KYMCO AHG1 Instruction Manual

Foreword
This service manual provides maintenance
guidelines for KYMCO AHG1 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.
ALL RIGHTS RESERVED. ANY REPRODUCTION
OR UNAUTHORIZED USE WITHOUT THE
WRITTEN PERMISSION OF KWANG YANG
MOTOR CO., LTD.IS STRICTLY PROHIBITED.
© KWANG YANG MOTOR CO., LTD.
By the Technology Training Section
First Edition –Jun. 2021
Quick Reference
1
External Components
2
Periodic Maintenance
3
Engine
Lubrication System
4
Engine Removal/ Installation
5
Cylinder Head/ Valve
6
Cylinder/ Piston
7
Drive & Driven Pulley
8
Final Reduction
9
Alternator / Start Clutch
10
Crankcase/ Crankshaft
11
Cooling System
12
Fi System
13
Frame
Front Assembly
14
Rear Assembly
15
Electrical
Battery & Charging System
16
Ignition System
17
Starting System
18
Switches/ Lights
19
EEC
EEC System
20
ABS
ABS/TCS
21

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

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
AHG1
Overall Length (mm)
2165
Overall Width (mm)
780
Overall High (mm)
1290
Wheel Base (mm)
1545
Engine Type
Four Stroke OHC
Displacement (cc)
124
Fuel Recommended
None lead 92#
Curb Weight (kg)
Front Wheel
80
Rear Wheel
99
Total
178
Max. weight capacity
(kg)
Front Wheel
125
Rear Wheel
219
Total
344
Tires
Front Wheel
120/80-14 58S
Rear Wheel
150/70-13 64S
Ground clearance (mm)
135
Performance
Braking distance (m)
7.9m/ 40km/h
Min. turning radius (mm)
R/L 2545
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)
⌀54*54.3
Compression ratio
11.2±0.2
Compression pressure (kgf/cm2)
15
Max. Horsepower (ps/rpm)
21.0/7500
Max. Torque (kg-m/rpm)
1.12/7000
Valve clearance (cold)
(mm)
Intake
0.1
Exhaust
0.1
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
1.2L
Exchange
1.0L
Gear Oil
Disassembly
0.13L
Exchange
0.12L
Cooling System
Cooling Type
Liquid Cooling
Coolant
capacity
Coolant radiator
0.87L
Reserve tank
0.49L
Fi System
Air cleaner type & No
Paper element, wet
Fuel capacity
12.5L
Throttle
Body
Type
M4C
Venturi dia (mm)
⌀27
Throttle Valve
Butterfly type
Electrical Equipment
Ignition System
Type
Inductive Ignition
Coil
Ignition Timing
ECU Controls
Spark plug
Spec
NGK-CPR7EA
Gap (mm)
0.7～0.8
Battery Capacity
12V 8Ah
Power Drive System
Clutch
Type
Dry Multi-clutch
Transmission
Gear
Type
CVT
Operation
Automatic
centrifugal type
Reduction
Gear
Type
2-staged Reduction
Reduction
Ratio
1 st
0.83~2.2
2 nd
10.41
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
Dual damper unit
swing arm
Chassis Type
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
General Torque Value4.1.
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
Engine4.2.
No.
ITEM
TORQUE
Remarks
DWG No.
N-m
Kgf-m
1
Bolt B Stud 8*210
6.9~10.8
0.7~1.1
Stud side
90032-KHD6-9000
2
Bolt B Stud 8*218
6.9~10.8
0.7~1.1
Stud side
90031-KHD6-9000
3
Tappet ADJ hole cap
9.8~19.6
1.0~2.0
12361-GFY6-9010
4
L Cover
7.8~8.8
0.8~0.9
9000A-KTDT-9000
5
Tube/ wire clamper
7.8~8.8
0.8~0.9
9000A-KTDT-9000
6
Cylinder head
6.9~10.8
0.7~1.1
Inlet pipe area
92900-06050-0B
6.9~10.8
0.7~1.1
EX pipe area
90033-GFY6-9000
6.9~10.8
0.7~1.1
A/I pipe area
90033-GFY6-9410
17.7~21.6
1.8~2.2
94050-08080
7
Cylinder head cover
7.8~8.8
0.8~0.9
9000B-KHD6-9000
8
Cam shaft set plate
9.8~13.7
1.0~1.4
9000z-GFY6-9010
9
Breather separator plate
2.5~3.9
0.25~0.4
93903-34120
10
Tappet ADJ nut
6.9~10.8
0.7~1.1
Apply oil
90206-0A01-0010
11
Cam chain tensioner pivot
7.8~11.8
0.8~1.2
14531-GLR0-0010
12
Tensioner lifter
9.8~13.7
1.0~1.4
90001-GBHB-6610
13
Tensioner lifter
3.4~4.9
0.35~0.5
90005-KAW1-9010
14
Oil pump
6.9~10.8
0.7~1.1
96001-06028-08
15
Reed valve
9.8~13.7
1.0~1.4
95701-06040-00
95701-06025-00
16
A/I pipe
9.8~13.7
1.0~1.4
90304-4H38-0010
17
Mission cover
9.8~13.7
1.0~1.4
96001-06025-08
96001-06032-08
18
L case gear oil drain bolt
7.8~11.8
0.8~1.2
95701-08012-08
19
L case engine oil drain bolt
19.6~29.4
2.0~3.0
9052A-LEB1-9000
20
Drive face
53.9~63.7
5.5~6.5
Apply oil
94050-12000
21
Clutch outer
49~58.9
5.0~6.0
94050-10080
22
Drive plate COMP
49~58.9
5.0~6.0
90202-IG87-0010
23
ACG flywheel
49~58.9
5.0~6.0
94080-12000
24
Spark plug
9.8~13.7
1.0~1.4
98056-57713-00
98056-57723-02
25
One-way clutch
17.6~24.5
1.8~2.5
96600-08015-10
26
Water pump impeller
9.8~13.7
1.0~1.4
L.H. screw
19215-KHE7-9000
27
Thermo unit
7.8~11.8
0.8~1.2
37750-PAC1-0050
28
ACG stator
7.8~9.8
0.8~1.0
92101-05032-0H
29
ACG pulse
3.9~6.8
0.4~0.7
93500-05016-0H
30
R cover hole cap
9.8~19.6
1.0~2.0
9008A-PTS1-9000
31
Others
7.8~11.8
0.8~1.2
32
Oxygen sensor
19.6~29.4
2.0~3.0
39450-LEA6-8000

