KYMCO Xciting 300i Technical Training Materials Technical Training Materials Download Page 30 | Manualshive

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INSTALLATION

1. Apply the engine oil to a new O-ring.

2. Install the fuel injector into the fuel pipe.

3. Ensure the tab of the fuel injector inserted into the
groove of the fuel pipe.

4. Install the fuel pipe into the intake manifold by
aligning the dowel pin.

5. Be careful not to damage the O-ring.

6. Tighten the fuel pipe mounting bolt.

Dowel pin

O-ring

Tab

Groove

FUEL INJECTOR REMOVAL / INSTALLATION

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Summary of Contents for Xciting 300i

Page 1: ...TECHNICAL TRAINING MATERIALS TECHNICAL TRAINING MATERIALS Xciting Xciting Series Series...

Page 2: ...P 1 51 Specification Xciting 500i...

Page 3: ...P 2 51 KEIHIN SYSTEM...

Page 4: ...P 3 51 XCITING 300i 500i FI PARTS LOCATION CPS O2 sensor ROLL Sensor ECU 300i 500i ECU is located under the front cover...

Page 5: ...P 4 51 ISC IGNITION COIL INJECTOR TPS FUEL PUMP AISV WTS MAP SENSOR...

Page 6: ...AGNOSTIC PROCEDURE XCITING Check Engine Lamp CELP Turn the ignition switch ON without start the engine The CELP lamp will light for two second then off It shows the lamp work normal PEOPLE S Check Eng...

Page 7: ...P 6 51 SELF DIAGNOSIS CELP FAILURE CODES...

Page 8: ...P 7 51 DTC LIST FOR KEIHIN...

Page 9: ...P 8 51...

Page 10: ...e throttle and wait for ten seconds 3 Release the throttle 4 The indicator will blink twice 0 5 second quickly NOTE The self diagnosis could not be reset if there s still trouble in Fi system Throttle...

Page 11: ...on 2 Fully open the throttle 3 Turn the key to the ON position 4 Release the throttle after waiting for 8 seconds 5 Turn the key to the OFF position 6 Turn the key to the ON position 7 TPS and ISC hav...

Page 12: ...P 11 51 KYMCO Fi Diagnostic tool ECU Version DTC Inspect DATA Analyze CO Adjust UP Button Down Button Enter or Exit Power indicator DTC indicator Failure codes Model No LEA7...

Page 13: ...PS ISC WITH Fi DIAGNOSTIC TOOL 1 Turn to page 02 on Fi diagnostic tool 2 Release the throttle 3 Refer to standard specifications as below Throttle position 1 below Throttle position sensor output volt...

Page 14: ...P 13 51 1 Fully open the throttle 2 Refer to standard specifications as below Throttle position TP 94 over Throttle position sensor output voltage 3 78 Volt RECHECK TPS ISC WITH Fi DIAGNOSTIC TOOL...

Page 15: ...P 14 51 Diagnostic Tool Connector Fi DIAGNOSTIC TOOL CONNECTION 1 Upward the side stand 2 Turn the engine stop switch to the RUN position RUN Upward side stand...

Page 16: ...P 15 51 DTC inspection...

Page 17: ...P 16 51...

Page 18: ...P 17 51...

Page 19: ...P 18 51 DTC cleared...

Page 20: ...P 19 51 Data Analysis...

Page 21: ...P 20 51...

Page 22: ...the throttle body MAP TPS ISC or ECU has been reinstalled ISC Set Plate Remove the screw then remove the ISC and set plate Install the ISC and set plate onto the throttle body Apply oil to new O ring...

Page 23: ...P 22 51 MAP O ring MAP Remove the screw of the MAP Carefully install the MAP into the hole of throttle body after using the engine oil onto the O ring REMOVAL INSTALLATION INSPECTION...

Page 24: ...P 23 51 INSPECTION TPS...

Page 25: ...TLE BODY CLEANING 1 Remove the throttle body 2 Use the carburetor cleaner to clean the throttle body s butterfly valve 3 Waiting for ten minutes 4 Blow the throttle body with a air gun 5 Install the t...

Page 26: ...P 25 51 FUEL PUMP RELAY INSPECTION...

Page 27: ...l pump Remove the six screws then remove the fuel pump and O ring Hose band Fuel pump connector Screw O ring INSTALLATION Place a new O ring onto fuel tank Be careful not damage the fuel pump wire and...

