KYMCO MYROAD 700i Service Manual

MYROAD 700i

unauthorized use without the written permission of

By KWANG YANG Motor Co., Ltd.

First Edition, FEB. 2011

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

4122-KKE5-S00

ELECTRICAL

Q

MYROAD 700i

This Service Manual describes the technical features and servicing procedures for the KYMCO XCITING

700. 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 higher 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 8 through 14 give instructions for disassembly, assembly and adjustment of engine parts. Section 15 through 17 is the removal/ installation of chassis. Section 18 through 21 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.

PREFACE

The information and contents included in this manual may be different from the motorcycle in case specifications are changed.

KYMCO reserves the right to make changes at any time without notice and without incurring any obligation.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1 FRAME COVERS /EXHAUST MUFFLER 2 INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4 CABLE & HARNESS ROUTING

AFI (AUTOMATIC FUEL INJECTION) 6 COOLING SYSTEM 7

ENGINE

ENGINE REMOVAL/INSTALLATION 8 CYLINDER HEAD/VALVES 9 CYLINDER/PISTON 10 DRIVE AND DRIVEN PULLEY 11 FINAL REDUCTION 12 A.C. GENEARTOR/STARTER CLUTCH 13 CRANKCASE/CRANKSHAFT 14 STEERING HANDLEBAR/FRONT

CHASSIS

WHEEL/FRONT SHOCK ABSORBER

REAR FORK/REAR WHEEL/REAR

SHOCK ABSORBER`

BRAKE SYSTEM 17 BATTERY/CHARGING SYSTEM 18

E UIPMENT

IGNITION SYSTEM 19 ELECTRIC STARTER 20 LIGHTS/METERS/SWITCHES 21 ANTI-LOCK BRAKE SYSTEM(ABS) 22

5

15

16

1. GENERAL INFORMATION

MYROAD 700i

1

__________________________________________________________________________________

1

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

SERIAL NUMBER-----------------------------------------------------------1 - 1 SPECIFICATIONS ---------------------------------------------------------1 - 2 SERVICE PRECAUTIONS-------------------------------------------------1 - 3 TORQUE VALUES ----------------------------------------------------------1 - 7 SPECIAL TOOLS ------------------------------------------------------------1 - 9 LUBRICATION POINTS ---------------------------------------------------1-10 TROUBLESHOOTING------------------------------------------------------1-12

1-0

1. GENERAL INFORMATION

r

SERIAL NUMBER

VEHICLE IDENTIFICATION NUMBER(VIN):

FRAME NUMBER(VIN):

Location of Engine Serial Numbe

MYROAD 700i

1-1

1. GENERAL INFORMATION

m

y

g

y

MYROAD 700i

SPECIFICATIONS

ITEM SPECIFICATIONS

Name MYROAD 700i Overall length 2330 mm Overall width 830 mm Overall height 1510 mm Wheel base 1615 mm Engine type D.O.H.C.

Displacement Fuel Used 92# nonleaded gasoline Front wheel 108 kg Dry weight Rear wheel 160 kg Total 268 kg Front wheel 116 kg Curb weight Rear wheel 168 kg Total 284 kg Front wheel 120/70-R15

Tires

Rear wheel 160/60-R14 Ground clearance 135 mm

Min. turning radius 2700 mm

Starting system Type Gasoline, 4-stroke Cylinder arrangement Twin cylinder Combustion chamber type ROOF Valve arrangement O.H.C.

Bore x stroke Compression ratio 10.5:1

Compression pressure

Engine

Intake valve

Exhaust valve Valve clearance

(cold)

Idle speed Rpm

Oil pump type Trochoid Oil filter type Full-flow filtration

Final reduction oil

Cooling Type Liquid cooled

Lubrication type

Lubrication

S stem

Oil capacity

capacity

Open 7° BTDC Close 40° ABDC Open 40° BBDC

Close 10° ATDC Intake 0.16 mm Exhaust 0.22 mm

699.5 cc

Electric starter motor

76.9X75.3 mm

13 kgf/cm²

Forced pressure & Wet sump

3 L

0.4 L

ITEM SPECIFICATIONS

Fuel S

Air cleaner type & No Wet paper type element Fuel capacity

stem

Throttle Body Venturi dia

Electrical Equipment

I

Spark plug DR8E

Spark plug gap 0.6~0.7 mm Battery Capacity 12V12AH

Power Drive System

Preliminary Final

Moving Device

Turning Left 40°

Brake syste type

Damping

Device

Frame type Double cradle

Type

nition S

Ignition timing ECU

stem

Clutch Type

Transmis-

sion Gear

Type Operation

Reduction

Ratio

Type CVT

FR/RR tire rolling circumference

Tire pressure (rider only/60 kg)

