KYMCO Downtown 300i ABS User manual

Downtown 300i ABS
By KWANG YANG Motor Co., Ltd.
1st Edition, Jan 2010
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T300-SK60AB-A2

Downtown 300i ABS
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
Downtown 300i ABS
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules
and service information for each part,
starting from periodic maintenance.
Sections 5 to 12 give instructions for
disassembly, assembly and
adjustment of engine parts. Section 13
is the AFI system. Section 14 to 15 is
the removal/ installation of chassis.
Section 16 to 19 states the testing and
measuring methods of electrical
equipment.
Most sections start with an assembly
or system illustration and
troubleshooting for the section. The
subsequent pages give detailed
procedures for the section.
KWANG YANG MOTOR CO., LTD.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
EXHAUST MUFFLER/FRAME
COVERS 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
DRIVE AND DRIVEN PULLEYS/V-
BELT 8
FINAL REDUCTION 9
A.C. GENERATOR/STARTER
CLUTCH 10
CRANKCASE/CRANKSHAFT 11
COOLING SYSTEM 12
FUEL INJECTION SYSTEM 13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER` 15
BATTERY/CHARGING SYSTEM 16
IGNITION SYSTEM 17
STARTING SYSTEM 18
LIGHTS SWITCHES / FUEL PUMP 19
EVAPORATIVE EMISSION CONTROL
SYSTEM 20
ABS ANTI-LOCK BRAKE SYSTEM 21
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS ELE
C
TRI
C
AL
EQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
Downtown 300i ABS
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
GENERAL INFORMATION
________________________________________________________________________________
SERIAL NUMBER-----------------------------------------------------------------------------------1-1
SPECIFICATION ------------------------------------------------------------------------------------1-2
SERVICE PRECAUTIONS------------------------------------------------------------------------1-3
TORQUE VALUES----------------------------------------------------------------------------------1-7
SPECIAL TOOLS -----------------------------------------------------------------------------------1-9
LUBRICATION POINTS------------------------------------------------------------------------- 1-12
CABLE & HARNESS ROUTING------------------------------------------------------------------ 1-13
TROUBLESHOOTING--------------------------------------------------------------------------- 1-17
1

1. GENERAL INFORMATION
1-1
Downtown 300i ABS
SERIAL NUMBER
Location of Frame Serial Number
(inside luggage box)
Location of Vehicle Identification
Number (VIN)
Location of Engine Serial Number

1. GENERAL INFORMATION
1-2
Downtown 300i ABS
SPECIFICATIONS
Name
Downtown 300i ABS
Model No. SK60AB
Overall length
2200 mm
Overall width
800 mm
Overall height 1410 mm
Wheel base
1545 mm
Engine type
4 stroke O.H.C.
Displacement 298.9 cc
Fuel Used
92# nonleaded
gasoline
Front wheel
79
Rear wheel 110
Total
189
Front wheel 149
Rear wheel 205
Total 354
Ground clearance (mm)
140
Braking distance (m) 7.9m / 40 km/hr
Min. turning radius (m) 2.6
Engine part
Starting system Starting motor
Type
Gasoline 4-cycle
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.-4V
Bore x stroke (mm)
φ
72.7 * 72
Compression ratio
10.8:1
Compression pressure
(kg/cm²-rpm)
16-570 rpm
Max. output (ps/rpm)
29 / 7750
Max. torque (kg-m/rpm)
2.7 / 6500
Open
-9.5° BTDC
Close 37.5° BTDC
Open
40° BTDC
Close 10° BTDC
Intake 0.10
Exhaust
0.10
Idle speed (rpm)
1620±100 rpm
Cooling Type
Liquid cooling
Lubrication type
Forced pressure &
wet sump
Oil pump type Inner/outer rotor
Oil filter type
Full-flow filtration
Oil capacity
1.5 liter
Exchanging capacity
1.3 liter
Fuel injection system
Air cleaner type & No
Paper element, wet
Fuel capacity
12.5 liters
Brand
Keihin
Throttle Body Butterfly type
Venturi diameter (mm) 34
Fuel pump pressure 43.4 psi (3.0 bar)
Electrical system
Ignition type ECU
Ignition timing
10°BTDC / idle
33° / 6500min
Spark plug
CR7E (NGK)
Spark plug gap
0.6
～
0.7mm
Battery Capacity
12V10AH
Transmission system
Clutch type
Dry multi-disc
Transmission type CVT
Operation type
Auto centrifugal
Reduction gear type
Two-stage reduction
1st
0.72 ~ 2.24
2nd 7.222
Moving device
Tire type
Tubeless
Front 120/80-14 58S
Rear
150/70-13 64S
Front
2.0
Rear
2.25
Wheel material
Aluminium
Left 40°
Right 40°
Front ABS
Rear ABS
Clearance between
Wheel Sensor and
Rotor
Front 0.4-1.2mm
Rear 0.4-1.2mm
Damping Device
Front Telescope
Rear Swing arm
Shock absorber
stroke Front 110 mm
Rear 100 mm
Curb weight
(kg)
Max. weight
(kg)
Valve clearance
Exhaust Timing
Intake Timing
Tire spec.
Tire pressure
(kg/cm
²
)
Turning angle
Brake type
Suspension
type
Reduction ratio

