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KYMCO K-XCT 300i, Owner'S Manual, Page: 637 / 656

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KYMCO K-XCT 300i Owner'S Manual Download Page 637

 
 

14. Quick Reference > Special Tools                                                                                  K- XCT 300i 

 
 

14

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11

 

 

  Special Tools 

 
 

ITEM TOOL 

NO 

DESCRIPTION 

FLYWHEEL PULLER 

A120E00003 

Flywheel removal 

Puller (M28x1) TAPPET ADJUSTER 

A120E00012 Adjusting 

valve clearance 

OIL SEAL & BEARING DRIVER 

A120E00014 

General Driver Set 

UNIVERSAL HOLDER 

A120E00021 

Holding clutch pulley and flywheel 

#41 NUT AND FITTING TOOL 

A120E00028 

Clutch disassembly 

THREAD PROTECTOR 

A120E00029 

Crankshaft thread protector 

CYLINDER COMPRESSION GAUAGE 

A120E00039 Engine 

cylinder 

compression measure 

FUEL PRESSURE GAUAGE 

A120E00048 

Fuel pump output pressure measure 

VALVE COTTER INSTALLER 

A120E00051 Valve 

cotter 

installation 

CLUTCH SPRING COMPRESSOR 

A120E00053 

Clutch disassembly 

SHAFT COLLAR PULLER 

A120E00088 

Bearing crankcase installation 

WIRES INJECTOR CONNECTOR 

A120E00090 

Injector cleaning for Keihin system 

SHAFT COLLAR DRIVER 

A120E00091 

Bearing crankcase removal 

SHAFT COLLAR INSTALLER 

A120E00092 

Bearing crankcase installation 

BEARING PULLER 

A120E00093 

General Puller Set 

VALVE CLEAN TOOL SET 

A120E00096 

Valve & Valve seat cleaning 

STEERING STEM LOCK NUT WRENCH (32 mm) 

A120F00002 

Steering stem removal & installation 

LOWER/UPPER RACE REMOVER & INSTALLER 

A120F00008 

Lower/Upper outer race installation 

LOWER/UPPER OUTER RACE SEPARATOR 

A120F00009 

Lower/Upper outer race removal 

STEERING STEM TOP THREAD WRENCH 

(46.5mm) 

A120F00029 

Steering stem removal & installation 

PLIERS FUEL PIPE   

A120F00031 

Fuel pump output pressure measure & 

Injector cleaning 

ELECTRIC REPAIR KIT   

A120F00032 

Troubleshooting electric system 

DIGITAL ELECTRIC GAUGE 

A120F00033 

Troubleshooting electric system 

RADIATOR PRESSURE GAUAGE 

A120F00035 

Radiator pressure measure 

USB LINKER 

3620A-LGJ9-E00 

Diagnostic tool software upgraded 

POWER WIRES 

32143-LGJ9-E00 

Diagnostic tool power connection 

INJECTOR CLEANER 

32143-LEA7-9000  Injector cleaning 

 

Summary of Contents for K-XCT 300i

Page 1: ...Luggage Box 1 14 1 16 Seat 1 17 1 19 Rear Carrier 1 20 1 22 Body Cover 1 23 1 32 Windshield 1 33 1 36 Front Cover Meter 1 37 1 38 Side Molding A 1 39 1 48 Side Cover 1 49 1 59 Front Fender 1 60 1 63 C...

Page 2: ...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 exhaust muffler Damaged exhaust muf...

Page 3: ...Exhaust System K XCT 300i 1 3 Remove the two exhaust pipe joint nuts with a 12 mm deep well socket Remove the O2 sensor wire band Unplug the O2 sensor connector Remove the three muffler mounting bolt...

Page 4: ...1 External components Exhaust System K XCT 300i 1 4 Remove the exhaust system Remove the exhaust pipe gasket and discard it...

Page 5: ...he O2 sensor with a 17 mm wrench Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperatur...

Page 6: ...0i 1 6 Measure the resistance between the white wire terminals of the O2 sensor connector Replace the O2 sensor if the reading is out of specification ITEM SPECIFICATIONS O2 heater sensor resistance a...

Page 7: ...1 External components Exhaust System K XCT 300i 1 7 Heat Shields Remove the three muffler heat shield bolts with a 10 mm socket if needed...

Page 8: ...1 External components Exhaust System K XCT 300i 1 8 To remove the four bolts to free the heat shield on the muffler Remove the heat shield...

Page 9: ...elds Install the heat shields and tighten the bolts securely O2 Sensor Apply anti seize compound to the threads of the O2 sensor Install the O 2 sensor and tighten it to specification with a 17 mm wre...

Page 10: ...1 External components Exhaust System K XCT 300i 1 10 Exhaust System Insert a new exhaust pipe gasket into the exhaust port Fit the exhaust system into place...

Page 11: ...K XCT 300i 1 11 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...

Page 12: ...1 12 Tighten the two exhaust pipe joint nuts to specification with a 12 mm deep well socket Item Torque N m kgf m Exhaust Pipe Joint Nuts 20 2 If the exhaust pipe and muffler were separated installed...

Page 13: ...1 External components Exhaust System K XCT 300i 1 13 Install a new O 2 sensor clamp...

Page 14: ...1 ExternalComponents Luggage Box K XCT 300i 1 14 Luggage Box Removal Remove the four luggage bolts with a 10 mm socket Remove the two luggage nuts with a 10 mm socket...

Page 15: ...nalComponents Luggage Box K XCT 300i 1 15 Lift up the luggage box to unplug the luggage box light connector Remove the luggage box Installation Plug in the luggage box light connector Install the lugg...

Page 16: ...1 ExternalComponents Luggage Box K XCT 300i 1 16 Install the four luggage bolts and tighten securely with a 10 mm socket Remove the two luggage nuts with a 10 mm socket Install the seat...

Page 17: ...1 External Components Seat K XCT 300i 1 17 Seat Removal Insert the key and turn it counterclockwise Remove the two seat hinge nuts with a 10 mm socket...

Page 18: ...ion switch to the seat latches The cable must be adjusted periodically so that the latches will open correctly Open the seat Loosen the lock nuts and turn the adjusters as needed to adjust the seat la...

Page 19: ...1 External Components Seat K XCT 300i 1 19 Installation Install the seat onto the hinge Install the two seat hinge nuts and tighten securely with a 10 mm socket...

Page 20: ...1 ExternalComponents Rear Carrier K XCT 300i 1 20 Rear Carrier Removal Pry off the carrier bolt covers with a small flat blade screwdriver the arrow mark indicates the pry point...

Page 21: ...1 ExternalComponents Rear Carrier K XCT 300i 1 21 Remove the four carrier bolts with a 6 mm Allen Remove the carrier each side...

Page 22: ...1 ExternalComponents Rear Carrier K XCT 300i 1 22 Installation Install the carrier Install the four carrier bolts on each side with a 6 mm Allen Push on the carrier bolt covers...

Page 23: ...1 External Components Body Cover K XCT 300i 1 23 Body Cover Removal Remove the two rear center cover screws with a 2 Phillips...

Page 24: ...1 External Components Body Cover K XCT 300i 1 24 Carefully unhook the tabs on both side of the rear center cover Remove the rear center cover Remove the four lower body cover nuts with a 10 mm socket...

Page 25: ...1 External Components Body Cover K XCT 300i 1 25 Remove the two plastic screws from the front of the body cover Carefully unhook the tabs on both sides of the body cover...

Page 26: ...1 External Components Body Cover K XCT 300i 1 26 Unplug the taillight connector Remove the body cover...

Page 27: ...1 External Components Body Cover K XCT 300i 1 27 Disassembly Rear Center Molding Remove the two Rear Center Molding screws with a 2 Phillips Remove the rear center molding...

Page 28: ...1 External Components Body Cover K XCT 300i 1 28 Rear Fender Remove the rear fender screws with a 2 Phillips Carefully unhook the tabs on both sides of the rear fender Remove the rear fender...

Page 29: ...Components Body Cover K XCT 300i 1 29 Taillight Assembly Remove the eight taillight assembly screws with a 2 Phillips Unhook the taillight section and separate from the body cover Remove the tailligh...

Page 30: ...Body Cover K XCT 300i 1 30 License Light Remove the two license light assembly screws with a screwdriver Disconnect the connector license light Remove the license light assembly Installation Fit the...

Page 31: ...Components Body Cover K XCT 300i 1 31 Plug in the taillight connector Carefully push the hooks into the corresponding tabs on both sides of the body cover Install the two screws on both sides of the...

Page 32: ...dy Cover K XCT 300i 1 32 Install the four lower body cover nuts and tighten securely with a 10 mm socket Carefully install the rear center cover Install the two rear center cover screws and tighten se...

Page 33: ...xternal Components Windshield K XCT 300i 1 33 Windshield Removal Open the hidden bolt cover Remove the hidden bolt with a 10 mm socket Depress the head of the fastener center piece Pull out the fasten...

Page 34: ...1 External Components Windshield K XCT 300i 1 34 Carefully pull out the front cover with a thinner driver on each side Lightly slap downward at the front cover on each side...

Page 35: ...1 External Components Windshield K XCT 300i 1 35 Remove the four bolts with a 12mm socket on each side Remove the front cover Remove the windshield...

Page 36: ...stall the windshield Install the four windshield bolts and tighten securely with a 12mm socket There are two bolts on each side Install the hidden bolt and tighten securely with a 10 mm socket Close t...

Page 37: ...ont Cover Meter K XCT 300i 1 37 Front Cover Meter Removal Remove the two front cover meter mounting nuts with a 10 mm socket Remove the two screws mounting on the front cover meter on each side Remove...

Page 38: ...ents Front Cover Meter K XCT 300i 1 38 Install Install the front cover meter Install the two screws mounting on the front cover meter on each side Install the two screws mounting on the front cover me...

Page 39: ...1 ExternalComponents Side Molding A K XCT 300i 1 39 Side Molding A Removal Remove the side molding mounting nuts with a 10 mm socket Carefully depress the front inner cover...

Page 40: ...1 ExternalComponents Side Molding A K XCT 300i 1 40 Carefully pull out the side molding and leg shield with a thinner driver on each side Carefully pull off the side molding with hand...

Page 41: ...1 ExternalComponents Side Molding A K XCT 300i 1 41 Carefully pull out the side molding and side skirt with hand on each side Unplug the headlight leads...

Page 42: ...1 ExternalComponents Side Molding A K XCT 300i 1 42 Gently pull the side molding forward and free the tabs Disassembly Light Assembly...

Page 43: ...1 ExternalComponents Side Molding A K XCT 300i 1 43 Remove the eight light assembly mounting screws with a 2 Phillips Separate the light assembly from the side molding A...

Page 44: ...ernalComponents Side Molding A K XCT 300i 1 44 Side Piece Remove the eight side piece screws with a 2 Phillips Assembly Side Piece Install the eight side piece screws and tighten securely with a 2 Phi...

Page 45: ...1 ExternalComponents Side Molding A K XCT 300i 1 45 Light Assembly Install the eight light assembly mounting screws and tighten securely with a 2 Phillips...

Page 46: ...1 ExternalComponents Side Molding A K XCT 300i 1 46 Install the headlight assembly on the side molding A Installation Plug in the headlight and turn signal leads...

Page 47: ...1 ExternalComponents Side Molding A K XCT 300i 1 47 Align front cover tabs Install the front cover Carefully Align the side molding and side skirt with hand on each side...

Page 48: ...1 ExternalComponents Side Molding A K XCT 300i 1 48 Carefully Align the side molding and leg shield Install the two front cover mounting nuts with a 10 mm socket...

Page 49: ...1 External Components Side Skirt K XCT 300i 1 49 Side Skirt Removal Pull up the footboard rubber covers Remove the four screws mounting the footboard with a 2 Phillips...

Page 50: ...1 External Components Side Skirt K XCT 300i 1 50 Remove the six leg shield mounting screws with a 2 Phillips There are three screws on each side...

Page 51: ...1 External Components Side Skirt K XCT 300i 1 51 Remove the six lower fairing push pins on each side including the undercover...

Page 52: ...Skirt K XCT 300i 1 52 Remove the left lower bolt under the side skirt with a 10mm socket Gently separate the floorboard from the side skirt Carefully free the tabs Remove the cover side skirt after th...

Page 53: ...1 External Components Side Skirt K XCT 300i 1 53 Remove the two cover side skirt mounting screws with a 2 Phillips Disassembly Remove the two screws from the side board A with a 2 Phillips...

Page 54: ...nal Components Side Skirt K XCT 300i 1 54 Separate the Side skirt and side board A Remove the three cover side skirt mounting screws with a 2 Phillips Carefully pull out the cover side skirt from side...

Page 55: ...1 External Components Side Skirt K XCT 300i 1 55 Remove the three winker assembly mounting screws with a 2 Phillips Remove the winker assembly from the cover side skirt...

