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

3. INSPECTION/ADJUSTMENT

3-0

DOWNTOWN 200i

3

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

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
SPARK PLUG --------------------------------------------------------------------------------------- 3- 6
VALVE CLEARANCE----------------------------------------------------------------------------- 3- 7
CYLINDER COMPRESSION--------------------------------------------------------------------- 3- 7
FINAL REDUCTION GEAR OIL---------------------------------------------------------------- 3- 8
DRIVE BELT ---------------------------------------------------------------------------------------- 3- 8
BRAKE SYSTEM----------------------------------------------------------------------------------- 3- 9
CLUTCH SHOE WEAR --------------------------------------------------------------------------- 3- 10
SUSPENSION --------------------------------------------------------------------------------------- 3- 10
NUTS/BOLTS/FASTENERS---------------------------------------------------------------------- 3- 11
WHEELS/TIRES ------------------------------------------------------------------------------------ 3- 11
STEERING HANDLEBAR------------------------------------------------------------------------ 3- 11
SIDE STAND ---------------------------------------------------------------------------------------- 3- 12

3

3. INSPECTION/ADJUSTMENT

3-1

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.

• Gasoline is extrem

ely flammable and is explosive under some conditions. The working area must be

well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.

SPECIFICATIONS
ENGINE

Throttle grip free play : 2～6 m

m

Spark plug : NGK: CR7E
Spark plug gap : 0.6 mm ~ 0.7 mm
Valve clearance : IN: 0.10 mm EX: 0.10 mm

Idle speed : 1600±100 rpm

Engine oil capacity:

Cylinder compression: 16±2 kg/cm²
At disassembly : 1.5 Liter Ignition timing : ECU
At change : 1.3 Liter Coolant type : Water Cooling

Gear oil capacity :

At disassembly : 0.23 Liter
At change : 0.21 Liter

TIRE

1 Rider 2 Riders

Front 2.00 kg/cm² 2.00 kg/cm²

Rear 2.25 kg/cm² 2.25 kg/cm²

TIRE SPECIFICATION

Front : 120/80-14 58S
Rear : 150/70-13 64S

TORQUE VALUES

Front axle nut : 2 kg-m
Rear axle nut : 12 kg-m

SPECIAL TOOL

Tappet Adjuster E012

3. INSPECTION/ADJUSTMENT

3-2

3. INSPECTION/ADJUSTMENT

3-3

DOWNTOWN 200i

THROTTLE OPERATION

Check the throttle grip for smooth movement.
Measure the throttle grip free play.

Free Play: 2～6 m

m

Major adjustment of the throttle grip free play is
m

ade with the adjusting nut at the throttle body

side. Adjust by loosening the lock nut and turning
the adjusting nut.

Minor adjustment is made with the adjusting nut
at the throttle grip side.
Slide the rubber cover(1) out and adjust by
loosening the lock nut(3) and turning

the

adjusting nut(2).

Lock Nu

t

Adjusting Nu

t

3. INSPECTION/ADJUSTMENT

3-4

DOWNTOWN 200i

ENGINE OIL

OIL LEVEL INSPECTION

Stop the engine and support the scooter upright
on the level ground.
Wait for 2～3 m

inutes and check the oil level
with the dipstick. Do not screw in the dipstick
when checking the oil level.

OIL CHANGE

Remove the oil drain bolt to drain the engine oil.
Install the aluminum washer and tighten the oil
drain bolt.

Torque: 2.5 kg-m

Pour the recommended oil through the oil filler
hole.

OIL CAPACITY

Engine oil capacity: 1.5 L
Engine oil exchanging capacity: 1.3 L
Engine Oil Viscosity : SAE 5W50

OIL FILTER SCREEN INSPECTION

Drain the engine oil.
Remove the oil filter screen attaching the left­under crankcase.
Clean the oil filter screen.
Install the oil filter screen and filter screen cap.
Fill the engine with recommended engine oil.

OIL FILTER REPLACEMENT

Remove the oil filler cap attaching the right-under
crankcase cover.

• Replace the aluminum washer with a new
one if it is deformed or damaged.

＊

Dipstick

Oil Drain Bol

t

Oil Filter Screen

Oil Filter Cap

3. INSPECTION/ADJUSTMENT

3-5

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.

Install a new oil filter.

RESERVE TANK

COOLANT LEVEL INSPECTION

The reserve tank is under left floorboard .Check the
coolant level through the inspection window(1) at the
left side skirt white the engine is at the normal
operating temperature , with the scooter In an upright
position.
If the coolant level is below the LOWER level
m

ark(3), remove the left floor mat ,remove the lid
screw(4), the reserve tank lid(5), and then the reserve
tank cap(6) to add coolant mixture until it reaches the
upper level mark .

Spring

Make sure the rubber seal on the oil filter

facing the left crankcase.

＊

Add coolant to the reserve tank only. Do not

attempt to add coolant by removing the
radiator cap. Coolant in the radiator is under
pressure and is very hot and can cause
serious burns.

＊

3. INSPECTION/ADJUSTMENT

3-6

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.

CHANGE INTERVAL

More frequent replacement is required when
riding in unusually dusty or rainy areas.

SPARK PLUG

Remove the spark plug cap and spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.

Specified Spark Plug: NGK-CR7E
Measure the spark plug gap.
Spark Plug Gap: 0.6 – 0.7 m

m

Torque:17.2 N-m

• The air cleaner element has a viscous type
paper element. Do not clean it with
compressed air.

