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13. fuel injection system

1. 10 1 SERVICE INFORMATION 10 2 TROUBLESHOOTING e stas Ese ee ie 10 2 RIGHT CRANKCASE COVER 10 3 STATOR REMOVAL 10 3 FLYWHEEL REMOVAL 10 4 STARTER CLUTCH 10 4 FLYWHEEL INSTALLATION 10 8 STATOR INSTALLATION 10 9 RIGHT CRANKCASE COVER INSTALLATION 10 9 10 0 10 GENERATOR STARTER CLUTCH DOWNTOWN 200i SCHEMATIC DRAWING quo Gs Bd xB BEDI AT PAL Mw D Li s 2 did 6122 d t Uu C 81 8043 AEN ix Lh Kail iu a 7 C ugsqg L HAZ WD 0 ji 1250 SC 5430 AI lint T T5 md 5 ue E 5422 s g1301LEAT 15231 rap 19232
2. ee 3 12 3 0 3 INSPECTION ADJUSTMENT DOWNTOWN 200i SERVICE INFORMATION GENERAL e Before running the engine make sure that the working area 1 well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people e Gasoline is extremely flammable and 15 explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6 mm Spark plug CR7E Spark plug gap 0 6 mm 0 7 mm Valve clearance IN 0 10 mm EX 0 10 mm Idle speed 1600 100 rpm Engine oil capacity Cylinder compression 16 2 kg cm At disassembly 1 5 Liter Ignition timing ECU At change 1 3 Liter Coolant type Water Cooling Gear oil capacity At disassembly 0 23 Liter At change 0 21 Liter TIRE T TIRE SPECIFICATION Front 120 80 14 58S Rear 150 70 13 645 TORQUE VALUES Front axle nut 2kg m Rear axle nut 12 kg m SPECIAL TOOL Tappet Adjuster E012 3 1 3 INSPECTION ADJUSTMENT Maintenance schedule INSPECTAND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY CLEAN R REPLACE A ADJUST L LUBRICATE WHICHEVER COMES FIRST ODOMETER READING _ s 101872572532 1000 06 12151
3. a 22 ENGINE 22 24 RESERVE 3 5 AIR CLEANER 3 6 SPARK PLUG 3 6 ese ste ec ee eee ae a CYLINDER 55 35 9 FINAL REDUCTION GEAR 3 8 DRIVE BELT 3 8 BRAKE SYSTEM 3 9 CLUTCH SHOE WEAR 3 10 SUSPENSION 3 10 NUTS BOLTS FASTENERS 3 11 WHEELS TIRES 3 11 STEERING HANDLEBAR 32 11 SIDE STAND
4. 13 27 DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 13 28 VEHICLE CAN NOT BE STARTED 13 40 MANUAL TROUBLE SHOOTING PROCEDURE 13 41 13 0 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e Scooter services can be done with the engine installed in the frame e Be sure to relieve the fuel pressure before fuel pump or fuel hose removal e Bending or twisting the control cables will affect operation and could cause the cables to stick or bind resulting in loss of vehicle control e Work in a fully ventilated area Smoking or allowing flames or sparks the work area or where gasoline 15 stored can cause a fire or explosion e Do not apply the Carburetor Cleaners to the inside of the throttle body which 15 coated with molybdenum e Do not snap the throttle valve from fully open to fully close after the throttle cable has been removed it may cause incorrect idle speed Do not loosen or tighten the painted bolts and screws of the throttle body Loosening or tighten them can cause throttle and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization
5. COVERS 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 To prevent the pawl from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face dC KYMCO DOWNTOWN 200i 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i FRAME COVERS REMOVAL INSTALLATION SEAT Unlock the seat with the 1gnition key Open the seat Remove the two nuts and the seat Installation 1s 1n the reverse order of removal LUGGAGE BOX Unlock the seat with the 1gnition key Open the seat Remove four bolts and the fastener on the right side of luggage box then lift luggage box Disconnect the luggage box light connector then remove the luggage box Installation 1s 1n the reverse order of removal 2 3 GQ KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i 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 four bolts and then remove the rear carrier 2 EXHAUST MUFFLER FRAME COVERS Installation 1
6. 6 9 CYLINDER HEAD COVER INSTALLATION 6 11 6 0 6 CYLINDER HEAD VALVES DOWNTOWN 200i SCHEMATIC DRAWING ur 25701 6016 wat ora de SU 952 MT 37750 T a 30308 Q 48 a4 o CUEN E d 18301 935009 D5016 12200 NP THA Fz ant m 37101 16211 Wm 9414 08 104 16201 im xa 5 14721 14761 14777 32990 05040 a ur 12203 2 14771 95 c p umm x ur 34304 12244 1443 14711 my oom ete j 94304 12204 14452 at 9 D 56001 06025 2 2 E Cop 94050 06090 Ae a NIU ye 12 44 du 26 E 90033 KGB4 4333 14100 oy 98059 7 ANS 54 on 14424 amp Cd LEE es To Ces r LT Wy re J 36001 08010 T ty a P oy E 9097 x2 6 CYLINDER HEAD VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS GQ KYMCO DOWNTOWN 200i e The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water hoses must be drained e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication e The valve rocker arms are lubricated by engine oil through the engine oil passages Clean and unclog oil passages befo
7. Ignition sw OFF MW 13 8 13 FUEL INJECTION SYSTEM DOWNTOWN 200i SELF DIAGNOSIS RESET PROCEDURE 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 4 Release the throttle 5 The indicator will blink twice 0 5 second after five seconds quickly Self diagnosis memory data 15 disappeared after the CELP lamp is off The self diagnosis not be reset when has still problem inside the system Throttle opened fully KEY ON 10s 10s 95 sees Throttle Throttle closed closed Indicator blinks twice continuously 13 9 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i CELP FAILURE CODES LIST Failure Blinks Codes Contents Causes Symptoms diagnostic Faulty TPS voltage range 0 3 4 5 V or poor connection on TPS Engine operates 06 0120 Faulty TPS Sensor normally e Open or short circuit on the TPS wire e Faulty TPS itself e Faulty MAP voltage range 1 4 2 V Loose or poor connection on Engine operates P0105 Faulty MAP Sensor normally e Open or short circuit on MAP wire e Faulty MAP itself e Faulty ECT Q range 209 18 8 Faulty WIS 40 1 136 0 100 C 0 1553 Engine operates 12 PO115 water Loose or poor connection on ECT normally temp
8. 11240 ac jc ug es T Ll lt 121905 es 112 3401 06050 ml 3 LEAT X4 ME Pas amp amen OE l uio r n ke 9001 00070 11 1 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e When separating the crankcase never use a driver to knock the crankcase forcedly to prevent damaging the mating surfaces e When installing the crankcase do not use an iron hammer to tap it e When installing the crankcase or crankshaft must be replaced in pair e The following parts must be removed before separating the crankcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pump SPECIFICATIONS lem Standard mm Service Limit mm Connecting rod big end side clearance 0 15 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 TORQUE VALUES Crankcase cover bolt 1 0 1 4 kgf m 11 8 N m Cam chain tensioner pivot 0 8 1 2 kgf m 9 8 N m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bearing pla
9. c e C p c m c I c c LA Lh I ae c Cautions for Using Coolant Use coolant of specified mixing rate Do not mix coolant concentrate of different brands Do not drink the coolant which 1s poisonous The freezing point of coolant mixture shall be 5 lower than the freezing point of the riding area dC KYMCO 12 COOLING SYSTEM DOWNTOWN 200i COOLING SYSTEM TESTING Radiator Tester 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 T Apply water to the sealing cap surface A 4 before testing Radiator Cap Radiator Cap Relief Pressure 0 9 0 15 kg cm Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks The test pressure should not exceed 1 05 kg cm Excessive pressure can damage the radiator and its hose connectors RADIATOR RADIATOR INSPECTION Remove the front cover 12 4 GQ KYMCO 12 COOLING SYSTEM DOWNTOWN 200i Inspect the radiator soldered joints and seams Outlet Tube of Reserve Tank for leaks Blow dirt out from between core fins with compressed air If insects are clogging the radiator wash
10. KYMCO DOWNTOWN 200i Bear Axle Collar Bear Axle Collar Bolts Bolts 15 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION DOWNTOWN 200i Suspension Each shock absorber 8 on your scooter has 5 spring preload adjustment positions for different 9 19 load or riding conditions Use a pin spanner to adjust the rear shock spring preload Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooteris heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions standard spring preload position 3 A CAUTION Always adjust the shock absorber pre load position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber 15 8 C KYMCO 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i BATTERY CHARGING SYSTEM CHARGING SYSTEM LAYOUT ue 16 1 SEER TING OR UI 16 1 SERVICE INFORMA TION 16 2 TROUBLESHOOTING 16 3 BATTERY CHARGING 16 4 CHARGING SYSTEM 16 6 REGULATOR RECTIFIER 16 6 16 0 KYMCO 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i CHARGING SYSTEM LAYOUT BATTERY REGULATOR RECTIFIER ACG 16 1 GQ KYMCO 16 BATTERY CHARG
11. Pulsar Coil A C Generator Stator Gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Dowel Pins Right Crankcase Cover Tighten 12 bolts attaching to right crankcase cover Connect the water hoses to the right crankcase cover and water pump cover Add the recommended engine oil Fil the cooling system with the specified coolant Water Pump Shaft Water Hose e Be sure to bleed air from the water hose after filling the coolant 10 9 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 200i CRANKCASE CRANKSHAFT SCHEMATIC DRA WING 11 1 SER VICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASE SEPARATION 11 3 CRANKSHAFT INSPECTION 11 4 CRANKCASE ASSEMBLY 11 5 11 0 dC KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 200i SCHEMATIC DRAWING 11224 4 95701 0407 cO Poz o 93105 31255 e 8 2 301 101 60 i AU E FF 0 Wika
12. INSTALLATION Installation 1s 1n the reverse order of removal After installation inspect and adjust the following e Throttle grip free play e Fill the cooling system with coolant and start the engine to bleed air from the system API ABV Reset Refer to chapter14 page 17 5 5 KYMCO DOWNTOWN 200i Mount Nut KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i ENGINE HANGER REMOVAL Remove the engine mount nut and pull it out Be careful to put engine down Remove the left right engine hanger mount bolt Remove the engine from frame INSTALLATION Installation 1s 1n the reverse order of removal Tighten the engine hanger mount bolts to the specified torque Torque 6 5 kgf m 65 N m GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i CYLINDER HEAD VALVES SCEMA ined ic eR 6 1 SER VICE INFORMATION aa MD M 6 2 TROUBLESHOOTING 6 3 CYLINDER HEAD COVER REMOVAL 6 4 CAMSHAFT REMOVAL 6 4 CYLINDER DEAD REMOVAL eis Ere e 6 6 CYLINDER HEAD oaeee 6 7 GYLINDERIHEAD ASSEMBL a e a 6 8 CYLINDER HE AD INSTAEEATIONG 6 9 TION
13. W SPARK PLUG For spark plug inspection and adjustment IGNITION COIL INSPECTION Remove the seat and met in box Remove the ignition coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil This is general test Accurate ignition coil test must be performed with an ignition unit tester Measure the ignition coil resistances at 20 Primary coil 3 57 4 83 0 Secondary coil with plug cap 15 19 4 Secondary coil without plug cap 10 42 14 49 KQ 17 3 GQ KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i A C GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION i This test is performed with the stator installed in the engine Remove the seat and met in box Disconnect the Crank Position Sensor Wire gt Coupler V 1 Measure the resistance between the blue white Crank Position Sensor Wire Coupler and green white wire terminals Blue Yellow Green White 100 1300 ROLL SENSOR INSPECTION Support the scooter level surface Put the side stand up and engine stop switch is at Turn the ignition switch to OFF Remove the screws washers and roll sensor Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged Place the roll sensor vertical as shown at the ignition switch Measure the voltag
14. Rear wheel rim runout Rear brake disk thickness O NENNEN NEM Rear brake disk runout __ Rear brake master cylinder I D 25 33 25 36 Rear brake master cylinder piston O D 25 40 25 45 TORQUE VALUES Exhaust muffler lock bolt 35 N m 4 kgf m Exhaust muffler pipe nut 20 N m 2 kgf m Rear axle nut 120 N m 12 kgf m Rear shock absorber lower mount bolt 40 N m 4 kgf m Rear shock absorber upper mount bolt 40 N m 4 kgf m Rear brake caliper holder bolt 27 N m 2 7 kgf m TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Air in brake system e Faulty tire e Deteriorated brake fluid e Axle not tightened properly e Contaminated brake pad surface e Worn brake pads Soft rear shock absorber e Clogged brake fluid line e Weak shock absorber spring e Deformed brake disk e Damper oil leaks e Unequal worn brake caliper Rear wheel noise e Worn rear wheel axle bearings e Worn rear fork bearings e Deformed rear fork 15 2 15 BRAKE REAR FORK REAR KYMCO NHEEL REAR SHOCK ABSORBER DOWNIOWN 2001 REAR BRAKE Brake Fluid Tube Bolt Brake Caliper 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 Remove the rear brake caliper When removing the brake fluid tube use shop towels to cover plastic parts and coate
15. Hill the radiator with coolant Connect the vent tube to the radiator filler After installation check for coolant leaks Overflow Tube Connect the outlet tube of the reservoir and secure with the tube clamp X If you want to refill the coolant the following procedure must be checked 1 Please make the radiator filler and the air vent tube to be separated 2 Start the engine filled in the coolant till the coolant flowed out from the air vent tube 12 7 12 COOLING SYSTEM 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 replace the mechanical seal WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose Remove four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller t The impeller has left hand threads Inspect the mechanical water seal and seal washer if wear or damage The mechanical seal and seal washer must be replace as a set KYMCO DOWNTOWN 200i Right Crankcase Cover Water Pump Telltale Hole Water Pump Cover Impeller Seal Washer Porcelain Mechanical Water Seal Water pump shaft 12 8 KYMCO 12 COOLING SYSTEM DOWNTOWN 200i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove bol
