KYMCO AHG5 Manuale utente

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 with an overall

explanation of the exploded diagram, system

diagram, maintenance troubleshooting, and

diagnosis description.

ALL INFORMATION, GRAPHICS AND

SPECIFICATIONS CONTAINED IN THIS

DOCUMENT ARE BASED ON THE LATEST

PRODUCT INFORMATION AVAILABLE AT THE

TIME OF MANUFACTURE. KWANG YANG

MOTOR CO., LTD. RESERVES THE RIGHT TO

MAKE CHANGES AT ANY TIME WITHOUT

NOTICE AND WITHOUT INCURRING ANY

OBLIGATION WHATEVER.

OR UNAUTHORIZED USE WITHOUT THE

WRITTEN PERMISSION OF KWANG YANG

MOTOR CO., LTD.IS STRICTLY PROHIBITED.

By the Technology Training Section

First Edition –Jun. 2021

Quick Reference

External Components

Periodic Maintenance

Engine

Lubrication System

Engine Removal/ Installation

Cylinder Head/ Valve

Cylinder/ Piston

Drive & Driven Pulley

Final Reduction

Alternator / Start Clutch

Crankcase/ Crankshaft

Cooling System

Fi System

Frame

Front Assembly

Rear Assembly

Electrical

Battery & Charging System

Ignition System

Starting System

Switches/ Lights

EEC

EEC System

ABS

ABS/TCS

1. Quick Reference

1-1

Quick Reference

1. Engine /Frame Serial Number............................................................................................................... 2

2. Specifications.............................................................................................................................................. 3

3. Operation precautions ............................................................................................................................ 4

4. Torque............................................................................................................................................................ 5

4.1. General Torque Value .................................................................................................................. 5

4.2. Engine............................................................................................................................................... 6

4.3. Frame ................................................................................................................................................ 7

5. Special Tool.................................................................................................................................................. 8

6. LUBRICATION POINTS-FRAME............................................................................................................. 9

7. Components Location ...........................................................................................................................10

8. General Troubleshooting......................................................................................................................13

8.1. Engine lacks power ....................................................................................................................13

8.2. Engine will not stat or is hard to start..................................................................................15

8.3. Poor handling...............................................................................................................................16

8.4. Poor performance at high speed..........................................................................................17

8.5. Poor performance at low and idle speed...........................................................................18

1. Quick Reference

1-2

1. Engine /Frame Serial Number

Frame Serial Number

Engine Serial Number

1. Quick Reference

1-3

2. Specifications

Model Code

SK64DA

Model Name

DT X360

Overall Length (mm)

2165

Overall Width (mm)

780

Overall High (mm)

1285

Wheel Base (mm)

1545

Engine Type

Four Stroke OHC

Displacement (cc)

320.6

Fuel Recommended

None lead 92#

Curb Weight (kg)

Front Wheel

Rear Wheel

106

Total

191

Max. weight capacity (kg)

Front Wheel

Rear Wheel

106

Total

183

Tires

Front Wheel

120/80-14 58S

Rear Wheel

150/70-13 64S

Ground clearance (mm)

140

Performance

Braking distance (m)

7.9m/ 40km/h

Min. turning radius (m)

R/L 2500

Engine

Starting system

Starting motor

Type

Gasoline,

4-stroke

Cylinder arrangement

Single Cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

OHC

Bore x stroke (mm)

⌀75.3*72.0

Compression ratio

10.7：1

Compression pressure (kgf/cm2)

12.0

Max. Horsepower (kW/rpm)

21.0/7500

Max. Torque (N∙m/rpm)

29.3/5750

Valve

timing

Intake

Open

10°ATDC

37°ABDC

Exhaust

Open

10°BBDC

40°ATDC

Valve clearance (cold)

(mm)

Intake

0.12

Exhaust

0.12

Idle speed (rpm)

1700±100

Lubricate

System

Lubrication type

Forced pressure

& Wet sump

Oil Pump Type

Inner/outer rotor

type

Oil Filter Type

Full-flow filtration

Engine

Oil

Disassembly

1.5L

Exchange

1.3L

Gear Oil

Disassembly

0.23L

Exchange

0.20L

Cooling Type

Liquid Cooling

Fi System

Air cleaner type & No

Paper element, wet

Fuel capacity

12.5L

Throttle

Body

Type

M4C

Venturi dia (mm)

⌀34.5

Throttle Valve

Butterfly type

Electrical Equipment

Ignition System

Type

Inductive Ignition

Coil

Ignition Timing

ECU Controls

Spark

plug

Spec

NGK-CR7E

Gap (mm)

0.7～0.8

Battery Capacity

12V 11.8Ah (20HR)

Power Drive System

Clutch

Type

Dry Multi-clutch

Transmission

Gear

Type

CVT

Operation

Automatic

centrifugal type

Reduction

Gear

Type

2-staged

Reduction

Ratio

1 st

2.65～0.78

2 nd

7.222

Moving Device

Wheel Type

Tubeless

Rim Material

Aluminum

Tire Pressure (kgf/cm2)

(2 People)

Front Wheel

2.0

Rear Wheel

2.25

Turning Angle

Left

40°

Right

40°

Brake System Type

Front

Single Disk （260）

Rear

Single Disk （240）

Damping

Suspension Type

Front

TELESCOPE

Rear

SWING ARM

車架型式

UNDER BONE

1. Quick Reference

1-4

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.

We recommend that you use genuine

lubricants and parts.

Please use dedicated or common tools when

working on any assembly and disassembly of

the parts during service operation.

After dismantling, the parts to be inspected

should be cleaned. During assembly, apply oil

to the frictional surface between parts for

lubrication.

Apply recommended lubricant on the specified

positions.

1. Quick Reference

1-5

4. Torque

4.1. General Torque Value

Item

Torque (kgf∙m)

Item

Torque (kgf∙m)

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

5mm Tapping screw (Point)

0.35~0.5

12mm Bolt/ Nut

5.0~6.0

6mm screw /SH bolt

0.7~1.1

14mm Bolt/ Nut

6.0~8.0

6mm Flange bolt/ Nut

1.0~1.4

8mm Flange bolt/ Nut

2.4~3.0

10mm Flange bolt/ Nut

3.5~4.5

1. Quick Reference

1-6

4.2. Engine

1. Quick Reference

1-7

4.3. Frame

1. Quick Reference

1-8

5. Special Tool

Tool Name

Tool No.

Performance

Photo

Flywheel Puller

A120E00003

A.C. generator flywheel

removal

Tappet Adjuster

A120E00012

Tappet adjustment

Oil Seal & Bearing

Installer

A120E00014

Oil seal & bearing installing

Flywheel Holder

A120E00021

A.C. generator flywheel

holding

#41 Nut & Fitting

A120E00028

Clutch disassembly &

assembly

Thread Protector

A120E00029

Protecting the crankshaft’s

thread

Valve Cotter Installer

A120E00051

Valve cotter installation

Clutch Spring

Compressor

A120E00053

Clutch disassembly &

assembly

Shaft Collar Puller

A120E00088

Bearing crankcase removal

Shaft Collar Driver

A120E00091

Bearing crankcase removal

Shaft Collar Installer

A120E00092

Bearing crankcase installation

Bearing Puller

A120E00093

Bearing removal

Lock Nut Socket

Wrench

A120F00002

Steering stem removal or

installation

Electric Repair Kit

A120F00032

Fuel injection system

diagnosis

1. Quick Reference

1-9

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

Cable

Brake Lever

Pivot

Front Wheel Axle

Center Stand Shaft/

Side Stand

Seat Lock

Rear Wheel Axle

Indice

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