KYMCO Downtown 200i Service Manual

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Owner's manual (50 pages)

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Summary of Contents for KYMCO Downtown 200i

Page 1 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...
Page 2: Table Of Contents
DOWNTOWN 200i PREFACE TABLE OF CONTENTS This Service Manual describes the technical features servicing GENERAL INFORMATION procedures KYMCO Downtown EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read them carefully before LUBRICATION SYSTEM operation is started.
Page 3: General Information
1. GENERAL INFORMATION DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1 SPECIFICATION ------------------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-3 TORQUE VALUES ----------------------------------------------------------------------------------- 1-4 SPECIAL TOOLS ------------------------------------------------------------------------------------- 1-6 LUBRICATION POINTS ---------------------------------------------------------------------------- 1-7 CABLE & HARNESS ROUTING--------------------------------------------------------------------- 1-8...
Page 4: General Information
1. GENERAL INFORMATION DOWNTOWN 200i SERIAL NUMBER Location of Frame Serial Number (inside luggage box) Location of Vehicle Identification Location of Engine Serial Number Number (VIN)
Page 5: Specification
1. GENERAL INFORMATION DOWNTOWN 200i SPECIFICATIONS Oil filter type Full-flow filtration Name Downtown 200i Oil capacity 1.5ℓ Model No. SK40AA Exchanging capacity 1.3 ℓ Overall length 2200 mm Fi injection system Overall width 800 mm Air cleaner type & No...
Page 6 1. GENERAL INFORMATION DOWNTOWN 200i Symbols: following symbols represent servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) Grease : Apply grease for lubrication.
Page 7: Torque Values
1. GENERAL INFORMATION DOWNTOWN 200i TORQUE VALUES...
Page 8 1. GENERAL INFORMATION DOWNTOWN 200i TORQUE VALUES FRAME...
Page 9: Special Tools
1. GENERAL INFORMATION Downtown 200i SPECIAL TOOLS Tool Name Tool No. Performance Photo Flywheel Puller A120E00003 A.C. generator flywheel removal Tappet Adjuster A120E00012 Tappet adjustment Oil Seal & Bearing A120E00014 Oil seal & bearing installing Installer Flywheel Holder A120E00021 A.C. generator flywheel holding #41 Nut &...
Page 10: Lubrication Points
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.
Page 11: Cable & Harness Routing
1. GENERAL INFORMATION DOWNTOWN 200i CABLE & HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Lo Beam Relay Ignition Switch Hi Beam Relay Winker Relay Horn...
Page 12 1. GENERAL INFORMATION DOWNTOWN 200i Throttle Body MAP Sensor Injector...
Page 13 1. GENERAL INFORMATION DOWNTOWN 200i Ignition Coil Fuel Pump Relay Oil controller Output Voltage Connector Coolant Reserve Tank 1-10...
Page 14 1. GENERAL INFORMATION DOWNTOWN 200i Starter Relay Regulator/Rectifier O2 Sensor 1-11...
Page 15: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14...
Page 16: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 17: Fastener Removal And Reinstallation
. EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls close. Insert the fastener into the installation hole.
Page 18: Frame Covers Removal/Installation
. EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i FRAME COVERS REMOVAL/ INSTALLATION SEAT Unlock the seat with the ignition key. Open the seat. Remove the two nuts and the seat. Installation is in the reverse order of removal. LUGGAGE BOX Unlock the seat with the ignition key.
Page 19 . 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...
Page 20 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i Installation is in 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”...
Page 21 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i WINDSHIELD/WINDSHIELD GARNISH Remove five bolts and windshield garnish.
Page 22 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i FRONT CENTER COVER Remove the windshield Remove four screws, then remove the front center cover. Remove the front cover. Installation is in the reverse order of removal. FRONT COVER Remove the small front cover(black) screw Remove the small front cover(black) Remove two nuts.
Page 23 . 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.
Page 24 . 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 is in the reverse order of removal. REAR FENDER Remove the body cover and then the rear fender.
Page 25 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i Taillight Connector TIRE FENDER Remove the body cover. Remove four bolts attaching to the tire fender Installation is in the reverse order of removal. FLOORBOARD Remove the body cover Remove the right /left skirt Remove two screws.
Page 26 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i Remove eight bolts, then remove the floorboard. UNDER COVER Remove four bolts Remove the under cover. 2-11...
Page 27 . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 200i Remove the fuel tank cap cover. Installation is in the reverse order of removal. Speedometer Wires METER PANEL Disconnect the speedometer wires. Disconnect the DC power connectors. DC power Connectors Remove one screws Remove the ignition key garnish Remove three screws from the inner cover, then remove the handler panel.
Page 28 . 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.
Page 29: Exhaust Muffler
. 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...
Page 30 . 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 N•m (2 kgf•m,)
Page 31: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION / ADJUSTMENT _________________________________________________________________________________________ SERVICE INFORMATION ----------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ------------------------------------------------------------------- 3- 2 THROTTLE OPERATION ------------------------------------------------------------------------ 3- 3 ENGINE OIL----------------------------------------------------------------------------------------- 3- 4 RESERVE TANK ----------------------------------------------------------------------------------- 3- 5 AIR CLEANER-------------------------------------------------------------------------------------- 3- 6...
