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KYMCO Downtown 300i ABS, Service Manual

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KYMCO Downtown 300i ABS Service Manual Download Page 200

15.

REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER

15-2

Downtown 300i ABS

SERVICE INFORMATION

GENERAL INSTRUCTIONS

•

When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid
scalding.

•

During servicing, keep oil or grease off the brake pads and brake disk.

SPECIFICATIONS

Item

Standard (mm)

Rear wheel rim runout

⎯

Rear brake disk thickness

5.0

Rear brake disk runout

⎯

Rear brake master cylinder I.D.

25.33 ~ 25.36

Rear brake master cylinder piston O.D.

25.40 ~ 25.45

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 absorber upper mount bolt

40 N-m (

4 kgf-m)

Rear brake caliper holder bolt

35 N-m (3.5

 kgf-m)

TROUBLESHOOTING

Rear wheel wobbling

Poor brake performance

•

Bent rim

•

 Air in brake system

•

Faulty tire

•

 Deteriorated brake fluid

•

Axle not tightened properly

•

 Contaminated brake pad surface

•

 Worn brake pads

Soft rear shock absorber 

•

 Clogged brake fluid line

•

Weak shock absorber spring

•

 Deformed brake disk

•

Damper oil leaks

•

 Unequal worn brake caliper

Rear wheel noise

•

Worn rear wheel axle bearings

•

Worn rear fork bearings

•

Deformed rear fork

Summary of Contents for Downtown 300i ABS

Page 1: ...00i ABS By KWANG YANG Motor Co Ltd 1st Edition Jan 2010 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300...

Page 2: ...pment Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD QUALITY TECH...

Page 3: ...___________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL IN...

Page 4: ...1 GENERAL INFORMATION 1 1 Downtown 300i ABS SERIAL NUMBER Location of Frame Serial Number inside luggage box Location of Vehicle Identification Number VIN Location of Engine Serial Number...

Page 5: ...e wet sump Oil pump type Inner outer rotor Oil filter type Full flow filtration Oil capacity 1 5 liter Exchanging capacity 1 3 liter Fuel injection system Air cleaner type No Paper element wet Fuel ca...

Page 6: ...parts Lubricate sliding surfaces with engine oil before reassembly Apply or add designated greases and lubricants to the specified lubrication points When two persons work together pay attention to th...

Page 7: ...nnector shall be inserted completely If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check for damaged terminal cover o...

Page 8: ...screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact...

Page 9: ...rding to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Symbols The following symbols repr...

Page 10: ...1 GENERAL INFORMATION 1 7 Downtown 300i ABS TORQUE VALUES...

Page 11: ...1 GENERAL INFORMATION 1 8 Downtown 300i ABS TORQUE VALUES FRAME...

Page 12: ...14 OIL SEAL BEARING DRIVER General size A120 E00019 BUSHING ABSORBER REMOVER O D 26 A120 E00021 FLYWHEEL HOLDER A120 E00028 NUT FITTING 41 A120 E00032 BUSHING ENGINE HANGER REMOVER O D 30 A120 E00035...

Page 13: ...STALLER A120 E00053 CLUTCH SPRING COMPRESSOR A120 E00055 THREAD PROTECTOR 12mm 14 mm A120 E00065 CRANKSHAFT BEARING REMOVER 32143 LEA7 9000 INJECTOR CLEANER Keihin system A120 E00085 INJECTOR CLEANER...

Page 14: ...ARING PULLER A120 F00009 Lower Upper Outer Race Separator A120 F00019 LOWER UPPER OUTER RACE INSTALLER A120 F00023 STEERING STEM TOP THREAD WRENCH 39mm with longer A120 F00031 PLIERS FUEL PIPE A120 F0...

Page 15: ...ation 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...

Page 16: ...GENERAL INFORMATION 1 13 Downtown 300i ABS CABLE HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Ignition Switch ECU Horn Winker Relay Hi Beam Relay Lo Beam Relay ECU ABS ECU HYDRAULIC UNI...

