KYMCO Downtown 350i Repair Manual Download Page 5

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KYMCO Repair Manual

Downtown 350i

5.Cooling System

This chapter covers the location and servicing of the cooling system components
for the KYMCO Downtown 350i model.

Coolant ............................................................................................5-3

Radiator ..........................................................................................5-12

Water Temperature Sensor (WTS) ................................................5-22

Water Pump ....................................................................................5-28

6.Fuel Injection System

This chapter covers the location and servicing of the fuel system components for
the KYMCO Downtown 350i model.

Airbox ..............................................................................................6-4

Fuel Tank ........................................................................................6-8

Fuel Pump .......................................................................................6-13

Throttle Body Removal ..................................................................6-21

Throttle Cable .................................................................................6-32

Throttle Body ..................................................................................6-35

Fuel Injector ....................................................................................6-41

TPS ISC Reset Procedure ..............................................................6-46

Self-Diagnosis ................................................................................6-47

F.I. Diagnostic Tool ........................................................................6-54

7.CVT Continuously Variable Transmission

This chapter covers the location and servicing of the CVT components for the
KYMCO Downtown 350i model.

Belt Case .........................................................................................7-2

CVT Removal ..................................................................................7-7

CVT Installation ..............................................................................7-26

Summary of Contents for Downtown 350i

Page 1: ...latest information available at the time of publication Illustrations in this manual are shown to help you with the basics of performing the jobs listed The pictures in this manual may not depict the...

Page 2: ...illustrations in this manual have been reviewed for accuracy it is up to the individual performing the procedures to use good judgement when performing any procedures described Every precaution has be...

Page 3: ...1 22 VIN and Engine Number Location 1 27 2 Periodic Maintenance This chapter covers the periodic maintenance for the KYMCO Downtown 350i Maintenance Schedule 2 2 Air Filter Servicing 2 4 Brake Fluid 2...

Page 4: ...Center Cover 3 10 Body Cover 3 11 Rear Inner Fender 3 16 Rear Tire Fender 3 17 Heat Shield 3 18 Exhaust System 3 20 4 Engine This chapter covers the location and servicing of the engine components for...

Page 5: ...the location and servicing of the fuel system components for the KYMCO Downtown 350i model Airbox 6 4 Fuel Tank 6 8 Fuel Pump 6 13 Throttle Body Removal 6 21 Throttle Cable 6 32 Throttle Body 6 35 Fu...

Page 6: ...l Drive Oil 8 3 Final Reduction 8 8 9 Electrical Systems This chapter covers the location and servicing of the electrical systems for the KYMCO Downtown 350i model Electrical Specifications 9 8 Fuses...

Page 7: ...r 10 26 Rear Brake Caliper 10 31 Brake Disc 10 37 ABS 10 42 11 Steering This chapter covers the location and servicing of the steering components for the KYMCO Downtown 350i model Handlebar 11 2 Grips...

Page 8: ...spension components of the KYMCO Downtown 350i model Shock Absorbers 13 2 Rear Fork 13 8 14 Wheels This chapter covers the location and servicing of the wheels for the KYMCO Downtown 350i model Bearin...

Page 9: ...hapter provides a quick reference source of technical specifications and information for KYMCO Downtown 350i models Component Location 1 2 Special Tools 1 5 Specifications 1 6 Torque Specifications 1...

Page 10: ...1 Quick Reference Downtown 350i 1 2 Component Location Radiator Cap Horn Winker Relay Turn Signal Relays Tilt Switch Oil Pressure Controller Coolant Reserve Tank Meter Instrument Couplers...

Page 11: ...1 Quick Reference Downtown 350i 1 3 Component Location Regulator Rectifier Starter Relay EFI ECU Ignition Coil Coolant Reserve Tank Ignition Switch Radiator Oxygen Sensor Stator and CPS...

Page 12: ...1 Quick Reference Downtown 350i 1 4 Component Location Throttle Body ISC TPS MAP Sensor Fuel Injector WTS Fuel Pump Spark Plug Air Temperature Sensor Wheel Speed Sensor ABS ECU...

Page 13: ...eneral Driver Set UNIVERSAL HOLDER A120E00021 Holding clutch pulley and flywheel 41 NUT AND FITTING TOOL A120E00028 Clutch disassembly THREAD PROTECTOR A120E00029 Crankshaft thread protector BEARING P...

Page 14: ...eight mm 1310 Wheel base mm 1553 Engine type 4 stroke OHC Displacement cc 321 Fuel recommended 90 nonleaded gasoline Curb weight kg Front wheel 78 Rear wheel 111 Total 189 Max weight capacity kg Front...

Page 15: ...atio 10 7 Compression pressure 12 kg cm2 Max Horsepower 30 05 7500 PS rpm Max Torque 3 2 5750 Kg m rpm Valve timing Intake Open 9 5 BTDC Close 37 5 ABDC Exhaust Open 40 BBDC Close 10 ATDC Valve cleara...

Page 16: ...ve System Clutch Type Dry multi clutch Transmission Gear Type CVT Operation Automatic centrifugal type Reduction Gear Type Two stage reduction Reduction ratio 1st 2 24 0 72 2nd 7 222 Moving Device Tir...

Page 17: ...mm EX 0 10 mm Idle speed 1600 100 rpm Cylinder compression 12 2 kg cm2 Ignition timing ECU Coolant type Coolant type Engine oil capacity At disassembly 1 5 Liter At change 1 3 Liter Gear oil type SAE...

Page 18: ...ht IN 34 2987 EX 34 1721 Valve rocker arm I D IN 10 00 10 015 EX 10 00 10 015 Valve rocker arm shaft O D IN 9 972 9 987 EX 9 972 9 987 Valve seat width IN 1 2 EX 1 2 Valve stem O D IN 4 990 4 975 EX 4...

Page 19: ...Piston to cylinder clearance 0 101 0 040 Piston pin hole I D 15 002 15 008 Piston pin O D 14 994 15 000 Piston to piston pin clearance 0 002 0 014 Connecting rod small end I D Bore 15 016 15 034 Item...

Page 20: ...ing System Radiator cap relief pressure 0 9 0 15 kg cm2 12 8 2 1 psi Thermostat temperature Begins to open 71 C Full open 80 C Valve lift 3 5 4 5 mm COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EF...

Page 21: ...064 1 062 45 1 080 1 078 1 076 1 074 1 072 1 069 50 1 086 1 084 1 082 1 080 1 077 1 074 55 1 095 1 093 1 091 1 088 1 085 1 082 60 1 100 1 098 1 095 1 092 1 089 1 086 Temp C Coolant concentration 30 35...

Page 22: ...3 Bar 294 6 kPa 42 0 9 psi Water temperature sensor resistance At 20 C 4 F 18 8 K At 40 C 104 F 1 136 K At 100 C 212 F 0 1553 K Intake pressure sensor MAP pressure at 1 4 2 V 13 332 kPa 0 13332 kgf c...

Page 23: ...onnection 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 Inclined angle 65 3...

Page 24: ...ire Faulty fuel pump Engine fails to be operated 43 Radiator fan relay Open radiator fan relay Detached coupler Engine operates normally 45 P0135 Faulty O2 sensor heater Faulty O2 sensor heater range...

Page 25: ...unout 0 4 mm Brake master cylinder I D 12 7 12 74 0 508 0 5096 Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 Front brake caliper piston O D 26 93 26 96 1 0602 1 0614 Front brake caliper cy...

Page 26: ...y coil 3 57 4 83 Secondary coil without plug cap 10 42 14 49 K Throttle Position Sensor 3500 6500 Fuel Pump 1 9 approx Fuel Injector 11 7 0 6 Water Temperature Sensor 2 076 K 10 25 C Oxygen Sensor eng...

Page 27: ...3 Apply thread lock Camshaft set plate bolt 1 1 2 2 0 Apply thread lock Final drive oil check drain bolt 2 8 0 8 1 2 5 79 8 68 Engine oil drain bolt 1 12 2 0 3 0 14 47 21 70 Engine oil strainer cap 1...

Page 28: ...1 Quick Reference Downtown 350i 1 20 FRAME...

Page 29: ...mm bolt nut 0 8 1 2 5 79 8 68 8 mm bolt nut 1 8 2 5 13 02 18 08 10 mm bolt nut 3 0 4 0 21 70 28 93 12 mm bolt nut 5 0 6 0 36 17 43 40 5 mm screw 0 45 0 6 3 25 4 34 6 mm screw SH bolt 0 7 1 1 5 06 7 9...

Page 30: ...th Fuel Pump Fuel Pump Relay It will turn off automatically in 5 10 seconds 3 Key On to check for any failure lamp light up on dashboard See theSelf Diagnosis topic for more information 4 Is the Idle...

Page 31: ...1 Quick Reference Downtown 350i 1 23 General Troubleshooting...

Page 32: ...1 Quick Reference Downtown 350i 1 24...

Page 33: ...1 Quick Reference Downtown 350i 1 25...

Page 34: ...1 Quick Reference Downtown 350i 1 26...

Page 35: ...1 Quick Reference Downtown 350i 1 27 VIN and Engine Number Location...

Page 36: ...ide Stand 2 38 Spark Plug 2 40 Steering 2 43 Suspension 2 44 Throttle Free Play 2 46 Tires 2 52 Final Drive Oil 2 54 Valve Clearance 2 60 WARNING Before running the engine make sure that the working a...

Page 37: ...he maintenance required to keep your DOWNTOWN 350i scooter in peak operating condition Maintenance work should be performed in accordance with KYMCO standards and specifications by properly trained an...

Page 38: ...ce I A I A I A Hose Inspection I I I Hose Inspection C C C C C C C Engine Oil R R R R R R R Engine Oil C R C R C R Engine Oil R R R R R R R Fuel Injection Diagnostic Tool I I I Final Drive Oil R R R R...

Page 39: ...rotective gloves and eyewear are recommended at this point Replace the air filter according to the Maintenance Schedule and more often in exceptionally rainy or dusty areas Removal Remove the 8 air fi...

Page 40: ...socket or a 2 Phillips screwdriver Remove the air filter from the airbox Discard the air filter in favor of a new item Caution The air cleaner element has a viscous type paper element Do not clean it...

Page 41: ...ke system has been taken apart and rebuilt Always use fresh brake fluid from a tightly sealed container SAFETY FIRST Protective gloves and eyewear are recommended at this point Warning Brake fluid is...

Page 42: ...2 Periodic Maintenance Downtown 350i 2 7 Draining The brake bleeding process is the same for the front and rear brakes Remove the two master cylinder cover screws with a 2 Phillips head screwdriver...

Page 43: ...Maintenance Downtown 350i 2 8 Remove the cylinder cover Remove the master cylinder cover plastic piece and rubber diaphragm Clean and inspect the rubber diaphragm for tears or other damage Replace as...

Page 44: ...n the bleeder valve on the brake caliper using an 8 mm wrench This valve is usually very tight so use a box end wrench or a 6 point socket and ratchet to prevent rounding off the head Snug the bleeder...

Page 45: ...g Place a length of 6 mm inside diameter clear hose on the bleeder valve and place the other end in a suitable container A spare battery vent hose works well for this job Fill the brake fluid with the...

Page 46: ...front brake lever Pump the lever several times again and repeat the process Be certain to check the master cylinder reservoir occasionally to make sure the reservoir doesn t run dry Add more brake flu...

Page 47: ...50i 2 12 Place the rubber diaphragm plastic piece and cover over the reservoir Thread in the reservoir cover screws and tighten them securely with a 2 Phillips screwdriver Check the function of the br...

Page 48: ...e Lever Adjuster There is adjuster on each brake lever Each adjuster has four positions so that the released lever position can be adjusted to suit the rider s hands To adjust the distance of the leve...

Page 49: ...tenance Downtown 350i 2 14 Brake Fluid Brake Pad Wear Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Note Keep grease and oil off the brake discs to avoid...

Page 50: ...ake sure the cylinder head bolts are tightened securely and the valve clearance is specification See theCylinder Head and Valve Clearance topics for more information Remove the spark plug See the Spar...

Page 51: ...tight valve with not enough valve clearance High compression is possibly an indication of excessive carbon buildup on the piston or performance modifications Install the spark plug See the Spark Plug...

Page 52: ...T Antifreeze is highly toxic and can kill pets and animals if drank Do not leave coolant where animals including children can get to it Inspection Start the engine and bring it up to operating tempera...

Page 53: ...th a 2 Phillips And remove the engine coolant lid Open the coolant reserve tank lid Siphon the coolant out of the reserve tank with an appropriate suction device If a suction device is unavailable rem...

Page 54: ...2 Periodic Maintenance Downtown 350i 2 19 Remove the engine coolant reserve tank cover Open the coolant reserve tank lid...

Page 55: ...c Maintenance Downtown 350i 2 20 Add coolant to the tank until it reaches the upper level mark Note Do not add coolant through the radiator cap For more information on the engine coolant see the Coola...

Page 56: ...Caution Hot engine oil can burn Avoid letting used motor oil contact exposed skin TROUBLESHOOTING Oil level too low 1 Natural oil consumption 2 Oil leaks 3 Worn or poorly installed piston rings 4 Worn...

Page 57: ...re longer service life of the scooter Only use oils that have a SJ rating above per the API service classification Engine oil viscosity SAE 5W 50 If these viscosities are not available select an alter...

Page 58: ...evel each day before operating the scooter Place the motorcycle upright on level ground for engine oil level check Run the engine for 2 3 minutes and check the oil level after the engine is stopped fo...

