Page 1
MYROAD 700i
unauthorized use without the written permission of
By KWANG YANG Motor Co., Ltd.
First Edition, FEB. 2011
All rights reserved. Any reproduction or
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4122-KKE5-S00
Page 2
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
Page 3
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
Page 4
1. GENERAL INFORMATION
r
SERIAL NUMBER
VEHICLE IDENTIFICATION NUMBER(VIN):
FRAME NUMBER(VIN):
Location of Engine Serial Numbe
MYROAD 700i
1-1
Page 5
1. GENERAL INFORMATION
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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
Page 6
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
Page 7
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
Page 8
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
Page 9
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
Page 10
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
Page 11
1. GENERAL INFORMATION
FRAME
MYROAD 700i
1-8
Page 12
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
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Page 13
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
Page 14
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
Grease
Throttle Cable
Center Stand/Side Stand Pivot
Engine Oil
Grease
Grease
Front/Rear Brake Lever Pivot
Front Wheel Bearing
MYROAD 700i
Grease
1-11
Page 15
1. GENERAL INFORMATION
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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
Page 16
1. GENERAL INFORMATION
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prop
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
combustion chamber
1-13
Page 17
1. GENERAL INFORMATION
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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
Page 18
1. GENERAL INFORMATION
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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
Page 19
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
Page 20
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
Page 21
1. GENERAL INFORMATION
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pplying
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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
Sympto
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
Page 22
1. GENERAL INFORMATION
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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
Normal
Abnormal
Good spark
Loose
Good
Abnormal
Abnormal
MYROAD 700i
Probable Cause
cFaulty spark plug
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
Page 23
1. GENERAL INFORMATION
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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
Normal
Symptom
Voltage does no
Resistance too low
Symptom
No voltage
Abnormal
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
Page 24
1. GENERAL INFORMATION
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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
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
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
Page 25
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
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
Probable Cause
Probable Cause
1-22
Page 26
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
Page 27
1. GENERAL INFORMATION
g
y
g
pect
t
N
N
b
t
r
t
r
prop
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
Page 28
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
Page 29
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
Page 30
1. GENERAL INFORMATION
t
t
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment Symptom Probable Cause
Connect the diagnostic
tool, then check EMS and
correct problems.
Check ignition timing
cFaulty spark plug
dFaulty ignition coil
eFaulty CPS
cImproperly adjusted valve
clearance
dWorn valve seat
cEmpty fuel tank
dClogged fuel hose or filter
eFaulty fuel pump
fClogged fuel injector
cClean and unclog
cCam timing gear aligning
marks not aligned
cFaulty spring
Check valve clearance
Check fuel pump for
fuel supply
Check throttle body or
air cleaner for clogging
Check valve timing
Check valve spring
tension
Correct timing
Correctly adjusted
Incorrect timing
Incorrectly adjusted
Fuel flows freely
Not clogged
Correc
Not weakened
Fuel flow restricted
Clogged
Incorrec
Weak spring
MYROAD 700i
1-27
Page 31
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
1-28
Page 32
1. GENERAL INFORMATION
pe p
)
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
slo
Engine lacks power at
high speed
There is abnormal noise
or smell while running
Symptom
erformance
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
1-29
Page 33
1. GENERAL INFORMATION
t
t
t
m
m
m
pplying
g
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
Sympto
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
1-30
Page 34
1. GENERAL INFORMATION
g
g
r
NO SPARK AT SPARK PLUG
Inspection/Adjustment Symptom
Connect the diagnostic
tool, then check EMS and
correct problems.
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 coil
Not loose
Good
Normal
Normal
Abnormal
Good spark
Loose
Good
Abnormal
Abnormal
MYROAD 700i
closed
Probable Cause
cFaulty spark plug
cFaulty spark plug
cPoorly connected coupler
cFaulty ignition switch
dFaulty CPS
eFaulty ignition coil
cBroken wire harness
dPoorly connected coupler
cFaulty ignition coil
1-31
Page 35
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
Normal
Symptom
Voltage does no
Resistance too low
Symptom
No voltage
Abnormal
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
1-32
Page 36
1. GENERAL INFORMATION
p
p
prop
n
prop
p
p
r
t
pty
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Inspection/Adjustment
Check battery circuit by
operating turn signals
Signals operate
erly
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
Pointer does not
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
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
1-33
Page 37
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
Symptom
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
(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
cWorn brake linings
dForeign matter on brake linings
eRough brake drum contacting area
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
fuel gauge
Probable Cause
Probable Cause
Probable Cause
1-34
Page 38
1. GENERAL INFORMATION
MYROAD 700i
1-35
Page 39
2. FRAME COVERS/
MYROAD 700i
EXHAUST MUFFLER
2
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
2
__________________________________________________________________________________
FRAME COVERS/EXHAUST MUFFLER
__________________________________________________________________________________
SCHEMATIC DRAWING ------------------------------------------------- 2- 1
SERVICE INFORMATION------------------------------------------------ 2- 2
TROUBLESHOOTING----------------------------------------------------- 2- 2
FRAME COVERS REMOVAL ------------------------------------------- 2- 3
EXHAUST MUFFLER ----------------------------------------------------- 2-17
2-0
Page 40
2. FRAME COVERS/
EXHAUST MUFFLER
SCHEMATIC DRAWING
MYROAD 700i
2-1
Page 41
2. FRAME COVERS/
EXHAUST MUFFLER
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
Muffler mount bolt 3.2~3.8 kg-m
Exhaust pipe joint nut 1.0~1.4 kg-m
Exhaust pipe band bolt 1.0~1.4 kg-m
TROUBLESHOOTING
MYROAD 700i
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
2-2
Page 42
2. FRAME COVERS/
t
r
t
N
r
EXHAUST MUFFLER
FRAME COVERS REMOVAL
SEAT
REMOVAL
Unlock the seat with the ignition key.
