Kymco Downtown 350i Service Manual

KYMCO Repair Manual	Downtown 350i

KYMCO Downtown 350i Service Manual

Using this manual

This manual has been designed to assist trained mechanics in servicing the models listed above. If you do not have the proper training or tools to perform a particular task it is best if you seek out a service professional.

This manual was written using the latest information available at the time of publication. Illustrations in this manual are shown to help you with the basics of performing the jobs listed. The pictures in this manual may not depict the actual vehicle you’re working on, however the procedures will be similar.

Inexperienced technicians without the correct tools and knowledge may not be able to perform these jobs as intended. Caution needs to be taken for the vehicle and its operator as serious injury can occur. Always read a procedure in its entirety before attempting any repairs.

1

KYMCO Repair Manual	Downtown 350i

KYMCO reserves all rights to this publication and does not permit the reproduction or use of this publication, in full or in part, in any manner without our express written permission. No trademark or patent liability is assumed with respect to the use of the information contained in this manual.

While the instructions, photographs and illustrations in this manual have been reviewed for accuracy it is up to the individual performing the procedures to use good judgement when performing any procedures described. Every precaution has been taken in the manufacture of this manual however the publisher assumes no responsibility for errors and omissions. Furthermore, no liability or responsibility is assumed for damages to property or injury to persons resulting from the use of the information contained in this guide. Use of this information to perform service procedures is done entirely at your own risk.

2

KYMCO Repair Manual	Downtown 350i

1. Quick Reference

This chapter provides a quick reference source of technical specifications and information for KYMCO Downtown 350i models.

Component Location .....................................................................	1-2
Special Tools ..................................................................................	1-6
Specifications .................................................................................	1-7
Torque Specifications ....................................................................	1-19
Troubleshooting .............................................................................	1-22
VIN and Engine Number Location ................................................	1-27

2.Periodic Maintenance

This chapter covers the periodic maintenance for the KYMCO Downtown 350i.

Maintenance Schedule .......................................................	2-2
Air Filter Servicing ..............................................................	2-4
Brake Fluid ...........................................................................	2-6
Brake Inspection .................................................................	2-13
Engine Compression Test ..................................................	2-15
Coolant Level Check ...........................................................	2-17
Engine Oil .............................................................................	2-21
General Lubrication ............................................................	2-36
Hose Inspection ..................................................................	2-37
Side Stand ............................................................................	2-38
Spark Plug ............................................................................	2-40
Steering ................................................................................	2-43
Suspension ..........................................................................	2-44
Throttle Free Play ................................................................	2-46
Tires ......................................................................................	2-52
Final Drive Oil ......................................................................	2-54
Valve Clearance ...................................................................	2-60

3

KYMCO Repair Manual	Downtown 350i

3.External Components

This chapter covers the location and servicing of the external components for the KYMCO Downtown 350i model.

REAR PART

Seat .................................................................................................	3-3
Luggage Box ..................................................................................	3-7
Rear Carrier ....................................................................................	3-9
Rear Center Cover ..........................................................................	3-10
Body Cover .....................................................................................	3-11
Rear Inner Fender ..........................................................................	3-16
Rear Tire Fender ............................................................................	3-17
Heat Shield .....................................................................................	3-18
Exhaust System .............................................................................	3-20

4.Engine

This chapter covers the location and servicing of the engine components for the KYMCO Downtown 350i model.

Cylinder Head Cover ......................................................................	4-5
Camshaft .........................................................................................	4-8
Cylinder Head .................................................................................	4-23
Valves ..............................................................................................	4-31
Cylinder and Piston .......................................................................	4-37
Starter Clutch .................................................................................	4-62
Generator ........................................................................................	4-69
Oil Pump .........................................................................................	4-73
Crankcase .......................................................................................	4-77
Crankshaft ......................................................................................	4-87
Engine Removal .............................................................................	4-90

4

KYMCO Repair Manual	Downtown 350i

5.Cooling System

This chapter covers the location and servicing of the cooling system components for the KYMCO Downtown 350i model.

Coolant ............................................................................................	5-3
Radiator ..........................................................................................	5-12
Water Temperature Sensor (WTS) ................................................	5-22
Water Pump ....................................................................................	5-28

6.Fuel Injection System

This chapter covers the location and servicing of the fuel system components for the KYMCO Downtown 350i model.

