KYMCO Downtown 200i, Downtown 300i ABS Service Manual
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
DOWNTOWN 200i
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
Downtown
200
i.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules
and service information for each part,
starting from periodic maintenance.
Sections 5 to 12 give instructions for
disassembly, assembly and
adjustment of engine parts. Section 13
is the AFI system. Section 14 to 15 is
the removal/ installation of chassis.
Section 16 to 19 states the testing and
measuring methods of electrical
equipment.
Most sections start with an assembly
or system illustration and
troubleshooting for the section. The
subsequent pages give detailed
procedures for the section.
KWANG YANG MOTOR CO., LTD.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME
COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS/VBELT
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER
CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL INJECTION SYSTEM
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
LIGHTS SWITCHES / FUEL PUMP
19
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS
ELE
C
TRI
C
AL
EQUIPMENT
ENGINE
1. GENERAL INFORMATION
1-0
DOWNTOWN 200i
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
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
1
1. GENERAL INFORMATION
1-1
DOWNTOWN 200i
SERIAL NUMBER
Location of Frame Serial Number
(inside luggage box)
Location of Vehicle Identification
Number (VIN)
Location of Engine Serial Number
1. GENERAL INFORMATION
1-2
DOWNTOWN 200i
SPECIFICATIONS
Name Downtown 200i
Model No. SK40AA
Overall length 2200 mm
Overall width 800 mm
Overall height 1410 mm
Wheel base 1545 mm
Engine type 4 stroke O.H.C.
Displacement 205 cc
Fuel Used 92# nonleaded
gasoline
Front wheel
70
Rear wheel
104
Total
174
Front wheel
149
Rear wheel
205
Total
354
Ground clearance (mm)
140
Braking distance (m)
7.9m / 30 km/hr
Min. turning radius (m)
2.6
Engine part
Starting system
Starting motor
Type
Gasoline 4-cycle
Cylinder arrangement Single cylinde
r
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.-4V
Bore x stroke (mm) φ66 * 60
Compression ratio 10.5:1
Compression pressure
(kg/cm²)
16
Max. output (ps/rpm)Engine 20.6 /8000
Max. torque (kg-m/rpm) 2.03 / 6500
Open 5° BTDC
Close 32° BTDC
Open 34° BTDC
Close 5° BTDC
Intake
0.10
Exhaust
0.10
Idle speed (rpm)
1600±100 rpm
Cooling Type
Liquid cooling
Lubrication type
Forced pressure &
wet sump
Oil pump type Inner/outer roto
r
Oil filter type Full-flow filtration
Oil capacity 1.5ℓ
Exchanging capacity 1.3 ℓ
Fi injection system
Air cleaner type & No Paper element, wet
Fuel capacity 12.5 ℓ
Brand Keihin(LGF9)
Throttle Body
Butterfly type
Venturi diameter (mm)
32
Fuel pump pressure
3 bar
Electrical system
Ignition type
ECU
Ignition timing
4°~32°
Spark plug CR7E (NGK)
Spark plug gap 0.6～0.7mm
Battery Capacity 12V10AH
Transmission system
Clutch type
Dry multi-disc
Transmission type
CVT
Operation type Auto centrifugal
Reduction gear type
Two-stage reduction
1
st
0.81 ~ 2.57
2nd 9.54
Moving device
Tire type
Tubeless
Front wheel
120/80-14 58S
Rear wheel
150/70-13 64S
Front wheel
2.0
Rear wheel
2.25
Wheel material
Aluminium
Left 40°
Right 40°
Front Disk brake
Rear Drum brake
Damping Device
Front
Telescope
Rear Swing arm
Front 110 mm
Shock absorber
stroke
Rear 100 mm
1. GENERAL INFORMATION
1-3
DOWNTOWN 200i
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
Special
Engine Oil
Grease
Gear Oil
＊
1. GENERAL INFORMATION
1-4
DOWNTOWN 200i
TORQUE VALUES
1. GENERAL INFORMATION
1-5
DOWNTOWN 200i
TORQUE VALUES
FRAME
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
Installer
A120E00014 Oil seal & bearing installing
Flywheel Holder A120E00021 A.C. generator flywheel holding
#41 Nut & Fitting A120E00028 Clutch disassembly & assembly
Thread Protector A120E00029 Protecting the crankshaft’s
thread
Valve Cotter Installer A120E00051 Valve cotter installation
Clutch Spring
Compressor
A120E00053 Clutch disassembly & assembly
Shaft Collar Puller A120E00088 Bearing crankcase removal
Shaft Collar Driver A120E00091 Bearing crankcase removal
Shaft Collar Installer A120E00092 Bearing crankcase installation
Bearing Puller A120E00093 Bearing removal
Lock Nut Socket Wrench A120F00002 Steering stem removal or
installation
Electric Repair Kit A120F00032 Fuel injection system diagnosis
1-6
1. GENERAL INFORMATION
1-7
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.