• Be sure to install the air cleaner element
and cover securely.

＊

• When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench.

＊

Air Cleaner Cove

r

Deformation

0.6~0.7 mm

｝

Gap
Wear
Fouling
Deposits

Cracks
Damage

Spark Plug

3. INSPECTION/ADJUSTMENT

3-7

DOWNTOWN 200i

VALVE CLEARANCE

Remove the seat assy and luggage box.
Remove the four bolts and then cylinder head
cover.

Turn the A.C. generator flywheel to the top dead
center (TDC) on

the compression stroke so that
the “T” mark on the flywheel aligns with the
index mark on the left crankcase cover.
Inspect and adjust valve clearance.

Valve Clearance:

IN: 0.10 mm
EX: 0.10 mm

Loosen the lock nut and adjust by turning the
adjusting nut

Valve Adjuster E012
Feeler Gauge

CYLINDER COMPRESSION

Warm up the engine before compression test.
Remove the center cover and luggage box.
Remove the spark plug.
Insert a compression gauge.
Open the throttle fully and push the starter button
to test the com

pression.

Max. Compression: 16±2 kg/cm

2

If the compression is low, check for the following:
‧Leaky

valves

‧Valve clearance too sm

all

‧Leaking cy

linder head gasket

‧Worn piston rings
‧Worn piston/cy

linder
If the compression is high, it indicates that carbon
deposits have accum

ulated on the combustion

chamber and the piston head.

• Inspect and adjust valve clearance while
the engine is cold (below 35℃).

＊

• Check the valve clearance again after the
lock nut is tightened.

＊

Bolts

Top Dead Center Mark

Special

Cylinder Head Cove

r

3. INSPECTION/ADJUSTMENT

3-8

DOWNTOWN 200i

FINAL REDUCTION GEAR OIL

Remove the transmission fluid drain bolt.
Remove the transmission fluid filler bolt, then
slowly

rotate the rear wheel to drain the fluid.
Fill the transmission with the recommend fluid to
the capacity

listed below.

Transmission fluid type: SAE 90
Transmission fluid capacity: 0.23 L
Transmission fluid exchanging
capacity: 0.21 L

Install the transmission filler bolt and tighten it to
the specified torque.

DRIVE BELT

Remove the left crankcase cover.
Inspect the drive belt for cracks or excessive wear.

Replace the drive belt with a new one if necessary
and in accordance with the Maintenance Schedule.

Oil FillerBol

t

• Place the scooter on its main stand on level
ground.

＊

Oil Drain Bol

t

Drive Bel

t

3. INSPECTION/ADJUSTMENT

3-9

DOWNTOWN 200i

BRAKE SYSTEM

There is adjuster on each brake lever.Each
adjuster has four positions so that the released
lever position can be adjusted to suit the rider’s
hands.
To adjust the distance of the lever from the
handlebar grip,push

the lever(1) forward and turn
the adjuster knob(2) to align the number with the
arrow mark(3) on the lever holder.

BRAKE DISK/BRAKE PAD

Check the brake disk surface for scratches,
unevenness or abnormal wear.
Check if the brake disk runout is within the
specified service lim

it.
Check if the brake pad wear exceeds the wear
indicator line.

BRAKE FLUID

Turn the steering handlebar upright and check if
both brake fluid levels is at the upper limit. If the
brake fluid is insufficient, fill to the upper limit.

Specified Brake Fluid: DOT-4

Keep grease or oil off the brake disk to

avoid brake failure.

＊

The brake fluid level will decrease if the

brake pads are worn.

＊

3. INSPECTION/ADJUSTMENT

3-10

DOWNTOWN 200i

CLUTCH SHOE WEAR

Start engine and check the clutch operation by
increasing the engine speed gradually.
If the motorcycle tends to creep or the engine stop,
check the

clutch shoes for wear and replace if

necessary.

SUSPENSION

FRONT

Check the action of the front shock absorbers by
compressing them several times.

Check the entire shock absorber assembly for oil
leaks, looseness or dam

age.

REAR

Each shock absorber(4) on your scooter has 5
spring preload adjustment positions for different
load or riding conditions.

Use a pin spanner(5) to adjust the rear shock
spring

preload. Position 1 is for light loads and
smooth road conditions. Position 3 to 5 increase
spring preload for a stiffer rear suspension and
can be used when the scooter is heavily loaded.

Be certain to adjust both shock absorbers to the
sam

e spring preload positions.

3. INSPECTION/ADJUSTMENT

3-11

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.

Tire Pressure

1 Rider 1 Rider (with

passenger)
Front 2.00 kg/cm² 2.00 kg/cm²
Rear 2.25 kg/cm² 2.25 kg/cm²

Tire Size:

Front 120/80-14 58S
Rear 150/70-13 64S

Check the front axle nut for looseness.
Check the rear axle nut for looseness.
If the axle nuts are loose, tighten them to the
specified torques.

Torque:

Front axle nut 2 kg-m
Rear axle nut 12 kg-m

STEERING HANDLEBAR

Raise the front wheel off the ground and check
that the steering handlebar rotates freely.
If the handlebar moves unevenly, binds, or has
vertical m

ovement, adjust the steering head

bearing.

• Tire pressure should be checked when tires
are cold.

＊

Front Axle Nut

Rear Axle Nut

3. INSPECTION/ADJUSTMENT

3-12

DOWNTOWN 200i

SIDE STAND

Your scooter's side stand is not only necessary when
you park, but it contains an important safety feature.
This feature cuts-off the ignition if you try to ride the
scooter when the side stand is down. Perform the
following side stand inspection.

