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KYMCO AHG5 Manuals
Manuals and User Guides for KYMCO AHG5. We have
1
KYMCO AHG5 manual available for free PDF download: Service Manual
KYMCO AHG5 Service Manual (363 pages)
Brand:
KYMCO
| Category:
Motorcycle
| Size: 32.54 MB
Table of Contents
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
General Troubleshooting
14
Engine Lacks Power
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
Service Information
23
General Instructions
23
Torque Value
23
Troubleshooting
23
External Components Removal
24
Wind Screen
24
Front Cover
24
Headlight Assy
24
Side Covers
25
Seat
26
Luggage Box
26
Rear Carriers
26
Center Cover
26
Tail Light Assy
27
Floor Panel Assy
27
Meter Cover
28
Leg Shield
30
Handlebar Covers
30
Front Fender
31
Rear Fenders
31
Undercover
32
Muffler Cover
32
Exhaust Assembly
33
Muffler
33
Exhaust Pipe
33
Periodic Maintenance
36
Service Information
36
Warning
36
Specifications
36
Maintenance Schedule
37
Fuel Line
39
Throttle Operation
39
Air Cleaner
40
Spark Plug
40
Valve Clearance
41
Inspection
41
Adjustment
43
Cylinder Compression
43
Engine Oil
44
Engine Oil Recommendation
44
Engine Oil Level Check
44
Engine Oil Replacement
45
Oil Strainer Screen Clean
46
Oil Filter Replacement
47
Transmission Oil
48
Oil Change
48
Idle Speed
49
Drive Belt
49
Clutch Shoe Wear
49
Headlight Aim
50
Coolant
50
Inspection
50
Add Coolant
50
Coolant Recommendation
51
Brake
52
Brake Fluid
52
Brake Pad Wear
52
Brake Levers
53
Nuts/Bolts/Fasteners
53
Wheels/Tires
54
Tire Pressure
54
Steering Handlebar
54
Suspension
55
Rear Suspension Adjustment
55
Side Stand
56
Functional Check
56
Lubrication Diagram
59
Service Information
60
General Instructions
60
Specifications
60
Troubleshooting
61
Engine Oil
62
Oil Pump
62
Removal
62
Disassembly
63
Inspection
64
Assembly
64
Installation
65
Schematic Drawing
73
Service Information
74
General Instructions
74
Specifications
74
Torque Values
75
Special Tools
75
Troubleshooting
76
Cylinder Head Cover
77
Removal
77
Camshaft
80
Removal
80
Inspection
84
Camshaft Installation
87
Cylinder Head
95
Removal
95
Valves
103
Removal
103
Inspection
105
Schematic Drawing
110
Service Information
111
General Instructions
111
Specifications
111
Troubleshooting
112
Cylinder Block
113
Removal
113
Inspection
118
Assembly
123
Schematic Drawing
128
Service Information
129
General Instructions
129
Specifications
129
Torque Values
129
Special Tools
129
Troubleshooting
130
Belt Case
131
Removal
131
Inspection
134
CVT Removal
136
Pulleys and Belt
136
Drive Pulley Disassembly
140
Clutch Disassembly
142
Driven Pulley Disassembly
148
Bearing Replacement
151
CVT Installation
154
Driven Pulley
154
Clutch
156
Drive Pulley
161
Pulleys and Belt
162
Schematic Drawing
168
Service Information
169
General Instructions
169
Specifications
169
Torque Values
169
Special Tools
169
Troubleshooting
169
Gear Oil
170
Draining
170
Filling
172
Final Reduction
174
Disassembly
174
Inspection
178
Installation
180
Schematic Drawing
184
Service Information
185
General Instructions
185
Specifications
185
Special Tools
185
Torque Values
185
Troubleshooting
185
Generator and Starter Clutch
186
Removal
186
Stator and Pulsar Coil/Crank Position Sensor
190
Flywheel
191
Starter Clutch
195
Installation
197
Starter Clutch
197
Flywheel
198
Stator and Crank Position Sensor
201
Generator Cover
202
Schematic Drawing
207
Service Information
208
General Instructions
208
Specifications
208
Torque Values
208
Troubleshooting
208
Crankcase
209
Splitting
209
Assembly
215
Crankshaft
219
Removal
219
Crankshaft Inspection
220
Crankshaft Bearings
221
Cooling System
223
Schematic Drawing
223
Service Information
223
General Instructions
223
Special Tool
223
Torque Values
223
Troubleshooting
224
Specifications
224
Coolant Gravity
225
Coolant Mixture (with Anti-Rust and Anti-Freezing Effects)
225
Radiator Cap Inspection
226
Coolant Replacement
227
Preparation
227
Replacement
227
Air Bleeding
228
Radiator
229
Removal
229
Inspection
230
Installation
230
Water Pump
231
Mechanical Seal (Water Seal) Inspection
231
Water Pump/Impeller Removal
231
Water Pump Shaft Removal
233
Water Pump/Impeller Installation
234
Water Temperature Sensor
235
Removal
235
Inspection
235
