KYMCO X-Town 250 ABS Service Manual

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PREFACE

This Service Manual describes the

technical

features

procedures for the KYMCO X-Town

250/300 ABS

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers

which

are

removal/installation frequency during

maintenance

operations.

Section 3 describes the inspection/

adjustment procedures, safety rules

and service information for each part,

starting from periodic maintenance.

Sections 5 to 12 give instructions for

disassembly,

adjustment of engine parts. Section

13 is the AFI system. Section 14 to 15

is the removal/ installation of chassis.

Section 16 to 19 states the testing

and measuring methods of electrical

equipment.

Most sections start with an assembly

system

troubleshooting for the section. The

subsequent

pages

procedures for the section.

The

information

included in this manual may be

different from the motorcycle in

case specifications are changed.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPT.

EDUCATION SECTION

and

servicing

subject

and

servicing

assembly

and

illustration

and

give

detailed

and

contents

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME

COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

A.C. GENERATOR/STARTER

CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL INJECTION SYSTEM

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS SWITCHES / FUEL PUMP

EVAPORATIVE EMISSION

CONTROL SYSTEM

ABS

ANTI-LOCK BRAKE SYSTEM

X-Town 250/300 ABS

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO X-Town 250 ABS

Page 1: Table Of Contents
PREFACE TABLE OF CONTENTS This Service Manual describes the technical features servicing GENERAL INFORMATION procedures for the KYMCO X-Town 250/300 ABS EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read them carefully before any LUBRICATION SYSTEM operation is started.
Page 2: General Information
1. GENERAL INFORMATION X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ----------------------------------------------------------------------------------- 1-1 SPECIFICATION ------------------------------------------------------------------------------------ 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------ 1-5 TORQUE VALUES ---------------------------------------------------------------------------------- 1-9 SPECIAL TOOLS --------------------------------------------------------------------------------- 1-10 LUBRICATION POINTS ------------------------------------------------------------------------- 1-11 CABLE & HARNESS ROUTING ------------------------------------------------------------------ 1-13 TROUBLESHOOTING --------------------------------------------------------------------------- 1-14...
Page 3: General Information
1. GENERAL INFORMATION X-Town250/300 ABS SERIAL NUMBER Location of Vehicle Identification Number (VIN) Location of Engine Serial Number...
Page 4: Specification
1. GENERAL INFORMATION X-Town250/300 ABS SPECIFICATIONS of X-Town 300 Oil filter type Full-flow filtration Name X-Town 300 ABS Oil capacity 1.1 liter Model No. ABD2 Exchanging capacity 0.9 liter Overall length 2250 mm Fi injection system Overall width 800 mm Air cleaner type &...
Page 5 1. GENERAL INFORMATION X-Town250/300 ABS SPECIFICATIONS of X-Town 250 Oil filter type Full-flow filtration Name X-Town 250 Oil capacity 1.1 liter Model No. ACJ2 Exchanging capacity 0.9 liter Overall length 2250 mm Fi injection system Overall width 800 mm Air cleaner type & No Paper element, wet Overall height 1385 mm...
Page 6: Service Precautions
1. GENERAL INFORMATION X-Town250/300 ABS  Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication  Make sure to install new gaskets, O-rings, points. circlips, cotter pins, etc. when reassembling.  When tightening bolts or nuts, begin with ...
Page 7 1. GENERAL INFORMATION X-Town250/300 ABS  Before connecting a terminal, check for  After operation, terminal caps shall be damaged terminal cover or loose negative installed securely. terminal. Confirm Capacity  When taking out the connector, the lock on  Check the double connector cover for the connector shall be released before proper coverage and installation.
Page 8 1. GENERAL INFORMATION X-Town250/300 ABS  Protect wires and harnesses with electrical  Do not squeeze wires against the weld or tape or tube if they contact a sharp edge its clamp. or corner. Do not pull too tight！  After clamping, check each harness to ...
Page 9 1. GENERAL INFORMATION X-Town250/300 ABS  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent surrounding parts steering positions.  When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
Page 10 1. GENERAL INFORMATION X-Town250/300 ABS  Symbols: following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication. Grease : Transmission Gear Oil (90#) Gear Oil...
Page 11: Torque Values
1. GENERAL INFORMATION X-Town250/300 ABS TORQUE VALUES...
Page 12 1. GENERAL INFORMATION X-Town250/300 ABS TORQUE VALUES FRAME 1-10...
Page 13: Special Tools
1. GENERAL INFORMATION X-Town250/300 ABS SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Flywheel puller E003 A.C. generator flywheel removal 4.10 Tappet adjuster E012 Tapper adjustment Oil seal & bearing installer E014 Oil seal & bearing install 9.10.11 Flywheel holder E021 A.C.
Page 14: Lubrication Points
1. GENERAL INFORMATION X-Town250/300 ABS LUBRICATION POINTS FRAME The following is the lubrication points for the frame. Use grease for parts not listed. Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise and damage the durability of the motorcycle.
Page 15: Cable & Harness Routing
1. GENERAL INFORMATION X-Town250/300 ABS CABLE & HARNESS ROUTING Hi Beam Relay Starter Relay Fuel Pump Relay Fan Relay ECU Relay Lo Beam Relay Coolant Reserve Tank Winker Relay Radiator Filler Cap OiL Pressure Controller ABS ECU Tilt Switch (APPLY ABS MODE) Ignition Switch ABS ECU (APPLY ABS MODE)
Page 16 1. GENERAL INFORMATION X-Town250/300 ABS Throttle Body MAP Sensor Injector 1-14...
Page 17 1. GENERAL INFORMATION X-Town250/300 ABS Fuse Diagnostic Tool Ignition Switch Regulator/Rectifier Ignition Coil Charcoal Canister/ Purge Control Valve( E3 mode dot have it) Horn 1-15...
Page 18 1. GENERAL INFORMATION X-Town250/300 ABS RR Speed sensor Starter Relay Hazard control unit O2 Sensor 1-16...
Page 19: Troubleshooting
1. GENERAL INFORMATION X-Town250/300 ABS TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Possible cause  Faulty fuel pump 1. Check for operation of the fuel pump Abnormal Normal  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal ...
Page 20 1. GENERAL INFORMATION X-Town250/300 ABS ENGINE LACKS POWER Possible cause  Brake dragging 1. Raise wheel off the ground Wheels do not  Worn or damaged wheel bearing and spin by hand spin freely Wheel spins freely  Faulty tire valve 2.
Page 21 1. GENERAL INFORMATION X-Town250/300 ABS Possible cause  Oil level too high 9. Check oil level and condition Incorrect  Oil level too low  Contaminated oil Correct  Clogged oil 10. Remove cylinder head cover Valve train not  Clogged oil control orifice and inspect lubrication lubricated properly Valve train lubricated properly...
Page 22 1. GENERAL INFORMATION X-Town250/300 ABS POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause  Improper ignition timing 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector Abnormal Normal ...
Page 23 1. GENERAL INFORMATION X-Town250/300 ABS POOR PERFORMANCE AT HIGH SPEED Possible cause  Faulty ECU 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector Abnormal Normal ...
Page 24: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 2- 1 TROUBLESHOOTING ----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION ------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14...
Page 25: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS SERVICE INFORMATION 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. TORQUE VALUES Exhaust muffler pipe nuts 1.8~2.2 kgf-m...
Page 26: Fastener Removal And Reinstallation
. EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls close. Insert the fastener into the installation hole. ＊...
Page 27: Frame Covers Removal/Installation
. EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS FRAME COVERS REMOVAL/ INSTALLATION SEAT Unlock the seat with the ignition key. Open the seat. Remove the two nuts and seat damper unit. Remove the two nuts and the seat. Installation is in the reverse order of removal. LUGGAGE BOX Unlock the seat with the ignition key.
Page 28 . EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS Center Cover Center Cover CENTER COVER Remove the luggage box. Remove the center cover. ＊ During removal, do not pull the joint claws forcedly to avoid damage. Installation is in the reverse order of removal. Remove the fuel tank cover by pushing the tank cover downward Rear carrier Cover...
Page 29 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS Installation is in the reverse order of removal. BODY COVER Rear Center Cover Remove the seat and luggage box(2-3) Remove the rear carrier cover(2-4). Remove the rear carrier(2-4). Remove two fasteners and then remove the rear center cover Remove two nuts bolt...
Page 30 . EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS Disconnect the taillight connector. , then remove the body cover. Installation is in the reverse order of removal. UPPER/LOWER HANDLEBAR COVER Remove the four screws and then remove upper handlebar cover. Remove the two screws, then remove the bottom handlebar cover.
Page 31 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS WINDSHIELD/WINDSHIELD GARNISH Remove five bolts and windshield garnish. screws FRONT CENTER COVER Remove the windshield Remove two screws and fastener then remove the front center cover. Remove the front cover. Installation is in the reverse order of removal fastener the rubber foot mat RIGHT/LEFT FOOT SKIRT...
