle Speed
1. Quick Reference 8.5. Poor performance at low and idle speed 1-18...
Page 20 2. External components, Exhaust pipe...
Page 21 2. External components, Exhaust pipe...
Page 22 2. External components, Exhaust pipe Service Information ................................. 3 1.1. General Instructions ..............................3 1.2. Torque value ................................3 1.3. Troubleshooting ............................... 3 External Components Removal ............................4 2.1. Wind screen................................4 2.2. Front cover .................................. 4 2.3. Headlight assy ................................4 Side covers ..................................
Page 23: Service Information
2. External components, Exhaust pipe 1. Service Information 1.1. 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 Routing. 1.2.
Page 24: External Components Removal
2. External components, Exhaust pipe 2. External Components Removal 2.1. Wind screen Remove the bolts and Allen bolts. Remove the wind screen and brackets. Install in the reverse order of work. 2.2. Front cover Remove the plastic screws. Remove the screws. Remove the front cover.
Page 25: Side Covers
2. External components, Exhaust pipe Remove the screws on each side of cover. Remove the leg shields mat and floor mats o each side of cover. Remove the screws. Side covers Remove the plastic screws on each side of the under cowl.
Page 26: Seat
2. External components, Exhaust pipe 2.4. Seat Open the seat. Remove the nuts. Remove the seat. Install in the reverse order of work. 2.5. Luggage box Remove the bolts and nuts. Disconnect the luggage box light connector. Remove the luggage box. Install in the reverse order of work.
Page 27: Tail Light Assy
2. External components, Exhaust pipe 2.8. Tail light assy Remove the center rubber cover. Remove the bolt. Remove the plastic screws on the upper and down side of each side cover. Disconnect all connectors of tail light assy. Remove the tail light assy. Install in the reverse order of work.
Page 28: Meter Cover
2. External components, Exhaust pipe Remove the bolts on each side of floor panels. Remove the plastic screw on each side of the leg shield. Remove the floor panel assy. Install in the reverse order of work. 2.10. Meter cover Remove the wind screen.
Page 29 2. External components, Exhaust pipe Loosen the screw of ignition switch cover. Turn the cover counterclockwise. Pull out the cover but do not over pull it. Disconnect the connector. Remove the ignition switch cover. Key cover Use a proper tool to pry out the lid. Remove the key cover.
Page 30: Leg Shield
2. External components, Exhaust pipe 2.11. Leg shield Remove the bolt on each side of the cover. Remove the cable of the fuel filling cap cover. Remove the leg shield. Install in the reverse of work. 2.12. Handlebar covers Remove the bolts on each side of lower handlebar cover.
Page 31: Front Fender
2. External components, Exhaust pipe 2.13. Front fender Remove the Allen bolt and the bolt on each side of the front fender. Remove the front fender. Install in the reverse order of work. 2.14. Rear fenders Remove the bolts on the lower rear fender. Remove the lower rear fender.
Page 32: Undercover
2. External components, Exhaust pipe 2.15. Undercover Remove the bolts on each side of the undercover. Remove the undercover. Install in the reverse order of work. 2.16. Muffler cover Remove the bolts. Remove the muffler cover. Install in the reverse order of work. 2-12...
Page 33: Exhaust Assembly
2. External components, Exhaust pipe 3. Exhaust assembly 3.1. Muffler Remove the Allen bolt. Remove the bolts. Remove the muffler Install in the reverse order of work. 3.2. Exhaust pipe Nuts Remove the muffler. Disconnect the O2 sensor connector. Remove the nuts on the front end of the exhaust pipe.
Page 34 3. PERIODIC MAINTENANCE DT X360 Periodic Maintenance Service Information ..................... 3 1.1. Warning ......................3 1.2. Specifications ....................3 Maintenance Schedule ....................4 Fuel Line ........................6 Throttle Operation ....................... 6 Air Cleaner ........................7 Spark Plug ........................7 Valve Clearance ......................8 7.1.
Page 35 3. PERIODIC MAINTENANCE DT X360 16.2. Brake pad wear ................... 19 16.3. Brake levers ....................20 17. Nuts/Bolts/Fasteners ....................20 18. Wheels/Tires ......................21 18.1. Tire pressure ....................21 19. Steering Handlebar ....................21 20. Suspension ....................... 22 20.1. Rear suspension adjustment ............... 22 21.
Page 36: Periodic Maintenance
3. PERIODIC MAINTENANCE DT X360 1. Service Information 1.1. Warning  Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. ...
Page 37: Maintenance Schedule
KYMCO by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. ＊ Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service data and is mechanically qualified.
Page 38 3. PERIODIC MAINTENANCE DT X360 Which Ever Comes First Odometer Reading (Note1) Frequency → Throttle Operation X1000 km 10 15 20 25 30 ↓ X1000 mi 12 15 18 Item Note Month 12 18 24 30 36 Air Cleaner Note2 Spark Plug Note4 Throttle Operation...
Page 39: Fuel Line
3. PERIODIC MAINTENANCE DT X360 3. Fuel Line Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. 4. Throttle Operation Check throttle grip smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle valve.
Page 40: Air Cleaner
3. The new air cleaner element installation is in the reverse order of removal. Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO...
Page 41: Valve Clearance
3. PERIODIC MAINTENANCE DT X360 7. Valve Clearance 7.1. Inspection Cylinder head cover  Inspect and adjust valve clearance while the engine is cold (below 35 ℃). Remove the four bolts, and then remove cylinder head cover. Bolts Remove the timing inspection cap from the right side of the engine with a large flat blade screwdriver.
Page 42 3. PERIODIC MAINTENANCE DT X360 For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the same time the "T" mark is lined up with the with the index notch in the timing inspection hole. Also the camshaft sprocket mounting boss should be visible above the cylinder head surface.
Page 43: Adjustment
3. PERIODIC MAINTENANCE DT X360 7.2. Adjustment Place a 9 mm box end wrench over the locknut, and loosen the locknut. If the valve clearance is tight back out the valve tappet adjusting screw with the tappet adjustment tool. If the clearance is too loose turn in the adjusting screw until there is a light drag on the feeler gauge.
Page 44: Engine Oil
3. PERIODIC MAINTENANCE DT X360 9. Engine Oil 9.1. Engine oil recommendation Engine oil capacity: Use a premium quality 4-stroke motor oil to At disassembly: ensure longer service life of your scooter. 1.2 L (0.968 lmp qt, 1.166 US qt) Use only oils which are rated, SJ under the At change: service...
Page 45: Engine Oil Replacement
3. PERIODIC MAINTENANCE DT X360 9.3. Engine oil replacement Used engine oil may cause skin cancer if Engine oil quality is the chief factor affecting repeatedly left in contact with the skin for engine service life. Change the engine oil as prolonged periods.
Page 46: Oil Strainer Screen Clean
3. PERIODIC MAINTENANCE DT X360 9.4. Oil strainer screen clean Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining.  Let the engine and exhaust system cool before working in those areas.
Page 47: Oil Filter Replacement
3. PERIODIC MAINTENANCE DT X360 9.5. Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining.  Let the engine and exhaust system cool before working in those areas.
Page 48: Transmission Oil
3. PERIODIC MAINTENANCE DT X360 Transmission Oil 10.1. Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.
Page 49: Idle Speed
3. PERIODIC MAINTENANCE DT X360 Idle Speed  It is not necessary to adjust idle Idle Speed: 1750±100 rpm speed for DOWNTOWN125i. The throttle body is factory pre-set, do not loosen or tighten the painted bolts and screws of throttle body. Loosening or tightening them can cause throttle and idle and valve synchronization failure.
Page 50: Headlight Aim
If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. 15.2. Add coolant Remove the screw (1). Press the cover at (2) part to release the joint claw.
Page 51: Coolant Recommendation
3. PERIODIC MAINTENANCE DT X360 Remove the reserve tank cap to add coolant mixture until it reaches the F level mark.  Removing the cap while the engine is hot that can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the cap.
Page 52: Brake
Inspect the pads at each regular maintenance interval. Front brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer for this service. 3-19...
Page 53: Brake Levers
DT X360 Rear brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer for this service. 16.3. Brake levers 1. Adjust brake lever clearance using adjustment knob (totally 4 adjustment positions).
Page 54: Wheels/Tires
3. PERIODIC MAINTENANCE DT X360 Wheels/Tires 18.1. Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter. Under inflated tires make smooth cornering difficult and overinflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control.
Page 55: Suspension
3. PERIODIC MAINTENANCE DT X360 Suspension Check the action of the front/rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
Page 56: Side Stand
2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your KYMCO dealer for service. Side Stand Down 3-23...
Page 57 4. LUBRICATION SYSTEM DT X360 Lubrication System...
Page 58 4. LUBRICATION SYSTEM DT X360 Lubrication Diagram ........................3 SERVICE INFORMATION ........................ 4 2.1. GENERAL INSTRUCTIONS ....................4 2.2. SPECIFICATIONS ........................ 4 2.3. TROUBLESHOOTING ......................5 Engine oil ............................6 Oil Pump ............................6 4.1. Removal ..........................6 4.2. Disassembly ........................7 4.3.
Page 59: Lubrication Diagram
4. LUBRICATION SYSTEM DT X360 1. Lubrication Diagram Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Pump Oil Filter Screen...
Page 60: Service Information
4. LUBRICATION SYSTEM DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  The maintenance of lubrication system can be performed with the engine installed in the frame.  Drain the coolant before starting any operations.  Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 61: Troubleshooting
4. LUBRICATION SYSTEM DT X360 2.3. TROUBLESHOOTING Oil level too low  Natural oil consumption  Oil leaks  Worn piston rings  Worn valve guide  Worn valve guide seal Poor lubrication pressure  Oil level too low Clogged oil filter or oil passage ...
Page 62: Engine Oil
4. LUBRICATION SYSTEM DT X360 3. Engine oil See the chapter 3 for more information. 4. Oil Pump 4.1. Removal Starter idle gear & Shaft Drain the engine oil. Remove the alternator cover, fly wheel, starter idle gear, shaft, pins and starter driven gear.
Page 63: Disassembly
4. LUBRICATION SYSTEM DT X360 Remove the two oil pump bolts to remove Oil Pump the oil pump.  When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. Turn the oil pump shaft by hand and make sure it turns smoothly.
Page 64: Inspection
4. LUBRICATION SYSTEM DT X360 4.3. Inspection Pump Body Outer Rotor Measure the pump body-to-outer rotor clearance. Measure the inner rotor-to-outer rotor Pump Body Inner Rotor clearance. Measure the rotor end-to-pump body clearance. Pump Body Rotor End 4.4. Assembly Pump Body Dowel Pin Install the outer rotor, inner rotor and pump shaft into the pump body.
Page 65: Installation
4. LUBRICATION SYSTEM DT X360 4.5. Installation Oil Pump Install the oil pump and oil pump and tighten the two bolts.  Make sure the pump shaft rotates freely and arrow mark which is on the oil pump is upside. Oil Pump Bolts Install the pump drive chain and driven Oil Pump Driven Sprocket...
