KYMCO XCITING 500 Service Manual
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KYMCO XCITING 500 Service Manual

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XCITING 500/500 AFI/250/300 AFI
By KWANG YANG Motor Co., Ltd.
First Edition, Apr 2006
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-SB30AA-A1

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  • Page 1 XCITING 500/500 AFI/250/300 AFI By KWANG YANG Motor Co., Ltd. First Edition, Apr 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-SB30AA-A1...
  • Page 2 The information and contents included in this manual may be different from the motorcycle in case specifications are changed. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. KWANG YANG MOTOR CO., LTD.

  • Page 3: Table Of Contents

    __________________________________________________________________________________ SERIAL NUMBER----------------------------------------------------------- 1 - 1 SPECIFICATIONS (XCITING 500)--------------------------------------- 1 - 2 SPECIFICATIONS (XCITING 500 AFI) --------------------------------- 1 - 3 SPECIFICATIONS (XCITING 250)--------------------------------------- 1 - 4 SPECIFICATIONS (XCITING 300 AFI) --------------------------------- 1 - 5 SERVICE PRECAUTIONS ------------------------------------------------- 1 - 6...

  • Page 4: General Information

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

  • Page 5: Specifications (Xciting 500)

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 Imp gal, Overall width 815 mm (33 in) 2.82 US gal...

  • Page 6: Specifications (Xciting 500 Afi)

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI SPECIFICATIONS (XCITING 500 AFI) ITEM SPECIFICATIONS ITEM SPECIFICATIONS Name XCITING 500 AFI Air cleaner type & No Wet paper type element Overall length 2250 mm (90 in) 12.8 L (3.38 Imp gal, Fuel capacity...

  • Page 7: Specifications (Xciting 250)

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 Imp gal, Fuel capacity Overall width 815 mm (33 in) 2.82 US gal...

  • Page 8: Specifications (Xciting 300 Afi)

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI SPECIFICATIONS (XCITING 300 AFI) ITEM SPECIFICATIONS ITEM SPECIFICATIONS Name XCITING 300 AFI Air cleaner type & No Wet paper type element Overall length 2250 mm (90 in) 12.8 L (3.38 Imp gal, Fuel capacity...

  • Page 9: Service Precautions

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 10 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 11 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 12 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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.

  • Page 13: Torque Values

    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/XCITING 500 AFI) Thread dia. Torque Item Q‘ty Remarks (mm) N•m (kgf•m, lbf•ft)
  • Page 14 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI ENGINE (XCITING 500/XCITING 500 AFI) (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 15 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI ENGINE (XCITING 250/XCITING 300 AFI) (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 16 20 (2, 15) 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 17: Special Tools

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI SPECIAL TOOLS XCITING 500/XCITING 500 AFI Tool Name Tool No. Remarks Oil seal & bearing installers A120E00014 Oil seal & bearing install Lock nut socket wrench A120E00015 Steering stem removal or install Universal holder...

  • Page 18: Lubrication Points

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 19 . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI 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 20: Cable & Harness Routing (Xciting 500)

    . GENERAL INFORMATION XCITING 500/500 AFI/250/300 AFI CABLE & HARNESS ROUTING (XCITING 500) 1-17...

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Afi/250Afi/300

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