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KYMCO MYROAD 700i, Service Manual

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KYMCO MYROAD 700i Service Manual Download Page 58

2

. FRAME COVERS/ 

EXHAUST MUFFLER

 

     

 

2-19

 

MYROAD 700i 

 

EXHAUST MUFFLER 

REMOVA

L 

Disconnect the connector with O2 heater/O2 
sensor. 
Remove screws from muffler protector. 
Loosen the rear muffler cover screws. 
 
 
 
 
 
 
 
 
Remove the exhaust pipe joint nuts and 
exhaust pipe. 
 
Remove the muffler. 
 
 
 
 
 
 
 
 
 
 

INSTALLATION 

Replace the gaskets with new ones. 
Install the exhaust pipe and tighten the joint 
nuts. 

Torque: 1.0~1.4 kg-m 

 
Install the muffler and tighten the mount 
bolts. 

Torque:

 

3.2~3.8 kg-m

 

 
Install and tighten the band bolts. 

Torque:

 

2.1 kg-m

 

 
 

 
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
                                 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 

 

                         

 

                           

Screws

 

Bolt                                                Bolt 

    Muffler protector

 

Summary of Contents for MYROAD 700i

Page 1: ...700i By KWANG YANG Motor Co Ltd First Edition FEB 2011 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 K...

Page 2: ...tem illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF C...

Page 3: ..._____________________________________ __________________________________________________________________________________ _______________________________________________________________________________...

Page 4: ...1 GENERAL INFORMATION 1 1 MYROAD 700i FRAME NUMBER VIN VEHICLE IDENTIFICATION NUMBER VIN SERIAL NUMBER Location of Engine Serial Number...

Page 5: ...0 22 mm Idle speed Rpm Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 3 L Final reduction oil capacity 0 4 L Cooling Type Liquid coo...

Page 6: ...engine oil before reassembly Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation When two persons wo...

Page 7: ...protruding or loose The connector shall be inserted completely If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check fo...

Page 8: ...d screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protec...

Page 9: ...operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before...

Page 10: ...Kgf m 5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 0 5 1 0 2 2 3 5 5 5 5mm screw 6mm screw SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange...

Page 11: ...1 GENERAL INFORMATION 1 8 MYROAD 700i FRAME...

Page 12: ...el holding Bearing pullers A120E00030 Bearing removal Tappet adjuster A120E00036 Tappet adjustment Bearing pullers A120E00037 Bearing removal Valve spring compressor A120E00040 Valve removal Oil filte...

Page 13: ...ton ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft Balancer shaft Crankshaft one way clutch movable part Oil pump drive chai...

Page 14: ...rts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Seat Lock Grease Throttle Cable Engin...

Page 15: ...s gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing cFaulty auto bystarter dAir leaking through intake pipe eIncorrect ignition timing fIncorrectly adjusted pilo...

Page 16: ...on timing too early jAir in cooling system cExcessive carbon build up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean g Ignition timing too early Start engine and accelerat...

Page 17: ...erator fFaulty ignition coil gBroken or shorted high tension wire hFaulty ignition switch cDamaged air cut off valve diaphragm dDamaged air cut off valve spring Remove spark plug and install it into s...

Page 18: ...tube cClean and unclog cCam timing gear aligning marks not aligned cFaulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump...

Page 19: ...xcessive carbon build up in combustion chamber cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain cFaulty crankshaft bearing dWorn crank pin bearing cWorn...

Page 20: ...bearings fWeak driven face spring gWorn or seized driven pulley bearings cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings cOil or grease fouled drive belt dWor...

Page 21: ...ning cFaulty starter pinion cStarter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of stop switch by applying...

Page 22: ...Poorly connected coupler cFaulty ignition unit Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Abnormal Normal No...

Page 23: ...gulator rectifier eBroken or poorly connected regulator rectifier black wire cLimit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an elec...

Page 24: ...mptom Symptom Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals d...

Page 25: ...g stem nut POOR BRAKE PERFORMANCE cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dForeign matter on brake linings eRough brake drum contacti...