Open the seat.
Remove the two nuts and seat damper unit.
Remove the two nuts and the seat.
INSTALLATION
Installation is in the reverse order of the
removal.
After installation, check the seat installation
by moving the seat.
LUGGAGE BOX REMOVAL
After removal the seat, side cover, carrier,
body cover, then you can remove the luggage
box.
Remove the screws and bolts.
Raise the luggage box, disconnect the
luggage box light and accessory socket
connectors.
INSTALLATION
Installation is in the reverse order of removal.
Screws
Nuts
Damper Uni
Accessory Socket Connecto
Luggage box ligh
MYROAD 700i
Nuts
uts
Bolts
Connecto
2-3
Page 43
2. FRAME COVERS/
t
EXHAUST MUFFLER
FUEL PUMP LID
REMOVAL
Remove the bolt and lid.
INSTALLATION
Installation is in the reverse order of removal.
REAR SPOILER
REMOVAL
Unlock the seat with the ignition key.
Open the seat.
Remove the rubber cap.
Remove four bolts and rear spoiler.
INSTALLATION
Installation is in the reverse order of removal.
FRONT FENDER
RE MOVAL
Remove the six bolts and front fender.
INSTALLATION
Installation is in the reverse order of removal.
Bol
MYROAD 700i
Fuel pump Lid
Rubber Cap
Bolts
Bolts
2-4
Page 44
2. FRAME COVERS/
EXHAUST MUFFLER
UPPER HANDLEBAR COVER
REMOVAL
Remove four screws and upper handlebar
cover.
INSTALLATION
Installation is in the reverse order of removal.
RIGHT/LEFT SIDE COVERS
REMOVAL
After removing seat, the priority you
should remove would be side covers, there
are some screws and bolts hiding in these
parts.
Remove the two bolts and side covers
.
Remove the hex bolt and foot step.
MYROAD 700i
Screws
Bolts
Side Cover
Hex Bolt Foot step
2-5
Page 45
2. FRAME COVERS/
EXHAUST MUFFLER
Remove the side cover following the way of
picture showing.
Specially notice not to damage the tabs on the
side covers, especially the hook structures on
the end of side covers.
＊
Be careful not to damage the tabs on the
side covers.
MYROAD 700i
2-6
Page 46
2. FRAME COVERS/
EXHAUST MUFFLER
RIGHT/LEFT FLOOR SKIRT
REMOVAL
Remove the floor mat.
Remove the right and left center body cover .
MYROAD 700i
Floor Mat
2-7
Page 47
2. FRAME COVERS/
EXHAUST MUFFLER
Remove the seven screws.
Remove two screws.
Remove the floor skirt.
＊
Be careful not to damage the tabs on the
floor skirt.
INSTALLATION
Installation is in the reverse order of removal.
FLOORBOARD
REMOVAL
Remove right and left center body cover.
Remove the right and left floor skirt.
Remove the luggage box.
Remove six bolts, four screws and
floorboard.
INSTALLATION
Installation is in the reverse order of removal.
Screws
Screws
Bolts
MYROAD 700i
2-8
Page 48
2. FRAME COVERS/
r
EXHAUST MUFFLER
LICENCE LIGHT
REMOVAL
Remove two screws.
Disconnect the license light connector and
remove the license light.
INSTALLATION
Installation is in the reverse order of removal.
REAR FENDER
REMOVAL
Remove the licence light.
Remove two screws.
Remove two nuts and rear fender.
INSTALLATION
Installation is in the reverse order of removal.
Screws Connecto
Screws
Screws
Screws
MYROAD 700i
2-9
Page 49
2. FRAME COVERS/
r
EXHAUST MUFFLER
RIGHT/LEFT SIDE BODY COVER
REMOVAL
Remove the luggage box.
Remove the rear spoiler.
Remove two bolts.
Raise the side body cover, disconnect the
taillight/rear turn signal light connector and
remove the side body cover.
INSTALLATINON
Installation is in the reverse order of removal
REAR BODY COVER
REMOVAL
Remove the luggage box.
Remove the rear spoiler.
Remove two screws and rear body cover.
＊
Be careful not to damage the tabs on the
rear body cover.
INSTALLATION
Installation is in the reverse order of removal.
Taillight/Rear Turn Signal Light Connecto
Screws
Body cover
MYROAD 700i
2-10
Page 50
2. FRAME COVERS/
EXHAUST MUFFLER
TAILIGHT/REAR TURN SIGNAL
LIGHT
REMOVAL
Remove the side and rear body cover.
Remove bolts and taillight/rear turn signal
light.
INSTALLATION
Installation is in the reverse order of removal.
REAR LOWER COVER
REMOVAL
Remove the side body cover.
Remove the rear lower cover.
REARVIEW MIRROR
REMOVAL
Remove bolts lid.