Page 32 . EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS FRONT COVER Remove two bolts. Remove fourteen screws from the inner cover. Remove ten fastener from the cowl under. Disconnect headlight/position light connector and right/left turn signal light connectors.
Page 33 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS Remove the front cover Installation is in the reverse order of removal. FRONT FENDER Remove four screws attaching to the front fender. Installation is in the reverse order of removal. RIGHT/LEFT FLOORBOARD Remove the body cover（2-5）. bolt Remove the front cover（2-8）...
Page 34 . EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS INNER COVER Remove the front cover. Remove right/left floorboard. Remove one screws Remove the ignition key garnish Remove remove the handler panel. ＊ During removal, do not pull the joint claws forcedly to avoid damage. reserve tank lid Remove one screws then remove the reserve...
Page 35 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS screw Remove six screws and two bolts bolt screw Remove one screw ,connect the left front box assy and inner cover Disconnect the DC power connectors. DC power connectors Remove the fuel tank fill cap and collection of fuel spill tank .
Page 36 . EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS speedometer wires METER PANEL Remove the front cover Remove the inner cover. Disconnect the speedometer wires Remove two bolts then remove meter panl Installation is in the reverse order of removal. bolts room temp sensor canistr-pcv FRONT INNER FENDER Remove canistr-pcv and room temp sensor .
Page 37 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS UNDER COVER Remove four bolts Remove the under cover. bolt TIRE FENDER Remove the body cover. Remove four bolts attaching to the tire fender Installation is in the reverse order of removal. FENDER,REAR INNER Remove rear cushion two bolts Remove five bolts Rear cushion...
Page 38: Exhaust Muffler
. EXHAUST MUFFLER/FRAME COVERS X-Town 250/300 ABS EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater/O2 sensor. Nuts Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. 2-14...
Page 39 . EXHAUST MUFFLER/FRAME COVERS X-Town250/300 ABS INSTALLATION Replace the gasket with a new one. Install the exhaust muffler and three mounting bolt. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m,) Gasket Tighten the three mounting bolts Torque: 35 N•m (3.5 kgf•m,)
Page 40: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION / ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION --------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE------------------------------------------------------------------ 3- 2 THROTTLE OPERATION ---------------------------------------------------------------------- 3- 3 ENGINE OIL --------------------------------------------------------------------------------------- 3- 4 RESERVE TANK --------------------------------------------------------------------------------- 3- 5 AIR CLEANER ------------------------------------------------------------------------------------ 3- 6 SPARK PLUG ------------------------------------------------------------------------------------- 3- 6 VALVE CLEARANCE---------------------------------------------------------------------------- 3- 7 CYLINDER COMPRESSION ------------------------------------------------------------------ 3- 7...
Page 41: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS SERVICE INFORMATION GENERAL ！ WARNING  Before running the engine, make sure that the working area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas, which may cause death to people.
Page 42: Maintenance Schedule
KVMCO 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 43 3. INSPECTION/ADJUSTMENT X-Town250/300 ABS THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side.
Page 44 3. INSPECTION/ADJUSTMENT X-Town250/300 ABS ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on the level ground. Wait for 2～3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when checking the oil level. OIL CHANGE Remove the oil drain bolt to drain the engine oil.
Page 45: Reserve Tank
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS RESERVE TANK COOLANT LEVEL INSPECTION The coolant reservoir In the front in the box. Check the coolant lever through the inspection window ①at the left side skirt white the engine is at the normal operating temperature,with the scooter in an upright position..
Page 46: Air Cleaner
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS AIR CLEANER AIR FILTER REPLACEMENT Remove the body cover. Remove seven screws attaching to the air cleaner cover. Remove six screws attaching to the filter. Check the filter and replace it if it is excessively dirty or damaged. Air Cleaner Cover CHANGE INTERVAL More frequent replacement is required when...
Page 47: Valve Clearance
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS Cylinder Head Cover VALVE CLEARANCE ＊  Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the seat assy and luggage box. Remove the four bolts and then cylinder head cover. Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...
Page 48: Final Reduction Gear Oil
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS FINAL REDUCTION GEAR OIL ＊  Place the scooter on its main stand on level ground. Remove the transmission fluid drain bolt. Remove the transmission fluid filler bolt, then slowly rotate the rear wheel to drain the fluid. Fill the transmission with the recommend fluid to the capacity listed below.
Page 49: Brake System
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS BRAKE SYSTEM There is adjuster on each brake lever.Each adjuster has four positions so that the released lever position can be adjusted to suit the rider’s hands. To adjust the distance of the lever from the handlebar grip,push the lever(1) forward and turn the adjuster knob(2) to align the number with the arrow mark(3) on the lever holder.
Page 50: Clutch Shoe Wear
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS CLUTCH SHOE WEAR Start engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep or the engine stop, check the clutch shoes for wear and replace if necessary. SUSPENSION FRONT Check...
Page 51: Nuts/Bolts/Fasteners
3. INSPECTION/ADJUSTMENT X-Town250/300 ABS NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊...
Page 52: Side Stand
3. Lower the side stand. The engine should stop as you put the side stand down. ＊ If the side stand system does not operate as described, see your KYMCO dealer for service. Engine limit lever rubber gasket Engine hanger bolt ①...
Page 53 . LUBRICATION SYSTEM X-Town250/300ABS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1 SERVICE INFORMATION ----------------------------------------------- 4- 3 TROUBLESHOOTING ---------------------------------------------------- 4- 5 OIL PRESSURE SWITCH ------------------------------------------------ 4- 6 OIL PUMP ------------------------------------------------------------------- 4- 7...
Page 54: Lubrication System Diagram
. LUBRICATION SYSTEM X-Town250/300 ABS X-Town300 ABS Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 55: Lubrication System
At draining 0.9 liter (0.95 US qt, 0.8 Imp qt) capacity  At disassembly 1.1 liter (1.17 US qt, 1 Imp qt) KYMCO 4-stroke oil or equivalent motor oil  Recommended engine oil API service classification SJ Viscosity: SAE 5W-50 Tip clearance 0.15 (0.006) max...
Page 56: Troubleshooting
. LUBRICATION SYSTEM X-Town250/300 ABS TROUBLESHOOTING Oil level low High oil pressure  Oil consumption  Pressure relief valve stuck closed  External oil leak  Plugged oil filter, gallery, or metering orifice  Worn piston ring  Faulty oil pump ...
Page 57: Oil Pressure Switch
. LUBRICATION SYSTEM X-Town250/300ABS Dust Cover OIL PRESSURE SWITCH CHECK Start the engine. Check the oil pressure indicator goes out after one or two seconds. If the oil pressure indicator stay on, stop the engine immediately and determine the cause. oil controller OIL CONTROLLER If oil pressure is lower than 0.15kg/cm2...
Page 58: Oil Pump
. LUBRICATION SYSTEM X-Town250/300 ABS Bolts OIL PUMP REMOVAL Remove the flywheel Remove the attaching bolt and oil separator cover. ＊ When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.. Oil Separator Cover Remove snap ring.
Page 59 . LUBRICATION SYSTEM X-Town250/300ABS Oil Pump Remove the two oil pump bolts to remove the oil pump. Bolts Oil Pump Cover DISASSEMBLY Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump shaft, oil pump outer rotor and inner rotor.
Page 60 . LUBRICATION SYSTEM X-Town250/300 ABS INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) ＊ Measure at several points and use the largest reading to compare the service limit.
Page 61 . LUBRICATION SYSTEM X-Town250/300ABS ASSEMBLY Dowel Pin Oil Pump Cover Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft. Install the dowel pin onto the oil pump body. Install the oil pump cover onto the oil pump body by aligning the dowel pin.
Page 62 . LUBRICATION SYSTEM X-Town250/300 ABS Drive Chain Driven Gear Install the oil pump driven sprocket and drive chain. Install the snap ring. Snap Ring Bolts Install the oil separator cover properly and tighten two bolts securely as shown. Oil Separator Cover...
Page 63: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION --------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-6...
Page 64 5. ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  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.  Use shop towels to protect the scooter body during engine removal. ...
Page 65 . ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS Regulator/Rectifier ENGINE REMOVAL/INSTALLATION REMOVAL Remove the air cleaner Disconnect the connector including of ISC, Throttle body, TPS, WTS, MAP sensor and injector. Disconnect the O2 sensor connector. Disconnect the throttle cables. ACG connector Disconnect the Regulator/Rectifier connector.