INTERLOCK FUNCTION CHECK

Check the side stand ignition cut-off system,

1. Place the scooter on its center stand.

2. Put the side stand up and start the engine.

3. Lower 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.

＊

4. LUBRICATION SYSTEM

4-0

DOWNTOWN 200i

4

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

LUBRICATION SYSTEM

________________________________________________________________________________

LUBRICATION SYSTEM------------------------------------------------------------------------- 4-1
SERVICE INFORMATION ----------------------------------------------------------------------- 4-2
TROUBLESHOOTING ---------------------------------------------------------------------------- 4-2
ENGINE OIL/OIL FILTER------------------------------------------------------------------------ 4-3
OIL PUMP-------------------------------------------------------------------------------------------- 4-5

4

4. LUBRICATION SYSTEM

4-1

DOWNTOWN 200i

LUBRICATION PART

Dipstick

Oil Filter

Oil Pump

Drive Chain

4. LUBRICATION SYSTEM

4-2

DOWNTOWN 200i

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The m

aintenance 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.

• Do not attem

pt to disassemble the oil pump. The oil pump must be replaced as a set when it reaches its

service limit.

• After the oil pum

p is installed, check each part for oil leaks.

SPECIFICATIONS
ENGINE OIL

Engine Oil Capacity At disassembly: 1.5 liter At change: 1.3 liter

Recommended Oil SAE5W50# API: SJ

TROUBLESHOOTING
Oil level too low Poor lubrication pressure

• Natural oil consum

ption • Oil level too low

• Oil leaks • Clogged oil filter or oil passage

• Worn piston rings • Faulty

oil pump

• Worn valve guide

• Worn valve guide seal

Oil contamination

• Oil not changed often enough

• Faulty

cylinder head gasket

• Loose cy

linder head bolts

4. LUBRICATION SYSTEM

4-3

DOWNTOWN 200i

ENGINE OIL/OIL FILTER

Remove the oil dipstick and check the oil level
with the oil dipstick.
If the level is near the lower level, fill to the upper
level with the recom

mended engine oil.

OIL CHANGE

Remove the oil drain bolt located at the left side
of the engine to drain the engine oil.
After the oil has been completely drained, install
the

aluminum washer and tighten the oil drain

bolt.
Torque: 24.5

N-m
Pour the recommended oil through the oil filler
hole.

OIL FILTER SCREEN

Drain the engine oil.
Remove the oil filter screen cap.
Remove the oil filter screen and spring.
Check the oil filter screen for clogging or damage
and

replace if necessary. Check the filter screen
O-ring for damage and replace if necessary.
Install the oil filter screen, spring, O-ring and
filter screen cap.

Torque: 12.7N-m

Recommended Oil: SAE5W50# API: SJ
Oil Capacity:

At disassembly: 1.5 liter
At change: 1.3 liter

Start the engine and check for oil leaks. Start
the engine and let it idle for few m

inutes, then

recheck the oil level.

Oil Dipstick

• 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.

＊

• The engine oil will drain more easily while
the engine is warm.

＊

4. LUBRICATION SYSTEM

4-4

DOWNTOWN 200i

OIL FILTER REPLACEMENT

Remove the oil filler cap attaching the right-under
crankcase cover.

The spring will come out when the filter cap is
rem

oved.
Let the engine oil drain out.
Check that the O-ring is in good condition.

Install a new oil filter.

Oil Filter Cap

Spring

Make sure the rubber seal on the oil filter
facing the left crankcase

＊

4. LUBRICATION SYSTEM

4-5

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

Remove the gasket and dowel pins.
Remove the starter idle gear and starter clutch.

Remove the two bolts and oil separator cover.

Remove the oil pump driven gear clip to remove
the oil pum

p driven gear and drive chain.

Dowel Pin

Starter Idle Gea

r

Oil Separator Cove

r

Oil Pump Drive Chain

4. LUBRICATION SYSTEM

4-6

DOWNTOWN 200i

Remove two oil pump mounting bolts and the oil
pump.

OIL PUMP INSTALLATION

Install the oil pump into the crankcase.

After the oil pump is installed, tighten the two
m

ounting bolts.
Install the pump driven gear and drive chain by
aligning

the pump driven gear with the cutout in
the pump shaft.
Install and tighten the pump driven gear bolts.
Install the oil separator cover and tighten the bolts.

Install the starter idle gear and starter clutch.
Install the gasket and dowel pins.

Install the right crankcase cover and tighten the
twelve bolts.

Torque: 1.2 kg-m

Arrow Mark

Pump Shaf

t

Diagonally tighten the bolts in 2～3 times.

＊

Install the oil pump with the arrow on the
pump body facing up and fill the oil pump
with engine oil before installation.

＊

Oil Separator Cove

r

Dowel Pin

Starter Idle Gea

r

5

. ENGINE REMOVAL/INSTALLATION

5-0

DOWNTOWN 200i

5

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

ENGINE REMOVAL/INSTALLATION

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 5-1
ENGINE REMOVAL/INSTALLATION

--------------------------------- 5-2

ENGINE HANGER

--------------------------------------------------------- 5-6

5

5. ENGINE REMOVAL/INSTALLATION

5-1

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.

• Drain the coolant before removing the engine.

• After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the

water jacket. Start the engine to check for coolant leaks.

• Before removing the engine, the rear brake caliper must be removed first. Be careful not to bend

or twist the brake fluid tube.