Remove three bolts and rearview mirror.
MYROAD 700i
Bolts
Screws
Rear Lower Cover
Bolts
2-11
Page 51
2. FRAME COVERS/
EXHAUST MUFFLER
Remove the two bolts, rearview mirror holder
and seat.
INSTALLATION
Installation is in the reverse order of removal
WINDSHIELD
REMOVAL
Remove four screws and windshield garnish.
Remove 6 bolts and windshield.
＊
Be careful not to scratch or damage the
windshield surface.
INSTALLATION
Installation is in the reverse order of removal.
Bolts
Screws
Windshield Garnish
Windshield
MYROAD 700i
2-12
Page 52
2. FRAME COVERS/
EXHAUST MUFFLER
FRONT COVER REMOVAL
The priority to remove is front cover (with
head lights, then tunnel leg shield
(81141-KKE5), there are some bolts and
screws hide inside.
MYROAD 700i
2-13
Page 53
2. FRAME COVERS/
r
EXHAUST MUFFLER
Tunnel leg shield removal
Remove six screws.
Remove two screws.
Remove one screw.
Disconnect headlight and turn signal light
connectors.
INSTALLATION
Installation is in the reverse order of removal.
MYROAD 700i
Screws
Screws
Turn Signal Light Connectors
Screw Headlight Connecto
2-14
Page 54
2. FRAME COVERS/
r
EXHAUST MUFFLER
HEADLIGHT
REMOVAL
Remove the front cover.
Remove 8 screws and headlight.
INSTALLATION
Installation is in the reverse order of removal.
TURN SIGNAL LIGHT
REMOVAL
Remove the front cover.
Remove three screws and turn signal light.
INSTALLATION
Installation is in the reverse order of removal.
FRONT METER VISOR
REMOVAL
Remove the windshield.
Remove the front cover.
Remove four bolts and windshield holder.
MYROAD 700i
Windshield Holde
Bolts
2-15
Page 55
2. FRAME COVERS/
r
EXHAUST MUFFLER
Remove two screws and front meter visor.
INSTALLATION
Installation is in the reverse order of removal.
METER PANEL
REMOVAL
Remove the front cover.
Remove the front meter visor.
Remove the tunnel leg shield.
Remove screws from instrument.
Disconnect the speedometer connector and
remove meter panel.
INSTALLATION
Installation is in the reverse order of removal.
MYROAD 700i
Screw
Meter Panel
Speedometer Connecto
2-16
Page 56
2. FRAME COVERS/
EXHAUST MUFFLER
METER
REMOVAL
Remove the meter panel.
Remove two screws and meter.
INNER COVER
REMOVAL
Remove the front cover.
Remove the floorboard.
Remove the meter panel.
Remove the shutter screw and shutter.
Turn the fuel fill cap garnish
counterclockwise and remove it.
Remove three screws and disconnect the fuel
fill duct.
MYROAD 700i
Screws
Cap Garnish
Screws
2-17
Page 57
2. FRAME COVERS/
EXHAUST MUFFLER
Remove 2 bolts from front panel floor.
INSTALLATION
Installation is in the reverse order of removal.
FRONT LOWER COVER
REMOVAL
Remove the panel floor.
Remove the screws from lower cover.
Remove the lower cover.
Bolts
MYROAD 700i
2-18
Page 58
2. FRAME COVERS/
S
t
EXHAUST MUFFLER
EXHAUST MUFFLER
REMOVAL
Disconnect the connector with O2 heater/O2
sensor.
Remove screws from muffler protector.
Loosen the rear muffler cover screws.
Remove the exhaust pipe joint nuts and
exhaust pipe.
Remove the muffler.
INSTALLATION
Replace the gaskets with new ones.
Install the exhaust pipe and tighten the joint
nuts.
Torque: 1.0~1.4 kg-m
Install the muffler and tighten the mount
bolts.
Torque: 3.2~3.8 kg-m
Install and tighten the band bolts.
Torque: 2.1 kg-m
MYROAD 700i
Bolt Bol
Muffler protector
crews
2-19
Page 59
3. INSPECTION/ADJUSTMENT
3
__________________________________________________________________________________
__________________________________________________________________________________
MYROAD 700i
__________________________________________________________________________________
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION-------------------------------------------------- 3-1
MAINTENANCE SCHEDUL ----------------------------------------------- 3- 3
FUEL LINE--------------------------------------------------------------------- 3- 5
THROTTLE OPERATION--------------------------------------------------- 3- 5
AIR CLEANER ---------------------------------------------------------------- 3-7
CRANKCASE BREATHER ------------------------------------------------- 3- 8
SPARK PLUG------------------------------------------------------------------ 3- 8
VALVE CLEARANCE------------------------------------------------------- 3-10
ENGINE OIL------------------------------------------------------------------- 3-13
ENGINE OIL FILTER CARTRIDGE -------------------------------------- 3-15
RADIATOR COOLANT ----------------------------------------------------- 3-16
COOLING SYSTEM---------------------------------------------------------- 3-17
TRANSMISSION OIL-------------------------------------------------------- 3-18
BRAKE FLUED --------------------------------------------------------------- 3-19
BRAKE PAD WEAR --------------------------------------------------------- 3-20
BRAKE SYSTEM ------------------------------------------------------------- 3-20
BRAKE LOCK OPERATION -----------------------------------------------3-21
HEADLIGHT AIM-------------------------------------------------------------3-22
SIDE STAND---------- ---------------------------------------------------------3-23
SUSPENSION-------------------------------------------------------------------3-24
WHEELS/TIRES--------------------------------------------------------- ------3-24
STEERING HEAD BEARINGS----------------------------------------------3-25
3
3-0
Page 60
3. INSPECTION/ADJUSTMENT
MYROAD 700i
SERVICE INFORMATION
GENERAL
Place the scooter on al level ground before starting any work.
