KYMCO XCITING 500 User manual

1. GENERAL INFORMATION
1-0
XCITING 500/250
1
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GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER-----------------------------------------------------------1 - 1
SPECIFICATIONS (XCITING 500)---------------------------------------1 - 2
SPECIFICATIONS (XCITING 250)---------------------------------------1 - 3
SERVICE PRECAUTIONS-------------------------------------------------1 - 4
TORQUE VALUES ----------------------------------------------------------1 - 8
SPECIAL TOOLS ------------------------------------------------------------1-12
LUBRICATION POINTS ---------------------------------------------------1-13
CABLE & HARNESS ROUTING (XCITING 500)-------------------------1-15
CABLE & HARNESS ROUTING (XCITING 250)-------------------------1-25
TROUBLESHOOTING------------------------------------------------------1-33
1

1. GENERAL INFORMATION
1-1
XCITING 500/250
SERIAL NUMBER
Location of Engine Serial Numbe
r
Location of Frame Serial Numbe
r

1. GENERAL INFORMATION
1-2
XCITING 500/250
SPECIFICATIONS (XCITING 500)
ITEM SPECIFICATIONS
Name XCITING 500
Overall length 2250 mm (90 in)
Overall width 815 mm (33 in)
Overall height 1450 mm (58 in)
Wheel base 1570 mm (63 in)
Engine type O.H.C.
Displacement 498.5 cm3 (30.4 cu-in)
Fuel Used 92# nonleaded gasoline
Front wheel 83 kg (183 lbs)
Dry weight Rear wheel 132 kg (290 lbs)
Total 215 kg (473 lbs)
Front wheel 90 kg (198 lbs)
Curb weight Rear wheel 141 kg (310 lbs)
Total 231 kg (508 lbs)
Front wheel 120/70-15
Rear wheel 150/70-14
Ground clearance 150 mm (6 in)
Min. turning radius 2750 mm (110 in)
Starting system Electric starter moto
r
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke 92 x75 mm
(3.7 x3 in)
Compression ratio 10.5:1
Compression pressure 13 kgf/c
m
²(1300kPa,
185 psi)
Open 2°BTDC
Intake valve Close 45°ABDC
Open 45°BBDC
Exhaust valve Close 5°ATDC
Valve clearance Intake 0.1 mm (0.004 in)
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed 1400 rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Trochoid
Oil filter type Full-flow filtration
Oil capacity 2.5 L (2.2 lmp qt,
2.65 Us qt)
Final reduction oil
capacity 0.55 L (0.5 lmp qt,
0.58 Us qt)
Cooling Type Liquid cooled
ITEM SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel capacity 12.8 L (3.38 lmp gal,
2.82 US gal
Type CVK
Main jet NO. 98
Venturi dia. φ36 mm (φ1.44 in)
Throttle type PISTON
Type Full transistor ignition
Spark plug CR8E
Ignition timing Throttle position senso
r
Spark plug gap 0.6～0.7mm (0.002～
0.003 in)
Battery Capacity 12V12AH
Clutch Type Dry, centrifugal
automatic
Type Helical gear/spur gear
Operation Automatic centrifugal
Type
Type CVT
Preliminary 2.68 – 1
Final 5.4
FR/RR tire rolling
circumference 1724/1778 mm (69/71 in)
Front 2 kg/cm²(200 Kpa, 28
psi)
Tire pressure
(rider only/60
kg) Rear 2.5 kg/c
m
²(250 Kpa, 36
psi)
Turning Left 40°
angle Right 40°
Brake s
y
ste
m
Rea
r
Disk brake
type Front Disk brake
Front Telescopic fork
Suspension
type Rear Unit swing
Frame type Back born
Tires
Fuel S
y
stem
Carbureto
r
Electrical Equipment
I
g
nition S
y
stem
Power Drive System
Transmis- sion Gear Reduction
Ratio
Moving Device Damping
Device
Lubrication S
y
stem
Engine