Page 59: ...dipstick and wipe off the oil Inspect the O ring and replace it as needed Insert the dipstick in without threading it in Remove the dipstick and check the oil level The level must be maintained betwee...

Page 60: ...e Downtown 350i 2 25 If the oil level is at or below the lower mark add more of the same type and brand of oil to the engine through the oil filler hole If the oil level is to high remove the drain pl...

Page 61: ...ll heat the engine and allow the oil to drain out faster and more completely The vehicle should be on level ground Stop the engine Caution Hot engine oil can burn Avoid letting used motor oil contact...

Page 62: ...2 Periodic Maintenance Downtown 350i 2 27 Loosen the engine oil drain bolt with a 17 mm socket Remove the bolt and allow the oil to drain into the pan...

Page 63: ...2 Periodic Maintenance Downtown 350i 2 28 Discard the old sealing washer Remove the oil filler cap to allow for faster oil draining Inspect the oil filler cap O ring and replace it as needed...

Page 64: ...th a new sealing washer Tighten the drain bolt to specification with a 17 mm socket Item Qty Torque Remarks kgf m lb ft Oil Drain bolt 1 2 5 18 08 New sealing washer Strainer Screen Remove the oil str...

Page 65: ...e O rings if they are in poor condition Inspect the oil strainer screen for debris and damage Clean it with a high flash point solvent and compressed air Metal debris in the strainer screen can be an...

Page 66: ...the engine Tighten the oil strainer screen cap to specification with a 17 mm socket Item Qty Torque kgf m lb ft Engine oil strainer cap 1 1 02 7 2 Filter Replacement The oil filter compartment is loc...

Page 67: ...2 Periodic Maintenance Downtown 350i 2 32 Loosen the oil filter cap with a 24 mm socket Remove the oil filter cap with spring and take out the used oil filter...

Page 68: ...nce Downtown 350i 2 33 Inspect the oil filter cap O ring and spring Replace the items if they are in poor condition Install the spring to the oil filter cap Apply a light coat of engine oil to the oil...

Page 69: ...oil filter Insert the oil filter into place with the rubber seal side facing up Install the oil filter cap with spring Makes sure the spring fits against the filter correctly Tighten the oil filter ca...

Page 70: ...to ensure longer service life of the scooter Only use oils that have a SJ rating above per the API service classification Engine oil viscosity SAE 5W 50 Engine oil capacity At disassembly 1 5 Liter A...

Page 71: ...ed at this point The frame lubrication points are listed below Use general purpose grease Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and...

Page 72: ...e Inspection Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Inspect the breather hose for damage and deterioration Inspec...

Page 73: ...re recommended at this point Interlock Function Check Your scooter s side stand is not only necessary when you park but it contains an important safety feature This feature cuts off the ignition if yo...

Page 74: ...cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower the side stand 4 The engine should stop as you put the side stand down Note If the side stan...

Page 75: ...e Box topic for more information The spark plug is located on the left side of the cylinder remove the spark plug wire off of the spark plug Clean off the area surrounding the spark plug with compress...

Page 76: ...the gap needs to be adjusted bend the ground electrode carefully Inspect the color of the porcelain nose of the spark plug The color of the spark plug can indicate how the mixture is burning A white c...

Page 77: ...ark plug socket Do not over tighten the spark plug The cylinder head is made out of soft metal and it can be easily damaged Item Torque Spark plug 17 2 N m 1 5 2 ft lb 10 84 14 47 kgf m Install the sp...

Page 78: ...wear are recommended at this point Inspection Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement a...

Page 79: ...ion SAFETY FIRST Protective gloves and eyewear are recommended at this point Front Suspension Check the action of the front shock absorbers by compressing them several times Check the entire shock abs...

Page 80: ...adjustment positions for different load or riding conditions Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for stiffer rear suspension and can be us...

Page 81: ...y rotating the throttle grip back until resistance is felt Throttle grip free play 2 6 mm Make sure the throttle moves smoothly and returns on its own Start the engine and let it warm up Turn the hand...

Page 82: ...of the throttle grip free play is made with the adjusting nut at the throttle body side Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for mo...

Page 83: ...2 Periodic Maintenance Downtown 350i 2 48 The top throttle cable is the opening cable and the bottom is the closing cable Loosen the lock nut forward with a 12 mm wrench...

Page 84: ...adjuster in place and tighten the locknut securely Adjust the closing cable as needed for a proper throttle action Install the luggage box See the Luggage Box topic for more information Install the se...

Page 85: ...2 Periodic Maintenance Downtown 350i 2 50 Slide down the rubber cover Loosen the throttle cable adjuster lock nut with a 10 mm wrench...

Page 86: ...ter with an 8 mm wrench to achieve the specified free play When the free play has been moved into specification hold the adjuster in place and tighten the locknut securely Slide the rubber cover over...

Page 87: ...recommended at this point Check tires before each ride for wear and air pressure Check tire air pressure before riding when tires are cold Cold inflation tire pressure Solo riding Front 2 00 kg cm2 2...

Page 88: ...2 Periodic Maintenance Downtown 350i 2 53 Replace tires if the tread depth reaches the wear mark or fails to meet the minimum tread depth Tires Front wheel 120 80 14 58S Rear wheel 150 70 13 64S...

Page 89: ...tective gloves and eyewear are recommended at this point Place the scooter on level ground and up on its center stand The oil drain bolt and oil filler bolt are located on the transmission Gear oil ty...

Page 90: ...ce Downtown 350i 2 55 Draining Place the vehicle on its center stand on level ground Place a suitable oil drain pan under the transmission oil drain plug Remove the transmission oil level filler bolt...

Page 91: ...lace a suitable container under the drain plug to capture the final drive oil Loosen the oil drain plug with a 12 mm socket Remove the drain plug and slowly rotate the rear wheel to drain the transmis...

Page 92: ...ic Maintenance Downtown 350i 2 57 Install the oil drain plug and washer with a 12 mm socket Tighten to specification Item Qty Thread size mm Torque kgf m lb ft Final drive oil drain bolt 1 8 0 8 1 2 5...

Page 93: ...eriodic Maintenance Downtown 350i 2 58 Filling Fill the final drive with the specified quantity of oil with a syringe Gear oil type SAE 90 Gear oil capacity At disassembly 0 23 Liter At change 0 21 Li...

Page 94: ...350i 2 59 Thread in the final drive oil level filler bolt Install the oil filler plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil fil...

Page 95: ...on Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the spark plug See the Spark Plug topic for more information Rem...

Page 96: ...ming inspection cap from the right side of the engine with a large flat blade screwdriver Inspect the O ring on the cap and replace it as needed The crankshaft must be rotated clockwise until the pist...

Page 97: ...shaft sprocket must be even with the cylinder head mating surface at the same time the T mark is lined up with the with the index notch in the timing inspection hole Also the camshaft sprocket mountin...

Page 98: ...the feeler gauge between the tappet adjusting screw and the valve stem The clearance is correct when there is a light drag on the feeler gauge The clearance is the same for the exhaust and intake valv...

Page 99: ...2 Periodic Maintenance Downtown 350i 2 64 Adjustment Use a tappet adjuster tool to adjust the valves SPECIAL TOOLS ITEM TOOL NO DESCRIPTION TAPPET ADJUSTER E012 Tappet adjustment...

Page 100: ...he feeler gauge Hold the adjusting screw locknut in place with the wrench to make sure it doesn t interfere with the adjustment Lubricate the tappet adjusting screw threads with fresh engine oil Hold...

Page 101: ...ing inspection and crankshaft caps to the right side of the engine Tighten the caps securely but not overly with a large flat blade screwdriver Install the cylinder head cover See the Cylinder Head Co...

Page 102: ...ter covers the location and servicing of the external components for the KYMCO Downtown 350i model REAR PART Seat 3 3 Luggage Box 3 7 Rear Carrier 3 9 Rear Center Cover 3 10 Body Cover 3 11 Rear Inner...

Page 103: ...ield 3 31 Front Meter Cover 3 32 Head Light Assembly 3 33 Key Cover 3 36 Dash Board 3 38 Side Covers And Skirts 3 40 Side Board A 3 43 Side Board B 3 45 Floor Panel 3 47 Leg Shield 3 49 Front Inner Fe...

Page 104: ...owntown 350i 3 3 General Instructions When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to th...

Page 105: ...3 External Components Downtown 350i 3 4 REAR PART Seat SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Insert the key and turn it counterclockwise Lift up the seat...

Page 106: ...3 External Components Downtown 350i 3 5 Remove the two piston pivot nuts with a 10 mm socket Lift off the piston pivot mounting plate...

Page 107: ...3 External Components Downtown 350i 3 6 Remove the two seat hinge nuts with a 10 mm socket Remove the seat...

Page 108: ...Components Downtown 350i 3 7 Seat Latch Cable The seat latch cable runs from the ignition switch to the seat latches The cable must be adjusted periodically so that the latches will open correctly Ope...

Page 109: ...mponents Downtown 350i 3 8 Luggage Box SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the seat See the Seat topic for more information Remove the two luggage b...

Page 110: ...ernal Components Downtown 350i 3 9 Remove the PDA panel located at the rear of the luggage box and free the PDA plug Lift up the luggage box to unplug the luggage box light connector Remove the luggag...

Page 111: ...Removal SAFETY FIRST Protective gloves and eyewear are recommended at this point Pry off the carrier bolt covers with a small flat blade screwdriver the arrow mark indicates the pry point Remove the f...

Page 112: ...this point Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Open the fueling protector cover Pull the center cover and fue...

Page 113: ...l Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for more information...

Page 114: ...3 External Components Downtown 350i 3 13 Remove the upper body cover bolt with a 10 mm socket Remove the two mounting nuts Remove the fasteners...

Page 115: ...3 External Components Downtown 350i 3 14 Unplug the taillight connector Unplug the tag light connector Remove the body cover...

Page 116: ...3 External Components Downtown 350i 3 15 Disassembly Taillight Assembly Remove the taillight assembly screws with a 2 Phillips Unplug the connector of the license light Remove the screws...

Page 117: ...3 External Components Downtown 350i 3 16 Separate the mud flap and the taillight assembly Remove the license light assembly...

Page 118: ...for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for more information Remove the body cover Remove the 3 n...

Page 119: ...ve the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for more information Remove...

Page 120: ...al Remove the seat See Remove the two rear center cover screws with a 2 Phillips Carefully unhook the tabs on both sides and remove the rear center cover Heat Shields Remove the muffler heat shield bo...

Page 121: ...3 External Components Downtown 350i 3 20 To remove the heat shield on the exhaust pipe remove the two bolts with an 8 mm socket...

Page 122: ...oving frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to the Cable Harness Routing Troubleshooting Noisy...

Page 123: ...box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for more information Remove the body cover See the Body Cover topic for more information Remove t...

Page 124: ...3 External Components Downtown 350i 3 23 Remove the three muffler mounting bolts with a 14 mm socket And remove the exhaust system Remove the exhaust pipe gasket and discard it...

Page 125: ...over 350 C while the engine is running Test the O2 sensor at room temperature Use a digital multimeter set to ohms of resistance to inspect the O2 sensor Measure the resistance between the white wire...

Page 126: ...3 External Components Downtown 350i 3 25 Exhaust System Installation Insert a new exhaust pipe gasket into the exhaust port Fit the exhaust system into place...

Page 127: ...350i 3 26 Install the two exhaust pipe joint nuts with a 12 mm deep well socket Do not tighten Install the three muffler mounting bolts and tighten to specification with a socket Item Torque N m kgf...

Page 128: ...ust pipe joint nuts to specification with a 12 mm deep well socket Item Torque N m kgf m Exhaust Pipe Joint Nuts 35 3 5 If the exhaust pipe and muffler were separated tighten the muffler clamp securel...

Page 129: ...0i 3 28 Installation O2 Sensor Apply anti seize compound to the threads of the O2 sensor Install the O2 sensor and tighten it to specification with a 17 mm wrench Use care not to pinch the wires Item...

Page 130: ...3 External Components Downtown 350i 3 29 FRONT PART Follow the dismantled order as below illustration...

Page 131: ...3 External Components Downtown 350i 3 30 Front Center Cover Removal Pull the front center cover with certain direction Remove the front center cover...

Page 132: ...3 External Components Downtown 350i 3 31 Front Cover Removal Remove the fastener Remove the screws And remove the front cover...

Page 133: ...3 External Components Downtown 350i 3 32 Windshield Removal Remove the 4 hex mounting bolts Rotate the KYMCO logo plate Remove the screw And remove the windshield...

Page 134: ...3 External Components Downtown 350i 3 33 Front Meter Cover Removal Remove the front meter cover...

Page 135: ...3 External Components Downtown 350i 3 34 Head Light Assembly Removal Remove the head light assembly and side moldings as a set Remove the two mounting nuts Push fender down to loosen the tabs...

Page 136: ...3 External Components Downtown 350i 3 35 Use pry tool to release the tabs Note Be carefully not to damage the tabs and surfaces of the board Unplug the coupler of headlight...

Page 137: ...3 External Components Downtown 350i 3 36 Remove the head light assembly...

Page 138: ...3 External Components Downtown 350i 3 37 Key Cover Removal Remove the front cover windshield and meter cover first Loosen the mounting screw then turn and remove the ignition cover...

Page 139: ...3 External Components Downtown 350i 3 38 Remove the left and right fasteners...

Page 140: ...3 External Components Downtown 350i 3 39 Dash Board Removal Remove the dash board and cover as a set Remove the left and right bolts...