Page 66 5. ENGINE DT X360 Engine ENGINE REMOVAL/INSTALLATION ....................4 1.1. Removal ..........................4 1.2. Installation ........................6...
Page 67 5. ENGINE DT X360 SERVICE INFORMATION GENERAL INSTRUCTIONS  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.  Use shop towels to protect the scooter body during engine removal. ...
Page 68 5. ENGINE DT X360 SPECIFICATIONS at disassembly 1.5 L ENGINE OIL CAPACITY at change 1. 3 L Radiator capacity 0.766 L Reserve tank capacity 0.59 L COOLANT CAPACITY Hot coolant hose 0.169 L Cold coolant hose 0.194 L Total capacity 1.719 L Engine hanger bolts (Engine side) 5.0 kgf-m...
Page 69 5. ENGINE DT X360 1. ENGINE REMOVAL/INSTALLATION 1.1. Removal WTS connector Fuel hose holder Remove the air cleaner. Remove a bolt from fuel hose holder. Disconnect the following connectors: - Idle air bypass valve - TPS - WTS - MAP - Intake air pressure sensor - O2 sensor - Rectifier/ Regulator...
Page 70 5. ENGINE DT X360 Loosen the rear axle nut. Support the scooter securely on its main stand. Remove the bolts, and then remove the rear brake caliper. Rear brake caliper bolts Disconnect the alternator cord including the crank position sensor cord. Remove the spark plug cap.
Page 71 5. ENGINE DT X360 Remove the engine mount nut. Pull out the engine mount bolt. Remove the engine from the frame.  At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
Page 72 6. CYLINDER HEAD/ VALVE DT X360 Cylinder Head/ Valve SCHEMATIC DRAWING ......................... 2 SERVICE INFORMATION ........................ 3 2.1. GENERAL INSTRUCTIONS ....................3 2.2. SPECIFICATIONS ........................ 3 2.3. TORQUE VALUES ....................... 4 2.4. SPECIAL TOOLS ......................... 4 2.5. TROUBLESHOOTING ......................5 Cylinder Head Cover ........................
Page 73: Schematic Drawing
6. CYLINDER HEAD/ VALVE DT X360 1. SCHEMATIC DRAWING...
Page 74: Service Information
6. CYLINDER HEAD/ VALVE DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first.  When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 75: Torque Values
6. CYLINDER HEAD/ VALVE DT X360 2.3. TORQUE VALUES Item Value Remark Cylinder head cover bolt 0.8~1.2 kgf-m Tensioner mounting bolt 1.0~1.4 kgf-m Tensioner sealing bolt 0.4 kgf-m Cylinder head nut 3.2~3.6 kgf-m Apply engine oil to threads Cylinder head bolt 0.7~1.1 kgf-m Valve clearance fixing nut 0.7~1.1 kgf-m...
Page 76: Troubleshooting
6. CYLINDER HEAD/ VALVE DT X360 2.5. 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 White smoke from exhaust muffler Worn valve stem or valve guide Damaged valve stem oil seal Compression too low Incorrect valve clearance adjustment...
Page 77: Cylinder Head Cover
6. CYLINDER HEAD/ VALVE DT X360 3. Cylinder Head Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 3.1. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Squeeze the breather hose clamp with needle nose pliers and slide if back.
Page 78 6. CYLINDER HEAD/ VALVE DT X360 Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose stay from the cylinder head cover. Loosen the four cylinder head cover bolts with a 10 mm socket. Remove the cylinder head cover bolts with washers and grommets.
Page 79 6. CYLINDER HEAD/ VALVE DT X360 Remove the cylinder head cover and gasket. Discard the gasket and replace it with a new item on installation. Remove the dowel pin.
Page 80: Camshaft
6. CYLINDER HEAD/ VALVE DT X360 4. Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 4.1. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Remove the spark plug.
Page 81 6. CYLINDER HEAD/ VALVE DT X360 Remove the cam chain tensioner cap bolt with a 10 mm socket. Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket. Lift the cam chain tensioner our of the cylinder. Remove the cam chain tensioner gasket. 6-10...
Page 82 6. CYLINDER HEAD/ VALVE DT X360 Use a 5 mm Allen wrench to remove the camshaft sprocket bolts. Remove the camshaft sprocket as shown. Support the chain so it does not fall into the cylinder head. Use a 5 mm Allen wrench to remove the set plate bolt. 6-11...
Page 83 6. CYLINDER HEAD/ VALVE DT X360 Remove the set plate as shown. Thread a bolt into the rocker arm shafts and pull the shafts out. Lift out the rocker arms as the shafts are removed. 6-12...
Page 84: Inspection
6. CYLINDER HEAD/ VALVE DT X360 Remove the camshaft from the cylinder head. 4.2. Inspection Inspect the camshaft cam heights for the intake and exhaust lobes. Inspect the camshaft bearings for excessive play or roughness. Replace the entire camshaft assembly if the bearings are rough or have excessive play.
Page 85 6. CYLINDER HEAD/ VALVE DT X360 Inspect the rocker arm shaft outer diameter for the intake and exhaust valves. Item Standard (mm) 9.972 - 9.987 Valve rocker arm shaft O.D. 9.972 - 9.987 Inspect the rocker arm inner diameter for the intake and exhaust valves. Item Standard (mm) 10.00 - 10.015...
Page 86 6. CYLINDER HEAD/ VALVE DT X360 Inspect the camshaft bearing journals for scoring or scratches. 6-15...
Page 87: Camshaft Installation
6. CYLINDER HEAD/ VALVE DT X360 Inspect the camshaft sprocket for worn teeth or other signs of wear or damage. 4.3. Camshaft Installation Clear out the cylinder head oil passages with compressed air. Make sure all cylinder head oil passages are free of clogs. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 88 6. CYLINDER HEAD/ VALVE DT X360 Remove the timing inspection cap from the right side of the engine with a large flat blade screwdriver. Inspect the O-ring on the cap and replace it as needed. The crankshaft must be rotate (clockwise) until the piston is at top dead center (TDC) on the compression stroke.
Page 89 6. CYLINDER HEAD/ VALVE DT X360 Insert the camshaft into the camshaft holders with the lobes facing down. Lubricate the inside diameter of the rocker arms and the roller with fresh engine oil. Position the rocker arms to accept the rocker arm shafts. Wipe the rocker arm shafts clean.
Page 90 6. CYLINDER HEAD/ VALVE DT X360 Install the camshaft set plate so it fits into the groove on the camshaft and between the projections on the rocker arm shafts. Apply a small amount of blue Loctite (non-permanent) to the threads of the set plate bolt. Thread in the bolt and tighten it to specification with a 5 mm Allen socket.
Page 91 6. CYLINDER HEAD/ VALVE DT X360 Install the camshaft sprocket onto the camshaft so the camshaft sprocket boss fits into the appropriate hole on the camshaft sprocket. Make sure the camshaft sprocket boss is facing up so it is visible above the edge of the cylinder head as shown. Align the horizontal marks on the camshaft sprocket with the top edge of the cylinder head as shown.
Page 92 6. CYLINDER HEAD/ VALVE DT X360 Double check the engine timing. Use a small flat blade screwdriver bring in the cam chain tensioner rod. Turn the screwdriver counter clockwise to retract the rod. The rod must be held in with the screwdriver until the cam chain tensioner mounting bolts have been installed.
Page 93 6. CYLINDER HEAD/ VALVE DT X360 Rotate the crankshaft 360° clockwise and check the engine timing one more time. Make sure the cam chain tensioner cap bolt O-ring is in good condition. Install the O-ring and cam chain tensioner cap bolt. Tighten the bolt to securely with a 10 mm socket. 6-22...
Page 94 6. CYLINDER HEAD/ VALVE DT X360 Valve Clearance Check the valve clearance. See the topic for more information. Make sure the O-rings on the crankshaft and timing plugs are in good condition. Replace them as needed. Install the timing inspection and crankshaft caps to the right side of the engine.
Page 95: Cylinder Head
6. CYLINDER HEAD/ VALVE DT X360 5. Cylinder Head SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 5.1. Removal Remove the spark plug. See the Spark Plug topic for more information. Remove the seat. See the Seat topic for more information. Remove the luggage box.
Page 96 6. CYLINDER HEAD/ VALVE DT X360 Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the thermostat. Allow any remaining coolant to drain into a suitable container. Squeeze the air bleed hose clamp with needle nose pliers and slide back the clamp. Free the air bleed hose from the thermostat.
Page 97 6. CYLINDER HEAD/ VALVE DT X360 Remove the two right side cylinder head bolts with an 8 mm socket. Also, loosen the two cylinder bolts below with an 8 mm socket. There are two cylinder head mounting nuts; one below the intake port and one below the exhaust port.
Page 98 6. CYLINDER HEAD/ VALVE DT X360 Loosen the upper nut with a 10 mm socket and the lower nut with a 10 mm wrench. Remove the two cylinder head mounting nuts. Remove the four camshaft holder nuts using a 14 mm socket. Loosen the camshaft holder nuts in a criss cross pattern over the course of 2-3 loosening sequences.
Page 99 6. CYLINDER HEAD/ VALVE DT X360 Lift the cylinder head off of the studs. Guide the cam chain through the opening in the cylinder head but do not allow the chain to fall into the crankcase. Remove the cylinder head gasket. Remove the two dowel pins from the left side cylinder head studs.
Page 100 6. CYLINDER HEAD/ VALVE DT X360 Remove the two intake mounting nuts with a 10 mm socket. Remove the intake from the cylinder head. Inspect the intake O-ring and replace it as needed. 6-29...
Page 101 6. CYLINDER HEAD/ VALVE DT X360 Remove the intake plate and gasket from the cylinder head. Use a 17 mm wrench to remove the water temperature sensor if needed. Clean the combustion chamber with contact cleaner, a plastic knife, brush and/or rag. Take care to only remove carbon and not scrape the head.
Page 102 6. CYLINDER HEAD/ VALVE DT X360 Place a straight edge across the bottom of the cylinder head and check for warp with a feeler gauge. You will need to check clearance readings from several places on the bottom of the cylinder head surface for warp. 6-31...
Page 103: Valves
6. CYLINDER HEAD/ VALVE DT X360 6. Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 6.1. Removal Remove the camshaft. See the Camshaft topic for more information. Remove the cylinder head. See the Cylinder Head topic for more information. IMPORTANT: Record the position of all parts so they can be returned to their proper place during reassembly.
Page 104 6. CYLINDER HEAD/ VALVE DT X360 Remove the spring retainer. Remove the valve springs. Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head. Rotate the valve as it is removed. 6-33...
Page 105: Inspection
6. CYLINDER HEAD/ VALVE DT X360 Remove the valve seal from the valve guide. The valve seals should be replaced if they are removed or you are going to install new valves. Remove the spring seat. 6.2. Inspection Inspect the valve springs for fatigue and damage. Replace the valve springs as needed or if the valve is also to be replaced.
Page 106 6. CYLINDER HEAD/ VALVE DT X360 6-35...
Page 107 6. CYLINDER HEAD/ VALVE DT X360 Inspect the valves for damage and burning. Measure the valve stem diameter in several places where the valve makes contact with the guide. If the measurement is below specification replace the valve. Item Standard (mm) 4.990 - 4.975 Valve stem O.D.