Airbox ..............................................................................................	6-4
Fuel Tank ........................................................................................	6-8
Fuel Pump .......................................................................................	6-13
Throttle Body Removal ..................................................................	6-21
Throttle Cable .................................................................................	6-32
Throttle Body ..................................................................................	6-35
Fuel Injector ....................................................................................	6-41
TPS ISC Reset Procedure ..............................................................	6-46
Self-Diagnosis ................................................................................	6-47
F.I. Diagnostic Tool ........................................................................	6-54

7.CVT Continuously Variable Transmission

This chapter covers the location and servicing of the CVT components for the KYMCO Downtown 350i model.

Belt Case .........................................................................................	7-2
CVT Removal ..................................................................................	7-7
CVT Installation ..............................................................................	7-26

5

KYMCO Repair Manual	Downtown 350i

8.Final Drive

This chapter covers the location and servicing of the final drive components for the KYMCO Downtown 350i model.

Final Drive Oil .................................................................................	8-3
Final Reduction ..............................................................................	8-8

9.Electrical Systems

This chapter covers the location and servicing of the electrical systems for the KYMCO Downtown 350i model.

Electrical Specifications ................................................................	9-8
Fuses ...............................................................................................	9-10
ECU Removal .................................................................................	9-11
Ignition System ..............................................................................	9-15
Charging System ...........................................................................	9-22
Battery .............................................................................................	9-24
Relays .............................................................................................	9-28
Starting System ..............................................................................	9-30
Starter Motor ..................................................................................	9-34
Switches .........................................................................................	9-36
Lights ..............................................................................................	9-48
Horn .................................................................................................	9-56

6

KYMCO Repair Manual	Downtown 350i

10.Brakes

This chapter covers the location and servicing of the brake system components for the KYMCO Downtown 350i model.

Brake Pad Replacement ................................................................	10-2
Master Cylinders ............................................................................	10-13
Master Cylinders ............................................................................	10-22
Front Brake Caliper ........................................................................	10-26
Rear Brake Caliper .........................................................................	10-31
Brake Disc ......................................................................................	10-37
ABS ...................................................................................................	10-42

11.Steering

This chapter covers the location and servicing of the steering components for the KYMCO Downtown 350i model.

Handlebar .......................................................................................	11-2
Grips ................................................................................................	11-8
Steering stem .................................................................................	11-8

12.Front Suspension

This chapter covers the location and servicing of the front fork components for the KYMCO Downtown 350i model.

Front Fork Removal .......................................................................	12-2
Front Fork Installation ...................................................................	12-6
Fork Disassembly ..........................................................................	12-8
Fork Assembly ...............................................................................	12-17

7

KYMCO Repair Manual	Downtown 350i

13.Rear Suspension

This chapter provides information on the rear suspension components of the KYMCO Downtown 350i model.

Shock Absorbers ...........................................................................	13-2
Rear Fork ..........................................................................................	13-8

14.Wheels

This chapter covers the location and servicing of the wheels for the KYMCO Downtown 350i model.

Bearing Replacement ....................................................................	14-2
Front Wheel ....................................................................................	14-6
Rear Wheel .....................................................................................	14-11
Wheel Inspection ............................................................................	14-19
Wheel Specifications .....................................................................	14-21

8

1.Quick Reference	Downtown 350i

1. Quick Reference

This chapter provides a quick reference source of technical specifications and information for KYMCO Downtown 350i models.

Component Location .....................................................................	1-2
Special Tools ..................................................................................	1-5
Specifications .................................................................................	1-6
Torque Specifications ....................................................................	1-19
Troubleshooting .............................................................................	1-22
VIN and Engine Number Location ................................................	1-27

1-1

1.Quick Reference	Downtown 350i

Component Location

			Meter Instrument
	Tilt Switch
			Couplers
			Relays
Radiator Cap
			Oil Pressure
			Controller
			Winker Relay
			(Turn Signal)
			Horn
			Coolant Reserve
			Tank