Page 141: ...3 External Components Downtown 350i 3 40 Remove the couplers Remove the dash board set...

Page 142: ...3 External Components Downtown 350i 3 41 Side Covers And Skirts Removal Remove the floor mat Remove the side cover turn signal light and skirt as a set...

Page 143: ...3 External Components Downtown 350i 3 42 Remove the screws which are mounted on floor panels Remove the screws Remove the screws...

Page 144: ...3 External Components Downtown 350i 3 43 Remove the fasteners Remove the skirt set...

Page 145: ...3 External Components Downtown 350i 3 44 Side Board A Removal Note 90652 LCA4 fasteners are mounted with body cover Remove the mounting bolts of side board A...

Page 146: ...3 External Components Downtown 350i 3 45 Use tool to pry the tabs Be carefully not to damage the tabs and surfaces of the board Remove both the right and left side board A...

Page 147: ...3 External Components Downtown 350i 3 46 Side Board B Removal...

Page 148: ...3 External Components Downtown 350i 3 47 Remove the mounting bolts of side board B Remove the right and left side board B...

Page 149: ...3 External Components Downtown 350i 3 48 Floor Panel Removal Remove the floor mat...

Page 150: ...3 External Components Downtown 350i 3 49 Remove the bolts and screws Remove the right and left floor panels...

Page 151: ...3 External Components Downtown 350i 3 50 Leg Shield Set Removal Use ignition key and remove the fueling cap...

Page 152: ...3 External Components Downtown 350i 3 51 Remove the left and right bolts Remove the coupler Remove the leg shield set...

Page 153: ...3 External Components Downtown 350i 3 52 Inner Fender Removal Remove the connecter of the air temperature sensor...

Page 154: ...3 External Components Downtown 350i 3 53 Remove the left and right fasteners and remove front inner fender Remove the screw Remove the rear inner fender set...

Page 155: ...3 External Components Downtown 350i 3 54 Under Cover Set Removal Remove the connecter of the air temperature sensor...

Page 156: ...3 External Components Downtown 350i 3 55 Remove the left and right fasteners and remove front inner fender Remove the screw Remove the rear inner fender set...

Page 157: ...nd eyewear are recommended at this point Removal The front fender is held in place with four bolts two on each side Remove the left forward front fender bolt with a 6 mm Allen And remove the left rear...

Page 158: ...3 External Components Downtown 350i 3 57 Remove the right forward front fender bolt with a 6 mm Allen And remove the right rear fender bolt with a 10 mm socket Remove the front fender from the forks...

Page 159: ...recommended at this point Removal Remove the handlebar covers See the Handlebar Covers topic for more information Remove the front cover See the Front Cover topic for more information Bar Ends Remove...

Page 160: ...ings and Throttle Remove the two right switch housing mounting screws with a 2 Phillips screwdriver Disconnect the switch Separate the switch housing from the handlebar Disconnect the throttle cables...

Page 161: ...omponents Downtown 350i 3 60 Slide off the throttle grip Remove the two left switch housing mounting screws with a 2 Phillips screwdriver Disconnect the switch Separate the left switch housing from th...

Page 162: ...50i 3 61 Handlebar Route the cables and lines from the handlebar cable guide Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut with a 17 mm socket Installation torque Item Torque N m...

Page 163: ...3 External Components Downtown 350i 3 62 Remove the handlebar lock nut and bolt Remove the handlebar...

Page 164: ...e relationship between the angle of the grip and the throttle tube so that the new grip can be installed with the correct angle NOTE Always wear safety glasses when using compressed air and never poin...

Page 165: ...on Switch Housings and Throttle Align the left switch housing and install on the handlebar Insert the two housing screws and tighten them securely with a 2 Phillips screwdriver Connect the switch Slid...

Page 166: ...hole in the bar Lubricate the end of the throttle in grease Fit the ends of the throttle cables into the throttle tube Insert the two housing screws and tighten them securely with a 2 Phillips screwdr...

Page 167: ...bar ends with a 6 mm Allen Install the front cover See the Front Cover topic for more information Install the handlebar covers See the Handlebar Covers topic for more information Check the throttle fr...

Page 168: ...3 External Components Downtown 350i 3 67 Handlebar Covers...

Page 169: ...nal Components Downtown 350i 3 68 Removal Upper Cover Remove the four cover screws with a 2 Phillips Lift up the rubber cover and loosen the mirror with a 17 mm wrench Remove both mirrors in the same...

Page 170: ...he upper handlebar cover Lower Cover Remove the luggage box See the Seat topic for more information Remove the throttle cables from the throttle body See the Throttle Body Removal and Installation top...

Page 171: ...3 External Components Downtown 350i 3 70 Remove the four cover bolts and screws Remove the lower cover...

Page 172: ...ternal Components Downtown 350i 3 71 Stands Side stand Removal Remove the luggage box See the Luggage Box topic for more information Remove the foot skirt Unplug the three pin side stand switch connec...

Page 173: ...3 External Components Downtown 350i 3 72 Remove the side stand spring with a spring puller Remove the side stand bolt switch and side stand...

Page 174: ...3 External Components Downtown 350i 3 73 Center Stand Removal Remove the center stand spring with a spring puller Remove the two center stand nuts and bolts Remove the center stand...

Page 175: ...h 4 62 Generator 4 69 Oil Pump 4 73 Crankcase 4 77 Crankshaft 4 87 Engine Removal 4 90 GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine in...

Page 176: ...me Coolant in the radiator and water hoses must be drained When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial l...

Page 177: ...learance adjustment Burned or bent valves Incorrect valve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plu...

Page 178: ...efore inspection If replacing the piston or cylinder they must be changed as a pair TROUBLESHOOTING Compression too low or uneven compression Worn stuck or broken piston rings Worn or damaged cylinder...

Page 179: ...re recommended at this point Removal Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Squeeze the breather hose clamp with...

Page 180: ...with an 8 mm socket Free the fuel hose stay from the cylinder head cover Loosen the four cylinder head cover bolts with a 10 mm socket Remove the cylinder head cover bolts with washers and grommets No...

Page 181: ...4 Engine Downtown 350i 4 7 Remove the cylinder head cover and gasket Discard the gasket and replace it with a new item on installation Remove the dowel pin...

Page 182: ...at See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the spark plug See the Spark Plug topic for more information Remove the cylinder...

Page 183: ...4 9 Remove the cam chain tensioner cap bolt with a 10 mm socket Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket Lift the cam chain tensioner our of the cylinder Remove the cam...

Page 184: ...i 4 10 Use a 5 mm Allen wrench to remove the camshaft sprocket bolts Remove the camshaft sprocket as shown Support the chain so it does not fall into the cylinder head Use a 5 mm Allen wrench to remov...

Page 185: ...4 Engine Downtown 350i 4 11 Remove the set plate as shown Thread a bolt into the rocker arm shafts and pull the shafts out Lift out the rocker arms as the shafts are removed...

Page 186: ...4 Engine Downtown 350i 4 12 Remove the camshaft from the cylinder head...

Page 187: ...gs for excessive play or roughness Replace the entire camshaft assembly if the bearings are rough or have excessive play Item Standard mm Camshaft cam height IN 34 2987 EX 34 1721 Inspect the rocker a...

Page 188: ...n 350i 4 14 Inspect the rocker arm inner diameter for the intake and exhaust valves Item Standard mm Valve rocker arm I D IN 10 00 10 015 EX 10 00 10 015 Inspect the camshaft bearing journals for scor...

Page 189: ...oil passages with compressed air Make sure all cylinder head oil passages are free of clogs NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone...

Page 190: ...The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Position the piston at top dead center as above The T mark should be aligned with the inde...

Page 191: ...icate the inside diameter of the rocker arms and the roller with fresh engine oil Position the rocker arms to accept the rocker arm shafts Wipe the rocker arm shafts clean Insert the rocker arm shafts...

Page 192: ...aft and between the projections on the rocker arm shafts Apply a small amount of blue Loctite non permanent to the threads of the set plate bolt Thread in the bolt and tighten it to specification with...

Page 193: ...the camshaft sprocket For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the same time the T mark is lined up with the with the index n...

Page 194: ...od must be held in with the screwdriver until the cam chain tensioner mounting bolts have been installed Install the camchain tensioner with a new gasket Insert the mounting bolts and tighten them eve...

Page 195: ...crankshaft 360 clockwise and check the engine timing one more time Make sure the cam chain tensioner cap bolt O ring is in good condition Install the O ring and cam chain tensioner cap bolt Tighten th...

Page 196: ...inspection and crankshaft caps to the right side of the engine Tighten the caps securely but not overly with a large flat blade screwdriver Install the cylinder head cover See the Cylinder Head Cover...

Page 197: ...ge box See the Luggage Box topic for more information Drain the coolant See the Coolant topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more information...

Page 198: ...illips screwdriver Slide up the clamp and free the coolant hose from the thermostat Allow any remaining coolant to drain into a suitable container Squeeze the air bleed hose clamp with needle nose pli...

Page 199: ...Remove the two right side cylinder head bolts with an 8 mm socket Also loosen the two cylinder bolts below with an 8 mm socket There are two cylinder head mounting nuts one below the intake port and...

Page 200: ...er nuts in a criss cross pattern over the course of 2 3 loosening sequences When installation Apply engine oil to the threads of the cylinder head nuts Thread on the four cylinder head nuts and tighte...

Page 201: ...inder head off of the studs Guide the cam chain through the opening in the cylinder head but do not allow the chain to fall into the crankcase Remove the cylinder head gasket Remove the two dowel pins...

Page 202: ...4 Engine Downtown 350i 4 28 Remove the two intake mounting nuts with a 10 mm socket Remove the intake from the cylinder head Inspect the intake O ring and replace it as needed...

Page 203: ...he cylinder head Use a 17 mm wrench to remove the water temperature sensor if needed Clean the combustion chamber with contact cleaner a plastic knife brush and or rag Take care to only remove carbon...

Page 204: ...i 4 30 Place a straight edge across the bottom of the cylinder head and check for warp with a feeler gauge You will need to check clearance readings from several places on the bottom of the cylinder h...

Page 205: ...pic for more information Remove the cylinder head See the Cylinder Head topic for more information IMPORTANT Record the position of all parts so they can be returned to their proper place during reass...

Page 206: ...e Downtown 350i 4 32 Remove the spring retainer Remove the valve springs Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head Rotate the valve as it is r...

Page 207: ...4 Engine Downtown 350i 4 33 Remove the valve seal from the valve guide The valve seals should be replaced if they are removed or you are going to install new valves Remove the spring seat...

Page 208: ...4 Engine Downtown 350i 4 34 Inspection Inspect the valve springs for fatigue and damage Replace the valve springs as needed or if the valve is also to be replaced...

Page 209: ...f the measurement is below specification replace the valve Item Standard mm Valve stem O D IN 4 990 4 975 EX 4 970 4 955 Inspect the valve seat and the valve seat width The valve seat should be center...

Page 210: ...e guides if the measurement is out of specification Calculate the valve stem to guide clearance Replace the guide and valve if the clearance is out of specification Item Standard mm Valve guide I D IN...

Page 211: ...nformation Remove the cylinder head cover See the Cylinder Head Cover topic for more information Remove the camshaft sprocket See the Camshaft topic for more information Remove the cylinder head See t...

Page 212: ...ose clamp with a 2 Phillips screwdriver Free the coolant hose from the cylinder Slide the cylinder off of the studs and piston Guide the cam chain through its opening and do not allow if to fall into...

Page 213: ...d around the base of the piston to prevent any parts or debris falling into the crankcase Remove the piston pin clips with a pick or needle nose pliers Discard the piston pin clips Remove the piston p...

Page 214: ...ton rings and lift them off opposite the gap Spread the rings the minimum amount during removal The rings can be easily damaged The two upper rings are each a single piece of metal The oil ring consis...

Page 215: ...ean the carbon build up off of the piston with a stiff bristled plastic brush or rag Never use a wire brush to clean a piston Also clean out the ring grooves You can use an old ring to scrape out any...

Page 216: ...cylinder and piston must be replaced as a set There are two sets of cylinder and piston combinations Make sure to have a No A cylinder with an A piston or a No B cylinder with a B piston Inspect the...

Page 217: ...nt height levels with a dial bore gauge Replace the cylinder and piston as a set if the cylinder is out of specification Calculate the cylinder taper The taper is the maximum difference between either...

Page 218: ...inder to calculate the piston to cylinder clearance Replace the piston and cylinder as needed to achieve a correct piston to cylinder clearance Item Standard mm Piston to cylinder clearance 0 010 0 03...

Page 219: ...of the connecting rod with vernier calipers Item Standard mm Connecting rod small end I D Bore 15 016 15 034 Measure the ring groove width and the ring to groove clearance with feeler gauges Item Sta...

Page 220: ...n the cylinder about an inch Use the piston to push in the ring to keep it square with the cylinder Measure the ring gap with a feeler gauge Repeat this procedure with second ring and the oil side rai...

Page 221: ...4 Engine Downtown 350i 4 47 Check the oil jet for clogs...

Page 222: ...amount possible to install them Do not try and force them on the piston Install the top and second rings with their markings facing up Install the rings to the piston as shown above so that no ring en...

Page 223: ...350i 4 49 Install the oil expander ring so that the ends are not overlapping Install the steel rails above and below the oil ring Lubricate the piston pin and the small end of the connecting rod with...

Page 224: ...hould face the intake side rear of the engine Place the piston over the connecting rod Insert the piston pin into the piston and rod Install new piston pin clips securely into their grooves Turn the g...

