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KYMCO Downtown 200i, Service Manual, Page: 9 / 230

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KYMCO Downtown 200i Service Manual Download Page 9

1. GENERAL INFORMATION

Downtown 200i

SPECIAL TOOLS

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

1-6

Summary of Contents for Downtown 200i

Page 1: ...200i By KWANG YANG Motor Co Ltd 1st Edition Dec 2009 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300 SK...

Page 2: ...ring methods of electrical equipment Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG...

Page 3: ..._____________________________________ ________________________________________________________________________________ ________________________________________________________________________________...

Page 4: ...1 GENERAL INFORMATION 1 1 DOWNTOWN 200i SERIAL NUMBER Location of Frame Serial Number inside luggage box Location of Vehicle Identification Number VIN Location of Engine Serial Number...

Page 5: ...ntake 0 10 Exhaust 0 10 Idle speed rpm 1600 100 rpm Cooling Type Liquid cooling Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor Oil filter type Full flow filtration Oil capac...

Page 6: ...ent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gear...

Page 7: ...1 GENERAL INFORMATION 1 4 DOWNTOWN 200i TORQUE VALUES...

Page 8: ...1 GENERAL INFORMATION 1 5 DOWNTOWN 200i TORQUE VALUES FRAME...

Page 9: ...assembly Thread Protector A120E00029 Protecting the crankshaft s thread Valve Cotter Installer A120E00051 Valve cotter installation Clutch Spring Compressor A120E00053 Clutch disassembly assembly Sha...

Page 10: ...ion 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 G...

Page 11: ...1 GENERAL INFORMATION 1 8 DOWNTOWN 200i CABLE HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Ignition Switch ECU Horn Winker Relay Hi Beam Relay Lo Beam Relay...

Page 12: ...1 GENERAL INFORMATION 1 9 DOWNTOWN 200i ISC Throttle Body TPS WTS Injector MAP Sensor...

Page 13: ...1 GENERAL INFORMATION 1 10 DOWNTOWN 200i Oil controller Fuel Pump Relay Ignition Coil Output Voltage Connector Coolant Reserve Tank...

Page 14: ...1 GENERAL INFORMATION 1 11 DOWNTOWN 200i Starter Relay Regulator Rectifier CPS O2 Sensor...

Page 15: ...______________________________________ __________________________________________________________________________________ ______________________________________________________________________________...

Page 16: ...ed Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler pipe nuts 1 8 2 2 kgf m Exhaust muffler brake RR Frok 3 2 3 8 kgf m RR fork Engine case...

Page 17: ...e Pull out the fastener INSTALLATION Let the center piece stick out toward the head so that the pawls close Insert the fastener into the installation hole Push in the head of center piece until it bec...

Page 18: ...nd the seat Installation is in the reverse order of removal LUGGAGE BOX Unlock the seat with the ignition key Open the seat Remove four bolts and the fastener on the right side of luggage box then lif...

Page 19: ...200i CENTER COVER Remove the luggage box Remove the center cover Installation is in the reverse order of removal Remove four bolts and then remove the rear carrier Center Cover During removal do not p...

Page 20: ...VER Remove the four screws and then remove upper handlebar cover Remove the four screws then remove the bottom handlebar cover Disconnect the throttle cable refer to the THROTTLE BODY TPS section then...

Page 21: ...2 EXHAUST MUFFLER FRAME COVERS 2 6 DOWNTOWN 200i WINDSHIELD WINDSHIELD GARNISH Remove five bolts and windshield garnish...

Page 22: ...emove four screws then remove the front center cover Remove the front cover Installation is in the reverse order of removal FRONT COVER Remove the small front cover black screw Remove the small front...

Page 23: ...lation is in the reverse order of removal FRONT FENDER Remove four screws attaching to the front fender Installation is in the reverse order of removal RIGHT LEFT FOOT SKIRT Remove the six screws atta...

Page 24: ...r Installation is in the reverse order of removal REAR FENDER Remove the body cover and then the rear fender Installation is in the reverse order of removal BODY COVER Remove the rear center cover Rem...

Page 25: ...NTOWN 200i TIRE FENDER Remove the body cover Remove four bolts attaching to the tire fender Installation is in the reverse order of removal FLOORBOARD Remove the body cover Remove the right left skirt...

