KYMCO X-Town 300 ABS Manual de usuario

X-Town 300 ABS

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO X-Town

300 ABS

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers

which are subject to

removal/installation frequency during

maintenance and servicing

operations.

Section 3 describes the inspection/

adjustment procedures, safety rules

and service information for each part,

starting from periodic maintenance.

Sections 5 to 12 give instructions for

disassembly, assembly and

adjustment of engine parts. Section

13 is the AFI system. Section 14 to 15

is the removal/ installation of chassis.

Section 16 to 19 states the testing

and measuring methods of electrical

equipment.

Most sections start with an assembly

or system illustration and

troubleshooting for the section. The

subsequent pages give detailed

procedures for the section.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPT.

EDUCATION SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME

COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN

PULLEYS/V-BELT

FINAL REDUCTION

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

The information and contents

included in this manual may be

different from the motorcycle in

case specifications are changed.

CHASSIS

ELECTRICAL

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

X-Town300 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

1. GENERAL INFORMATION

1-1

X-Town300 ABS

SERIAL NUMBER

Location of Frame Serial Number

(inside luggage box)

Location of Vehicle Identification

Number (VIN)

Location of Engine Serial Number

1. GENERAL INFORMATION

1-2

X-Town300 ABS

SPECIFICATIONS

Name X-Town 300 ABS

Model No. KS60AB

Overall length 2250 mm

Overall width 800 mm

Overall height 1385 mm

Wheel base 1545 mm

Engine type 4 stroke O.H.C.

Displacement 275.6 cc

Fuel Used 92# nonleaded

gasoline

Front wheel 78

Rear wheel 117

Total 195

Front wheel 125

Rear wheel 220

Total 345

Ground clearance (mm) 150

Braking distance (m) 7.9m / 40 km/hr

Min. turning radius (m) 2.6

Engine part

Starting system Starting motor

Type Gasoline 4-cycle

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-

sphere

Valve arrangement

O.H.C. 4V

Bore x stroke (mm)

72.7 * 66.4

Compression ratio

10.6:1

Compression pressure

(kg/cm

²-

rpm)

Max. output (

/rpm)

17.05 / 8000

Max. torque (

N.m

/rpm)

22.5 / 6500

Open 13° BTDC

Close 38° BTDC

Open 40° BTDC

Close 3° BTDC

Intake 0.1

Exhaust 0.1

Idle speed (rpm) 1600±100

rpm

Cooling Type

Liquid cooling

Lubrication type Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

Oil filter type

Full-flow filtration

Oil capacity

1.1 liter

Exchanging capacity

0.9 liter

Fi injection system

Air cleaner type & No Paper element, wet

Fuel capacity 13 liters

Brand Keihin

Throttle Body Butterfly type

Venturi diameter (mm) 32

Fuel pump pressure 3.0 bar

Electrical system

Ignition type ECU

Ignition timing 10°BTDC / idle

33° / 6500min

Spark plug

DPR6EA-9

Spark plug gap

0.8~0.9mm

Battery Capacity

12V12AH

Transmission system

Clutch type

Dry multi-disc

Transmission type CVT

Operation type Auto centrifugal

Reduction gear type

Two-stage reduction

1st 1

2nd 7.3

Moving device

Tire type Tubeless

Front wheel 120/80-14 58S

Rear wheel 150/70-13 64S

Front wheel 2.0

Rear wheel 2.25

Wheel material Aluminium

Left 40

Right 40

Front ABS

Rear ABS

Damping Device

Front Telescope

Rear Swing arm

Shock absorber

stroke

Front 110 mm

Rear 100 mm

Curb weight

(kg)

Max. weight

(kg)

Valve

clearance

Exhaust

Timing

Intake Timing

Tire spec.

Tire pressure

(kg/cm²)

Turning angle

Brake type

Suspension

type

Reduction

ratio

1. GENERAL INFORMATION

1-3

X-Town300 ABS

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure to

use special tools for removal and

installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

 Apply or add designated greases and

lubricants to the specified lubrication

points.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-)

terminal before operation.

 When using a spanner or other tools,

make sure not to damage the motorcycle

surface.

 After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

 If the fuse is burned out, find the cause

and repair it. Replace it with a new one

according to the specified capacity.

1. GENERAL INFORMATION

1-4

X-Town300 ABS

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock on

the connector shall be released before

operation.

 Hold the connector body when connecting

or disconnecting it.

 Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

 The connector shall be inserted

completely.

 If the double connector has a lock, lock

it at the correct position.

 Check if there is any loose wire.

 Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

 Check the double connector cover for

proper coverage and installation.

 Insert the terminal completely.

 Check the terminal cover for proper

coverage.

 Do not make the terminal cover opening

face up.

 Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

 After clamping, check each wire to make

sure it is secure.

Confirm

Capacity

1. GENERAL INFORMATION

1-5

X-Town300 ABS

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

 When fixing the wire harnesses, do not

make it contact the parts that will generate

high heat.

 Route wire harnesses to avoid sharp

edges or corners. Avoid the projected

ends of bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

 Route harnesses so they are neither

pulled tight nor have excessive slack.

 Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge

or corner.

 When rubber protector cover is used to

protect the wire harnesses, it shall be

installed securely.

 Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or

replace it.

 When installing other parts, do not press

or squeeze the wires.

 After routing, check that the wire

harnesses are not twisted or kinked.

Do not pull

too tight！

No Contact

Do not press or

squeeze the wire

1. GENERAL INFORMATION

1-6

X-Town300 ABS

 Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or surrounding parts in all steering

positions.

 When a testing device is used, make sure

to understand the operating methods

thoroughly and operate according to the

operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Do you understand

the instrument？

Remove Rust！

1. GENERAL INFORMATION

1-7

X-Town300 ABS

 Symbols:

The 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

lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil

Grease

Gear Oil

＊

1. GENERAL INFORMATION

1-8

X-Town300 ABS

TORQUE VALUES

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