1. GENERAL INFORMATION
1-3
Downtown 300i ABS
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
Apply or add designated greases and
lubricants to the specified lubrication
points.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-)
terminal before operation.
When using a spanner or other tools,
make sure not to damage the motorcycle
surface.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the
positive (+) terminal must be connected
first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-4
Downtown 300i ABS
If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
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 for
damaged terminal cover or loose negative
terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
After clamping, check each wire to make
sure it is secure.
Confirm
Capacity

1. GENERAL INFORMATION
1-5
Downtown 300i ABS
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts that will generate
high heat.
Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and 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.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge
or corner.
When rubber protector cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape or
replace it.
When installing other parts, do not press
or squeeze the wires.
After routing, check that the wire
harnesses are not twisted or kinked.
Do not pull
too tight！
No Contact
Do not press or
squeeze the wire

1. GENERAL INFORMATION
1-6
Downtown 300i ABS
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
When a testing device is used, make sure
to understand the 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 connecting.
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
:Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
:Apply grease for lubrication.
:Transmission Gear Oil (90#)
:Use special tool.
:Caution
:Warning
Special
Grease
Gear Oil
Do you understand
the instrument？
＊
Remove Rust

1. GENERAL INFORMATION
1-7
Downtown 300i ABS
TORQUE VALUES

1. GENERAL INFORMATION
1-8
Downtown 300i ABS
TORQUE VALUES
FRAME

1. GENERAL INFORMATION
1-9
Downtown 300i ABS
SPECIAL TOOLS
A120 E00003 FLYWHEEL PULLER M28X1
A120 E00012 TAPPET ADJUSTER
A120 E00014 OIL SEAL & BEARING
DRIVER General size
A120 E00019 BUSHING ABSORBER
REMOVER O.D. 26
A120 E00021 FLYWHEEL HOLDER
A120 E00028 NUT & FITTING #41
A120 E00032 BUSHING ENGINE
HANGER REMOVER O.D. 30
A120 E00035 BUSHING REMOVER O.D. 39
A120 E00038 CVT CLUTCH SPECIAL
LOCKING NUT WRENCH
HEX
39,41,46,50
A120 E00039 CYLINDER
COMPRESSION GAUAGE

1. GENERAL INFORMATION
1-10
Downtown 300i ABS
A120 E00048 FUEL PRESSURE GAUAGE
A120 E00051 VALVE COTTER
INSTALLER
A120 E00053 CLUTCH SPRING
COMPRESSOR
A120 E00055 THREAD PROTECTOR 12mm/14 mm
A120 E00065 CRANKSHAFT BEARING
REMOVER
32143-LEA7-9000 INJECTOR CLEANER Keihin system
A120 E00085 INJECTOR CLEANER AI 600
A120 E00088 SHAFT COLLAR PULLER
A120 E00091 SHAFT COLLAR DRIVER
A120 E00092 SHAFT COLLAR
INSTALLER

1. GENERAL INFORMATION
1-11
Downtown 300i ABS
A120 E00093 BEARING PULLER
A120 F00009 Lower/Upper Outer
Race Separator
A120 F00019
LOWER & UPPER
OUTER RACE
INSTALLER
A120 F00023
STEERING STEM
TOP THREAD
WRENCH
39mm with longer
A120 F00031 PLIERS FUEL PIPE
A120 F00032 ELECTRIC REPAIR
KIT
A120 F00033 DIGITAL ELECTRIC
GAUGE

1. GENERAL INFORMATION
1-12
Downtown 300i ABS
LUBRICATION POINTS
FRAME
The following is the lubrication points for the frame.
Use grease for parts not listed.
Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise
and damage the durability of the motorcycle.
Grease
Grease
Front wheel axle &nut
Rear wheel axle &nut
Grease
Side stand pivot
& Main stand pivot

1. GENERAL INFORMATION
1-13
Downtown 300i ABS
CABLE & HARNESS ROUTING
Tilt Switch Speedometer
Radiator Filler Cap
Ignition Switch
ECU
Horn
Winker Relay
Hi Beam Relay
Lo Beam Relay
ECU
ABS ECUHYDRAULIC UNIT

1. GENERAL INFORMATION
1-14
Downtown 300i ABS
ISC Throttle Body TPS WTS
InjectorMAP Sensor

1. GENERAL INFORMATION
1-15
Downtown 300i ABS
Oil controller
Fuel Pump Relay
Ignition Coil
Output Voltage Connector
Coolant Reserve Tank

1. GENERAL INFORMATION
1-16
Downtown 300i ABS
Starter Relay Regulator/Rectifier
CPS O2 Sensor

1. GENERAL INFORMATION
1-17
Downtown 300i ABS
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Possible cause
1. Check for operation of the fuel pump Abnormal Faulty fuel pump
Normal
2. Inspect the fuel flow Abnormal Faulty pressure regulator
Normal
3. Inspect the fuel injector Abnormal Faulty injector
Normal
4. Perform spark test Weak or no spark Faulty spark plug
Fouled spark plug
Faulty 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 open
Worn cylinder and piston ring
Damaged cylinder head gasket
Compression normal Seized valve
Improper valve timing
6. Starting following normal procedure Engine start Intake pipe leaking
but stops Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
Engine does not start Fuel contaminated
7. Remove and inspect spark plug Wet plug Throttle valve open
Clogged air cleaner