Page 108 6. CYLINDER HEAD/ VALVE DT X360 Measure the inside diameter of the valve guides. Replace the guides if the measurement is out of specification. Calculate the valve stem-to-guide clearance. Replace the guide and valve if the clearance is out of specification. Item Standard (mm) 5.00 - 5.012...
Page 109 7. CYLINDER/ PISTON DT X360 Cylinder/ Piston SCHEMATIC DRAWING ......................... 2 SERVICE INFORMATION ........................ 3 2.1. GENERAL INSTRUCTIONS ....................3 2.2. SPECIFICATIONS ........................ 3 2.3. TROUBLESHOOTING ......................4 Cylinder Block ..........................5 3.1. Removal ..........................5 3.2. Inspection ........................10 3.3.
Page 110: Schematic Drawing
7. CYLINDER/ PISTON DT X360 1. SCHEMATIC DRAWING...
Page 111: Service Information
7. CYLINDER/ PISTON DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  The cylinder and piston can be serviced with the engine installed in the frame.  When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 112: Troubleshooting
7. CYLINDER/ PISTON DT X360 2.3. TROUBLESHOOTING When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven compression ...
Page 113: Cylinder Block
7. CYLINDER/ PISTON DT X360 3. Cylinder Block 3.1. Removal Remove the engine from the frame. See the Engine Removal topic for more information. Remove the cylinder head cover. See the Cylinder Head Cover topic for more information. Remove the camshaft sprocket. See the Camshaft topic for more information. Remove the cylinder head.
Page 114 7. CYLINDER/ PISTON DT X360 Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver. Free the coolant hose from the cylinder. Slide the cylinder off of the studs and piston. Guide the cam chain through its opening and do not allow if to fall into the crankcase.
Page 115 7. CYLINDER/ PISTON DT X360 Remove the two cylinder dowel pins from the left studs. 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. Remove the piston pin and the piston.
Page 116 7. CYLINDER/ PISTON DT X360 Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal. The rings can be easily damaged. The two upper rings are each a single piece of metal. The oil ring consists of an expander ring and two side rails.
Page 117 7. CYLINDER/ PISTON DT X360 Clean the carbon build up off of the piston with a stiff bristled plastic brush or rag. Never use a wire brush to clean a piston. Also clean out the ring grooves. You can use an old ring to scrape out any carbon build up in the grooves.
Page 118: Inspection
7. CYLINDER/ PISTON DT X360 3.2. Inspection The cylinder and piston must be replaced as a set. There are two sets of cylinder and piston combinations. Make sure to have a No.A cylinder with an "A" piston or a No.B cylinder with a "B"...
Page 119 7. CYLINDER/ PISTON DT X360 Measure the cylinder diameter as described below with a telescoping gauge. Inspect the cylinder front to back and side to side at three different height levels with a dial bore gauge. Replace the cylinder and piston as a set if the cylinder is out of specification. Calculate the cylinder taper.
Page 120 7. CYLINDER/ PISTON DT X360 Measure the outside diameter of the piston at 9 mm up from the bottom of the skirt at a 90° angle to the piston pin. Measure the piston with vernier calipers or a micrometer. Check the piston for wear, damage, and extreme discoloration.
Page 121 7. CYLINDER/ PISTON DT X360 Measure the inside diameter of the small end of the connecting rod with vernier calipers. Item Standard (mm) Connecting rod small end I.D. Bore 18.016~18.034 Measure the ring groove width and the ring-to-groove clearance with feeler gauges. Item Standard mm 0.015 - 0.055...
Page 122 7. CYLINDER/ PISTON DT X360 Insert the top ring into the cylinder. Push the top ring in the cylinder about an inch. Use the piston to push in the ring to keep it square with the cylinder. Measure the ring gap with a feeler gauge. Repeat this procedure with second ring and the oil side rails.
Page 123: Assembly
7. CYLINDER/ PISTON DT X360 Check the oil jet for clogs. 3.3. Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Do not try and force them on the piston. 7-15...
Page 124 7. CYLINDER/ PISTON DT X360 Install the top and second rings with their markings facing up. Install the rings to the piston as shown above so that no ring end gaps line up with the piston pin or perpendicular to the piston pin.
Page 125 7. CYLINDER/ PISTON DT X360 Place the piston over the connecting rod. Insert the piston pin into the piston and rod. Install new piston pin clips securely into their grooves. Turn the gap in the clips away from the access gap. Make sure the cylinder head mating surface is clean.
Page 126 7. CYLINDER/ PISTON DT X360 Coat the inside of the cylinder, piston rings, and piston in fresh engine oil. Lower the cylinder over the studs and guide the piston into the cylinder while you are compressing the rings with your fingers. Be careful to not damage the rings during this step. Bring the cam chain and guide through the opening.
Page 127 8. DRIVE & DRIVEN PULLEYS DT X360 Drive & Driven Pulleys SCHEMATIC DRAWING ......................... 2 SERVICE INFORMATION ........................ 3 2.1. General Instructions ......................3 2.2. Specifications ........................3 2.3. Torque Values ........................3 2.4. Special Tools ........................3 2.5. Troubleshooting ....................... 4 Belt Case ............................
Page 128: Schematic Drawing
8. DRIVE & DRIVEN PULLEYS DT X360 1. SCHEMATIC DRAWING...
Page 129: Service Information
8. DRIVE & DRIVEN PULLEYS DT X360 2. SERVICE INFORMATION 2.1. General Instructions  The drive pulley, clutch and driven pulley can be serviced with the engine installed.  Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 130: Troubleshooting
8. DRIVE & DRIVEN PULLEYS DT X360 2.5. Troubleshooting Engine starts but motorcycle won‘t move  Worn drive belt  Broken ramp plate  Worn or damaged clutch lining  Broken driven face spring Engine stalls or motorcycle creeps  Broken clutch weight spring Lack of power ...
Page 131: Belt Case
8. DRIVE & DRIVEN PULLEYS DT X360 3. Belt Case SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 3.1. Removal Remove the mounting bolts of belt case cover. Remove the belt case cover.
Page 132 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the bolts of belt case and remove the belt case. Remove the bolts of filter and remove the filter.
Page 133 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the belt case cover and gasket. Remove the two dowel pins.
Page 134: Inspection
8. DRIVE & DRIVEN PULLEYS DT X360 3.2. Inspection Inspect the drive belt for cracks or excessive wear. Inspect the belt case bearing by turning it with a finger. Replace the bearing if it is rough or noisy. Remove the bearing snap ring with snap ring pliers.
Page 135 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the bearing with a suitable bearing puller. Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing. Install a new snap ring with snap ring pliers.
Page 136: Cvt Removal
8. DRIVE & DRIVEN PULLEYS DT X360 4. CVT Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the belt case. See the Belt Case topic for more information. 4.1. Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen the nut with a 19 mm socket.
Page 137 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the left face of the drive pulley. Loosen the driven pulley nut with a 19 mm socket. Remove the driven pulley nut and bushing. 8-11...
Page 138 8. DRIVE & DRIVEN PULLEYS DT X360 Slide the driven pulley off of the shaft. Remove the belt from the driven pulley. Inspect the drive belt for cracks or excessive wear. 8-12...
Page 139 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the right (movable) face of the drive pulley from the crankshaft. Slide the bushing out of the movable drive face. Remove the washer from the crankshaft. 8-13...
Page 140: Drive Pulley Disassembly
8. DRIVE & DRIVEN PULLEYS DT X360 4.2. Drive Pulley Disassembly Inspect the faces of the drive pulley. Clean away any grease from the faces. Lift the ramp plate out of the back of the movable drive pulley face. Remove the rubber damper pieces from the ramp. 8-14...
Page 141 8. DRIVE & DRIVEN PULLEYS DT X360 There are eight weight rollers in the back of the movable face of the drive pulley. Remove the rollers and check them for excessive or uneven wear. Measure the outside diameter of the rollers. Replace the weight rollers as needed. Item Standard (mm) Service Limit (mm)
Page 142: Clutch Disassembly
8. DRIVE & DRIVEN PULLEYS DT X360 4.3. Clutch Disassembly Lift the clutch outer off of the centrifugal clutch. Inspect the inside of the clutch outer for excessive wear and damage. Measure the inside diameter of the clutch outer and replace the part as needed. Item Standard (mm) Service Limit (mm)
Page 143 8. DRIVE & DRIVEN PULLEYS DT X360 Inspect the clutch shoe lining thickness. Replace the shoes if the wear is below the service limit. Item Standard (mm) Service Limit (mm) Clutch lining thickness To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch.
Page 144 8. DRIVE & DRIVEN PULLEYS DT X360 Use the clutch spring compressor tool to compress the spring in the driven pulley assembly. Secure the spring compressor tool in a vise. Loosen the clutch drive plate nut with the special socket that comes with the fitting tool. Remove the clutch drive plate nut.
Page 145 8. DRIVE & DRIVEN PULLEYS DT X360 Inspect the left side bearing by turning it with a finger. If the bearing is rough turning or noisy it should be replaced. Remove the clutch spring compressor tool. Lift off the centrifugal clutch. 8-19...
Page 146 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the collars and spring. Measure the free length of the clutch spring. Replace the spring if the measurement fails to meet the service limit. 8-20...
Page 147 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver. Lift off the plate. Slide the clutch shoes off of the pivots on the drive plate. 8-21...
Page 148: Driven Pulley Disassembly
8. DRIVE & DRIVEN PULLEYS DT X360 Inspect the clutch shoe bumpers and replace them as needed. 4.4. Driven Pulley Disassembly Remove the clutch as shown above. Remove the four guide rollers with guide roller pins. 8-22...
Page 149 8. DRIVE & DRIVEN PULLEYS DT X360 Separate the left and right faces of the driven pulley. Inspect the faces of the driven pulley. Clean away any grease from the faces where the belt rides. 8-23...
Page 150 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the seals from the left face of the driven pulley. Drive in the new seals with a suitable driver with the same outside diameter as the seal. Remove the O-rings on the left face. Clean the left face and roller pins with a high flash point solvent and compressed air.
Page 151: Bearing Replacement
8. DRIVE & DRIVEN PULLEYS DT X360 Bearing Replacement Inspect the bearings in the right face of the driven pulley. Remove the needle bearing with a suitable puller. 8-25...
Page 152 8. DRIVE & DRIVEN PULLEYS DT X360 Remove the collar, snap ring, and bearing from the right face of the driven pulley. Clean the right face with a high flash point solvent and compressed air. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 153 8. DRIVE & DRIVEN PULLEYS DT X360 Lubricate the bearings in the right face of the driven pulley with grease. 8-27...
Page 154: Cvt Installation
8. DRIVE & DRIVEN PULLEYS DT X360 5. CVT Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 5.1. Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease. Drive in the new seals with a suitable driver with the same outside diameter as the seal.
Page 155 8. DRIVE & DRIVEN PULLEYS DT X360 Install the O-rings to the left face of the driven pulley. Coat the O-rings seals, and inside of the left face where it rides on the right face with grease. Fit the left face onto the right face. Wipe away any grease that gets on the faces where the belt will ride.
