KymcoForum.com
Scooters - 125 to 300 => Downtown 300 => Topic started by: boksaman on March 03, 2021, 02:48:29 PM
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I have just bought used Kymco Downtown 2011 300i with 46 000 kilometers.
I'm pretty happy about it - plastics are good, its goes straight, looks like it was not fallen from it, i love the acceleration, brakes, lights etc.. looks good - so far had no problems.
Only thing i have noticed is "clank" sound coming from variator housing, it happens when i accelerate (pull the throttle) from stop and when i lay off the throttle suddenly - i can hear it once or twice - sounds somewhat metallic. It happens also when the bike is on the main stand when i pull the throttle.
I have recorded the sound in order to help with identifying problem
https://www.youtube.com/watch?v=8Lwzcb88dyQ
Does anyone have experience with this sound and does it indicate serious problem? Any help is greatly appreciated.
Thanks
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Exhaust leak. I vote for an exhaust leak anywhere from the pipe connection at the cylinder head to the slip-on connection at the front of the muffler. Rusted holes are also a possibility. Otherwise, sounds good!
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CROSSBOLT Thanks for the quick answer, i'll make sure to do the full inspection ASAP. I have ordered filters, oils, etc for regular service so i'm looking forward to work on this machine. Today in store i've seen some sort of kit for fixing minor exhaust holes - hope that will suffice if minor exhaust leak is the problem..
Does anybody else has suggestions what this noise can be ?
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doesn't really sound metallic to me..but difficult to tell from a video. If it's not an exhaust leak like Crossbolt suggested you can always take the cvt cover off and look to make sure everything is working properly.
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CROSSBOLT Thanks for the quick answer, i'll make sure to do the full inspection ASAP. I have ordered filters, oils, etc for regular service so i'm looking forward to work on this machine. Today in store i've seen some sort of kit for fixing minor exhaust holes - hope that will suffice if minor exhaust leak is the problem..
Does anybody else has suggestions what this noise can be ?
This is a good machine. More good points than bad points. Keep us posted!
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doesn't really sound metallic to me..but difficult to tell from a video. If it's not an exhaust leak like Crossbolt suggested you can always take the cvt cover off and look to make sure everything is working properly.
I will disassemble CVT in next month or two, and post videos here and notify if i manage to fix issue.
One of things i need to check is that maybe belt is slapping on CVT housing like in this video - https://www.youtube.com/watch?v=ftjBGlAzgxs
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Boksa, jesi li iz Srbije?
If not, let me switch to English. Me too bet on slipping belt. I have just rebuild my transmission. Disassembled and cleaned up everything, changed rubbish RMS rollers with Polini ones, and changed Bando belt with Mitsuboshi one. I had similar sound like Yours followed with "takatakatak" sound when revs were idling. Everything symptom i had was because of wrong belt. When compared new belt with the old one, old was not quite for my scooter. Really similar but not quite the same. The old one is few mm longer and one mm narrower. That's why my belt was slipping.
I recommend buying original or Mitsuboshi belt exactly for DT 300 and i am pretty sure Your "sounds" will dissapear.
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Boksa, jesi li iz Srbije?
If not, let me switch to English. Me too bet on slipping belt. I have just rebuild my transmission. Disassembled and cleaned up everything, changed rubbish RMS rollers with Polini ones, and changed Bando belt with Mitsuboshi one. I had similar sound like Yours followed with "takatakatak" sound when revs were idling. Everything symptom i had was because of wrong belt. When compared new belt with the old one, old was not quite for my scooter. Really similar but not quite the same. The old one is few mm longer and one mm narrower. That's why my belt was slipping.
I recommend buying original or Mitsuboshi belt exactly for DT 300 and i am pretty sure Your "sounds" will dissapear.
Da da iz Srbije sam :)) Kako si pogodio ? (Yes I'm from Serbia, how did you guess?)
Thats great news, i have talked with parts store yesterday and they offered "Mitsuboshi" belt for my bike when i asked for sevice/maintenance parts, lubricants etc - now i'm definitely gonna buy that part.
Also i was browsing online for replacement belts, and got stuck trying to figure out what is exact part number for my bike:
-23100-LEA7-E00 or
-23100-LEA7-E01
What do you think is this item worth ordering (if the part number is correct)?:
https://www.aliexpress.com/item/4000668370575.html?spm=a2g0o.cart.0.0.73ad3c00CpSsft&mp=1
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I'm not sure that i would recommend buying Chinese belt from aliexpress. Only experience i had with Chinese belts was more than 15 years ago when i used to drive Chinese scooter. Bought it brand new and the belt snapped after 2 or 3 thousand km.
Mitsuboshi should last 20K km.
My advice is: save some money and buy the real deal!
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Da da iz Srbije sam :)) Kako si pogodio ? (Yes I'm from Serbia, how did you guess?)
Thats great news, i have talked with parts store yesterday and they offered "Mitsuboshi" belt for my bike when i asked for sevice/maintenance parts, lubricants etc - now i'm definitely gonna buy that part.
