KYMCO XCITING S 400 Manual

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1.Quick Reference

XCITING S 400

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

1-1

Table of Contents

Troubleshooting

Summary of Contents for KYMCO XCITING S 400

Page 1 1.Quick Reference XCITING S 400 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 ..............
Page 2 1.Quick Reference XCITING S 400 Component Location Regulator/Rectifier Air Cleaner/Element Seat Open Motor Spark Plug Fuel Tank Ignition Coil Horn Side Standard Switch Coolant Reserve Tank Hazard Controller Ignition Switch Front Wheel Speed Canister Sensor Connector Starter Relay Battery FUSE BOX...
Page 3 1.Quick Reference XCITING S 400 Component Location Meter Instrument Couplers Winker Relay (Turn Signal) Battery Tilt Switch ABS ECU Fuel Cap Battery Box Fuse Box Fuel Pump Throttle Body Diagnostic Tool Connector...
Page 4 1.Quick Reference XCITING S 400 Component Location MAP Sensor Throttle Body ISC (Idle Speed Controller) 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)
Page 5 1.Quick Reference XCITING S 400 Special Tools ITEM TOOL NO DESCRIPTION Puller (M28x1) TAPPET ADJUSTER A120E00036 Adjusting valve clearance OIL SEAL & BEARING DRIVER A120E00014 General Driver Set UNIVERSAL HOLDER A120E00021 Holding clutch pulley and flywheel #41 NUT AND FITTING TOOL...
Page 6 1.Quick Reference XCITING S 400 General Information Name & Model No. ADG5 Motorcycle Name & Type XCITING S 400 Overall length (mm) 2190 Overall width (mm) Overall height (mm) 1345 Wheel base (mm) 1565 Engine type 4 stroke SOHC Displacement (cc)
Page 7 1.Quick Reference XCITING S 400 Air cleaner type & No Paper element, wet Fuel capacity 12.5 liter Brand Keihin Type Throttle body Fuel System Venturi dia.(mm) 40.5 Injection Fuel pump pressure 3.0 Bar Type Ignition Spec CR7E (NGK) Electrical Spark plug System 0.7~0.8mm...
Page 8 1.Quick Reference XCITING S 400 Cooling System Radiator cap relief 0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi) Begins to open 71 °C Full-open 80 °C Thermostat temperature Valve lift 3.5 - 4.5 mm Radiator: 1450 cc Coolant capacity Total 1700 cc...
Page 9 1.Quick Reference XCITING S 400 COOLANT GRAVITY CHART Temp. C° Coolant 1.009 1.009 1.008 1.008 1.007 1.006 1.018 1.107 1.017 1.016 1.015 1.014 1.028 1.027 1.026 1.025 1.024 1.022 1.036 1.035 1.034 1.033 1.031 1.029 1.045 1.044 1.044 1.042 1.040 1.038...
Page 10 1.Quick Reference XCITING S 400 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.
Page 11 1.Quick Reference XCITING S 400 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)
Page 12 1.Quick Reference XCITING S 400 Torque Engine Specifications 1-12...
Page 13 1.Quick Reference XCITING S 400 Torque Frame Specifications 1-13...
Page 14 1.Quick Reference XCITING S 400 General Torque Specifications Torque Item 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...
Page 15 1.Quick Reference XCITING S 400 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.
Page 16 1.Quick Reference XCITING S 400 General Troubleshooting 1-16...
Page 17 1.Quick Reference XCITING S 400 1-17...
Page 18 1.Quick Reference XCITING S 400 1-18...
Page 19 1.Quick Reference XCITING S 400 1-19...
Page 20 1.Quick Reference XCITING S 400 VIN and Engine Number Location 1-20...
Page 21 2.Periodic Maintenance XCITING S 400 2.Periodic Maintenance This chapter covers the periodic maintenance for the KYMCO XCITING S 400. Maintenance Schedule ............2-2 Air Filter Servicing ............. 2-4 Brake Fluid ................. 2-5 Brake Inspection ............... 2-9 Coolant ................2-15 Engine Oil ................2-19 General Lubrication ............
Page 22 Your KYMCO dealer meets all of these requirements. * Should be serviced by your KYMCO dealer, unless you have the proper tools, service data and are technically qualified. ** In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
Page 23 2.Periodic Maintenance XCITING S 400...
Page 24 2.Periodic Maintenance XCITING S 400 Air Filter Servicing Replace Air Filter as specified in Regular Maintenance Schedule. Check and replace Air Filter Cartridge more frequently if vehicle is often used in dusty environments or damp areas. Replace Air Filter Cartridge 1.
Page 25 XCITING S 400 Brake Fluid The KYMCO XCITING S 400 uses DOT 4 brake fluid that should be inspected after 3,000 mi (5,000 km) of use. It should be flushed and bled every 12 months, 6,000 mi (10,000 km), whenever the brakes feel spongy, or if the brake system has been taken apart and rebuilt.