Page 225: ...se gasket onto the crankcase Coat the inside of the cylinder piston rings and piston in fresh engine oil Lower the cylinder over the studs and guide the piston into the cylinder while you are compress...

Page 226: ...2 Phillips screwdriver Insert the lower cam chain guide and make sure it is seated correctly Install the cylinder head See the Cylinder Head topic Install the camshaft See the Camshaft topic for more...

Page 227: ...and eyewear are recommended at this point Removal Drain engine oil and remove the oil filter See the Engine Oil topic for more information Drain the coolant See the Coolant topic for more information...

Page 228: ...e the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the right crankcase coolant hose clamp with a 2 Phillips screwdriver Slide up the clamp and...

Page 229: ...4 Engine Downtown 350i 4 55 Remove the 12 generator cover bolts with an 8 mm socket Utilize the pry points and remove the generator cover Remove the generator cover gasket...

Page 230: ...4 Engine Downtown 350i 4 56 Remove the two dowel pins Remove the two oil filter chamber O rings Inspect the O rings and replace them as needed...

Page 231: ...harging System topic For crank position sensor inspection see the Ignition System topic Free the rubber wire grommet from the right crankcase cover Remove the three stator mounting bolts and the two c...

Page 232: ...4 Engine Downtown 350i 4 58 Flywheel To remove the fly wheel two special tools are needed ITEM TOOL NO UNIVERSAL HOLDER E021 ITEM TOOL NO FLYWHEEL PULLER E003...

Page 233: ...4 Engine Downtown 350i 4 59 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket Remove the flywheel nut and washer...

Page 234: ...e threads of the flywheel puller tool before using it Thread the puller onto the flywheel Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the cran...

Page 235: ...4 Engine Downtown 350i 4 61 Slide the starter driven gear off of the crankshaft Remove the woodruff key from the crankshaft...

Page 236: ...starter idle gear and shaft for wear and damage Replace the idle gear and shaft as needed Inspect the starter driven gear for wear and damage Measure the inside and outside diameter of the starter dri...

Page 237: ...starter clutch should only allow the driven gear to turn in one direction If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the starter c...

Page 238: ...ywheel Apply blue Loctite to the threads of the three starter clutch mounting bolts Insert the three starter clutch mounting bolts Tighten the starter clutch mounting bolts to specification with a 6 m...

Page 239: ...ntown 350i 4 65 Lubricate the starter idle gear shaft with fresh engine oil Install the starter idle gear and shaft into the crankcase Flywheel Install the woodruff key into its slot on the end of the...

Page 240: ...l as shown Clean off the tapered end of the crankshaft where the flywheel will ride and make sure the inside of the flywheel is oil free where it will contact the crankshaft Line up the groove in the...

Page 241: ...and flywheel nut Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft ACG flywheel nut 1 14 5 5 6 5...

Page 242: ...generator cover together as shown Insert the two crank position sensor mounting bolts and the three stator mounting bolts Tighten the bolts securely with an 8 mm socket Coat the rubber grommet in sil...

Page 243: ...350i 4 69 Generator Cover Make sure the generator cover mating surface is clean Install the two dowel pins and a new generator cover gasket Make sure the oil filter chamber O rings are in place and i...

Page 244: ...ntown 350i 4 70 Fit the generator cover into place Make sure the water pump shaft engages correctly with the oil pump shaft Insert the 12 generator cover bolts Tighten the bolts securely in a with an...

Page 245: ...right crankcase cover pipe Secure the hose with the clamp and tighten the coolant hose clamp securely with a 2 Phillips screwdriver Connect the coolant hose to the water pump Move the clamp into plac...

Page 246: ...rank position sensor wire coupler on the right side of the frame Fill the engine oil See the Engine Oil topic for more information Install the exhaust system See the Exhaust System topic for more info...

Page 247: ...ow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is i...

Page 248: ...Engine Oil topic for more information Remove the generator cover flywheel starter idle gear and starter driven gear See the A C Generator and Starter clutch topic The oil pump is driven by a chain off...

Page 249: ...over bolts and the oil pump cover Remove the snap ring on the oil pump shaft with snap ring pliers Remove the oil pump drive chain and driven sprocket Inspect the oil pump drive chain and sprocket for...

Page 250: ...pump screws with an impact 3 Phillips screwdriver Remove the filter Remove the oil pump Turn the oil pump shaft by hand and make sure it turns smoothly If the oil pump shaft will not rotate smoothly t...

Page 251: ...e Camshaft topic for more information Remove the cylinder head See the Cylinder Head topic for more information Remove the cylinder and piston See the Cylinder and Piston topic for more information Re...

Page 252: ...ngine Downtown 350i 4 78 Remove the upper cam chain guide bolt with an 8 mm Allen Remove the upper cam chain guide Inspect the cam chain guides for damage and excessive wear Replace the guides as need...

Page 253: ...ankshaft and crankcase Inspect the cam chain for wear and damage Replace the cam chain as needed There are 11 crankcase bolts Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm socket...

Page 254: ...e with the bottom two crankcase bolts Set the crankcases on the right side Separate the halves of the crankcase If needed gently tap the reinforced areas of the right crankcase half with a rubber mall...

Page 255: ...own 350i 4 81 Remove the dowel pins from the crankcase Inspect the O ring and replace it as needed To remove the crankshaft see the Crankshaft topic Replace the left crankshaft seal if the crankcases...

Page 256: ...e the seal with a seal pick Drive the new seal into the left crankcase from the outside with a suitable driver The driver should have the same outside diameter as the seal Lubricate the new crankshaft...

Page 257: ...face Apply sealant uniformly to the crankcase mating surface as indicated Do not allow sealant to enter oil passages or get in bearings Set the right case half down on top of the left Install the engi...

Page 258: ...Insert the 11 crankcase bolts The plate goes on with the bottom two bolts Tighten the bolts securely and evenly in a crisscross pattern with an 8 mm socket Install the cam chain around the timing spro...

Page 259: ...gf m lb ft Cam chain tensioner pivot 1 8 0 8 1 2 5 79 8 68 Install the oil pump See the Oil Pump topic for more information Install the starter idle gear driven gear flywheel and the generator cover S...

Page 260: ...d See the Cylinder Head topic Install the camshaft See the Camshaft topic for more information Install the cylinder head cover See the Cylinder Head Cover topic for more information Install the rear w...

Page 261: ...350i 4 87 Crankshaft SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Split the crankcases See the Crankcase topic for more information Lift the crankshaft out of the l...

Page 262: ...with a feeler gauge Item Standard mm Service Limit mm Crankshaft Connecting rod big end side clearance 0 15 0 35 0 6 Grip the small end of the connecting rod and try and push the rod down towards the...

Page 263: ...how any kind of imperfection Note the bearing color code and crankcase code The crank weights are also marked with a size code When the crankshaft and or crankcases must be replaced also replace both...

Page 264: ...e removal Use shop towels to protect the scooter body during engine removal Place the scooter on the center stand Remove the following external components Seat Center Cover Front Cover Front Lower Cov...

Page 265: ...rake caliper See the Rear Brake Caliper topic for more information Remove the throttle body See the Throttle Body Removal and Installationtopic for more information Remove the exhaust system See the E...

Page 266: ...d nut with a 10 mm wrench Free the cable lead from the starter motor Thread the nut back on to keep track of it Loosen the water pump hose clamp with a 2 Phillips screwdriver Slide up the clamp and fr...

Page 267: ...illips screwdriver Slide up the clamp and free the coolant hose from the thermostat Allow any remaining coolant to drain into a suitable container Squeeze the air bleed hose clamp with needle nose pli...

Page 268: ...an 8 mm socket Remove the bolt and free the engine ground from the right side of the engine Unplug the oil pressure switch wire at the bullet connector The oil pressure switch is located below the cy...

Page 269: ...95 Support the engine with a suitable jack or stand Remove the rear shock absorbers See the Shock Absorbers topic for more information Hold the engine mounting bolts with a 14 mm wrench and loosen the...

Page 270: ...4 Engine Downtown 350i 4 96 Lift up the engine mounting bracket Carefully move the engine back and separate it from the chassis...

Page 271: ...ne Other cooling system service can be done with the engine installed in the frame The engine must be cool before servicing the cooling system When the coolant temperature is over 100 never remove the...

Page 272: ...rmostat Insufficient coolant Passages blocked in hoses or water jacket Clogged radiator fins Passages blocked in radiator Faulty water pump Temperature gauge shows the wrong temperature Faulty tempera...

Page 273: ...or working on the cooling system components To check the coolant level see the Coolant Level Check topic for more information Draining SAFETY FIRST Antifreeze is highly toxic and can kill pets and an...

Page 274: ...p in two stages Allow any built up pressure to vent and then open the cap all the way and remove it The water pump is located on the right side of the engine Ready a drain pan under the water pump dra...

Page 275: ...ng System Downtown 350i 5 5 Remove the drain bolt and sealing washer and allow the coolant to drain into a suitable container The coolant reserve tank is under the left floorboard Remove the left floo...

Page 276: ...2 Phillips And remove the engine coolant lid Open the coolant reserve tank lid Siphon the coolant out of the reserve tank with an appropriate suction device If a suction device is unavailable remove...

Page 277: ...5 Cooling System Downtown 350i 5 7 When the coolant has fished draining return the drain bolt to the water pump with a new sealing washer Tighten the drain bolt securely with an 8 mm socket...

Page 278: ...trate 859cc distilled water is 50 Do not mix coolant concentrate of different brands Do not drink the coolant which is poisonous The freezing point of coolant mixture shall be 5 C lower than the freez...

Page 279: ...cooling system Place the vehicle on its center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles...

Page 280: ...ing System Downtown 350i 5 10 Install the coolant reserve tank lid Install the engine coolant reserve tank cover Insert the screw and tighten its securely with a 2 Phillips Install the left floorboard...

Page 281: ...5 Cooling System Downtown 350i 5 11 Install the front meter cover Install the windshield See the Windshield topic for more information...

Page 282: ...loves and eyewear are recommended at this point Warning Allow the engine sufficient time to cool before handling or working on the cooling system components Pressure Testing Remove the windshield See...

Page 283: ...er neck Pump the tester up until the gauge reads 0 84 kg cm2 or 12 psi The cooling system should hold this pressure for at least 6 seconds If it does not you will need to inspect the entire system for...

Page 284: ...pic for more information Unplug the cooling fan motor connector There are three coolant hoses that connect to the radiator The top right hose runs to the filler neck and cap The top left hose runs to...

Page 285: ...olant hose clamps with a 2 Phillips screwdriver Free the filler neck coolant hose from the stay and remove it from the radiator Remove the water pump and thermostat hoses in the same manner Remove the...

Page 286: ...5 Cooling System Downtown 350i 5 16 Slide the radiator to the left and free the grommet from the post above the right side of the radiator Remove the radiator from the frame...

Page 287: ...tank is mounting to the frame with two bolts There are two hoses that connect to the reserve tank The top hose is a dump hose that hangs over the other side The bottom hose is the overflow hose that...

Page 288: ...ck the clamp and free the overflow hose from the bottom of the reserve tank Allow the coolant in the reserve tank to drain into the container Remove the two reserve tank mounting bolts with a 10 mm so...

Page 289: ...5 Cooling System Downtown 350i 5 19 To remove the reserve tank bracket take off the mounting nuts with a 10 mm socket Remove the reserve tank bracket from the studs on the frame...

Page 290: ...for damage and clogging To remove the fan take out the three mounting bolts with a 10 mm socket Clean out the fins with low pressure compressed air and water NOTE Always wear safety glasses when usin...

Page 291: ...Check the radiator for any bent or damaged fins Use a small flat blade screwdriver to straighten them out but be careful not to puncture the radiator Jump a 12 volt battery to the fan connector and m...

Page 292: ...ore information Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for mor...

Page 293: ...5 Cooling System Downtown 350i 5 23 Use a 17 mm wrench to remove the water temperature sensor Discard the WTS O ring and replace it with a new item...

Page 294: ...sen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Squeeze the air bleed hose clamp with needle nose pliers and slide back the...

Page 295: ...5 Cooling System Downtown 350i 5 25 Remove the two thermostat mounting bolts with an impact 3 Phillips screwdriver Lift off the thermostat cover...

Page 296: ...O ring and discard it Inspection Water Temperature Sensor Inspect the WTS in a simlar manner as the thermosensor Measure the resistance between the WTS terminals and compare this to the specification...

Page 297: ...not touching the pot Bring the temperature up to the specification slowly and check the operation of the thermostat The valve should begin to open around 71 C 160 F The valve should lift 3 5 4 5 mm 0...

Page 298: ...r pump for signs of coolant leaking If there is coolant coming from this hole the mechanical seal is compromised and must be replaced Removal Water Pump Cover Drain the coolant See the Coolant topic f...

Page 299: ...5 Cooling System Downtown 350i 5 29 Loosen the four water pump cover bolts with an 8 mm socket Remove the bolts and the water pump cover Remove the two dowel pins and the water pump cover gasket...

Page 300: ...r clutchtopic for more information Hold the water pump shaft and loosen the impeller with a 12 mm socket The impeller has left hand threads Remove the impeller Remove the seal washer from the back of...

Page 301: ...Note Left hand threads Hold the water pump shaft and tighten the impeller to specification with a 12 mm socket Remember the impeller has left hand threads Item Qty Thread size mm Torque kgf m lb ft Wa...