Page 156: Clutch
8. DRIVE & DRIVEN PULLEYS DT X360 Lubricate the guide pins and rollers with grease. Place the rollers on the pins and insert the pins into driven pulley as shown. 5.2. Clutch Apply a light coat of grease to the brake shoe pivot pins on the drive plate. Install the three rubber bumpers.
Page 157 8. DRIVE & DRIVEN PULLEYS DT X360 Connect the clutch shoes with the springs as shown. Slide the clutch shoes onto the drive plate pivots. Fit the plate onto the clutch shoe pivots. 8-31...
Page 158 8. DRIVE & DRIVEN PULLEYS DT X360 Install the three clutch shoe pivot circlips. Install the seal collar and spring. Install the spring collar into the spring and set the centrifugal clutch on top of the spring collar. 8-32...
Page 159 8. DRIVE & DRIVEN PULLEYS DT X360 Set the clutch fitting tool to onto the clutch. Use the clutch spring compressor tool to compress the spring in the driven pulley assembly. Thread on the clutch drive plate nut. 8-33...
Page 160 8. DRIVE & DRIVEN PULLEYS DT X360 Tighten the clutch drive plate nut to specification with the special socket that comes with the fitting tool. Torque Item kgf-m lb-ft Clutch drive plate nut 5.0~6.0 36.17-43.40 Wipe away any excess grease. Do not allow grease to contact the clutch shoe linings or the driven faces where the belt will ride.
Page 161: Drive Pulley
8. DRIVE & DRIVEN PULLEYS DT X360 5.3. Drive Pulley Install the rollers into the back of the movable drive face of the driven pulley. Position the rollers so that their colored sides are clockwise. Insert the four rubber damper pieces into the ramp. Fit the ramp into the back of the movable drive face of the drive pulley.
Page 162: Pulleys And Belt
8. DRIVE & DRIVEN PULLEYS DT X360 5.4. Pulleys and Belt Slide the drive pulley washer onto the crankshaft. Insert the bushing into movable drive face of the drive pulley. Slide the movable face of the drive pulley onto the crankshaft. Make sure the drive face are clean and grease free where they will contact the belt.
Page 163 8. DRIVE & DRIVEN PULLEYS DT X360 Fit the Belt in between the faces of the driven pulley. Spread the faces by had if needed in get the belt to fit. Slide the driven pulley and clutch assembly onto the final drive shaft. Position the front end of the belt around the crankshaft.
Page 164 8. DRIVE & DRIVEN PULLEYS DT X360 Install the driven pulley bushing and nut. Torque the driven pulley nut to specification with a 19 mm socket. Torque Thread Item size (mm) kgf-m lb-ft Clutch outer nut (driven pulley) 5.0-6.0 36.17-43.40 8-38...
Page 165 8. DRIVE & DRIVEN PULLEYS DT X360 Slide the left face of the drive pulley onto the crankshaft. Lubricate the threads of the drive pulley nut with engine oil. Install the drive pulley washer and nut. 8-39...
Page 166 8. DRIVE & DRIVEN PULLEYS DT X360 Hold the drive pulley with a universal holder tool and torque the nut to specification with a 19 mm socket. Torque Thread Item size (mm) kgf-m lb-ft Drive face nut 9.0-10.0 65.10-72.33 Install the belt case. See the Belt Case topic for more information. 8-40...
Page 167 9. FINAL REDUCTION DT X360 Final Reduction SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 3 2.1. General Instructions ..................3 2.2. Specifications ....................3 2.3. Torque Values ....................3 2.4. Special Tools..................... 3 2.5. Troubleshooting ....................3 Gear Oil ........................4 3.1.
Page 168: Schematic Drawing
9. FINAL REDUCTION DT X360 1. SCHEMATIC DRAWING...
Page 169: Service Information
9. FINAL REDUCTION DT X360 2. SERVICE INFORMATION 2.1. General Instructions  The servicing operations of this section can be made with the engine installed.  When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
Page 170: Gear Oil
9. FINAL REDUCTION DT X360 3. Gear Oil 3.1. Draining Place the vehicle on its center stand on level ground. Place a suitable oil drain pan under the transmission oil drain plug. Remove the transmission oil level filler bolt with a 12 mm socket. Place a suitable container under the drain plug to capture the final drive oil.
Page 171 9. FINAL REDUCTION DT X360 Inspect the drain plug and washer. Install the oil drain plug and washer with a 12 mm socket. Tighten to specification. Torque Thread Item size (mm) kgf-m lb-ft Final drive oil drain bolt 0.8 - 1.2 5.79 - 8.68...
Page 172: Filling
9. FINAL REDUCTION DT X360 3.2. Filling Fill the final drive with the specified quantity of oil with a syringe. Gear oil type: SAE 90 Gear oil capacity: At disassembly 0.23 Liter At change 0.20 Liter Thread in the final drive oil level filler bolt.
Page 173 9. FINAL REDUCTION DT X360 Install the oil filler plug and torque it to specification with a 12 mm socket. Torque Thread Item size (mm) kgf-m lb-ft Final drive oil filler bolt 0.8 - 1.2 5.79 - 8.68...
Page 174: Final Reduction
9. FINAL REDUCTION DT X360 4. Final Reduction SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 4.1. 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 175 9. FINAL REDUCTION DT X360 Remove the 9 transmission case cover bolts using a 12 mm socket. Utilize the reinforced pry points and remove the case cover.
Page 176 9. FINAL REDUCTION DT X360 Use a press to remove the drive shaft. Thread a nut onto the drive shaft to protect the threads. If the drive shaft is to be replaced also replace the seal. Remove the two dowel pins and the gasket. Remove the final shaft gear.
Page 177 9. FINAL REDUCTION DT X360 Remove the countershaft. Remove the final shaft. 9-11...
Page 178: Inspection
9. FINAL REDUCTION DT X360 4.2. Inspection Inspect the countershaft gear for wear or damage. Inspect the final gear and final shaft for wear, damage or seizure. If the final shaft snap ring is removed replace it with a new item. Check the left crankcase bearings for excessive play.
Page 179 9. FINAL REDUCTION DT X360 Check the transmission case cover bearings for excessive play. Inspect the drive shaft, drive shaft bearing and oil seal for wear or damage. Use a bearing puller to remove the crankcase or transmission case covers. Use a seal pick to remove the oil seals.
Page 180: Installation
9. FINAL REDUCTION DT X360 Use a bearing driver to install any new bearings into the crankcase and transmission case cover. The driver should have the same outside diameter as the bearings. The bearings should go in square and have their markings facing out.
Page 181 9. FINAL REDUCTION DT X360 Insert the final shaft through the oil seal and bearing. Install the countershaft into its bearing as shown. Install the final gear onto the final shaft as shown. Install the dowel pins. Install a new gasket onto the transmission case. 9-15...
Page 182 9. FINAL REDUCTION DT X360 Install the transmission case cover onto the transmission. Fit the drive into its bearing in the case and make sure it gear engages correctly with the countershaft gear. Turn the drive shaft and make sure the final shaft turns. Insert the 9 transmission case cover bolts.
Page 183 10. A.C. GENERATOR & STARTER CLUTCH DT X360 A.C. Generator & Starter Clutch SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 3 2.1. General Instructions ..................3 2.2. Specifications ....................3 2.3. Special Tools..................... 3 2.4. Torque Values ....................3 2.5. Troubleshooting ....................
Page 184: Schematic Drawing
10. A.C. GENERATOR & STARTER CLUTCH DT X360 1. SCHEMATIC DRAWING 10-2...
Page 185: Service Information
10. A.C. GENERATOR & STARTER CLUTCH DT X360 2. SERVICE INFORMATION 2.1. General Instructions  All servicing operations and inspections in this section can be made with the engine installed.  Drain the coolant before removing the right crankcase cover. ...
Page 186: Generator And Starter Clutch
10. A.C. GENERATOR & STARTER CLUTCH DT X360 3. A.C. GENERATOR AND STARTER CLUTCH SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 3.1. Removal Drain engine oil and remove the oil filter. See the Engine Oil topic for more information. Drain the coolant.
Page 187 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container.
Page 188 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Remove the 12 generator cover bolts with an 8 mm socket. Utilize the pry points and remove the generator cover. Remove the generator cover gasket. 10-6...
Page 189 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Remove the two dowel pins. Remove the two oil filter chamber O-rings. Inspect the O-rings and replace them as needed. 10-7...
Page 190: Stator And Pulsar Coil/Crank Position Sensor
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Stator and Pulsar Coil/Crank Position Sensor To inspect the stator see the Charging System topic. For crank position sensor inspection see the Ignition System topic. Free the rubber wire grommet from the right crankcase cover. Remove the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket.
Page 191: Flywheel
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Flywheel To remove the fly wheel two special tools are needed. ITEM TOOL NO. UNIVERSAL HOLDER E021 ITEM TOOL NO. FLYWHEEL PULLER A120E00099 10-9...
Page 192 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket. Remove the flywheel nut and washer. 10-10...
Page 193 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Apply grease to the threads of the flywheel puller tool before using it. Thread the puller onto the flywheel. Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the crankshaft.
Page 194 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Slide the starter driven gear off of the crankshaft. Remove the woodruff key from the crankshaft. 10-12...
Page 195: Starter Clutch
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Starter Clutch Remove the starter idle gear and shaft from the crankcase. Inspect the starter idle gear and shaft for wear and damage. Replace the idle gear and shaft as needed. Inspect the starter driven gear for wear and damage. Measure the inside and outside diameter of the starter driven gear and replace it as needed.
Page 196 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Fit the boss of the starter driven gear into the starter clutch. The starter clutch should only allow the driven gear to turn in one direction. If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced.
Page 197: Installation
10. A.C. GENERATOR & STARTER CLUTCH DT X360 3.2. Installation Starter Clutch Fit the starter clutch to the back of the flywheel. Apply blue Loctite to the threads of the three starter clutch mounting bolts. Insert the three starter clutch mounting bolts. Tighten the starter clutch mounting bolts to specification with a 6 mm Allen socket.
Page 198: Flywheel
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Flywheel Install the woodruff key into its slot on the end of the crankshaft. Lubricate the inside of the starter driven gear with fresh engine oil. Slide the starter driven gear onto the flywheel as shown. Clean off the tapered end of the crankshaft where the flywheel will ride and make sure the inside of the flywheel is oil free where it will contact the crankshaft.
Page 199 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft. Guide the starter driven gear into the starter clutch on the back of the flywheel. Install the washer and flywheel nut.
Page 200 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket. Torque Thread Item size (mm) kgf-m lb-ft ACG flywheel nut 5.5-6.5 39.78-47.01 ITEM TOOL NO.
Page 201: Stator And Crank Position Sensor
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Stator and Crank Position Sensor Fit the stator and the crankshaft position sensor into the generator cover together as shown. Insert the two crank position sensor mounting bolts and the three stator mounting bolts. Tighten the bolts securely with an 8 mm socket.