Page 28: ...hose clamp 3 Disconnect the fuel hose from the fuel injector 4 Connect the fuel pressure gauge 5 Turn the key to the ON position 5 Check the fuel pressure Standard 3 0 Bar Caution If the fuel output p...

Page 29: ...nd fuel injector from the Inlet pipe 4 Remove the fuel injector from the fuel pipe Connector Bolt O ring Fuel Injector Caution Ensure the fuel pipe without any pressure then remove the fuel injector S...

Page 30: ...l pipe 3 Ensure the tab of the fuel injector inserted into the groove of the fuel pipe 4 Install the fuel pipe into the intake manifold by aligning the dowel pin 5 Be careful not to damage the O ring...

Page 31: ...r block With some carbons Troubleshooting 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container 3 Connect the battery as picture 4 The injector cleaner w...

Page 32: ...P 31 51 TILT SWITCH INSPECTION...

Page 33: ...P 32 51 WATER TEMPERATURE SENSOR RESISTANCE...

Page 34: ...P 33 51 O2 SENSOR...

Page 35: ...To hear if any noisy 2 FUEL LEVEL F 7 3 E 95 5 10 17 12 43 18 8K when temperature 20 1 136K when temperature 40 0 1553K when temperature 100 Primary coil 3 57 4 83 Secondary coil 10 42 14 49K 1 Check...

Page 36: ...P 35 51 XCITING 500Ri ABS...

Page 37: ...er position This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving it stays off If something is wrong with the ABS the indicator comes on a...

Page 38: ...llowing characteristics ABS can not compensate for adverse road conditions misjudgment or improper application of brakes You must take the same care as with vehicle not equipped with ABS ABS isn t des...

Page 39: ...ning of ABS and lead to extended braking distance The rider could have an accident as a result Always use standard for this recommended vehicle NOTICE When the ABS is functioning you may feel a pulsin...

Page 40: ...Front Wheel speed Sensor Rotor 3 Rear Wheel speed Sensor 4 Rear Wheel speed Sensor Rotor 5 ABS Indicator Light 6 ABS Hydraulic Unit 7 ABS diagnosis tool Connector Near battery position 1 2 3 4 5 6 7 A...

Page 41: ...P 40 51 Diagnostic tool connector 1 Connect the KYMCO Fi Diagnostic tool 2 Put the side stand and engine stop switch is at RUN position 3 Connect the diagnostic tool connector DIAGNOSTIC PROCEDURE...

Page 42: ...P 41 51 DATA Analyze Down Button ECU Version DTC Inspect Adjust UP Button Enter or Exit Power DTC Failure codes Vehicle s Model R D Drawing NO Fi Diagnostic Tool...

Page 43: ...P 42 51 Picture 1 Picture 2 Picture 3...

Page 44: ...P 43 51 Picture 4 Picture 5 Picture 6 Picture 7 Picture 8...

Page 45: ...P 44 51 Picture 9 Picture 10 Picture 11 Picture 12...

Page 46: ...P 45 51 KYMCO Diagnosis 01 Fr Speed 5 km hr Re Speed 5 km hr Battery Volt 12 6V Battery volt 9 6 16 7V keep function The adjust is without function Picture 13 Picture 14 Picture 15...

Page 47: ...or front wheel Disconnect the connector for front wheel Remove the screw for rear wheel Disconnect the connector for rear wheel Wheel Speed Sensor Removal And Installation Standard clearance between S...

Page 48: ...P 47 51 ABS ECU Hydraulic Unit Warning I f remove the ABS ECU screws cause to damage the ECU or Hydraulic Unit parts Kymco do not guarantee the parts...

Page 49: ...P 48 51 1 2 TORQUE 1 Oil bolts 4 35 0N m 3 5kgf m 2 Nut 2 8 0N m 0 8 kgf m NOTE D o n o t d r a i n b r a k e o i l w h e n replacing the new Hydraulic Unit Because brake oil is fully inside...

Page 50: ...P 49 51 WHEEL SPEED SENSOR INSPECTION Front wheel speed Rear wheel speed sensors Standard 3500 6500...

Page 51: ...P 50 51 FI Diagnostic Software For PC Version Double click to change the serial port To close this basic display To change language Connect ECU to begin diagnosis Ver 2 18...

Page 52: ...photo Vehicle running condition signal showing Start to diagnosis Command message Change port ECU version Failure code list Failure item Showing failure part location photo automatically RPM condition...

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