Page 302: ...ICE INFORMATION GENERAL INSTRUCTIONS Scooter services can be done with the engine installed in the frame Be sure to relieve the fuel pressure before fuel pump or fuel hose removal Bending or twisting...

Page 303: ...synchronization Do not take the fuel pump on the ground downward Always replace the packing when the fuel pump is removed The electronic fuel injection system is equipped with the self diagnostic sys...

Page 304: ...pump operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Backfiring or misfiring during acceleration Ignition system malfunction Engine stall hard to s...

Page 305: ...s point Removal Remove the air filter see the Air Filter Servicing topic for more information Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic f...

Page 306: ...6 Fuel System Downtown 350i 6 5 Remove the breather hose from the airbox Remove the two rear airbox bolts and washers...

Page 307: ...6 Fuel System Downtown 350i 6 6 Remove the breather hose connecting of the gear box and airbox Remove the two front airbox bolts with an 8 mm socket And remove the airbox...

Page 308: ...6 Fuel System Downtown 350i 6 7...

Page 309: ...gloves and eyewear are recommended at this point Warning Gas is extremely flammable Do not work around an open flame or a source of sparks Removal Seat Windshield Front Cover Front Center Cover Handl...

Page 310: ...e the fuel pressure unplug the fuel pump connecter Start the engine and let it run until it dies of fuel starvation Turn the ignition switch off Loosen the fuel hose clamp Slide back the clamp and fre...

Page 311: ...6 Fuel System Downtown 350i 6 10 Note When slide back the fuel hose carefully not to damage the fuel pump pipe and replace the clamp with a new one when installation Remove the fuel tank mounting nuts...

Page 312: ...6 Fuel System Downtown 350i 6 11 Remove the fuel tank mounting nuts Remove the fuel tank mounting nuts and brackets Remove the fuel tank from the bottom of the frame...

Page 313: ...6 Fuel System Downtown 350i 6 12...

Page 314: ...t work around an open flame or a source of sparks Input Voltage Inspection Remove the seat See the Seat topic for more information Remove the luggage box See the Seat topic for more information Remove...

Page 315: ...side of the fuel pump connector with the positive lead touching the red black wire terminal and the negative lead touching the green wire terminal Turn the ignition switch on The battery voltage shoul...

Page 316: ...lease the fuel pressure unplug the fuel pump connecter Start the engine and let it run until it dies of fuel starvation Turn the ignition switch off Loosen the fuel hose clamp Slide back the clamp and...

Page 317: ...e back the clamp and free the injector fuel hose from the fuel pump pipe Clean up any remaining fuel immediately Remove the 6 fuel pump bolts with a 7 mm socket or 2 Phillips screwdriver Lift the fuel...

Page 318: ...tor terminals green and yellow white with the float raised to the positions indicted below When installation replace the O ring with new item and apply a small amount of fresh engine oil to the new O...

Page 319: ...6 Fuel System Downtown 350i 6 18 Fuel Level Float Position Resistance Full 1100 33 Empty 100 3 Replace the fuel level float unit with a new part if the resistance is out of specification...

Page 320: ...tput Pressure Turn the key to the OFF position Use a fuel hose clamp as shown Disconnect the fuel hose from the fuel injector Connect the fuel pressure gauge Remove the fuel hose clamp Turn the key to...

Page 321: ...0 bar may fail to start the engine or in trouble in case of riding Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose Return the fuel line to the injector To inspect t...

Page 322: ...the voltage is over 12V with a voltmeter after replacement Check and confirm if the other connectors are installed correctly after replacement Do not damage the throttle body it may cause the throttle...

Page 323: ...cooter on a level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON position Measure if the ECU voltage outputs to the MAP between the following terminals o...

Page 324: ...Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal Vi...

Page 325: ...c for more information Remove the luggage box See the Seat topic for more information Adjust the throttle cables for maximum free play at the throttle body See the Throttle Free Play topic for more in...

Page 326: ...en flame or a source of sparks Disconnect the Component Location or Fuel Pump In order to release fuel pressure from the fuel pipe when removing the fuel injector unplug the fuel pump connecter Start...

Page 327: ...jector mounting bolt with a 10 mm socket Unplug the fuel injector connector Lift the fuel injector out of the intake pipe Loosen the fuel hose clamp with a 2 Phillips screwdriver Slide back the clamp...

Page 328: ...6 Fuel System Downtown 350i 6 27 Lift the fuel pipe off the top of the injector...

Page 329: ...6 Fuel System Downtown 350i 6 28 Sensors Unplug the MAP sensor Unplug the ISC connector...

Page 330: ...6 29 Throttle Body Unplug the throttle position sensor TPS connector Loosen the airbox hose clamp screw at the throttle body with a 2 Phillips Loosen the intake hose clamp screw at the throttle body w...

Page 331: ...6 Fuel System Downtown 350i 6 30 Remove the throttle out of the airbox and intake boots To disassemble the throttle body see the Throttle Body topic for more information...

Page 332: ...ISC have to be reset when the throttle body MAP TPS ISC or ECU have been reinstalled See the TPS ISC Reset Procedure for more information Apply a light coat of fresh engine oil to a new fuel injector...

Page 333: ...Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the handlebar covers See the Handlebar Covers topic for more information Adjust the throttl...

Page 334: ...ousing mounting screws with a 2 Phillips screwdriver Disconnect the switch Separate the switch housing from the handlebar Disconnect the throttle cables and free the right switch housing from the hand...

Page 335: ...Downtown 350i 6 34 Notes of installation Route the throttle body end of the cables through the opening in the lower handlebar cover Route the cables through the guide Route the cables to the throttle...

Page 336: ...he end of the throttle in grease Fit the ends of the throttle cables into the throttle tube Adjust the throttle cable free play with 12 mm wrenches See the Throttle Free Play topic for more informatio...

Page 337: ...point Remove the throttle body See the Throttle Body Removal and Installationtopic for more information Disassembly The throttle position sensor TPS and idle air bypass valve ISC have to be reset whe...

Page 338: ...l System Downtown 350i 6 37 MAP Sensor Remove the MAP sensor set plate screw with a 2 Phillips Remove the set plate and MAP sensor ISC Air Bypass Valve Remove the ISC screw with a 2 Phillips Remove th...

Page 339: ...TPS Sensor Remove the TPS sensor with a T 25 Torx Assembly TPS Sensor Apply oil onto a new O ring Install the TPS onto the throttle body being careful not to damage the O ring Install and tighten the...

Page 340: ...ntown 350i 6 39 ISC Air Bypass Valve Apply oil onto a new O ring Install the ISC and set plate onto the throttle body being careful not to damage the O ring Install the ISC screw and tighten securely...

Page 341: ...w O ring Install the MAP onto the throttle body being careful not to damage the O ring Install the MAP sensor set plate screw and tighten securely with a 2 Phillips Install the throttle body See the T...

Page 342: ...ore information Remove the luggage box See the Luggage Box topic for more information SAFETY FIRST Protective gloves and eyewear are recommended at this point Warning Gas is extremely flammable Do not...

Page 343: ...Inspect the fuel hose for signs of deterioration or damaged Replace the fuel hose as needed Unplug the fuel injector connector Remove the fuel injector mounting bolt with a 10 mm socket Lift the fuel...

Page 344: ...6 Fuel System Downtown 350i 6 43 Loosen the fuel hose clamp Slide back the clamp and free the injector fuel pipe from the fuel hose Lift the fuel pipe off the top of the injector...

Page 345: ...ure the resistance between the fuel injector terminals ITEM SPECIFICATIONS Fuel injector resistance at 20 C 68 F 9 9 13 5 Inspect the seals on both sides of the fuel injector Replace the injector if t...

Page 346: ...dard 1 6ms ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container 3 Connect the battery as pictu...

Page 347: ...tion when the engine is running because the ECU or the throttle body has been reinstalled It can cause engine to stop hard to start engine or rough idling speed The throttle position sensor TPS and id...

Page 348: ...nt Note No matter when the CELP illuminated while riding condition should find out the cause of the problem as soon as possible The check engine lamp CELP or Fi indicator is located next to the batter...

Page 349: ...6 Fuel System Downtown 350i 6 48 Without Diagnostic Special Tool SELF DIAGNOSTIC PROCEDURES Place the scooter on its main stand and put the side stand up Set the engine stop switch to the RUN position...

Page 350: ...odes would be appeared repeatedly It can be performed without diagnostics program EFI SELF DIAGNOSIS FAILURE CODES The CELP denotes the failure codes When the indicator lights for one second that is e...

Page 351: ...Tilt switch voltage range inclined angle 65 0 4 1 4 V Inclined angle 65 3 7 4 4 V Loose or poor connection on Tilt switch Open or short circuit in Tilt switch wire Faulty tilt switch Engine operates n...

Page 352: ...aulty O2 sensor heater range 6 7 9 5 Loose or poor connection on O2 sensor heater Open or short circuit on O2 sensor heater wire Faulty O2 sensor heater Engine starts normally but not smooth 49 P1505...

Page 353: ...the side stand up and engine stop switch is at RUN 2 Turn the key to the ON position and wait for ten seconds 3 Fully open the throttle and wait for ten seconds 4 Release the throttle 5 After 5 secon...

Page 354: ...idling speed ISC has a motor inside which controls air bypass valve to obtain a smooth idling speed The ECU may record the incorrect ISC position when the ECU or the throttle body has been reinstalle...

Page 355: ...00 This tool has been developed by KYMCO and for KYMCO vehicles only The tool software can be updated for new models with a computer via the USB cable Please refer to the specifications when serving t...

Page 356: ...6 Fuel System Downtown 350i 6 55 Remove the PDA panel located at the rear of the luggage box and free the PDA plug...

Page 357: ...e side stand up prior to using the diagnostic tool The functions of the diagnostic tool include ECU version model name data analysis and reset ECU version includes model name ECU number identification...

Page 358: ...l display when the tool is powered on The model name will show LEA7 for the Downtown 300i Pressing the enter button on the ECU version will show model name ECU number identifications number and softwa...

Page 359: ...i 6 58 DTC Diagnostic Trouble Code INSPECTION PROCEDURE Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring...

Page 360: ...down button to select the load DTC option Press the enter button on the Load DTC item to display the DTC options Move the selector to the Current option and press enter to display current DTC The dia...

Page 361: ...Tilt switch voltage range inclined angle 65 0 4 1 4 V Inclined angle 65 3 7 4 4 V Loose or poor connection on Tilt switch Open or short circuit in Tilt switch wire Faulty tilt switch Engine operates n...

Page 362: ...7 9 5 Loose or poor connection on O2 sensor heater Open or short circuit on O2 sensor heater wire Faulty O2 sensor heater Engine starts normally but not smooth 49 P1505 Faulty ISC Loose or poor conta...

Page 363: ...m Downtown 350i 6 62 DTC Clear Procedure Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring up the options...

Page 364: ...own 350i 6 63 Move the selector down to the Clear DTC option and press enter The diagnostic tool will show when the DTC in memory are cleared Also the DTC indicator light between the center and right...

Page 365: ...button right to move the item selector down to the DATA Analyze item Press enter to bring up the DATA Analyze page 01 shown below Press the down button to continue through the seven DATA Analyze page...

Page 366: ...m Downtown 350i 6 65 Page 02 The 02 page shows TPS position intake pressure and intake air temperature if available Page 03 The 03 page shows atmosphere pressure fuel injector interval and ignition ad...

Page 367: ...6 Fuel System Downtown 350i 6 66 Page 04 The 04 page shows engine temperature 02 sensor voltage and 02 heater activation Page 05 The 05 page shows the ISC target ISC step and ISC learn step...

Page 368: ...6 Fuel System Downtown 350i 6 67 Page 06 The 06 page shows the ISC motor stage Page 07 The 07 page shows the Cut Out voltage...

Page 369: ...en pulley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive...

Page 370: ...nuously Variable Transmission Downtown 350i 7 2 Belt Case SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the mounting bolts of belt case cover Remove the belt...

Page 371: ...7 CVT Continuously Variable Transmission Downtown 350i 7 3 Remove the bolts of belt case and remove the belt case Remove the bolts of filter and remove the filter...

Page 372: ...7 CVT Continuously Variable Transmission Downtown 350i 7 4 Remove the belt case cover and gasket Remove the two dowel pins...

Page 373: ...ion Downtown 350i 7 5 Inspection Inspect the drive belt for cracks or excessive wear Inspect the belt case bearing by turning it with a finger Replace the bearing if it is rough or noisy Remove the be...

Page 374: ...ransmission Downtown 350i 7 6 Remove the bearing with a suitable bearing puller Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing Install a new sn...

Page 375: ...ective gloves and eyewear are recommended at this point Remove the belt case See the Belt Case topic for more information Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen...

Page 376: ...7 CVT Continuously Variable Transmission Downtown 350i 7 8 Remove the left face of the drive pulley Loosen the driven pulley nut with a 19 mm socket Remove the driven pulley nut and bushing...

Page 377: ...7 CVT Continuously Variable Transmission Downtown 350i 7 9 Slide the driven pulley off of the shaft Remove the belt from the driven pulley Inspect the drive belt for cracks or excessive wear...

Page 378: ...ntinuously Variable Transmission Downtown 350i 7 10 Remove the right movable face of the drive pulley from the crankshaft Slide the bushing out of the movable drive face Remove the washer from the cra...

Page 379: ...ion Downtown 350i 7 11 Drive Pulley Disassembly Inspect the faces of the drive pulley Clean away any grease from the faces Lift the ramp plate out of the back of the movable drive pulley face Remove t...

