4,000 mile service

[MJR]

The oil service light came on just before 4,000 miles, time for the 4K service. Time to change the engine oil, filter, clean the crankcase vent, check the air filter, and check the clutch pad wear.

Changing the oil.







This is the first time the owners manual calls for cleaning the crankcase vent tube. Looks like it should have been sooner, look at the gunk that came out pulling the plug.





Look at what you have to take apart to check/change the air filter. It still looks like I'll get more miles out of this one. They are oiled so you can't just blow it out. I found the air filter cover seal out of place and put it back in.







Next up pulling the CVT covers, clutch bell and checking the clutch pad thickness, looks good. Looks it's dry in the CVT, the dealer finally fixed my oil leak that was getting in the CVT case.






Don't lose the alignment sleeves.






My homemade clutch holder tool.

[Stig / Major Tom]

Nice job MJ,
That's  a big air filter! Funny to see those gy6 oil screens in such a big motor.
Thought the LIKE200i  had a filter that never seems to get dirty....yours  too?
I've  notice more stuff in crank vent tube after high speed usage.
Again, nice pix of your work. That is an impressive kymco model and too rare....we hardly ever get much discussion of it.
Stig

[MJR]

Nice job MJ,
That's  a big air filter! Funny to see those gy6 oil screens in such a big motor.
Thought the LIKE200i  had a filter that never seems to get dirty....yours  too?
I've  notice more stuff in crank vent tube after high speed usage.
Again, nice pix of your work. That is an impressive kymco model and too rare....we hardly ever get much discussion of it.
Stig

Yup big filter for the big air pump the bike has. It's funny cast into the cap is GY6. Some stuff collects in it but I'd expect that to drop over time.



Here's what the screen looks like after pulling the plug.



I'm one of only three owners I know of, it's even rarer than my new to me Aprilia Atlantic 500. One I met online here and the other through a Craigslist because his wife wanted him to sell it and fix his Burgman 650 but I think he is gonna keep it.

[Stig / Major Tom]

Say MJ,
I noticed that your big Kymco has an oil level sight glass.
What instruction does the owner's manual give for checking the oil level?
Stig

[MJR]

Say MJ,
I noticed that your big Kymco has an oil level sight glass.
What instruction does the owner's manual give for checking the oil level?
Stig

Below are excerpts from the owners and service manuals. My Burgmans also have sight glasses for engine oil and I wish the Aprilia Atlantic did as well instead of a dipstick. The MyRoad uses a sight glass for engine oil and dipstick for the rear diff oil, the Aprilia uses dipsticks for both engine/rear diff oil , and the Burgmans use a sight glass for engine oil and a fill to level plug for the rear diff.

Engine oil level inspection
1. Start the engine and let it idle for a few minutes.
2. Stop the engine and put the scooter on its center stand on level ground.

CAUTION
Running the engine with insufficient oil pressure can cause serious engine damage. Check the engine oil level each day before riding your scooter. The level must be maintained between the upper and lower level marks on the oil inspection screen.

3. After a few minutes. The oil level should be between the upper(H) and lower(L) marks on the oil inspection screen.
4. If required, remove the oil filler cap and add the specified oil so the oil level touches the upper level mark on the screen. Do not overfill.
5. Reinstall the oil filler cap. Check for oil leaks.

ENGINE OIL LEVEL INSPECTION
Start the engine and let it idle for 2－3 minutes.
Turn off the engine and support the scooter level surface.
Check the engine oil level. The level must be maintained between the upper H (1) and lower level L (2) marks on the oil inspection screen (3).
If the oil level is below or near the lower level line, add the recommended engine oil until the oil level is to the upper level.

[Stig / Major Tom]

Below are excerpts from the owners and service manuals. My Burgmans also have sight glasses for engine oil and I wish the Aprilia Atlantic did as well instead of a dipstick. The MyRoad uses a sight glass for engine oil and dipstick for the rear diff oil, the Aprilia uses dipsticks for both engine/rear diff oil , and the Burgmans use a sight glass for engine oil and a fill to level plug for the rear diff.

Well, that's even more bleeping confusing than the Burgman 400 check oil level system !! (which requires a pet monkey, and/or a crew to hold dead-level a 500 lb scooter and do deep knee bends into a puddle at the gas pump!)
One 700 manual says do it on center stand, other says do it with scoot level.!
Put ALL scooters and motorcycles on center stand and pull the bleeping dip-stick!!
Weld up those windows!
not stig

[MJR]

One 700 manual says do it on center stand, other says do it with scoot level.!
Put ALL scooters and motorcycles on center stand and pull the bleeping dip-stick!!

It takes some of that not so common common sense. Level ground on centerstand.

[Mr. Paul]

Nice write-up and pics. I fabricated the same clutch-holding tool.

[MJR]

Nice write-up and pics. I fabricated the same clutch-holding tool.

Thanks, I didn't get into all the nuts/bolts but an overview. It's cool making your own tools for jobs.