Page 26 2.Periodic Maintenance XCITING S 400 Replenishing Brake Fluid 1. Straighten the Handlebar, remove 2 fixing screws of Reservoir and remove Reservoir Cover. 2. Replenish Reservoir with recommended DOT-4 Brake Fluid to the Upper Scale. Replace Reservoir Cover and tighten 2 fixing screws.
Page 27 2.Periodic Maintenance XCITING S 400 Draining The brake bleeding process is the same for the front and rear brakes. Remove the two master cylinder cover screws with a #2 Phillips head screwdriver. Remove the master cylinder cover, plastic piece and rubber accordion diaphragm.
Page 28 2.Periodic Maintenance XCITING S 400 Pump the brake lever several times and hold the lever in. While holding the lever in, crack open the bleeder valve. The front brake lever will travel all the way to the grip and brake fluid and/or air will come out of the bleeder valve into the 6 mm hose.
Page 29 2.Periodic Maintenance XCITING S 400 Brake Inspection Brake Lever Adjuster There is adjuster on each brake lever. Each adjuster has four positions so that the released lever position can be adjusted to suit the rider’s hands.To adjust the distance of the lever from the handlebar grip, push the lever forward and turn the adjuster knob to align the number with the arrow mark on the lever holder.
Page 30 2.Periodic Maintenance XCITING S 400 Brake Pad ◆ Is braking effective? ◆ Verify braking effect of front and rear brakes in low speed. Caliper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Brake Pads Push the caliper body inward to push in the pistons.
Page 31 2.Periodic Maintenance XCITING S 400 Remove the two caliper mounting bolts with a 12 mm socket. Discard the brake caliper mounting bolts. Remove the front brake caliper. The brake calipers are each mounted to the front fork with two bolts.
Page 32 2.Periodic Maintenance XCITING S 400 Free the brake pads from the pad retainer. Remove the brake pads. Remove the brake pad Clips with a splcier. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Always replace brake pads as a set.
Page 33 2.Periodic Maintenance XCITING S 400 Caliper Place a suitable container under the banjo bolt to catch any remaining brake fluid. Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket. Discard the two sealing washers.
Page 34 2.Periodic Maintenance XCITING S 400 Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.
Page 35 2.Periodic Maintenance XCITING S 400 Coolant For the sake of safety, check level of cooling water before riding the vehicle. Replace the cooling liquid as specified in Regular Maintenance Schedule. Check Level of Cooling Water 1. Park the vehicle on level ground and brace it up with Main Stand.
Page 36 In case of fault of vehicle: Go to a KYMCO dealer for check and repair if any fault occurs when riding the vehicle. Use only original parts for replacement. Check following items if engine does not start or engine stops when riding the vehicle: ◆...
Page 37 When the coolant has fished draining return the drain bolt to the water pump with a new sealing washer. Tighten the drain bolt securely with an socket. Fill the cooling system with a mix of distilled water and KYMCO SIGMA Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown.
Page 38 2.Periodic Maintenance XCITING S 400 Add coolant to the reserve tank until it reaches the upper level mark. Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes.
Page 39 2.Periodic Maintenance XCITING S 400 Engine Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Caution: Hot engine oil can burn. Avoid letting used motor oil contact exposed skin. TROUBLESHOOTING Oil level too low 1. Natural oil consumption 2.
Page 40 2.Periodic Maintenance XCITING S 400 Oil Level Inspection Check the engine oil level each day before operating the scooter. Place the motorcycle upright on level ground for engine oil level check. Run the engine for 2 ~ 3 minutes and check the oil level after the engine is stopped for 2 ~ 3 minutes.
Page 41 Applicable Temperature of Engine Oil NOTICE ◆ To avoid using poor quality oil, please go to a KYMCO dealer for oil change. Oil Change Method 1. Remove Oil Scale. Remove Drain Cock. Drain all the oil. Warming up the engine before changing oil facilitates oil draining.
Page 42 ◆ Do not mix-use oils of different brand, class or low quality ones; they may cause engine faults. ◆ Kymco Emissary Engine Oil contains additives (e.g., spirits, etc.) during the manufacturing process. ◆ Arbitrarily mixing additives bought from the market may deteriorate the oil, affect lubricating properties and shorten the service life of engine.