Gasoline is extremely flammable and is explosive under certain conditions.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where
the gasoline is stored can cause a fire or explosion.
If the engine must be running to do some work, make sure the area is well ventilated. Never run
the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
may lead to death. Run the engine in an open area or with an exhaust evacuation sustem in and
enclosed area.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttle free play 2-6 mm (1/16 – 1/4 in)
Spark plug
Spark plug gap 0.6~0.7 mm
Engine oil capacity
Recommended engine oil
Engine idle speed 1250±100 rpm
Final reduction
oil capacity
Recommended final reduction oil SAE 90
Recommended brake fluid DOT 4
Tire size
Tire air pressure
Minimum tire tread depth
NGK DR8E
IN 0.16 mm Valve clearance
EX 0.22 mm)
At draining 2.75 liter
Total amount 3.0 liter
KYMCO 4-stroke oil or equivalent
motor oil API service classification: SJ
Viscosity: 5W50
At draining 0.36 liter
Total amount 0.4 liter
Front 120/70-R15
Rear 160/60-R14
Solo riding
Two up riding
Front 2 kgf/cm2
Rear 2.25 kgf/cm2
Front 2 kgf/cm2
Rear 2.5 kgf/cm2
Front 1.6 mm (0.06 in)
Rear 2.0 mm (0.08 in)
3-1
Page 61
3. INSPECTION/ADJUSTMENT
TORQURE VALUES
Engine oil drain plug 2.5 kgf•m
Oil strainer screen cap 1.2~1.8 kgf•m
Apply oil to the threads and seating surface.
Oil filter cartridge 1~2 kgf•m
Apply oil to the threads and seating surface.
Transmission oil drain bolt 2~3 kgf•m
Transmission oil filler bolt 1.2~1.8 kgf•m
SPECIAL TOOLS
Oil filter cartridge wrench A120E00061
MYROAD 700i
3-2
Page 62
3. INSPECTION/ADJUSTMENT
MYROAD 700i
MAINTENANCE SCHEDULE
Perform the pre-ride inspection in the owner’s manual at each scheduled maintenance period.
This interval should be judged by odometer reading or months, whichever comes first.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
3-3
Page 63
3. INSPECTION/ADJUSTMENT
NOTE:
1 At higher odometer readings, repeat at the frequency interval established here.
2 Service more frequently if the scooter is ridden in unusually wet or dusty areas.
3 Service more frequently when riding in rain or at full throttle.
4 Inspect every 18000 km (12000 mi) after replacement.
5 Replace every 1 year, or every 10000km (6000mi), whichever comes first.
6 Replace every 2 year, or at indicated odometer interval, whichever comes first.
7 Replace every 2 years. Replacement requires mechanical skill.
MYROAD 700i
3-4
Page 64
3. INSPECTION/ADJUSTMENT
r
＊
• Do not smoke or allow flames or
sparks in your working area.
FUEL FILTER
Visually check the fuel filter. If accumulation
of sediment or clogging is found, replace the
fuel filter with a new one.
THROTTLE OPERATION
Check for smooth throttle grip full opening
and automatic full closing in all steering
positions.
Check the throttle cables and replace them if
they are deteriorated, kinked or damaged.
Lubricate the throttle cables, if throttle
operation is not smooth.
Measure the throttle grip free play.
Free Play: 2～6 mm (1/16～1/4 in)
MYROAD 700i
Fuel Filte
3-5
Page 65
3. INSPECTION/ADJUSTMENT
MYROAD 700i
Throttle grip free play can be adjusted at
either end of the throttle cable.
Minor adjustment is made with the upper
adjuster.
Slide the rubber sleeve back to expose the
throttle cable adjuster.
Adjust the free play by loosening the lock nut
and turning the adjuster.
3-6
Page 66
3. INSPECTION/ADJUSTMENT
AIR CLEANER
The air cleaner should be serviced at regular
intervals. Service more frequently when
riding in unusually wet or dusty areas.
Install a new air cleaner element. Use the
KYMCO genuine air cleaner element or an
equivalent air cleaner element specified for
your model. Using the wrong. KYMCO air
cleaner element or a non-KYMCO air cleaner
which is not of equivalent quality may cause
premature engine wear or performance
problems.
Air cleaner element removal/installation
Remove the screws and air cleaner housing
cover
3-7
MYROAD 700i
Page 67
3. INSPECTION/ADJUSTMENT
t
Remove the air cleaner element.
Check the cleaner element.
Install the removed parts in the reverse order
of removal.
Air cleaner element removal/installation
Remove the luggage box.
Remove the six screws and air cleaner cover.
CRANKCASE BREATHER
Remove the crankcase breather tube plug
from the tube and drain deposits into a
suitable container.
Reinstall the crankcase breather tube plug.