Installation
236
Thermostat
237
Removal
237
Installation
237
Disassembly
237
Inspection
238
Assembly
238
System Diagram
240
Ems Components Location
241
Ems Components Introduction
243
ECU (Electronic Control Unit)
243
Fuel Injector
243
Fuel Pump
243
Idle Air Bypass Valve or ISC (Idle Speed Control)
244
Inductive Ignition Coil
244
ETS (Engine Temperature Sensor)
244
PPTS (MAP Sensor (Manifold Absolute Pressure)/ TPS (Throttle Position Sensor)/Inlet Air Temp Sensor)
245
CPS, Crank Position Sensor
245
Oxygen Sensor
246
Engine Components
247
Flywheel with Encoder Teeth
247
Fuel Pressure Regulator
247
Exhaust Pipe a
247
Service Information
248
Fi System Service Information
248
General Instructions
250
Troubleshooting
251
Obd P-Code List
255
Checking Component
258
Ecu Wiring
259
Diagnostic Standard Specifications
260
Schematic Drawing
264
Service Information
266
General Instructions
266
Specifications
266
Torque Values
266
Special Tools
267
Troubleshooting
267
Front Wheel
268
Removal
268
Inspection
268
Disassembly
269
Assembly
270
Front Brake Fluid
271
Check
271
Fluid Replacement/Air Bleeding
271
Brake Fluid Draining
271
Brake Fluid Filling/Air Bleeding
272
Front Brake Pad
273
Brake Pad Replacement
273
Brake Disc
274
Inspection
274
Removal
274
Handlebar
275
Removal
275
Installation
275
Disassembly
276
Assembly
277
Front Shock Absorber
278
Removal
278
Inspection
278
Steering Stem
279
Removal
279
Installation
281
Schematic Drawing
284
Service Information
285
General Instructions
285
Specifications
285
Torque Values
285
Troubleshooting
286
Rear Brake
287
Rear Brake Caliper Removal
287
Inspection
287
Disassembly
288
Assembly
289
Installation
290
Rear Fork
291
Removal
291
Inspection
291
Rear Wheel
292
Removal
292
Inspection
292
Installation
292
Rear Shock Absorber
293
Removal
293
Installation
293
Charging System Layout
295
Service Information
296
General Instructions
296
Specifications
297
Troubleshooting
297
Battery
298
Removal
298
Installation
298
Voltage Inspection
298
Battery Charging
299
Charging System Inspection
300
Charging Voltage
300
Regulator/Rectifier
301
Inspection
301
Removal/Installation
302
Service Information
305
General Instructions
305
Specifications
305
Troubleshooting
306
Spark Plug
307
Inspection
307
Ignition Coil
307
Removal
307
Inspection
308
Crank Position Sensor
308
Rollover Sensor
309
Inspection
309
Removal
309
Ecu
310
Removal/Installation
310
Starting System Layout
312
Service Information
313
General Instructions
313
Torque Values
313
Troubleshooting
313
Start Motor
314
Inspection
314
Installation
314
Starter Relay
315
Removal
315
Installation
315
Inspection
315
Service Information
319
General Instructions
319
Specification
319
Troubleshooting
319
Front Lights Assy
320
Headlight
320
Front Turn Signal Lights
320
Rear Lights Assy
321
Tail Light Assy
321
License Plate Light
322
Speed Sensors
322
Front Speed Sensor
322
Inspection
323
Switches
324
Brake Light Switch
324
Ignition Switch
324
Right Handlebar Switch
325
Left Handlebar Switch
326
Luggage Box Light Sensor
327
Inspection
327
Oil Pressure Sensor
328
Inspection
328
Removal
329
Installation
329
Fuel Pump
330
Removal
330
Inspection
331
Installation
332
Side Stand Switch
333
Inspection
333
Removal
333
Installation
333
Horn
334
Abs
337
Indicator Light
337
Introduction
337
Troubleshooting Outline
339
Removal
342
Installation
342
Diagnostic Tool
343
PC Version
343
Diagnostic Tool Operation
344
Operation Instructions
344
Connection
345
DTC Inspect
346
DTC Displayed
346
DTC Cleared
347
Data Analyze
347
Air Bleeding
347
DTC List
348
Bosch ABS91 DTC List
348
TCS DTC List
348
Introduction to KYMCO TCS System
349
Diagram
353
Evaporates Emission Control System Diagram
353
Pollution Emission System Diagram
353
System Introduction
354
Evaporative Emission Control System
354
Crankcase Emission Control System
354
Exhaust Emission Control System
354
Noise Exhaust Emission Control System
354
Function
355
Trouble Shooting
355
Maintenance Schedule
356
Maintenance Schedule Legend
356
Maintenance Information
358
Canister
359
Removal
359
Inspection
359
Installation of Canister
360
Inspection
361
Air Filter
361
Inspection of Emission System
362
Oxygen Sensor
363
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