45,000km Downtown - maintenence report

[mousejunks]

My DT300i passed the 45,000km mark a few weeks ago and I have made up a list of things which failed but were fixed.

- The plastic cover over the magnetic part of the key was peeling off. I ripped it off and covered the gap with epoxy glue to prevent it from further damage.
- Seat won't close - adjusted the two seat cables to increase the tension, also making it easier to open with the key.
- Oil leak from right crankcase cover - there is a small circular cover on the right side of the engine. This can simply be tightened with a coin or sealed up with gasket maker. There was also an oil leak from where the wires insert into the stator, also sealed up with gasket maker.
- Indicators won't cancel - the left handlebar controls were disassembled and a blob of solder was put onto the pin that actuated the sliding switch.
- Yellow cracked windshield - replaced
- Holes in air filter - the air filter box has an intake tube that came loose. This caused it to move around and damaged the paper element of the air filter. The tube was glued back into place and the air filter replaced.
- Exhaust muffler paint fade - repainted with high-heat black paint (Dupli-Color brand).
- Exhaust muffler cover wobbling - the rubber around bolts breaks down due to heat from the muffler, as well as dropping the bike. I simply removed the cover.

Despite these issues, they did not affect the mechanical reliability of the bike. It starts everytime and runs smoothly and I expect it to last for many more years. I also bought it second-hand without any servicing history, so it was mistreated before I owned it - the cracked headlight housing and black grime in the transmission were clues.

[CROSSBOLT]

28000 miles for us yanks is not bad! Kinda speaks for DT300i reliability plus you mech/tech skills!

Karl

[ScooterWolf]

I think that's about equal to one trip around the equator. I'm still a baby. I just crossed over 9k miles, or 14,484.096 kilometers.

- Wolf

[kneeslider]

Mine just reached 41000kms. Here is my list:

1) Had the small exhaust cover fall off.
    Replaced it.
2) Engine wouldn't crank.
    Had to clean out the contacts on the starter switch as it was gunked up with crap which prevented electrical contact.
3) Oil leak from that huge screw above the oil filler plug.
    Tightened it up with a screwdriver.
4) Breather hose from rear hub to airbox came loose and leaked that oil all over the rear hub and wheel.
    Placed back the hose.
5) Exhaust cover rattling.
    Rubber grommets crumpled into pieces, left it as it is.
6) Micro cracks in windscreen, and it's yellowing due to the UV rays.
    Left as is.
7) Steering head bearings were notched.
    Replaced the top and lower steering cone bearings.
8.) Throttle cable snapped.
    Replaced with new item.
9) Front wheel bearing failed.
    Replaced with new bearings (1 pair).
10) Radiator fluid reservoir mounting screw fell off.
      Used a zip tie to get it back in place.
11) Engine wouldn't crank.
       Replaced spark plug, but I guess that's my fault for not changing it.
12) Bolt holding down the airbox and rear hugger fell off.
       Replaced wit a new bolt.
13) Caddy Hook, some plastic part broke off, so now it doesn't spring back into place.
      Left it as it is.

[mrbios]

Great info!  My 2005 GV250 is aging and has 20K miles but still starts right up so I'm looking around.  Also the rear fender broke off - with the help of a Mercedes which hit me while I was stopped at a stop sign! 

[de dee]

  2011 downtown  85,000 Km.+  main thing wrong is wearing out tires,  to fast ,  found a leak right side cover spot of oil after ride  fixed it- bought a 2009 frost - yager ,  now only thing wrong is to much snow, 

[ScooterWolf]

Congrats, De Dee. Sounds like you’ll have plenty of fun come early Spring.

- Wolf

[Aminkymco]

There has been many posts about DT300 here but I have never seen any about DT125 ,is there anyone here having experience of owning or riding Downtown 125 cc ?Is it as reliable as DT300 ?


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[Aminkymco]

My DT300i passed the 45,000km mark a few weeks ago and I have made up a list of things which failed but were fixed.

- The plastic cover over the magnetic part of the key was peeling off. I ripped it off and covered the gap with epoxy glue to prevent it from further damage.
- Seat won't close - adjusted the two seat cables to increase the tension, also making it easier to open with the key.
- Oil leak from right crankcase cover - there is a small circular cover on the right side of the engine. This can simply be tightened with a coin or sealed up with gasket maker. There was also an oil leak from where the wires insert into the stator, also sealed up with gasket maker.
- Indicators won't cancel - the left handlebar controls were disassembled and a blob of solder was put onto the pin that actuated the sliding switch.
- Yellow cracked windshield - replaced
- Holes in air filter - the air filter box has an intake tube that came loose. This caused it to move around and damaged the paper element of the air filter. The tube was glued back into place and the air filter replaced.
- Exhaust muffler paint fade - repainted with high-heat black paint (Dupli-Color brand).
- Exhaust muffler cover wobbling - the rubber around bolts breaks down due to heat from the muffler, as well as dropping the bike. I simply removed the cover.

Despite these issues, they did not affect the mechanical reliability of the bike. It starts everytime and runs smoothly and I expect it to last for many more years. I also bought it second-hand without any servicing history, so it was mistreated before I owned it - the cracked headlight housing and black grime in the transmission were clues.

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[Aminkymco]

Good maintenance ! How often do you do the oil change for your downtown?


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[de dee]

2011 downtown 300i  oil changes ,  3200 Km.   (   2000 MILES)  full syn. oil,   oil changes done HOT,. since new!!  gear oil  and engine at same time,.  switched from mobil 1 5W 50  to rotela T6 5 W 40  at 50,000 Km.  both seem to work fine,.  in the gears I use valvaline 75/145  full Syn.  on changes it looks like new oil,   

[Aminkymco]

2011 downtown 300i  oil changes ,  3200 Km.   (   2000 MILES)  full syn. oil,   oil changes done HOT,. since new!!  gear oil  and engine at same time,.  switched from mobil 1 5W 50  to rotela T6 5 W 40  at 50,000 Km.  both seem to work fine,.  in the gears I use valvaline 75/145  full Syn.  on changes it looks like new oil,

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[Aminkymco]

Thanks de dee !


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[mousejunks]

Good maintenance ! How often do you do the oil change for your downtown?


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I change my engine oil every 4000-5000km and gear oil every 5000-10000km. The gear oil always comes out clear straw-coloured with no bits.

[mousejunks]

I'm almost at 50,000km so I replaced the drive belt. The old one was a Kymco Mitsuboshi, the new one was just Kymco. My commutes are mostly highway so there was barely any wear or damage to the belt after 15,000km, just slight glazing on the sides.

One tip when replacing belts - ALWAYS greases the splines where the axle contacts the variator. They will rust and seize together if you don't.