Page 26: ...2 EXHAUST MUFFLER FRAME COVERS 2 11 DOWNTOWN 200i Remove eight bolts then remove the floorboard UNDER COVER Remove four bolts Remove the under cover...

Page 27: ...rse order of removal METER PANEL Disconnect the speedometer wires Disconnect the DC power connectors Remove one screws Remove the ignition key garnish Remove three screws from the inner cover then rem...

Page 28: ...OWN 200i INNER COVER Remove the front cover Remove the front lower cover Remove the floorboard Remove four bolts and front glove box one screw Remove two fastener bolts then remove the fuel tank fill...

Page 29: ...FFLER FRAME COVERS 2 14 DOWNTOWN 200i EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater O2 sensor Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and...

Page 30: ...the gasket with a new one Install the exhaust muffler and three mounting bolt Install and tighten the two exhaust pipe joint nuts to the specified torque Torque 20 N m 2 kgf m Tighten the three mount...

Page 31: ..._____________________________________________ INSPECTION ADJUSTMENT _________________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDU...

Page 32: ...he working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6 mm Spark plug NGK CR7E Spark plug gap 0 6 mm 0 7 mm Valve clearance IN 0 10 mm EX 0 10 mm Idle speed 1600 100 rpm...

Page 33: ...3 INSPECTION ADJUSTMENT 3 2...

Page 34: ...or adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the a...

Page 35: ...recommended oil through the oil filler hole OIL CAPACITY Engine oil capacity 1 5 L Engine oil exchanging capacity 1 3 L Engine Oil Viscosity SAE 5W50 OIL FILTER SCREEN INSPECTION Drain the engine oil...

Page 36: ...engine is at the normal operating temperature with the scooter In an upright position If the coolant level is below the LOWER level mark 3 remove the left floor mat remove the lid screw 4 the reserve...

Page 37: ...rk plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7E Measure the spark plug...

Page 38: ...N Warm up the engine before compression test Remove the center cover and luggage box Remove the spark plug Insert a compression gauge Open the throttle fully and push the starter button to test the co...

Page 39: ...w Transmission fluid type SAE 90 Transmission fluid capacity 0 23 L Transmission fluid exchanging capacity 0 21 L Install the transmission filler bolt and tighten it to the specified torque DRIVE BELT...

Page 40: ...on the lever holder BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk runout is within the specified service limit Check if the brake...

Page 41: ...em several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Each shock absorber 4 on your scooter has 5 spring preload adjustment positions for different load or r...

Page 42: ...cm Rear 2 25 kg cm 2 25 kg cm Tire Size Front 120 80 14 58S Rear 150 70 13 64S Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to t...

Page 43: ...ride the scooter when the side stand is down Perform the following side stand inspection INTERLOCK FUNCTION CHECK Check the side stand ignition cut off system 1 Place the scooter on its center stand 2...

Page 44: ...________________________________________________________ ________________________________________________________________________________ ______________________________________________________________...

Page 45: ...4 LUBRICATION SYSTEM 4 1 DOWNTOWN 200i LUBRICATION PART Dipstick Oil Filter Oil Pump Drive Chain...

Page 46: ...pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS ENGINE OIL Engine Oil Capacity At disassembl...

Page 47: ...the oil filter screen cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if n...

Page 48: ...attaching the right under crankcase cover The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new oil filter Oil...

Page 49: ...special tool Special tool Flywheel Puller E003 Universal Holder E021 Remove the gasket and dowel pins Remove the starter idle gear and starter clutch Remove the two bolts and oil separator cover Remov...

Page 50: ...the pump shaft Install and tighten the pump driven gear bolts Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch Install the gasket and dowel pins...

Page 51: ...________________________________________________________________________ __________________________________________________________________________________ ____________________________________________...

Page 52: ...t Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil cap...

Page 53: ...sensor and injector Disconnect the O2 sensor connector Disconnect the throttle cables Disconnect the Regulator Rectifier connector Disconnect the starter relay wire from starter motor Remove a bolt f...

Page 54: ...m 120 N m Remove two bolts 3 attaching to rear brake hose clamps Remove two bolts 4 attaching to the rear brake caliper Torque 3 2 kgf m 32 N m Disconnect the alternator connector 5 Disconnect the ign...