16. SISSVHO INAWdINOA 1 21412313 GQ KYMCO DOWNTOWN 200i TABLE OF CONTENTS GENERAL INFORMATION EXHAUST MUFFLER FRAME COVERS 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 1 s s s REAR BRAKE REAR FORK REAR 1 WHEEL REAR SHOCK ABSORBER parrenviowancne syste uss swTOHES FUEL POMP GQ KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i GENERAL INFORMATION SERIAL NUMBER te eia io uae ocio eaa ected eee ene 1 1 SPECIFICATION 1 2 SERVICE 5 1 3 TO 1 4 SPECIAL 1 6 LUBRICATION POINTS 1 7 CABLE S HARNESS ROUTING enia eiae 1 8 1 0 dC KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i SERIAL NUMBER Location of Frame Serial Number inside luggage box Location of Vehicle Identification Number VIN Location of Engine Serial Number 1 1 GQ KYMCO 1 GENERAL INFORMATION DOWNTOWN 200
17. SOU 22 oe ver LL 128 4 9120 rA 58210105012 X2 l jv to 31110 are SGBOD DUOT5 X3 Pu m d Ta et Ran gt 31200 NT pU he ad TE 1 G SOLE M E s p y I S MEOH s lt 2 us a ug E ge fl 5 2 y sasip 15105 pate Ee 97500 05912 Ye eee 207 AT 100 Ti zo HH Es 151244 ds pre 15133 i i AE Hise us 12410 16442 ix 10 1 GQ KYMCO 10 A C GENERA TOR STARTER CLUTCH DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e All operations and inspections in this section can be made with the engine installed e Should drain the coolant before removing the right crankcase cover e Be careful not to drain the coolant when the engine temperature is high Perform this operation when the engine 15 cold e Drain the coolant into a clean container e Drain the engine oil into a clean container before removing the right crankcase cover e When the right crankcase cover is installed fill with the recommended engine oil and coolant Remember to bleed air from the water hose SPECIFICATIONS Engine oil SAE 5 50 API SJ above Oil capacity at change 1 5 1 3 Liter Coolant capacity Radiator capacity 0 766 liter Hose with cool coolant 0 169 liter Hose with hot coolant 0 194 liter Upper limit f
18. e Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 Thermostat 74 Thermometer THERMOSTAT INSTALLATION T Replace the O ring with a new one and apply grease to it Fil the cooling system with the specified coolant GQ KYMCO 13 FUEL INJECTION SYSTEM DONNEOSN ZU FUEL INJECTION SYSTEM SERVICE INFORMATION 2225252225522 ares 13 1 SPECIFICATIONS i23 2s 13 2 INJECTION SYSTEM DIAGRAM 13 3 PARIS LOCATION 13 4 13 6 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOO 13 7 SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODI E 13 8 SELF DIAGNOSIS RESET PROCEDURE 13 9 CELP FAILURE CODES 13 10 TIPS 13 13 PUELPUMD 13 14 PUBL CUT OFF RELAY 13 16 i eee ee eee 13 17 ELECTRONIC CONTROL UNIT 13 18 ese 13 20 WIS SINS CRs a ee 13 22 O ST NS OR datei E ee 13 23 THROTTLE BODY MAP ISC TPS 13 24 DIAGNOSTIC TOOL
19. tester electrical Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make absolutely certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000 rpm Standard Battery charging voltage 14 15V 16 5 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i REGULATOR RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator rectifier connectors Check the connectors for loose contacts of corroded terminals 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 There should be continuity at all times KYMCO 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals Standard 0 4 0 6 20 C 68 F Disconnect the regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side ground There should be no continuity REMOVAL INSTALLATION Remove the side body cover Disconnect the r
20. Clutch spring compressor E053 Fittings amp Nut Wrench 41mm E033 TROUBLESHOOTING Engine starts but motorcycle won t move Lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Broken driven face spring e Faulty driven face Engine stalls or motorcycle creeps e Broken clutch weight spring 8 2 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i LEFT CRANKCASE COVER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the protector cover of left crankcase cover Remove the bolts attaching to the left crankcase cover Remove the gasket and dowel pins Left Crankcase Cover INSPECTION Check the bearing for wear or damage Replace the bearing with a new one if the bearing is noisy or have excessive play DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover Bearing Hold the drive pulley using a universal holder and remove the drive face nut and washer Remove the drive pulley face Universal Holder E017 CLUTCH OUTER DRIVEN PULLEY V BELT REMOVAL Remove the drive pulley face Hold the clutch outer with the universal holder and remove the clutch outer nut bushing and washer Universal Holder E017 Bushing Nut Remove the clutch outer driven pulley and belt together Remove the drive belt from the mo
21. ED a DN D hr 423 DCN d Y E a 4 gue i at x uh o ro E 2 ae LI m a 19910 bw DE 9404 09025 ena 1 i Ep 9p 1 DB 4D gs 19215 Aj 1T850E LB 2 P V a q i 1541 i i B P nnd mes d ees mM 5 8451 0 1 490 E A lt 5707 19272 90001 06022 301 pore ot 15457 E es x m 12 1 GQ KYMCO 12 COOLING SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e The water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame e 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 e Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as soon as possible e After servicing the system check for leaks with a cooling system tester TORQUE VALUES Water pump impeller 1 0 1 4 kgf m 11 8 N m Water pump cover bolt 1 0 1 4 kgf m 11 8 N m TROUBLESHOOTING Engine temperature too high Coolant leaks e Faulty temperature gauge or
22. Hi Beam Relay Winker Relay ECU Horn KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i ISC Throttle Body TPS WTS MAP Sensor Injector 1 9 KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i Ignition Coil Output Voltage Connector Coolant Reserve Tank 1 10 KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i Starter Relay Regulator Rectifier CPS O2 Sensor 1 11 GQ KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i H EXHAUST MUFFLER FRAME COVERS SERVICE INFORMATION 2 1 TROUBLESHOOTING eene eade 2 1 FASTENER REMOVAL AND REINSTALLATION 252 FRAME COVERS REMOVAL INSTALLATION 2 3 EXHAUST MO PEER 2 14 2 0 KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use care not to pull them by force because the cover joint claws may be damaged e Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler pipe nuts 1 8 2 2 kgf m Exhaust muffler brake RR Frok 3 2 3 8 kgf m RR fork Engine case 3 0 4 0 kgf 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 2 EXHAUST
23. LUGGAGE BOX LIGHT SWITCH 19 9 IBI 19 10 SIDE 19 12 18191202 ee 19 13 19 0 GQ KYMCO 19 LIGHTS SWITCHES FUEL PUMP DOWNTOWN 200i ELECTRICAL EQUIPMENT LAYOUT Tilt switch speedometer ET d Radiator filler cap te Lo beam relay Ignition switch y Hi beam relay ECU Horn Fuel pump replay Oil controller Radiator 19 1 GQ KYMCO 19 LIGHTS SWITCHES FUEL PUMP DOWNTOWN 200i SERVICE INFORMATION GENERAL A halogen head light bulb becomes very hot while the head light 15 and remains for a while after it is turned off Be sure to let it cool down before servicing e Note the following when replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put finger prints on the headlight bulb as they may create hot spots on the bulb and cause it to fail f you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb e Check the battery condition before performing any inspection that requires proper battery voltage e A continuity test can be made with the switches installed on the scooter e Route the wires and cables properly after servicing each component TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not regis
24. Lock nut wrench F00023 14 15 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 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 A Remove the bottom ball race by using a pipe if necessary Bottom Balls Remove the bottom cone race by using a Bottom Cone Race chisel if necessary Be careful not to damage the steering stem 14 16 14 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 200i 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 Install the steering stem Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check the steering stem rotates freely without vertical play Special tool Lock nut wrench F00023 Install the steering stem lock nut and tighten it to the specified torque by using the special tool while holding the top cone race Torque
25. plug by hand and then tighten it with a spark plug wrench NE ee Cracks a Er 4 Torque 17 2 N m Gap Deformation Wear Fouling 0 0 0 7 mm Deposits 3 INSPECTION ADJUSTMENT DOWNTOWN 200i Cylinder Head Cover VALVE CLEARANCE X 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 mark on the flywheel aligns with the Bolts index mark on the left crankcase cover Inspect and adjust valve clearance Top Dead Center Mark Valve Clearance IN 0 10 mm EX 0 10 mm Loosen the lock nut and adjust by turning the adjusting nut Valve Adjuster E012 Feeler Gauge X e Check the valve clearance again after the lock nut is tightened CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and luggage box Remove the spark plug Insert a compression gauge Open the throttle fully and push the starter button to test the compression Max Compression 16 2 kg cm If the compression is low check for the following Leaky valves Valve clearance too small Leaking cylinder head gasket Worn piston rings Worn piston cylinder If the compression is high it indicates that carbon deposits hav
26. Be careful not to damage the scooter body cables and wires during engine removal e Use shop towels to protect the scooter body during engine removal e Drain the coolant before removing the engine e After the engine 15 installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks e Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil capacity At disassembly 1 5 L At change 1 3 L Coolant capacity Radiator 870 cc Reserve tank 490 cc Total capacity 1360 cc TORQUE VALUES 90304 8 0040 Engine hanger Engine side 5 0 kgf m 50 N m 90305 LBD4 9000 Engine hanger Frame side 6 5 kgf m 65 N m 95801 10060 Rear fork mount bolts 3 5 kgf m 35 N m 90305 6 9120 Rear axle nut 12 0 kgf m 120 N m 95801 10035 00 Rear cushion lower upper mount bolts 4 0 kgf m 40 N m dC KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i ENGINE REMOVAL INSTALLATION body WTS REMOVAL w 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 Disconnect the Regulator Rectifier connector MAP sensor Injector Fuel hose guide Disconnect the starter relay wire from starter motor Remo
27. Do not take the fuel pump on the ground downward Always replace the packing when the fuel pump is removed The electronic fuel injection system 15 equipped with the self diagnostic system If the Check Engine Lamp CELP illuminate while riding follow the self diagnostic procedures to solve the problem faulty AFI problem 15 often related to poorly connected or corroded connectors Check those connections before proceeding When disassembling the fuel injection parts note the location of the O rings Replace them with new ones upon reassembly Do not disconnect the battery negative or positive cable while engine is running it may cause ECU damage e Do not disconnect or connect ECU connector during the ignition switch ON it may cause the ECU damage 13 1 dC KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i SPECIFICATIONS Fuel pump resistance at 20 C 68 F Water temperature Inductive ignition coil Secondary 10 42 14 49K Throttle position sensor TPS resistance at rank position sensor voltage at 200 rpm 100 130 heater sensor resistance at 20 C 68 F 6 7 9 5 0 Standard 4 14 Roll 13 2 dC KYMCO 13 FUEL INJECTION SYSTEM DOWNTOSNOUE INJECTION SYSTEM DIAGRAM MM a da 1 HT 08 FRESH AIR Wb EXHAUST GAS 13 3 dC KYMCO DOWNTOWN 200i 13 FUEL INJECTION
28. SYSTEM PARTS LOCATION Tilt switch opeedometer Radiator filler cap o beam relay Ignition switch Py gt X 1 Hi beam relay Winker relay ECU 4 3 M Horn lt S A 1 2 Injector 13 4 dO KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i Ignition coil Fuel pump replay Oil controller Output voltage connector Coolant reserve tank Starter relay Regulator Rectifier CPS O2 sensor 13 5 13 FUEL INJECTION SYSTEM TROUBLESHOOTING Engine fail to start e ntake manifold air leak e Fuel contaminated deteriorated e Pinched or clogged fuel hose e Faulty fuel pump e Clogged fuel filter throttle body e Sticking fuel injector needle e Faulty fuel pump operating system e Carbon deposit stayed on the fuel injector e Spark plug dirty e Fuel pressure incorrect Engine stall hard to start rough idling e ntake air leak e Fuel contaminated deteriorated e Pinched or clogged fuel hose e dle speed fail to adjust e Fail to perform PTS ISC reset GQ KYMCO DOWNTOWN 200i Backfiring or misfiring during acceleration e Ignition system malfunction Poor performance drive ability and poor fuel economy e Pinched or clogged fuel hose e Faulty injector 13 6 KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL SELF DIAGNOSTIC PROCEDURES
29. The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is the excessive voltage may damage the ignition control module or ECU Always turn off the ignition switch before servicing e faulty ignition system is often related to poor connections Check those connections before proceeding e Make sure the battery 1s adequately charged Using the starter motor with weak battery results in a slower engine cranking speed as well as no spark at the spark plug e Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS Inductive Ignition Coil secondary coil without plug cap 10 42 14 49 Oxygen Sensor engine warming condition 6 70 9 5Q Crank Position Sensor 100 1300 0 4V 1 4V normal Roll Sensor 3 7V 4 4V fall down TROUBLESHOOTING No peak voltage e Short circuit in engine stop switch or ignition switch wire e Faulty engine stop switch or ignition switch e Loose or poorly connected ignition control module connectors e Open circuit or poor connection in ground wire of the ignition control module e Faulty crank position sensor e Faulty ignition control module Peak voltage is normal but no spark jumps at the plug e Faulty spark plug or leaking ignition coil secondary current e Faulty ignition coil 17 2 dC KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i Ignition Coil