angle

Suspension type

Front

Rear

Right 40° Rear Disk brake

Front Disk brake Front

Rear

14 L

φ 38 mm Full transistor ignition

Dry, centrifugal automatic

Helical gear/spur gear

Automatic centrifugal Type

0.99

5.58

mm

2 kg/cm²

2.25 kg/cm²

Telescopic fork

Unit swing

1-2

1. GENERAL INFORMATION

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure to

use special tools for removal and installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil before reassembly.

MYROAD 700i

 Apply or add designated greases and

lubricants to the specified lubrication points.

 After reassembly, check all parts for proper

tightening and operation.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-) terminal

before operation.

 When using a spanner or other tools, make

sure not to damage the motorcycle surface.

 After operation, check all connecting

points, fasteners, and lines for proper connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

1-3

1. GENERAL INFORMATION

MYROAD 700i

 If the fuse is burned out, find the cause and

repair it. Replace it with a new one according to the specified capacity.

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock on

the connector shall be released before operation.

 Hold the connector body when connecting

or disconnecting it.

 Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

Confirm Capacity

 The connector shall be inserted

completely.

 If the double connector has a lock, lock

it at the correct position.

 Check if there is any loose wire.

 Before connecting a terminal, check for

damaged terminal cover or loose negative terminal.

 Check the double connector cover for

proper coverage and installation.

 Insert the terminal completely.  Check the terminal cover for proper

coverage.

 Do not make the terminal cover opening

face up.

 Secure wire harnesses to the frame with

their respective wire bands at the designated locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

1-4

1. GENERAL INFORMATION

MYROAD 700i

 After clamping, check each wire to make

sure it is secure.

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness to

make sure that it is not interfering with any moving or sliding parts.

 When fixing the wire harnesses, do not

make it contact the parts which will generate high heat.

 Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid the projected ends of bolts and screws.

 Route harnesses so they are neither

pulled tight nor have excessive slack.

Do not pull too tight！

 Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or corner.

 When rubber protecting cover is used to

protect the wire harnesses, it shall be installed securely.

 Do not break the sheath of wire.  If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or replace it.

 When installing other parts, do not press or

squeeze the wires.

Do not press or squeeze the

1-5

1. GENERAL INFORMATION

MYROAD 700i

 After routing, check that the wire harnesses

are not twisted or kinked.

 Wire harnesses routed along with

handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.

 When a testing device is used, make sure to

understand the operating methods thoroughly and operate according to the operating instructions.

Do you understand the instrument？

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent before connecting.

Remove Rust！

 Symbols: The following symbols represent the

servicing methods and cautions included in this service manual.

Engine Oil

: Apply engine oil to the

specified points. (Use designated engine oil for lubrication.)

: Apply grease for lubrication.

Grease

: Transmission Gear Oil (90#)

Gear Oil

＊

: Note

1-6

1. GENERAL INFORMATION

TORQUE VALUES

STANDARD TORQUE VALUES

5mm bolt and nut 6mm bolt and nut

8mm bolt and nut 10mm bolt and nut 12mm bolt and nut

Torque specifications listed below are for important fasteners. ENGINE

Item

Torque

Kg-m

0.5

1.0

2.2

3.5

5.5

5mm screw 6mm screw, SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange bolt and nut

Item

MYROAD 700i

Torque

Kgf-m

0.4

0.9

1.2

2.7

4.0

1-7

1. GENERAL INFORMATION

FRAME

MYROAD 700i

1-8

1. GENERAL INFORMATION

SPECIAL TOOLS

Tool Name Tool No. Remarks

Lock nut socket wrench A120F00007 Steering stem removal or install Oil seal & bearing installers A120E00014 Oil seal & bearing install Universal holder A120E00017 Holding clutch for removal

MYROAD 700i

Flywheel holder A120E00021 A.C. generator flywheel holding Bearing pullers A120E00030 Bearing removal Tappet adjuster A120E00036 Tappet adjustment Bearing pullers A120E00037 Bearing removal Valve spring compressor A120E00040 Valve removal Oil filter cartridge wrench A120E00052 Cartridge removal or install