Page 380: ...drive pulley Remove the rollers and check them for excessive or uneven wear Measure the outside diameter of the rollers Replace the weight rollers as needed Item Standard mm Service Limit mm Weight ro...

Page 381: ...mbly Lift the clutch outer off of the centrifugal clutch Inspect the inside of the clutch outer for excessive wear and damage Measure the inside diameter of the clutch outer and replace the part as ne...

Page 382: ...s below the service limit Item Standard mm Service Limit mm Clutch lining thickness 4 0 2 0 To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch ITEM TOOL NO DESC...

Page 383: ...Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Secure the spring compressor tool in a vise Loosen the clutch drive plate nut with the special socket that co...

Page 384: ...Transmission Downtown 350i 7 16 Inspect the left side bearing by turning it with a finger If the bearing is rough turning or noisy it should be replaced Remove the clutch spring compressor tool Lift...

Page 385: ...CVT Continuously Variable Transmission Downtown 350i 7 17 Remove the collars and spring Measure the free length of the clutch spring Replace the spring if the measurement fails to meet the service lim...

Page 386: ...usly Variable Transmission Downtown 350i 7 18 Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver Lift off the plate Slide the clutch shoes off of the pivots on th...

Page 387: ...7 CVT Continuously Variable Transmission Downtown 350i 7 19 Inspect the clutch shoe bumpers and replace them as needed...

Page 388: ...ously Variable Transmission Downtown 350i 7 20 Driven Pulley Disassembly Remove the clutch as shown above Remove the four guide rollers with guide roller pins Separate the left and right faces of the...

Page 389: ...ontinuously Variable Transmission Downtown 350i 7 21 Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides Remove the seals from the left face of the driven...

Page 390: ...itable driver with the same outside diameter as the seal Remove the O rings on the left face Clean the left face and roller pins with a high flash point solvent and compressed air NOTE Always wear saf...

Page 391: ...7 CVT Continuously Variable Transmission Downtown 350i 7 23 Bearing Replacement Inspect the bearings in the right face of the driven pulley Remove the needle bearing with a suitable puller...

Page 392: ...sed air NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else Drive in the new baring so the sealed side face out towards the clutch Install...

Page 393: ...7 CVT Continuously Variable Transmission Downtown 350i 7 25 Lubricate the bearings in the right face of the driven pulley with grease...

Page 394: ...Installation SAFETY FIRST Protective gloves and eyewear are recommended at this point Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease Drive in the new seals wi...

Page 395: ...Install the O rings to the left face of the driven pulley Coat the O rings seals and inside of the left face where it rides on the right face with grease Fit the left face onto the right face Wipe awa...

Page 396: ...s and rollers with grease Place the rollers on the pins and insert the pins into driven pulley as shown Clutch Apply a light coat of grease to the brake shoe pivot pins on the drive plate Install the...

Page 397: ...CVT Continuously Variable Transmission Downtown 350i 7 29 Connect the clutch shoes with the springs as shown Slide the clutch shoes onto the drive plate pivots Fit the plate onto the clutch shoe pivot...

Page 398: ...ariable Transmission Downtown 350i 7 30 Install the three clutch shoe pivot circlips Install the seal collar and spring Install the spring collar into the spring and set the centrifugal clutch on top...

Page 399: ...y Variable Transmission Downtown 350i 7 31 Set the clutch fitting tool to onto the clutch Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Thread on the clutc...

Page 400: ...n with the special socket that comes with the fitting tool Item Qty Torque kgf m lb ft Clutch drive plate nut 1 7 5 55 32 Wipe away any excess grease Do not allow grease to contact the clutch shoe lin...

Page 401: ...he back of the movable drive face of the driven pulley Position the rollers so that their colored sides are clockwise Insert the four rubber damper pieces into the ramp Fit the ramp into the back of t...

Page 402: ...and Belt Slide the drive pulley washer onto the crankshaft Insert the bushing into movable drive face of the drive pulley Slide the movable face of the drive pulley onto the crankshaft Make sure the d...

Page 403: ...350i 7 35 Fit the Belt in between the faces of the driven pulley Spread the faces by had if needed in get the belt to fit Slide the driven pulley and clutch assembly onto the final drive shaft Positio...

Page 404: ...mission Downtown 350i 7 36 Install the driven pulley bushing and nut Torque the driven pulley nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft Clutch outer nut drive...

Page 405: ...nuously Variable Transmission Downtown 350i 7 37 Slide the left face of the drive pulley onto the crankshaft Lubricate the threads of the drive pulley nut with engine oil Install the drive pulley wash...

Page 406: ...Hold the drive pulley with a universal holder tool and torque the nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft Drive face nut 1 14 9 0 10 0 65 10 72 33 Install...

Page 407: ...components for the KYMCO Downtown 350i model Final Drive Oil 8 3 Final Reduction 8 8 Downtown 350i parts diagram GENERAL INSTRUCTIONS The servicing operations of this section can be made with the engi...

Page 408: ...50i 8 2 TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high...

Page 409: ...ve gloves and eyewear are recommended at this point Place the scooter on level ground and up on its center stand The oil drain bolt and oil filler bolt are located on the transmission Gear oil type SA...

Page 410: ...n pan under the transmission oil drain plug Remove the transmission oil level filler bolt with a 12 mm socket Place a suitable container under the drain plug to capture the final drive oil Loosen the...

Page 411: ...wn 350i 8 5 Inspect the drain plug and washer Install the oil drain plug and washer with a 12 mm socket Tighten to specification Item Qty Thread size mm Torque kgf m lb ft Final drive oil drain bolt 1...

Page 412: ...350i 8 6 Filling Fill the final drive with the specified quantity of oil with a syringe Gear oil type SAE 90 Gear oil capacity At disassembly 0 23 Liter At change 0 21 Liter Thread in the final drive...

Page 413: ...Final Drive Downtown 350i 8 7 Install the oil filler plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil filler bolt 1 8 0 8 1 2 5 79 8 6...

Page 414: ...t If the drive shaft is replaced make sure to also replace the bearing and oil seal Remove the belt case See the Belt Case topic for more information Remove the CVT belt and pulleys See the CVT Remova...

Page 415: ...8 Final Drive Downtown 350i 8 9 Remove the 9 transmission case cover bolts using a 12 mm socket Utilize the reinforced pry points and remove the case cover...

Page 416: ...8 10 Use a press to remove the drive shaft Thread a nut onto the drive shaft to protect the threads If the drive shaft is to be replaced also replace the seal Remove the two dowel pins and the gasket...

Page 417: ...8 Final Drive Downtown 350i 8 11 Remove the countershaft Remove the final shaft...

Page 418: ...ntershaft gear for wear or damage Inspect the final gear and final shaft for wear damage or seizure If the final shaft snap ring is removed replace it with a new item Check the left crankcase bearings...

Page 419: ...transmission case cover bearings for excessive play Inspect the drive shaft drive shaft bearing and oil seal for wear or damage Use a bearing puller to remove the crankcase or transmission case cover...

Page 420: ...e same outside diameter as the bearings The bearings should go in square and have their markings facing out Drive in a new seals in the same manner if needed Installation Lubricate the final drive bea...

Page 421: ...Insert the final shaft through the oil seal and bearing Install the countershaft into its bearing as shown Install the final gear onto the final shaft as shown Install the dowel pins Install a new ga...

Page 422: ...transmission case cover bolts Tighten the bolts to specification using a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Transmission case bolts 9 8 0 8 1 2 1 7 2 6 Install the rear wheel See...

Page 423: ...battery can be charged and discharged repeatedly If a discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after it is u...

Page 424: ...cified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition s...

Page 425: ...mittent power Loose battery cable connection Loose charging system connection Loose connection or short circuit in the ignition system Low power Weak battery Loose battery connection Charging system f...

Page 426: ...factory The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn...

Page 427: ...round wire of the ignition control module Faulty crank position sensor Faulty ignition control module Peak voltage is normal but no spark jumps at the plug Faulty spark plug or leaking ignition coil s...

Page 428: ...otor Starter motor rotates but engine does not start Faulty starter pinion Starter motor rotates in reverse Weak battery Lights Switches AND Fuel Pump GENERAL INSTRUCTIONS Note the following when repl...

Page 429: ...each component TROUBLESHOOTING Lights do not come on when ignition switch is ON Burned bulb Faulty switch Poorly connected broken or shorted wire Temperature gauge does not register correctly Faulty...

Page 430: ...ark plug Standard type NGKCR7E Spark plug gap 0 6 0 7 mm Inductive Ignition Coil Primary coil 3 57 4 83 Secondary coil without plug cap 10 42 14 49 K Throttle Position Sensor 3500 6500 Fuel Pump 1 9 a...

Page 431: ...40 C 104 F 1 136 K At 100 C 212 F 0 1553 K Item Standard Service Limit Starter motor brush length 12 5 mm 8 5 mm Fuse 10A 15A 30A 40A ABS Model Headlight bulb 12V 55W 55W 2 Front position LED 12V LED...

Page 432: ...es SAFETY FIRST Protective gloves and eyewear are recommended at this point Fuse Box Remove the seat and the luggage box See the Seat topic for more information The fuse box is located on top of the b...

Page 433: ...e the front cover See the Front Cover topic for more information Note The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON The excessive volt...

Page 434: ...9 Electrical Systems Downtown 350i 9 12 Remove the two mounting nuts with a socket Remove the bracket and remove the ECU...

Page 435: ...between pin 9 and 10 of the ECU side connector There should be continuity at all times Check for continuity between each pins 2 4 and 23 of the ECU side connector There should be continuity at all tim...

Page 436: ...e electrical connections are not loose or corroded Spark Plug Inspection Check the spark plug to see if it is the correct type and gapped properly If the spark plug is black and fouled replace it See...

Page 437: ...9 Electrical Systems Downtown 350i 9 15 Ignition Coil Removal Remove the two ignition coil leads Remove the two ignition coil mounting bolts with an 8 mm socket Remove the ignition coil...

Page 438: ...on Coil Resistance Primary Set the multimeter to read ohms of resistance Touch the positive and negative meter leads to the ignition coil terminals as shown Measure the resistance Ignition Coil Primar...

Page 439: ...ositive meter lead to the spark plug cap as shown Secondary Resistance With Plug Cap 15 19 k Secondary Without Plug Cap Check the secondary resistance between the ignition coil terminal and the spark...

Page 440: ...is performed with the stator installed in the engine Disconnect the crank position sensor wire coupler Measure the resistance between the and green white and blue yellow wire terminals Resistance Blu...

Page 441: ...pic for more information Note The battery should be fully charged prior to making charging system checks Start the engine and warm it up to the operating temperature stop the engine Connect the multim...

Page 442: ...the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information The regulator rectifier is located on the left side of the vehicle Disconnect the regulator re...

Page 443: ...Battery Wire Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all times Ground Wire Check the continuity between the Green wire terminal and ground...

Page 444: ...the generator 3 pin connector Check the connectors for loose contacts or corroded terminals Measure the resistance between each Yellow wire terminals Check for continuity between each yellow wire term...

Page 445: ...9 Electrical Systems Downtown 350i 9 23 Removal Disconnect the two regulator rectifier connectors Remove the two mounting nuts with a 10 mm socket Remove the regulator rectifier...

Page 446: ...id is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention Removal Remove the seat See the...

Page 447: ...ack of the vehicle Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the negative cable from the battery Remove the positive battery cable bolt with a 10 mm soc...

Page 448: ...ray Testing Check the battery voltage with a multi meter Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal If the battery reads under...

Page 449: ...y terminals Keep open flames away from a charging battery Standard Charge 1 2 Amps 5 10 Hours Note For battery charging do not exceed the charging current and time specified on the battery Using exces...

Page 450: ...9 Electrical Systems Downtown 350i 9 28 Relays SAFETY FIRST Protective gloves and eyewear are recommended at this point...

Page 451: ...hms of resistance Connect the multimeter to the fuel cut off relay connector terminals Connection Black Red Black Connect 12 V battery with the fuel cut off relay connector Connection Blue Black Black...

Page 452: ...r are recommended at this point You will need a digital multimeter to inspect the starting system Starter Relay Inspection Remove the body cover See the Body Cover topic for more information The start...

Page 453: ...ter button is depressed If there is no continuity check the starter button for continuity and inspect the wire Operation Test Remove the battery cover See the Battery topic for more information Turn t...

Page 454: ...9 Electrical Systems Downtown 350i 9 32 Remove the two terminal covers Remove the nuts that hold the starter motor lead and battery lead wires to the starter relay with a 10 mm socket...

Page 455: ...t to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter...

Page 456: ...l Remove the battery cover See the Battery topic for more information Turn the ignition switch to OFF Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the nega...

Page 457: ...starter motor lead nut with a 10 mm wrench Free the cable lead from the starter motor Thread the nut back on to keep track of it Remove the two starter motor mounting bolts with an 8 mm socket Inspect...

Page 458: ...ntown 350i 9 36 Switches SAFETY FIRST Protective gloves and eyewear are recommended at this point You will need a digital multimeter to inspect the switches Ignition Switch Unplug the white six pin ig...

Page 459: ...9 Electrical Systems Downtown 350i 9 37 Use a digital multimeter to check for continuity to inspect the ignition switches Continuity should exist between the wires as indicated...

Page 460: ...9 Electrical Systems Downtown 350i 9 38 Removal Remove the seat latch cable cover...

Page 461: ...screw with a 2 Phillips screwdriver Remove the seat latch cable screw and free the seat latch cable from the ignition switch To remove the anti tamper bolts use a punch and a hammer to strike the bolt...

