K-XCT300iSM v2 PDF

1.
External Components K- XCT 300i
External Components
This chapter covers the location and servicing of the external components for
the KYMCO K-XCT 300i.
• Exhaust System ...............................................................1-2~1-13

• Luggage Box ..................................................................1-14~1-16
• Seat................................................................................1-17~1-19
• Rear Carrier ...................................................................1-20~1-22
• Body Cover ....................................................................1-23~1-32
• Windshield .....................................................................1-33~1-36
• Front Cover Meter ..........................................................1-37~1-38
• Side Molding A ...............................................................1-39~1-48
• Side Cover .....................................................................1-49~1-59
• Front Fender ..................................................................1-60~1-63
• Center Cover ..................................................................1-64~1-66
• Under Cover ...................................................................1-67~1-68
• Rear Meter Cover.......................................................... 1-69~1-72
• Floorboard ....................................................................1-73~1-78
• Leg Shield ..................................................................... 1-79~1-83
• Handle Cover ...............................................................1-84~1-89
• Rear Tire Fender ..........................................................1-90~1-94
• Stands ..........................................................................1-95~1-99
1-1
1. External components > Exhaust System K-XCT 300i
Exhaust System
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.
Troubleshooting
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Removal
1-2
Remove the two exhaust pipe joint nuts with a 12 mm deep well socket.
Remove the O2 sensor wire band.
Unplug the O2 sensor connector.
Remove the three muffler mounting bolts with a 14 mm socket.
1-3
Remove the exhaust system.
Remove the exhaust pipe gasket and discard it.
1-4
O2 Sensor
Removal
Remove the O2 sensor with a 17 mm wrench. Use care not to pinch the wires.
The O2 sensor issues signal to ECU when the temperature is over 350°C while the engine
is running.
Test the O2 sensor at room temperature.
Use a digital multimeter set to ohms of resistance to inspect the O2 sensor.
1-5
Measure the resistance between the white wire terminals of the O2 sensor connector.
Replace the O2 sensor if the reading is out of specification.
ITEM SPECIFICATIONS
2
O heater sensor resistance (at 20°C/68°F) 6.7 - 9.5 Ω (engine warming condition)
1-6
Heat Shields
Remove the three muffler heat shield bolts with a 10 mm socket if needed.
1-7
To remove the four bolts to free the heat shield on the muffler.
Remove the heat shield.
1-8
Installation
Heat Shields
Install the heat shields and tighten the bolts securely.
O2 Sensor
Apply anti-seize compound to the threads of the O2 sensor.

Install the O2 sensor and tighten it to specification with a 17 mm
wrench. Use care not to pinch the wires.
Torque
Item
N-m lb-ft
2
O Sensor 25 18
1-9
Exhaust System
Insert a new exhaust pipe gasket into the exhaust port.
Fit the exhaust system into place
1-10
Install the two exhaust pipe joint nuts with a 12 mm deep well socket. Do
not tighten.
Install the three muffler mounting bolts and tighten to specification with a
socket.
Torque
Item
N-m kgf-m
Muffler Mounting Bolts 35 3.5
1-11
Tighten the two exhaust pipe joint nuts to specification with a 12 mm

deep well socket.
Torque
Item
N-m kgf-m
Exhaust Pipe Joint Nuts 20 2
If the exhaust pipe and muffler were separated installed the muffler clamp securely.
Plug in the O2 sensor.
1-12
Install a new O2 sensor clamp.
1-13
1. ExternalComponents > Luggage Box K-XCT 300i
Luggage Box
Removal
Remove the four luggage bolts with a 10 mm socket.
Remove the two luggage nuts with a 10 mm socket.
1-14
Lift up the luggage box to unplug the luggage box light connector.
Remove the luggage box.
Installation
Plug in the luggage box light connector.
Install the luggage box.
1-15
Install the four luggage bolts and tighten securely with a 10 mm socket.
Remove the two luggage nuts with a 10 mm socket.
Install the seat.
1-16
1. External Components > Seat K-XCT 300i
Seat
Removal
Insert the key and turn it counterclockwise.
Remove the two seat hinge nuts with a 10 mm socket.
1-17
Seat Latch Cable
The seat latch cable runs from the ignition switch to the seat latches.
The cable must be adjusted periodically so that the latches will open correctly.
Open the seat.
Loosen the lock nuts and turn the adjusters as needed to

adjust the seat latch cable operation.
There is one adjuster for each latch. Tighten the locknuts

securely when finished.
1-18
Installation
Install the seat onto the hinge.
Install the two seat hinge nuts and tighten securely with a 10 mm socket.
1-19
1. ExternalComponents > Rear Carrier K-XCT 300i
Rear Carrier
Removal
Pry off the carrier bolt covers with a small flat blade screwdriver,
the arrow mark indicates the pry point.
1-20
Remove the four carrier bolts with a 6 mm Allen.
Remove the carrier each side.
1-21
Installation
Install the carrier.
Install the four carrier bolts on each side with a 6 mm Allen.
Push on the carrier bolt covers.
1-22
1. External Components > Body Cover K-XCT 300i
Body Cover
Removal
Remove the two rear center cover screws with a #2 Phillips.
1-23
Carefully unhook the tabs on both side of the rear center cover.
Remove the rear center cover.
Remove the four lower body cover nuts with a 10 mm socket.
1-24
Remove the two plastic screws from the front of the body cover.
Carefully unhook the tabs on both sides of the body cover.
1-25
Unplug the taillight connector.
Remove the body cover.
1-26
Disassembly
Rear Center Molding
Remove the two Rear Center Molding screws with a #2 Phillips.

Remove the rear center molding.
1-27
Rear Fender
Remove the rear fender screws with a #2 Phillips.
Carefully unhook the tabs on both sides of the rear fender.
Remove the rear fender.
1-28
Taillight Assembly
Remove the eight taillight assembly screws with a #2 Phillips.
Unhook the taillight section and separate from the body cover.
Remove the taillight assembly
1-29
License Light
Remove the two license light assembly screws with a screwdriver.
Disconnect the connector license light.
Remove the license light assembly.
Installation
Fit the body cover into place.
1-30
Plug in the taillight connector.
Carefully push the hooks into the corresponding tabs on both sides of
the body cover.
Install the two screws on both sides of the body cover.
1-31
Install the four lower body cover nuts and tighten securely with a 10 mm
socket.
Carefully install the rear center cover.
Install the two rear center cover screws and tighten securely with
a #2 Phillips.
1-32
1. External Components > Windshield K-XCT 300i
Windshield
Removal
Open the hidden bolt cover.
Remove the hidden bolt with a 10 mm socket.
Depress the head of the fastener center piece.

Pull out the fastener.
1-33
Carefully pull out the front cover with a thinner driver on each side.
Lightly slap downward at the front cover on each side.
1-34
Remove the front cover.
Remove the four bolts with a 12mm socket on each side.
Remove the windshield.
1-35
Installation
Install the windshield.
Install the four windshield bolts and tighten securely with a 12mm socket.
There are two bolts on each side.
Install the center cover carefully. Install the push pin
Install the hidden bolt and tighten securely with a 10 mm socket. Close the cover.
1-36
1. ExternalComponents > Front Cover Meter K-XCT 300i
Front Cover Meter
Removal
Remove the two front cover meter mounting nuts with a 10 mm socket
Remove the two screws mounting on the front cover meter on each side.
Remove the front cover meter
1-37
1. ExternalComponents > Front Cover Meter K-XCT 300i
Install
Install the front cover meter
Install the two screws mounting on the front cover meter on each side.
Install the two screws mounting on the front cover meter on each side.
1-38
1. ExternalComponents > Side Molding A K-XCT 300i
Side Molding A
Removal
Remove the side molding mounting nuts with a 10 mm socket.
Carefully depress the front inner cover.
1-39
Carefully pull out the side molding and leg shield with a thinner driver on each side.
Carefully pull off the side molding with hand.
1-40
Carefully pull out the side molding and side skirt with hand on each side.
Unplug the headlight leads.
1-41
Gently pull the side molding forward and free the tabs.
Disassembly
Light Assembly
1-42
Remove the eight light assembly mounting screws with a #2 Phillips.
Separate the light assembly from the side molding A.
1-43
Side Piece
Remove the eight side piece screws with a #2 Phillips.
Assembly
Side Piece
Install the eight side piece screws and tighten securely with a #2 Phillips.
1-44
Light Assembly
Install the eight light assembly mounting screws and tighten securely with a #2 Phillips.
1-45
Install the headlight assembly on the side molding A.
Installation
Plug in the headlight and turn signal leads.
1-46
Align front cover tabs. Install the front cover.
Carefully Align the side molding and side skirt with hand on each side.
1-47
Carefully Align the side molding and leg shield
Install the two front cover mounting nuts with a 10 mm socket.
1-48
1. External Components > Side Skirt K-XCT 300i
Side Skirt
Removal
Pull up the footboard rubber covers.
Remove the four screws mounting the footboard with a #2 Phillips.
1-49
Remove the six leg shield mounting screws with a #2 Phillips.
There are three screws on each side.
1-50
Remove the six lower fairing push pins on each side including the undercover.
1-51
Remove the left lower bolt under the side skirt with a 10mm socket.
Gently separate the floorboard from the side skirt. Carefully free the tabs.
Remove the cover side skirt after the turn signal leads removed.
1-52
Remove the two cover side skirt mounting screws with a #2 Phillips.
Disassembly
Remove the two screws from the side board A with a #2 Phillips.
1-53
Separate the Side skirt and side board A.
Remove the three cover side skirt mounting screws with a #2 Phillips.
Carefully pull out the cover side skirt from side skirt.
1-54
Remove the three winker assembly mounting screws with a #2 Phillips.
Remove the winker assembly from the cover side skirt.
1-55
Assembly
Winker Assembly
Install the three winker assembly mounting screws with a #2 Phillips.
Install the three screws onto the cover side skirt.
1-56
Installation
Install the side skirt. Carefully fit the upper tabs of the side board A into the
floorboard. Install the side board A while aligning the tabs.
Install the four screws under the footboard rubber cover with a #2 Phillips on
each side. Tighten them securely.
Install the left lower bolt under the footboard rubber cover with a 10mm
socket.
1-57
Install the footboard rubber covers.
Install the two cover side skirt mounting screws with a #2 Phillips.
Connect the turn signal leads removed.
1-58
Install the six leg shield mounting screws with a #2 Phillips.
There are three screws on each side.
Install the six lower fairing push pins on each side including the undercover.
1-59
1. External Components > Front Fender K-XCT 300i
Front Fender
Removal
Remove the left forward front fender bolt with a 6 mm Allen.
Remove the left rear fender bolt with a 10 mm socket.
Remove the right forward front fender bolt with a 6 mm Allen.
1-60
Remove the right rear fender bolt with a 10 mm socket.
Remove the front fender from the forks.
1-61
Installation
Guide the fender between the forks.
Install the right rear fender bolt with a 10 mm socket.
Install the right forward front fender bolt with a 6 mm Allen.
1-62
Install the left rear fender bolt with a 10 mm socket.
Install the left forward front fender bolt with a 6 mm Allen.
1-63
1. External Components > Center Cover K- XCT 300i
Center Cover
Removal
Note: Do not force the cover and damage the claws.
Pull the center cover back and up to free the claws and then
move the cover backward to free it from the scooter.
1-64
Remove the center cover.
Installation
Place the center cover on the scooter.
1-65
Push the cover down and forward to lock in the claws.
1-66
1. External Components > Under Cover K-XCT 300i
Under Cover
Removal
Remove the two cover bolts mounting the under cover each side
with a 10 mm socket.
Remove the under cover.
1-67
1. External Components > Under Cover K-XCT 300i
Installation
Install the under cover.
Install the two under cover bolts on the each side and tighten
securely with a 10 mm socket.
1-68
1. External Components > Rear Meter Cover K-XCT 300i
Rear Meter Cover
Removal
Remove the two push pins below the handlebar. Depress the
head of the fastener center piece. Pull out the fastener.
Remove the bolt attaching the rear meter cover on the left with a
10 mm socket.
Remove the bolt attaching the speedometer cover on the right

1-69
Remove two screws mounting the rear meter cover on both

sides with a #2 Phillips.
Remove the connector speedometer assembly.
Remove the speedometer assembly
1-70
Installation
Install the speedometer assembly
Install the connector speedometer assembly.
Install two screws mounting the speedometer cover on both sides

with a #2 Phillips.
1-71
Install the bolt attaching the rear meter cover on the left with a 10
mm socket.
Install the bolt attaching the speedometer cover on the right with
a 10 mm socket.
Install the two push pins below the handlebar. Depress the head
of the fastener center piece. Pull out the fastener.
Note: To prevent the pawl from damage, insert the fastener all
the way into the installation hole.
1-72
1. External Components > Floorboard K-XCT 300i
Floorboard
Removal
Remove the two bolts mounting the floorboard on the left side
Remove the two bolts mounting the floorboard on the right

side with a 10 mm socket.
Remove the two bolts mounting the side board A on each side
1-73
Remove the two nuts mounting the side board A on each side
Carefully unhook the tabs on both sides of the side board A.
1-74
Remove the floorboard on each side.
Disassembly
Remove the four screws mounting the side board A
Separate the floorboard from side board A.
1-75
Disassembly
Install the four screws mounting the side board A
Installation
Install the floorboard on each side.
1-76
Carefully install the tabs on both sides of the side board A.
Install the two nuts mounting the side board A on each side
1-77
Install the four bolt mounting the floorboard on each side with a
10 mm socket.
Install the two bolt mounting the side board A on each side with a
10 mm socket.
1-78
1. External Components > Leg Shield K-XCT 300i
Leg Shield
Removal
Remove the screw mounting the collar ignition switch with a #2 Phillips.
Take off the collar.
Open the fuel cap panel.
1-79
Remove the fuel cap with the key.
Remove the Lid fuel cap maint.
1-80
Remove the gas cap overflow pad.
Lift off the leg shield.
1-81
Installation
Install the leg shield.
Align the pin hole of the body frame.
1-82
Install the gas cap overflow pad and the Lid fuel cap maint.
1-83
1. External Components > Handlebar Cover K-XCT 300i
Handlebar Covers
Removal
Upper Cover
Remove the four cover screws with a #2 Phillips.
1-84
Carefully free the tabs and remove the upper handlebar cover.
Lower Cover
Route the throttle cables out of the handlebar cover.
1-85
Remove the two handle lower cover screws with a #2 Phillips.
1-86
Remove the lower cover.
Installation
Place the lower cover onto the handlebar.
1-87
Route the throttle cables into the handlebar cover.
Carefully install the upper handlebar cover.
1-88
Remove the four cover screws with a #2 Phillips.
1-89
1. External Components > Rear Tire Fender K-XCT 300i
Rear Tire Fender
Removal
Remove the two fender mounting bolts with a 8 mm socket on the right side.
1-90
Remove the two airbox mounting bolts with a 8mm socket.
Remove the connecting tube screw with a 2# Phillips.
Remove the fender mounting bolt with a 8 mm socket on the left side.
1-91
Remove the rear fender.
Installation
Install the rear fender.
1-92
Install the fender mounting bolt with a 8 mm socket on the left side.
Install the connecting tube screw with a 2# Phillips.
Install the two fender mounting bolts with a 8 mm socket on the right side.
1-93
Install the two airbox mounting bolts with a 8mm socket.

Install the airbox.
1-94
1. ExternalComponents > Stands K-XCT 300i
Stands
Side stand
Removal
Unplug the three-pin side stand switch connector.
Remove the side stand spring with a spring puller.
1-95
Remove the side stand bolt, switch, and side stand.
Installation
Install the side stand, switch, and bolt. Make sure to fit the switch into
place correctly. Tighten the bot securely.
1-96
Install the side stand spring with a spring puller.
Plug in the side stand switch connector.
1-97
Center Stand
Removal
Remove the center stand spring with a spring puller.
Remove the two center stand nuts and bolts. Remove the center stand.
1-98
Installation
Install the nuts and bolts. Tighten them securely.
Install the center stand spring with a spring puller.
1-99
2. Periodic Maintenance > Periodic Maintenance Chart K- XCT 300i
Maintenance Schedule
Perform the pre-ride inspection (Owner's Manual) at each scheduled maintenance

period. This interval should be judged by odometer reading or months, whichever
comes first.
Maintenance schedule legend
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR

REPLACE IF NECESSARY
C: CLEAN
A: ADJUST
R: REPLACE
L: LUBRICATE
I: INSPECTION
The maintenance schedule specifies the maintenance required to keep your K-XCT
300i scooter in peak operating condition. Maintenance work should be performed in
accordance with KYMCO standards and specifications by properly trained and
equipped technicians. Your KYMCO dealer meets all of these requirements.
* Should be serviced by your KYMCO dealer, unless you have the proper tools, service
data and are technically qualified.
** In the interest of safety, we recommend these items be serviced only by your

KYMCO dealer. KYMCO recommends that your KYMCO dealer road test your
scooter after each periodic maintenance service is completed.
2-1
2. Periodic Maintenance > Periodic Maintenance Chart K- XCT 300i
WHICHEVER
FREQUENCY COMES FIRST ODOMETER READING
ITEM X 1000 km 1 5 10 15 20 25 30 REFER

X 1000 mi 0.6 3 6 9 12 15 18 TO
MONTH 1 6 12 18 24 30 36 PAGE
AIR CLEANER R R R R R R 33
SPARK PLUGS I R I R I R 34
THROTTLE OPERATION I I I I I I 33
VALVE CLEARANCE I A I A I A -
FUEL LINE I I I -
CRANKCASE BREATHER C C C C C C C -
ENGINE OIL R R R R R R R 29
ENGINE OIL SCREEN C R C R C R -
ENGINE OIL FILTER R R R R R R R -
ENGINE IDLE SPEED I I I -
TRANSMISSION FLUID R R R R R R R 32
DRIVE BELT I I I R I I -
WHICHEVER
COMES FIRST ODOMETER READING
FREQUENCY
X 1000 km 1 5 10 15 20 25 30 REFER
ITEM X 1000 mi 0.6 3 6 9 12 15 18 TO
MONTH 1 6 12 18 24 30 36 PAGE
CLUTCH SHOE WEAR I I I -
BRAKE FLUID I R I R I R 38
BRAKE PAD WEAR I I I I I I 40
BRAKE SYSTEM I I I I I I -
BRAKE LIGHT SWITCH I I I I I I -
STEERING BEARINGS I I I I I I -
HEADLIGHT AIM I I I I I I -
NUTS, BOLTS, FASTENERS I I I I I I -
WHEELS/TIRES I I I I I I 42
COOLANT I R I R I R 35
2-2
2. Periodic Maintenance > Air Filter Servicing K- XCT 300i
Air Filter Servicing

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Replace the air filter according to the Maintenance Schedule, and more often in
exceptionally rainy or dusty areas.
Removal
Remove the 8 air filter cover screws with a #2 Phillips screwdriver.
2-3
Remove the air filter cover.
Remove the 7 air filter bolts with an 8 mm socket or a #2 Phillips

screwdriver.
2-4
Remove the air filter from the airbox. Discard the air filter in favor of a
new item.
Caution:
• The air cleaner element has a viscous type paper element. Do not
clean it with compressed air.
• Be sure to install the air cleaner element and cover securely.
Installation
Fit the new air filter into place.
2-5
Insert the 7 air filter bolts. Tighten the air filter bolts securely with an 8
mm socket or a #2 Phillips screwdriver.
Install the air filter cover.
2-6
Install the 8 air filter cover screws and tighten them securely
with a #2 Phillips screwdriver.
2-7
2. Periodic Maintenance > Brake Fluid K- XCT 300i
Brake Fluid
The KYMCO K-XCT 300i uses DOT 4 brake fluid that should be inspected
after 3,000 mi (5,000 km) of use. It should be flushed and bled every 12
months, 6,000 mi (10,000 km), whenever the brakes feel spongy, or if the
brake system has been taken apart and rebuilt. Always use fresh brake
fluid from a tightly sealed container.
SAFETY FIRST: Protective gloves and eyewear are recommended at this

point.
Warning: Brake fluid is very caustic and can damage paint, chrome and
plastic. Wipe up any spills immediately.
Inspection
Turn the handlebars until the top of the master cylinder reservoir is level
with the ground. Do this for both master cylinder reservoirs and check
the level of brake fluid.
2-8
Draining
The brake bleeding process is the same for the front and rear brakes.
Remove the two master cylinder cover screws with a #2 Phillips head
screwdriver.
Remove the master cylinder cover, plastic piece and rubber diaphragm.
Clean and inspect the rubber diaphragm for tears or other damage.
Replace as necessary.
2-9
Pull off the rubber cap over the bleeder valve and crack open the
bleeder valve on the brake caliper using an 8 mm wrench. This valve is
usually very tight so use a box end wrench or a 6 point socket and
ratchet to prevent rounding off the head. Snug the bleeder valve back
down.
Open the valve and remove the old brake fluid with a Mighty -Vac or a
similar device.
2-10
Bleeding
Place a length of 6 mm inside diameter clear hose on the bleeder valve

and place the other end in a suitable container. A spare battery vent
hose works well for this job.
Fill the brake fluid with the proper type from a fresh, newly opened
container.
2-11
Pump the brake lever several times and hold the lever in. While holding
the lever in, crack open the bleeder valve. The front brake lever will
travel all the way to the grip and brake fluid and/or air will come out of
the bleeder valve into the 6 mm hose. Tighten the bleeder valve before
releasing the front brake lever. Pump the lever several times again and
repeat the process.
Be certain to check the master cylinder reservoir occasionally to make

sure the reservoir doesn't run dry. Add more brake fluid as necessary.
Continue this process until clean brake fluid comes out of the bleeder
valve and there are no air bubbles. The brake lever should feel firm.
Tighten the bleeder valve to specification and push its rubber cover over
the nipple.
(Air Bleeder Valve Torque: 7.5 N-m or 5.5 lb-ft)
Make sure the reservoir has the proper amount of fluid.
2-12
Place the rubber diaphragm, plastic piece and cover over the reservoir.
Thread in the reservoir cover screws and tighten them securely with a
#2 Phillips screwdriver.
2-13
2. PeriodicMaintenance > Compression Test K- XCT 300i
Engine Compression Test

Remove the seat. See the Seat topic for more information.
Remove the luggage box. See the Luggage Box topic for more information.
Before testing the compression make sure the cylinder head bolts are
tightened securely and the valve clearance is specification. See the
Cylinder Head and Valve Clearance topics for more information.
Remove the spark plug. See the Spark Plug topic for more information.
Thread a compression tester into the spark plug hole hand tight. Hold
the throttle all the way open. Crank the engine with the starter motor
until the needle on the gauge stops rising. Do not crank the engine more
than a few seconds.
Cylinder compression 16 ± 2 kg/cm2 228 ± 28.4 psi
Low compression is an indication of excessive engine wear, possibly

worn rings or poorly sealing valves, or maybe a tight valve with not
enough valve clearance. High compression is possibly an indication of
excessive carbon buildup on the piston or performance modifications.
Install the spark plug.
2-14
2. Periodic Maintenance > Engine Oil K- XCT 300i
Engine Oil
Caution: Hot engine oil can burn. Avoid letting used motor oil contact exposed skin.
TROUBLESHOOTING
Oil level too low
1. Natural oil consumption
2. Oil leaks
3. Worn or poorly installed piston rings
4. Worn valve guide or seal
Poor lubrication pressure

1. Oil level too low
2. Clogged filter or oil passages
3. No use the specified oil
Oil Specifications
Use a fully synthetic quality 4-stroke engine oil to ensure longer service
life of the scooter. Only use oils that have a SJ rating above per the API
service classification.
Engine oil viscosity : SAE 5W-50
2-15
If these viscosities are not available, select an alternative engine oil

according to the chart shown above.
Engine oil capacity

At disassembly 1.5 Liter
At change 1.3 Liter
Inspection
Oil Level
Check the engine oil level each day before operating the scooter.
Place the motorcycle upright on level ground for engine oil level check.
Run the engine for 2 ~ 3 minutes and check the oil level after the engine is
stopped for 2 ~ 3 minutes.
2-16
The oil filler cap/dipstick is located on the right side of the engine.
Remove the oil filler cap/dipstick and wipe off the oil. Inspect the O-ring
and replace it as needed. Insert the dipstick in without threading it in.
Remove the dipstick and check the oil level.
2-17
The level must be maintained between the upper (1) and lower level (2)
marks on the oil filler cap/dipstick.
If the oil level is at or below the lower mark add more of the same type
and brand of oil to the engine through the oil filler hole. If the oil level is to
high remove the drain plug and the excess oil.
Servicing
Draining
Warm the engine as with the inspection, this will heat the engine and
allow the oil to drain out faster and more completely. The vehicle should
be on level ground. Stop the engine.
Caution: Hot engine oil can burn. Avoid letting used motor oil contact
exposed skin.
2-18
Place an oil pan under the engine. The oil drain bolt is located on the left
side of the engine.
2-19
Loosen the engine oil drain bolt with a 17 mm socket. Remove the bolt
and allow the oil to drain into the pan.
Discard the old sealing washer.
2-20
Remove the oil filler cap to allow for faster oil draining. Inspect the oil
filler cap O-ring and replace it as needed.
When the oil has drained completely Install the drain bolt with a new
sealing washer. Tighten the drain bolt to specification with a 17 mm
socket.
Torque
Item Qty Remarks
kgf-m lb-ft
Oil Drain bolt 1 2.5 18.08 New sealing washer
2-21
Strainer Screen
Remove the oil strainer screen bolt with a 17 mm socket. Inspect the
strainer screen bolt O-ring and replace it as needed.
Remove the oil strainer screen.
2-22
Remove the O-rings from the oil strainer screen and inspect them.
Replace the O-rings if they are in poor condition. Inspect the oil strainer
screen for debris and damage. Clean it with a high flash point solvent
and compressed air. Metal debris in the strainer screen can be an
indicator of engine wear or damage.
NOTE: Always wear safety glasses when using compressed air and
never point it directly at yourself or anyone else.
2-23
Return the O-rings to the oil strainer screen and install it into the left side
of the engine. Tighten the oil strainer screen cap to specification with a
17 mm socket.
Torque
Item Qty
kgf-m lb-ft
Engine oil strainer cap 1 1.02 7.2
Filter Replacement
The oil filter compartment is located on the bottom of the engine below
the oil filler cap/dipstick. Ready an oil drain pan to catch any remaining
engine oil.
2-24
Loosen the oil filter cap with a 24 mm socket.
Remove the oil filter cap with spring and take out the used oil filter.
2-25
Inspect the oil filter cap O-ring and spring. Replace the items if they are
in poor condition.
Install the spring to the oil filter cap. Apply a light coat of engine oil to the
oil filter cap O-ring.
2-26
Pour a small amount of fresh engine oil into the oil filter. Insert the oil
filter into place with the rubber seal side facing up.
Install the oil filter cap with spring. Makes sure the spring fits against the
filter correctly. Tighten the oil filter cap securely with a 24 mm socket.
2-27
Filling
Add the oil to the engine through the oil filler/dipstick hole.
Use a fully synthetic quality 4-stroke engine oil to ensure longer service
life of the scooter. Only use oils that have a SJ rating above per the API
service classification.
Engine oil viscosity : SAE 5W-50
Engine oil capacity