SPECIFICATIONS

Engine oil capacity:

At disassembly: 1.5 L

At change: 1.3 L

Coolant capacity:

Radiator: 870 cc
Hose with cool coolant: 169 cc

Hose with hot coolant: 194 cc

Reserve tank: 490 cc
Total capacity: 1360 cc

TORQUE VALUES

90304-GHE8-0040 Engine hanger (Engine side) 5.0 kgf-m (50 N-m)
90305-LBD4-9000 Engine hanger (Frame side) 6.5 kgf-m (65 N-m)
95801-10060 Rear fork mount bolts 3.5 kgf-m (35 N-m)
90305-KFW6-9120-M1 Rear axle nut 12.0 kgf-m (120 N-m)
95801-10035-00 Rear cushion lower/upper mount bolts 4.0 kgf-m (40 N-m)

5

. ENGINE REMOVAL/INSTALLATION

5-2

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 the Regulator/Rectifier

connector.
Disconnect the starter relay wire from

starter motor.
Remove a bolt from fuel hose guide.
Disconnect the fuel hose from fuel injector.

Disconnect the input water hose.
Disconnect the air bleed hose.

Fuel hose guide

Water pumpOil filter

Water hose

5. ENGINE REMOVAL/INSTALLATION

5-3

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.
Remove two bolts (4) attaching to the rear

brake caliper.
Torque: 3.2 kgf-m (32 N-m)

Disconnect the alternator connector (5).
Disconnect the ignition pulse generator

connector (6).

Release the rubber cap and remove the
terminal screw (7) to disconnect the start
motor cable from the start motor.

Remove the bolt and engine ground cable.

(6) (5)

(7)

(3)

(2)

(1)

(4)

5

. ENGINE REMOVAL/INSTALLATION

5-4

DOWNTOWN 200i

Remove the spark plug cap.

Disconnect the lower radiator hose from
lower radiator pipe.

Remove the right and left rear cushion lower
m

ount bolts.

Torque: 4.0 kgf-m

(40N-m)

Spark Plug Cap

Mount Bolt

Radiator Hose

5. ENGINE REMOVAL/INSTALLATION

5-5

DOWNTOWN 200i

Remove the engine mount nut and pull it out.
Remove the engine from the frame.

Torque: 6.5 kgf-m (65 N-m)

INSTALLATION

Installation is in the reverse order of removal.

After installation, inspect and adjust the
following:

• Throttle grip free play

• Fill the cooling system with coolant and

start the engine to bleed air from the system.

API/ABV Reset (Refer to chapter14, page 17)

At removing the engine, be careful not
to catch your hand or finger between
the engine hanger and crankcase.

＊

Mount Nut

5

. ENGINE REMOVAL/INSTALLATION

5-6

DOWNTOWN 200i

ENGINE HANGER

REMOVAL

Remove the engine mount nut and pull it out.

Remove the left/right engine hanger mount
bolt.

Remove the engine from frame.

INSTALLATION

Installation is in the reverse order of removal.

Tighten the engine hanger mount bolts to the
specified torque.

Torque: 6.5 kgf-m (65 N-m)

Be careful to put the engine down.

＊

Mount Nut

6. CYLINDER HEAD/VALVES

6-0

DOWNTOWN 200i

6 .

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

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
CYLINDER HEAD DISASSEMBLY------------------------------------------------------------ 6- 7
CYLINDER HEAD ASSEMBLY ---------------------------------------------------------------- 6- 8
CYLINDER HEAD INSTALLATION----------------------------------------------------------- 6- 9
CAMSHAFT INSTALLATION------------------------------------------------------------------- 6- 9
CYLINDER HEAD COVER INSTALLATION------------------------------------------------ 6- 11

6

6. CYLINDER HEAD/VALVES

6-1

DOWNTOWN 200i

SCHEMATIC DRAWING

6. CYLINDER HEAD/VALVES

6-2

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.

• The valve rocker arms are lubricated by engine oil through the engine oil passages. Clean and unclog the

oil passages before assembling the cylinder head.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

• After removal, mark and arrange the removed parts in order. When assembling, install them in the reverse

order of removal.

SPECIFICATIONS

Standard (mm)

Ite

m

IN 0.10

EX 0.10

Cylinder head compression pressure 16 kg/cm²

IN 35.8281

EX 35.8437

IN 12.00～12.018

EX 12.00～12.018

Valve rocker arm shaf

t

IN 11.966～11.984

O.D. EX 11.966～11.984

IN 1.2

EX 1.2

IN 4.990～4.975

EX 4.970～4.955

IN 5.00～5.012

EX 5.00～5.012
Valve stem-to-guide IN 0.010～0.037
clearance EX 0.030～0.057

TORQUE VALUES

SPECIAL TOOL

Valve spring compressor E063

Valve clearance (cold)

Camshaft cam height

Valve rocker arm I.D.

Valve guide I.D.

Valve stem O.D.

Valve seat width

6. CYLINDER HEAD/VALVES

6-3

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

• Damaged valve stem oil seal

Compression too low

• Incorrect valve clearance adjustment Abnormal noise

• Burned or bend valves • Incorrect valve clearance adjustment

• Incorrect valve timing • Sticking valve or broken valve spring

• Broken valve spring • Damaged or worn camshaft

• Poor valve and seat contact • Worn cam chain tensioner

• Leaking cylinder head gasket • Worn camshaft and rocker arm

• Warped or cracked cylinder head

• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion
chamber

6. CYLINDER HEAD/VALVES

6-4

DOWNTOWN 200i

CYLINDER HEAD COVER REMOVAL

Remove the met-in box.
Remove the body cover and center cover.
Disconnect the breather hose to air cleaner.
Remove the cylinder head cover four bolts.
Remove the cylinder head cover.

