KYMCO AHG1 Manuals

Manuals and User Guides for KYMCO AHG1. We have 1 KYMCO AHG1 manual available for free PDF download: Maintenance Manuallines

KYMCO AHG1 Maintenance Manuallines

KYMCO AHG1 Maintenance Manuallines (244 pages)

Brand: KYMCO | Category: Engine | Size: 5 MB

Table of Contents

1. Quick Reference 1

2
- Table of Contents
  2
- Engine /Frame Serial Number
  3
- Specifications
  4
- Operation Precautions
  5
- Torque
  6
- General Torque Value
  6
- Engine
  7
- Frame
  8
- Special Tool
  9
- Lubrication Points-Frame
  10
- Components Location
  11
- Engine Lacks Power
  14
- General Troubleshooting
  14
- Engine will Not Stat or Is Hard to Start
  16
- Poor Handling
  17
- Poor Performance at High Speed
  18
- Poor Performance at Low and Idle Speed
  19
2. External Components, Exhaust Pipe

22
- General Instructions
  23
- Service Information
  23
- Torque Value
  23
- Troubleshooting
  23
- External Components Removal
  24
- Front Cover
  24
- Headlight Assy
  24
- Wind Screen
  24
- Side Covers
  25
- Center Cover
  26
- Luggage Box
  26
- Rear Carriers
  26
- Seat
  26
- Floor Panel Assy
  27
- Tail Light Assy
  27
- Meter Cover
  28
- Handlebar Covers
  30
- Leg Shield
  30
- Front Fender
  31
- Rear Fenders
  31
- Muffler Cover
  32
- Undercover
  32
- Exhaust Assembly
  33
- Exhaust Pipe
  33
- Muffler
  33
3. Periodic Maintenance

34
- Service Information
  36
- Specifications
  36
- Warning
  36
- Maintenance Schedule
  37
- Irregular Maintenance
  38
- Notes
  38
- Fuel Line
  39
- Throttle Operation
  39
- Air Cleaner
  40
- Spark Plug
  40
- Inspection
  41
- Valve Clearance
  41
- Adjustment
  42
- Cylinder Compression
  42
- Engine Oil
  43
- Engine Oil Level Check
  43
- Engine Oil Recommendation
  43
- Engine Oil Replacement
  44
- Oil Strainer Screen Clean
  45
- Oil Filter Replacement
  46
- Oil Change
  48
- Transmission Oil
  48
- Clutch Shoe Wear
  49
- Drive Belt
  49
- Idle Speed
  49
- Add Coolant
  50
- Coolant
  50
- Headlight Aim
  50
- Inspection
  50
- Coolant Recommendation
  51
- Brake
  52
- Brake Fluid
  52
- Brake Pad Wear
  52
- Brake Levers
  53
- Nuts/Bolts/Fasteners
  53
- Steering Handlebar
  54
- Tire Pressure
  54
- Wheels/Tires
  54
- Rear Suspension Adjustment
  55
- Suspension
  55
- Functional Check
  56
- Side Stand
  56
4. Lubrication System

58
- Lubrication Diagram
  59
- General Instructions
  60
- Service Information
  60
- Specifications
  60
- Troubleshooting
  61
- Engine Oil
  62
- Oil Pump
  62
- Removal
  62
- Disassembly
  63
- Inspection
  63
- Assembly
  64
- Installation
  65
6. Cylinder Head/ Valve

72
- Schematic Drawing
  73
- General Instructions
  74
- Service Information
  74
- Specifications
  74
- Special Tools
  75
- Torque Values
  75
- Troubleshooting
  76
- Cylinder Head Cover
  77
- Installation
  77
- Removal
  77
- Camshaft Holder
  78
- Installation
  78
- Removal
  78
- Disassembly
  79
- Inspection
  79
- Assembly
  80
- Camshaft
  81
- Removal
  81
- Camshaft
  82
- Inspection
  82
- Installation
  82
- Disassembly
  83
- Inspection
  84
- Valve Spring
  84
- Valve/ Valve Guide
  84
- Assembly
  85
- Cylinder Head
  85
7. Cylinder/ Piston

86
- Schematic Drawing
  87
- General Instructions
  88
- Service Information
  88
- Specifications
  88
- Troubleshooting
  89
- Cylinder and Piston
  90
- Removal
  90
- Inspection
  91
- Piston Ring
  91
- Cylinder
  92
- Piston/Piston Pin
  92
- Installation
  94
- Piston Ring
  94
- Cylinder/Piston
  95
8. Drive & Driven Pulleys

96
- Schematic Drawing
  97
- General Instructions
  98
- Service Information
  98
- Special Tools
  98
- Specifications
  98
- Torque Values
  98
- Troubleshooting
  99
- Installation
  100
- Left Crankcase Cover
  100
- Removal
  100
- Drive Pulley, Drive Belt and Driven Pulley
  101
- Removal
  101
- Installation
  103
- Disassembly
  104
- Drive Pulley
  104
- Inspection
  105
- Movable Drive Face/Slide Pieces/Drive Pulley Face
  105
- Weight Rollers
  105
- Assembly
  106
- Disassembly
  107
- Driven Pulley
  107
- Inspection
  108
- Assembly
  109
9. Final Reduction

110
- Schematic Drawing
  111
- General Instructions
  112
- Service Information
  112
- Special Tools
  112
- Specifications
  112
- Torque Values
  112
- Troubleshooting
  112
- Draining
  113
- Gear Oil
  113
- Filling
  115
- Final Reduction
  117
- Removal
  117
- Inspection
  118
- Installation
  119
- Bearing Replacement
  120
- Transmission Case
  120
- Transmission Case Cover
  120
Table of Contents