At change 1.3 Liter
2-28
2. Periodic Maintenance > General Lubrication K- XCT 300i
General Lubrication
The frame lubrication points are listed below. Use general purpose
grease. Apply clean engine oil or grease to cables and movable parts
not specified. This will avoid abnormal noise and increase the durability
of the motorcycle.
Front Wheel Axle

Side Stand Pivot
Center Stand Pivot
Rear Wheel axle
2-29
2. Periodic Maintenance > Hose Inspection K- XCT 300i
Hose Inspection
Inspect the breather hose for damage and deterioration.
Inspect the fuel hose for damage and deterioration.
2-30
2. Periodic Maintenance > Spark Plug K- XCT 300i
Spark Plug
SAFETY FIRST: Protective gloves and eyewear are recommended
at this point.
Removal
The spark plug is located on the left side of the cylinder.
remove the spark plug wire off of the spark plug.
2-31
Clean off the area surrounding the spark plug with compressed air or a
shop towel to make sure debris doesn't get into the combustion chamber
when the spark plug is removed.
Remove the spark plug with a spark plug with a 5/8 in socket.
Spark plug NGKCR7E
2-32
Inspection
Always check the gap of the spark plug before installation. If the gap
needs to be adjusted bend the ground electrode carefully. Inspect the
color of the porcelain nose of the spark plug. The color of the spark plug
can indicate how the mixture is burning. A white colored plug shows a
lean mixture, where a dark plug shows a rich mixture. Do not hesitate to
replace a spark plug. Always replace a spark plug if any part of it is
damaged.
Spark plug gap 0.6 - 0.7 mm
Installation
Thread the spark plug by hand before using a socket to tighten. Torque
to specification with a 5/8" spark plug socket. Do not over tighten the
spark plug. The cylinder head is made out of soft metal, and it can be
easily damaged.
2-33
Item Torque
Spark plug 17.2 N-m (1.5 - 2 ft-lb, 10.84 - 14.47 kgf-m)
Install the spark plug wire over the plug.
Install the luggage box. See the LuggageBox topic for more information.
Install the seat. See the Seat topic for more information.
2-34
2. Periodic Maintenance > Steering K- XCT 300i
Steering
at this point.
Inspection
Raise the front wheel off the ground and check that the steering
handlebar rotates freely. If the handlebar moves unevenly, binds, or has
vertical movement, adjust the steering head bearing. See the Steering
topic for more information.
2-35
2. Periodic Maintenance > Suspension K- XCT 300i
Suspension
Front Suspension
Check the action of the front shock absorbers by compressing them

several times. Check the entire shock absorber assembly for oil leaks,
looseness or damage.
2-36
2. Periodic Maintenance > Suspension K- XCT 300i
Pre-Load Setting
Each shock absorber on the scooter has 5 spring preload adjustment

positions for different load or riding conditions.
Position 1 is for light loads and smooth road conditions. Position 3 to 5

increase spring preload for stiffer rear suspension and can be used
when the scooters heavily loaded. Be certain to adjust both shock
absorbers to the same spring preload positions.
Use a pin spanner to adjust the rear shock spring preload. The shock
absorbers are adjustable for pre-load. There are 5 settings. Position 1
is the softest and 5 is the stiffest.
Caution: Always adjust the shock absorber pre-load position in

sequence (1-2-3-4-5 or 5-4-3-2-1). Attempting to adjust directly from 1
to 5 or 5 to 1 may damage the shock absorber. (Pre-Load Standard
Setting: Position 3)
2-37
2. PeriodicMaintenance > Tires K- XCT 300i
Tires
at this point.
Check tires before each ride for wear and air pressure.
Check tire air pressure before riding when tires are cold.
Solo riding Front 2.00 kg/cm2(28.4 psi)

Cold inflation tire Rear 2.25 kg/cm2(32 psi)
pressure Dual riding Front 2.00 kg/cm2(28.4 psi)
Rear 2.25 kg/cm2(32 psi)
2-38
2. PeriodicMaintenance > Tires K- XCT 300i
Replace tires if the tread depth reaches the wear mark or fails to meet
the minimum tread depth.
Front wheel 120/70-14

Tires
Rear wheel 150/70-13
2-39
2. Periodic Maintenance > Valve Adjustment K- XCT 300i
Valve Clearance
SAFETY FIRST: Protective gloves and eyewear are recommended at
this point.
The valve clearance specification is only relevant if the engine is cold

(below 35°C or 95°F).
Inspection
Remove the luggage box. See the LuggageBox topic for more
information.
Remove the spark plug. See the SparkPlug topic for more information.
Remove the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Remove the crankshaft cap on the right side of the engine with a large
flat blade screwdriver. Inspect the O-ring on the cap and replace it as
needed.
Remove the timing inspection cap from the right side of the engine with
a large flat blade screwdriver. Inspect the O-ring on the cap and
replace it as needed.
2-40
The crankshaft must be rotate (clockwise) until the piston is at top dead
center (TDC) on the compression stroke.
Turn crankshaft clockwise until the "T" mark aligns with the index notch
in the timing inspection hole.
2-41
For correct engine timing the marks on the camshaft sprocket must be
even with the cylinder head mating surface at the same time the "T"
mark is lined up with the with the index notch in the timing inspection
hole. Also the camshaft sprocket mounting boss should be visible above
the cylinder head surface.
If this is not the case, rotate the crankshaft 360° clockwise until the "T"
mark is once again aligned with the notch on the case cover.
2-42
Measure the valve clearance with a thickness feeler gauge. Insert the
feeler gauge between the tappet adjusting screw and the valve stem.
The clearance is correct when there is a light drag on the feeler gauge.
The clearance is the same for the exhaust and intake valves. If the
clearance is out of spec move on to the adjustment section.
Valve clearance IN: 0.10 mm EX: 0.10 mm
2-43
Adjustment
Use a tappet adjuster tool to adjust the valves.
SPECIAL TOOLS
ITEM TOOL NO. DESCRIPTION
TAPPET ADJUSTER E012 Tappet adjustment
2-44
Place a 9 mm box end wrench over the locknut, and loosen the locknut.
If the valve clearance is tight back out the valve tappet adjusting screws
with the tappet adjustment tool. If the clearance is to loose turn in the
adjusting screw until there is a light drag on the feeler gauge. Hold the
adjusting screw locknut in place with the wrench to make sure it doesn't
interfere with the adjustment.
Lubricate the tappet adjusting screw threads with fresh engine oil. Hold
the adjuster in place and tighten the locknut. Always recheck the
clearance after tightening the locknut. Also, recheck after turning the
engine over a full 360°.
Thread Torque
Item Qty Remarks
size (mm) kgf-m lb-ft
Valve adjusting lock nut 4 5 0.7-1.1 5.06-7.96 Apply oil to thread
Make sure the O-rings on the crankshaft and timing plugs are in good
condition. Replace them as needed. Install the timing inspection and
crankshaft caps to the right side of the engine. Tighten the caps
securely but not overly with a large flat blade screwdriver.
2-45
3. Engine K- XCT 300i
Engine
This chapter covers the location and servicing of the engine components for the
KYMCO K-XCT 300i.
• Engine Removal ....................................................3-4~3-13

• Cylinder Head Cover ...........................................3-14~3-19
• Camshaft .............................................................3-20~3-37
• Valves .................................................................3-38~3-47
• Cylinder and Piston .............................................3-48~3-65
• Generator ............................................................3-66~3-86
• Oil Pump .............................................................3-87~3-93
• Crankcase .........................................................3-94~3-105
• Camshaft .........................................................3-106~3-110
• Engine Installation ...........................................3-111~3-118
• Specifications ..................................................3-119~3-127
GENERAL INSTRUCTIONS
Lubrication System
The maintenance of lubrication system can be performed with the engine installed in the
frame. Use care when removing and installing the oil pump not to allow dust and foreign
matters to enter the engine and oil line.
Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set
when it reaches its service limit.
After the oil pump is installed, check each part for oil leaks.
TROUBLESHOOTING
Oil level too low

2. Oil leaks
3-1

3. No use the specified oil
Cylinder Head, Camshaft, and Valves
• The cylinder head can be serviced with the engine installed in the frame. Coolant in
the radiator and water hoses must be drained.
• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide
movable parts and valve arm sliding surfaces for initial lubrication.
• The valve rocker arms are lubricated by engine oil through the engine oil passages.
Clean and unclog the oil passages before assembling the cylinder head.
• After disassembly, clean the removed parts and dry them with compressed air before
inspection.
• After removal, mark and arrange the removed parts in order. When assembling, install
them in the reverse order of removal.
TROUBLESHOOTING
• The poor cylinder head operation can be diagnosed by a compression test or by

tracing engine top-end noises.
Poor performance at idle speed
• Compression too low
Compression too low
• Incorrect valve clearance adjustment

• Burned or bent valves
• Incorrect valve timing
• Broken valve spring
• Poor valve and seat contact
• Leaking cylinder head gasket
• Warped or cracked cylinder head
• Poorly installed spark plug
3-2
Compression too high
• Excessive carbon build-up in combustion chamber
Abnormal noise
• Incorrect valve clearance adjustment
• Sticking valve or broken valve spring
• Damaged or worn camshaft
• Worn cam chain tensioner
• Worn camshaft and rocker arm
White smoke from exhaust muffler

• Worn valve stem or valve guide
• Damaged valve stem oil seal
Cylinder and Piston

• The cylinder and piston cannot be serviced with the engine installed in the frame.
• After disassembly, clean the removed parts and dry them with compressed air before
inspection.
• If replacing the piston or cylinder, they must be changed as a pair.
TROUBLESHOOTING
Compression too low or uneven compression
• Worn, stuck or broken piston rings

• Worn or damaged cylinder and piston
Compression too high
• Excessive carbon build-up in combustion chamber or on piston head.
Excessive smoke from exhaust muffler
• Worn or damaged piston rings

• Worn or damaged cylinder and piston
Abnormal noisy piston
• Worn cylinder, piston and piston rings

• Worn piston pin hole and piston pin
3-3
3. Engine > Engine Removal K- XCT 300i
Engine Removal
• A floor jack or other adjustable support is required to support and maneuver the
engine. Be careful not to damage the scooter body, cables and wires during engine
removal.
• Use shop towels to protect the scooter body during engine removal.
Place the scooter on the center stand.
Remove the following external components:
. Seat
. Luggage Box
. Center Cover
. Front Cover
. Front Lower Cover
. Foot Skirt
. Rear Carrier
. Body Cover
. Under Cover
Disconnect the cables from the battery terminals. See the Battery topic for more information.
Remove the spark plug cap. See the Spark Plug topic for more information.
Drain the coolant. See the Coolant topic for more information.
Drain the engine oil. See the Engine Oil topic for more information.
Remove the air box. See the Air box topic for more information.
Remove the rear brake caliper. See the Rear Brake Caliper topic for more information.
Remove the throttle body. See the Throttle Body topic for more information.
Remove the exhaust system. See the Exhaust System topic for more information.
3-4
The regulator/rectifier is located on the right side of the vehicle.
Disconnect the generator 3-pin connector.
Disconnect the crank position sensor wire coupler.
3-5
Unplug the water temperature sensor.
Unplug the thermo sensor unit and thermo unit ground connectors.
Pull back the rubber starter motor lead cover.
3-6
Remove the starter motor lead nut with a 10 mm wrench. Free the cable
lead from the starter motor. Thread the nut back on to keep track of it.
Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose
stay from the cylinder head cover.
3-7
Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide
up the clamp and free the coolant hose from the water pump. Allow any
remaining coolant to drain into a suitable container.
Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide

up the clamp and free the coolant hose from the thermostat. Allow any
Squeeze the air bleed hose clamp with needle nose pliers and slide
back the clamp. Free the air bleed hose from the thermostat.
3-8
Loosen the main engine ground bolt with an 8 mm socket. Remove the
bolt and free the engine ground from the right side of the engine.
Free the starter motor lead from the stay on the right crankcase cover.
Unplug the oil pressure switch wire at the bullet connector. The oil
pressure switch is located below the cylinder.
3-9
Free the wiring harness from its guide above the intake pipe.
Support the engine with a suitable jack or stand.
3-10
Remove the rear shock absorbers. See the ShockAbsorbers topic for more information.
Loosen the engine mounting bracket damper nut with a 14 mm socket.

Remove the nut and washer.
Hold the engine mounting bolts with a 14 mm wrench and loosen the
nuts with a 19 mm socket.
Remove the engine mounting nuts and bolts from both sides.
3-11
Loosen the engine mounting bracket damper bolt and nut with a 17 mm
wrench for the nut and a 14 mm socket for the bolt.
Remove the engine mounting bracket damper bolt and nut.
Remove the engine mounting bracket.
3-12
Remove the engine mounting bracket damper assembly.
Carefully move the engine back and separate it from the chassis.
To install the engine see the Engine Installation topic.
3-13
3. Engine > Cylinder Head Cover K- XCT 300i
Cylinder Head Cover

Removal
Squeeze the breather hose clamp with needle nose pliers and slide if
back. Remove the breather hose from the cylinder head cover.
3-14
Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose
stay from the cylinder head cover.
Loosen the four cylinder head cover bolts with a 10 mm socket. Remove
the cylinder head cover bolts with washers and grommets. Note the gold
colored and longer bolts are on the left side.
Remove the cylinder head cover and gasket. Discard the gasket and
replace it with a new item on installation.
3-15
Remove the dowel pin.
Installation
Install the dowel pin into the cylinder head.
3-16
Fit the cylinder head cover gasket onto the cylinder head. Make sure the
projection fits into the groove in front of the camshaft sprocket correctly.
Install the cylinder head cover over the gasket. Make sure the ridge on
the gasket fits into the groove on the cylinder head cover correctly. Align
the bolt holes and dowel pin.
3-17
Coat the cylinder head cover bolt seals in fresh engine oil. Insert the
cylinder head cover bolts with grommet seals and washers. Note the
gold colored and longer bolts go on the left side.
Tighten the cylinder head cover bolts securely in two steps and in a
crisscross pattern with an 8 mm socket.
3-18
Fit the fuel stay into place. Tighten the stay bolt securely with an 8 mm
socket.
Install the breather hose to the cylinder head cover. Secure the hose
with the clamp.
Install the spark plug. See the SparkPlug topic for more information.
Install the luggage box. See the LuggageBox topic for more information.
3-19
3. Engine > Camshaft K- XCT 300i
Camshaft
Removal
Remove the cylinder head cover. See the Cylinder Head Cover topic for more information.
Remove the crankshaft cap on the right side of the engine with a large
flat blade screwdriver. Inspect the O-ring on the cap and replace it as
needed.
Remove the timing inspection cap from the right side of the engine with
a large flat blade screwdriver. Inspect the O-ring on the cap and replace
it as needed.
3-20
The crankshaft must be rotate (clockwise) until the piston is at top dead
center (TDC) on the compression stroke.
Turn crankshaft clockwise until the "T" mark aligns with the index notch
in the timing inspection hole.
3-21
The piston should now be at TDC on the compression stroke. You can
make sure that it is on the compression stroke by checking that there is
some slack in the rocker arms. If the rocker arms are rigid, rotate the
crankshaft 360° clockwise until the "T" mark is once again aligned with
the notch on the case cover.
The cam chain tensioner is located on the back of the cylinder.
3-22
Remove the cam chain tensioner cap bolt with a 10 mm socket.
Loosen the cam chain tensioner mounting bolts evenly with an 8 mm

socket.
Lift the cam chain tensioner our of the cylinder. Remove the cam chain
tensioner gasket.
3-23
Use a 5 mm Allen wrench to remove the camshaft sprocket bolts.
Remove the camshaft sprocket as shown. Support the chain so it does

not fall into the cylinder head.
Use a 5 mm Allen wrench to remove the set plate bolt.
3-24
Remove the set plate as shown.
Thread a bolt into the rocker arm shafts and pull the shafts out.
3-25
Lift out the rocker arms as the shafts are removed.
Remove the camshaft from the cylinder head.
3-26
Inspection
Inspect the camshaft cam heights for the intake and exhaust lobes.
Inspect the camshaft bearings for excessive play or roughness.
Replace the entire camshaft assembly if the bearings are rough or have
excessive play.
Item Standard (mm)

IN 34.2987
Camshaft cam height
EX 34.1721
Inspect the rocker arm shaft outer diameter for the intake and exhaust
valves.
Item Standard (mm)

IN 9.972 - 9.987
Valve rocker arm shaft O.D.
EX 9.972 - 9.987
3-27
Inspect the rocker arm inner diameter for the intake and exhaust valves.
Item Standard (mm)

IN 10.00 - 10.015
Valve rocker arm I.D.
EX 10.00 - 10.015
Inspect the camshaft bearing journals for scoring or scratches.
3-28
Inspect the camshaft sprocket for worn teeth or other signs of wear or
damage.
Camshaft Installation
Clear out the cylinder head oil passages with compressed air. Make
sure all cylinder head oil passages are free of clogs.
3-29
Position the piston at top dead center as above. The "T" mark should be
aligned with the index notch in the timing inspection hole. Support the
cam chain if the crank must be turned to position the piston correctly.
Lubricate the camshaft lobes and bearings with fresh engine oil.
Insert the camshaft into the camshaft holders with the lobes facing
down.
3-30
Lubricate the inside diameter of the rocker arms and the roller with fresh
engine oil. Position the rocker arms to accept the rocker arm shafts.
Wipe the rocker arm shafts clean. Insert the rocker arm shafts through
the camshaft holders and rocker arms. Install the rocker arm shafts so
that the end sits as shown.
3-31
Install the camshaft set plate so it fits into the groove on the camshaft
and between the projections on the rocker arm shafts.
Apply a small amount of blue Loctite (non-permanent) to the threads of

the set plate bolt. Thread in the bolt and tighten it to specification with a
5 mm Allen socket.
Thread size Torque

Item Qty
(mm) kgf-m lb-ft
Camshaft set plate bolt 1 5 1.2 2.0
3-32
Install the camshaft sprocket onto the camshaft so the camshaft

sprocket boss fits into the appropriate hole on the camshaft sprocket.
Make sure the camshaft sprocket boss is facing up so it is visible above
the edge of the cylinder head as shown. Align the horizontal marks on
the camshaft sprocket with the top edge of the cylinder head as shown.
Fit the camchain over the camshaft sprocket.
For correct engine timing the marks on the camshaft sprocket must be
even with the cylinder head mating surface at the same time the "T"
mark is lined up with the with the index notch in the timing inspection
hole. The camshaft lobes should be facing down and their should be
slack in the rocker arms.
Apply a small amount of blue Loctite (non-permanent) to the threads of

the camshaft sprocket bolts.Thread in the camshaft sprocket bolts and
tighten to specification using a 5 mm Allen socket.
3-33
Thread Torque
Item Qty
Cam sprocket bolt 2 6 1.0-1.4 7.23-10.13
Double check the engine timing.
Use a small flat blade screwdriver bring in the cam chain tensioner rod.
Turn the screwdriver counter clockwise to retract the rod. The rod must
be held in with the screwdriver until the cam chain tensioner mounting
bolts have been installed.
3-34
Install the camchain tensioner with a new gasket. Insert the mounting
bolts and tighten them evenly to specification with an 8 mm socket.
Remove the screwdriver and release the camchain tensioner rod.
Thread Torque
Item Qty
Cam chain tensioner bolt 2 6 1.0-1.4 7.23-10.13
3-35
Rotate the crankshaft 360° clockwise and check the engine timing one
more time.
Make sure the cam chain tensioner cap bolt O-ring is in good condition.
Install the O-ring and cam chain tensioner cap bolt. Tighten the bolt to
Check the valve clearance. See the Valve Clearance topic for more
information.
3-36
Make sure the O-rings on the crankshaft and timing plugs are in good
condition. Replace them as needed. Install the timing inspection and
crankshaft caps to the right side of the engine. Tighten the caps securely
but not overly with a large flat blade screwdriver.
Install the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Install the spark plug. See the Spark Plug topic for more information.
Install the luggage box. See the Luggage Box topic for more information.
3-37
3. Engine > Valves K- XCT 300i
Valves
Removal
Remove the camshaft. See the Camshaft topic for more information.
Remove the cylinder head. See the Cylinder Head topic for more
information.
IMPORTANT: Record the position of all parts so they can be returned to

their proper place during reassembly.
Push down the valve springs with a valve spring compressor.
Special Tool- Valve Spring Compressor: E040
3-38
Remove the split keepers. There are two per valve.
Remove the spring retainer.
Remove the valve springs.
3-39
Push the valve stem down and remove the valve from the combustion chamber side of
the cylinder head. Rotate the valve as it is removed.
Remove the valve seal from the valve guide. The valve seals should be
replaced if they are removed or you are going to install new
valves.
3-40
Remove the spring seat.
Inspection
Inspect the valve springs for fatigue and damage. Replace the valve
springs as needed or if the valve is also to be replaced.
3-41
Inspect the valves for damage and burning. Measure the valve stem diameter in several
places where the valve makes contact with the guide. If the measurement is below
specification replace the valve.
Item Standard (mm)

IN 4.990 - 4.975
Valve stem O.D.
EX 4.970 - 4.955
Inspect the valve seat and the valve seat width. The valve seat should
3-42
be centered on the valve face. If the seat is pitted, worn out, or fits
poorly on the valve face the valve seat must be resurfaced.
Item Standard (mm)

IN 1.2
Valve seat width
EX 1.2
Measure the inside diameter of the valve guides. Replace the guides if
the measurement is out of specification. Calculate the valve stem-to-
guide clearance. Replace the guide and valve if the clearance is out of
specification
Item Standard (mm)

IN 5.00 - 5.012
Valve guide I.D
EX 5.00 - 5.012
IN 0.010 - 0.037
Valve stem-to-guide clearance
EX 0.030 - 0.057
3-43
Installation
Clean the cylinder head components thoroughly with a high flash-point

solvent and compressed air. Return the components to their original
locations.
Install the spring seat.
Coat the new valve seal in fresh engine oil and install it onto the valve
guide.
3-44
Coat the valve stem in fresh engine oil and insert the valve into the valve
guide and through the seal. Turn the valve slowly as it is inserted. If you
are installing a new valve you must ream the valve guide first. Make
sure the valve will move smoothly in the valve guide without wobble.
Install the valve springs. The tightly coiled end of the springs should sit
against the spring seat.
3-45
Place the spring retainer on top of the spring.
Push down the valve springs with a valve spring compressor to allow
enough room to install the split keepers. The valve cotter installer tool
can also be used to install the split keepers.
Special Tool- Valve Spring Compressor: E040
3-46
Apply grease to the inside of the split keepers. Apply a dab of grease to
the end of a flat blade screwdriver. Set the keeper in the grease on the
screwdriver and insert it onto the valve stem. Repeat this with the other
keeper.
After the valves have been reassemble place a clean shop towel under
the cylinder head in the combustion chamber area and gently tap each
valve stem with a plastic rod and rubber mallet to make sure the valves
are seated properly.
Install the cylinder head. See the Cylinder Head topic for more
information.
Install the camshaft. See the Camshaft topic for more information.
3-47
3. Engine > Cylinders and Pistons K- XCT 300i
Cylinders and Pistons

at this point.
Cylinder Block Removal
Remove the engine from the frame. See the Engine Removal topic for
more information.
Remove the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Remove the camshaft sprocket. See the Camshaft topic for more
information.
Remove the cylinder head. See the Cylinder Head topic for more
information.
Slide out the lower cam chain guide. Inspect the guide for excessive
wear and damage. Replace the guide as needed.
3-48
Remove the two right side cylinder bolts with an 8 mm socket.
Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver.