Page 66 . ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS ④ Remove the muffler. Remove the rear fork mounting bolts ① attaching to the crankcase. Torque: 3.5 kgf-m (35 N-m) Remove the rear axle nut②. Torque: 12.0 kgf-m (120 N-m) Remove two bolts ③ attaching to the rear brake caliper.
Page 67 . ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS Remove the spark plug cap. Spark Plug Cap Disconnect the lower radiator hose from lower radiator pipe. Radiator Hose Remove the right and left rear cushion lower mount bolts. Torque: 4.0 kgf-m (40N-m) Mount Bolt...
Page 68 . ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS Remove the engine mount nut and pull it out. Remove the engine from the frame. ＊ At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase. Torque: 6.5 kgf-m (65 N-m) Mount Nut INSTALLATION...
Page 69 . ENGINE REMOVAL/INSTALLATION X-Town250/300 ABS ENGINE HANGER Mount Nut REMOVAL Remove the engine mount nut and pull it out. ＊ Be careful to put the engine down. Remove the left/right engine hanger mount bolt. Remove the engine from frame. INSTALLATION Installation is in the reverse order of removal.
Page 70: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/VALVES ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 6-1 SERVICE INFORMATION --------------------------------------------------------------------- 6- 2 TROUBLESHOOTING -------------------------------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ----------------------------------------------------- 6- 4 CAMSHAFT REMOVAL ------------------------------------------------------------------------ 6- 4 CYLINDER HEAD REMOVAL ----------------------------------------------------------------- 6- 6 CYLINDER HEAD DISASSEMBLY ---------------------------------------------------------- 6- 7 CYLINDER HEAD ASSEMBLY --------------------------------------------------------------- 6- 8 CYLINDER HEAD INSTALLATION ---------------------------------------------------------- 6- 9...
Page 71: Schematic Drawing
6. CYLINDER HEAD/VALVES X-Town250/300 ABS SCHEMATIC DRAWING...
Page 72: Service Information
6. CYLINDER HEAD/VALVES X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained.  When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 73: Troubleshooting
6. CYLINDER HEAD/VALVES X-Town250/300 ABS TROUBLESHOOTING  The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler  Compression too low  Worn valve stem or valve guide ...
Page 74: Cylinder Head Cover Removal
6. CYLINDER HEAD/VALVES X-Town250/300 ABS breather hose Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the met-in box. Remove the body cover and center cover. Disconnect the breather hose to air cleaner. Remove the cylinder head cover four bolts. Remove the cylinder head cover. Bolts Injector CAMSHAFT REMOVAL...
Page 75 6. CYLINDER HEAD/VALVES X-Town250/300 ABS Cap Nuts Remove the four cap nuts attaching the camshaft holder. ＊  Diagonally loosen the cylinder head cap nuts in 2 or 3 times. Camshaft Holder Camshaft Holder/Dowel Pins Remove the camshaft holder and dowel pins. Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft.
Page 76 6. CYLINDER HEAD/VALVES X-Town250/300 ABS INSPECTION Camshaft Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: IN :36.46mm (1.4354in) EX:36.26mm (1.4275in) Camshaft Bearings Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.
Page 77 6. CYLINDER HEAD/VALVES X-Town250/300 ABS REMOVAL Valve Rocker Arms Remove the camshaft . Remove the rocker arm shafts and then remove the rocker arms. INSPECTION Camshaft holder Rocker Arm Shafts Inspect the bearing surface of camshaft holder for scoring, scratches, or evidence of insufficient lubrication.
Page 78 6. CYLINDER HEAD/VALVES X-Town250/300 ABS REMOVAL First drain the coolant from the radiator and water jacket, then remove the thermostat water hose. Remove the camshaft. Remove the carburetor and intake pipe. Remove the two cylinder bolts. Cylinder Bolts Remove the bolt attaching the thermostat housing and the thermostat housing.
Page 79: Cylinder Head Disassembly
6. CYLINDER HEAD/VALVES X-Town250/300 ABS Valve Spring Compressor CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊  Be sure to compress the valve springs with a valve spring compressor. ...
Page 80 6. CYLINDER HEAD/VALVES X-Town250/300 ABS VALVE /VALVE GUIDE INSPECTION Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D. Measure each valve guide I.D.
Page 81 6. CYLINDER HEAD/VALVES X-Town250/300 ABS Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 2.95 kg (at 26.6 mm, 1.064 in) Outer: 10.45 kg (at 29.6 mm, 1.184 in) Measure the spring tilt. Replace if out of specification. Standard: Inner: 0.81 mm (0.0324 in) Outer: 1.07 mm (0.0428 in)
Page 82 6. CYLINDER HEAD/VALVES X-Town250/300 ABS Gasket INSTALLATION Install the cam chain guide. Install the dowel pins and a new cylinder head gasket. Cam Chain Guide Dowel Pins Cam Chain Install the cylinder head and take out the cam chain Valve Rocker Arms Assemble the camshaft holder.
Page 83 6. CYLINDER HEAD/VALVES X-Town250/300 ABS Punch Marks Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the right crankcase cover. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the cam chain over the...
Page 84 6. CYLINDER HEAD/VALVES X-Town250/300 ABS Tensioner Screw Turn the cam chain tension screw counterclockwise to release it. Apply engine oil to a new O-ring and install O-ring Tighten the cam chain tension cap screw. ＊ Be sure to install the gasket into the groove properly.
Page 85: Cylinder/Piston
7. CYLINDER/PISTON X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER/PISTON ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 7-1 SERVICE INFORMATION --------------------------------------------------------------------- 7-2 TROUBLESHOOTING -------------------------------------------------------------------------- 7-2 CYLINDER REMOVAL -------------------------------------------------------------------------- 7-3 PISTON REMOVAL ------------------------------------------------------------------------------ 7-3 PISTON INSTALLATION ----------------------------------------------------------------------- 7-7 CYLINDER INSTALLATION ------------------------------------------------------------------- 7-7...
Page 86 7. CYLINDER/PISTON X-Town250/300 ABS SCHEMATIC DRAWING...
Page 87 7. CYLINDER/PISTON X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder and piston can be serviced with the engine installed in the frame.  When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 88 7. CYLINDER/PISTON X-Town250/300 ABS Dowel Pins REMOVAL Remove the cylinder head. Remove the water hose from the cylinder. Remove the cylinder head gasket and dowel pine. Water Hose Gasket Cylinder Remove the cam chain guide. Remove the cylinder. Cam Chain Guide Gasket Remove the cylinder gasket and dowel pins.
Page 89 7. CYLINDER/PISTON X-Town250/300 ABS PISTON RING REMOVAL Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 90 7. CYLINDER/PISTON X-Town250/300 ABS Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 72.6 mm (2.904 in) at (A): 9 mm Calculate the cylinder-to-piston clearance Measure the piston pin hole.
Page 91 7. CYLINDER/PISTON X-Town250/300 ABS Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 92 7. CYLINDER/PISTON X-Town250/300 ABS Measure the connecting rod small end I.D.. Service Limit: 17.06 mm (0.6824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
Page 93 7. CYLINDER/PISTON X-Town250/300 ABS CYLINDER/PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊  Be careful not to drop foreign matters into the crankcase. “IN” Mark Piston Install the piston, piston pin and a new piston pin clip. ＊...
Page 94 7. CYLINDER/PISTON X-Town250/300 ABS Install the cam chain guide. ＊  Insert the tab on the cam chain guide into the cylinder groove. Cam Chain Guide Dowel Pins Install the cylinder gasket and dowel pins. Connect the water hose to the cylinder. Gasket...
Page 95: Drive And Driven Pulleys/V-Belt
8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/V-BELT ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 8- 1 SERVICE INFORMATION --------------------------------------------------------------------- 8- 2 TROUBLESHOOTING -------------------------------------------------------------------------- 8- 2 LEFT CRANKCASE COVER ------------------------------------------------------------------ 8- 3 DRIVE PULLEY ----------------------------------------------------------------------------------- 8- 3 CLUTCH OUTER/DRIVEN PULLEY/V-BELT --------------------------------------------- 8- 3...
Page 96 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS SCHEMATIC DRAWING...
Page 97 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT SERVICE INFORMATION GENERAL INSTRUCTIONS  The drive pulley, clutch and driven pulley can be serviced with the engine installed.  Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 98 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS LEFT CRANKCASE COVER REMOVAL Remove the bolts attaching to the left crankcase cover. Remove the gasket and dowel pins. Left Crankcase Cover Dowel Pins DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Seal Rubber Remove the left crankcase cover.
Page 99 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Replace a new belt at every 15,000km. ＊  Use specified genuine parts replacement. MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face, clutch outer, driven pulley and belt.
Page 100 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS INSPECTION Check each weight roller for wear or damage. Check the movable drive face bushing for wear or damage. ASSEMBLY...