Page 56: ...1 External Components Side Skirt K XCT 300i 1 56 Assembly Winker Assembly Install the three winker assembly mounting screws with a 2 Phillips Install the three screws onto the cover side skirt...

Page 57: ...it the upper tabs of the side board A into the floorboard Install the side board A while aligning the tabs Install the four screws under the footboard rubber cover with a 2 Phillips on each side Tight...

Page 58: ...1 External Components Side Skirt K XCT 300i 1 58 Install the footboard rubber covers Install the two cover side skirt mounting screws with a 2 Phillips Connect the turn signal leads removed...

Page 59: ...omponents Side Skirt K XCT 300i 1 59 Install the six leg shield mounting screws with a 2 Phillips There are three screws on each side Install the six lower fairing push pins on each side including the...

Page 60: ...ront Fender K XCT 300i 1 60 Front Fender Removal Remove the left forward front fender bolt with a 6 mm Allen Remove the left rear fender bolt with a 10 mm socket Remove the right forward front fender...

Page 61: ...1 External Components Front Fender K XCT 300i 1 61 Remove the right rear fender bolt with a 10 mm socket Remove the front fender from the forks...

Page 62: ...al Components Front Fender K XCT 300i 1 62 Installation Guide the fender between the forks Install the right rear fender bolt with a 10 mm socket Install the right forward front fender bolt with a 6 m...

Page 63: ...1 External Components Front Fender K XCT 300i 1 63 Install the left rear fender bolt with a 10 mm socket Install the left forward front fender bolt with a 6 mm Allen...

Page 64: ...ents Center Cover K XCT 300i 1 64 Center Cover Removal Note Do not force the cover and damage the claws Pull the center cover back and up to free the claws and then move the cover backward to free it...

Page 65: ...1 External Components Center Cover K XCT 300i 1 65 Remove the center cover Installation Place the center cover on the scooter...

Page 66: ...1 External Components Center Cover K XCT 300i 1 66 Push the cover down and forward to lock in the claws...

Page 67: ...1 External Components Under Cover K XCT 300i 1 67 Under Cover Removal Remove the two cover bolts mounting the under cover each side with a 10 mm socket Remove the under cover...

Page 68: ...1 External Components Under Cover K XCT 300i 1 68 Installation Install the under cover Install the two under cover bolts on the each side and tighten securely with a 10 mm socket...

Page 69: ...val Remove the two push pins below the handlebar Depress the head of the fastener center piece Pull out the fastener Remove the bolt attaching the rear meter cover on the left with a 10 mm socket Remo...

Page 70: ...ternal Components Rear Meter Cover K XCT 300i 1 70 Remove two screws mounting the rear meter cover on both sides with a 2 Phillips Remove the connector speedometer assembly Remove the speedometer asse...

Page 71: ...mponents Rear Meter Cover K XCT 300i 1 71 Installation Install the speedometer assembly Install the connector speedometer assembly Install two screws mounting the speedometer cover on both sides with...

Page 72: ...t with a 10 mm socket Install the bolt attaching the speedometer cover on the right with a 10 mm socket Install the two push pins below the handlebar Depress the head of the fastener center piece Pull...

Page 73: ...ard Removal Remove the two bolts mounting the floorboard on the left side with a 10 mm socket Remove the two bolts mounting the floorboard on the right side with a 10 mm socket Remove the two bolts mo...

Page 74: ...1 External Components Floorboard K XCT 300i 1 74 Remove the two nuts mounting the side board A on each side with a 10 mm socket Carefully unhook the tabs on both sides of the side board A...

Page 75: ...1 External Components Floorboard K XCT 300i 1 75 Remove the floorboard on each side Disassembly Remove the four screws mounting the side board A Separate the floorboard from side board A...

Page 76: ...1 External Components Floorboard K XCT 300i 1 76 Disassembly Install the four screws mounting the side board A Installation Install the floorboard on each side...

Page 77: ...1 External Components Floorboard K XCT 300i 1 77 Carefully install the tabs on both sides of the side board A Install the two nuts mounting the side board A on each side with a 10 mm socket...

Page 78: ...ternal Components Floorboard K XCT 300i 1 78 Install the four bolt mounting the floorboard on each side with a 10 mm socket Install the two bolt mounting the side board A on each side with a 10 mm soc...

Page 79: ...1 External Components Leg Shield K XCT 300i 1 79 Leg Shield Removal Remove the screw mounting the collar ignition switch with a 2 Phillips Take off the collar Open the fuel cap panel...

Page 80: ...1 External Components Leg Shield K XCT 300i 1 80 Remove the fuel cap with the key Remove the Lid fuel cap maint...

Page 81: ...1 External Components Leg Shield K XCT 300i 1 81 Remove the gas cap overflow pad Lift off the leg shield...

Page 82: ...1 External Components Leg Shield K XCT 300i 1 82 Installation Install the leg shield Align the pin hole of the body frame...

Page 83: ...1 External Components Leg Shield K XCT 300i 1 83 Install the gas cap overflow pad and the Lid fuel cap maint...

Page 84: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 84 Handlebar Covers Removal Upper Cover Remove the four cover screws with a 2 Phillips...

Page 85: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 85 Carefully free the tabs and remove the upper handlebar cover Lower Cover Route the throttle cables out of the handlebar cover...

Page 86: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 86 Remove the two handle lower cover screws with a 2 Phillips...

Page 87: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 87 Remove the lower cover Installation Place the lower cover onto the handlebar...

Page 88: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 88 Route the throttle cables into the handlebar cover Carefully install the upper handlebar cover...

Page 89: ...1 ExternalComponents Handlebar Cover K XCT 300i 1 89 Remove the four cover screws with a 2 Phillips...

Page 90: ...1 External Components Rear Tire Fender K XCT 300i 1 90 Rear Tire Fender Removal Remove the two fender mounting bolts with a 8 mm socket on the right side...

Page 91: ...ponents Rear Tire Fender K XCT 300i 1 91 Remove the two airbox mounting bolts with a 8mm socket Remove the connecting tube screw with a 2 Phillips Remove the fender mounting bolt with a 8 mm socket on...

Page 92: ...1 External Components Rear Tire Fender K XCT 300i 1 92 Remove the rear fender Installation Install the rear fender...

Page 93: ...r Tire Fender K XCT 300i 1 93 Install the fender mounting bolt with a 8 mm socket on the left side Install the connecting tube screw with a 2 Phillips Install the two fender mounting bolts with a 8 mm...

Page 94: ...1 External Components Rear Tire Fender K XCT 300i 1 94 Install the two airbox mounting bolts with a 8mm socket Install the airbox...

Page 95: ...1 ExternalComponents Stands K XCT 300i 1 95 Stands Side stand Removal Unplug the three pin side stand switch connector Remove the side stand spring with a spring puller...

Page 96: ...lComponents Stands K XCT 300i 1 96 Remove the side stand bolt switch and side stand Installation Install the side stand switch and bolt Make sure to fit the switch into place correctly Tighten the bot...

Page 97: ...1 ExternalComponents Stands K XCT 300i 1 97 Install the side stand spring with a spring puller Plug in the side stand switch connector...

Page 98: ...1 ExternalComponents Stands K XCT 300i 1 98 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 99: ...1 ExternalComponents Stands K XCT 300i 1 99 Installation Install the nuts and bolts Tighten them securely Install the center stand spring with a spring puller...

Page 100: ...schedule specifies the maintenance required to keep your K XCT 300i scooter in peak operating condition Maintenance work should be performed in accordance with KYMCO standards and specifications by pr...

Page 101: ...R R R C R I R R R A A A I I 33 34 33 29 DRIVE BELT TRANSMISSION FLUID R R R R 32 1 1 R R I I I I I I I I I I I C C C R R R I I I I I ENGINE OIL SCREEN R R R R R R R R FREQUENCY ITEM MONTH X 1000 km X...

Page 102: ...ervicing SAFETY FIRST Protective 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 Remo...

Page 103: ...2 PeriodicMaintenance Air Filter Servicing K XCT 300i 2 4 Remove the air filter cover Remove the 7 air filter bolts with an 8 mm socket or a 2 Phillips screwdriver...

Page 104: ...ter 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 with compressed air Be sure to install the air cleane...

Page 105: ...PeriodicMaintenance Air Filter Servicing K XCT 300i 2 6 Insert the 7 air filter bolts Tighten the air filter bolts securely with an 8 mm socket or a 2 Phillips screwdriver Install the air filter cove...

Page 106: ...2 PeriodicMaintenance Air Filter Servicing K XCT 300i 2 7 Install the 8 air filter cover screws and tighten them securely with a 2 Phillips screwdriver...

Page 107: ...brake 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...

Page 108: ...cess is the same for the front and rear brakes Remove the two master cylinder cover screws with a 2 Phillips head screwdriver Remove the master cylinder cover plastic piece and rubber diaphragm Clean...

Page 109: ...k open 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 bl...

Page 110: ...eding 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...

Page 111: ...the 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...

Page 112: ...odicMaintenance Brake Fluid K XCT 300i 2 13 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 screw...

Page 113: ...r more information Remove the spark plug See the Spark Plug topic for more information Thread a compression tester into the spark plug hole hand tight Hold the throttle all the way open Crank the engi...

Page 114: ...too low 1 Natural oil consumption 2 Oil leaks 3 Worn or poorly installed piston rings 4 Worn valve guide or seal Poor lubrication pressure 1 Oil level too low 2 Clogged filter or oil passages 3 No us...

Page 115: ...chart shown above Engine oil capacity At disassembly 1 5 Liter At change 1 3 Liter Inspection Oil Level Check the engine oil level each day before operating the scooter Place the motorcycle upright on...

Page 116: ...l filler cap dipstick is located on the right side of the engine Remove the oil filler cap dipstick and wipe off the oil Inspect the O ring and replace it as needed Insert the dipstick in without thre...

Page 117: ...same type and brand of oil to the engine through the oil filler hole If the oil level is to high remove the drain plug and the excess oil Servicing Draining Warm the engine as with the inspection thi...

Page 118: ...2 Periodic Maintenance Engine Oil K XCT 300i 2 19 Place an oil pan under the engine The oil drain bolt is located on the left side of the engine...

Page 119: ...2 Periodic Maintenance Engine Oil K XCT 300i 2 20 Loosen the engine oil drain bolt with a 17 mm socket Remove the bolt and allow the oil to drain into the pan Discard the old sealing washer...

Page 120: ...il draining Inspect the oil filler cap O ring and replace it as needed When the oil has drained completely Install the drain bolt with a new sealing washer Tighten the drain bolt to specification with...

Page 121: ...c Maintenance Engine Oil K XCT 300i 2 22 Strainer Screen Remove the oil strainer screen bolt with a 17 mm socket Inspect the strainer screen bolt O ring and replace it as needed Remove the oil straine...

Page 122: ...f 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 indicator o...

Page 123: ...e of 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...

Page 124: ...2 Periodic Maintenance Engine Oil K XCT 300i 2 25 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 125: ...Engine Oil K XCT 300i 2 26 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...

Page 126: ...ount of fresh engine oil into the 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 c...

Page 127: ...e oil filler dipstick hole Use a fully synthetic quality 4 stroke engine oil to ensure longer service life of the scooter Only use oils that have a SJ rating above per the API service classification E...

Page 128: ...re recommended 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 abnorma...

Page 129: ...30 Hose 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...

Page 130: ...ves and eyewear are 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 The spark plug is lo...

Page 131: ...sed air or a shop towel to make sure debris doesn t get into the combustion chamber when the spark plug is removed NOTE Always wear safety glasses when using compressed air and never point it directly...

Page 132: ...indicate how the mixture is burning A white colored plug shows a lean mixture where a dark plug shows a rich mixture Do not hesitate to replace a spark plug Always replace a spark plug if any part of...

Page 133: ...00i 2 34 Item Torque Spark plug 17 2 N m 1 5 2 ft lb 10 84 14 47 kgf m Install the spark plug wire over the plug Install the luggage box See the LuggageBox topic for more information Install the seat...

Page 134: ...es and eyewear 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...

Page 135: ...pension 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...

Page 136: ...can be used when the scooters heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions Use a pin spanner to adjust the rear shock spring preload The shock absorbe...

Page 137: ...e 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...

Page 138: ...2 PeriodicMaintenance Tires K XCT 300i 2 39 Replace tires if the tread depth reaches the wear mark or fails to meet the minimum tread depth Tires Front wheel 120 70 14 Rear wheel 150 70 13...

Page 139: ...uggage box See the LuggageBox topic for more information Remove the spark plug See the SparkPlug topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more in...

Page 140: ...stment K XCT 300i 2 41 The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Turn crankshaft clockwise until the T mark aligns with the index not...

Page 141: ...er 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 mounting boss should be visible above the cylinder...

Page 142: ...Insert 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 inta...

Page 143: ...2 Periodic Maintenance Valve Adjustment K XCT 300i 2 44 Adjustment Use a tappet adjuster tool to adjust the valves SPECIAL TOOLS ITEM TOOL NO DESCRIPTION TAPPET ADJUSTER E012 Tappet adjustment...

