KYMCO K-XCT 300i Owner's Manual

Table of Contents

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1. External Components

External Components

This chapter covers the location and servicing of the external components for

the KYMCO K-XCT 300i.

• Exhaust System ...............................................................1-2~1-13

• Luggage Box ..................................................................1-14~1-16

• Seat ................................................................................1-17~1-19

• Rear Carrier ...................................................................1-20~1-22

• Body Cover ....................................................................1-23~1-32

• Windshield .....................................................................1-33~1-36

• Front Cover Meter ..........................................................1-37~1-38

• Side Molding A ...............................................................1-39~1-48

• Side Cover .....................................................................1-49~1-59

• Front Fender ..................................................................1-60~1-63

• Center Cover ..................................................................1-64~1-66

• Under Cover ...................................................................1-67~1-68

• Rear Meter Cover .......................................................... 1-69~1-72

• Floorboard ....................................................................1-73~1-78

• Leg Shield ..................................................................... 1-79~1-83

• Handle Cover ...............................................................1-84~1-89

• Rear Tire Fender ..........................................................1-90~1-94

• Stands ..........................................................................1-95~1-99

1-1

K- XCT 300i

Chapters

Table of Contents

Summary of Contents for KYMCO K-XCT 300i

Page 1: Table Of Contents
1. External Components K- XCT 300i External Components This chapter covers the location and servicing of the external components for the KYMCO K-XCT 300i. • Exhaust System ...............1-2~1-13 • Luggage Box ..............1-14~1-16 • Seat ................1-17~1-19 • Rear Carrier ..............1-20~1-22 • Body Cover ..............1-23~1-32 •...
Page 2: Exhaust System
1. External components > Exhaust System K-XCT 300i Exhaust System General Instructions • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 3 1. External components > Exhaust System K-XCT 300i Remove the two exhaust pipe joint nuts with a 12 mm deep well socket. Remove the O2 sensor wire band. Unplug the O2 sensor connector. Remove the three muffler mounting bolts with a 14 mm socket.
Page 4 1. External components > Exhaust System K-XCT 300i Remove the exhaust system. Remove the exhaust pipe gasket and discard it.
Page 5 1. External components > Exhaust System K-XCT 300i O2 Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. The O sensor issues signal to ECU when the temperature is over 350°C while the engine is running.
Page 6 1. External components > Exhaust System K-XCT 300i Measure the resistance between the white wire terminals of the O sensor connector. Replace the O sensor if the reading is out of specification. ITEM SPECIFICATIONS 6.7 - 9.5 Ω (engine warming condition)
Page 7 1. External components > Exhaust System K-XCT 300i Heat Shields Remove the three muffler heat shield bolts with a 10 mm socket if needed.
Page 8 1. External components > Exhaust System K-XCT 300i To remove the four bolts to free the heat shield on the muffler. Remove the heat shield.
Page 9 1. External components > Exhaust System K-XCT 300i Installation Heat Shields Install the heat shields and tighten the bolts securely. Sensor Apply anti-seize compound to the threads of the O sensor. Install the O sensor and tighten it to specification with a 17 mm wrench.
Page 10 1. External components > Exhaust System K-XCT 300i Exhaust System Insert a new exhaust pipe gasket into the exhaust port. Fit the exhaust system into place 1-10...
Page 11 1. External components > Exhaust System K-XCT 300i Install the two exhaust pipe joint nuts with a 12 mm deep well socket. Do not tighten. Install the three muffler mounting bolts and tighten to specification with a socket. Torque Item...
Page 12 1. External components > Exhaust System K-XCT 300i Tighten the two exhaust pipe joint nuts to specification with a 12 mm deep well socket. Torque Item kgf-m Exhaust Pipe Joint Nuts If the exhaust pipe and muffler were separated installed the muffler clamp securely.
Page 13 1. External components > Exhaust System K-XCT 300i Install a new O sensor clamp. 1-13...
Page 14: Luggage Box
1. External Components > Luggage Box K-XCT 300i Luggage Box Removal Remove the four luggage bolts with a 10 mm socket. Remove the two luggage nuts with a 10 mm socket. 1-14...
Page 15 1. External Components > Luggage Box K-XCT 300i Lift up the luggage box to unplug the luggage box light connector. Remove the luggage box. Installation Plug in the luggage box light connector. Install the luggage box. 1-15...
Page 16 1. External Components > Luggage Box K-XCT 300i Install the four luggage bolts and tighten securely with a 10 mm socket. Remove the two luggage nuts with a 10 mm socket. Install the seat. 1-16...
Page 17: Seat
1. External Components > Seat K-XCT 300i Seat Removal Insert the key and turn it counterclockwise. Remove the two seat hinge nuts with a 10 mm socket. 1-17...
Page 18 1. External Components > Seat K-XCT 300i Seat Latch Cable The seat latch cable runs from the ignition switch to the seat latches. The cable must be adjusted periodically so that the latches will open correctly. Open the seat. Loosen the lock nuts and turn the adjusters as needed to adjust the seat latch cable operation.
Page 19 1. External Components > Seat K-XCT 300i Installation Install the seat onto the hinge. Install the two seat hinge nuts and tighten securely with a 10 mm socket. 1-19...
Page 20: Rear Carrier
1. External Components > Rear Carrier K-XCT 300i Rear Carrier Removal Pry off the carrier bolt covers with a small flat blade screwdriver, the arrow mark indicates the pry point. 1-20...
Page 21 1. External Components > Rear Carrier K-XCT 300i Remove the four carrier bolts with a 6 mm Allen. Remove the carrier each side. 1-21...
Page 22 1. External Components > Rear Carrier K-XCT 300i Installation Install the carrier. Install the four carrier bolts on each side with a 6 mm Allen. Push on the carrier bolt covers. 1-22...
Page 23: Body Cover
1. External Components > Body Cover K-XCT 300i Body Cover Removal Remove the two rear center cover screws with a #2 Phillips. 1-23...
Page 24 1. External Components > Body Cover K-XCT 300i Carefully unhook the tabs on both side of the rear center cover. Remove the rear center cover. Remove the four lower body cover nuts with a 10 mm socket. 1-24...
Page 25 1. External Components > Body Cover K-XCT 300i Remove the two plastic screws from the front of the body cover. Carefully unhook the tabs on both sides of the body cover. 1-25...
Page 26 1. External Components > Body Cover K-XCT 300i Unplug the taillight connector. Remove the body cover. 1-26...
Page 27 1. External Components > Body Cover K-XCT 300i Disassembly Rear Center Molding Remove the two Rear Center Molding screws with a #2 Phillips. Remove the rear center molding. 1-27...
Page 28 1. External Components > Body Cover K-XCT 300i Rear Fender Remove the rear fender screws with a #2 Phillips. Carefully unhook the tabs on both sides of the r ear fender . Remove the r ear fender . 1-28...
Page 29 1. External Components > Body Cover K-XCT 300i Taillight Assembly Remove the eight taillight assembly screws with a #2 Phillips. Unhook the taillight section and separate from the body cover. Remove the taillight assembly 1-29...
Page 30 1. External Components > Body Cover K-XCT 300i License Light Remove the two license light assembly screws with a screwdriver. Disconnect the connector license light. Remove the license light assembly. Installation Fit the body cover into place. 1-30...
Page 31 1. External Components > Body Cover K-XCT 300i Plug in the taillight connector. Carefully push the hooks into the corresponding tabs on both sides of the body cover. Install the two screws on both sides of the body cover. 1-31...
Page 32 1. External Components > Body Cover K-XCT 300i Install the four lower body cover nuts and tighten securely with a 10 mm socket. Carefully install the rear center cover. Install the two rear center cover screws and tighten securely with a #2 Phillips.
Page 33: Windshield
1. External Components > Windshield K-XCT 300i Windshield Removal Open the hidden bolt cover. Remove the hidden bolt with a 10 mm socket. Depress the head of the fastener center piece. Pull out the fastener. 1-33...
Page 34 1. External Components > Windshield K-XCT 300i Carefully pull out the front cover with a thinner driver on each side. Lightly slap downward at the front cover on each side. 1-34...
Page 35 1. External Components > Windshield K-XCT 300i Remove the front cover. Remove the four bolts with a 12mm socket on each side. Remove the windshield. 1-35...
Page 36 1. External Components > Windshield K-XCT 300i Installation Install the windshield. Install the four windshield bolts and tighten securely with a 12mm socket. There are two bolts on each side. Install the center cover carefully. Install the push pin Install the hidden bolt and tighten securely with a 10 mm socket. Close the cover.
Page 37: Front Cover Meter
1. External Components > Front Cover Meter K-XCT 300i Front Cover Meter Removal Remove the two front cover meter mounting nuts with a 10 mm socket Remove the two screws mounting on the front cover meter on each side. Remove the front cover meter...
Page 38 1. External Components > Front Cover Meter K-XCT 300i Install Install the front cover meter Install the two screws mounting on the front cover meter on each side. Install the two screws mounting on the front cover meter on each side.
Page 39: Side Molding
1. External Components > Side Molding A K-XCT 300i Side Molding A Removal Remove the side molding mounting nuts with a 10 mm socket. Carefully depress the front inner cover. 1-39...
Page 40 1. External Components > Side Molding A K-XCT 300i Carefully pull out the side molding and leg shield with a thinner driver on each side. Carefully pull off the side molding with hand. 1-40...
Page 41 1. External Components > Side Molding A K-XCT 300i Carefully pull out the side molding and side skirt with hand on each side. Unplug the headlight leads. 1-41...
Page 42 1. External Components > Side Molding A K-XCT 300i Gently pull the side molding forward and free the tabs. Disassembly Light Assembly 1-42...
Page 43 1. External Components > Side Molding A K-XCT 300i Remove the eight light assembly mounting screws with a #2 Phillips. Separate the light assembly from the side molding A. 1-43...
Page 44 1. External Components > Side Molding A K-XCT 300i Side Piece Remove the eight side piece screws with a #2 Phillips. Assembly Side Piece Install the eight side piece screws and tighten securely with a #2 Phillips. 1-44...
Page 45 1. External Components > Side Molding A K-XCT 300i Light Assembly Install the eight light assembly mounting screws and tighten securely with a #2 Phillips. 1-45...
Page 46 1. External Components > Side Molding A K-XCT 300i Install the headlight assembly on the side molding A. Installation Plug in the headlight and turn signal leads. 1-46...
Page 47 1. External Components > Side Molding A K-XCT 300i Align front cover tabs. Install the front cover. Carefully Align the side molding and side skirt with hand on each side. 1-47...
Page 48 1. External Components > Side Molding A K-XCT 300i Carefully Align the side molding and leg shield Install the two front cover mounting nuts with a 10 mm socket. 1-48...
Page 49 1. External Components > Side Skirt K-XCT 300i Side Skirt Removal Pull up the footboard rubber covers. Remove the four screws mounting the footboard with a #2 Phillips. 1-49...
Page 50 1. External Components > Side Skirt K-XCT 300i Remove the six leg shield mounting screws with a #2 Phillips. There are three screws on each side. 1-50...
Page 51 1. External Components > Side Skirt K-XCT 300i Remove the six lower fairing push pins on each side including the undercover. 1-51...
Page 52 1. External Components > Side Skirt K-XCT 300i Remove the left lower bolt under the side skirt with a 10mm socket. Gently separate the floorboard from the side skirt. Carefully free the tabs. Remove the cover side skirt after the turn signal leads removed.
Page 53 1. External Components > Side Skirt K-XCT 300i Remove the two cover side skirt mounting screws with a #2 Phillips. Disassembly Remove the two screws from the side board A with a #2 Phillips. 1-53...
Page 54 1. External Components > Side Skirt K-XCT 300i Separate the Side skirt and side board A. Remove the three cover side skirt mounting screws with a #2 Phillips. Carefully pull out the cover side skirt from side skirt. 1-54...
Page 55 1. External Components > Side Skirt K-XCT 300i Remove the three winker assembly mounting screws with a #2 Phillips. Remove the winker assembly from the cover side skirt. 1-55...
Page 56 1. External Components > Side Skirt K-XCT 300i Assembly Winker Assembly Install the three winker assembly mounting screws with a #2 Phillips. Install the three screws onto the cover side skirt . 1-56...
Page 57 1. External Components > Side Skirt K-XCT 300i Installation Install the side skirt. Carefully fit the upper tabs of the side board A into the floorboard. Install the side board A while aligning the tabs. Install the four screws under the footboard rubber cover with a #2 Phillips on each side.
Page 58 1. External Components > Side Skirt K-XCT 300i Install the footboard rubber covers. Install the two cover side skirt mounting screws with a #2 Phillips. Connect the turn signal leads removed. 1-58...
Page 59 1. External Components > Side Skirt K-XCT 300i Install the six leg shield mounting screws with a #2 Phillips. There are three screws on each side. Install the six lower fairing push pins on each side including the undercover. 1-59...
Page 60: Front Fender
1. External Components > Front Fender K-XCT 300i Front Fender Removal Remove the left forward front fender bolt with a 6 mm Allen. Remove the left rear fender bolt with a 10 mm socket. Remove the right forward front fender bolt with a 6 mm Allen.
Page 61 1. External Components > Front Fender K-XCT 300i Remove the right rear fender bolt with a 10 mm socket. Remove the front fender from the forks. 1-61...
Page 62 1. External Components > Front Fender K-XCT 300i Installation Guide the fender between the forks. Install the right rear fender bolt with a 10 mm socket. Install the right forward front fender bolt with a 6 mm Allen. 1-62...
Page 63 1. External Components > Front Fender K-XCT 300i Install the left rear fender bolt with a 10 mm socket. Install the left forward front fender bolt with a 6 mm Allen. 1-63...
Page 64: Center Cover
1. External Components > Center Cover K- XCT 300i Center Cover Removal Note: Do not force the cover and damage the claws. Pull the center cover back and up to free the claws and then move the cover backward to free it from the scooter. 1-64...
Page 65 1. External Components > Center Cover K- XCT 300i Remove the center cover. Installation Place the center cover on the scooter. 1-65...
Page 66 1. External Components > Center Cover K- XCT 300i Push the cover down and forward to lock in the claws. 1-66...
Page 67: Under Cover
1. External Components > Under Cover K-XCT 300i Under Cover Removal Remove the two cover bolts mounting the under cover each side with a 10 mm socket. Remove the under cover. 1-67...
Page 68 1. External Components > Under Cover K-XCT 300i Installation Install the under cover. Install the two under cover bolts on the each side and tighten securely with a 10 mm socket. 1-68...
Page 69: Rear Meter Cover
1. External Components > Rear Meter Cover K-XCT 300i Rear Meter Cover Removal Remove the two push pins below the handlebar. Depress the head of the fastener center piece. Pull out the fastener. Remove the bolt attaching the rear meter cover on the left with a 10 mm socket.
Page 70 1. External Components > Rear Meter Cover K-XCT 300i Remove two screws mounting the rear meter cover on both sides with a #2 Phillips. Remove the connector speedometer assembly. Remove the speedometer assembly 1-70...
Page 71 1. External Components > Rear Meter Cover K-XCT 300i Installation Install the speedometer assembly Install the connector speedometer assembly. Install two screws mounting the speedometer cover on both sides with a #2 Phillips. 1-71...
Page 72 1. External Components > Rear Meter Cover K-XCT 300i Install the bolt attaching the rear meter cover on the left with a 10 mm socket. Install the bolt attaching the speedometer cover on the right with a 10 mm socket.
Page 73: Floorboard
1. External Components > Floorboard K-XCT 300i Floorboard Removal Remove the two bolts mounting the floorboard on the left side with a 10 mm socket. Remove the two bolts mounting the floorboard on the right side with a 10 mm socket.
Page 74 1. External Components > Floorboard K-XCT 300i Remove the two nuts mounting the side board A on each side with a 10 mm socket. Carefully unhook the tabs on both sides of the side board A. 1-74...
Page 75 1. External Components > Floorboard K-XCT 300i Remove the floorboard on each side. Disassembly Remove the four screws mounting the side board A Separate the floorboard from side board A. 1-75...
Page 76 1. External Components > Floorboard K-XCT 300i Disassembly Install the four screws mounting the side board A Installation Install the floorboard on each side. 1-76...
Page 77 1. External Components > Floorboard K-XCT 300i Carefully install the tabs on both sides of the side board A. Install the two nuts mounting the side board A on each side with a 10 mm socket. 1-77...
Page 78 1. External Components > Floorboard K-XCT 300i Install the four bolt mounting the floorboard on each side with a 10 mm socket. Install the two bolt mounting the side board A on each side with a 10 mm socket. 1-78...
Page 79: Leg Shield
1. External Components > Leg Shield K-XCT 300i Leg Shield Removal Remove the screw mounting the collar ignition switch with a #2 Phillips. Take off the collar. Open the fuel cap panel. 1-79...
Page 80 1. External Components > Leg Shield K-XCT 300i Remove the fuel cap with the key. Remove the Lid fuel cap maint. 1-80...
Page 81 1. External Components > Leg Shield K-XCT 300i Remove the gas cap overflow pad. Lift off the leg shield. 1-81...
Page 82 1. External Components > Leg Shield K-XCT 300i Installation Install the leg shield. Align the pin hole of the body frame. 1-82...
Page 83 1. External Components > Leg Shield K-XCT 300i Install the gas cap overflow pad and the Lid fuel cap maint. 1-83...
Page 84 1. External Components > Handlebar Cover K-XCT 300i Handlebar Covers Removal Upper Cover Remove the four cover screws with a #2 Phillips. 1-84...
Page 85 1. External Components > Handlebar Cover K-XCT 300i Carefully free the tabs and remove the upper handlebar cover. Lower Cover Route the throttle cables out of the handlebar cover. 1-85...