Page 32: Service Information
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i SERVICE INFORMATION GENERAL ！ WARNING • Before running the engine, make sure that the working area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas, which may cause death to people.
Page 33 3. INSPECTION/ADJUSTMENT...
Page 34: Throttle Operation
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.
Page 35: Engine Oil
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on the level ground. Wait for 2～3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when checking the oil level.
Page 36: Reserve Tank
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i 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. Spring Install a new oil filter. ＊ Make sure the rubber seal on the oil filter facing the left crankcase.
Page 37: Air Cleaner
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i AIR CLEANER AIR FILTER REPLACEMENT Remove the body cover. Remove seven screws attaching to the air cleaner cover. Remove six screws attaching to the filter. Check the filter and replace it if it is excessively dirty or damaged.
Page 38: Valve Clearance
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i Cylinder Head Cover VALVE CLEARANCE ＊ • Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the seat assy and luggage box. Remove the four bolts and then cylinder head cover. Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...
Page 39: Final Reduction Gear Oil
3. INSPECTION/ADJUSTMENT DOWNTOWN 200i FINAL REDUCTION GEAR OIL ＊ • Place the scooter on its main stand on level ground. Remove the transmission fluid drain bolt. Remove the transmission fluid filler bolt, then slowly rotate the rear wheel to drain the fluid.
Page 40: Brake System
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...
Page 41: Clutch Shoe Wear
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.
Page 42: Nuts/Bolts/Fasteners
3. INSPECTION/ADJUSTMENT 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.
Page 43: Side Stand
2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down. ＊ If the side stand system does not operate as described, see your KYMCO dealer for service. 3-12...
Page 44: Lubrication System
4. LUBRICATION SYSTEM DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ LUBRICATION SYSTEM------------------------------------------------------------------------- 4-1 SERVICE INFORMATION ----------------------------------------------------------------------- 4-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER------------------------------------------------------------------------ 4-3 OIL PUMP-------------------------------------------------------------------------------------------- 4-5...
Page 45: Lubrication System
4. LUBRICATION SYSTEM DOWNTOWN 200i LUBRICATION PART Dipstick Oil Filter Oil Pump Drive Chain...
Page 46: Service Information
4. LUBRICATION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed on the frame. • Drain the coolant before starting any operations. • Carefully when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 47: Engine Oil/Oil Filter
4. LUBRICATION SYSTEM DOWNTOWN 200i Oil Dipstick ENGINE OIL/OIL FILTER • Place the scooter upright on level ground for engine oil level check. • Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
Page 48 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.
Page 49: Oil Pump
4. LUBRICATION SYSTEM DOWNTOWN 200i 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 Starter Idle Gear Remove the gasket and dowel pins.
Page 50 4. LUBRICATION SYSTEM DOWNTOWN 200i Arrow Mark 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.
Page 51: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION--------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-6...
Page 52 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal. • Use shop towels to protect the scooter body during engine removal.
Page 53 . ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i ENGINE REMOVAL/INSTALLATION REMOVAL Remove the air cleaner Disconnect the connector including of ISC, Throttle body, TPS, WTS, MAP sensor and injector. Disconnect the O2 sensor connector. Disconnect the throttle cables. Disconnect Regulator/Rectifier connector. Fuel hose guide Disconnect the starter relay wire from starter motor.
Page 54 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i Remove the muffler. Remove the rear fork mounting bolts (1) attaching to the crankcase. Torque: 3.5 kgf-m (35 N-m) Remove the rear axle nut (2). Torque: 12.0 kgf-m (120 N-m) Remove two bolts (3) attaching to rear brake hose clamps.
Page 55 . ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i Remove the spark plug cap. Spark Plug Cap Radiator Hose Disconnect the lower radiator hose from lower radiator pipe. Remove the right and left rear cushion lower mount bolts. Torque: 4.0 kgf-m (40N-m) Mount Bolt...
Page 56 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i 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.
Page 57 . ENGINE REMOVAL/INSTALLATION DOWNTOWN 200i ENGINE HANGER Mount Nut REMOVAL Remove the engine mount nut and pull it out. ＊ Be careful to put the engine down. Remove the left/right engine hanger mount bolt. Remove the engine from frame. INSTALLATION Installation is in the reverse order of removal.
Page 58: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/VALVES _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 6-1 SERVICE INFORMATION ----------------------------------------------------------------------- 6- 2 TROUBLESHOOTING ---------------------------------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL------------------------------------------------------- 6- 4 CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL------------------------------------------------------------------ 6- 6...
Page 59: Schematic Drawing
6. CYLINDER HEAD/VALVES DOWNTOWN 200i SCHEMATIC DRAWING...
Page 60: Service Information
6. CYLINDER HEAD/VALVES DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 61: Troubleshooting
6. CYLINDER HEAD/VALVES DOWNTOWN 200i TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low • Worn valve stem or valve guide •...
Page 62: Cylinder Head Cover Removal
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.