Free the coolant hose from the cylinder.
3-49
Slide the cylinder off of the studs and piston. Guide the cam chain
through its opening and do not allow if to fall into the crankcase.
Remove the cylinder.
Remove the base gasket.
3-50
Remove the two cylinder dowel pins from the left studs.
Place a clean shop towel under and around the base of the piston to
prevent any parts or debris falling into the crankcase.
Remove the piston pin clips with a pick or needle nose pliers. Discard
the piston pin clips.
Remove the piston pin and the piston.
3-51


Clean off the cylinder mating surface, but take care to keep debris from
falling into the crankcase.
Spread the piston rings and lift them off opposite the gap.
Spread the rings the minimum amount during removal. The
rings can be easily damaged.
The two upper rings are each a single piece of metal. The oil ring
consists of an expander ring and two side rails.
3‐52

The two upper rings are each a single piece of metal. The oil ring
consists of an expander ring and two side rails.
Clean the carbon build up off of the piston with a stiff bristled plastic
brush or rag. Never use a wire brush to clean a piston.
Also clean out the ring grooves. You can use an old ring to scrape out
any carbon build up in the grooves.
3-53
Inspection
The cylinder and piston must be replaced as a set. There are two sets of
cylinder and piston combinations. Make sure to have a No.1 cylinder
with an "A" piston or a No.2 cylinder with a "B" piston.
No. Mark Piston O.D. (mm) Cylinder I.D. (mm)

1 A 72.680 - 72.690 72.700 - 72.710
2 B 72.690 - 72.700 72.710 - 72.720
Inspect the cylinder bore for damage and abnormal wear
3-54
Measure the cylinder diameter as described below with a telescoping

gauge.
Inspect the cylinder front to back and side to side at three different
height levels with a dial bore gauge.
Item Standard (mm)

Cylinder I.D. 72.7
Calculate the cylinder taper. The taper is the maximum difference

between either yellow and brown or blue and green.
3-55
Item Limit (mm)

Cylinder Taper 0.05
Calculate the cylinder out of round. The out of round is greatest out of
yellow, purple, or brown minus the smallest of blue, red, or green.
Item Limit (mm)

Cylinder Out of round 0.05
Measure the outside diameter of the piston at 9 mm up from the bottom

of the skirt at a 90° angle to the piston pin. Measure the piston with
vernier calipers or a micrometer. Check the piston for wear, damage,
and extreme discoloration.
Subtract the diameter of the piston from the maximum front to rear
diameter measurement of the cylinder to calculate the piston-to-cylinder
clearance. Replace the piston and cylinder as needed to achieve a
correct piston-to-cylinder clearance.
Item Standard (mm)

Piston-to-cylinder clearance 0.010 - 0.030
3-56
Measure the piston pin diameter with a micrometer. Measure the piston
pin bore diameter with vernier calipers or a small bore gauge. Measure
at three different points for each. Replace the parts if any of the
specifications are not met.
Item Standard (mm)

Piston pin hole I.D. 15.002 - 15.008
Piston pin O.D. 14.994 - 15.000
Piston-to-piston pin clearance 0.002 - 0.014
Measure the inside diameter of the small end of the connecting rod with
vernier calipers.
Item Standard (mm)

Connecting rod small end I.D. Bore 15.016 - 15.034
3-57
Measure the ring groove width and the ring-to-groove clearance with
feeler gauges.
Item Standard mm
1st 0.015 - 0.055
Piston ring-to-groove clearance 2nd 0.015 - 0.055
Insert the top ring into the cylinder. Push the top ring in the cylinder about
an inch. Use the piston to push in the ring to keep it square with the
cylinder.
3-58
Measure the ring gap with a feeler gauge. Repeat this procedure with
second ring and the oil side rails.
Item Standard mm
Top 0.10 - 0.25
Ring end gap Second 0.10 - 0.25
Oil side rail 0.2 - 0.7
Check the oil jet for clogs.
3-59
Assembly
Clean the piston ring grooves and apply fresh engine oil to the piston
rings. Spread the rings the minimum amount possible to install them. Do
not try and force them on the piston.
Install the top and second rings with their markings facing up. Install the
rings to the piston as shown above so that no ring end gaps line up with
the piston pin or perpendicular to the piston pin. The rings should turn
easily on the piston without sticking or roughness.
3-60
Install the oil expander ring so that the ends are not overlapping. Install
the steel rails above and below the oil ring.
Lubricate the piston pin and the small end of the connecting rod with
fresh engine oil.
The "IN" mark should face the intake side (rear) of the engine.
3-61
Place the piston over the connecting rod. Insert the piston pin into the
piston and rod.
Install new piston pin clips securely into their grooves. Turn the gap in
the clips away from the access gap.
Make sure the cylinder head mating surface is clean. Install the two
dowel pins as shown.
3-62
Install the new base gasket onto the crankcase.
3-63
Coat the inside of the cylinder, piston rings, and piston in fresh engine
oil. Lower the cylinder over the studs and guide the piston into the
cylinder while you are compressing the rings with your fingers. Be
careful to not damage the rings during this step. Bring the cam chain
and guide through the opening.
Thread in the two cylinder bolts on the right side of the engine.
Fit the coolant hose to the cylinder. Tighten the cylinder coolant hose
clamp to securely with a #2 Phillips screwdriver.
Insert the lower cam chain guide and make sure it is seated correctly.
3-64
Install the cylinder head. See the Cylinder Head topic.
Install the cylinder head cover. See the Cylinder Head Cover topic for
more information.
Install the engine into the frame. See the Engine Installation topic for
more information.
3-65
3. Engine > Generator K- XCT 300i
A.C. Generator and Starter clutch

Removal
Generator Cover
Remove the following components -
# Seat
# Luggage Box
# Center Cover
# Rear Carrier
# Body Cover
# Front Cover
# Front Lower Cover
# Foot Skirt
Drain engine oil and remove the oil filter. See the Engine Oil topic for more information.
Disconnect the generator 3-pin connector.
Disconnect the crank position sensor wire coupler.
3-66
Loosen the right crankcase coolant hose clamp with a #2 Phillips

screwdriver. Slide up the clamp and free the coolant hose from the right
crankcase cover. Allow any remaining coolant to drain into a suitable
container.
3-67
Remove the 12 generator cover bolts with an 8 mm socket. Note the

upper most bolt holds a wire stay.
Utilize the pry points and remove the generator cover.
3-68
Remove the generator cover gasket.
Remove the two dowel pins.
3-69
Remove the two oil filter chamber O-rings. Inspect the O-rings and
replace them as needed.
Stator and Pulsar Coil/Crank Position Sensor
Free the rubber wire grommet from the right crankcase cover.
Remove the three stator mounting bolts and the two crank position
sensor bolts with an 8 mm socket. Remove the stator and the crank
position sensor together.
3-70
Flywheel
To remove the fly wheel two special tools are needed.
ITEM TOOL NO.

UNIVERSAL HOLDER E021
ITEM TOOL NO.

FLYWHEEL PULLER E003
3-71
Hold the flywheel with the universal holder and loosen the nut with a 19
mm socket.
Remove the flywheel nut and washer.
3-72
Apply grease to the threads of the flywheel puller tool before using it.
Thread the puller onto the flywheel. Hold the tool with a large wrench
and turn in the bolt until the pressure separates the flywheel from the
crankshaft.
Remove the flywheel from the crankshaft.
3-73
Slide the starter driven gear off of the crankshaft.
Remove the woodruff key from the crankshaft.
3-74
Starter Clutch
Remove the starter idle gear and shaft from the crankcase.
Inspect the starter idle gear and shaft for wear and damage. Replace the
idle gear and shaft as needed.
Inspect the starter driven gear for wear and damage. Measure the inside
and outside diameter of the starter driven gear and replace it as needed.
3-75
Item Service Limit (mm)

Starter drive gear I.D. 22.15
Starter drive gear O.D. 41.50
Fit the boss of the starter driven gear into the starter clutch. The starter
clutch should only allow the driven gear to turn in one direction. If the
starter clutch allows turning both ways or will not let the driven gear
rotate smoothly in one direction the starter clutch must be replaced.
Remove the three starter clutch mounting bolts with a 6 mm Allen

socket.
Installation
Starter Clutch
Fit the starter clutch to the back of the flywheel. Apply blue Loctite to the
threads of the three starter clutch mounting bolts. Insert the three starter
clutch mounting bolts.
3-76
Tighten the starter clutch mounting bolts to specification with a 6 mm

Allen socket.
Thread Torque
Item Qty
Oneway clutch bolt 3 8 1.8-2.2 13.02-15.91
Lubricate the starter idle gear shaft with fresh engine oil. Install the
starter idle gear and shaft into the crankcase.
3-77
Flywheel
Install the woodruff key into its slot on the end of the crankshaft.
Lubricate the inside of the starter driven gear with fresh engine oil. Slide
the starter driven gear onto the flywheel as shown.
Clean off the tapered end of the crankshaft where the flywheel will ride
and make sure the inside of the flywheel is oil free where it will contact
the crankshaft.
3-78
Line up the groove in the flywheel with the key and fit the flywheel onto
the crankshaft. Guide the starter driven gear into the starter clutch on
the back of the flywheel.
Install the washer and flywheel nut.
3-79
Hold the flywheel with the universal holder and torque the flywheel nut to
specification with a 19 mm socket.
Thread Torque
Item Qty
ACG flywheel nut 1 14 5.5-6.5 39.78-47.01
ITEM TOOL NO.

UNIVERSAL HOLDER E021
3-80
Stator and Crank Position Sensor
Fit the stator and the crankshaft position sensor into the generator cover
together as shown. Insert the two crank position sensor mounting bolts
and the three stator mounting bolts. Tighten the bolts securely with an 8
mm socket.
Coat the rubber grommet in silicone sealant where it contacts the

generator cover. Fit the rubber wire grommet into its cutout in the
crankcase cover.
3-81
Generator Cover
Make sure the generator cover mating surface is clean. Install the two
dowel pins and a new generator cover gasket.
3-82
Make sure the oil filter chamber O-rings are in place and in good
condition.
Fit the generator cover into place. Make sure the water pump shaft
engages correctly with the oil pump shaft.
3-83
Insert the 12 generator cover bolts. Note the upper most bolt holds a
wire stay. Tighten the bolts securely in a with an 8 mm socket.
Fit the coolant hose to the right crankcase cover pipe. Secure the hose
with the clamp and tighten the coolant hose clamp securely with a #2
Phillips screwdriver.
3-84
Connect the coolant hose to the water pump. Move the clamp into place
and tighten it securely with a #2 Phillips screwdriver.
Plug in the regulator/rectifier 3-pin connector.
3-85
Plug in the crank position sensor wire coupler on the right side of the frame.
Fill the engine oil. See the Engine Oil topic for more information.
Install the exhaust system. See the Exhaust System topic for more information.
Fill the coolant and bleed the coolant. See the Coolant topic for more information.
Install the following components-

! Foot Skirt
! Front Lower Cover
! Front Cover
! Body Cover
! Rear Carrier
! Center Cover
! Luggage Box
! Seat
3-86
3. Engine > Oil Pump K- XCT 300i
Oil Pump
at this point.
The maintenance of lubrication system can be performed with the

engine installed in the frame. Use care when removing and installing the
oil pump not to allow dust and foreign matters to enter the engine and oil
line.
Do not attempt to disassemble the oil pump. The oil pump must be
replaced as a set when it reaches its service limit.
After the oil pump is installed, check each part for oil leaks.
TROUBLESHOOTING
Oil level too low
2. Oil leaks

3. Not using the specified oil
Oil Pump Removal
Drain the engine oil. See the Engine Oiltopic for more information.
Remove the generator cover, flywheel, starter idle gear and starter
driven gear. See the Generatortopic.
3-87
The oil pump is driven by a chain off of the crankshaft.
Loosen the two oil pump cover bolts with an 8 mm socket.
3-88
Remove the two oil pump cover bolts and the oil pump cover.
Remove the snap ring on the oil pump shaft with snap ring pliers.
Remove the oil pump drive chain and driven sprocket.
3-89
Inspect the oil pump drive chain and sprocket for signs of wear and
damage. Replace the parts as needed.
Remove the two oil pump screws with an impact #3 Phillips screwdriver.
Remove the oil pump.
3-90
Turn the oil pump shaft by hand and make sure it turns smoothly. If the
oil pump shaft will not rotate smoothly the oil pump should be replaced
with a new unit.
Oil Pump Installation
Fit the oil pump into place so that the arrow is pointing up.
3-91
Insert the two oil pump mounting screws and tighten them securely with
an impact #3 Phillips screwdriver.
Fit the oil pump driven sprocket into the drive chain. Install the gear onto
the oil pump shaft and fit the chain onto its teeth on the crankshaft.
Install a new snap ring into its groove with snap ring pliers.
3-92
Install the oil pump cover and its two mounting bolts.
Tighten the two oil pump cover bolts securely with an 8 mm socket.
Install the starter driven gear, flywheel, and the generator cover. See the Generator topic.
Fill the engine oil. See the Engine Oil topic for more information.
3-93
3. Engine > Crankcase K- XCT 300i
Crankcase
Splitting
Drain the engine oil and remove the strainer screen. See the Engine Oil topic for more
information.
Remove the engine. See the Engine Removal topic for more information.
Remove the cylinder head cover. See the Cylinder Head Cover topic for more information.
Remove the camshaft sprocket. See the Camshaft topic for more information.
Remove the cylinder head. See the Cylinder Head topic for more information.
Remove the generator cover, flywheel, starter idle gear and starter
driven gear. See the Generator topic.
Remove the starter motor. See the Starter Motor topic for more information.
Remove the oil pump. See the Oil Pump topic for more information.
Remove the CVT pulleys and belt. See the CVT Removal topic.
Remove the rear wheel. See the Rear Wheel topic for more information.
Remove the upper cam chain guide bolt with an 8 mm Allen.
3-94
Remove the upper cam chain guide.
Inspect the cam chain guides for damage and excessive wear. Replace
the guides as needed.
3-95
Remove the cam chain from the crankshaft and crankcase. Inspect the
cam chain for wear and damage. Replace the cam chain as needed.
There are 11 crankcase bolts.
3-96
Loosen the 11 crankcase bolts in a crisscross pattern with an 8 mm

socket. Remove the crankcase bolts from the left side of the engine.
Remove the plate with the bottom two crankcase bolts.
3-97
Set the crankcases on the right side.
Separate the halves of the crankcase. If needed gently tap the reinforced areas of the right
crankcase half with a rubber mallet. Lift the right crankcase off of the left.
3-98
Remove the three dowel pins from the crankcase. Inspect the O-ring
and replace it as needed.
3-99
To remove the crankshaft see the Crankshaft topic.
Replace the left crankshaft seal if the crankcases are separated.
Remove the seal with a seal pick.
3-100
Drive the new seal into the left crankcase from the outside with a
suitable driver. The driver should have the same outside diameter as the
seal. Lubricate the new crankshaft seal lips with fresh engine oil.
Assembly
Thoroughly clean the crankcase mating surface.
Apply sealant uniformly to the crankcase mating surface as indicated.

Do not allow sealant to enter oil passages or get in bearings.
3-101
Set the right case half down on top of the left. Install the engine mount
spacer.
Insert the 11 crankcase bolts. The plate goes on with the bottom two
bolts.
3-102
Tighten the bolts securely and evenly in a crisscross pattern with an 8mm socket.
Install the cam chain around the timing sprocket teeth on the crankshaft.
3-103
Fit the upper cam chain guide into place.
Insert the upper cam chain guide mounting bolt and tighten it to
specification with an 8 mm Allen socket.
Thread Torque
Item Qty
Size(mm)
kgf-m lb-ft
Cam chain tensioner pivot 1 8 0.8-1.2 5.79 - 8.68
Install the oil pump. See the Oil Pump topic for more information.
Install the starter idle gear, driven gear, flywheel, and the generator cover. See the
Generator topic.
Install the starter motor. See the Starter Motor topic for more information.
Install the CVT pulleys and belt. See the CVT Installation topic for more information.
3-104
Install the cylinder and piston. See the Cylinder and Piston topic for more information.
Install the cylinder head. See the Cylinder Head topic.
Install the cylinder head cover. See the Cylinder Head Cover topic for more information.
Install the rear wheel. See the Rear Wheel topic for more information.
Install the engine into the frame. See the Engine Installation topic for more information.
3-105
3. Engine > Crankshaft K- XCT 300i
Crankshaft
Removal
Split the crankcases. See the Crankcase topic for more information.
Lift the crankshaft out of the left crankcase half.
3-106
Remove the thrust washer from the right side of the crankshaft.
Crankshaft Inspection
Check the side clearance of the big end of the connecting

rod with a feeler gauge.
3-107
Item Standard (mm) Service Limit (mm)

Crankshaft Connecting rod big
0.15 - 0.35 0.6
end side clearance
Grip the small end of the connecting rod and try and push
the rod down towards the crank weights. If there is definite
play between the connecting rod and crank the crankshaft
should be replaced.
3-108
Crankshaft Bearings
Inspect the crankshaft bearings for signs of damage and

wear. Replace the bearings if they show any kind of
imperfection. Note the bearing color code and crankcase
code.
The crank weights are also marked with a size code.
Bearing Color
Crankshaft mark
Crankshaft mark A B C D
A black green green red
B green green red ----
When the crankshaft and or crankcases must be replaced also replace both
crank bearings according to the chart below.
3-109
Installation
Place the thrust washer on the crankshaft as shown.
Lubricate the connecting rod big end and crankshaft shaft

bearings with fresh engine oil.
Fit the crankshaft into the left crankcase bearing. Take

care to avoid damaging the new oil seal.
Join the crankcases. See the Crankcase topic for more information.
3-110
3. Engine > Engine Installation K- XCT 300i
Engine Installation
at this point.
Before the engine is returned to the install the rear wheel. See the Rear
Wheel topic for more information.
Set the chassis on its center stand. Use a jack to support the engine.
Guide the engine into the back of the frame.
3-111
Fit the engine mounting bracket and damper assembly into place.
Install the two engine mounting bracket to frame mounting bolts and
nuts. Insert the bolts from the outside of the frame.
Insert the engine mounting bracket and damper bolt from the right side.
Thread on the nut.
3-112
Install the engine mounting bracket damper washer and nut.
Hold the engine mounting bolts with a 14 mm wrench and

torque the nuts to specification with a 19 mm socket.
Thread Torque
Item Qty size (mm) Remarks
kgf-m lb-ft
Engine hanger:
2 14 6.0-7.0 43.40-50.63 U-nut
Frame side
3-113
Tighten the engine mounting bracket damper bolt and nut with a
17 mm wrench for the nut and a 14 mm socket for the bolt.
Torque
Item Qty Thread Remarks
size(mm)
kgf-m lb-ft
Engine hanger: Engine side 1 10 4.5-5.5 32.55-39.78 U-nut
Tighten the damper nut securely with a 14 mm socket.
3-114
Install the rear shock absorbers. See the Shock Absorbers topic for
more information.
Route the wiring harness through its guide above the intake pipe.
Plug in the oil pressure switch bullet connector.
Route the starter motor lead to the starter motor and secure it in
the stay on the right crankcase cover.
3-115
Fit the starter motor cable lead onto the terminal and thread on
the nut. Tighten the starter motor lead nut securely with a 10 mm
wrench.
Fit the rubber starter motor lead cover into place.
3-116
Install the main engine ground to the right side of the engine.
Tighten the main engine ground bolt securely with an 8 mm socket.
Install air bleed hose and secure it with the clamp.
Connect the coolant hose to the thermostat. Move the clamp into
place and tighten it securely with a #2 Phillips screwdriver.
Connect the coolant hose to the water pump. Move the clamp into
place and tighten it securely with a #2 Phillips screwdriver.
3-117
Fit the fuel stay into place. Tighten the stay bolt securely with an
8 mm socket.
Plug in the thermo sensor unit and ground connectors.
Plug in the water temperature sensor connector.
3-118
3. Quick Reference > Specifications K- XCT 300i
General Information
Name & Model No. LKG7
Motorcycle Name & Type K-XCT300i
Overall length (mm) 2145
Overall width (mm) 800
Overall height (mm) 1290
Wheel base (mm) 1450
Engine type 4 stroke OHC
Displacement (cc) 298.9
Fuel recommended 90 # nonleaded gasoline
Front wheel 76
Net weight (kg) Rear wheel 106.5
Total 182.5
Front wheel 138
Max. weight capacity (kg) Rear wheel 220
Total 358
Front wheel 120/70-14
Tires
Ground clearance (mm) 140
Braking distance (m) 7.9m / 40 km/hr
Performance
Min. turning radius (m) 2.45
Starting system Starting motor
Type Gasoline, 4-stroke
Cylinder arrangement SINGLE CYLINDER
Combustion chamber type Semi-sphere
Valve arrangement O.H.C. Chain drive
Bore x stroke (mm) 72.7 x 72
Compression ratio 10.8:1
Compression pressure 16 (kg/cm2), 228 (psi)
Max. Horsepower 28 / 7750 PS/rpm
Max. Torque 2.7 / 6500 Kg-m/rpm
Engine Open 9.5° BTDC
Intake
Close 37.5° ABDC
Valve timing Open 40° BBDC
Exhaust
Close 10°ATDC
Intake 0.10
Valve clearance (cold) (mm)
Exhaust 0.10
Idle speed (rpm) 1600 ± 100
Lubrication type Forced pressure & Wet pump
Oil pump type Inner/outer rotor type
Lubrication System
Oil filter type Full-flow filtration
Oil capacity 1.5 liter
Cooling Type Liquid cooling
Air cleaner type & No Paper element, wet
Fuel capacity 10 liter
Brand Keihin
Fuel System
Type Throttle body
Injection
Venturi dia.(mm) 34
Fuel pump pressure 3.0 Bar
3-119
Type ECU
Ignition timing 8° - 12° BTDC
Electrical Ignition System
Spec CR7E (NGK)
Equipment Spark plug
Gap 0.6-.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-clutch
Transmission Gear Type CVT
Power Drive Operation Automatic centrifugal type
System Type Two-stage reduction
Reduction Gear
1st 2.24 ~ 0.72
Reduction ratio
2nd 7.222
Tire type Tubeless
Wheel material Aluminum
Front 2.0 (28.4)
Moving Device Tire pressure Kg/cm2 (psi)
Rear 2.25 (32)
Left 40°
Handle turning angle(L/R)
Right 40°
Front Wavy Disc brake
Brake system type
Rear Disc brake
Front Telescope
Suspension type
Rear Swing arm
Damping Device
Front 110 mm
Shock absorber stroke
Rear 93 mm
Frame type UNDER BONE
ENGINE
Throttle grip free play 2 ~ 6 mm
Spark plug NGK: CR7E
Spark plug gap 0.6 mm ~ 0.7 mm
Idle speed 1600 ± 100 rpm
Ignition timing ECU
Coolant type Coolant type
Engine oil capacity
At change 1.3 Liter
Gear oil type: SAE 90
Gear oil capacity
At change 0.21 Liter
3-120
Coolant capacity
Radiator 766 cc
Hose with cool coolant 169 cc
Hose with hot coolant 194 cc
Reserve tank 590 cc
Total capacity 1719 cc
Engine
Item Standard (mm)
IN 0.10
Valve clearance (cold)
EX 0.10
Cylinder head compression pressure 16 kg/cm2, 228 psi
IN 34.2987
Camshaft cam heigh
EX 34.1721
IN 10.00 - 10.015
Valve rocker arm I.D
EX 10.00 - 10.015
IN 9.972 - 9.987
Valve rocker arm shaft O.D
EX 9.972 - 9.987
IN 1.2
Valve seat width
EX 1.2
IN 4.990 - 4.975
Valve stem O.D
EX 4.990 - 4.975
IN 5.00 - 5.012
Valve guide I.D
EX 5.00 - 5.012
IN 0.010 - 0.037
EX 0.010 - 0.037
Item Standard (mm)

I.D. 72.7
Cylinder Taper limit 0.05
Out of round limit 0.05
Top 0.015 - 0.055
Ring-to-groove clearance
Second 0.015 - 0.055
Top 0.10 - 0.25
Piston piston
ring
Piston O.D 72.67 – 72.69
Piston O.D. measuring point 9 mm from bottom of skirt
Piston pin O.D 14.994 - 15.000
3-121
Connecting rod big end side clearance 0.15 - 0.35 0.6

Crankshaft
Connecting rod big end radial clearance 0 - 0.008 0.05
Bearing Color
Crankcase mark
B green green red ---
Starter drive gear I.D 22.15
CVT
Clutch lining thickness 4.0 2.0
Clutch outer I.D. 152.1 - 152.2 152.2
Weight roller O.D (Drive Pulley) 19.92 - 20.08 20.08
Cooling System
Radiator cap relief pressure 0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
Begins to open 71 °C
Thermostat temperature Full-open 80 °C
Valve lift 3.5 - 4.5 mm

Radiator: 766 cc
Coolant capacity Total 1719 cc Reserve tank: 590 cc
Hose: 363 cc
3-122
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS)

Freezing Mixing Coolant Distilled
Point Rate Concentrate Water
-9°C 20% 344 cc 1375 cc
-15°C 30% 516 cc 1203 cc
-25'°C 40 688 cc 1031 cc
-37°C 50% 860 cc 859 cc
-44.5°C 55% 945 cc 774 cc
COOLANT GRAVITY CHART