Page 462: ...o OFF Note Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged The tilt switch is located in the front near the radiator cap Remove the two tilt...

Page 463: ...tage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 3 7 4 4 V Note Repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON Di...

Page 464: ...tches Remove the front cover See the Front Cover topic for more information To remove the handle bar switches see the Handlebar topic Unplug the black connector for the left handlebar switches Unplug...

Page 465: ...Electrical Systems Downtown 350i 9 43 Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indicate...

Page 466: ...Electrical Systems Downtown 350i 9 44 Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indicated...

Page 467: ...350i 9 45 Luggage Box Switch Remove the luggage box See the Luggage Box topic for more information Unplug the two pin luggage box light switch connector with red white and green red wires Remove the...

Page 468: ...he three pin side stand switch connector Use a digital multimeter to check for continuity With the side stand retracted there should be continuity between the yellow green wire and the green wire term...

Page 469: ...e the upper handlebar cover See the Handlebar Covers topic for more information Unplug the brake light switch connectors Check for continuity between the brake light switch connectors There should be...

Page 470: ...ed at this point For general information and troubleshooting for the lights see the Electrical Systems chapter landing page Headlight Bulb Replacement Make sure the machine has been off for several mi...

Page 471: ...9 Electrical Systems Downtown 350i 9 49 Remove the front position LED connecter Slide back the head light bulb connecter...

Page 472: ...ur bare hands if you plan to reuse it Do not touch your new bulb with your bare hand The oils on your hand can cause an early failure of the headlight bulb If you do touch the bulb with your bare hand...

Page 473: ...9 Electrical Systems Downtown 350i 9 51 Aim Turn the screws to adjust the head light aim as needed...

Page 474: ...9 Electrical Systems Downtown 350i 9 52 Front Turn Signals Remove 3 screws of the turn signal light set And remove the turn signal light set Replace the turn signal light bulb if needed...

Page 475: ...the Seat topic for more information Remove the turn signal sockets with bulbs from the turn signal lamps Remove the bulbs from the tail light housing by turning it counterclockwise Replace the bulbs...

Page 476: ...op light LED Remove the rear cover See the Body Cover topic for more information Repalce Check the tail stop light LED if the LED fail to light replace the whole module with a new one Change the whole...

Page 477: ...ht Remove the license tag light from the mud flap See the Body Cover topic for more information Remove the screws Pull the rubber tag light socket out of its housing Pull the bulb straight out and ins...

Page 478: ...this point Remove the front cover See the Front Cover for more information Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds wh...

Page 479: ...10 22 Front Brake Caliper 10 26 Rear Brake Caliper 10 31 Brake Disc 10 37 ABS 10 42 GENERAL INSTRUCTIONS During servicing keep oil or grease off the brake pads and brake disk TROUBLESHOOTING Poor bra...

Page 480: ...stem Downtown 350i 8 2 Brake Pad Replacement SAFETY FIRST Protective gloves and eyewear are recommended at this point Replace the pads if the brake wear exceeds the wear indicator lines or if the wear...

Page 481: ...10 Brake System Downtown 350i 8 3 Front Remove the screw and loosen the brake pad pin with a 5 mm Allen Remove the two caliper mounting bolts with a 12 mm socket And remove the front caliper...

Page 482: ...eter sensor mounting bolt with an 8 mm socket And remove the speedometer sensor Remove the brake pad pin Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or if...

Page 483: ...hown Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring and insert the brake pad pin It may be necessary to spread the pads and force the pistons back in...

Page 484: ...front caliper Guide the brake disc between the pads Line up the caliper bracket mounts with the fork Install the two caliper bracket mounting bolts Tighten the mounting bolts to specification Item Tor...

Page 485: ...or mounting bolt with an 8 mm socket Item Torque N m lb ft Speed sensor cable 9 80 13 73 7 23 10 13 Tighten the brake pad pin securely with a 5 mm Allen Pump the brake lever to seat the caliper piston...

Page 486: ...on Remove the rear fender See the Rear Fender topic for more information If the caliper is to be disassembled the brake hose must be removed Drain the rear brake fluid See the Brake Fluid topic for mo...

Page 487: ...10 Brake System Downtown 350i 8 9 Remove the two rear caliper mounting bolts with a 12 mm socket Remove the rear caliper from the swingarm...

Page 488: ...ve the brake pads to the center gap in the pad retainers and lift the pad out If needed use the piston side pad to push the pistons in to allow for more room Replace the pads if the brake wear exceeds...

Page 489: ...and then move the pad into the retainer If needed use the piston side pad to push the pistons in to allow for more room Install the rear caliper onto the swingarm Install the two caliper bracket moun...

Page 490: ...system with fresh brake fluid and bleed out the air See the Brake Fluid topic for more information Pump the brake lever to seat the caliper pistons against the pads Check the operation on the brakes b...

Page 491: ...paints and some plastics Avoid contact with skin Removal The master cylinders for the front and rear brakes are essentially the same Remove the handlebar covers See the Handlebar topic for more inform...

Page 492: ...10 Brake System Downtown 350i 8 14 Unplug the brake light switch connector Remove the two master cylinder mounting bolts with an 8 mm socket Remove the master cylinder clamp Remove the master cylinder...

Page 493: ...em Downtown 350i 8 15 Remove the two master cylinder cover screws with a 2 Phillips head screwdriver Remove the master cylinder cover plastic piece and rubber accordion diaphragm Pour out any remainin...

Page 494: ...e System Downtown 350i 8 16 Disassembly Brake Levers Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt with a flat blade screwdriver Remove the pivot nut and bolt Remove the brak...

Page 495: ...he brake light switch mounting bolt with a 2 Phillips screwdriver Remove the brake light switch Piston Remove the rubber piston cover Remove the snap ring using a pair of internal snap ring pliers Use...

Page 496: ...10 Brake System Downtown 350i 8 18 Remove the piston spring and cups Remove the spring from the piston and...

Page 497: ...e the parts as needed Inspect the piston and cups for wear and damage Measure the outside diameter of the piston Item Standard mm in Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 Inspect t...

Page 498: ...ston Place a film of clean DOT 4 brake fluid on the piston spring and master cylinder bore Install the master cylinder piston and spring into the master cylinder bore Compress the snap ring with inter...

Page 499: ...10 Brake System Downtown 350i 8 21 Install the rubber boot over the end of the master cylinder piston...

Page 500: ...10 Brake System Downtown 350i 8 22 Brake Light Switch Install the brake light switch Tighten the mounting screw securely with a 2 Phillips screwdriver Brake Levers Install the brake lever...

Page 501: ...350i 8 23 Apply a light coat of grease to brake lever pivot bolt Insert the pivot bolt from above and thread on the nut Tighten the brake lever bolt with a flat blade screwdriver and then tighten the...

Page 502: ...on Position the master cylinder on the handlebar Install the master cylinder clamp Be sure to insert the pin on the clamp into the hole on the handlebar Install the two master cylinder mounting bolts...

Page 503: ...banjo bolt Use new sealing washers Tighten the banjo bolt to specification with a 12 mm socket Item Torque N m lb ft Banjo bolt 35 25 8 Fill the master cylinder reservoir s with brake fluid and bleed...

Page 504: ...Caliper SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the screw and loosen the brake pad pin with a 5 mm Allen Remove the two caliper mounting bolts with a 1...

Page 505: ...meter sensor mounting bolt with an 8 mm socket And remove the speedometer sensor Remove the brake pad pin Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or i...

Page 506: ...shown Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring and insert the brake pad pin It may be necessary to spread the pads and force the pistons back i...

Page 507: ...pect the pistons for wear and damage Measure the outside diameter of the piston with a micrometer and compare the measurement with the specification Replace the pistons as needed Item Standard mm in B...

Page 508: ...ores for wear and damage Inspect the piston bores for wear and damage Measure the inside diameter of the piston bore with a telescoping gauge and micrometer Replace the caliper as needed Item Standard...

Page 509: ...ion Remove the rear fender See the Rear Fender topic for more information If the caliper is to be disassembled the brake hose must be removed Drain the rear brake fluid See the Brake Fluid topic for m...

Page 510: ...10 Brake System Downtown 350i 8 32 Remove the two rear caliper mounting bolts with a 12 mm socket Remove the rear caliper from the swingarm...

Page 511: ...tainer under the banjo bolt to catch any remaining brake fluid Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket Discard the two sealing washers Replace the brake hos...

Page 512: ...wntown 350i 8 34 Installation Install the rear caliper onto the swingarm Install the two caliper bracket mounting bolts Tighten the mounting bolts to specification Item Torque N m lb ft Front Rear cal...

Page 513: ...e System Downtown 350i 8 35 Install the banjo bolt with new sealing washers and tighten to specification with a 12 mm socket Item Torque N m lb ft Banjo bolt 35 25 8 Fit the rear brake hose guide into...

Page 514: ...brake fluid and bleed out the air See the Brake Fluid topic for more information Pump the brake lever to seat the caliper pistons against the pads Check the operation on the brakes before returning th...

Page 515: ...eter ITEM STANDARD Brake disc thickness Front 3 8 4 2 mm 0 15 0 165 in Rear 5 0 mm 0 2 in Check if the brake rotor runout is within service limit Measure the runout of the brake disc with a dial gauge...

Page 516: ...10 Brake System Downtown 350i 8 38 Front Removal Remove the front wheel See the Front Wheel topic for more information Remove the five brake disc mounting bolts with an Allen wrench...

Page 517: ...10 Brake System Downtown 350i 8 39 Remove the front brake disc and front wheel speed sensor rotor Separate the wheel speed sensor rotor from the brake disc...

Page 518: ...Brake System Downtown 350i 8 40 Inspect the wheel speed sensor and brake disc for wear and damage Replace the parts as needed Set the front brake disc and speed sensor rotor in place on the front whe...

Page 519: ...n Allen socket Set the speed sensor rotor on the front brake disc Position the rotor so that its sharp side sits against the brake disc Insert the front brake disc mounting bolts Tighten the bolts to...

Page 520: ...eyewear are recommended at this point ABS Component Location 1 Front Wheel speed Sensor 2 Front Wheel speed Sensor Rotor 3 Rear Wheel speed Sensor 4 Rear Wheel speed Sensor Rotor 5 ABS Indicator Light...

Page 521: ...conditions misjudgment or improper application of brakes You must take the same care as with vehicle not equipped with ABS o ABS isn t designed to shorten the braking distance On loose uneven or down...

Page 522: ...result Always use the standard tires for this vehicle Notice o When the ABS is functioning you may feel a pulsing in the brake lever This is normal you need not suspend applying the brakes o ABS does...

Page 523: ...nnectors are disconnected The ABS hydraulic unit memorizes service codes Do not spray water on the electrical parts ABS parts connectors leads and wiring Whenever the ABS electrical connections are to...

Page 524: ...ally Service codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the...

Page 525: ...re different in size from the standard size is being used Replace with standard size When the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of confirming continuity...

Page 526: ...10 Brake System Downtown 350i 8 48 Pre diagnosis Inspection Chart 1...

Page 527: ...10 Brake System Downtown 350i 8 49 Pre diagnosis Inspection Chart 2...

Page 528: ...ight will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving The light stays off as long as the system is ok If something is wrong with the ABS the ind...

Page 529: ...k lead terminal of the meter connector and ground Turn the ignition switch ON Terminal Voltage Standard About 8V If the terminal voltage correct replace the meter assembly 2nd step test Disconnect the...

Page 530: ...ntinuity between the ABS signal wire Pink lead terminal of the meter side connector and the ABS signal wire Pink lead terminal of the ABS unit side connector If there is the continuity in the lead rep...

Page 531: ...lead replace the ABS hydraulic unit If there is not the continuity in the lead replace or repair the main harness Solenoid Valve Inspection Service Code 13 14 17 18 1st step test Recheck the service...

Page 532: ...ize 3 Deformation of the wheel or tire 4 Sensor rotor for missing teeth and clogging with foreign matter If the all parts are correct move on to the 2nd step 2nd step test Recheck the service code ind...

Page 533: ...r and sensor rotor Standard 1 mm 0 04 in If the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the clearance Check that there is iron or oth...

Page 534: ...he lead replace the rear wheel rotation sensor Rear Wheel Rotation Sensor Wiring Inspection service code 44 1st step test Measure the clearance between the rear wheel rotation sensor and sensor rotor...

Page 535: ...ector and rear wheel sensor connector Short the light blue brown and black red lead terminals of the main harness side connector with a jumper lead and check for continuity between the light blue brow...

Page 536: ...battery terminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 9 6V or more 3rd step test Inspect the following parts...

Page 537: ...battery terminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 16 6V or less 3rd step test Inspect the following parts...

Page 538: ...heck the service code indication erase the service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code If the ABS indicator light lit faulty ECU in the ABS hydraulic unit R...

Page 539: ...10 Brake System Downtown 350i 8 61 ABS Diagnostic Tool Connect the diagnostic tool and set the ECU to the ABS See the Diagnostic Tool topic for more information...

Page 540: ...ve malfunction AV 05 5019 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 Plausibi...

Page 541: ...BS system the front and rear wheel speed sensors should show speed when the wheels are rotated Inspect the wheel speed sensors rotors wires and connectors if the speed doesn t show correctly Check the...

Page 542: ...ABS unit for the brake Front F and Rear R brake hose positions Do not attempt to disassemble the ABS unit If the ABS unit must be replaced the new unit should come filled with brake fluid Install the...