1-2

1.Quick Reference	Downtown 350i

Component Location

Ignition Switch

Regulator/Rectifier

Ignition Coil

Coolant Reserve

Tank

Radiator

Oxygen Sensor

Starter Relay

Stator and CPS

EFI ECU

1-3

1.Quick Reference Downtown 350i

Component Location

			MAP Sensor			ISC
		Fuel Injector
								Throttle Body
Fuel Pump

TPS

WTS

Spark Plug

ABS ECU

Wheel Speed

Sensor

Air Temperature

Sensor

1-4

1.Quick Reference	Downtown 350i

Special Tools

SPECIAL TOOLS

	ITEM	TOOL NO.	DESCRIPTION
	FLYWHEEL PULLER	A120E00003	Flywheel Puller (M28x1)
	TAPPET ADJUSTER	A120E00012	Adjusting valve clearance
	OIL SEAL & BEARING DRIVER	A120E00014	General Driver Set
	UNIVERSAL HOLDER	A120E00021	Holding clutch pulley and flywheel
	#41 NUT AND FITTING TOOL	A120E00028	Clutch disassembly
	THREAD PROTECTOR	A120E00029	Crankshaft thread protector
	BEARING PULLER	A120E00037	General Puller Set
	VALVE COTTER INSTALLER	A120E00051	Valve cotter installation
	CLUTCH SPRING COMPRESSOR	A120E00053	Clutch disassembly
	STEERING STEM LOCK NUT	F002	Steering stem removal & installation
	WRENCH (32 mm)

1-5

1.Quick Reference	Downtown 350i

KYMCO Downtown 350i Specifications

General Information

	Name (Model Code)		Downtown 350i (ACD5)
	Overall length (mm)		2250
	Overall width (mm)		780
	Overall height (mm)		1310
	Wheel base (mm)		1553
	Engine type		4 stroke OHC
	Displacement (cc)		321
	Fuel recommended		90 # nonleaded gasoline
		Front wheel	78
	Curb weight (kg)	Rear wheel	111
		Total	189
		Front wheel	130
	Max. weight capacity (kg)	Rear wheel	234
		Total	364
		Front wheel	120/80-14
	Tires
		Rear wheel	150/70-13
	Ground clearance (mm)		140
		Braking distance (m)	7.9m / 40 km/hr
	Performance
		Min. turning radius (m)	2.5

1-6

1.Quick Reference					Downtown 350i
	Starting system				Starting motor
	Type				Gasoline, 4-stroke
	Cylinder arrangement				SINGLE CYLINDER
	Combustion chamber type				Semi-sphere
	Valve arrangement				O.H.C. Chain drive
	Bore x stroke (mm)				75.3 x 72
	Compression ratio				10.7
	Compression pressure				12 (kg/cm2)
	Max. Horsepower				30.05/7500 PS/rpm
	Max. Torque				3.2 / 5750 Kg-m/rpm
				Open	9.5° BTDC
Engine		Intake
				Close	37.5° ABDC
	Valve timing
				Open	40° BBDC
		Exhaust
				Close	10° ATDC
			Intake		0.10
	Valve clearance (cold) (mm)
			Exhaust		0.10
	Idle speed (rpm)				1600 ± 100
		Lubrication type			Forced pressure & Wet pump
		Oil pump type			Inner/outer rotor type
	Lubrication System
		Oil filter type			Full-flow filtration
		Oil capacity			1.5 liter
	Cooling Type				Liquid cooling

1-7

1.Quick Reference				Downtown 350i
	Air cleaner type & No			Paper element, wet
	Fuel capacity			12.5 liter
		Brand		Keihin
Fuel System
		Type		Throttle body
	Injection
		Venturi dia.(mm)		34
		Fuel pump pressure		3 Bar
		Type		ECU
	Ignition System		Spec.	CR7E (NGK)
Electrical Equipment		Spark plug
			Gap	0.6-0.7 mm
	Battery Capacity			12V10AH
	Clutch Type			Dry multi-clutch
		Type		CVT
	Transmission Gear
		Operation		Automatic centrifugal type
Power Drive System
		Type		Two-stage reduction
	Reduction Gear		1st	2.24 ~ 0.72
		Reduction ratio
			2nd	7.222
	Tire type			Tubeless
	Wheel material			Aluminum
Moving Device	Tire pressure		Front	2.0 (28.4)
	Kg/cm2 (psi)
			Rear	2.25 (32)
			Left	40°
	Handle turning angle(L/R)
				40°
			Right
			Front	Disc brake
Brake system type
			Rear	Disc brake
			Front	Telescope
	Suspension type
			Rear	Swing arm
Damping Device
			Front	110 mm
	Shock absorber stroke
			Rear	100 mm
Frame type				UNDER BONE