Page 101 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT Install the weight rollers into the movable drive face. ＊  The direction of all weight rolls is same. The color side is towards to clockwise. Ramp Plate Install the ramp plate. Insert the drive pulley collar into the movable drive face.
Page 102 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS Clutch Spring Compressor CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Set the tool in a vise and remove the clutch drive plate nut. ＊  Be sure to use a clutch spring compressor to avoid spring damage.
Page 103 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT INSPECTION Measure the driven face spring free length. Service Limit: 136 mm replace if below Outer Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play. Drive the inner needle bearing out of the driven pulley face.
Page 104 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS Press a new needle bearing into the driven face. Clips Retainer Plate CLUTCH DISASSEMBLY Remove the clips and retainer plate to disassemble the clutch. ＊  Keep grease off the clutch linings. Clutch Lining...
Page 105 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT CLUTCH ASSEMBLY Clips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the clips. Drive Plate CLUTCH / DRIVEN PULLEY ASSEMBLY Movable Driven Face...
Page 106 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide Grooves roller pins and then install them into the holes of the driven face. Install the seal collar. Remove any excessive grease.
Page 107 8. DRIVE AND DRIVEN PULLEYS/ X-Town250/300 ABS V-BELT INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft. Drive Pulley Collar Movable Drive Face Assembly Movable Drive Face Assembly Put the drive belt on the driven pulley. Put the drive belt on the drive pulley collar.
Page 108 8. DRIVE AND DRIVEN PULLEYS/ V-BELT X-Town250/300 ABS Install the left crankcase cover. Left Crankcase Cover 8-13...
Page 109: Final Reduction
9. FINAL REDUCTION X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 9-1 SERVICE INFORMATION --------------------------------------------------------------------- 9-2 TROUBLESHOOTING -------------------------------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY ------------------------------------------------------- 9-3 FINAL REDUCTION INSPECTION ---------------------------------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ------------------------------------------------------------ 9-5...
Page 110 9. FINAL REDUCTION X-Town250/300 ABS SCHEMATIC DRAWING...
Page 111 9. FINAL REDUCTION X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  The servicing operations of this section can be made with the engine installed.  When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: SAE 90# Oil Capacity:...
Page 112 9. FINAL REDUCTION X-Town250/300 ABS Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear brake caliper. Remove the right rear shock absorber. Remove the rear fork. Remove the rear wheel. Drain the transmission gear oil into a clean container.
Page 113 9. FINAL REDUCTION X-Town250/300 ABS Countershaft Remove the countershaft Final Gear Remove the final gear. Driveshaft Remove the driven pulley. Press the driveshaft out or the left crankcase. Check the drive shaft for wear or damage.
Page 114 9. FINAL REDUCTION X-Town250/300 ABS Oil Seal Remove the driveshaft oil seal and bearing from the transmission case. Driveshaft Bearing If the bearing is left on the driveshaft, remove it with the special tool. Special tool: Universal bearing puller A120E00030 Universal Bearing Puller Countershaft Driveshaft...
Page 115 9. FINAL REDUCTION X-Town250/300 ABS Driveshaft Bearing Bearing Puller Check the oil seal and bearings in the left crankcase for wear or damage. BEARING REPLACEMENT (TRANSMISSION CASE) Remove the countershaft or final gear shaft bearing using the special tool. Special tool: Bearing puller A120E00037 Countershaft Bearing Final Gear Shaft Bearing...
Page 116 9. FINAL REDUCTION X-Town250/300 ABS Remove the final gear shaft bearing. Final Gear Shaft Bearing Remove the countershaft or drive shaft Countershaft Bearing bearing using the special tool. Special tool: Bearing puller A120E00037 Drive Shaft Bearing...
Page 117 9. FINAL REDUCTION X-Town250/300 ABS Oil Seal & Bearing Driver Apply engine oil to new bearings cavities. Drive new bearings into the transmission cover. Special tool: Oil seal & bearing driver A120E00014 Apply engine oil to new final gear shaft bearing cavity.
Page 118 9. FINAL REDUCTION X-Town250/300 ABS Oil Seal Apply oil to a new final gear shaft oil seal lip and outer surface. Install the final gear shaft oil seal. Final Gear FINAL REDUCTION ASSEMBLY Install the final gear to the transmission case. Countershaft Install the countershaft to the transmission case.
Page 119 9. FINAL REDUCTION X-Town250/300 ABS Final Gear Shaft Gasket Install the final gear shaft to transmission case. Install the dowel pins. Clean the mating surfaces of the left crankcase and transmission cover. Install the new gasket. Dowel Pins Bolts Install the transmission cover and tighten the eight bolts in a crisscross pattern in 2 –...
Page 120: Generator/Starter Clutch
10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 10-1 SERVICE INFORMATION --------------------------------------------------------------------- 10-2 TROUBLESHOOTING -------------------------------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL ------------------------------------------------- 10-3 STATOR REMOVAL ----------------------------------------------------------------------------- 10-3 FLYWHEEL REMOVAL ------------------------------------------------------------------------- 10-4 STARTER CLUTCH ----------------------------------------------------------------------------- 10-4 FLYWHEEL INSTALLATION ------------------------------------------------------------------ 10-6 10-0...
Page 121 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS SCHEMATIC DRAWING 10-1...
Page 122 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  All operations and inspections in this section can be made with the engine installed.  Should drain the coolant before removing the right crankcase cover.  Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.) ...
Page 123 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS Bolts Water Inlet Hose RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover. Disconnect the water hoses from the right crankcase cover. Remove 9 bolts attaching the right crankcase cover and the cover. Water Outlet Hose A.C.
Page 124 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS Flywheel Holder Nut/Washer FLYWHEEL/STARTER CLUTCH REMOVAL Remove the right crankcase cover. Hold the flywheel with the special tool and loosen the flywheel nut. Special tool: Flywheel holder A120E00021 Remove the flywheel nut and washer. Flywheel Puller Remove the flywheel/starter driven gear assembly using the special tool.
Page 125 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS Starter Idle Gear Remove the reduction gear and shaft. Reduction Gear Inspect the reduction gear and shaft for wear or damage. Shaft Driven gear INSPECTION Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise.
Page 126 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS Reduction Gear Apply oil to the starter reduction gear. Install the starter reduction gear to the right crankcase. Reduction Gear Shaft Apply oil to the starter reduction gear and shaft. Install the starter reduction gear and shaft to the right crankcase.
Page 127 10. A.C. GENERATOR/STARTER CLUTCH X-Town250/300 ABS Clean any oil from tapered portion of the crankshaft. Install the woodruff key in the crankshaft key groove. Woodruff Key Flywheel Holder Nut/Washer Clean any oil from the tappered portion of the flywheel I.D.. Install the flywheel/driven gear onto the crankshaft, aligning the key way with woodruff key.
Page 128: Crankcase/Crankshaft
11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 11-1 SERVICE INFORMATION --------------------------------------------------------------------- 11-2 TROUBLESHOOTING -------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION ------------------------------------------------------------------ 11-3 CRANKSHAFT INSPECTION ----------------------------------------------------------------- 11-4 CRANKCASE ASSEMBLY --------------------------------------------------------------------- 11-5 11-0...
Page 129 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS SCHEMATIC DRAWING 11-1...
Page 130 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.  When separating the crankcase, never use a driver to knock the crankcase forcedly to prevent damaging the mating surfaces.
Page 131 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS REMOVAL Remove the cam chain guide bolt. Remove the cam chain guide and cam chain INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage. Cam chain Inspect the cam chain for cracks or stiff.
Page 132 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS CRANKCASE SEPARATION Bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. ＊  Never use a driver to pry the crankcase mating surfaces apart. Gasket Remove the gasket and dowel pins. Dowel Pins Crankshaft Remove the crankshaft from the left...
Page 133 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS Measure the connecting rod big end side clearance. Service Limit: 0.6 mm (0.024 in) Measure the connecting rod small end I.D. Service Limit: 17.06 mm (0.6824 in) CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
Page 134 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS Oil Seal Install a new oil seal into the left crankcase. Left Crankcase Place the left crankcase down and install the crankshaft into the left crankcase. ＊  Avoid damaging the oil seal.  Apply grease to the lip of the oil seal. Gasket Install the two dowel pins and a new gasket.