Page 144: ...with the adjustment Lubricate the tappet adjusting screw threads with fresh engine oil Hold the adjuster in place and tighten the locknut Always recheck the clearance after tightening the locknut Also...

Page 145: ...9 3 127 GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine installed in the frame Use care when removing and installing the oil pump not to...

Page 146: ...ne oil passages Clean and unclog the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark an...

Page 147: ...ed with the engine installed in the frame After disassembly clean the removed parts and dry them with compressed air before inspection If replacing the piston or cylinder they must be changed as a pai...

Page 148: ...er Front Cover Front Lower Cover Foot Skirt Rear Carrier Body Cover Under Cover Disconnect the cables from the battery terminals See the Battery topic for more information Remove the spark plug cap Se...

Page 149: ...3 Engine Engine Removal K XCT 300i 3 5 The regulator rectifier is located on the right side of the vehicle Disconnect the generator 3 pin connector Disconnect the crank position sensor wire coupler...

Page 150: ...3 Engine Engine Removal K XCT 300i 3 6 Unplug the water temperature sensor Unplug the thermo sensor unit and thermo unit ground connectors Pull back the rubber starter motor lead cover...

Page 151: ...move the 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 Loosen the fuel hose stay bolt with an 8 mm socket Free the fu...

Page 152: ...any remaining coolant to drain into a suitable container Loosen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Allow any remai...

Page 153: ...an 8 mm socket Remove the bolt and free the engine ground from the right side of the engine Free the starter motor lead from the stay on the right crankcase cover Unplug the oil pressure switch wire...

Page 154: ...3 Engine Engine Removal K XCT 300i 3 10 Free the wiring harness from its guide above the intake pipe Support the engine with a suitable jack or stand...

Page 155: ...hockAbsorbers topic for more information Loosen the engine mounting bracket damper nut with a 14 mm socket Remove the nut and washer Hold the engine mounting bolts with a 14 mm wrench and loosen the n...

Page 156: ...K XCT 300i 3 12 Loosen the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt Remove the engine mounting bracket damper bolt and nut Remove the...

Page 157: ...ine Engine Removal K XCT 300i 3 13 Remove the engine mounting bracket damper assembly Carefully move the engine back and separate it from the chassis To install the engine see the Engine Installation...

Page 158: ...int Removal 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 inform...

Page 159: ...rom 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 Note the gold colored and longer bolts are on t...

Page 160: ...3 Engine Cylinder Head Cover K XCT 300i 3 16 Remove the dowel pin Installation Install the dowel pin into the cylinder head...

Page 161: ...the cylinder head Make sure the projection fits into the groove in front of the camshaft sprocket correctly Install the cylinder head cover over the gasket Make sure the ridge on the gasket fits into...

Page 162: ...ver bolt seals in fresh engine oil Insert the cylinder head cover bolts with grommet seals and washers Note the gold colored and longer bolts go on the left side Tighten the cylinder head cover bolts...

Page 163: ...ly with an 8 mm socket Install the breather hose to the cylinder head cover Secure the hose with the clamp Install the spark plug See the SparkPlug topic for more information Install the luggage box S...

Page 164: ...e the spark plug See the Spark Plug topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more information Remove the crankshaft cap on the right side of the...

Page 165: ...T 300i 3 21 The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Turn crankshaft clockwise until the T mark aligns with the index notch in the t...

Page 166: ...ake sure that it is on the compression stroke by checking that there is some slack in the rocker arms If the rocker arms are rigid rotate the crankshaft 360 clockwise until the T mark is once again al...

Page 167: ...i 3 23 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...

Page 168: ...300i 3 24 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 re...

Page 169: ...3 Engine Camshaft K XCT 300i 3 25 Remove the set plate as shown Thread a bolt into the rocker arm shafts and pull the shafts out...

Page 170: ...3 Engine Camshaft K XCT 300i 3 26 Lift out the rocker arms as the shafts are removed Remove the camshaft from the cylinder head...

Page 171: ...rings 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 rocke...

Page 172: ...XCT 300i 3 28 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 s...

Page 173: ...ther signs of wear or damage Camshaft Installation Clear out the cylinder head oil passages with compressed air Make sure all cylinder head oil passages are free of clogs NOTE Always wear safety glass...

Page 174: ...k should be aligned with the index notch in the timing inspection hole Support the cam chain if the crank must be turned to position the piston correctly Lubricate the camshaft lobes and bearings with...

Page 175: ...ocker 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 through the camshaft holders and...

Page 176: ...shaft 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 wi...

Page 177: ...cylinder head as shown Fit the camchain over 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...

Page 178: ...2 6 1 0 1 4 7 23 10 13 Double check the engine timing Use a small flat blade screwdriver bring in the cam chain tensioner rod Turn the screwdriver counter clockwise to retract the rod The rod must be...

Page 179: ...ner with a new gasket Insert the mounting bolts and tighten them evenly to specification with an 8 mm socket Remove the screwdriver and release the camchain tensioner rod Item Qty Thread size mm Torqu...

Page 180: ...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 the bolt to securely with a 10 mm soc...

Page 181: ...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 topic for more information Install...

Page 182: ...mshaft See the Camshaft topic 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...

Page 183: ...3 Engine Valves K XCT 300i 3 39 Remove the split keepers There are two per valve Remove the spring retainer Remove the valve springs...

Page 184: ...down and remove the valve from the combustion chamber side of the cylinder head Rotate the valve as it is removed Remove the valve seal from the valve guide The valve seals should be replaced if they...

Page 185: ...3 Engine Valves K XCT 300i 3 41 Remove the spring seat 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 186: ...e the valve stem diameter in several places where the valve makes contact with the guide If the measurement is below specification replace the valve Valve stem O D Item Standard mm IN 4 990 4 975 EX 4...

Page 187: ...Valve seat width IN 1 2 EX 1 2 Measure the inside diameter of the valve guides Replace the guides if the measurement is out of specification Calculate the valve stem to guide clearance Replace the gu...

Page 188: ...lash point solvent and compressed air Return the components to their original locations NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else...

Page 189: ...guide and through the seal Turn the valve slowly as it is inserted If you are installing a new valve you must ream the valve guide first Make sure the valve will move smoothly in the valve guide witho...

Page 190: ...ner on top of the spring Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers The valve cotter installer tool can also be used to install the sp...

Page 191: ...alve stem Repeat this with the other keeper After the valves have been reassemble place a clean shop towel under the cylinder head in the combustion chamber area and gently tap each valve stem with a...

Page 192: ...e See the Engine Removal topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more information Remove the camshaft sprocket See the Camshaft topic for more i...

Page 193: ...Cylinders and Pistons K XCT 300i 3 49 Remove the two right side cylinder bolts with an 8 mm socket Loosen the cylinder coolant hose clamp with a 2 Phillips screwdriver Free the coolant hose from the...

Page 194: ...inders and Pistons K XCT 300i 3 50 Slide the cylinder off of the studs and piston Guide the cam chain through its opening and do not allow if to fall into the crankcase Remove the cylinder Remove the...

Page 195: ...pins from the left studs Place a clean shop towel under and 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 n...

Page 196: ...keep debris from falling into the crankcase Spread the piston 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...

Page 197: ...al The oil ring consists of an expander ring and two side rails Clean 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 cle...

Page 198: ...set There are two sets of cylinder and piston combinations Make sure to have a No 1 cylinder with an A piston or a No 2 cylinder with a B piston No Mark Piston O D mm Cylinder I D mm 1 A 72 680 72 69...

Page 199: ...below with a telescoping gauge Inspect the cylinder front to back and side to side at three different height levels with a dial bore gauge Item Standard mm Cylinder I D 72 7 Calculate the cylinder ta...

Page 200: ...iston at 9 mm up from the bottom of the skirt at a 90 angle to the piston pin Measure the piston with vernier calipers or a micrometer Check the piston for wear damage and extreme discoloration Subtra...

Page 201: ...Measure at three different points for each Replace the parts if any of the specifications are not met Item Standard mm Piston pin hole I D 15 002 15 008 Piston pin O D 14 994 15 000 Piston to piston p...

Page 202: ...e ring to groove clearance with feeler gauges Item Standard mm 1st 0 015 0 055 Piston ring to groove clearance 2nd 0 015 0 055 Insert the top ring into the cylinder Push the top ring in the cylinder a...

Page 203: ...K XCT 300i 3 59 Measure the ring gap with a feeler gauge Repeat this procedure with second ring and the oil side rails Ring end gap Item Standard mm Top 0 10 0 25 Second 0 10 0 25 Oil side rail 0 2 0...

Page 204: ...e minimum 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...

Page 205: ...he 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 fresh engine oil Th...

Page 206: ...ver the connecting rod Insert the piston pin into the piston and rod Install new piston pin clips securely into their grooves Turn the gap in the clips away from the access gap Make sure the cylinder...

Page 207: ...3 Engine Cylinders and Pistons K XCT 300i 3 63 Install the new base gasket onto the crankcase...

Page 208: ...ou are compressing the rings with your fingers Be careful to not damage the rings during this step Bring the cam chain and guide through the opening Thread in the two cylinder bolts on the right side...

Page 209: ...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 engine...

Page 210: ...oint Removal Generator Cover Remove the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot Skirt Drain engine oil and remove the oil filter S...

Page 211: ...free 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...

Page 212: ...3 Engine Generator K XCT 300i 3 68 Remove the 12 generator cover bolts with an 8 mm socket Note the upper most bolt holds a wire stay Utilize the pry points and remove the generator cover...

Page 213: ...3 Engine Generator K XCT 300i 3 69 Remove the generator cover gasket Remove the two dowel pins...

Page 214: ...ings and replace them as needed Stator and Pulsar Coil Crank Position Sensor Free the rubber wire grommet from the right crankcase cover Remove the three stator mounting bolts and the two crank positi...

Page 215: ...3 Engine Generator K XCT 300i 3 71 Flywheel To remove the fly wheel two special tools are needed ITEM TOOL NO UNIVERSAL HOLDER E021 ITEM TOOL NO FLYWHEEL PULLER E003...

Page 216: ...3 Engine Generator K XCT 300i 3 72 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket Remove the flywheel nut and washer...

Page 217: ...the 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 c...

Page 218: ...3 Engine Generator K XCT 300i 3 74 Slide the starter driven gear off of the crankshaft Remove the woodruff key from the crankshaft...

Page 219: ...r and shaft from the crankcase Inspect the 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 ins...

Page 220: ...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 clutch must be replaced Remove the three starter clutch mou...

Page 221: ...mounting bolts to specification with a 6 mm Allen socket Item Qty Thread size mm Torque kgf m lb ft Oneway clutch bolt 3 8 1 8 2 2 13 02 15 91 Lubricate the starter idle gear shaft with fresh engine o...

Page 222: ...crankshaft Lubricate the inside of the starter driven gear with fresh engine oil Slide the starter driven gear onto the flywheel as shown Clean off the tapered end of the crankshaft where the flywheel...

Page 223: ...XCT 300i 3 79 Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft Guide the starter driven gear into the starter clutch on the back of the flywheel Install the was...

Page 224: ...80 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 39 78 47 01 ITE...

Page 225: ...the 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...

Page 226: ...3 Engine Generator K XCT 300i 3 82 Generator Cover Make sure the generator cover mating surface is clean Install the two dowel pins and a new generator cover gasket...

Page 227: ...Generator K XCT 300i 3 83 Make sure the oil filter chamber O rings are in place and in good condition Fit the generator cover into place Make sure the water pump shaft engages correctly with the oil p...

Page 228: ...r bolts Note the upper most bolt holds a wire stay Tighten the bolts securely in a with an 8 mm socket Fit the coolant hose to the right crankcase cover pipe Secure the hose with the clamp and tighten...

Page 229: ...ngine Generator K XCT 300i 3 85 Connect the coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Plug in the regulator rectifier 3 pin connect...

Page 230: ...See the Engine Oil topic for more information Install the exhaust system See the Exhaust System topic for more information Fill the coolant and bleed the coolant See the Coolant topic for more informa...

Page 231: ...e the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks TROUBLESHOOTING Oil level too low 1 Natural oil co...

Page 232: ...3 Engine Oil Pump K XCT 300i 3 88 The oil pump is driven by a chain off of the crankshaft Loosen the two oil pump cover bolts with an 8 mm socket...

Page 233: ...ine Oil Pump K XCT 300i 3 89 Remove the two oil pump cover 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 spro...

Page 234: ...Pump K XCT 300i 3 90 Inspect the oil pump drive chain and sprocket for signs of wear and damage Replace the parts as needed Remove the two oil pump screws with an impact 3 Phillips screwdriver Remove...

Page 235: ...the oil pump shaft by hand and make sure it turns smoothly If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit Oil Pump Installation Fit the oil pump into p...