Page 26: ...o small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing Inspection Adjustment Probable Cause S...

Page 27: ...fuel hExcessive carbon buildup in combustion chamber iIgnition timing too early jAir in cooling system Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause...

Page 28: ...ORMATION 1 25 MYROAD 700i cExcessive carbon build up in combustion chamber dPoor quality fuel eClutch slipping fIgnition timing too early Engine does not knock Engine knocks Rapidly accelerate or run...

Page 29: ...high tension wire fFaulty spark plug cFouled throttle body dFaulty TPI reset Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment...

Page 30: ...r aligning marks not aligned cFaulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check throttle body or air cleaner for clogging Check fuel pump for fuel supply Correct t...

Page 31: ...xcessive carbon build up in combustion chamber cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain cFaulty crankshaft bearing dWorn crank pin bearing cWorn...

Page 32: ...bearings fWeak driven face spring gWorn or seized driven pulley bearings cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings cOil or grease fouled drive belt dWor...

Page 33: ...turning cFaulty starter pinion cStarter relay shorted or stuck Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of stop switch by applying bra...

Page 34: ...oil Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Abnormal Normal Normal Abnormal Abnormal Measure resistance b...

Page 35: ...gulator rectifier eBroken or poorly connected regulator rectifier black wire cLimit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an elec...

Page 36: ...Symptom Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim re...

Page 37: ...eering stem nut POOR BRAKE PERFORMANCE cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dForeign matter on brake linings eRough brake drum con...

Page 38: ...1 GENERAL INFORMATION 1 35 MYROAD 700i...

Page 39: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

Page 40: ...2 FRAME COVERS EXHAUST MUFFLER 2 1 MYROAD 700i SCHEMATIC DRAWING...

Page 41: ...damaged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Muffler mount bolt 3 2 3 8 kg m Exhaust pipe joint nut 1 0 1 4 kg m Exhaust pipe band bolt 1 0 1 4...

Page 42: ...the removal After installation check the seat installation by moving the seat LUGGAGE BOX REMOVAL After removal the seat side cover carrier body cover then you can remove the luggage box Remove the s...

Page 43: ...REAR SPOILER REMOVAL Unlock the seat with the ignition key Open the seat Remove the rubber cap Remove four bolts and rear spoiler INSTALLATION Installation is in the reverse order of removal FRONT FEN...

Page 44: ...four screws and upper handlebar cover INSTALLATION Installation is in the reverse order of removal RIGHT LEFT SIDE COVERS REMOVAL After removing seat the priority you should remove would be side cover...

Page 45: ...ROAD 700i Remove the side cover following the way of picture showing Specially notice not to damage the tabs on the side covers especially the hook structures on the end of side covers Be careful not...

Page 46: ...2 FRAME COVERS EXHAUST MUFFLER 2 7 MYROAD 700i Floor Mat RIGHT LEFT FLOOR SKIRT REMOVAL Remove the floor mat Remove the right and left center body cover...

Page 47: ...on is in the reverse order of removal FLOORBOARD REMOVAL Remove right and left center body cover Remove the right and left floor skirt Remove the luggage box Remove six bolts four screws and floorboar...

Page 48: ...ense light connector and remove the license light INSTALLATION Installation is in the reverse order of removal REAR FENDER REMOVAL Remove the licence light Remove two screws Remove two nuts and rear f...

Page 49: ...n signal light connector and remove the side body cover INSTALLATINON Installation is in the reverse order of removal REAR BODY COVER REMOVAL Remove the luggage box Remove the rear spoiler Remove two...

Page 50: ...dy cover Remove bolts and taillight rear turn signal light INSTALLATION Installation is in the reverse order of removal REAR LOWER COVER REMOVAL Remove the side body cover Remove the rear lower cover...

Page 51: ...ATION Installation is in the reverse order of removal WINDSHIELD REMOVAL Remove four screws and windshield garnish Remove 6 bolts and windshield INSTALLATION Installation is in the reverse order of re...

Page 52: ...2 FRAME COVERS EXHAUST MUFFLER 2 13 MYROAD 700i FRONT COVER REMOVAL The priority to remove is front cover with head lights then tunnel leg shield 81141 KKE5 there are some bolts and screws hide inside...

Page 53: ...leg shield removal Remove six screws Remove two screws Remove one screw Disconnect headlight and turn signal light connectors INSTALLATION Installation is in the reverse order of removal Screws Screws...

Page 54: ...nstallation is in the reverse order of removal TURN SIGNAL LIGHT REMOVAL Remove the front cover Remove three screws and turn signal light INSTALLATION Installation is in the reverse order of removal F...

Page 55: ...the reverse order of removal METER PANEL REMOVAL Remove the front cover Remove the front meter visor Remove the tunnel leg shield Remove screws from instrument Disconnect the speedometer connector and...

Page 56: ...e two screws and meter INNER COVER REMOVAL Remove the front cover Remove the floorboard Remove the meter panel Remove the shutter screw and shutter Turn the fuel fill cap garnish counterclockwise and...

Page 57: ...2 18 MYROAD 700i Remove 2 bolts from front panel floor INSTALLATION Installation is in the reverse order of removal FRONT LOWER COVER REMOVAL Remove the panel floor Remove the screws from lower cover...

Page 58: ...rear muffler cover screws Remove the exhaust pipe joint nuts and exhaust pipe Remove the muffler INSTALLATION Replace the gaskets with new ones Install the exhaust pipe and tighten the joint nuts Torq...

Page 59: ..._______________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDUL 3 3 FUEL LINE 3 5 THROTTLE OPERATION 3 5 AIR CLEANER 3 7 CRANKCASE BREATHER 3 8 SPAR...

Page 60: ...n an open area or with an exhaust evacuation sustem in and enclosed area SPECIFICATIONS ITEM SPECIFICATIONS Throttle free play 2 6 mm 1 16 1 4 in Spark plug NGK DR8E Spark plug gap 0 6 0 7 mm IN 0 16...

Page 61: ...strainer screen cap 1 2 1 8 kgf m Apply oil to the threads and seating surface Oil filter cartridge 1 2 kgf m Apply oil to the threads and seating surface Transmission oil drain bolt 2 3 kgf m Transm...

Page 62: ...m the pre ride inspection in the owner s manual at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first I INSPECT AND CLEAN ADJUST LUBRI...

Page 63: ...ridden in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Inspect every 18000 km 12000 mi after replacement 5 Replace every 1 year or every 10000km 60...

Page 64: ...N Check for smooth throttle grip full opening and automatic full closing in all steering positions Check the throttle cables and replace them if they are deteriorated kinked or damaged Lubricate the t...

Page 65: ...p free play can be adjusted at either end of the throttle cable Minor adjustment is made with the upper adjuster Slide the rubber sleeve back to expose the throttle cable adjuster Adjust the free play...

Page 66: ...ll a new air cleaner element Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong KYMCO air cleaner element or a non KYMCO air cleane...

Page 67: ...r CRANKCASE BREATHER Remove the crankcase breather tube plug from the tube and drain deposits into a suitable container Reinstall the crankcase breather tube plug Service more frequently when riding i...

Page 68: ...park plug is suitable for your type of usage A normal operating spark plug should be light brown or tan color If the spark plug is very white or glazed appearing then it has been operating much too ho...

Page 69: ...with the index mark on the right crankcase cover The punch marks in and ex on the camshaft should be aligned with the boundary of cylinder head as shown If the punch marks on the camshaft are facing d...

Page 70: ...he valve lifters and shims The shims may stick to the inside of the valve lifter Don t allow the shims to fall into the crankcase Mark all of shims and valve lifters to ensure correct reassembly in or...

Page 71: ...85 185 03 1 90 190 04 1 95 195 05 2 00 200 06 2 05 205 07 2 10 210 08 2 15 215 09 2 20 220 10 2 25 225 11 2 30 230 12 2 35 235 13 2 40 240 14 2 45 245 15 2 50 250 16 2 55 255 17 2 60 260 18 2 65 265 1...

Page 72: ...sed engine oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the...