Page 63 6. CYLINDER HEAD/VALVES DOWNTOWN 200i Nuts Remove four nuts attaching to the cylinder head. • Diagonally loosen the cylinder head cap nuts in 2 or 3 times. Bolts Remove two bolts attaching to the camshaft gear. Remove the camshaft gear from the cam chain...
Page 64: Cylinder Head Removal
6. CYLINDER HEAD/VALVES DOWNTOWN 200i Remove the rocker arm with bolt as shown. Rocker Arm CAMSHAFT INSPECTION Check each cam lobe for 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.
Page 65: Cylinder Head Disassembly
6. CYLINDER HEAD/VALVES DOWNTOWN 200i 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.
Page 66: Cylinder Head Assembly
6. CYLINDER HEAD/VALVES DOWNTOWN 200i VALVE STEM INSPECTION Inspect each valve for bending, burning, or abnormal stem wear. Intake valve Exhaust valve Valves Remove carbon deposits from the combustion chamber. Clean off any gasket remnants from the cylinder head contact surface.
Page 67: Cylinder Head Installation
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. • Clean the intake valve rocker arm shaft off any grease before installation. Gasket Cam chain guide Cylinder Head Install the cylinder head.
Page 68 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 A.C. generator flywheel so that the “T” Camshaft Gear...
Page 69: Cylinder Head Cover Installation
6. CYLINDER HEAD/VALVES DOWNTOWN 200i CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance. Thermostat Injector Install a new cylinder head cover O-ring and install the cylinder head cover. Be sure to install the O-ring into the groove properly. Install the inlet pipe.
Page 70: Cylinder/Piston
7. CYLINDER/PISTON DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER/PISTON _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 7-1 SERVICE INFORMATION ----------------------------------------------------------------------- 7-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 7-2 CYLINDER REMOVAL--------------------------------------------------------------------------- 7-3 PISTON REMOVAL ------------------------------------------------------------------------------- 7-3 PISTON INSTALLATION ------------------------------------------------------------------------ 7-7 CYLINDER INSTALLATION-------------------------------------------------------------------- 7-7...
Page 71: Schematic Drawing
7. CYLINDER/PISTON DOWNTOWN 200i SCHEMATIC DRAWING...
Page 72: Service Information
7. CYLINDER/PISTON DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 73: Cylinder Removal
7. CYLINDER/PISTON DOWNTOWN 200i CYLINDER REMOVAL Cylinder Dowel Pins Remove the cylinder head. Remove the cam chain guide. Remove the cylinder. Water Hose Gasket Cam Chain Guide Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.
Page 74 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 carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
Page 75 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.
Page 76 7. CYLINDER/PISTON DOWNTOWN 200i Measure the connecting rod small end I.D. 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. • Be careful not to damage the piston and piston rings during assembly.
Page 77: Piston Installation
7. CYLINDER/PISTON DOWNTOWN 200i PISTON INSTALLATION Remove any gasket material from the crankcase surface. • Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip. • Position the piston “IN” mark on the intake valve side.
Page 78 7. CYLINDER/PISTON DOWNTOWN 200i Install the cam chain guide. Gasket Dowel Pin • Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head gasket and dowel Cam Chain Guide pins. Connect the water hose to the cylinder.
Page 79: Drive And Driven Pulleys/V- Belt
8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/V-BELT _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 8- 1 SERVICE INFORMATION ----------------------------------------------------------------------- 8- 2 TROUBLESHOOTING ---------------------------------------------------------------------------- 8- 2 LEFT CRANKCASE COVER -------------------------------------------------------------------- 8- 3 DRIVE PULLEY ------------------------------------------------------------------------------------ 8- 3...
Page 80 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i SCHEMATIC DRAWING...
Page 81 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 82 8. DRIVE AND DRIVEN PULLEYS/ 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.
Page 83 8. DRIVE AND DRIVEN PULLEYS/ 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. • Use specified genuine parts replacement. MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face, clutch outer, driven pulley and belt.
Page 84 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i INSPECTION Check each weight roller for wear or damage. Check the movable drive face bushing for wear or damage. ASSEMBLY...
Page 85 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i Install the weight rollers into the movable drive face. • The direction of all weight rolls is same. The color side is towards to clockwise. Ramp Plate Install the ramp plate. Insert the drive pulley collar into the movable drive face.
Page 86 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i Clutch Spring Compressor CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Set the tool in a vise and remove the clutch drive plate nut. • Be sure to use a clutch spring compressor to avoid spring damage.
Page 87 8. DRIVE AND DRIVEN PULLEYS/ 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.
Page 88 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i Press a new needle bearing into the driven face. Clips Retainer Plate CLUTCH DISASSEMBLY Remove clips retainer plate disassemble the clutch. • Keep grease off the clutch linings. Clutch Lining...
Page 89 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i CLUTCH ASSEMBLY Clips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the clips.
Page 90 8. DRIVE AND DRIVEN PULLEYS/ 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.
Page 91 8. DRIVE AND DRIVEN PULLEYS/ 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 Movable Drive Face Assembly Put the drive belt on the driven pulley.
Page 92 8. DRIVE AND DRIVEN PULLEYS/ V-BELT DOWNTOWN 200i Install the left crankcase cover. Left Crankcase Cover 8-13...
