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By KWANG YANG Motor Co., Ltd. First Edition, FEB

1. 4 3 OIL PRESSURE SWITCH 4 4 OIL PRESSURE RELIEF VALV E 4 4 OIL 4 5 OIL COOLER 4 8 4 0 KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 4 1 KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 SERVICE INFORMATION GENERAL INSTRUCTIONS The pump service may be done with the engine installed In the frame e When removing and installing the oil pump use care not to allow dust or dirt to enter the engine e f any portion of the oil pump 15 worn beyond the specified service limits replace the oil pump as an assembly e After the engine has been installed check that there are no oil leaks and that oil pressure 15 correct e For oil pressure indicator inspection refer to section 20 of this manual SPECIFICATIONS Unit mm STANDARD SERVICE LIMIT 4 stroke or equivalent motor Recommended engine API service classification SJ Viscosity SAE 5W 50 Oil pump rotor Body clearance 0 15 0 2 mm 0 25 mm Side clearance 0 04 0 09 mm 0 12 mm TORQUE VALUES Oil pump bolt 0 8 1 2 kgfem Oil cooler bolt 1 2 1 8 kgfem Oil pressure switch 1 1 4 kgfem Oil filter cartridge 2 0 3 0 kgfem TOOLS Oil filter wrench A120E00061 4 LUBRICATION SYSTEM TROUBLESHOOTING
2. 9 5 Faulty intake manifold Remove spark plug and O ring install it into spark plug Cap to test e connecting it to engine d EE OFaulty CPS Faulty ignition coil Broken or shorted high tension wire Faulty spark plug Fouled throttle body Faulty TPI reset 1 26 1 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Connect the diagnostic tool then check EMS and correct problems eee Incorrect timing Correctly adjusted Incorrectly adjusted Check fuel pump for fuel supply Fuel flows freely Fuel flow restricted Check throttle body or air cleaner for clogging Not clogged Clogged Correct Incorrect Check valve spring tension 1 27 KYMCO MYROAD 7001 Probable Cause Faulty spark plug Faulty ignition coil Faulty CPS OImproperly adjusted valve clearance Worn valve seat Empty fuel tank Clogged fuel hose or filter Faulty fuel pump Clogged fuel injector Clean and unclog Cam timing gear aligning marks not aligned OFaulty spring KYMCO 1 GENERAL INFORMATION MYROAD 7001 ENGINE NOISE Q Valve clearance too large Valve 1 Worn camshaft lobe Q Worn piston rings Piston noise Worn piston pin and connecting rod small end Excessive carbon build up in combustion chamber Damaged cam chain tensioner
3. Probable Cause Turn ignition switch e OFF Not stopped Stopped DFaulty starter pinion Starter relay shorted or stuck 1 30 1 GENERAL INFORMATION MYROAD 7001 closed NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Connect the diagnostic tool then check EMS and correct problems Replace with a new spark plug and inspect again Faulty spark plug high tension wire for looseness Faulty spark plug E Check ignition unit i coupler for looseness Measure resistance between terminals of ignition unit coupler OFaulty ignition switch Faulty CPS Faulty ignition coil Broken wire harness Poorly connected coupler Faulty ignition coil KYMCO 1 GENERAL INFORMATION MYROAD 7001 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection A djustment Probable Cause Start engine and test bes gt limit voltage of battery terminals edil aT E Normal voltage o Faulty regulator rectifier Faulty battery s E between Generator arueemsu atti gt i coll terminals Open circuit between AC generator 3 yellow wires Test output voltage of I regulator rectifier coupler red wire DEl Faulty AC generator Normal voltage Loose regulator rectifier coupler OLimi
4. wi kass Lamm Ee LE meer m an werr zs 20 28 2 4 use posos ae AA man sino 2 43 0 24 30 2 1 fume soc 3901 05 06 iras memo 20 25 ps Ramen was eese no 45 S feer mo ere 0 3 1 5 1 GENERAL INFORMATION SPECIAL TOOLS MYROAD 7001 Lock nut socket wrench Oil seal amp bearing installers Universal holder Flywheel holder Bearing pullers Tappet adjuster Bearing pullers Valve spring compressor Oil filter cartridge wrench Clutch spring compressor Flywheel puller Clutch fixed bolt Balancer gear nut wrench Connecting rod bolts wrench 1 9 120 00007 120 00014 120 00017 120 00021 A120E00030 A120E00036 A120E00037 A120E00040 A120E00052 A120E00053 A120E00061 A120E00038 120 00080 120 00081 Steering stem removal or install Oil seal amp bearing install Holding clutch for removal A C generator flywheel holding Bearing removal Tappet adjustment Bearing removal Valve removal Cartridge removal or install Clutch disassembly A C generator flywheel removal Clutch Balancer gear Connecting rod KYMCO 1 GENERAL INFORMATION MYROAD 7001 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAE 5W 50 Camshaft protruding surface eAPI SJ Eng
5. 5 000 BOLT SPECIAL MI8XI 0 521 8 1 8 2 2 LIFTER TENSIONER HEAD COMP 90018 KKE5 E000 BOLT HEAD 1 8 11 8 0 8 1 2 APPLY THREAD LOCK OO WAN BLUE Pater 2 2 2 2 APPLY THREAD LOCK NYLOK BLUE PATCH 2 d d APPLY THREAD LOCK NYLOK BLUE PATCH 1 8 9 30 31 32 1 GENERAL INFORMATION KYMCO MYROAD 7001 re MIL EE BEE rr mus e ass ra oci IO O E mer 2 re tor screw Jrs esce pmaur mens sess 3x fp otE WoT 1 cur SUSPENSION maur roer 7474 zm 23 nora m nee O a8 40 AE 4 gweE J j wes Je ze EE Lais TO e mazo 124 19 1 afan sl O 12 2 2 6 SCREW FLAT 93600 04012 16 umm EE Modulator ABS OE a base zm hr baang 75 65 jo wr Dous mr sunt T3 8 5 75 65 jo oe wana wisi pe loud ie 12 Mr we monas 3 5 1 3545 ico puer snc sono pwrruw O 10 5 m EE SR A xx
6. 22282 connectors motor directly to 2 battery Worn brushes GE Starter RT n Starter does not turn Q Open shorted wires or rotor Open starter motor cable Loose connectors Open wire harness 2 Starter motor turns Suen or idles Inspection Adjustment Probable Cause O ees gt Check battery circuit i by operating turn signals Signals operate properly S ta een gt Signals dim remain on or don t operate Starter motor turns normally Hard to turn DWeak or dead battery Connect starter u motor directly to u S EI battery Starter motor turns slowly Turns easily Loose connector or terminal 2Poor contact in starter relay Faulty starter clutch Seized cylinder Broken or shorted starter motor cable 3 Starter motor does not stop turning Imspection Adjustment Probable Cause Turn ignition switch v OFF Not stopped Faulty starter pinion Stopped Starter relay shorted or stuck closed 1 18 KYMCO 1 GENERAL INFORMATION MYROAD 7001 NO SPARK AT SPARK PLUG Inspection A djustment Probable Cause Replace with a new spark plug and inspect again DP gt Weak spark Good OFaulty spark plug high tension wire gt looseness Check ignition unit S coupler for looseness g
7. 35500 KED9 9000 SW ASSY OIL PRESSURE ER us 13 1 L CRANK CASE 12361 GFY6 9010 HOLE CAP TAPPET ADJUSTING 5 19 6 1 2 14 7 L CRANK CASE 15421 LBA2 E000 BOLT OIL COOLER 1 2 1 8 14 7 L CRANK CASE 1541A LBA2 E000 ELEMENT COMP OIL FILTER M20XI 5 4 6 5 I 6 6 3 6 5 9 4 9 4 I 9 4 33 3 9 2 3 3 3 33 2 48 1 4 5 APPLY Loctite 243 8 1 2 wasa EE NUT LOCK 22 MM R H 22 1 COUNTER SHAFT 90023 KKE5 E000 BOLT 12 45 9 127 5 11 13 DRIVE SHAFT 90201 5 000 NUT FLANGE 16MM 18 5 88 3 8 1 2 2 131 3 APPLY Loctite 243 OIL PUMP 95701 06025 08 BOLT FLANGE 6X25 NOE 0X1 25 1 25 L CRANK 9052A GFY6 9500 BOLT ASSY DRAIN PLUG 19 6 29 4 2 2X1 0 2X1 25 122 3 1200 APPLY OIL 8 d d d d 24 APPLY OIL 2 2 3 5 1 0 l 2 3 5 6 APPLY THREAD LOCK NYLOK BLUE PATCH 23 5 29 4 2 MISSION COVER 95101 08035 08 BOLT FLANGE 835 C 1 25 24 5 28 4 2 5 2 9 95701 08045 08 BOLT FLANGE 8245 C FLANGE SWING 90010 KKE5 E000 SPOCKET BOLT 8x22 B 34 3 2 5 3 5 ARM CASE PIVOT R SWING 90010 KKE5 E000 5 BOLT 8x22 B wu 34 3 2 5 3 5 ARM FLANGE SWING 90010 KKE5 E100 SPOCKET BOLT 8x30 B 55 34 3 2 5 3 5 ARM ENCODER PLATE 94050 06080 NUT FLANGE 6MM C Sue 0 8 1 2 PHASE MAIN GEAR A 23115 5 1000 BOLT 8 1 25 8 1 25 31 4 35 3 3 2 3 6 ASSY SPRING CASE ASSY 90005
