KYMCO X-Town 300 ABS User manual

X-Town 300 ABS
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO X-Town
300 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
ELECTRICAL EQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
X-Town300 ABS
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
GENERAL INFORMATION
________________________________________________________________________________
SERIAL NUMBER ----------------------------------------------------------------------------------- 1-1
SPECIFICATION ------------------------------------------------------------------------------------ 1-2
SERVICE PRECAUTIONS ------------------------------------------------------------------------ 1-5
TORQUE VALUES ---------------------------------------------------------------------------------- 1-9
SPECIAL TOOLS --------------------------------------------------------------------------------- 1-10
LUBRICATION POINTS ------------------------------------------------------------------------- 1-11
CABLE & HARNESS ROUTING ------------------------------------------------------------------ 1-13
TROUBLESHOOTING --------------------------------------------------------------------------- 1-14
1

1. GENERAL INFORMATION
1-1
X-Town300 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
X-Town300 ABS
SPECIFICATIONS
Name X-Town 300 ABS
Model No. KS60AB
Overall length 2250 mm
Overall width 800 mm
Overall height 1385 mm
Wheel base 1545 mm
Engine type 4 stroke O.H.C.
Displacement 275.6 cc
Fuel Used 92# nonleaded
gasoline
Front wheel 78
Rear wheel 117
Total 195
Front wheel 125
Rear wheel 220
Total 345
Ground clearance (mm) 150
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)
72.7 * 66.4
Compression ratio
10.6:1
Compression pressure
(kg/cm
²-
rpm)
15
Max. output (
kw
/rpm)
17.05 / 8000
Max. torque (
N.m
/rpm)
22.5 / 6500
Open 13° BTDC
Close 38° BTDC
Open 40° BTDC
Close 3° BTDC
Intake 0.1
Exhaust 0.1
Idle speed (rpm) 1600±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
1.1 liter
Exchanging capacity
0.9 liter
Fi injection system
Air cleaner type & No Paper element, wet
Fuel capacity 13 liters
Brand Keihin
Throttle Body Butterfly type
Venturi diameter (mm) 32
Fuel pump pressure 3.0 bar
Electrical system
Ignition type ECU
Ignition timing 10°BTDC / idle
33° / 6500min
Spark plug
DPR6EA-9
Spark plug gap
0.8~0.9mm
Battery Capacity
12V12AH
Transmission system
Clutch type
Dry multi-disc
Transmission type CVT
Operation type Auto centrifugal
Reduction gear type
Two-stage reduction
1st 1
2nd 7.3
Moving device
Tire type Tubeless
Front wheel 120/80-14 58S
Rear wheel 150/70-13 64S
Front wheel 2.0
Rear wheel 2.25
Wheel material Aluminium
Left 40
Right 40
Front ABS
Rear ABS
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/cm²)
Turning angle
Brake type
Suspension
type
Reduction
ratio

1. GENERAL INFORMATION
1-3
X-Town300 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.
 If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.

1. GENERAL INFORMATION
1-4
X-Town300 ABS
 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
X-Town300 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
X-Town300 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.
Do you understand
the instrument？
Remove Rust！

1. GENERAL INFORMATION
1-7
X-Town300 ABS
 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
Engine Oil
Grease
Gear Oil
＊

1. GENERAL INFORMATION
1-8
X-Town300 ABS
TORQUE VALUES

1. GENERAL INFORMATION
1-9
X-Town300 ABS
TORQUE VALUES
FRAME

1. GENERAL INFORMATION
1-10
X-Town300 ABS
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
Flywheel puller
E003
A.C. generator flywheel removal
4.10
Tappet adjuster
Oil seal & bearing installer
Flywheel holder
Clutch spring compressor
#41 Nut & Fitting
Thread protector
Bearing puller 10,12,15,18mm
E012
E014
E021
E053
E028
E029
E037
Tapper adjustment
Oil seal & bearing install
A.C. generator flywheel holding
Clutch disassembly
Clutch disassembly
Protect the crankshaft’s thread
Bearing removal
3.7
9.10.11
4.10
9
9
10
10
Valve cotter installer
E051 Valve cotter installation
7
Lock nut socket wrench
F002 Steering stem removal or install
12

1. GENERAL INFORMATION
1-11
X-Town300 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
1-12
X-Town300 ABS
CABLE & HARNESS ROUTING
Tilt Switch
Fuel Pump Relay
Radiator Filler Cap
Coolant Reserve Tank
ECU
Winker Relay
Hi Beam Relay
Lo Beam Relay
ECU
ABS ECU
HYDRAULIC UNIT
Fan Relay
Starter Relay
ECU Relay
ABS ECU
OiL Pressure Controller
Ignition Switch

1. GENERAL INFORMATION
1-13
X-Town300 ABS
ISC
Throttle Body
TPS
WTS
Injector
MAP Sensor

1. GENERAL INFORMATION
1-14
X-Town300 ABS
Diagnostic Tool
Ignition Switch
Ignition Coil
Regulator/Rectifier
Horn
Fuse

1. GENERAL INFORMATION
1-15
X-Town300 ABS
Starter Relay
CPS
O2 Sensor
Hazard control unit
RR Speed sensor

1. GENERAL INFORMATION
1-16
X-Town300 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

1. GENERAL INFORMATION
1-17
X-Town300 ABS
ENGINE LACKS POWER
Possible cause
1. Raise wheel off the ground Wheels do not  Brake dragging
and spin by hand spin freely  Worn or damaged wheel bearing
Wheel spins freely
2. Check tire pressure Pressure low  Faulty tire valve
 Punctured tire
Pressure normal
3. Accelerate lightly Engine speed does  Air cleaner dirty
not increase  Restricted fuel flow
 Clogged muffler
Engine speed increase  Pinched fuel tank breather
4. Check ignition timing Incorrect  Faulty ECU
 Faulty ignition pulse generator
Correct
5. Test cylinder compression Incorrect  Valve stuck open
 Worn cylinder and piston rings
 Leaking head gasket
Normal  Improper valve timing
6. Inspect fuel flow Abnormal  Faulty pressure regulator
Normal
7. Inspect the fuel injector Abnormal  Faulty injector
Normal
8. Remove spark plug Fouled or discolored  Faulty spark plug
Not fouled or discolored

1. GENERAL INFORMATION
1-18
X-Town300 ABS
Possible cause
9. Check oil level and condition Incorrect  Oil level too high
 Oil level too low
 Contaminated oil
Correct
10. Remove cylinder head cover Valve train not  Clogged oil
and inspect lubrication lubricated properly  Clogged oil control orifice
Valve train lubricated properly
11. Check for engine overheating Overheating  Fan motor not working
 Excessive carbon build-up in
combustion chamber
 Use of poor quality fuel
Not overheating  Wrong type of fuel
 Drive and driven pulleys/clutch
slipping
12. Accelerate or run at high Engine knocks  Worn piston and cylinder
speed  Worn type of fuel
 Excessive carbon build-up in
combustion chamber
 Ignition timing to advanced
(faulty ECU)
Engine does not knock  Lean fuel mixture