1. GENERAL INFORMATION
1-3
XCITING 500/250
SPECIFICATIONS (XCITING 250)
ITEM SPECIFICATIONS
Name XCITING 250
Overall length 2250 mm (90 in)
Overall width 815 mm (33 in)
Overall height 1450 mm (58 in)
Wheel base 1570 mm (63 in)
Engine type O.H.C.
Displacement 251/249.1 cm3
(15.3/15.8 cu-in)
Fuel Used 92# nonleaded gasoline
Front wheel 75 kg (165 lbs)
Dry weight Rear wheel 110 kg (242 lbs)
Total 185 kg (407 lbs)
Front wheel 81 kg (178 lbs)
Curb weight Rear wheel 119 kg (262 lbs)
Total 200 kg (440 lbs)
Front wheel 120/70-15
Rear wheel 150/70-14
Ground clearance 170 mm (6.8 in)
Min. turning radius 2600 mm (104 in)
Starting system Electric starter moto
r
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke 72.7 x60 mm
(2.908 x2.4 in)
Compression ratio 10.3:1
Compression pressure 15 kgf/c
m
²(1500kPa,
213 psi)
Open 9°BTDC
Intake valve Close 45°ABDC
Open 38°BBDC
Exhaust valve Close 10°ATDC
Valve clearance Intake 0.1 mm (0.004 in)
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed 1600 rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Trochoid
Oil filter type Full-flow filtration
Oil capacity 1.1 L (0.97 lmp qt,
1.17 Us qt)
Final reduction oil
capacity 0.2 L (0.18 lmp qt,
0.21 Us qt)
Cooling Type Liquid cooled
ITEM SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel capacity 12.8 L (3.38 lmp gal,
2.82 US gal
Type CVK
Main jet NO. 94
Venturi dia. φ30 mm (φ1.2 in)
Throttle type PISTON
Type Full transistor ignition
Spark plug DPR7EA-9
Ignition timing Throttle position senso
r
Spark plug gap 0.6～0.7mm (0.002～
0.003 in)
Battery Capacity 12V12AH
Clutch Type Dry, centrifugal
automatic
Type Helical gear/spur gear
Operation Automatic centrifugal
Type
Type CVT
Preliminary 0.83 – 2.2
Final 8.72
FR/RR tire rolling
circumference 1724/1778 mm (69/71 in)
Front 2 kg/cm²(200 Kpa, 28
psi)
Tire pressure
(rider only/60
kg) Rear 2.5 kg/c
m
²(250 Kpa, 36
psi)
Turning Left 40°
angle Right 40°
Brake s
y
ste
m
Rea
r
Disk brake
type Front Disk brake
Front Telescopic fork
Suspension
type Rear Unit swing
Frame type Back born
Tires
Fuel S
y
stem
Carbureto
r
Electrical Equipment
I
g
nition S
y
stem
Power Drive System
Transmis- sion Gear Reduction
Ratio
Moving Device Damping
Device
Lubrication S
y
stem
Engine

1. GENERAL INFORMATION
1-4
XCITING 500/250
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
XCITING 500/250
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Confir
m
Capacity

1. GENERAL INFORMATION
1-6
XCITING 500/250
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight！
N
o Contac
t
Do not press or
squeeze the
i

1. GENERAL INFORMATION
1-7
XCITING 500/250
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Note
Engine Oil
Grease
Gear Oil
＊
Do you understand
the instrument？
Remove Rust！