8. Bent fork tube or shock rod Fork tube and slider binding Fork spring and slider binding Damaged shock stopper rubber Loose steering stem nut Probable Cause Q Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Q Worn brake linings Foreign matter on brake linings GRough brake drum contacting area Q Worn brake linings Worn brake cam contacting area on Q Worn brake linings Foreign matter on brake linings OSluggish or elongated brake cables Brake shoes improperly contact Water and mud in brake system or grease on brake linings 1 22 KYMCO 1 GENERAL INFORMATION MYROAD 7001 TROUBLESHOOTING XCITING 250 ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Make sure engine stop switch is ON Put the side stand up Connect the diagnostic tool then check EMS and correct problems Empty fuel tank Clogged fuel pump Fuel reaches fuel Fuel does not reach filter injector fuel injector Faulty fuel pump Faulty fuel cut off Remove spark plug and G Cracked fuel hose install it into spark plug cap to test spark by connecting It to engine x eet gt ground OFaulty spark plug d cmd Fouled spark plug Faulty ignition coil Spark jumps Weak or no spark 5 Broken or shorted ignition coil Broken or shorted CPS
9. KYMCO MYROAD 7001 KWANG YANG Motor Co Ltd First Edition FEB 2011 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 KKES S00 This Service Manual describes the technical features and servicing procedures for the KYMCO XCITING 700 Section contains precautions for all operations stated in this manual Read them carefully before any operation 1s started Section 2 15 the removal installation procedures for the frame covers which are subject to higher 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 8 through 14 give instructions for disassembly assembly and adjustment of engine parts Section 15 through 17 1s the removal installation of chassis Section 18 through 21 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 The information and contents included in this manual may be different from the motorcycle in case specifications are changed KYMCO reserves the right to make changes at any time without notice and without incurr
10. 4 10
11. Worn cam gear teeth Cam chain noise Worn or damaged cam chain Extended cam chain OFaulty crankshaft bearing Crankshaft noise Worn crank pin bearing Q Worn or damaged final reduction gears Gear noise Worn final reduction gear shaft splines 1 28 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS 1 29 Symptom Engine starts but motor cycle does not Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There 1s abnormal noise or smell while running KYMCO MYROAD 7001 Probable Cause Q Worn or slipping drive belt Broken ramp plate Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot Worn or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings DWorn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings or grease fouled drive belt 2 Worn drive belt Weak driven face spring Worn or seized driven pulley bearings KYMCO 1 GENERAL INFORMATION MYROAD 7001 STARTER MOTOR 1 Starter motor won t turn
12. Imspection Adjustment Probable Cause Stoplight does not come on Check operation of stop switch by applying brake Stoplight comes on Burned out fuse 2Weak or dead battery Faulty stop switch Loose or disconnected Check battery circuit connectors operating turn S Broken or shorted ME signals switch wire Signals operate Signals dim remain i starter relay by depressing starter button GE E EE Relay operates Relay SC OPoor sia buton connection properly operate 2 or shorted starter relay Gees 4 connectors motor directly to Dunes bn necem ur REDE gt battery Worn brushes Seu de Siirler Hotar Ge Starter dogs not Q Open Of shorted wires rotor Open starter motor cable Loose connectors Q Open wire harness 2 Starter motor turns hw or idles Imspection Adjustment Probable Cause O AO Bee Check battery circuit by operating turn signals Sisto mirare ue NS dea TED M DET UR DP P SDN S Signals operate Signals dun TUR properly on or don t operate DWeak or dead battery Connect starter motor directly to SE battery dc E DLoose connec tor or terminal rns slowl 2 Bx Faulty starter clutch Broken or shorted starter motor cable O gt 3 Starter motor does not stop turning Inspection Adjustment
13. Oil level low consumption e External oil leak e Worn piston ring e ncorrect piston ring installation e Worn valve guide or seal Oil contamination White appearance e From coolant mixing with oil Faulty water pump mechanical seal Faulty head gasket Water leak In crankcase No oil pressure e Oil level too low e Oil pump drive chain broken e Oil pump drive sprocket broken e Oil pump damaged pump shaft e nternal oil leak Low oil pressure e Pressure relief valve stuck open e Clogged oil filter and strainer screen e Oil pump worn or damaged e nternal oil leak e ncorrect oil being used e Oil level too low KYMCO MYROAD 700i High oil pressure e Pressure relief valve stuck closed e Plugged oil filter gallery or metering orifice e Faulty oil pump Seized engine e No or low oil pressure e Clogged oil orifice passage e Internal oil leak e Non recommended oil used Oil contamination e Deteriorated oil e Faulty oil filter e Worn piston ring White appearance with water or moisture Damaged water pump mechanical seal Damaged head gasket Oil relief not frequent enough Oil pressure warning indicator does not work e Faulty oil pressure switch e Short circuit in the indicator wire e Low or no oil pressure KYMCO 4 LUBRICATION SYSTEM MYROAD 700i OIL PRESSURE SWITCH CHECK Start the engine Check the o1l pressure indicator goes out after one or tw
14. Rear Brake Lever 3 20 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 sure front wheel does not turn while the brake lever 1s operated Firmly apply the brake lever and check that no atr has entered the system If the lever feels soft or spongy when operated bleed the air from the system Inspect the brake hose and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE LOCK OPERATION INSPECTION Stop the engine and put the scooter on its center stand on level ground Pull up the parking brake lever slowly and check the parking brake lever stroke Parking brake lever stroke 3 6 cm If out of specification adjust the parking brake lever 3 21 3 INSPECTION ADJUSTMENT ADJUSTMENT Place the scooter on its center stand Release the parking brake lever lock Pull up the parking brake lever Loosen the lock nut Turn the adjust bolt until you feel resistance when turn the rear wheel by your hand Hold the adjust bolt and tighten the lock nut securely Release the parking brake lever Make sure the rear wheel turns smoothly Pull the parking brake lever slowly and check the lever stroke Standard 3 6 notches HEADLIGHT AIM Place the scooter on a level surface Adjust the headlight beam vertically by turning the vertical beam adjuster
15. Speedometer Connector Disconnect the speedometer connector and remove meter panel INSTALLATION Installation 15 the reverse order of removal KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER METER REMOVAL Remove the meter panel Remove two screws and meter INNER COVER REMOVAL Remove the front cover Remove the floorboard Remove the meter panel Remove the shutter screw and shutter Cap Garnish Turn the fuel fill cap garnish counterclockwise and remove it Remove three screws and disconnect the fuel fill duct Screws 2 17 KYMCO 2 COVERS EXHAUST MUFFLER 700 Remove 2 bolts from front panel floor INSTALLATION Installation 15 1n the reverse order of removal FRONT LOWER COVER REMOVAL Remove the panel floor Remove the screws from lower cover Remove the lower cover 2 19 KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater O2 sensor Remove screws from muffler protector Loosen the rear muffler cover screws Remove the exhaust pipe joint nuts and gt exhaust pipe Remove muffler Bolt Bolt INSTALLATION Replace the gaskets with new ones Install the exhaust pipe and tighten the joint nuts Torque 1 0 1 4 Install the muffler and tighten the mount bolts Torque 3 2 3 8 kg m
