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KYMCO Downtown 350i User Manual

KYMCO Downtown 350i
616 pages
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KYMCO Repair Manual
Downtown 350i
1
KYMCO Downtown 350i Service Manual
Using this manual
This manual has been designed to assist trained mechanics in servicing the
models listed above. If you do not have the proper training or tools to perform a
particular task it is best if you seek out a service professional.
This manual was written using the latest information available at the time of
publication. Illustrations in this manual are shown to help you with the basics of
performing the jobs listed. The pictures in this manual may not depict the actual
vehicle you’re working on, however the procedures will be similar.
Inexperienced technicians without the correct tools and knowledge may not be
able to perform these jobs as intended. Caution needs to be taken for the vehicle
and its operator as serious injury can occur. Always read a procedure in its
entirety before attempting any repairs.

Table of Contents

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KYMCO Downtown 350i Specifications

General IconGeneral
Displacement320.6 cc
Fuel SystemElectronic Fuel Injection
TransmissionCVT
Front SuspensionTelescopic Fork
Rear SuspensionDual Shocks
Fuel Capacity12.5 liters
Front Tire120/80-14
Rear Tire150/70-13
StarterElectric
Width780 mm
Height1310 mm
Wheelbase1555 mm
Engine Type4-stroke
Max Torque30 Nm @ 5750 rpm
Rear Brake240mm Disc
IgnitionElectric
Front Brake260mm Disc
Weight199 kg (dry)

Summary

Quick Reference

Component Location

Identifies the location of key components on the KYMCO Downtown 350i.

Special Tools

Lists and describes specialized tools required for service procedures.

Specifications

Provides detailed technical specifications for the KYMCO Downtown 350i.

Torque Specifications

Lists critical torque values for engine and frame components during assembly.

Troubleshooting

Offers solutions for common operational issues and malfunctions.

VIN and Engine Number Location

Details the location of the Vehicle Identification Number and Engine Serial Number.

Periodic Maintenance

Maintenance Schedule

Outlines recommended service intervals based on mileage or time.

Air Filter Servicing

Describes the procedure for inspecting and replacing the air filter element.

Brake Fluid

Details inspection, draining, and bleeding procedures for brake fluid.

Brake Inspection

Covers inspection of brake levers, pads, and discs for wear and function.

Engine Compression Test

Explains how to perform a compression test to assess engine health.

Coolant Level Check

Provides instructions for checking and maintaining the engine coolant level.

Engine Oil

Details engine oil specifications, level check, and servicing procedures.

General Lubrication

Identifies frame lubrication points and recommended grease for longevity.

Hose Inspection

Guides the inspection of breather and fuel hoses for damage or deterioration.

Side Stand

Describes the interlock function check for the side stand safety feature.

Spark Plug

Covers spark plug removal, inspection, gap check, and installation.

Steering

Details inspection procedures for the handlebar and steering stem.

Suspension

Describes inspection of front and rear shock absorbers and pre-load setting.

Throttle Free Play

Explains how to check and adjust throttle cable free play.

Tires

Covers tire wear inspection and cold inflation pressure specifications.

Final Drive Oil

Details gear oil type, capacity, draining, and filling procedures.

Valve Clearance

Provides instructions for checking and adjusting engine valve clearance.

External Components

Rear Part

Covers the removal and servicing of rear body panels and components.

Front Part

Details the removal and servicing of front body panels and components.

Engine

Cylinder Head Cover

Procedure for removing and installing the cylinder head cover.

Camshaft

Covers camshaft removal, inspection, and installation procedures.

Cylinder Head

Details the removal and installation process for the cylinder head.

Valves

Describes valve removal, inspection, and replacement procedures.

Cylinder and Piston

Covers the removal, inspection, and installation of cylinder and piston.

Starter Clutch

Details the removal, inspection, and installation of the starter clutch.

Generator

Procedure for removing, inspecting, and installing the AC generator.

Oil Pump

Covers oil pump removal, inspection, and installation procedures.

Crankcase

Details the process of splitting and assembling the crankcase halves.