30. X 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 Turn key to On position The CELP will be lighting for two seconds and then off the engine has problem the CELP will Upward side blink to show the failure codes stand e 11 failure codes for the KEHIN system If the vehicle gets more failure codes the CELP will be blinking from a lower number then show the higher number after three seconds All failure codes would be d tedly Battery warning indicator No matter when the CELP illuminated C while riding condition should find out the cause of the problem as soon as Fi indicator 13 7 dC KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES If more than a damaged part has occurred the The CELP denotes the failure codes CELP begins blinking in order When the indicator lights for one second that is equal to ten For example If the indicator blinks six times For example one longer blink illumination then shows one second illumination and two and two shorter blinks 0 5 second x 2 of blinks so there are two failures have occurred the indicator is equal to 12 blinks Follow Follow code 6 and 12 code 12 Put the ucdestandupand engine stad switch is zr UIN 11
31. been reinstalled It can cause engine stop hard to start engine or rough idling speed 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 TPS ISC RESET PROCEDURE 1 Put the side stand up and engine stop switch 15 at RUN Turn the key to the OFF position Fully open the throttle Turn the key to the ON position Release the throttle after waiting for eight seconds Turn the key to the OFF position Turn the key to the ON position 8 TPS and ISC have been reset successfully A 92 N If fail to reset repeat the steps from 1 to 8 13 13 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i FUEL PUMP INSPECTIION Full Position Put the side stand up and the engine stop switch 1s at Disconnect fuel pump fuel unit connector Connect the multimeter probe to the Red Black terminal and the multi meter probe to the Green terminal Turn the ignition switch to and measure the voltage between the terminals It should be shown the current battery voltage for a few seconds If there is still battery voltage replace the Yellow White fuel pump If there 1s not any battery voltage inspect the following 1 e Fuse B 10 A 7 e Fuel cut off relay e ECU Measure the resistance between the Empty Position Red Black and Green terminals of the fuel pu
32. e Loose or poor connection on O Engine starts Faulty O 45 pees sensor heater normally but not Open short circuit sensor smooth heater wire e Faulty O sensor heater e Loose or poor contacts on ISC Faulty ISC e Open or short circuit in ISC wire e Faulty ISC e Loose or poor connection on CPS Engine operates normally Engine starts Faulty CPS 7 e Open or short circuit CPS wire e Faulty CPS sensor 13 11 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 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 1 wet by fuel perform the spark plug anti flood to purge the fuel the engine Close the thratile turn switeh to Replace fully charged battery Open and hold the throtile fully pressing starter switch more than 3 seconds 13 12 dC KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i TPS ISC RESET e 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 15 has a motor inside which controls ISC valve to obtain smooth idling speed The ECU may record the incorrect ISC position during the engine speed isn t working when the ECU or the throttle body has
33. engine oil 20W 40 20W 50 Remove the oil filter screen cap Remove the oil filter screen and spring puma posui pone minem Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and filter screen cap 10 0 10 20 30 400 Torque 12 7N m 0 20 40 60 80 100 Recommended Oil SAESW50 API SJ Oil Capacity At disassembly 1 5 liter At change 1 3 liter Start the engine and check for oil leaks Start the engine and let it idle for few minutes then recheck the oil level 4 3 dC KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 200i OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right under crankcase cover Oil Filter Cap The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new filter Make sure the rubber seal on the filter facing the left crankcase 4 LUBRICATION SYSTEM OIL PUMP REMOVAL Remove twelve bolts attaching the right crankcase cover Remove the A C generator flywheel with special tool Special tool Flywheel Puller E003 Universal Holder E021 Remove the gasket and dowel pins Remove the starter idle gear and starter clutch Remove the two bolts and oil separator cover Remove the oil pump driven ge
34. engine till the engine stop working O ring Fuel Iniector 13 20 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 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 Tab Install the fuel pipe into the intake manifold by aligning the dowel pin Be careful not to damage the O ring Tighten the fuel pipe mounting bolt FUEL INJECTOR CLEANING PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard lt 1 6ms Fuel ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container Connect the battery as picture The injector cleaner with the flash relay Samo Keeping the fuel Injector operation d 9 Waiting for 20 30 minutes 7 Cleaning the carbons completely Flash Relay 13 21 KYMCO 13 FUEL INJECTION SYSTEM MN S 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 T Always replace an O ring with a new one Tighten the WTS sensor to the specified torque To
35. on the pump shaft Oil Pump Drive chain Cam Chain Oil Pump Driven Gear Clip Install the oil separator cover properly Fit the tab of the separator cover into the slit in the separator Oil Separator Cover Bolts 10 7 10 GENERATOR STARTER CLUTCH Install the starter idle gear and shaft Install the starter driven gear onto the crankshaft FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel e Before installation check and make sure that the inside of the flywheel is not contaminated Install washer and nut Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 5 5 6 5 kgf m 58 8 N m Remove the flywheel nut and washer Flywheel holder E021 KYMCO DOWNTOWN 200i starter Idle Gear Shaft Key Starter Driven Gear Flywheel Flywheel Holder 10 8 KYMCO 10 A C GENERATOR STARTER CLUTCH DOWNTOWN 200i STATOR INSTALLATION Install the A C generator stator on the right Screws crankcase cover and secure it with the three bolts Install the pulsar coil on the right crankcase cover and secure it with the two screws Install the wire grommet in the groove in the right crankcase cover securely Be sure to route the stator wire under the pulsar coil RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket
36. the oil pump is installed check each part for oil leaks SPECIFICATIONS ENGINE OIL Engine Oil Capacity At disassembly 1 5 liter At change 1 3 liter Recommended Oil 5 5 50 API SJ TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption e Oil level too low e Oil leaks e Clogged oil filter or oil passage e Worn piston rings e Faulty oil pump e Worn valve guide e Worn valve guide seal Oil contamination e Oil not changed often enough e Faulty cylinder head gasket e Loose cylinder head bolts 4 2 dC KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 200i Oil Dipstick ENGINE OIL OIL FILTER e Place the scooter upright on level ground for engine oil level check e Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level is near the lower level fill to the upper level with the recommended engine oil OIL CHANGE e The engine oil will drain more easily while the engine is warm Remove the oil drain bolt located at the left side of the engine to drain the engine oil After the oil has been completely drained install the aluminum washer and tighten the oil drain bolt Torque 24 5 N m 2 Uh Filter Screen Pour the recommended oil through the oil filler hole OIL FILTER SCREEN ENGINE OIL VISCOSITIES Drain the
37. will be damaged Turn off the ignition switch before operation e t is not necessary to check the MF battery electrolyte or fill with distilled water e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done in an emergency e Remove the battery from the motorcycle for charging e When replacing the battery do not use a traditional battery e When charging check the voltage with an electric tester SPECIFICATIONS Standard 2 Fully charged 13 2V battery Insufficient charged lt 12 3V Charging current 1 2 5 10H 16 2 GQ KYMCO 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i TROUBLESHOOTING No power e Dead battery e Disconnected battery cable e Fuse burned out e Faulty ignition switch Low power e Weak battery e Loose battery connection e Charging system failure e Faulty regulator rectifier 16 3 Intermittent power e Loose battery cable connection e Loose charging system connection e Loose connection or short circuit in ignition system Charging system failure e Loose broken or shorted wire or connector e Faulty regulator rectifier e Faulty A C generator 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i BATTERY Screws REMOVAL The battery 1s in the battery box below seat Remove the seat Remove the met in box 3 Remove four screws and then the battery retainer N 4 Pull battery
38. 008 in WHEEL RIM INSPECTION Check the wheel rim runout 14 HANDLEBAR FRONT WHEEL FRONT BRAKE ___ FRONT SHOCK ABSORBER STEERING STEM__POWNTOWN 200i _ Collar INSTALLATION gt p 78 Apply grease to the collar then install the e A collar onto the wheel ow 2 Install the speedometer speed wheel sensor DISASSEMBLY Remove the side collar and dust seal Speed Wheel Sensor Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Remove the front wheel bearing by using the special tool Special tool Bearing puller E00037 Remove the distance collar from wheel 14 7 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 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 Install the front wheel bearing by using the special tool Apply grease to the collar then install the collar onto the wheel h I4 HANDLEBAR FRONT WHEEL FRONT FRONT SHOCK ABSORBER STEERING STEM
39. 1 4 kgf m 11 8 N m KYMCO DOWNTOWN 200i Impeller Seal Washer Porcelain Mechanical Water Seal 12 10 12 COOLING SYSTEM DOWNTOWN 200i THERMOSENSOR THERMOSENSOR REMOVAL Thermosensor Wire Remove the met in box Drain the coolant Disconnect the thermosensor wire Remove the thermosensor Thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up 50 80 100 120 12 11 GQ KYMCO 12 COOLING SYSTEM DOWNTOWN 200i THERMOSTAT THERMOSTAT REMOVAL Remove the met in box Drain the coolant Disconnect the thermosensor wire from the thermosensor Disconnect the water hose from the thermostat housing Disconnect the vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Thermosensor Wire THERMOSTAT INSPECTION Suspend the thermostat a pan of water over burner and gradually raise the water temperature to check its operation Technical Data Valve lift e Do not make the thermostat touch the pan EM Thermostat as it will give a false reading e Replace the thermostat if the valve stays open at room temperature
40. 1 Stud bolt Inlet pipe side 2 5 9 bolt EX pipe side Cylinder head stud nut Right crankcase cover bolt Left crankcase cover bolt Bolt B stud 10 180 Valve adjusting lock nut Cam sprocket bolt Transmission oil checkidrain bolt Engine oil drain bolt Clutch outer nut starter motor mounting bolt Mission case bolt Drive face nut Drive plate comp Cam chain tensioner Cam chain tensioner pivot Oneway clutch ACG flywheel nut opark plug Water pump impeller M i um Double end bolt Double end bolt Apply oil to thread Apply oil to thread Apply oil to thread Apply thread lock Left thread KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i TORQUE VALUES FRAME Steering 1 Stem lock nut 2 Handle post bolt 3 Bridge bolt 4 Race nut head Brake 1 Front Rear caliper bolt 2 Brake hose bolt 3 Disk bolt Engine hanger 1 side 2 Engine side Rear fork bolt speed sensor cable Q2 sensor Rear carrier Front axle nut Rear axle nut Rear cushion upper lower 1 5 1 GENERAL INFORMATION Downtown 200i SPECIAL TOOLS mamme T jl Flywheel Puller A120E00003 A C generator flywheel removal Tappet Adjuster A120E00012 Tappet adjustment Oil Seal amp Bearing A120E00014 Oil seal amp bearing installing Installer Flywheel Holder A120E00021 A C generator flywheel ho
41. 5mm repair or replace if over Cylindricity 0 05 mm repair or replace if over Middle Bottom 7 5 KYMCO 7 CYLINDER PISTON DOWNTOWN 200i MP Measure the connecting rod small end I D Em Service Limit 17 06 mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring e Be careful not to damage the piston piston rings during assembly rings should be installed with the markings facing up e After installing the rings they should rotate freely without sticking e Stagger the ring end gaps as the figure shown 7 6 KYMCO 7 CYLINDER PISTON DOWNTOWN 200i PISTON INSTALLATION Remove any gasket material from crankcase surface X careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip e Position the piston mark on the intake valve side ePlace a clean towel in the crankcase to keep the piston pin clip from falling into the crankcase CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase T The piston must be changed in pair with cylinder La wis Piston PISTON 00 CYLINDER CLEARANCE 7 7 KYMCO 7 CYLINDER PISTON DOWNTOWN 200i Install the cam chain guide X e Insert the tab on the cam chain guid
42. 7 kgf m 70 N m Special tool Lock nut wrench F00002 14 17 15 REAR BRAKE REAR FORK REAR REARBRAKE REAR FORK REAR REARSHOCK ABSORBER SCHEMATIC DRA WING 15 1 SERVICE INFORMATION 15 2 TROUBLESHOOTING 15 2 REAR BRAKE 3 cose M hase ae ese 15 3 REAR BOR 15 6 REAR echa ui 15 7 REAR SHOCK 5 15 7 15 0 GQ KYMCO DOWNTOWN 200i 15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SCHEMATIC DRAWING BB TH E 95901 10040 GE amp Rm i E met Sieb 35801 10049 5 Ag Ta 42600 4 42112 203605 Mos py 901224 EAT 15 1 15 BRAKE REAR FORK REAR SERVICE INFORMATION GENERAL INSTRUCTIONS e When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Standard mm
43. 8 mont 12 18 24 30 36 PAGE AIRCLEANER TR RRL SPARKPLUGS _ THROTTLE OPERATION FUEL LINE NNUS CN _ CRANKCASE BREATHER ENGINE OIL R R R R R R 29 ENGINEOLSCREEN C R C R C R gt p _ ENGINE IDLE SPEED Jif 1 TRANSMSSIONOL RIR R RIRIRR 32 Shidi WHICHEVER COMES FIRST ODOMETER READING X 1000 km REFER X 1000 10 613 6 9 12 15 18 TO MONTH 1 6 12 18 24 30 36 PAGE CVTTRANSMISSION SYSTEM 1 BRAKE FLUID 1111 37 _NUTS BOLTS FASTENERS IJ WHEELSTIRES GO E mM E 4 KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i 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 Adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber out and adjust by loosening the lock nut 3 and turning the adjusting nut 2 3 3 KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i ENGINE OIL OIL LEVEL INSPECTION Stop the en