16. terminal completely Check the terminal cover for proper coverage not make the terminal cover opening face up B Secure wire harnesses to the frame with thelr respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses X X KS S 4 1 GENERAL INFORMATION After clamping check each wire to make sure 1t 15 secure O X 999 pe Pa Do not squeeze wires against the weld or 1ts clamp O x Qu A B After clamping check each harness to make sure that it is not interfering with any moving or sliding parts O Eat T a E B When fixing the wire harnesses do not make it contact the parts which will generate high heat B Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws B Route wire harnesses passing through the side of bolts and screws Avoid projected ends of bolts and screws KYMCO MYROAD 700i 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 B When rubber protecting cover is used to protect the wire harnesses it shall be installed securely 4 Do not break the sheath of wire B f a wire or harness 15 with a broken sheath repair by wrapping
17. A clockwise rotation moves the beam up and counterclockwise rotation moves beam down Adjust the headlight beam horizontally by turning the horizontal beam adjuster A clockwise rotation moves the beam toward the right side of the rider Adjust the headlight beam as specified by local laws and regulations KYMCO MYROAD 7001 N WN ab p Nut Bolt Horizontally Adjusting Screw Vertically Adjusting Screw 3 22 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i SIDESTAND Support the scooter on a level surface Check the side stand spring for fatigue or damage Check the side stand assembly for smooth movement and lubricate the side stand pivot if necessary Check the side stand ignition cut off system Start the engine Y Fully lower the side stand while running the engine Y The engine should stop as the side stand is lowered If there 15 a problem with the system check the side stand switch SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times Check the entire assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts 3 23 3 INSPECTION ADJUSTMENT SUSPENSION INSPECTION Check the action of the shock absorber by compressing 1t several times Check the entire shock absorber
18. Body cover REAR BODY COVER REMOVAL Remove the luggage box Remove the rear spoiler Remove two screws and rear body cover Be careful not to damage the tabs on the rear body cover INSTALLATION Installation is in tise reverse order of removal KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER TAILIGHT REAR TURN SIGNAL LIGHT REMOVAL Remove the side and rear body cover Remove bolts and taillight rear turn signal light INSTALLATION Installation 15 1n the reverse order of removal REAR LOWER COVER REMOVAL Remove the side body cover Remove the rear lower cover Rear Lower Cover REARVIEW MIRROR REMOVAL Remove bolts lid Remove three bolts and rearview mirror 2 11 KYMCO 2 FRAME COVERS MYROAD 7001 EXHAUST MUFFLER Remove the two bolts rearview mirror holder and seat INSTALLATION Installation 15 1n the reverse order of removal WINDSHIELD REMOVAL Remove four screws and windshield garnish ES le Windshield Garnish Remove 6 bolts and windshield Be careful not to scratch or damage the windshield surface INSTALLATION Installation is 1n the reverse order of removal 2 12 KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER FRONT COVER REMOVAL The priority to remove is front cover with head lights then tunnel leg shield 1141 KKES5 there are some bolts and screws hide inside If you pull bo
19. Faulty ignition switch Remove the fuel InJector start starter motor to check fuel x gt injector operation e m i supply No fuel supply Clogged fuel 3 Faulty ECU To 77 compression gt Starter motor idles but A crankshaft does not rotate 2 Valve clearance too small Improper valve and seat contact 4 Worn cylinder and piston rings P SE Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing 1 23 KYMCO 1 GENERAL INFORMATION MYROAD 7001 ENGINE LACKS POWER Inspection A djustment Probable Cause Connect the diagnostic tool then check EMS and correct problems ETPTPLTTLFLPLTTLFPPLLLLPPLLLLPLLLLLPLPLLLLLPULLLLPULLLLLULLLLLPLLLLLPLLLLLPLLLLLLLPULLLLPLLLLLPLLLLLLLLLLLLPLLLLLHFH Start engine and accelerate lightly for i observation Engine speed does Faulty fuel pump not increase Faulty fuel injector sufficiently Improper valve timing Low or no compression DImproper valve clearance 2 Worn valve seat valve stem too protruding DImproper valve and seat contact Normal Abnormal 2 Worn cylinder and piston rings compression compression Blown cylinder head gasket Flaws in cylinder head Check fuelinjesorfor Lon S Improper valve timing clogging Not Clogged Clogged DFouled fuel injector Remove spark plugand 000 inspect
20. Plug not fouled or Plug fouled or DFouled spark plug discolored discolored 2 Incorrect heat range plug A Remove oil dipstickand check oil level and condition s Oil level too high contaminated contaminated Oil not changed gt Valve train lubricated Valve train not Faulty oil pump properly lubricated properly CSC Sg bolts and inspect OInsufficient coolant Check if engine overheats essemus gt 2 Faulty thermostat Worn cylinder and piston rings Mixture too lean Engine does not G Poor quality fuel overheats 5 Excessive carbon buildup in combustion chamber Ignition timing too early Air in cooling system 1 24 1 GENERAL INFORMATION MYROAD 7001 A eege eege Gebees eet Eesen kaa MExcessive carbon build up In 4 2 oe Engine d t knock Poor quality fue lIenition timing too early 1 25 KYMCO 1 GENERAL INFORMATION MYROAD 7001 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Connect the tool then check EMS and Correct problems E tt e AO e D Faulty ignition coil Faulty CPS O Faulty ECU clogging Fouled fuel injector Faulty fuel pump Check intake manifold for air leaks Damage insulator rubber Throttle body not securely
21. 15 very white or glazed appearing then it has been operating much too hot This spark plug should be replaced with the colder plug 4 Recommended spark plug DRSE Measure the spark plug gap between the center and side electrodes with the feeler gauge If necessary adjust the gap by bending the 0 6 0 7 mm side electrode carefully Spark plug gap 0 6 0 7 mm 0 024 0 028 in Install the spark plug in the cylinder head and hand tighten fnen torque to the specification Torque 1 0 1 4 kgem Install the spark plug cap Install the removed parts in the reverse order of removal 3 9 3 INSPECTION ADJUSTMENT KYMCO MYROAD 7001 Inspect and adjust valve clearance while the engine 15 cold Below 35 C 95 F Inspection and adjust Remove the cylinder head cover Remove the timing hole cap and O ring Remove the crankshaft hole cap and O ring Turn the crankshaft clockwise and align the T mark on the flywheel with the index mark on the right crankcase cover The punch marks in and ex on the camshaft should be aligned with the boundary of cylinder head as shown If the punch marks on the camshaft are facing downward turn the crankshaft clockwise one full turn 360 and the punch marks are facing upward Timing Hole Cap O ring gt A Crankshaft Hole Cap O ring Mark i e
22. Cause Check i enition timin g E DFaulty ignition unit Faulty A C generator Correct timing Incorrect timing OImproperly adjusted valve clearance 2 Worn valve seat Check fuel pump for fuel supply DEmpty fuel tank Fuel flows freely Fuel flow restricted GE filter 4 Cracked fuel pump vacuum tube Check carburetor Jets for clogging Incorrect Cam timing gear aligning marks not aligned Check valve spring tension Weak spring Faulty spring 1 15 KYMCO 1 GENERAL INFORMATION MYROAD 7001 ENGINE NOISE Symptom Probable Cause Q Valve clearance too large Valve nolse Worn camshaft lobe Q Worn piston rings Piston noise Worn piston pin and connecting rod small end Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Cam chain noise Worn or damaged cam chain Extended cam chain OFaulty crankshaft bearing Crankshaft noise Worn crank pin bearing Q Worn or damaged final reduction gears Gear noise Q Worn final reduction gear shaft splines 1 16 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS Symptom Engine starts but motor cycle does not Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance There 1s abnorm