Also i was browsing online for replacement belts, and got stuck trying to figure out what is exact part number for my bike:
-23100-LEA7-E00 or
-23100-LEA7-E01
What do you think is this item worth ordering (if the part number is correct)?:
https://www.aliexpress.com/item/4000668370575.html?spm=a2g0o.cart.0.0.73ad3c00CpSsft&mp=1
I agree with francuz69 that aliexpress is probably a poor copy of Mitsuboshi.
Don't know the differences in part numbers.
Please tell us when you find out the cause!
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Today i have disassembled cvt housing and confirmed that belt is making noise while hitting cvt housing - proof lies in black marks on housing underneath & over the belt as seen in pictures below:
housing bottom part - underneath the belt:
https://imgur.com/m2JBJl4
housing top part - over the belt:
https://imgur.com/kLVTwyD
here is the video
https://www.youtube.com/watch?v=wMVxMLhzek0
i believe all parts are stock, belt seems brand new (no cracks) - can anyone guess why would belt act like that and have a lot of slack. I will post below all pictures and videos that can help with diagnosing the issue
on belt is written: MITSUBOSHI KYMCO 23100-LEA7-E00 made in japan
https://imgur.com/IEZDHx2
variator close up
https://imgur.com/gGrcFQR
clutch spring seems bit rusty ?
https://imgur.com/hpyhLc4
https://www.youtube.com/watch?v=m79BO-sCFs4
belt slack:
https://www.youtube.com/watch?v=7vR9b-QfLqU
with more throttle:
https://www.youtube.com/watch?v=WuTGhPN1SMk
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Today i have disassembled cvt housing and confirmed that belt is making noise while hitting cvt housing - proof lies in black marks on housing underneath & over the belt as seen in pictures below:
housing bottom part - underneath the belt:
https://imgur.com/m2JBJl4
housing top part - over the belt:
https://imgur.com/kLVTwyD
here is the video
https://www.youtube.com/watch?v=wMVxMLhzek0
i believe all parts are stock, belt seems brand new (no cracks) - can anyone guess why would belt act like that and have a lot of slack. I will post below all pictures and videos that can help with diagnosing the issue
on belt is written: MITSUBOSHI KYMCO 23100-LEA7-E00 made in japan
https://imgur.com/IEZDHx2
variator close up
https://imgur.com/gGrcFQR
clutch spring seems bit rusty ?
https://imgur.com/hpyhLc4
https://www.youtube.com/watch?v=m79BO-sCFs4
belt slack:
https://www.youtube.com/watch?v=7vR9b-QfLqU
with more throttle:
https://www.youtube.com/watch?v=WuTGhPN1SMk
What I see on the bottom of your housing is rubber dust. I also cannotbsee the belt slap the housing in the first video.
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What about that picture named "housing top part - over the belt" ? I'ts easier to see those are marks made by belt
I agree that is not so easy to see the belt hitting on this video - i will try to record better video, maybe even in slow motion, one thing i'm sure now is that sound is coming from inside the cvt housing in my opinion.
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@boksaman,
for me it is clearly the V-belt slapping at least at the lower housing. Since you don't know what the previous owner did or let somebody do on this scoot, l would risk an original belt to buy and mount. It's most probably the less expensive remedy.
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Yep new belt, plus a clutch spring as it seems to be riding too low in the rear pulley.
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All right, i'm in process of ordering all service parts + belt & spring - will post all work i do on scooter in pictures & video..
@mousejunks i believe also that the belt is riding too low
@Ruffus i'm cheap bastard :) but ill try to get original part
thanks everybody !
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My experience with now 30 years and 400,000 miles with rubber band drive maxiscooters---all parts need to be exact OEM and in good condition and not worn out to work right, period. There is no cheap way around drive belts!
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Couple of updates while waiting on belt - coronavirus situation made harder getting the OEM belt for scoot so i was busy tinkering around the bike:
- changed the oil filter and engine oil (IPONE 4T Scoot 4 10W40)
https://imgur.com/wmbA5GM
- changed the transmission oil (IPONE Trans 4 80W90 1L)
https://imgur.com/2tPyIg1
- changed air filter (OEM 17211-LEA7-E00)
https://imgur.com/YLHYHsS
- changed the spark plug (for DENSO Iridium: IU22)
https://imgur.com/yi4z9i2
https://imgur.com/x9Bbm61
one thing i noticed is that this bike had petrol in airbox - looks like not much but still worries me, got me thinking that my dirty engine is indicating oil/fuel/coolant leak somewhere
https://imgur.com/0QLGyEx
https://imgur.com/S9yfL4O
what are your opinions on this situation ?
can i wash the engine with pressure washer (to expose leak spot) ? will that damage electrical components etc .. how does one wash engine on scooter ?
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Been gunkin' and pressure washing several Kymcos and no electrical problems. Did get water in the cable release seat latch cables and had to rebuild them.
