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KYMCO X-Town 300 ABS User Manual

KYMCO X-Town 300 ABS
271 pages
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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

Table of Contents

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KYMCO X-Town 300 ABS Specifications

General IconGeneral
BrandKYMCO
ModelX-Town 300 ABS
CategoryScooter
LanguageEnglish

Summary

PREFACE

Section 1: Precautions

Safety precautions for all operations in the manual.

Section 2: Frame Covers

Procedures for removing and installing frame covers.

Section 3: Inspection & Adjustment

Inspection and adjustment procedures for parts.

Engine Parts Service

Instructions for disassembly and assembly of engine parts.

Chassis Components Service

Removal and installation of chassis parts.

Electrical Equipment Testing

Testing and measuring methods for electrical equipment.

1. GENERAL INFORMATION

SERIAL NUMBER

Vehicle and engine identification numbers.

SPECIFICATIONS

Detailed technical specifications of the vehicle.

SERVICE PRECAUTIONS

Important safety and service guidelines.

TORQUE VALUES

Specified torque for various parts.

SPECIAL TOOLS

Recommended tools for service procedures.

LUBRICATION POINTS

Locations requiring lubrication.

CABLE & HARNESS ROUTING

Guidelines for routing wires and cables.

TROUBLESHOOTING

Diagnosing and resolving common issues.

SYMBOLS

Explanation of symbols used in the manual.

2. EXHAUST MUFFLER/FRAME COVERS

SERVICE INFORMATION

General instructions, torque values, and troubleshooting.

FASTENER REMOVAL AND REINSTALLATION

Specific procedure for fasteners.

FRAME COVERS

Covers removal and installation for seat, luggage box, etc.

EXHAUST MUFFLER

Procedures for removing and installing the muffler.

3. INSPECTION/ADJUSTMENT

SERVICE INFORMATION & MAINTENANCE SCHEDULE

General info and periodic maintenance plan.

ENGINE COMPONENTS INSPECTION

Throttle, oil, air cleaner, spark plug, valve, compression checks.

DRIVETRAIN INSPECTION

Gear oil and drive belt checks.

BRAKE SYSTEM INSPECTION

Fluid, pads, discs, and lever checks.

CHASSIS COMPONENTS INSPECTION

Suspension, wheels, tires, steering, and side stand.

4. LUBRICATION SYSTEM

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

OIL PRESSURE SWITCH & OIL PUMP SERVICE

Testing switch and servicing oil pump.

5. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION & TORQUE VALUES

General instructions and torque specifications for engine mounting.

ENGINE REMOVAL/INSTALLATION

Step-by-step procedures for engine removal.

ENGINE HANGER SERVICE

Removal and installation of the engine hanger.

6. CYLINDER HEAD/VALVES

SCHEMATIC DRAWING

Exploded view of cylinder head components.

SERVICE INFORMATION & SPECIFICATIONS

General info, specs, and torque values.

TROUBLESHOOTING

Diagnosing cylinder head and valve issues.

CYLINDER HEAD & VALVE REMOVAL/INSPECTION

Procedures for removing and inspecting components.

CYLINDER HEAD & VALVE ASSEMBLY & INSTALLATION

Steps for reassembling and installing.

7. CYLINDER/PISTON

SCHEMATIC DRAWING

Exploded view of cylinder and piston parts.

SERVICE INFORMATION & TROUBLESHOOTING

General instructions and troubleshooting.

CYLINDER & PISTON REMOVAL/INSTALLATION

Procedures for removing and installing cylinder and piston.

PISTON RING & COMPONENT INSPECTION

Inspecting piston rings and measuring dimensions.

8. DRIVE AND DRIVEN PULLEYS/V-BELT

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, tools, and troubleshooting.

PULLEY & BELT REMOVAL

Procedures for removing covers, pulleys, and belt.

PULLEY & CLUTCH INSPECTION & DISASSEMBLY

Checking and disassembling components.

PULLEY & CLUTCH ASSEMBLY & INSTALLATION

Reassembling and installing components.

9. FINAL REDUCTION

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, tools, and troubleshooting.

FINAL REDUCTION DISASSEMBLY

Step-by-step disassembly of components.

DRIVESHAFT & BEARING SERVICE

Removing, inspecting, and replacing driveshaft and bearings.