Page 17: ...1 GENERAL INFORMATION 1 14 Downtown 300i ABS ISC Throttle Body TPS WTS Injector MAP Sensor...

Page 18: ...1 GENERAL INFORMATION 1 15 Downtown 300i ABS Oil controller Fuel Pump Relay Ignition Coil Output Voltage Connector Coolant Reserve Tank...

Page 19: ...1 GENERAL INFORMATION 1 16 Downtown 300i ABS Starter Relay Regulator Rectifier CPS O2 Sensor...

Page 20: ...ty ECU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck...

Page 21: ...r cleaner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct...

Page 22: ...ntrol orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating...

Page 23: ...regulator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or in...

Page 24: ...t Camshaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steer...

Page 25: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

Page 26: ...aged 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 cas...

Page 27: ...ece 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 b...

Page 28: ...and 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 l...

Page 29: ...0i ABS 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...

Page 30: ...COVER 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 th...

Page 31: ...2 EXHAUST MUFFLER FRAME COVERS 2 6 Downtown 300i ABS WINDSHIELD WINDSHIELD GARNISH Remove five bolts and windshield garnish...

Page 32: ...Remove 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 fron...

Page 33: ...allation 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 at...

Page 34: ...ver 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 R...

Page 35: ...own 300i ABS 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 ski...

Page 36: ...2 EXHAUST MUFFLER FRAME COVERS 2 11 Downtown 300i ABS Remove eight bolts then remove the floorboard UNDER COVER Remove four bolts Remove the under cover...

Page 37: ...verse 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 r...

Page 38: ...n 300i ABS 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 fil...

Page 39: ...LER FRAME COVERS 2 14 Downtown 300i ABS 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 an...

Page 40: ...ce 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 mou...

Page 41: ...___________________________________________________ INSPECTION ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE...

Page 42: ...the 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 r...

Page 43: ...3 INSPECTION ADJUSTMENT 3 2 Downtown 300i ABS...

Page 44: ...ajor 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...

Page 45: ...r the 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 engin...

Page 46: ...he 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 reser...

Page 47: ...park 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 plu...

Page 48: ...arm 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 compr...

Page 49: ...low 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 BE...

Page 50: ...3 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 bra...

Page 51: ...them 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...

Page 52: ...g 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...

Page 53: ...o 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...

Page 54: ...__________________________________________________________ ________________________________________________________________________________ ____________________________________________________________...

Page 55: ...4 LUBRICATION SYSTEM 4 1 DOWNTOWN 300I ABS LUBRICATION PART Dipstick Oil Filter Oil Pump Drive Chain...

Page 56: ...il 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 disassem...

Page 57: ...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 nece...

Page 58: ...drain out Check that the O ring is in good condition Install a new oil filter MESH FILTER REPLACEMENT Drain the engine oil Remove the right crankcase cover Clean the mesh filter at every 10000km Check...

Page 59: ...h 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 Rem...

Page 60: ...in 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 pin...

Page 61: ...__________________________________________________________________________ __________________________________________________________________________________ __________________________________________...

Page 62: ...ket 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 c...

Page 63: ...AP 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...

Page 64: ...f 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 i...

Page 65: ...5 4 Downtown 300i ABS 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...

Page 66: ...nstallation 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 t...

Page 67: ...mount 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...

Page 68: ...____________________________________________ ________________________________________________________________________________ CYLINDER HEAD VALVES _____________________________________________________...

Page 69: ...6 CYLINDER HEAD VALVES 6 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 70: ...ead 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 o...

Page 71: ...lve 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 val...

Page 72: ...the breather 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...

Page 73: ...attaching 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 th...

Page 74: ...have 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 Remov...

Page 75: ...face 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 f...

Page 76: ...stall 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...

Page 77: ...he 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...

Page 78: ...align 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...

Page 79: ...just 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 s...

Page 80: ..._________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLI...