CAMSHAFT REMOVAL

Remove the injector and inlet pipe.
Remove two screws attaching the thermostat.

Turn the cam chain tensioner screw clockwise to
tighten it.

Torque: 1.0 kgf-m (9.8 N-m)

Cylinder Head Cover

Bolts

Cam chain tensioner

Thermosta

t

Inlet pipe

Injector

6. CYLINDER HEAD/VALVES

6-5

DOWNTOWN 200i

Remove four nuts attaching to the cylinder head.

.
Remove two bolts attaching to the camshaft gear.
Remove the camshaft gear from the cam chain

Remove the set plate located beside the rocker
arm shaft.

• Diagonally loosen the cylinder head cap
nuts in 2 or 3 times.

＊

Set Plate

N

uts

Bolts

6. CYLINDER HEAD/VALVES

6-6

DOWNTOWN 200i

Remove the rocker arm with bolt as shown.

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.

CYLINDER HEAD REMOVAL

Remove the muffler.
Remove the throttle body.
Drain the coolant from the radiator and water
hose, then remove the thermostat water hose.
Remove the camshaft.
Remove the Temp/Map Sensor and intake
manifold.
Remove the bolt attaching the thermostat housing
and the thermostat housing.
Remove the cylinder head.

If the surface of rocker arm is worn, check
each cam lobe for wear or damage.

＊

Rocker Arm

Rocker Ar

m

Camshaft

Bol

t

Thermosta

t

6. CYLINDER HEAD/VALVES

6-7

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.
Remove all gasket material from the cylinder
head mating surface.

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers,
springs, spring seats and valve stem seals using a
valve spring compressor.

Valve spring compressor E040

Remove carbon deposits from the exhaust port
and combustion chamber.

• Be sure to compress the valve springs
with a valve spring compressor.

• Mark all disassembled parts to ensure
correct reassembly.

＊

Be careful not to drop any gasket material
into the engine.

＊

Special

Dowel pinsCylinder Head Gaske

t

Cam Chain Guide

Valve Spring Compresso

r

Nut

Bolts

6. CYLINDER HEAD/VALVES

6-8

DOWNTOWN 200i

VALVE STEM INSPECTION

Inspect each valve for bending, burning, or
abnormal stem wear.

Remove carbon deposits from the combustion
chamber.

Clean off any gasket remnants from the cylinder
head contact surface.

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and stem seals.
Lubricate each valve stem with engine oil and

insert the valves into the valve guides.
Be sure to install new valve stem seals.
Install the valve spring.

Valve spring compressor E040

Be careful not to damage the cylinder head
mating surface.

＊

Special

• Tap the valve stems gently with a plastic
hammer for 2～3 times to firmly seat the
cotters.

• Be careful not to damage the valves.

＊

Exhaust valveIntake valve

Valve spring compressor

Valves

6. CYLINDER HEAD/VALVES

6-9

DOWNTOWN 200i

CYLINDER HEAD INSTALLATION

Install the dowel pins and a new cylinder head
gasket.

Install the cam chain guide.

Install the cylinder head.
Install the camshaft.

Install the intake valve rocker arm and the rocker
arm shafts.

CAMSHAFT INSTALLATION

Install the set plate to prevent the rocker arm shaft
from pull out.

Torque: 1.2 kgf-m (8.9 N-m)

• Clean the intake valve rocker arm shaf

t

off any grease before installation.

＊

Dowel Pins

Gasket

Cam chain guide

Nut

Bolts

Cylinder Head

Fix plateBolt

6. CYLINDER HEAD/VALVES

6-10

DOWNTOWN 200i

Tighten the four cylinder head nuts and the four
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”
mark on the flywheel aligns with the index mark
on the right crankcase cover.
Keep the round hole on the camshaft gear facing
up and align two bolts on the camshaft gear with
the cylinder head surface (Position the intake and
exhaust cam lobes down.) and install the cam
chain over the camshaft gear.

Install the thermostat bolt.
Torque: 1.2 kgf-m (11.8 N-m)

Turn the cam chain tension screw counter­clockwise to release it.

• Apply engine oil to the threads of the
cylinder head cap nuts.

• Diagonally tighten the cylinder head cap
nuts in 2～3 times.

• First tighten the cylinder head cap nuts and
then tighten the bolts between the cylinder
and cylinder head to avoid cracks.

＊

N

uts

Camshaft Gea

r

Round hole

Bolts

6. CYLINDER HEAD/VALVES

6-11

DOWNTOWN 200i

CYLINDER HEAD COVER
INSTALLATION

Adjust the valve clearance.
Install a new cylinder head cover O-ring and
install the cylinder head cover.

Install the inlet pipe.
Install the injector.
Install and tighten the cylinder head cover bolts.

Be sure to install the O-ring into the groove
properly.