Page 55: ...ON 5 4 DOWNTOWN 200i Remove the spark plug cap Disconnect the lower radiator hose from lower radiator pipe Remove the right and left rear cushion lower mount bolts Torque 4 0 kgf m 40N m Spark Plug Ca...

Page 56: ...tallation is in the reverse order of removal After installation inspect and adjust the following Throttle grip free play Fill the cooling system with coolant and start the engine to bleed air from the...

Page 57: ...unt nut and pull it out Remove the left right engine hanger mount bolt Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts t...

Page 58: ..._____________________________________ ________________________________________________________________________________ CYLINDER HEAD VALVES ____________________________________________________________...

Page 59: ...6 CYLINDER HEAD VALVES 6 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 60: ...After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order...

Page 61: ...e stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve...

Page 62: ...er hose to air cleaner Remove the cylinder head cover four bolts Remove the cylinder head cover CAMSHAFT REMOVAL Remove the injector and inlet pipe Remove two screws attaching the thermostat Turn the...

Page 63: ...taching to the cylinder head Remove two bolts attaching to the camshaft gear Remove the camshaft gear from the cam chain Remove the set plate located beside the rocker arm shaft Diagonally loosen the...

Page 64: ...ve excessive play CYLINDER HEAD REMOVAL Remove the muffler Remove the throttle body Drain the coolant from the radiator and water hose then remove the thermostat water hose Remove the camshaft Remove...

Page 65: ...ce CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor Valve spring compressor E040 Remove carbon deposits fro...

Page 66: ...all the valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Install the valve spring Valve s...

Page 67: ...cylinder head Install the camshaft Install the intake valve rocker arm and the rocker arm shafts CAMSHAFT INSTALLATION Install the set plate to prevent the rocker arm shaft from pull out Torque 1 2 k...

Page 68: ...ign two bolts on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear Install the thermostat bolt Torque 1 2...

Page 69: ...st the valve clearance Install a new cylinder head cover O ring and install the cylinder head cover Install the inlet pipe Install the injector Install and tighten the cylinder head cover bolts Be sur...

Page 70: ...___________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER P...

Page 71: ...7 CYLINDER PISTON 7 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 72: ...asuring position 9mm from bottom of skirt Piston to cylinder clearance 0 010 0 030 0 1 over Piston pin hole I D 17 002 17 008 17 06 over Piston pin O D 16 994 17 000 16 80 belw Piston to piston pin cl...

Page 73: ...asket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Water Hose Dowel Pins Cam Chain Guide Gasket C...

Page 74: ...oove clearance Service Limits Top 0 09 mm replace if over 2nd 0 09 mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Servi...

Page 75: ...the piston pin in both X and Y directions Service Limit 66 1 mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1 mm repair or replace if over The true roundness is...

Page 76: ...ton rings onto the piston Apply engine oil to each piston ring Be careful not to damage the piston and piston rings during assembly All rings should be installed with the markings facing up After inst...

Page 77: ...n clip CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Be careful not to drop foreign matters into the crankcase Position the piston IN mark on the intake valve...

Page 78: ...chain guide Install the cylinder head gasket and dowel pins Connect the water hose to the cylinder Install the cylinder head Tighten the cylinder base bolt Insert the tab on the cam chain guide into t...

Page 79: ...________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE...

Page 80: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 81: ...4 0 2 0 Clutch outer I D 152 1 152 2 152 2 Weight roller O D 19 92 20 08 20 TORQUE VALUES Drive face nut 9 5 kgf m 93 1 N m Apply oil Clutch outer nut 5 5 kgf m 54 N m Clutch drive plate nut 5 5 kgf m...

Page 82: ...xcessive play DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover Hold the drive pulley using a universal holder and remove the drive face nut and washer Remove the drive pulley fac...

Page 83: ...a new belt at every 20 000km MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face clutch outer driven pulley and belt Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY R...

Page 84: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 5 DOWNTOWN 200i INSPECTION Check each weight roller for wear or damage Check the movable drive face bushing for wear or damage ASSEMBLY...

Page 85: ...he movable drive face INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 153 5 mm replace if over Check the clutch shoes for wear or damage Measure the c...

Page 86: ...E033 Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from t...

Page 87: ...ve the inner needle bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the d...

