KYMCO XCITING S 400 User manual

1.Quick Reference XCITING S 400
1-1
1. Quick Reference
This chapter provides a quick reference source of technical specifications and
information for KYMCO XCITING S 400 model.
Component Location ........................................................1-2
Special Tools ..................................................................... 1-5
Specifications ....................................................................1-6
Torque Specifications .......................................................1-12
Troubleshooting ................................................................ 1-15
VIN and Engine Number Location ....................................1-20

1.Quick Reference XCITING S 400
1-2
Component Location
Regulator/Rectifier
Hazard Controller
ECU
Ignition Coil
Coolant Reserve Tank
Ignition Switch
Radiator
Fuel Tank
Air Cleaner/Element
Canister
Muffler
Front Wheel Speed
Sensor Connector
Horn
FUSE BOX
O2 Sensor
Side Standard Switch
Seat Open Motor
Spark Plug
Battery
Starter Relay

1.Quick Reference XCITING S 400
1-3
Component Location
Throttle Body
Fuel Pump
Winker Relay
(Turn Signal)
Tilt Switch
Diagnostic Tool Connector
Battery
Fuel Cap
ABS ECU
Meter Instrument Couplers
Fuse Box
Battery Box

1.Quick Reference XCITING S 400
1-4
Component Location
Fuel Pump
MAP Sensor
ISC (Idle Speed Controller)
Throttle Body
TPS(Throttle
Position Sensor)
Seat Open Motor Relay/ Starter Relay/ Fuel Pump Relay/ ECU Relay/ Fan Relay
(The location refer to the wiring diagram wire color)

1.Quick Reference XCITING S 400
1-5
Special Tools
ITEM TOOL NO DESCRIPTION
Puller (M28x1) TAPPET ADJUSTER A120E00036 Adjusting valve clearance
OILSEAL&BEARINGDRIVER
A120E00014
GeneralDriverSet
UNIVERSAL HOLDER A120E00021 Holdingclutchpulleyandflywheel
#41NUTANDFITTINGTOOL A120E00028 Clutch disassembly
THREAD PROTECTOR A120E00029 Crankshaft thread protector
CYLINDER COMPRESSION GAUAGE A120E00039 Engine cylinder compression measure
FUEL PRESSURE GAUAGE
A120E00048
Fuel pump output pressure measure
VALVE COTTER INSTALLER A120E00051 Valvecotterinstallation
CLUTCH SPRING COMPRESSOR A120E00053 Clutch disassembly
BEARING PULLER A120E00093 GeneralPullerSet
VALVE CLEAN TOOL SET A120E00096 Valve&Valveseatcleaning
FLYWHEEL PULLER
A120E00097
Flywheel removal
STEERINGSTEMLOCKNUTWRENCH(32mm) A120F00002 Steeringstemremoval&installation
LOWER/UPPER OUTER RACE SEPARATOR A120F00009 Lower/Upper outer race removal
LOWER/UPPER RACE REMOVER & INSTALLER A120F00019 Lower/Upper outer race installation
STEERING STEM TOP THREAD WRENCH
(46.5mm)
A120F00029 Steeringstemremoval&installation
PLIERS FUEL PIPE A120F00031
Fuelpumpoutputpressuremeasure&
Injector cleaning
ELECTRIC REPAIR KIT A120F00032 Troubleshooting electric system
RADIATOR PRESSURE GAUAGE
A120F00035
Radiator pressure measure
USB LINKER 3620A-LGJ9-E00 Diagnostic tool software upgraded
POWER WIRES 32143-LGJ9-E00 Diagnostic tool power connection
INJECTOR CLEANER 32143-LEA7-9000 Injector cleaning

1.Quick Reference XCITING S 400
1-6
General Information
Name & Model No.
ADG5
Motorcycle Name & Type
XCITING S 400
Overall length (mm)
2190
Overall width (mm)
800
Overall height (mm)
1345
Wheel base (mm)
1565
Engine type
4 stroke SOHC
Displacement (cc)
400
Fuel recommended
95 # nonleaded gasoline
Dry weight (kg)
Front wheel
82
Rear wheel
113
Total
195
Max. weight capacity (kg)
Front wheel
127
Rear wheel
251
Total
378
Tires
Front wheel
120/70-15
Rear wheel
150/70-14
Ground clearance (mm)
120
Performance
Braking distance (m)
12.3m/50km/hr
Min. turning radius
2500mm
Engine
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
SINGLE CYLINDER
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C. 4V Chain drive
Bore x stroke (mm)
84 x 72.1
Compression ratio
10.8:1
Compression pressure
15 (kg/cm2), 213 (psi)
Max. Horsepower
35 / 7500 PS/rpm
Max. Torque
36 / 6000 N-m/rpm
Valve timing
Intake
Open
0° BTDC
Close
35° ABDC
Exhaust
Open
45° BBDC
Close
0°ATDC
Valve clearance (cold) (mm)
Intake
0.10
Exhaust
0.10
Idle speed (rpm)
1400 ± 100
Lubrication System
Lubrication type
Forced pressure & Wet
Oil pump type
Inner/outer rotor type
Oil filter type
Full-flow filtration
Oil capacity
1.5 liter
Cooling Type
Liquid cooling