FINAL REDUCTION ASSEMBLY

Reassembling the final reduction unit.

10. A.C. GENERATOR/STARTER CLUTCH

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

COMPONENT REMOVAL

Procedures for removing covers, stator, flywheel, and starter clutch.

INSPECTION & INSTALLATION

Checking and installing starter components and flywheel.

11. CRANKCASE/CRANKSHAFT

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

CRANKCASE SEPARATION & INSPECTION

Separating cases and inspecting crankshaft/rod.

CRANKCASE ASSEMBLY

Procedures for assembling the crankcase.

12. COOLING SYSTEM

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

COOLING SYSTEM TESTING & RADIATOR SERVICE

Testing system, inspecting and removing radiator.

WATER PUMP SERVICE

Inspecting and removing water pump components.

SENSORS & THERMOSTAT SERVICE

Inspecting and removing thermosensor and thermostat.

13. FUEL INJECTION SYSTEM

OVERVIEW & SPECIFICATIONS

General info, specs, system diagram, and parts location.

TROUBLESHOOTING & DIAGNOSTICS

Diagnosing issues, self-diagnosis, error codes, and reset procedures.

COMPONENT SERVICE

Fuel pump, injector, sensors, ECU, throttle body, relays, and switches.

DIAGNOSTIC TOOL OPERATION

Using the FI diagnostic tool for analysis and clearing codes.

14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/STEERING STEM

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

HANDLEBAR & STEERING STEM SERVICE

Procedures for handlebar and steering stem.

FRONT WHEEL SERVICE

Front wheel removal, inspection, and bearing replacement.

FRONT BRAKE SERVICE

Fluid replacement, pad replacement, and disc inspection.

FRONT SHOCK ABSORBER SERVICE

Removal, installation, and inspection of front shock absorbers.

15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, and troubleshooting.

REAR BRAKE SERVICE

Caliper and pad removal and disassembly.

REAR WHEEL & FORK SERVICE

Rear wheel and fork removal procedures.

REAR SHOCK ABSORBER SERVICE

Removal, installation, and adjustment of rear shock absorbers.

16. BATTERY/CHARGING SYSTEM

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, and troubleshooting.

BATTERY SERVICE

Removal, installation, charging, and voltage inspection.

CHARGING SYSTEM & REGULATOR/RECTIFIER SERVICE

Inspecting charging voltage, wiring, and regulator/rectifier.

17. IGNITION SYSTEM

IGNITION SYSTEM OVERVIEW

Layout and circuit diagrams.

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, and troubleshooting.

IGNITION SYSTEM COMPONENTS INSPECTION

Spark plug, ignition coil, AC generator, and sensors.

18. STARTING SYSTEM

STARTING SYSTEM OVERVIEW

Layout and circuit diagrams.

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, torque, tools, and troubleshooting.

STARTER MOTOR SERVICE

Removal and installation of the starter motor.

19. LIGHTS SWITCHES/ FUEL PUMP

ELECTRICAL EQUIPMENT OVERVIEW

Layout and diagram of electrical components.

SERVICE INFORMATION & TROUBLESHOOTING

General info, specs, and troubleshooting for lights/switches.

BULB REPLACEMENT

Procedures for replacing license and headlight bulbs.

SWITCHES INSPECTION

Inspection of brake, ignition, handlebar, luggage box, and side stand switches.

FUEL PUMP & HORN SERVICE

Fuel pump removal/inspection and horn inspection.

20. EVAPORATIVE EMISSION CONTROL SYSTEM

SYSTEM OVERVIEW & TROUBLESHOOTING

Diagram, function, and troubleshooting.

SERVICE INFORMATION & COMPONENT SERVICE

General info, tools, purge control valve, and charcoal canister service.

21. ANTI-LOCK BRAKE SYSTEM (ABS)

ABS INTRODUCTION & INDICATOR LIGHT

Explanation of ABS function and warning light.

PARTS LOCATION & WHEEL SENSOR SERVICE

Identifying components and servicing wheel sensors.

ABS ECU & HYDRAULIC UNIT SERVICE

Removal and installation of ECU and hydraulic unit.

DIAGNOSTIC TOOL OPERATION & DTC LIST

Using the diagnostic tool, inspecting and clearing DTCs.

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