Temp. C°
Coolant 0 5 10 15 20 25
concentration
5% 1.009 1.009 1.008 1.008 1.007 1.006
10% 1.018 1.107 1.017 1.016 1.015 1.014
15% 1.028 1.027 1.026 1.025 1.024 1.022
20% 1.036 1.035 1.034 1.033 1.031 1.029
25% 1.045 1.044 1.044 1.042 1.040 1.038
30% 1.053 1.051 1.051 1.049 1.047 1.045
35% 1.063 1.065 1.060 1.058 1.056 1.054
40% 1.072 1.070 1.068 1.066 1.064 1.062
45% 1.080 1.078 1.076 1.074 1.072 1.069
50% 1.086 1.084 1.082 1.080 1.077 1.074
55% 1.095 1.093 1.091 1.088 1.085 1.082
60% 1.100 1.098 1.095 1.092 1.089 1.086
Temp. C°
Coolant 30 35 40 45 50
concentration
5% 1.005 1.003 1.001 0.009 0.99
10% 0.013 1.011 1.009 1.007 1.005
15% 1.020 1.018 1.016 1.014 1.012
20% 1.027 1.025 1.023 1.021 1.019
25% 1.036 1.034 1.031 1.028 1.025
30% 1.043 1.041 1.038 1.035 1.032
35% 1.052 1.049 1.046 1.043 1.040
40% 1.059 1.056 1.053 1.050 1.047
45% 1.056 1.063 1.062 1.057 1.054
50% 1.071 1.068 1.065 1.062 1.059
55% 1.079 1.076 1.073 1.070 1.067
60% 1.083 1.080 1.077 1.074 1.071
3-123
Fuel Injection System
ITEM SPECIFICATIONS
Throttle body identification number LKG7
Throttle grip free play 2 - 6 mm (1/16 - 1/4 in)
Fuel injector resistance (at 20°C/68°F) 11.7 ± 0.6 9Ω
Float at full
1100 ± 33 9Ω
position
Fuel pump resistance(at 20°C/68°F)
Float at empty
100 ± 3 9Ω
position
Fuel pump standard pressure (at 40L/Hr) 294 ± 6 kPa (3 Bar)
At -20°C/-4°F 18.8 KΩ
Water temperature sensor resistance At 40°C/104°F 1.136 KΩ
At100°C/212°F 0.1553 KΩ
13.332 kPa (0.13332 kgf/ cm2, 1.89 psi) - 119.99

Intake pressure sensor (MAP) pressure(at 1 - 4.2V)
KPa (1.1999 kgf/ cm2, 17.04 psi)
Inductive ignition coil Primary: 3.57 - 4.83Ω Secondary: 10.42~14.49KΩ
Throttle position sensor (TPS)
3500 - 6500Ω
resistance (at 20°C/68°F)
Crank position sensor voltage (at 200rpm) 100 - 130Ω
O2 heater sensor resistance (at 20C/68°F) 6.7 - 9.5Ω (engine warming condition)
Standard 0.4 - 1.4 V

Tilt switch voltage
Over 65° (fall down) 3.7 - 4.4 V
3-124
CELP FAILURE CODES LIST
Failure Codes Contents Causes Symptoms
• Faulty TPS voltage range (0.3 -4.5 V)

• Loose or poor connection on TPS Sensor Engine operates
06 P0120 Faulty TPS normally
• Open or short circuit on the TP Swire
• Faulty TPS itself
• Faulty MAP voltage range (1 - 4.2V)

Engine operates
09 P0105 Faulty MAP • Loose or poor connection on MAP Sensor
• Open or short circuit on MAP wire normally
• Faulty MAP itself
• Faulty ECT range (-20°C: 18.8 /40°C: 1.136/100°C:

Faulty WTS 0.1553 ) Engine operates
12 P0115 • Loose or poor connection on ECT normally
(water temp.)
• Open or short circuit on ECT wire
• Faulty ECT
• Faulty Tilt switch voltage range (inclined angle <65°:

Faulty Tilt switch 0.4 - 1.4 V/ Inclined angle >65°: 3.7 - 4.4 V) Engine operates
15 P1630 (Roll) • Loose or poor connection on Tilt switch normally
• Open or short circuit in Tilt switch wire
• Faulty tilt switch
• Faulty O2 sensor voltage range(A/F below 14.7: > 0.7V/

Faulty O2 A/F over14.7: < 0.18 V) Engine operates
17 P0130 sensor • Loose or poor connection on O2 sensor normally
• Open or short circuit on O2 sensor wire
• Faulty O2 sensor
• Faulty Fuel injector range(9.945 - 13.5)
Faulty injector • Loose or poor connection on injector Engine fails to be
33 P0201 operated
(Nozzle) • Open or short circuit on injector wire
• Faulty fuel injector
• Faulty Inductive ignition coil !range (4.2 ! ± 15%)
Faulty inductive • Loose or poor connection on inductive ignition coil Engine fails to be
37 P0351 ignition coil • Open or short circuit on inductive ignition coil wire operated
• Faulty inductive ignition coil
• Faulty Fuel pump fl range (F:1100 ± 33 ! E: 100 + 3 !)
• Loose or poor connection on fuel pump Engine fails to be
41 P0230 Faulty fuel pump operated
• Open or short circuit on fuel pump wire
• Faulty fuel pump
• Faulty O2 sensor heater ! range(6.7 -9.5 !)
Faulty O2 • Loose or poor connection on O2 sensor heater Engine starts normally
45 P0135 but not smooth
sensor heater • Open or short circuit on O2 sensor heater wire
• Faulty O2 sensor heater
• Loose or poor contacts on ISC Engine operates

49 P1505 Faulty ISC • Open or short circuit in ISC wire
• Faulty ISC normally
• Loose or poor connection on CPS sensor Engine starts normally

66 P0335 Faulty CPS • Open or short circuit on CPS wire but not smooth
• Faulty CPS sensor
3-125
Axle/Brakes/Wheels
Item Standard mm (in) Service Limit
Axle shaft run out – 0.2 mm(0.008 in)
Brake disk thickness (front) 3.8 - 4.2(0.15 - 0.165) 0.3 mm(0.012 in)
Brake disk thickness (rear) 5.0 (0.2 –
Brake disk run out – 0.4 mm
Brake master cylinder I.D 12.7 - 12.74(0.508 - 0.5096) –
Brake master cylinder piston O.D. 12.65 - 12.68(0.506 - 0.5072) –
Front brake caliper piston O.D 26.93 - 26.96(1.0602 - 1.0614) –
Front brake caliper cylinder I.D 27 - 27.05(1.063 - 1.065) –
Item Standard (mm)

Wheel rim run out service limit max 5
Rear brake disk thickness 5.0
Rear brake disk run out max 0.4
Rear brake caliper piston O.D. 25.33 - 25.36
Rear brake caliper cylinder I.D. 25.40 - 25.45
Electrical
Item Standard
Capacity 12V 10AH
Fully charged 13.2V
Battery Voltage (20°C)
Insufficient charged < 12.3V
Charging current 1.2A* 5 - 10H
3-126
Item Standard
Spark plug Standard type NGK CR7E
Primary coil 3.57 - 4.83Ω
Inductive Ignition Coil
Secondary coil without plug cap 10.42 - 14.49 KΩ
Throttle Position Sensor 3500 - 6500Ω

Fuel Injector 1.9 9 approx.
Water Temperature Sensor 2.076 KΩ± 10% (25°C)
Oxygen Sensor ( engine warming condition ) 6.7 - 9.5Ω
Crank Position Sensor 115 9 ± 15 9Ω
0.4V - 1.4V(normal)
Tilt Switch
3.7V - 4.4V (fall down)
At -20°C/-4°F 18.8 KΩ
At 100°C/212°F 0.1553 KΩ
Item Standard Service Limit
Starter motor brush length 12.5 mm 8.5 mm
Fuse 10A,15A,30A
Headlight bulb 12V 35W/35W *2
Turn signal light bulb 12V 21 W(Front) / 10W(Rear)
Stoplight 12V2W LED
Taillight 12V0.2W LED
3-127
4. CVT Continuously Variable Transmission K- XCT 300i
CVT Continuously Variable Transmission

This chapter covers the location and servicing of the CVT components
for the KYMCO K-XCT 300i.
• Belt Case ................................................................... 4-2~4-11

• CVT Removal .......................................................... 4-12~4-31
• CVT Installation ................................................................ 4-32
• The drive pulley, clutch and driven pulley can be serviced with the engine installed.
• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or
grease from them to minimize the slipping of drive belt and drive pulley.
TROUBLESHOOTING
Engine starts but motorcycle won't move

• Worn drive belt
• Broken ramp plate
• Worn or damaged clutch lining
• Broken driven face spring
Engine stalls or motorcycle creeps

• Broken clutch weight spring
Lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight roller
• Faulty driven face
4-1
4. CVT Transmission > Belt Case K- XCT 300i
Belt Case
Removal
Seat
Luggage Box
Center Cover
Rear Carrier
Body Cover
Front Cover
Front Lower Cover
Foot Skirt
Disconnect the drain hose from the plastic belt case cover.
4-2
Remove the belt case plastic cover bolts with an 8 mm socket.
Remove the belt case bodywork.
Inspect the plastic belt case cover and replace it if it is damaged.
4-3
Remove the belt case cover bolts with an 8 mm socket.
Use the pry points to free the belt case cover.
4-4
Remove the belt case cover and gasket.
Remove the two dowel pins.
4-5
Inspection
Inspect the drive belt for cracks or excessive wear.
Inspect the belt case bearing by turning it with a finger. Replace the
bearing if it is rough or noisy.
4-6
Remove the bearing snap ring with snap ring pliers.
Remove the bearing with a suitable bearing puller.
Drive in a new bearing with a suitable bearing driver that has the same
outside diameter as the bearing.
4-7
Install a new snap ring with snap ring pliers.
Installation
Install the two dowel pins into the belt case.
Install a new gasket with the belt case cover.
4-8
Install the belt case cover bolts and tighten them securely with an 8 mm
socket.
4-9
Install the belt case plastic cover.
Insert the plastic cover bolts and tighten them securely with an 8 mm
socket.
4-10
Fit the drain hose to the plastic belt case cover as shown.
4-11
4. CVT Transmission > CVT Removal K- XCT 300i
CVT Removal
Remove the belt case. See the Belt Case topic for more information.
Pulleys and Belt
Hold the drive pulley with a universal holder tool and loosen the
nut with a 19 mm socket.
Remove the drive pulley nut and washer from the crankshaft.
4-12
Remove the left face of the drive pulley.
Loosen the driven pulley nut with a 19 mm socket.
4-13
Remove the driven pulley nut and bushing.
Slide the driven pulley off of the shaft.
4-14
Remove the belt from the driven pulley.
Inspect the drive belt for cracks or excessive wear.
4-15
Remove the right (movable) face of the drive pulley from the crankshaft.
Slide the bushing out of the movable drive face.
Remove the washer from the crankshaft.
4-16
Drive Pulley Disassembly
Inspect the faces of the drive pulley. Clean away any grease from the
faces.
Lift the ramp plate out of the back of the left drive pulley face.
Remove the rubber damper pieces from the ramp.
4-17
There are eight weight rollers in the back of the right face of the drive
pulley.
Remove the rollers and check them for excessive or uneven wear.
Measure the outside diameter of the rollers. Replace the weight rollers
as needed.

4-18
Inspect the movable drive face and bushing for wear and damage.
Replace the parts as needed.
Clutch Disassembly
Lift the clutch outer off of the centrifugal clutch.
Inspect the inside of the clutch outer for excessive wear and damage.
Measure the inside diameter of the clutch outer and replace the part as
needed.
Clutch outer I.D. 152.1 - 152.2 152.2
4-19
Inspect the clutch shoe lining thickness. Replace the shoes if the wear is
below the service limit.

To disassemble the clutch and driven pulley set the clutch fitting tool to
onto the clutch.
ITEM TOOL NO. DESCRIPTION
#41 NUT AND FITTING TOOL A120E00028 Clutch disassembly
Fit the clutch and fitting tool into the clutch spring compressor tool.
4-20
Use the clutch spring compressor tool to compress the spring in the
driven pulley assembly.
Loosen the clutch drive plate nut with the special socket that comes with
the fitting tool.
Remove the clutch drive plate nut.
4-21
Inspect the left side bearing by turning it with a finger. If the bearing is
rough turning or noisy it should be replaced.
Remove the clutch spring compressor tool. Lift off the centrifugal clutch.
4-22
Remove the collars and spring.
Measure the free length of the clutch spring. Replace the spring if the
measurement fails to meet the service limit.
4-23
Remove the three circlips from the clutch pivot pins with a small flat
blade screwdriver.
Lift off the plate.
4-24
Slide the clutch shoes off of the pivots on the drive plate.
Inspect the clutch shoe bumpers and replace them as needed.
4-25
Driven Pulley Disassembly
Remove the clutch as shown above.
Remove the four guide rollers with guide roller pins.
Separate the left and right faces of the driven pulley.
4-26
Inspect the faces of the driven pulley. Clean away any grease from the
faces where the belt rides.
Remove the seals from the left face of the driven pulley.
4-27
Drive in the new seals with a suitable driver with the same outside
diameter as the seal.
Remove the O-rings on the left face.
Clean the left face and roller pins with a high flash point solvent and
compressed air.
4-28
Bearing Replacement
Inspect the bearings in the right face of the driven pulley.
Remove the needle bearing with a suitable puller.
4-29
Remove the collar, snap ring, and bearing from the right face of the
driven pulley.
Clean the right face with a high flash point solvent and compressed air.
4-30
Drive in the new baring so the sealed side face out towards the clutch.
Install the snap ring into the groove. Install the collar and drive in the
new needle bearing so that its markings face out. Drive in the bearings
with a suitable driver with the same outside diameter as the bearing.
Lubricate the bearings in the right face of the driven pulley with grease
4-31
4. CVT Transmission > CVT Installation K- XCT 300i
CVT Installation
Driven Pulley
Lubricate the bearings in the right face of the driven pulley with grease.
Drive in the new seals with a suitable driver with the same outside
diameter as the seal.
4-32
5. Final Drive K- XCT 300i
Final Drive
This chapter covers the location and servicing of the final drive
components for the KYMCO K-XCT 300i.
• Final Reduction ................................................................... 5-2
• Final Drive Oil .............................................................. 5-3~5-8
• The servicing operations of this section can be made with the engine
installed.
• When replacing the drive shaft, use a special tool to hold the bearing
inner race for this operation.
TROUBLESHOOTING
Engine starts but motorcycle won't move
• Damaged transmission
• Seized or burnt transmission
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal
5-1
5. Final Drive > Final Reduction K- XCT 300i
Final Reduction
Disassembly
Note: Do not remove the transmission case cover except for necessary
part replacement. If the drive shaft is replaced, make sure to also
replace the bearing and oil seal.
There are 9 transmission case cover bolts

.
5-2
5. Final Drive > Transmission Oil K- XCT 300i
Final Drive Oil
Place the scooter on level ground and up on its center stand.
The oil drain bolt and oil filler bolt are located on the transmission.
Gear oil capacity:
5-3
Inspection
Place the vehicle on its center stand on level ground.
Remove the transmission oil level check bolt with a 12 mm socket. The
oil level is correct when oil flows from the bolt hole. Install the oil level
check bolt and tighten it to specification with a 12 mm socket.
Torqu
Item Qty Thread size (mm)
kgf-m lb-ft
Final Drive oil

check bolt 1 8 0.8 - 1.2 5.79 - 8.68
5-4
If the level is too high allow the oil to flow out of the check hole until the
level is even with the bolt hole.
If the level is low add more of the same type and brand of oil as shown
below. Inspect for leaks.
Draining
Place the vehicle on its center stand on level ground. Place a suitable oil
drain pan under the transmission oil drain plug.
Place a suitable container under the drain plug to capture the final drive oil.
Loosen the oil drain plug with a 12 mm socket. Remove the drain
plug and slowly rotate the rear wheel to drain the transmission oil.
5-5
Inspect the drain plug and washer.
Install the oil drain plug and washer with a 12 mm socket. Tighten to
specification.
5-6
Torqu
kgf-m lb-ft
Final Drive oil

1 8 0.8 - 1.2 5.79 - 8.68
check bolt
Filling
Fill the final drive oil with a syringe until oil begins to flow from the level
check bolt hole.
Gear oil capacity:
5-7
Thread in the final drive oil level check bolt.
Install the oil check plug and torque it to specification with a 12 mm

socket.
Torque
kgf-m lb-ft
Final drive oil 1 8 0.8 - 1.2 5.79 - 8.68

check bolt
5-8
6. Cooling System K- XCT 300i
Cooling System
This chapter covers the location and servicing of the cooling system components
for the KYMCO K-XCT 300i.
• Coolant ..................................................................6-3~6-11
• Radiator ..............................................................6-12~6-29
• Thermostat ..........................................................6-30~6-40
• Water Pump ........................................................6-41~6-49
• The water pump must be serviced after removing the engine. Other cooling
system service can be done with the engine installed in the frame.
• The engine must be cool before servicing the cooling system. When the
coolant temperature is over 100 , never remove the radiator cap to release
the pressure because the boiling coolant may cause danger.
• Avoid spilling coolant on painted surfaces because the coolant will corrode the
painted surfaces. Wash off any spilled coolant with fresh water as soon as
possible.
• After servicing the system, check for leaks with a cooling system tester.
TROUBLESHOOTING
Engine temperature too high

• Faulty temperature gauge or sensor
• Faulty radiator cap
• Faulty thermostat
• Insufficient coolant
• Passages blocked in hoses or water jacket
• Clogged radiator fins
• Passages blocked in radiator
• Faulty water pump
6‐1

6. Cooling System K- XCT 300i
Temperature gauge shows the wrong temperature

• Faulty temperature gauge or sensor
• Faulty thermostat
Coolant leaks
• Faulty pump mechanical (water) seal
• Deteriorated O-rings
• Damaged or deteriorated water hoses
6‐2

6. Cooling System > Coolant K- XCT 300i
Coolant
Warning: Allow the engine sufficient time to cool before handling or working
on the cooling system components.
To check the coolant level, see the Coolant Level Check topic for more information.
Draining
SAFETY FIRST: Antifreeze is highly toxic and can kill pets and animals if drank. Do not
leave coolant where animals (including children!) can get to it.
Remove the radiator coolant panel screws with a #2 Phillips

screwdriver.
Remove the panel to access the radiator cap.

6-3
Remove the radiator cap in two stages. Allow any built up pressure to
vent and then open the cap all the way and remove it.
The water pump is located on the right side of the engine. Ready a drain
pan under the water pump drain bolt.
Loosen the coolant drain bolt with an 8 mm socket.
6-4
Remove the drain bolt and sealing washer and allow the coolant to drain
into a suitable container.
The coolant reserve tank is under the inner cover.

Remove the engine coolant lid screw with a #2 Phillips.
Remove the engine coolant lid.
6-5
Open the coolant reserve tank lid. Siphon the coolant out of the
reserve tank with an appropriate suction device. If a suction
device is unavailable remove the reserve tank and poor it out.
See the Radiator topic for more information.
When the coolant has fished draining return the drain bolt to the water
pump with a new sealing washer.
Tighten the drain bolt securely with an 8 mm socket.
6-6
Filling
Coolant capacity
Radiator 766 cc
Reserve tank 590 cc
• Use coolant of specified mixing rate. (The mixing rate of 860cc

coolant concentrate + 859cc distilled water is 50%.)
• Do not mix coolant concentrate of different brands.
• Do not drink the coolant, which is poisonous.
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS

KYMCO SIGMA Coolant
Freezing Point Mixing Rate Distilled Water
Concentrate
-9°C 20% 344 cc 1375 cc
-15°C 30% 516 cc 1203 cc
-25'°C 40% 688 cc 1031 cc
-37°C 50% 860 cc 859 cc
-44.5°C 55% 945 cc 774 cc
• The freezing point of coolant mixture shall be 5°C lower than the freezing
point of the riding area.
6-7
Fill the cooling system with a mix of distilled water and Coolant
Concentrate. Continue filling until the coolant until it reaches the
bottom of the filler neck as shown.
Add coolant to the reserve tank until it reaches the upper level
mark.
6-8
Gently rock the vehicle side-to-side to release any air bubbles trapped in
the cooling system.
Place the vehicle on its center stand and start the engine. Let it run for
several minutes. This will purge any air out of the cooling system.
Check for coolant leaks
When the air bubbles stop coming up turn off the engine and recheck
the coolant level, add coolant if necessary. Check the reserve tank and
add coolant if needed.
Wet the seal of the radiator cap and install.
Install the coolant reserve tank lid.
6-9
Install the engine coolant reserve tank cover. Insert the screw and
tighten its securely with a #2 Phillips.
Install the radiator cap access panel.
6-10
Install the radiator coolant panel screws and tighten securely with
a #2 Phillips screwdriver.
6-11
6. Cooling System > Radiator K- XCT 300i
Radiator
Warning: Allow the engine sufficient time to cool before handling

or working on the cooling system components.
Pressure Testing
Remove the radiator coolant panel screws with a #2 Phillips

screwdriver.
Remove the panel to access the radiator cap.
6-12
Remove the radiator cap in two stages. Allow any built up pressure to
vent and then open the cap all the way and remove it.
When checking the cooling system for leaks you will need a pressure
tester. Remove the radiator cap, wet the tester seal, and install the end of
the pressure tester onto the filler neck. Pump the tester up until the
gauge reads 0.84 kg/cm2 or 12 psi. The cooling system should hold this
pressure for at least 6 seconds. If it does not you will need to inspect the
entire system for leaks. Do not pressurize the cooling system more than
1.05 kg/cm2 or 14.9 psi.
CAUTION: Never remove the radiator cap when the engine is hot.
6-13
Wet the seal on the radiator cap and install it to the pressure tester.
Replace the cap if it does not relieve the pressure as specified.
Radiator cap relief pressure 0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
Removal
Unplug the thermostatic switch connectors.
6-14
Unplug the cooling fan motor connector.
There are three coolant hoses that connect to the radiator. The top right
hose runs to the filler neck and cap. The top left hose runs to the
thermostat on the cylinder head. The bottom right hose runs to the water
pump.
6-15
Loosen the coolant hose clamps with a #2 Phillips screwdriver.
Free the filler neck coolant hose from the stay and remove it from the
radiator.
Remove the water pump and thermostat hoses in the same manner.
6-16
Remove the two radiator mounting bolts with a 10 mm socket.
Slide the radiator to the left and free the grommet from the post above
the right side of the radiator.
6-17
Remove the radiator from the frame.
Coolant Reserve Tank
The coolant reserve tank is mounting to the frame with two bolts. There
are two hoses that connect to the reserve tank. The top hose is a dump
hose that hangs over the other side. The bottom hose is the overflow
hose that runs to the filler neck.
6-18
Position a suitable container below the reserve tank.
Pull back the clamp and free the overflow hose from the bottom of the
reserve tank. Allow the coolant in the reserve tank to drain into the
container.
6-19
Remove the two reserve tank mounting bolts with a 10 mm socket.
Remove the reserve tank from the frame.
6-20
To remove the reserve tank bracket take off the mounting nuts with a 10
mm socket.
6-21
Remove the reserve tank bracket from the studs on the frame.
Inspection
Inspect the radiator fins for damage and clogging. To remove the fan
take out the three mounting bolts with a 10 mm socket.
6-22
Clean out the fins with low pressure compressed air and water.
Check the radiator for any bent or damaged fins. Use a small flat blade
screwdriver to straighten them out, but be careful not to puncture the
radiator.
Jump a 12 volt battery to the fan connector and make sure the radiator
fan operates.
6-23
If the thermostatic switch needs to be removed use a 22 mm wrench.

The thermostatic switch should be off below 85°C (185°F) and on above
90°C (194°F).
Installation
Coolant Reserve Tank
Fit the coolant reserve tank bracket to the studs on the left side of the
frame.
6-24
Install the two reserve tank mounting nuts and tighten them securely
Fit the reserve tank to its bracket.
Insert the two reserve tank mounting bolts and tighten them securely
6-25
Connect the dump hose to the top of the reserve tank and the
overflow hose to the bottom. Secure the hoses with the clamps.
Radiator
6-26
Fit the radiator into place so that the post on the frame fits into the
rubber grommet on the right side of the radiator.
Install the two radiator mounting bolts and tighten them securely with a
10 mm socket.
6-27
Route the filler neck coolant hose through the guide to the top right of
the radiator.
Connect the coolant hose from the thermostat on the cylinder head to
the top left of the radiator. Connect the coolant hose from the water
pump to the bottom right of the radiator.
Tighten the coolant hose clamp screws securely with a #2 Phillips

screwdriver.
6-28
Plug in the cooling fan motor connector.
Plug in the thermostatic switch connectors.
6-29
6. Cooling System > Thermostat K- XCT 300i
Thermostat and Thermosensor

Removal
Thermosensor
Unplug the thermosensor unit and thermo unit ground connectors.
Remove the thermosensor unit with a 12 mm deep well socket
6-30
Water Temperature Sensor (WTS)
Unplug the water temperature sensor.
Use a 17 mm wrench to remove the water temperature sensor.
6-31
Discard the WTS O-ring and replace it with a new item.
Thermostat
Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide

up the clamp and free the coolant hose from the thermostat.
Squeeze the air bleed hose clamp with needle nose pliers and slide
back the clamp. Free the air bleed hose from the thermostat.
6-32
Remove the two thermostat mounting bolts with an impact #3 Phillips

screwdriver.
6-33
Lift off the thermostat cover.
Lift out the thermostat. Remove the thermostat O-ring and discard it.
6-34
Inspection
Thermosensor
Set a digital multimeter to read ohms of resistance ( )
Suspend the thermosensor in a pan of water over a burner and measure

the resistance through the sensor as the water heats up. Do not allow the
thermosensor or the thermometer to contact the sides of the pan.
At 50 °C/122 °F 154 Ω
At 80 °C/176 °F 52 Ω
Thermosensor resistance
At 100 °C/212 °F 27 Ω
At 120 °C/248 °F 16 Ω
Water Temperature Sensor
Inspect the WTS in a simlar manner as the thermosensor. Measure the

resistance between the WTS terminals and compare this to the
specifications.
At -20 °C/-4 °F 18.8 kΩ

WTS resistance At 40 °C/104 °F 1.136 kΩ
At 100 °C/212 °F 0.1553 kΩ
6-35
Thermostat
The thermostat should be closed at room temperature.
Suspend the thermostat and a thermometer in a pot of water with string.