1-8

1.Quick Reference			Downtown 350i
	ENGINE
Throttle grip free play		2 ~ 6 mm
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
Cylinder compression	12 ± 2 kg/cm2
Ignition timing		ECU
Coolant type		Coolant type
Engine oil capacity:
At disassembly		1.5 Liter
At change		1.3 Liter
Gear oil type:		SAE 90
Gear oil capacity:
At disassembly		0.23 Liter
At change		0.21 Liter

Coolant capacity:

Radiator and hose with cool coolant	870 cc
Reserve tank	490 cc

1-9

1.Quick Reference		Downtown 350i
Engine
Item		Standard (mm)
	IN	0.10
Valve clearance (cold)
	EX	0.10
	IN	34.2987
Camshaft cam height
	EX	34.1721
	IN	10.00 - 10.015
Valve rocker arm I.D.
	EX	10.00 - 10.015
	IN	9.972 - 9.987
Valve rocker arm shaft O.D.
	EX	9.972 - 9.987
	IN	1.2
Valve seat width
	EX	1.2
	IN	4.990 - 4.975
Valve stem O.D.
	EX	4.970 - 4.955
	IN	5.00 - 5.012
Valve guide I.D.
	EX	5.00 - 5.012
	IN	0.010 - 0.037
Valve stem-to-guide clearance
	EX	0.030 - 0.057

1-10

1.Quick Reference

Downtown 350i

Item

Standard (mm)

I.D.

75.3

Cylinder

Taper limit

0.05

Out of round limit

0.05

Top

0.015

- 0.055

Ring-to-groove clearance

Second

0.015

- 0.055

Top

0.10

- 0.25

Ring end gap

Second

0.10

- 0.25

Piston,

Oil side rail

0.2

- 0.7

piston ring

Piston O.D.

Piston O.D. measuring point

9 mm from bottom of skirt

Piston-to-cylinder clearance

0.101

- 0.040

Piston pin hole I.D.

15.002

- 15.008

Piston pin O.D.

14.994

- 15.000

Piston-to-piston pin clearance

0.002

- 0.014

Connecting rod small end I.D. Bore

15.016

- 15.034

Item

Standard (mm)

Service Limit (mm)

Connecting rod big

0.15 - 0.35

0.6

end side clearance

Crankshaft

0 - 0.008

0.05

Connecting rod big

end radial clearance

Bearing Color

Crankcase mark

Crankshaft mark

A

B

C

D

A

black

green

green

red

B

green

green

red

---

Item

Service Limit (mm)

Starter drive gear I.D.

22.15

Starter drive gear O.D.

41.50

1-11

1.Quick Reference		Downtown 350i
CVT
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 (Drive Pulley)	19.92 - 20.08	20.08

Cooling System

Radiator cap relief pressure					0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
		Begins to open				71 °C
Thermostat temperature			Full-open			80 °C
			Valve lift			3.5 - 4.5 mm
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS)
Freezing	Mixing		KYMCO SIGMA Coolant					Distilled
Point	Rate			Concentrate				Water
-9°C	20%				344 cc			1375 cc
-15°C	30%				516 cc			1203 cc
-25'°C	40%				688 cc			1031 cc
-37°C	50%				860 cc			859 cc
-44.5°C	55%				945 cc			774 cc

