KYMCO XCITING 500 User manual

1. GENERAL INFORMATION
1-0
XCITING 500/250
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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