Page 202: Generator Cover
10. A.C. GENERATOR & STARTER CLUTCH DT X360 Generator Cover Make sure the generator cover mating surface is clean. Install the two dowel pins and a new generator cover gasket. Make sure the oil filter chamber O-rings are in place and in good condition. 10-20...
Page 203 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Fit the generator cover into place. Make sure the water pump shaft engages correctly with the oil pump shaft. Insert the 12 generator cover bolts. Tighten the bolts securely in a with an 8 mm socket. 10-21...
Page 204 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Fit the coolant hose to the right crankcase cover pipe. Secure the hose with the clamp and tighten the coolant hose clamp securely with a #2 Phillips screwdriver. Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 205 10. A.C. GENERATOR & STARTER CLUTCH DT X360 Plug in the crank position sensor wire coupler on the right side of the frame. Fill the engine oil. See the Engine Oil topic for more information. Install the exhaust system. See the Exhaust System topic for more information. Fill the coolant and bleed the coolant.
Page 206 11. CRANK CASE DT X360 Crank Case SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 3 General Instructions ..................3 2.1. Specifications ....................3 2.2. Torque Values ....................3 2.3. Troubleshooting ....................3 2.4. Crankcase ........................4 Splitting ......................4 3.1. Assembly ......................
Page 207: Schematic Drawing
11. CRANK CASE DT X360 1. SCHEMATIC DRAWING 11-2...
Page 208: Service Information
11. CRANK CASE DT X360 2. SERVICE INFORMATION 2.1. General Instructions  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.  When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
Page 209: Crankcase
11. CRANK CASE DT X360 3. Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 3.1. Splitting Drain the engine oil and remove the strainer screen. See the Engine Oil topic for more information. Remove the engine. See the Engine Removal topic for more information. Remove the cylinder head cover.
Page 210 11. CRANK CASE DT X360 Remove the upper cam chain guide bolt with an 8 mm Allen. Remove the upper cam chain guide. Inspect the cam chain guides for damage and excessive wear. Replace the guides as needed. 11-5...
Page 211 11. CRANK CASE DT X360 Remove the cam chain from the crankshaft and crankcase. Inspect the cam chain for wear and damage. Replace the cam chain as needed. There are 11 crankcase bolts. Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm socket. Remove the crankcase bolts from the left side of the engine.
Page 212 11. CRANK CASE DT X360 Remove the plate with the bottom two crankcase bolts. Set the crankcases on the right side. Separate the halves of the crankcase. If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet. Lift the right crankcase off of the left. 11-7...
Page 213 11. CRANK CASE DT X360 Remove the dowel pins from the crankcase. Inspect the O-ring and replace it as needed. To remove the crankshaft see the Crankshaft topic. Replace the left crankshaft seal if the crankcases are separated. 11-8...
Page 214 11. CRANK CASE DT X360 Remove the seal with a seal pick. Drive the new seal into the left crankcase from the outside with a suitable driver. The driver should have the same outside diameter as the seal. Lubricate the new crankshaft seal lips with fresh engine oil.
Page 215: Assembly
11. CRANK CASE DT X360 3.2. Assembly 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. Set the right case half down on top of the left. Install the engine mount spacer. Note: Make sure the Right/Left crankcases with the same number.
Page 216 11. CRANK CASE DT X360 Insert the 11 crankcase bolts. The plate goes on with the bottom two bolts. Tighten the bolts securely and evenly in a crisscross pattern with an 8 mm socket. Install the cam chain around the timing sprocket teeth on the crankshaft. 11-11...
Page 217 11. CRANK CASE DT X360 Fit the upper cam chain guide into place. Insert the upper cam chain guide mounting bolt and tighten it to specification with an 8 mm Allen socket. Torque Thread Item size (mm) kgf-m lb-ft Cam chain tensioner pivot 0.8-1.2 5.79 - 8.68 Install the oil pump.
Page 218 11. CRANK CASE DT X360 Install the cylinder and piston. See the Cylinder and Piston topic for more information. Install the cylinder head. See the Cylinder Head topic. Install the camshaft. See the Camshaft topic for more information. Install the cylinder head cover. See the Cylinder Head Cover topic for more information. Install the rear wheel.
Page 219: Crankshaft
11. CRANK CASE DT X360 4. Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 4.1. Removal Split the crankcases. See the Crankcase topic for more information. Lift the crankshaft out of the left crankcase half. 11-14...
Page 220: Crankshaft Inspection
11. CRANK CASE DT X360 4.2. Crankshaft Inspection Check the side clearance of the big end of the connecting rod with a feeler gauge. Item Standard (mm) Service Limit (mm) Connecting rod big Crankshaft 0.15 - 0.35 end side clearance Grip the small end of the connecting rod and try and push the rod down towards the crank weights.
Page 221: Crankshaft Bearings
11. CRANK CASE DT X360 4.3. Crankshaft Bearings Inspect the crankshaft bearings for signs of damage and wear. Replace the bearings if they show any kind of imperfection. Note the bearing color code and crankcase code. The crank weights are also marked with a size code. When the crankshaft and or crankcases must be replaced also replace both crank bearings according to the chart below.
Page 222 12. COOLING SYSTEM DT X360 Cooling System SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 2 2.1. General Instructions ..................2 2.2. Special Tool ...................... 2 2.3. Torque Values ....................2 2.4. Troubleshooting ....................3 2.5. Specifications ....................3 2.6. Coolant Gravity ....................4 2.7.
Page 223: Cooling System
12. COOLING SYSTEM DT X360 1. SCHEMATIC DRAWING 2. SERVICE INFORMATION 2.1. General Instructions  The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame.  The engine must be cool before servicing the cooling system.
Page 224: Troubleshooting
12. COOLING SYSTEM DT X360 2.4. Troubleshooting Engine temperature too high  Faulty temperature gauge or thermo sensor  Faulty radiator cap  Faulty thermostat  Insufficient coolant  Passages blocked in hoses or water jacket  Clogged radiator fins ...
Page 225: Coolant Gravity
-37°C -44.5°C Cautions for Using Coolant: Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30 %.) Do not mix coolant concentrate of different brands. Do not drink the coolant which is poisonous.
Page 226: Radiator Cap Inspection
12. COOLING SYSTEM DT X360 3. RADIATOR CAP INSPECTION SAFETY FIRST: Protective gloves and eyewear are recommended at this point.  Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. ...
Page 227: Coolant Replacement
12. COOLING SYSTEM DT X360 4. COOLANT REPLACEMENT 4.1. Preparation  Antifreeze is highly toxic and can kill pets and animals if drank. Do not leave coolant where animals (including children!) can get to it.  The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage.
Page 228: Air Bleeding
12. COOLING SYSTEM DT X360 Remove the screw (3) and reserve tank lid (4). Open the coolant reserve tank lid. Siphon the coolant out of the reserve tank with an appropriate suction device. If a suction device is unavailable remove the reserve tank and poor it out.
Page 229: Radiator
12. COOLING SYSTEM DT X360 5. RADIATOR 5.1. Removal Drain the coolant. Disconnect the siphon hose (1) and air bleed hose (2). Remove the nut (3). Loosen the hose bands, and then disconnect the output hose (4) (to the water pump), coolant filling hose (5) and input hose (6) (from the engine) from the radiator.
Page 230: Inspection
12. COOLING SYSTEM DT X360 5.2. Inspection Inspect the radiator fins for damage and clogging. To remove the fan, take out the three mounting bolts with a 10 mm socket. Clean out the fins with low pressure compressed air and water. Check the radiator for any bent or damaged fins.
Page 231: Water Pump
12. COOLING SYSTEM DT X360 6. WATER PUMP 6.1. Mechanical Seal (Water Water Pump Seal) Inspection Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
Page 232 12. COOLING SYSTEM DT X360 Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Bolts Water Pump Cover Remove the water pump impeller. Impeller (Left Hand Treads)  The impeller has left hand threads. Inspect the mechanical (water) seal and seal Seal Washer (Porcelain) washer for wear or damage.
Page 233: Water Pump Shaft Removal
12. COOLING SYSTEM DT X360 6.3. Water Pump Shaft Removal Disconnect the water hose from the right crankcase cover. Remove the 5 bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Remove the water pump shaft clip and Water Pump Shaft water pump shaft Install the water pump shaft and shaft inner...
Page 234: Water Pump/Impeller Installation
12. COOLING SYSTEM DT X360 6.4. Water Pump/Impeller Seal Washer (Porcelain) Installation Mechanical Seal When the mechanical seal is replaced, a new seal washer must be installed to the impeller. Impeller Install the impeller onto the water pump Impeller (Left Hand Treads) shaft.
Page 235: Water Temperature Sensor
12. COOLING SYSTEM DT X360 7. WATER TEMPERATURE SENSOR 7.1. Removal Remove the luggage box. Drain the coolant. Disconnect the water temperature sensor connectors. Remove the water temperature sensor from thermostat. 7.2. Inspection Connect the water temperature sensor to Sensor the ohmmeter and dip it in oil contained in a pan which is placed on an electric heater.
Page 236: Installation
12. COOLING SYSTEM DT X360 7.3. Installation With thread lock applied to the threaded part, tighten the water temperature sensor. Torque: 0.8 kgf-m (8 N-m, 5.8 lbf-ft) Connect the sensor connectors. After the water temperature sensor has been installed, fill coolant and perform air bleeding 12-15...
Page 237: Thermostat
12. COOLING SYSTEM DT X360 8. THERMOSTAT 8.1. Removal Drain the coolant. Remove the luggage box. Disconnect the water hose (1) from the thermostat housing. Remove the mounting bolts (2) and the thermostat housing from the cylinder head. 8.2. Installation The installation sequence is the reverse of removal.
Page 238: Inspection
12. COOLING SYSTEM DT X360 8.4. Inspection Thermostat Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermometer temperature to check its operation. Technical Data Begins to open 80 - 82°C (176 - 180°F) Full-open 90°C (198°F) Valve lift...
Page 239 13. Fi DIAGNOSTIC TOOL DT X360 Fuel Injection System SYSTEM DIAGRAM ......................2 EMS COMPONENTS LOCATION ..................3 EMS COMPONENTS INTRODUCTION ................5 3.1. ECU (Electronic Control Unit) ..................5 3.2. Fuel Injector ........................ 5 3.3. Fuel Pump ........................5 3.4.
Page 240: System Diagram
13. Fi DIAGNOSTIC TOOL DT X360 1. SYSTEM DIAGRAM...
Page 241: Ems Components Location
13. Fi DIAGNOSTIC TOOL DT X360 2. EMS COMPONENTS LOCATION Rollover Ignition sensor switch OBD connector KEYLESS controller Start relay Fuse box ABS controller...
Page 242 13. Fi DIAGNOSTIC TOOL DT X360 Throttle body Idle air bypass valve Fuel injector TTPS (Intake air temperature Fuel pump sensor/MAP/TPS) Ignition coil Rectifier/Regulator Alternator Oxygen sensor...
