KYMCO xciting 500 User Manual

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Manual (500 pages)

Service manual (349 pages)

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. GENERAL INFORMATION

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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

GENERAL INFORMATION

XCITING 500/250

1-0

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Summary of Contents for KYMCO xciting 500

Page 1 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...
Page 2: General Information
. GENERAL INFORMATION XCITING 500/250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...
Page 3 . GENERAL INFORMATION XCITING 500/250 SPECIFICATIONS (XCITING 500) ITEM SPECIFICATIONS ITEM SPECIFICATIONS Name XCITING 500 Air cleaner type & No Wet paper type element Overall length 2250 mm (90 in) Fuel capacity 12.8 L (3.38 lmp gal, Overall width 815 mm (33 in) 2.82 US gal...
Page 4 . GENERAL INFORMATION XCITING 500/250 SPECIFICATIONS (XCITING 250) ITEM SPECIFICATIONS ITEM SPECIFICATIONS Name XCITING 250 Air cleaner type & No Wet paper type element Overall length 2250 mm (90 in) 12.8 L (3.38 lmp gal, Fuel capacity Overall width 815 mm (33 in) 2.82 US gal...
Page 5 . GENERAL INFORMATION XCITING 500/250 Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. After reassembly, check all parts for proper tightening and operation.
Page 6 . GENERAL INFORMATION XCITING 500/250 If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.
Page 7 . GENERAL INFORMATION XCITING 500/250 After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight！ Do not squeeze wires against the weld or its clamp.
Page 8 . GENERAL INFORMATION XCITING 500/250 After routing, check that the wire harnesses Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use...
Page 9 27 (2.7, 20) 8mm flange bolt and nut 70 (7, 50) 10mm flange bolt and nut 40 (4, 29) 14mm bolt and nut Torque specifications listed below are for important fasteners. ENGINE (XCITING 500) Thread dia. Torque Item Q‘ty Remarks (mm) N•m (kgf•m, lbf•ft)
Page 10 . GENERAL INFORMATION XCITING 500/250 ENGINE (XCITING 500) (Cont’d) Thread dia. Torque Item Q‘ty Remarks (mm) N•m (kgf•m, lbf•ft) Drive plate nut 78 (7.8, 56) ALTERNATOR ACG flywheel nut 55 (5.5, 40) FINAL REDUCTION: Transmission cover bolt 27 (2.7, 20)
Page 11 . GENERAL INFORMATION XCITING 500/250 ENGINE (XCITING 250) (Cont’d) Thread dia. Torque Item Q‘ty Remarks (mm) N•m (kgf•m, lbf•ft) DRIVE/DRIVEN PULLEY: Apply oil 93 (9.3, 67) Drive face nut 54 (5.4, 39) Clutch outer nut 54 (5.4, 39) Clutch drive plate nut 12 (1.2, 8.6)
Page 12 17 (1.7, 12) WHEEL: Front axle bolt 20 (2, 15) Front fork bolt 23 (2.3, 17) Rear axle nut (XCITING 500) 180 (18, 130) Rear axle nut (XCITING 250) 140 (14, 100) SUSPENSION: Rear shock absorber bolt 40 (4, 29) Rear fork 32 (3.2, 23)
Page 13 . GENERAL INFORMATION 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...
Page 14 . GENERAL INFORMATION XCITING 500/250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE 5W-50) Valve guide/valve stem movable part •API SJ Engine Oil Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut...
Page 15 . GENERAL INFORMATION 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.
Page 16 . GENERAL INFORMATION XCITING 500/250 CABLE & HARNESS ROUTING (XCITING 500) 1-15...
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Page 26 . GENERAL INFORMATION XCITING 500/250 CABLE & HARNESS ROUTING (XCITING 250) 1-25...
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Page 34: Troubleshooting
. GENERAL INFORMATION XCITING 500/250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged carburetor fuel inlet tube, vacuum tube or fuel tube...
Page 35 . GENERAL INFORMATION XCITING 500/250 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel line between fuel tank and carburetor Engine speed does Engine speed Clogged exhaust muffler...
Page 36 . GENERAL INFORMATION XCITING 500/250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too rich (turn screw...
Page 37 . GENERAL INFORMATION XCITING 500/250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Correct timing Incorrect timing Faulty A.C. generator Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...
Page 38 . GENERAL INFORMATION XCITING 500/250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Worn piston pin and connecting rod small Piston noise Excessive carbon build-up in combustion chamber Damaged cam chain tensioner...
Page 39 . GENERAL INFORMATION XCITING 500/250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Engine starts but motor- Separated clutch lining cycle does not move Damaged driven pulley shaft splines...
Page 40 . GENERAL INFORMATION XCITING 500/250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight does not Faulty stop switch Stoplight comes on...
Page 41 . GENERAL INFORMATION XCITING 500/250 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness...
Page 42 . GENERAL INFORMATION XCITING 500/250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Faulty AC generator Voltage does not Normal voltage Faulty regulator/rectifier increase Faulty battery Measure resistance...
Page 43 . GENERAL INFORMATION XCITING 500/250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate...
Page 44 . GENERAL INFORMATION XCITING 500/250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play Front or rear wheel is...

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Xciting 250

KYMCO xciting 500 User Manual

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Summary of Contents for KYMCO xciting 500

Page 2: General Information

Page 34: Troubleshooting

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