Page 236: ...and tighten them securely with an impact 3 Phillips screwdriver Fit the oil pump driven sprocket into the drive chain Install the gear onto the oil pump shaft and fit the chain onto its teeth on the...

Page 237: ...cover and its two mounting bolts Tighten the two oil pump cover bolts securely with an 8 mm socket Install the starter driven gear flywheel and the generator cover See the Generator topic Fill the en...

Page 238: ...tion Remove the camshaft sprocket See the Camshaft topic for more information Remove the cylinder head See the Cylinder Head topic for more information Remove the generator cover flywheel starter idle...

Page 239: ...3 Engine Crankcase K XCT 300i 3 95 Remove the upper cam chain guide Inspect the cam chain guides for damage and excessive wear Replace the guides as needed...

Page 240: ...3 Engine Crankcase K XCT 300i 3 96 Remove the cam chain from the crankshaft and crankcase Inspect the cam chain for wear and damage Replace the cam chain as needed There are 11 crankcase bolts...

Page 241: ...ankcase K XCT 300i 3 97 Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm socket Remove the crankcase bolts from the left side of the engine Remove the plate with the bottom two crank...

Page 242: ...XCT 300i 3 98 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 mallet Lift the right crank...

Page 243: ...3 Engine Crankcase K XCT 300i 3 99 Remove the three dowel pins from the crankcase Inspect the O ring and replace it as needed...

Page 244: ...3 Engine Crankcase K XCT 300i 3 100 To remove the crankshaft see the Crankshaft topic Replace the left crankshaft seal if the crankcases are separated Remove the seal with a seal pick...

Page 245: ...river The driver should have the same outside diameter as the seal Lubricate the new crankshaft seal lips with fresh engine oil Assembly Thoroughly clean the crankcase mating surface Apply sealant uni...

Page 246: ...3 Engine Crankcase K XCT 300i 3 102 Set the right case half down on top of the left Install the engine mount spacer Insert the 11 crankcase bolts The plate goes on with the bottom two bolts...

Page 247: ...3 Engine Crankcase K XCT 300i 3 103 Tighten the bolts securely and evenly in a crisscross pattern with an 8mm socket Install the cam chain around the timing sprocket teeth on the crankshaft...

Page 248: ...Size mm Torque kgf m lb ft Cam chain tensioner pivot 1 8 0 8 1 2 5 79 8 68 Install the oil pump See the OilPump topic for more information Install the starter idle gear driven gear flywheel and the g...

Page 249: ...head See the CylinderHead 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...

Page 250: ...CT 300i 3 106 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 t...

Page 251: ...Engine Crankshaft K XCT 300i 3 107 Remove the thrust washer from the right side of the crankshaft Crankshaft Inspection Check the side clearance of the big end of the connecting rod with a feeler gaug...

Page 252: ...Service Limit mm 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 crank weights If there is definite play between...

Page 253: ...ey show any kind of imperfection Note the bearing color code and crankcase code The crank weights are also marked with a size code Bearing Color Crankshaft mark Crankshaft mark A B C D A black green g...

Page 254: ...n the crankshaft as shown Lubricate the connecting rod big end and crankshaft shaft bearings with fresh engine oil Fit the crankshaft into the left crankcase bearing Take care to avoid damaging the ne...

Page 255: ...Protective gloves and eyewear are recommended at this point Before the engine is returned to the install the rear wheel See the Rear Wheel topic for more information Set the chassis on its center stan...

Page 256: ...e mounting bracket and damper assembly into place Install the two engine mounting bracket to frame mounting bolts and nuts Insert the bolts from the outside of the frame Insert the engine mounting bra...

Page 257: ...ngine mounting bracket damper washer and nut Hold the engine mounting bolts with a 14 mm wrench and torque the nuts to specification with a 19 mm socket Item Qty Thread size mm Torque Remarks kgf m lb...

Page 258: ...e mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt Item Qty Thread size mm Torque Remarks kgf m lb ft Engine hanger Engine side 1 10 4 5 5 5 32 55 3...

Page 259: ...bers See the Shock Absorbers topic for more information Route the wiring harness through its guide above the intake pipe Plug in the oil pressure switch bullet connector Route the starter motor lead t...

Page 260: ...nstallation K XCT 300i 3 116 Fit the starter motor cable lead onto the terminal and thread on the nut Tighten the starter motor lead nut securely with a 10 mm wrench Fit the rubber starter motor lead...

Page 261: ...und bolt securely with an 8 mm socket Install air bleed hose and secure it with the clamp Connect the coolant hose to the thermostat Move the clamp into place and tighten it securely with a 2 Phillips...

Page 262: ...ne Installation K XCT 300i 3 118 Fit the fuel stay into place Tighten the stay bolt securely with an 8 mm socket Plug in the thermo sensor unit and ground connectors Plug in the water temperature sens...

Page 263: ...otor Type Gasoline 4 stroke Cylinder arrangement SINGLE CYLINDER Combustion chamber type Semi sphere Valve arrangement O H C Chain drive Bore x stroke mm 72 7 x 72 Compression ratio 10 8 1 Compression...

Page 264: ...psi Front 2 0 28 4 Rear 2 25 32 Handle turning angle L R Left 40 Right 40 Brake system type Front Wavy Disc brake Rear Disc brake Damping Device Suspension type Front Telescope Rear Swing arm Shock a...

Page 265: ...width IN 1 2 EX 1 2 Valve stem O D IN 4 990 4 975 EX 4 990 4 975 Valve guide I D IN 5 00 5 012 EX 5 00 5 012 Valve stem to guide clearance IN 0 010 0 037 EX 0 010 0 037 Item Standard mm Cylinder I D 7...

Page 266: ...reen green red Item Service Limit mm Starter drive gear I D 22 15 Starter drive gear O D 41 50 CVT Cooling System Radiator cap relief pressure 0 9 0 15 kg cm2 12 8 2 1 psi Thermostat temperature Begin...

Page 267: ...042 1 040 1 038 30 1 053 1 051 1 051 1 049 1 047 1 045 35 1 063 1 065 1 060 1 058 1 056 1 054 40 1 072 1 070 1 068 1 066 1 064 1 062 45 1 080 1 078 1 076 1 074 1 072 1 069 50 1 086 1 084 1 082 1 080...

Page 268: ...ressure at 40L Hr 294 6 kPa 3 Bar Water temperature sensor resistance At 20 C 4 F 18 8 K At 40 C 104 F 1 136 K At100 C 212 F 0 1553 K Intake pressure sensor MAP pressure at 1 4 2V 13 332 kPa 0 13332 k...

Page 269: ...nsor Open or short circuit on O2 sensor wire Faulty O2 sensor Engine operates normally 33 P0201 Faulty injector Nozzle Faulty Fuel injector range 9 945 13 5 Loose or poor connection on injector Open o...

Page 270: ...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 cylinder I D 27 27 05 1 063 1 065 Item Standard mm Wheel rim run...

Page 271: ...x Water Temperature Sensor 2 076 K 10 25 C Oxygen Sensor engine warming condition 6 7 9 5 Crank Position Sensor 115 9 15 9 Tilt Switch 0 4V 1 4V normal 3 7V 4 4V fall down Water temperature sensor res...

Page 272: ...n 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 p...

Page 273: ...FIRST Protective gloves and eyewear are recommended at this point Removal Remove the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot Skir...

Page 274: ...CVT Transmission Belt Case K XCT 300i 4 3 Remove the belt case plastic cover bolts with an 8 mm socket Remove the belt case bodywork Inspect the plastic belt case cover and replace it if it is damage...

Page 275: ...4 CVT Transmission Belt Case K XCT 300i 4 4 Remove the belt case cover bolts with an 8 mm socket Use the pry points to free the belt case cover...

Page 276: ...4 CVT Transmission Belt Case K XCT 300i 4 5 Remove the belt case cover and gasket Remove the two dowel pins...

Page 277: ...T Transmission Belt Case K XCT 300i 4 6 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 n...

Page 278: ...Case K XCT 300i 4 7 Remove the bearing snap ring with snap ring pliers Remove the bearing with a suitable bearing puller Drive in a new bearing with a suitable bearing driver that has the same outside...

Page 279: ...4 CVT Transmission Belt Case K XCT 300i 4 8 Install a new snap ring with snap ring pliers Installation Install the two dowel pins into the belt case Install a new gasket with the belt case cover...

Page 280: ...4 CVT Transmission Belt Case K XCT 300i 4 9 Install the belt case cover bolts and tighten them securely with an 8 mm socket...

Page 281: ...4 CVT Transmission Belt Case K XCT 300i 4 10 Install the belt case plastic cover Insert the plastic cover bolts and tighten them securely with an 8 mm socket...

Page 282: ...4 CVT Transmission Belt Case K XCT 300i 4 11 Fit the drain hose to the plastic belt case cover as shown...

Page 283: ...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 the n...

Page 284: ...4 CVT Transmission CVT Removal K XCT 300i 4 13 Remove the left face of the drive pulley Loosen the driven pulley nut with a 19 mm socket...

Page 285: ...4 CVT Transmission CVT Removal K XCT 300i 4 14 Remove the driven pulley nut and bushing Slide the driven pulley off of the shaft...

Page 286: ...4 CVT Transmission CVT Removal K XCT 300i 4 15 Remove the belt from the driven pulley Inspect the drive belt for cracks or excessive wear...

Page 287: ...CVT Transmission CVT Removal K XCT 300i 4 16 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 crankshaf...

Page 288: ...l K XCT 300i 4 17 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 left drive pulley face Remove the rubbe...

Page 289: ...in the back of the right face of the 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...

Page 290: ...lace the parts as needed Clutch Disassembly 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...

Page 291: ...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 DESCRIPTION...

Page 292: ...K XCT 300i 4 21 Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Loosen the clutch drive plate nut with the special socket that comes with the fitting tool Re...

Page 293: ...VT Removal K XCT 300i 4 22 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 off th...

Page 294: ...4 CVT Transmission CVT Removal K XCT 300i 4 23 Remove the collars and spring Measure the free length of the clutch spring Replace the spring if the measurement fails to meet the service limit...

Page 295: ...4 CVT Transmission CVT Removal K XCT 300i 4 24 Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver Lift off the plate...

Page 296: ...4 CVT Transmission CVT Removal K XCT 300i 4 25 Slide the clutch shoes off of the pivots on the drive plate Inspect the clutch shoe bumpers and replace them as needed...

Page 297: ...ransmission CVT Removal K XCT 300i 4 26 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 driven...

Page 298: ...4 CVT Transmission CVT Removal K XCT 300i 4 27 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 pulley...

Page 299: ...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 safety gla...

Page 300: ...4 CVT Transmission CVT Removal K XCT 300i 4 29 Bearing Replacement Inspect the bearings in the right face of the driven pulley Remove the needle bearing with a suitable puller...

Page 301: ...e collar snap ring and bearing from the right face of the driven pulley Clean the right face with a high flash point solvent and compressed air NOTE Always wear safety glasses when using compressed ai...

Page 302: ...rds the clutch Install the snap ring into the groove Install the collar and drive in the new needle bearing so that its markings face out Drive in the bearings with a suitable driver with the same out...

Page 303: ...tallation 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 with a...

Page 304: ...TIONS The servicing operations of this section can be made with the engine installed When replacing the drive shaft use a special tool to hold the bearing inner race for this operation TROUBLESHOOTING...

Page 305: ...tective gloves and eyewear are recommended at this point Disassembly Note Do not remove the transmission case cover except for necessary part replacement If the drive shaft is replaced make sure to al...

Page 306: ...rotective 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...

Page 307: ...round Remove the transmission oil level check bolt with a 12 mm socket The oil level is correct when oil flows from the bolt hole Install the oil level check bolt and tighten it to specification with...

Page 308: ...type and brand of oil as shown below Inspect for leaks Draining Place the vehicle on its center stand on level ground Place a suitable oil drain pan under the transmission oil drain plug Place a suit...

Page 309: ...5 Final Drive Transmission Oil K XCT 300i 5 6 Inspect the drain plug and washer Install the oil drain plug and washer with a 12 mm socket Tighten to specification...

Page 310: ...ize mm Torqu kgf m lb ft Final Drive oil check bolt 1 8 0 8 1 2 5 79 8 68 Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole Gear oil type SAE 90 G...

Page 311: ...K XCT 300i 5 8 Thread in the final drive oil level check bolt Install the oil check plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil c...

Page 312: ...oling system When the coolant temperature is over 100 never remove the radiator cap to release the pressure because the boiling coolant may cause danger Avoid spilling coolant on painted surfaces beca...

Page 313: ...XCT 300i 6 2 Temperature gauge shows the wrong temperature Faulty temperature gauge or sensor Faulty thermostat Coolant leaks Faulty pump mechanical water seal Deteriorated O rings Damaged or deterio...

Page 314: ...rking 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 animals...

Page 315: ...cap 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 d...

Page 316: ...6 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 inner cover Remove the engine coolant lid screw with a 2 Phi...