Page 135 11. CRANKCASE/CRANKSHAFT X-Town250/300 ABS Bolts Place the right crankcase over the crankshaft and onto the left crankcase. ＊  Install the right crankcase squarely and do not tap it with an iron or plastic hammer. Install and tighten the right and left crankcase attaching bolts.
Page 136: Cooling System
12. COOLING SYSTEM X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 12- 1 SERVICE INFORMATION --------------------------------------------------------------------- 12- 2 TROUBLESHOOTING -------------------------------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------------------------------- 12- 4 RADIATOR ----------------------------------------------------------------------------------------- 12- 4 WATER PUMP ------------------------------------------------------------------------------------ 12- 8 THERMOSENSOR ------------------------------------------------------------------------------- 12- 11 THERMOSTAT ----------------------------------------------------------------------------------- 12- 12 12-0...
Page 137 12. COOLING SYSTEM X-Town250/300 ABS SCHEMATIC DRAWING 12-1...
Page 138 12. COOLING SYSTEM X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame.  The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃, never remove the radiator cap to release the pressure because the boiling coolant may cause danger.
Page 139 945cc 774cc ＊  Use coolant of specified mixing rate. (The mixing rate of 860cc KYMCO SIGMA coolant concentrate + 859cc distilled water is 50%.)  Do not mix coolant concentrate of different brands.  Do not drink the coolant, which is poisonous.
Page 140 12. COOLING SYSTEM X-Town250/300 ABS Radiator Tester COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the sealing cap surface before testing.
Page 141 12. COOLING SYSTEM X-Town250/300 ABS Radiator Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins. Outlet Tube of Reserve Tank RADIATOR REMOVAL Drain the coolant.
Page 142 12. COOLING SYSTEM X-Town250/300 ABS Bolts Remove three bolts on the radiator. Remove the radiator. Bolts RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator. Check fan motor by battery. 12-6...
Page 143 12. COOLING SYSTEM X-Town250/300 ABS Air Vent Tube RADIATOR INSTALLATION Install the fan rubber on the radiator with three bolts. Install the radiator on the radiator bracket with three bolts/nuts. Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire.
Page 144 12. COOLING SYSTEM X-Town250/300 ABS Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
Page 145 12. COOLING SYSTEM X-Town250/300 ABS WATER PUMP SHAFT REMOVAL Water Pump Shaft Disconnect the water hose from the right crankcase cover. Remove bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly. Remove the water pump shaft and inner bearing.
Page 146 12. COOLING SYSTEM X-Town250/300 ABS Install the dowel pins and a new gasket and then install the water pump assembly Seal Washer (Porcelain) Impeller to the right crankcase cover. Tighten 9bolts to secure the right crankcase cover. ＊ When installing water pump assembly, aligning the groove on the...
Page 147 12. COOLING SYSTEM X-Town250/300 ABS THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor THERMOSENSOR INSPECTION Thermosensor Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
Page 148 12. COOLING SYSTEM X-Town250/300 ABS THERMOSTAT THERMOSTAT REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing.
Page 149: Fuel Injection System
13. FUEL INJECTION SYSTEM X-Town250/300 ABS __________________________________________________________________________________ __________________________________________________________________________________ FUEL INJECTION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 13- 1 SPECIFICATIONS ---------------------------------------------------------- 13- 2 INJECTION SYSTEM DIAGRAM --------------------------------------- 13- 3 PARTS LOCATION -------------------------------------------------------- 13- 4 TROUBLESHOOTING ----------------------------------------------------- 13- 6 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL ------------------------------------------------------- 13- 7 EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE CODES-------------------------------------------------------------------------13-8 SELF-DIAGNOSIS RESET PROCEDURE ----------------------------- 13- 9...
Page 150 13. FUEL INJECTION SYSTEM X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
Page 151 13. FUEL INJECTION SYSTEM X-Town250/300 ABS SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number ABD2/ACJ2 Idle speed 1700± 100 rpm Throttle grip free play 2～6 mm (1/16～1/4 in) Fuel injector resistance (at 20° C/68° F) 11.7± 0.6Ω 1100± 33 Ω Fuel pump resistance Float at full position Float at empty position 100±...
Page 152 13. FUEL INJECTION SYSTEM X-Town250/300 ABS INJECTION SYSTEM DIAGRAM FULL NAME ABBREVIATIONS (01) Electronic control unit (02) Tilt switch (Angle detect sensor) ROLL (03) Fuel pump/Fuel level unit (04) Water temperature sensor WTS sensor (05) Crank position sensor (Pulser) (06) Oxygen/Oxygen heater sensor Heat sensor (08)
Page 153 13. FUEL INJECTION SYSTEM X-Town250/300 ABS PARTS LOCATION 13-4...
Page 154 13. FUEL INJECTION SYSTEM X-Town250/300 ABS 13-5...
Page 155 13. FUEL INJECTION SYSTEM X-Town250/300 ABS TROUBLESHOOTING Engine fail to start Backfiring or misfiring during acceleration  Intake manifold air leak  Ignition system malfunction  Fuel contaminated/deteriorated  Pinched or clogged fuel hose  Faulty fuel pump  Clogged fuel filter, throttle body ...
Page 156: Self-Diagnostic Procedures Without
13. FUEL INJECTION SYSTEM X-Town250/300 ABS SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL (APPLY to Euro3 model) SELF-DIAGNOSTIC PROCEDURES ＊ It can be performed without diagnostics program. Place the scooter on its main stand. Put the side stand up and the engine stop switch is at “RUN”.
Page 157: Efi Self-Diagnosis Check Engine Lamp (Celp) Failure
13. FUEL INJECTION SYSTEM X-Town250/300 ABS EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE CODES (APPLY to Euro3 model) The “CELP” denotes the failure codes. If more than a damaged part has occurred, the “CELP” begins blinking in order. When the indicator lights for one second that is equal to ten.
Page 158: Self-Diagnosis Reset Procedure
13. FUEL INJECTION SYSTEM X-Town250/300 ABS SELF-DIAGNOSIS RESET PROCEDURE (APPLY to Euro3 model) 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. Fully open the throttle and wait for ten seconds.
Page 159 13. FUEL INJECTION SYSTEM X-Town250/300 ABS CELP FAILURE CODES LIST (APPLY to Euro3 model) Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty TPS voltage range (0.3~4.5 V) ● Loose or poor connection on TPS Engine operates Sensor P0120 Faulty TPS normally ●...
Page 160 13. FUEL INJECTION SYSTEM X-Town250/300 ABS Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty Inductive ignition coil  range (4.2  ± 15%) Faulty ● Loose or poor connection on Engine fail to be inductive P0351 inductive ignition coil operated ignition coil ●...
Page 161 13. FUEL INJECTION SYSTEM X-Town250/300 ABS CELP FAILURE CODES LIST (APPLY to Euro4 model) NO. Failure Component Trouble Description code Control module Control CPU error or Sub CPU communication error. (ECU / P0603 module Reading value and writing value in data are PCU) error different.
Page 162 13. FUEL INJECTION SYSTEM X-Town250/300 ABS NO. Failure Component Trouble Description code O2 sensor The sensor input is = or > Timer to confirm (binary / P0131 input HG sensor malfunction (low voltage). linear) voltage signals The sensor input is = or < TH sensor voltage input to judge the short to ground and a period is = P0120...
Page 163 13. FUEL INJECTION SYSTEM X-Town250/300 ABS NO. Failure Component Trouble Description code Control A period of the circuit malfunction is > Timer P0030 module to confirm HG heater for #1 malfunction (low error voltage) O2 sensor heater Crank A period of the circuit malfunction is > Timer P0032 sensor to confirm HG sensor malfunction (high...
Page 164 13. FUEL INJECTION SYSTEM X-Town250/300 ABS SPARK PLUG ANTI-FLOOD When have not failure code occurs and pressing starter switch repeatedly, can still not start the engine, maybe the spark plug is wet by fuel, perform the spark plug anti-flood to purge the fuel in the engine. 13-15...
Page 165: Tps/Isc Reset
13. FUEL INJECTION SYSTEM X-Town250/300 ABS TPS/ISC RESET (APPLY to Euro3 model) ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS 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 166: Fuel Pump
13. FUEL INJECTION SYSTEM X-Town250/300 ABS FUEL PUMP INSPECTIION Put the side stand up and the engine stop Full Position switch is at “RUN” Disconnect fuel pump/fuel unit connector. Connect the multimeter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal.
Page 167 13. FUEL INJECTION SYSTEM X-Town250/300 ABS Hose band Fuel Pump Connector REMOVAL Disconnect the connector and fuel band from the fuel pump. Remove the six screws onto the fuel pump. Remove the fuel pump and O-ring. Screw Connector INSTALLATION Replace a new O-ring on the fuel tank. Don’t damage the fuel pump wire and ensure the connector rearward carefully.
Page 168: Fuel Cut-Off Relay
13. FUEL INJECTION SYSTEM X-Town250/300 ABS Battery FUEL CUT-OFF RELAY INSPECTION Remove the fuel cut-off relay. Connect the ohmmeter to the fuel cut-off relay connector terminals. Connection: Black – Red/Black Connect 12 V battery with the fuel cut-off Fuel Cut-Off Relay relay connector.
Page 169: Tilt Switch
13. FUEL INJECTION SYSTEM X-Town250/300 ABS TILT SWITCH INSPECTION Support the scooter level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch. ＊ Do not disconnect the tilt switch connector during inspection.