Page 93: Final Reduction
9. FINAL REDUCTION DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 9-1 SERVICE INFORMATION ----------------------------------------------------------------------- 9-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY --------------------------------------------------------- 9-3 FINAL REDUCTION INSPECTION ------------------------------------------------------------ 9-3 FINAL REDUCTION ASSEMBLY-------------------------------------------------------------- 9-5...
Page 94: Schematic Drawing
9. FINAL REDUCTION DOWNTOWN 200i SCHEMATIC DRAWING...
Page 95: Service Information
9. FINAL REDUCTION DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
Page 96: Final Reduction Inspection
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.
Page 97: Final Reduction Assembly
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 Drive Shaft Bearing play and inspect the oil seal for wear or damage.
Page 98 9. FINAL REDUCTION DOWNTOWN 200i Dowel Pin 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.
Page 99: Generator/Starter Clutch
10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH ________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 10-1 SERVICE INFORMATION ----------------------------------------------------------------------- 10-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL --------------------------------------------------- 10-3 STATOR REMOVAL ------------------------------------------------------------------------------ 10-3 FLYWHEEL REMOVAL-------------------------------------------------------------------------- 10-4 STARTER CLUTCH ------------------------------------------------------------------------------- 10-4...
Page 100: Schematic Drawing
10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i SCHEMATIC DRAWING 10-1...
Page 101: Service Information
10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • All operations and inspections in this section can be made with the engine installed. • Should drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
Page 102: Right Crankcase Cover Removal
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...
Page 103: Flywheel Removal
10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i Flywheel FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer. Special Flywheel holder E021 Flywheel Holder Remove the flywheel with a flywheel puller. Special Flywheel puller E003...
Page 104 10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i Oil Separator Cover OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover. Bolts Oil Pump Drive chain Cam Chain Spread the clip off and remove the oil pump driven gear, then remove the oil pump drive chain.
Page 105 10. A.C. 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. I.D. Service Limits: I.D.: 22.15mm replace if over O.D.: 41.50mm replace if below O.D. Inspect the starter idle gear and shaft for wear or Starter Idle Gear damage.
Page 106 10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i Arrow Mark Bolts Cam 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 on the pump shaft.
Page 107: Flywheel Installation
10. A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 200i Starter Idle Gear Shaft Install the starter idle gear and shaft. Install the starter driven gear onto the crankshaft. Starter Driven Gear Flywheel FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel.
Page 108: Stator Installation
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.
Page 109: Crankcase/Crankshaft
11. CRANKCASE/CRANKSHAFT DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 11-1 SERVICE INFORMATION ----------------------------------------------------------------------- 11-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION -------------------------------------------------------------------- 11-3 CRANKSHAFT INSPECTION ------------------------------------------------------------------- 11-4 CRANKCASE ASSEMBLY----------------------------------------------------------------------- 11-5 11-0...
Page 110: Schematic Drawing
11. CRANKCASE/CRANKSHAFT DOWNTOWN 200i SCHEMATIC DRAWING 11-1...
Page 111: Service Information
11. CRANKCASE/CRANKSHAFT DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to knock the crankcase forcedly to prevent damaging the mating surfaces.
Page 112: Crankcase Separation
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. • Never use a driver to knock the crankcase mating surfaces apart.
Page 113: Crankshaft Inspection
11. CRANKCASE/CRANKSHAFT DOWNTOWN 200i 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.
Page 114: Crankcase Assembly
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. • Avoid damaging the oil seal. • Apply grease to the lip of the oil seal.
Page 115: Cooling System
12. COOLING SYSTEM DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 12- SERVICE INFORMATION ----------------------------------------------------------------------- 12- TROUBLESHOOTING ---------------------------------------------------------------------------- 12- COOLING SYSTEM TESTING ------------------------------------------------------------------ 12- RADIATOR ------------------------------------------------------------------------------------------ 12- WATER PUMP -------------------------------------------------------------------------------------- 12- 8 THERMOSENSOR --------------------------------------------------------------------------------- 12- 11...
Page 116: Schematic Drawing
12. COOLING SYSTEM DOWNTOWN 200i SCHEMATIC DRAWING 12-1...
Page 117: Service Information
12. COOLING SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system.
Page 118 12. COOLING SYSTEM DOWNTOWN 200i 12-3...
Page 119: Radiator
12. COOLING SYSTEM DOWNTOWN 200i Radiator Tester COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the sealing cap surface before testing.
Page 120 12. COOLING SYSTEM DOWNTOWN 200i Outlet Tube of Reserve Tank Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins.
Page 121 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...
Page 122 12. COOLING SYSTEM DOWNTOWN 200i THERMOSTATIC SWITCH Thermostatic Switch When the coolant temperature is lower than 88~92 ℃, the thermostatic switch OFF. When coolant temperature is over 88~92 ℃, the thermostatic switch ON. RADIATOR INSTALLATION Air Vent Tube Install the fan rubber on the radiator with three bolts.