Service more frequently when riding in rain,
at full throttle, or after the scooter is washed
or overturned. Service if the deposit level can
be seen in the transparent section of the drain
tube.
SPARK PLUG
REMOVAL
Remove the spark plug maintenance lid
Air Cleaner Elemen
Spark Plug Cap
Spark plug lid
MYROAD 700i
3-8
Page 68
3. INSPECTION/ADJUSTMENT
Remove the spark plug using a equipped
spark plug wrench or an equivalent tool.
Inspect or replace as described in the
maintenance schedule.
INSPECTION
Remove the carbon deposits from the spark
plug with a small wire brush or a spark plug
cleaning machine.
The spark plug should be replaced
periodically. Whenever removing the carbon
deposits, be sure to observe the operational
color of the spark plug's porcelain tip. This
color tells you whether or not the standard
spark plug is suitable for your type of usage.
A normal operating spark plug should be
light brown or tan color. If the spark plug is
very white or glazed appearing, then it has
been operating much too hot. This spark plug
should be replaced with the colder plug.
Recommended spark plug: DR8E
Measure the spark plug gap between the
center and side electrodes with the feeler
gauge.
If necessary, adjust the gap by bending the
side electrode carefully.
Spark plug gap:
0.6－0.7 mm (0.024－0.028 in)
Install the spark plug in the cylinder head and
hand tighten, then torque to the specification.
Torque: 1.0~1.4 kg•m
Install the spark plug cap.
Install the removed parts in the reverse order
of removal.
Spark Plug
MYROAD 700i
0.6~0.7 mm
3-9
Page 69
3. INSPECTION/ADJUSTMENT
VALVE CLEARANCE
＊
Inspect and adjust the valve clearance
while the engine is cold (Below
35°C/95°F).
Inspection and adjust
Remove the cylinder head cover.
Remove the timing hole cap and O-ring.
Remove the crankshaft hole cap and O-ring.
Turn the crankshaft clockwise and align the
“T” mark on the flywheel with the index
mark on the right crankcase cover.
The punch marks “in” and “ex” on the
camshaft should be aligned with the boundary
of cylinder head as shown.
If the punch marks on the camshaft are facing
downward, turn the crankshaft clockwise one
full turn (360°) and the punch marks are
facing upward.
Timing Hole Cap/O-ring
Crankshaft Hole Cap/O-ring
“T” Mark
Index Mark
Mark “in”
Mark “ex”
MYROAD 700i
3-10
Page 70
3. INSPECTION/ADJUSTMENT
r
r
m
Insert the feeler gauge between the valve
lifter and the cam lobe.
Check the valve clearance for the valves
using a feeler gauge.
Valve Clearance
IN:0.16 mm(0.006 in)
EX:0.22 mm(0.009in)
Remove the camshaft.
Remove the valve lifters and shims.
The shims may stick to the inside of the valve
lifter. Don’t allow the shims to fall into the
crankcase.
Mark all of shims and valve lifters to ensure
correct reassembly in original locations.
The valve lifter can be easily removed with a
valve lapping tool or magnet.
The shims can be easily removed with
tweezers or magnet.
Clean the valve shim contact area in the valve
lifter with compressed air.
MYROAD 700i
Shi
Valve Lifte
Valve Lifte
3-11
Page 71
3. INSPECTION/ADJUSTMENT
Measure the shim thickness and record it.
Calculate the new shims thickness using the
equation below.
A+C=B+D
A: New shim thickness
B: Record valve clearance
C: Specified valve clearance
D: Old shim thickness
Grade number “T” Thickness Mark
01 1.80 180
02 1.85 185
03 1.90 190
04 1.95 195
05 2.00 200
06 2.05 205
07 2.10 210
08 2.15 215
09 2.20 220
10 2.25 225
11 2.30 230
12 2.35 235
13 2.40 240
14 2.45 245
15 2.50 250
16 2.55 255
17 2.60 260
18 2.65 265
19 2.70 270
20 2.75 275
21 2.80 280
22 2.85 285
23 2.90 290
24 2.95 295
25 3.00 300
Make sure the correct shim is selected by
measuring it with a micrometer.
Reface the valve seat if carbon deposits result
in a clearance of over 2.8mm
Install the removed parts in the reverse order
of removal.
MYROAD 700i
3-12
Page 72
3. INSPECTION/ADJUSTMENT
ENGINE OIL
OIL LEVEL INSPECTION
Start the engine and let it idle for 2－3
minutes.
Turn off the engine and support the scooter
level surface.
Check the engine oil level. The level must be
maintained between the upper H (1) and
lower level L (2) marks on the oil inspection
screen (3).
If the oil level is below or near the lower
level line, add the recommended engine oil
until the oil level is to the upper level.
Recommended engine oil:
KYMCO 4-stroke oil or equivalent motor
oil API service classification: SJ
Viscosity: SAE 5W50
＊
Other viscosities shown in the chart may
be used when the average temperature in
your riding area is within the indicated
range.
ENGINE OIL & STARINER SCREEN
When running in very dusty conditions, oil
changes should be performed more frequently
than specified in the maintenance schedule.
Please dispose of used engine oil in a manner
that is compatible with the environment. We
suggest you take it in a sealed container to
your local recycling center or service station
for reclamation. Do not throw it in the trash
or pour it on the ground or down a drain.