Page 88: ...S V BELT 8 9 DOWNTOWN 200i Press a new needle bearing into the driven face CLUTCH DISASSEMBLY Remove the clips and retainer plate to disassemble the clutch Keep grease off the clutch linings Clips Ret...

Page 89: ...stall the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the clips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease f...

Page 90: ...assembly onto the clutch spring compressor Compress the tool and install the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 75 N m Clutch Spring...

Page 91: ...the clutch outer nut Hold the clutch outer with the universal holder to tighten clutch outer nut Torque 54 N m Universal Holder E017 Install the drive pulley face washer and drive face nut Hold the d...

Page 92: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 13 DOWNTOWN 200i Install the left crankcase cover Left Crankcase Cover...

Page 93: ...__________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUC...

Page 94: ...9 FINAL REDUCTION 9 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 95: ...on SPECIFICATIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 23 liter At change 0 21 liter TORQUE VALUES Transmission case bolt 0 8 1 2 kgf m 9 8 N m Oil check drain bolt 1 8 2 2 kgf m 19 7 N...

Page 96: ...er Remove the clutch outer driven pulleys Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket...

Page 97: ...shaft and gear for wear or damage Check the transmission case covers bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Drive Shaft Bearing Countershaft Beari...

Page 98: ...he reverse order of removal Torque Transmission case bolt 0 8 1 2 kgf m 9 8 N m After installation fill the transmission case with the specified oil Specified Gear Oil SAE90 Oil Capacity At disassembl...

Page 99: ...______________________________________________________________ ________________________________________________________________________________ A C GENERATOR STARTER CLUTCH ___________________________...

Page 100: ...10 A C GENERATOR STARTER CLUTCH 10 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 101: ...lant Remember to bleed air from the water hose SPECIFICATIONS Engine oil SAE 5W 50 API SJ above Oil capacity at change 1 5 1 3 Liter Coolant capacity Radiator capacity 0 766 liter Hose with cool coola...

Page 102: ...ing the right crankcase cover and the cover Remove the bolt between water pump cover and oil filter Remove right crankcase cover STATOR REMOVAL Remove two screws attaching the pulsar coil Remove three...

Page 103: ...move the flywheel nut and washer Flywheel holder E021 Remove the flywheel with a flywheel puller Flywheel puller E003 STARTER CLUTCH REMOVAL Remove the starter driven gear Remove the starter idle gear...

Page 104: ...ts and oil separator cover Spread the clip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the cam chain Remove the two oil pump bolts to remove the oil pump Bolts...

Page 105: ...wear or damage Measure the starter driven gear I D and O D Service Limits I D 22 15mm replace if over O D 41 50mm replace if below Inspect the starter idle gear and shaft for wear or damage Inspect th...

Page 106: ...of oil pump is upside Install cam chain Install the pump drive chain and driven gear then set the clip securely on the pump shaft Install the oil separator cover properly Cam Chain Arrow Mark Fit the...

Page 107: ...key on the crankshaft with the groove in the flywheel Install washer and nut Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 5 5 6 5 kgf m 58 8 N m Remove the flywheel...

Page 108: ...o dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten 12 bolts attaching to right crankcase cover Conn...

Page 109: ..._________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRAN...

Page 110: ...11 CRANKCASE CRANKSHAFT 11 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 111: ...aced in pair The following parts must be removed before separating the crankcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rea...

Page 112: ...ankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the engine oil screen Remove the crankshaft from the left crankcase Never use a d...

Page 113: ...INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6 mm replace if over Measure the connecting rod small end I D Service Limit 17 06 mm replace if over Measure the crankshaft...

Page 114: ...and tighten the right and left crankcase attaching bolts Install the engine oil screen Install the right crankcase squarely and do not tap it with an iron or plastic hammer Avoid damaging the oil sea...

Page 115: ...________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTE...

Page 116: ...12 COOLING SYSTEM 12 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 117: ...m check for leaks with a cooling system tester TORQUE VALUES Water pump impeller 1 0 1 4 kgf m 11 8 N m Water pump cover bolt 1 0 1 4 kgf m 11 8 N m TROUBLESHOOTING Engine temperature too high Coolant...

Page 118: ...12 COOLING SYSTEM 12 3 DOWNTOWN 200i...

Page 119: ...re 0 9 0 15 kg cm Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for lea...