Page 86 1. External Components > Handlebar Cover K-XCT 300i Remove the two handle lower cover screws with a #2 Phillips. 1-86...
Page 87 1. External Components > Handlebar Cover K-XCT 300i Remove the lower cover. Installation Place the lower cover onto the handlebar. 1-87...
Page 88 1. External Components > Handlebar Cover K-XCT 300i Route the throttle cables into the handlebar cover. Carefully install the upper handlebar cover. 1-88...
Page 89 1. External Components > Handlebar Cover K-XCT 300i Remove the four cover screws with a #2 Phillips. 1-89...
Page 90: Rear Tire Fender
1. External Components > Rear Tire Fender K-XCT 300i Rear Tire Fender Removal Remove the two fender mounting bolts with a 8 mm socket on the right side. 1-90...
Page 91 1. External Components > Rear Tire Fender K-XCT 300i Remove the two airbox mounting bolts with a 8mm socket . Remove the connecting tube screw with a 2# Phillips. Remove the fender mounting bolt with a 8 mm socket on the left side.
Page 92 1. External Components > Rear Tire Fender K-XCT 300i Remove the rear fender. Installation Install the rear fender. 1-92...
Page 93 1. External Components > Rear Tire Fender K-XCT 300i Install the fender mounting bolt with a 8 mm socket on the left side. Install the connecting tube screw with a 2# Phillips. Install the two fender mounting bolts with a 8 mm socket on the right side.
Page 94 1. External Components > Rear Tire Fender K-XCT 300i Install the two airbox mounting bolts with a 8mm socket. Install the airbox. 1-94...
Page 95: Stands
K -XCT 300i 1. External Components > Stands Stands Side stand Removal Unplug the three-pin side stand switch connector. Remove the side stand spring with a spring puller. 1-95...
Page 96 K -XCT 300i 1. External Components > Stands Remove the side stand bolt, switch, and side stand. Installation Install the side stand, switch, and bolt. Make sure to fit the switch into place correctly. Tighten the bot securely. 1-96...
Page 97 K -XCT 300i 1. External Components > Stands Install the side stand spring with a spring puller. Plug in the side stand switch connector. 1-97...
Page 98 K -XCT 300i 1. External Components > Stands Center Stand Removal Remove the center stand spring with a spring puller. Remove the two center stand nuts and bolts. Remove the center stand. 1-98...
Page 99 K -XCT 300i 1. External Components > Stands Installation Install the nuts and bolts. Tighten them securely. Install the center stand spring with a spring puller. 1-99...
Page 100 KYMCO standards and specifications by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. * Should be serviced by your KYMCO dealer, unless you have the proper tools, service data and are technically qualified.
Page 101 K- XCT 300i 2. Periodic Maintenance > Periodic Maintenance Chart WHICHEVER ODOMETER READING COMES FIRST FREQUENCY X 1000 km 30 REFER ITEM X 1000 mi PAGE MONTH AIR CLEANER SPARK PLUGS THROTTLE OPERATION VALVE CLEARANCE FUEL LINE CRANKCASE BREATHER ENGINE OIL ENGINE OIL SCREEN ENGINE OIL FILTER ENGINE IDLE SPEED...
Page 102 K- XCT 300i 2. Periodic Maintenance > Air Filter Servicing Air Filter Servicing SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace the air filter according to the Maintenance Schedule, and more often in exceptionally rainy or dusty areas. Removal Remove the 8 air filter cover screws with a #2 Phillips screwdriver.
Page 103 K- XCT 300i 2. Periodic Maintenance > Air Filter Servicing Remove the air filter cover. Remove the 7 air filter bolts with an 8 mm socket or a #2 Phillips screwdriver.
Page 104 K- XCT 300i 2. Periodic Maintenance > Air Filter Servicing Remove the air filter from the airbox. Discard the air filter in favor of a new item. Caution: • The air cleaner element has a viscous type paper element. Do not clean it with compressed air.
Page 105 K- XCT 300i 2. Periodic Maintenance > Air Filter Servicing Insert the 7 air filter bolts. Tighten the air filter bolts securely with an 8 mm socket or a #2 Phillips screwdriver. Install the air filter cover.
Page 106 K- XCT 300i 2. Periodic Maintenance > Air Filter Servicing Install the 8 air filter cover screws and tighten them securely with a #2 Phillips screwdriver.
Page 107 2. Periodic Maintenance > Brake Fluid Brake Fluid The KYMCO K-XCT 300i uses DOT 4 brake fluid that should be inspected after 3,000 mi (5,000 km) of use. It should be flushed and bled every 12 months, 6,000 mi (10,000 km), whenever the brakes feel spongy, or if the brake system has been taken apart and rebuilt.
Page 108 K- XCT 300i 2. Periodic Maintenance > Brake Fluid Draining The brake bleeding process is the same for the front and rear brakes. Remove the two master cylinder cover screws with a #2 Phillips head screwdriver. Remove the master cylinder cover, plastic piece and rubber diaphragm. Clean and inspect the rubber diaphragm for tears or other damage.
Page 109 K- XCT 300i 2. Periodic Maintenance > Brake Fluid Pull off the rubber cap over the bleeder valve and crack open the bleeder valve on the brake caliper using an 8 mm wrench. This valve is usually very tight so use a box end wrench or a 6 point socket and ratchet to prevent rounding off the head.
Page 110 K- XCT 300i 2. Periodic Maintenance > Brake Fluid Bleeding Place a length of 6 mm inside diameter clear hose on the bleeder valve and place the other end in a suitable container. A spare battery vent hose works well for this job. Fill the brake fluid with the proper type from a fresh, newly opened container.
Page 111 K- XCT 300i 2. Periodic Maintenance > Brake Fluid Pump the brake lever several times and hold the lever in. While holding the lever in, crack open the bleeder valve. The front brake lever will travel all the way to the grip and brake fluid and/or air will come out of the bleeder valve into the 6 mm hose.
Page 112 K- XCT 300i 2. Periodic Maintenance > Brake Fluid Place the rubber diaphragm, plastic piece and cover over the reservoir. Thread in the reservoir cover screws and tighten them securely with a #2 Phillips screwdriver. 2-13...
Page 113 2. Periodic Maintenance > Compression Test K- XCT 300i Engine Compression Test SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Before testing the compression make sure the cylinder head bolts are tightened securely and the valve clearance is specification.
Page 114 K- XCT 300i 2. Periodic Maintenance > Engine Oil Engine Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Caution: Hot engine oil can burn. Avoid letting used motor oil contact exposed skin. TROUBLESHOOTING Oil level too low 1.
Page 115 K- XCT 300i 2. Periodic Maintenance > Engine Oil If these viscosities are not available, select an alternative engine oil according to the chart shown above. Engine oil capacity At disassembly 1.5 Liter At change 1.3 Liter Inspection Oil Level Check the engine oil level each day before operating the scooter.
Page 116 K- XCT 300i 2. Periodic Maintenance > Engine Oil The oil filler cap/dipstick is located on the right side of the engine. Remove the oil filler cap/dipstick and wipe off the oil. Inspect the O-ring and replace it as needed. Insert the dipstick in without threading it in. Remove the dipstick and check the oil level.
Page 117 K- XCT 300i 2. Periodic Maintenance > Engine Oil The level must be maintained between the upper (1) and lower level (2) marks on the oil filler cap/dipstick. If the oil level is at or below the lower mark add more of the same type and brand of oil to the engine through the oil filler hole.
Page 118 K- XCT 300i 2. Periodic Maintenance > Engine Oil Place an oil pan under the engine. The oil drain bolt is located on the left side of the engine. 2-19...
Page 119 K- XCT 300i 2. Periodic Maintenance > Engine Oil Loosen the engine oil drain bolt with a 17 mm socket. Remove the bolt and allow the oil to drain into the pan. Discard the old sealing washer. 2-20...
Page 120 K- XCT 300i 2. Periodic Maintenance > Engine Oil Remove the oil filler cap to allow for faster oil draining. Inspect the oil filler cap O-ring and replace it as needed. When the oil has drained completely Install the drain bolt with a new sealing washer.
Page 121 K- XCT 300i 2. Periodic Maintenance > Engine Oil Strainer Screen Remove the oil strainer screen bolt with a 17 mm socket. Inspect the strainer screen bolt O-ring and replace it as needed. Remove the oil strainer screen. 2-22...
Page 122 K- XCT 300i 2. Periodic Maintenance > Engine Oil Remove the O-rings from the oil strainer screen and inspect them. Replace the O-rings if they are in poor condition. Inspect the oil strainer screen for debris and damage. Clean it with a high flash point solvent and compressed air.
Page 123 K- XCT 300i 2. Periodic Maintenance > Engine Oil Return the O-rings to the oil strainer screen and install it into the left side of the engine. Tighten the oil strainer screen cap to specification with a 17 mm socket. Torque Item kgf-m...
Page 124 K- XCT 300i 2. Periodic Maintenance > Engine Oil Loosen the oil filter cap with a 24 mm socket. Remove the oil filter cap with spring and take out the used oil filter. 2-25...
Page 125 K- XCT 300i 2. Periodic Maintenance > Engine Oil Inspect the oil filter cap O-ring and spring. Replace the items if they are in poor condition. Install the spring to the oil filter cap. Apply a light coat of engine oil to the oil filter cap O-ring.
Page 126 K- XCT 300i 2. Periodic Maintenance > Engine Oil Pour a small amount of fresh engine oil into the oil filter. Insert the oil filter into place with the rubber seal side facing up. Install the oil filter cap with spring. Makes sure the spring fits against the filter correctly.
Page 127 K- XCT 300i 2. Periodic Maintenance > Engine Oil Filling Add the oil to the engine through the oil filler/dipstick hole. Use a fully synthetic quality 4-stroke engine oil to ensure longer service life of the scooter. Only use oils that have a SJ rating above per the API service classification.
Page 128 K- XCT 300i 2. Periodic Maintenance > General Lubrication General Lubrication SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The frame lubrication points are listed below. Use general purpose grease. Apply clean engine oil or grease to cables and movable parts not specified.
Page 129 K- XCT 300i 2. Periodic Maintenance > Hose Inspection Hose Inspection Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Inspect the breather hose for damage and deterioration. Inspect the fuel hose for damage and deterioration.
Page 130 K- XCT 300i 2. Periodic Maintenance > Spark Plug Spark Plug SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. The spark plug is located on the left side of the cylinder.
Page 131 K- XCT 300i 2. Periodic Maintenance > Spark Plug Clean off the area surrounding the spark plug with compressed air or a shop towel to make sure debris doesn't get into the combustion chamber when the spark plug is removed. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 132 K- XCT 300i 2. Periodic Maintenance > Spark Plug Inspection Always check the gap of the spark plug before installation. If the gap needs to be adjusted bend the ground electrode carefully. Inspect the color of the porcelain nose of the spark plug. The color of the spark plug can indicate how the mixture is burning.
Page 133 K- XCT 300i 2. Periodic Maintenance > Spark Plug Item Torque Spark plug 17.2 N-m (1.5 - 2 ft-lb, 10.84 - 14.47 kgf-m) Install the spark plug wire over the plug. Install the luggage box. See the Luggage Box topic for more information. Install the seat.
Page 134 K- XCT 300i 2. Periodic Maintenance > Steering Steering SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.
Page 135 K- XCT 300i 2. Periodic Maintenance > Suspension Suspension SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Front Suspension Check the action of the front shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage.
Page 136 K- XCT 300i 2. Periodic Maintenance > Suspension Pre-Load Setting Each shock absorber on the scooter has 5 spring preload adjustment positions for different load or riding conditions. Position 1 is for light loads and smooth road conditions. Position 3 to 5 increase spring preload for stiffer rear suspension and can be used when the scooters heavily loaded.
Page 137 K- XCT 300i 2. Periodic Maintenance > Tires Tires SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Check tires before each ride for wear and air pressure. Check tire air pressure before riding when tires are cold. Solo riding Front 2.00 kg/cm2(28.4 psi)
Page 138 K- XCT 300i 2. Periodic Maintenance > Tires Replace tires if the tread depth reaches the wear mark or fails to meet the minimum tread depth. Front wheel 120/70-14 Tires Rear wheel 150/70-13 2-39...
Page 139 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment Valve Clearance SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The valve clearance specification is only relevant if the engine is cold (below 35°C or 95°F). Inspection Remove the seat. See the Seat topic for more information. Remove the luggage box.
Page 140 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment The crankshaft must be rotate (clockwise) until the piston is at top dead center (TDC) on the compression stroke. Turn crankshaft clockwise until the "T" mark aligns with the index notch in the timing inspection hole.
Page 141 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the same time the "T" mark is lined up with the with the index notch in the timing inspection hole.
Page 142 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment Measure the valve clearance with a thickness feeler gauge. Insert the feeler gauge between the tappet adjusting screw and the valve stem. The clearance is correct when there is a light drag on the feeler gauge. The clearance is the same for the exhaust and intake valves.
Page 143 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment Adjustment Use a tappet adjuster tool to adjust the valves. SPECIAL TOOLS ITEM TOOL NO. DESCRIPTION TAPPET ADJUSTER E012 Tappet adjustment 2-44...
Page 144 K- XCT 300i 2. Periodic Maintenance > Valve Adjustment Place a 9 mm box end wrench over the locknut, and loosen the locknut. If the valve clearance is tight back out the valve tappet adjusting screws with the tappet adjustment tool. If the clearance is to loose turn in the adjusting screw until there is a light drag on the feeler gauge.
Page 145 3. Engine K- XCT 300i Engine This chapter covers the location and servicing of the engine components for the KYMCO K-XCT 300i. • Engine Removal ............ 3-4~3-13 • Cylinder Head Cover ........... 3-14~3-19 • Camshaft ............. 3-20~3-37 • Valves ..............3-38~3-47 •...
Page 146 3. Engine K- XCT 300i Poor lubrication pressure 1. Oil level too low 2. Clogged filter or oil passages 3. No use the specified oil Cylinder Head, Camshaft, and Valves • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained.
Page 147 3. Engine K- XCT 300i Compression too high • Excessive carbon build-up in combustion chamber Abnormal noise • Incorrect valve clearance adjustment • Sticking valve or broken valve spring • Damaged or worn camshaft • Worn cam chain tensioner • Worn camshaft and rocker arm White smoke from exhaust muffler •...
Page 148: Engine Removal
K- XCT 300i 3. Engine > Engine Removal Engine Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal.
Page 149 K- XCT 300i 3. Engine > Engine Removal The regulator/rectifier is located on the right side of the vehicle. Disconnect the generator 3-pin connector. Disconnect the crank position sensor wire coupler.
Page 150 K- XCT 300i 3. Engine > Engine Removal Unplug the water temperature sensor. Unplug the thermo sensor unit and thermo unit ground connectors. Pull back the rubber starter motor lead cover.
Page 151 K- XCT 300i 3. Engine > Engine Removal Remove the starter motor lead nut with a 10 mm wrench. Free the cable lead from the starter motor. Thread the nut back on to keep track of it. Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose stay from the cylinder head cover.
Page 152 K- XCT 300i 3. Engine > Engine Removal Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container. Loosen the thermostat hose clamp with a #2 Phillips screwdriver.
Page 153 K- XCT 300i 3. Engine > Engine Removal Loosen the main engine ground bolt with an 8 mm socket. Remove the bolt and free the engine ground from the right side of the engine. Free the starter motor lead from the stay on the right crankcase cover. Unplug the oil pressure switch wire at the bullet connector.
Page 154 K- XCT 300i 3. Engine > Engine Removal Free the wiring harness from its guide above the intake pipe. Support the engine with a suitable jack or stand. 3-10...
Page 155 K- XCT 300i 3. Engine > Engine Removal Remove the rear shock absorbers. See the Shock Absorbers topic for more information. Loosen the engine mounting bracket damper nut with a 14 mm socket. Remove the nut and washer. Hold the engine mounting bolts with a 14 mm wrench and loosen the nuts with a 19 mm socket.
Page 156 K- XCT 300i 3. Engine > Engine Removal Loosen the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt. Remove the engine mounting bracket damper bolt and nut. Remove the engine mounting bracket.
Page 157 K- XCT 300i 3. Engine > Engine Removal Remove the engine mounting bracket damper assembly. Carefully move the engine back and separate it from the chassis. To install the engine see the Engine Installation topic. 3-13...
Page 158: Cylinder Head Cover
K- XCT 300i 3. Engine > Cylinder Head Cover Cylinder Head Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Remove the spark plug.
Page 159 K- XCT 300i 3. Engine > Cylinder Head Cover Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose stay from the cylinder head cover. Loosen the four cylinder head cover bolts with a 10 mm socket. Remove the cylinder head cover bolts with washers and grommets.
Page 160 K- XCT 300i 3. Engine > Cylinder Head Cover Remove the dowel pin. Installation Install the dowel pin into the cylinder head. 3-16...
Page 161 K- XCT 300i 3. Engine > Cylinder Head Cover Fit the cylinder head cover gasket onto the cylinder head. Make sure the projection fits into the groove in front of the camshaft sprocket correctly. Install the cylinder head cover over the gasket. Make sure the ridge on the gasket fits into the groove on the cylinder head cover correctly.
Page 162 K- XCT 300i 3. Engine > Cylinder Head Cover Coat the cylinder head cover bolt seals in fresh engine oil. Insert the cylinder head cover bolts with grommet seals and washers. Note the gold colored and longer bolts go on the left side. Tighten the cylinder head cover bolts securely in two steps and in a crisscross pattern with an 8 mm socket.
Page 163 K- XCT 300i 3. Engine > Cylinder Head Cover Fit the fuel stay into place. Tighten the stay bolt securely with an 8 mm socket. Install the breather hose to the cylinder head cover. Secure the hose with the clamp. Install the spark plug.
Page 164: Camshaft
K- XCT 300i 3. Engine > Camshaft Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information. Remove the spark plug.
Page 165 K- XCT 300i 3. Engine > Camshaft The crankshaft must be rotate (clockwise) until the piston is at top dead center (TDC) on the compression stroke. Turn crankshaft clockwise until the "T" mark aligns with the index notch in the timing inspection hole. 3-21...