Make sure the thermostat and the thermometer are not touching the pot.
Bring the temperature up to the specification slowly and check the
operation of the thermostat.
The valve should begin to open around 71° C (160° F). The valve should
lift 3.5 - 4.5 mm (0.14 - 0.18 in) at 80° C (176° F).
After the thermostat has been open for around 5 min. allow the thermostat
to cool. The thermostat should close at 70° C (158° F).
Replace the thermostat with a new unit if it fails to function properly.
6-36
Installation
Thermosensor
Tighten the thermosensor unit securely with a 12 mm deep well socket
Plug in the thermosensor unit and ground connectors.
6-37
Water Temperature Sensor
Install the WTS with a new O-ring. Tighten the WTS to specification with
a 17 mm wrench.
Plug in the water temperature sensor connector.
6-38
Thermostat
Make sure the thermostat seal is in good condition. Replace the

thermostat if needed. Apply a light coat of waterproof grease to the
thermostat seal. Insert the thermostat into its cavity in the cylinder head.
Fit the thermostat cover into place.
6-39
Insert the two thermostat bolts and tighten them securely with an impact
Install air bleed hose and secure it with the clamp.
Connect the coolant hose to the thermostat. Move the clamp into place
6-40
6. Cooling System > Water Pump K- XCT 300i
Water Pump
Mechanical Seal Inspection
Inspect the telltale hole in the generator cover below the water pump for
signs of coolant leaking. If there is coolant coming from this hole the
mechanical seal is compromised and must be replaced.
Removal
Water Pump Cover
' Seat
' Luggage Box
' CenterCover
' RearCarrier
' BodyCover
' FrontCover
' FrontLowerCover
' Foot Skirt
' Exhaust System
6-41
Loosen the four water pump cover bolts with an 8 mm socket.
Remove the bolts and the water pump cover.
6-42
Remove the two dowel pins and the water pump cover gasket.
Impeller and Shaft
Hold the water pump shaft and loosen the impeller with a 12 mm socket.
The impeller has left hand threads.
Remove the impeller.

6-43
Remove the seal washer from the back of the impeller. Inspect the
impeller blades and seal. Replace the seal washer if the mechanical
seal is to be replaced.
Remove the water pump shaft from the generator cover.
6-44
To replace the mechanical and oil seals drive them out from the
inside of the generator cover.
Assembly
Seals, Shaft, and Impeller
Coat the lips of the new oil seal in fresh engine oil and drive it in with a
suitable drive that is the same outside diameter as the oil seal.
Apply silicone sealant to the outside of the mechanical seal. Press in the
seal with a suitable drive that is the same outside diameter as the oil seal.
6-45
Place the washer and thrust washer on the water pump shaft. Install a
new snap ring onto the water pump shaft if the snap ring was removed.
Lubricate the water pump shaft with fresh engine oil where it will ride in
the case. Insert the water pump shaft into the generator cover from the
inside.
6-46
Install a new washer into the back of the impeller if the mechanical seal
was replaced.
Install the impeller to the water pump shaft. Note: Left hand threads.
6-47
Hold the water pump shaft and tighten the impeller to specification with a
12 mm socket. Remember the impeller has left hand threads.
Thread Torque
Item Qty
Water pump impeller 1 7 1.0-1.4 7.23-10.13
Make sure the water pump cover mating surface is clean.
Install the two dowel pins into the generator cover and set a new water
pump cover gasket in place.
6-48
Install the water pump cover and insert the four bolts.
Tighten the water pump cover bolts to specification with an 8 mm

socket.
Connect the coolant hose to the water pump. Move the clamp into place
6-49
7. Fuel Injection System K- XCT 300i
This chapter covers the location and servicing of the fuel system components for the
KYMCO K-XCT 300i.
• Air box .......................................................................... 7-2~7-8

• Fuel Tank ................................................................... 7-9~7-12
• Fuel Pump and Fuel Level Gauge .......................... 7-13~7-22
• Throttle Body Removal and Installation .................. 7-23~7-39
• Throttle Body .................................................................... 7-40
• Fuel Injector ............................................................. 7-41~7-49
• Self-Diagnosis ......................................................... 7-50~7-51
• Fuel Injector Diagnostic Tool............................................ 7-52
• Throttle Cable .......................................................... 7-53~7-59
• TPS ISC Reset Procedure ............................................... 7-60
SERVICE INFORMATION
Scooter services can be done with the engine installed in the frame.
Be sure to relieve the fuel pressure before fuel pump or fuel hose removal.
Bending or twisting the control cables will affect operation and could cause the cables to
stick or bind, resulting in loss of vehicle control.
Work in a fully ventilated area. Smoking or allowing flames or sparks in the work area or
where gasoline is stored can cause a fire or explosion.
Do not apply the Carburetor Cleaners to the inside of the throttle body, which is coated
with molybdenum.
Do not snap the throttle valve from fully open to fully close after the throttle cable has
been removed; it may cause incorrect idle speed.
Do not loosen or tighten the painted bolts and screws of the throttle body. Loosening or
tighten them can cause throttle and idle valve synchronization failure.
Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris
from entering the intake ports after the throttle body has been removed.
Do not damage the throttle body. It may cause incorrect throttle and idle valve
synchronization.
Do not take the fuel pump on the ground downward.
7-1
7. Fuel System> Air box K- XCT 300i
Air box
Removal
Loosen the air box connecting hose clamp screw at the throttle body with
a #2 Phillips.
Remove the breather hose from the air box.
7-2
Disconnect the transmission vent hose.
7-3
Remove the two rear air box screws with an 8 mm socket.
Remove the two front air box screws with an 8 mm socket.
7-4
Remove the air box.
Installation
Fit the air box into the frame and guide the boot over the mouth of the
throttle body.
7-5
Tighten the air box connecting hose clamp screw at the throttle body with
a Phillips.
7-6
Install the two front air box screws and tighten securely with an 8 mm
socket.
Install the two rear air box screws and tighten securely with an 8 mm
socket.
7-7
Connect the transmission vent hose.
Connect the breather hose to the air box.
7-8
7. Fuel System> Fuel Tank K- XCT 300i
Fuel Tank
Warning: Gas is extremely flammable! Do not work around an open flame or a

source of sparks.
Removal
In order to drain the fuel from the fuel pipe and release the fuel pressure
unplug the fuel pump connecter. Start the engine and let it run until it
dies of fuel starvation. Turn the ignition switch off.
Loosen the fuel hose clamp with a #2 Phillips screwdriver. Slide back
the clamp and free the injector fuel hose from the fuel pump pipe. Clean
up any remaining fuel immediately.
7-9
Remove the fuel tank mounting nuts and brackets. Remove the fuel tank
from the bottom of the frame.
7-10
Installation
Fit the fuel tank into place.
Install the brackets and nuts. Tighten the nuts securely
Connect the fuel hose to the outlet pipe on the fuel pump. Tighten the
clamp securely with a #2 Phillips screwdriver.
7-11
Plug in the fuel pump connecter.
7-12
7. Fuel System> Fuel Pump K- XCT 300i
Fuel Pump

source of sparks.
Input Voltage Inspection
Turn the ignition switch off.
Place the scooter on its main stand and put the side stand up.
7-13
Set the engine stop switch to the “RUN” position.
Unplug the fuel pump connecter.
Set the multi meter to read battery voltage.
Touch the multi meter leads to the harness side of the fuel pump
connector, with the positive lead touching the red/black wire terminal
and the negative lead touching the green wire terminal.
Turn the ignition switch on. The battery voltage should show for a few
seconds. Replace the fuel pump if it is not functioning and the input
voltage is correct.
If the battery voltage is not present check the following:
Fuse B (10 A)
Fuel cut-off relay
ECU
7-14
Removal
In order to drain the fuel from the fuel pipe and release the fuel pressure
unplug the fuel pump connecter. Start the engine and let it run until it
dies of fuel starvation. Turn the ignition switch off.
the clamp and free the injector fuel hose from the fuel pump pipe. Clean
up any remaining fuel immediately.
Remove the 6 fuel pump bolts with a 7 mm socket or #2 Phillips

screwdriver.
7-15
Lift the fuel pump out of the tank.
Discard the fuel pump O-ring, and replace it with a new item on
assembly.
7-16
Fuel Level Gauge Inspection
Using a digital multi meter set to ohms of resistance ( ), measure the

resistance between the fuel pump/level gauge connector terminals
(green and yellow/white) with the float raised to the positions indicted
below.
7-17
Fuel Level Float Position Resistance
Full 1100 ± 33
Empty 100 ± 3
Replace the fuel level float unit with a new part if the resistance is out of
specification.
7-18
Fuel Output Pressure
Turn the key to the OFF position.
Use a fuel hose clamp as shown.
Disconnect the fuel hose from the fuel injector. Connect the fuel
pressure gauge. Remove the fuel hose clamp. Turn the key to the ON
position. Check the fuel pressure.
If the fuel output pressure is less than 3.0 bar, may fail to start the
engine or in trouble in case of riding.
7-19
Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose.
Return the fuel line to the injector.
To inspect the fuel pump relay see the Relays topic.
Fuel Pump Relay
See the Relay topic.
Installation
Replace the O-ring with new item and apply a small amount of fresh
engine oil to the new O-ring.
7-20
Carefully insert the fuel pump into the tank. Avoid damaging the fuel
pump wire. The fuel delivery pipe should face to the rear.
Insert the 6 fuel pump mounting bolts. Tighten the bolts to specification
with a 7 mm socket or #2 Phillips screwdriver.
Torque
Item Qty
kgf-m lb-ft
Fuel Pump Bolts 6 0.35 2.5
7-21
Connect the fuel hose to the outlet pipe on the fuel pump. Tighten the
clamp securely with a #2 Phillips screwdriver.
Plug in the fuel pump connecter.
7-22
7. Fuel System> Throttle Body Removal K- XCT 300i
Throttle Body Removal and Installation

Inspection
Throttle Body /MAP/ISC/TPS
Turn off the ignition switch during removal/installation.

Check and confirm if the voltage is over 12V with a voltmeter after replacement.
Check and confirm if the other connectors are installed correctly after replacement.
Do not damage the throttle body, it may cause the throttle and idle valve to fail
synchronization.
The throttle body is preset in KYMCO factory, do not disassemble it incorrectly.
Do not loosen or tighten the painted bolts and screws for the throttle body.
Loosening or tightening them can cause the throttle and idle valve synchronization to
fail.
TPS and ISC have to be reset after the throttle body MAP, TPS, ISC or ECU has
been reinstalled.
MAP Inspection
Support the scooter on a level surface.
Put the side stand up and engine stop switch is at “RUN”.
Turn the ignition switch to “ON” position.
7-23
Measure if the ECU voltage outputs to the MAP between the following
terminals of the MAP connector.
Terminal Normal
Violet/Red (+) – Green/Pink (-) 5V
TPS Inspection
Support the scooter on a level surface.
Put the side stand up and engine stop switch

is at “RUN”.
Turn the ignition switch to “ON”.
7-24
Measure if the ECU voltage outputs to TPS between the following

terminals of the TPS connector.
Terminal Normal
Violet/Red (+) – Green/Pink (-) 5V
Throttle Position Sensor (TPS)

3500 - 6500
7-25
Removal
Throttle Cables
Free the throttle cables from the throttle drum.
7-26
Fuel Injector

source of sparks.
Disconnect the Fuel Pump Relay or Fuel Pump Connector.
In order to release fuel pressure from the fuel pipe when removing the
fuel injector, unplug the fuel pump connecter. Start the engine and let it
run until it dies of fuel starvation. Turn the ignition switch off.
Inspect the fuel hose for signs of deterioration or damaged. Replace the
fuel hose as needed.
7-27
Remove the fuel injector mounting bolt with a 10 mm socket.
Unplug the fuel injector connector.
7-28
Lift the fuel injector out of the intake pipe.
the clamp and free the injector fuel pipe from the fuel hose.
7-29
Lift the fuel pipe off the top of the injector.
Sensors
Unplug the MAP sensor.
7-30
Unplug the ISC connector.
Throttle Body
Unplug the throttle position sensor (TPS) connector.
7-31
Loosen the air box hose clamp screw at the throttle body with a #2
Phillips.
Loosen the intake hose clamp screw at the throttle body with a flat blade
screwdriver.
Remove the throttle out of the air box and intake boots.
7-32
Installation
Throttle Body
Fit the throttle body into the air box and intake boots.
Tighten the intake hose clamp securely with a flat blade screwdriver.
7-33
Throttle Cables
Connect the throttle cables to the throttle drum.
Adjust the throttle cable free play with 12 mm wrenches.
7-34
Sensors
Plug in the TPS connector.
Plug in the ISC connector.
7-35
Plug in the MAP sensor.
Fuel Injector
Apply a light coat of fresh engine oil to a new fuel injector O-ring.
7-36
Fit the fuel injector pipe onto the top of the injector. The tab on the
injector must fit into the pipe.
Fit the fuel hose onto the fuel injector pipe. Secure the hose to the fuel
injector with the clamp. Tighten the clamp securely with a #2 Phillips
screwdriver.
7-37
Fit the injector into the intake pipe as shown.
Plug in the fuel injector connector and thread in the mounting bolt.
7-38
Tighten the fuel injector bolt securely with a 10 mm socket.
Connect the Fuel Pump Relay or Fuel Pump Connector.
The throttle position sensor (TPS) and idle air bypass valve (ISC) have
to be reset when the throttle body MAP, TPS, ISC or ECU have been
reinstalled. See the TPS/ISC Reset Procedure for more information.
7-39
7. Fuel System> Throttle Body K- XCT 300i
Throttle Body
Remove the throttle body. See the Throttle Body Removal topic for more information.
Disassembly
The throttle position sensor (TPS) and idle air bypass valve (ISC) have
to be reset when the throttle body MAP, TPS, ISC or ECU have been
reinstalled.
MAP Sensor
7-40
7. Fuel System > Fuel Injector K- XCT 300i
Fuel Injector

source of sparks.
Removal
In order to release fuel pressure from the fuel pipe when removing the
fuel injector, unplug the fuel pump connecter. Start the engine and let it
run until it dies of fuel starvation. Turn the ignition switch off.
Inspect the fuel hose for signs of deterioration or damaged. Replace the
fuel hose as needed.
7-41
Remove the fuel injector mounting bolt with a 10 mm socket.
Unplug the fuel injector connector.
7-42
Lift the fuel injector out of the intake pipe.
the clamp and free the injector fuel pipe from the fuel hose.
7-43
Lift the fuel pipe off the top of the injector.
Inspection
A digital multi meter is needed to test the fuel injector.
Measure the resistance between the fuel injector terminals
ITEM SPECIFICATIONS
Fuel injector resistance (at 20°C/68°F) 11.7 ± 0.6
7-44
Inspect the seals on both sides of the fuel injector. Replace the injector if
the seals are in poor condition.
Check for signs of clogging.
Set the multi meter to read ohms of resistance ( ).
Cleaning
PROBLEM
1. Fuel Injector cannot output the fuel.
2. The Injector injection time (ms) is shorter or longer.
Standard: < 1.6ms
ANALYSIS
Injector block (With some carbons).
TROUBLESHOOTING
1. Use the specified injector cleaner.
2. Pouring the liquid of carburetor cleaner until half container.
3. Connect the battery as picture.
4. The injector cleaner with the flash relay.
5. Keeping the fuel Injector operation.
6. Waiting for 20-30 minutes.
7. Cleaning the carbons completely.
7-45
7-46
Installation
Apply a light coat of fresh engine oil to the fuel injector O-ring seals.
Fit the fuel injector pipe onto the top of the injector. The tab on the
injector must fit into the pipe.
7-47
Fit the fuel hose onto the fuel injector pipe. Secure the hose to the fuel
injector with the clamp. Tighten the clamp securely with a #2 Phillips
screwdriver.
Fit the injector into the intake pipe as shown.
Plug in the fuel injector connector and thread in the mounting bolt.
7-48
Tighten the fuel injector bolt securely with a 10 mm socket.
Plug in the fuel pump connector.
7-49
7. Electrical System > Self-Diagnosis K- XCT 300i
Self-Diagnosis
Note: No matter when the CELP illuminated while riding condition, should find out the
cause of the problem as soon as possible.
The check engine lamp (CELP) or Fi indicator is located next to the battery warning
indicator.
If the ECM connectors, or battery leads are disconnected the stored malfunction codes
will be lost.
7-50
7. Electrical System > Self-Diagnosis K- XCT 300i
Without Diagnostic Special Tool

SELF-DIAGNOSTIC PROCEDURES
The “CELP” denotes the failure codes. When the indicator lights for one second is
equal to ten.
For example: one longer blink illumination and two shorter blinks (0.5 second x 2) of
the indicator are equal to 12 blinks. Follow code 12.
If more than a damaged part has occurred, the “CELP” begins blinking in order.
For example: If the indicator blinks six times, then shows one second illumination and
two blinks, so there are two failures have occurred. Follow code 6 and 12.
7-51
7. Fuel System> F.I. Diagnostic Tool K- XCT 300i
Fuel Injection Diagnostic Tool

OPERATION INSTRUCTIONS
Diagnostic tool Part Number: 3620A-LEB2-E00
This tool has been developed by KYMCO and for KYMCO vehicles only.
The tool software can be updated for new models with a computer via the
USB cable.
Please refer to the specifications when serving this vehicle. See the K-
XCT 300i Specifications topic for more information.
This tool does not have an internal battery. The power for the tool is
provided by the vehicle when connected. The vehicle should have a fully
charged battery when using the diagnostic tool.
7-52
7. Fuel System> Throttle Cable K- XCT 300i
Throttle Cable
Removal
Adjust the throttle cables for maximum free play at the throttle body.
Free the throttle cables from the throttle drum.
7-53
Remove the two right switch housing mounting screws with a #2 Phillips
screwdriver. Disconnect the switch.
Separate the switch housing from the handlebar.
Disconnect the throttle cables and free the right switch housing from the
handlebar.
7-54
Guide the throttle cables out towards the handlebar side.
Installation
Route the throttle body end of the cables through the opening in the
lower handlebar cover.
7-55
Route the cables through the guide.
Route the cables down the inside of the left side of the frame.
7-56
Route the cables to the throttle body as shown.
7-57
Connect the throttle cables to the throttle drum.
Slide the throttle grip onto the right side of the handlebar.
Install the right switch and throttle housing. The post on the housing
should fit into the hole in the bar.
7-58
Lubricate the end of the throttle in grease. Fit the ends of the throttle
cables into the throttle tube.
Adjust the throttle cable free play with 12 mm wrenches.
7-59
7. Fuel System> TPS ISC Reset Procedure K- XCT 300i
TPS ISC Reset Procedure

When opening and closing the throttle grip randomly, the ECU may record the
incorrect TPS reading when the ECU or the throttle body has been reinstalled. It
can cause hard to start engine or idling speed is not smooth when engine
installation.
ISC has a motor inside, which controls the ISC valve to obtain a smooth idling
speed. The ECU may record the incorrect ISC position when the engine is running
because the ECU or the throttle body has been reinstalled. It can cause engine to
stop, hard to start engine or rough idling speed.
The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset
when throttle body, MAP, TPS, ISC or ECU have been reinstalled.
TPS/ISC RESET PROCEDURE
1. Put the side stand up and engine stop switch is at “RUN”.
2. Turn the key to the "OFF" position.
3. Fully open the throttle.
4. Turn the key to the "ON" position.
5. Release the throttle after waiting for eight seconds.
6. Turn the key to the "OFF" position.
7. Turn the key to the "ON" position.
8. TPS and ISC have been reset successfully.
If the procedure fails, repeat the steps from 1 to 8.
7-60
8. Steering K- XCT 300i
Steering
This chapter covers the location and servicing of the steering components for the
KYMCO K-XCT 300i.
• Steering Stem and Bearing Removal ............................................................... 8-2~8-8

• Steering Stem and Bearing Installation ......................................................... 8-9~8-14
• Handlebar ..................................................................................................... 8-15~8-25
TROUBLESHOOTING
Hard steering (heavy)
• Excessively tightened steering stem top cone race
• Broken steering balls
• Insufficient tire pressure
Steers to one side or does not track straight

• Uneven front shock absorbers
• Bent front fork
• Bent front axle or uneven tire
8-1
8. Steering > Removal K- XCT 300i
Steering Stem Removal

Support the vehicle with a suitable stand or jack so that the front wheel is off the ground.
Grip the bottom of the fork legs and turn the front end side-to-side. If the movement is
rough the bearings should be greased or replaced. If the movement is to tight or loose the
steering stem adjusting nut may need to be adjusted.
The KYMCO K-XCT 300i uses ball bearings in the steering. Always replace the races at
the same time as the bearings.
8-2
A special lock nut wrench is needed to loosen the steering stem lock nut.
Special Tool - Lock Nut Wrench: A120F00002
8-3
Slide the special tool over the steering stem and loosen the lock nut.
Remove the steering stem lock nut.
Slide off the lock washer.
Support the steering stem and loosen the steering stem adjusting nut
with a pin spanner.
8-4
Remove the steering stem adjusting nut.
Remove the dust cover and grease seal.
Lower the steering stem out of the frame.
8-5
Remove the upper bearing inner race.

Lift out the upper ball bearings.
Slide the lower ball bearings up and off of the steering stem.
Inspect the bearings and races for wear and damage. Replace them as
needed.
8-6
Use a chisel to remove the bottom bearing inner race and dust seal. Do
not damage the steering stem.
Use the special tools or a drift and hammer to drive out the bearing
races in the steering head.
8-7
Have the drift set against the lip of the race, and work around the race
evenly to drive it out. Repeat the process with the remaining bearing
race.
8-8
8. Steering > Installation K- XCT 300i
Steering Stem Installation
Coat the new dust seal in grease and slide it down the steering stem.
Drive the new lower bearing inner race onto the steering stem with a
pipe with the same outside diameter as the bearing race.
Drive the new bearing races into the steering head with a suitable driver
with the same outside diameter as the bearing race.
8-9
Lubricate the upper bearing with grease and set it into place.
Lubricate the new lower bearing with grease and place it on the steering
stem.
8-10
Set the upper bearing inner race into the upper bearing.
Guide the steering stem into the steering head of the frame.
8-11
Lubricate the grease seal with grease. Set the grease seal and dust
cover into place over the steering stem.
Thread on the steering stem adjusting nut.
8-12
Tighten the steering stem adjusting nut. Turn the steering stem lock-to-
lock several times to seat the bearings.
Loosen the adjusting nut 1/4 to 1/2 half turn. Adjust the nut so the
steering moves correctly. The adjusting nut should be tight enough so
that the steering doesn't flop back and forth and vertical movement is
eliminated. However, it should not be so tight as to cause binding or
require excessive force to turn.
Slide the lock washer onto the steering stem as shown.
8-13
Thread the steering stem lock nut onto the steering stem.
Torque the steering stem lock nut to specification with the lock nut
wrench special tool.
Torque
kgf-m lb-ft
Steering Stem lock nut 1 BC1 6.0-8.0 43.40-57.86
Special Tool - Lock Nut Wrench: A120F00002
8-14
8. Steering > Handlebar K- XCT 300i
Handlebar
Removal
Bar Ends
Remove the bar ends with a 6 mm Allen.
To remove the brake master cylinders see the. Brake Master Cylinder
topic.
Switch Housings and Throttle
Remove the two right switch housing mounting screws with a #2 Phillips
screwdriver. Disconnect the switch.
8-15
Separate the switch housing from the handlebar.
Disconnect the throttle cables and free the right switch housing from the
handlebar.
Slide off the throttle grip.
8-16
Remove the two left switch housing mounting screws with a #2 Phillips
screwdriver.
Disconnect the switch. Separate the left switch housing from the
handlebar.
8-17
Handlebar
Route the cables and lines from the handlebar cable guide.
Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut
8-18
Remove the handlebar lock nut and bolt.
Remove the handlebar.
8-19
Grips
If you plan to replace the grips you can slice them lengthwise with a razor blade and peel
them off. To remove the grips without cutting them use a screwdriver to open a gap
between the grip and the handlebar.
Spray in contact cleaner to break up the grip cement. Use compressed air to expand the
grip so it can be easily slid off the end of the handlebar. Note the relationship between
the angle of the grip and the throttle tube so that the new grip can be installed with the
correct angle.
NOTE: Always wear safety glasses when using compressed air and never point it directly
at yourself or anyone else.
Before installing the grips to either the throttle tube or the handlebar, wipe down the area
with a brake or parts cleaner that will dry without leaving a residue. When you are sure
the area is dry apply grip cement to the bar or tube. Install the left grip at an angle of your
preference. Install the throttle grip onto the tube with the same angle as the original grip.
8-20
Installation
Handlebar
Install the handlebar onto the steering stem and align the holes.
Install the handlebar lock bolt and thread on the nut.
8-21
Hold the handlebar lock bolt with a 14 mm wrench and tighten the nut to
lorque
Item
N-m lb-ft
Handlebar Lock Nut 45 32
Route the cables and lines through the handlebar cable guide.
8-22
Switch Housings and Throttle
Align the left switch housing and install on the handlebar.
Insert the two housing screws and tighten them securely with a #2
Phillips screwdriver. Connect the switch.
8-23
Slide the throttle grip onto the right side of the handlebar.
Install the right switch and throttle housing. The post on the housing
should fit into the hole in the bar.
Lubricate the end of the throttle in grease. Fit the ends of the throttle
cables into the throttle tube.
8-24
Insert the two housing screws and tighten them securely with a #2
Phillips screwdriver. Tighten the front bolt before the rear.
Bar Ends
Install the bar ends with a 6 mm Allen.
8-25
9. Brakes K- XCT 300i
Brakes
This chapter covers the location and servicing of the brake system
components for the KYMCO Downtown 300i.
• Master Cylinders ........................................................ 9-2~9-16

• Front Caliper ............................................................ 9-17~9-26
• Rear Caliper ............................................................ 9-27~9-33
• Brake Discs ............................................................. 9-34~9-42
• Brake Pad Replacement ......................................... 9-43~9-54
• During servicing, keep oil or grease off the brake pads and brake disk.
TROUBLESHOOTING
Poor brake performance
• Worn brake pads
• Contaminated brake pad surface
• Deformed brake disk
• Air in brake system
• Deteriorated brake fluid
• Worn brake master cylinder piston oil seal
• Clogged brake fluid line
• Unevenly worn brake caliper
9-1
8. Brakes > Master Cylinders K- XCT 300i
Master Cylinders
NOTE: Brake fluid is a corrosive chemical and can damage paints and some plastics.
Avoid contact with skin.
Removal
Remove the brake hose banjo bolt from the master cylinder using a 12
mm socket. Discard the sealing washers.
9-2
Unplug the brake light switch connector.
Remove the two master cylinder mounting bolts with an 8 mm socket.
Remove the master cylinder clamp.
9-3
Remove the master cylinder.
Remove the two master cylinder cover screws with a #2 Phillips head
screwdriver.
9-4
Remove the master cylinder cover, plastic piece and rubber accordion
diaphragm. Pour out any remaining brake fluid.
9-5
Disassembly
Brake Levers
Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt
with a flat blade screwdriver.
Remove the pivot nut and bolt.
9-6
Remove the brake lever.
Brake Light Switch
Remove the brake light switch mounting bolt with a #2 Phillips

screwdriver. Remove the brake light switch.
9-7
Piston
Remove the rubber piston cover.
Remove the snap ring using a pair of internal snap ring pliers. Use a
suitable tool to hold back the piston as it can spring out.
9-8
Remove the piston, spring and cups.
Remove the spring from the piston and
9-9
Inspection
Clean the master cylinder components with fresh brake fluid. Inspect the
master cylinder components for wear and damage. Replace the parts as
needed
Inspect the piston and cups for wear and damage. Measure the outside
diameter of the piston.
Item Standard mm (in)

Brake master cylinder piston O.D. 12.65 - 12.68 (0.506 - 0.5072)
9-10
Inspect the master cylinder bore for wear and damage. Measure the
inside diameter of the brake master cylinder.