Page 123: Water Pump
12. COOLING SYSTEM DOWNTOWN 200i Water Pump Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover replace mechanical seal.
Page 124 12. COOLING SYSTEM DOWNTOWN 200i Water Pump Shaft WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly.
Page 125 12. COOLING SYSTEM DOWNTOWN 200i Install the dowel pins and a new gasket and Seal Washer (Porcelain) Impeller then install the water pump assembly to the right crankcase cover. Tighten 12 bolts to secure the right crankcase cover. ＊ When installing the water pump assembly, aligning the groove on the water pump shaft with the tab on the oil pump shaft.
Page 126: Thermosensor
12. COOLING SYSTEM DOWNTOWN 200i THERMOSENSOR Thermosensor Wire THERMOSENSOR REMOVAL 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 Thermosensor through the sensor as the water heats up.
Page 127: Thermostat
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 air vent tube from the thermostat housing.
Page 128: Fuel Injection System
13. FUEL INJECTION SYSTEM DOWNTOWN 200i __________________________________________________________________________________ __________________________________________________________________________________ FUEL INJECTION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 13- 1 SPECIFICATIONS ---------------------------------------------------------- 13- 2 INJECTION SYSTEM DIAGRAM --------------------------------------- 13- 3 PARTS LOCATION -------------------------------------------------------- 13- 4 TROUBLESHOOTING----------------------------------------------------- 13- 6 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL------------------------------------------------------- 13- 7...
Page 129: Fuel Injection System
13. FUEL INJECTION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
Page 130: Specifications
13. FUEL INJECTION SYSTEM DOWNTOWN 200i SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number LGF9 Idle speed 1600±100 rpm Throttle grip free play 2～6 mm (1/16～1/4 in) Fuel injector resistance (at 20°C/68°F) 9.945~13.5 Fuel pump resistance Float at full position About 1100 Ω...
Page 131: Injection System Diagram
13. FUEL INJECTION SYSTEM DOWNTOWN 200i INJECTION SYSTEM DIAGRAM FULL NAME ABBREVIATIONS (01) Electronic control unit (02) Tilt switch (Angle detect sensor) ROLL (03) Fuel pump/Fuel level unit (04) Water temperature sensor WTS sensor (05) Crank position sensor (Pulser) (06)
Page 132: Parts Location
13. FUEL INJECTION SYSTEM DOWNTOWN 200i PARTS LOCATION Tilt switch Speedometer Radiator filler cap Lo beam relay Hi beam relay Ignition switch Winker relay Horn Throttle body MAP sensor Injector 13-4...
Page 133 13. FUEL INJECTION SYSTEM DOWNTOWN 200i Ignition coil Fuel pump replay Oil controller Output voltage connector Coolant reserve tank Starter relay Regulator/Rectifier O2 sensor 13-5...
Page 134: Troubleshooting
13. FUEL INJECTION SYSTEM DOWNTOWN 200i TROUBLESHOOTING Engine fail to start Backfiring or misfiring during acceleration • Intake manifold air leak • Ignition system malfunction • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Faulty fuel pump • Clogged fuel filter, throttle body •...
Page 135: Self-Diagnostic Procedures Without Diagnostic Tool
13. FUEL INJECTION SYSTEM DOWNTOWN 200i SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL SELF-DIAGNOSTIC PROCEDURES It can be performed without diagnostics program. Place the scooter on its main stand. Put the side stand up and the engine stop switch is at “RUN”.
Page 136: Efi Self-Diagnosis Check Engine Lamp (Celp) Failure Codes
13. FUEL INJECTION SYSTEM DOWNTOWN 200i EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE If more than a damaged part has occurred, the CODES “CELP” begins blinking in order. The “CELP” denotes the failure codes. When the indicator lights for one second that For example: If the indicator blinks six times, is equal to ten.
Page 137: Self-Diagnosis Reset Procedure
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.
Page 138: Celp Failure Codes List
13. FUEL INJECTION SYSTEM DOWNTOWN 200i CELP FAILURE CODES LIST Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty TPS voltage range (0.3~4.5 V) ● Loose or poor connection on TPS Engine operates Sensor P0120 Faulty TPS normally ● Open or short circuit on the TPS wire ●...
Page 139 13. FUEL INJECTION SYSTEM DOWNTOWN 200i Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty Inductive ignition coil Ω range (4.2 Ω ± 15%) Faulty ● Loose or poor connection on Engine fail to be inductive P0351 inductive ignition coil...
Page 140 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 is wet by fuel, perform the spark plug anti- flood to purge the fuel in the engine.
Page 141: Tps/Isc Reset
13. FUEL INJECTION SYSTEM DOWNTOWN 200i TPS/ISC RESET ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.
Page 142: Fuel Pump
13. FUEL INJECTION SYSTEM DOWNTOWN 200i FUEL PUMP Full Position INSPECTIION Put the side stand up and the engine stop switch is at “RUN” Disconnect fuel pump/fuel unit connector. Connect the multimeter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal.
Page 143 13. FUEL INJECTION SYSTEM DOWNTOWN 200i Hose band Fuel Pump Connector REMOVAL Disconnect the connector and fuel band from the fuel pump. Remove the six screws onto the fuel pump. Remove the fuel pump and O-ring. Screw Connector INSTALLATION Replace a new O-ring on the fuel tank.
Page 144: Fuel Cut-Off Relay
13. FUEL INJECTION SYSTEM DOWNTOWN 200i Battery FUEL CUT-OFF RELAY INSPECTION Remove the fuel cut-off relay. Connect the ohmmeter to the fuel cut-off relay connector terminals. Connection: Black – Red/Black Connect 12 V battery with the fuel cut-off Fuel Cut-Off Relay relay connector.
Page 145: Tilt Switch
13. FUEL INJECTION SYSTEM 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 the tilt switch connector during inspection.
Page 146: Electronic Control Unit (Ecu)
13. FUEL INJECTION SYSTEM DOWNTOWN 200i ELECTRIC CONTROL UNIT (ECU) REMOVAL/INSTALLATION ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when throttle body, MAP, TPS, ISC or ECU has been reinstalled.
Page 147 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.
