KYMCO XCITING 400i Manual
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KYMCO XCITING 400i Manual

KYMCO XCITING 400i Manual

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Table of Contents

1. External Components
External Components
This chapter covers the location and servicing of the external components for the
KYMCO XCITING 400i.
• Front Cover
1-1
XCITING 400i
2-11
12-13
14-16
17-18
19-20
21-22
23-32
33-45
46-49
50-57
58-60
61-66
67-71
72-73

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Table of Contents
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Summary of Contents for KYMCO XCITING 400i

  • Page 1: Table Of Contents

    XCITING 400i 1. External Components External Components 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 •...

  • Page 2: Exhaust System

    XCITING 400 i 1. External components > Exhaust System Exhaust System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. General Instructions • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.
  • Page 3 XCITING 400 i 1. External components > Exhaust System Remove the two exhaust pipe joint nuts with a 12 mm deep well socket. Unplug the O sensor connector. Heat Shields Remove the four muffler heat shield bolts with a 10 mm socket. 1‐3 ...
  • Page 4 XCITING 400 i 1. External components > Exhaust System Remove the heat shield. To remove the four bolts to free the heat shield on the muffler. 1‐4 ...
  • Page 5 XCITING 400 i 1. External components > Exhaust System Remove the three muffler mounting bolts with a 14 mm socket. Remove the exhaust system. 1‐5 ...
  • Page 6 XCITING 400 i 1. External components > Exhaust System Remove the exhaust pipe gasket and discard it. Sensor Removal Remove the O2 sensor with a 17 mm wrench. Use care not to pinch the wires. 1‐6 ...
  • Page 7 XCITING 400 i 1. External components > Exhaust System The O sensor issues signal to ECU when the temperature is over 350°C while the engine is running. Test the O 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 sensor connector.
  • Page 8 XCITING 400 i 1. External components > Exhaust System Sensor Apply anti-seize compound to the threads of the O sensor. Install the O sensor and tighten it to specification with a 17 mm wrench. Use care not to pinch the wires. Torque Item lb-ft...
  • Page 9 XCITING 400 i 1. External components > Exhaust System Exhaust System Insert a new exhaust pipe gasket into the exhaust port. Fit the exhaust system into place 1‐9 ...
  • Page 10 XCITING 400 i 1. External components > Exhaust System 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. Torque Item kgf-m Muffler Mounting Bolts...
  • Page 11 XCITING 400 i 1. External components > Exhaust System If the exhaust pipe and muffler were separated tighten the muffler clamp securely. Plug in the O sensor. 1‐11 ...

  • Page 12: Seat

    1. External Components > Seat XCITING 400i Seat SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Insert the key and turn it counterclockwise . Remove the two luggage box hinge nuts with a 10 mm socket.
  • Page 13 1. External Components > Seat XCITING 400i Installation Install the seat with the piston pivot onto the hinge. Install the two seat plastic screws from the front of body cover. Install the two luggage box hinge nuts and tighten securely with a 10 mm socket.

  • Page 14: Luggage Box

    1. External Components > Luggage Box XCITING 400i Luggage Box Removal Remove the four luggage nuts with a 10 mm socket. Remove the two luggage bolts with a 10 mm socket. 1-14...
  • Page 15 1. External Components > Luggage Box XCITING 400i Lift up the luggage box to unplug the luggage box light connector. Remove the luggage box. Installation Plug in the luggage box light connector. Install the luggage box. Install the two luggage bolts with a 10 mm socket.
  • Page 16 1. External Components > Luggage Box XCITING 400i Install the four luggage nuts and tighten securely with a 10 mm socket. 1-16...

  • Page 17: Rear Carrier

    1. External Components > Rear Carrier XCITING 400i Rear Carrier Removal Remove the four carrier bolts with a 6 mm Allen. Remove the carrier. 1-17...
  • Page 18 1. External Components > Rear Carrier XCITING 400i Installation Install the carrier. Install the two upper carrier bolts with a 6 mm Allen. Install the two carrier bolts on each side with a 6 mm Allen. 1-18...

  • Page 19: Center Cover

    1. External Components > Center Cover XCITING 400i Center Cover Removal Note: Do not force the cover and damage the claws. Remove the two seat plastic screws from the front of body cover. Remove the seat with the piston pivot.
  • Page 20 1. External Components > Center Cover XCITING 400i Pull the center cover back and up to free the claws and then move the cover backward to free it from the scooter. Remove the center cover. Installation Place the center cover on the scooter.

  • Page 21: Side Covers

    XCITING 400i 1. External Components > Side Covers Side Covers Removal Free the tabs on the left side covers. Free the tabs on the right side covers. Remove the side cover from the vehicle. 1-21...
  • Page 22 XCITING 400i 1. External Components > Side Covers Installation Fit the right side cover into place. Fit the right side cover tabs into their matching slots. Fit the left side cover into place. Fit the left side cover tabs into their matching slots.