44. B R RAN STOP SW Wd STOP SW 730A STARTER SW G Y R W R G 12V10AH i T 18 1 GQ KYMCO 18 STARTING SYSTEM DOWNTOWN 2001 SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed e After the starter clutch 1s installed be sure to add the engine oil and coolant and then bleed air from the cooling system SPECIFICATIONS Standard mm Service Limit mm TORQUE VALUES Starter motor mounting bolt I Okgf m 10N m TROUBLESHOOTING Starter motor won t turn Lack of power e Fuse burned out e Weak battery e Weak battery e Loosed wire or connection e Faulty ignition switch e Foreign matter stuck in starter motor e Faulty starter clutch gear e Faulty front or rear stop switch e Faulty starter relay Starter motor rotates but engine does e Poorly connected broken or shorted wire not start e Faulty starter motor e Faulty starter pinion e Starter motor rotates reversely e Weak battery 18 2 GQ KYMCO 18 STARTING SYSTEM DOWNTOWN 200i 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 Remove the seat met in box and carrier Remove the body cover center cover and rear fender A together Remove the nut goes to t
45. CO DOWNTOWN 200i Nut r Bolts Cylinder Head Gasket Dowel pins Valve Spring Compressor dC KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i VALVE STEM INSPECTION Inspect each valve for bending burning or abnormal stem wear Intake valve Exhaust valve Remove carbon deposits from the combustion chamber Clean off any gasket remnants from the cylinder head contact surface X Be careful not to damage the cylinder head mating surface CYLINDER HEAD ASSEMBLY Install the valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Install the valve spring Special Valve spring compressor E040 e the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters e Be careful not to damage the valves 6 CYLINDER HEAD VALVES DOWNTOWN 200i CYLINDER HEAD INSTALLATION Dowel Pins Install the dowel pins and a new cylinder head gasket Install the cam chain guide the intake valve rocker arm shaft off any grease before installation Gasket chain guide Install the cylinder head Cylinder Head Install the camshaft Install the intake valve rocker arm and the rocker arm shafts Bolts CAMSHAFT INSTALLATION Install the set plate
46. Compress the tool and install the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 75 N m X e Be sure to use a clutch spring compressor to avoid spring damage Lock Nut Wrench Clutch Driven Pulley Clutch Spring Compressor E053 Fittings amp Nut Wrench 41mm E033 8 11 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft Drive Pulley Collar Movable Drive Face Assembly Put the drive belt on the driven pulley Put the drive belt on the drive pulley collar Install the clutch driven pulley and clutch outer onto the drive shaft e Keep grease off the drive shaft Install washer and the clutch outer nut Clutch Outer Hold the clutch outer with the universal holder to tighten clutch outer nut Torque 54 N m Universal Holder E017 1 Install the drive pulley face washer and drive face nut Hold the drive pulley with the universal holder JJ 7 and tighten the drive face nut P amp Torque 93 1 N m YI 7 y X e Do not get oil or grease on the drive belt or gt drive pulley faces i L r v9 Universal Holder 8 12 _ 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i Install the left crankcase cover Left Cran
47. EBAR 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 Lighting Switch Starter Switch LIGHTING SW STARTER SW ENGINE STOP SW OFO 19 8 dC KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i Dimmer Switch LEFT HANDLEBAR SWITCH INSPECTION Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows WINKER SW HORN SW MR UR Horn Switch Turn Signal light Switch Passing Switch _ DIMMER Sw PASSING SW LUGGAGE BOX LIGHT SWITCH Luggage box light switch _ Connector INSPECTION a Remove luggage box Disconnect the luggage box light switch connector and check the luggage box light switch for continuity between the switch terminals There should be no continuity with the luggage box light switch pushed and there should be continuity with the luggage box light switch 15 released 19 9 dC KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i 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 si
48. FRONT BRAKE FLUID FLUID REPLACEMENT AIR BLEEDING contaminated brake disc pad reduces stopping power Discard contaminated pads clean contaminated disc with a high quality brake degreasing agent Do not allow foreign material to enter the system when filling the reservoir Avoid spilling brake fluid on painted plastic or rubber parts Place a rag over these parts whenever the system 1 serviced BRAKE FLUID DRAINING Make sure that the master cylinder parallel to the ground before removing the reservoir cover Remove two screws Remove the reservoir cover diaphragm plate and diaphragm Connect a bleed hose to the bleed valve 14 9 dO KYMCO DOWNTOWN 200i 2 A e lt I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 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 Fill the master cylinder with DOT 4 to the upper level Connect a commercially available brake bleeder to the front caliper bleed valve Check the fluid level often while bleeding the brake to prevent air from being pumped into the system Pump the brake bleeder and loosen the front caliper b
49. ING SYSTEM DOWNTOWN 200i 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 e he battery can be charged and discharged repeatedly If a discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after 1 15 used for 2 3 years capacity decreased battery will resume its voltage after 1t 1 recharged but its voltage decreases suddenly and then increases when a load is added e When a battery is overcharged some symptoms be found If there is a short circuit inside battery no voltage is produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life e battery is not used for a long time it will discharge by itself and should be recharged every 3 months e A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life e Inspect the charging system according to the sequence specified in the Troubleshooting e Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier
50. LEAR PROCEDURE A Check the DTC is for Downtown 2001 is for Downtown 2001 C Choose Load DTC Press the Down button FIGI PW 3 4 TNT 2 1 L 5 35 5 FUELINJECTION SYSTEM DOWNTOWN 200i D Press the Enter button and the indicator 1 lighting KYMCO 9 lt Prev Load DTC E Clearing DTC completed if the indicator is off KYMCO Diagnostic Clearing DIC Completed 5 36 GC KYMCO 5 FUEL INJECTION SYSTEM DOWNTOWN 200 4 DATA ANALYSIS PROCEDURE A Press the Down twice B Choose Data Analyze Press the Enter button to enter page O1 is for Downtown 2001 Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Down button to enter page 02 Diagnosis H1 1 j 1 12 6 VU 5 37 13 FUEL INJECTION SYSTEM DOWNTOWN 2001 D Down page 02 The measure figures including of TPS position Intake pressure and Intake air temperature Press the Down button to enter page 03 E Down page 03 measure figures including of Atmosphere pressure Fuel Injector interval and Ignition advance timing Press the Down button to enter page 04 F Down page 04 The measure figures including of Engine temperature O2 sen
51. Loosen the air cleaner connecting hose band screw Loosen the intake manifold band screw Remove the throttle body MAP sensor TPS sensor and ISC sensor as a set 13 25 C KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i Screw Set Plate DISASSEMBLY The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the throttle body MAP TPS ISC or ECU has been reinstalled Remove the screw and then remove the ISC and set plate Remove the screw and set plate Remove the MAP Remove the screw AND then remove the Screw ISC Set Plate TPS TPS ASSEMBLY The throttle position sensor TPS and idle air bypass valve ISC have to reset when the throttle body MAP TPS ISC or ECU has been reinstalled Apply oil onto a new O ring When install the TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely MAP 13 26 dC KYMCO 13 FUEL INJECTION SYSTEM DONNIEOVUNOUDI Apply oil onto a new O ring When install the MAP onto the throttle body being careful not to damage the O ring Install the set plate and tighten the screw securely Apply oil onto a new O ring When install the ISC and set plate onto the throttle body being careful not to damage the O ring Screw ISC Set Plate DIAGNOSTIC TOOL CONNECTOR INSPECTION Put the side stand up and engine stop switch is at RUN
52. ONS Unit mm in Axle shaft runout _ 02mm 0 008 in Brake disk runout Brake master cylinder ID 12 7 12 74 0 508 0 5096 Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 2 Brake caliper piston O D 26 93 26 96 1 0602 10644 Brake caliper cylinder LD 27 27 05 1063 1 065 TORQUE VALUES Handlebar lock nut Steering stem lock nut Steering stem pinch bolt Front axle 45 N m 4 5 kgf m 70 N m 7 0kgf m 27 N m 2 7 kgf m 20 N m 2 0 kgf m Master cylinder reservoir cover screw 1 6N m_ 0 16 kgf m Master cylinder holder bolt 12 N m 1 2 kgf m 2 0 N m 0 2 kgf m 10 0 N m 1 0 kgf m 1 0 N m 0 1 kgf m 35 N m 3 5 kgf m ALOC bolt replace with a new one 5 5N m 0 55 kgf m Brake lever pivot bolt Brake lever pivot nut Brake light switch screw Brake caliper mounting bolt Brake caliper bleed screw Brake hose oil bolt 35 N m 3 5 kgf m SPECIAL TOOLS Lock nut wrench F00002 Oil seal and bearing installer E00014 Bearing puller 00037 Lock nut wrench F00023 Ball cone remover F00009 Ball cone installer F00019 14 1 14 HANDLEBAR FRONT WHEEL FRONTBRAKE FRONT SHOCK ABSORBER STEERING STEM TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e Bent front fork e Bent front axle
53. P Power indicator Enter or Exit DTC indicator Failure codes 13 29 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 2 DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power 15 for Downtown 2001 version Including of model number identifications number and software version Press the Enter button LGF9is for Downtown 2001 13 30 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i B Press the Down button and then turn to the first page C Press the Enter button to check the DTC failure code 13 31 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 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 Curr ent DTC List Current DTC 13 32 5 FUEL INJECTION SYSTEM DOWNTOWN 200i 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 Diagnostic Previous z 1 e i Clear DTC 5 33 5 FUELINJECTION SYSTEM DOWNTOWN 200i J Press the Enter button and then turn to the first page is for Downtown 2001 5 34 GC KYMCO 5 FUEL INJECTION SYSTEM DOWNTOWN 200i 3 DTC C
54. 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 Remove the speedometer cable guide from left front shock absorber Remove two mounting bolts and then remove the right left front shock absorber INSTALLATION Installation 1s the reverse order of removal Tighten the shock absorber mounting bolt to the specified torque Torque 2 7 kgf m 27 N m 19 5 Specified Oil SS 8 Oil Capacity 185 cc Mounting Bolts INSPECTION Inspect the following items and replace if necessary eFront shock absorber tube bending damage or wear eWeak front shock absorber spring Left eDamper and damper rod bending if Qil seal damage or wear 14 14 14 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM POWNTOWN 200i _ 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 remove the steering stem lock nut by using the special tool Special tool Lock nut wrench F00002 Top Cone Race Remove the top cone race and washer Remove the steering stem Be careful not to lose the steel balls 26 on top race and 19 on bottom race Special tool
55. STMENT DOWNTOWN 200i 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 X e Tire pressure should be checked when tires are cold Tire Pressure Rider Rider with passenger 2 25 ke cm 2 25 ke cm Front Axle Nut Tire Size Front 120 80 14 585 150 70 13 645 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the specified torques Torque Front axle nut 2 kg m Rear axle nut 12 kg m Rear Axle Nut STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing 3 11 3 INSPECTION ADJUSTMENT KYMCO DOWNTOWN 200i SIDE STAND Your scooter s side stand is not only necessary when you park but it contains an important safety feature This feature cuts off the ignition if you try to ride the scooter when the side stand is down Perform the following side stand inspection INTERLOCK FUNCTION CHECK Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower t
56. T WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 P Install the front and rear master cylinders and connect the brake light switch wires 1 E DISASSEMBLY Remove two screws attaching to the right handlebar switch Screws Disconnect the throttle cable from the throttle grip Remove the right handlebar switch 14 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM__POWNTOWN 200 Remove two screws and then remove the left handlebar switch ASSEMBLY gom Install the left handlebar switch Pin Align the pin the left handlebar switch with the hole on the handlebar Install and tighten the two screws securely Install the right handlebar switch Align the the right handlebar switch with the hole on the handlebar Lubricate the throttle grip front end with grease and then connect the throttle cable to the throttle grip Install and tighten the two screws 14 5 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 FRONT WHEEL REMOVAL Jack 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 The actual runout is 1 2 of the total indicator reading Service Limit 0 2 mm 0
57. Turn the ignition switch to Measure the voltage between the following terminals of the diagnostic tool connector with PDA tester Terminal Normal Black Green Battery voltage Battery voltage Diagnostic Connector White Yellow Green 13 27 13 FUEL INJECTION SYSTEM DOWNTOWN 200i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 EO00 ENGLISH VERSION 13 28 dO KYMCO 13 FUELINJECTION SYSTEM DOWNTOWN 200i FI DIAGNOSTIC TOOL This tool 15 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 This software can be updated with computer for new model through the USB cable The power required of tool 1 connected with 12V battery For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch e The side stand must be upward when serving the diagnostic procedure e Thefunction includes ECU version model name data analysis and reset ECU version includes model name ECU number identifications number and software version Failure codes DTC reading DTC clearing and troubleshooting Data analysis For ECU s software inspection Reset For the setting function adjustment Model No ECU Version DTC Inspect DATA Analyze Down Button U