Clutch spring compressor A120E00053 Clutch disassembly Flywheel puller A120E00061 A.C. generator flywheel removal Clutch fixed bolt A120E00038 Clutch Balancer gear nut wrench A120F00080 Balancer gear Connecting rod bolts wrench A120F00081 Connecting rod

1-9

1. GENERAL INFORMATION

LUBRICATION POINTS

ENGINE

MYROAD 700i

Valve guide/valve stem movable part Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft Balancer shaft Crankshaft one-way clutch movable part Oil pump drive chain Starter reduction gear engaging part O-ring face Oil seal lip

Lubrication Points Lubricant

•Genuine KYMCO Engine Oil (SAE 5W-50)

•API SJ Engine Oil

Drive gear shaft Countershaft Final gear Final gear shaft

Transmission gearshaft bearing part A.C. generator connector Adhesive

Transmission oil: SAE 90

1-10

1. GENERAL INFORMATION

FRAME

The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

Seat Lock

Rear Wheel Bearing

Grease

Throttle Cable

Center Stand/Side Stand Pivot

Engine Oil

Grease

Front/Rear Brake Lever Pivot

Front Wheel Bearing

MYROAD 700i

Grease

1-11

1. GENERAL INFORMATION

g p

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment

Check if fuel reaches carburetor by loosening drain screw

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Test cylinder compression

Start engine by follow-ing normal startin

Remove spark plug and inspect again

Fuel reaches carburetor/fuel injector

rocedure

Spark jumps

Normal

compression

Engine does not

fire

Dry spark plug

Symptom

Fuel does not reach carburetor/fuel injector

Weak or no spark

Low or no

compression

Engine fires but

does not start

Wet spark plug

MYROAD 700i

Probable Cause

cEmpty fuel tank dClogged carburetor fuel inlet

tube, vacuum tube or fuel tube

eClogged auto fuel valve fClogged float oil passage gClogged fuel tank cap

breather hole

hClogged fuel strainer iClogged fuel filter jFaulty fuel pump

cFaulty spark plug dFouled spark plug eFaulty ignition unit fFaulty A.C. generator gBroken or shorted ignition coil hBroken or shorted exciter coil iFaulty ignition switch

cStarter motor idles but

crankshaft does not rotate

dValve clearance too small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing

cFaulty auto bystarter dAir leaking through intake

pipe

eIncorrect ignition timing fIncorrectly adjusted pilot screw

cFlooded carburetor dFaulty auto bystarter eThrottle valve excessively

open

1-12

1. GENERAL INFORMATION

g

y

g

t

N

b

t

r

t

r

prop

y

ENGINE LACKS POWER

Inspection/Adjustment

Start engine and accelerate lightly for

Check ignition timing (using a timing light)

Check valve clearance

Test cylinder compression

Check carburetor for clogging

Remove spark plug and inspect

Remove oil dipstick and check oil level and condition

Remove cylinder head

olts and inspect

Check if engine overheats

Rapidly accelerate or run at hi

h speed

Engine speed

Correct timin

Correct

ormal

compression

ot Clogged

Plug not fouled o

Correct and no

Valve train lubricated

erly

Engine does no

overheats

Engine does not knock

Symptom

Engine speed does

not increase

sufficientl

Valve train not lubricated

Incorrect timin

Incorrec

Abnormal compression

Clogged

Plug fouled or

Incorrect o

erl

Engine overheats

Engine knocks

MYROAD 700i

Probable Cause

cClogged air cleaner dRestricted fuel flow eClogged fuel line between fuel

tank and carburetor

fClogged exhaust muffler gFaulty auto bystarter hSplit carburetor vacuum piston

diaphragm

cFaulty dFaulty A.C. generator

cImproper valve clearance dWorn valve seat (valve stem too

cImproper valve and seat contact dWorn cylinder and piston rings eBlown cylinder head gasket fFlaws in cylinder head gImproper valve timing

cClogged carburetor jets

cFouled spark plug dIncorrect heat range plug

cOil level too high dOil level too low eOil not changed

cFaulty oil pump

cInsufficient coolant dFaulty thermostat eWorn cylinder and piston rings fMixture too lean gPoor quality fuel hExcessive carbon buildup in