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it
is still advisable to thoroughly wash your
hands with soap and water as soon as possible
after handling used oil.
MYROAD 700i
Change the engine oil with the engine at
normal operating temperature and the scooter
on its center stand to assure complete and
rapid draining.
Remove the oil filler cap from the right
crankcase cover.
H
L
Engine oil capacity: 3.0 L
Engine oil exchanging capacity: 2.6 L
3-13
Page 73
3. INSPECTION/ADJUSTMENT
Place a drain pan under the crankcase and
remove the oil strainer cap.
The setting spring and oil strainer screen will
come out when the oil strainer cap is
removed.
Clean the oil strainer screen.
After draining the oil completely, install the
strainer screen and setting spring into the
engine.
Apply clean engine oil to the strainer cap
threads, flange surface and a new O-ring.
Install and tighten the strainer cap with a new
O-ring.
Torque: 1~2 kgf•m
Oil Strainer Screen
MYROAD 700i
Strainer Screen
Setting Spring
O-ring
Strainer Cap
Strainer Screen
Strainer Screen
Setting Spring
O-ring
Strainer Cap
3-14
Page 74
3. INSPECTION/ADJUSTMENT
Fill the crankcase with the recommended
engine oil.
Engine oil capacity: 3.0 L
Engine oil exchanging capacity: 2.6 L
Install the oil filler cap.
Check the engine oil level.
Make sure there are no oil leaks
.
ENGINE OIL FILTER
CARTRIDGE
REPLACEMENT
Drain the engine oil.
Remove and discard the oil filter cartridge
using the special tool.
Tool:
Oil filter wrench: A120 E00061
Apply clean engine oil to the new oil filter
cartridge threads, flange surface and a new
O-ring.
Install the new oil filter cartridge and tighten
it to the specified torque.
Torque: 2.4~3 kgf•m
Refill the engine oil
O-ring
MYROAD 700i
3-15
Page 75
3. INSPECTION/ADJUSTMENT
RADIATOR COOLANT
Place the scooter on its center stand.
The reserve tank is under left footboard.
Check the coolant level through the
inspection window (1) at the
left side skirt while the engine is at the
normal operating
temperature with the scooter in an upright
position. If the coolant
level is below the LOWER level mark (3),
remove the left floor
mat, remove the lid screw and reserve tank
lid and the
Reserve tank cap (4) and add coolant mixture
until it reaches the upper
level mark (2).
Remove the left floor mat and remove screw
and reserve tank lid.
Remove reserve tank cap.
Check to see if there are any coolant leaks
when the coolant level decrease very rapidly.
If reserve tank becomes completely empty,
there is a possibility of air getting into the
cooling system.
Be sure to remove all air from the cooling
system.
Reinstall the filler cap.
(1)
Rubber plate
F
L
Lid
MYROAD 700i
(2)
(3)
(4)
Screw
3-16
Page 76
3. INSPECTION/ADJUSTMENT
COOLING SYSTEM
Check for any coolant leakage from the water
pump, radiator hoses and hose joints.
Check the radiator hoses for cracks or
deterioration and replace if necessary.
Check that all hose clamps are tight.
Check the radiator air passages for clogs or
damage.
Straighten any bent fins, and remove insects,
mud or other obstructions with compressed
air or low water pressure.
Replace the radiator if the air flow is
restricted over more than 20% of the
radiating surface.
Rubber plate
Lid
MYROAD 700i
Screw
3-17
Page 77
3. INSPECTION/ADJUSTMENT
il drain bolt (1)
fill
(2)
TRANSMISSION OIL
OIL CHANGE
Place the scooter in its center stand.
Remove the transmission oil drain bolt (1)
and the transmission oil filler bolt (2), slowly
turn the rear wheel and drain the oil.
After draining the oil completely, install the
oil drain bolt with a new sealing washer and
tighten it.
Torque: 2~3 kgf•m
Fill the transmission case with recommended
oil.
Recommended transmission oil: SAE 90
Oil capacity: 0.40 L
Oil exchanging capacity: 0.32L
Install the transmission oil filler bolt with a
new sealing washer and tighten it.
o
oil
MYROAD 700i
er bolt
3-18
Page 78
3. INSPECTION/ADJUSTMENT
BRAKE FLUID
＊
Do not mix different type of fluid, as
they are not compatible with each
other.
Do not allow foreign material to enter
the system when filling the reservoir.
Avoid spilling fluid on painted, plastic
or rubber parts. Place a rag over these
parts whenever the system is serviced.
Brake fluid level inspection:
With the scooter in an upright position, check
the front and rear fluid level. The level should
be above the lower level mark. If the level is
at or below the lower level mark "L", check
the brake pads for wear.
Worn break pads should be replaced
immediately. If the pads are not worn, have
your brake system inspected for leaks. Do not
ride your scooter unless the brakes are in
perfect working order.
Brake fluid type: DOT 4 (from a sealed
container)
Note: Other checks- Make sure there are no
fluid leaks. Check for deterioration or cracks
in the hoses and fittings.
MYROAD 700i
3-19
Page 79
3. INSPECTION/ADJUSTMENT
r
BRAKE PAD WEAR
Brake pad wear depends upon the severity of
usage, the type of riding, and road conditions.
(Generally, the pads will wear faster on wet
and dirty roads.) Inspect the pads at each
regular maintenance interval.