Page 317: ...ank with an appropriate suction device If a suction device is unavailable remove the reserve tank and poor it out See the Radiator topic for more information When the coolant has fished draining retur...

Page 318: ...9cc distilled water is 50 Do not mix coolant concentrate of different brands Do not drink the coolant which is poisonous COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing Point Mixing...

Page 319: ...Fill the cooling system with a mix of distilled water and Coolant Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Add coolant to the reserve tan...

Page 320: ...d 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 stop coming up turn off the engine and recheck the...

Page 321: ...6 Cooling System Coolant K XCT 300i 6 10 Install the engine coolant reserve tank cover Insert the screw and tighten its securely with a 2 Phillips Install the radiator cap access panel...

Page 322: ...6 Cooling System Coolant K XCT 300i 6 11 Install the radiator coolant panel screws and tighten securely with a 2 Phillips screwdriver...

Page 323: ...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 radiator coolant pane...

Page 324: ...Remove the radiator cap wet the tester seal and install the end of the pressure tester onto the filler neck Pump the tester up until the gauge reads 0 84 kg cm2 or 12 psi The cooling system should hol...

Page 325: ...et the seal on the radiator cap and install it to the pressure tester Replace the cap if it does not relieve the pressure as specified Radiator cap relief pressure 0 9 0 15 kg cm2 12 8 2 1 psi Removal...

Page 326: ...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 the thermostat on the cylinder h...

Page 327: ...tor K XCT 300i 6 16 Loosen the coolant 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 ho...

Page 328: ...Cooling System Radiator K XCT 300i 6 17 Remove the two radiator mounting bolts with a 10 mm socket Slide the radiator to the left and free the grommet from the post above the right side of the radiato...

Page 329: ...frame Coolant Reserve Tank The coolant reserve 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...

Page 330: ...tor K XCT 300i 6 19 Position a suitable container below the reserve tank Pull back the clamp and free the overflow hose from the bottom of the reserve tank Allow the coolant in the reserve tank to dra...

Page 331: ...6 Cooling System Radiator K XCT 300i 6 20 Remove the two reserve tank mounting bolts with a 10 mm socket Remove the reserve tank from the frame...

Page 332: ...6 Cooling System Radiator K XCT 300i 6 21 To remove the reserve tank bracket take off the mounting nuts with a 10 mm socket...

Page 333: ...Radiator K XCT 300i 6 22 Remove the reserve tank bracket from the studs on the frame Inspection Inspect the radiator fins for damage and clogging To remove the fan take out the three mounting bolts wi...

Page 334: ...ty glasses when using compressed air and never point it directly at yourself or anyone else Check the radiator for any bent or damaged fins Use a small flat blade screwdriver to straighten them out bu...

Page 335: ...hermostatic switch needs to be removed use a 22 mm wrench The thermostatic switch should be off below 85 C 185 F and on above 90 C 194 F Installation Coolant Reserve Tank Fit the coolant reserve tank...

Page 336: ...XCT 300i 6 25 Install the two reserve tank mounting nuts and tighten them securely with a 10 mm socket Fit the reserve tank to its bracket Insert the two reserve tank mounting bolts and tighten them s...

Page 337: ...6 Cooling System Radiator K XCT 300i 6 26 Connect the dump hose to the top of the reserve tank and the overflow hose to the bottom Secure the hoses with the clamps Radiator...

Page 338: ...r K XCT 300i 6 27 Fit the radiator into place so that the post on the frame fits into the rubber grommet on the right side of the radiator Install the two radiator mounting bolts and tighten them secu...

Page 339: ...de to the top right of the radiator Connect the coolant hose from the thermostat on the cylinder head to the top left of the radiator Connect the coolant hose from the water pump to the bottom right o...

Page 340: ...6 Cooling System Radiator K XCT 300i 6 29 Plug in the cooling fan motor connector Plug in the thermostatic switch connectors...

Page 341: ...Thermostat and Thermosensor SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Thermosensor Unplug the thermosensor unit and thermo unit ground connectors Remove the ther...

Page 342: ...6 Cooling System Thermostat K XCT 300i 6 31 Water Temperature Sensor WTS Unplug the water temperature sensor Use a 17 mm wrench to remove the water temperature sensor...

Page 343: ...with a new item Thermostat Loosen 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...

Page 344: ...6 Cooling System Thermostat K XCT 300i 6 33 Remove the two thermostat mounting bolts with an impact 3 Phillips screwdriver...

Page 345: ...6 Cooling System Thermostat K XCT 300i 6 34 Lift off the thermostat cover Lift out the thermostat Remove the thermostat O ring and discard it...

Page 346: ...r heats up Do not allow the thermosensor or the thermometer to contact the sides of the pan Thermosensor resistance At 50 C 122 F 154 At 80 C 176 F 52 At 100 C 212 F 27 At 120 C 248 F 16 Water Tempera...

Page 347: ...are 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 m...

Page 348: ...6 Cooling System Thermostat K XCT 300i 6 37 Installation Thermosensor Tighten the thermosensor unit securely with a 12 mm deep well socket Plug in the thermosensor unit and ground connectors...

Page 349: ...Cooling System Thermostat K XCT 300i 6 38 Water Temperature Sensor Install the WTS with a new O ring Tighten the WTS to specification with a 17 mm wrench Plug in the water temperature sensor connecto...

Page 350: ...mostat Make sure the thermostat seal is in good condition Replace the thermostat if needed Apply a light coat of waterproof grease to the thermostat seal Insert the thermostat into its cavity in the c...

Page 351: ...o thermostat bolts and tighten them securely with an impact 3 Phillips screwdriver Install air bleed hose and secure it with the clamp Connect the coolant hose to the thermostat Move the clamp into pl...

Page 352: ...spect the telltale hole in the generator cover below the water pump for signs of coolant leaking If there is coolant coming from this hole the mechanical seal is compromised and must be replaced Remov...

Page 353: ...se clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the four water pump cover...

Page 354: ...Pump K XCT 300i 6 43 Remove the two dowel pins and the water pump cover gasket Impeller and Shaft Hold the water pump shaft and loosen the impeller with a 12 mm socket The impeller has left hand threa...

Page 355: ...p K XCT 300i 6 44 Remove the seal washer from the back of the impeller Inspect the impeller blades and seal Replace the seal washer if the mechanical seal is to be replaced Remove the water pump shaft...

Page 356: ...over Assembly Seals Shaft and Impeller Coat the lips of the new oil seal in fresh engine oil and drive it in with a suitable drive that is the same outside diameter as the oil seal Apply silicone seal...

Page 357: ...ust washer on the water pump shaft Install a new snap ring onto the water pump shaft if the snap ring was removed Lubricate the water pump shaft with fresh engine oil where it will ride in the case In...

Page 358: ...6 CoolingSystem Water Pump K XCT 300i 6 47 Install a new washer into the back of the impeller if the mechanical seal was replaced Install the impeller to the water pump shaft Note Left hand threads...

Page 359: ...ion with a 12 mm socket Remember the impeller has left hand threads Item Qty Thread size mm Torque kgf m lb ft Water pump impeller 1 7 1 0 1 4 7 23 10 13 Make sure the water pump cover mating surface...

Page 360: ...tall the water pump cover and insert the four bolts Tighten the water pump cover bolts to specification with an 8 mm socket Connect the coolant hose to the water pump Move the clamp into place and tig...

Page 361: ...ables to stick or bind resulting in loss of vehicle control Work in a fully ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explos...

Page 362: ...300i 7 2 Air box SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Loosen the air box connecting hose clamp screw at the throttle body with a 2 Phillips Remove the brea...

Page 363: ...7 Fuel System Air box K XCT 300i 7 3 Disconnect the transmission vent hose...

Page 364: ...7 Fuel System Air box K XCT 300i 7 4 Remove the two rear air box screws with an 8 mm socket Remove the two front air box screws with an 8 mm socket...

Page 365: ...7 Fuel System Air box K XCT 300i 7 5 Remove the air box Installation Fit the air box into the frame and guide the boot over the mouth of the throttle body...

Page 366: ...7 Fuel System Air box K XCT 300i 7 6 Tighten the air box connecting hose clamp screw at the throttle body with a Phillips...

Page 367: ...7 Fuel System Air box K XCT 300i 7 7 Install the two front air box screws and tighten securely with an 8 mm socket Install the two rear air box screws and tighten securely with an 8 mm socket...

Page 368: ...7 Fuel System Air box K XCT 300i 7 8 Connect the transmission vent hose Connect the breather hose to the air box...

Page 369: ...urce of sparks Removal In order to drain the fuel from the fuel pipe and release the fuel pressure unplug the fuel pump connecter Start the engine and let it run until it dies of fuel starvation Turn...

Page 370: ...7 Fuel System Fuel Tank K XCT 300i 7 10 Remove the fuel tank mounting nuts and brackets Remove the fuel tank from the bottom of the frame...

Page 371: ...XCT 300i 7 11 Installation Fit the fuel tank into place Install the brackets and nuts Tighten the nuts securely Connect the fuel hose to the outlet pipe on the fuel pump Tighten the clamp securely wit...

Page 372: ...7 Fuel System Fuel Tank K XCT 300i 7 12 Plug in the fuel pump connecter...

Page 373: ...rotective 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 Input Voltage Inspection Turn the ignition switch o...

Page 374: ...ess 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 s...

Page 375: ...necter Start the engine and let it run until it dies of fuel starvation Turn the ignition switch off Loosen the fuel hose clamp with a 2 Phillips screwdriver Slide back the clamp and free the injector...

Page 376: ...7 Fuel System Fuel Pump K XCT 300i 7 16 Lift the fuel pump out of the tank Discard the fuel pump O ring and replace it with a new item on assembly...

Page 377: ...7 Fuel Level Gauge Inspection Using a digital multi meter set to ohms of resistance measure the resistance between the fuel pump level gauge connector terminals green and yellow white with the float r...

Page 378: ...7 Fuel System Fuel Pump K XCT 300i 7 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 379: ...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 the ON position Check the fuel pressure If the fuel...

Page 380: ...e the fuel hose clamp to block the fuel hose Return the fuel line to the injector To inspect the fuel pump relay see the Relays topic Fuel Pump Relay See the Relay topic Installation Replace the O rin...

Page 381: ...p into the tank Avoid damaging the fuel pump wire The fuel delivery pipe should face to the rear Insert the 6 fuel pump mounting bolts Tighten the bolts to specification with a 7 mm socket or 2 Philli...

Page 382: ...7 Fuel System Fuel Pump K XCT 300i 7 22 Connect the fuel hose to the outlet pipe on the fuel pump Tighten the clamp securely with a 2 Phillips screwdriver Plug in the fuel pump connecter...

Page 383: ...after replacement Do not damage the throttle body it may cause the throttle and idle valve to fail synchronization The throttle body is preset in KYMCO factory do not disassemble it incorrectly Do no...

Page 384: ...ECU voltage outputs to the MAP between the following terminals of the MAP connector Terminal Normal Violet Red Green Pink 5 V TPS Inspection Support the scooter on a level surface Put the side stand...

Page 385: ...y Removal K XCT 300i 7 25 Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal Violet Red Green Pink 5 V Throttle Position Sensor TPS resistan...

Page 386: ...7 Fuel System Throttle Body Removal K XCT 300i 7 26 Removal Throttle Cables Free the throttle cables from the throttle drum...

Page 387: ...an open flame or a source of sparks Disconnect the Fuel Pump Relay or Fuel Pump Connector In order to release fuel pressure from the fuel pipe when removing the fuel injector unplug the fuel pump con...

Page 388: ...7 Fuel System Throttle Body Removal K XCT 300i 7 28 Remove the fuel injector mounting bolt with a 10 mm socket Unplug the fuel injector connector...

Page 389: ...Throttle Body Removal K XCT 300i 7 29 Lift the fuel injector out of the intake pipe Loosen the fuel hose clamp with a 2 Phillips screwdriver Slide back the clamp and free the injector fuel pipe from...

Page 390: ...7 Fuel System Throttle Body Removal K XCT 300i 7 30 Lift the fuel pipe off the top of the injector Sensors Unplug the MAP sensor...

Page 391: ...7 Fuel System Throttle Body Removal K XCT 300i 7 31 Unplug the ISC connector Throttle Body Unplug the throttle position sensor TPS connector...

Page 392: ...l K XCT 300i 7 32 Loosen the air box hose clamp screw at the throttle body with a 2 Phillips Loosen the intake hose clamp screw at the throttle body with a flat blade screwdriver Remove the throttle o...

Page 393: ...Fuel System Throttle Body Removal K XCT 300i 7 33 Installation Throttle Body Fit the throttle body into the air box and intake boots Tighten the intake hose clamp securely with a flat blade screwdrive...

Page 394: ...7 Fuel System Throttle Body Removal K XCT 300i 7 34 Throttle Cables Connect the throttle cables to the throttle drum Adjust the throttle cable free play with 12 mm wrenches...