Page 170 13. FUEL INJECTION SYSTEM X-Town250/300 ABS ELECTRIC CONTROL UNIT (ECU) REMOVAL/INSTALLATION ＊ ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when throttle body, MAP, TPS, ISC or ECU has been reinstalled.
Page 171 13. FUEL INJECTION SYSTEM X-Town250/300 ABS 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, 23 and 4 of the ECU side connector.
Page 172: Fuel Injector
13. FUEL INJECTION SYSTEM X-Town250/300 ABS FUEL INJECTOR INSPECTION Disconnect the fuel injector connector. Measure the resistance between 2 pins of the fuel injector connector. Standard: 11.7± 0.6 Ω (at 20° C/68° F) REMOVAL Disconnect the connector from the fuel injector.
Page 173 13. FUEL INJECTION SYSTEM X-Town250/300 ABS Groove INSTALLATION Apply the engine oil to a new O-ring. Install the fuel injector into the fuel pipe. Ensure the tab of the fuel injector inserted into the groove of the fuel pipe. Install the fuel pipe into the intake manifold by aligning the dowel pin.
Page 174: Wts Sensor
13. FUEL INJECTION SYSTEM X-Town250/300 ABS WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring. Install a new O-ring and WTS sensor. ＊...
Page 175: O 2 Sensor
13. FUEL INJECTION SYSTEM X-Town250/300 ABS SENSOR The O sensor issues signal to ECU when the temperature is over 350° C during the engine is working. The temperature is up to 350° C earlier than the muffler for O heater sensor. So the O sensor begins performance.
Page 176: Throttle Body/Map/Isc/Tps
● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
Page 177 13. FUEL INJECTION SYSTEM X-Town250/300 ABS TPS INSPECTION Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector.
Page 178 13. FUEL INJECTION SYSTEM X-Town250/300 ABS DISASSEMBLY ＊ Screw/Set Plate The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU has been reinstalled. Remove the screw and then remove the ISC and set plate.
Page 179: Diagnostic Tool Connector
13. FUEL INJECTION SYSTEM X-Town250/300 ABS Apply oil onto a new O-ring. When install the MAP onto the throttle body, being careful not to damage the O-ring. ＊ Always replace an O-ring with a new one. Install the set plate and tighten the screw securely.
Page 180 13. FUEL INJECTION SYSTEM X-Town250/300 ABS FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00 Note: For EURO 4 models Use the Sub cord, OBD diagnostics connecter (part number:36205-LFA7-E00) to connect between vehicle and diagnostic tool. To: Vehicle To Diagnostic tool 13-28...
Page 181 13. FUEL INJECTION SYSTEM X-Town250/300 ABS FI DIAGNOSTIC TOOL  This tool is developed by KYMCO and for KYMCO vehicle only.  Please refer to the specification when serving this vehicle.  This tool is without battery inside. The power is provided from vehicle.
Page 182 13. FUEL INJECTION SYSTEM X-Town250/300 ABS DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power. ACJ2/ABD2 is for X-Town250/300 ABS A). ECU version: Including of model name, ECU number, identifications number and software version. Press the " Enter " button ACJ2/ABD2 is for X-Town250/300 ABS 13-30...
Page 183 13. FUEL INJECTION SYSTEM X-Town250/300 ABS B). Press the " Down " button and then turn to the first page. ACJ2/ABD2 is for X-Town250/300 ABS C). Press the " Enter " button to check the DTC failure code ACJ2/ABD2 is for X-Town250/300 ABS 13-31...
Page 184 13. FUEL INJECTION SYSTEM X-Town250/300 ABS D). Press the " Enter " button E). Press the " Enter " button F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page 13-32...
Page 185 13. FUEL INJECTION SYSTEM X-Town250/300 ABS G). Press the " UP " button H). Press the " Enter " button and then turn to the previous page with red color. I). Press the " UP " button 5-33...
Page 186 13. FUEL INJECTION SYSTEM X-Town250/300 ABS J). Press the " Enter " button and then turn to the first page. ACJ2/ABD2 is for X-Town250/300 ABS ACJ2/ABD2 is for X-Town250/300 ABS 5-34...
Page 187 13. FUEL INJECTION SYSTEM X-Town250/300 ABS 三. DTC CLEAR PROCEDURE ). Check the DTC ACJ2/ABD2 is for X-Town250/300 ABS ). Press the " Enter " button ACJ2/ABD2 is for X-Town250/300 ABS ). Choose " Load DTC " Press the " Down " button 5-35...
Page 188 13. FUEL INJECTION SYSTEM X-Town250/300 ABS ). Press the " Enter " button and the indicator is lighting. ). Clearing DTC completed if the indicator is off. 5-36...
Page 189 13. FUEL INJECTION SYSTEM X-Town250/300 ABS 四. DATA ANALYSIS PROCEDURE ). Press the " Down " twice ACJ2/ABD2 is for X-Town250/300 ABS ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 ACJ2/ABD2 is for X-Town250/300 ABS ).
Page 190 13. FUEL INJECTION SYSTEM X-Town250/300 ABS ). Down-page 02 The measure figures including of TPS position, Intake pressure and Intake air temperature. Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of Atmosphere pressure, Fuel Injector interval and Ignition advance timing.
Page 191 13. FUEL INJECTION SYSTEM X-Town250/300 ABS ). Down-page 05 The measure figures including of ISC target, ISC step and ISC learn step. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of ISC motor state. Press the “...
Page 192: Vehicle Can Not Be Started
13. FUEL INJECTION SYSTEM X-Town250/300 ABS Vehicle can not be started – Handling method (Steps) Preliminary Checking: 6 basic inspection 1. Is the battery with voltage (12 V or higher) 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 193: Manual Trouble Shooting Procedure
13. FUEL INJECTION SYSTEM X-Town250/300 ABS Manual Trouble Shooting Procedure How to read DTC from speedometer? New Phase 5 Fuel Injection Engine Vehicle DTC Reading: Automatic indication – ECU upgrade version (with Oxygen sensor): Reading DTC from speedometer directly. Key On light off in 2 seconds. When the engine inspection lamp is light up again, it starts to deliver failure code.
Page 194 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 14- 1 TROUBLESHOOTING ----------------------------------------------------- 14- 2 HANDLEBAR --------------------------------------------------------------- 14- 3 FRONT WHEEL ------------------------------------------------------------- 14- 6 FRONT BRAKE FLUID ---------------------------------------------------- 14- 9 FRONT BRAKE PAD ------------------------------------------------------ 14-12 BRAKE DISC INSPECTION ---------------------------------------------- 14-13...
Page 195: Service Information
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS  Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 196: Troubleshooting
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling  Excessively tightened steering stem top  Bent rim  Loose front axle cone race  Broken steering balls  Bent spoke plate  Insufficient tire pressure ...
Page 197: Handlebar
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover. Remove two bolts and disconnect the brake light switch wire, then remove the rear brake master cylinder. Remove the two bolts and disconnect the brake light switch wire, then remove the front brake master cylinder.
Page 198 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Install the front and rear master cylinders and connect the brake light switch wires. DISASSEMBLY Remove two screws attaching to the right handlebar switch. Screws Throttle cable Disconnect the throttle cable from the throttle grip.
Page 199 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Remove two screws and then remove the left handlebar switch. ASSEMBLY Screws Install the left handlebar switch. ＊ Align the pin on the left handlebar switch with the hole on the handlebar. Install and tighten the two screws securely.
Page 200: Steering Handlebar/Front Wheel/Front Brake/Front
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM FRONT WHEEL REMOVAL The scooter front wheel off the ground. Remove the bolt and then pull out the axle. Remove the front wheel and collar. Bolt AXLE RUNOUT INSPECTION Set the axle in V blocks and measure the runout using a dial gauge.
Page 201 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Colla INSTALLATION Apply grease to the collar, then install the collar onto the wheel. Dust Seal Install the speedometer speed wheel sensor. DISASSEMBLY Remove the side collar and dust seal. Turn the inner race of each bearing with your Speed Wheel Sensor finger to see if they turn smoothly and quietly.
Page 202 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Remove the front wheel bearing by using the Bearing special tool. Special tool: Bearing puller E00037 ASSEMBLY Install the front wheel bearing by using the special tool. Special tool: Bearing installer E00014 Install the distance collar.
Page 203: Front Brake Fluid
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE FLUID FLUID REPLACEMENT/AIR BLEEDING ＊ ● A contaminated brake disc or pad reduces stopping power. Discard contaminated pads clean contaminated disc with a high quality brake degreasing agent. ●...
Page 204 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Loosen the bleed valve and apply the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING ＊ Do not mix different types of fluid since they are not compatible.
Page 205 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
Page 206: Front Brake Pad
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the two caliper mounting bolts, then remove the caliper. Bolts Brake Pads Remove the brake pads. ＊ Always replace the brake pads in pairs to ensure even disc pressure.
Page 207: Brake Disc Inspection
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
Page 208: Front Shock Absorber
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. Remove the front brake caliper Remove the front wheel Remove the speed wheel sensor bolt and then remove the brake hose guide from right front shock absorber.
Page 209: Steering Stem
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM STEERING STEM REMOVAL Remove the steering handlebar. Remove the front brake hose and speed wheel sensor connector from the guide. Hold the steering stem top cone race and Right remove the steering stem lock nut by using the special tool.