1.Quick Reference XCITING S 400
1-7
Fuel System
Air cleaner type & No
Paper element, wet
Fuel capacity
12.5 liter
Injection
Brand
Keihin
Type
Throttle body
Venturi dia.(mm)
40.5
Fuel pump pressure
3.0 Bar
Electrical
Equipment
Ignition
System
Type
ECU
Spark plug
Spec
CR7E (NGK)
Gap
0.7~0.8mm
Battery Capacity
12V10AH
Power Drive
System
Clutch Type
Dry multi-clutch
Transmission Gear
Type
CVT
Operation
Automatic centrifugal type
Reduction Gear
Type
Two-stage reduction
Reduction
ratio
1st
2.4~0.8
2nd
6.967
Moving Device
Tire type
Tubeless
Wheel material
Aluminum
Tire pressure
Front
2.0 (28.4)
Rear
2.25 (32)
Handle turning angle(L/R)
Left
40°
Right
40°
Brake system type
Front
Dual Disc brake
Rear
Single Disc brake
Damping
Device
Suspension type
Front
Telescope
Rear
Unit swing with 5-steps preload
adjustment
Shock absorber stroke
Front
110 mm
Rear
107 mm
Frame type
STEELL PIPE
ENGINE
Throttle grip free play
2 ~ 6 mm
Spark plug
NGK: CR7E
Spark plug gap
0.7~0.8 mm
Valve clearance
IN: 0.10 mm
EX: 0.10 mm
Idle speed
1400 ± 100 rpm
Cylinder compression
15 kg/cm2
213 psi
Ignition timing
ECU
Coolant type
Coolant type
Engine oil capacity
At disassembly
1.5 Liter
At change
1.3 Liter
Gear oil type:
SAE 90
Gear oil capacity
At disassembly
0.23 Liter
At change
0.21 Liter

1.Quick Reference XCITING S 400
1-8
Cooling System
Radiator cap relief
0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
Thermostat
temperature
Begins to open
71 °C
Full-open 80 °C
Valve lift
3.5 - 4.5 mm
Coolant capacity Total 1700 cc
Radiator: 1450 cc
Reserve tank: 250 cc
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS
Freezing Point Mixing Rate
KYMCO SIGMA Coolant
Concentrate
Distilled Water
-9°C
20%
340 cc
1360 cc
-15°C 30% 510 cc 1190 cc
-25'°C
40%
680 cc
1020 cc
-37°C
50%
850 cc
850 cc
-44.5°C 55% 935 cc 765 cc

1.Quick Reference XCITING S 400
1-9
COOLANT GRAVITY CHART
Temp. C°
Coolant
0
5
10
15
20
25
5%
1.009
1.009
1.008
1.008
1.007
1.006
10%
1.018
1.107
1.017
1.016
1.015
1.014
15%
1.028
1.027
1.026
1.025
1.024
1.022
20%
1.036
1.035
1.034
1.033
1.031
1.029
25%
1.045
1.044
1.044
1.042
1.040
1.038
30%
1.053
1.051
1.051
1.049
1.047
1.045
35%
1.063
1.065
1.060
1.058
1.056
1.054
40%
1.072
1.070
1.068
1.066
1.064
1.062
45%
1.080
1.078
1.076
1.074
1.072
1.069
50%
1.086
1.084
1.082
1.080
1.077
1.074
55%
1.095
1.093
1.091
1.088
1.085
1.082
60%
1.100
1.098
1.095
1.092
1.089
1.086
Temp. C°
Coolant
30 35 40 45 50
5%
1.005
1.003
1.001
0.009
0.99
10%
0.013
1.011
1.009
1.007
1.005
15%
1.020
1.018
1.016
1.014
1.012
20%
1.027
1.025
1.023
1.021
1.019
25%
1.036
1.034
1.031
1.028
1.025
30%
1.043
1.041
1.038
1.035
1.032
35%
1.052
1.049
1.046
1.043
1.040
40%
1.059
1.056
1.053
1.050
1.047
45%
1.056
1.063
1.062
1.057
1.054
50%
1.071
1.068
1.065
1.062
1.059
55%
1.079
1.076
1.073
1.070
1.067
60%
1.083
1.080
1.077
1.074
1.071