iIgnition timing too early jAir in cooling system

cExcessive carbon build-up in dPoor quality fuel

eClutch slipping fMixture too lean g Ignition timing too early

ignition unit

adjustment protruding

combustion chamber

1-13

1. GENERAL INFORMATION

g

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

cFaulty ignition unit dFaulty A.C. generator

cMixture too rich (turn screw

out)

dMixture too lean (turn screw

in)

cDamaged insulator rubber dCarburetor not securely

tightened

eFaulty intake manifold gasket fDeformed carburetor O-ring

cFaulty or fouled spark plug dFaulty ignition unit eFaulty A.C. generator fFaulty ignition coil gBroken or shorted high

tension wire

hFaulty ignition switch

cDamaged air cut-off valve

diaphragm

dDamaged air cut-off valve

spring

Check carburetor pilot screw adjustment

Check intake manifold for air leaks

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine

round

Check carburetor air cut-off valve

Correct timing

Incorrect timing

Correctly adjusted

No air leak

Good spark

Good

Incorrectly adjusted

Air leaks

Weak or inter-

mittent spark

Faulty

MYROAD 700i

1-14

1. GENERAL INFORMATION

t

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

cFaulty ignition unit dFaulty A.C. generator

cImproperly adjusted valve

clearance

dWorn valve seat

cEmpty fuel tank dClogged fuel tube or filter eFaulty fuel pump fCracked fuel

tube

cClean and unclog

cCam timing gear aligning

marks not aligned

cFaulty spring

Check valve clearance

Check fuel pump for fuel supply

Check carburetor jets for clogging

Check valve timing

Check valve spring tension

Correct timing

Correctly adjusted

Fuel flows freely

Not clogged

Correc

Not weakened

Incorrect timing

Incorrectly adjusted

Fuel flow restricted

Clogged

Incorrec

Weak spring

MYROAD 700i

pump vacuum

1-15

1. GENERAL INFORMATION

ENGINE NOISE

Symptom

Valve noise

Piston noise

Cam chain noise

Crankshaft noise

Gear noise

MYROAD 700i

Probable Cause

cValve clearance too large dWorn camshaft lobe

cWorn piston rings dWorn piston pin and connecting rod small

end

eExcessive carbon build-up in combustion

chamber

cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain

cFaulty crankshaft bearing dWorn crank pin bearing

cWorn or damaged final reduction gears dWorn final reduction gear shaft splines

1-16

1. GENERAL INFORMATION

)

CLUTCH, DRIVE AND DRIVEN PULLEYS

Engine starts but motor-cycle does not

Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)

Engine lacks power at start of a grade(poor slope performance

Engine lacks power at high speed

There is abnormal noise or smell while running

Symptom

MYROAD 700i

Probable Cause

cWorn or slipping drive belt dBroken ramp plate eBroken drive face spring fSeparated clutch lining gDamaged driven pulley shaft splines hDamaged final gear iSeized final gear

cBroken shoe spring dClutch outer and clutch weight stuck eSeized pivot

cWorn or slipping drive belt dWorn weight rollers eSeized drive pulley bearings fWeak driven face spring gWorn or seized driven pulley bearings

cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings

cOil or grease fouled drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings

1-17

1. GENERAL INFORMATION

t

m

pplying

g

n

b

prop

n

STARTER MOTOR

1. Starter motor won‘t turn

Inspection/Adjustmen Check operation of

stop switch by a

Check battery circuit by operating turn si

Check operation of starter relay by depressing starter

utton

Connect starter motor directly to battery

brake

Stoplight comes on

nals

Signals operate properly

Relay operates properly

Starter motor turns

2. Starter motor turns slowly or idles

Inspection/Adjustmen

Check battery circuit by operating turn

nals

si

Signals operate

erly

Connect starter motor directly to battery

Rotate crankshaft

Starter motor turns slowly

Turns easily

3. Starter motor does not stop turning

Inspection/Adjustmen

Turn ignition switch OFF

Not stopped

Sympto

Stoplight does not come on

Signals dim, remai on or don‘t operate

Relay does not

operate

Starter does not turn

Signals dim, remai on or don‘t operate

Starter motor

turns normally

Hard to turn

Stopped

MYROAD 700i

Probable Cause

cBurned out fuse dWeak or dead battery eFaulty stop switch fLoose or disconnected