58. ar clip to remove the oil pump driven gear and drive chain dC KYMCO DOWNTOWN 200i 4 LUBRICATION SYSTEM Remove two oil pump mounting bolts and the oil pump OIL PUMP INSTALLATION Install the oil pump into the crankcase Install the oil pump with the arrow on the pump body facing up and fill the oil pump with engine oil before installation After the oil pump is installed tighten the two mounting bolts Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft Install and tighten the pump driven gear bolts Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch Install the gasket and dowel pins Install the right crankcase cover and tighten the twelve bolts Torque 1 2 kg m Diagonally tighten the bolts in 2 3 times dC KYMCO DOWNTOWN 200i Arrow Mark Starter Idle Gear Dowel Pin GQ KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i ENGINE REMOVAL INSTALLATION SERVICE INFORMATION ereire oo 5 1 ENGINE REMOVAL INSTALLATION 5 2 ENGINE NG a tL eee 5 6 5 0 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e A floor jack or other adjustable support is required to support and maneuver the engine
59. cified torque Torque 2 N m 0 2 kgf m 1 1 Ibf ft 14 11 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE FRONT SHOCK ABSORBER STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the pad pins Remove the two caliper mounting bolts then remove the caliper Remove the brake pads Always replace the brake pads in pairs to ensure even disc pressure cy am Bolts Brake Pads dO KYMCO DOWNTOWN 200i 14 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM__POWNTOWN 200 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 Install the front caliper onto the fork leg and then install and tighten the new two caliper mounting bolts to the specified torque Torque 35 N m 3 5 kgf m Tighten the pad pins to the specified torque Torque 18 N m 1 8 kgf m 13 Ibf ft BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness Service limits 3 mm 0 12 in Replace the brake disc if the smallest measurement 1s less than the service limit Measure the brake disc warpage Service limits 0 3 mm 0 012 in 14 13 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 FRONT
60. d surfaces to avoid damage Bolts INSPECTION Inspect the brake pads and brake disk Measure the brake disk thickness Visually check the brake pad thickness DISASSEMBLY Remove two brake pads dowel pins and three bolts from the brake caliper Remove the brake pads Brake pads 15 3 15 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION DOWNTOWN 200i 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 Check the piston cylinder for scratches or wear and replace if necessary Check the caliper cylinder for scratches or wear and measure the cylinder bore ASSEMBLY Install the two spring plates onto the groove of the caliper 15 4 15 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION DOWNTOWN 200i Make sure the spring plate next to the Caliper Inside brake pad dowel pin orientation 4 1 WO OM 4 E 4 i t ft Shorter 4 mus Caliper Outside Install two brake pads Brake Pads INSTALLATION Install the brake caliper to the rear fork and Brake Fluid Tube Bolt Caliper tighten the two bolts Torque 35 N m 3 5 kgf m Connect the brake fluid tube to the brake caliper and install fluid tube bolt copp
61. dC KYMCO DOWNTOWN 200i By KWANG YANG Motor Co Ltd 1st Edition Dec 2009 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300 SK40AA A1 This Service Manual describes the technical features and servicin rocedures for the KYMC owntown 200i oection 1 contains the precautions for all operations stated in this manual Head them carefully before 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 oection 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 The information and contents 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
62. e accumulated on the combustion chamber and the piston head 3 7 KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i FINAL REDUCTION GEAR OIL K e 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 Hill the transmission with the recommend fluid to the capacity listed below Oil Drain Bolt Transmission fluid type SAE 90 Transmission fluid capacity 0 23 L Transmission fluid exchanging capacity 0 21 L Install the transmission filler bolt and tighten it to the specified torque Oil Filler Bolt DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule Drive Belt 3 8 3 INSPECTION ADJUSTMENT DOWNTOWN 200i 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 BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk runout is within the sp
63. e as below Violet Red 5 V ECU voltage Black Blue E Green Pink 0 4 1 4 V less Incline the roll sensor 65x10 degrees to the left or Sensor E E right at the ignition switch Measure NI voltage as below Violet Red Green Pink 5 V voltage AVY V p N 3 W 4 Black Blue x Green Pink SUM If repeat this test first turn the ignition switch to OFF then turn the ignition switch to Connector 17 4 dC KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i REMOVAL INSTALLATION Roll Sensor UP Mark Screws Disconnect the connector and remove two screws then remove roll sensor Installation is in the reverse order of removal K Install the roll sensor with its up mark facing up Tighten the mounting screws securely Connector 17 5 dO KYMCO 18 STARTING SYSTEM DOWNTOWN 200i STARTING SYSTEM 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 2 STARTER MOTOR ere eccL ee 18 3 STARTER RELAY INSPECTION 18 4 18 0 18 STARTING SYSTEM DOWNTOWN 200i STARTING SYSTEM LAYOUT Starter Relay Ignition Switch STARTING CIRCUIT MAIN SW 15 BELACA
64. e into the cylinder groove Install the cylinder head gasket and dowel pins Connect the water hose to the cylinder Install the cylinder head Tighten the cylinder base bolt 7 8 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i DRIVE AND DRIVEN PULLEYS V BELT et 8 1 SERVICE IN TORNA TON e E TROUBLESHOOTING 55 2 c cip MA DEI IEEE 8 3 E eee 8 3 CLUTCH OUTER DRIVEN PULLEY V BELT 8 3 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i SCHEMATIC DRAWING 30605 5 2301 e IT 5 Ed 22132 4 22 it LO a 22110 8 1 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed e 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 SPECIFICATIONS TORQUE VALUES Drive face nut 9 5 kgf m 93 1 N m Apply oil Clutch outer nut 5 5 kgf m 54 N m Clutch drive plate nut 5 5 kgf m 54 N m SPECIAL TOOLS Universal holder E017
65. eal Drive Shaft 9 FINAL REDUCTION FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Put the final gear on the left crankcase Install the countershaft and gear into the left crankcase Install the final shaft into the final gear and transmission case Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch outer driven pulley Install other removed parts in the reverse order of removal Torque Transmission case bolt 0 8 1 2 kgf m 9 8 N m After installation fill the transmission case with the specified oil e Place the scooter on its main stand on level ground e Check the oil sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity At disassembly 0 23 liter At change 0 21 liter Install and tighten the oil check bolt Torque Oil filler drain bolt 1 8 2 2 kgf m 19 7 N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low 9 5 Countershaft dC KYMCO DOWNTOWN 200i Dowel Pin Cw Final Gear Transmission Case Cover Drain Bolt under filler Bolt GQ KYMCO 10 A C GENERA TOR STARTER CLUTCH DOWNTOWN 200i A C GENERATOR STARTER CLUTCH SCHEMATIC
66. ealed end facing up Grooves Seat the snap ring in its groove Apply grease to the driven face bore areas Guide Pins 8 8 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i Press a new needle bearing into the driven face CLUTCH DISASSEMBLY Remove the clips and retainer plate to disassemble the clutch e Keep grease off the clutch linings Clutch Lining 8 9 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i CLUTCH ASSEMBLY 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 CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease from them Apply grease to the O rings and install them onto the moveable driven face 6 10 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i Install the movable driven face onto the driven Grooves face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Install the seal collar Remove any excessive grease X e Be sure to clean the driven face off any grease Set the driven pulley assembly driven face spring Guide Pins and clutch assembly onto the clutch spring compressor e Align the flat surface of the driven face with the flat on the clutch drive plate Clutch Spring Compressor
67. ecified service limit Check if the brake pad wear exceeds the wear indicator line X Keep grease or oil off the brake disk to T avoid brake failure Rear Brake disk BRAKE FLUID Turn the steering handlebar upright and check if both brake fluid levels is at the upper limit If the Brake fluid reservoir brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 X The brake fluid level will decrease 1f the brake pads are worn 3 9 KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i 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 the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Each shock absorber 4 on your scooter has 5 spring preload adjustment positions for different 4 load or riding conditions Use spanner 5 to adjust the rear shock spring preload Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooter is heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions 3 10 GQ KYMCO 3 INSPECTION ADJU
68. egulator rectifier connectors Remove the two bolts regulator rectifier Installation 1s 1n the reverse order of removal Connectors 16 7 GQ KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i IGNITION SYSTEM IGNITION SYSTEM LAYOUT edo 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING 172 MD 17 3 ICNITION COML INSPECTION ee 17 3 AC GENERATOR INSPEC ION 17 4 ROEESENSOR INSPECTION reie 17 4 17 0 dC KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i IGNITION SYSTEM LAYOUT Roll Sensor Ignition Coil Ignition Switch ECU Generator Crank Position Sensor IGNITION CIRCUIT Ignition Switch Switch Side Stand Switch TPS o YB Roll Sensor ECU Relay amp 5 ACG Pulser Coil ignition Coil 17 1 dO KYMCO 17 IGNITION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present e When servicing the ignition system always follow the steps in the troubleshooting on page 17 2 e The ignition timing cannot be adjusted since the ignition control module 1s already adjusted in factory e
69. ement e Do not damage the throttle body it may cause the throttle and idle valve isn t synchronization e 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 Loosen or tighten them can cause the throttle and idle valve to synchronization failure TPS and ISC have to be reset after the throttle body MAP TPS ISC or ECU has been reinstalled MAP 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 position Measure if the ECU voltage outputs to the MAP between the following terminals of the MAP connector Terminal Normal Violet Red Green Pink 13 24 dO KYMCO 13 FUEL INJECTION SYSTEM NNNM CM 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 Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal Violet Red Green Pink Throttle position sensor TPS resistance at 20 C 68 F 3500 6500 TPS Cable Ends P REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from throttle seat Disconnect the TPS ISC and MAP sensor connectors
70. emoval do not pull the joint claws forcedly to avoid damage Installation is in the reverse order of removal 2 8 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i FRONT LOWER COVER Remove the front cover Remove the foot skirt Remove seven screws and front lower cover Installation 1s 1n the reverse order of removal REAR FENDER Remove the body cover and then the rear fender Installation 1s 1n the reverse order of removal BODY COVER Remove the rear center cover Remove the right and left foot skirts Remove the rear carrier Remove six screws and two nuts then remove the body cover 2 9 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i Taillight Connector TIRE FENDER Remove the body cover Remove four bolts attaching to the tire fender Installation 1s 1n the reverse order of removal FLOORBOARD Remove the body cover Remove the right left skirt Remove two screws 2 10 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i Remove eight bolts then remove the floorboard UNDER COVER Remove four bolts Remove the under cover 2 11 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i Remove the fuel tank cap cover Installation 1s 1n the reverse order of removal Speedometer Wires METER PANEL Disconnect the speedometer wires Disconnect the DC power connectors Remove one screws Remove the ignitio
71. er washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system When installing the brake fluid tube be sure to install the two copper sealing washers 15 5 15 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION DOWNTOWN 200i REAR FORK REMOVAL Remove the exhaust muffler Y 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 Remove the rear fork The installation sequence 15 the reverse of removal Bear Axle Collar 15 6 15 REAR WHEEL REAR BRAKE 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 INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 40 N m 4 kgf m Rear axle nut 120 N m 12 kgf m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers INSTALLATION Install the rear suspension in the reverse order of removal Torque Upper Mount Bolt 40 N m 4 kgf m Lower Mount Bolt 40 N m 4 kgf m 15 7