Brake master cylinder I.D. 12.7 - 12.74 (0.508 - 0.5096)
Assembly
Piston
Place a film of clean DOT 4 brake fluid on the piston,spring and master
cylinder bore.
9-11
Install the master cylinder piston and spring into the master cylinder bore.
Compress the snap ring with internal snap ring pliers and Install the snap
ring.
9-12
Install the rubber boot over the end of the master cylinder piston.
Brake Light Switch
Install the brake light switch. Tighten the mounting screw securely with a
Brake Levers
9-13
Install the brake lever.
Apply a light coat of grease to brake lever pivot bolt. Insert the pivot bolt
from above and thread on the nut.
Tighten the brake lever bolt with a flat blade screwdriver and then tighten
the nut with a 10 mm socket.
Installation
9-14
Position the master cylinder on the handlebar.
Install the master cylinder clamp. Be sure to insert the pin on the clamp
into the hole on the handlebar.
Install the two master cylinder mounting bolts and tighten them securely
with an 8 mm socket.
9-15
Plug in the brake light switch connector.
Install the brake hose to the master cylinder with the banjo bolt. Use new
sealing washers. Tighten the banjo bolt to specification with a 12 mm
socket.
Torque
Item
N-m lb-ft
Banjo bolt 35 25.8
Fill the master cylinder reservoir/s with brake fluid and bleed the system.
9-16
9. Brakes > Front Brake Caliper K- XCT 300i
Front Caliper
Removal
Drain the brake fluid if the caliper is to be disassembled.
Remove the two caliper mounting bolts with a 12 mm socket.
Remove the speedometer sensor mounting bolt with an 8 mm socket.
9-17
Remove the speedometer sensor.
Remove the front caliper.
9-18
Brake Pad Removal
Loosen the brake pad pin with a 5 mm Allen.

Remove the brake pad pin.
9-19
Remove the brake pads. Replace the pads if the brake wear exceeds
the wear indicator lines or if the wear is uneven.
Disassembly
Remove the pad spring.
9-20
Inspection
Inspect the pistons for wear and damage.
Measure the outside diameter of the piston with a micrometer

and compare the measurement with the specification. Replace
the pistons as needed.

Brake caliper piston O.D. 26.93 - 26.96 (1.0602 - 1.0614)
9-21
Inspect the piston bores for wear and damage.
Inspect the piston bores for wear and damage. Measure the inside
diameter of the piston bore with a telescoping gauge and micrometer.
Replace the caliper as needed.

Brake caliper cylinder I.D. 27 - 27.05 (1.063 - 1.065)
9-22
Brake Pad Installation
Insert the brake pads into the caliper.
Fit the ends of the pads into the pad retainer as shown.
9-23
Apply a light coat of waterproof grease to the brake pad pin.

Push the pads against the pad spring and insert the brake pad pin.
Installation
Install the front caliper. Guide the brake disc between the pads.
Line up the caliper bracket mounts with the fork.
9-24
Install the two caliper bracket mounting bolts. Tighten the

mounting bolts to specification.
Torque
Item
N-m Lb-ft
Front/Rear caliper bolt 35 25.8
Install the banjo bolt with new sealing washers and tighten to
Torque
Item
N-m Lb-ft
Banjo bolt 35 25.8
9-25
Install the speedometer sensor.
Install the speedometer sensor mounting bolt with an 8 mm socket.
Torque
Item
N-m Lb-ft
Speed sensor cable 9.80 - 13.73 7.23 - 10.13
Tighten the brake pad pin securely with a 5 mm Allen.
9-26
8. Brakes > Rear Brake Caliper K- XCT 300i
Rear Caliper
Warning: Brake fluid is very caustic and can damage paint, chrome and plastic.
Wipe up any spills immediately.
Removal
If the caliper is to be disassembled the brake hose must be removed.
Remove the two rear brake hose clamp bolts with a 8 mm socket.
Remove the rear brake hose clamp.
9-27
Remove the two rear caliper mounting bolts with a 12 mm socket.
9-28
Remove the rear caliper from the swingarm.
Disassembly
One at a time, move the brake pads to the center gap in

the pad retainers and lift the pad out. If needed, use the
piston side pad to push the pistons in to allow for more
room.
Replace the pads if the brake wear exceeds the wear
indicator lines or if the wear is uneven.
9-29
Inspection
Measure the outside diameter of the piston with a micrometer

and compare the measurement with the specification. Replace
the pistons as needed.
Item Standard (mm)

Rear brake caliper piston O.D. 25.33-25.36
Inspect the piston bores for wear and damage.
9-30
Inspect the piston bores for wear and damage. Measure the inside
diameter of the piston bore with a telescoping gauge and micrometer.
Replace the caliper as needed.
Item Standard (mm)

Rear brake caliper bore I.D. 25.40 - 25.45
Assembly
Lubricate the caliper pistons, the caliper piston bores and the seals with
DOT 4 brake fluid from a tightly sealed container.
NOTE: Brake fluid is a corrosive chemical and can damage paints and
some plastics. Avoid contact with skin.
One at a time, fit the brake pads into the center gap in the
pad retainers and then move the pad into the retainer. If
needed, use the piston side pad to push the pistons in to
allow for more room.
9-31
Installation
Install the rear caliper onto the swingarm.
Install the two caliper bracket mounting bolts.

Tighten the mounting bolts to specification.
Item Torque
N-m lb-ft
9-32
Fit the rear brake hose guide into place.

Insert the two rear brake hose clamp bolts and tighten them securely
Fill the rear brake system with fresh brake fluid and bleed out the air.
See the Brake Fluid topic for more information.
Pump the brake lever to seat the caliper pistons against the pads. Check
the operation on the brakes before returning the vehicle to service.
9-33
9. Brakes > Brake Disc K- XCT 300i
Disc Brake
Inspection
Measure the thickness of the brake rotor with a Vernire caliper or

micrometer.
ITEM STANDARD
Front 3.8 - 4.2 mm(0.15 - 0.165 in)

Brake disc thickness
Rear 5.0 mm(0.2 in)
9-34
Check if the brake rotor runout is within service limit.
Measure the runout of the brake disc with a dial gauge. If the reading is
out of specification remove the disc from the wheel and recheck.
Item Standard (mm)

Rear brake disk runout max 0.4
9-35
Front
Removal
Remove the front wheel. See the Front Wheel topic for more information.
Remove the five brake disc mounting bolts with an Allen wrench.
9-36
Remove the front brake disc and front wheel speed sensor rotor.
Separate the wheel speed sensor rotor from the brake disc.
9-37
Inspect the wheel speed sensor and brake disc for wear and damage.
Replace the parts as needed.
Set the front brake disc and speed sensor rotor in place on the front wheel.
9-38
Installation
Coat the threads of the disc bolts in a non-permanent thread locking

agent. Thread in the bolts and torque them to specification with an Allen
socket.
Set the speed sensor rotor on the front brake disc. Position the rotor so
that its sharp side sits against the brake disc.
Insert the front brake disc mounting bolts. Tighten the bolts to specification
with an Allen socket.
Thread size Torque

Item Qty (mm) kgf-m lb-ft
Disk bolt 5 8 3.2-3.8 23.15-27.48
Install the front wheel. See the Front Wheel topic for more information.
9-39
Rear
Removal
Remove the five brake disc mounting bolts with an Allen wrench.
9-40
Lift the brake disc off of the rear wheel.
Installation
Coat the threads of the disc bolts in a non-permanent thread locking agent.
Thread in the bolts and torque them to specification with an Allen socket.
Set the rear brake disc in place as shown.
9-41
Insert the five rear brake disc mounting bolts and tighten them to
specification with an Allen socket.
Thread size Torque

Item Qty
(mm)
kgf-m lb-ft
Disk bolt 5 8 3.2-3.8 23.15-27.48
9-42
9.Brakes > Brake Pad Replacement K- XCT 300i
Brake Pad Replacement

Replace the pads if the brake wear exceeds the wear indicator
lines or if the wear is uneven.
Front
Loosen the brake pad pin with a 5 mm Allen.

9-43
Remove the two caliper mounting bolts with a 12 mm socket.
Remove the speedometer sensor mounting bolt with an 8 mm socket.
Remove the speedometer sensor.
9-44
Remove the front caliper.
Remove the brake pad pin.
9-45
Remove the brake pads. Replace the pads if the brake wear
exceeds the wear indicator lines or if the wear is uneven. Insert
new brake pads as needed.
Fit the ends of the pads into the pad retainer as shown.
9-46
Apply a light coat of waterproof grease to the brake pad pin.

Push the pads against the pad spring and insert the brake pad pin.
It may be necessary to spread the pads and force the pistons

back into the caliper in order to allow room for the brake disc to
fit between the new pads.
Install the front caliper. Guide the brake disc between the pads.
Line up the caliper bracket mounts with the fork.
9-47

Torque
Item
N-m lb-ft
Install the speedometer sensor.
9-48
Install the speedometer sensor mounting bolt with an 8 mm socket.
Torque
Item
N-m lb-ft
Speed sensor cable 9.80 - 13.73 7.23 - 10.13
Tighten the brake pad pin securely with a 5 mm Allen.
Pump the brake lever to seat the caliper pistons against the pads.
Check the operation on the brakes before returning the vehicle to
service.
9-49
Rear
If the caliper is to be disassembled the brake hose must be removed.

Drain the rear brake fluid. See the Brake Fluid topic for more information.
Remove the two rear brake hose clamp bolts with a 10 mm socket.
Remove the rear brake hose clamp.
9-50
Remove the two rear caliper mounting bolts with a 12 mm socket.
Remove the rear caliper from the swingarm.
9-51
One at a time, move the brake pads to the center gap

in the pad retainers and lift the pad out. If needed,
use the piston side pad to push the pistons in to allow
for more room.
Replace the pads if the brake wear exceeds the

wear indicator lines or if the wear is uneven.
One at a time, fit the brake pads into the center gap in the pad
retainers and then move the pad into the retainer. If needed,
use the piston side pad to push the pistons in to allow for more
room.
9-52
Install the rear caliper onto the swingarm.

Item Torque
N-m lb-ft
9-53
Fit the rear brake hose guide into place.

Insert the two rear brake hose clamp bolts and tighten them
Pump the brake lever to seat the caliper pistons against the
pads. Check the operation on the brakes before returning the
vehicle to service.
9-54
10. Front Suspension K- XCT 300i
Front Suspension
This chapter covers the location and servicing of the front fork
components for the KYMCO K-XCT 300i.
• Front Fork Removal and Installation ....................... 10-2~10-7

• Fork Disassembly .................................................. 10-8~10-19
• Fork Assembly ..................................................... 10-20~10-27
TROUBLESHOOTING
Soft front shock absorber

• Weak shock springs
• Insufficient damper oil
Front shock absorber noise

• Slider bending
• Loose fork fasteners
• Lack of lubrication
10-1
10. Front Suspension > Front Fork Removal K- XCT 300i
Front Fork Removal and Installation

at this point.
Removal
Remove the front wheel speed sensor mounting bolt with an 8 mm

socket.
10-2
Remove the front wheel speed sensor from the bottom of the
right fork leg.
10-3
Remove the speed sensor wire and front brake hose guide mounting
bolt with an 8 mm socket. Free the guide from the fork clamp.
Loosen the fork clamp pinch bolts with a 12 mm socket. The top bolts
must be removed.
10-4
Slide the forks legs down and out of the fork clamp using a twisting
motion.
Installation
Slide the fork legs up into fork clamp using a twisting motion.
10-5
Install the fork legs so that the upper fork clamp bolt hole lines up with
the groove on the inner fork tube. Insert the fork clamp upper bolt.
Tighten the fork clamp bolts securely and evenly with a 12 mm socket.
Install the speed sensor wire and front brake hose guide to the fork clamp.
Insert the guide mounting bolt and tighten it to specification with an 8 mm
socket.
10-6
Thread Torque
Item Qty
Speed sensor
cable 1 6 1.0-1.4 7.23-10.13
Fit the front wheel speed sensor into place on the right fork leg.
Insert the bolt and tighten it to specification with an 8 mm socket.
10-7
10. Front Suspension > Fork Disassembly K- XCT 300i
Fork Disassembly
at this point.
Remove the front forks. See the Front Fork Removal and Installation
topic for more information.
Clean the outside of the forks before disassembly and inspect them for
any cracks, dents or other damage.
Slide off the fork protectors.
10-8
Remove the rubber fork cap.
Place the fork leg in a soft jawed vice.
10-9
Push down on the top plug and remove the snap ring.
Remove the top plug.
Lift out the fork spring.
10-10
Dump the fork oil into a suitable container. Pump the fork through its
stroke several times to free as much oil as possible. Hold the fork
inverted for several minutes to let the oil drain completely.
Use a flat blade screwdriver to pop the dust seal out of the fork slider.
Take care to avoid scratching the fork tube.
10-11
Use a small flat blade screwdriver to pry out the fork oil seal stopper
ring. Take care to avoid scratching the fork tube.
Slide off the stopper ring.
10-12
Place the axle holder of the outer fork tube in a soft jawed.
Insert an 8 mm Allen socket into the damper rod. Hold the damper rod
and loosen the fork bottom bolt with an 8 mm Allen wrench.
10-13
Remove the fork bottom bolt from the bottom of the fork slider. Discard
the sealing washer.
Separate the inner and outer fork tubes by pulling them apart using a
slide hammer motion.
Remove the oil lock piece. The oil lock piece may come out with the
damper rod in the inner fork tube or it may be left in the slider.
10-14
Remove the damper rod and rebound spring.
Inspect the oil seal and the bushing in the fork slider.
10-15
Place a rag across the top of the fork slider and pry our the oil seal as
shown.
Remove the oil seal and spacer from the fork slider.
10-16
Inspection
Inspect the top plug O-ring O-ring and replace it if needed.
Insect the slider bushing and replace it as needed.
10-17
Inspect the fork springs for signs of fatigue. Replace the fork springs if
they vary dramatically in length.
Inspect the damper rod and seal. Replace the components as needed.
10-18
Inspect the inner fork tube for bends and damage. Replace it as needed.
For assembly see the Fork Assembly topic.
10-19
10. Front Suspension > Fork Assembly K- XCT 300i
Fork Assembly
at this point.
Clean all of the fork components with aerosol brake cleaner and a lint
free cloth. Coat the bushing and seals with fork oil before installation.
Drive the fork slider bushing into the slider with a suitable driver with the
same outside diameter as the bushing.
Insert the damper rod with rebound spring into the inner fork tube. Place
the fork oil lock piece on the end of the damper rod.
Slide the dust seal, oil seal stopper ring and oil seal onto the bottom of
the inner fork tube.
10-20
Place the spacer into the fork slider.
Insert the inner fork tube into the inner fork tube.
10-21
Place a new sealing washer on the fork bottom bolt. Insert the fork
bottom bolt into the bottom the fork slider and thread it into the damper
rod.
Place the axle holder of the outer fork tube in a soft jawed.
10-22
Insert an 8 mm Allen socket into the damper rod. Hold the damper rod
and tighten the fork bottom bolt securely with an 8 mm Allen wrench.
Drive in the fork oil seal with the fork seal driver.
10-23
Insert the stopper ring into its groove.
Install the dust seal securely into the outer fork tube.
10-24
Compress the fork tube all the way. Fill the fork tube with the specified
quantity of fork oil 185 cc or 6.26 US oz. Use fork oil type SS#8 (10W).
Pump the fork slowly through its stroke several times to release any
trapped air.
Fully extend the fork and insert the fork spring with its tightly coiled end
facing down towards the axle.
10-25
Lubricate the top plug O-ring with fresh fork oil and insert the plug into
the top of the inner fork tube as shown.
Push the top plug down against the spring and install the stopper ring
into its groove. Release the pressure on the top plug and make sure the
plug seats against the ring.
10-26
Install the rubber fork cap.
Fit the fork protectors into place so that they face forward.
Install the front fork. See the Front Fork Removal and Installation topic
for more information.
10-27
11. Rear Suspension K- XCT 300i
Rear Suspension
This chapter provides information on the rear suspension components of the KYMCO
K-XCT 300i.
• Shock Absorbers ..................................................... 11-2~11-9

• Swingarm ............................................................. 11-10~11-14
TROUBLESHOOTING
Soft rear shock absorber
• Weak shock absorber spring
• Damper oil leaks
11-1
11. Rear Suspension > Shock Absorbers K- XCT 300i
Shock Absorbers
Pre-Load Setting
Each shock absorber on the scooter has 5 spring preload

adjustment positions for different load or riding conditions.
Position 1 is for light loads and smooth road conditions.

Position 3 to 5 increase spring preload for stiffer rear
suspension and can be used when the scooters heavily loaded.
Be certain to adjust both shock absorbers to the same spring
preload positions.
Use a pin spanner to adjust the rear shock spring preload. The
shock absorbers are adjustable for pre-load. There are 5
settings. Position 1 is the softest and 5 is the stiffest.
Caution: Always adjust the shock absorber pre-load position in

sequence (1-2-3-4-5 or 5-4-3-2-1). Attempting to adjust directly
from 1 to 5 or 5 to 1 may damage the shock absorber.
(Pre-Load Standard Setting: Position 3)
11-2
Removal
Place the vehicle on its center stand.
Remove the body cover to access the upper shock absorber mounts.
See the Body Cover topic for more information.
Remove the two rear shock mounting bolt with a 12 mm socket.
11-3
Remove the right side rear shock mounting bolt with a 14 mm socket.
Free the lower mount of the rear shock.
11-4
Remove the upper shock absorber mounting bolt with a 12 mm socket.

Free the shock absorber from the frame.
11-5
Remove the left shock absorber in the same manner as the right.
Inspect the shock absorbers for wear and damage. Replace the
shock absorbers as needed.
Check over the shock absorber for damage and oil leaks.
Replace the shock absorber if needed. Do not attempt to
disassemble the shock absorber.
11-6
Installation
Fit the shock absorber into place. Make sure the preload arrow
indicator faces out from the lower mount.
Install the upper shock absorber mounting bolt and torque it to

11-7
Torque
Item
kgf-m lb-ft
Shock absorber mounting bolt 4 28.93
Install the lower shock absorber mounting bolt and torque it to

Torque
Item
kgf-m lb-ft
11-8
Install the other shock absorber in the same manner.
11-9
11. Rear Suspension > Swingarm K- XCT 300i
Rear Fork
Removal
Place the vehicle on its center stand.
11-10
Hold the rear brake to keep the rear wheel from turning. Remove
the rear axle nut with a 24 mm socket.
Remove the two rear fork bolts with a 14 mm socket.
Slide the rear fork out and remove it from the right side of the vehicle.
Inspect the rear fork for damage and replace it as needed.
11-11
Installation
Fit the rear fork into place.
Install the two rear fork mounting bolts and tighten them securely
11-12
Install the rear axle nut and tighten it to specification with a 24 mm

socket.
Thread Torque
Item Qty size Remarks
(mm) kgf-m lb-ft
Rear axle nut 1 16 11-13 79.56-94.03 U-nut
11-13

Torque
Item
kgf-m lb-ft
11-14
12. Wheels K- XCT 300i
Wheels
This chapter covers the location and servicing of the wheels for the KYMCO K-XCT 300i.
• Front Wheel ............................................................ 12-2~12-7

• Rear Wheel .......................................................... 12-8~12-17
• Wheel Inspection ........................................................... 12-18
• Bearing Replacement ......................................... 12-19~12-22
Troubleshooting
Front wheel wobbling
• Bent rim
• Loose front axle
• Bent spoke plate
• Faulty tire
• Improperly tightened axle nut
Rear wheel wobbling

• Bent rim
• Faulty tire
• Axle nor tightened properly
Rear wheel noise

• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork
12‐1

12. Weels > Front Wheel K- XCT 300i
Front Wheel
Removal
Loosen the front axle pinch bolt with a 6 mm Allen.
Loosen the front axle with an 8 mm socket.
12-2
Lift the front end of the vehicle with a suitable stand or jack so
that the front wheel comes off of the ground.
Support the front wheel and slide the front axle out from the left side.
12-3
Guide the front wheel out from the fork legs and the brake disc
out from between the pads. Do not squeeze the brake lever
while the disc is not present between the pads.
Remove the collars from each side of the wheel. Inspect the
bearing seals and the O-rings seals on the collars. Replace the
seals if they are in poor condition.
Inspect the wheel bearings by turning them in the hub. If the

bearings have play in them or are rough replace all the bearings
for that wheel. See the Bearing Replacement topic for more
information.
To remove the wheel speed sensor rotor loosen the three bolts
with an
12-4
Installation
Apply grease to the lips of the dust seals and collar O-rings.
Insert the collars into the hub as shown.
Make sure the tire direction of rotation marker is correct.

Slide the front wheel into the fork. Fit the brake disc
between the brake pads in the front caliper.
Apply a light coat of grease to the front axle. Insert the axle
from the left side.
12-5
Set the front wheel on the ground. Pump the front suspension up and
down several times to seat the front axle
Torque the axle to specification with an 8 mm Allen.
Item Qty size (mm) Torque

Kgf-m lb-ft
Front axle 1 14
1.5-2.5 10.84-18.08
12-6
Tighten the front axle pinch bolt securely with a 6 mm Allen.
Pump the front brake lever to establish pressure and to seat

the pads against the disc. If the Brakes do not pump up
correctly check the brake fluid.
12-7
12. Wheels > Rear Wheel K- XCT 300i
Rear Wheel
• When performing the services stated in this section, the engine and exhaust muffler
must be cold to avoid scalding.
• During servicing, keep oil or grease off the brake pads and brake disk.
Removal
12-8
Move the rear shock out of the way.
Hold the rear brake to keep the rear wheel from turning.
Remove the rear axle nut with a 24 mm socket.
Remove the two rear fork bolts with a 14 mm socket.
12-9
Slide the rear fork out and remove it from the right side of the vehicle.
Remove the rear axle collar from the right side of the rear axle.
12-10
To remove the rear wheel support the right rear shock absorber
so that it is out of the way or remove it.
Remove the upper shock absorber mounting bolt with a 12 mm socket.

Free the right shock absorber from the frame.
Slide the rear wheel to the right and off of the rear axle. Inspect the
wheel bearings by turning them with a finger. If the bearings have play
in them or are rough replace all the bearings for that wheel.
12-11
Installation
Line up the splines on the rear wheel with those of the rear axle. Slide
the rear wheel on to the axle so that the brake disc sits on the right side.
Install the right shock absorber if it was removed. Install the upper
mounting bolt and tighten it to specification with a 12 mm socket.
Torque
Item
kgf-m lb-ft
12-12
Slide on the rear axle collar.
Fit the rear fork into place.
12-13
Install the two rear fork mounting bolts and tighten them securely
12-14
Install the rear axle nut and tighten it to specification with a 24 mm

socket.
Thread Torque
Item Qty size Remarks
(mm) kgf-m lb-ft
Fit the shock absorber into place. Make sure the preload arrow
indicator faces out from the lower mount.
12-15
Install the upper shock absorber mounting bolt and torque it to

Torque
Item
kgf-m lb-ft
12-16

Torque
Item
kgf-m lb-ft
12-17
12. Wheels > Wheel Inspection K- XCT 300i
Wheel Inspection
Turn the inner race of each bearing with your finger to see if they turn
smoothly and quietly. Also check if the outer race fits tightly in the hub.
Replace the bearings if the races do not turn smoothly, quietly, or if they
fit loosely in the hub.
Place the wheel on a truing stand and use a dial indicator to check if the
rim is out of true. The specifications for the front and rear wheels are the
same. Check for lateral wobble. The service limit is 2.0 mm (0.08 in) or less.
12‐18

12. Wheels > Bearing Replacement K- XCT 300i

Wheel Bearing Replacement
Replace bearings as a set, and do not reuse old bearings.

