KYMCO AK 550 User manual

KYMCO Repair Manual AK 550
KYMCO AK 550 Service Manual
Using this manual
This manual has been designed to assist trained mechanics in servicing the
models listed above. If you do not have the proper training or tools to perform a
particular task it is best if you seek out a service professional.
This manual was written using the latest information available at the time of
publication. Illustrations in this manual are shown to help you with the basics of
performing the jobs listed. The pictures in this manual may not depict the actual
vehicle you’re working on, however the procedures will be similar.
Inexperienced technicians without the correct tools and knowledge may not be
able to perform these jobs as intended. Caution needs to be taken for the vehicle
and its operator as serious injury can occur. Always read a procedure in its
entirety before attempting any repairs.
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KYMCO Repair Manual AK 550
KYMCO reserves all rights to this publication and does not permit the
reproduction or use of this publication, in full or in part, in any manner without our
express written permission. No trademark or patent liability is assumed with
respect to the use of the information contained in this manual.
While the instructions, photographs and illustrations in this manual have been
reviewed for accuracy it is up to the individual performing the procedures to use
good judgement when performing any procedures described. Every precaution
has been taken in the manufacture of this manual however the publisher
assumes no responsibility for errors and omissions. Furthermore, no liability or
responsibility is assumed for damages to property or injury to persons resulting
from the use of the information contained in this guide. Use of this information to
perform service procedures is done entirely at your own risk.
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KYMCO Repair Manual AK 550
1. Quick Reference
Component Location ..........................................................1-2
Special Tools .......................................................................1-5
Specifications ......................................................................1-7
Fuel Injection System .........................................................1-12
Fuel Injection System Failure Code ..................................1-13
Torque Specifications .........................................................1-15
Troubleshooting ..................................................................1-18
VIN and Engine Number Location .....................................1-23
2.Periodic Maintenance
Maintenance Schedule .......................................................2-2
Air Filter Servicing ..............................................................2-4
Brake Fluid ...........................................................................2-6
Brake Inspection .................................................................2-10
Coolant .................................................................................2-14
Engine Oil .............................................................................2-18
General Lubrication ............................................................2-23
Side Stand ............................................................................2-24
Spark Plug ............................................................................2-25
Engine Compression Test ..................................................2-27
Steering Inspection...............................................................2-28
Throttle Free Play ................................................................2-29
Parking Brake ......................................................................2-30
Light Inspection ..................................................................2-32
Tires ......................................................................................2-33
TPMS Tire Pressure Management System.........................2-34
Drive Belt Inspection ..........................................................2-39
Drive Belt Tension Adjustment ..........................................2-40
Valve Clearance Adjustment................................................2-45
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KYMCO Repair Manual AK 550
3.External Components
General Instructions........................................................................3-2
Dismantled and assembly order.....................................................3-3
Windscreen Cover/Windscreen/ Windscreen Holder....................3-4
Front Meter Cover/Back Mirror/Mats Of Floor And Leg Shield....3-5
Side Cover/Side Skirt Set................................................................3-6
Panel Floor .......................................................................................3-7
Seat...................................................................................................3-8
Luggage Box....................................................................................3-9
Center Cover B/Side Board A.........................................................3-10
Front Cover Set................................................................................3-11
Meter Cover Set ...............................................................................3-13
Leg Shield Set..................................................................................3-14
Front Inner Fender/Under Cowl Set................................................3-15
Front Fender Set..............................................................................3-16
Up And Low Handle Cover..............................................................3-17
Rear Carriers/Rear Center Cover....................................................3-18
Rear Fender Set...............................................................................3-19
Body Cover Set................................................................................3-20
Heat Shield.......................................................................................3-21
Exhaust System...............................................................................3-22
Muffler...............................................................................................3-23
Exhaust Pipe ....................................................................................3-24
O2 Sensor.........................................................................................3-25
Side Stand........................................................................................3-26
Center Stand ....................................................................................3-27
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KYMCO Repair Manual AK 550
4.Engine
General Instructions ......................................................................4-1
Troubleshooting .............................................................................4-2
Engine Torque Specifications .......................................................4-5
Cylinder Head Cover ......................................................................4-7
Camshaft .........................................................................................4-11
Cylinder Head .................................................................................4-16
Cylinder ...........................................................................................4-19
Piston ..............................................................................................4-20
CVT ..................................................................................................4-21
Left Side Cover ...............................................................................4-36
Fly Wheel ........................................................................................4-38
Mission Box ....................................................................................4-42
Crankcase .......................................................................................4-53
Crankshaft/Balancer Gear/Plane Bearing ....................................4-56
Plane Bearing Selection ................................................................4-57
Engine Removal .............................................................................4-62
5.Cooling System
General Instructions ......................................................................5-1
Troubleshooting .............................................................................5-2
Coolant ............................................................................................5-3
Radiator ..........................................................................................5-7
Water Temperature Sensor (WTS) ................................................5-11
Water Pump ....................................................................................5-16
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KYMCO Repair Manual AK 550
6.Fuel Injection System
GENERAL INSTRUCTIONS ............................................................6-2
TROUBLESHOOTING .....................................................................6-3
COMPONENT LOCATION ..............................................................6-4
ECU .................................................................................................6-7