Page 395: ...7 Fuel System Throttle Body Removal K XCT 300i 7 35 Sensors Plug in the TPS connector Plug in the ISC connector...

Page 396: ...7 Fuel System Throttle Body Removal K XCT 300i 7 36 Plug in the MAP sensor Fuel Injector Apply a light coat of fresh engine oil to a new fuel injector O ring...

Page 397: ...the fuel injector pipe onto the top of the injector The tab on the injector must fit into the pipe Fit the fuel hose onto the fuel injector pipe Secure the hose to the fuel injector with the clamp Ti...

Page 398: ...7 Fuel System Throttle Body Removal K XCT 300i 7 38 Fit the injector into the intake pipe as shown Plug in the fuel injector connector and thread in the mounting bolt...

Page 399: ...lt securely with a 10 mm socket Connect the Fuel Pump Relay or Fuel Pump Connector The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the throttle body MAP TPS ISC or...

Page 400: ...nd eyewear are recommended at this point Remove the throttle body See the Throttle Body Removal topic for more information Disassembly The throttle position sensor TPS and idle air bypass valve ISC ha...

Page 401: ...Do not work around an open flame or a source of sparks Removal In order to release fuel pressure from the fuel pipe when removing the fuel injector unplug the fuel pump connecter Start the engine and...

Page 402: ...7 Fuel System Fuel Injector K XCT 300i 7 42 Remove the fuel injector mounting bolt with a 10 mm socket Unplug the fuel injector connector...

Page 403: ...stem Fuel Injector K XCT 300i 7 43 Lift the fuel injector out of the intake pipe Loosen the fuel hose clamp with a 2 Phillips screwdriver Slide back the clamp and free the injector fuel pipe from the...

Page 404: ...Lift the fuel pipe off the top of the injector Inspection A digital multi meter is needed to test the fuel injector Measure the resistance between the fuel injector terminals ITEM SPECIFICATIONS Fuel...

Page 405: ...1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard 1 6ms ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector clea...

Page 406: ...7 Fuel System Fuel Injector K XCT 300i 7 46...

Page 407: ...el Injector K XCT 300i 7 47 Installation Apply a light coat of fresh engine oil to the fuel injector O ring seals Fit the fuel injector pipe onto the top of the injector The tab on the injector must f...

Page 408: ...hose onto the fuel injector pipe Secure the hose to the fuel injector with the clamp Tighten the clamp securely with a 2 Phillips screwdriver Fit the injector into the intake pipe as shown Plug in the...

Page 409: ...7 Fuel System Fuel Injector K XCT 300i 7 49 Tighten the fuel injector bolt securely with a 10 mm socket Plug in the fuel pump connector...

Page 410: ...this point 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 t...

Page 411: ...d is equal to ten For example one longer blink illumination and two shorter blinks 0 5 second x 2 of the indicator are equal to 12 blinks Follow code 12 If more than a damaged part has occurred the CE...

Page 412: ...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 this vehicle See the K...

Page 413: ...K XCT 300i 7 53 Throttle Cable SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Adjust the throttle cables for maximum free play at the throttle body Free the throttle...

Page 414: ...7 54 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 and free the...

Page 415: ...uel System Throttle Cable K XCT 300i 7 55 Guide the throttle cables out towards the handlebar side Installation Route the throttle body end of the cables through the opening in the lower handlebar cov...

Page 416: ...7 Fuel System Throttle Cable K XCT 300i 7 56 Route the cables through the guide Route the cables down the inside of the left side of the frame...

Page 417: ...7 Fuel System Throttle Cable K XCT 300i 7 57 Route the cables to the throttle body as shown...

Page 418: ...XCT 300i 7 58 Connect the throttle cables to the throttle drum Slide the throttle grip onto the right side of the handlebar Install the right switch and throttle housing The post on the housing shoul...

Page 419: ...Fuel System Throttle Cable K XCT 300i 7 59 Lubricate the 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 wrenche...

Page 420: ...ct ISC position 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...

Page 421: ...d Bearing Removal 8 2 8 8 Steering Stem and Bearing Installation 8 9 8 14 Handlebar 8 15 8 25 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering ball...

Page 422: ...that the front wheel is off the ground Grip the bottom of the fork legs and turn the front end side to side If the movement is rough the bearings should be greased or replaced If the movement is to ti...

Page 423: ...8 Steering Removal K XCT 300i 8 3 A special lock nut wrench is needed to loosen the steering stem lock nut Special Tool Lock Nut Wrench A120F00002...

Page 424: ...00i 8 4 Slide the special tool over the steering stem and loosen the lock nut Remove the steering stem lock nut Slide off the lock washer Support the steering stem and loosen the steering stem adjusti...

Page 425: ...8 Steering Removal K XCT 300i 8 5 Remove the steering stem adjusting nut Remove the dust cover and grease seal Lower the steering stem out of the frame...

Page 426: ...K XCT 300i 8 6 Remove the upper bearing inner race Lift out the upper ball bearings Slide the lower ball bearings up and off of the steering stem Inspect the bearings and races for wear and damage Rep...

Page 427: ...oval K XCT 300i 8 7 Use a chisel to remove the bottom bearing inner race and dust seal Do not damage the steering stem Use the special tools or a drift and hammer to drive out the bearing races in the...

Page 428: ...8 Steering Removal K XCT 300i 8 8 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...

Page 429: ...his point Coat the new dust seal in grease and slide it down the steering stem Drive the new lower bearing inner race onto the steering stem with a pipe with the same outside diameter as the bearing r...

Page 430: ...8 Steering Installation K XCT 300i 8 10 Lubricate the upper bearing with grease and set it into place Lubricate the new lower bearing with grease and place it on the steering stem...

Page 431: ...8 Steering Installation K XCT 300i 8 11 Set the upper bearing inner race into the upper bearing Guide the steering stem into the steering head of the frame...

Page 432: ...8 Steering Installation K XCT 300i 8 12 Lubricate the grease seal with grease Set the grease seal and dust cover into place over the steering stem Thread on the steering stem adjusting nut...

Page 433: ...n the adjusting nut 1 4 to 1 2 half turn Adjust the nut so the steering moves correctly The adjusting nut should be tight enough so that the steering doesn t flop back and forth and vertical movement...

Page 434: ...stem lock nut onto the steering stem Torque the steering stem lock nut to specification with the lock nut wrench special tool Item Qty Thread size mm Torque kgf m lb ft Steering Stem lock nut 1 BC1 6...

Page 435: ...are recommended at this point Removal Bar Ends Remove the bar ends with a 6 mm Allen To remove the brake master cylinders see the Brake Master Cylinder topic Switch Housings and Throttle Remove the tw...

Page 436: ...8 Steering Handlebar K XCT 300i 8 16 Separate the switch housing from the handlebar Disconnect the throttle cables and free the right switch housing from the handlebar Slide off the throttle grip...

Page 437: ...8 Steering Handlebar K XCT 300i 8 17 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 438: ...8 Steering Handlebar K XCT 300i 8 18 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 439: ...8 Steering Handlebar K XCT 300i 8 19 Remove the handlebar lock nut and bolt Remove the handlebar...

Page 440: ...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 point...

Page 441: ...8 Steering Handlebar K XCT 300i 8 21 Installation Handlebar Install the handlebar onto the steering stem and align the holes Install the handlebar lock bolt and thread on the nut...

Page 442: ...T 300i 8 22 Hold the handlebar lock bolt with a 14 mm wrench and tighten the nut to specification with a 17 mm socket Item lorque N m lb ft Handlebar Lock Nut 45 32 Route the cables and lines through...

Page 443: ...lebar K XCT 300i 8 23 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 Conn...

Page 444: ...le grip onto the right side of the handlebar Install the right switch and throttle housing The post on the housing should fit into the hole in the bar Lubricate the end of the throttle in grease Fit t...

Page 445: ...ering Handlebar K XCT 300i 8 25 Insert the two housing screws and tighten them securely with a 2 Phillips screwdriver Tighten the front bolt before the rear Bar Ends Install the bar ends with a 6 mm A...

Page 446: ...27 9 33 Brake Discs 9 34 9 42 Brake Pad Replacement 9 43 9 54 GENERAL INSTRUCTIONS During servicing keep oil or grease off the brake pads and brake disk TROUBLESHOOTING Poor brake performance Worn br...

Page 447: ...ective gloves and eyewear are recommended at this point NOTE Brake fluid is a corrosive chemical and can damage paints and some plastics Avoid contact with skin Removal Remove the brake hose banjo bol...

Page 448: ...8 Brakes Master Cylinders K XCT 300i 9 3 Unplug the brake light switch connector Remove the two master cylinder mounting bolts with an 8 mm socket Remove the master cylinder clamp...

Page 449: ...8 Brakes Master Cylinders K XCT 300i 9 4 Remove the master cylinder Remove the two master cylinder cover screws with a 2 Phillips head screwdriver...

Page 450: ...8 Brakes Master Cylinders K XCT 300i 9 5 Remove the master cylinder cover plastic piece and rubber accordion diaphragm Pour out any remaining brake fluid...

Page 451: ...8 Brakes Master Cylinders K XCT 300i 9 6 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...

Page 452: ...8 Brakes Master Cylinders K XCT 300i 9 7 Remove the brake lever Brake Light Switch Remove the brake light switch mounting bolt with a 2 Phillips screwdriver Remove the brake light switch...

Page 453: ...rakes Master Cylinders K XCT 300i 9 8 Piston Remove the rubber piston cover Remove the snap ring using a pair of internal snap ring pliers Use a suitable tool to hold back the piston as it can spring...

Page 454: ...8 Brakes Master Cylinders K XCT 300i 9 9 Remove the piston spring and cups Remove the spring from the piston and...

Page 455: ...nents with fresh brake fluid Inspect the master cylinder components for wear and damage Replace the parts as needed Inspect the piston and cups for wear and damage Measure the outside diameter of the...

Page 456: ...ylinder bore for wear and damage Measure the inside diameter of the brake master cylinder Item Standard mm in Brake master cylinder I D 12 7 12 74 0 508 0 5096 Assembly Piston Place a film of clean DO...

Page 457: ...8 Brakes Master Cylinders K XCT 300i 9 12 Install the master cylinder piston and spring into the master cylinder bore Compress the snap ring with internal snap ring pliers and Install the snap ring...

Page 458: ...inders K XCT 300i 9 13 Install the rubber boot over the end of the master cylinder piston Brake Light Switch Install the brake light switch Tighten the mounting screw securely with a 2 Phillips screwd...

Page 459: ...all the brake lever 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 ti...

Page 460: ...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 and...

Page 461: ...onnector Install the brake hose to the master cylinder with the 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...

Page 462: ...AFETY FIRST Protective gloves and eyewear are recommended at this point Removal Drain the brake fluid if the caliper is to be disassembled Remove the two caliper mounting bolts with a 12 mm socket Rem...

Page 463: ...9 Brakes Front Brake Caliper K XCT 300i 9 18 Remove the speedometer sensor Remove the front caliper...

Page 464: ...9 Brakes Front Brake Caliper K XCT 300i 9 19 Brake Pad Removal Loosen the brake pad pin with a 5 mm Allen Remove the brake pad pin...

Page 465: ...9 Brakes Front Brake Caliper K XCT 300i 9 20 Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Disassembly Remove the pad spring...

Page 466: ...n Inspect 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...

Page 467: ...ton bores 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 Sta...

Page 468: ...9 Brakes Front Brake Caliper K XCT 300i 9 23 Brake Pad Installation Insert the brake pads into the caliper Fit the ends of the pads into the pad retainer as shown...

Page 469: ...y a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring and insert the brake pad pin Installation Install the front caliper Guide the brake disc between the pads...

Page 470: ...iper bracket mounting bolts Tighten the mounting bolts to specification Item Torque N m Lb ft Front Rear caliper bolt 35 25 8 Install the banjo bolt with new sealing washers and tighten to specificati...

Page 471: ...K XCT 300i 9 26 Install the speedometer sensor Install the speedometer sensor 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 pi...

Page 472: ...recommended at this point Warning Brake fluid is very caustic and can damage paint chrome and plastic Wipe up any spills immediately Removal If the caliper is to be disassembled the brake hose must be...

Page 473: ...8 Brakes Rear Brake Caliper K XCT 300i 9 28 Remove the two rear caliper mounting bolts with a 12 mm socket...

Page 474: ...arm Disassembly One at a time move 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 th...

Page 475: ...tion 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 Rear brake caliper piston O D 25 33...

Page 476: ...I D 25 40 25 45 Assembly Lubricate the caliper pistons the caliper piston bores and the seals with DOT 4 brake fluid from a tightly sealed container NOTE Brake fluid is a corrosive chemical and can da...

Page 477: ...liper K XCT 300i 9 32 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 Rea...

Page 478: ...clamp bolts and tighten them securely with a 10 mm socket Fill the rear brake system with fresh brake fluid and bleed out the air See the Brake Fluid topic for more information Pump the brake lever to...