Page 120: ...sconnect the outlet tube of the reserve tank Remove the overflow tube clamp and disconnect the overflow tube Disconnect the air vent tube from the radiator filler Disconnect the fan motor wire coupler...

Page 121: ...EM 12 6 DOWNTOWN 200i Remove three bolts nuts on the radiator Remove the radiator RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator Check fan motor by battery Bo...

Page 122: ...s Connect the thermostatic switch wire Connect the fan motor wire couplers Connect the overflow tube and secure with the tube clamp Fill the radiator with coolant Connect the vent tube to the radiator...

Page 123: ...UMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose Remove four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller Inspect the mechanical water seal a...

Page 124: ...ECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembl...

Page 125: ...laced a new seal washer must be installed to the impeller Install the impeller onto the water pump shaft Torque 1 0 1 4 kgf m 11 8 N m Install two dowel pins and a new gasket Install the water pump co...

Page 126: ...Disconnect the thermosensor wire Remove the thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water hea...

Page 127: ...ostat housing THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data Begins to open 80 2 Full open...

Page 128: ...RAM 13 3 PARTS LOCATION 13 4 TROUBLESHOOTING 13 6 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL 13 7 EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES 13 8 SELF DIAGNOSIS RESET PROCEDURE 13...

Page 129: ...ause throttle and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body ha...

Page 130: ...ard pressure at 40 L Hr 294 6 kPa 3 Bar At 20 C 4 F 18 8 K At 40 C 104 F 1 136 K Water temperature sensor resistance At 100 C 212 F 0 1553 K Intake pressure sensor MAP pressure at 1 4 2 V 13 332 kPa 0...

Page 131: ...ch Angle detect sensor ROLL 03 Fuel pump Fuel level unit FP 04 Water temperature sensor WTS sensor 05 Crank position sensor Pulser CPS 06 Oxygen Oxygen heater sensor O2 O2 Heat sensor 08 Inductive ign...

Page 132: ...INJECTION SYSTEM 13 4 DOWNTOWN 200i PARTS LOCATION Horn Ignition switch ECU Speedometer Lo beam relay Hi beam relay Radiator filler cap Winker relay Tilt switch Throttle body MAP sensor Injector WTS...

Page 133: ...13 FUEL INJECTION SYSTEM 13 5 DOWNTOWN 200i Ignition coil Coolant reserve tank Output voltage connector Oil controller Fuel pump replay Regulator Rectifier Starter relay CPS O2 sensor...

Page 134: ...p Clogged fuel filter throttle body Sticking fuel injector needle Faulty fuel pump operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Engine stall har...

Page 135: ...ne has problem the CELP will blink to show the failure codes There re 11 failure codes for the KEHIN system If the vehicle gets more failure codes the CELP will be blinking from a lower number then sh...

Page 136: ...is equal to ten For example one longer blink illumination and two shorter blinks 0 5 second x 2 of the indicator is equal to 12 blinks Follow code 12 If more than a damaged part has occurred the CELP...

Page 137: ...y open the throttle and wait for ten seconds 4 Release the throttle 5 The indicator will blink twice 0 5 second after five seconds quickly 6 Self diagnosis memory data is disappeared after the CELP la...

Page 138: ...Loose or poor connection on ECT Open or short circuit on ECT wire Faulty ECT Engine operates normally 15 P1630 Faulty Tilt switch Roll Faulty Tilt switch voltage range inclined angle 65 0 4 1 4 V Inc...

Page 139: ...3 Loose or poor connection on fuel pump Open or short circuit on fuel pump wire Faulty fuel pump Engine fail to be operated 45 P0135 Faulty O2 sensor heater Faulty O2 sensor heater range 6 7 9 5 Loos...

Page 140: ...OWN 200i SPARK PLUG ANTI FLOOD When have not failure code occurs and pressing starter switch repeatedly can still not start the engine maybe the spark plug is wet by fuel perform the spark plug anti f...

Page 141: ...en the ECU or the throttle body has been reinstalled It can cause engine stop hard to start engine or rough idling speed The throttle position sensor TPS and idle air bypass valve ISC have to be reset...

Page 142: ...ent battery voltage for a few seconds If there is still battery voltage replace the fuel pump If there is not any battery voltage inspect the following Fuse B 10 A Fuel cut off relay ECU Measure the r...

Page 143: ...the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 lbf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose from the fuel...

Page 144: ...s Connection Black Red Black Connect 12 V battery with the fuel cut off relay connector Connection Blue Black Black There should be continuity only when 12 V battery connected If there is not continui...

Page 145: ...nk 0 4 1 4 V Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage between the following terminals of the tilt switch connector with the...

Page 146: ...emove the ECU from the frame Installation is in the reverse order of the removal Do not disconnect or connect the ECU connector during the ignition switch ON it may cause the ECU damaged The throttle...

Page 147: ...tion power 19 BATT Battery 2 ROLL Roll sensor Tilt switch 20 3 CRK P Crank pulse sensor 21 MIL Multi indicator lamp ECLP 4 22 TW Water temperature sensor ECT 5 TH Throttle position sensor 23 6 PM Mani...

Page 148: ...onnector from the fuel injector Remove the bolt of the fuel injector Take out of the fuel pipe and fuel injector from the Inlet pipe Remove the fuel injector from the fuel pipe Connector Bolt Ensure t...

Page 149: ...ounting bolt FUEL INJECTOR CLEANING PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard 1 6ms ANALYSIS Injector block With some carbons TROUBL...

Page 150: ...nsor Remove the WTS sensor and O ring Install a new O ring and WTS sensor Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Connect the WTS sensor connector Fill the co...

Page 151: ...y controls the fuel injector operation INSPECTION Disconnect the O2 sensor connector Measure the resistance between each White wire terminals of the O2 sensor side connector Standard 7 7 1 2 at 20 C 6...

Page 152: ...MCO factory do not disassemble it by a wrong way Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchroniza...

Page 153: ...inal Normal Violet Red Green Pink 5 V Throttle position sensor TPS resistance at 20 C 68 F 3500 6500 REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from...

Page 154: ...e TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the thro...

Page 155: ...the throttle body being careful not to damage the O ring DIAGNOSTIC TOOL CONNECTOR INSPECTION Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure the voltage...

Page 156: ...13 FUELINJECTION SYSTEM 13 28 DOWNTOWN 200i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00 ENGLISH VERSION...

Page 157: ...connection please connect this tool with the connector of ECU It s available when turning on the ignition switch z The side stand must be upward when serving the diagnostic procedure z The function i...

Page 158: ...INSPECTION PROCEDURE Showing four functions on the screen when switching on power A ECU version Including of model name ECU number identifications number and software version Press the Enter button L...

Page 159: ...13 FUELINJECTION SYSTEM 31 13 31 DOWNTOWN 200i B Press the Down button and then turn to the first page C Press the Enter button to check the DTC failure code LGF9...

Page 160: ...13 FUELINJECTION SYSTEM 13 32 DOWNTOWN 200i D Press the Enter button E Press the Enter button F Display what s DTC number on this DTC List Press the Enter button and then turn to the previous page...

Page 161: ...5 FUELINJECTION SYSTEM 5 33 DOWNTOWN 200i G Press the UP button H Press the Enter button and then turn to the previous page with red color I Press the UP button...

Page 162: ...5 FUELINJECTION SYSTEM 5 34 DOWNTOWN 200i J Press the Enter button and then turn to the first page LGF9 is for Downtown 200i...

Page 163: ...5 FUELINJECTION SYSTEM 5 35 DOWNTOWN 200i 3 DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button C Choose Load DTC Press the Down button LGF9 is for Downtown 200i LGF9 is for Downtown 200i...

Page 164: ...5 FUELINJECTION SYSTEM 5 36 DOWNTOWN 200i D Press the Enter button and the indicator is lighting E Clearing DTC completed if the indicator is off...

Page 165: ...PROCEDURE A Press the Down twice B Choose Data Analyze Press the Enter button to enter page 01 C Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Dow...

Page 166: ...Press the Down button to enter page 03 E Down page 03 The measure figures including of Atmosphere pressure Fuel Injector interval and Ignition advance timing Press the Down button to enter page 04 F...

Page 167: ...ng of ISC target ISC step and ISC learn step Press the Down button to enter page 06 H Down page 06 The measure figures including of ISC motor state Press the Down button to enter page 07 I Down page 0...

Page 168: ...hrottle Valve being changed or loose 5 Has the vehicle under regular service Is the gas station a good one 6 Is the spark plug the correct model of specified by the vehicle builder Vehicle can not be...

Page 169: ...ond x 2 of the indicator equals 12 blinks Refer to DTC 12 2 If more than one failure occurs the CELP shows the blinks in the occurred order For example if the indicator blinks 6 times then shows one s...

Page 170: ..._____________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHEEL...

Page 171: ...linder piston O D 12 65 12 68 0 506 0 5072 Brake caliper piston O D 26 93 26 96 1 0602 1 0614 Brake caliper cylinder I D 27 27 05 1 063 1 065 TORQUE VALUES Handlebar lock nut 45 N m 4 5 kgf m Steering...

Page 172: ...ned axle nut Steers to one side or does not track straight Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper...

Page 173: ...ove the two bolts and disconnect the brake light switch wire then remove the front brake master cylinder Remove the inner cover Remove the handlebar lock nut and take out the bolt Remove the handlebar...

Page 174: ...OWNTOWN 200i Install the front and rear master cylinders and connect the brake light switch wires DISASSEMBLY Remove two screws attaching to the right handlebar switch Disconnect the throttle cable fr...

Page 175: ...switch Install and tighten the two screws securely Install the right handlebar switch Lubricate the throttle grip front end with grease and then connect the throttle cable to the throttle grip Install...

Page 176: ...wheel off the ground Remove the bolt and then pull out the axle Remove the front wheel and collar AXLE RUNOUT INSPECTION Set the axle in V blocks and measure the runout using a dial gauge The actual...

Page 177: ...collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the rac...

Page 178: ...using the special tool Special tool Bearing puller E00037 ASSEMBLY Install the front wheel bearing by using the special tool Special tool Bearing installer E00014 Install the distance collar Install...

Page 179: ...two screws Remove the reservoir cover diaphragm plate and diaphragm Connect a bleed hose to the bleed valve A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean...

Page 180: ...front caliper bleed valve Check the fluid level often while bleeding the brake to prevent air from being pumped into the system Pump the brake bleeder and loosen the front caliper bleed valve Add flu...

Page 181: ...nds and close the bleed valve 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system...

Page 182: ...NG STEM 14 12 DOWNTOWN 200i FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the pad pins Remove the two caliper mounting bolts then remove the caliper Remove the brake pads Always replace the brake pads...

Page 183: ...ront caliper onto the fork leg and then install and tighten the new two caliper mounting bolts to the specified torque Torque 35 N m 3 5 kgf m Tighten the pad pins to the specified torque Torque 18 N...

Page 184: ...rom left front shock absorber Remove two mounting bolts and then remove the right left front shock absorber INSTALLATION Installation is in the reverse order of removal Specified Oil SS 8 Oil Capacity...

Page 185: ...heel sensor connector from the guide Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool Special tool Lock nut wrench F00002 Remove the top cone race a...

Page 186: ...ge Replace if necessary Remove the top balls Remove the upper ball race by using a chisel if necessary Remove the bottom balls Remove the bottom ball race by using a pipe if necessary Remove the botto...

Page 187: ...om ball race Install the steering stem Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls conta...

Page 188: ...______________________________________ ________________________________________________________________________________ ________________________________________________________________________________...

Page 189: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 DOWNTOWN 200i SCHEMATIC DRAWING...

Page 190: ...45 TORQUE VALUES Exhaust muffler lock bolt 35 N m 4 kgf m Exhaust muffler pipe nut 20 N m 2 kgf m Rear axle nut 120 N m 12 kgf m Rear shock absorber lower mount bolt 40 N m 4 kgf m Rear shock absorbe...

Page 191: ...rear brake caliper Remove the rear brake caliper INSPECTION Inspect the brake pads and brake disk Measure the brake disk thickness Visually check the brake pad thickness DISASSEMBLY Remove two brake p...

Page 192: ...the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Check th...

Page 193: ...id tube to the brake caliper and install fluid tube bolt copper washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system Make...

Page 194: ...Remove the exhaust muffler Remove the rear brake caliper Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork The installation seq...

Page 195: ...wer mount bolt 40 N m 4 kgf m Rear axle nut 120 N m 12 kgf m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the righ...