Front/Rear brake
Check the cutout in each brake pad, the
cutout should be visible, indicating that brake
pad is not worn down to the brake rotor. If
either pad is worn to the cutout, replace both
pads as a set.
BRAKE SYSTEM
INSPECTION
Check the free play of front/rear brake lever.
Standard of free play: 10~20 mm
Rear Brake Leve
MYROAD 700i
3-20
Page 80
3. INSPECTION/ADJUSTMENT
Operate the rear brake lever.
Make sure the front wheel does not turn while
the brake lever is operated.
Firmly apply the brake lever and check that
no air has entered the system.
If the lever feels soft or spongy when
operated, bleed the air from the system.
Inspect the brake hose and fittings for
deterioration, cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.
BRAKE LOCK OPERATION
INSPECTION
Stop the engine and put the scooter on its
center stand on level ground.
Pull up the parking brake lever slowly and
check the parking brake lever stroke.
Parking brake lever stroke: 3－6 cm
If out of specification, adjust the parking
brake lever.
MYROAD 700i
3-21
Page 81
3. INSPECTION/ADJUSTMENT
t
ADJUSTMENT
Place the scooter on its center stand.
Release the parking brake lever lock.
Pull up the parking brake lever.
Loosen the lock nut.
Turn the adjust bolt until you feel resistance
when turn the rear wheel by your hand.
Hold the adjust bolt and tighten the lock nut
securely.
Release the parking brake lever.
Make sure the rear wheel turns smoothly.
Pull the parking brake lever slowly and check
the lever stroke.
Standard: 3－6 notches
.
HEADLIGHT AIM
Place the scooter on a level surface.
Adjust the headlight beam vertically by
turning the vertical beam adjuster.
A clockwise rotation moves the beam up and
counterclockwise rotation moves the beam
down.
Adjust the headlight beam horizontally by
turning the horizontal beam adjuster.
A clockwise rotation moves the beam toward
the right side of the rider.
＊
Adjust the headlight beam as specified
by local laws and regulations.
Horizontally Adjusting Screw
Nut Bol
Vertically Adjusting Screw
MYROAD 700i
3-22
Page 82
3. INSPECTION/ADJUSTMENT
SIDE STAND
Support the scooter on a level surface.
Check the side stand spring for fatigue or
damage.
Check the side stand assembly for smooth
movement and lubricate the side stand pivot
if necessary.
Check the side stand ignition cut-off system:
9 Start the engine.
9 Fully lower the side stand while running
the engine.
9 The engine should stop as the side stand is
lowered.
If there is a problem with the system, check
the side stand switch.
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the
front brakes and compressing the front
suspension several times.
Check the entire assembly for signs of leaks,
damage or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.
MYROAD 700i
3-23
Page 83
3. INSPECTION/ADJUSTMENT
REAR SUSPENSION INSPECTION
Check the action of the shock absorber by
compressing it several times.
Check the entire shock absorber assembly for
signs of leaks, damage or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are
tightened to their correct torque values (page
1-9).
Check that all safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELES/TIRES
Tire pressure should be checked when the
tires are cold.
MYROAD 700i
3-24
Page 84
3. INSPECTION/ADJUSTMENT
Recommended tire size:
Tire size: front ..................120/70-R15
Tire size: rear.....................160/60-R14
Check the tires for cuts, embedded nails, or
other damage.
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the
tires.
Replace the tires when the tread depth
reaches the following limits.
Minimum tread depth:
Front: 1.6 mm
Rear: 2.2 mm
STEERING HEAD BEARINGS
Check that the control cables do not interfere
with handlebar rotation.
Support the scooter securely and raise the
front wheel off the ground.
Check that the handlebar moves freely from
side to side.
If the handlebar moves unevenly, binds, or
has vertical movement, inspect the steering
head bearings.
MYROAD 700i
3-25
Page 85
4. LUBRICATION SYSTEM
MYROAD 700i
4
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
4
LUBRICATION SYSTEM
__________________________________________________________________________________
SERVICE INFORMATION----------------------------------------------- 4- 2
TROUBLESHOOTING---------------------------------------------------- 4- 3
OIL PRESSURE SWITCH ------------------------------------------------ 4- 4
OIL PRESSURE RELIEF VALVE--------------------------------------- 4- 4
OIL PUMP ------------------------------------------------------------------- 4- 5
OIL COOLER --------------------------------------------------------------- 4-8
4-0
Page 86
4. LUBRICATION SYSTEM
MYROAD 700i
4-1
Page 87
4. LUBRICATION SYSTEM
MYROAD 700i
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The oil pump service may be done with the engine installed in the frame.
• When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as
an assembly.
• After the engine has been installed check that there are no oil leaks and that oil pressure is
correct.
• For oil pressure indicator inspection, refer to section 20 of this manual.