1. GENERAL INFORMATION
1-8
XCITING 500/250
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque
N•m (kgf•m, lbf•ft) Item Torque N•m (kgf•m, lbf•ft)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
5(0.5, 4)
10 (1, 7)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)
70 (7, 50)
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
3 (0.3, 2)
4 (0.4, 3)
9 (0.9, 6.5)
12 (1.2, 9)
27 (2.7, 20)
40 (4, 29)
Torque specifications listed below are for important fasteners.
ENGINE (XCITING 500)
Item Q‘ty Thread dia.
(mm) Torque N•m (kgf•m, lbf•ft) Remarks
MAINTENANCE:
Engine oil drain plug
Oil strainer screen cap
Oil filter cartridge
Transmission oil drain bolt
Transmission oil filler bolt
Spark plug
Tappet adjust nut
LUBRICATION SYSTEM:
Oil pump screw
Oil cooler bolt
COOLING SYSTEM:
Water pump cover bolt
CYLINDER HEAD:
Breather separator bolt
Cylinder head bolt (1 – 4)
Cylinder head bolt (5 – 13)
Cylinder head cover bolt
Cam chain tensioner bolt
Tensioner pivot bolt
Rocker arm shaft
DRIVE/DRIVEN PULLEY:
Drive face nut
Clutch out nut
1
1
1
1
1
1
4
1
2
2
3
4
9
4
2
1
2
1
1
12
30
20
8
8
10
5
4
16
6
6
10
8
6
6
8
18
18
14
25 (2.5, 18)
15 (1.5, 11)
10 (1, 7)
20 (2, 15)
20 (2, 15)
12 (1.2, 9)
9 (0.9, 6)
3 (0.3, 2)
35 (3.5, 25)
13 (1.3, 9)
13 (1.3, 9)
48 (4.8, 35)
23 (2.3, 17)
10 (1, 7)
12 (1.2, 9)
10 (1, 7)
45 (4.5, 32)
135 (13.5, 97)
80 (8, 58)
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil
Apply oil

1. GENERAL INFORMATION
1-9
XCITING 500/250
ENGINE (XCITING 500) (Cont’d)
Item Q‘ty Thread dia.
(mm) Torque N•m (kgf•m, lbf•ft) Remarks
Drive plate nut
ALTERNATOR
ACG flywheel nut
FINAL REDUCTION:
Transmission cover bolt
CRANKCASE:
Crankcase bolt
Oil pipe bolt
Cam chain guide
SWITCH:
Oil pressure switch
1
1
8
13
2
2
1
28
14
8
6
16
8
PT 1/8
78 (7.8, 56)
55 (5.5, 40)
27 (2.7, 20)
12 (1.2, 9)
43 (4.3, 31)
20 (2, 15)
22 (2.2, 16)
Apply oil
Apply oil
Apply seal
ENGINE (XCITING 250)
Item Q‘ty Thread
dia.(mm) Torque
N•
m
(
k
g
f•
m
,
lbf•ft
)
Remarks
MAINTENANCE:
Valve adjusting lock nut
Spark plug
Transmission oil drain bolt
Transmission oil check/fill bolt
Crank case oil drain bolt
Oil filter screen cap
LUBRICATION SYSTEM:
Oil pump screw
COOLING SYSTEM:
Water pump impeller
CYLINDER HEAD:
Cylinder head cap nut
Tensioner lifter bolt
Cylinder head cover bolt
Cam chain tensioner bolt
2
1
1
1
1
1
1
1
4
1
4
2
5
10
12
8
12
30
3
7
8
6
6
6
9 (0.9, 6.5)
12 (1.2, 9)
20 (2, 15)
20 (2, 15)
25 (2.5, 18)
15 (1.5, 10.8)
2 (0.2, 1.4)
12 (1.2, 8.6)
25 (2.5, 18)
4 (0.4, 3)
12 (1.2, 8.6)
12 (1.2, 8.6)
Apply oil
Apply oil
Left screw
Apply oil