72. erature Open or short circuit on ECT wire Faulty ECT Faulty Tilt switch voltage range inclined angle lt 65 0 4 1 4 V Inclined angle gt 65 3 7 4 4 V Faulty Tilt Engine operates 15 P1630 e Loose or poor connection on Tilt switch Roll normally switch e Open or short circuit Tilt switch wire Faulty tilt switch Faulty O sensor voltage range A F below 14 7 gt 0 7V 5 A F over 14 7 lt 0 18 V 17 0130 e Loose or poor connection on Engine sensor normally sensor e Open or short circuit on sensor wire Faulty O sensor e Faulty Fuel injector range Faulty 9 945 13 5 2 Engine fail to be 33 P0201 injector e Loose or poor connection on injector operated Nozzle e Open or short circuit on injector wire e Faulty fuel injector 13 10 KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i Failure Blinks Contents Causes symptoms e Faulty Inductive ignition coil Q range 4 2 1596 Faulty e Loose or poor connection on 37 inductive inductive ignition coil Engine ignition coil Open or short circuit on inductive Operated ignition coil wire Faulty inductive ignition coil Faulty Fuel pump Q range F 1100733 100130 41 Loose or poor connection on fuel operated e Open or short circuit on fuel pump wire Faulty fuel pump e Faulty O sensor heater Q range 6 7 2 0 50 2
73. ere should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery 1s connected replace a fuel cut off relay REMOVAL Disconnect the fuel cut off relay connector and remove it from frame Fuel pump replay Oil controller 13 FUEL INJECTION SYSTEM GQ KYMCO DOWNTOWN 200i 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 switch connector during inspection Place the tilt switch vertical as shown and turn the ignition switch to Measure the voltage between the following terminals of the tilt switch connector with the connector connected Normal Violet Red Green Pink 6 Black Blue Green Pink 0 4 1 4 V Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage between the following terminals of the tilt switch connector with the connector connected Terminal Terminal Normal Violet Red Green Pink P Y Black Blue Green Pink 3 7 4 4 V If repeat this test first turn the ignition switch to OFF then turn the ignition switch to REMOVAL INSTALLATION Disconnect the connector and remove two
74. evel too high e Worn or damaged oil seal dO KYMCO 9 FINAL REDUCTION DOWNTOWN 200i 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 Remove the left crankcase cover Remove the clutch outer driven pulleys Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Transmission Case Cover Dowel Pin Remove the gasket and dowel pins Remove the final shaft Remove the final gear and countershaft Final Shaft Final Gear FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft GQ KYMCO 9 FINAL REDUCTION DOWNTOWN 200i Drive Shaft Bearing Inspect the final gear and final shaft for wear damage or seizure Drive Shaft Check the left crankcase bearings for excessive play and inspect the oil seal for wear Drive Shaft Bearing damage Inspect the drive shaft and gear for wear or damage Countershaft Bearing Check the transmission case covers bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Drive Shaft Bearing Do not remove the transmission case cover except for necessary part replacement When replacing the drive shaft also replace the bearing and oil s
75. gine 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 Install the aluminum washer and tighten the oil drain bolt Torque 2 5 kg m e Replace the aluminum washer with new one if it is deformed or damaged Pour the recommended oil through the oil filler hole OIL CAPACITY Engine oil capacity 1 51 Engine oil exchanging capacity 1 3 L Engine Oil Viscosity SAE 5W50 Oil Drain Bolt OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen attaching the left under crankcase Clean the oil filter screen Install the oil filter screen and filter screen cap Fill the engine with recommended engine oil OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right under crankcase cover Oil Filter Cap 3 INSPECTION ADJUSTMENT The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new filter K Make sure the rubber seal on the oil filter facing the left crankcase RESERVE TANK COOLANT LEVEL INSPECTION The reserve tank is under left floorboard Check the coolant level through the inspection window 1 at the left side skirt white the engine is at the normal operating temperatu
76. he cylinder head cover bolts Inlet pipe 6 11 GQ KYMCO 7 CYLINDER PISTON DOWNTOWN 200i CYLINDER PISTON AW 7 1 SERVICE INFORMATION sea 2 2 TROUBLESHOOTING Ta CYLINDER REMOVAL T3 PISTON REMOVAL 7 3 PISTON INSTAT LAT 17 CYLINDERJINSTALEATION 7 0 GQ KYMCO 7 CYLINDER PISTON DOWNTOWN 200i SCHEMATIC DRAWING 90402 130 90005 3001 4 7 92 90004 91906 14520 7 7 4 T NUM ie s 14510 7 1 GQ KYMCO 7 CYLINDER PISTON DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder and piston can be serviced with the engine installed in the frame e When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed e After disassembly clean the removed parts and dry them with compressed air before inspection Standard mm Service Limit mm 66 07 66 02 0 015 0 055 0 015 0 055 0 15 0 30 0 30 045 piston ring 0 2 0 7 65 98 65 99 66 99 66 00 SPECIFICATIONS Piston O D measuring position 9mm from bottom of skirt TROUBLESHOOTING e When hard starting or poor performance at lo
77. he 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 3 12 dO KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 200i LUBRICATION SYSTEM LUBRICATION 4 1 SERVICE INFORMATION 4 2 TROUBLESHOOTING 4 2 ENGINE OIL OIL FILTER 4 3 OTOM aac AE E AEA EAE EE LE 4 5 4 0 dC KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 200i LUBRICATION PART 96001 06022 D is MS 96001 06028 19014 96001 06035 96001 06022 42 19505 LBA2 96001 06028 19229 96001 06010 90478 19221 94301 08140 19215 15423 8 90428 TAE O 94510 s1303 LEAT C_ 4 19232 s 62 Filter Oil Pump Drive Chain 22 KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed on the frame e Drain the coolant before starting any operations e Carefully when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line e Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After
78. he starter relay and relax cable band to disconnect the starter motor cable Remove two start motor mounting bolts and the motor Bolts 18 3 dC KYMCO 18 STARTING SYSTEM DOWNTOWN 200i 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 STARTER RELAY INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire and green yellow wire There should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal if there is continuity and hear sounds Starter Relay test chart 18 4 GQ KYMCO 19 LIGHTS SWITCHES FUEL PUMP DOWNTOWN 200i LIGHTS METERS SWITCHES SERVICE INFORMA TION eee 19 1 BULB REPLACEMENT eccriene EEs 19 2 BRAKE LIGHT S WITO arcs a atte 19 6 IGNITION WITO 19 6 HANDLEBAR SW 19 7
79. i SPECIFICATIONS Downtown 200i Model No SK40AA a T Overall length 2200 mm Fi injection system Overall width Overall height 1410 mm 12 54 Wheel base 1545 mm Engine type 4 stroke O H C Fuel Used 921 nonleaded ECU Rear wheel Ignition type Total Battery Capacit Transmission system Clutch type Dry multi disc Transmission type CVT Operation type Auto centrifugal Reduction gear type Two stage reduction 1 0 81 2 57 2 9 54 Moving device Front wheel Wheel material Left Right Front Rear Front EN Rear Front stroke Rear A iN NO ON kg cm Open Close Close Oil pump type 1 2 1 GENERAL INFORMATION Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use Engine Oil designated engine oil for lubrication nn Grease Apply grease for lubrication Transmission Gear Oil 904 Special Use special tool Caution Warning GQ KYMCO DOWNTOWN 200i TORQUE VALUES STANDARD TORQUE VALUES 5mm bolt nut 6mm bolt nut mm bolt nut 10mm bolt nut 12mm bolt nut ENGINE 1 GENERAL INFORMATION KYMCO DOWNTOWN 200i Mem 1 Torque kgf m omm screw 6mm screw SH bolt 6mm flange bolt nut emm flange bolt nut 10mm flange bolt nut Teed sce Tuer Cylinder head stud bolt
80. kcase Cover 8 13 KYMCO 9 FINAL REDUCTION DOWNTOWN 200i FINAL REDUCTION SCHEMATIC DRAWING epee 9 1 SERVICE INFOR NA TON 9 2 IROUBLES HOO ING err 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION INSPECTION 9 3 FINALREDUCTION ASSEMBLY 9 5 9 0 9 1 9 FINAL REDUCTION SCHEMATIC DRAWING Nos 23431 9 94510 25000 a RET rns Th EIUS 23411 95701 08040 95701 09035 25701 02040 KYMCO DOWNTOWN 200i GQ KYMCO 9 FINAL REDUCTION DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS e The servicing operations of this section can be made with the engine installed e When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil SAE 90s Oil Capacity At disassembly 0 23 liter At change 0 21 liter TORQUE VALUES Transmission case bolt 0 8 1 2 kgf m 9 8 N m check drain bolt 1 8 2 2 kgf m 19 7 N m SPECIAL TOOLS Bearing puller E037 TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks e Oil l
81. lding 41 Nut amp Fitting A120E00028 Clutch disassembly amp assembly Thread Protector A120E00029 Protecting the crankshaft s thread Valve Cotter Installer 120 00051 Valve cotter installation Clutch Spring A120E00053 Clutch disassembly amp assembly Compressor Shaft Collar Puller A120E00088 Bearing crankcase removal Shaft Collar Driver A120E00091 Bearing crankcase removal Shaft Collar Installer A120E00092 Bearing crankcase installation A120E00093 Bearing removal Lock Nut Socket Wrench A120F00002 Steering stem removal or installation Electric Repair Kit A120F00032 Fuel injection system diagnosis KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i 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 Ge im y vi p z 9 1 ali 5 7 i 5 d 4 7 NJA 2 1 v A p uq n E MR 4 A 2 D 27 24 OE E gt T Tk Ae 44 24 Grease _ Grease Front wheel axle amp nut Side stand pivot Rear wheel axle amp nut amp Main stand pivot 1 7 KYMCO 1 GENERAL INFORMATION DOWNTOWN 200i CABLE amp HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Lo Beam Relay Ignition Switch
82. leed valve Add fluid when the fluid level in the master cylinder 1 low to prevent drawing air into the system Repeat the above procedures until no air bubbles appear in the plastic hose Close the front caliper bleeding valve and operate the front brake lever If it s still spongy bleeding the system again 14 10 14 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 200i If the brake bleeder 1 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 1 Pump the brake lever several times then squeeze the brake lever all the way and loosen the bleed valve 1 4 turn Wait several seconds and close the bleed valve X Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system 3 Repeat the steps 1 2 until there are no air bubbles in the bleed hose After bleeding air completely tighten the bleed valve to the specified torque Torque 6 N m 0 6 kgf m 4 3 Ibf ft Fill the reservoir to the casting ledge with DOT 4 to the upper level Install the diaphragm set plate and reservoir cover and tighten the screws to the spe
83. mp side connector Standard at 20 C 68 F 1 90 3 Q Fuel level sensor inspection Measure the resistance between the Yellow White and Green terminals of the fuel pump side connector Standard at 20 C 68 F Float at full position About 1000 Float at empty position Aboutl00 13 14 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i Fuel Pump Connector Hose band s 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 INSTALLATION Replace a new O ring on the fuel tank Don t damage the fuel pump wire and ensure the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 Ibf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose from the fuel injector Connect the fuel pressure gauge Turn the key to the ON position Check the fuel pressure Standard 3 0 Bar If the fuel output pressure is less than 3 0 bar may fail to start the engine or in trouble in case of riding KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 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 Connection Blue Black Black Th
84. n deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09 mm replace if over 2nd 0 09 mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the hole I D of piston pin Service Limit 17 06 mm replace if over KYMCO 7 CYLINDER PISTON DOWNTOWN 200i Measure the piston pin O D Service Limit 16 8 mm replace if below Measure the piston O D Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 65 9mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder 1 0 at three levels of top middle and bottom at 90 to the piston pin 1n both X and Y directions Service Limit 66 1 mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1 mm repair or replace if over The true roundness 15 the difference between the values measured X and Y directions The cylindricity difference between the values measured at the three levels 1s subject to the maximum value calculated Service Limits True Roundness 0 0
85. n key garnish Remove three screws from the inner cover then remove the handler panel Installation 1s 1n the reverse order of removal 2 12 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i INNER COVER Remove the front cover Remove the front lower cover Remove the floorboard Remove four bolts and front glove box one screw Remove two fastener bolts then remove the fuel tank fill cap Remove the inner cover 2 13 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i 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 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i 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 Nem 2 kgfem Tighten the three mounting bolts Gasket Torque 35 Nem 3 5 kgfem Remove the coolant tank cover 2 15 KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i INSPECTION ADJUSTMENT SERVICE INFORMATION 35 gt 1 MAINTENANCE SCHEDULE a 0 THROTTLE OPERATION
86. n not stated and keep the engine inspection lamp light up for 4 cycles If it is off automatically it means the historical DTC 1s cleared automatically Use PDA or diagnosis tool clear Historical Failure code Check again to confirm DTC 1s excluded Turn on power again When there 15 no residual historical failure cod Start the engine and 1f no failure lamp is or flashing it is Okay 13 41 I4 HANDLEBAR FRONT WHEEL FRONTBRAKE dO KYMCO FRONT SHOCK ABSORBER STEERING STEM DOWNTOWN 2001 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM SERVICE INFORMA T ON 14 1 TROUBLESHOO TINO aerer 14 2 14 3 FERONT WHE ol eee ee ae 14 6 FRONT BRAKE FEUD Eaa eee ee eset 14 9 FRONT ERAKI DAT eee 14 12 BRAKE DISC INSPECTION ce 14 13 FRONT SHOCK ABSOR DBE e Etico 14 14 STEERING 14 15 14 0 GQ KYMCO DOWNTOWN 200i I4 HANDLEBAR FRONT WHEEL FRONT FRONT SHOCK ABSORBER STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS e 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 e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATI
87. nd 36 of the ECU side connector There should be no continuity at all times ECU PIN FUNCTION PIN NO NAME FUNCTION PIN NAME FUNCTION 1 J Jgniionpowr 19 Batter 2 JROLL Roll sensor Tilt switch m 3 CRKP Multi indicator lamp ECLP 22 TW Water temperature sensor ECT ensor ground Intake pressure sensor E 0007 gt sensor ts ee 221550 _ l 79 106 LINE Diagnostictool 28 _ EE m power output ISCAN Idle speed control ISC A 14 SCBP T control ISC ISCBN Idle speed control ISC B is scar degere Injection 34 Injection sensor 13 19 C KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i FUEL INJECTOR INSPECTION Disconnect the fuel injector connector Measure the resistance between 2 pins of the fuel injector connector Standard 11 7 0 6 Q at 20 C 68 F REMOVAL Disconnect the connector from the fuel injector Remove the bolt of the fuel injector Take out of the fuel pipe and fuel injector from the Inlet pipe Remove the fuel injector from the fuel pipe Ensure the fuel pipe without any pressure then remove the fuel injector STEP 1 Disconnect the fuel pump relay or fuel pump connector STEP 2 Turn the key to the ON position Starting the
88. ocket 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 1 the reverse order of removal TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL LIGHT Remove the seat and then remove the taillight bulb socket 19 5 KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i 3 i REAR TURN SIGNAL LIGHT mD A Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal P Rear Turn Signal Light Taillight Brake Light 19 6 GQ KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 2001 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 Front Brake Light Switch He IGNITION SWITCH 2 AR Rear Brake Light Switch INSPECTION Remove the front cover Disconnect the ignition switch connector and check the ignition switch for continuity at the switch side connector terminals Continuity should exist between the color code wires as follows COMB SW 19 7 dO KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i RIGHT HANDL
89. oof rubber Press the waterproof rubber around with hand until its seat INSPECTION Confirm if the waterproof rubber is covered firmly If the waterproof rubber isn t installed firmly headlamp 15 possible to be burned out after water into the headlight unit 19 14 KYMCO DOWNTOWN 200i Waterproof Rubber Highlight wires
90. or reserve tank capacity 0 590 liter Lower limit for reserve tank capacity 0 370 liter SPECIAL TOOLS Flywheel puller E003 Flywheel holder E021 SPECIFICATIONS Standard mm Service Limit mm Starter driven gear I D 22 026 22 045 22 15mm Starter driven gear 42 195 42 208 TORQUE VALUES Flywheel nut 5 5 6 5 kgf m 58 8 N m TROUBLESHOOTING Refer to chapter 1 for A C generator troubleshooting Starter motor rotates but engine does not start e Faulty starter clutch e Starter motor rotates reversely e Weak battery 10 2 KYMCO 10 A C GENERATOR STARTER CLUTCH DOWNTOWN 200i RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover Disconnect the water hoses from the right crankcase cover Remove 12 bolts attaching the right crankcase cover and the cover Water Hose Oil filter Remove the bolt between water pump cover and oil filter Remove right crankcase cover STATOR REMOVAL Remove two screws attaching the pulsar coil Remove three A C generator stator bolts and the stator When removing the pulsar coil and stator be careful not to damage them to avoid short circuit or broken wire Pulsar Coil A C Stator 10 3 KYMCO 10 A C GENERA TOR STARTER CLUTCH DOWNTOWN 200i Nut Flywheel FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer Flywheel holde
91. or uneven tire Poor brake performance e Worn brake pads e Contaminated brake pad surface e Deformed brake disk e Air in brake system e Deteriorated brake fluid e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Unevenly worn brake caliper GQ KYMCO DOWNTOWN 2001 Front wheel wobbling e Bent rim e Loose front axle e Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs e Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 14 2 14 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM__POWNTOWN 2001 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 p Remove the inner cover Brake Light Front Light Switch Wire Switch Wire Remove the handlebar lock nut and take out the bolt Remove the handlebar and collar Bolt ollar Lock nut INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 4 5 kgf m 45 N m 32 Ibf ft 14 3 I4 HANDLEBAR FRON
92. orrect valve timing e Sticking valve or broken valve spring e Broken valve spring e Damaged or worn camshaft e Poor valve and seat contact e Worn cam chain tensioner e Leaking cylinder head gasket e Worn camshaft and rocker arm e Warped or cracked cylinder head e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber dC KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i 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 CAMSHAFT REMOVAL Remove the injector and inlet pipe Thermostat ilm Injector Remove two screws attaching the thermostat Inlet pipe Turn the cam chain tensioner screw clockwise to Cam chain tensioner tighten it Torque 1 0 kgf m 9 8 N m 6 4 GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i Nuts Remove four nuts attaching to the cylinder head X e Diagonally loosen the cylinder head cap nuts in 2 or 3 times Remove two bolts attaching to the camshaft gear Remove the camshaft gear from the cam chain Set Plate Remove the set plate located beside the rocker arm shaft 6 5 dC KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i Remove the rocker arm with bolt as shown Rocker Arm CAMSHAFT INSPECTION Check each cam lobe for
93. out to expose the terminal leads 5 Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead 6 Remove the battery from the battery box BATTERY INSTALLATION Install in the reverse order of the removal X When install the battery first connect the positive cable and then negative cable to avoid short circuit VOLTAGE INSPECTION Remove the battery cover Measure the battery voltage by using a commercially available digital multimeter Voltage 20 C 68 F Fully charged 13 0 13 2 V Insufficient charged lt 12 3 V 16 4 dC KYMCO 16 BATTERY CHARGING SYSTEM DOWNTOWN 200i 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 charger not at the battery terminals CHARGING CURRENT Standard 1 2A 5 10 Hours For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery CHARGING VOLTAGE INSPECTION Be sure that the battery 1s in good condition before performing this test Do not disconnect the battery any cable in the charging system without first switching off the ignition switch Failure to follow this precaution can damage
94. r E021 Remove the flywheel with a flywheel puller Flywheel puller E003 Flywheel Puller Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter driven gear Remove the starter idle gear and shaft Starter Driven Gear 10 4 KYMCO 10 A C GENERATOR STARTER CLUTCH DOWNTOWN 200i Oil Separator Cover OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover Bolts Spread the clip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the cam chain Oil Pump Driven Gear Clip Bolts Remove the two oil pump bolts to remove the oil pump Oil pump 10 5 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWN 200i INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits I D 22 15mm replace if over O D 41 50mm replace if below Inspect the starter idle gear and shaft for wear or Starter Idle Gear damage m Inspect the starter one way clutch for wear or damage Starter One way Clutch 10 6 KYMCO 10 A C GENERATOR STARTER CLUTCH DOWNTOWN 200i Arrow Mark Bolts Chain INSTALLATION Install oil pump and tighten two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install cam chain Oil pump Install the pump drive chain and driven gear then set the clip securely
95. re read the Failure Code Methods 1 Reading from speedometer if PDA or diagnosis tool 1 not available 2 Reading DTC from Diagnosis tool if it is available 13 40 dC KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 6 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 If no show there 1s without any failure Note 1 The CELP denotes the failure codes When the indicator lights for 1 second it is equivalent 10 blinks For example a second illumination and two blinks 0 5 second x 2 of the indicator equals 12 blinks Refer to DTC 12 2 If more than one failure occurs the CELP shows the blinks in the occurred order For example if the indicator blinks 6 times then shows one second illumination and two blinks two failures have occurred Refer to DTC 6 and DTC 12 De et sangup ar Ean Dl Phir es at t DIa Dn s la Leos oc CIR DM lv VES PM er esr After excluding trouble how the be cleared Confirm the failure is excluded on power but maintai
96. re with the scooter In an upright position If the coolant level is below LOWER level mark 3 remove the left floor mat remove the lid screw 4 the reserve tank lid 5 and then the reserve tank cap 6 to add coolant mixture until it reaches the upper level mark Add coolant to the reserve tank only Do not attempt to add coolant by removing the radiator cap Coolant in the radiator is under pressure and is very hot and can cause serious burns KYMCO DOWNTOWN 200i KYMCO 3 INSPECTION ADJUSTMENT DOWNTOWN 200i AIR CLEANER AIR FILTER REPLACEMENT Remove the body cover Remove seven screws attaching to the air cleaner Remove six screws attaching to the filter Check the filter and replace it if it 15 excessively dirty or damaged Air Cleaner Cover CHANGE INTERVAL Screws More frequent replacement is required when riding in unusually dusty or rainy areas e The air cleaner element has a viscous type paper element Do not clean it with compressed air e Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7E Measure the spark plug gap Spark Plug Gap 0 6 0 7 mm Spark Plug e When installing first screw in the spark
97. re assembling the cylinder head e After disassembly clean the removed parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Standard mm Item ee el ted p LEE Cylinder head compression pressure 16 kg cm IN 35 8281 Camshaft cam height 35 8437 12 00 12 018 12 00 12 018 IN 11 966 11 984 11 966 11 984 vanced 4 990 4 975 Valve quide I D 5 00 5 012 clearance 0 030 0 057 Valve rocker arm 1 0 Valve rocker arm shaft O D TM 9 07 TORQUE VALUES Cylinder head stud bolt 1 Stud bolt Inlet pipe side 2 Stud bolt EX pipe side Bolt B stud 10 180 Valve adjusting lock nut Cam sprocket bolt SPECIAL TOOL Valve spring compressor E063 Double end bolt Double end bolt Apply oil to thread Apply oil to thread 6 2 dO KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 2001 TROUBLESHOOTING e 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 e Compression too low e Worn valve stem or valve guide e Damaged valve stem oil seal Compression too low e Incorrect valve clearance adjustment Abnormal noise e Burned or bend valves e Incorrect valve clearance adjustment e Inc
98. rque 1 2 kgf m 12 N m 8 6 Ibf ft Connect the WTS sensor connector Fill the cooling system with the recommended coolant O ring INSPECTION Measure the resistance at the WTS sensor terminals STANDARD 13 22 dO KYMCO 13 FUEL INJECTION SYSTEM NNNM CM O SENSOR The sensor issues signal to ECU when the temperature is over 350 C during the engine 15 working The temperature 15 up to 350 C earlier than the muffler for O heater sensor So the O sensor begins performance The function of sensor only controls the fuel injector operation INSPECTION Disconnect the sensor connector Measure the resistance between each White wire terminals of the O sensor side connector Standard 7 71 2 Q at 20 C 68 F REMOVAL INSTALLATION Starter relay Regulator Rectifier 2 Disconnect the sensor connector and then remove it from exhaust muffler Installation is in the reverse order of removal Apply anti seize compound on the surface of thread area before sensor Tighten the sensor to specified torque Torque 2 5 kgf m 25 N m 18 Ibf ft 13 23 13 FUEL INJECTION SYSTEM DOWNTOWN 200i THROTTLE BODY MAP ISC TPS off the ignition switch while TPS ISC MAP replacement e Check and confirm if the voltage is over 12V by a voltmeter after replacement e Check and confirm if the other connectors are installed correctly after replac
99. s 1n the reverse order of removal UPPER LOWER HANDLEBAR COVER Remove the four screws and then remove upper handlebar cover Remove the four screws then remove the bottom handlebar cover Disconnect the throttle cable refer to the THROTTLE BODY TPS section then pull the throttle cable out from the lower cover Remove the lower cover Installation 1s 1n the reverse order of removal 2 5 dC KYMCO DOWNTOWN 200i dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i WINDSHIELD WINDSHIELD GARNISH Remove five bolts and windshield garnish 2 6 2 EXHAUST MUFFLER FRAME COVERS FRONT CENTER COVER Remove the windshield Remove four screws then remove the front center cover Remove the front cover Installation 1s 1n the reverse order of removal FRONT COVER Remove the small front cover black screw Remove the small front cover black Remove two nuts Remove eight screws from the inner cover Remove the front cover dC KYMCO DOWNTOWN 200i 2 7 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 200i Disconnect headlight position light connector and right left turn signal light connectors 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 FOOT SKIRT Remove the six screws attaching to the right or left skirt During r
100. screws Remove the Tilt switch Installation is in the reverse order of removal X Install the tilt switch with its UP mark facing up Tighten the mounting screws securely 13 17 Tilt swi switch Speedometer Radiator filler cap jJ Lo beam relay Ignition switch y Hi beam relay Winker relay ECU Hom 13 FUEL INJECTION SYSTEM C KYMCO DOWNTOWN 200i ELECTRIC CONTROL UNIT ECU REMOVAL INSTALLATION e Do not disconnect or connect 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 Disconnect the ECU connector and remove the ECU from the frame Installation is in the reverse order of the removal Tilt switch opeedomelter L Radiator filler Lo beam relay Ignition switch m relay 5 Winker relay ECU Horm 13 18 KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i INSPECTION Disconnect and remove the ECU from the frame Check for continuity between pin 35 and 36 of the ECU side connector There should be continuity at all times Check for continuity between each pins 8 9 and 24 of the ECU side connector There should be continuity at all times Check for continuity between pin 24 a
