KYMCO AHG5 User manual

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.
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
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
85
Rear Wheel
106
Total
191
Max. weight capacity (kg)
Front Wheel
77
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
Close
37°ABDC
Exhaust
Open
10°BBDC
Close
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
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

1. Quick Reference
1-10
7. Components Location
Front brake
fluid reservoir
Rear brake fluid hose
Rear brake
fluid reservoir
USB charger wires
Right handlebar
switch
Front brake fluid hose
Left handlebar
switch
Start relay
Fuse box
OBD connector
Coolant filling cap

1. Quick Reference
1-11
Fuel pump
Throttle body
ISC (Idle air bypass valve)
Fuel injector
PPTS (Intake air
temp/MAP/TPS)
Fuel hose
Spark plug
cap
Thermostat
Throttle cables
Inductive ignition
coil
Rectifier/Regulator
Canister
Hazard light
controller

1. Quick Reference
1-12
USB charger
controller
Long-distance
antenna
Tilt switch
KEYLESS
controller
Ignition
switch
Engine oil
indicator
controller
ECU
Headlight
controller
Coolant
reserve tank
電瓶盒
Start relay
ABS controller
Coolant
radiator

1. Quick Reference
1-13
8. General Troubleshooting
8.1. Engine lacks power

1. Quick Reference
1-14

1. Quick Reference
1-15
8.2. Engine will not stat or is hard to start

1. Quick Reference
1-16
8.3. Poor handling

1. Quick Reference
1-17
8.4. Poor performance at high speed

1. Quick Reference
1-18
8.5. Poor performance at low and idle speed

2. External components, Exhaust pipe
2-0
2