＊

Thermostat

Inlet pipe

Injector

7. CYLINDER/PISTON

7-0

DOWNTOWN 200i

7

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

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

7

7. CYLINDER/PISTON

7-1

DOWNTOWN 200i

SCHEMATIC DRAWING

7. CYLINDER/PISTON

7-2

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.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

SPECIFICATIONS

Item

Standard (mm) Service Limit (mm)

Cylinder

I.D. 66.0～66.02 66.10 over
Ring-to-groove top

0.015～0.055 0.09 over

clearance

Second

0.015～0.055 0.09 over

top

0.15～0.30 0.50 over

Piston, Ring end gap Second

0.30～0.45 0.50 over

piston ring Oil side rail

0.2～0.7

1.0 over

Piston O.D.(A)

65.98～65.99 65.9belw

Piston O.D.(B

)

66.99~66.00

65.9belw

Piston O.D. measuring position

9mm from bottom of skirt

. Piston-to-cylinder clearance

0.010～0.030 0.1 over

Piston pin hole I.D.

17.002～17.008 17.06 over

Piston pin O.D

16.994～17.000 16.80 belw

Piston-to-piston pin clearance

0.002～0.014 0.02 over

Connecting rod small end I.D. bore

17.016~17.034 17.06 over

TROUBLESHOOTING

• When hard starting or poor performance at low speed occurs, check the crankcase breather for white
smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven
compression Excessive smoke from exhaust muffler

• Worn or damaged cylinder and piston rings • Worn or damaged piston rings

• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

7. CYLINDER/PISTON

7-3

DOWNTOWN 200i

CYLINDER REMOVAL

Remove the cylinder head.
Remove the cam chain guide.
Remove the cylinder.

Remove the cylinder gasket and dowel pins.
Clean any gasket material from the cylinder
surface.

PISTON REMOVAL

Remove the piston pin clip.
Press the piston pin out of the piston.

Water Hose

Dowel Pins

Cam Chain Guide

Gaske

t

Cylinde

r

Piston PinPiston Piston Rings

Place a clean towel in the crankcase to
keep the piston pin clip from falling into
the crankcase.

＊

Dowel Pins

7. CYLINDER/PISTON

7-4

DOWNTOWN 200i

Inspect the piston, piston pin and piston rings.
Remove the piston rings.

Clean carbon deposits from the piston ring
grooves.

Install the piston rings onto the piston and
measure the piston ring-to-groove clearance.

Service Limits:

Top: 0.09 mm replace if over
2nd: 0.09 mm replace if over

Remove the piston rings and insert each
piston ring into the cylinder bottom.

Measure the piston ring end gap.
Service Limit: 0.5mm replace if over

Measure the hole I.D. of piston pin
Service Limit: 17.06 mm replace if over

Take care not to damage or break the

piston rings during removal.

＊

Use the piston head to push each piston

ring into the cylinder.

＊

7. CYLINDER/PISTON

7-5

DOWNTOWN 200i

Measure the piston pin O.D.
Service Limit: 16.8 mm replace if below

Measure the piston O.D.

Service Limit: 65.9mm replace if below
Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. at three levels of
top, middle and bottom at 90° to the piston
pin (in both X and Y directions).

Service Limit:

66.1 mm repair or replace if over

Measure the cylinder-to-piston clearance.
Service Limit:

0.1 mm repair or replace if over

The true roundness is the difference between
the values measured in X and Y directions.
The cylindricity (difference between the
values measured at the three levels) is subject
to the maximum value calculated.

Service Limits:
True Roundness:

0.05mm repair or replace if over

Cylindricity: 0.05 mm repair or replace if over

Middle

Bottom

Top

Take measurement at 9mm from the bottom

and 90° to the piston pin hole.

＊

7. CYLINDER/PISTON

7-6

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.

• All rings should be installed with the
markings facing up.

• After installing the rings, they should
rotate freely without sticking.

• Stagger the ring end gaps as the figure
shown.

＊

Second

Side Rail

Top

Second

Top

Side Rail

Oil Ring

7. CYLINDER/PISTON

7-7

DOWNTOWN 200i

PISTON INSTALLATION

Remove any gasket material from the
crankcase surface.

Install the piston, piston pin and a new piston
pin clip.

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder
gasket on the crankcase.

• Be careful not to drop foreign matters into
the crankcase.

＊

• Position the piston “IN” mark on the intake
valve side.

• Place a clean towel in the crankcase to
keep the piston pin clip from falling into
the crankcase.

＊

The piston must be changed in pair with

cylinder.

＊

Piston

7. CYLINDER/PISTON

7-8

DOWNTOWN 200i

Install the cam chain guide.

Install the cylinder head gasket and dowel
pins.

Connect the water hose to the cylinder.
Install the cylinder head.

Tighten the cylinder base bolt.

• Insert the tab on the cam chain guide into
the cylinder groove.

＊

Gaske

t

Dowel Pin

Cam Chain Guide

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-0

DOWNTOWN 200i

8

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

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
CLUTCH OUTER/DRIVEN PULLEY/V-BELT----------------------------------------------- 8- 3

8

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-1

DOWNTOWN 200i

SCHEMATIC DRAWING

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-2

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.

SPECIFICATIONS

Item

Standard (mm) Service Limit (mm)

Clutch lining thickness

4.0 2.0

Clutch outer I.D.

152.1～152.2 152.2

Weight roller O.D

19.92～20.08 20

TORQUE VALUES

Drive face nut 9.5 kgf-m (93.1 N-m) Apply oil
Clutch outer nut 5.5 kgf-m (54 N-m)
Clutch drive plate nut 5.5 kgf-m (54 N-m)

SPECIAL TOOLS

Universal holder E017
Clutch spring compressor E053
Fittings & Nut Wrench, 41mm E033

TROUBLESHOOTING
Engine starts but motorcycle won‘t move Lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Broken driven face spring • Faulty driven face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-3

DOWNTOWN 200i

LEFT CRANKCASE COVER
REMOVAL

Remove the met-in box and carrier.
Remove the body cover, center cover and rear
fender A together.
Remove the protector cover of left crankcase
cover.
Remove the bolts attaching to the left crankcase
cover.
Remove the gasket and dowel pins.