Page 210 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary. Top Ball Cone Race Bottom Ball Race Remove the bottom balls.
Page 211 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ X-Town250/300 ABS FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race.
Page 212: Rear Brake/Rear Fork/Rear
15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER _________________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------------------------------------- 15-2 TROUBLESHOOTING -------------------------------------------------------------------------------- 15-2 REAR BRAKE ------------------------------------------------------------------------------------------ 15-3 REAR FORK --------------------------------------------------------------------------------------------- 15-6 REAR WHEEL ------------------------------------------------------------------------------------------ 15-7 REAR SHOCK ABSORBER ------------------------------------------------------------------------- 15-7 15-0...
Page 213 15. REAR BRAKE/REAR FORK/REAR X-Town250/300 ABS WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...
Page 214 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER X-Town250/300 ABS SERVICE INFORMATION GENERAL INSTRUCTIONS  When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding.  During servicing, keep oil or grease off the brake pads and brake disk. SPECIFICATIONS Item Standard (mm)
Page 215 15. REAR BRAKE/REAR FORK/REAR X-Town250/300 ABS WHEEL/REAR SHOCK ABSORBER REAR BRAKE Brake Fluid Tube Bolt REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper.
Page 216 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION X-Town250/300 ABS Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston.
Page 217 . REAR WHEEL/REAR BRAKE/ X-Town250/300 ABS REAR SUSPENSION ＊ Make sure the spring plate next to the brake pad dowel pin orientation. Install two brake pads. Brake Pads INSTALLATION Brake Fluid Tube Bolt Install the brake caliper to the rear fork and tighten the two bolts.
Page 218 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION X-Town250/300 ABS REAR FORK REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Bear Axle Nut Bolt Remove the right rear shock absorber lower mount bolt. Remove the rear axle nut and remove the collar.
Page 219 . REAR WHEEL/REAR BRAKE/ X-Town250/300 ABS REAR SUSPENSION REAR WHEEL REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. Remove the rear wheel. Bear Axle Collar INSTALLATION The installation sequence is the reverse of removal.
Page 220 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION X-Town250/300 ABS 15-8...
Page 221: Battery/Charging System
. BATTERY/CHARGING SYSTEM X-Town250/300 ABS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 16-1 CHARGING CIRCUIT ----------------------------------------------------- 16-1 SERVICE INFORMATION ------------------------------------------------ 16-2 TROUBLESHOOTING ----------------------------------------------------- 16-3 BATTERY CHARGING --------------------------------------------------- 16-4 CHARGING SYSTEM ---------------------------------------------------- 16-6 REGULATOR/RECTIFIER ---------------------------------------------- 16-6 16-0...
Page 222 . BATTERY/CHARGING SYSTEM X-Town250/300 ABS CHARGING SYSTEM LAYOUT BATTERY REGULATOR/RECTIFIER 16-1...
Page 223 X-Town250/300 ABS . BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ 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 224 . BATTERY/CHARGING SYSTEM X-Town250/300 ABS TROUBLESHOOTING No power Intermittent power  Dead battery  Loose battery cable connection  Disconnected battery cable  Loose charging system connection  Fuse burned out  Loose connection or short circuit in  Faulty ignition switch ignition system Low power Charging system failure...
Page 225 X-Town250/300 ABS . BATTERY/CHARGING SYSTEM BATTERY REMOVAL The battery is in the battery box below seat. 1. Remove the seat. 2. Remove the met-in box 3. Remove the battery retainer. 4. Pull battery out to expose the terminal leads 5. Disconnect the negative (-) terminal lead from the battery first, then disconnect the positive (+) terminal lead.
Page 226 . BATTERY/CHARGING SYSTEM X-Town250/300 ABS BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. ＊ Turn the power ON/OFF at the charger, not at the battery terminals.
Page 227 X-Town250/300 ABS . BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator/rectifier connectors. Check the connectors for loose contacts of corroded terminals. Regulator/Rectifier BATTERY WIRE Measure the voltage between the Red/White wire terminal and ground. There should be battery voltage at all times. GROUND WIRE Check the continuity between the Green wire terminal and ground.
Page 228 . BATTERY/CHARGING SYSTEM X-Town250/300 ABS CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals. Standard: 0.4 ~ 0.6  (20º C/68º F) Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground. There should be no continuity.
Page 229: Ignition System
17. IGNITION SYSTEM X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM ________________________________________________________________________________ IGNITION SYSTEM LAYOUT ----------------------------------------------------------------- 17-1 SERVICE INFORMATION --------------------------------------------------------------------- 17-2 TROUBLESHOOTING -------------------------------------------------------------------------- 17-2 SPARK PLUG ------------------------------------------------------------------------------------- 17-3 IGNITION COIL INSPECTION ---------------------------------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------------------------------ 17-4 TILT SWITCH INSPECTION ------------------------------------------------------------------ 17-4 17-0...
Page 230: Ignition System Layout
17. IGNITION SYSTEM X-Town250/300 ABS IGNITION SYSTEM LAYOUT Ignition Switch Crank Position Sensor Tilt Switch Ignition Coil IGNITION CIRCUIT 17-1...
Page 231: Service Information
17. IGNITION SYSTEM X-Town250/300 ABS SERVICE INFORMATION 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 17-2. ...
Page 232: Spark Plug
17. IGNITION SYSTEM X-Town250/300 ABS Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. (  2-6) Remove the ignition coil. Primary Coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil, primary coil and secondary coil.
Page 233: Generator Inspection
17. IGNITION SYSTEM X-Town250/300 ABS A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Crank Position Sensor Wire Coupler Measure resistance between...
Page 234 17. IGNITION SYSTEM X-Town250/300 ABS REMOVAL/INSTALLATION Tilt Switch Connector Screws Disconnect the connector and remove two screws, then remove tilt switch. Installation is in the reverse order of removal. ＊ Install the tilt switch with its “up” mark facing up. Tighten the mounting screws securely.
Page 235: Starting System
18. STARTING SYSTEM X-Town250/300 ABS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM ________________________________________________________________________________ STARTING SYSTEM LAYOUT --------------------------------------------------------------- 18-1 SERVICE INFORMATION --------------------------------------------------------------------- 18-2 TROUBLESHOOTING -------------------------------------------------------------------------- 18-2 STARTER MOTOR ------------------------------------------------------------------------------ 18-3 STARTER RELAY INSPECTION ------------------------------------------------------------- 18-4 18-0...
Page 236 18. STARTING SYSTEM X-Town250/300 ABS STARTING SYSTEM LAYOUT Starter Relay Starter Motor STARTING CIRCUIT Relay 18-1...
Page 237 X-Town250/300 ABS 18. STARTING SYSTEM SERVICE INFORMATION 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 238 18. STARTING SYSTEM X-Town250/300 ABS STARTER MOTOR REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to make sure the starter motor can’t operate securely.
Page 239 18. STARTING SYSTEM X-Town250/300 ABS Starter Motor Cable INSTALLATION Connect the starter motor cable. Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install it to the starter motor. Tighten the two mounting bolts. O-ring STARTER RELAY INSPECTION Disconnect the starter relay wire connector.
Page 240: Lights Switches/ Fuel Pump
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 19- 1 BULB REPLACEMENT --------------------------------------------------- 19- 2 BRAKE LIGHT SWITCH -------------------------------------------------- 19- 6 IGNITION SWITCH -------------------------------------------------------- 19- 6 HANDLEBAR SWITCH --------------------------------------------------- 19- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 19- 9 FUEL PUMP ----------------------------------------------------------------- 19-10 SIDE STAND SWITCH ---------------------------------------------------- 19-13...
Page 241 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS ELECTRICAL EQUIPMENT LAYOUT 19-1...
Page 242: Service Information
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS SERVICE INFORMATION GENERAL ＊ A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing. ...
Page 243: Bulb Replacement
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS BULB REPLACEMENT LICENECE LIGHT Remove the seat assembly and luggage box. Remove the body covers. Disconnect the license bulb socket. Remove the bulb and replace with a new one. 19-3...
Page 244 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Connector Headlight Bulb HEADLIGHT ＊ A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF. Be sure to let it cool down before servicing. REMOVAL Remove the front cover Disconnect the headlight cover...