  • Page 23: Body Cover

    1. External Components > Body Cover XCITING 400i Body Cover Removal Remove the upper body cover bolt with a 10 mm socket. Remove the two lower body cover nuts with a 10 mm socket. Remove the two license plate nuts with a 10 mm socket.
  • Page 24 1. External Components > Body Cover XCITING 400i Unplug the taillight connector. Carefully unhook the tabs on both sides of the body cover. 1-24...
  • Page 25 1. External Components > Body Cover XCITING 400i Remove the body cover. Disassembly Center cover Remove the two rear center cover screws. Remove the rear center cover. 1-25...
  • Page 26 1. External Components > Body Cover XCITING 400i Taillight Assembly Remove the ten taillight assembly screws with a #2 Phillips. 1-26...
  • Page 27 1. External Components > Body Cover XCITING 400i Unhook the taillight section and separate from the body cover. Remove the four mud flap screws with a #2 Phillips. Disconnect the license light wires with the harness wires. 1-27...
  • Page 28 1. External Components > Body Cover XCITING 400i Separate the mud flap from the taillight assembly. 1-28...
  • Page 29 1. External Components > Body Cover XCITING 400i License Light Remove the two license light cover screws with a screwdriver. Remove the license light cover. 1-29...
  • Page 30 1. External Components > Body Cover XCITING 400i Remove the two license light assembly screws with a screwdriver. Remove the two license light assembly 1-30...
  • Page 31 1. External Components > Body Cover XCITING 400i Installation Fit the body cover into place. Carefully push the hooks into the corresponding tabs on both sides of the body cover. 1-31...
  • Page 32 1. External Components > Body Cover XCITING 400i Plug in the taillight connector. Install the two license plate nuts with a 10 mm socket. Install the two lower body cover nuts and tighten securely with a 10 mm socket. Install the upper body cover bolts and tighten securely with a 10 mm socket.
  • Page 33 XCITING 400i 1. External Components > Front Cover Windshield Removal Remove four windshield cover bolts on both sides with a 10mm socket. 1-33...
  • Page 34 XCITING 400i 1. External Components > Front Cover Remove the four windshield bolts with a 10mm socket. There are two bolts on each side. Remove the windshield. 1-34...
  • Page 35 XCITING 400i 1. External Components > Front Cover Remove the center front cover mounting screw with a #2 Phillips Remove the push pin. Depress the head of the fastener center piece. Pull out the fastener. Carefully pull out the small silver cover.
  • Page 36 XCITING 400i 1. External Components > Front Cover Pull up the footboard rubber covers. Remove the right leg shield mounting screws with a #2 Phillips. Remove the left leg shield mounting screws with a #2 Phillips. Unplug the headlight and turn signal leads.
  • Page 37 XCITING 400i 1. External Components > Front Cover Gently pull the cover forward and free the tabs. Remove the front cover. Remove the six lower fairing push pins. Remove the lower fairing. 1-37...
  • Page 38 XCITING 400i 1. External Components > Front Cover Disassembly Light Assembly Remove the ten front side skirt mounting screws with a #2 Phillips. 1-38...
  • Page 39 XCITING 400i 1. External Components > Front Cover Remove the front side skirt. Remove the turn signal light assembly screws from the front cover. 1-39...
  • Page 40 XCITING 400i 1. External Components > Front Cover Remove the turn signal light assembly. Remove the headlight assembly screws from the front cover. Remove the headlight assembly. 1-40...
  • Page 41 XCITING 400i 1. External Components > Front Cover Assembly Light Assembly Install the light assembly on the front cover. Install the headlight assembly mounting screws and tighten securely with a #2 Phillips. 1-41...
  • Page 42 XCITING 400i 1. External Components > Front Cover Install the turn signal light assembly. install the turn signal light assembly screws from the front cover. 1-42...
  • Page 43 XCITING 400i 1. External Components > Front Cover Install the front side skirt. Install the ten front side skirt mounting screws with a #2 Phillips. 1-43...
  • Page 44 XCITING 400i 1. External Components > Front Cover Installation Plug in the headlight and turn signal leads. Align front cover tabs. Install the front cover. Install the four front cover mounting screws and tighten securely with a #2 Phillips. There are two screws on each side.
  • Page 45 XCITING 400i 1. External Components > Front Cover Install the left leg shield mounting screws with a #2 Phillips. Install the right leg shield mounting screws with a #2 Phillips. Install the center front cover mounting screw with a #2 Phillips Align the two posts with the grommets.

  • Page 46: Front Cover Meter

    1. External Components > Front Cover Meter XCITING 400i Front Cover Meter Removal Remove the four cover windshield bolts with a 6mm Allen. There are two bolts on each side. Remove the left/right cover windshield. 1-46...
  • Page 47 1. External Components > Front Cover Meter XCITING 400i Remove the two nuts mounting on the front cover meter on both side. Remove the two screws mounting on the front cover meter on both side. Remove the front cover meter...
  • Page 48 1. External Components > Front Cover Meter XCITING 400i Install Install the front cover meter Install the two screws mounting on the front cover meter on both side. Install the two nuts mounting on the front cover meter on both side.
  • Page 49 1. External Components > Front Cover Meter XCITING 400i Install the four cover windshield bolts with a 6mm Allen. There are two bolts on each side 1-49...