Page 543: ...YMCO Downtown 350i model Handlebar 11 2 Grips 11 8 Steering stem 11 8 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls Insufficient tire pres...

Page 544: ...mended at this point Removal Remove the handlebar covers See the Handlebar Covers topic for more information Remove the front cover See the Front Cover topic for more information Bar Ends Remove the b...

Page 545: ...emove the two right switch housing mounting screws with a 2 Phillips screwdriver Disconnect the switch Separate the switch housing from the handlebar Disconnect the throttle cables and free the right...

Page 546: ...11 Steering Downtown 350i 11 4 Remove the two left switch housing mounting screws with a 2 Phillips screwdriver Disconnect the switch Separate the left switch housing from the handlebar...

Page 547: ...11 Steering Downtown 350i 11 5 Handlebar Route the cables and lines from the handlebar cable guide Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut with a 17 mm socket...

Page 548: ...11 Steering Downtown 350i 11 6 Remove the handlebar lock nut and bolt Remove the handlebar The torque of installation Item Torque N m lb ft Handlebar Lock Nut 45 32...

Page 549: ...ationship between the angle of the grip and the throttle tube so that the new grip can be installed with the correct angle NOTE Always wear safety glasses when using compressed air and never point it...

Page 550: ...m adjusting nut may need to be adjusted The KYMCO Downtown 350i uses ball bearings in the steering Always replace the races at the same time as the bearings Remove the handlebar covers See the Handleb...

Page 551: ...eeded to loosen the steering stem lock nut Special Tool Lock Nut Wrench F00002 Slide the special tool over the steering stem and loosen the lock nut Installation torque Item Qty Thread size mm Torque...

Page 552: ...11 Steering Downtown 350i 11 10 Remove the steering stem lock nut Slide off the lock washer Support the steering stem and loosen the steering stem adjusting nut...

Page 553: ...11 Steering Downtown 350i 11 11 Remove the steering stem adjusting nut Remove the dust cover and grease seal Lower the steering stem out of the frame...

Page 554: ...ball bearings Slide the lower ball bearings up and off of the steering stem Inspect the bearings and races for wear and damage Replace them as needed Use a chisel to remove the bottom bearing inner r...

Page 555: ...ive out the bearing races in the steering head Have the drift set against the lip of the race and work around the race evenly to drive it out Repeat the process with the remaining bearing race To inst...

Page 556: ...nt fork components for the KYMCO Downtown 350i model Front Fork Removal 12 2 Front Fork Installation 12 6 Fork Disassembly 12 8 Fork Assembly 12 17 TROUBLESHOOTING Soft front shock absorber Weak shock...

Page 557: ...FIRST Protective gloves and eyewear are recommended at this point Removal Remove the front cover See the Front Cover topic for more information Remove the front fender See the Front Fender topic for...

Page 558: ...pension Downtown 350i 12 3 Remove the two caliper mounting bolts with a 12 mm socket And remove the front caliper Remove the speedometer sensor mounting bolt with an 8 mm socket And remove the speedom...

Page 559: ...the right fork leg Remove the front brake caliper See the Front Caliper topic for more information Remove the front wheel See the Front Wheel topic for more information Remove the speed sensor wire an...

Page 560: ...Loosen the fork clamp pinch bolts with a 12 mm socket The top bolts must be removed Slide the forks legs down and out of the fork clamp using a twisting motion To disassemble the forks see the Fork D...

Page 561: ...ork legs up into fork clamp using a twisting motion Install the fork legs so that the upper fork clamp bolt hole lines up with the groove on the inner fork tube Insert the fork clamp upper bolt Tighte...

Page 562: ...le 1 6 1 0 1 4 7 23 10 13 Install the front wheel See the Front Wheel topic for more information Install the front brake caliper See the Front Caliper topic for more information Fit the front wheel sp...

Page 563: ...e gloves and eyewear are recommended at this point Remove the front forks See the Front Fork Removal and Installation topic for more information Clean the outside of the forks before disassembly and i...

Page 564: ...12 Front Suspension Downtown 350i 12 9 Remove the rubber fork cap Place the fork leg in a soft jawed vice Push down on the top plug and remove the snap ring...

Page 565: ...emove the top plug Lift out the fork spring Dump the fork oil into a suitable container Pump the fork through its stroke several times to free as much oil as possible Hold the fork inverted for severa...

Page 566: ...lade screwdriver to pop the dust seal out of the fork slider Take care to avoid scratching the fork tube Use a small flat blade screwdriver to pry out the fork oil seal stopper ring Take care to avoid...

Page 567: ...of the outer fork tube in a soft jawed vise Insert an 8 mm Allen socket into the damper rod Hold the damper rod and loosen the fork bottom bolt with an 8 mm Allen wrench Remove the fork bottom bolt f...

Page 568: ...inner and outer fork tubes by pulling them apart using a slide hammer motion Remove the oil lock piece The oil lock piece may come out with the damper rod in the inner fork tube or it may be left in...

Page 569: ...nsion Downtown 350i 12 14 Inspect the oil seal and the bushing in the fork slider Place a rag across the top of the fork slider and pry out the oil seal as shown Remove the oil seal and spacer from th...

Page 570: ...12 Front Suspension Downtown 350i 12 15 Inspection Inspect the top plug O ring and replace it if needed Insect the slider bushing and replace it as needed...

Page 571: ...ngs for signs of fatigue Replace the fork springs if they vary dramatically in length Inspect the damper rod and seal Replace the components as needed Inspect the inner fork tube for bends and damage...

Page 572: ...cloth Coat the bushing and seals with fork oil before installation Drive the fork slider bushing into the slider with a suitable driver with the same outside diameter as the bushing Insert the damper...

Page 573: ...18 Place the spacer into the fork slider Insert the inner fork tube into the outer fork tube Place a new sealing washer on the fork bottom bolt Insert the fork bottom bolt into the bottom the fork sli...

Page 574: ...he axle holder of the outer fork tube in a soft jawed vise Insert an 8 mm Allen socket into the damper rod Hold the damper rod and tighten the fork bottom bolt securely with an 8 mm Allen wrench Drive...

Page 575: ...Insert the stopper ring into its groove Install the dust seal securely into the outer fork tube Compress the fork tube all the way Fill the fork tube with the specified quantity of fork oil 185 cc or...

Page 576: ...e fork spring with its tightly coiled end facing down towards the axle Lubricate the top plug O ring with fresh fork oil and insert the plug into the top of the inner fork tube as shown Push the top p...

Page 577: ...spension Downtown 350i 12 22 Install the rubber fork cap Fit the fork protectors into place so that they face forward Install the front fork See the Front Fork Removal and Installation topic for more...

Page 578: ...3 Rear Suspension This chapter provides information on the rear suspension components of the KYMCO Downtown 350i model Shock Absorbers 13 2 Rear Fork 13 8 TROUBLESHOOTING Soft rear shock absorber Weak...

Page 579: ...0i 13 2 Shock Absorbers SAFETY FIRST Protective gloves and eyewear are recommended at this point Pre Load Setting Each shock absorber on the scooter has 5 spring preload adjustment positions for diffe...

Page 580: ...hock absorbers to the same spring preload positions Use a pin spanner to adjust the rear shock spring preload The shock absorbers are adjustable for pre load There are 5 settings Position 1 is the sof...

Page 581: ...e luggage box See the Luggage Box topic for more information Remove the rear carrier See the Rear Carrier topic for more information Remove the body cover to access the upper shock absorber mounts See...

Page 582: ...ck absorber from the frame Remove the left shock absorber in the same manner as the right Inspect the shock absorbers for wear and damage Replace the shock absorbers as needed Check over the shock abs...

Page 583: ...he shock absorber into place Make sure the preload arrow indicator faces out from the lower mount Install the upper shock absorber mounting bolt and torque it to specification with a 12 mm socket Item...

Page 584: ...mm socket Item Torque kgf m lb ft Shock absorber mounting bolt 4 28 93 Install the other shock absorber in the same manner Install the rear carrier See the Rear Carrier topic for more information Ins...

Page 585: ...wear are recommended at this point Removal Place the vehicle on its center stand Remove the muffler See the Exhaust System topic for more information Remove the rear fender See the Rear Fender topic f...

Page 586: ...pension Downtown 350i 13 9 Hold the rear brake to keep the rear wheel from turning Remove the rear axle nut with a 24 mm socket Remove the rear brake caliper See the Rear Brake Caliper topic for more...

Page 587: ...spension Downtown 350i 13 10 Remove the two rear fork bolts with a 14 mm socket Slide the rear fork out and remove it from the right side of the vehicle Inspect the rear fork for damage and replace it...

Page 588: ...13 Rear Suspension Downtown 350i 13 11 Installation Fit the rear fork into place...

Page 589: ...nstall the rear axle nut and tighten it to specification with a 24 mm socket Item Qty Thread size mm Torque Remarks kgf m lb ft Rear axle nut 1 16 11 13 79 56 94 03 U nut Install the rear brake calipe...

Page 590: ...3 13 Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket Item Torque kgf m lb ft Shock absorber mounting bolt 4 28 93 Install the muffler See the Exhaust...

Page 591: ...nt Wheel 14 6 Rear Wheel 14 11 Wheel Inspection 14 19 Wheel Specifications 14 21 Troubleshooting Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire Improperly tightened axle n...

Page 592: ...plan to install them Do not let the wheel rest on its brake disc To remove the Brake discs see the Disc Brake topic Front Wheel Remove the dust seal from the right side of the front wheel using a seal...

Page 593: ...i 14 3 Remove one of the bearings with a bearing puller Special Tools Bearing Puller E00037 Remove the distance collar Repeat the procedure and remove the other bearing and seal The seal should be rep...

Page 594: ...bearing out of the freezer and install it You can use a bearing installer tool or a socket with the same outside diameter as the bearing Make sure the bearing is fully seated and the marked side is f...

Page 595: ...other bearing The bearing should fit against the distance collar Do not continue to force the bearing in or the distance collar will begin to push the right bearing back out Apply grease to the lips...

Page 596: ...Downtown 350i 14 6 Front Wheel SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Loosen the front axle pinch bolt with a 6 mm Allen Loosen the front axle with an 8 mm Al...

Page 597: ...ck so that the front wheel comes off of the ground Support the front wheel and slide the front axle out from the left side Guide the front wheel out from the fork legs and the brake disc out from betw...

Page 598: ...eels and axle See the Wheel Inspection topic for more information Inspect the wheel bearings by turning them in the hub If the bearings have play in them or are rough replace all the bearings for that...

Page 599: ...ke sure the tire direction of rotation marker is correct Slide the front wheel into the fork Fit the brake disc between the brake pads in the front caliper Apply a light coat of grease to the front ax...

Page 600: ...rque kgf m lb ft Front axle 1 14 1 5 2 5 10 84 18 08 Tighten the front axle pinch bolt securely with a 6 mm Allen Pump the front brake lever to establish pressure and to seat the pads against the disc...

Page 601: ...st muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk Removal Remove the muffler See the Exhaust System topic for more information Remove the...

Page 602: ...rear brake to keep the rear wheel from turning Remove the rear axle nut with a 24 mm socket Remove the rear brake caliper See the Rear Brake Caliper topic for more information Hold the rear brake to...

Page 603: ...14 Wheels Downtown 350i 14 13 Remove the rear brake caliper See the Rear Brake Caliper topic for more information Remove the two rear fork bolts with a 14 mm socket...

Page 604: ...k absorber mounting bolt with a 12 mm socket Free the right shock absorber from the frame Slide the rear wheel to the right and off of the rear axle Inspect the wheel bearings by turning them with a f...

Page 605: ...Slide the rear wheel on to the axle so that the brake disc sits on the right side Install the right shock absorber if it was removed Install the upper mounting bolt and tighten it to specification wi...

Page 606: ...14 Wheels Downtown 350i 14 16 Fit the rear fork into place Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket...

Page 607: ...nut and tighten it to specification with a 24 mm socket Item Qty Thread size mm Torque Remarks kgf m lb ft Rear axle nut 1 16 11 13 79 56 94 03 U nut Fit the shock absorber into place Make sure the pr...

Page 608: ...rber mounting bolt and torque it to specification with a 12 mm socket Item Torque kgf m lb ft Shock absorber mounting bolt 4 28 93 Install the rear brake caliper See the Rear Brake Caliper topic for m...

Page 609: ...if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub See the Wheel Bearing Replacement topic for more information...

Page 610: ...he service limit is 2 0 mm 0 08 in or less Check the front axle runout The axle runout specification is half of the total indicator reading Replace the axle if the measurement exceeds 0 2 mm or 0 008...

Page 611: ...t 0 4 mm Brake master cylinder I D 12 7 12 74 0 508 0 5096 Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 Front brake caliper piston O D 26 93 26 96 1 0602 1 0614 Front brake caliper cylind...

Page 612: ...4 BTDC Battery Voltage V 12 V O2 Sensor Voltage V 0 05 0 90 V ISC Step step 70 20 IDLE CO 0 3 1 5 Before muffler CO Set 0 Suggestion Value 5 5 Engine speed rpm 1720 100 rpm Intake Pressure Kpa 35 0 40...

Page 613: ...Report Version Report ID...

Page 614: ...2 8ms 3 5ms 2 8ms 3 5ms Memo OWNTOWN 350i 3 5 3 8V e Temp 80 C e Temp 80 C up at an elevation of 1000 re pressure goes down 12kpa...

Page 615: ...Jan 29 2015...

Page 616: ...DOWNTOWN 350i Wiring Diagram...

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KYMCO Downtown 350i, Repair Manual

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