Grease
Grease
Front wheel axle &nut
Rear wheel axle &nut
Grease
Side stand pivot
& Main stand pivot
1. GENERAL INFORMATION
1-8
DOWNTOWN 200i
CABLE & HARNESS ROUTING
Tilt Switch Speedometer
Radiator Filler Cap
Ignition Switch
ECU
Horn
Winker Relay
Hi Beam Relay
Lo Beam Relay
1. GENERAL INFORMATION
1-9
DOWNTOWN 200i
ISC Throttle Body TPS WTS
InjectorMAP Sensor
1. GENERAL INFORMATION
1-10
DOWNTOWN 200i
Oil controller
Fuel Pump Relay
Ignition Coil
Output Voltage Connector
Coolant Reserve Tank
1. GENERAL INFORMATION
1-11
DOWNTOWN 200i
Starter Relay Regulator/Rectifier
CPS O2 Sensor
2
. EXHAUST MUFFLER/FRAME COVERS
2-0
DOWNTOWN 200i
2
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
2
2
. EXHAUST MUFFLER/FRAME COVERS
2-1
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.
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
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
2
. EXHAUST MUFFLER/FRAME COVERS
2-2
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.
Push in the head of center piece until it
becomes flush with the fastener outside face.
To prevent the pawl | from damage,
insert the fastener all the way into the
installation hole
＊
2
. EXHAUST MUFFLER/FRAME COVERS
2-3
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.
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 is in the reverse order of removal.
Luggage Box Light Connecto
r
2
. EXHAUST MUFFLER/FRAME COVERS
2-4
DOWNTOWN 200i
CENTER COVER
Remove the luggage box.
Remove the center cover.
Installation is in the reverse order of removal.
Remove four bolts and then remove the rear
carrier.
Center Cove
r
During removal, do not pull the joint
claws forcedly to avoid damage.
＊
2
. EXHAUST MUFFLER/FRAME COVERS
2-5
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” section, then
pull the throttle cable out from the lower
cover. Remove the lower cover.
Installation is in the reverse order of removal.
2
. EXHAUST MUFFLER/FRAME COVERS
2-6
DOWNTOWN 200i
WINDSHIELD/WINDSHIELD GARNISH
Remove five bolts and windshield garnish.
2
. EXHAUST MUFFLER/FRAME COVERS
2-7
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.
Remove eight screws from the inner cover.
Remove the front cover
2
. EXHAUST MUFFLER/FRAME COVERS
2-8
DOWNTOWN 200i
Disconnect the 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.
Installation is in the reverse order of removal.
During removal, do not pull the joint
claws forcedly to avoid damage.
＊
2
. EXHAUST MUFFLER/FRAME COVERS
2-9
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.
Installation is in 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.
Disconnect the taillight connector.
2
. EXHAUST MUFFLER/FRAME COVERS
2-10
DOWNTOWN 200i
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.
Taillight Connecto
r
2
. EXHAUST MUFFLER/FRAME COVERS
2-11
DOWNTOWN 200i
Remove eight bolts, then remove the
floorboard.
UNDER COVER
Remove four bolts
Remove the under cover.
2
. EXHAUST MUFFLER/FRAME COVERS
2-12
DOWNTOWN 200i
Remove the fuel tank cap cover.
Installation is in the reverse order of removal.
METER PANEL
Disconnect the speedometer wires.
Disconnect the DC power connectors.
Remove one screws
Remove the ignition key garnish
Remove three screws from the inner cover,
then remove the handler panel.
Installation is in the reverse order of removal.
Speedometer Wires
DC power Connectors
2
. EXHAUST MUFFLER/FRAME COVERS
2-13
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
(3)
(1)
(2)
(2)
(4)
(5)
(6)
2
. EXHAUST MUFFLER/FRAME COVERS
2-14
DOWNTOWN 200i
EXHAUST MUFFLER
REMOVAL
Disconnect the connector with O2 heater/O2
sensor.
Remove the two exhaust pipe joint nuts
Remove three muffler mount bolts and
muffler and gasket.
N
uts
2
. EXHAUST MUFFLER/FRAME COVERS
2-15
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,)
Tighten the three mounting bolts
Torque: 35 N•m (3.5 kgf•m,)
Remove the coolant tank cover.
Gaske
t
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