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how I've cleaned my engine? - a bottle of your favorite detail spray, general purpose cleaner or degreaser and a few old microfiber towels...
spray and wipe off / clean a section at a time. It will eventually look like new.
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Cleaned scooter and bycicles with BBQ or oven foam spray, just sprayed it on - let it work in, took a long handle painters-brush and helped where necessary, then flushed with garden hose.
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Used contact cleaner that leaves protective film around electrical contacts, then pressure washed the engine - i can say i'm happy with results
https://imgur.com/fqIBOs8
can throttle body have leaks ? on the picture before cleaning, gunk and dirt is all the way on the top of engine - so logically thinking whatever the leak is coming from must be from the highest point in engine bay
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now that's my kind of clean engine! Nice job. About the leak - I wouldn't necessarily assume the leak follows gravity. It's possible for certain leaks to spread around...but with a clean motor you'll now have a better chance of locating the leak.
I'm starting to sound like a broken record but the mess in your airbox...make sure your gear oil isn't overfilled as many of our scoots vent the gearbox into the airbox and will soak the filter if overfilled.
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Quick update
Keeping myself busy while waiting on replacement belt to arrive, OEM belt or branded belts are harder to find in my country in this moment because coronavirus situation, so i have ordered that cheap belt from china just until i can find the better option.
I have painted scratches on exhaust cover in the meantime
https://imgur.com/ryaa4XB
https://imgur.com/IE9MCC0
https://imgur.com/8lk73wN
i have also done valve clearance and it has made engine work much smoother - really happy about that
@ Iahawk i have looked into airbox and i think everything is all right with gear oil - it is not venting and soaking the air filter, thanks for the suggestion
I'm in process of buying manometer to test the engine compression - what kind of values should i expect?
In cyclepedia manual i have this values:
https://imgur.com/MOQ8rIL
does that mean that i should get the reading around 228 psi ?
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One more question - does this part of engine suppose to have oil in it on Downtown 300i?
Have done some research regarding the leak mentioned earlier, preliminary inspection shows that leak is happening somewhere underneath starter motor.. people say that oil can escape from place marked on picture - but i'm not sure what model of bike they are talking about ..
https://imgur.com/Q8Hgrhu
thanks in advance
edit: after some research i realized that generator has oil in it, and hopefully some silicone around the place where electrical cables go out of generator housing will stop the leak
yellow - puddle of fresh oil appears
blue - starter motor
green - electrical cables
https://imgur.com/xh8SjVz
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One more question - does this part of engine suppose to have oil in it on Downtown 300i?
Have done some research regarding the leak mentioned earlier, preliminary inspection shows that leak is happening somewhere underneath starter motor.. people say that oil can escape from place marked on picture - but i'm not sure what model of bike they are talking about ..
https://imgur.com/Q8Hgrhu
thanks in advance
edit: after some research i realized that generator has oil in it, and hopefully some silicone around the place where electrical cables go out of generator housing will stop the leak
yellow - fresh oil appears
blue - starter motor
green - electrical cables
https://imgur.com/xh8SjVz
yellow
The black plastic block is the seal for the 3 stator wires (yellow) and the crankshaft position sensor wires. It's always soaked in oil and it is a common point of leakage as the plastic hardens over time.
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Quick update:
Finally had time and all tools to disassemble CVT, looks like the problem was not bad belt but weak contra spring - how do i know ?
I have stretched the spring by hand from 135mm to 155mm after reinstall there was minimum vibration and that "clapping/slapping" noise for first 45 minutes of riding - after that noise is coming back. I believe it is because spring lost its "power" or "push" - what i want to say it is weak (i don't know if it OEM to be honest).
Stretching can do so much until spring comes back to its normal operation.
Also i should note that i have installed lighter rollers from 15.5gr to 13.43gr and things changed dramatically! I believe that lighter rollers have counteracted to weak spring. Anyway i have ordered white and yellow malossi springs from ebay. When they arrive ill make sure to post pictures and results after change.
Pictures of whole process are attached, hopefully they help someone like this forum and youtube videos helped me.
Cheers!! Downtown 300i is a best bike !
https://imgur.com/gallery/CCnFjOR
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After a long waiting time for springs & belt, vacation on island of Thassos i have changed OM contra spring with malossi spring. I have ordered 2 springs - white and yellow, only difference between the two is the stiffness. After instal i decided to keep the yellow one because that flapping noise from belt is almost completely gone with the yellow one.
The belt i have received from aliexpress is out of spec, namely the width is not specified 2.53cm but 2.7cm, so i kept the OEM. What do you guys think, can this belt still be used?
For now i'm pretty happy with the results, bike is working much more smoothly it is not jerky like before and flapping sound can be only heard when completely stopping only "tap tap" somewhat quieter for a second - not like before when it flapped any time when lowering the speed to 10-15km/h like "tap tap tap tap tap tap"
Hope this helps someone in future
https://imgur.com/wJOh3vo
https://imgur.com/3yUM95F