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KYMCO
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Downtown 300i ABS
KYMCO Downtown 300i ABS User Manual
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7. CYLINDER/PISTON
7-8
Downtow
n 300i ABS
Install the cam chain guide.
Install the cylinder head gasket and dowel
pins.
Connect the water hose to the cylinder.
Install the cylinder head.
Tighten the cylinder base bolt.
•
Insert the tab on the cam chain guide
into the cylinder groove.
*
Gasket
Dowel Pin
Cam Chain Guide
87
89
Table of Contents
Preface
2
Table of Contents
2
General Information
3
Serial Number
4
General Information
4
Specification
5
Service Precautions
6
Torque Values
10
Special Tools
12
Lubrication Points
15
Cable & Harness Routing
16
Troubleshooting
20
2. Exhaust Muffler/Frame Covers
25
Exhaust Muffler/Frame Covers
25
Exhaust Muffler/Frame Covers
26
Service Information
26
Troubleshooting
26
Fastener Removal and Reinstallation
27
Frame Covers Removal/Installation
28
Exhaust Muffler
39
3. Inspection/Adjustment
41
Inspection/Adjustment
41
Inspection/Adjustment
42
Service Information
42
Throttle Operation
44
Engine Oil
45
Reserve Tank
46
Air Cleaner
47
Spark Plug
47
Valve Clearance
48
Cylinder Compression
48
Final Reduction Gear Oil
49
Drive Belt
49
Brake System
50
Clutch Shoe Wear
51
Suspension
51
Nuts/Bolts/Fasteners
52
Wheels/Tires
52
Steering Handlebar
52
Side Stand
53
4. Lubrication System
54
Lubrication System
54
Lubrication System
55
Service Information
56
Troubleshooting
56
Engine Oil/Oil Filter
57
Oil Pump
60
Engine Removal/Installation
61
6. Cylinder Head/Valves
68
Cylinder Head/Valves
68
Schematic Drawing
69
Service Information
70
Troubleshooting
71
Cylinder Head Cover Removal
72
Camshaft Removal
72
Cylinder Head Removal
74
Cylinder Head Disassembly
75
Cylinder Head Assembly
76
Cylinder Head Installation
77
Camshaft Installation
77
Cylinder Head Cover Installation
79
7. Cylinder/Piston
80
Cylinder/Piston
80
Schematic Drawing
81
Service Information
82
Troubleshooting
82
Cylinder Removal
83
Piston Installation
87
Cylinder Installation
87
Drive and Driven Pulleys/V- Belt
89
9. Final Reduction
102
Final Reduction
102
Schematic Drawing
103
Service Information
104
Final Reduction Disassembly
104
Final Reduction Inspection
105
Final Reduction Assembly
106
10. A.C. Generator/Starter Clutch
108
Generator/Starter Clutch
108
Schematic Drawing
109
Service Information
110
Troubleshooting
110
Right Crankcase Cover Removal
111
Stator Removal
111
Flywheel Removal
112
Starter Clutch
112
Flywheel Installation
116
Stator Installation
117
Right Crankcase Cover Installation
117
11. Crankcase/Crankshaft
118
Crankcase/Crankshaft
118
Schematic Drawing
119
Service Information
120
Troubleshooting
120
Crankcase Separation
121
Crankshaft Inspection
122
Crankcase Assembly
123
12. Cooling System
124
Cooling System
124
Schematic Drawing
125
Service Information
126
Troubleshooting
126
Cooling System Testing
126
Radiator
128
Water Pump
132
Thermosensor
135
Thermostat
136
13. Fuel Injection System 13
137
Fuel Injection System
137
Fuel Injection System
138
Service Information
138
Specifications
139
Injection System Diagram
140
Parts Location
141
Troubleshooting
143
Self-Diagnostic Procedures Without Diagnostic Tool
144
Efi Self-Diagnosis Check Engine Lamp (Celp) Failure Codes
145
Self-Diagnosis Reset Procedure
146
Tps/Isc Reset
150
Fuel Pump
151
Fuel Cut-Off Relay
153
Tilt Switch
154
Electronic Control Unit (Ecu)
155
Fuel Injector
157
Wts Sensor
159
O 2 Sensor
160
Throttle Body/Map/Isc/Tps
161
Diagnostic Tool Connector
164
Vehicle Can Not be Started
177
Manual Trouble Shooting Procedure
178
Diagnostic Report
179
Steering Handlebar/Front Wheel/Front Brake/Front
186
Rear Brake/Rear Fork/Rear
198
16. Battery/Charging System
207
Battery/Charging System
207
Battery/Charging System
208
Charging System Layout
208
Service Information
209
Troubleshooting
210
Battery Charging
212
Regulator/Rectifier
213
17. Ignition System
215
Ignition System
215
Service Information
217
Troubleshooting
217
Spark Plug
218
Ignition Coil Inspection
218
Generator Inspection
219
Tilt Switch Inspection
219
Starting System
221
Lights/Meters/Switches
226
Lights Switches/ Fuel Pump
226
Brake Light Switch
234
Ignition Switch
234
Handlebar Switch
236
Luggage Box Light Switch
236
Fuel Pump
237
Side Stand Switch
239
Horn
240
Evaporative Emission Control System
241
Schematic Drawing
242
Evaporative Emission Control System Function
243
Troubleshooting
243
Service Information
244
Charcoal Canister
247
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KYMCO Downtown 300i ABS Specifications
General
Brand
KYMCO
Model
Downtown 300i ABS
Category
Motorcycle
Language
English
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