KYMCO Downtown 350i Manuals

Manuals and User Guides for KYMCO Downtown 350i. We have 1 KYMCO Downtown 350i manual available for free PDF download: Repair Manual

KYMCO Downtown 350i Repair Manual (617 pages)

Brand: KYMCO | Category: Motorcycle | Size: 50.09 MB

Quick Reference
3
Periodic Maintenance
3
Table of Contents
3
External Components
4
Engine
4
Cooling System
5
Fuel Injection System
5
CVT Continuously Variable Transmission
5
Component Location
10
Coolant
11
Special Tools
13
KYMCO Downtown 350I Specifications
14
General Information
14
Radiator
20
Coolant Gravity Chart
21
Specifications
22
Axle/Brakes/Wheels
25
Electrical
26
Torque Specifications
27
Frame
28
General Torque Specifications
29
Troubleshooting
30
Vehicle Can Not be Started
30
General Troubleshooting
31
Engine will Not Start or Is Hard to Start
31
Engine Lacks Power
32
Poor Performance at Low and Idle Speed
33
Poor Performance at High Speed
34
Poor Handling
34
VIN and Engine Number Location
35
Vehicle Identification Number (VIN)
35
Periodic Maintenance
36
Maintenance Schedule
37
Maintenance Schedule Legend
37
Air Filter Servicing
39
Brake Fluid
41
Draining
42
Brake Inspection
48
Brake Lever Adjuster
48
Brake Pad Wear
49
Engine Compression Test
50
Coolant Level Check
52
Coolant Level Inspection
53
Engine Oil
56
Oil Level too Low
56
Poor Lubrication Pressure
56
Oil Specifications
57
Engine Oil Viscosity
57
Oil Level
58
Strainer Screen
64
Filter Replacement
66
Filling
70
General Lubrication
71
Hose Inspection
72
Side Stand
73
Interlock Function Check
73
Spark Plug
75
Steering
78
Handlebar
78
Front Suspension
79
Shock Absorbers
79
Pre-Load Setting
80
Throttle Free Play
81
Major Adjustment
82
Minor Adjustment
84
Grips
84
Tires
87
Final Drive Oil
89
Valve Clearance
95
General Instructions
104
Rear Part
105
Seat
105
Seat Latch Cable
108
Luggage Box
109
Rear Carrier
111
Rear Center Cover
112
Body Cover
113
Rear Inner Fender Removal
118
Rear Tire Fender Removal
119
Heat Shield Removal
120
Heat Shields
120
Exhaust System
122
Noisy Exhaust Muffler
122
Lack of Power
122
O2 Sensor
125
Exhaust System Installation
126
Front Part
130
Front Center Cover Removal
131
Front Cover Removal
132
Windshield Removal
133
Front Meter Cover Removal
134
Head Light Assembly Removal
135
Key Cover Removal
138
Dash Board Removal
140
Side Covers and Skirts Removal
142
Side Board a Removal
145
Side Board B Removal
147
Floor Panel Removal
149
Leg Shield Set Removal
151
Inner Fender Removal
153
Under Cover Set Removal
155
Front Inner Fender
157
Front Tire Fender
157
Handlebar
159
Switch Housings and Throttle
160
Grips
164
When Installation
165
Bar Ends
167
Handlebar Covers
168
Upper Cover
169
Lower Cover
170
Stands
172
Center Stand
174
Lubrication System
175
Poor Performance at Idle Speed
177
Compression too Low
177
Compression too High
177
Abnormal Noise
177
White Smoke from Exhaust Muffler
178
Cylinder and Piston
178
Compression too Low or Uneven Compression
178
Excessive Smoke from Exhaust Muffler
178
Cylinder Head Cover
179
Camshaft
182
Camshaft Installation
189
Cylinder Head
197
Valves
205
Cylinder Block Removal
211
Cylinder and Piston
211
A.C. Generator and Starter Clutch
227
Stator and Pulsar Coil/Crank Position Sensor
231
Flywheel
232
Starter Clutch
236
Stator and Crank Position Sensor
242
Generator
243
Oil Pump
247
Oil Pump Removal
248
Crankcase
251
Assembly
257
Crankshaft
261
Crankshaft Inspection
262
Crankshaft Bearings
263
Engine Removal
264
Engine Temperature too High
272
Temperature Gauge Shows the Wrong Temperature
272
Coolant Leaks
272
Water Pump
272
Coolant Draining
273
Radiator
282
Pressure Testing
282
Coolant Reserve Tank
287
Water Temperature Sensor (WTS)
292
Thermostat
294
Water Temperature Sensor
296
Water Pump
298
Mechanical Seal Inspection
298
Impeller and Shaft
300
When Assembly
301
Engine Fail to Start
304
Backfiring or Misfiring During Acceleration
304
Engine Stall, Hard to Start, Rough Idling
304
Poor Performance (Drive Ability) and Poor Fuel Economy
304
Airbox
305
Fuel Tank
309
Fuel Pump
314
Input Voltage Inspection
314
Fuel Level Gauge Inspection
318
Fuel Output Pressure
320
Throttle Body Removal and Installation
322
MAP Inspection
323
TPS Inspection
324
Fuel Injector
326
Sensors
329