connectors

gBroken or shorted ignition

switch wire

hFaulty side stand switch cFaulty or weak battery

cPoor starter button connection dOpen or shorted starter relay eLoose or disconnected

connectors

cWorn brushes dOpen or shorted wires or rotor eOpen starter motor cable fLoose connectors

cOpen wire harness

Probable Cause

cWeak or dead battery

cLoose connector or terminal dPoor contact in starter relay eFaulty starter clutch

cSeized cylinder cBroken or shorted starter

motor cable

Probable Cause

cFaulty starter pinion cStarter relay shorted or stuck

closed

1-18

1. GENERAL INFORMATION

g

r

NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom

Replace with a new spark plug and inspect

ain

a

Weak or no spark

Check spark plug cap and high-tension wire for looseness

Check ignition unit coupler for looseness

Measure resistance between terminals of

nition unit couple

i

Check related parts

Check ignition unit

Not loose

Good

Normal

Abnormal

Good spark

Loose

Good

Abnormal

MYROAD 700i

Probable Cause

cFaulty spark plug

cPoorly connected coupler

cFaulty ignition switch dFaulty exciter coil eFaulty pulser coil fFaulty ignition coil

cBroken wire harness dPoorly connected coupler

cFaulty ignition unit

1-19

1. GENERAL INFORMATION

r

t

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

Inspection/Adjustment

Start engine and test limit voltage of battery terminals

Measure resistance between AC generator coil terminals

Test output voltage of regulator/rectifier coupler red wire

Overcharging

Inspection/Adjustment

Measure battery limit voltage with an electric teste

Check resistance between regulator/ rectifier terminals

Normal voltage

Normal

Normal voltage

Normal

Symptom

Voltage does no

Resistance too low

Symptom

No voltage

Abnormal

Probable Cause

cFaulty AC generator dFaulty regulator/rectifier eFaulty battery

cShorted AC generator coil dOpen circuit between AC

generator 3 yellow wires

cFaulty regulator/rectifier dFaulty AC generator eLoose regulator/rectifier

coupler

fLimit voltage too high

Probable Cause

cFaulty battery dFaulty regulator/rectifier eBroken or poorly connected

regulator/rectifier black wire

cLimit voltage too high

MYROAD 700i

1-20

1. GENERAL INFORMATION

p

prop

n

prop

p

r

t

pty

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment

Check battery circuit by operating turn signals

Remove fuel unit and check operation of pointer by moving float

and down

u

Float up: Full Float down: Em

Check operation of pointer by opening and shorting fuel unit terminal on wire harness

Check connectors for proper connection

Signals operate

erly

Pointer does not

Good

2. Pointer fluctuates or swings (Ignition switch ON) Inspection/Adjustment

Check battery circuit by operating turn signals and horn

Remove fuel unit and check operation of pointer by moving float u

Move float up and down rapidly (1 round /sec.) to check the o

Check connectors for proper connection.

and down

eration of pointe

Signals operate

erly

Pointer moves

Pointer moves in accordance with floa

Good Faulty

Symptom

Signals dim, remai on or don‘t operate

Pointer moves

Symptom

Signals dim, remain on or don‘t o

Pointer does not move

Pointer does not move in accord-ance with

Faulty

erate

MYROAD 700i

Probable Cause

cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected

connectors

gBroken wire harness

cFaulty float

cBroken or shorted fuel unit

wire

cDisconnected dIncorrectly connected

connector

eBroken or shorted wire in

fuel gauge

connector

Probable Cause

cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected

connector

gBroken wire harness

cPoor contact in fuel unit

cInsufficient damping oil in

fuel gauge

cLoose or disconnected connector cBroken or shorted wire in

fuel gauge

1-21

1. GENERAL INFORMATION

g

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

Steering is heavy

Front or rear wheel is wobblin

Steering handlebar pulls to one side

POOR SUSPENSION PERFORMANCE

Suspension is too soft

Suspension is too hard

Suspension is noisy

POOR BRAKE PERFORMANCE

Soft brake lever

Hard brake lever

Hard to brake

Poor brake performance

Brake squeaks

Symptom

(Front and rear tire pressures are normal)

cSteering stem nut too tight dBroken steering steel balls

cExcessive wheel bearing play dBent rim eLoose axle nut

cMisaligned front and rear wheels dBent front fork

Symptom

(Front and rear tire pressures are normal)

cWeak shock spring dExcessive load eShock damper oil leaking

cBent fork tube or shock rod cFork tube and slider binding

dFork spring and slider binding eDamaged shock stopper rubber fLoose steering stem nut

Symptom

cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area

cWorn brake linings dWorn brake cam contacting area on

cWorn brake linings dForeign matter on brake linings

cSluggish or elongated brake cables dBrake shoes improperly contact eWater and mud in brake system fOil or grease on brake linings

MYROAD 700i

Probable Cause

1-22

1. GENERAL INFORMATION

g

TROUBLESHOOTING (XCITING 250 AFI)

ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment

1. Make sure engine stop switch

is ON.