Page 166 K- XCT 300i 3. Engine > Camshaft The piston should now be at TDC on the compression stroke. You can make sure that it is on the compression stroke by checking that there is some slack in the rocker arms. If the rocker arms are rigid, rotate the crankshaft 360°...
Page 167 K- XCT 300i 3. Engine > Camshaft Remove the cam chain tensioner cap bolt with a 10 mm socket. Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket. Lift the cam chain tensioner our of the cylinder. Remove the cam chain tensioner gasket.
Page 168 K- XCT 300i 3. Engine > Camshaft Use a 5 mm Allen wrench to remove the camshaft sprocket bolts. Remove the camshaft sprocket as shown. Support the chain so it does not fall into the cylinder head. Use a 5 mm Allen wrench to remove the set plate bolt. 3-24...
Page 169 K- XCT 300i 3. Engine > Camshaft Remove the set plate as shown. Thread a bolt into the rocker arm shafts and pull the shafts out. 3-25...
Page 170 K- XCT 300i 3. Engine > Camshaft Lift out the rocker arms as the shafts are removed. Remove the camshaft from the cylinder head. 3-26...
Page 171 K- XCT 300i 3. Engine > Camshaft Inspection Inspect the camshaft cam heights for the intake and exhaust lobes. Inspect the camshaft bearings for excessive play or roughness. Replace the entire camshaft assembly if the bearings are rough or have excessive play.
Page 172 K- XCT 300i 3. Engine > Camshaft Inspect the rocker arm inner diameter for the intake and exhaust valves. Item Standard (mm) 10.00 - 10.015 Valve rocker arm I.D. 10.00 - 10.015 Inspect the camshaft bearing journals for scoring or scratches. 3-28...
Page 173 K- XCT 300i 3. Engine > Camshaft Inspect the camshaft sprocket for worn teeth or other signs of wear or damage. Camshaft Installation Clear out the cylinder head oil passages with compressed air. Make sure all cylinder head oil passages are free of clogs. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 174 K- XCT 300i 3. Engine > Camshaft Position the piston at top dead center as above. The "T" mark should be aligned with the index notch in the timing inspection hole. Support the cam chain if the crank must be turned to position the piston correctly. Lubricate the camshaft lobes and bearings with fresh engine oil.
Page 175 K- XCT 300i 3. Engine > Camshaft Lubricate the inside diameter of the rocker arms and the roller with fresh engine oil. Position the rocker arms to accept the rocker arm shafts. Wipe the rocker arm shafts clean. Insert the rocker arm shafts through the camshaft holders and rocker arms.
Page 176 K- XCT 300i 3. Engine > Camshaft Install the camshaft set plate so it fits into the groove on the camshaft and between the projections on the rocker arm shafts. Apply a small amount of blue Loctite (non-permanent) to the threads of the set plate bolt.
Page 177 K- XCT 300i 3. Engine > Camshaft Install the camshaft sprocket onto the camshaft so the camshaft sprocket boss fits into the appropriate hole on the camshaft sprocket. Make sure the camshaft sprocket boss is facing up so it is visible above the edge of the cylinder head as shown.
Page 178 K- XCT 300i 3. Engine > Camshaft Torque Thread Item kgf-m lb-ft size (mm) Cam sprocket bolt 1.0-1.4 7.23-10.13 Double check the engine timing. Use a small flat blade screwdriver bring in the cam chain tensioner rod. Turn the screwdriver counter clockwise to retract the rod. The rod must be held in with the screwdriver until the cam chain tensioner mounting bolts have been installed.
Page 179 K- XCT 300i 3. Engine > Camshaft Install the camchain tensioner with a new gasket. Insert the mounting bolts and tighten them evenly to specification with an 8 mm socket. Remove the screwdriver and release the camchain tensioner rod. Torque Thread Item kgf-m...
Page 180 K- XCT 300i 3. Engine > Camshaft Rotate the crankshaft 360° clockwise and check the engine timing one more time. Make sure the cam chain tensioner cap bolt O-ring is in good condition. Install the O-ring and cam chain tensioner cap bolt. Tighten the bolt to securely with a 10 mm socket.
Page 181 K- XCT 300i 3. Engine > Camshaft Make sure the O-rings on the crankshaft and timing plugs are in good condition. Replace them as needed. Install the timing inspection and crankshaft caps to the right side of the engine. Tighten the caps securely but not overly with a large flat blade screwdriver.
Page 182: Valves
K- XCT 300i 3. Engine > Valves Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the camshaft. See the Camshaft topic for more information. Remove the cylinder head. See the Cylinder Head topic for more information.
Page 183 K- XCT 300i 3. Engine > Valves Remove the split keepers. There are two per valve. Remove the spring retainer. Remove the valve springs. 3-39...
Page 184 K- XCT 300i 3. Engine > Valves Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head. Rotate the valve as it is removed. Remove the valve seal from the valve guide. The valve seals should be replaced if they are removed or you are going to install new valves.
Page 185 K- XCT 300i 3. Engine > Valves Remove the spring seat. Inspection Inspect the valve springs for fatigue and damage. Replace the valve springs as needed or if the valve is also to be replaced. 3-41...
Page 186 K- XCT 300i 3. Engine > Valves Inspect the valves for damage and burning. Measure the valve stem diameter in several places where the valve makes contact with the guide. If the measurement is below specification replace the valve. Item Standard (mm) 4.990 - 4.975 Valve stem O.D.
Page 187 K- XCT 300i 3. Engine > Valves be centered on the valve face. If the seat is pitted, worn out, or fits poorly on the valve face the valve seat must be resurfaced. Item Standard (mm) Valve seat width Measure the inside diameter of the valve guides. Replace the guides if the measurement is out of specification.
Page 188 K- XCT 300i 3. Engine > Valves Installation Clean the cylinder head components thoroughly with a high flash-point solvent and compressed air. Return the components to their original locations. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else. Install the spring seat.
Page 189 K- XCT 300i 3. Engine > Valves Coat the valve stem in fresh engine oil and insert the valve into the valve guide and through the seal. Turn the valve slowly as it is inserted. If you are installing a new valve you must ream the valve guide first. Make sure the valve will move smoothly in the valve guide without wobble.
Page 190 K- XCT 300i 3. Engine > Valves Place the spring retainer on top of the spring. Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers. The valve cotter installer tool can also be used to install the split keepers.
Page 191 K- XCT 300i 3. Engine > Valves Apply grease to the inside of the split keepers. Apply a dab of grease to the end of a flat blade screwdriver. Set the keeper in the grease on the screwdriver and insert it onto the valve stem. Repeat this with the other keeper.
Page 192: Cylinder And Piston
K- XCT 300i 3. Engine > Cylinders and Pistons Cylinders and Pistons SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Cylinder Block Removal Remove the engine from the frame. See the Engine Removal topic for more information. Remove the cylinder head cover.
Page 193 K- XCT 300i 3. Engine > Cylinders and Pistons Remove the two right side cylinder bolts with an 8 mm socket. Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver. Free the coolant hose from the cylinder. 3-49...
Page 194 K- XCT 300i 3. Engine > Cylinders and Pistons Slide the cylinder off of the studs and piston. Guide the cam chain through its opening and do not allow if to fall into the crankcase. Remove the cylinder. Remove the base gasket. 3-50...
Page 195 K- XCT 300i 3. Engine > Cylinders and Pistons Remove the two cylinder dowel pins from the left studs. Place a clean shop towel under and around the base of the piston to prevent any parts or debris falling into the crankcase. Remove the piston pin clips with a pick or needle nose pliers.
Page 196 K- XCT 300i 3. Engine > Cylinders and Pistons Clean off the cylinder mating surface, but take care to keep debris from falling into the crankcase. Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal. The rings can be easily damaged.
Page 197 K- XCT 300i 3. Engine > Cylinders and Pistons The two upper rings are each a single piece of metal. The oil ring consists of an expander ring and two side rails. Clean the carbon build up off of the piston with a stiff bristled plastic brush or rag.
Page 198 K- XCT 300i 3. Engine > Cylinders and Pistons Inspection The cylinder and piston must be replaced as a set. There are two sets of cylinder and piston combinations. Make sure to have a No.1 cylinder with an "A" piston or a No.2 cylinder with a "B" piston. Mark Piston O.D.
Page 199 K- XCT 300i 3. Engine > Cylinders and Pistons Measure the cylinder diameter as described below with a telescoping gauge. Inspect the cylinder front to back and side to side at three different height levels with a dial bore gauge. Item Standard (mm) Cylinder...
Page 200 K- XCT 300i 3. Engine > Cylinders and Pistons Item Limit (mm) Cylinder Taper 0.05 Calculate the cylinder out of round. The out of round is greatest out of yellow, purple, or brown minus the smallest of blue, red, or green. Item Limit (mm) Cylinder...
Page 201 K- XCT 300i 3. Engine > Cylinders and Pistons Measure the piston pin diameter with a micrometer. Measure the piston pin bore diameter with vernier calipers or a small bore gauge. Measure at three different points for each. Replace the parts if any of the specifications are not met.
Page 202 K- XCT 300i 3. Engine > Cylinders and Pistons Measure the ring groove width and the ring-to-groove clearance with feeler gauges. Item Standard mm 0.015 - 0.055 Piston ring-to-groove clearance 0.015 - 0.055 Insert the top ring into the cylinder. Push the top ring in the cylinder about an inch.
Page 203 K- XCT 300i 3. Engine > Cylinders and Pistons Measure the ring gap with a feeler gauge. Repeat this procedure with second ring and the oil side rails. Item Standard mm 0.10 - 0.25 Ring end gap Second 0.10 - 0.25 Oil side rail 0.2 - 0.7 Check the oil jet for clogs.
Page 204 K- XCT 300i 3. Engine > Cylinders and Pistons Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Do not try and force them on the piston. Install the top and second rings with their markings facing up.
Page 205 K- XCT 300i 3. Engine > Cylinders and Pistons Install the oil expander ring so that the ends are not overlapping. Install the steel rails above and below the oil ring. Lubricate the piston pin and the small end of the connecting rod with fresh engine oil.
Page 206 K- XCT 300i 3. Engine > Cylinders and Pistons Place the piston over the connecting rod. Insert the piston pin into the piston and rod. Install new piston pin clips securely into their grooves. Turn the gap in the clips away from the access gap. Make sure the cylinder head mating surface is clean.
Page 207 K- XCT 300i 3. Engine > Cylinders and Pistons Install the new base gasket onto the crankcase. 3-63...
Page 208 K- XCT 300i 3. Engine > Cylinders and Pistons Coat the inside of the cylinder, piston rings, and piston in fresh engine oil. Lower the cylinder over the studs and guide the piston into the cylinder while you are compressing the rings with your fingers. Be careful to not damage the rings during this step.
Page 209 K- XCT 300i 3. Engine > Cylinders and Pistons Install the cylinder head. See the Cylinder Head topic. Install the camshaft. See the Camshaft topic for more information. Install the cylinder head cover. See the Cylinder Head Cover topic for more information.
Page 210 K- XCT 300i 3. Engine > Generator A.C. Generator and Starter clutch SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Generator Cover Remove the following components - # Seat # Luggage Box # Center Cover # Rear Carrier # Body Cover # Front Cover # Front Lower Cover...
Page 211 K- XCT 300i 3. Engine > Generator Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container. Loosen the right crankcase coolant hose clamp with a #2 Phillips screwdriver.
Page 212 K- XCT 300i 3. Engine > Generator Remove the 12 generator cover bolts with an 8 mm socket. Note the upper most bolt holds a wire stay. Utilize the pry points and remove the generator cover. 3-68...
Page 213 K- XCT 300i 3. Engine > Generator Remove the generator cover gasket. Remove the two dowel pins. 3-69...
Page 214 K- XCT 300i 3. Engine > Generator Remove the two oil filter chamber O-rings. Inspect the O-rings and replace them as needed. Stator and Pulsar Coil/Crank Position Sensor Free the rubber wire grommet from the right crankcase cover. Remove the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket.
Page 215: Generator
K- XCT 300i 3. Engine > Generator Flywheel To remove the fly wheel two special tools are needed. ITEM TOOL NO. UNIVERSAL HOLDER E021 ITEM TOOL NO. FLYWHEEL PULLER E003 3-71...
Page 216 K- XCT 300i 3. Engine > Generator Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket. Remove the flywheel nut and washer. 3-72...
Page 217 K- XCT 300i 3. Engine > Generator Apply grease to the threads of the flywheel puller tool before using it. Thread the puller onto the flywheel. Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the crankshaft.
Page 218 K- XCT 300i 3. Engine > Generator Slide the starter driven gear off of the crankshaft. Remove the woodruff key from the crankshaft. 3-74...
Page 219 K- XCT 300i 3. Engine > Generator Starter Clutch Remove the starter idle gear and shaft from the crankcase. Inspect the starter idle gear and shaft for wear and damage. Replace the idle gear and shaft as needed. Inspect the starter driven gear for wear and damage. Measure the inside and outside diameter of the starter driven gear and replace it as needed.
Page 220 K- XCT 300i 3. Engine > Generator Item Service Limit (mm) Starter drive gear I.D. 22.15 Starter drive gear O.D. 41.50 Fit the boss of the starter driven gear into the starter clutch. The starter clutch should only allow the driven gear to turn in one direction. If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced.
Page 221 K- XCT 300i 3. Engine > Generator Tighten the starter clutch mounting bolts to specification with a 6 mm Allen socket. Torque Thread Item kgf-m lb-ft size (mm) Oneway clutch bolt 1.8-2.2 13.02-15.91 Lubricate the starter idle gear shaft with fresh engine oil. Install the starter idle gear and shaft into the crankcase.
Page 222 K- XCT 300i 3. Engine > Generator Flywheel Install the woodruff key into its slot on the end of the crankshaft. Lubricate the inside of the starter driven gear with fresh engine oil. Slide the starter driven gear onto the flywheel as shown. Clean off the tapered end of the crankshaft where the flywheel will ride and make sure the inside of the flywheel is oil free where it will contact the crankshaft.
Page 223 K- XCT 300i 3. Engine > Generator Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft. Guide the starter driven gear into the starter clutch on the back of the flywheel. Install the washer and flywheel nut. 3-79...
Page 224 K- XCT 300i 3. Engine > Generator Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket. Torque Thread Item kgf-m lb-ft size (mm) ACG flywheel nut 5.5-6.5 39.78-47.01 ITEM TOOL NO. UNIVERSAL HOLDER E021 3-80...
Page 225 K- XCT 300i 3. Engine > Generator Stator and Crank Position Sensor Fit the stator and the crankshaft position sensor into the generator cover together as shown. Insert the two crank position sensor mounting bolts and the three stator mounting bolts. Tighten the bolts securely with an 8 mm socket.
Page 226 K- XCT 300i 3. Engine > Generator Generator Cover Make sure the generator cover mating surface is clean. Install the two dowel pins and a new generator cover gasket. 3-82...
Page 227 K- XCT 300i 3. Engine > Generator Make sure the oil filter chamber O-rings are in place and in good condition. Fit the generator cover into place. Make sure the water pump shaft engages correctly with the oil pump shaft. 3-83...
Page 228 K- XCT 300i 3. Engine > Generator Insert the 12 generator cover bolts. Note the upper most bolt holds a wire stay. Tighten the bolts securely in a with an 8 mm socket. Fit the coolant hose to the right crankcase cover pipe. Secure the hose with the clamp and tighten the coolant hose clamp securely with a #2 Phillips screwdriver.
Page 229 K- XCT 300i 3. Engine > Generator Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver. Plug in the regulator/rectifier 3-pin connector. 3-85...
Page 230 K- XCT 300i 3. Engine > Generator Plug in the crank position sensor wire coupler on the right side of the frame. Fill the engine oil. See the Engine Oil topic for more information. Install the exhaust system. See the Exhaust System topic for more information. Fill the coolant and bleed the coolant.
Page 231: Oil Pump
K- XCT 300i 3. Engine > Oil Pump Oil Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 232 K- XCT 300i 3. Engine > Oil Pump The oil pump is driven by a chain off of the crankshaft. Loosen the two oil pump cover bolts with an 8 mm socket. 3-88...
Page 233 K- XCT 300i 3. Engine > Oil Pump Remove the two oil pump cover bolts and the oil pump cover. Remove the snap ring on the oil pump shaft with snap ring pliers. Remove the oil pump drive chain and driven sprocket. 3-89...
Page 234 K- XCT 300i 3. Engine > Oil Pump Inspect the oil pump drive chain and sprocket for signs of wear and damage. Replace the parts as needed. Remove the two oil pump screws with an impact #3 Phillips screwdriver. Remove the oil pump. 3-90...
Page 235 K- XCT 300i 3. Engine > Oil Pump Turn the oil pump shaft by hand and make sure it turns smoothly. If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit. Oil Pump Installation Fit the oil pump into place so that the arrow is pointing up.
Page 236 K- XCT 300i 3. Engine > Oil Pump Insert the two oil pump mounting screws and tighten them securely with an impact #3 Phillips screwdriver. Fit the oil pump driven sprocket into the drive chain. Install the gear onto the oil pump shaft and fit the chain onto its teeth on the crankshaft. Install a new snap ring into its groove with snap ring pliers.
Page 237 K- XCT 300i 3. Engine > Oil Pump Install the oil pump cover and its two mounting bolts. Tighten the two oil pump cover bolts securely with an 8 mm socket. Install the starter driven gear, flywheel, and the generator cover. See the Generator topic. Fill the engine oil.
Page 238: Crankcase
K- XCT 300i 3. Engine > Crankcase Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Splitting Drain the engine oil and remove the strainer screen. See the Engine Oil topic for more information. Remove the engine. See the Engine Removal topic for more information. Remove the cylinder head cover.
Page 239 K- XCT 300i 3. Engine > Crankcase Remove the upper cam chain guide. Inspect the cam chain guides for damage and excessive wear. Replace the guides as needed. 3-95...
Page 240 K- XCT 300i 3. Engine > Crankcase Remove the cam chain from the crankshaft and crankcase. Inspect the cam chain for wear and damage. Replace the cam chain as needed. There are 11 crankcase bolts. 3-96...
Page 241 K- XCT 300i 3. Engine > Crankcase Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm socket. Remove the crankcase bolts from the left side of the engine. Remove the plate with the bottom two crankcase bolts. 3-97...
Page 242 K- XCT 300i 3. Engine > Crankcase Set the crankcases on the right side. Separate the halves of the crankcase. If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet. Lift the right crankcase off of the left. 3-98...