1. Quick Reference
1-7
Frame4.3.
No.
ITEM
TORQUE
Remarks
DWG No.
N-m
Kgf-m
1
Steering
Nut STRG, Stem lock
58.8~68.6
6.0~7.0
---
90106-PUA3-B000-IN
BOT, bridge (Fork pipe)
23.5~29.4
2.4~3.0
---
95801-08040-08G
Stem lock
58.8~63.7
6.0~6.5
---
50306-IF96-C000
Race nut (Head)
17.7~21.6
1.8~2.2
---
53220-LBA2
Handle
49.0~58.8
5.0~6.0
---
94001-1008G-0S
2
Wheel
RR wheel axle nut
107.9~127.5
11.0~13.0
U-nut
90305-KKAK-C000
FR wheel axle
14.7~24.5
1.5~2.5
---
44301-LEA7-C000
3
Suspension
FR fork bolt
19.6~25.5
2.0~2.6
---
96700-KED9-C000
RR CUSH. upper
34.3~44.1
3.5~4.5
Flange bolt
95801-10040-07G
RR CUSH. lower
34.3~44.1
3.5~4.5
Flange bolt
95801-10040-07G
4
Brake
FR caliper
29.4~39.2
3.0~4.0
---
90122-LEA7-C100
RR caliper
29.4~39.2
3.0~4.0
---
90122-LEA7-C100
Brake oil bolt
29.4~39.2
3.0~4.0
---
90145-9A61-C100
Brake oil bolt (ABS-M)
29.4~39.2
3.0~4.0
---
90145-LFH1-E000
M/C holder
9.8~13.7
1.0~1.4
Flange bolt
95701-06028-06
M/C cap screw
1.2~2.0
0.12~0.2
---
93600-04012-IG
C/P bleeder
3.9~6.9
0.4~0.7
---
43352-LBA2-C000
43352-KKD6-C000
Disk bolt
31.4~37.3
3.2~3.8
---
90105-KCR3-C200
90105-LEA7-C100
Modulator, ABS bolt
7.6~8.1
0.77~0.83
---
90113-LGE5-C100
90114-LGE5-C100
5
ENG. Hanger
Frame side
58.8~68.6
6.0~7.0
U-nut
90305-MAA1-C100
ENG side
44.1~53.9
4.5~5.5
U-nut
90304-GHE8-C100
6
Muffler
EXH. Muffler
17.7~21.6
1.8~2.2
---
90033-GFY6-C000
Muffler bracket/ RR fork
39.2~49.0
4.0~5.0
Flange bolt
90309-GFW0-9020-M1
7
Rear fork
RR fork/ ENG case
29.4~39.2
3.0~4.0
Flange bolt
95801-10075-07G
8
Others
SPDMT sensor cable
9.8~13.7
1.0~1.4
---
96001-06012-06
IGN coil
9.8~13.7
1.0~1.4
---
94050-06080
Oxygen sensor
19.6~29.4
2.0~3.0
---
---
Main stand
29.4~39.2
3.0~4.0
U-nut
90304-LEA1-C000
Fuel pump
2.7~4.1
0.28~0.42
Flange bolt
95701-LDF2-8000
RR carrier
19.6~27.5
2.0~2.8
---
90106-KKC4-9000
Start relay
2.5~3.4
0.25~0.35
---
94050-06080

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