Page 148: Fuel Injector
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 Ω (at 20°C/68°F) REMOVAL Disconnect the connector from the fuel injector. Remove the bolt of the fuel injector.
Page 149 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. Install the fuel pipe into the intake manifold by aligning the dowel pin.
Page 150: Wts Sensor
13. FUEL INJECTION SYSTEM DOWNTOWN 200i WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring. Install a new O-ring and WTS sensor.
Page 151: O 2 Sensor
13. FUEL INJECTION SYSTEM DOWNTOWN 200i SENSOR The O sensor issues signal to ECU when the temperature is over 350°C during the engine is working. The temperature is up to 350°C earlier than the muffler for O heater sensor. So the O sensor begins performance.
Page 152: Throttle Body/Map/Isc/Tps
● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
Page 153 13. FUEL INJECTION SYSTEM DOWNTOWN 200i TPS INSPECTION Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector.
Page 154 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.
Page 155: Diagnostic Tool Connector
13. FUEL INJECTION SYSTEM DOWNTOWN 200i Apply oil onto a new O-ring. When install the MAP onto the throttle body, being careful not to damage the O-ring. Always replace an O-ring with a new one. Install the set plate and tighten the screw securely.
Page 156: Operation Instructions
13. FUEL INJECTION SYSTEM DOWNTOWN 200i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00(ENGLISH VERSION) 13-28...
Page 157 13. FUEL INJECTION SYSTEM DOWNTOWN 200i 1. FI DIAGNOSTIC TOOL This tool is developed by KYMCO and for KYMCO vehicle only. Please refer to the specification when serving this vehicle. This tool is without battery inside. The power is provided from vehicle.
Page 158 13. FUEL INJECTION SYSTEM DOWNTOWN 200i 2. DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power. LGF9 is for Downtown 200i A). ECU version: Including of model name, ECU number, identifications number and software version. Press the " Enter " button...
Page 159 13. FUEL INJECTION SYSTEM DOWNTOWN 200i B). Press the " Down " button and then turn to the first page. LGF9 C). Press the " Enter " button to check the DTC failure code 13-31...
Page 160 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...
Page 161 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 5-33...
Page 162 5. FUEL INJECTION SYSTEM DOWNTOWN 200i J). Press the " Enter " button and then turn to the first page. LGF9 is for Downtown 200i 5-34...
Page 163 5. FUEL INJECTION SYSTEM DOWNTOWN 200i 3. DTC CLEAR PROCEDURE ). Check the DTC LGF9 is for Downtown 200i ). Press the " Enter " button LGF9 is for Downtown 200i ). Choose " Load DTC " Press the " Down " button...
Page 164 5. FUEL INJECTION SYSTEM DOWNTOWN 200i ). Press the " Enter " button and the indicator is lighting. ). Clearing DTC completed if the indicator is off. 5-36...
Page 165 5. FUEL INJECTION SYSTEM DOWNTOWN 200i 4. DATA ANALYSIS PROCEDURE ). Press the " Down " twice ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 LGF9 LGF9 is for Downtown 200i ). Down-page 01 The measure figures including of Engine speed, Battery voltage and DTC number.
Page 166 13. FUEL INJECTION SYSTEM DOWNTOWN 200i ). Down-page 02 The measure figures including of TPS position, Intake pressure and Intake air temperature. Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of Atmosphere pressure, Fuel Injector interval and Ignition advance timing.
Page 167 13. FUEL INJECTION SYSTEM DOWNTOWN 200i ). Down-page 05 The measure figures including of ISC target, ISC step and ISC learn step. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of ISC motor state.
Page 168 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.
Page 169: Manual Trouble Shooting Procedure
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.
Page 170 14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14- 1 TROUBLESHOOTING----------------------------------------------------- 14- 2 HANDLEBAR --------------------------------------------------------------- 14- 3 FRONT WHEEL------------------------------------------------------------- 14- 6 FRONT BRAKE FLUID---------------------------------------------------- 14- 9...
Page 171: Service Information
14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 172: Troubleshooting
14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Loose front axle cone race • Broken steering balls • Bent spoke plate • Insufficient tire pressure •...
Page 173: Handlebar
14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover. Remove two bolts and disconnect the brake light switch wire, then remove the rear brake master cylinder. Remove the two bolts and disconnect the brake light switch wire, then remove the front brake master cylinder.
Page 174 14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Install the front and rear master cylinders and connect the brake light switch wires. DISASSEMBLY Remove two screws attaching to the right handlebar switch. Screws Throttle cable Disconnect the throttle cable from the throttle grip.
Page 175 14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Remove two screws and then remove the left handlebar switch. ASSEMBLY Screws Install the left handlebar switch. Align the pin on the left handlebar switch with the hole on the handlebar.
Page 176: Steering Handlebar/Front Wheel/Front Brake/Front
14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM 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.
Page 177 14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Collar INSTALLATION Apply grease to the collar, then install the collar onto the wheel. Dust Seal Install the speedometer speed wheel sensor. DISASSEMBLY Remove the side collar and dust seal. Speed Wheel Sensor Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
Page 178 14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Remove the front wheel bearing by using the Bearing special tool. Special tool: Bearing puller E00037 ASSEMBLY Install the front wheel bearing by using the special tool. Special tool: Bearing installer E00014 Install the distance collar.
Page 179: Front Brake Fluid