23. Install and tighten the band bolts Torque 2 1 kg m 2 19 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i INSPECTION ADJUSTMENT SERVICE INFORMATION 3 1 MAINTENANCE SCHEDUL FUEL LINE 3 5 THROTTLE OPERATION 3 5 AIR CLEANER 3 7 CRANKCASE BREATHER 3 8 SPARK PLUG 3 8 VALVE CLEARANCE 3 10 ENGINE OIL 3 13 ENGINE OIL FILTER CARTRIDGE 3 15 RADIATOR COOLANT 3 16 COOLING SYSTEM 3 17 TRANSMISSION OIL 3 18 BRAKE FLUED 3 19 BRAKE PAD WEAR 3 20 BRAKE SYSTEM 3 20 BRAKE LOCK OPERATION 3 21 HE
24. Mat REMOVAL Remove the floor mat Remove the right and left center body cover KYMCO 2 FRAME COVERS MYROAD 7001 EXHAUST MUFFLER Remove the seven screws Screws Remove two screws Screws Remove the floor skirt Be careful not to damage the tabs on the floor skirt INSTALLATION Installation 15 1n the reverse order of removal FLOORBOARD REMOVAL Remove right and left center body cover Remove right and left floor skirt Remove the luggage box Remove six bolts four screws and floorboard INSTALLATION Installation 15 1n the reverse order of removal 2 8 KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER LICENCE LIGHT REMOVAL Remove two screws Disconnect the license light connector and remove the license light INSTALLATION Installation 15 1n the reverse order of removal Screws Connector REAR FENDER REMOVAL Remove the licence light Remove two screws Remove two nuts and rear fender INSTALLATION Installation 1s in the reverse order of removal 4 Screws 2 9 KYMCO 2 FRAME COVERS MYROAD 700 EXHAUST MUFFLER RIGHT LEFT SIDE BODY COVER REMOVAL Remove the luggage box Remove the rear spoiler Remove two bolts Raise the side body cover disconnect the taillight rear turn signal light connector and remove the side body cover INSTALLATINON Installation 1s 1n the reverse order of removal
25. it with protective tape or replace it s gt B When installing other parts do not press or squeeze the wires Do not press or squeeze the KYMCO 1 GENERAL INFORMATION MYROAD 7001 After routing check that the wire harnesses Symbols are not twisted or kinked The following symbols represent the servicing methods and cautions included in C gt x this service manual D Apply engine oil to the Wire harnesses routed along with WW P ped 2 handlebar should not be pulled tight have E excessive slack or interfere with adjacent lubrication or surrounding parts in all steering positions zt Apply grease for lubrication Grease Transmission Gear Oil 90 Gear Oil E When a testing device is used make sure to Note understand the operating methods thoroughly and operate according to the operating 1 tions Do you understand t ing Ament When rust is found on a terminal remove the rust with sand paper or equivalent before connecting 1 6 KYMCO 1 GENERAL INFORMATION MYROAD 7001 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque 0 5 0 4 5mm bolt and nut E 5mm screw 6mm bolt and nut 1 0 6mm screw SH bolt 0 9 8mm bolt and nut 2 2 6mm flange bolt and nut 1 2 10mm bolt and nut 3 5 Smm flange bolt and nut 2 1 12mm bolt and nut 5 5 10mm flange and nut 4 0 Torque specification
26. the operation of pointer oo Pointer moves in accordance with p float Check connectors for proper connection O Signals operate Signals dim remain properly on or don t operate Probable Cause Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness Poor contact in fuel unit Pointer does not move Pointer does not move in OInsufficient damping oil in accord ance with fuel gauge Loose or disconnected connector Broken or shorted wire in fuel gauge 1 GENERAL INFORMATION KYMCO MYROAD 7001 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Steering 1s heavy Front or rear wheel 15 wobbling Steering handlebar pulls to one side POOR SUSPENSION PERFORMANCE Symptom Suspension 15 too soft Suspension 15 too hard Suspension 15 noisy Symptom Soft brake lever Hard brake lever Hard to brake Poor brake performance Brake squeaks Probable Cause Front and rear tire pressures are normal stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim 3 Loose axle nut Misaligned front and rear wheels 2 Bent front fork Probable Cause Front and rear tire pressures are normal Weak shock spring Excessive load Shock damper oil leaking
27. 01 COOLING SYSTEM _ Lid Screw Check for any coolant leakage from the water pump radiator hoses and hose joints Check the radiator hoses for cracks or deterioration and replace 1f necessary Check that all hose clamps are tight Rubber plate p i TID Check radiator air passages for clogs or T n E d damage _ Straighten any bent fins and remove insects itl ni n Al T i mud or other obstructions with compressed MEET air or low water pressure Replace the radiator if the air flow is restricted over more than 20 of the radiating surface 3 17 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 TRANSMISSION CHANGE Place the scooter in its center stand Remove the transmission oil drain bolt 1 and the transmission oil filler bolt 2 slowly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it EUN Torque 2 3 kgfem oil drain bolt 1 oil filler bolt 2 Fill the transmission case with recommended oil Recommended transmission oil SAE 90 Oil capacity 0 40 L Oil exchanging capacity 0 32L Install the transmission oil filler bolt with a new sealing washer and tighten it 3 18 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 BRAKE FLUID not different type of fluid they are not compatible with ea
28. ADLIGHT AIM 3 22 SIDE STAND 2303 SUSPENSION 3 24 WHEELS TIRES 3 04 STEERING HEAD BEARINGS 3 25 3 0 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i SERVICE INFORMATION GENERAL 4 Place scooter on al level ground before starting any work Gasoline is extremely flammable and is explosive under certain conditions 4 Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasoline 15 stored can cause a fire or explosion 4 the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area 4 The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation sustem in and enclosed area SPECIFICATIONS ITEM SPECIFICATIONS Throttle free play 2 6 mm 1 16 1 4 in Spark plug gap 0 6 0 7 mm Valve clearance 10 22 mm ne oil capacity Atdraining 2 75 Titer Engine oil capacity KYMCO 4 stroke or equivalent Recommended engine oil motor oil API service classification SJ Viscosity 5W50 E
29. CTION ADJUSTMENT MYROAD 700i Remove the atr cleaner element Check the cleaner element Install the removed parts In the reverse order of removal Cleaner Element Air cleaner element removal installation Remove the luggage box Remove the six screws and air cleaner cover CRANKCASE BREATHER Remove the crankcase breather tube plug from the tube and drain deposits into a suitable container Reinstall the crankcase breather tube plug BREATHER HOSE Service more frequently when riding in rain at full throttle or after the scooter 15 washed or overturned Service 1f the deposit level can be seen in the transparent section of the drain tube SPARK PLUG REMOVAL Remove the spark plug maintenance lid Za Spark plug lid 3 8 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 Remove spark plug using a equipped spark plug vvrench or an equivalent tool Inspect or replace as described in the maintenance schedule INSPECTION Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine periodically Whenever removing the carbon deposits be sure to observe the operational color of the spark plug s porcelain tip This color tells you whether or not the standard spark plug is suitable for your type of usage A normal operating spark plug should be The spark plug should be replaced light brown tan color If the spark plug