Throttle Body
330
Throttle Cable
333
Notes of Installation
335
Throttle Body
335
Throttle Body
337
ISC (Air Bypass Valve)
340
Fuel Injector
342
Cleaning
346
TPS ISC Reset Procedure
347
When Opening and Closing the Throttle Grip Randomly
347
Tps/Isc Reset Procedure
347
Self-Diagnosis
348
Without Diagnostic Special Tool
349
Self-Diagnostic Procedures
349
Efi Self-Diagnosis Failure Codes
350
Celp Failure Codes List
351
Self-Diagnosis Reset Procedure
353
Spark Plug Anti-Flood
354
TPS/ISC Reset
354
Fuel Injection Diagnostic Tool
355
Diagnostic Tool
357
ECU Version
358
DTC (Diagnostic Trouble Code) INSPECTION PROCEDURE
359
DTC Clear Procedure
363
Data Analysis Procedure
365
Engine Starts but Motorcycle Won't Move
369
Engine Stalls or Motorcycle Creeps
369
Belt Case
370
CVT Removal
375
Pulleys and Belt
375
Drive Pulley Disassembly
379
Driven Pulley Disassembly
388
Bearing Replacement
391
CVT Installation
394
Driven Pulley
394
Clutch
396
Drive Pulley
401
Final Drive
407
Final Reduction
407
Final Reduction
414
Electrical Systems
423
Electrical Specifications
423
No Power
425
Intermittent Power
425
Low Power
425
Charging System Failure
425
Ignition System
426
No Peak Voltage
427
Peak Voltage Is Normal, but no Spark Jumps at the Plug
427
Starter Motor will Not Turn
428
Starter Motor Rotates but Engine Does Not Start
428
Lights Do Not Come on When Ignition Switch Is “ON”
429
Temperature Gauge Does Not Register Correctly
429
Fuel Gauge Does Not Work or Shows Wrong Figures
429
Fuses
432
Fuse Box
432
ECU Removal
433
Spark Plug Inspection
436
Ignition System
436
Ignition Coil
437
Ignition Coil Resistance
438
Secondary with Plug Cap
438
Secondary Without Plug Cap
439
AC Generator Inspection
440
Crank Position Sensor Inspection
440
Charging System
441
Charging Voltage Inspection
441
Regulator/Rectifier
442
Battery Wire
443
Ground Wire
443
Charging Coil Wire
444
Battery
446
Battery Charging
449
Standard Charge
449
Relays
450
Starting System
452
Starter Relay
452
Operation Test
453
Starter Motor
456
Switches
458
Ignition Switch
458
Tilt Switch
462
Handlebar Switches
464
Right Handlebar Switches
465
Lighting Switch
465
Left Handlebar Switches
466
Luggage Box Switch
467
Side Stand Switch
468
Brake Light Switches
469
Lights
470
Headlight
470
Bulb Replacement
470
Aim
473
Front Turn Signals
474
Rear Turn Signal Lights
475
Tail/Stop Light(LED)
476
License Tag Light
477
Horn
478
Brakes
479
Poor Brake Performance
479
Brake Pad Replacement
480
Front
481
Rear
486
Master Cylinders
491
Master Cylinders
492
Brake Levers
494
Front Caliper
504
Disc Brake
515
Abs
520
ABS Component Location
520
Introduction to KYMCO Anti-Lock Brake System
521
ABS Servicing Precautions
523
ABS Troubleshooting Outline
525
Meter Instruments
528
ABS Indicator Light Is Unlit
529
ABS Indicator Light Lights
531
Solenoid Valve Inspection
531
ABS Solenoid Valve Relay Inspection
531
Front, Rear Wheel Rotation Difference Abnormal
532
ABS Motor Relay Inspection
533
Front Wheel Rotation Sensor Signal Abnormal
533
Front Wheel Rotation Sensor Wiring Inspection
534
Rear Wheel Rotation Sensor Wiring Inspection
534
Power Supply Voltage Abnormal (Under-Voltage)
536
Power Supply Voltage Abnormal (Over-Voltage)
537
ECU Inspection (Service Code 55)
538
ABS Diagnostic Tool
539
Bosch Abs9M DTC LIST
540
ABS Unit
542
Hard Steering (Heavy)
543
Steers to One Side or Does Not Track Straight
543
Steering Stem
543
Steering Stem Removal
550
Front Fork Removal
550
Installation Torque
551
Front Fork Installation
556
Soft Front Shock Absorber
556
Front Shock Absorber Noise
556
Front Fork Removal and Installation
557
Front Brake Caliper
559
Fork Disassembly
563
Fork Assembly
571
Fork Assembly
572
Rear Suspension
578
Soft Rear Shock Absorber
578
Rear Fork
578
Shock Absorbers
579
Rear Fork
585
Rear Brake Caliper
586
Wheels
591
Front Wheel Wobbling
591
Rear Wheel Wobbling
591
Rear Wheel Noise
591
Wheel Bearing Replacement
592
Front Wheel
592
Front Wheel
596
Rear Wheel
601
Wheel Inspection
609
DOWNTOWN 350I Wiring Diagram
616

KYMCO Categories

Scooter Offroad Vehicle Motorcycle Engine Wheelchair

More KYMCO Manuals

KYMCO Downtown 350i Manuals

KYMCO Downtown 350i Repair Manual (617 pages)

Table of Contents

Related Products

KYMCO Categories