Page 243: Ems Components Introduction
13. Fi DIAGNOSTIC TOOL DT X360 3. EMS COMPONENTS INTRODUCTION 3.1. ECU (Electronic Control Unit) Input: DC 8~16V Battery voltage There are 36 pins. The ECU is a single-chip microprocessor. The chip is recorded program of control module, Fuel Maps, self-diagnostic and etc. The ECU also has the processing module of every sensors and the drive module of the fuel injector, fuel pump and the ignition coil.
Page 244: Idle Air Bypass Valve Or Isc (Idle Speed Control)
13. Fi DIAGNOSTIC TOOL DT X360 3.4. Idle Air Bypass Valve or ISC (Idle Speed Control) 4 Pins Power Input Grounded Heater Signal Output Input: DC 8~16V Battery voltage The ISC is combined by two sets of independent coils. The operation is controlled by the ECU in small steps to open and restrict the valve through timing.
Page 245: Ppts (Map Sensor (Manifold Absolute Pressure)/ Tps (Throttle Position Sensor)/Inlet Air Temp Sensor)
13. Fi DIAGNOSTIC TOOL DT X360 3.7. PPTS (MAP Sensor (Manifold Absolute Pressure)/ TPS (Throttle Position Sensor)/Inlet air temp sensor) 3 Pins Power Grounded Signal Input output Input: DC 5V from ECU The PPTS is located at left side of throttle body.
Page 246: Oxygen Sensor
13. Fi DIAGNOSTIC TOOL DT X360 3.9. Oxygen Sensor 4 Pins Power Input Grounded Heater Signal Output Input: DC 8~16V from battery Oxygen sensor is located at front part of the exhaust pipe to detect the A/F ratio and then send the data to ECU for controlling the fuel injecting.
Page 247: Engine Components
13. Fi DIAGNOSTIC TOOL DT X360 4. ENGINE COMPONENTS 4.1. Flywheel with Encoder Teeth There are 22 teeth and 2 missing teeth. There are 15 degrees between each tooth include the missing tooth, therefore, each tooth is just right on the 24 equal line. When the flywheel is rotating, the magnetic field around the windings is cut by the teeth, which causes the CPS to send the inductive...
Page 248: Service Information
If the engine does not be start, the indicator will not go off. If the indicator is still lit after 10 seconds of engine start, the vehicle should have any malfunction. Please have KYMCO authorized dealers or workshop to check. Inspection specifications: See the EMS specifications.
Page 249 13. Fi DIAGNOSTIC TOOL DT X360 D. Troubleshooting Troubleshooting Timing: The CELP is flashing when turn on the ignition switch or during riding the vehicle, which indicates that the EMS of the vehicle has failed. Inspection Procedure: 2.1 To connect the diagnostic tool to the Fi system vehicle, the ignition switch should be turn on but do not start the engine, then connect the communication cable to the diagnostic connector in the vehicle.
Page 250: General Instructions
13. Fi DIAGNOSTIC TOOL DT X360 5.2. 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 251: Troubleshooting
13. Fi DIAGNOSTIC TOOL DT X360 5.3. TROUBLESHOOTING Complaint Symptom Probable Cause Engine will not Starter motor does Ignition switch malfunction start, or is hard to not run Starter motor malfunction start. Battery low Starter relay malfunction Start button bad connection Open circuit, short circuit Start button malfunction Engine stop switch malfunction...
Page 252 13. Fi DIAGNOSTIC TOOL DT X360 Complaint Symptom Probable Cause malfunction Ignition coil malfunction A.C. Generator signal cord malfunction Ignition switch or engine stop switch short circuit Short circuit or open circuit in the harness wire Ground wire poor connection Fuse burnt Air-fuel ratio too lean Air cleaner clogged/ no sealed/ no installed...
Page 253 13. Fi DIAGNOSTIC TOOL DT X360 Complaint Symptom Probable Cause Others ECU broken Engine oil viscosity too high/ add too much Transmission system malfunction Gear oil viscosity too high/ add too much Brake delay or interference Engine overheat or too cool Slipping clutch Engine lacks...
Page 254 13. Fi DIAGNOSTIC TOOL DT X360 Complaint Symptom Probable Cause Exhaust pipe clogged Excessive smoke White smoke Cylinder worn Valve oil seal worn Piston oil ring worn Valve guides or valve stem seals worn Too much engine oil Black smoke Air cleaner clogged Brown smoke Air cleaner clogged/ no sealed/ no installed...
Page 255: Obd P-Code List
13. Fi DIAGNOSTIC TOOL DT X360 6. OBD P-CODE LIST Failure Codes P-Codes Fault Description P0030 O2 sensor heater malfunction P0031 O2 sensor heater Voltage Low P0032 O2 sensor heater Voltage High P0105 MAP sensor malfunction P0107 MAP sensor Voltage Low P0108 MAP sensor Voltage High P0110...
Page 256 13. Fi DIAGNOSTIC TOOL DT X360 Failure Codes P-Codes Fault Description P0508 ISAV idle speed actuator valve Voltage Low P0509 ISAV idle speed actuator valve Voltage High P0562 Battery voltage VBK too Low P0563 Battery voltage VBK too High P0650 MIL Voltage High P0700 Engine overspeed detected...
Page 257 13. Fi DIAGNOSTIC TOOL DT X360 Failure Codes P-Codes Fault Description P2303 Ignition malfunction or Voltage Low P2304 Ignition malfunction or Voltage High P0642 Sensor Power Voltage Low P0643 Sensor Power Voltage High P0615 Starter Relay malfunction P0616 Starter Relay Voltage Low P0617 Starter Relay Voltage High...
Page 258: Checking Component
13. Fi DIAGNOSTIC TOOL DT X360 7. CHECKING COMPONENT Inspection Item Diagnostic Standard Remark Multimeter tool On board testing (with the diagnostic tool) Fuel 10.5±0.53 Ω 9.945~11.03Ω injector Resistance of the Fuel pump fuel pump: 1.9Ω ISC (Idle air On board testing bypass (with the valve)
Page 259: Ecu Wiring
13. Fi DIAGNOSTIC TOOL DT X360 8. ECU WIRING...
Page 260: Diagnostic Standard Specifications
13. Fi DIAGNOSTIC TOOL DT X360 9. DIAGNOSTIC STANDARD SPECIFICATIONS Diagnostic Report – AHG5 Customer: Eng. No: Date of Production: Date of Repair: Mileage: Reason of repair: □Maintenance □Breakdown Item Data Reference Remark ECU No AHG5 M4C Hardware Ver. Software Ver.
Page 261 13. Fi DIAGNOSTIC TOOL DT X360 Engine Speed 1700 ±100 rpm IDLE(rpm) Coolant fan motor operating Engine Temp. (°C) 87~96 °C temperature Air Temp (°C) MAP (kPa) 30~40 kPa Fuel Injection 1.8~2.8 ms duration (ms) Ign. Angle (°) 4~14 BTDC Ignition Charge 3.0~3.1 ms for 14V battery;...
Page 262 13. Fi DIAGNOSTIC TOOL DT X360 Engine Speed 1700 ±100 rpm IDLE(rpm) Coolant fan motor operating Engine Temp. (°C) 87~96 °C temperature Air Temp (°C) MAP (kPa) 30~40 kPa Fuel Injection 1.8~2.8 ms duration (ms) Ign. Angle (°) 4~14 BTDC Ignition Charge 3.0~3.1 ms for 14V battery;...
Page 263 14. FRONT ASSEMBLY DT X360 Front Assembly SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 4 2.1. GENERAL INSTRUCTIONS ................4 2.2. SPECIFICATIONS .................... 4 2.3. TORQUE VALUES.................... 4 2.4. SPECIAL TOOLS ....................5 2.5. TROUBLESHOOTING ..................5 Front Wheel ......................... 6 3.1.
Page 264: Schematic Drawing
14. FRONT ASSEMBLY DT X360 1. SCHEMATIC DRAWING 14-2...
Page 265 14. FRONT ASSEMBLY DT X360 14-3...
Page 266: Service Information
14. FRONT ASSEMBLY DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. ...
Page 267: Special Tools
14. FRONT ASSEMBLY DT X360 2.4. SPECIAL TOOLS Lock nut wrench A120F00002 Oil seal and bearing installer A120E00014 Bearing piller A120E00037 Lock nut wrench A120F00023 Bearing race remover A120F00009 Bearing race installer A120F00019 2.5. TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling ...
Page 268: Front Wheel
14. FRONT ASSEMBLY DT X360 3. Front Wheel 3.1. Removal Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground. Loosen the front axle pinch bolt (2) with a 6 mm Allen.
Page 269: Disassembly
14. FRONT ASSEMBLY DT X360 Wheel Rim Place the wheel on a truing stand and use a dial indicator to check if the rim is out of true. The specifications for the front and rear wheels are the same. Check for lateral wobble.
Page 270: Assembly
14. FRONT ASSEMBLY DT X360 Remove the front wheel bearing by using the special tool. Special tool: Bearing puller: A120E00037 Remove the distance collar from wheel. 3.4. Assembly Heat the bearing area of the wheel with a heat gun, take the bearing out of the freezer and install it.
Page 271: Front Brake Fluid
14. FRONT ASSEMBLY DT X360 4. Front Brake Fluid 4.1. Check Brake fluid: Fluid leakage → Replace. Cracks/wear/damage → Brake hose: Replace. Apply the brake lever several times. Brake hose clamp: Loosen → Tighten 4.2. Fluid Replacement/Air  A contaminated brake disc or pad Bleeding reduces stopping...
Page 272: Brake Fluid Filling/Air Bleeding
14. FRONT ASSEMBLY DT X360 Loosen the bleed valve and pump the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. 4.4. Brake Fluid Filling/Air Bleeding  Do not mix different types of fluid since they are not compatible. Fill the master cylinder with DOT 4 brake fluid to the upper level.
Page 273: Front Brake Pad
14. FRONT ASSEMBLY DT X360 5. Front Brake Pad 5.1. Brake Pad Replacement Remove the pad pins (1). Remove the two caliper mounting bolts (2), and then remove the caliper. Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven.
Page 274: Brake Disc
14. FRONT ASSEMBLY DT X360 6. Brake Disc 6.1. Inspection Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits: 4 mm Replace the brake disc if the smallest measurement is less than the service limit. Measure the brake disc warpage.
Page 275: Handlebar
14. FRONT ASSEMBLY DT X360 7. Handlebar 7.1. Removal Remove the lower handlebar cover and front cover. Remove the 4 bolts and disconnect the brake light switch wire, then remove the front and rear brake master cylinder. Remove the inner cover Route the cables and lines from the handlebar cable guide.
Page 276: Disassembly
14. FRONT ASSEMBLY DT X360 7.3. Disassembly Switches Remove screws from right handlebar switch. Disconnect the throttle cables and free the right switch housing from the handlebar. Remove the two screws and then remove the left handlebar switch. Disconnect the switch. Separate the left switch housing from the handlebar.
Page 277: Assembly
14. FRONT ASSEMBLY DT X360 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 278: Front Shock Absorber
14. FRONT ASSEMBLY DT X360 8. Front Shock Absorber 8.1. Removal Remove the front cover and front fender. Remove the front brake caliper. Remove the front wheel. Remove the speed wheel sensor bolt (1). Remove the speed sensor wire and front brake hose guide mounting bolt with an 8 mm socket.