30. E ERE NEE RER ERR RER ERR ERE RER EEN ERR ERR RER 4 Limit voltage too high 1 20 1 GENERAL INFORMATION 1 FUEL GAUGE MYROAD 7001 1 Pointer does not Sec correctly Ignition switch ON Inspection Adjustment dwasnssaasaanaanaanaanaanaanaanaanaanaannanaanaanaanaanaanaannanaanaanaanaanaanaanaanaanaanaanaanaasaanaanaaanana Check battery circuit by operating turn signals Remove fuel unit and check operation of i pointer by moving float x up and down Float up Full Float down Empty Check operation of pointer opening and shorting fuel unit terminal on wire harness 5o 0 0S 0 E SA A Check connectors for proper connection Probable Cause Burned out fuse 2Weak or dead battery Faulty ignition switch Loose or disconnected connectors Broken wire harness Signals dim remain on or don t operate Faulty float Broken or shorted fuel unit wire Disconnected connector Incorrectly connected connector Broken or shorted wire in fuel gauge 2 Pointer fluctuates or Ignition switch ON Inspection Adjustment Check battery circuit ba Operating turn signals horn Remove fuel unit and check operation of pointer by moving float Oe gt and down a ciertas LU HE E eee RRA D Pointer MOves Move float up and i down rapidly 1 round _ sec to check
31. GINE OIL FILTER CARTRIDGE REPLACEMENT Drain the engine oil Remove and discard the oil filter cartridge using the special tool Tool Oil filter wrench 120 00061 Apply clean engine oil to the new oil filter cartridge threads flange surface and a new O ring Install the new oil filter cartridge and tighten it to the specified torque Torque 2 4 3 kgfem Refill the engine oil 3 15 3 INSPECTION ADJUSTMENT RADIATOR Place scooter on its center stand The reserve tank s under left footboard Check the coolant level through the inspection window 1 at the left side skirt while the engine 15 at the normal operating temperature with the scooter in an upright position If the coolant level 1s below the LOWER level mark 3 remove the left floor mat remove the lid screw and reserve tank lid and the Reserve tank cap 4 and add coolant mixture until 1t reaches the upper level mark 2 Remove the left floor mat and remove screw and reserve tank lid Remove reserve tank cap Check to see if there are any coolant leaks when the coolant level decrease very rapidly If reserve tank becomes completely empty there 1s a possibility of air getting into the cooling system Be sure to remove all air from the cooling system Reinstall the filler cap KYMCO MYROAD 700i Screw Rubber plate 3 16 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 70
32. IONS KYMCO MYROAD 7001 e 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 amp Harness Routing TORQUE VALUES Muffler mount bolt 3 2 3 8 kg m Exhaust pipe joint nut 1 0 1 4 kg m Exhaust pipe band bolt 1 0 1 4 kg m TROUBLESHOOTING Noisy exhaust muffler e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power e Caved exhaust muffler e Clogged exhaust muffler e Exhaust muffler air leaks KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER FRAME COVERS REMOVAL SEAT REMOVAL Unlock the seat with the 1gnition key Open the seat Remove the two nuts and seat damper unit Remove the two nuts and the seat INSTALLATION Installation 1s 1n the reverse order of the removal After installation check the seat installation Nuts by moving the seat LUGGAGE BOX REMOVAL After removal the seat side cover carrier body cover then you can remove the luggage box Remove the screws and bolts Raise the luggage box disconnect the luggage box light and accessory socket connectors INSTALLATION Installation 1s 1n the reverse order of removal Luggage box light Connector 2 3 2 FRAME COVERS EXHAUST MUFFLER FUEL PUMP LID REMOVAL Remove the bolt and lid INSTALLATION Installation 15 1n the reverse order of rem
33. NGINE OIL STRAINER Sua SNR ENGINE IDLE SPEED RADIATORCOOLANT NOTE6 __ i I IR COOLING SYSTEM uu Tc E TUIS SUPPLY SYSTEM TRANSMISSIONOIL 5 DRIVEBELT j NOTE4 J CLUTCH SHOE WEAR BRAKE LL 5 BRAKELIGHTSWITCH BRAKE LOCK OPERATION i SIDESTAND suseNsoON ELL HEADUGHTAM o NUTS BOLTS FASTENERS i ilinh WHEELSTIRES STEERINGBEARINGS Jii Ji 3 3 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i NOTE 1 At higher odometer readings repeat at the frequency interval established here 2 Service more frequently if the scooter 15 ridden in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Inspect every 18000 km 12000 mi after replacement 5 Replace every 1 year or every 10000km 6000m1 whichever comes first 6 Replace every 2 year or at indicated odometer interval whichever comes first 7 Replace every 2 years Replacement requires mechanical skill KYMCO 3 INSPECTION ADJUSTMENT 7001 K e Do not smoke or allow flames or sparks in your working area FUEL FILTER Visually check the fuel filter If accumulation of sediment or clogging is found r
34. al noise or smell while running Engine lacks power at high speed KYMCO MYROAD 7001 Probable Cause Q Worn or slipping drive belt Broken ramp plate Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot Q Worn or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings DWorn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings KYMCO 1 GENERAL INFORMATION MYROAD 7001 STARTER MOTOR 1 Starter motor won t turn Imspection Adjustment Probable Cause Check operation of i stop switch by Burned out fuse applying brake Weak or dead battery Stoplight comes on Stoplight does not Faulty stop switch E ES MES come on Loose or disconnected Check battery circuit connectors by operating turn M gt Broken or shorted i signals switch wire signals operate Signals dim remain starter relay by depressing starter button ON Relay operates Relay SE Poor pus button someon properly operate Open or shorted starter relay s
35. assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 9 Check that all safety clips clamps and cable stays are In place and properly secured WHEELES TIRES Tire pressure should be checked when the tires are cold KYMCO MYROAD 700i 3 24 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i Recommended tire size Tire size front 120 70 R15 Tire size rear 160 60 R 14 Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limits Minimum tread depth Front 1 6 mm Rear 2 2 mm STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar rotation Support the scooter securely and raise the front wheel off the ground Check that the handlebar moves freely from side to side If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings 3 25 KYMCO 4 LUBRICATION SYSTEM MYROAD 700i LUBRICATIONSYSTEM SERVICE INFORMATION 4 2 TROUBLESHOOTING
36. ch other Do not allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system 15 serviced Brake fluid level inspection With the scooter in an upright position check the front and rear fluid level The level should be above the lower level mark If the level 1s at or below the lower level mark L check the brake pads for wear Worn break pads should be replaced immediately If the pads are not worn have your brake system inspected for leaks Do not ride your scooter unless the brakes are in perfect working order Brake fluid type DOT 4 from a sealed container Note Other checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings 3 19 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 PAD WEAR Brake pad wear depends upon severity of usage the type of riding and road conditions Generally the pads will wear faster on wet and dirty roads Inspect the pads at each regular maintenance interval Front Rear brake Check the cutout in each brake pad the cutout should be visible indicating that brake pad 15 not worn down to the brake rotor If either pad is worn to the cutout replace both pads as a set BRAKE SYSTEM INSPECTION Check the free play of front rear brake lever Standard of free play 10 20 mm