14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE FLUID FLUID REPLACEMENT/AIR BLEEDING ● A contaminated brake disc or pad reduces stopping power. Discard contaminated pads clean contaminated disc with a high quality brake degreasing agent. ● Do not allow foreign material to enter the system when filling the reservoir.
Page 180 14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Loosen the bleed valve and apply the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING Do not mix different types of fluid since they are not compatible.
Page 181 14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
Page 182: Front Brake Pad
14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i 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. Bolts Pad Pins Brake Pads Remove the brake pads. Always replace the brake pads in pairs to ensure even disc pressure.
Page 183: Brake Disc Inspection
14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
Page 184: Front Shock Absorber
14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. Remove the front brake caliper Remove the front wheel Remove the speed wheel sensor bolt and then remove the brake hose guide from right front shock absorber.
Page 185: Steering Stem
14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM STEERING STEM REMOVAL Remove the steering handlebar. Remove the front brake hose and speed wheel sensor connector from the guide. Right Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool.
Page 186 14.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary.
Page 187 14.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DOWNTOWN 200i FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race.
Page 188: Rear Brake/Rear Fork/Rear
15. REAR BRAKE/REAR FORK/REAR DOWNTOWN 200i WHEEL/REAR SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER _________________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------- 15-1 SERVICE INFORMATION ----------------------------------------------------------------------- 15-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 15-2 REAR BRAKE--------------------------------------------------------------------------------------- 15-3 REAR FORK----------------------------------------------------------------------------------------- 15-6 REAR WHEEL -------------------------------------------------------------------------------------- 15-7...
Page 189: Schematic Drawing
15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 200i SCHEMATIC DRAWING 15-1...
Page 190: Service Information
15. REAR BRAKE/REAR FORK/REAR DOWNTOWN 200i WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk.
Page 191: Rear Brake
15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 200i 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.
Page 192: Rear Suspension
. REAR WHEEL/REAR BRAKE/ 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.
Page 193 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION DOWNTOWN 200i Make sure the spring plate next to the brake pad dowel pin orientation. Install two brake pads. Brake Pads INSTALLATION Brake Fluid Tube Bolt Caliper Install the brake caliper to the rear fork and tighten the two bolts.
Page 194: Rear Fork
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION DOWNTOWN 200i REAR FORK REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Bear Axle Nut Bolt Remove the right rear shock absorber lower mount bolt. Remove the rear axle nut and remove the collar.
Page 195: Rear Wheel
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION DOWNTOWN 200i REAR WHEEL REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. Remove the rear wheel. Bear Axle Collar INSTALLATION The installation sequence is the reverse of removal.
Page 196 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION DOWNTOWN 200i 15-8...
Page 197: Battery/Charging System
. BATTERY/CHARGING SYSTEM DOWNTOWN 200i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 16-1 CHARGING CIRCUIT ----------------------------------------------------- 16-1 SERVICE INFORMATION------------------------------------------------ 16-2 TROUBLESHOOTING----------------------------------------------------- 16-3 BATTERY CHARGING --------------------------------------------------- 16-4 CHARGING SYSTEM ----------------------------------------------------- 16-6 REGULATOR/RECTIFIER ----------------------------------------------- 16-6 16-0...
Page 198: Battery/Charging System
. BATTERY/CHARGING SYSTEM DOWNTOWN 200i CHARGING SYSTEM LAYOUT BATTERY REGULATOR/RECTIFIER 16-1...
Page 199: Service Information
. BATTERY/CHARGING 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 •...
Page 200: Troubleshooting
. BATTERY/CHARGING SYSTEM DOWNTOWN 200i TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in • Faulty ignition switch...
Page 201 . BATTERY/CHARGING SYSTEM DOWNTOWN 200i Screws BATTERY REMOVAL The battery is in the battery box below seat. 1. Remove the seat. 2. Remove the met-in box 3. Remove four screws and then the battery retainer. Terminal (-) Terminal 4. Pull battery out to expose the terminal leads 5.
Page 202: Battery Charging
. 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 the charger, not at the battery terminals.
Page 203: Regulator/Rectifier
. 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. Regulator/Rectifier BATTERY WIRE Measure the voltage between the Red/White wire terminal and ground. There should be battery voltage at all times.
Page 204 . BATTERY/CHARGING SYSTEM DOWNTOWN 200i CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals. Standard: 0.4 ~ 0.6 Ω (20ºC/68ºF) Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground. There should be no continuity.
Page 205: Ignition System
17. IGNITION SYSTEM DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM ________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------------------------------ 17-1 SERVICE INFORMATION ----------------------------------------------------------------------- 17-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 17-2 SPARK PLUG --------------------------------------------------------------------------------------- 17-3 IGNITION COIL INSPECTION ------------------------------------------------------------------ 17-3 A.C. GENERATOR INSPECTION--------------------------------------------------------------- 17-4 ROLL SENSOR INSPECTION ------------------------------------------------------------------- 17-4...