Page 43 2.Periodic Maintenance XCITING S 400 General Lubrication SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The frame lubrication points are listed below. Use general purpose grease. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and increase the durability of the motorcycle.
Page 44 2.Periodic Maintenance XCITING S 400 Side Stand Interlock Function Check Your scooter's side stand is not only necessary when you park, but it contains an important safety feature. This feature cuts-off the ignition if you try to ride the scooter when the side stand is down. Perform the following side stand inspection.
Page 45 2.Periodic Maintenance XCITING S 400 Spark Plug remove the spark plug wire off of the spark plug. Remove the connectors of the ignition coil. Remove the two ignition coil mounting bolts and remove the ignition coil. Clean off the area surrounding the spark plug with compressed air or a shop towel to make sure debris doesn't get into the combustion chamber when the spark plug is removed.
Page 46 2.Periodic Maintenance XCITING S 400 Check the spark plug to see if it is the correct type and gapped properly. If the spark plug is black and fouled, replace it. If the spark plug center electrode or side electrode are corroded or damaged, or if the insulator is cracked, replace the plug.
Page 47 2.Periodic Maintenance XCITING S 400 Engine Compression Test SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the under cowl set. See the external topic for more information. Before testing the compression make sure the cylinder head bolts are tightened securely and the valve clearance is specification.
Page 48 2.Periodic Maintenance XCITING S 400 Steering Inspection Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. See the Steering Stem Removal topic for more information.
Page 49 2.Periodic Maintenance XCITING S 400 Throttle Free Play Inspection Closed Resistance First Felt Check the throttle cable free play by gently rotating the throttle grip back until resistance is felt. Throttle grip free play 2 ~ 6 mm Make sure the throttle moves smoothly and returns on its own. Start the engine and let it warm up.
Page 50 2.Periodic Maintenance XCITING S 400 Parking Brake Adjustment Release the fixed nut, and rotate the adjust nut to adjust the parking brake. Fixed nut Adjust nut Note: Do not use the rear brake lock lever while driving. 9-30...
Page 51 Kymco dealer for replacing with new one. Excessive wear of tire tread pattern will result in widened tread which is more prone to be punctured.
Page 52 2.Periodic Maintenance XCITING S 400 Valve Clearance The valve clearance specification is only relevant if the engine is cold. Inspection Remove the timing inspection cap from the left side of the engine. And rotate the crankshaft from the right side of the engine.
Page 53 2.Periodic Maintenance XCITING S 400 For correct engine timing the marks on the camshaft sprocket must be even with the cylinder head mating surface at the same time the "T" mark is lined up with the with the index notch in the timing inspection hole.
Page 54 2.Periodic Maintenance XCITING S 400 Measure the valve clearance with a thickness feeler gauge. Insert the feeler gauge between the tappet adjusting screw and the valve stem. The clearance is correct when there is a light drag on the feeler gauge. The clearance is the same for the exhaust and intake valves.
Page 55 2.Periodic Maintenance XCITING S 400 SPECIAL TOOLS ITEM TOOL NO. DESCRIPTION TAPPET ADJUSTER A120E000012 Tappet adjustment Place a 9 mm box end wrench over the locknut, and loosen the locknut. If the valve clearance is tight back out the valve tappet adjusting screws with the tappet adjustment tool.
Page 56 2.Periodic Maintenance XCITING S 400 Make sure the O-rings on the timing plugs are in good condition. Replace it as needed. Install the timing inspection to the right side of the engine. Tighten the caps securely but not overly with a large flat blade screwdriver.
Page 57 XCITING S 400 3.External Components This chapter covers the location and servicing of the external components for the KYMCO XCITING S 400 model. General Instructions ............... 3-2 Windscreen Cover/Windscreen/ Front Meter Cover..... 3-4 Leg Shield Lid / Front Cover Set ..........3-5 Back Mirror/ Mats Of Floor/ Side Cover Set ........
Page 58 3.External Components XCITING S 400 General Instructions • 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...
Page 59 3.External Components XCITING S 400 Dismantled and assembly order Follow the dismantled order as below illustration. Assembly is reverse of dismantled order. Note: • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.