1-12

1.Quick Reference									Downtown 350i
COOLANT GRAVITY CHART
Temp. C°			0			5	10	15			20		25
Coolant concentration
5%			1.009			1.009	1.008	1.008			1.007		1.006
10%			1.018			1.107	1.017	1.016			1.015		1.014
15%			1.028			1.027	1.026	1.025			1.024		1.022
20%			1.036			1.035	1.034	1.033			1.031		1.029
25%			1.045			1.044	1.043	1.042			1.040		1.038
30%			1.053			1.051	1.051	1.049			1.047		1.045
35%			1.063			1.062	1.060	1.058			1.056		1.054
40%			1.072			1.070	1.068	1.066			1.064		1.062
45%			1.080			1.078	1.076	1.074			1.072		1.069
50%			1.086			1.084	1.082	1.080			1.077		1.074
55%			1.095			1.093	1.091	1.088			1.085		1.082
60%			1.100			1.098	1.095	1.092			1.089		1.086
Temp. C°
Coolant		30			35		40			45			50
concentration
5%		1.005			1.003		1.001		0.009				0.997
10%		0.013			1.011		1.009		1.007				1.005
15%		1.020			1.018		1.016		1.014				1.012
20%		1.027			1.025		1.023		1.021				1.019
25%		1.036			1.034		1.031		1.028				1.025
30%		1.043			1.041		1.038		1.035				1.032
35%		1.052			1.049		1.046		1.043				1.040
40%		1.059			1.056		1.053		1.050				1.047
45%		1.056			1.063		1.062		1.057				1.054
50%		1.071			1.068		1.065		1.062				1.059
55%		1.079			1.076		1.073		1.070				1.067
60%		1.083			1.080		1.077		1.074				1.071

1-13

1.Quick Reference		Downtown 350i
Fuel Injection System
ITEM		SPECIFICATIONS
Throttle body identification number		ACD5
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)		9.9 - 13.5 Ω
	Float at full	1100 ± 33 Ω
	position
Fuel pump resistance
(at 20°C/68°F)
	Float at empty	100 ± 3 Ω
	position
Fuel pump standard pressure (at 40		3 Bar
		294 ± 6 kPa
L/Hr)
		42 ± 0.9 psi
	At -20°C/-4°F	18.8 KΩ
Water temperature
	At 40°C/104°F	1.136 KΩ
sensor resistance
	At 100°C/212°F	0.1553 KΩ
Intake pressure sensor (MAP) pressure		13.332 kPa (0.13332 kgf/ cm2, 1.89 psi) - 119.99
(at 1 - 4.2 V)		KPa (1.1999 kgf/ cm2, 17.04 psi)
Inductive ignition coil		Primary: 3.57 - 4.83 Ω Secondary: 10.42~14.49
		KΩ
Throttle position sensor (TPS) resistance		3500 - 6500 Ω
(at 20°C/68°F)
Crank position sensor voltage (at 200		100 - 130 Ω
rpm)
O2 heater sensor resistance (at		6.7 - 9.5 Ω (engine warming condition)
20°C/68°F)
	Standard	0.4 - 1.4 V
Tilt switch voltage
	Over 65° (fall	3.7 - 4.4 V
	down)

1-14

1.Quick Reference			Downtown 350i
		CELP FAILURE CODES LIST
Blinks	Failure	Contents	Causes	Symptoms
	Codes
			• Faulty TPS voltage range (0.3 - 4.5 V)
06	P0120	Faulty TPS	• Loose or poor connection on TPS Sensor	Engine operates
			• Open or short circuit on the TPS wire	normally
			• Faulty TPS itself.
			• Faulty MAP voltage range (1 - 4.2 V)
09	P0105	Faulty MAP	• Loose or poor connection on MAP Sensor	Engine operates
			• Open or short circuit on MAP wire	normally
			• Faulty MAP itself
			• Faulty ECT Ω range (-20°C: 18.8 Ω/40°C:
		Faulty WTS	1.136 Ω/100°C: 0.1553 Ω)	Engine operates
12	P0115		• Loose or poor connection on ECT
		(water temp.)		normally
			• Open or short circuit on ECT wire
			• Faulty ECT
			• Faulty Tilt switch voltage range (inclined angle
			<65°: 0.4 - 1.4 V/ Inclined angle >65°: 3.7 - 4.4
15	P1630	Faulty Tilt	V)	Engine operates
		switch (Roll)	• Loose or poor connection on Tilt switch	normally
			• Open or short circuit in Tilt switch wire
			• Faulty tilt switch
			• Faulty O2 sensor voltage range (A/F below 14.7:
		Faulty	> 0.7V/ A/F over 14.7: < 0.18 V)	Engine operates
17	P0130		• Loose or poor connection on O2 sensor
		O2 sensor		normally
			• Open or short circuit on O2 sensor wire
			• Faulty O2 sensor
		Faulty	• Faulty Fuel injector Ω range (9.945 - 13.5 Ω)
			• Loose or poor connection on injector	Engine fails to be
33	P0201	injector
			• Open or short circuit on injector wire	operated
		(Nozzle)
			• Faulty fuel injector