SPECIFICATIONS Unit: mm
Engine oil
capacity
Recommended engine oil
Oil pump rotor
TORQUE VALUES
Oil pump bolt 0.8~1.2 kgf•m
Oil cooler bolt 1.2~1.8 kgf•m
Oil pressure switch 1~1.4 kgf•m
Oil filter cartridge 2.0~3.0 kgf•m
TOOLS
Oil filter wrench A120E00061
ITEM STANDARD SERVICE LIMIT
At draining 2.6 liter ⎯
At disassembly 3.0 liter ⎯
KYMCO 4-stroke oil or
equivalent motor oil
API service classification SJ
Viscosity: SAE 5W-50
Tip clearance 0.15 mm 0.2 mm
Body clearance 0.15 – 0.2 mm 0.25 mm
Side clearance 0.04 – 0.09 mm 0.12 mm
⎯
4-2
Page 88
4. LUBRICATION SYSTEM
MYROAD 700i
TROUBLESHOOTING
Oil level low High oil pressure
• Oil consumption • Pressure relief valve stuck closed
• External oil leak • Plugged oil filter, gallery, or metering orifice
• Worn piston ring • Faulty oil pump
• Incorrect piston ring installation
• Worn valve guide or seal Seized engine
• No or low oil pressure
Oil contamination (White appearance) • Clogged oil orifice/passage
• From coolant mixing with oil • Internal oil leak
─ Faulty water pump mechanical seal • Non-recommended oil used
─ Faulty head gasket
─ Water leak in crankcase Oil contamination
• Deteriorated oil
No oil pressure • Faulty oil filter
• Oil level too low • Worn piston ring (White appearance with water or
• Oil pump drive chain broken moisture)
• Oil pump drive sprocket broken ─ Damaged water pump mechanical seal
• Oil pump damaged (pump shaft) ─ Damaged head gasket
• Internal oil leak ─ Oil relief not frequent enough
Low oil pressure Oil pressure warning indicator does not work
• Pressure relief valve stuck open • Faulty oil pressure switch
• Clogged oil filter and strainer screen • Short circuit in the indicator wire
• Oil pump worn or damaged • Low or no oil pressure
• Internal oil leak
• Incorrect oil being used
• Oil level too low
4-3
Page 89
4. LUBRICATION SYSTEM
r
Oil
OIL PRESSURE SWITCH
CHECK
Start the engine.
Check the oil pressure indicator goes out after
one or two seconds. If the oil pressure
indicator stay on, stop the engine
immediately and determine the cause.
OIL PRESSURE RELIEF VALVE /
OIL PUMP
REMOVAL
Remove the right crankcase cover.
Remove the pressure relief valve and O-ring
from the right crankcase
.
INSPECTION
Check the operation of the pressure relief
valve by pushing on the piston.
INSTALLATION
Apply oil to a new O-ring and install the
pressure relief valve groove, and install the
relief valve to the right crankcase.
Dust Cove
O-ring
Oil Pump
Piston
O-Ring
Pressure Relief Valve
Oil Pressure Relief Valve
MYROAD 700i
4-4
Page 90
4. LUBRICATION SYSTEM
r
r
OIL PUMP
DISASSEMBLY
Remove bolts and oil pump cover.
Remove the dowel pin, pin,oil pump shaft, oil
pump outer rotor and inner rotor.
MYROAD 700i
Oil PumpCove
Bolts
Oil Pump Body Inner Roto
Outer Rotor Pin Oil Pump Shaft
Dowel Pin
4-5
Page 91
4. LUBRICATION SYSTEM
INSPECTION
Temporarily install the oil pump shaft.
Install the outer and inner rotors into the oil
pump body.
Measure the tip clearance.
Service limit: 0.2 mm (0.008 in)
＊
Measure at several points and use the
largest reading to compare the service
limit.
Measure the pump body clearance.
Service limit: 0.25 mm (0.01 in)
Measure the side clearance with the straight
edge and feeler gauge.
Service limit: 0.12 mm (0.0048 in)
MYROAD 700i
4-6
Page 92
4. LUBRICATION SYSTEM
r
r
r
ASSEMBLY
Dip all parts in clean engine oil.
Install the outer rotor into the oil pump body.
Install the inner rotor into the outer rotor.
Install the oil pump shaft.
Install the pin onto the oil pump body.
Install the oil pump cover onto the oil pump
body by aligning the dowel pin.
Install and tighten the bolts to the specified
torque.
Torqur: 1.2 kgf•m
INSTALLATION
Install the oil pump and tighten the two bolts
securely.
＊
Make sure the pump shaft rotates freely
and arrow on the oil pump is upside.
MYROAD 700i
Oil Pump Cove
Oil Pump Cove
Oil PumpCove
Screw
Bolts
Dowel Pin
Bolts
Oil Pump
4-7
Page 93
4. LUBRICATION SYSTEM
r
r
OIL COOLER
REMOVAL
Drain the engine oil and remove the oil filter
cartridge.
Drain the coolant from the system.
Loosen the hose bands and disconnect the oil
cooler hoses from the cooler.
Remove the oil cooler mounting bolts, oil
cooler.
INSPECTION
Check the cooler for damage.
Hose
Oil Coole
Bolts
Coole
MYROAD 700i
4-8
Page 94
4. LUBRICATION SYSTEM
INSTALLATION
Install the removed parts in the reverse order
of removal.
Install the oil cooler bolts with the specified
torque.
Torque: 0.8~1.2 kgf•m
Remember to install the dowel pin(15x10)
And O-ring (14.8x2.4)
Oil Cooler
MYROAD 700i
4-9
Page 95
4. LUBRICATION SYSTEM
Installation of oil filter cartridge
Standard Torque:
Oil filter cartridge 1.2~1.8 kgf•m
MYROAD 700i
4-10
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