Page 81: ...7 CYLINDER PISTON 7 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 82: ...m from bottom of skirt Piston to cylinder clearance 0 010 0 040 0 1 Piston pin hole I D 15 002 15 008 15 04 Piston pin O D 14 994 15 000 16 96 Piston to piston pin clearance 0 002 0 014 0 02 Connectin...

Page 83: ...gasket 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...

Page 84: ...groove 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 Ser...

Page 85: ...to the piston pin in both X and Y directions Service Limit 72 70 mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1 mm repair or replace if over The true roundnes...

Page 86: ...iston 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 in...

Page 87: ...pin 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 val...

Page 88: ...m 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...

Page 89: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 90: ...ckness 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...

Page 91: ...e excessive 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...

Page 92: ...ce 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...

Page 93: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 5 Downtown 300i ABS INSPECTION Check each weight roller for wear or damage Check the movable drive face bushing for wear or damage ASSEMBLY...

Page 94: ...the 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...

Page 95: ...m 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...

Page 96: ...rive 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...

Page 97: ...V BELT 8 9 Downtown 300i ABS 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 R...

Page 98: ...Install 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...

Page 99: ...ch 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 Spri...

Page 100: ...nd 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...

Page 101: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 13 Downtown 300i ABS Install the left crankcase cover Left Crankcase Cover...

Page 102: ...________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL...

Page 103: ...9 FINAL REDUCTION 9 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 104: ...tion 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...

Page 105: ...over 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 gask...

Page 106: ...ve 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 Bea...

Page 107: ...the 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 disassem...

Page 108: ...________________________________________________________________ ________________________________________________________________________________ A C GENERATOR STARTER CLUTCH _________________________...

Page 109: ...10 A C GENERATOR STARTER CLUTCH 10 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 110: ...mber to bleed air from the water hose SPECIFICATIONS Engine oil SAE 5W 50 API SJ above Engine quality Synthetic Oil capacity at change 1 5 Liter Coolant capacity Radiator capacity 0 766 liter Hose wit...

Page 111: ...ching 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 thr...

Page 112: ...remove 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 ge...

Page 113: ...olts 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 Bolt...

Page 114: ...r 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...

Page 115: ...ow 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 t...

Page 116: ...he 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 flywhee...

Page 117: ...two 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 Co...

Page 118: ..._______________________________________ ________________________________________________________________________________ _______________________________________________________________________________...

Page 119: ...11 CRANKCASE CRANKSHAFT 11 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 120: ...placed 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 r...

Page 121: ...crankcase 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...

Page 122: ...T 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 cranksha...

Page 123: ...ll 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 s...

Page 124: ..._______________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLIN...

Page 125: ...12 COOLING SYSTEM 12 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 126: ...r 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 leaks Fau...

Page 127: ...059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1 095 1 093 1 091 1 088 1 085 1...

Page 128: ...sure 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 l...

Page 129: ...Disconnect 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 coupl...

Page 130: ...12 6 Downtown 300i ABS 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...

Page 131: ...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 132: ...PUMP 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...

Page 133: ...MECHANICAL 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 assem...

Page 134: ...eplaced 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...

Page 135: ...rear fender cover A Drain the coolant Disconnect the thermosensor wire Remove the thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistan...

Page 136: ...s Remove the thermostat from the thermostat housing THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Techni...

Page 137: ...ARTS 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 9 CELP FA...

Page 138: ...cause 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...

Page 139: ...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 13332 kgf cm2...

Page 140: ...itch 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 i...

Page 141: ...NJECTION SYSTEM 13 4 Downtown 300i ABS 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 WT...

Page 142: ...13 FUEL INJECTION SYSTEM 13 5 Downtown 300i ABS Ignition coil Coolant reserve tank Output voltage connector Oil controller Fuel pump replay Regulator Rectifier Starter relay CPS O2 sensor...

Page 143: ...ump 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 h...

Page 144: ...gine 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...

Page 145: ...t 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 CEL...

Page 146: ...lly 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...

Page 147: ...53 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 I...

Page 148: ...00 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 Lo...

Page 149: ...n 300i ABS 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...

Page 150: ...when 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 res...

Page 151: ...current 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 t...

Page 152: ...re 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 fue...

Page 153: ...als 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 contin...

Page 154: ...Pink 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 th...

Page 155: ...remove 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 throttl...

Page 156: ...nition 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 Ma...

Page 157: ...connector 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...

Page 158: ...mounting 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 TROU...

Page 159: ...sensor 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...

Page 160: ...nly 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...

Page 161: ...KYMCO 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 synchroni...

Page 162: ...rminal 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 fro...

Page 163: ...the 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 th...

Page 164: ...to 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 volta...

Page 165: ...13 FUELINJECTION SYSTEM 28 13 28 Downtown 300i ABS FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00...

Page 166: ...he power required of tool is connected with 12V battery z For 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...

Page 167: ...TC 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...

Page 168: ...INJECTION SYSTEM 31 13 31 Downtown 300i ABS B Press the Down button and then turn to the first page C Press the Enter button to check the DTC failure code LEA7 is for Downtown 300i LEA7 is for Downtow...

Page 169: ...FUELINJECTION SYSTEM 32 13 32 Downtown 300i ABS 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 pag...

Page 170: ...5 FUELINJECTION SYSTEM 5 33 Downtown 300i ABS 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 171: ...5 FUELINJECTION SYSTEM 5 34 Downtown 300i ABS J Press the Enter button and then turn to the first page LEA7 is for Downtown 300i LEA7 is for Downtown 300i...

Page 172: ...5 FUELINJECTION SYSTEM 5 35 Downtown 300i ABS DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button C Choose Load DTC Press the Down button LEA7 is for Downtown 300i LEA7 is for Downtown 300i...

Page 173: ...5 FUELINJECTION SYSTEM 5 36 Downtown 300i ABS D Press the Enter button and the indicator is lighting E Clearing DTC completed if the indicator is off...

Page 174: ...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 Down button...

Page 175: ...re 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...

Page 176: ...ing 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...

Page 177: ...Throttle 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 178: ...cond 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...

Page 179: ...ing 0 E ngine s peed rpm 1620 100 rpm E ngine Tem p 80 C Intak e P res s ure K pa 34 0 41 0 k pa E n g in e Te m p C C F uel Injec t Interval m s 1 6 2 7m s E ngine Tem p 80 C Ignition Tim ing 8 14 B...

Page 180: ..._______________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHE...

Page 181: ...cylinder 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 Steeri...

Page 182: ...tened 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 dampe...

Page 183: ...emove 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 handleb...

Page 184: ...ntown 300i ABS 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...

Page 185: ...r 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 Insta...

Page 186: ...nt 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 actua...

Page 187: ...de 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 r...

Page 188: ...by 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 Instal...

Page 189: ...e 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 clea...

Page 190: ...he 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 f...

Page 191: ...conds 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 syst...

Page 192: ...STEM 14 12 Downtown 300i ABS 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 pad...

Page 193: ...front 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...

Page 194: ...from 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 Capaci...

Page 195: ...wheel 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...

Page 196: ...mage 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 bot...

Page 197: ...ttom 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 con...

Page 198: ...________________________________________ ________________________________________________________________________________ ______________________________________________________________________________...

Page 199: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 Downtown 300i ABS SCHEMATIC DRAWING...

Page 200: ...QUE 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 absorber upper...

Page 201: ...e 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...

Page 202: ...gh 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...

Page 203: ...luid 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 Ma...

Page 204: ...AL 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 s...

Page 205: ...lower 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 ri...

Page 206: ...15 REAR WHEEL REAR BRAKE REAR SUSPENSION Downtown 300i ABS 15 8...

Page 207: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ BAT...

Page 208: ...16 BATTERY CHARGING SYSTEM 16 1 Downtown 300i ABS CHARGING SYSTEM LAYOUT ACG BATTERY REGULATOR RECTIFIER...

Page 209: ...should 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 n...

Page 210: ...battery 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 o...

Page 211: ...the 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 b...

Page 212: ...rforming 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...

Page 213: ...ectifier 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...

Page 214: ...e 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...

Page 215: ..._______________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTE...

Page 216: ...17 IGNITION SYSTEM 17 1 Downtown 300I ABS IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Crank Position Sensor Ignition Switch Ignition Coil ECU A C Generator Tilt switch...

Page 217: ...slower 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 St...

Page 218: ...NUITY TEST Inspect 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...

Page 219: ...ical 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 tilt switch 65 10 degrees...

Page 220: ...TALLATION Disconnect the connector and remove two screws then remove tilt switch Installation is in the reverse order of removal Tighten the mounting screws securely Install the tilt switch with its u...

Page 221: ...___________________________________________________ ________________________________________________________________________________ ___________________________________________________________________...

Page 222: ...18 STARTING SYSTEM 18 1 Downtown 300I ABS STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Relay R Ignition Switch...

Page 223: ...mounting bolt 6 7 10 8 N m Starter motor case screw 2 9 4 9 N m Starter clutch bolt 9 8 13 7 N m SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING Starter motor won t turn Lack...

Page 224: ...ut 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 O...

Page 225: ...here 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 s...

Page 226: ...________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWI...

Page 227: ...19 LIGHTS SWITCHES FUEL PUMP 19 1 Downtown 300i ABS ELECTRICAL EQUIPMENT LAYOUT Radiator...

Page 228: ...on the 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...

Page 229: ...TCHES FUEL PUMP 19 3 Downtown 300i ABS 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 wi...

Page 230: ...eadlight connector from the headlight bulb INSTALLATION Install a new bulb into the headlight case Install the headlight and connect the headlight connector A halogen headlight bulb becomes hot while...

Page 231: ...ver 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...

Page 232: ...the 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...

Page 233: ...ES 19 7 Downtown 300i ABS 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...

Page 234: ...continuity 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 th...

Page 235: ......

Page 236: ...ollows 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 T...

Page 237: ...ove 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 R...

Page 238: ...ignition 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 Bef...

Page 239: ...ggage 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...

Page 240: ...town 300i ABS 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...

Page 241: ...TEM Downtown 300i ABS 20 EVAPORATIVEEMISSIONCONTROLSYSTEM SCHEMATIC DRAWING 20 1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION 20 2 TROUBLESHOOTING 20 2 SERVICE INFORMATION 20 3 PERGE CONTROL VALVE 20...

Page 242: ...20 EVAPORATIVEEMISSIONCONTROLSYSTEM Downtown 300i ABS SCHEMATIC DRAWING Fuel Injector Throttle Body Air Cleaner Charcoal Canister Purge Control Valve 20 1...

Page 243: ...r in the charcoal canister is drawn into the engine for re burning Charcoal Canister Absorb and store the vaporized HC from the fuel tank and carburetor The vaporized HC is absorbed in the charcoal ca...

Page 244: ...n Replace any damaged tube with a new one Make sure to tighten the connector of each tube securely TOOLS Vacuum pump A937 014 Pressure pump SPECIFICATIONS Purge control valve vacuum pressure 45mm Hg C...

Page 245: ...ir cleaner and apply vacuum pressure of 250mm Hg The specified vacuum must be maintained for one minute Replace the purge control valve with a new one if vacuum is not maintained Connect a vacuum pump...

Page 246: ...st be over 9 4 liters per minute and replace the purge control valve with a new one if the specified flow is not reached INSTALLATION 1 Install the purge control valve in the reverse order of removal...

Page 247: ...t a hose to the canister Blow the hose with mouth The charcoal canister is normal if air can be blown into it If clogged replace it with a new one 2 Check the charcoal for cracks and replace if necess...

Page 248: ...i ABS 21 ABS Indicator Light 21 01 ABS Introduction 21 02 ABS Parts Location 21 03 Wheel Speed 21 04 ABS ECU ABS Hydraulic Unit 21 06 ABS ECU GUARANTEE 21 07 Diagnostic Tool Operation 21 08 Bosch ABS8...