Page 479: ...SAFETY FIRST Protective gloves and eyewear are recommended at this point Inspection Measure the thickness of the brake rotor with a Vernire caliper or micrometer ITEM STANDARD Brake disc thickness Fro...

Page 480: ...eck if the brake rotor runout is within service limit Measure the runout of the brake disc with a dial gauge If the reading is out of specification remove the disc from the wheel and recheck Item Stan...

Page 481: ...9 Brakes Brake Disc K XCT 300i 9 36 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 482: ...9 Brakes Brake Disc K XCT 300i 9 37 Remove the front brake disc and front wheel speed sensor rotor Separate the wheel speed sensor rotor from the brake disc...

Page 483: ...rakes Brake Disc K XCT 300i 9 38 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 484: ...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 485: ...9 Brakes Brake Disc K XCT 300i 9 40 Rear Removal Remove the five brake disc mounting bolts with an Allen wrench...

Page 486: ...the brake disc off of the rear wheel Installation Coat the threads of the disc bolts in a non permanent thread locking agent Thread in the bolts and torque them to specification with an Allen socket S...

Page 487: ...s Brake Disc K XCT 300i 9 42 Insert the five rear brake disc mounting bolts and tighten them to specification with an Allen socket Item Qty Thread size mm Torque kgf m lb ft Disk bolt 5 8 3 2 3 8 23 1...

Page 488: ...9 43 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 is uneven Front L...

Page 489: ...9 Brakes Brake Pad Replacement K XCT 300i 9 44 Remove the two caliper mounting bolts with a 12 mm socket Remove the speedometer sensor mounting bolt with an 8 mm socket Remove the speedometer sensor...

Page 490: ...9 Brakes Brake Pad Replacement K XCT 300i 9 45 Remove the front caliper Remove the brake pad pin...

Page 491: ...ement K XCT 300i 9 46 Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Insert new brake pads as needed Fit the ends of the pads into t...

Page 492: ...s against the pad spring and insert the brake pad pin It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the ne...

Page 493: ...ake Pad Replacement K XCT 300i 9 48 Install the two caliper bracket mounting bolts Tighten the mounting bolts to specification Item Torque N m lb ft Front Rear caliper bolt 35 25 8 Install the speedom...

Page 494: ...ng 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 pistons against...

Page 495: ...0 Rear If the caliper is to be disassembled the brake hose must be removed Drain the rear brake fluid See the Brake Fluid topic for more information Remove the two rear brake hose clamp bolts with a 1...

Page 496: ...9 Brakes Brake Pad Replacement K XCT 300i 9 51 Remove the two rear caliper mounting bolts with a 12 mm socket Remove the rear caliper from the swingarm...

Page 497: ...the piston side pad to push the pistons in to allow for more room Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven One at a time fit the brake pads into th...

Page 498: ...d Replacement K XCT 300i 9 53 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 499: ...r brake hose guide into place Insert the two rear brake hose clamp bolts and tighten them securely with a 10 mm socket Pump the brake lever to seat the caliper pistons against the pads Check the opera...

Page 500: ...t fork components for the KYMCO K XCT 300i Front Fork Removal and Installation 10 2 10 7 Fork Disassembly 10 8 10 19 Fork Assembly 10 20 10 27 TROUBLESHOOTING Soft front shock absorber Weak shock spri...

Page 501: ...ront Fork Removal K XCT 300i 10 2 Front Fork Removal and Installation SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the front wheel speed sensor mounting bolt...

Page 502: ...10 Front Suspension Front Fork Removal K XCT 300i 10 3 Remove the front wheel speed sensor from the bottom of the right fork leg...

Page 503: ...emoval K XCT 300i 10 4 Remove the speed sensor wire and front brake hose guide mounting bolt with an 8 mm socket Free the guide from the fork clamp Loosen the fork clamp pinch bolts with a 12 mm socke...

Page 504: ...Front Suspension Front Fork Removal K XCT 300i 10 5 Slide the forks legs down and out of the fork clamp using a twisting motion Installation Slide the fork legs up into fork clamp using a twisting mot...

Page 505: ...ole lines up with the groove on the inner fork tube Insert the fork clamp upper bolt Tighten the fork clamp bolts securely and evenly with a 12 mm socket Install the speed sensor wire and front brake...

Page 506: ...l K XCT 300i 10 7 Item Qty Thread size mm Torque kgf m lb ft Speed sensor cable 1 6 1 0 1 4 7 23 10 13 Fit the front wheel speed sensor into place on the right fork leg Insert the bolt and tighten it...

Page 507: ...otective 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 disassembl...

Page 508: ...10 Front Suspension Fork Disassembly K XCT 300i 10 9 Remove the rubber fork cap Place the fork leg in a soft jawed vice...

Page 509: ...10 Front Suspension Fork Disassembly K XCT 300i 10 10 Push down on the top plug and remove the snap ring Remove the top plug Lift out the fork spring...

Page 510: ...ble container Pump the fork through its stroke several times to free as much oil as possible Hold the fork inverted for several minutes to let the oil drain completely Use a flat blade screwdriver to...

Page 511: ...0 Front Suspension Fork Disassembly K XCT 300i 10 12 Use a small flat blade screwdriver to pry out the fork oil seal stopper ring Take care to avoid scratching the fork tube Slide off the stopper ring...

Page 512: ...Fork Disassembly K XCT 300i 10 13 Place the axle holder of the outer fork tube in a soft jawed Insert an 8 mm Allen socket into the damper rod Hold the damper rod and loosen the fork bottom bolt with...

Page 513: ...rom the bottom of the fork slider Discard the sealing washer Separate the inner and outer fork tubes by pulling them apart using a slide hammer motion Remove the oil lock piece The oil lock piece may...

Page 514: ...10 Front Suspension Fork Disassembly K XCT 300i 10 15 Remove the damper rod and rebound spring Inspect the oil seal and the bushing in the fork slider...

Page 515: ...10 Front Suspension Fork Disassembly K XCT 300i 10 16 Place a rag across the top of the fork slider and pry our the oil seal as shown Remove the oil seal and spacer from the fork slider...

Page 516: ...10 Front Suspension Fork Disassembly K XCT 300i 10 17 Inspection Inspect the top plug O ring O ring and replace it if needed Insect the slider bushing and replace it as needed...

Page 517: ...ension Fork Disassembly K XCT 300i 10 18 Inspect the fork springs for signs of fatigue Replace the fork springs if they vary dramatically in length Inspect the damper rod and seal Replace the componen...

Page 518: ...10 Front Suspension Fork Disassembly K XCT 300i 10 19 Inspect the inner fork tube for bends and damage Replace it as needed For assembly see the Fork Assembly topic...

Page 519: ...free 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 d...

Page 520: ...10 Front Suspension Fork Assembly K XCT 300i 10 21 Place the spacer into the fork slider Insert the inner fork tube into the inner fork tube...

Page 521: ...embly K XCT 300i 10 22 Place a new sealing washer on the fork bottom bolt Insert the fork bottom bolt into the bottom the fork slider and thread it into the damper rod Place the axle holder of the out...

Page 522: ...Fork Assembly K XCT 300i 10 23 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 in the fork oil seal with t...

Page 523: ...10 Front Suspension Fork Assembly K XCT 300i 10 24 Insert the stopper ring into its groove Install the dust seal securely into the outer fork tube...

Page 524: ...the fork tube with the specified quantity of fork oil 185 cc or 6 26 US oz Use fork oil type SS 8 10W Pump the fork slowly through its stroke several times to release any trapped air Fully extend the...

Page 525: ...plug O ring with fresh fork oil and insert the plug into the top of the inner fork tube as shown Push the top plug down against the spring and install the stopper ring into its groove Release the pre...

Page 526: ...on Fork Assembly K XCT 300i 10 27 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...

Page 527: ...ar Suspension This chapter provides information on the rear suspension components of the KYMCO K XCT 300i Shock Absorbers 11 2 11 9 Swingarm 11 10 11 14 TROUBLESHOOTING Soft rear shock absorber Weak s...

Page 528: ...pring preload for stiffer rear suspension and can be used when the scooters heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions Use a pin spanner to adjust th...

Page 529: ...s K XCT 300i 11 3 Removal Place the vehicle on its center stand Remove the body cover to access the upper shock absorber mounts See the Body Cover topic for more information Remove the two rear shock...

Page 530: ...11 Rear Suspension Shock Absorbers K XCT 300i 11 4 Remove the right side rear shock mounting bolt with a 14 mm socket Free the lower mount of the rear shock...

Page 531: ...11 Rear Suspension Shock Absorbers K XCT 300i 11 5 Remove the upper shock absorber mounting bolt with a 12 mm socket Free the shock absorber from the frame...

Page 532: ...ck 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 absorber for damage and oil leaks Replace the sho...

Page 533: ...rs K XCT 300i 11 7 Installation Fit the 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 s...

Page 534: ...K XCT 300i 11 8 Item Torque kgf m lb ft Shock absorber mounting bolt 4 28 93 Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket Item Torque kgf m lb ft S...

Page 535: ...11 Rear Suspension Shock Absorbers K XCT 300i 11 9 Install the other shock absorber in the same manner...

Page 536: ...wingarm K XCT 300i 11 10 Rear Fork SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Place the vehicle on its center stand Remove the right side rear shock mounting bolt...

Page 537: ...to keep the rear wheel from turning Remove the rear axle nut with a 24 mm socket 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 ve...

Page 538: ...11 Rear Suspension Swingarm K XCT 300i 11 12 Installation Fit the rear fork into place Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket...

Page 539: ...Suspension Swingarm K XCT 300i 11 13 Install 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...

Page 540: ...Rear Suspension Swingarm K XCT 300i 11 14 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 9...

Page 541: ...el 12 8 12 17 Wheel Inspection 12 18 Bearing Replacement 12 19 12 22 Troubleshooting Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire Improperly tightened axle nut Rear whee...

Page 542: ...ont Wheel K XCT 300i 12 2 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...

Page 543: ...ront Wheel K XCT 300i 12 3 Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground Support the front wheel and slide the front axle out from the...

Page 544: ...e collars from each side of the wheel Inspect the bearing seals and the O rings seals on the collars Replace the seals if they are in poor condition Inspect the wheel bearings by turning them in the h...

Page 545: ...collar O rings Insert the collars into the hub as shown Make 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...

Page 546: ...6 Set the front wheel on the ground Pump the front suspension up and down several times to seat the front axle Torque the axle to specification with an 8 mm Allen Item Qty size mm Torque Front axle 1...

Page 547: ...XCT 300i 12 7 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 If the Brakes do not pump up correctly...

Page 548: ...are recommended at this point When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads...

Page 549: ...ar Wheel K XCT 300i 12 9 Move the rear shock out of the way Hold the rear brake to keep the rear wheel from turning Remove the rear axle nut with a 24 mm socket Remove the two rear fork bolts with a 1...

Page 550: ...12 Wheels Rear Wheel K XCT 300i 12 10 Slide the rear fork out and remove it from the right side of the vehicle Remove the rear axle collar from the right side of the rear axle...

Page 551: ...y or remove it Remove the upper shock 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 whe...

Page 552: ...se of the rear axle 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...

Page 553: ...12 Wheels Rear Wheel K XCT 300i 12 13 Slide on the rear axle collar Fit the rear fork into place...

Page 554: ...12 Wheels Rear Wheel K XCT 300i 12 14 Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket...

Page 555: ...xle 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 th...

Page 556: ...12 Wheels Rear Wheel K XCT 300i 12 16 Install the upper 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...

Page 557: ...12 Wheels Rear Wheel K XCT 300i 12 17 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...

Page 558: ...turn smoothly and quietly Also check 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 Place the wheel on a tr...

Page 559: ...e freezer about an hour before you plan to install them Do not let the wheel rest on its brake disc Front Wheel Remove the dust seal from the right side of the front wheel using a seal pick or large f...

Page 560: ...CT 300i 12 20 Remove one of the bearings with a bearing puller Special Tools Bearing Puller A120E00037 Remove the distance collar Repeat the procedure and remove the other bearing and seal The seal sh...

Page 561: ...ake the 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 si...

Page 562: ...ve in the 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...

Page 563: ...battery will decrease after it is used for 2 3 years A capacity decreased battery will resume its voltage after it is recharged but its voltage decreases suddenly and then increases when a load is ad...

Page 564: ...mergency Remove the battery from the motorcycle for charging When replacing the battery do not use a traditional battery When charging check the voltage with an electric tester TROUBLESHOOTING No powe...

Page 565: ...cing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with weak battery resul...

Page 566: ...oling system TROUBLESHOOTING Starter motor will not turn Fuse burned out Weak battery Faulty ignition switch Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Poorly...

Page 567: ...Check the battery condition before performing any inspection that requires proper battery voltage A continuity test can be made with the switches installed on the scooter Route the wires and cables pr...

Page 568: ...ecommended at this point Warning The battery electrolyte sulfuric acid is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with wa...