  • Page 50: Inner Cover

    1. External Components > Inner Cover XCITING 400i Inner Cover Removal Remove the three mounting bolts on right side with a 10 mm socket. Remove the mounting screw with a #2 Phillips on right side. Lift off the right footboard.
  • Page 51 1. External Components > Inner Cover XCITING 400i Remove the three mounting bolts on left side with a 10 mm socket. Remove the mounting screw with a #2 Phillips on left side. Lift off the left footboard. 1-51...
  • Page 52 1. External Components > Inner Cover XCITING 400i Remove the two screws below the handlebar. Gently separate the inner cover from the meter cover and free the tabs. 1-52...
  • Page 53 1. External Components > Inner Cover XCITING 400i Remove the bolt mounting the ignition switch and then collar ignition switch. Remove the fuel cap with the key. Remove the gas cap overflow pad. Remove the connector output voltage device. Remove the bottom hose is the overflow hose that runs to the filler neck.
  • Page 54 1. External Components > Inner Cover XCITING 400i Remove the inner cover. Installation Install the inner cover and align the bolt holes. 1-54...
  • Page 55 1. External Components > Inner Cover XCITING 400i Install the bottom hose is the overflow hose that runs to the filler neck. Install the connector output voltage device. Install the bolt mounting the ignition switch and then collar ignition switch.
  • Page 56 1. External Components > Inner Cover XCITING 400i Install the two screws below the handlebar. Install the left footboard. 1-56...
  • Page 57 1. External Components > Inner Cover XCITING 400i Install the right footboard. Install the three mounting bolts on right side with a 10 mm socket. Install the mounting screw with a #2 Phillips on right side. 1-57...

  • Page 58: Front Fender

    1. External Components > Front Fender XCITING 400i Front Fender Removal Note: The front fender is held in place with four bolts, two on each side. Remove the forward front fender bolts with a 6 mm Allen on both side.
  • Page 59 1. External Components > Front Fender XCITING 400i Remove the left forward front fender bolt with a 10 mm socket. Remove the front fender from the forks. 1-59...
  • Page 60 1. External Components > Front Fender XCITING 400i Installation Guide the fender between the forks. Install the forward front fender bolts with a 6 mm Allen on both side. Install the forward front fender bolts with a 10 mm socket on both side.

  • Page 61: Rear Fender

    1. External Components > Rear Fender XCITING 400i Rear Fender Removal Remove the two right fender mounting bolts with a 10 mm socket. Remove the left fender mounting bolts with a 10 mm socket on the back side. 1-61...
  • Page 62 1. External Components > Rear Fender XCITING 400i Remove the left fender mounting bolts with a 8 mm socket on the front side. Remove the screw mounting the connecting tube airbox. Disconnect the blow-by tube mounting the cylinder head with a splicer.
  • Page 63 1. External Components > Rear Fender XCITING 400i Disconnect the blow-by tube mounting the transmission box assy. Remove the left fender mounting bolts with a 10 mm socket on the front side. Remove the airbox . Remove the rear fender.
  • Page 64 1. External Components > Rear Fender XCITING 400i Installation Install the rear fender. Install the left fender mounting bolts with a 10 mm socket on the front side. onnect the blow-by tube mounting the transmission box assy. 1-64...
  • Page 65 1. External Components > Rear Fender XCITING 400i onnect the blow-by tube mounting the cylinder head with a splicer. Install the screw mounting the connecting tube airbox. Install the left fender mounting bolts with a 8 mm socket on the front side.
  • Page 66 1. External Components > Rear Fender XCITING 400i Install the left fender mounting bolts with a 10 mm socket on the back side. Install the two right fender mounting bolts with a 10 mm socket. 1-66...

  • Page 67: Handlebar Cover

    1. External Components > Handlebar Cover XCITING 400i Handlebar Covers Removal Upper Cover Remove the two upper handlebar cover screws with a #2 Phillips. Carefully free the tabs and remove the upper handlebar cover. 1-67...
  • Page 68 1. External Components > Handlebar Cover XCITING 400i Lower Cover 1-68...
  • Page 69 1. External Components > Handlebar Cover XCITING 400i Remove the two lower handlebar cover screws with a #2 Phillips. Route the throttle cables out of the handlebar cover. Remove the lower cover. 1-69...
  • Page 70 1. External Components > Handlebar Cover XCITING 400i Installation Place the lower cover onto the handlebar. Route the throttle cables into the handlebar cover. Install the two lower handlebar cover screws with a #2 Phillips. 1-70...
  • Page 71 1. External Components > Handlebar Cover XCITING 400i Install the tabs and the upper handlebar cover. Install the two upper handlebar cover screws with a #2 Phillips. 1-71...

  • Page 72: Under Cover

    1. External Components > Under Cover XCITING 400i Under Cover Removal Remove the two under cover screws on both sides with a 10 mm socket. Remove the two under cover bolts on both sides with a 10 mm socket. Remove the under cover.
  • Page 73 1. External Components > Under Cover XCITING 400i Installation Install the under cover. Install the two undercover bolts on both sides and then tighten securely with a 10 mm socket. Install the two under cover screws on both sides with a 10 mm socket.

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