121
- Generator & Starter Clutch
  122
- GENERATOR & STARTER CLUTCH Downtown 125I
  122
- Alternator Stator
  124
- Removal
  124
- Inspection
  125
- Installation
  125
- Removal
  126
- Starter Clutch
  126
- Inspection
  127
- Installation
  128
Crank Case & Crank Shaft

129
- Crank Case & Crank Shaft
  130
- Schematic Drawing
  130
- General Instructions
  131
- Service Information
  131
- Specifications
  131
- Torque Values
  131
- Troubleshooting
  131
- Crankcase
  132
- Splitting
  132
- Crankshaft Inspection
  135
- Crankcase Assembly
  136
12. Cooling System

138
- Cooling System
  139
- General Instructions
  139
- Schematic Drawing
  139
- Service Information
  139
- Special Tool
  139
- Torque Values
  139
- Specifications
  140
- Troubleshooting
  140
- Coolant Gravity
  141
- Coolant Mixture (with Anti-Rust and Anti-Freezing Effects)
  141
- Radiator Cap Inspection
  142
- Coolant Replacement
  143
- Preparation
  143
- Replacement
  143
- Air Bleeding
  144
- Radiator
  145
- Removal
  145
- Inspection
  146
- Installation
  146
- Mechanical Seal (Water Seal) Inspection
  147
- Water Pump
  147
- Water Pump/Impeller Removal
  147
- Water Pump Shaft Removal
  149
- Water Pump/Impeller Installation
  150
- Inspection
  151
- Removal
  151
- Water Temperature Sensor
  151
- Installation
  152
- Disassembly
  153
- Installation
  153
- Removal
  153
- Thermostat
  153
- Assembly
  154
- Inspection
  154
14. Front Assembly

155
- Front Assembly
  156
- Schematic Drawing
  156
- General Instructions
  158
- Service Information
  158
- Specifications
  158
- Torque Values
  158
- Special Tools
  159
- Troubleshooting
  159
- Front Wheel
  160
- Inspection
  160
- Removal
  160
- Disassembly
  161
- Assembly
  162
- Brake Fluid Draining
  163
- Check
  163
- Fluid Replacement/Air Bleeding
  163
- Front Brake Fluid
  163
- Brake Fluid Filling/Air Bleeding
  164
- Brake Pad Replacement
  165
- Front Brake Pad
  165
- Brake Disc
  166
- Inspection
  166
- Removal
  166
- Handlebar
  167
- Installation
  167
- Removal
  167
- Disassembly
  168
- Assembly
  169
- Front Shock Absorber
  170
- Inspection
  170
- Removal
  170
- Removal
  171
- Steering Stem
  171
- Installation
  173
15. Rear Assembly

175
- Schematic Drawing
  176
- General Instructions
  177
- Service Information
  177
- Specifications
  177
- Torque Values
  177
- Troubleshooting
  178
- Inspection
  179
- Rear Brake
  179
- Rear Brake Caliper Removal
  179
- Disassembly
  180
- Assembly
  181
- Installation
  182
- Inspection
  183
- Rear Fork
  183
- Removal
  183
- Inspection
  184
- Installation
  184
- Rear Wheel
  184
- Removal
  184
- Installation
  185
- Rear Shock Absorber
  185
- Removal
  185
16. Battery/Charging System

186
- Charging System Layout
  187
- General Instructions
  188
- Service Information
  188
- Specifications
  189
- Troubleshooting
  189
- Battery
  190
- Installation
  190
- Removal
  190
- Voltage Inspection
  190
- Battery Charging
  191
- Charging System Inspection
  192
- Charging Voltage
  192
- Inspection
  193
- Regulator/Rectifier
  193
- Removal/Installation
  194
18. Starting System

195
- Starting System Layout
  196
- General Instructions
  197
- Service Information
  197
- Torque Values
  197
- Troubleshooting
  197
- Inspection
  198
- Installation
  198
- Removal
  198
- Start Motor
  198
- Inspection
  199
- Installation
  199
- Removal
  199
- Starter Relay
  199
20. Anti-Lock Brake System (Abs)

220
- Abs
  221
- Indicator Light
  221
- Introduction
  221
- Troubleshooting Outline
  223
- Installation
  226
- Removal
  226
- Diagnostic Tool
  227
- PC Version
  227
- Diagnostic Tool Operation
  228
- Operation Instructions
  228
- Connection
  229
- DTC Displayed
  230
- DTC Inspect
  230
- Air Bleeding
  231
- Data Analyze
  231
- DTC Cleared
  231
- Bosch ABS91 DTC List
  232
- DTC List
  232
21. Eec System

233
- Diagram
  234
- Evaporates Emission Control System Diagram
  234
- Pollution Emission System Diagram
  234
- Crankcase Emission Control System
  235
- Evaporative Emission Control System
  235
- Exhaust Emission Control System
  235
- Noise Exhaust Emission Control System
  235
- System Introduction
  235
- Function
  236
- Trouble Shooting
  236
- Maintenance Schedule
  237
- Maintenance Information
  239
- Canister
  240
- Inspection
  240
- Removal
  240
- Installation of Canister
  241
- Air Filter
  242
- Inspection
  242
- Inspection of Emission System
  243
- Oxygen Sensor
  244

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