Page 245 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Highlight wires Put the headlight wires into the headlight unit and then cover the waterproof rubber. Waterproof Rubber Press the waterproof rubber around with hand until its seat. Waterproof Rubber INSPECTION Confirm if the waterproof rubber is covered firmly.
Page 246 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Socket FRONT TURN SIGNAL LIGHT Remove the front cover. Turn the bulb socket, then remove the front turn signal light. Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal.
Page 247 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS REAR TURN SIGNAL LIGHT Remove four Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal. Rear Turn Signal Light 19-7...
Page 248: Brake Light Switch
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS BRAKE LIGHT SWITCH Remove the upper handlebar cover. Disconnect front or rear brake light switch connectors and check for continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.
Page 249 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS RIGHT HANDLEBAR SWITCH Engine Stop Switch INSPECTION Remove the front cover Disconnect right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Starter Switc 19-9...
Page 250: Luggage Box Light Switch
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Dimmer Switch LEFT HANDLEBAR SWITCH INSPECTION Disconnect left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Horn Switch Turn Signal light Switch Passing Switch LUGGAGE BOX LIGHT SWITCH uggage box light switch...
Page 251: Fuel Pump
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Connector FUEL PUMP REMOVAL Remove the seat and met-in Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose. Remove the six nuts and fuel unit connectors then remove the fuel hose.
Page 252 19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. ＊ Before performing the following test, operate the turn signals to determine that the battery circuit is normal. Measure resistance between Red/Black and Green wire of the fuel unit connector.
Page 253: Side Stand Switch
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS Connector SIDE STAND SWITCH INSPECTION Remove the luggage box. Side stand switch is located on side stand. Disconnect the side stand switch connector. There should be continuity between the Yellow/Green and Green with the side stand is up.
Page 254: Horn
19. LIGHTS SWITCHES/ FUEL PUMP X-Town250/300 ABS HORN INSPECTION Remove the front cover. 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 255: Evaporative Emission Control System
EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS EVAPORATIVE EMISSION CONTROL SYSTEM (Apply to models with evaporative emission control system ) SCHEMATIC DRAWING ---------------------------------------------------------- 20-1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION ------------ 20-2 TROUBLESHOOTING -------------------------------------------------------------- 20-2 SERVICE INFORMATION -------------------------------------------------------- 20-3 PERGE CONTROL VALVE ------------------------------------------------------- 20-4 CHARCOAL CANISTER ----------------------------------------------------------- 20-6...
Page 256 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-0 SCHEMATIC DRAWING Air Cleaner Charcoal Canister/ Purge Control Valve Throttle Body Fuel Injector...
Page 257 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION FOREWORD: The Evaporative Emission Control System is abbreviated to E.E.C. System. This device collects the fuel vapor from the fuel tank and then the fuel vapor is drawn into the engine for re-burning to avoid air pollution caused by the fuel vapor diffused into the air.
Page 258 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  Do not smoke or allow flames or sparks near the working area.  Note the locations of tubes for proper installation.  Replace any damaged tube with a new one. ...
Page 259 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-3 PURGE CONTROL VALVE To Throttle Body REMOVAL 1. Remove the front cover. 2. Disconnect the purge control valve vacuum tube that goes to the throttle body and the tubes that go to the air cleaner and charcoal canister.
Page 260 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-5 20-4 PURGE CONTROL VALVE FLOW INSPECTION 1. Connect a vacuum pump to the purge control valve vacuum tube and apply vacuum pressure of 45mm/Hg. 2. Connect a pressure pump to the tube that Pressure Pump goes to the charcoal canister and apply pressure.
Page 261 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS CHARCOAL CANISTER Charcoal Canister To Throttle Body REMOVAL 1. Remove the front cover. 2. Disconnect the charcoal canister tubes that go to the fuel tank and purge control valve. 3. Remove the charcoal canister. To Air Cleaner INSPECTION 1.
Page 262 EVAPORATIVE EMISSION CONTROL SYSTEM X-Town250/300 ABS 20-6...
Page 263 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS ANTI-LOCK BRAKE SYSTEM (ABS) ABS Indicator Light ---------------------------------------- --------- 21－01 ABS Introduction -------------------------------------------- --------- 21－02 ABS Parts Location ----------------------------------------- --------- 21－03 Wheel Speed ------------------------------------------------- --------- 21－04 ABS ECU & ABS Hydraulic Unit ------------------------ --------- 21－06 ABS ECU GUARANTEE ---------------------------------- --------- 21－07 Diagnostic Tool Operation --------------------------------- --------- 21－08 Bosch ABS8m DTC List ----------------------------------- --------- 21－14...
Page 264 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS ABS Indicator Light The ABS indicator light in the meter position. This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving at speed 6km/hr min. It stays off.
Page 265 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS ABS Introduction ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
Page 266 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS Parts Location Front Wheel speed Sensor Front Wheel speed Sensor Rotor Front Wheel speed Sensor’s connector Rear Wheel speed Sensor’s connector Front Wheel speed Sensor Rotor Rear Wheel speed Sensor ABS ECU & ABS Hydraulic Unit ABS diagnosis tool Connector (Near battery position) 21-3...
Page 267 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS WHEEL SENSOR Front Wheel Speed Sensor REMOVAL & INSPECTION Remove the front wheel speed sensor. Install the front wheel speed sensor. Front Wheel Speed Sensor Rotor Remove a bolt attaching to the front wheel speed sensor Front Wheel speed Sensor’s connector Remove the connector of front wheel speed sensor <Front Wheel Speed Sensor>...
Page 268 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS Remove the rear wheel speed sensor. Front Wheel Speed Sensor Rotor Rear Wheel Speed Sensor Remove the connector of rear wheel speed sensor Rear Wheel speed Sensor’s connector <Rear Wheel Speed Sensor> ※ Standard clearance: Less than 0.8mm between the Front wheel speed sensor and Front Wheel Speed Sensor Rotor 21-5...
Page 269 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS ABS ECU REMOVAL& INSTALLATION The coupler is used for automobile’s waterproof. Please take car of operation. Please keep a good ventilating about ECU in order to prevent the ABS ECU from high temperature. (一) Push upward (二) Take right out (三) Finished ABS ECU &...
Page 270 DIAGNOSTIC TOOL OPERATION 1. Connect the KYMCO Fi Diagnostic tool 2. Put the side stand upward and ENG. stop switch is at “RUN” position. 3. Connect the diagnostic tool connector. (KYMCO Fi Diagnostic tool Power comes from vehicle’s Battery) Self-Diagnostic Tool Connector...
Page 271 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS 4. Choose Fi ECU Version and then push down button for three times. ABD2 5. Choose No.2 ABS SYS ECU and then push up button to previous. 6. Confirming ECU Version and then enter ABS system. ABS9.1M 21-8...
Page 272 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS 7. Choose ECU Version and then push “Enter” button. 8. Confirm ABS ECU Version if is LEA7-E00 1.1.1 A7-E00 9. Choose DTC Inspect 21-9...
Page 273 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS 10. Load DTC (Active 、Occurred、History) DTC DISPLAYED 1. Rear wheel speed sensor disconnect 2. Front wheel speed sensor disconnect 21-10...
Page 274 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS DTC CLEARED 1. Choose “Clear DTC” and then push “Enter” button. 2. Clearing DTC completed until the DTC red lamp is off. DATA ANALYZE 1. Choose “DATA Analyze” and then push “Enter” button 21-11...
Page 275 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS 2. Front wheel speed & Rear wheel speed & Battery volt Battery volt: Standard 9.6~16.7V KYMCO Diagnosis 01 Fr Speed 5 km/hr Re Speed 5 km/hr Battery Volt 12.6V ＊ You can turn the front or rear wheel to check if the wheel speed is figured.
Page 276 ANTI-LOCK BRAKE SYSTEM (ABS) X-Town250/300 ABS Bosch ABS8m DTC List Bosch ABS8m DTC LIST Code NO (Diagnostic description Tool ) (PDA) 3620A-LEB2- 5013 Rear Inlet Valve malfunction(EV) 5014 Rear Outlet Valve malfunction (AV) 5017 Front Inlet Valve malfunction (EV) 5018 Front Outlet Valve malfunction (AV) 5019 Valve Relay malfunction (Failsafe relay) 5025 Deviation between Wheel speeds (WSS_GENERIC) 5035 Pump Motor Malfunction...

This manual is also suitable for:

X-town 300 abs

KYMCO X-Town 250 ABS Service Manual

Preface

Exhaust Muffler/Frame Covers

Inspection/Adjustment

Lubrication System

Cylinder Head/Valves

Fuel Injection System

Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem

Ignition System

Lights/Meters/Switches

Quick Links

TABLE OF CONTENTS

Chapters

Troubleshooting

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Summary of Contents for KYMCO X-Town 250 ABS

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Table of Contents