INSPECTION

Check the bearing for wear or damage.
Replace the bearing with a new one if the bearing
is noisy or have excessive play.

DRIVE PULLEY
DRIVE PULLEY FACE REMOVAL

Remove the left crankcase cover.
Hold the drive pulley using a universal holder and
remove the drive face nut and washer.
Remove the drive pulley face.

Universal Holder E017

CLUTCH OUTER/DRIVEN PULLEY/V­BELT

REMOVAL

Remove the drive pulley face.
Hold the clutch outer with the universal holder
and remove the clutch outer nut, bushing and
washer.

Universal Holder E017

Remove the clutch outer, driven pulley and belt
together.

Remove the drive belt from the movable drive
face.

Special

Special

Left Crankcase Cove

r

Drive Pulley Face

Universal Holde

r

Movable Drive Face

Bushing Nu

t

Bearing

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-4

DOWNTOWN 200i

INSPECTION

Check the drive belt for cracks, separation or
abnormal or excessive wear.

Replace a new belt at every 20,000km.

MOVABLE DRIVE FACE ASSEMBLY

Remove the pulley face, clutch outer, driven
pulley and belt.
Remove the movable drive face assembly.
Remove the drive pulley collar.

DISASSEMBLY

Remove the ramp plate.

Remove the weight rollers.

• Use specified genuine parts for
replacement.

＊

Ramp Plate

Weight Rolle

r

Movable Drive Face Assembly

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-5

DOWNTOWN 200i

INSPECTION

Check each weight roller for wear or damage.

Check the movable drive face bushing for wear or
damage.

ASSEMBLY

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-6

DOWNTOWN 200i

Install the weight rollers into the movable drive
face.

Install the ramp plate.
Insert the drive pulley collar into the movable

drive face.

INSPECTION

Inspect the clutch outer for wear or damage.
Measure the clutch outer I.D.

Service Limit: 153.5 mm replace if over

Check the clutch shoes for wear or damage.
Measure the clutch lining thickness.

Service Limit: 2.0 mm replace if below

• The direction of all weight rolls is same. The
color side is towards to clockwise.

＊

Ramp Plate

Clutch Linin

g

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-7

DOWNTOWN 200i

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.

Clutch Spring Compressor E053
Fittings & Nut Wrench, 41mm E033

Loosen the clutch spring compressor and
disassemble the clutch/driven pulley assembly.
Remove the seal collar.

Pull out the guide roller pins and guide rollers.
Remove the movable driven face from the driven
face.

Remove the oil seal from the movable driven
face.

ASSEMBLY

• Be sure to use a clutch spring compressor
to avoid spring damage.

＊

Guide Roller Pin

Oil Seal

Special

Clutch/Driven Pulle

y

Clutch Spring Compresso

r

Lock Nut Wrench

Movable Driven Face

O-rin

g

Guide Rolle

r

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-8

DOWNTOWN 200i

INSPECTION

Measure the driven face spring free length.

Service Limit: 136 mm replace if below

DRIVEN PULLEY FACE BEARING
REPLACEMENT

Check the bearings for play and replace them if
they have excessive play.
Drive the inner needle bearing out of the driven
pulley face.

Remove the snap ring and drive the outer bearing
out of the driven face.

Apply grease to the outer bearing.
Drive a new outer bearing into the driven face
with the sealed end facing up.

Seat the snap ring in its groove.
Apply grease to the driven face bore areas.

• Discard the removed bearing and replace
with a new one.

＊

• Discard the removed bearing and replace
with a new one.

＊

Outer Bearing

Guide Pins

Grooves

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-9

DOWNTOWN 200i

Press a new needle bearing into the driven face.

CLUTCH DISASSEMBLY

Remove the clips and retainer plate to
disassemble the clutch.

• Keep grease off the clutch linings.

＊

Clips

Retainer Plate

Clutch Linin

g

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-10

DOWNTOWN 200i

CLUTCH ASSEMBLY

Install the damper rubbers on the drive plate pins.
Install the clutch weights/shoes and clutch springs
onto the drive plate.
Install the retainer plate and secure with the clips.

CLUTCH / DRIVEN PULLEY ASSEMBLY

Clean the pulley faces and remove any grease
from them.
Apply grease to the O-rings and install them onto
the moveable driven face.

Movable Driven Face

Clips

Drive Plate

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-11

DOWNTOWN 200i

Install the movable driven face onto the driven
face.
Apply grease to the guide rollers and guide roller
pins and then install them into the holes of the
driven face.

Install the seal collar.
Remove any excessive grease.

Set the driven pulley assembly, driven face spring
and clutch assembly onto the clutch spring
compressor.

Compress the tool and install the drive plate nut.

Set the tool in a vise and tighten the drive plate
nut to the specified torque.

Torque: 75 N-m

Clutch Spring Compressor E053
Fittings & Nut Wrench, 41mm E033

• Be sure to clean the driven face off any
grease.

＊

• Align the flat surface of the driven face
with the flat on the clutch drive plate.

＊

• Be sure to use a clutch spring compressor
to avoid spring damage.