37. d auto fuel valve Clogged float oil passage Clogged fuel tank cap breather hole OClogged fuel strainer Clogged fuel filter Faulty fuel pump OR 5 Fuel reaches carburetor fuel injector Remove spark plug and install it into spark plug Cap to test spark by connecting it to engine ground Faulty spark plug Fouled spark plug Faulty ignition unit Spark jumps Weak or no spark Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil DFaulty ignition switch Test cylinder mn Starter motor idles but 2 Valve clearance too small 3 Improper valve and seat contact 4 Worn cylinder and piston rings Ge EE Blown cylinder head gasket Flaws 1 cylinder head VsSeized valve Improper valve timing BEE follow ing normal Starting procedure DFaulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Engine fires but does not start Remove spark plug and inspect again NN gt Dry spark plug Flooded carburetor Faulty auto bystarter Throttle valve excessively open Wet spark plug 1 12 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection A djustment Symptom Start engine and 00 m ji accelerate lightly for Engine speed Engine speed does increases not increase II sufficiently Check ignition tim
38. ean Poor quality fuel Excessive carbon buildup in combustion chamber Qlenition timing too early Air in cooling system DExcessive carbon build up in combustion chamber Poor quality fuel Clutch slipping 4 Mixture too lean Ignition timing too early KYMCO 1 GENERAL INFORMATION MYROAD 7001 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause DFaulty ignition unit Faulty A C generator Check carburetor pilot i screw adjustment D Mixture too rich turn screw out Mixture too lean turn screw in Check intake manifold for air leaks Damaged insulator rubber cd 3 Faulty intake manifold gasket Remove spark plug and 4 Deformed carburetor O ring install it into spark plug Cap to test spark by connecting it to engine ground DFaulty or fouled spark plug 2 Faulty ignition unit k ter SFaulty A C generator Good Good spark Faulty ignition coil Broken or shorted high 1 tension wire Faulty ignition switch Check carburetor atr i cut off valve nanan Aseo E e EELER akaqa RU Damaged air cut off valve diaphragm 2 Damaged air cut off valve spring 1 14 KYMCO 1 GENERAL INFORMATION MYROAD 7001 POOR PERFORMANCE AT HIGH SPEED Inspection A djustment Probable
39. ent ePoony connected coupler between terminals of Ignition unit coupler 0 ETPHTLTPPLTLTPFPLLLPPPULLLPPULLLLPULLLLLLPLLLLPPLLLLPLLLLLPLLLLLLLPULLLLPULLLLLLLLLLLLLLLLLLLLLLLPLLLLLPLLLLLLLHLH OFaulty ignition switch Faulty exciter coil Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler D Faulty ignition unit 1 19 KYMCO 1 GENERAL INFORMATION MYROAD 7001 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection A djustment Probable Cause SE and test A gt limit voltage of battery terminals DFaulty AC generator Normal voltage 9 BEER Faulty regulator rectifier Faulty battery P Ht x between AC generator i coll terminals Open circuit between AC generator 3 yellow wires Test output voltage of dee Ee WEE regulator rectifier Coupler red wire QM CNN Eege Faulty AC generator Normal voltage Loose regulator rectifier coupler OLimit voltage too high Overcharging Inspection A djustment Symptom Probable Cause O Measure battery limit voltage with an electric tester DFaulty battery Faulty regulator rectifier Broken or poorly connected regulator rectifier black wire Check resistance between regulator AN dro LR et add B gt rectifier terminals AR RER ERR ERE RER RER ERE ERR RER KE
40. eplace the fuel filter with a new one Fuel Filter THROTTLE OPERATION 2 6 mm 1 16 1 4 in Check for smooth throttle grip full opening and automatic full closing in all steering positions Check the throttle cables and replace them if they are deteriorated kinked or damaged Lubricate the throttle cables 1f throttle operation is not smooth Measure the throttle grip free play Free Play 2 6 mm 1 16 1 4 in 3 5 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i Throttle grip free play be adjusted at ADJUST NUT either end of the throttle cable Minor adjustment is made with upper n adjuster Slide the rubber sleeve back to expose the m throttle cable adjuster Adjust free play by loosening lock out and turning the adjuster NEAN LOCK NUT KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i AIR CLEANER The air cleaner should be serviced at regular intervals Service more frequently when riding in unusually wet or dusty areas Install a new air cleaner element Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong air cleaner element a non K YMCO air cleaner which 15 not of equivalent quality may cause premature engine wear or performance problems Atr cleaner element removal installation Remove the screws and air cleaner housing cover KYMCO 3 INSPE
41. i Fuel capacity I4 L eel Body Venturi Full transistor 1gnition Spark plug Ignition timing ECU 6 0 7 mm ttery 2V12AH Dry centrifugal automatic 2 T1 laUrdrnb ony Helical gear spur gear Automatic centrifugal RS z Neta gear ger 0 O FR RR tire rolling circumference 2 kg cm Tire pressure Front rider only 60 kg Rear Turning 40 angle 40 2 25 kg cm IMA SUIAO A 3 ei c Brake system type Disk brake 99 Suspension type Front Telescopic fork Frametype Double cradle 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling o B 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 i B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly KYMCO MYROAD 700i m Apply or add designated greases lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons wor
42. ine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft Balancer shaft Crankshaft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part O ring face Oil seal lip Drive gear shaft Countershaft Final gear Transmission oil SAE 90 Final gear shaft Transmission gearshaft bearing part 1 10 KYMCO 1 GENERAL INFORMATION MYROAD 7001 FRAME The following 15 the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle A Engine Oil Grease Front Rear Brake Lever Pivot Grease Seat Lock Throttle Cable Rear Wheel c Center Stand Side Stand Pivot Front Wheel Bearing sa Grease asa Orgase 1 11 KYMCO 1 GENERAL INFORMATION MYROAD 7001 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Check if fuel reaches carburetor by tee gt drain screw Fuel does not reach carburetor fuel injector Probable Cause Empty fuel tank Clogged carburetor fuel inlet tube vacuum tube or fuel tube GClogge
43. ing using a timing light Correct timing EEERERERREEEREEEEREREREEREREEREEEREEEERER ER EEREREEREEEREEEERER ER EEREREEREEEREEEEREREEEERER ERR ER EREEREREE KEE ENER Incorrect timine Incorrect Check carburetor for A 5 clogging u Not Clogged Clogged Remove spark plug and e Inspect eee Remove oil dipstick and E Ind EE Remove cylinder head bolts and inspect UT Valve train lubricated Valve train not properly lubricated properly Check if engine overheats S Engine does not Engine overheats overheats Engine does not knock Rapidly accelerate or run _at high speed Engine knocks 1 13 KYMCO MYROAD 700i Probable Cause OClogged air cleaner Restricted fuel flow Clogged fuel line between fuel tank and carburetor Clogged exhaust muffler Faulty auto bystarter OSplit carburetor vacuum piston diaphragm OFaulty ignition unit Faulty A C generator OImproper valve clearance adjustment Worn valve seat valve stem too protruding OImproper valve and seat contact Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head Improper valve timing Clogged carburetor jets DFouled spark plug 2 Incorrect heat range plug Oil level too high level too low Oil not changed OFaulty oil pump Olnsufficient coolant Faulty thermostat Worn cylinder and piston rings Mixture too l