Crankshaft

Covers crankshaft removal, inspection, and installation procedures.

Engine Removal

Provides a step-by-step guide for removing the engine from the chassis.

Cooling System

Coolant

Details coolant draining, filling, and general system precautions.

Radiator

Covers radiator inspection, pressure testing, and removal procedures.

Water Temperature Sensor (WTS)

Describes the removal and inspection of the water temperature sensor.

Water Pump

Covers water pump removal, inspection, and assembly procedures.

Fuel Injection System

Airbox

Details the removal and installation process for the airbox assembly.

Fuel Tank

Covers fuel tank removal and handling precautions for flammable fuel.

Fuel Pump

Describes fuel pump inspection, removal, and installation procedures.

Throttle Body Removal and Installation

Procedure for removing, installing, and resetting the throttle body.

Throttle Cables

Details the removal and adjustment of throttle cables.

Throttle Body

Covers disassembly and inspection of the throttle body components.

Fuel Injector

Procedure for removing, inspecting, and cleaning the fuel injector.

TPS ISC Reset Procedure

Step-by-step guide for resetting Throttle Position Sensor and ISC.

Self-Diagnosis

Explains how to access and interpret self-diagnosis failure codes.

F.I. Diagnostic Tool

Provides operation instructions for the Fuel Injection diagnostic tool.

CVT Continuously Variable Transmission

Belt Case

Procedure for removing and inspecting the CVT belt case.

CVT Removal

Details the disassembly of CVT pulleys and drive belt.

CVT Installation

Covers the assembly of CVT components including pulleys and belt.

Final Drive

Final Drive Oil

Details procedures for draining and filling final drive gear oil.

Final Reduction

Covers disassembly and inspection of the final reduction gears.

Electrical Systems

Electrical Specifications

Lists standard electrical values for components like battery, spark plug, and sensors.

Fuses

Details the location and function of the fuse box and individual fuses.

ECU Removal

Procedure for disconnecting and removing the Engine Control Unit (ECU).

Ignition System

Covers inspection of spark plug, ignition coil, and system checks.

Charging System

Details charging voltage inspection and battery charging procedures.

Battery

Procedure for removing, testing, and charging the motorcycle battery.

Relays

Inspection procedure for the fuel pump relay (cut-off relay).

Starting System

Covers inspection of the starter relay and operation test.

Starter Motor

Procedure for removing and inspecting the starter motor.

Switches

Details inspection of ignition, handlebar, and other control switches.

Lights

Covers bulb replacement for headlights, turn signals, and taillights.

Horn

Procedure for testing the horn function and switch.

Brakes

Brake Pad Replacement

Guides the replacement of front and rear brake pads based on wear.

Master Cylinders

Covers removal, disassembly, and inspection of brake master cylinders.

Front Brake Caliper

Procedure for removing and installing the front brake caliper and pads.

Rear Brake Caliper

Details removal and installation of the rear brake caliper and pads.

Brake Disc

Covers inspection of brake disc thickness and runout.

ABS

Provides location of ABS components and system introduction.

Steering

Handlebar

Procedure for removing and installing the handlebar and related components.

Grips

Instructions for removing and installing throttle and handlebar grips.

Steering Stem Removal

Details the process of removing the steering stem and bearings.

Front Suspension

Front Fork Removal and Installation

Covers the procedure for removing and installing the front fork assembly.

Fork Disassembly

Step-by-step guide for disassembling the front fork components.

Fork Assembly

Details the process of assembling the front fork components.

Rear Suspension

Shock Absorbers

Covers pre-load setting adjustment for rear shock absorbers.

Rear Fork

Procedure for removing and installing the rear fork assembly.

Wheels

Bearing Replacement

Details the procedure for replacing front and rear wheel bearings.

Front Wheel

Covers the removal and installation of the front wheel assembly.

Rear Wheel

Procedure for removing and installing the rear wheel assembly.

Wheel Inspection

Guides inspection of wheel bearings, rim runout, and spoke tension.

Wheel Specifications

Provides standard measurements for axles, brakes, and wheel components.

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