1.Quick Reference XCITING S 400
1-10
Fuel Injection System
ITEM
SPECIFICATIONS
Throttle body identification number
ADG5
Idle speed
1400 ± 100 rpm
Throttle grip free play
2 - 6 mm (1/16 - 1/4 in)
Fuel injector resistance (at 20°C/68°F) 9.9 – 13.5 Ω approx.
Fuel pump resistance(at 20°C/68°F) 1.9±0.3Ω
Fuel pump standard pressure (at 40L/Hr) 294 ± 6 kPa (3 Bar)
Water temperature sensor resistance 2.076 KΩ ± 10% (25°C)
Intake pressure sensor (MAP) pressure(at 1 - 4.2 V) 34 – 40 kpa
Inductive ignition coil
Primary: 3.57 - 4.83Ω Secondary: 0.42~14.49KΩ
Throttle position sensor (TPS) resistance (at
20°C/68°F)
3500Ω - 6500Ω
Crank position sensor voltage (at 200rpm) 100Ω - 130Ω
O2 heater sensor resistance (at 20C/68°F)
6.7 - 9.5Ω (engine warming condition)
Tilt switch voltage
Standard 0.4 - 1.4 V
Over 65° (fall down)
3.7 - 4.4 V

1.Quick Reference XCITING S 400
1-11
Axle/Brakes/Wheels
Item
Standard mm (in)
Service Limit mm (in)
Axle shaft run out
–
0.2 (0.008)
Brake disk thickness (front)
3.8 - 4.2 (0.15 - 0.17)
3 (0.12)
Brake disk thickness (rear)
4.8 - 5.2 (0.19 - 0.20)
4 (0.16)
Brake disk run out
–
0.03 (0.012)
Brake master cylinder I.D
12.7 - 12.74(0.508 - 0.5096)
–
Brake master cylinder piston O.D.
12.65 - 12.68(0.506 - 0.5072)
–
Front brake caliper cylinder I.D
25.4(1.0)
–
Brake lining thickness
5.4(0.21)
–
Item
Standard (mm)
Wheel rim run out service limit
max 5
Rear brake disk thickness
5.0
Rear brake disk run out
max 0.4
Rear brake caliper piston O.D.
25.33 - 25.36
Rear brake caliper cylinder I.D.
25.40 - 25.45

1.Quick Reference XCITING S 400
1-12
Torque Engine Specifications

1.Quick Reference XCITING S 400
1-13
Torque Frame Specifications

1.Quick Reference XCITING S 400
1-14
General Torque Specifications
Item
Torque
kgf-m
lb-ft
5 mm bolt, nut
0.45 - 0.6
3.25 - 4.34
6 mm bolt, nut
0.8 - 1.2
5.79 - 8.68
8 mm bolt, nut
1.8 - 2.5
13.02 - 18.08
10 mm bolt, nut
3.0 - 4.0
21.70 - 28.93
12 mm bolt, nut
5.0 - 6.0
36.17 - 43.40
5 mm screw
0.45 - 0.6
3.25 - 4.34
6 mm screw, SH bolt
0.7 - 1.1
5.06 - 7.96
6 mm flange bolt, nut
1.0 - 1.4
7.23 - 10.13
8 mm flange bolt, nut
2.4 - 3.0
17.36 - 21.70
10 mm flange bolt, nut
3.0 - 4.5
21.70 - 32.55

1.Quick Reference XCITING S 400
1-15
Troubleshooting
Vehicle can not be started
Preliminary 6 Step Inspection
1. Is the battery fully charged (12 V or higher). See the Battery topic for more
information.
2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn
off automatically in 5-10 seconds)
3. Key-On to check for any failure lamp light up on dashboard. See
theSelf-Diagnosis topic for more information.
4. Is the Idle screw of Throttle Valve being changed or loose?
5. Has the vehicle under regular service? Is the gas station a good one?
6. Is the spark plug the correct model of specified by the vehicle builder? See
the Spark Plug topic for more information.

1.Quick Reference XCITING S 400
1-16
General Troubleshooting

1.Quick Reference XCITING S 400
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1.Quick Reference XCITING S 400
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1.Quick Reference XCITING S 400
1-19

1.Quick Reference XCITING S 400
1-20
VIN and Engine Number Location