2. Put the side stand up.

3. Connect the diagnostic tool,

then check EMS and correct problems.

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine

round

Remove the fuel injector, start the starter motor to check fuel injector operation.

Test cylinder compression

Fuel reaches fuel injector

Fuel supply

compression

Spark jumps

Normal

Symptom

Fuel does not reach fuel injector

Weak or no spark

No fuel supply

Low or no

compression

MYROAD 700i

Probable Cause

cEmpty fuel tank dClogged fuel pump

filter

eFaulty fuel pump fFaulty fuel cut-off

relay

gCracked fuel hose

cFaulty spark plug dFouled spark plug eFaulty ignition coil fFaulty CPS gBroken or shorted ignition coil hBroken or shorted CPS iFaulty ignition switch

cFaulty fuel injector dClogged fuel injector eFaulty ECU

cStarter motor idles but

crankshaft does not rotate

dValve clearance too small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing

1-23

1. GENERAL INFORMATION

g

y

g

pect

t

N

b

t

r

t

r

prop

y

ENGINE LACKS POWER

Inspection/Adjustment

Connect the diagnostic tool, then check EMS and correct problems.

Start engine and accelerate lightly for

Check ignition timing

Check valve clearance

Test cylinder compression

Check fuel injector for clogging

Remove spark plug and ins

Remove oil dipstick and check oil level and condition

Remove cylinder head

olts and inspect

Check if engine overheats

Engine speed

Correct timin

Correct

ormal

compression

ot Clogged

Plug not fouled o

Correct and no

Valve train lubricated

erly

Engine does no

overheats

Symptom

Engine speed does

not increase

sufficientl

Abnormal compression

Plug fouled or

Incorrect o

Valve train not lubricated

Incorrect timin

Incorrec

Clogged

erl

Engine overheats

MYROAD 700i

Probable Cause

cClogged air cleaner dClogged exhaust muffler eFaulty spark plug fFaulty throttle gFaulty fuel pump hFaulty fuel injector

iImproper valve timing jLow or no compression

cFaulty dFaulty CPS

cImproper valve clearance dWorn valve seat (valve stem too

cImproper valve and seat contact dWorn cylinder and piston rings eBlown cylinder head gasket fFlaws in cylinder head gImproper valve timing

cFouled fuel injector

cFouled spark plug dIncorrect heat range plug

cOil level too high dOil level too low eOil not changed

cFaulty oil pump

cInsufficient coolant dFaulty thermostat eWorn cylinder and piston rings fMixture too lean gPoor quality fuel hExcessive carbon buildup in

iIgnition timing too early jAir in cooling system

ECU

adjustment protruding

combustion chamber

1-24

1. GENERAL INFORMATION

Rapidly accelerate or run at high speed

Engine does not knock

Engine knocks

MYROAD 700i

cExcessive carbon build-up in

combustion chamber

dPoor quality fuel eClutch slipping fIgnition timing too early

1-25

1. GENERAL INFORMATION

g

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom Probable Cause

Connect the diagnostic tool, then check EMS and correct problems.

Check ignition timing

cFaulty ignition coil dFaulty CPS eFaulty ECU

cFouled fuel injector dFaulty fuel pump

cDamage insulator rubber dThrottle body not securely

tighten

eFaulty intake manifold

O-ring

cFaulty CPS dFaulty ignition coil eBroken or shorted

high tension wire

fFaulty spark plug

cFouled throttle body dFaulty TPI reset

Check fuel injector for clogging

Check intake manifold for air leaks

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine

round

Check throttle body

Correct timing

Not Clogged

Incorrect timing

Clogged

No air leak

Good spark

Good

Air leaks

Weak or intermittent spark

Faulty

MYROAD 700i

1-26

KYMCO MYROAD 700i Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual