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KYMCO X-Town 300, Manual

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KYMCO X-Town 300 Manual Download Page 59

 

 

 

 

 

 
 

 
 
 
 
 
 

 

 

 
 

MAINTENANCE

 

Fuse

 

When fuse fails frequently, it usually indicates a 
short circuit or an overload in the electrical 
system.

 

WARNING

 

∎

Never use a fuse of different rating. 

∎

If the new fuse blows in a short time, consult 

WARNING 

Electrolyte is toxic and dangerous since it 
contains sulfuric acid, which causes severe 
burns. Avoid any contact with skin, eyes or 
clothing and always shield your eyes when 
working near batteries. In case of contact, 
administer the following FIRST AID. 

∎

External: Flush with plenty of water. 

∎

Internal: Drink large quantities of water or 

milk and immediately call a physician. 

∎

Eyes: Flush with water for 15 minutes and 

seek prompt medical attention.  

Batteries produce explosive hydrogen gas. 
Therefore, keep sparks, flames, cigarettes, 
etc., away from the battery and provide 
sufficient ventilation when charging it in an 
enclosed space. 
KEEP THIS AND ALL BATTERIES OUT 
OF THE REACH OF CHILDREN. 

41 

Summary of Contents for X-Town 300

Page 1: ...could cause fuel and engine oil deterioration and probably get into a non start situation Service more frequently when operating in severe conditions such as dusty area high speed riding frequent start and stop or extreme riding habit Make sure to keep away from any flammable materials such as dry grasses or leaves avoid them in contact with the exhaust pipe or muffler when parking the vehicle ...

Page 2: ...n vehicle This Owner s Manual should be considered a permanent part of the vehicle keep it with the motorcycle ON ROAD USE ONLYfor this motorcycle Particularly important information is provided in this manual by the following symbols and signal words The SAFETY ALERT symbol means ATTENTION BE ALERT YOUR SAFETYCAN BE AFFECTED WARNING CAUTION Failure to follow these instructions can result in severe...

Page 3: ...ification Number VIN Engine Serial Number ESN Record the Vehicle Identification Number Engine Serial Number in the blanks above for a reference to assist you in ordering parts from the authorized KYMCO dealer or in case the vehicle is stolen 1 2 ...

Page 4: ...el Recommendation Seat Suspension Side stand SECTION 3 OPERATION Pre ride Inspection Break In Startin g the Engin e ABS Syste m Optio nal 1 1 2 4 5 8 8 9 10 16 17 18 19 20 22 23 24 24 25 26 28 SECTION 4 MAINTENANCE Maintenance Schedule Engine Oil Engine Oil Replacement Transmission Fluid Change Air Filter Element Throttle Operation Spark Plug Brake Fluid Level Inspection Brake Lever Adjusters Brak...

Page 5: ...Blow by Drain Storage EMISSION CONTROL SPECIFICATIONS 29 30 33 34 35 36 36 37 38 39 40 41 42 43 45 47 47 48 49 50 ...

Page 6: ...roducts as they have been specially designed for the vehicle and manufactured to meet the standards Keep this owner s manual with the motorcycle at all times so that you can refer to it whenever you need information This manual should be considered a permanent part of the motorcycle and should remain with the vehicle when it is sold All information illustrations photographs and specifications cont...

Page 7: ...ion of personal skill Know these limits and stay within them will help you to avoid accidents 2 Keep the vehicle in safe condition For safe riding it s important to inspect the vehicle before every ride and perform all recommended maintenance Never exceed load limits and only use the approved accessories Inspect the vehicle before riding Do not forget to perform an entire safety inspection to ensu...

Page 8: ...eet and ankles Leather gloves to keep your hands warm and prevent blisters cuts burns and bruises A motorcycle suit is designed for comfort as well as protection Bright color with reflection strips can make you more noticeable Be sure to avoid loose clothes that could get caught on any part of the vehicle The recommended riding gears Wear gloves Clothes should be fit properly Always wear a helmet ...

Page 9: ...3 ...

Page 10: ...rectly Use extreme caution when selecting and installing the accessories No modifications KYMCO strongly advises you against removing any original equipment or modifying the vehicle in any way that would change its design or operation WARNING Improper accessories or modifications can make the vehicle unsafe and can lead to an accident Never modify the vehicle through the improper installation or u...

Page 11: ...ignal Light 4 Fuel Filler Cap 5 Helmet Hook 6 Side Stand 7 Seat 8 Engine Number 9 Air Cleaner 10 Rear Left Turn Signal Light 11 Tail Brake Light 12 Luggage Box 13 Reflector NOTE Your scooter may differ slightly in appearance from the images in this manual 5 1 2 3 4 7 10 13 11 12 5 6 8 9 13 ...

Page 12: ...ck 17 Center Stand 18 Rear Passenger Foot Peg 19 Front Brake Lever 20 Right Turn Signal Light 21 Right Handlebar Switch 22 Ignition Switch 23 Vehicle Identification Number VIN NOTE Your scooter may differ slightly in appearance from the images in this manual 23 14 22 21 20 19 15 16 17 18 6 ...

Page 13: ...al Light 25 Headlight 26 Left Storage Compartment Accessory Socket 27 Tail Brake Light 28 Rear Turn Signal Light 29 Right Storage Compartment NOTE Your scooter may differ slightly in appearance from the images in this manual 7 24 24 27 29 28 28 26 ...

Page 14: ...tion start or run Position The ignition circuit is ON and engine can be started The key can not be removed from the ignition switch in this position Pull up on the back portion of the seat to lift it up Position To lock the steering turn the handlebar all the way to the left push down and turn the key to the position and remove the key All electrical circuits are off Position With the ignition key...

Page 15: ...counterclockwise from to the position 8 ...

Page 16: ... shut the ignition switch security shutter Insert the specific key until the notch is aligned with the pin Turn clockwise to open the security shutter The keys have a unique code that is stamped on the tab with the keys This code is required if you need to duplicate the key Record this important code on the blank column below Security shutter key code 1 2 2 3 2 ...

Page 17: ...9 ...

Page 18: ...rip A B Oil Service or Empty mode Press the RESET button for 3 seconds to reset on the Trip A B Oil Service mode Press the MODE and RESET buttons for 3 seconds to set the unit of km h or MPH Clock Fuel Warning Indicator This indicator lights when the fuel tank is near empty to alert the rider to refill the fuel tank as soon as possible High Beam Indicator Light This light is illuminated when the h...

Page 19: ...10 10 ...

Page 20: ...il service indicator It lights up when reaching the oil service mileage interval Whenever the ignition switch is turned on it goes on then off at once after starting engine Press the MODE button to enter the ODO Trip A B Empty display Service Mode Press the RESET button for 3 seconds to reset on the Oil Service mode 11 Battery Warning Indicator If the battery voltage is too low while starting the ...

Page 21: ...leages from last reset after oil service 13 Cruise information Press the FUNC button to switch the mode for battery voltage ambient temperature 14 Engine Warning Indicator It goes with the Fi error code EURO 4 models do not have this function 1 2 1 3 1 4 12 ...

Page 22: ... previous reset after the oil service Press the RESET button for 3 seconds to reset the oil service indicator and the oil service trip meter The Fi error code indicator Display the error code of fuel injection system If appear any error codes and display continuously have the KYMCO authorized dealer check the vehicle NOTE If any error codes show up for a moment then goes off and not repeat it coul...

Page 23: ...igits will be flashing and the hour can be adjusted at that moment 4 Push the RESET button to set the hour 14 5 Push the MODE button it will change to make the minute digits be flashing 6 Push the RESET button to set the minute 7 Push both the MODE and RESET buttons at the same time to finish the clock setting NOTE The adjustment will be cancelled if any button is not pressed within approximately ...

Page 24: ...hicle starts moving The ABS indicator light will stay off as long as the ABS system works normally If an ABS fault is detected by the ABS ECU the ABS indicator will light on and stay on until the fault is resolved Even there s an ABS system failure the system will work normally in conventional braking condition just like a vehicle without ABS system NOTE If the ABS indicates a fault it s very impo...

Page 25: ...ccessory USB power supply turn on the ignition switch and then start the engine Open the door of the left storage compartment Open the USB power socket cap Plug the charge connector into the USB socket The rated capacity Output voltage DC 5V Maximum output current 2A 16 CAUTION For battery charge of mobile phone only Use other electronic appliances may cause damage on electrical system 2 2 1 2 ...

Page 26: ... fully stored up Engine stop switch Switch button to the ignition system is on before turning on the ignition switch Switch button to the ignition system is off after turning off the ignition switch NOTE If the ignition system is on which might cause the battery to discharge gradually Hazard switch Switch button to all the turn signals and turn signal indicator will blink to warn other drivers 1 2...

Page 27: ...17 ...

Page 28: ... pushed left or right for left turn for right turn To stop the turn signal push the switch again Horn button Press the horn button to sound the horn Dimmer switch Switch to select the light with high or low beam for low beam for high beam Passing button Press this button to flash the headlight with high beam to signal other drivers ahead for an intention to overtake 18 2 2 3 2 4 2 5 2 ...

Page 29: ...ock the fuel cap 4 Once unlock it s able to take the fuel cap away 5 To install the fuel cap do the following 1 Press it back into place on the fuel filler neck 2 Push back the fuel cap with key inserted 3 Make sure the triangle mark is toward front side 3 Remove the key and close the fuel tank filler cover NOTE Don t push key while installing the fuel cap Fuel recommendation Use unleaded gasoline...

Page 30: ...e ignition key in the position the engine is not running turn the counterclockwise from the to the position Open the seat by pulling up the rear end of seat Helmet holder To use the helmet holders open the seat and hang the helmet on the holder hook then lock the seat securely WARNING Use the helmet holder only on parking Do not ride with a helmet hanged on the holder 1 2 1 2 ...

Page 31: ...ear end of the seat due to there are no the lock hooks beneath therefore the seat is possibly not locked securely that will make stolen more easily Before riding pull the seat edge on the right side to make sure the seat is locked securely 21 CAUTION Do not put any objects may interfere the lock catch that might get caught while closing it will lead to lock insecurely or fail to open ...

Page 32: ...e spring preload for a more stiff rear suspension and can be used under heavy loading NOTE Always adjust the shock absorber pre load position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber Standard spring preload position 3 22 WARNING Be certain to adjust both shock absorbers to the same spring preload positions Improper setting...

Page 33: ...ut down Perform the following side stand inspection for interlock function check Check the ignition cut off on the side stand Position the vehicle on the level ground by using the center stand Put the side stand up and start the engine Lower the side stand The engine should stop as doing NOTE If the side stand system does not operate as described see your KYMCO dealer for service 2 2 1 2 ...

Page 34: ...23 ...

Page 35: ... KYMCO dealer to fix it WARNING Improperly maintain the motorcycle or fail to solve a problem before riding can cause a crash in which you could be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems 1 Engine oil level Add engine oil if required page35 36 Check if there s a kind of leakage 2 Fuel level Fill fuel tank when necessary page 19 Check...

Page 36: ...miles of riding is very important to the life of usage Proper break in operation during this period will help ensure maximum life and performance The reliability and performance depend on a special care and limited operation during the break in period The following limitations should be complied during the break in period Initial 800km 500 miles Less than 1 2 throttle or not over Up to 1600km 1000...

Page 37: ...w speed even of light load may cause the running part a fit in problem Be sure to start up the engine gently during the break in period Avoid full throttle operation Operate the engine at high speed may cause running part a lubrication problem Be sure to keep in the limited speed range during the break in period 25 ...

Page 38: ...ing too long and do not use leaded gasoline CAUTION To prevent damage to the starter motor do not operate the starter motor for more than 5 seconds at a time If fail to start successfully check the fuel level and the battery condition and waiting for 15 seconds between each fail to start 1 Position the motorcycle by the center stand and put the side stand up 2 Insert the ignition key and turn i t ...

Page 39: ...26 ...

Page 40: ...Press the starter button with the throttle closed releases it at once as the engine starts 5 Keep the throttle closed while warming up the engine 6 Keep the engine warming up thoroughly before each ride CAUTION If the engine is running with insufficient oil pressure can cause serious engine damage 27 ...

Page 41: ... brakes automatically It needs to apply the brakes at the right time and with the right amount of braking force The ABS system only starts to work after applying the brake lever WARNING The ABS does not prevent from falling down while cornering into a slippery condition WARNING ABS is not a substitute for safe driving Even with ABS you must remain alert react appropriately and in a timely and defe...

Page 42: ...ied in the maintenance schedule Consult with the KYMCO dealer for recommendations about your personal needs NOTE Always follow the inspections service recommendations and schedules on later pages WARNING If the motorcycle turnovers or becomes involved in a crash be sure to have the KYMCO dealer inspect all major parts even if you are able to make some repairs Improperly maintain the motorcycle or ...

Page 43: ...zed KYMCO dealer Be serviced by the KYMCO dealer unless you have the proper tools service data and are technically qualified For safety reason we recommend these items be serviced only by the KYMCO dealer KYMCO recommends that the KYMCO dealer should take a road test after each maintenance service NOTES 1 For higher odometer readings repeat by the service interval illustrated here 2 Service more f...

Page 44: ...18 AIR CLEANER NOTE 2 R R R R R R 36 SPARK PLUG NOTE 4 I R I 37 THROTTLE OPERATION I I I I I I 36 VALVE CLEARANCE A A FUEL LINE I CRANKCASE BREATHER NOTE 3 C C C C C C C ENGINE OIL R R R R R R R 33 ENGINE OIL SCREEN C C C R C C R ENGINE IDLE SPEED I I I TRANSMISSION OIL NOTE 5 R R R R 35 DRIVE BELT I I I R I RADIATOR COOLANT Replace at every10000km or every year ...

Page 45: ...BRAKE FLUID NOTE 6 Replace at every10000km or every year 38 BRAKE PAD WEAR I I I I I I 40 BRAKE SYSTEM I I I I I I BRAKE LIGHT SWITCH I I I I I I STEERING BEARINGS I I I I I I HEADLIGHT AIM I I I I I I NUTS BOLTS FASTENERS I I I I I I WHEEL TIRES I I I I I I 43 CVT FILTER C C C INJECTOR D D C D D C ENGINE LIMIT LEVER RUBBER GASKET every 10000km Inspection every 30000Km replacement 32 ...

Page 46: ...is not compliable choose alternative engine oil according to the following chart Full capacity 1 1 L 1 16 US qt Exchange capacity 0 9L 0 95 US qt Engine oil level inspection Check the engine oil level each day before riding The oil level must be between the high line and low line on the oil level dipstick CAUTION Running the engine with insufficient oil pressure can cause serious engine parts burn...

Page 47: ...hen inspecting the oil level so not to suffer burns Make the engine and exhaust system cool down before inspection Engine oil replacement Engine oil quality is the major factor that affects engine life Change your scooter s engine oil as specified in the maintenance schedule Warm engine up thoroughly then stop Stand vehicle by using the center stand Place an oil container beneath the drain hole Re...

Page 48: ...o reach the capacity listed below 5 Install the transmission filler bolt and tighten it to the specified torque Gear oil type SAE 90 Full capacity 0 23 L 0 24 US qt Exchange capacity 0 18L 0 19 US qt CAUTION Use the genuine engine oil or another with the same quality and grade to avoid burnout on the bearing or damage on the gear set CAUTION Must follow the local regulation and obey the related pr...

Page 49: ...areas CAUTION Using the wrong KYMCO air cleaner element or a non KYMCO air cleaner element which is not of equivalent quality may cause engine wear quickly or performance problems Throttle operation 1 Before riding check for smooth rotation from fully open to fully closed at both full end of steering 2 Measure the throttle free play as shown at right Throttle free play 2 0 6 0 mm 0 08 0 24 in 1 2 ...

Page 50: ...be replaced periodically Recommend to consult with the KYMCO dealer when choosing an alternative spark plug instead Recommended spark plug300 DPR6EA 9 CAUTION An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which will not be covered under warranty Never use a spark plug with an improper heat range as it could result in severe engin...

Page 51: ...37 ...

Page 52: ...ce schedule The fluid level should be above the lower level line If the fluid level is below the lower level mark L check over the worn brake pad or leakage NOTE Make sure there is no fluid leaking Check for fluid deterioration or crack on the brake hoses andfittings Brake fluid type DOT 4 WARNING Use only DOT4 brake fluid from a sealed container Clean the filler cap before removing 1 2 38 ...

Page 53: ......

Page 54: ...e adjusted to suit the personal grabbing requirement To adjust the distance of the lever from the handlebar grip push the lever forward and turn the adjuster to align the number with the mark on the brake lever NOTE The nearest distance from the grip to the released lever is set at number 1 and the farthest is set at number 4 1 2 2 2 3 2 Push 39 ...

Page 55: ......

Page 56: ...at the brake pad is worn and requires replacement Before riding apply braking several times to reach the proper lever stroke and firm feel on braking action that will ensure the brake pads are pressed against the brake disks securely WARNING The brakes will wear quickly if the lever is continually applied during riding The worn brake pad will increase the stop distance and may cause an accident ea...

Page 57: ...40 ...

Page 58: ...ery seems weak and or the electrolyte is leaking to cause hard start or other electrical troubles contact the KYMCO dealer immediately Disconnect the negative terminal Disconnect the positive terminal Remove the disabled battery To reinstall is the reverse sequence of removal NOTE If the cap strip is removed the battery will become permanently damaged 1 2 2 2 ...

Page 59: ...r clothing and always shield your eyes when working near batteries In case of contact administer the following FIRST AID External Flush with plenty of water Internal Drink large quantities of water or milk and immediately call a physician Eyes Flush with water for 15 minutes and seek prompt medical attention Batteries produce explosive hydrogen gas Therefore keep sparks flames cigarettes etc away ...

Page 60: ...ler immediately Fuse Allocation All functional fuses are located in the fuse box there s a sticker on the back of the fuse box cover Fuse should be inserted according to this sticker Equipped with ABS Good Blown 42 ...

Page 61: ...cm2 one rider 2 25kg cm2 rider and passenger Tire size Front tire 120 80 14M C 58S Rear tire 150 70 13M C 64S WARNING Fail to follow the instruction below may result in an accident due to tire failure The rider s personal safety is dependent on the condition of the scooter s tires Check tire condition and pressure and adjust the inflation pressure before each ride Avoid overload on the vehicle Rep...

Page 62: ...a puncture or the tire Proper wheel balance is important to avoid variable contact between tire and ground and to avoid uneven tire wear NOTE Replace the tires if there s visual evidence of damage as cracks or cuts WARNING An improperly repaired installed or balanced tire can cause you to lose control of your scooter or shorten tire life Ask the authorized KYMCO dealer or a qualified tire shop to ...

Page 63: ...ith the scooter in an upright position If the level is below the LOW level line remove the left foot mat remove the lid screw the reservoir lid and the reservoir tank cap to add coolant until it reaches the FULL level line WARNING Engine coolant is toxic Keep coolant away from children If coolant is swallowed call for emergency If contact with skin or eyes wash out with considerable water 2 2 3 2 ...

Page 64: ...the label on the container A 50 50 solution of anti freeze and distilled water is required It s for most operating temperature and also with good corrosion protection MAINTENANCE CAUTION Use only low mineral drinking water or distilled water as a part of the anti freeze solution Use tap water will cause engine damage Use a higher concentration of anti freeze in freezing weather and be replaced by ...

Page 65: ...Blow by Drain The air cleaner has a drain tube that is for draining the oil condensed fluid from the crankcase When the fluid has accumulated to a certain amount in the transparent drain tube remove the clip and plug drain the fluid into a container and then reinstall in place NOTE Drain frequently if often riding in the rain often at full throttle or the vehicle has been overturned Follow the oil...

Page 66: ...l unpainted metal Inflate all tires to the rated pressure and put the wheel stands to raise tires off the ground Cover the vehicle store indoors and keep dry Removal from Storage Remove cover from the vehicle Check the battery voltage or charge it if necessary and then install it in the vehicle Fill the fuel tank with fuel Check all the points listed in the Pre ride Inspection section EMISSION CON...

Page 67: ...ust system also includes the catalytic converter in the muffler Evaporative Emission Control System The evaporative emission control system is used to prevent gasoline vapors from escaping into the atmosphere from the fuel tank and fuel system Noise Exhaust Emission Control System The engine intake and exhaust systems of the motorcycle are designed to comply with federal or local noise regulations...

Page 68: ...2 7 X 66 4 mm Compression ratio 10 6 Max Horsepower 17 05kW 8000rpm Spark plug DPR6EA 9 Idle speed 1600 100 rpm Fuel system Fuel injection Ignition system ECU full transistor Tire size front 120 80 14 Tire size rear 150 70 13 Brake front ABS Brake rear ABS Electrical Ignition type Inductive ignition coil Battery 12V10 5A Headlight 12V 35W 35W Tail light 12v 0 7Wx2 LED Brake light 12v 3 5Wx2 LED Tu...

Page 69: ...50 ...

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