KYMCO XCITING 400i User manual

1. E xt e r na l Com p one nt s XCITING 400 i
1-1
E x t e r n a l C o m pon e n t s
This chapter covers the location and servicing of the external components for the
KYMCO XCITING 400i.
• Exhaust System 2-11
• Seat 12-13
• Luggage Box 14-16
• Rear Carrier 17-18
• Center Cover 19-20
• Side Covers 21-22
• Body Cover 23-32
• Front Cover 33-45
• Front Cover Meter 46-49
• Inner Cover 50-57
• Front Fender 58-60
• Rear Fender 61-66
• Handlebar Cover 67-71
• Under Cover 72-73

1. External components > E xha us t S ys t e m XCITING400
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1‐2
E
x h a u s t S ys t e m
S
A FETY FIRST : P r o t e c t i v e g l o v e s a nd e y e w ea r a r e r e c o mm e nd e d a t t h i s po i n t .
Ge
n e r a l I n s t r u c t i on s
• When removing frame covers, use care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
T
r oub l e s hoo t i ng
N
o i sy e x h a u s t m u ff l e r
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
L a ck o f po w e r
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Re
m o v a l

1. External components > E xha us t S ys t e m XCITING400
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1‐3
Remove the two exhaust pipe joint nuts with a 12 mm deep well socket.
Unplug the O
2 sensor connector.
Hea
t S h i e l d s
Remove the four muffler heat shield bolts with a 10 mm socket.

1. External components > E xha us t S ys t e m XCITING400
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1‐4
Remove the heat shield.
To remove the four bolts to free the heat shield on the muffler.

1. External components > E xha us t S ys t e m XCITING400
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1‐5
Remove the three muffler mounting bolts with a 14 mm socket.
Remove the exhaust system.

1. External components > E xha us t S ys t e m XCITING400
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1‐6
Remove the exhaust pipe gasket and discard it.
O
2 Se
n s o r
R
e m oval
Remove the O2 sensor with a 17 mm wrench.
Use care not to pinch the wires.

1. External components > E xha us t S ys t e m XCITING400
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1‐7
The O
2 sensor issues signal to ECU when the temperature is over 350°C while the engine
is running.
Test the O
2 sensor at room temperature.
Use a digital multimeter set to ohms of resistance to inspect the O2 sensor.
Measure the resistance between the white wire terminals of the
O
2
sensor connector. Replace the O
2 sensor if the reading is out
of specification.
I T E M SP EC I F I C A T I O N S
O
2
h ea t e r s e n s o r r e s i s t a nc e ( a t 20 ° C / 68 ° F )
6.7 - 9.5 Ω ( e ng i n e w a r m i ng cond i t i on )
I
n s t a ll a t i on
Hea
t S h i e l d s
Install the heat shields and tighten the bolts securely.

1. External components > E xha us t S ys t e m XCITING400
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1‐8
O
2 Se
n s o r
Apply anti-seize compound to the threads of the O
2 sensor.
Install the O
2 sensor and tighten it to specification with a 17 mm
wrench. Use care not to pinch the wires.
I t e m
T or qu e
N-m l b- ft
O
2
S e ns or 25 18

1. External components > E xha us t S ys t e m XCITING400
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E x h a u s t S ys t e m
Insert a new exhaust pipe gasket into the exhaust port.
Fit the exhaust system into place

1. External components > E xha us t S ys t e m XCITING400
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1‐10
Install the two exhaust pipe joint nuts with a 12 mm deep well socket.
Do not tighten.
Install the three muffler mounting bolts and tighten to specification
with a socket.
I t e m
T or qu e
N-m k gf -m
M uf f l e r M ount i ng Bolt s 40 4.0
Tighten the two exhaust pipe joint nuts to specification with a 12 mm
deep well socket.
I t e m
T or qu e
N-m k gf -m
E xha us t P i p e J oi nt N ut s 20 2.0