Page 279: Steering Stem
14. FRONT ASSEMBLY DT X360 9. Steering Stem 9.1. Removal Support the vehicle with a suitable stand or jack so that the front wheel is off the ground. Grip the bottom of the fork legs and turn the front end side-to-side. If the movement is rough the bearings should be greased or replaced.
Page 280 14. FRONT ASSEMBLY DT X360 Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the bottom balls. Use the special tools or a drift and hammer to drive out the bearing races in the steering head.
Page 281: Installation
14. FRONT ASSEMBLY DT X360 9.2. Installation Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race.
Page 282 14. FRONT ASSEMBLY DT X360 Bottom Ball Race Remove Special Tool Bottom Ball Race Top Ball Cone Race Install special tool Install special tool 14-20...
Page 283 15. REAR ASSEMBLY DT X360 Rear Assembly SCHEMATIC DRAWING ..................... 2 SERVICE INFORMATION ................... 3 2.1. GENERAL INSTRUCTIONS ................3 2.2. SPECIFICATIONS .................... 3 2.3. TORQUE VALUES.................... 3 2.4. TROUBLESHOOTING ..................4 Rear Brake ........................5 3.1. Rear Brake Caliper Removal ................5 3.2.
Page 284: Schematic Drawing
15. REAR ASSEMBLY DT X360 1. SCHEMATIC DRAWING 15-2...
Page 285: Service Information
15. REAR ASSEMBLY DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  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. 2.2.
Page 286: Troubleshooting
15. REAR ASSEMBLY DT X360 2.4. TROUBLESHOOTING Rear wheel wobbling  Bent rim  Faulty tire  Axle not tightened properly  Engine not tightened properly  Tire pressure too low  Unbalanced wheel Soft suspension  Weak shock absorber spring ...
Page 287: Rear Brake
15. REAR ASSEMBLY DT X360 3. Rear Brake 3.1. Rear Brake Caliper Removal Drain the rear brake fluid. Place a suitable container under the banjo bolt to catch any remaining brake fluid. Remove the banjo bolt that holds the brake hose.
Page 288: Disassembly
15. REAR ASSEMBLY DT X360 3.3. Disassembly Remove two brake pads dowel pins and three bolts from the brake caliper. Remove the brake pads. Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston.
Page 289: Assembly
15. REAR ASSEMBLY DT X360 3.4. Assembly Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out. ...
Page 290: Installation
15. REAR ASSEMBLY DT X360 3.5. Installation Install the brake caliper to the rear fork and tighten the two bolts. Torque: 27 N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt. Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.
Page 291: Rear Fork
15. REAR ASSEMBLY DT X360 4. Rear Fork 4.1. Removal Lower bolt Speed sensor Place the vehicle on its center stand. Remove the exhaust muffler. Remove the rear brake caliper. Remove the speed sensor. Remove the speed sensor wire and the rear brake fluid hose holder.
Page 292: Rear Wheel
15. REAR ASSEMBLY DT X360 5. Rear Wheel 5.1. Removal Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. Remove the rear wheel. 5.2. Inspection Measure the rear wheel rim runout. 5.3.
Page 293: Rear Shock Absorber
15. REAR ASSEMBLY DT X360 6. Rear Shock Absorber 6.1. Removal Remove the met-in box and carrier. Remove the body cover, center cover and rear fender together. Remove the right/left rear shock absorber upper and lower mount bolts. Remove the right and left rear shock absorbers.
Page 294 16. BATTERY/CHARGING SYSTEM DT X360 Battery/Charging System CHARGING SYSTEM LAYOUT ......................2 SERVICE INFORMATION ........................ 3 2.1. GENERAL INSTRUCTIONS ....................3 2.2. SPECIFICATIONS ........................ 4 2.3. TROUBLESHOOTING ......................4 Battery ............................5 3.1. Removal ..........................5 3.2. Installation ........................5 3.3.
Page 295: Charging System Layout
16. BATTERY/CHARGING SYSTEM DT X360 1. CHARGING SYSTEM LAYOUT Negative cord Positive cord OBD connector REGULATOR/RECTIFIER 16-2...
Page 296: Service Information
16. BATTERY/CHARGING SYSTEM DT X360 2. SERVICE INFORMATION 2.1. GENERAL INSTRUCTIONS  The battery can be charged and discharged repeatedly. If a discharged battery is not used for a long time, its service life will be shortened. Generally, the capacity of a battery will decrease after it is used for 2～3 years.
Page 297: Specifications
16. BATTERY/CHARGING SYSTEM DT X360 2.2. SPECIFICATIONS Item Standard Capacity 12V 11.8Ah Fully charged 13.0~13.2V Voltage (20℃) Battery Undercharged 12.3V Normal 1.0X5~10H Charging current Quick 10AX0.5H Capacity 240W/5000rpm Charging coil resistance (20℃) Yellow-Yellow Alternator RPM of charging start Under 1300prm (14V) Charging performance 18A/ 5000rpm 14..5±0.5V...
Page 298: Battery
16. BATTERY/CHARGING SYSTEM DT X360 3. Battery 3.1. Removal Positive cable Negative cable The battery is in the front part of the vehicle. 1. Remove the wind screen and front cover. 2. Remove the screws. 3. Remove the battery cover. 4.
Page 299: Battery Charging
16. BATTERY/CHARGING SYSTEM DT X360 3.4. Battery Charging Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal.  Clean the battery terminals and position the battery as far as away from the charger as the leads will permit.
Page 300: Charging System Inspection
16. BATTERY/CHARGING SYSTEM DT X360 4. Charging System Inspection 4.1. Charging Voltage Positive terminal Negative terminal  Perform this inspection after the battery is fully charged. Start the engine and warm it up to the operating temperature; stop the engine. Connect multimeter between...
Page 301: Regulator/Rectifier
16. BATTERY/CHARGING SYSTEM DT X360 5. Regulator/Rectifier 5.1. Inspection Disconnect regulator/rectifier connectors. Check the connectors for loose contacts of corroded terminals. Battery line Measure voltage between Red/White wire terminal and ground. There should be battery voltage at all times. Ground line Check the continuity between the Green wire terminal and ground.
Page 302: Removal/Installation
16. BATTERY/CHARGING SYSTEM DT X360 5.2. Removal/Installation Regulator /rectifier Remove the side body cover Disconnect regulator/rectifier connectors. Remove the two bolts, regulator/rectifier. Installation is in the reverse order of removal. 16-9...
Page 303 17. IGNITION SYSTEM DT X360 Ignition System Ignition System Layout ....................2 Service Information ..................... 3 2.1. General instructions ..................3 2.2. Specifications ....................3 2.3. Troubleshooting ....................4 Spark Plug ........................5 3.1. Inspection ......................5 Ignition Coil ......................... 5 4.1.
Page 304 17. IGNITION SYSTEM DT X360 1. Ignition System Layout Rollover sensor Ignition switch Ignition coil 17-2...
Page 305: Service Information
17. IGNITION SYSTEM DT X360 2. Service Information 2.1. 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. ˙...
Page 306: Troubleshooting
17. IGNITION SYSTEM DT X360 Troubleshooting 2.3. LOW PEAK VOLTAGE ˙ Cranking speed is too low (battery is undercharged). ˙ Poorly connected connectors or an open circuit in the ignition system. ˙ Faulty ignition-coil. ˙ Faulty ignition control module. NO PEAK VOLTAGE ˙...
Page 307: Spark Plug
17. IGNITION SYSTEM DT X360 3. Spark Plug 3.1. Inspection 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. See the Spark Plug topic for more information.
Page 308: Inspection
17. IGNITION SYSTEM DT X360 4.2. Inspection Set the multimeter to read ohms of resistance (Ω). Touch the positive and negative meter probes to the ignition coil terminals as shown. Measure the resistance Primary resistance 2.38~3.22Ω Check the secondary resistance between the ignition coil terminal and the spark plug cap.
Page 309: Rollover Sensor
17. IGNITION SYSTEM DT X360 6. Rollover Sensor 6.1. Inspection Support the scooter level surface. Put the side stand up and engine stop switch on “RUN”. Turn the ignition switch to “OFF”.  Do disconnect sensor connector during inspection.  The capacity of battery must be fully charged.
Page 310: Ecu
17. IGNITION SYSTEM DT X360 7. ECU 7.1. Removal/installation The ECU is located at the front part of the vehicle. Disconnect the harness cable. Remove the mounting nuts. Remove the ECU.  The ignition control module or ECU may be damaged if dropped, soak in water, connector disconnected when the key is “ON".
Page 311 18. STARTING SYSTEM DT X360 Starting System Starting System Layout ....................2 Service Information ..................... 3 2.1. General Instructions ..................3 2.2. Torque Values ....................3 2.3. Troubleshooting ....................3 Start Motor ........................4 3.1. Inspection ......................4 3.2. Removal ......................4 3.3.
Page 312: Starting System Layout
18. STARTING SYSTEM DT X360 1. Starting System Layout Start MAG. switch Start Motor Battery 18-2...
Page 313: Service Information
18. STARTING SYSTEM DT X360 2. Service Information 2.1. General Instructions  The removal of starter motor can be accomplished with the engine installed.  For the starter clutch removal, refer to the chapter 10.  After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 314: Start Motor
18. STARTING SYSTEM DT X360 3. Start Motor 3.1. Inspection Connect the start motor cable directly to the battery positive terminal. If the start motor does not turn, the starter motor is faulty. 3.2. Removal Rubber cap Cable Turn the ignition switch turned to “OFF” Release the rubber cap and remove the terminal screw to disconnect the cable from the start motor.
Page 315: Starter Relay
18. STARTING SYSTEM DT X360 4. Starter Relay 4.1. Removal Disconnect the starter relay wire connector. Release the rubber caps and remove the nuts, then disconnect the start motor cable, battery positive cable and harness wire. Remove the starter relay. 4.2.
Page 316 18. STARTING SYSTEM DT X360 Starter Relay Voltage Turn on the ignition switch. Use a multimeter to measure the voltage. One probe touch the Y/R wire the other touch the ground. The measurement result will be close to the battery voltage Grounding Circuit Disconnect the connector.
Page 317 19. ELECTRICAL SYSTEM DT X360 Electrical System SERVICE INFORMATION ................... 3 1.1. GENERAL INSTRUCTIONS ................3 1.2. Specification ..................... 3 1.3. Troubleshooting ....................3 Front Lights assy ......................4 2.1. Headlight ......................4 2.2. Front turn signal lights..................4 Rear Lights assy......................5 3.1.
Page 318 19. ELECTRICAL SYSTEM DT X360 10.1. Inspection ....................18 10.2. Removal/Installation ..................18 11. Rollover sensor ......................19 11.1. Inspection ....................19 11.2. Removal/Installation ..................19 19-2...
Page 319: Service Information
19. ELECTRICAL SYSTEM DT X360 1. SERVICE INFORMATION 1.1. GENERAL INSTRUCTIONS  Note the following when replacing the halogen headlight bulb  Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. ...
