KYMCO K-XCT 300i User manual

1. E xt e r na l Com p one nt sK - XCT 300i
1-1
E x t e r n a l C o m pon e n t s
This chapter covers the location and servicing of the external components for
the KYMCO K-XCT 300i.
• Exhaust System ...............................................................1-2~1-13
• Luggage Box..................................................................1-14~1-16
• Seat................................................................................1-17~1-19
• Rear Carrier ...................................................................1-20~1-22
• Body Cover ....................................................................1-23~1-32
• Windshield .....................................................................1-33~1-36
• Front Cover Meter..........................................................1-37~1-38
• Side Molding A...............................................................1-39~1-48
• Side Cover.....................................................................1-49~1-59
• Front Fender..................................................................1-60~1-63
• Center Cover..................................................................1-64~1-66
• Under Cover...................................................................1-67~1-68
• Rear Meter Cover.......................................................... 1-69~1-72
• Floorboard ....................................................................1-73~1-78
• Leg Shield..................................................................... 1-79~1-83
• Handle Cover ...............................................................1-84~1-89
• Rear Tire Fender ..........................................................1-90~1-94
• Stands ..........................................................................1-95~1-99

1. External components > E xha us t S ys t e mK-XCT 300i
1-2
E xh a us t S ys t e m
Ge
n e r a l I ns t r uc t i ons
• When removing frame covers, use care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
T
r oub l e shoo t i ng
N
o i sy e x h a u s t m u ff l e r
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
L a ck o f pow e r
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Re
m ov a l

1. External components > E xha us t S ys t e mK-XCT 300i
1-3
Remove the two exhaust pipe joint nuts with a 12 mm deep well socket.
Remove the O2 sensor wire band.
Unplug the O2 sensor connector.
Remove the three muffler mounting bolts with a 14 mm socket.

1. External components > E xha us t S ys t e mK-XCT 300i
1-4
Remove the exhaust system.
Remove the exhaust pipe gasket and discard it.

1. External components > E xha us t S ys t e mK-XCT 300i
1-5
O2 Sensor
Re m ov a l
Remove the O2 sensor with a 17 mm wrench. Use care not to pinch the wires.
The O2 sensor issues signal to ECU when the temperature is over 350°C while the engine
is running.
Test the O2 sensor at room temperature.
Use a digital multimeter set to ohms of resistance to inspect the O2 sensor.

1. External components > E xha us t S ys t e mK-XCT 300i
1-6
Measure the resistance between the white wire terminals of the O2 sensor connector.
Replace the O2 sensor if the reading is out of specification.
I T E M SP EC I F I C A T I O N S
O
2
h ea t e r s e n s o r r e s i s t a nc e ( a t 20 ° C / 68 ° F )
6.7 - 9.5 Ω ( e ng i n e w a r m i ng cond i t i on )

1. External components > E xha us t S ys t e mK-XCT 300i
1-7
Heat Shields
Remove the three muffler heat shield bolts with a 10 mm socket if needed.

1. External components > E xha us t S ys t e mK-XCT 300i
1-8
To remove the four bolts to free the heat shield on the muffler.
Remove the heat shield.

1. External components > E xha us t S ys t e mK-XCT 300i
1-9
Installation
Hea
t S h i e l d s
Install theheat shields and tighten the bolts securely.
O2 Se
n s o r
Apply anti-seize compound to the threads of the O2 sensor.
Install the O2 sensor and tighten it to specification with a 17 mm
wrench. Use care not to pinch the wires.
I t e m
T or qu e
N-m
l b- ft
O
2
S e ns or
25
18

1. External components > E xha us t S ys t e mK-XCT 300i
1-10
E x h a u s t S ys t e m
Insert a new exhaust pipe gasket into the exhaust port.
Fit the exhaust system into place

1. External components > E xha us t S ys t e mK-XCT 300i
1-11
Install the two exhaust pipe joint nuts with a 12 mm deep well socket. Do
not tighten.
Install the three muffler mounting bolts and tighten to specification with a
socket.
I t e m
T or qu e
N-m k gf -m
M uf f l e r M ount i ng Bolt s 35 3.5

1. External components > E xha us t S ys t e mK-XCT 300i
1-12
Tighten the two exhaust pipe joint nuts to specification with a 12 mm
deep well socket.
I t e m
T or qu e
N-m k gf -m
E xha us t P i p e J oi nt N ut s
20
2
If the exhaust pipe and muffler were separated installed the muffler clamp securely.
Plug in the O2 sensor.

1. External components > E xha us t S ys t e mK-XCT 300i
1-13
Install a new O2 sensor clamp.

1. E xt e r na l Com p one nt s > L ugga ge B ox K-XCT 300i
1-14
Lugg a g e B ox
Re
m ov a l
Remove the four luggage bolts with a 10 mm socket.
Remove the two luggage nuts with a 10 mm socket.

1. E xt e r na l Com p one nt s > L ugga ge B ox K-XCT 300i
1-15
Lift up the luggage box to unplug the luggage box light connector.
Remove the luggage box.
I
ns t a ll a t i on
Plug in the luggage box light connector.
Install the luggage box.

1. E xt e r na l Com p one nt s > L ugga ge B ox K-XCT 300i
1-16
Install the four luggage bolts and tighten securely with a 10 mm socket.
Remove the two luggage nuts with a 10 mm socket.
Install the seat.

1. E xt e r na l Com p one nt s > S ea t K-XCT 300i
1-17
Sea t
Re
m ov a l
Insert the key and turn it counterclockwise.
Remove the two seat hinge nuts with a 10 mm socket.

1. E xt e r na l Com p one nt s > S ea t K-XCT 300i
1-18
Sea
t L a t ch Ca b l e
The seat latch cable runs from the ignition switch to the seat latches.
The cable must be adjusted periodically so that the latches will open correctly.
Open the seat.
Loosen the lock nuts and turn the adjusters as needed to
adjust the seat latch cable operation.
There is one adjuster for each latch. Tighten the locknuts
securely when finished.

1. E xt e r na l Com p one nt s > S ea t K-XCT 300i
1-19
I
ns t a ll a t i on
Install the seat onto the hinge.
Install the two seat hinge nuts and tighten securely witha10 mm socket.

1. E xt e r na l Com p one nt s > R ea r C a rr i e r K-XCT 300i
1-20
Rea r Ca rr i e r
Re
m ov a l
Pry off the carrier bolt covers with a small flat blade screwdriver,
the arrow mark indicates the pry point.