101. sor voltage and O2 heater activation Press the Down button to enter page 05 13 38 GQ KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i G Down page 05 The measure figures including of ISC target ISC step and ISC learn step Press the Down button to enter page 06 H Down page 06 The measure figures including of ISC motor state Press the Down button to enter page 07 1 Down page 07 The measure figures including of Cut Out voltage f l j Fx dn z els ee 2 ri 1 J Press the UP to previous page 13 39 dO KYMCO 13 FUEL INJECTION SYSTEM DOWNTOWN 200i 5 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 Key On to check for any failure lamp light up on dashboard 4 Is the Idle screw of Throttle Valve being changed or loose 5 Has the vehicle under regular service Is the gas station a good one 6 Is the spark plug the correct model of specified by the vehicle builder Vehicle can not be started Check for any Failure code Failure Lamp on How to tell the Failure code Turn on power to see if the engine inspection failure lamp off If flashes continuously or light up for long time the vehicle 15 at failu
102. tch 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 X e Be sure to use a clutch spring compressor to avoid spring damage Lock Nut Wrench Clutch Driven Pulley Clutch Spring Compressor E053 Fittings amp Nut Wrench 41mm E033 Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Remove the oil seal from the movable driven face ASSEMBLY 25225228 IN d Movable Driven Face Vm 226 1 23226 0912114 9135 23225 Guide Roller 23238 8 7 8 DRIVE AND DRIVEN PULLEYS dC KYMCO V BELT DOWNTOWN 200i 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 X e Discard the removed bearing and replace with a new one Remove the snap ring and drive the outer bearing out of the driven face X e Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the s
103. ter switch is ON correctly e Burned bulb e Faulty temperature gauge e Faulty switch e Faulty thermosensor e Poorly connected broken or shorted wire e Broken or shorted wire between the temperature gauge and thermosensor Fuel gauge does not work or wrong show figures e Faulty fuel gauge e Faulty fuel unit e Poorly connected wire between fuel gauge and fuel unit e Fuse burned out SPECIFICATIONS Fuse 10A 15A 30A Headlight bulb 12V 35W 35W 2 H8 Turn signal light bulb 12V 21W Front 10W Rear otoplight taillight 12V 21W 5W 19 2 dO KYMCO 19 LIGHTS SWITCHES FUEL PUMP DOWNTOWN 200i 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 dC KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i Connector Headlight Bulb S HEADLIGHT A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it 15 turned OFF sure to let it cool down before servicing Remove the front cover Disconnect the headlight cover Disconnect the headlight connector from the headlight bulb 4 y n Install a new bulb into the headlight case Install the headlight and connect the headlight connector 1944 dO KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i FRONT TURN SIGNAL LIGHT Remove the front cover S
104. th an iron or plastic hammer Install and tighten the right and left crankcase attaching bolts Install the engine oil screen e To install the crankshaft or crankcase must be replaced in pair Crankcase Crankcase mark Bearing 11 5 12 COOLING SYSTEM DOWNTOWN 200i COOLING SYSTEM SCHEMATIC DRAWING ette 12 SERVICE INFORMATION ee nca sr 12 2 TROUBLESHOOTING 12 2 COOLING SYSTEM TESTING 12 4 RADIATOR 12 4 WATER PUMP cee eiee seii 12 8 THERMOSENSOR 12 11 THERMOSTAT 12 12 12 0 KYMCO DOWNTOWN 200i 12 COOLING SYSTEM SCHEMATIC DRAWING ML NIE g405D DEORO X2 m 2 is AC E 19210 z 1510z x ge v B1 4 v 15104 T 18111 PN st 19012 c E _ 1810A 31241 4b Eng T ar T e NM 19003 1350p LHA 19016 fr 15014 Lee Th Fiai ED T6 X2 53
105. them off Carefully straighten any bent fins Radiator RADIATOR REMOVAL Drain the coolant Disconnect the outlet tube of the reserve tank Remove the overflow tube clamp and Air Vent Tube disconnect the overflow tube Disconnect the air vent tube from the radiator filler Disconnect the fan motor wire coupler Loosen the hose band and disconnect the upper hose and lower hose from the radiator Disconnect the thermostatic switch wire coupler O det Tube Reserve Tank Thermostatic Switch Outlet Tube of Reserve Tank 12 5 KYMCO 12 COOLING SYSTEM DOWNTOWN 200i Bolts nuts Remove three bolts nuts 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 KYMCO 12 COOLING SYSTEM DOWNTOWN 200i THERMOSTATIC SWITCH When the coolant temperature is lower than Thermostatic Switch 88 92 thermostatic switch OFF When coolant temperature is over 88 92 the thermostatic switch ON RADIATOR INSTALLATION Install the fan rubber on the radiator with three Air Vent Tube 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 Connect the fan motor wire couplers Connect the overflow tube and secure with the tube clamp
106. thermosensor e Faulty pump mechanical water seal e Faulty radiator cap e Deteriorated O rings e Faulty thermostat e Damaged or deteriorated water hoses e nsufficient coolant e Passages blocked in hoses or water Jacket e Clogged radiator fins e Passages blocked in radiator e Faulty water pump Temperature gauge shows the wrong temperature e Faulty temperature gauge or thermosensor e Faulty thermostat SPECIFICATIONS Radiator cap relief pressure 0 9 kgf cm 8042 Thermostat temperature Valve lift 3 5 4 5mm Coolant it Radiator Hose 870 cc Ren ae Reserve tank 490 cc 12 2 GQ KYMCO 12 COOLING SYSTEM DOWNTOWN 200i SPECIFICATIONS Radiator cap relief pressure kPa 0 9 kgf cm 12 Begins to open 80 82 C 176 180 F Thermostat temperature Full open 909 198 Valve lift 5 Radiator and engine 087 Reserve tank 0 49 Standard coolant concentration 1 1 mixture with soft water Coolant capacity COOLANT GRAVITY 000 L007 CAN Lo ios ee eee ofa rn 1049 1 04 1053 55 Les Lob GR LU 1071067 COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water m c e 82 c C pet c EL I c ma j c c o c M tn c
107. to prevent the rocker arm shaft Bolt Fix plate from pull out Torque 1 2 kgf m 8 9 N m 6 9 dC KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 200i Tighten the four cylinder head nuts and the four Nuts bolts between the cylinder head and cylinder Torque Cylinder head nuts 3 6 kgf m 35 3 N m Turn the generator flywheel so that the mark on the flywheel aligns with the index mark Camshaft Gear Round hole on the right crankcase cover Keep the round hole on the camshaft gear facing up and align two bolts on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear K eApply engine oil to the threads of the cylinder head cap nuts eDiagonally tighten the cylinder head cap nuts in 2 3 times e First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks Install the thermostat bolt Torque 1 2 kgf m 11 8 N m Turn the cam chain tension screw counter clockwise to release it 6 10 GQ KYMCO 6 CYLINDER HEAD VALVES Dite ZO CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance Install a new cylinder head cover O ring and install the cylinder head cover X Be sure to install the O ring into the groove properly Install the inlet pipe Thermostat Injector Install the injector Install and tighten t
108. ts attaching the right crankcase Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and inner bearing Snap Ring Remove the water pump shaft outer bearing MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside Apply sealant to the right crankcase cover of a new mechanical seal and then drive in the mechanical seal Water Pump Shaft WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Install the water pump shaft and shaft inner bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly Mechanical Seal 12 9 12 COOLING SYSTEM Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover Tighten 12 bolts to secure the right crankcase When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Install the impeller onto the water pump shaft Torque 1 0 1 4 kgf m 11 8 N m t The impeller has left hand threads Install two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 1 0
109. vable drive face Movable Drive Face 6 3 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Replace a new belt at every 20 000km X Use specified genuine parts for replacement MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face clutch outer driven pulley and belt Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i INSPECTION Check each weight roller for wear or damage v k Check movable drive face bushing for wear or damage ASSEMBLY 8 5 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i Install the weight rollers into the movable drive face e The direction of all weight rolls is same The color side is towards to clockwise Install the ramp plate Insert the drive pulley collar into the movable drive face INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 153 5 mm replace if over Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0 mm replace if below Clutch Lining 6 6 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT DOWNTOWN 200i Clu
110. ve a bolt from fuel hose guide e Starter relay Ronulator Rectifi Disconnect the fuel hose from fuel injector 3egulator Rectifier Disconnect the input water hose Disconnect the air bleed hose Water hose filter Water pump 5 2 KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i Remove muffler Remove the rear fork mounting bolts 1 attaching to the crankcase Torque 3 5 kgf m 35 N m Remove the rear axle nut 2 Torque 12 0 kgf m 120 N m Remove two bolts 3 attaching to rear brake hose clamps Remove two bolts 4 attaching to the rear brake caliper Torque 3 2 kgf m 32 N m Disconnect the alternator connector 5 Disconnect the ignition pulse generator connector 6 7 Release the rubber cap and remove the terminal screw 7 to disconnect the start motor cable from the start motor Remove the bolt and engine ground cable 5 3 dC KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 200i Remove the spark plug cap Spark Plug Cap Disconnect the lower radiator hose from Radiator Hose lower radiator pipe Remove the right and left rear cushion lower mount bolts Torque 4 0 kgf m 40N m 5 ENGINE REMOVAL INSTALLATION 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
111. w speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler e Worn or damaged cylinder and piston rings e Worn or damaged piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high Abnormal noisy piston e Excessive carbon build up in combustion e Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and piston pin e Incorrectly installed piston 7 2 7 CYLINDER PISTON KYMCO DOWNTOWN 2001 CYLINDER REMOVAL Remove the cylinder head Remove the cam chain guide Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Place clean towel crankcase to keep the piston pin clip from falling into the crankcase 7 3 Cylinder Dowel Pins Water Hose Cam Chain Guide Gasket Dowel Pins Piston Pin gt Piston Piston Rings iba 5 30 _ m i p ue dC KYMCO 7 CYLINDER PISTON DOWNTOWN 200i Inspect the piston piston pin and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbo
112. wear or damage 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 Rocker Arm If the surface of rocker arm 15 worn check each cam lobe for wear or damage Camshaft CYLINDER HEAD REMOVAL Remove the muffler Remove the throttle body Drain the coolant from the radiator and water hose then remove the thermostat water hose Remove the camshaft Remove the Temp Map Sensor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Thermostat 6 6 6 CYLINDER HEAD VALVES Remove two nuts attaching to the upper lower side of cylinder head Remove two bolts attaching to the cylinder head Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface X Be careful not to drop any gasket material into the engine CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor e sure to compress the valve springs with a valve spring compressor eMark all disassembled parts to ensure correct reassembly Special Valve spring compressor E040 Remove carbon deposits from the exhaust port and combustion chamber dC KYM
113. x nuts and fuel unit connectors then remove the fuel hose Remove the fuel pump Check the fuel pump O ring If was damage replace a new one GQ KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i INSPECTION Connect the fuel unit wire connectors and turn the ignition switch Before performing the following test operate the turn signals to determine that the battery circuit is normal Measure the resistance between the Red Black and Green wire of the fuel unit connector Standard at 20 C 68 F Float at full position About 1100 Float at empty position About 100 Q 19 11 dC KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 200i Connector SIDE STAND SWITCH INSPECTION Remove the luggage box Side stand switch 1s 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 There should be continuity between the Yellow Black and Green with the side stand is down DOWN 19 12 GQ KYMCO 19 LIGHTS METERS SWITCHES DOWNTOWN 2001 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 19 13 19 LIGHTS METERS SWITCHES Put the headlight wires into the headlight unit and then cover the waterpr
114. y e Worn piston pin and piston pin hole 11 2 dC KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 200i CRANKCASE SEPARATION Remove bolts attaching left crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase K e Never use a driver to knock the crankcase mating surfaces apart Remove the engine oil screen Remove the crankshaft from the left crankcase 11 3 11 CRANKCASE CRANKSHAFT DOWNTOWN 2004 Oil Seal Remove the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6 mm replace if over Measure the connecting rod small end I D Service Limit 17 06 mm replace if over Measure the crankshaft bearing play Service Limits Axial 0 20 mm replace if over Radial 0 05 mm replace if over 11 4 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 200i Left Crankcase CRANKCASE ASSEMBLY Install a new oil seal onto the left crankcase Place the left crankcase down and install the crankshaft into the left crankcase X e Avoid damaging the oil seal DN e Apply grease to the of the oil seal e Avoid damaging the crankcase mating surfaces Crankshaft Install the two dowel pins Place the right crankcase over the crankshaft and onto the left crankcase e Install the right crankcase squarely and do not tap it wi

13. fuel injection system

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