Page 73: ...he oil strainer screen After draining the oil completely install the strainer screen and setting spring into the engine Apply clean engine oil to the strainer cap threads flange surface and a new O ri...

Page 74: ...ke sure there are no oil leaks ENGINE OIL FILTER CARTRIDGE REPLACEMENT Drain the engine oil Remove and discard the oil filter cartridge using the special tool Tool Oil filter wrench A120E00061 Apply c...

Page 75: ...mark 3 remove the left floor mat remove the lid screw and reserve tank lid and the Reserve tank cap 4 and add coolant mixture until it reaches the upper level mark 2 Remove the left floor mat and rem...

Page 76: ...cracks or deterioration and replace if necessary Check that all hose clamps are tight Check the radiator air passages for clogs or damage Straighten any bent fins and remove insects mud or other obstr...

Page 77: ...e rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it Torque 2 3 kgf m Fill the transmission case with recommended oil Re...

Page 78: ...worn have your brake system inspected for leaks Do not ride your scooter unless the brakes are in perfect working order Brake fluid type DOT 4 from a sealed container Note Other checks Make sure ther...

Page 79: ...dirty roads Inspect the pads at each regular maintenance interval Front Rear brake Check the cutout in each brake pad the cutout should be visible indicating that brake pad is not worn down to the br...

Page 80: ...perated bleed the air from the system Inspect the brake hose and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE LOCK OPE...

Page 81: ...hly Pull the parking brake lever slowly and check the lever stroke Standard 3 6 notches HEADLIGHT AIM Place the scooter on a level surface Adjust the headlight beam vertically by turning the vertical...

Page 82: ...art the engine 9 Fully lower the side stand while running the engine 9 The engine should stop as the side stand is lowered If there is a problem with the system check the side stand switch SUSPENSION...

Page 83: ...s of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their co...

Page 84: ...enter of the tires Replace the tires when the tread depth reaches the following limits Minimum tread depth Front 1 6 mm Rear 2 2 mm STEERING HEAD BEARINGS Check that the control cables do not interfer...

Page 85: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 86: ...4 LUBRICATION SYSTEM 4 1 MYROAD 700i...

Page 87: ...and that oil pressure is correct For oil pressure indicator inspection refer to section 20 of this manual SPECIFICATIONS Unit mm ITEM STANDARD SERVICE LIMIT At draining 2 6 liter At disassembly 3 0 li...

Page 88: ...il used Faulty head gasket Water leak in crankcase Oil contamination Deteriorated oil No oil pressure Faulty oil filter Oil level too low Worn piston ring White appearance with water or Oil pump drive...

Page 89: ...E RELIEF VALVE OIL PUMP REMOVAL Remove the right crankcase cover Remove the pressure relief valve and O ring from the right crankcase INSPECTION Check the operation of the pressure relief valve by pus...

Page 90: ...ROAD 700i OIL PUMP DISASSEMBLY Remove bolts and oil pump cover Remove the dowel pin pin oil pump shaft oil pump outer rotor and inner rotor Oil Pump Cover Bolts Outer Rotor Pin Oil Pump Shaft Oil Pump...

Page 91: ...into the oil pump body Measure the tip clearance Service limit 0 2 mm 0 008 in Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feele...

Page 92: ...the pin onto the oil pump body Install the oil pump cover onto the oil pump body by aligning the dowel pin Install and tighten the bolts to the specified torque Torqur 1 2 kgf m INSTALLATION Install...

Page 93: ...gine oil and remove the oil filter cartridge Drain the coolant from the system Loosen the hose bands and disconnect the oil cooler hoses from the cooler Remove the oil cooler mounting bolts oil cooler...

Page 94: ...ROAD 700i INSTALLATION Install the removed parts in the reverse order of removal Install the oil cooler bolts with the specified torque Torque 0 8 1 2 kgf m Remember to install the dowel pin 15x10 And...

Page 95: ...4 LUBRICATION SYSTEM 4 10 MYROAD 700i Installation of oil filter cartridge Standard Torque Oil filter cartridge 1 2 1 8 kgf m...

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