1. GENERAL INFORMATION
1-10
XCITING 500/250
ENGINE (XCITING 250) (Cont’d)
Item Q‘ty Thread dia.
(mm) Torque N•m (kgf•m, lbf•ft) Remarks
DRIVE/DRIVEN PULLEY:
Drive face nut
Clutch outer nut
Clutch drive plate nut
Left crankcase cover bolt
ALTERNATOR
A.C.G. stator
Flywheel nut
FINAL REDUCTION:
Transmission case cover bolt
CRANKCASE:
Cam chain guide bolt
SWITCH:
Oil pressure switch
1
1
1
6
5
1
9
1
1
14
12
28
6
5
14
8
6
PT 1/8
93 (9.3, 67)
54 (5.4, 39)
54 (5.4, 39)
12 (1.2, 8.6)
9 (0.9, 6.5)
55 (5.5, 40)
20 (2, 14.4)
10 (1, 7)
22 (2.2, 16)
Apply oil
Apply seal

1. GENERAL INFORMATION
1-11
XCITING 500/250
FRAME
Item Q‘ty Thread dia.(mm)
Torque
N•m (kgf•m,
lbf•ft) Remarks
STEERING:
Handlebar bolt
Upper pinch bolt
Lower pinch bolt
Bridge stem nut
Steering stem lock nut
Top thread
WHEEL:
Front axle bolt
Front fork bolt
Rear axle nut (XCITING 500)
Rear axle nut (XCITING 250)
SUSPENSION:
Rear shock absorber bolt
Rear fork
BRAKE:
Front caliper mounting bolt
Rear caliper mounting bolt
Brake fluid bolt
Master cylinder bolt
ENGINE HANGER:
Engine hanger bolt
Engine mounting bolt/nut
(XCITING 500)
Engine mounting bolt/nut
(XCINTING 250)
Engine hanger rod nut
MUFFLER
Exhaust pipe nut
Muffler mount bolt
4
2
4
1
1
1
1
2
1
1
4
2
4
2
6
4
4
1
1
1
2
3
8
8
8
22
25.4
25.4
18
8
20
16
10
8
8
8
10
6
10
14
10
10
8
10
23 (2.3, 17)
23 (2.3, 17)
32 (3.2, 23)
62 (6.2, 45)
45 (4.5, 32)
17 (1.7, 12)
20 (2, 15)
23 (2.3, 17)
180 (18, 130)
140 (14, 100)
40 (4, 29)
32 (3.2, 23)
32 (3.2, 23)
32 (3.2, 23)
35 (3.5, 25)
12 (1.2, 9)
50 (5, 36)
80 (8, 58)
50 (5, 36)
35 (3.5, 25)
20 (2, 14)
35 (3.5, 25)
Replace a new one
Replace a new one

1. GENERAL INFORMATION
1-12
XCITING 500/250
SPECIAL TOOLS
XCITING 500
Tool Name Tool No. Remarks
Clutch spring compressor E053 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E054 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Oil filter cartridge wrench E052 Cartridge removal or install
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install
XCITING 250
Tool Name Tool No. Remarks
Clutch spring compressor E034 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E003 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install

1. GENERAL INFORMATION
1-13
XCITING 500/250
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Balancer shaft
Crankshaft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE 5W-50)
•API SJ Engine Oil
Drive gear shaft
Countershaft
Final gear
Final gear shaft
Transmission gearshaft bearing part
Transmission oil: SAE 90
A.C. generator connector Adhesive

1. GENERAL INFORMATION
1-14
XCITING 500/250
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Seat Loc
k
Grease
Throttle Cable
Engine Oil
Grease
Grease
Front/Rear Brake Lever Pivot
Grease
Grease
Rear Wheel Bearing Front Wheel Bearing
Center Stand/Side Stand Pivot

1. GENERAL INFORMATION
1-15
XCITING 500/250
CABLE & HARNESS ROUTING (XCITING 500)

1. GENERAL INFORMATION
1-16
XCITING 500/250

1. GENERAL INFORMATION
1-17
XCITING 500/250

1. GENERAL INFORMATION
1-18
XCITING 500/250

1. GENERAL INFORMATION
1-19
XCITING 500/250