Page 569: ...under the seat 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 socket...

Page 570: ...tray 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 unde...

Page 571: ...all the specified battery Fit the battery into the battery tray Connect the positive battery cable and install the bolt with a 10 mm socket or 3 Phillips screwdriver Connect the negative battery cable...

Page 572: ...motorcycle specific battery charger at the specified rate Connect the charger leads to their appropriate battery terminals Keep open flames away from a charging battery Standard Charge 1 2 Amps 5 10...

Page 573: ...attery 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 multimeter between the positive and negat...

Page 574: ...is not adjustable Perform the following checks Before performing any tests make sure the electrical connections are not loose or corroded Spark Test Check the spark plug to see if it is the correct ty...

Page 575: ...switch to ON lift the side stand hold in one of the brake levers and push the engine start button The plug should spark Caution Do not touch the spark plug or spark plug wire while cranking or runnin...

Page 576: ...13 Electrical System Ignition System K XCT 300i 13 14 Remove the two ignition coil leads Remove the two ignition coil mounting bolts with an 8 mm socket Remove the ignition coil...

Page 577: ...leads to the ignition coil terminals as shown Measure the resistance Ignition Coil Primary Resistance 3 57 4 83 Secondary With Plug Cap Check the secondary resistance between the ignition coil termina...

Page 578: ...e meter lead to the terminal and the positive meter lead to the spark plug wire as shown Secondary Resistance Without Plug Cap 10 14 AC Generator Inspection Crank Position Sensor Inspection Note This...

Page 579: ...Protective gloves and eyewear 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 f...

Page 580: ...nect the starter relay wire connector Check for continuity between the yellow red wire and green yellow wire There should be continuity when the starter button is depressed If there is no continuity c...

Page 581: ...System K XCT 300i 13 19 Operation Test Turn the ignition switch to OFF Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the negative cable from the battery Re...

Page 582: ...ting System K XCT 300i 13 20 Remove the nuts that hold the starter motor lead and battery lead wires to the starter relay with a 10 mm socket Remove the leads from the starter relay Disconnect the sta...

Page 583: ...e 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 relay large terminals The rel...

Page 584: ...RST Protective gloves and eyewear are recommended at this point Removal Turn the ignition switch to OFF Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the ne...

Page 585: ...ystem Fuses K XCT 300i 13 23 Fuses SAFETY FIRST Protective gloves and eyewear are recommended at this point Fuse Box The fuse box is located in the front of the battery Open the covers to access the f...

Page 586: ...wear are recommended at this point Note 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 co...

Page 587: ...13 Electrical System ECU Removal K XCT 300i 13 25 Remove the two mounting nuts with a socket Remove the ECU...

Page 588: ...frame Check for continuity 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 sho...

Page 589: ...13 Electrical System ECU Removal K XCT 300i 13 27 Installation Install the two mounting nuts and tighten securely with a socket Connect the ECU harness...

Page 590: ...his point 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...

Page 591: ...al System Self Diagnosis K XCT 300i 13 29 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...

Page 592: ...failure codes 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...

Page 593: ...13 lectrical System Self Diagnosis K XCT 300i 13 31...

Page 594: ...side the system 1 Put 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 thr...

Page 595: ...ect 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 reinsta...

Page 596: ...TY FIRST Protective gloves and eyewear are recommended at this point Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the...

Page 597: ...nt Headlight Bulb Replacement Make sure the machine has been off for several minutes before removing the headlight bulb Slide back the rubber headlight covers and then remove the headlight bulbs to fr...

Page 598: ...an cause an early failure of the headlight bulb If you do touch the bulb with your bare hand wipe off the bulb with a clean shop towel and alcohol Fit the bulb into the lamp and then remove the headli...

Page 599: ...13 Electrical System Lights K XCT 300i 13 37 Aim Turn the screws to adjust the head light aim as needed Front Turn Signals Turn the turn signal bulb socket counterclockwise and free it from the lamp...

Page 600: ...the bulb and rotate it clockwise to remove if from the socket Insert the new bulb Push down on the bulb and rotate it counterclockwise to lock it into place Insert the turn signal bulb and socket int...

Page 601: ...T 300i 13 39 Taillights LED Replacement Remove the five taillight mounting the tail light housing Remove two screws mounting the clips Remove the LED taillight assy Replace the LED as needed Install t...

Page 602: ...hts K XCT 300i 13 40 Rear Turn Signals Turn the socket counterclockwise and remove it from the lamp Push in the bulb and turn it counterclockwise Remove the bulb Insert the new bulb and turn it clockw...

Page 603: ...ectrical System Lights K XCT 300i 13 41 License Tag Light Remove the license tag light from the mud flap Pull the rubber tag light socket out of its housing Pull the bulb straight out and insert a new...

Page 604: ...elays K XCT 300i 13 42 Relays SAFETY FIRST Protective gloves and eyewear are recommended at this point High Low Beam Relays Remove the front cover Remove and disconnect the high beam relay The Low bea...

Page 605: ...uel Pump Relay Remove the luggage box The fuel pump relay is located in front of battery Remove and disconnect the fuel pump relay Inspection Use a digital multimeter to inspect the fuel cut off relay...

Page 606: ...fuel cut off relay connector Connection Blue Black Black There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is connected replace the fuel cut...

Page 607: ...sition Keep the side switch upward Apply the brake lever fully Connect the multimeter to the start relay connector terminals Set the multimeter to read ohms of resistance Connection Yellow Green Black...

Page 608: ...13 Electrical System Relays K XCT 300i 13 46 FAN Relay Remove the front cover The Fan relay is on the left Remove and disconnect the Fan relay...

Page 609: ...mmended at this point You will need a digital multimeter to inspect the switches Ignition Switch Remove the front cover Unplug the white six pin ignition switch connector Use a digital multimeter to c...

Page 610: ...13 Electrical System Switches K XCT 300i 13 48 Removal Remove the front cover Remove the dash...

Page 611: ...tem Switches K XCT 300i 13 49 Remove the seat latch cable cover Loosen the seat latch cable screw with a 2 Phillips screwdriver Remove the seat latch cable screw and free the seat latch cable from the...

Page 612: ...to strike the bolts so that they rotate loose Turn the bolts clockwise to loosen them Installation Install new anti tamper bolts and tighten them securely Fit the end of the seat latch cable into the...

Page 613: ...move the front cover Support the scooter level surface Put the side stand up and engine stop switch on RUN Turn the ignition switch to OFF Note Do not disconnect the tilt switch connector during inspe...

Page 614: ...ow Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the tilt switch 65 10 degrees to the left or right at the ignition switch ON Measure the voltage...

Page 615: ...remove the tilt switch Note Install the tilt switch with its up mark facing up and tighten the two screws securely Handlebar Switches Remove the front cover To remove the handle bar switches see the...

Page 616: ...300i 13 54 Unplug the green connector for the right handlebar switches Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should ex...

Page 617: ...13 Electrical System Switches K XCT 300i 13 55...

Page 618: ...lectrical System Switches K XCT 300i 13 56 Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indic...

Page 619: ...light LED switch connector with red white and green wires Use a digital multimeter to check for continuity Test the switch side of the connector for continuity as the switch is manipulated There shou...

Page 620: ...Electrical System Switches K XCT 300i 13 58 Luggage box light LED switch Side Stand Switch Remove the luggage box Place the vehicle on the center stand Unplug the three pin side stand switch connecto...

Page 621: ...ctrical System Switches K XCT 300i 13 59 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 622: ...uld be continuity between the yellow black wire and the green wire terminals Brake Light Switches Test the front and rear brake light switches in the same manner Use a digital multimeter to check for...

Page 623: ...13 Electrical System Switches K XCT 300i 13 61 Check for continuity between the brake light switch connectors There should be continuity when the lever is pulled and none when released...

Page 624: ...SOR ANGLE DETECT G P2 V R B L2 12V 12AH BATTERY R W 26 B L2 G P2 V R 30A 7 R W COMB SW IGNITION COIL SPARK PLUG G BR 1 B3 B3 B1 Start Relay B W1 B W1 Y G Y G G Brake Sw G Y Start Mag Y BR Start Sw G Y...

Page 625: ...ACG REG REC FUSE R R W Y Y Y Y Y Y 12V 12AH BATTERY G CHARGING SYSTEM K XCT 300i 13 63 COMB SW B1...

Page 626: ...K XCT 300i WIRING DIAGRAM Revised 2012 10 01...

Page 627: ...reference source of technical specifications and information for KYMCO K XCT 300i models Component Location 14 2 14 10 Special Tools 14 11 K XCT 300i Specifications 14 12 14 20 Torque Specifications 1...

Page 628: ...14 Quick Reference Component Location K XCT 300i 14 2 Component Location...

Page 629: ...14 Quick Reference Component Location K XCT 300i 14 3...

Page 630: ...14 Quick Reference Component Location K XCT 300i 14 4...

Page 631: ...14 Quick Reference Component Location K XCT 300i 14 5 Fuel Pump To Thermostat Bleed Fuel Hose Blow By Tube Throttle Cable inside Seat Catch Cable...

Page 632: ...14 Quick Reference Component Location K XCT 300i 14 6...

Page 633: ...14 Quick Reference Component Location K XCT 300i 14 7...

Page 634: ...14 Quick Reference Component Location K XCT 300i 14 8...

Page 635: ...14 Quick Reference Component Location K XCT 300i 14 9...

Page 636: ...14 Quick Reference Component Location K XCT 300i 14 10 ECU ECU RELAY...

Page 637: ...eihin system SHAFT COLLAR DRIVER A120E00091 Bearing crankcase removal SHAFT COLLAR INSTALLER A120E00092 Bearing crankcase installation BEARING PULLER A120E00093 General Puller Set VALVE CLEAN TOOL SET...

Page 638: ...stance m 7 9m 40 km hr Min turning radius m 2 6 Engine Starting system Starting motor Type Gasoline 4 stroke Cylinder arrangement SINGLE CYLINDER Combustion chamber type Semi sphere Valve arrangement...

Page 639: ...vice Tire type Tubeless Wheel material Aluminum Tire pressure Kg cm2 psi Front 2 0 28 4 Rear 2 25 32 Handle turning angle L R Left 40 Right 40 Brake system type Front Wavy Disc brake Rear Disc brake D...

Page 640: ...ve guide I D IN 5 00 5 012 EX 5 00 5 012 Valve stem to guide clearance IN 0 010 0 037 EX 0 030 0 057 Item Standard mm Cylinder I D 72 7 Taper limit 0 05 Out of round limit 0 05 Piston piston ring Ring...

Page 641: ...ins to open 71 C Full open 80 C Valve lift 3 5 4 5 mm Coolant capacity Total 1719 cc Radiator 766 cc Reserve tank 590 cc Hose 363 cc COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing P...

Page 642: ...1 066 1 064 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 concentrati...

Page 643: ...ssure at 40L Hr 294 6 kPa 3 Bar Water temperature sensor resistance At 20 C 4 F 18 8 K At 40 C 104 F 1 136 K At100 C 212 F 0 1553 K ntake pressure sensor MAP pressure at 1 4 2 V 13 332 kPa 0 13332 kgf...

Page 644: ...ensor Open or short circuit on O2 sensor wire Faulty O2 sensor Engine operates normally 33 P0201 Faulty injector Nozzle Faulty Fuel injector range 9 945 13 5 Loose or poor connection on injector Open...

Page 645: ...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 cylinder I D 27 27 05 1 063 1 065 Item Standard mm Wheel rim run...

Page 646: ...prox Water Temperature Sensor 2 076 K9 10 25 C Oxygen Sensor engine warming condition 6 7 9 9 5 Crank Position Sensor 115 9 15 Tilt Switch 0 4V 1 4V normal 3 7V 4 4V fall down Water temperature sensor...

Page 647: ...7 23 10 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...

Page 648: ...0 4 0 21 70 28 93 Speed sensor cable 1 6 1 0 1 4 7 23 10 13 02 sensor 1 12 2 0 3 0 14 47 21 70 Rear carrier 4 8 2 0 2 8 14 47 20 25 Front axle 1 14 1 5 2 5 10 84 18 08 Rear axle nut 1 16 11 13 79 56...

Page 649: ...3 Key On to check for any failure lamp light up on dashboard See the Self Diagnosis topic for more information 4 Is the Idle screw of Throttle Valve being changed or loosed 5 Has the vehicle under re...

Page 650: ...y ECU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck...

Page 651: ...aner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct 5 Tes...

Page 652: ...l orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating Wro...

Page 653: ...lator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or interm...

Page 654: ...shaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering h...

Page 655: ...eference VIN and Engine Number Location K XCT 300i 14 29 VIN and Engine Number Location The VIN is stamped on a plate on the lower right side The engine serial number is stamped on bottom of the left...

Page 656: ...14 Quick Reference VIN and Engine Number Location K XCT 300i 14 30 The VIN is also stamped on the frame inside of the luggage box...

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