＊

Special

Guide Pins

Grooves

Clutch/Driven Pulle

y

Clutch Spring Compresso

r

Lock Nut Wrench

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-12

DOWNTOWN 200i

INSTALLATION

Install the movable drive face assembly and drive
pulley collar onto the crankshaft.

Put the drive belt on the driven pulley.
Put the drive belt on the drive pulley collar.
Install the clutch/driven pulley and clutch outer
onto the drive shaft.

Install washer and the clutch outer nut.
Hold the clutch outer with the universal holder to

tighten clutch outer nut.
Torque: 54 N-m

Universal Holder E017

Install the drive pulley face, washer and drive
face nut.
Hold the drive pulley with the universal holder
and tighten the drive face nut.

Torque: 93.1 N-m

Movable Drive Face Assembl

y

• Keep grease off the drive shaft.

＊

Special

• Do not get oil or grease on the drive belt or
drive pulley faces.

＊

Drive Pulley Colla

r

Movable Drive Face Assembly

Clutch Oute

r

Bushing Nu

t

Drive Pulley Face

Universal Holde

r

8. DRIVE AND DRIVEN PULLEYS/
V-BELT

8-13

DOWNTOWN 200i

Install the left crankcase cover.

Left Crankcase Cove

r

9. FINAL REDUCTION

9-0

DOWNTOWN 200i

9

________________________________________________________________________________

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________________________________________________________________________________

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

9

9. FINAL REDUCTION

9-1

DOWNTOWN 200i

SCHEMATIC DRAWING

9. FINAL REDUCTION

9-2

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.

SPECIFICATIONS

Specified Oil: SAE 90#
Oil Capacity:

At disassembly : 0.23 liter

At change : 0.21 liter

TORQUE VALUES

Transmission case bolt 0.8-1.2 kgf-m (9.8 N-m)
Oil check/drain bolt 1.8-2.2 kgf-m (19.7 N-m)

SPECIAL TOOLS

Bearing puller E037

TROUBLESHOOTING
Engine starts but motorcycle won‘t move

• Damaged transmission

• Seized or burnt transmission

Abnormal noise

• Worn, seized or chipped gears

• Worn bearing

Oil leaks

• Oil level too high

• Worn or damaged oil seal

9. FINAL REDUCTION

9-3

DOWNTOWN 200i

FINAL REDUCTION DISASSEMBLY

Remove the exhaust muffler.
Remove the rear brake caliper.
Remove the right rear shock absorber.
Remove the rear fork.
Remove the rear wheel.
Remove the left crankcase cover.
Remove the clutch outer/driven pulleys.
Drain the transmission gear oil into a clean
container.
Remove the transmission case cover attaching
bolts.
Remove the transmission case cover.

Remove the gasket and dowel pins.

Remove the final shaft.
Remove the final gear and countershaft.

FINAL REDUCTION INSPECTION

Inspect the countershaft and gear for wear or
damage.

Countershaf

t

Final Gea

r

Final Shaf

t

Transmission Case Cove

r

Dowel Pin

9. FINAL REDUCTION

9-4

DOWNTOWN 200i

Inspect the final gear and final shaft for wear,
damage or seizure.

Check the left crankcase bearings for excessive
play and inspect the oil seal for wear or
damage.

Inspect the drive shaft and gear for wear or
damage.

Check the transmission case covers bearings for
excessive play and inspect the final shaft
bearing oil seal for wear or damage.

Drive Shaft Bearing

Countershaft Bearing

Do not remove the transmission case cover
except for necessary part replacement.
When replacing the drive shaft, also replace
the bearing and oil seal.

＊

Drive Shaft Bearing

Drive Shaf

t

Drive Shaft Bearing

Drive Shaf

t

9. FINAL REDUCTION

9-5

DOWNTOWN 200i

FINAL REDUCTION ASSEMBLY

Install the drive shaft into the left crankcase.
Put the final gear on the left crankcase.

Install the countershaft and gear into the left
crankcase.

Install the final shaft into the final gear and
transmission case.

Install the dowel pins and a new gasket.

Install the transmission case cover.
Install and tighten the transmission case cover

bolts.
Install the clutch outer/driven pulley.
Install other removed parts in the reverse order
of removal.

Torque:
Transmission case bolt 0.8-1.2 kgf-m (9.8

N-m)

After installation, fill the transmission case with
the specified oil.

Specified Gear Oil: SAE90#
Oil Capacity:

At disassembly : 0.23 liter
At change : 0.21 liter

Install and tighten the oil check bolt.
Torque:
Oil filler/drain bolt 1.8-2.2 kgf-m (19.7 N-m)

Start the engine and check for oil leaks.
Check the oil level from the oil check bolt hole
and add the specified oil to the proper level if
the oil level is low.

Countershaf

t

Final Gea

r

• Place the scooter on its main stand on
level ground.

• Check the oil-sealing washer for wear or
damage.

＊

Oil filler Bol

t

Drain Bolt (under)

Dowel Pin

Transmission Case Cove

r

10. A.C. GENERATOR/STARTER CLUTCH

10-0

DOWNTOWN 200i

10

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

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
FLYWHEEL INSTALLATION------------------------------------------------------------------- 10-8
STATOR INSTALLATION ----------------------------------------------------------------------- 10-9
RIGHT CRANKCASE COVER INSTALLATION-------------------------------------------- 10-9

10

10. A.C. GENERATOR/STARTER CLUTCH

10-1

DOWNTOWN 200i

SCHEMATIC DRAWING