Page 243 K- XCT 300i 3. Engine > Crankcase Remove the three dowel pins from the crankcase. Inspect the O-ring and replace it as needed. 3-99...
Page 244 K- XCT 300i 3. Engine > Crankcase To remove the crankshaft see the Crankshaft topic. Replace the left crankshaft seal if the crankcases are separated. Remove the seal with a seal pick. 3-100...
Page 245 K- XCT 300i 3. Engine > Crankcase Drive the new seal into the left crankcase from the outside with a suitable driver. The driver should have the same outside diameter as the seal. Lubricate the new crankshaft seal lips with fresh engine oil. Assembly Thoroughly clean the crankcase mating surface.
Page 246 K- XCT 300i 3. Engine > Crankcase Set the right case half down on top of the left. Install the engine mount spacer. Insert the 11 crankcase bolts. The plate goes on with the bottom two bolts. 3-102...
Page 247 K- XCT 300i 3. Engine > Crankcase Tighten the bolts securely and evenly in a crisscross pattern with an 8mm socket. Install the cam chain around the timing sprocket teeth on the crankshaft. 3-103...
Page 248 K- XCT 300i 3. Engine > Crankcase Fit the upper cam chain guide into place. Insert the upper cam chain guide mounting bolt and tighten it to specification with an 8 mm Allen socket. Thread Torque Item Size(mm) kgf-m lb-ft Cam chain tensioner pivot 0.8-1.2 5.79 - 8.68...
Page 249 K- XCT 300i 3. Engine > Crankcase Install the cylinder and piston. See the Cylinder and Piston topic for more information. Install the cylinder head. See the Cylinder Head topic. Install the camshaft. See the Camshaft topic for more information. Install the cylinder head cover.
Page 250 K- XCT 300i 3. Engine > Crankshaft Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Split the crankcases. See the Crankcase topic for more information. Lift the crankshaft out of the left crankcase half. 3-106...
Page 251 K- XCT 300i 3. Engine > Crankshaft Remove the thrust washer from the right side of the crankshaft. Crankshaft Inspection Check the side clearance of the big end of the connecting rod with a feeler gauge. 3-107...
Page 252 K- XCT 300i 3. Engine > Crankshaft Item Standard (mm) Service Limit (mm) Connecting rod big Crankshaft 0.15 - 0.35 end side clearance Grip the small end of the connecting rod and try and push the rod down towards the crank weights. If there is definite play between the connecting rod and crank the crankshaft should be replaced.
Page 253 K- XCT 300i 3. Engine > Crankshaft Crankshaft Bearings Inspect the crankshaft bearings for signs of damage and wear. Replace the bearings if they show any kind of imperfection. Note the bearing color code and crankcase code. The crank weights are also marked with a size code. Bearing Color Crankshaft mark Crankshaft mark...
Page 254 K- XCT 300i 3. Engine > Crankshaft Installation Place the thrust washer on the crankshaft as shown. Lubricate the connecting rod big end and crankshaft shaft bearings with fresh engine oil. Fit the crankshaft into the left crankcase bearing. Take care to avoid damaging the new oil seal.
Page 255: Engine Installation
K- XCT 300i 3. Engine > Engine Installation Engine Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Before the engine is returned to the install the rear wheel. See the Rear Wheel topic for more information. Set the chassis on its center stand.
Page 256 K- XCT 300i 3. Engine > Engine Installation Fit the engine mounting bracket and damper assembly into place. Install the two engine mounting bracket to frame mounting bolts and nuts. Insert the bolts from the outside of the frame. Insert the engine mounting bracket and damper bolt from the right side. Thread on the nut.
Page 257 K- XCT 300i 3. Engine > Engine Installation Install the engine mounting bracket damper washer and nut. Hold the engine mounting bolts with a 14 mm wrench and torque the nuts to specification with a 19 mm socket. Torque Thread Item Remarks size (mm)
Page 258 K- XCT 300i 3. Engine > Engine Installation Tighten the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt. Torque Thread Item Remarks size(mm) kgf-m lb-ft Engine hanger: Engine side 4.5-5.5 32.55-39.78...
Page 259 K- XCT 300i 3. Engine > Engine Installation Install the rear shock absorbers. See the Shock Absorbers topic for more information. Route the wiring harness through its guide above the intake pipe. Plug in the oil pressure switch bullet connector. Route the starter motor lead to the starter motor and secure it in the stay on the right crankcase cover.
Page 260 K- XCT 300i 3. Engine > Engine Installation Fit the starter motor cable lead onto the terminal and thread on the nut. Tighten the starter motor lead nut securely with a 10 mm wrench. Fit the rubber starter motor lead cover into place. 3-116...
Page 261 K- XCT 300i 3. Engine > Engine Installation Install the main engine ground to the right side of the engine. Tighten the main engine ground bolt securely with an 8 mm socket. Install air bleed hose and secure it with the clamp. Connect the coolant hose to the thermostat.
Page 262 K- XCT 300i 3. Engine > Engine Installation Fit the fuel stay into place. Tighten the stay bolt securely with an 8 mm socket. Plug in the thermo sensor unit and ground connectors. Plug in the water temperature sensor connector. 3-118...
Page 263 K- XCT 300i 3. Quick Reference > Specifications General Information Name & Model No. LKG7 Motorcycle Name & Type K-XCT300i Overall length (mm) 2145 Overall width (mm) Overall height (mm) 1290 Wheel base (mm) 1450 Engine type 4 stroke OHC Displacement (cc) 298.9 Fuel recommended...
Page 264 K- XCT 300i 3. Quick Reference > Specifications Type Ignition timing 8° - 12° BTDC Ignition System Electrical Spec CR7E (NGK) Equipment Spark plug 0.6-.7mm Battery Capacity 12V10AH Clutch Type Dry multi-clutch Transmission Gear Type Power Drive Operation Automatic centrifugal type System Type Two-stage reduction...
Page 265 K- XCT 300i 3. Quick Reference > Specifications Coolant capacity Radiator 766 cc Hose with cool coolant 169 cc Hose with hot coolant 194 cc Reserve tank 590 cc Total capacity 1719 cc Engine Item Standard (mm) 0.10 Valve clearance (cold) 0.10 Cylinder head compression pressure 16 kg/cm2, 228 psi...
Page 266 K- XCT 300i 3. Quick Reference > Specifications Item Standard (mm) Service Limit (mm) Connecting rod big end side clearance 0.15 - 0.35 Crankshaft Connecting rod big end radial clearance 0 - 0.008 0.05 Bearing Color Crankcase mark Crankshaft mark black green green...
Page 267 K- XCT 300i 3. Quick Reference > Specifications COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Mixing Distilled Coolant Concentrate Point Rate Water -9°C 344 cc 1375 cc -15°C 516 cc 1203 cc -25'°C 688 cc 1031 cc -37°C 860 cc 859 cc -44.5°C 945 cc...
Page 268 K- XCT 300i 3. Quick Reference > Specifications Fuel Injection System ITEM SPECIFICATIONS Throttle body identification number LKG7 Idle speed 1620 ± 100 rpm Throttle grip free play 2 - 6 mm (1/16 - 1/4 in) Fuel injector resistance (at 20°C/68°F) 11.7 ±...
Page 269 K- XCT 300i 3. Quick Reference > Specifications CELP FAILURE CODES LIST Symptoms Failure Codes Contents Causes • Faulty TPS voltage range (0.3 -4.5 V) Engine operates • Loose or poor connection on TPS Sensor P0120 Faulty TPS normally • Open or short circuit on the TP Swire •...
Page 270 K- XCT 300i 3. Quick Reference > Specifications Axle/Brakes/Wheels Item Standard mm (in) Service Limit Axle shaft run out – 0.2 mm(0.008 in) 0.3 mm(0.012 in) Brake disk thickness (front) 3.8 - 4.2(0.15 - 0.165) Brake disk thickness (rear) 5.0 (0.2 –...
Page 271 K- XCT 300i 3. Quick Reference > Specifications Item Standard Spark plug Standard type NGK CR7E Spark plug gap 0.6 - 0.7 mm Primary coil 3.57 - 4.83Ω Inductive Ignition Coil Secondary coil without plug cap 10.42 - 14.49 KΩ Throttle Position Sensor 3500 - 6500Ω...
Page 272 4. CVT Continuously Variable Transmission CVT Continuously Variable Transmission This chapter covers the location and servicing of the CVT components for the KYMCO K-XCT 300i. • Belt Case ..............4-2~4-11 • CVT Removal ............4-12~4-31 • CVT Installation ..............4-32 GENERAL INSTRUCTIONS •...
Page 273 K- XCT 300i 4. CVT Transmission > Belt Case Belt Case SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the following components - ◦ Seat ◦ Luggage Box ◦ Center Cover ◦ Rear Carrier ◦ Body Cover ◦...
Page 274 K- XCT 300i 4. CVT Transmission > Belt Case Remove the belt case plastic cover bolts with an 8 mm socket. Remove the belt case bodywork. Inspect the plastic belt case cover and replace it if it is damaged.
Page 275 K- XCT 300i 4. CVT Transmission > Belt Case Remove the belt case cover bolts with an 8 mm socket. Use the pry points to free the belt case cover.
Page 276 K- XCT 300i 4. CVT Transmission > Belt Case Remove the belt case cover and gasket. Remove the two dowel pins.
Page 277 K- XCT 300i 4. CVT Transmission > Belt Case Inspection Inspect the drive belt for cracks or excessive wear. Inspect the belt case bearing by turning it with a finger. Replace the bearing if it is rough or noisy.
Page 278 K- XCT 300i 4. CVT Transmission > Belt Case Remove the bearing snap ring with snap ring pliers. Remove the bearing with a suitable bearing puller. Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing.
Page 279 K- XCT 300i 4. CVT Transmission > Belt Case Install a new snap ring with snap ring pliers. Installation Install the two dowel pins into the belt case. Install a new gasket with the belt case cover.
Page 280 K- XCT 300i 4. CVT Transmission > Belt Case Install the belt case cover bolts and tighten them securely with an 8 mm socket.
Page 281 K- XCT 300i 4. CVT Transmission > Belt Case Install the belt case plastic cover. Insert the plastic cover bolts and tighten them securely with an 8 mm socket. 4-10...
Page 282 K- XCT 300i 4. CVT Transmission > Belt Case Fit the drain hose to the plastic belt case cover as shown. 4-11...
Page 283 K- XCT 300i 4. CVT Transmission > CVT Removal CVT Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the belt case. See the Belt Case topic for more information. Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen the nut with a 19 mm socket.
Page 284 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the left face of the drive pulley. Loosen the driven pulley nut with a 19 mm socket. 4-13...
Page 285 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the driven pulley nut and bushing. Slide the driven pulley off of the shaft. 4-14...
Page 286 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the belt from the driven pulley. Inspect the drive belt for cracks or excessive wear. 4-15...
Page 287 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the right (movable) face of the drive pulley from the crankshaft. Slide the bushing out of the movable drive face. Remove the washer from the crankshaft. 4-16...
Page 288 K- XCT 300i 4. CVT Transmission > CVT Removal Drive Pulley Disassembly Inspect the faces of the drive pulley. Clean away any grease from the faces. Lift the ramp plate out of the back of the left drive pulley face. Remove the rubber damper pieces from the ramp.
Page 289 K- XCT 300i 4. CVT Transmission > CVT Removal There are eight weight rollers in the back of the right face of the drive pulley. Remove the rollers and check them for excessive or uneven wear. Measure the outside diameter of the rollers. Replace the weight rollers as needed.
Page 290 K- XCT 300i 4. CVT Transmission > CVT Removal Inspect the movable drive face and bushing for wear and damage. Replace the parts as needed. Clutch Disassembly Lift the clutch outer off of the centrifugal clutch. Inspect the inside of the clutch outer for excessive wear and damage. Measure the inside diameter of the clutch outer and replace the part as needed.
Page 291 K- XCT 300i 4. CVT Transmission > CVT Removal Inspect the clutch shoe lining thickness. Replace the shoes if the wear is below the service limit. Item Standard (mm) Service Limit (mm) Clutch lining thickness To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch.
Page 292 K- XCT 300i 4. CVT Transmission > CVT Removal Use the clutch spring compressor tool to compress the spring in the driven pulley assembly. Loosen the clutch drive plate nut with the special socket that comes with the fitting tool. Remove the clutch drive plate nut.
Page 293 K- XCT 300i 4. CVT Transmission > CVT Removal Inspect the left side bearing by turning it with a finger. If the bearing is rough turning or noisy it should be replaced. Remove the clutch spring compressor tool. Lift off the centrifugal clutch. 4-22...
Page 294 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the collars and spring. Measure the free length of the clutch spring. Replace the spring if the measurement fails to meet the service limit. 4-23...
Page 295 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver. Lift off the plate. 4-24...
Page 296 K- XCT 300i 4. CVT Transmission > CVT Removal Slide the clutch shoes off of the pivots on the drive plate. Inspect the clutch shoe bumpers and replace them as needed. 4-25...
Page 297 K- XCT 300i 4. CVT Transmission > CVT Removal Driven Pulley Disassembly Remove the clutch as shown above. Remove the four guide rollers with guide roller pins. Separate the left and right faces of the driven pulley. 4-26...
Page 298 K- XCT 300i 4. CVT Transmission > CVT Removal Inspect the faces of the driven pulley. Clean away any grease from the faces where the belt rides. Remove the seals from the left face of the driven pulley. 4-27...
Page 299 K- XCT 300i 4. CVT Transmission > CVT Removal Drive in the new seals with a suitable driver with the same outside diameter as the seal. Remove the O-rings on the left face. Clean the left face and roller pins with a high flash point solvent and compressed air.
Page 300 K- XCT 300i 4. CVT Transmission > CVT Removal Bearing Replacement Inspect the bearings in the right face of the driven pulley. Remove the needle bearing with a suitable puller. 4-29...
Page 301 K- XCT 300i 4. CVT Transmission > CVT Removal Remove the collar, snap ring, and bearing from the right face of the driven pulley. Clean the right face with a high flash point solvent and compressed air. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 302 K- XCT 300i 4. CVT Transmission > CVT Removal Drive in the new baring so the sealed side face out towards the clutch. Install the snap ring into the groove. Install the collar and drive in the new needle bearing so that its markings face out. Drive in the bearings with a suitable driver with the same outside diameter as the bearing.
Page 303 4. CVT Transmission > CVT Installation K- XCT 300i CVT Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease. Drive in the new seals with a suitable driver with the same outside diameter as the seal.
Page 304 5. Final Drive K- XCT 300i Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO K-XCT 300i. • Final Reduction ..............5-2 • Final Drive Oil .............. 5-3~5-8 GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed.
Page 305 5. Final Drive > Final Reduction K- XCT 300i Final Reduction SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Disassembly Note: Do not remove the transmission case cover except for necessary part replacement. If the drive shaft is replaced, make sure to also replace the bearing and oil seal.
Page 306 5. Final Drive > Transmission Oil K- XCT 300i Final Drive Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Place the scooter on level ground and up on its center stand. The oil drain bolt and oil filler bolt are located on the transmission. Gear oil type: SAE 90 Gear oil capacity:...
Page 307 5. Final Drive > Transmission Oil K- XCT 300i Inspection Place the vehicle on its center stand on level ground. Remove the transmission oil level check bolt with a 12 mm socket. The oil level is correct when oil flows from the bolt hole. Install the oil level check bolt and tighten it to specification with a 12 mm socket.
Page 308 5. Final Drive > Transmission Oil K- XCT 300i If the level is too high allow the oil to flow out of the check hole until the level is even with the bolt hole. If the level is low add more of the same type and brand of oil as shown below.
Page 309 5. Final Drive > Transmission Oil K- XCT 300i Inspect the drain plug and washer. Install the oil drain plug and washer with a 12 mm socket. Tighten to specification.
Page 310 5. Final Drive > Transmission Oil K- XCT 300i Torqu Item Thread size (mm) kgf-m lb-ft Final Drive oil 0.8 - 1.2 5.79 - 8.68 check bolt Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole.
Page 311 5. Final Drive > Transmission Oil K- XCT 300i Thread in the final drive oil level check bolt. Install the oil check plug and torque it to specification with a 12 mm socket. Torque Item Thread size (mm) kgf-m lb-ft Final drive oil 0.8 - 1.2 5.79 - 8.68...
Page 312 6. Cooling System K- XCT 300i Cooling System This chapter covers the location and servicing of the cooling system components for the KYMCO K-XCT 300i. • Coolant ..............6-3~6-11 • Radiator .............. 6-12~6-29 • Thermostat ............6-30~6-40 • Water Pump ............6-41~6-49 GENERAL INSTRUCTIONS •...
Page 313 6. Cooling System K- XCT 300i Temperature gauge shows the wrong temperature • Faulty temperature gauge or sensor • Faulty thermostat Coolant leaks • Faulty pump mechanical (water) seal • Deteriorated O-rings • Damaged or deteriorated water hoses 6‐2 ...
Page 314 6. Cooling System > Coolant K- XCT 300i Coolant SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. To check the coolant level, see the Coolant Level Check topic for more information. Draining SAFETY FIRST: Antifreeze is highly toxic and can kill pets and animals if drank.
Page 315 6. Cooling System > Coolant K- XCT 300i Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it. The water pump is located on the right side of the engine. Ready a drain pan under the water pump drain bolt.
Page 316 6. Cooling System > Coolant K- XCT 300i Remove the drain bolt and sealing washer and allow the coolant to drain into a suitable container. The coolant reserve tank is under the inner cover. Remove the engine coolant lid screw with a #2 Phillips. Remove the engine coolant lid.
Page 317 6. Cooling System > Coolant K- XCT 300i Open the coolant reserve tank lid. Siphon the coolant out of the reserve tank with an appropriate suction device. If a suction device is unavailable remove the reserve tank and poor it out. See the Radiator topic for more information.
Page 318 + 859cc distilled water is 50%.) • Do not mix coolant concentrate of different brands. • Do not drink the coolant, which is poisonous. COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS KYMCO SIGMA Coolant Freezing Point Mixing Rate Distilled Water Concentrate -9°C...
Page 319 6. Cooling System > Coolant K- XCT 300i Fill the cooling system with a mix of distilled water and Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown. Add coolant to the reserve tank until it reaches the upper level mark.
Page 320 6. Cooling System > Coolant K- XCT 300i Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes. This will purge any air out of the cooling system. Check for coolant leaks When the air bubbles stop coming up turn off the engine and recheck the coolant level, add coolant if necessary.