Page 206: Ignition System Layout
17. IGNITION SYSTEM DOWNTOWN 200i IGNITION SYSTEM LAYOUT Roll Sensor Ignition Coil Ignition Switch A.C. Generator Crank Position Sensor IGNITION CIRCUIT Roll Sensor 17-1...
Page 207: Service Information
17. IGNITION SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2.
Page 208: Spark Plug
17. IGNITION SYSTEM DOWNTOWN 200i Ignition Coil 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 Primary Coil TEST Inspect the continuity of the ignition coil, primary coil and secondary coil.
Page 209: Generator Inspection
17. IGNITION SYSTEM DOWNTOWN 200i A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Measure the resistance between the blue/white Crank Position Sensor Wire Coupler and green/white wire terminals.
Page 210 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. Install the roll sensor with its “up” mark facing up.
Page 211: Starting System
18. STARTING SYSTEM DOWNTOWN 200i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM _________________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------------------------------- 18-1 SERVICE INFORMATION ----------------------------------------------------------------------- 18-2 TROUBLESHOOTING ---------------------------------------------------------------------------- 18-2 STARTER MOTOR--------------------------------------------------------------------------------- 18-3 STARTER RELAY INSPECTION --------------------------------------------------------------- 18-4 18-0...
Page 212: Starting System Layout
18. STARTING SYSTEM DOWNTOWN 200i STARTING SYSTEM LAYOUT Starter Relay Ignition Switch STARTING CIRCUIT Relay 18-1...
Page 213: Service Information
18. STARTING SYSTEM DOWNTOWN 200i SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 214: Starter Motor
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.
Page 215: Starter Relay Inspection
18. STARTING SYSTEM DOWNTOWN 200i Starter Motor Cable INSTALLATION Connect the starter motor cable. Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install it to the starter motor. Tighten the two mounting bolts.
Page 216: Lights Switches/ Fuel Pump
19. LIGHTS SWITCHES/ FUEL PUMP DOWNTOWN 200i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 19- 1 BULB REPLACEMENT --------------------------------------------------- 19- 2 BRAKE LIGHT SWITCH-------------------------------------------------- 19- 6 IGNITION SWITCH -------------------------------------------------------- 19- 6 HANDLEBAR SWITCH --------------------------------------------------- 19- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 19- 9...
Page 217 19. LIGHTS SWITCHES/ FUEL PUMP DOWNTOWN 200i ELECTRICAL EQUIPMENT LAYOUT Radiator 19-1...
Page 218: Service Information
19. LIGHTS SWITCHES/ FUEL PUMP DOWNTOWN 200i SERVICE INFORMATION GENERAL A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
Page 219: Bulb Replacement
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...
Page 220 19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i Connector Headlight Bulb HEADLIGHT A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF. Be sure to let it cool down before servicing. Remove the front cover...
Page 221 19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i FRONT TURN SIGNAL LIGHT Socket Remove the front cover. Turn the bulb socket, then remove the front turn signal light. Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal.
Page 222 19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i REAR TURN SIGNAL LIGHT Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal. Rear Turn Signal Light Taillight/Brake Light 19-6...
Page 223: Brake Light Switch
19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i BRAKE LIGHT SWITCH Remove the upper handlebar cover. Disconnect front or rear brake light switch connectors and check for continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.
Page 224: Right Handlebar Switch
19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i RIGHT HANDLEBAR SWITCH Engine Stop Switch INSPECTION Remove the front cover Disconnect right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Starter Switc...
Page 225: Luggage Box Light Switch
19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i Dimmer Switch LEFT HANDLEBAR SWITCH INSPECTION Disconnect left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Horn Switch Turn Signal light Switch...
Page 226: Fuel Pump
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 six nuts and fuel unit connectors then remove the fuel hose.
Page 227 19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. Before performing the following test, operate the turn signals to determine that the battery circuit is normal. Measure resistance between Red/Black and Green wire of the fuel unit connector.
Page 228: Side Stand Switch
19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i Connector SIDE STAND SWITCH INSPECTION Remove the luggage box. Side stand switch is located on side stand. Disconnect the side stand switch connector. There should be continuity between the Yellow/Green and Green with the side stand is up.
Page 229: Horn
19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i HORN INSPECTION Remove the front cover. Disconnect the horn connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.
Page 230 19. LIGHTS/METERS/SWITCHES DOWNTOWN 200i Put the headlight wires into the headlight unit Waterproof Rubber and then cover the waterproof rubber. Highlight wires Press the waterproof rubber around with hand until its seat. INSPECTION Confirm if the waterproof rubber is covered firmly.

KYMCO Downtown 200i Service Manual

Preface

2. Exhaust Muffler/Frame Covers

3. Inspection/Adjustment

4. Lubrication System

6. Cylinder Head/Valves

7. Cylinder/Piston

9. Final Reduction

10. A.C. Generator/Starter Clutch

11. Crankcase/Crankshaft

12. Cooling System

Fuel Injection System

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

Wheel/Rear Shock Absorber 15

16. Battery/Charging System

17. Ignition System

Quick Links

Chapters

Troubleshooting

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Questions and answers

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Summary of Contents for KYMCO Downtown 200i