Page 320: Front Lights Assy
19. ELECTRICAL SYSTEM DT X360 2. Front Lights assy 2.1. Headlight  Place a cloth under the headlight assy after removal prevent scratches. Remove the headlight assy. Remove screws. Remove the headlight. Install in the reverse order of work. 2.2. Front turn signal lights Remove the headlight assy.
Page 321: Rear Lights Assy
19. ELECTRICAL SYSTEM DT X360 3. Rear Lights assy 3.1. Tail light assy Remove the rear light assy. Remove screws on the each side of cover. Remove the side covers. Remove the rear center cover. Remove the screws. Remove the tail light assy. Installation is in the reverse order of removal.
Page 322: License Plate Light
19. ELECTRICAL SYSTEM DT X360 3.2. License Plate Light Remove the rear light assy. Remove the screws. Remove the license plate light. Remove the screws. Push and turn the bulb counterclockwise to remove it, and then replace with a new one. Specification: 12V 5W Installation is in the reverse order of removal.
Page 323: Inspection
19. ELECTRICAL SYSTEM DT X360 Rear Speed Sensor Remove the right side cover, Disconnect the speed sensor connector. Remove the bolt. Remove the rear speed sensor. Install in the reverse order of removal. 4.2. Inspection After remove the speed sensor, rotate the wheel to check the speed sensor ring.
Page 324: Switches
19. ELECTRICAL SYSTEM DT X360 5. Switches 5.1. Brake Light Switch Remove the upper handlebar cover. Disconnect front rear light switch connectors and check for continuity between the switch terminals (1). There should be continuity with the front or rear brake lever squeezed, and there should be no continuity when the front or rear brake lever (2) is released.
Page 325: Right Handlebar Switch
19. ELECTRICAL SYSTEM DT X360 5.3. Right handlebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Engine Stop SW Engine stop switch BAT3 COLOR 19-9...
Page 326: Left Handlebar Switch
19. ELECTRICAL SYSTEM DT X360 5.4. Left Handlebar Switch Disconnect the left handlebar switch Turn Signal Light Switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Horn Switch Passing Switch Dimmer switch 19-10...
Page 327: Luggage Box Light Sensor
19. ELECTRICAL SYSTEM DT X360 6. Luggage Box Light Sensor 6.1. INSPECTION Remove the luggage box. Disconnect the luggage box light sensor connector and check the luggage box light sensor for continuity between the sensor terminals. There should be no continuity with the luggage box light sensor being covered up, and there should be continuity with the luggage box light sensor being not covered...
Page 328: Oil Pressure Sensor
19. ELECTRICAL SYSTEM DT X360 7. Oil pressure sensor 7.1. Inspection Check the engine oil level is at the standard before inspection. The engine oil pressure will maintain in a certain pressure after start the engine. To inspect the oil pressure sensor, the ignition switch should be turned on.
Page 329: Removal
19. ELECTRICAL SYSTEM DT X360 7.2. Removal Remove the protective cap and disconnect the wire. Remove the engine oil pressure sensor. 7.3. Installation 3~4mm Apply suitable sealant as shown and do not seize the sensor. Tighten the oil pressure sensor to specified torque.
Page 330: Fuel Pump
19. ELECTRICAL SYSTEM DT X360 8. Fuel Pump 8.1. Removal Remove the seat. Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose. Remove the 6 nuts (1) and fuel unit connectors(2) then remove...
Page 331: Inspection
19. ELECTRICAL SYSTEM DT X360 8.2. Inspection Connect the fuel unit wire connectors and turn the ignition switch “ON”.  Before performing the following test, operate the turn signals to determine that the battery circuit is normal.  Use a good condition and fully charged battery to perform the inspection.
Page 332: Installation
19. ELECTRICAL SYSTEM DT X360 Measure the resistance between the Yellow/White and Blue/White terminals of the fuel unit connector. Standard (at 20°C/68°F): About1100 Ω Float at full position Float at empty position About100 Ω 8.3. Installation Installation is in the reverse order of removal.
Page 333: Side Stand Switch
19. ELECTRICAL SYSTEM DT X360 9. Side Stand Switch 9.1. Inspection Disconnect the side stand switch connector (1). There should be continuity between the Yellow/Green and Green with the side stand retracted. There should be continuity between the Yellow/Black and Green with the side stand applied.
Page 334: Horn
19. ELECTRICAL SYSTEM DT X360 Horn 10.1. Inspection Remove the front cover. Disconnect the horn connectors (1) from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.
Page 335 19. ELECTRICAL SYSTEM DT X360 Rollover sensor 11.1. Inspection Place the vehicle on a level ground and on its center stand. Remove the front cover. Turn on theignition switch. Use probes of a multimeter to test the voltage of the rollover sensor. Termials Standard Rollover sensor...
Page 336 3.5. DTC Cleared ........................12 3.6. Data Analyze ........................12 3.7. Air Bleeding ........................12 DTC List ............................13 4.1. Bosch ABS91 DTC List ..................... 13 4.2. TCS DTC List ........................13 Introduction to KYMCO TCS System ................... 14 21-1...
Page 337: Abs
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 1. ABS 1.1. Indicator Light The ABS indicator light in the meter position. This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving at speed 6km/hr. min. It stays off.
Page 338 21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 ˙ ABS will help prevent wheel lock-up when braking in straight line but it cannot control wheel slip, which may be caused by braking during cornering. When turning a corner, it is better to limit braking to the light application of both brakes or not to brake at all. Reduce your speed before you get into the corner.
Page 339: Troubleshooting Outline
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 1.3. 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.
Page 340 21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 Pre-diagnosis Inspection Chart 1 21-5...
Page 341 21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 Pre-diagnosis Inspection Chart 2 21-6...
Page 342: Removal
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 1.4. Removal Rear brake Front brake  When replacing a new Hydraulic fluid output fluid output Unit, don’t need to drain the brake fluid. Place a cloth under the ABS module. Remove the input and output bolts. Rear brake Front brake...
Page 343: Diagnostic Tool
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 2. Diagnostic Tool 2.1. PC version Open the diagnostic tool software. Remove the front cover. Connect the integrated linker to the OBD connector. Turn on the ignition switch. OBD connector Chose the ABS brake system. Check the ECU version which should be ACD5.
Page 344: Diagnostic Tool Operation
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 3. Diagnostic Tool Operation 3.1. Operation Instructions Part No. 3620A-LEB2-E00 ACD5 KEY FUNCTION ① Model No. ⑥ UP Button ② Down Button ⑦ Adjust (TPI and ABV reset function) ③ DTC indicator (Failure codes) ⑧...
Page 345: Connection
3.2. Connection Connect the sub cord to the OBD connector then connect KYMCO Fi diagnostic tool. (KYMCO Fi Diagnostic tool Power comes from vehicle’s Battery) OBD Connector Put the side stand upward and ENG. stop switch is at “RUN” position.
Page 346: Dtc Inspect
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 3.3. DTC Inspect ABS91 Choose DTC Inspect Load DTC (Active 、Occurred、History) 3.4. DTC Displayed 1. Rear wheel speed sensor disconnect 2. Front wheel speed sensor disconnect 21-11...
Page 347: Dtc Cleared
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 3.5. DTC Cleared 1. Choose “Clear DTC” and then push “Enter” button. 2. Clearing DTC completed until the DTC red lamp is off. 3.6. Data Analyze ABS91 Choose “DATA Analyze” and then push “Enter”...
Page 348: Dtc List
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 4. DTC List Bosch ABS91 DTC List 4.1. Code NO DTC Code Description 5013 Rear Inlet Valve malfunction (EV) 5014 Rear Outlet Valve malfunction (AV) 5017 Front Inlet Valve malfunction (EV) 5018 Front Outlet Valve malfunction (AV) 5019 Valve Relay malfunction (Failsafe relay) 5025...
Page 349: Introduction To Kymco Tcs System
21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 5. Introduction to KYMCO TCS System 21-14...
Page 350 21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 21-15...
Page 351 21. ANTI-LOCK BRAKE SYSTEM (ABS) DT X360 21-16...
Page 352 20. EEC SYSTEM DT X360 EEC System Diagram ........................2 1.1. Evaporates Emission Control System Diagram ..........2 1.2. Pollution Emission System Diagram .............. 2 E.E.C System Introduction ..................3 2.1. Evaporative Emission Control System ............3 2.2. Crankcase Emission Control System ............. 3 2.3.
Page 353: Diagram
20. EEC SYSTEM DT X360 1. Diagram 1.1. Evaporates Emission Control System Diagram Negative pressure Fuel injector Fuel Fuel Air cleaner pump Canister Fuel vapors Water Fuel tank atmosphere bleed hole Negative pressure Fuel Fuel vapors 1.2. Pollution Emission System Diagram Fuel vapors Intake Throttle body...
Page 354: System Introduction
20. EEC SYSTEM DT X360 2. E.E.C System Introduction WARNING: • Before running the engine, make sure that the working area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas, which may cause death to people. •...
Page 355: Function
20. EEC SYSTEM DT X360 3. Function Item Function Description It is used to prevent gasoline Evaporative Storage the gasoline vapors to canister, vapors from escaping into the Emission conduct the gasoline vapors to engine atmosphere from the fuel tank Control Valve by vacuum when starting the engine.
Page 356: Maintenance Schedule
KYMCO by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. ＊ Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service data and is mechanically qualified.
Page 357 20. EEC SYSTEM DT X360 Which Ever Comes First Odometer Reading (Note1) Frequency → Throttle Operation X1000 km 10 15 20 25 30 ↓ X1000 mi 12 15 18 Item Note Month 12 18 24 30 36 Air Cleaner Note2 Spark Plug Note4 Throttle Operation...
Page 358: Maintenance Information
20. EEC SYSTEM DT X360 5. Maintenance Information Note of maintenance: • Flame or spark should keep away when performing maintenance. • Install the tubes in correct position. • If the tubes broken should be replaced with a new one. •...
Page 359: Canister
20. EEC SYSTEM DT X360 6. Canister 6.1. Removal 1. Remove the windshield, front cover and head light assembly. 2. Remove the canister tube set and canister. Canister 6.2. Inspection Canister Evaporative Control Valve Connect a vacuum pump to the tube of canister.
Page 360: Installation Of Canister
20. EEC SYSTEM DT X360 Flow Rate of the Canister Vacuum Valve 1. Using a vacuum pump connecting to the vacuum tube of canister and apply 45m/mHg negative pressure. 2. Apply pressure to the emission control valve of canister, if the flow rate above 9.4 liters per minute that means the valve is in good condition, otherwise the canister...
Page 361: Inspection
Air filter cover cleaner element. The new air cleaner element installation is in the reverse order of removal. Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO cleaner...
Page 362: Inspection Of Emission System
20. EEC SYSTEM DT X360 7.3. Inspection of emission system Inspect the air cleaner. Inspect the spark plug. Inspect the ignition system. Plug in the diagnostic tool the check the information. Warm up the engine reach above 80°C. This model equipped the catalyst in the muffler to reduce the pollution emission.
Page 363: Oxygen Sensor
20. EEC SYSTEM DT X360 8. 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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