Place the new bearings in the freezer about an hour before you plan to install them.
Do not let the wheel rest on its brake disc.
Front Wheel
Remove the dust seal from the right side of the front wheel using a seal
pick or large flat blade screwdriver. Discard the dust seal, it should be
replaced by a new item.
Inspect the wheel bearings by turning them in the hub. If the bearings
have excessive play in them or are rough replace all the bearings for
that wheel.
12‐19

Remove one of the bearings with a bearing puller.
Special Tools- Bearing Puller: A120E00037
Remove the distance collar.
Repeat the procedure and remove the other bearing and seal. The seal
should be replaced with a new item.
12‐20

Heat the bearing area of the wheel with a heat gun, take the bearing out
of the freezer and install it. You can use a bearing installer tool or a
socket with the same outside diameter as the bearing. Make sure the
bearing is fully seated and the marked side is facing out.
Special Tools-Bearing Installer: A120E00014
Insert the distance collar into the hub.
12‐21

Drive in the other bearing. The bearing should fit against the distance
collar. Do not continue to force the bearing in or the distance collar will
begin to push the right bearing back out.
Apply grease to the lips of the dust seals. Drive in new dust seals.
12‐22

13. Electrical Systems K- XCT 300i
Electrical Systems
This chapter covers the location and servicing of the electrical systems for the
KYMCO K-XCT 300i.
• Battery .................................................................. 13-6~13-10

• Charging System ........................................................... 13-11
• Ignition System ................................................... 13-12~13-16
• Starting System .................................................. 13-17~13-21
• Starter Motor ................................................................. 13-22
• Fuses............................................................................. 13-23
• ECU Removal..................................................... 13-24~13-27
• Self-Diagnosis .................................................... 13-28~13-33
• Horn............................................................................... 13-34
• Lights .................................................................. 13-35~13-41
• Relays ................................................................ 13-42~13-46
• Switches ............................................................. 13-47~13-61
• Wiring Diagrams ................................................. 13-62~13-64
CHARGING SYSTEM AND BATTERY

• The battery can be charged and discharged repeatedly. If a discharged battery is not
used for a long time, its service life will be shortened. Generally, the capacity of a
battery will decrease after it is used for 2 3 years. A capacity-decreased battery will
resume its voltage after it is recharged but its voltage decreases suddenly and then
increases when a load is added.
• When a battery is overcharged, some symptoms can be found. If there is a short circuit
inside the battery, no voltage is produced on the battery terminals. If the rectifier won‘t
operate, the voltage will become too high and shorten the battery service life.
• If a battery is not used for a long time, it will discharge by itself and should be
recharged every 3 months.
• A new battery filled with electrolyte will generate voltage within a certain time and it
should be recharged when the capacity is insufficient. Recharging a new battery will
prolong its service life.
• Inspect the charging system according to the sequence specified in the

Troubleshooting
13‐1

• Do not disconnect and soon reconnect the power of any electrical equipment because
the electronic parts in the regulator/rectifier will be damaged. Turn off the ignition
switch before operation.
• It is not necessary to check the MF battery electrolyte or fill with distilled water.
• Check the load of the whole charging system.
• Do not quick charge the battery. Quick charging should only be done in an emergency.
• Remove the battery from the motorcycle for charging.
• When replacing the battery, do not use a traditional battery.
• When charging, check the voltage with an electric tester.
TROUBLESHOOTING
No power
• Dead battery
• Disconnected battery cable
• Fuse burned out
• Faulty ignition switch
Intermittent power
• Loose battery cable connection

• Loose charging system connection
• Loose connection or short circuit in the ignition system
Low power
• Weak battery
• Loose battery connection
• Charging system failure
• Faulty regulator/rectifier
Charging system failure
• Loose, broken or shorted wire or connector

• Faulty regulator/rectifier
• Faulty A.C. generator
13‐2

IGNITION SYSTEM
• Some electrical components may be damaged if terminals or connectors are

connected or disconnected while the ignition switch is “ON” and current is present.
• When servicing the ignition system, always follow the steps in the troubleshooting on
page above.
• The ignition timing cannot be adjusted since the ignition control module is already
adjusted in factory.
• The ignition control module or ECU maybe damaged if dropped or the connector is
disconnected when the key is "ON", the excessive voltage may damage the ignition
control module or ECU. Always turn off the ignition switch before servicing.
• A faulty ignition system is often related to poor connections. Check those connections
before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with weak
battery results in a slower engine cranking speed as well as no spark at the spark
plug.
• Use a spark plug of the correct heat range. Using spark plug with an incorrect heat
range can damage the engine.
TROUBLESHOOTING
No peak voltage
• Short circuit in engine stop switch or ignition switch wire.

• Faulty engine stop switch or ignition switch.
• Loose or poorly connected ignition control module connectors.
• Open circuit or poor connection in ground wire of the ignition control module.
• Faulty crank position sensor.
• Faulty ignition control module.
Peak voltage is normal, but no spark jumps at the plug
• Faulty spark plug or leaking ignition coil secondary current.

• Faulty ignition coil.
13‐3

Starting System
• The removal of starter motor can be accomplished with the engine installed.
• After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air
from the cooling system.
TROUBLESHOOTING
Starter motor will not turn
• Fuse burned out

• Weak battery
• Faulty ignition switch
• Faulty starter clutch or gear
• Faulty front or rear stop switch
• Faulty starter relay
• Poorly connected, broken or shorted wire
• Faulty starter motor
Lack of power
• Weak battery
• Loosed wire or connection
• Foreign matter stuck in starter motor
Starter motor rotates but engine does not start
• Faulty starter pinion

• Starter motor rotates in reverse
• Weak battery
13‐4

LIGHTS, SWITCHES, AND FUEL PUMP

• Note the following when replacing the halogen headlight bulb
1. Wear clean gloves while replacing the bulb. Do not put finger prints on
the headlight bulb, as they may create hot spots on the bulb and cause
it to fail.
2. If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.
3. Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before performing any inspection that requires proper battery
voltage.
• A continuity test can be made with the switches installed on the scooter.
• Route the wires and cables properly after servicing each component.
TROUBLESHOOTING
Lights do not come on when ignition switch is “ON”
• Burned bulb
• Faulty switch
• Poorly connected, broken or shorted wire
Temperature gauge does not register correctly
• Faulty temperature gauge

• Faulty thermosensor
• Broken or shorted wire between the temperature gauge and thermosensor
Fuel gauge does not work or shows wrong figures
• Faulty fuel gauge

• Faulty fuel unit
• Poorly connected wire between fuel gauge and fuel unit
• Fuse burned out
13‐5

13. Electrical System > Battery K- XCT 300i

Battery
Warning: The battery electrolyte (sulfuric acid) is poisonous and may seriously
damage the skin and eyes. Avoid contact with skin. eyes, or clothing. In
case of contact, flush with water and get prompt medical attention.
Removal
Remove the battery cover screw. Remove the battery cover.
13‐6


The battery is located under the seat.
Remove the negative battery cable bolt with a 10 mm socket or #3

Phillips screwdriver. Free the negative cable from the battery.
Remove the positive battery cable bolt with a 10 mm socket or #3

Phillips screwdriver. Free the positive cable from the battery.
13‐7


Lift the battery out of the battery tray.
Testing
Check the battery voltage with a multi-meter. Place the positive

probe onto the positive battery terminal and the negative probe
to the negative battery terminal. If the battery reads under 12.3 V
it is undercharged.
Battery Voltage (20°C/68°F)
Fully Charged 13.0 - 13.2 V
13‐8


Installation
Only install the specified battery
Fit the battery into the battery tray.
Connect the positive battery cable and install the bolt with a 10
mm socket or #3 Phillips screwdriver.
Connect the negative battery cable and install the bolt with a 10
mm socket or #3 Phillips screwdriver.
13‐9


Install the battery cover. Install the four battery cover screws and
tighten them securely.
Battery Charging
Charge the battery with a motorcycle specific battery charger at the specified
rate. Connect the charger leads to their appropriate battery terminals. Keep
open flames away from a charging battery.
Standard Charge
1.2 Amps 5 - 10 Hours
Note: For battery charging, do not exceed the charging current and time
specified on the battery. Using excessive current or extending the
charging time may damage the battery.
13‐10

13. Electrical System > Charging System K- XCT 300i
Charging System
You will need a digital multimeter to inspect the charging system.
Charging Voltage Inspection
Remove the battery cover. See the Battery topic for more information.
Note: The battery should be fully charged prior to making charging system checks.
Start the engine and warm it up to the operating temperature;

stop the engine. Connect the multimeter between the positive (+)
and negative (-) terminals of the battery. To prevent short, make
absolutely certain which are the positive (+) and negative (-)
terminals or cable.
With the headlight on and turned to the high beam position,

restart the engine. Measure the voltage on the multimeter when
the engine runs at 5000 rpm.
Battery charging voltage@ 5000 rpm 14 ~ 15V
13‐11

13. Electrical System > Ignition System K- XCT 300i
Ignition System
The ignition timing is set at the factory and is not adjustable. Perform the following
checks. Before performing any tests make sure the electrical connections are not
loose or corroded.
Spark Test
Check the spark plug to see if it is the correct type and gapped properly.
If the spark plug is black and fouled, replace it.
Leave the old spark plug installed. Connect known good spark plug to
the coil and ground the plug to the cylinder head.
13‐12

Turn the ignition switch to ON, lift the side stand, hold in one of the brake
levers, and push the engine start button. The plug should spark.
Caution: Do not touch the spark plug or spark plug wire while cranking
or running the engine as this can result in a severe shock.
Ignition Coil
Removal
13‐13

Remove the two ignition coil leads.
Remove the two ignition coil mounting bolts with an 8 mm socket.
Remove the ignition coil.
13‐14


Ignition Coil Resistance
Primary
Set the multimeter to read ohms of resistance ( ).
Touch the positive and negative meter leads to the ignition coil
terminals as shown. Measure the resistance.
Ignition Coil Primary Resistance 3.57 - 4.83

Secondary With Plug Cap
Check the secondary resistance between the ignition coil

terminal and the spark plug cap. Touch the negative meter lead
to the terminal and the positive meter lead to the spark plug cap
as shown.
Secondary Resistance With Plug Cap 15 - 19
13‐15


Secondary Without Plug Cap
Check the secondary resistance between the ignition coil terminal and
the spark plug wire without the cap. Touch the negative meter lead to
the terminal and the positive meter lead to the spark plug wire as shown.
Secondary Resistance Without Plug Cap 10 - 14
AC Generator Inspection
Crank Position Sensor Inspection
Note: This test is performed with the stator installed in the engine.
Disconnect the crank position sensor wire coupler. Measure the

resistance between the and green/white wire terminals.
Blue/White - Green/White 115 ± 15
13‐16

13. Electrical System > Starting System K- XCT 300i
Starting System
You will need a digital multimeter to inspect the starting system.
Starter Relay
Inspection
Remove the body cover. See the Body Cover topic for more information.
The starter relay is located on the right side of the vehicle.
13‐17

Disconnect the starter relay wire connector.
Check for continuity between the yellow/red wire and

green/yellow wire. There should be continuity when the starter
button is depressed. If there is no continuity, check the starter
button for continuity and inspect the wire.
13‐18

Operation Test
Turn the ignition switch to "OFF".

Remove the two terminal covers.
13‐19

Remove the nuts that hold the starter motor lead and battery lead
wires to the starter relay with a 10 mm socket.
Remove the leads from the starter relay.
Disconnect the starter relay wire connector.
13‐20

Connect the electric meter to the starter relay terminals that connect to
the battery positive cable and the starter motor cable. Connect a fully
charged battery across the starter relay yellow/red and green/yellow wire
terminals. Check for continuity between the starter relay large terminals.
The relay is normal if there is continuity and hear sounds.
Warning: Do not apply the battery voltage jump for more than five
seconds or the relay may be damaged.
13‐21

13. Electrical System > Starter Motor K- XCT 300i
Starter Motor
Removal
Turn the ignition switch to "OFF".

Pull back the rubber starter motor lead cover.
13‐22

13. Electrical System > Fuses K- XCT 300i
Fuses
Fuse Box
Fuses box
The fuse box is located in the front of the battery.
Open the covers to access the fuses.
13‐23

13. Electrical System > ECU Removal K- XCT 300i
ECU Removal
Note: The ignition control module or ECU maybe damaged if

dropped or the connector is disconnected when the key is “ ON" .
The excessive voltage may damage the ignition control module
or ECU. Always turn off the ignition switch before servicing.
Disconnect the ECU harness.
13‐24

Remove the two mounting nuts with a socket.
Remove the ECU.
13‐25


Inspection
Disconnect and remove the ECU from the frame.
Check for continuity between pin 9 and 10 of the ECU side connector.
There should be continuity at all times.
Check for continuity between each pins 2, 4 and 23 of the ECU side connector.
There should be continuity at all times.
Check for continuity between pin 24 and 10 of the ECU side connector.
13‐26


Installation
Install the two mounting nuts and tighten securely with a socket.
Connect the ECU harness.
13‐27

13. lectrical System > Self-Diagnosis K- XCT 300i
Self-Diagnosis
Note: No matter when the CELP illuminated while riding condition, should find out
the cause of the problem as soon as possible.
CELP
The check engine lamp (CELP) or Fi indicator is located next to the battery warning
indicator.
If the ECM connectors, or battery leads are disconnected the stored malfunction
codes will be lost.
13‐28


Without Diagnostic Special Tool
SELF-DIAGNOSTIC PROCEDURES
Place the scooter on its main stand and put the side stand up.
Set the engine stop switch to the “RUN” position.
13‐29


Turn key to On position.
The CELP will be lighting for two seconds and then off.
If the engine has problem, the CELP will blink to show the failure codes.
There’re 11 failure codes for the KEHIN system.
If the vehicle gets more failure codes, the CELP will be blinking from a lower number,
then show the higher number after three seconds. All failure codes would be
appeared repeatedly. It can be performed without diagnostics program.
EFI SELF-DIAGNOSIS FAILURE CODES
The CELP denotes the failure codes. When the indicator lights for one second that is
equal to ten.
For example: one longer blink illumination and two shorter blinks (0.5 second x 2) of
the indicator is equal to 12 blinks. Follow code 12.
If more than a damaged part has occurred, the CELP begins blinking in order.
For example: If the indicator blinks six times, then shows one second illumination and
two blinks, so there are two failures have occurred. Follow code 6 and 12.
13‐30

13‐31


Self-Diagnosis Reset Procedure
Note: The self-diagnosis cannot be reset when has still problem inside the system.
2. Turn the key to the ON position and wait for ten seconds.
3. Fully open the throttle and wait for ten seconds.
4. Release the throttle.
5. The indicator will blink twice (0.5 second) after five seconds quickly.
6. Self-diagnosis memory data is disappeared after the CELP lamp is off.
13‐32


Spark Plug Anti-Flood
When no failure code occurs and pressing starter switch repeatedly can still not start
the engine the spark plug maybe fouled be a flooded engine. Perform the spark plug
anti-flood to purge the fuel in the engine.
Make sure the battery voltage is greater than 12 V.
1. Close the throttle, turn the ignition switch to ON.
2. Open and hold the throttle fully, pressing starter switch more than 3 seconds.
TPS/ISC Reset
If the throttle is being moved when the throttle body or TPS is installed it can cause
a hard to start engine or incorrect idling speed.
ISC has a motor inside, which controls air bypass valve to obtain a smooth idling
speed. The ECU may record the incorrect ISC position when the ECU or the
throttle body has been reinstalled. It can cause engine stop, hard to start engine or
rough idling speed.
The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset
when throttle body, MAP, TPS, ISC or ECU have been reinstalled.
TPS/ISC RESET PROCEDURE
2. Turn the key to the OFF position.
3. Fully open the throttle.
4. Turn the key to the ON position.
5. Release the throttle after waiting for eight seconds.
6. Turn the key to the OFF position.
7. Turn the key to the ON position.
8. TPS and ISC have been reset successfully. If fail to reset, repeat the steps from 1
to 8.
13‐33

13. Electrical System > Horn K- XCT 300i
Horn
Disconnect the horn connectors from the horn. Connect a 12 V battery to

the horn terminals. The horn is normal if it sounds when the 12 V battery
is connected across the horn terminals.
13‐34

13. Electrical System > Lights K- XCT 300i

Lights
Headlight
Bulb Replacement
Make sure the machine has been off for several minutes before
removing the headlight bulb.
Slide back the rubber headlight covers and then remove the
headlight bulbs to free it from the lamp.
Unplug the bulb from its connector. Do not touch the bulb with
your bare hands if you plan to reuse it.
13‐35


Do not touch your new bulb with your bare hand. The oils on
your hand can cause an early failure of the headlight bulb. If
you do touch the bulb with your bare hand wipe off the bulb
with a clean shop towel and alcohol.
Fit the bulb into the lamp and then remove the headlight bulbs to
free it from the lamp.
Fit the rubber cover into place. Make sure the rubber covers
are secured in place.
13‐36


Aim
Turn the screws to adjust the head light aim as needed.
Front Turn Signals
Turn the turn signal bulb socket counterclockwise and free it

from the lamp.
13‐37


Push in on the bulb and rotate it clockwise to remove if from

the socket. Insert the new bulb. Push down on the bulb and
rotate it counterclockwise to lock it into place.
Insert the turn signal bulb and socket into place. Turn the
socket clockwise to lock it into place.
13‐38


Taillights
LED Replacement
Remove the five taillight mounting the tail light housing.
Remove two screws mounting the clips.
Remove the LED taillight assy.

Replace the LED as needed.
Install the taillight socket into the LED.
13‐39


Rear Turn Signals
Turn the socket counterclockwise and remove it from the lamp.
Push in the bulb and turn it counterclockwise. Remove the bulb.

Insert the new bulb and turn it clockwise to lock it in place.
13‐40


License Tag Light
Remove the license tag light from the mud flap.
Pull the rubber tag light socket out of its housing. Pull the bulb
straight out and insert a new one.
13‐41

13. Electrical System > Relays K- XCT 300i
Relays
High/Low Beam Relays
Remove and disconnect the high beam relay. The Low beam
relay is on the left.
13‐42


Fuel Pump Relay
The fuel pump relay is located in front of battery. Remove and

disconnect the fuel pump relay.
Inspection
Use a digital multimeter to inspect the fuel cut-off relay. Set the multimeter to read ohms
of resistance.
13‐43


Connect the multimeter to the fuel cut-off relay connector terminals
Connection: Black - Red/Black
Connect 12 V battery with the fuel cut-off relay connector. Connection: Blue/Black - Black
There should be continuity only when 12 V battery connected.
If there is not continuity when the 12 V battery is connected, replace the fuel cut-off relay.
Start Relay
The start relay is located in front of battery. Remove and

disconnect the start relay.
Inspection
Use a digital multimeter to inspect the start relay.
13‐44

Turn on the ignition switch to “ON” position.
Turn on the engine stop switch to “RUN” position.
Keep the side switch upward.
Apply the brake lever fully.

Connect the multimeter to the start relay connector terminals. Set the multimeter to
read ohms of resistance.
Connection: Yellow/Green – Black/White
ECU Relay
Remove the body cover.
The ECU relay is located in the rear next to the ECU. Remove and disconnect the
ECU relay.
13‐45


FAN Relay

The Fan relay is on the left.
Remove and disconnect the Fan relay.
13‐46

13. Electrical System > Switches K- XCT 300i

Switches
You will need a digital multimeter to inspect the switches.
Ignition Switch
Unplug the white six-pin ignition switch connector.
Use a digital multimeter to check for continuity to inspect the ignition

switches. Continuity should exist between the wires as indicated.
13‐47


Removal
Remove the dash.
13‐48


Remove the seat latch cable cover.
Loosen the seat latch cable screw with a #2 Phillips screwdriver.
Remove the seat latch cable screw and free the seat latch cable from
the ignition switch.
13‐49


To remove the anti-tamper bolts use a punch and a hammer to strike the
bolts so that they rotate loose. Turn the bolts clockwise to loosen them.
Installation
Install new anti-tamper bolts and tighten them securely.
Fit the end of the seat latch cable into the ignition switch.
Install the seat latch cable screw and tighten it securely with a #2 Phillips
screwdriver.
13‐50


Install the seat latch cable cover.
Tilt Switch
Support the scooter level surface.
Put the side stand up and engine stop switch on “RUN”. Turn the ignition
switch to “OFF”.
Note: Do not disconnect the tilt switch connector during inspection.

The capacity of battery must be fully charged.
The tilt switch is next to the radiator cap.
13‐51


Remove the two tilt switch bolts with a 10 mm socket.
Place the tilt switch vertical as shown and the ignition switch “ON”.
Measure the voltage as below.
Terminal Standard
Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage)
Black/Blue (+) ~ Green/Pink (-) 0.4 - 1.4 V less
Incline the tilt switch 65±10 degrees to the left or right at the ignition
switch “ON”. Measure the voltage as below.
Terminal Standard
Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage)
Black/Blue (+) ~ Green/Pink (-) 3.7 - 4.4 V
Note: Repeat this test, first turn the ignition switch to “OFF”, then turn
the ignition switch to “ON”.
13‐52


Disconnect the connector to remove the tilt switch.
Note: Install the tilt switch with its “up” mark facing up and tighten the
two screws securely.
Handlebar Switches
To remove the handle bar switches see the Handlebar topic.
Unplug the black connector for the left handlebar switches.
13‐53


Unplug the green connector for the right handlebar switches.
Right Handlebar Switches
Use a digital multimeter to check for continuity to inspect the handlebar

switches. Continuity should exist between the wires as indicated.

13‐54


13‐55


Left Handlebar Switches
Use a digital multimeter to check for continuity to inspect the

handlebar switches. Continuity should exist between the wires as
indicated.
13‐56


Luggage Box Switch
Unplug the two-pin luggage box light LED switch connector with
red/white and green wires.
Use a digital multimeter to check for continuity. Test the switch
side of the connector for continuity as the switch is manipulated.
There should be continuity when the switch is pushed and none
when it is released.
The switch is located both the side seat latch.

13‐57


Luggage box light LED switch
Side Stand Switch
Place the vehicle on the center stand.
Unplug the three-pin side stand switch connector.