1-15

1.Quick Reference							Downtown 350i
					• Faulty Inductive ignition coil Ω range (4.2 Ω ±
					15%)
		Faulty inductive			• Loose or poor connection on inductive ignition			Engine fails to be
37	P0351				coil
		ignition coil						operated
					• Open or short circuit on inductive ignition coil
					wire
					• Faulty inductive ignition coil
					• Faulty Fuel pump fl range (F: 1100 ± 33 Ω E:
					100 + 3 Ω)			Engine fails to be
41	P0230	Faulty fuel pump			• Loose or poor connection on fuel pump
								operated
					• Open or short circuit on fuel pump wire
					• Faulty fuel pump
43	-	Radiator fan relay			Open radiator fan relay			Engine operates
					Detached coupler			normally
					• Faulty O2 sensor heater Ω range (6.7 -9.5 Ω)			Engine starts
		Faulty			• Loose or poor connection on O2 sensor heater
45	P0135							normally but not
		O	2	sensor heater	• Open or short circuit on O	2	sensor heater wire
								smooth
					• Faulty O2 sensor heater
					• Loose or poor contacts on ISC			Engine operates
49	P1505	Faulty ISC			• Open or short circuit in ISC wire
								normally
					• Faulty ISC
					• Loose or poor connection on CPS sensor			Engine starts
66	P0335	Faulty CPS			• Open or short circuit on CPS wire			normally but not
					• Faulty CPS sensor			smooth

1-16

1.Quick Reference				Downtown 350i
Axle/Brakes/Wheels
Item	Standard mm (in)			Service Limit
Axle shaft runout	—			0.2 mm
				(0.008 in)
Brake disk thickness (front)	3.8 - 4.2			0.3 mm
	(0.15 - 0.165)			(0.012 in)
Brake disk thickness (rear)	5.0			—
	(0.2)
Brake disk runout	—			0.4 mm
Brake master cylinder I.D.	12.7 - 12.74			—
	(0.508 - 0.5096)
Brake master cylinder piston O.D.	12.65 - 12.68			—
	(0.506 - 0.5072)
Front brake caliper piston O.D.	26.93 - 26.96			—
	(1.0602 - 1.0614)
Front brake caliper cylinder I.D.	27 - 27.05			—
	(1.063 - 1.065)
Item		Standard (mm)
Wheel rim runout service limit				max 5
Rear brake disk thickness			5.0
Rear brake disk runout				max 0.4
Rear brake caliper piston O.D.			25.33 - 25.36
Rear brake caliper cylinder I.D.			25.40 - 25.45

1-17

1.Quick Reference

Downtown 350i

Electrical

Item

Standard

Capacity

12V 10AH

Fully charged

13.2V

Battery

Voltage (20°C)

Insufficient charged

< 12.3V

Charging current

1.2A* 5 - 10H

Item

Standard

Spark plug

Standard type

NGKCR7E

Spark plug gap

0.6 - 0.7 mm

Primary coil

3.57 - 4.83 Ω

Inductive Ignition Coil

Secondary coil without plug cap

10.42 - 14.49 KΩ

Throttle Position Sensor

3500 - 6500 Ω

Fuel Pump

1.9 Ω approx.