Page 321 6. Cooling System > Coolant K- XCT 300i Install the engine coolant reserve tank cover. Insert the screw and tighten its securely with a #2 Phillips. Install the radiator cap access panel. 6-10...
Page 322 6. Cooling System > Coolant K- XCT 300i Install the radiator coolant panel screws and tighten securely with a #2 Phillips screwdriver. 6-11...
Page 323 K- XCT 300i 6. Cooling System > Radiator Radiator SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. Pressure Testing Remove the radiator coolant panel screws with a #2 Phillips screwdriver.
Page 324 K- XCT 300i 6. Cooling System > Radiator Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it. When checking the cooling system for leaks you will need a pressure tester.
Page 325 K- XCT 300i 6. Cooling System > Radiator Wet the seal on the radiator cap and install it to the pressure tester. Replace the cap if it does not relieve the pressure as specified. Radiator cap relief pressure 0.9 ± 0.15 kg/cm (12.8 ±...
Page 326 K- XCT 300i 6. Cooling System > Radiator Unplug the cooling fan motor connector. There are three coolant hoses that connect to the radiator. The top right hose runs to the filler neck and cap. The top left hose runs to the thermostat on the cylinder head.
Page 327 K- XCT 300i 6. Cooling System > Radiator Loosen the coolant hose clamps with a #2 Phillips screwdriver. Free the filler neck coolant hose from the stay and remove it from the radiator. Remove the water pump and thermostat hoses in the same manner. 6-16...
Page 328 K- XCT 300i 6. Cooling System > Radiator Remove the two radiator mounting bolts with a 10 mm socket. Slide the radiator to the left and free the grommet from the post above the right side of the radiator. 6-17...
Page 329 K- XCT 300i 6. Cooling System > Radiator Remove the radiator from the frame. Coolant Reserve Tank The coolant reserve tank is mounting to the frame with two bolts. There are two hoses that connect to the reserve tank. The top hose is a dump hose that hangs over the other side.
Page 330 K- XCT 300i 6. Cooling System > Radiator Position a suitable container below the reserve tank. Pull back the clamp and free the overflow hose from the bottom of the reserve tank. Allow the coolant in the reserve tank to drain into the container.
Page 331 K- XCT 300i 6. Cooling System > Radiator Remove the two reserve tank mounting bolts with a 10 mm socket. Remove the reserve tank from the frame. 6-20...
Page 332 K- XCT 300i 6. Cooling System > Radiator To remove the reserve tank bracket take off the mounting nuts with a 10 mm socket. 6-21...
Page 333 K- XCT 300i 6. Cooling System > Radiator Remove the reserve tank bracket from the studs on the frame. Inspection Inspect the radiator fins for damage and clogging. To remove the fan take out the three mounting bolts with a 10 mm socket. 6-22...
Page 334 K- XCT 300i 6. Cooling System > Radiator Clean out the fins with low pressure compressed air and water. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else. Check the radiator for any bent or damaged fins. Use a small flat blade screwdriver to straighten them out, but be careful not to puncture the radiator.
Page 335 K- XCT 300i 6. Cooling System > Radiator If the thermostatic switch needs to be removed use a 22 mm wrench. The thermostatic switch should be off below 85°C (185°F) and on above 90°C (194°F). Installation Coolant Reserve Tank Fit the coolant reserve tank bracket to the studs on the left side of the frame.
Page 336 K- XCT 300i 6. Cooling System > Radiator Install the two reserve tank mounting nuts and tighten them securely with a 10 mm socket. Fit the reserve tank to its bracket. Insert the two reserve tank mounting bolts and tighten them securely with a 10 mm socket.
Page 337 K- XCT 300i 6. Cooling System > Radiator Connect the dump hose to the top of the reserve tank and the overflow hose to the bottom. Secure the hoses with the clamps. Radiator 6-26...
Page 338 K- XCT 300i 6. Cooling System > Radiator Fit the radiator into place so that the post on the frame fits into the rubber grommet on the right side of the radiator. Install the two radiator mounting bolts and tighten them securely with a 10 mm socket.
Page 339 K- XCT 300i 6. Cooling System > Radiator Route the filler neck coolant hose through the guide to the top right of the radiator. Connect the coolant hose from the thermostat on the cylinder head to the top left of the radiator. Connect the coolant hose from the water pump to the bottom right of the radiator.
Page 340 K- XCT 300i 6. Cooling System > Radiator Plug in the cooling fan motor connector. Plug in the thermostatic switch connectors. 6-29...
Page 341 K- XCT 300i 6. Cooling System > Thermostat Thermostat and Thermosensor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Thermosensor Unplug the thermosensor unit and thermo unit ground connectors. Remove the thermosensor unit with a 12 mm deep well socket 6-30...
Page 342 K- XCT 300i 6. Cooling System > Thermostat Water Temperature Sensor (WTS) Unplug the water temperature sensor. Use a 17 mm wrench to remove the water temperature sensor. 6-31...
Page 343 K- XCT 300i 6. Cooling System > Thermostat Discard the WTS O-ring and replace it with a new item. Thermostat Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the thermostat. Squeeze the air bleed hose clamp with needle nose pliers and slide back the clamp.
Page 344 K- XCT 300i 6. Cooling System > Thermostat Remove the two thermostat mounting bolts with an impact #3 Phillips screwdriver. 6-33...
Page 345 K- XCT 300i 6. Cooling System > Thermostat Lift off the thermostat cover. Lift out the thermostat. Remove the thermostat O-ring and discard it. 6-34...
Page 346: Specifications
K- XCT 300i 6. Cooling System > Thermostat Inspection Thermosensor Set a digital multimeter to read ohms of resistance ( ) Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up. Do not allow the thermosensor or the thermometer to contact the sides of the pan.
Page 347 K- XCT 300i 6. Cooling System > Thermostat Thermostat The thermostat should be closed at room temperature. Suspend the thermostat and a thermometer in a pot of water with string. Make sure the thermostat and the thermometer are not touching the pot. Bring the temperature up to the specification slowly and check the operation of the thermostat.
Page 348 K- XCT 300i 6. Cooling System > Thermostat Installation Thermosensor Tighten the thermosensor unit securely with a 12 mm deep well socket Plug in the thermosensor unit and ground connectors. 6-37...
Page 349 K- XCT 300i 6. Cooling System > Thermostat Water Temperature Sensor Install the WTS with a new O-ring. Tighten the WTS to specification with a 17 mm wrench. Plug in the water temperature sensor connector. 6-38...
Page 350 K- XCT 300i 6. Cooling System > Thermostat Thermostat Make sure the thermostat seal is in good condition. Replace the thermostat if needed. Apply a light coat of waterproof grease to the thermostat seal. Insert the thermostat into its cavity in the cylinder head. Fit the thermostat cover into place.
Page 351 K- XCT 300i 6. Cooling System > Thermostat Insert the two thermostat bolts and tighten them securely with an impact #3 Phillips screwdriver. Install air bleed hose and secure it with the clamp. Connect the coolant hose to the thermostat. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 352 K- XCT 300i 6. Cooling System > Water Pump Water Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Mechanical Seal Inspection Inspect the telltale hole in the generator cover below the water pump for signs of coolant leaking. If there is coolant coming from this hole the mechanical seal is compromised and must be replaced.
Page 353 K- XCT 300i 6. Cooling System > Water Pump Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container. Loosen the four water pump cover bolts with an 8 mm socket.
Page 354 K- XCT 300i 6. Cooling System > Water Pump Remove the two dowel pins and the water pump cover gasket. Impeller and Shaft Hold the water pump shaft and loosen the impeller with a 12 mm socket. The impeller has left hand threads. Remove the impeller.
Page 355 K- XCT 300i 6. Cooling System > Water Pump Remove the seal washer from the back of the impeller. Inspect the impeller blades and seal. Replace the seal washer if the mechanical seal is to be replaced. Remove the water pump shaft from the generator cover. 6-44...
Page 356 K- XCT 300i 6. Cooling System > Water Pump To replace the mechanical and oil seals drive them out from the inside of the generator cover. Assembly Seals, Shaft, and Impeller Coat the lips of the new oil seal in fresh engine oil and drive it in with a suitable drive that is the same outside diameter as the oil seal.
Page 357 K- XCT 300i 6. Cooling System > Water Pump Place the washer and thrust washer on the water pump shaft. Install a new snap ring onto the water pump shaft if the snap ring was removed. Lubricate the water pump shaft with fresh engine oil where it will ride in the case.
Page 358 K- XCT 300i 6. Cooling System > Water Pump Install a new washer into the back of the impeller if the mechanical seal was replaced. Install the impeller to the water pump shaft. Note: Left hand threads. 6-47...
Page 359 K- XCT 300i 6. Cooling System > Water Pump Hold the water pump shaft and tighten the impeller to specification with a 12 mm socket. Remember the impeller has left hand threads. Torque Thread Item kgf-m lb-ft size (mm) Water pump impeller 1.0-1.4 7.23-10.13 Make sure the water pump cover mating surface is clean.
Page 360 K- XCT 300i 6. Cooling System > Water Pump Install the water pump cover and insert the four bolts. Tighten the water pump cover bolts to specification with an 8 mm socket. Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 361 K- XCT 300i Fuel Injection System This chapter covers the location and servicing of the fuel system components for the KYMCO K-XCT 300i. • Air box ................7-2~7-8 • Fuel Tank ..............7-9~7-12 • Fuel Pump and Fuel Level Gauge ......7-13~7-22 •...
Page 362: Air Box
7. Fuel System> Air box K- XCT 300i Air box SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the air box connecting hose clamp screw at the throttle body with a #2 Phillips. Remove the breather hose from the air box.
Page 363 7. Fuel System> Air box K- XCT 300i Disconnect the transmission vent hose.
Page 364 7. Fuel System> Air box K- XCT 300i Remove the two rear air box screws with an 8 mm socket. Remove the two front air box screws with an 8 mm socket.
Page 365 7. Fuel System> Air box K- XCT 300i Remove the air box. Installation Fit the air box into the frame and guide the boot over the mouth of the throttle body.
Page 366 7. Fuel System> Air box K- XCT 300i Tighten the air box connecting hose clamp screw at the throttle body with a Phillips.
Page 367 7. Fuel System> Air box K- XCT 300i Install the two front air box screws and tighten securely with an 8 mm socket. Install the two rear air box screws and tighten securely with an 8 mm socket.
Page 368 7. Fuel System> Air box K- XCT 300i Connect the transmission vent hose. Connect the breather hose to the air box.
Page 369: Fuel Tank
7. Fuel System> Fuel Tank K- XCT 300i Fuel Tank SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Removal In order to drain the fuel from the fuel pipe and release the fuel pressure unplug the fuel pump connecter.
Page 370 7. Fuel System> Fuel Tank K- XCT 300i Remove the fuel tank mounting nuts and brackets. Remove the fuel tank from the bottom of the frame. 7-10...
Page 371 7. Fuel System> Fuel Tank K- XCT 300i Installation Fit the fuel tank into place. Install the brackets and nuts. Tighten the nuts securely Connect the fuel hose to the outlet pipe on the fuel pump. Tighten the clamp securely with a #2 Phillips screwdriver. 7-11...
Page 372 7. Fuel System> Fuel Tank K- XCT 300i Plug in the fuel pump connecter. 7-12...
Page 373 7. Fuel System> Fuel Pump K- XCT 300i Fuel Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Input Voltage Inspection Turn the ignition switch off.
Page 374 7. Fuel System> Fuel Pump K- XCT 300i Set the engine stop switch to the “RUN” position. Unplug the fuel pump connecter. Set the multi meter to read battery voltage. Touch the multi meter leads to the harness side of the fuel pump connector, with the positive lead touching the red/black wire terminal and the negative lead touching the green wire terminal.
Page 375 7. Fuel System> Fuel Pump K- XCT 300i Removal In order to drain the fuel from the fuel pipe and release the fuel pressure unplug the fuel pump connecter. Start the engine and let it run until it dies of fuel starvation. Turn the ignition switch off. Loosen the fuel hose clamp with a #2 Phillips screwdriver.
Page 376 7. Fuel System> Fuel Pump K- XCT 300i Lift the fuel pump out of the tank. Discard the fuel pump O-ring, and replace it with a new item on assembly. 7-16...
Page 377 7. Fuel System> Fuel Pump K- XCT 300i Fuel Level Gauge Inspection Using a digital multi meter set to ohms of resistance (Ω), measure the resistance between the fuel pump/level gauge connector terminals (green and yellow/white) with the float raised to the positions indicted below.
Page 378 7. Fuel System> Fuel Pump K- XCT 300i Fuel Level Float Position Resistance 1100 ± 33 Ω Full 100 ± 3 Ω Empty Replace the fuel level float unit with a new part if the resistance is out of specification. 7-18...
Page 379 7. Fuel System> Fuel Pump K- XCT 300i Fuel Output Pressure Turn the key to the OFF position. Use a fuel hose clamp as shown. Disconnect the fuel hose from the fuel injector. Connect the fuel pressure gauge. Remove the fuel hose clamp. Turn the key to the ON position.
Page 380 7. Fuel System> Fuel Pump K- XCT 300i Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose. Return the fuel line to the injector. To inspect the fuel pump relay see the Relays topic. Fuel Pump Relay See the Relay topic.
Page 381 7. Fuel System> Fuel Pump K- XCT 300i Carefully insert the fuel pump into the tank. Avoid damaging the fuel pump wire. The fuel delivery pipe should face to the rear. Insert the 6 fuel pump mounting bolts. Tighten the bolts to specification with a 7 mm socket or #2 Phillips screwdriver.
Page 382 7. Fuel System> Fuel Pump K- XCT 300i Connect the fuel hose to the outlet pipe on the fuel pump. Tighten the clamp securely with a #2 Phillips screwdriver. Plug in the fuel pump connecter. 7-22...
Page 383: Throttle Body Removal And Installation
● Do not damage the throttle body, it may cause the throttle and idle valve to fail synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it incorrectly. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
Page 384 7. Fuel System> Throttle Body Removal K- XCT 300i Measure if the ECU voltage outputs to the MAP between the following terminals of the MAP connector. Terminal Normal Violet/Red (+) – Green/Pink (-) TPS Inspection Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”.
Page 385 7. Fuel System> Throttle Body Removal K- XCT 300i Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal Violet/Red (+) – Green/Pink (-) Throttle Position Sensor (TPS) 3500 - 6500 Ω resistance (at 20°C/68°F) 7-25...
Page 386 7. Fuel System> Throttle Body Removal K- XCT 300i Removal Throttle Cables Free the throttle cables from the throttle drum. 7-26...
Page 387 7. Fuel System> Throttle Body Removal K- XCT 300i Fuel Injector SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Disconnect the Fuel Pump Relay or Fuel Pump Connector. In order to release fuel pressure from the fuel pipe when removing the fuel injector, unplug the fuel pump connecter.
Page 388 7. Fuel System> Throttle Body Removal K- XCT 300i Remove the fuel injector mounting bolt with a 10 mm socket. Unplug the fuel injector connector. 7-28...
Page 389 7. Fuel System> Throttle Body Removal K- XCT 300i Lift the fuel injector out of the intake pipe. Loosen the fuel hose clamp with a #2 Phillips screwdriver. Slide back the clamp and free the injector fuel pipe from the fuel hose. 7-29...
Page 390 7. Fuel System> Throttle Body Removal K- XCT 300i Lift the fuel pipe off the top of the injector. Sensors Unplug the MAP sensor. 7-30...
Page 391 7. Fuel System> Throttle Body Removal K- XCT 300i Unplug the ISC connector. Throttle Body Unplug the throttle position sensor (TPS) connector. 7-31...
Page 392 7. Fuel System> Throttle Body Removal K- XCT 300i Loosen the air box hose clamp screw at the throttle body with a #2 Phillips. Loosen the intake hose clamp screw at the throttle body with a flat blade screwdriver. Remove the throttle out of the air box and intake boots. 7-32...
Page 393 7. Fuel System> Throttle Body Removal K- XCT 300i Installation Throttle Body Fit the throttle body into the air box and intake boots. Tighten the intake hose clamp securely with a flat blade screwdriver. 7-33...
Page 394 7. Fuel System> Throttle Body Removal K- XCT 300i Throttle Cables Connect the throttle cables to the throttle drum. Adjust the throttle cable free play with 12 mm wrenches. 7-34...
Page 395 7. Fuel System> Throttle Body Removal K- XCT 300i Sensors Plug in the TPS connector. Plug in the ISC connector. 7-35...
Page 396 7. Fuel System> Throttle Body Removal K- XCT 300i Plug in the MAP sensor. Fuel Injector Apply a light coat of fresh engine oil to a new fuel injector O-ring. 7-36...
Page 397 7. Fuel System> Throttle Body Removal K- XCT 300i Fit the fuel injector pipe onto the top of the injector. The tab on the injector must fit into the pipe. Fit the fuel hose onto the fuel injector pipe. Secure the hose to the fuel injector with the clamp.
Page 398 7. Fuel System> Throttle Body Removal K- XCT 300i Fit the injector into the intake pipe as shown. Plug in the fuel injector connector and thread in the mounting bolt. 7-38...
Page 399 7. Fuel System> Throttle Body Removal K- XCT 300i Tighten the fuel injector bolt securely with a 10 mm socket. Connect the Fuel Pump Relay or Fuel Pump Connector. The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU have been reinstalled.
Page 400: Throttle Body
7. Fuel System> Throttle Body K- XCT 300i Throttle Body SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the throttle body. See the Throttle Body Removal topic for more information. Disassembly The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU have been reinstalled.
Page 401: Fuel Injector
7. Fuel System > Fuel Injector K- XCT 300i Fuel Injector SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Removal In order to release fuel pressure from the fuel pipe when removing the fuel injector, unplug the fuel pump connecter.
Page 402 7. Fuel System > Fuel Injector K- XCT 300i Remove the fuel injector mounting bolt with a 10 mm socket. Unplug the fuel injector connector. 7-42...
Page 403 7. Fuel System > Fuel Injector K- XCT 300i Lift the fuel injector out of the intake pipe. Loosen the fuel hose clamp with a #2 Phillips screwdriver. Slide back the clamp and free the injector fuel pipe from the fuel hose. 7-43...
Page 404 7. Fuel System > Fuel Injector K- XCT 300i Lift the fuel pipe off the top of the injector. Inspection A digital multi meter is needed to test the fuel injector. Measure the resistance between the fuel injector terminals ITEM SPECIFICATIONS 11.7 ±...
Page 405 7. Fuel System > Fuel Injector K- XCT 300i Inspect the seals on both sides of the fuel injector. Replace the injector if the seals are in poor condition. Check for signs of clogging. Set the multi meter to read ohms of resistance (Ω). Cleaning PROBLEM 1.