Page 249: ...he ignition switch is turned on and goes off shortly after the vehicle starts moving at speed 6km hr min It stays off If something is wrong with the ABS the indicator comes on and remains it When the...

Page 250: ...vehicle with ABS may be longer than that of an equivalent vehicle without ABS Use special caution in such areas z ABS will help prevent wheel lock up when braking in straight line but it cannot contro...

Page 251: ...on Front Wheel speed Sensor Front Wheel speed Sensor Rotor Front Wheel speed Sensor s connector Front Wheel speed Sensor Rotor Rear Wheel speed Sensor Rear Wheel speed Sensor s connector ABS ECU ABS H...

Page 252: ...eel speed sensor Remove a bolt attaching to the front wheel speed sensor Remove the connector of front wheel speed sensor Standard clearance 0 4 1 2mm between the Front wheel speed sensor and Front Wh...

Page 253: ...speed sensor Remove the connector of rear wheel speed sensor Standard clearance 0 4 1 2mm between the Rear wheel speed sensor and Rear Wheel Speed Sensor Rotor Rear Wheel Speed Sensor Front Wheel Spee...

Page 254: ...order to prevent the ABS ECU from high temperature ABS ECU ABS Hydraulic Unit Remove the screws attaching to the Hydraulic Unit To install the sensor is in the reverse order of removal 1 Oil boltsX4...

Page 255: ...BS ECU GUARANTEE Don t need to drain the brake fluid if replace a new ECU Hydraulic unit Oil tube bolt 4 3 5 kgf m Don t remove four special bolts to take out the ABS ECU If remove it during the guara...

Page 256: ...OSTIC TOOL OPERATION 1 Connect the KYMCO Fi Diagnostic tool 2 Put the side stand upward and ENG stop switch is at RUN position 3 Connect the diagnostic tool connector KYMCO Fi Diagnostic tool Power co...

Page 257: ...SYSTEM ABS 21 9 Downtown 300i ABS 4 Choose Fi ECU Version and then push down button for three times 5 Choose No 2 ABS SYS ECU and then push up button to previous 6 Confirming ECU Version and then ent...

Page 258: ...21 ANTI LOCK BRAKE SYSTEM ABS 21 10 Downtown 300i ABS 7 Choose ECU Version and then push Enter button 8 Confirm ABS ECU Version if is LEA7 E00 9 Choose DTC Inspect 1 1 1 LE...

Page 259: ...21 ANTI LOCK BRAKE SYSTEM ABS 21 11 Downtown 300i ABS 10 Load DTC Active Occurred History DTC DISPLAYED 1 Rear wheel speed sensor disconnect 2 Front wheel speed sensor disconnect...

Page 260: ...RAKE SYSTEM ABS 21 12 Downtown 300i ABS DTC CLEARED 1 Choose Clear DTC and then push Enter button 2 Clearing DTC completed until the DTC red lamp is off DATAANALYZE 1 Choose DATA Analyze and then push...

Page 261: ...wn 300i ABS 2 Front wheel speed Rear wheel speed Battery volt Battery volt Standard 9 6 16 7V KYMCO Diagnosis 01 Fr Speed 5 km hr Re Speed 5 km hr Battery Volt 12 6V You can turn the front or rear whe...

Page 262: ...Valve Relay malfunction Failsafe relay 06 5025 Deviation between Wheel speeds WSS_GENERIC 07 5035 Pump Motor Malfunction 08 5042 Front wheel speed sensor malfunction Plausibility 09 5043 Front wheel...

Page 263: ...EEN LED ORANGE LED RED LED BLUE CLOCK ODO TRIP METER LCD FUEL METER TACHO METER SPEED METER TEMP METER PCB OIL SERVICE LED RED BAT VOLTAGE LED RED OIL PILOT LED RED LED RED V PCB GND PCB GND TEMP I H...

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