IGNITION COIL ...............................................................................6-9
SPARK PLUG .................................................................................6-10
CRANK POSITION SENSOR ..........................................................6-12
O2 SENSOR ....................................................................................6-13
RELAYS ..........................................................................................6-14
FUEL TANK .....................................................................................6-15
FUEL PUMP ....................................................................................6-21
FUEL INJECTOR ............................................................................6-27
THROTTLE BODY ...........................................................................6-32
T-MAP SENSOR .............................................................................6-36
TPS SENSOR....................................................................................6-37
ISC.....................................................................................................6-38
TILT SWITCH ..................................................................................6-40
WATER TEMPERATURE SENSOR ................................................6-42
SELF-DIAGNOSIS ............................................................................6-43
DIAGNOSTIC TOOL ........................................................................6-34
FAILURE CODE................................................................................6-50
DIAGNOSTIC REPORT ....................................................................6-57
7.CVT Continuously Variable Transmission
General Instructions ......................................................................7-1
Troubleshooting .............................................................................7-1
Schematic Drawing ........................................................................7-2
Belt Case .........................................................................................7-3
CVT Removal ..................................................................................7-8
Driven Pulley Disassembly ...........................................................7-10
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KYMCO Repair Manual AK 550
8.Final Drive
SCHEMATIC DRAWING .................................................................8-1
TROUBLESHOOTING .....................................................................8-2
FINAL REDUCTION ........................................................................8-3
9.Electrical Systems
General Instructions........................................................................9-1
Troubleshooting ..............................................................................9-3
Component Location.......................................................................9-8
Fuses ...............................................................................................9-12
ECU ................................................................................................9-13
Ignition System ..............................................................................9-15
Spark Plug ......................................................................................9-16
Charging System ...........................................................................9-19
Battery .............................................................................................9-23
Starting System ..............................................................................9-25
Relays .............................................................................................9-27
Switches .........................................................................................9-28
Lights ..............................................................................................9-42
Grip Heater .....................................................................................9-50
Horn .................................................................................................9-54
Meter Instrument ............................................................................9-55
noodoe Meter .................................................................................9-56
Tire Pressure Management System ..............................................9-58
Tire Pressure Management System ..............................................9-58
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KYMCO Repair Manual AK 550
10.Brakes
GENERAL INSTRUCTIONS ............................................................10-1
TROUBLESHOOTING .....................................................................10-2
DIAGRAM ........................................................................................10-3
Brake Pad Replacement ................................................................10-4
MASTER CYLINDERS......................................................................10-11
BLEED THE BRAKE FLUID ...........................................................10-12
PARKING BRAKE ............................................................................10-18
DISC BRAKE ...................................................................................10-19
ABS SYSTEM ..................................................................................10-20
ABS TROUBLESHOOTING OUTLINE ...........................................10-25
11.Steering
TROUBLESHOOTING .....................................................................11-2
Up And Low Handle Cover Removal ............................................11-2
Handlebar .......................................................................................11-3
Switch Housings and Throttle ......................................................11-4
Grips ................................................................................................11-9
Steering stem .................................................................................11-10
12.Front Suspension
TROUBLESHOOTING .....................................................................12-1
Front Fender Assy. Removal ........................................................12-2
Front Fork Removal .......................................................................12-3
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KYMCO Repair Manual AK 550
13.Rear Suspension
TROUBLESHOOTING ......................................................................13-1
Rear CUSHION .................................................................................13-2
Rear Wheel Removal .......................................................................13-3
Drive Belt Inspection.......................................................................13-13
Drive Belt Installation......................................................................13-14
Rear Fork..........................................................................................13-19
14.Wheels
This chapter covers the location and servicing of the wheels for the KYMCO AK
550 model.
Troubleshooting .............................................................................14-1
Front Wheel ....................................................................................14-2
Front Fender Assy. Removal ........................................................14-2
Front Wheel Disassembly .............................................................14-6
Bearing Replacement ....................................................................14-9
Rear Wheel .....................................................................................14-11
Rear Wheel Inspection ...................................................................14-17
Rear Wheel Installation ..................................................................14-22
Tire Pressure Sensor.......................................................................14-28
15.EEC SYSTEM
E.E.C System Introduction .................................................15-2
Function ...............................................................................15-3
Trouble Shooting .................................................................15-3
Air Filter Servicing ..............................................................15-4
Maintenance Information ....................................................15-5
Dismantle Of Canister .........................................................15-6
Oxygen Sensor ....................................................................15-9
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1.Quick Reference AK 550
1-1
1. Quick Reference
This chapter provides a quick reference source of technical specifications and
information for KYMCO AK 550 model.
Component Location ..........................................................1-2
Special Tools .......................................................................1-5
Specifications ......................................................................1-7
Fuel Injection System Failure Code ..................................1-12
Torque Specifications .........................................................1-14
Troubleshooting ..................................................................1-17
VIN and Engine Number Location .....................................1-22