Page 406 7. Fuel System > Fuel Injector K- XCT 300i 7-46...
Page 407 7. Fuel System > Fuel Injector K- XCT 300i Installation Apply a light coat of fresh engine oil to the fuel injector O-ring seals. Fit the fuel injector pipe onto the top of the injector. The tab on the injector must fit into the pipe. 7-47...
Page 408 7. Fuel System > Fuel Injector K- XCT 300i Fit the fuel hose onto the fuel injector pipe. Secure the hose to the fuel injector with the clamp. Tighten the clamp securely with a #2 Phillips screwdriver. Fit the injector into the intake pipe as shown. Plug in the fuel injector connector and thread in the mounting bolt.
Page 409 7. Fuel System > Fuel Injector K- XCT 300i Tighten the fuel injector bolt securely with a 10 mm socket. Plug in the fuel pump connector. 7-49...
Page 410: Self-Diagnosis
7. Electrical System > Self-Diagnosis K- XCT 300i Self-Diagnosis SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: No matter when the CELP illuminated while riding condition, should find out the cause of the problem as soon as possible. The check engine lamp (CELP) or Fi indicator is located next to the battery warning indicator.
Page 411 7. Electrical System > Self-Diagnosis K- XCT 300i Without Diagnostic Special Tool SELF-DIAGNOSTIC PROCEDURES The “CELP” denotes the failure codes. When the indicator lights for one second is equal to ten. For example: one longer blink illumination and two shorter blinks (0.5 second x 2) of the indicator are equal to 12 blinks.
Page 412 SAFETY FIRST: Protective gloves and eyewear are recommended at this point. OPERATION INSTRUCTIONS Diagnostic tool Part Number: 3620A-LEB2-E00 This tool has been developed by KYMCO and for KYMCO vehicles only. The tool software can be updated for new models with a computer via the USB cable.
Page 413: Throttle Cable
7. Fuel System> Throttle Cable K- XCT 300i Throttle Cable SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Adjust the throttle cables for maximum free play at the throttle body. Free the throttle cables from the throttle drum. 7-53...
Page 414 7. Fuel System> Throttle Cable K- XCT 300i Remove the two right switch housing mounting screws with a #2 Phillips screwdriver. Disconnect the switch. Separate the switch housing from the handlebar. Disconnect the throttle cables and free the right switch housing from the handlebar.
Page 415 7. Fuel System> Throttle Cable K- XCT 300i Guide the throttle cables out towards the handlebar side. Installation Route the throttle body end of the cables through the opening in the lower handlebar cover. 7-55...
Page 416 7. Fuel System> Throttle Cable K- XCT 300i Route the cables through the guide. Route the cables down the inside of the left side of the frame. 7-56...
Page 417 7. Fuel System> Throttle Cable K- XCT 300i Route the cables to the throttle body as shown. 7-57...
Page 418 7. Fuel System> Throttle Cable K- XCT 300i Connect the throttle cables to the throttle drum. Slide the throttle grip onto the right side of the handlebar. Install the right switch and throttle housing. The post on the housing should fit into the hole in the bar. 7-58...
Page 419 7. Fuel System> Throttle Cable K- XCT 300i Lubricate the end of the throttle in grease. Fit the ends of the throttle cables into the throttle tube. Adjust the throttle cable free play with 12 mm wrenches. 7-59...
Page 420: Tps Isc Reset Procedure
7. Fuel System> TPS ISC Reset Procedure K- XCT 300i TPS ISC Reset Procedure SAFETY FIRST: Protective gloves and eyewear are recommended at this point. ● When opening and closing the throttle grip randomly, the ECU may record the incorrect TPS reading when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.
Page 421 K- XCT 300i Steering This chapter covers the location and servicing of the steering components for the KYMCO K-XCT 300i. • Steering Stem and Bearing Removal ............... 8-2~8-8 • Steering Stem and Bearing Installation ............8-9~8-14 • Handlebar ..................... 8-15~8-25...
Page 422 If the movement is to tight or loose the steering stem adjusting nut may need to be adjusted. The KYMCO K-XCT 300i uses ball bearings in the steering. Always replace the races at the same time as the bearings.
Page 423 8. Steering > Removal K- XCT 300i A special lock nut wrench is needed to loosen the steering stem lock nut. Special Tool - Lock Nut Wrench: A120F00002...
Page 424 8. Steering > Removal K- XCT 300i Slide the special tool over the steering stem and loosen the lock nut. Remove the steering stem lock nut. Slide off the lock washer. Support the steering stem and loosen the steering stem adjusting nut with a pin spanner.
Page 425 8. Steering > Removal K- XCT 300i Remove the steering stem adjusting nut. Remove the dust cover and grease seal. Lower the steering stem out of the frame.
Page 426 8. Steering > Removal K- XCT 300i Remove the upper bearing inner race. Lift out the upper ball bearings. Slide the lower ball bearings up and off of the steering stem. Inspect the bearings and races for wear and damage. Replace them as needed.
Page 427 8. Steering > Removal K- XCT 300i Use a chisel to remove the bottom bearing inner race and dust seal. Do not damage the steering stem. Use the special tools or a drift and hammer to drive out the bearing races in the steering head.
Page 428 8. Steering > Removal K- XCT 300i Have the drift set against the lip of the race, and work around the race evenly to drive it out. Repeat the process with the remaining bearing race.
Page 429 8. Steering > Installation K- XCT 300i Steering Stem Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Coat the new dust seal in grease and slide it down the steering stem. Drive the new lower bearing inner race onto the steering stem with a pipe with the same outside diameter as the bearing race.
Page 430 8. Steering > Installation K- XCT 300i Lubricate the upper bearing with grease and set it into place. Lubricate the new lower bearing with grease and place it on the steering stem. 8-10...
Page 431 8. Steering > Installation K- XCT 300i Set the upper bearing inner race into the upper bearing. Guide the steering stem into the steering head of the frame. 8-11...
Page 432 8. Steering > Installation K- XCT 300i Lubricate the grease seal with grease. Set the grease seal and dust cover into place over the steering stem. Thread on the steering stem adjusting nut. 8-12...
Page 433 8. Steering > Installation K- XCT 300i Tighten the steering stem adjusting nut. Turn the steering stem lock-to- lock several times to seat the bearings. Loosen the adjusting nut 1/4 to 1/2 half turn. Adjust the nut so the steering moves correctly. The adjusting nut should be tight enough so that the steering doesn't flop back and forth and vertical movement is eliminated.
Page 434 8. Steering > Installation K- XCT 300i Thread the steering stem lock nut onto the steering stem. Torque the steering stem lock nut to specification with the lock nut wrench special tool. Torque Item Thread size (mm) kgf-m lb-ft Steering Stem lock nut 6.0-8.0 43.40-57.86 Special Tool - Lock Nut Wrench: A120F00002...
Page 435 8. Steering > Handlebar K- XCT 300i Handlebar SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Bar Ends Remove the bar ends with a 6 mm Allen. To remove the brake master cylinders see the. Brake Master Cylinder topic.
Page 436 8. Steering > Handlebar K- XCT 300i Separate the switch housing from the handlebar. Disconnect the throttle cables and free the right switch housing from the handlebar. Slide off the throttle grip. 8-16...
Page 437 8. Steering > Handlebar K- XCT 300i Remove the two left switch housing mounting screws with a #2 Phillips screwdriver. Disconnect the switch. Separate the left switch housing from the handlebar. 8-17...
Page 438 8. Steering > Handlebar K- XCT 300i Handlebar Route the cables and lines from the handlebar cable guide. Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut with a 17 mm socket. 8-18...
Page 439 8. Steering > Handlebar K- XCT 300i Remove the handlebar lock nut and bolt. Remove the handlebar. 8-19...
Page 440 8. Steering > Handlebar K- XCT 300i Grips If you plan to replace the grips you can slice them lengthwise with a razor blade and peel them off. To remove the grips without cutting them use a screwdriver to open a gap between the grip and the handlebar.
Page 441 8. Steering > Handlebar K- XCT 300i Installation Handlebar Install the handlebar onto the steering stem and align the holes. Install the handlebar lock bolt and thread on the nut. 8-21...
Page 442 8. Steering > Handlebar K- XCT 300i Hold the handlebar lock bolt with a 14 mm wrench and tighten the nut to specification with a 17 mm socket. lorque Item lb-ft Handlebar Lock Nut Route the cables and lines through the handlebar cable guide. 8-22...
Page 443 8. Steering > Handlebar K- XCT 300i Switch Housings and Throttle Align the left switch housing and install on the handlebar. Insert the two housing screws and tighten them securely with a #2 Phillips screwdriver. Connect the switch. 8-23...
Page 444 8. Steering > Handlebar K- XCT 300i Slide the throttle grip onto the right side of the handlebar. Install the right switch and throttle housing. The post on the housing should fit into the hole in the bar. Lubricate the end of the throttle in grease. Fit the ends of the throttle cables into the throttle tube.
Page 445 8. Steering > Handlebar K- XCT 300i Insert the two housing screws and tighten them securely with a #2 Phillips screwdriver. Tighten the front bolt before the rear. Bar Ends Install the bar ends with a 6 mm Allen. 8-25...
Page 446 9. Brakes K- XCT 300i Brakes This chapter covers the location and servicing of the brake system components for the KYMCO Downtown 300i. • Master Cylinders ............9-2~9-16 • Front Caliper ............9-17~9-26 • Rear Caliper ............9-27~9-33 • Brake Discs ............. 9-34~9-42 •...
Page 447 8. Brakes > Master Cylinders K- XCT 300i Master Cylinders SAFETY FIRST: Protective gloves and eyewear are recommended at this point. NOTE: Brake fluid is a corrosive chemical and can damage paints and some plastics. Avoid contact with skin. Removal Remove the brake hose banjo bolt from the master cylinder using a 12 mm socket.
Page 448 8. Brakes > Master Cylinders K- XCT 300i Unplug the brake light switch connector. Remove the two master cylinder mounting bolts with an 8 mm socket. Remove the master cylinder clamp.
Page 449 8. Brakes > Master Cylinders K- XCT 300i Remove the master cylinder. Remove the two master cylinder cover screws with a #2 Phillips head screwdriver.
Page 450 8. Brakes > Master Cylinders K- XCT 300i Remove the master cylinder cover, plastic piece and rubber accordion diaphragm. Pour out any remaining brake fluid.
Page 451 8. Brakes > Master Cylinders K- XCT 300i Disassembly Brake Levers Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt with a flat blade screwdriver. Remove the pivot nut and bolt.
Page 452 8. Brakes > Master Cylinders K- XCT 300i Remove the brake lever. Brake Light Switch Remove the brake light switch mounting bolt with a #2 Phillips screwdriver. Remove the brake light switch.
Page 453 8. Brakes > Master Cylinders K- XCT 300i Piston Remove the rubber piston cover. Remove the snap ring using a pair of internal snap ring pliers. Use a suitable tool to hold back the piston as it can spring out.
Page 454 8. Brakes > Master Cylinders K- XCT 300i Remove the piston, spring and cups. Remove the spring from the piston and...
Page 455 8. Brakes > Master Cylinders K- XCT 300i Inspection Clean the master cylinder components with fresh brake fluid. Inspect the master cylinder components for wear and damage. Replace the parts as needed Inspect the piston and cups for wear and damage. Measure the outside diameter of the piston.
Page 456 8. Brakes > Master Cylinders K- XCT 300i Inspect the master cylinder bore for wear and damage. Measure the inside diameter of the brake master cylinder. Item Standard mm (in) Brake master cylinder I.D. 12.7 - 12.74 (0.508 - 0.5096) Assembly Piston Place a film of clean DOT 4 brake fluid on the piston,spring and master...
Page 457 8. Brakes > Master Cylinders K- XCT 300i Install the master cylinder piston and spring into the master cylinder bore. Compress the snap ring with internal snap ring pliers and Install the snap ring. 9-12...
Page 458 8. Brakes > Master Cylinders K- XCT 300i Install the rubber boot over the end of the master cylinder piston. Brake Light Switch Install the brake light switch. Tighten the mounting screw securely with a #2 Phillips screwdriver. Brake Levers 9-13...
Page 459 8. Brakes > Master Cylinders K- XCT 300i Install the brake lever. Apply a light coat of grease to brake lever pivot bolt. Insert the pivot bolt from above and thread on the nut. Tighten the brake lever bolt with a flat blade screwdriver and then tighten the nut with a 10 mm socket.
Page 460 8. Brakes > Master Cylinders K- XCT 300i Position the master cylinder on the handlebar. Install the master cylinder clamp. Be sure to insert the pin on the clamp into the hole on the handlebar. Install the two master cylinder mounting bolts and tighten them securely with an 8 mm socket.
Page 461 8. Brakes > Master Cylinders K- XCT 300i Plug in the brake light switch connector. Install the brake hose to the master cylinder with the banjo bolt. Use new sealing washers. Tighten the banjo bolt to specification with a 12 mm socket.
Page 462 9. Brakes > Front Brake Caliper K- XCT 300i Front Caliper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Drain the brake fluid if the caliper is to be disassembled. Remove the two caliper mounting bolts with a 12 mm socket. Remove the speedometer sensor mounting bolt with an 8 mm socket.
Page 463 9. Brakes > Front Brake Caliper K- XCT 300i Remove the speedometer sensor. Remove the front caliper. 9-18...
Page 464 9. Brakes > Front Brake Caliper K- XCT 300i Brake Pad Removal Loosen the brake pad pin with a 5 mm Allen. Remove the brake pad pin. 9-19...
Page 465 9. Brakes > Front Brake Caliper K- XCT 300i Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Disassembly Remove the pad spring. 9-20...
Page 466 9. Brakes > Front Brake Caliper K- XCT 300i Inspection Inspect the pistons for wear and damage. Measure the outside diameter of the piston with a micrometer and compare the measurement with the specification. Replace the pistons as needed. Item Standard mm (in) Brake caliper piston O.D.
Page 467 9. Brakes > Front Brake Caliper K- XCT 300i Inspect the piston bores for wear and damage. Inspect the piston bores for wear and damage. Measure the inside diameter of the piston bore with a telescoping gauge and micrometer. Replace the caliper as needed. Item Standard mm (in) Brake caliper cylinder I.D.
Page 468 9. Brakes > Front Brake Caliper K- XCT 300i Brake Pad Installation Insert the brake pads into the caliper. Fit the ends of the pads into the pad retainer as shown. 9-23...
Page 469 9. Brakes > Front Brake Caliper K- XCT 300i Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. Installation Install the front caliper. Guide the brake disc between the pads. Line up the caliper bracket mounts with the fork.
Page 470 9. Brakes > Front Brake Caliper K- XCT 300i Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Torque Item Lb-ft Front/Rear caliper bolt 25.8 Install the banjo bolt with new sealing washers and tighten to specification with a 12 mm socket.
Page 471 9. Brakes > Front Brake Caliper K- XCT 300i Install the speedometer sensor. Install the speedometer sensor mounting bolt with an 8 mm socket. Torque Item Lb-ft Speed sensor cable 9.80 - 13.73 7.23 - 10.13 Tighten the brake pad pin securely with a 5 mm Allen. 9-26...
Page 472 8. Brakes > Rear Brake Caliper K- XCT 300i Rear Caliper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Brake fluid is very caustic and can damage paint, chrome and plastic. Wipe up any spills immediately. Removal If the caliper is to be disassembled the brake hose must be removed.
Page 473 8. Brakes > Rear Brake Caliper K- XCT 300i Remove the two rear caliper mounting bolts with a 12 mm socket. 9-28...
Page 474 8. Brakes > Rear Brake Caliper K- XCT 300i Remove the rear caliper from the swingarm. Disassembly One at a time, move the brake pads to the center gap in the pad retainers and lift the pad out. If needed, use the piston side pad to push the pistons in to allow for more room.
Page 475 8. Brakes > Rear Brake Caliper K- XCT 300i Inspection Measure the outside diameter of the piston with a micrometer and compare the measurement with the specification. Replace the pistons as needed. Item Standard (mm) Rear brake caliper piston O.D. 25.33-25.36 Inspect the piston bores for wear and damage.
Page 476 8. Brakes > Rear Brake Caliper K- XCT 300i Inspect the piston bores for wear and damage. Measure the inside diameter of the piston bore with a telescoping gauge and micrometer. Replace the caliper as needed. Item Standard (mm) Rear brake caliper bore I.D. 25.40 - 25.45 Assembly Lubricate the caliper pistons, the caliper piston bores and the seals with...
Page 477 8. Brakes > Rear Brake Caliper K- XCT 300i Installation Install the rear caliper onto the swingarm. Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Torque Item lb-ft Front/Rear caliper bolt 25.8 9-32...
Page 478 8. Brakes > Rear Brake Caliper K- XCT 300i Fit the rear brake hose guide into place. Insert the two rear brake hose clamp bolts and tighten them securely with a 10 mm socket. Fill the rear brake system with fresh brake fluid and bleed out the air. See the Brake Fluid topic for more information.
Page 479 9. Brakes > Brake Disc K- XCT 300i Disc Brake SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Measure the thickness of the brake rotor with a Vernire caliper or micrometer. ITEM STANDARD Front 3.8 - 4.2 mm(0.15 - 0.165 in) Brake disc thickness 5.0 mm(0.2 in) Rear...
Page 480 9. Brakes > Brake Disc K- XCT 300i Check if the brake rotor runout is within service limit. Measure the runout of the brake disc with a dial gauge. If the reading is out of specification remove the disc from the wheel and recheck. Item Standard (mm) Rear brake disk runout...
Page 481 9. Brakes > Brake Disc K- XCT 300i Front Removal Remove the front wheel. See the Front Wheel topic for more information. Remove the five brake disc mounting bolts with an Allen wrench. 9-36...
Page 482 9. Brakes > Brake Disc K- XCT 300i Remove the front brake disc and front wheel speed sensor rotor. Separate the wheel speed sensor rotor from the brake disc. 9-37...
Page 483 9. Brakes > Brake Disc K- XCT 300i Inspect the wheel speed sensor and brake disc for wear and damage. Replace the parts as needed. Set the front brake disc and speed sensor rotor in place on the front wheel. 9-38...
Page 484 9. Brakes > Brake Disc K- XCT 300i Installation Coat the threads of the disc bolts in a non-permanent thread locking agent. Thread in the bolts and torque them to specification with an Allen socket. Set the speed sensor rotor on the front brake disc. Position the rotor so that its sharp side sits against the brake disc.
Page 485 9. Brakes > Brake Disc K- XCT 300i Rear Removal Remove the five brake disc mounting bolts with an Allen wrench. 9-40...
Page 486 9. Brakes > Brake Disc K- XCT 300i Lift the brake disc off of the rear wheel. Installation Coat the threads of the disc bolts in a non-permanent thread locking agent. Thread in the bolts and torque them to specification with an Allen socket. Set the rear brake disc in place as shown.
