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

ELECTRICAL

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

Downtown 300i 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

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)

φ72.7 * 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

1^st

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/cm²)

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.

„ If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

Confirm

Capacity

1. GENERAL INFORMATION

1-4

Downtown 300i 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.

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.

Do you understand

the instrument？

Remove Rust！

1. GENERAL INFORMATION

1-7

Downtown 300i 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

Downtown 300i ABS

TORQUE VALUES

1. GENERAL INFORMATION

1-9

Downtown 300i ABS

TORQUE VALUES

FRAME

1. GENERAL INFORMATION

1-10

Downtown 300i ABS

SPECIAL TOOLS

1. GENERAL INFORMATION

1-11

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

1-12

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 ECU

HYDRAULIC UNIT