Fuel Injector

11.7 ± 0.6 Ω

Water Temperature Sensor

2.076 KΩ ± 10% (25°C)

Oxygen Sensor ( engine warming condition )

6.7 Ω - 9.5 Ω

Crank Position Sensor

115 Ω ± 15 Ω

Tilt Switch

0.4V - 1.4V(normal)

3.7V - 4.4V (fall down)

At -20°C/-4°F

18.8 KΩ

Water temperature

At 40°C/104°F

1.136 KΩ

sensor resistance

At 100°C/212°F

0.1553 KΩ

Item

Standard

Service Limit

Starter motor brush length

12.5 mm

8.5 mm

1-18

1.Quick Reference Downtown 350i

Torque Specifications

ENGINE

			Thread	Torque
	Item	Qty	size (mm)			Remarks
				kgf-m	lb-ft
	Cylinder head stud bolt:
	1. Stud bolt (Inlet pipe side)	2	6	0.7-1.1	5.06-7.96	Double end bolt
	2. Stud bolt (EX pipe side)	2	8	0.7-1.1	5.06-7.96	Double end bolt
	Cylinder head stud nut	4	10	3.4-3.8	24.59-27.48
	Right crankcase cover bolt	15	6	1.0-1.4	7.23-10.13
	Left crankcase cover bolt	15	6	1.0-1.4	7.23-10.13
	Transmission case bolts	9	8	0.8-1.2	1.7-2.6
	Bolt B stud 10*180	4	10	1.0-1.4	7.23-10.13	Apply oil to thread
	Valve adjusting lock nut	4	5	0.7-1.1	5.06-7.96	Apply oil to thread
	Cam sprocket bolt	2	6	1.0-1.4	7.23-10.13	Apply thread lock
	Camshaft set plate bolt	1		1.2	2.0	Apply thread lock
	Final drive oil check\drain bolt	2	8	0.8-1.2	5.79-8.68
	Engine oil drain bolt	1	12	2.0-3.0	14.47-21.70
	Engine oil strainer cap	1		1.02	7.2
	Clutch outer nut (driven pulley)	1	12	5.0-6.0	36.17-43.40
	Starter motor mounting bolt	2	6	1.0-1.4	7.23-10.13
	Mission case bolt	6	8	1.8-2.2	13.02-15.91
	Drive face nut	1	14	9.0-10.0	65.10-72.33	Apply oil to thread
	Clutch drive plate nut	1		7.5	55.32
	Drive plate comp	1	28	5.0-6.0	36.17-43.40
	Cam chain tensioner bolt	2	6	1.0-1.4	7.23-10.13
	Cam chain tensioner pivot	1	8	0.8-1.2	5.79 - 8.68
	Oneway clutch bolt	3	8	1.8-2.2	13.02-15.91	Apply thread lock
	ACG flywheel nut	1	14	5.5-6.5	39.78-47.01
	Spark plug	1	12	1.5-2.0	10.84-14.47
	Water pump impeller	1	7	1.0-1.4	7.23-10.13	Left thread
	Water pump cover bolts	4	6	1.0-1.4	7.23-10.13

1-19

1.Quick Reference	Downtown 350i

FRAME

1-20

1.Quick Reference			Downtown 350i
General Torque Specifications
Item		Torque
	kgf-m		lb-ft
5 mm bolt, nut	0.45 - 0.6		3.25	- 4.34
6 mm bolt, nut	0.8 - 1.2		5.79	- 8.68
8 mm bolt, nut	1.8 - 2.5		13.02	- 18.08
10 mm bolt, nut	3.0 - 4.0		21.70	- 28.93
12 mm bolt, nut	5.0 - 6.0		36.17	- 43.40
5 mm screw	0.45 - 0.6		3.25	- 4.34
6 mm screw, SH bolt	0.7 - 1.1		5.06	- 7.96
6 mm flange bolt, nut	1.0 - 1.4		7.23 - 10.13
8 mm flange bolt, nut	2.4 - 3.0		17.36	- 21.70
10 mm flange bolt, nut	3.0 - 4.5		21.70	- 32.55

1-21

1.Quick Reference	Downtown 350i

Troubleshooting

Vehicle can not be started

Preliminary 6 Step Inspection

1.Is the battery fully charged (12 V or higher). See the Battery topic for more information.

2.Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds)

3.Key-On to check for any failure lamp light up on dashboard. See

theSelf-Diagnosis topic for more information.

4.Is the Idle screw of Throttle Valve being changed or loose?

5.Has the vehicle under regular service? Is the gas station a good one?

6.Is the spark plug the correct model of specified by the vehicle builder? See the Spark Plug topic for more information.

1-22