Page 487 9. Brakes > Brake Disc K- XCT 300i Insert the five rear brake disc mounting bolts and tighten them to specification with an Allen socket. Torque Thread size Item (mm) kgf-m lb-ft Disk bolt 3.2-3.8 23.15-27.48 9-42...
Page 488 9.Brakes > Brake Pad Replacement K- XCT 300i Brake Pad Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Front Loosen the brake pad pin with a 5 mm Allen.
Page 489 9.Brakes > Brake Pad Replacement K- XCT 300i Remove the two caliper mounting bolts with a 12 mm socket. Remove the speedometer sensor mounting bolt with an 8 mm socket. Remove the speedometer sensor. 9-44...
Page 490 9.Brakes > Brake Pad Replacement K- XCT 300i Remove the front caliper. Remove the brake pad pin. 9-45...
Page 491 9.Brakes > Brake Pad Replacement K- XCT 300i Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Insert new brake pads as needed. Fit the ends of the pads into the pad retainer as shown. 9-46...
Page 492 9.Brakes > Brake Pad Replacement K- XCT 300i Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.
Page 493 9.Brakes > Brake Pad Replacement K- XCT 300i Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Torque Item lb-ft Front/Rear caliper bolt 25.8 Install the speedometer sensor. 9-48...
Page 494 9.Brakes > Brake Pad Replacement K- XCT 300i Install the speedometer sensor mounting bolt with an 8 mm socket. Torque Item lb-ft Speed sensor cable 9.80 - 13.73 7.23 - 10.13 Tighten the brake pad pin securely with a 5 mm Allen. Pump the brake lever to seat the caliper pistons against the pads.
Page 495 9.Brakes > Brake Pad Replacement K- XCT 300i Rear If the caliper is to be disassembled the brake hose must be removed. Drain the rear brake fluid. See the Brake Fluid topic for more information. Remove the two rear brake hose clamp bolts with a 10 mm socket. Remove the rear brake hose clamp.
Page 496 9.Brakes > Brake Pad Replacement K- XCT 300i Remove the two rear caliper mounting bolts with a 12 mm socket. Remove the rear caliper from the swingarm. 9-51...
Page 497 9.Brakes > Brake Pad Replacement K- XCT 300i One at a time, move the brake pads to the center gap in the pad retainers and lift the pad out. If needed, use the piston side pad to push the pistons in to allow for more room.
Page 498 9.Brakes > Brake Pad Replacement K- XCT 300i Install the rear caliper onto the swingarm. Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Item Torque lb-ft Front/Rear caliper bolt 25.8 9-53...
Page 499 9.Brakes > Brake Pad Replacement K- XCT 300i Fit the rear brake hose guide into place. Insert the two rear brake hose clamp bolts and tighten them securely with a 10 mm socket. Pump the brake lever to seat the caliper pistons against the pads.
Page 500 K- XCT 300i Front Suspension This chapter covers the location and servicing of the front fork components for the KYMCO K-XCT 300i. • Front Fork Removal and Installation ....... 10-2~10-7 • Fork Disassembly ..........10-8~10-19 • Fork Assembly ............. 10-20~10-27...
Page 501 10. Front Suspension > Front Fork Removal K- XCT 300i Front Fork Removal and Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the front wheel speed sensor mounting bolt with an 8 mm socket. 10-2...
Page 502 10. Front Suspension > Front Fork Removal K- XCT 300i Remove the front wheel speed sensor from the bottom of the right fork leg. 10-3...
Page 503 10. Front Suspension > Front Fork Removal K- XCT 300i Remove the speed sensor wire and front brake hose guide mounting bolt with an 8 mm socket. Free the guide from the fork clamp. Loosen the fork clamp pinch bolts with a 12 mm socket. The top bolts must be removed.
Page 504 10. Front Suspension > Front Fork Removal K- XCT 300i Slide the forks legs down and out of the fork clamp using a twisting motion. Installation Slide the fork legs up into fork clamp using a twisting motion. 10-5...
Page 505 10. Front Suspension > Front Fork Removal K- XCT 300i Install the fork legs so that the upper fork clamp bolt hole lines up with the groove on the inner fork tube. Insert the fork clamp upper bolt. Tighten the fork clamp bolts securely and evenly with a 12 mm socket. Install the speed sensor wire and front brake hose guide to the fork clamp.
Page 506 10. Front Suspension > Front Fork Removal K- XCT 300i Torque Thread Item size (mm) kgf-m lb-ft Speed sensor 1.0-1.4 7.23-10.13 cable Fit the front wheel speed sensor into place on the right fork leg. Insert the bolt and tighten it to specification with an 8 mm socket. 10-7...
Page 507 10. Front Suspension > Fork Disassembly K- XCT 300i Fork Disassembly SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the front forks. See the Front Fork Removal and Installation topic for more information. Clean the outside of the forks before disassembly and inspect them for any cracks, dents or other damage.
Page 508 10. Front Suspension > Fork Disassembly K- XCT 300i Remove the rubber fork cap. Place the fork leg in a soft jawed vice. 10-9...
Page 509 10. Front Suspension > Fork Disassembly K- XCT 300i Push down on the top plug and remove the snap ring. Remove the top plug. Lift out the fork spring. 10-10...
Page 510 10. Front Suspension > Fork Disassembly K- XCT 300i Dump the fork oil into a suitable container. Pump the fork through its stroke several times to free as much oil as possible. Hold the fork inverted for several minutes to let the oil drain completely. Use a flat blade screwdriver to pop the dust seal out of the fork slider.
Page 511 10. Front Suspension > Fork Disassembly K- XCT 300i Use a small flat blade screwdriver to pry out the fork oil seal stopper ring. Take care to avoid scratching the fork tube. Slide off the stopper ring. 10-12...
Page 512 10. Front Suspension > Fork Disassembly K- XCT 300i Place the axle holder of the outer fork tube in a soft jawed. Insert an 8 mm Allen socket into the damper rod. Hold the damper rod and loosen the fork bottom bolt with an 8 mm Allen wrench. 10-13...
Page 513 10. Front Suspension > Fork Disassembly K- XCT 300i Remove the fork bottom bolt from the bottom of the fork slider. Discard the sealing washer. Separate the inner and outer fork tubes by pulling them apart using a slide hammer motion. Remove the oil lock piece.
Page 514 10. Front Suspension > Fork Disassembly K- XCT 300i Remove the damper rod and rebound spring. Inspect the oil seal and the bushing in the fork slider. 10-15...
Page 515 10. Front Suspension > Fork Disassembly K- XCT 300i Place a rag across the top of the fork slider and pry our the oil seal as shown. Remove the oil seal and spacer from the fork slider. 10-16...
Page 516 10. Front Suspension > Fork Disassembly K- XCT 300i Inspection Inspect the top plug O-ring O-ring and replace it if needed. Insect the slider bushing and replace it as needed. 10-17...
Page 517 10. Front Suspension > Fork Disassembly K- XCT 300i Inspect the fork springs for signs of fatigue. Replace the fork springs if they vary dramatically in length. Inspect the damper rod and seal. Replace the components as needed. 10-18...
Page 518 10. Front Suspension > Fork Disassembly K- XCT 300i Inspect the inner fork tube for bends and damage. Replace it as needed. For assembly see the Fork Assembly topic. 10-19...
Page 519 10. Front Suspension > Fork Assembly K- XCT 300i Fork Assembly SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Clean all of the fork components with aerosol brake cleaner and a lint free cloth. Coat the bushing and seals with fork oil before installation. Drive the fork slider bushing into the slider with a suitable driver with the same outside diameter as the bushing.
Page 520 10. Front Suspension > Fork Assembly K- XCT 300i Place the spacer into the fork slider. Insert the inner fork tube into the inner fork tube. 10-21...
Page 521 10. Front Suspension > Fork Assembly K- XCT 300i Place a new sealing washer on the fork bottom bolt. Insert the fork bottom bolt into the bottom the fork slider and thread it into the damper rod. Place the axle holder of the outer fork tube in a soft jawed. 10-22...
Page 522 10. Front Suspension > Fork Assembly K- XCT 300i Insert an 8 mm Allen socket into the damper rod. Hold the damper rod and tighten the fork bottom bolt securely with an 8 mm Allen wrench. Drive in the fork oil seal with the fork seal driver. 10-23...
Page 523 10. Front Suspension > Fork Assembly K- XCT 300i Insert the stopper ring into its groove. Install the dust seal securely into the outer fork tube. 10-24...
Page 524 10. Front Suspension > Fork Assembly K- XCT 300i Compress the fork tube all the way. Fill the fork tube with the specified quantity of fork oil 185 cc or 6.26 US oz. Use fork oil type SS#8 (10W). Pump the fork slowly through its stroke several times to release any trapped air.
Page 525 10. Front Suspension > Fork Assembly K- XCT 300i Lubricate the top plug O-ring with fresh fork oil and insert the plug into the top of the inner fork tube as shown. Push the top plug down against the spring and install the stopper ring into its groove.
Page 526 10. Front Suspension > Fork Assembly K- XCT 300i Install the rubber fork cap. Fit the fork protectors into place so that they face forward. Install the front fork. See the Front Fork Removal and Installation topic for more information. 10-27...
Page 527 11. Rear Suspension K- XCT 300i Rear Suspension This chapter provides information on the rear suspension components of the KYMCO K-XCT 300i. • Shock Absorbers ............. 11-2~11-9 • Swingarm ............. 11-10~11-14 TROUBLESHOOTING Soft rear shock absorber • Weak shock absorber spring •...
Page 528 11. Rear Suspension > Shock Absorbers K- XCT 300i Shock Absorbers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Pre-Load Setting Each shock absorber on the scooter has 5 spring preload adjustment positions for different load or riding conditions. Position 1 is for light loads and smooth road conditions.
Page 529 11. Rear Suspension > Shock Absorbers K- XCT 300i Removal Place the vehicle on its center stand. Remove the body cover to access the upper shock absorber mounts. See the Body Cover topic for more information. Remove the two rear shock mounting bolt with a 12 mm socket. 11-3...
Page 530 11. Rear Suspension > Shock Absorbers K- XCT 300i Remove the right side rear shock mounting bolt with a 14 mm socket. Free the lower mount of the rear shock. 11-4...
Page 531 11. Rear Suspension > Shock Absorbers K- XCT 300i Remove the upper shock absorber mounting bolt with a 12 mm socket. Free the shock absorber from the frame. 11-5...
Page 532 11. Rear Suspension > Shock Absorbers K- XCT 300i Remove the left shock absorber in the same manner as the right. Inspect the shock absorbers for wear and damage. Replace the shock absorbers as needed. Check over the shock absorber for damage and oil leaks. Replace the shock absorber if needed.
Page 533 11. Rear Suspension > Shock Absorbers K- XCT 300i Installation Fit the shock absorber into place. Make sure the preload arrow indicator faces out from the lower mount. Install the upper shock absorber mounting bolt and torque it to specification with a 12 mm socket. 11-7...
Page 534 11. Rear Suspension > Shock Absorbers K- XCT 300i Torque Item kgf-m lb-ft Shock absorber mounting bolt 28.93 Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft Shock absorber mounting bolt 28.93 11-8...
Page 535 11. Rear Suspension > Shock Absorbers K- XCT 300i Install the other shock absorber in the same manner. 11-9...
Page 536 11. Rear Suspension > Swingarm K- XCT 300i Rear Fork SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Place the vehicle on its center stand. Remove the right side rear shock mounting bolt with a 14 mm socket. 11-10...
Page 537 11. Rear Suspension > Swingarm K- XCT 300i Hold the rear brake to keep the rear wheel from turning. Remove the rear axle nut with a 24 mm socket. Remove the two rear fork bolts with a 14 mm socket. Slide the rear fork out and remove it from the right side of the vehicle.
Page 538 11. Rear Suspension > Swingarm K- XCT 300i Installation Fit the rear fork into place. Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket. 11-12...
Page 539 11. Rear Suspension > Swingarm K- XCT 300i Install the rear axle nut and tighten it to specification with a 24 mm socket. Torque Thread Item size Remarks (mm) kgf-m lb-ft Rear axle nut 11-13 79.56-94.03 U-nut 11-13...
Page 540 11. Rear Suspension > Swingarm K- XCT 300i Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft Shock absorber mounting bolt 28.93 11-14...
Page 541 12. Wheels K- XCT 300i Wheels This chapter covers the location and servicing of the wheels for the KYMCO K-XCT 300i. • Front Wheel ............12-2~12-7 • Rear Wheel ............12-8~12-17 • Wheel Inspection ............12-18 • Bearing Replacement ......... 12-19~12-22...
Page 542 12. Weels > Front Wheel K- XCT 300i Front Wheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the front axle pinch bolt with a 6 mm Allen. Loosen the front axle with an 8 mm socket. 12-2...
Page 543 12. Weels > Front Wheel K- XCT 300i Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground. Support the front wheel and slide the front axle out from the left side. 12-3...
Page 544 12. Weels > Front Wheel K- XCT 300i Guide the front wheel out from the fork legs and the brake disc out from between the pads. Do not squeeze the brake lever while the disc is not present between the pads. Remove the collars from each side of the wheel.
Page 545 12. Weels > Front Wheel K- XCT 300i Installation Apply grease to the lips of the dust seals and collar O-rings. Insert the collars into the hub as shown. Make sure the tire direction of rotation marker is correct. Slide the front wheel into the fork. Fit the brake disc between the brake pads in the front caliper.
Page 546 12. Weels > Front Wheel K- XCT 300i Set the front wheel on the ground. Pump the front suspension up and down several times to seat the front axle Torque the axle to specification with an 8 mm Allen. Item size (mm) Torque Kgf-m...
Page 547 12. Weels > Front Wheel K- XCT 300i Tighten the front axle pinch bolt securely with a 6 mm Allen. Pump the front brake lever to establish pressure and to seat the pads against the disc. If the Brakes do not pump up correctly check the brake fluid.
Page 548 12. Wheels > Rear Wheel K- XCT 300i Rear Wheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. •...
Page 549 12. Wheels > Rear Wheel K- XCT 300i Move the rear shock out of the way. Hold the rear brake to keep the rear wheel from turning. Remove the rear axle nut with a 24 mm socket. Remove the two rear fork bolts with a 14 mm socket. 12-9...
Page 550 12. Wheels > Rear Wheel K- XCT 300i Slide the rear fork out and remove it from the right side of the vehicle. Remove the rear axle collar from the right side of the rear axle. 12-10...
Page 551 12. Wheels > Rear Wheel K- XCT 300i To remove the rear wheel support the right rear shock absorber so that it is out of the way or remove it. Remove the upper shock absorber mounting bolt with a 12 mm socket. Free the right shock absorber from the frame.
Page 552 12. Wheels > Rear Wheel K- XCT 300i Installation Line up the splines on the rear wheel with those of the rear axle. Slide the rear wheel on to the axle so that the brake disc sits on the right side. Install the right shock absorber if it was removed.
Page 553 12. Wheels > Rear Wheel K- XCT 300i Slide on the rear axle collar. Fit the rear fork into place. 12-13...
Page 554 12. Wheels > Rear Wheel K- XCT 300i Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket. 12-14...
Page 555 12. Wheels > Rear Wheel K- XCT 300i Install the rear axle nut and tighten it to specification with a 24 mm socket. Torque Thread Item size Remarks (mm) kgf-m lb-ft Rear axle nut 11-13 79.56-94.03 U-nut Fit the shock absorber into place. Make sure the preload arrow indicator faces out from the lower mount.
Page 556 12. Wheels > Rear Wheel K- XCT 300i Install the upper shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft Shock absorber mounting bolt 28.93 12-16...
Page 557 12. Wheels > Rear Wheel K- XCT 300i Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft Shock absorber mounting bolt 28.93 12-17...
Page 558 12. Wheels > Wheel Inspection K- XCT 300i Wheel Inspection SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.
Page 559 12. Wheels > Bearing Replacement K- XCT 300i Wheel Bearing Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace bearings as a set, and do not reuse old bearings. Place the new bearings in the freezer about an hour before you plan to install them. Do not let the wheel rest on its brake disc.
Page 560 12. Wheels > Bearing Replacement K- XCT 300i Remove one of the bearings with a bearing puller. Special Tools- Bearing Puller: A120E00037 Remove the distance collar. Repeat the procedure and remove the other bearing and seal. The seal should be replaced with a new item. 12‐20 ...
Page 561 12. Wheels > Bearing Replacement K- XCT 300i Heat the bearing area of the wheel with a heat gun, take the bearing out of the freezer and install it. You can use a bearing installer tool or a socket with the same outside diameter as the bearing. Make sure the bearing is fully seated and the marked side is facing out.
Page 562 12. Wheels > Bearing Replacement K- XCT 300i Drive in the other bearing. The bearing should fit against the distance collar. Do not continue to force the bearing in or the distance collar will begin to push the right bearing back out. Apply grease to the lips of the dust seals.
Page 563 13. Electrical Systems K- XCT 300i Electrical Systems This chapter covers the location and servicing of the electrical systems for the KYMCO K-XCT 300i. • Battery ..............13-6~13-10 • Charging System ............13-11 • Ignition System ........... 13-12~13-16 • Starting System ..........13-17~13-21 •...
Page 564 13. Electrical Systems K- XCT 300i • Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator/rectifier will be damaged. Turn off the ignition switch before operation. • It is not necessary to check the MF battery electrolyte or fill with distilled water. •...
Page 565 13. Electrical Systems K- XCT 300i IGNITION SYSTEM GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page above.
Page 566 13. Electrical Systems K- XCT 300i Starting System GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 567 13. Electrical Systems K- XCT 300i LIGHTS, SWITCHES, AND FUEL PUMP GENERAL INSTRUCTIONS • Note the following when replacing the halogen headlight bulb 1. Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail.
Page 568: Battery
13. Electrical System > Battery K- XCT 300i Battery SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin. eyes, or clothing. In case of contact, flush with water and get prompt medical attention.
Page 569 13. Electrical System > Battery K- XCT 300i The battery is located under the seat. Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver. Free the negative cable from the battery. Remove the positive battery cable bolt with a 10 mm socket or #3 Phillips screwdriver.
Page 570 13. Electrical System > Battery K- XCT 300i Lift the battery out of the battery tray. Testing Check the battery voltage with a multi-meter. Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal. If the battery reads under 12.3 V it is undercharged.