44. ing any obligation KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION HNIDONH LNHINdI QOH IVOTeLLOH TA KYMCO MYROAD 700i TABLE OF CONTENTS GENERAL INFORMATION FRAME COVERS EXHAUST MUFFLER INSPECTION ADJUSTMENT COL kusa Sa gt gt 9 Z ve E GNITION SYSTEM LECTRICSTARTER LIGHTS METERS SWITCHES ANTI LOCK SYSTEM ABS 22 6 8 El 22 KYMCO 1 GENERAL INFORMATION MYROAD 7001 GENERAL INFORMATION SERIAL NUMBER reete eran ecrire teneri 1 1 SPEGIFICATIONS 1 2 SERVICE PRECAUTION Sciacca u L 1 3 KU 1 7 REES 1 9 LUBRICATION POIN TS eene 1 10 HEEN 1 12 1 0 KYMCO 1 GENERAL INFORMATION MYROAD 7001 SERIAL NUMBER FRAME NUMBER VIN a r gt Y 4 Y A 1 1 r Location of Engine Serial Number 1 GENERAL INFORMATION SPECIFICATIONS Engine type D O H C Rear wheel 160 60 R14 35 mm 700 mm Type Gasoline 4 stroke Twin cylinder Combustion chambertype ROOF Valve arrangement Borexsmoke 769 75 3 10 5 1 7 cold Idle speed Lubrication yee apo capacity Final reduction oil 0 4 L pac Cooling Type Liquid cooled Dry weight Curb weight Intake valve Exhaust valve uorneonqnT KYMCO MYROAD 700
45. k together pay attention to the mutual working safety B Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 GENERAL INFORMATION B f the fuse 15 burned out find the cause and repair it Replace it with a new one according to the specified capacity Confirm Y Capacit B After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation E Hold the connector body when connecting or disconnecting it Do not pull the connector wire BEX BRO if any connector terminal is bending protruding or loose KYMCO MYROAD 700i The connector shall be inserted completely B If the double connector has a lock lock 1t at the correct position B Check if there is any loose wire ADO Before connecting a terminal check for damaged terminal cover or loose negative terminal me Check the double connector cover for proper coverage and installation ZO Insert
46. let it idle for 2 3 minutes Turn off the engine and support the scooter level surface Check the engine level The level must maintained between the upper H 1 and lower level L 2 marks on the oil inspection screen 3 If the oil level is below or near the lower level line add the recommended engine oil until the oil level 1s to the upper level Recommended engine oil 4 stroke or equivalent motor oil API service classification SJ Viscosity SAE 5W50 X Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range ENGINE OIL amp STARINER SCREEN When running in very dusty conditions oil changes should be performed more frequently than specified in the maintenance schedule Please dispose of used engine oil in a manner that is compatible with the environment We suggest you take 1 In a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer 1f repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil 3 13 KYMCO MYROAD 700i Change the engine oil with the engine at normal ope
47. ngine idle speed 1250 100 rpm Final reduction 0 56 liter oil capacity Total amount 0 4 liter Tire air pressure idi Front Minimum tire tread depth 3 1 3 INSPECTION ADJUSTMENT TORQURE VALUES Engine oil drain plug Oil strainer screen cap Oil filter cartridge Transmission oil dran bolt Transmission oil filler bolt SPECIAL TOOLS Oil filter cartridge wrench 2 5 kgfem 1 2 1 8 kgfem Apply oil to the threads and seating surface 1 2 kgfem Apply oil to the threads and seating surface 2 3 kgfem 1 2 1 8 kgfem 120 00061 KYMCO MYROAD 7001 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 MAINTENANCE SCHEDULE Perform the pre ride inspection in the owner s manual at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE WHICHEVER ODOMETER READING Bu c NOTE 1 x1000km 1 6 42148 24 130 136 x000mi 0614 12 16 1201 24 NOTE MONTH Le 12 18 24 30 36 AIRCLCEANER 2 SPARKPLUSS L TRI TRT THROTTLE OPERATION il li VAVECLEARANCE BS AA IE __ lclclclclclc ENGINEOIL IRIRIRIRIRIRIR_ ENGINEOLFLTER RIRIRIRIRIRIR E
48. o seconds If the oil pressure indicator stay on stop the engine immediately and determine the cause Dust Cover OIL PRESSURE RELIEF VALVE REMOVAL Remove the right crankcase cover Remove the pressure relief valve and O ring from the right crankcase O ring Oil Pressure Relief Valve Piston Oil Pressure Relief Valve INSPECTION Check the operation of the pressure relief valve by pushing on the piston INSTALLATION Apply oil to a new O ring and install the pressure relief valve groove and install the relief valve to the right crankcase KYMCO 4 LUBRICATION SYSTEM________________ 700 OIL PUMP Oil Pump Cover DISASSEMBLY Remove bolts and oil pump cover Oil Pump Body Inner Rotor Dowel Pin Remove dowel pin pin oil pump shaft oil pump outer rotor and inner rotor Outer Rotor Pin Oil Pump Shaft 4 5 KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 INSPECTION Temporarily install the 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 Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feeler gauge Service limit 0 12 mm 0 0048 in 4 LUBRICATION SYSTEM ASSEMBLY Dip all par
49. oval REAR SPOILER REMOVAL Unlock the seat with the 1gnition key Open the seat Remove the rubber cap Remove four bolts and rear spoiler INSTALLATION Installation 1s 1n the reverse order of removal FRONT FENDER RE MOVAL Remove the six bolts and front fender INSTALLATION Installation 1s 1n the reverse order of removal KYMCO MYROAD 700i Bolt TO Fuel pump Lid Rubber Cap Bolts 2 FRAME COVERS EXHAUST MUFFLER UPPER HANDLEBAR COVER REMOVAL Remove four screws and upper handlebar cover INSTALLATION Installation 15 1n the reverse order of removal RIGHT LEFT SIDE COVERS REMOVAL After removing seat the priority you should remove would be side covers there are some screws and bolts hiding in these parts Remove the two bolts and side covers Remove the hex bolt and foot step 2 5 KYMCO MYROAD 700i Side Cover Hex Bolt Foot step KYMCO 2 COVERS EXHAUST MUFFLER MYROAD 700 Remove the side cover following the way of picture showing Specially notice not to damage the tabs on side covers especially hook structures the end of side covers OMA RR pe Be careful not to damage the tabs on side covers Slap here to remove the Installation priority KYMCO 2 FRAME COVERS evens aay EXHAUST MUFFLER RIGHT LEFT FLOOR SKIRT Floor
50. rating temperature and the scooter on its center stand to assure complete and rapid draining Remove the oil filler cap from the right crankcase cover Engine oil capacity 3 0 L Engine oil exchanging capacity 2 6 L 110 F SAE 10W 30 SAE 10W 40 SAE 20W 40 SAE 20W 50 30 40 3 INSPECTION ADJUSTMENT Place a drain pan under the crankcase and remove the oll strainer cap The setting spring and oil strainer screen will come out when oil strainer cap is removed Clean the oil strainer screen After draining the oil completely install the strainer screen and setting spring into the engine Apply clean engine oil to the strainer cap threads flange surface and a new O ring Install and tighten the strainer cap with a new O ring Torque 1 2 kgfem KYMCO MYROAD 7001 Strainer Screen Setting Spring Strainer Cap Oil Strainer Screen Strainer Screen Strainer Screen Ta 2 2 Setting Spring Serine Strainer Cap 3 14 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i Fill the crankcase with the recommended engine oil Engine oil capacity 3 0 L Engine oil exchanging capacity 2 6 L Install the oil filler cap Check the engine oil level Make sure there are no oil leaks EN
51. ressures are normal stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim 3 Loose axle nut Misaligned front and rear wheels 2 Bent front fork Probable Cause Front and rear tire pressures are normal Weak shock spring Excessive load Shock damper oil leaking Bent fork tube or shock rod Fork tube and slider binding Fork spring and slider binding Damaged shock stopper rubber Loose steering stem nut Probable Cause Q Worn brake linings 2 Foreign matter on brake linings Rough brake drum contacting area Q Worn brake linings 2 Foreign matter on brake linings GRough brake drum contacting area DWorn brake linings Worn brake cam contacting area on Q Worn brake linings Foreign matter on brake linings OSluggish or elongated brake cables Brake shoes improperly contact Water and mud in brake system or grease on brake linings 1 34 KYMCO 1 GENERAL INFORMATION MYROAD 7001 1 33 KYMCO 2 COVERS EXHAUST MUFFLER ISO 700 2 FRAME COVERS EXHAUST MUFFLER SCHEMATIC DRA WING EE 2 SERVICE INFORMATION eege 2 TROUBEESHOOTIN se rete ee 2 5 FRAME COVERS REMOVAL 2 3 EXHAUST E E 2 17 2 0 KYMCO 2 COVERS 7001 EXHAUST MUFFLER SCHEMATIC DRAWING 2 FRAME COVERS EXHAUST MUFFLER SERVICE INFORMATION GENERAL INSTRUCT