13‐58


Use a digital multimeter to check for continuity.
With the side stand retracted there should be continuity between the
yellow/green wire and the green wire terminals.
13‐59


With the side stand extended there should be continuity between the
yellow/black wire and the green wire terminals.
Brake Light Switches
Test the front and rear brake light switches in the same manner. Use a
digital multimeter to check for continuity.
Remove the upper handlebar cover.
Unplug the brake light switch connectors.
13‐60


Check for continuity between the brake light switch connectors. There
should be continuity when the lever is pulled and none when released.
13‐61

IGNITION SYSTEM K-XCT 300i
SIDE
Engine Stop Sw Start Sw Brake Sw
STAND SW
Start Relay Start Mag
D
O 12V 12AH
U
P W BATTERY
E N
B/G B/ W1 G Y/R B/W1 G/Y

BR/L G Y/G Y/BR
SENSOR,
ANGLE BR/L
DETECT
R
B/L2 V/R
G/P2
R/W
30A
15A
Y/G
10A
B3
B/W1
COMB SW
R B1
G/BR
G/P2 R/W L/Y B/L2
B3 V/R G/W1
G/W1
1 4 6 7 11 12 23 26
L/Y
IGNITION
COIL EFI ECU
SPARK PULSER
PLUG
13-62
CHARGING SYSTEM K-XCT 300i
FUSE
12V 12AH
BATTERY
R R/W
COMB SW
B1 Y Y Y YY Y
REG REC ACG
13-63
K-XCT 300i WIRING DIAGRAM
Revised:2012.10.01

14. Quick Reference K- XCT 300i
Quick Reference
This chapter provides a quick reference source of technical specifications and
information for KYMCO K-XCT 300i models.
• Component Location .........................................14-2~14-10
• Special Tools.............................................................. 14-11
• K-XCT 300i Specifications ..............................14-12~14-20
• Torque Specifications ......................................14-21~14-22
• Troubleshooting ..............................................14-23~14-28
• VIN and Engine Number Location ...................14-29~14-30
14‐1

14. Quick Reference > Component Location K- XCT 300i

Component Location
14‐2

14‐3

14‐4

Fuel Pump
To Thermostat
Bleed Fuel Hose
Blow By Tube
Seat Catch
Cable
Throttle Cable
inside
14‐5

14‐6

14‐7

14‐8

14‐9

ECU
ECU RELAY
14‐10

14. Quick Reference > Special Tools K- XCT 300i

Special Tools
ITEM TOOL NO DESCRIPTION

FLYWHEEL PULLER A120E00003 Flywheel removal
Puller (M28x1) TAPPET ADJUSTER A120E00012 Adjusting valve clearance
OIL SEAL & BEARING DRIVER A120E00014 General Driver Set
UNIVERSAL HOLDER A120E00021 Holding clutch pulley and flywheel
#41 NUT AND FITTING TOOL A120E00028 Clutch disassembly
THREAD PROTECTOR A120E00029 Crankshaft thread protector
CYLINDER COMPRESSION GAUAGE A120E00039 Engine cylinder compression measure
FUEL PRESSURE GAUAGE A120E00048 Fuel pump output pressure measure
VALVE COTTER INSTALLER A120E00051 Valve cotter installation
CLUTCH SPRING COMPRESSOR A120E00053 Clutch disassembly
SHAFT COLLAR PULLER A120E00088 Bearing crankcase installation
WIRES INJECTOR CONNECTOR A120E00090 Injector cleaning for Keihin system
SHAFT COLLAR DRIVER A120E00091 Bearing crankcase removal
SHAFT COLLAR INSTALLER A120E00092 Bearing crankcase installation
BEARING PULLER A120E00093 General Puller Set
VALVE CLEAN TOOL SET A120E00096 Valve & Valve seat cleaning
STEERING STEM LOCK NUT WRENCH (32 mm) A120F00002 Steering stem removal & installation
LOWER/UPPER RACE REMOVER & INSTALLER A120F00008 Lower/Upper outer race installation
LOWER/UPPER OUTER RACE SEPARATOR A120F00009 Lower/Upper outer race removal
STEERING STEM TOP THREAD WRENCH
A120F00029 Steering stem removal & installation
(46.5mm)
Fuel pump output pressure measure &
PLIERS FUEL PIPE A120F00031
Injector cleaning
ELECTRIC REPAIR KIT A120F00032 Troubleshooting electric system
DIGITAL ELECTRIC GAUGE A120F00033 Troubleshooting electric system
RADIATOR PRESSURE GAUAGE A120F00035 Radiator pressure measure
USB LINKER 3620A-LGJ9-E00 Diagnostic tool software upgraded
POWER WIRES 32143-LGJ9-E00 Diagnostic tool power connection
INJECTOR CLEANER 32143-LEA7-9000 Injector cleaning
14‐11


General Information
Name & Model No. LKG7

Motorcycle Name & Type K-XCT300i
Overall length (mm) 2145
Overall width (mm) 800
Overall height (mm) 1290
Wheel base (mm) 1450
Engine type 4 stroke OHC
Displacement (cc) 298.9
Fuel recommended 90 # nonleaded gasoline
Front wheel 76
Curb weight (kg) Rear wheel 106.5
Total 182.5
Front wheel 138
Max. weight capacity (kg) Rear wheel 220
Total 358
Tires Front wheel 120/70-14
Ground clearance (mm) 140
Braking distance (m) 7.9m / 40 km/hr
Performance
Min. turning radius
2.6
(m)
Starting system Starting motor
Type Gasoline, 4-stroke
Cylinder arrangement SINGLE CYLINDER
Combustion chamber type Semi-sphere
Valve arrangement O.H.C. Chain drive
Bore x stroke (mm) 72.7 x 72
Compression ratio 10.8:1
Compression pressure 16 (kg/cm2), 228 (psi)
Max. Horsepower 28 / 7750 PS/rpm
Max. Torque 2.7 / 6500 Kg-m/rpm
Intake Open 9.5° BTDC
Engine
Valve timing Close 37.5° ABDC
Exhaust Open 40° BBDC
Close 10°ATDC
Valve clearance (cold) (mm) Intake 0.10
Exhaust 0.10
Idle speed (rpm) 1600 ± 100
Forced pressure & Wet
Lubrication type
pump
Lubrication System Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.5 liter
Cooling Type Liquid cooling
14‐12


Air cleaner type & No Paper element, wet

Fuel capacity 12.5 liter
Brand Keihin
Fuel System
Type Throttle body
Injection
Venturi dia.(mm) 34
Fuel pump pressure 3.0 Bar
Type ECU
10° BTDC at idle to
Ignition Ignition timing
Electrical 33° at 6500 rpm
System
Equipment Spec CR7E (NGK)
Spark plug
Gap 0.6-.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-clutch
Type CVT
Transmission Gear
Power Drive Operation Automatic centrifugal type
System Type Two-stage reduction
Reduction Gear Reduction 1st 2.24 ~ 0.72
ratio 2nd 7.222
Tire type Tubeless
Wheel material Aluminum
Tire pressure Front 2.0 (28.4)
Moving Device
Kg/cm2 (psi) Rear 2.25 (32)
Left 40°
Handle turning angle(L/R)
Right 40°
Front Wavy Disc brake
Brake system type
Rear Disc brake
Front Telescope
Suspension type
Damping Rear Swing arm
Device Front 110 mm
Shock absorber stroke
Rear 93 mm
Frame type UNDER BONE
ENGINE
Throttle grip free play 2 ~ 6 mm
Spark plug NGK: CR7E
Spark plug gap 0.6 mm ~ 0.7 mm
Ignition timing ECU
Coolant type Coolant type
Engine oil capacity
At change with element oil filter 1.35 Liter
Engine oil type: SAE 5W50
Gear oil capacity
14‐13


Coolant capacity
Radiator 766 cc
Reserve tank 590 cc
Engine
Item Standard (mm)
IN 0.10
Valve clearance (cold)
EX 0.10
Cylinder head compression pressure 16 kg/cm2, 228 psi
IN 34.2987
Camshaft cam heigh
EX 34.1721
IN 10.00 - 10.015
Valve rocker arm I.D
EX 10.00 - 10.015
IN 9.972 - 9.987
Valve rocker arm shaft O.D
EX 9.972 - 9.987
IN 1.2
Valve seat width
EX 1.2
IN 4.990 - 4.975
Valve stem O.D
EX 4.970 - 4.955
IN 5.00 - 5.012
Valve guide I.D
EX 5.00 - 5.012
IN 0.010 - 0.037
EX 0.030 - 0.057
Item Standard (mm)

I.D. 72.7
Cylinder Taper limit 0.05
Out of round limit 0.05
Top 0.015 - 0.055
Ring-to-groove clearance
Second 0.015 - 0.055
Top 0.10 - 0.25
Piston piston
ring
Piston O.D
Piston O.D. measuring point 9 mm from bottom of skirt
Piston pin O.D 14.994 - 15.000
Standard
(mm)
Connecting rod big end side clearance 0.15 - 0.35 0.6
Crankshaft
Connecting rod big end radial clearance 0 - 0.008 0.05
14‐14


Bearing Color
Crankcase mark
B green green red ---

Starter drive gear I.D 22.15
CVT
Clutch outer I.D. 152.1 - 152.2 152.2
Cooling System
Radiator cap relief

0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
pressure
Begins to open 71 °C
Thermostat Full-open 80 °C
temperature
Valve lift 3.5 - 4.5 mm
Radiator: 766 cc
Coolant capacity Total 1719 cc Reserve tank: 590 cc
Hose: 363 cc
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS

KYMCO SIGMA Coolant
Freezing Point Mixing Rate Distilled Water
Concentrate
-9°C 20% 344 cc 1375 cc
-15°C 30% 516 cc 1203 cc
-25'°C 40% 688 cc 1031 cc
-37°C 50% 860 cc 859 cc
-44.5°C 55% 945 cc 774 cc
14‐15


COOLANT GRAVITY CHART

Temp. C°
Coolant 0 5 10 15 20 25
concentration
5% 1.009 1.009 1.008 1.008 1.007 1.006
10% 1.018 1.107 1.017 1.016 1.015 1.014
15% 1.028 1.027 1.026 1.025 1.024 1.022
20% 1.036 1.035 1.034 1.033 1.031 1.029
25% 1.045 1.044 1.044 1.042 1.040 1.038
30% 1.053 1.051 1.051 1.049 1.047 1.045
35% 1.063 1.065 1.060 1.058 1.056 1.054
40% 1.072 1.070 1.068 1.066 1.064 1.062
45% 1.080 1.078 1.076 1.074 1.072 1.069
50% 1.086 1.084 1.082 1.080 1.077 1.074
55% 1.095 1.093 1.091 1.088 1.085 1.082
60% 1.100 1.098 1.095 1.092 1.089 1.086
Temp. C°
Coolant 30 35 40 45 50
concentration
5% 1.005 1.003 1.001 0.009 0.99
10% 0.013 1.011 1.009 1.007 1.005
15% 1.020 1.018 1.016 1.014 1.012
20% 1.027 1.025 1.023 1.021 1.019
25% 1.036 1.034 1.031 1.028 1.025
30% 1.043 1.041 1.038 1.035 1.032
35% 1.052 1.049 1.046 1.043 1.040
40% 1.059 1.056 1.053 1.050 1.047
45% 1.056 1.063 1.062 1.057 1.054
50% 1.071 1.068 1.065 1.062 1.059
55% 1.079 1.076 1.073 1.070 1.067
60% 1.083 1.080 1.077 1.074 1.071
14‐16



ITEM SPECIFICATIONS
Throttle body identification number LKG7
Throttle grip free play 2 - 6 mm (1/16 - 1/4 in)
Fuel injector resistance (at 20°C/68°F) 11.7 ± 0.6 Ω
Float at full position 1100 ± 33 Ω
Fuel pump resistance(at 20°C/68°F)
Float at empty position 100 ± 3 Ω
Fuel pump standard pressure (at 40L/Hr) 294 ± 6 kPa (3 Bar)
At -20°C/-4°F 18.8 KΩ
At100°C/212°F 0.1553 KΩ
ntake pressure sensor (MAP) pressure(at 1 - 4.2 13.332 kPa (0.13332 kgf/ cm2, 1.89 psi) - 119.99
V) KPa (1.1999 kgf/ cm2, 17.04 psi)
Inductive ignition coil Primary: 3.57 - 4.83Ω Secondary: 10.42~14.49KΩ
Throttle position sensor (TPS)
3500 - 6500
Crank position sensor voltage (at 200rpm) 100 - 130
O2 heater sensor resistance (at 20C/68°F) 6.7 - 9.5 (engine warming condition)
Standard 0.4 - 1.4 V
Tilt switch voltage
Over 65° (fall down) 3.7 - 4.4 V
14‐17


CELP FAILURE CODES LIST
Failure Codes Contents Causes Symptoms

• Faulty TPS voltage range (0.3 -4.5 V)
• Loose or poor connection on TPS Sensor Engine operates
06 P0120 Faulty TPS
• Open or short circuit on the TP Swire normally
• Faulty TPS itself
• Faulty MAP voltage range (1 - 4.2V)

09 P0105 Faulty MAP • Loose or poor connection on MAP Sensor Engine operates
• Open or short circuit on MAP wire normally
• Faulty MAP itself
• Faulty ECT range (-20°C: 18.8 /40°C: 1.136/100°C:

Faulty WTS 0.1553 ) Engine operates
12 P0115 • Loose or poor connection on ECT
(water temp.) normally
• Open or short circuit on ECT wire
• Faulty ECT
• Faulty Tilt switch voltage range (inclined angle <65°:

Faulty Tilt switch 0.4 - 1.4 V/ Inclined angle >65°: 3.7 - 4.4 V) Engine operates
15 P1630 • Loose or poor connection on Tilt switch
(Roll) normally
• Open or short circuit in Tilt switch wire
• Faulty tilt switch
• Faulty O2 sensor voltage range(A/F below 14.7: > 0.7V/

Faulty O2 A/F over14.7: < 0.18 V) Engine operates
17 P0130 • Loose or poor connection on O2 sensor
sensor normally
• Open or short circuit on O2 sensor wire
• Faulty O2 sensor
• Faulty Fuel injector range(9.945 - 13.5)
Faulty injector • Loose or poor connection on injector Engine fails to be
33 P0201 (Nozzle) • Open or short circuit on injector wire operated
• Faulty fuel injector
• Faulty Inductive ignition coil !range (4.2 ! ± 15%)
Faulty inductive • Loose or poor connection on inductive ignition coil Engine fails to be
37 P0351 ignition coil • Open or short circuit on inductive ignition coil wire operated
• Faulty inductive ignition coil
• Faulty Fuel pump fl range (F:1100 ± 33 ! E: 100 + 3 !)
41 P0230 Faulty fuel pump • Loose or poor connection on fuel pump Engine fails to be
• Open or short circuit on fuel pump wire operated
• Faulty fuel pump
• Faulty O2 sensor heater ! range(6.7 -9.5 !) Engine starts
45 P0135 Faulty O2 • Loose or poor connection on O2 sensor heater normally but not
sensor heater • Open or short circuit on O2 sensor heater wire
• Faulty O2 sensor heater smooth
• Loose or poor contacts on ISC

49 P1505 Faulty ISC • Open or short circuit in ISC wire Engine operates
normally
• Faulty ISC
• Loose or poor connection on CPS sensor Engine starts

66 P0335 Faulty CPS • Open or short circuit on CPS wire normally but not
• Faulty CPS sensor smooth
14‐18


Axle/Brakes/Wheels
Item Standard mm (in) Service Limit
Axle shaft run out – 0.2 mm(0.008 in)
Brake disk thickness (front) 3.8 - 4.2(0.15 - 0.165) 0.3 mm(0.012 in)
Brake disk thickness (rear) 5.0 (0.2 –
Brake disk run out – 0.4 mm
Brake master cylinder I.D 12.7 - 12.74(0.508 - 0.5096) –
Brake master cylinder piston O.D. 12.65 - 12.68(0.506 - 0.5072) –
Front brake caliper piston O.D 26.93 - 26.96(1.0602 - 1.0614) –
Front brake caliper cylinder I.D 27 - 27.05(1.063 - 1.065) –
Item Standard (mm)

Wheel rim run out service limit max 5
Rear brake disk thickness 5.0
Rear brake disk run out max 0.4
Rear brake caliper piston O.D. 25.33 - 25.36
Rear brake caliper cylinder I.D. 25.40 - 25.45
Electrical
Item Standard
Capacity 12V 10AH
Fully charged 13.2V
Battery Voltage (20°C)
Insufficient charged < 12.3V
Charging current 1.2A* 5 - 10H
14‐19


Item Standard
Spark plug Standard type NGKCR7E
Primary coil 3.57 - 4.83 Ω
Inductive Ignition Coil
Secondary coil without plug cap 10.42 - 14.49 KΩ
Throttle Position Sensor 3500 - 6500 Ω

Fuel Injector 1.9 9 approx.
Water Temperature Sensor 2.076 K9 ± 10% (25°C)
Oxygen Sensor ( engine warming condition ) 6.7 9 - 9.5 Ω
Crank Position Sensor 115 9 ± 15 Ω
0.4V - 1.4V(normal)
Tilt Switch
3.7V - 4.4V (fall down)
At -20°C/-4°F 18.8 KΩ
At 100°C/212°F 0.1553 KΩ
Item Standard Service Limit
Starter motor brush length 12.5 mm 8.5 mm
Fuse 10A,15A,30A
Headlight bulb 12V 35W/35W *2
Turn signal light bulb 12V 21 W(Front) / 10W(Rear)
Stoplight/taillight 12V2W/0.2W LED
14‐20

14. Quick Reference > Torque Specifications K- XCT 300i

Torque Specifications
ENGINE
Torque
Item Qty Thread size (mm) Remarks
kgf-m lb-ft
Cylinder head stud bolt
1. Stud bolt (Inlet pipe side) 2 6 0.7-1.1 5.06-7.96 Double end bolt
2. Stud bolt (EX pipe side) 2 8 0.7-1.1 5.06-7.96 Double end bolt
Cylinder head stud nut 4 10 3.4-3.8 24.59-27.48
Right crankcase cover bolt 15 6 1.0-1.4 7.23-10.13
Left crankcase cover bolt 15 6 1.0-1.4 7.23-10.13
Transmission case bolts 9 8 0.8-1.2 1.7-2.6
Bolt B stud 10*180 4 10 1.0-1.4 7.23-10. Apply oil to
thread Valve adjusting lock nut 4 5 0.7-1.1 5.06-7.96 Apply oil to
thread Cam sprocket bolt 2 6 1.0-1.4 7.23-10 Apply thread
lock Camshaft set plate bolt 1 1.2 2.0 Apply thread lock
Final drive oil check\drain bolt 2 8 0.8-1.2 5.79-8.68
Engine oil drain bolt 1 12 2.0-3.0 14.47-21.70
Engine oil strainer cap 1 1.02 7.2
Clutch outer nut (driven pulley) 1 12 5.0-6.0 36.17-43.40
Starter motor mounting bolt 2 6 1.0-1.4 7.23-10.13
Mission case bolt 6 8 1.8-2.2 13.02-15.91
Drive face nut 1 14 9.0-10.0 65.10-72.33 Apply oil to thread
Clutch drive plate nut 1 7.5 55.32
Drive plate comp 1 28 5.0-6.0 36.17-43.40
Cam chain tensioner bolt 2 6 1.0-1.4 7.23-10.13
Cam chain tensioner pivot 1 8 0.8-1.2 5.79 - 8.68
One way clutch bolt 3 8 1.8-2.2 13.02-15.91 Apply thread lock
ACG flywheel nut 1 14 5.5-6.5 39.78-47.01
Spark plug 1 12 1.5-2.0 10.84-14.47
Water pump impeller 1 7 1.0-1.4 7.23-10.13 Left thread
Water pump cover bolts 4 6 1.0-1.4 7.23-10.13
14‐21
14. Quick Reference > Torque Specifications K- XCT 300i
FRAME
Torque
Item Qty Thread size (mm) Remarks
kgf-m lb-ft
Steering:
1. Stem lock nut 1 BC1 6.0-6.5 43.20-46.8
2. Handle post bolt 1 10 4.0-5.0 28.93-36.17 U-nut
3. Bridge bolt 1 8 2.4-3.0 17.36-21.70
4. Race nut (head) 1 BC1 1.8-2.2 13.02-15.91
Brake:
1. Front/Rear caliper bolt 1 10 3.0-4.0 21.70-28.93
2. Brake hose bolt 1 10 3.0-4.0 21.70-28.93
3. Disk bolt 5 8 3.2-3.8 23.15-27.48
Engine hanger:
1. Frame side 2 14 6.0-7.0 43.40-50.63 U-nut
2. Engine side 1 10 4.5-5.5 32.55-39.78 U-nut
Rear fork bolt 2 10 3.0-4.0 21.70-28.93
Speed sensor cable 1 6 1.0-1.4 7.23-10.13
02 sensor 1 12 2.0-3.0 14.47-21.70
Rear carrier 4 8 2.0-2.8 14.47-20.25
Front axle 1 14 1.5-2.5 10.84-18.08
Rear cushion upper/lower bolt 2 10 3.5-4.5 25.32-32.55
Suspension:
Fuel Pump Bolts 6 0.35 2.5
General Torque Specifications
Torque
Item
kgf-m lb-ft
5 mm bolt, nut 0.45 - 0.6 3.25 - 4.34
6 mm bolt, nut 0.8 - 1.2 5.79 - 8.68
8 mm bolt, nut 1.8 - 2.5 13.02 - 18.08
10 mm bolt, nut 3.0 - 4.0 21.70 - 28.93
12 mm bolt, nut 5.0 - 6.0 36.17 - 43.40
5 mm screw 0.45 - 0.6 3.25 - 4.34
6 mm screw, SH bolt 0.7 - 1.1 5.06 - 7.96
6 mm flange bolt, nut 1.0 - 1.4 7.23 - 10.13
14‐22
14. Troubleshooting K- XCT 300i
Troubleshooting
Vehicle can not be started

Preliminary 6 Step Inspection
1. Is the battery fully charged (12V or higher). See the Battery topic for more
information.
2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn
off automatically in 5-10 seconds)
3. Key-On to check for any failure lamp light up on dashboard. See the Self-
Diagnosis topic for more information.
4. Is the Idle screw of Throttle Valve being changed or loosed?
5. Has the vehicle under regular service? Is the gas station a good one?
6. Is the spark plug the correct model of specified by the vehicle builder?
Troubleshooting by section
• Brakes
• Cooling System
• CVTContinuouslyVariable Transmission
• Electrical Systems
• Engine
• FinalDrive
• FrontSuspension
• FuelInjectionSystem
• Rear Suspension
• Steering
• Wheels
14‐23


General Troubleshooting
ENGINE WILL NOT START OR IS HARD TO START
Possible cause
1. Check for operation of the fuel pump Abnormal Faulty fuel pump
Normal
2. Inspect the fuel flow Abnormal Faulty pressure regulator
Normal
3. Inspect the fuel injector Abnormal Faulty injector
Normal
4. Perform spark test Weak or no spark Faulty spark plug

Fouled spark plug
Faulty ECU
Good spark Broken or shorted spark plug wire
Faulty ignition switch
Faulty ignition pulse generator
Loose or disconnected spark plug
wire
5. Test cylinder compression Low compression Valve stuck open

Worn cylinder and piston ring
Damaged cylinder head gasket
Compression normal Seized valve
Improper valve timing
6. Starting following normal procedure Engine start Intake pipe leaking

but stops Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
Engine does not start Fuel contaminated
7. Remove and inspect spark plug Wet plug Throttle valve open
Clogged air cleaner
14‐24


ENGINE LACKS POWER
Possible cause
1. Raise wheel off the ground Wheels do not Brake dragging

and spin by hand spin freely Worn or damaged wheel bearing
Wheel spins freely
2. Check tire pressure Pressure low Faulty tire valve

Punctured tire
Pressure normal
3. Accelerate lightly Engine speed does Air cleaner dirty

not increase Restricted fuel flow
Clogged muffler
Engine speed increase Pinched fuel tank breather
4. Check ignition timing Incorrect Faulty ECU

Correct
5. Test cylinder compression Incorrect Valve stuck open

Worn cylinder and piston rings
Leaking head gasket
Normal Improper valve timing
6. Inspect fuel flow Abnormal Faulty pressure regulator
Normal
Normal
8. Remove spark plug Fouled or discolored Faulty spark plug
Not fouled or discolored
14‐25


Possible cause
9. Check oil level and condition Incorrect Oil level too high
Oil level too low
Contaminated oil
Correct
10. Remove cylinder head cover Valve train not Clogged oil
and inspect lubrication lubricated properly Clogged oil control orifice
Valve train lubricated properly
11. Check for engine overheating Overheating Fan motor not working
Excessive carbon build-up in
combustion chamber
Use of poor quality fuel
Not overheating Wrong type of fuel
Drive and driven pulleys/clutch
slipping
12. Accelerate or run at high Engine knocks Worn piston and cylinder
speed Worn type of fuel
Excessive carbon build-up in
combustion chamber
Ignition timing to advanced (faulty
ECU)
Engine does not knock Lean fuel mixture
14‐26


POOR PERFORMANCE AT LOW AND IDLE SPEED
Possible cause
1. Check ignition timing Incorrect Improper ignition timing
Correct
Normal
Normal
4. Check for leaks in the intake pipe Leaking Loose insulator clamp
Damage insulator
No leak
5. Perform spark test Weak or intermittent spark Faulty the spark plug
Faulty carbon or wet fouled spark
plug
Faulty ECU
Faulty ignition coil
Faulty ignition switch
Loose or disconnected spark plug
wires
Good spark
14‐27


POOR PERFORMANCE AT HIGH SPEED
Possible cause
1. Check ignition timing Incorrect Faulty ECU
Correct
Normal
Normal
4. Check valve timing Incorrect Camshaft not installed properly
Correct
5. Check valve spring Weak Faulty valve spring
Not weak
POOR HANDLING
Possible cause
1. If steering is heavy Steering stem adjusting nut too tight

Damaged steering head bearings
2. If either wheel is wobbling Excessive wheel bearing play

Bent rim
Improper installed wheel hub
Swing arm pivot bearing excessively
worn
Bent frame
3. If the motorcycle pulled to one side Faulty the shock absorber

Front and rear wheel not aligned
Bent fork
Bent swing arm
Bent axle
14‐28

14. Quick Reference > VIN and Engine Number Location K- XCT 300i
VIN and Engine Number Location
The VIN is stamped on a plate on the lower right side.
The engine serial number is stamped on bottom of the left crankcase.
14‐29

14. Quick Reference > VIN and Engine Number Location K- XCT 300i
The VIN is also stamped on the frame inside of the luggage box.
14‐30

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1.

External Components K- XCT 300i

• Exhaust System ...............................................................1-2~1-13

Remove the O2 sensor wire band.

Unplug the O2 sensor connector.

Remove the three muffler mounting bolts with a 14 mm socket.

Remove the exhaust system.

Remove the exhaust pipe gasket and discard it.

Test the O2 sensor at room temperature.

Use a digital multimeter set to ohms of resistance to inspect the O2 sensor.

Replace the O2 sensor if the reading is out of specification.

Remove the heat shield.

Install the heat shields and tighten the bolts securely.

Apply anti-seize compound to the threads of the O2 sensor.

Insert a new exhaust pipe gasket into the exhaust port.

Fit the exhaust system into place

Tighten the two exhaust pipe joint nuts to specification with a 12 mm

Plug in the O2 sensor.

Install a new O2 sensor clamp.

Remove the four luggage bolts with a 10 mm socket.

Remove the two luggage nuts with a 10 mm socket.

Remove the luggage box.

Plug in the luggage box light connector.

Install the luggage box.

Remove the two luggage nuts with a 10 mm socket.

Install the seat.

Insert the key and turn it counterclockwise.

Remove the two seat hinge nuts with a 10 mm socket.

Seat Latch Cable

Open the seat.

Loosen the lock nuts and turn the adjusters as needed to

There is one adjuster for each latch. Tighten the locknuts

Install the seat onto the hinge.

Remove the four carrier bolts with a 6 mm Allen.

Remove the carrier each side.

Install the carrier.

Install the four carrier bolts on each side with a 6 mm Allen.

Push on the carrier bolt covers.

Remove the two rear center cover screws with a #2 Phillips.

Remove the rear center cover.

Remove the four lower body cover nuts with a 10 mm socket.

Carefully unhook the tabs on both sides of the body cover.

Unplug the taillight connector.

Remove the body cover.

Remove the two Rear Center Molding screws with a #2 Phillips.

Remove the rear fender screws with a #2 Phillips.

Carefully unhook the tabs on both sides of the rear fender.

Remove the rear fender.

Remove the eight taillight assembly screws with a #2 Phillips.

Remove the taillight assembly

Remove the two license light assembly screws with a screwdriver.

Disconnect the connector license light.

Remove the license light assembly.

Fit the body cover into place.

Plug in the taillight connector.

Carefully install the rear center cover.

Open the hidden bolt cover.

Remove the hidden bolt with a 10 mm socket.