Page 571 13. Electrical System > Battery K- XCT 300i Installation Only install the specified battery Fit the battery into the battery tray. Connect the positive battery cable and install the bolt with a 10 mm socket or #3 Phillips screwdriver. Connect the negative battery cable and install the bolt with a 10 mm socket or #3 Phillips screwdriver.
Page 572 13. Electrical System > Battery K- XCT 300i Install the battery cover. Install the four battery cover screws and tighten them securely. Battery Charging Charge the battery with a motorcycle specific battery charger at the specified rate. Connect the charger leads to their appropriate battery terminals. Keep open flames away from a charging battery.
Page 573: Charging System
13. Electrical System > Charging System K- XCT 300i Charging System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the charging system. Charging Voltage Inspection Remove the battery cover. See the Battery topic for more information. Note: The battery should be fully charged prior to making charging system checks.
Page 574: Ignition System
13. Electrical System > Ignition System K- XCT 300i Ignition System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The ignition timing is set at the factory and is not adjustable. Perform the following checks. Before performing any tests make sure the electrical connections are not loose or corroded.
Page 575 13. Electrical System > Ignition System K- XCT 300i Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
Page 576 13. Electrical System > Ignition System K- XCT 300i Remove the two ignition coil leads. Remove the two ignition coil mounting bolts with an 8 mm socket. Remove the ignition coil. 13‐14 ...
Page 577 13. Electrical System > Ignition System K- XCT 300i Ignition Coil Resistance Primary Set the multimeter to read ohms of resistance (Ω). Touch the positive and negative meter leads to the ignition coil terminals as shown. Measure the resistance. 3.57 - 4.83 Ω...
Page 578 13. Electrical System > Ignition System K- XCT 300i Secondary Without Plug Cap Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap. Touch the negative meter lead to the terminal and the positive meter lead to the spark plug wire as shown. 10 - 14 Ω...
Page 579: Starting System
13. Electrical System > Starting System K- XCT 300i Starting System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the starting system. Starter Relay Inspection Remove the body cover. See the Body Cover topic for more information. The starter relay is located on the right side of the vehicle.
Page 580 13. Electrical System > Starting System K- XCT 300i Disconnect the starter relay wire connector. Check continuity between the yellow/red wire and green/yellow wire. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
Page 581 13. Electrical System > Starting System K- XCT 300i Operation Test Turn the ignition switch to "OFF". Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver. Free the negative cable from the battery. Remove the two terminal covers. 13‐19 ...
Page 582 13. Electrical System > Starting System K- XCT 300i Remove the nuts that hold the starter motor lead and battery lead wires to the starter relay with a 10 mm socket. Remove the leads from the starter relay. Disconnect the starter relay wire connector. 13‐20 ...
Page 583 13. Electrical System > Starting System K- XCT 300i Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable. Connect a fully charged battery across the starter relay yellow/red and green/yellow wire terminals.
Page 584: Starter Motor
13. Electrical System > Starter Motor K- XCT 300i Starter Motor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Turn the ignition switch to "OFF". Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver.
Page 585: Fuses
13. Electrical System > Fuses K- XCT 300i Fuses SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Fuse Box Fuses box The fuse box is located in the front of the battery. Open the covers to access the fuses. 13‐23 ...
Page 586: Ecu Removal
13. Electrical System > ECU Removal K- XCT 300i ECU Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is “ ON" . The excessive voltage may damage the ignition control module or ECU.
Page 587 13. Electrical System > ECU Removal K- XCT 300i Remove the two mounting nuts with a socket. Remove the ECU. 13‐25 ...
Page 588 13. Electrical System > ECU Removal K- XCT 300i Inspection Disconnect and remove the ECU from the frame. Check for continuity between pin 9 and 10 of the ECU side connector. There should be continuity at all times. Check for continuity between each pins 2, 4 and 23 of the ECU side connector.
Page 589 13. Electrical System > ECU Removal K- XCT 300i Installation Install the two mounting nuts and tighten securely with a socket. Connect the ECU harness. 13‐27 ...
Page 590: Self-Diagnosis
13. lectrical System > Self-Diagnosis K- XCT 300i Self-Diagnosis SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: No matter when the CELP illuminated while riding condition, should find out the cause of the problem as soon as possible. CELP ...
Page 591 13. lectrical System > Self-Diagnosis K- XCT 300i Without Diagnostic Special Tool SELF-DIAGNOSTIC PROCEDURES Place the scooter on its main stand and put the side stand up. Set the engine stop switch to the “RUN” position. 13‐29 ...
Page 592 13. lectrical System > Self-Diagnosis K- XCT 300i ● Turn key to On position. ● The CELP will be lighting for two seconds and then off. ● If the engine has problem, the CELP will blink to show the failure codes. ●...
Page 593 13. lectrical System > Self-Diagnosis K- XCT 300i 13‐31 ...
Page 594 13. lectrical System > Self-Diagnosis K- XCT 300i Self-Diagnosis Reset Procedure Note: The self-diagnosis cannot be reset when has still problem inside the system. 1. Put the side stand up and engine stop switch is at “RUN”. 2. Turn the key to the ON position and wait for ten seconds. 3.
Page 595 13. lectrical System > Self-Diagnosis K- XCT 300i Spark Plug Anti-Flood When no failure code occurs and pressing starter switch repeatedly can still not start the engine the spark plug maybe fouled be a flooded engine. Perform the spark plug anti-flood to purge the fuel in the engine.
Page 596: Horn
13. Electrical System > Horn K- XCT 300i Horn SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Disconnect the horn connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.
Page 597: Lights
13. Electrical System > Lights K- XCT 300i Lights SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Headlight Bulb Replacement Make sure the machine has been off for several minutes before removing the headlight bulb. Slide back the rubber headlight covers and then remove the headlight bulbs to free it from the lamp.
Page 598 13. Electrical System > Lights K- XCT 300i Do not touch your new bulb with your bare hand. The oils on your hand can cause an early failure of the headlight bulb. If you do touch the bulb with your bare hand wipe off the bulb with a clean shop towel and alcohol.
Page 599 13. Electrical System > Lights K- XCT 300i Turn the screws to adjust the head light aim as needed. Front Turn Signals Turn the turn signal bulb socket counterclockwise and free it from the lamp. 13‐37 ...
Page 600 13. Electrical System > Lights K- XCT 300i Push in on the bulb and rotate it clockwise to remove if from the socket. Insert the new bulb. Push down on the bulb and rotate it counterclockwise to lock it into place. Insert the turn signal bulb and socket into place.
Page 601 13. Electrical System > Lights K- XCT 300i Taillights LED Replacement Remove the five taillight mounting the tail light housing. Remove two screws mounting the clips. Remove the LED taillight assy. Replace the LED as needed. Install the taillight socket into the LED. 13‐39 ...
Page 602 13. Electrical System > Lights K- XCT 300i Rear Turn Signals Turn the socket counterclockwise and remove it from the lamp. Push in the bulb and turn it counterclockwise. Remove the bulb. Insert the new bulb and turn it clockwise to lock it in place. 13‐40 ...
Page 603 13. Electrical System > Lights K- XCT 300i License Tag Light Remove the license tag light from the mud flap. Pull the rubber tag light socket out of its housing. Pull the bulb straight out and insert a new one. 13‐41 ...
Page 604: Relays
13. Electrical System > Relays K- XCT 300i Relays SAFETY FIRST: Protective gloves and eyewear are recommended at this point. High/Low Beam Relays Remove the front cover. Remove and disconnect the high beam relay. The Low beam relay is on the left. 13‐42 ...
Page 605 13. Electrical System > Relays K- XCT 300i Fuel Pump Relay Remove the luggage box. The fuel pump relay is located in front of battery. Remove and disconnect the fuel pump relay. Inspection Use a digital multimeter to inspect the fuel cut-off relay. Set the multimeter to read ohms of resistance.
Page 606 13. Electrical System > Relays K- XCT 300i Connect the multimeter to the fuel cut-off relay connector terminals Connection: Black - Red/Black Connect 12 V battery with the fuel cut-off relay connector. Connection: Blue/Black - Black There should be continuity only when 12 V battery connected. If there is not continuity when the 12 V battery is connected, replace the fuel cut-off relay.
Page 607 13. Electrical System > Relays K- XCT 300i Turn on the ignition switch to “ON” position. Turn on the engine stop switch to “RUN” position. Keep the side switch upward. Apply the brake lever fully. Connect the multimeter to the start relay connector terminals. Set the multimeter to read ohms of resistance.
Page 608 13. Electrical System > Relays K- XCT 300i FAN Relay Remove the front cover. The Fan relay is on the left. Remove and disconnect the Fan relay. 13‐46 ...
Page 609: Switches
13. Electrical System > Switches K- XCT 300i Switches SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the switches. Ignition Switch Remove the front cover. Unplug the white six-pin ignition switch connector. Use a digital multimeter to check for continuity to inspect the ignition switches.
Page 610 13. Electrical System > Switches K- XCT 300i Removal Remove the front cover. Remove the dash. 13‐48 ...
Page 611 13. Electrical System > Switches K- XCT 300i Remove the seat latch cable cover. Loosen the seat latch cable screw with a #2 Phillips screwdriver. Remove the seat latch cable screw and free the seat latch cable from the ignition switch.
Page 612 13. Electrical System > Switches K- XCT 300i To remove the anti-tamper bolts use a punch and a hammer to strike the bolts so that they rotate loose. Turn the bolts clockwise to loosen them. Installation Install new anti-tamper bolts and tighten them securely. Fit the end of the seat latch cable into the ignition switch.
Page 613 13. Electrical System > Switches K- XCT 300i Install the seat latch cable cover. Tilt Switch Remove the front cover. Support the scooter level surface. Put the side stand up and engine stop switch on “RUN”. Turn the ignition switch to “OFF”.
Page 614 13. Electrical System > Switches K- XCT 300i Remove the two tilt switch bolts with a 10 mm socket. Place the tilt switch vertical as shown and the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage)
Page 615 13. Electrical System > Switches K- XCT 300i Disconnect the connector to remove the tilt switch. Note: Install the tilt switch with its “up” mark facing up and tighten the two screws securely. Handlebar Switches Remove the front cover. To remove the handle bar switches see the Handlebar topic.
Page 616 13. Electrical System > Switches K- XCT 300i Unplug the green connector for the right handlebar switches. Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated. ...
Page 617 13. Electrical System > Switches K- XCT 300i 13‐55 ...
Page 618 13. Electrical System > Switches K- XCT 300i Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated. 13‐56 ...
Page 619 13. Electrical System > Switches K- XCT 300i Luggage Box Switch Remove the luggage box. Unplug the two-pin luggage box light LED switch connector with red/white and green wires. Use a digital multimeter to check for continuity. Test the switch side of the connector for continuity as the switch is manipulated.
Page 620 13. Electrical System > Switches K- XCT 300i Luggage box light LED switch Side Stand Switch Remove the luggage box. Place the vehicle on the center stand. Unplug the three-pin side stand switch connector. 13‐58 ...
Page 621 13. Electrical System > Switches K- XCT 300i Use a digital multimeter to check for continuity. With the side stand retracted there should be continuity between the yellow/green wire and the green wire terminals. 13‐59 ...
Page 622 13. Electrical System > Switches K- XCT 300i With the side stand extended there should be continuity between the yellow/black wire and the green wire terminals. Brake Light Switches Test the front and rear brake light switches in the same manner. Use a digital multimeter to check for continuity.
Page 623 13. Electrical System > Switches K- XCT 300i Check for continuity between the brake light switch connectors. There should be continuity when the lever is pulled and none when released. 13‐61 ...
Page 624 IGNITION SYSTEM K-XCT 300i SIDE STAND SW Start Sw Engine Stop Sw Brake Sw Start Mag Start Relay 12V 12AH BATTERY B/G B/ W1 B/W1 Y/BR BR/L SENSOR, BR/L ANGLE DETECT B/L2 G/P2 B/W1 COMB SW G/BR B/L2 G/P2 G/W1...
Page 625 CHARGING SYSTEM K-XCT 300i FUSE 12V 12AH BATTERY R R/W COMB SW Y Y Y Y Y Y REG REC 13-63...
Page 626 K-XCT 300i WIRING DIAGRAM Revised:2012.10.01...
Page 627 14. Quick Reference K- XCT 300i Quick Reference This chapter provides a quick reference source of technical specifications and information for KYMCO K-XCT 300i models. • Component Location ......... 14-2~14-10 • Special Tools .............. 14-11 • K-XCT 300i Specifications ......14-12~14-20 •...
Page 628: Component Location
K- XCT 300i 14. Quick Reference > Component Location Component Location 14‐2 ...
Page 629 K- XCT 300i 14. Quick Reference > Component Location 14‐3 ...
Page 630 K- XCT 300i 14. Quick Reference > Component Location 14‐4 ...
Page 631 K- XCT 300i 14. Quick Reference > Component Location Fuel Pump To Thermostat Bleed Fuel Hose Blow By Tube Seat Catch Cable Throttle Cable inside 14‐5 ...
Page 632 K- XCT 300i 14. Quick Reference > Component Location 14‐6 ...
Page 633 K- XCT 300i 14. Quick Reference > Component Location 14‐7 ...
Page 634 K- XCT 300i 14. Quick Reference > Component Location 14‐8 ...
Page 635 K- XCT 300i 14. Quick Reference > Component Location 14‐9 ...
Page 636 K- XCT 300i 14. Quick Reference > Component Location ECU ECU RELAY 14‐10 ...
Page 637: Special Tools
K- XCT 300i 14. Quick Reference > Special Tools Special Tools ITEM TOOL NO DESCRIPTION FLYWHEEL PULLER A120E00003 Flywheel removal Puller (M28x1) TAPPET ADJUSTER A120E00012 Adjusting valve clearance OIL SEAL & BEARING DRIVER A120E00014 General Driver Set UNIVERSAL HOLDER A120E00021 Holding clutch pulley and flywheel #41 NUT AND FITTING TOOL...
Page 638 K- XCT 300i 14. Quick Reference > Specifications General Information Name & Model No. LKG7 Motorcycle Name & Type K-XCT300i Overall length (mm) 2145 Overall width (mm) Overall height (mm) 1290 Wheel base (mm) 1450 Engine type 4 stroke OHC Displacement (cc) 298.9 Fuel recommended...
Page 639 K- XCT 300i 14. Quick Reference > Specifications Air cleaner type & No Paper element, wet Fuel capacity 12.5 liter Brand Keihin Fuel System Type Throttle body Injection Venturi dia.(mm) Fuel pump pressure 3.0 Bar Type 10° BTDC at idle to Ignition Ignition timing 33°...
Page 640 K- XCT 300i 14. Quick Reference > Specifications Coolant capacity Radiator 766 cc Hose with cool coolant 169 cc Hose with hot coolant 194 cc Reserve tank 590 cc Total capacity 1719 cc Engine Item Standard (mm) 0.10 Valve clearance (cold) 0.10 Cylinder head compression pressure 16 kg/cm2, 228 psi...
Page 641 3.5 - 4.5 mm Radiator: 766 cc Coolant capacity Total 1719 cc Reserve tank: 590 cc Hose: 363 cc COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS KYMCO SIGMA Coolant Freezing Point Mixing Rate Distilled Water Concentrate -9°C 344 cc 1375 cc -15°C...
Page 642 K- XCT 300i 14. Quick Reference > Specifications COOLANT GRAVITY CHART Temp. C° Coolant concentration 1.009 1.009 1.008 1.008 1.007 1.006 1.018 1.107 1.017 1.016 1.015 1.014 1.028 1.027 1.026 1.025 1.024 1.022 1.036 1.035 1.034 1.033 1.031 1.029 1.045 1.044 1.044...
Page 643 K- XCT 300i 14. Quick Reference > Specifications Fuel Injection System ITEM SPECIFICATIONS Throttle body identification number LKG7 Idle speed 1600 ± 100 rpm Throttle grip free play 2 - 6 mm (1/16 - 1/4 in) 11.7 ± 0.6 Ω Fuel injector resistance (at 20°C/68°F) 1100 ±...
Page 644 K- XCT 300i 14. Quick Reference > Specifications CELP FAILURE CODES LIST Failure Codes Contents Causes Symptoms • Faulty TPS voltage range (0.3 -4.5 V) • Loose or poor connection on TPS Sensor Engine operates P0120 Faulty TPS normally •...
Page 645 K- XCT 300i 14. Quick Reference > Specifications Axle/Brakes/Wheels Item Standard mm (in) Service Limit Axle shaft run out – 0.2 mm(0.008 in) 0.3 mm(0.012 in) Brake disk thickness (front) 3.8 - 4.2(0.15 - 0.165) Brake disk thickness (rear) 5.0 (0.2 –...
Page 646 K- XCT 300i 14. Quick Reference > Specifications Item Standard Spark plug Standard type NGKCR7E Spark plug gap 0.6 - 0.7 mm 3.57 - 4.83 Ω Primary coil Inductive Ignition Coil Secondary coil without plug cap 10.42 - 14.49 KΩ 3500 - 6500 Ω...
Page 647: Torque Specifications
K- XCT 300i 14. Quick Reference > Torque Specifications Torque Specifications ENGINE Torque Item Thread size (mm) Remarks kgf-m lb-ft Cylinder head stud bolt 1. Stud bolt (Inlet pipe side) 0.7-1.1 5.06-7.96 Double end bolt 2. Stud bolt (EX pipe side) 0.7-1.1 5.06-7.96 Double end bolt...
Page 648 K- XCT 300i 14. Quick Reference > Torque Specifications FRAME Torque Remarks Item Thread size (mm) kgf-m lb-ft Steering: 1. Stem lock nut 6.0-6.5 43.20-46.8 2. Handle post bolt 4.0-5.0 28.93-36.17 U-nut 3. Bridge bolt 2.4-3.0 17.36-21.70 4. Race nut (head) 1.8-2.2 13.02-15.91 Brake:...
Page 649: Troubleshooting
14. Troubleshooting K- XCT 300i Troubleshooting Vehicle can not be started Preliminary 6 Step Inspection 1. Is the battery fully charged (12V or higher). See the Battery topic for more information. 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
Page 650 14. Troubleshooting K- XCT 300i General 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.
Page 651 14. Troubleshooting K- XCT 300i 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 ...
Page 652 14. Troubleshooting K- XCT 300i 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 ...
Page 653 14. Troubleshooting K- XCT 300i POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check ignition timing Incorrect  Improper ignition timing Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal ...
Page 654 14. Troubleshooting K- XCT 300i POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Check ignition timing Incorrect  Faulty ECU Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal  Faulty injector Normal 4.
Page 655: Vin And Engine Number Location
K- XCT 300i 14. Quick Reference > VIN and Engine Number Location VIN and Engine Number Location The VIN is stamped on a plate on the lower right side. The engine serial number is stamped on bottom of the left crankcase. 14‐29 ...
Page 656 K- XCT 300i 14. Quick Reference > VIN and Engine Number Location The VIN is also stamped on the frame inside of the luggage box. 14‐30 ...

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