52. s listed below are for Important fasteners ENGINE ITEM THREAD DWG NO DWG NAME THREAD SIZE TORQUE AND TYPE 90017 KKE5 E000 BOLT HEAD COVER wus 0 8 1 2 gt 90083 KED9 9000 BOLT KNOCK 6MM AA 0 8 1 2 E HEAD 90007 KKE5 E000 BOLT WASHER 10X160 4 8 5 2 REMARKS lt 0 B VALUES APPLY THREAD LOCK APPLY OIL APPLY OIL m eue HEAD 90008 KKE5 E000 BOLT WASHER 10X170 10 1 25 pecu S me 98059 58916 00 SPARK PLUG CR8E 13 1 HOLDER 96001 06045 08 BOLT FLANGE SH 6245 PES 0 8 1 2 1 I APPLY OIL APPLY THREAD LOCK APPLY Loctite 243 MIOX PUMP SHAFT 1 94050 10080 NUT FLANGE IOMM C MIOX 19 6 29 4 2 sam 14531 KED9 9000 PIVOT TENSION GUIDE M8XI APPLY OIL X X X 11 1 3 1 8 2 8 580 8 62 7 6 0 6 4 13 5 83 4 1 9 59 9 d APPLY OIL 100 30 APPLY 011 ACG CRANKSHAFT TAPPER AREA APPLY Loctite 648 CONROD 13213 KKE5 E000 BOLT CONN ROD ae c CRANK SHAFT 90015 KED9 9000 BOLT UBS 10X35 137 3 APPLY Loctite 243 120 CRANK SHAFT 90241 KKES E000 NUT 30 1 0 M30XI 0 L H 127 5 147 1 13 15 k dll ONE WAY ACG 96600 08015 10 SOCKET BOLT 8X15 B illl in THREAD LOCK 850 210 300 300 300 340 200 R L CRANK CASE 90084 KKE5 000 CAP OIL CHANNEL 1 2 1 8 2 2 2 04 3 534 2 2 9 9 9 APPLY SEAL j FS i 4 5 0 8 8 4 I 9 4 4 1 E 4 5
53. t voltage too high Overcharging Inspection A djustment Symptom Probable Cause O Measure battery limit voltage with an electric tester EPCTTPLPLLTFLPLLLLLPLPLLLLLPLLLLPPLLLLLLLLLLLLPLLLLLPLLLLLPLPLLLLLPLLLLLPLLLLLLLLLLLLLLLLLLLLLLLLPLLLLLPLLLLLLLHLH Faulty battery Faulty regulator rectifier G Broken or poorly connected regulator rectifier black wire Check resistance between reeulator Leet gt rectifier terminals Limit voltage too high 1 32 1 GENERAL INFORMATION MYROAD 7001 FUEL GAUGE 1 Pointer does not all correctly Ignition switch ON Inspection Adjustment Probable Cause aEREEEREEER RER EREERE RER RRE EREEER RER EREERE RER EE RER EREERE RER SERERE REN RER ER EERE RER RRE RER ER E Ra HR G0 Check battery circuit by operating turn signals EE Ee Burned out fuse Weak or dead battery Signals operate Signals dim remain Faulty ignition switch properly on Or dont operate Loose disconnected Remove fuel unit and i check operation of pointer by moving float EURO T and down Float up Full connectors Broken wire harness Float down Empty DFaulty float Check operation of pointer by opening and shorting fuel unit terminal on wire harness wire Check connectors for proper connection Incorrectly connected connec
54. tor Broken or shorted wire in fuel gauge 2 Pointer fluctuates or Ignition switch ON Inspection Adjustment Probable Cause O Check battery circuit ba operating turn signals horn Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector GBroken wire harness Remove fuel unit and Signals operate properly i check operation of pointer by moving float tee gt Signals dim remain on or don t operate up and down Pointer moves Pointer does not Poor contact in fuel unit ore Move float up and down rapidly 1 round _ sec to check operation of pointer accordance with move in OInsufficient damping oil in _ float accord ance with fuel gauge Check connectors for connection E E Faulty Loose or disconnected connector Broken or shorted wire in 1 GENERAL INFORMATION KYMCO MYROAD 7001 uel gauge STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Steering 15 heavy Front or rear wheel 1s wobbling Steering handlebar pulls to one side POOR SUSPENSION PERFORMANCE Symptom Suspension 15 too soft Suspension 15 too hard Suspension 15 noisy A POOR BRAKE PERFORMANCE Symptom Soft brake lever Hard brake lever Hard to brake Poor brake performance Brake squeaks Probable Cause Front and rear tire p
55. ts 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 pin onto the oil pump body Install the pump cover onto the oil pump body by aligning the dowel pin Install and tighten the bolts to the specified torque Torqur 1 2 kgfem INSTALLATION Install the oil pump and tighten the two bolts securely Make sure the pump shaft rotates freely and arrow on the oil pump 15 upside 4 7 KYMCO MYROAD 700i Dowel Pin Oil Pump Cover Oil Pump Cover Oil Pump Cover Bolts Screw Oil Pump KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 OIL COOLER REMOVAL Drain the engine oil and remove the oil filter cartridge Drain the coolant from the system Loosen the hose bands and disconnect the oil cooler hoses from the cooler Oil Cooler Remove the oil cooler mounting bolts oil cooler Cooler INSPECTION Check the cooler for damage KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 INSTALLATION Install the removed parts in the reverse order of removal Install the ol cooler bolts with the specified torque Torque 0 8 1 2 kgfem Remember to install the dowel pin 15x10 And O ring 14 8x2 4 Oil Cooler KYMCO 4 LUBRICATION SYSTEM MYROAD 7001 Installation of oil filter cartridge Standard Torque Oil filter cartridge 1 2 1 8 kgfem
56. ttom end too hard directly it would break the combined structures Pull with correct direction 2 13 KYMCO 2 FRAME COVERS MYROAD 7001 EXHAUST MUFFLER Tunnel leg shield removal Screws Tunnel leg shield Main switch cover Loosen the screw before removing the main switch cover and tunnel leg shield E Screws Turn Signal Light Connectors Remove two screws Remove one screw Disconnect headlight and turn signal light connectors INSTALLATION Installation 15 1n the reverse order of removal Headlight Connector 2 14 KYMCO 2 COVERS MYROAD 7001 EXHAUST MUFFLER HEADLIGHT REMOVAL Remove the front cover Remove 8 screws and headlight INSTALLATION Installation 15 1n the reverse order of removal TURN SIGNAL LIGHT REMOVAL Remove the front cover Remove three screws and turn signal light INSTALLATION Installation 15 1n the reverse order of removal Windshield Holder FRONT METER VISOR REMOVAL Remove the windshield Remove the front cover Remove four bolts and windshield holder 2 15 KYMCO 2 COVERS EXHAUST MUFFLER 700 Remove two screws and front meter visor INSTALLATION Installation is 1n the reverse order of removal METER PANEL REMOVAL Remove the front cover Remove the front meter visor Remove the tunnel leg shield Remove screws from instrument Meter Panel
57. y Index Mark Mark in Mark ex KYMCO 3 INSPECTION ADJUSTMENT MYROAD 7001 Insert feeler gauge between valve and the lobe Check the valve clearance for the valves using feeler gauge Valve Clearance IN 0 16 mm 0 006 in EX 0 22 mm 0 009in Remove the camshaft Shim Remove the valve lifters and shims The shims may stick to the inside of the valve lifter Don t allow the shims to fall into the crankcase Mark all of shims and valve lifters to ensure correct reassembly in original locations The valve lifter can be easily removed with a valve lapping tool or magnet The shims can be easily removed with tweezers or magnet Clean the valve shim contact area 1n the valve lifter with compressed air Valve Lifter 3 11 KYMCO 3 INSPECTION ADJUSTMENT MYROAD 700i Measure the shim thickness and record 1t Calculate the new shims thickness using the equatlon below A C B D A New shim thickness B Record valve clearance C Specified valve clearance D Old shim thickness O 205 25 08 215 25 0 220 20 295 Make sure the correct shim 1s selected by measuring it with a micrometer Reface the valve seat if carbon deposits result in a clearance of over 2 8mm Install the removed parts m the reverse order of removal 3 12 3 INSPECTION ADJUSTMENT ENGINE OIL OIL LEVEL INSPECTION Start the engine and

By KWANG YANG Motor Co., Ltd. First Edition, FEB

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