Page 196: ...15 REAR WHEEL REAR BRAKE REAR SUSPENSION DOWNTOWN 200i 15 8...

Page 197: ...____________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTE...

Page 198: ...16 BATTERY CHARGING SYSTEM 16 1 DOWNTOWN 200i CHARGING SYSTEM LAYOUT ACG BATTERY REGULATOR RECTIFIER...

Page 199: ...ould be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not...

Page 200: ...ttery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or...

Page 201: ...he battery first then disconnect the positive terminal lead 6 Remove the battery from the battery box BATTERY INSTALLATION Install in the reverse order of the removal VOLTAGE INSPECTION Remove the bat...

Page 202: ...orming this test Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make ab...

Page 203: ...tifier connectors Check the connectors for loose contacts of corroded terminals BATTERY WIRE Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all t...

Page 204: ...regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity REMOVAL INSTALLATION Remove the side body cover D...

Page 205: ..._____________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM...

Page 206: ...17 IGNITION SYSTEM 17 1 DOWNTOWN 200i IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Crank Position Sensor Ignition Switch Ignition Coil ECU A C Generator Roll Sensor Roll Sensor...

Page 207: ...er engine cranking speed as well as no spark at the spark plug Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS Item Standa...

Page 208: ...ct the continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 Primary coil 3 57 4 83 Secondary coil with plug cap 15 19 K Secondary coil without pl...

Page 209: ...cal as shown at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the roll sensor 65 10 degrees t...

Page 210: ...LLATION Disconnect the connector and remove two screws then remove roll sensor Installation is in the reverse order of removal Tighten the mounting screws securely Install the roll sensor with its up...

Page 211: ...____________________________________________ ________________________________________________________________________________ __________________________________________________________________________...

Page 212: ...18 STARTING SYSTEM 18 1 DOWNTOWN 200i STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Relay R Ignition Switch...

Page 213: ...motor brush length 12 5mm 8 5mm TORQUE VALUES Starter motor mounting bolt 1 0kgf m 10N m TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loosed wire o...

Page 214: ...goes to the starter relay and relax cable band to disconnect the starter motor cable Remove two start motor mounting bolts and the motor Before removing the starter motor turn the ignition switch OFF...

Page 215: ...re should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric meter to the sta...

Page 216: ...______________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITC...

Page 217: ...19 LIGHTS SWITCHES FUEL PUMP 19 1 DOWNTOWN 200i ELECTRICAL EQUIPMENT LAYOUT Radiator...

Page 218: ...he scooter Route the wires and cables properly after servicing each component TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON correctly Burned bulb...

Page 219: ...WITCHES FUEL PUMP 19 3 DOWNTOWN 200i BULB REPLACEMENT LICENECE LIGHT Remove the seat assembly and luggage box Remove the body covers Disconnect the license bulb socket Remove the bulb and replace with...

Page 220: ...headlight connector from the headlight bulb Install a new bulb into the headlight case Install the headlight and connect the headlight connector A halogen headlight bulb becomes hot while the headligh...

Page 221: ...e bulb socket then remove the front turn signal light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE L...

Page 222: ...CHES 19 6 DOWNTOWN 200i REAR TURN SIGNAL LIGHT Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal Rear Turn Signal Light T...

Page 223: ...ontinuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front cover Disconnect the...

Page 224: ...WITCH INSPECTION Remove the front cover Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires...

Page 225: ...ows LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box Disconnect the luggage box light switch connector and check the luggage box light switch for continuity between the switch terminals Ther...

Page 226: ...e the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose Remove the six nuts and fuel unit connectors then remove the fuel hose Rem...

Page 227: ...gnition switch ON Measure the resistance between the Red Black and Green wire of the fuel unit connector Standard at 20 C 68 F Float at full position About 1100 Float at empty position About 100 Befor...

Page 228: ...age box Side stand switch is located on side stand Disconnect the side stand switch connector There should be continuity between the Yellow Green and Green with the side stand is up There should be co...

Page 229: ...WNTOWN 200i HORN INSPECTION Remove the front cover Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is co...

Page 230: ...er the waterproof rubber Press the waterproof rubber around with hand until its seat INSPECTION Confirm if the waterproof rubber is covered firmly Waterproof Rubber Highlight wires If the waterproof r...

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