Page 60 3.External Components XCITING S 400 Windscreen Cover Removal Remove four fasteners and remove the windscreen covers. Windscreen Removal Remove four bolts and remove the windscreen. Front Meter Cover Removal Remove screws and remove the front meter cover.
Page 61 3.External Components XCITING S 400 Leg Shield Lid Removal Remove two fasteners and remove the right and left leg shield lids. Front Cover Set Removal Remove nuts, screws and coupler, remove the front cover set.
Page 62 3.External Components XCITING S 400 Back Mirror Removal Remove four bolts and remove the back mirrors. Mats Of Floor Removal Remove four mats of floor. Side Cover Set Removal Remove screws, fasteners and remove the left and right side cover sets.
Page 63 3.External Components XCITING S 400 Under Cowl Removal Remove 4 screws, 6 small fasteners and remove the left and right side skirts set. Under Cover Removal Remove the 4 bolts and remove the under cover. Panel Floor Removal Remove screws, bolts, remove the right and left panel floor.
Page 64 3.External Components XCITING S 400 Center Cover Set Removal Open the fuel cap lid and remove screws and remove the center cover set. Side Board Set Removal Remove fasteners, screws and couplers and remove the right and left side boards.
Page 65 3.External Components XCITING S 400 Leg Shield Assy. Removal Remove the screw, rotate and remove the main switch plate.
Page 66 3.External Components XCITING S 400 Up And Low Handle Cover Removal Remove the top handle cover. Remove the bolts, screws and remove the up handle cover. Remove the bolts, screws. Remove throttle and parking brake cables and remove the low handle cover.
Page 67 3.External Components XCITING S 400 Front Inner Fender Removal Remove screws and remove the front inner fender. Front Fender Assy. Removal Remove the bolts, plates and reflectors. Remove the front fender assembly. 3-11...
Page 68 3.External Components XCITING S 400 Seat Removal Turn the ignition switch counter clockwise to open the seat. Lift up the seat and remove 2 nuts and remove the seat. 3-12...
Page 69 3.External Components XCITING S 400 Battery Cover Removal Remove screws, nuts, remove the battery cover. Back Carriers Removal Remove 4 bolts and remove the right and left back carriers. Rear Seat Removal Remove 4 bolts and remove the right and left rear seat.
Page 70 3.External Components XCITING S 400 Luggage Box Removal Remove screws, bolts and couplers then remove the luggage box. Rear Center Cover Removal Remove fasteners and remove the rear center cover. 3-14...
Page 71 3.External Components XCITING S 400 Body Cover Set Removal Remove fasteners, bolts, screws, coupler and remove the body cover set. 3-15...
Page 72 3.External Components XCITING S 400 Heat Shield Removal Remove bolts and remove the heat shields. 3-16...
Page 73 3.External Components XCITING S 400 Exhaust System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Troubleshooting Noisy exhaust muffler • Damaged exhaust muffler • Exhaust muffler joint air leaks Lack of power • Caved exhaust muffler • Clogged exhaust muffler •...
Page 74 3.External Components XCITING S 400 Muffler Removal Remove bolts of the muffler. Remove the muffler. Replace the new exhaust pipe gasket(18391) when installation. 3-18...
Page 75 3.External Components XCITING S 400 Exhaust Pipe Removal Unplug the O sensor connector. Remove nuts of the exhaust pipe. Remove the exhaust pipe. Replace the new exhaust pipe gasket(18291) when installation. 3-19...
Page 76 3.External Components XCITING S 400 O2 Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. Installation torque: 2~3 kgf-m (20~30 N-m) 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.
Page 77 3.External Components XCITING S 400 Side Stand Removal Unplug the three-pin side stand switch connector. Remove the spring, side stand bolt, switch, and side stand. 3-21...
Page 78 3.External Components XCITING S 400 Center Stand Removal Lift up the vehicle by a jack carefully. Remove the center stand spring with a spring puller. Remove the nuts and bolts. Remove the center stand. 3-22...
Page 79 4. Engine XCITING 400i/XCITING S 400 Engine This chapter covers the location and servicing of the engine components for the KYMCO Xciting 400i and Xciting S 400. • Engine Removal ............4-4~4-12 • Cylinder Head Cover ...........4-13~4-17 • Camshaft.............4-18~4-32 • Valves ..............4-33~4-44 •...
Page 80 4. Engine XCITING 400i/XCITING S 400 Poor lubrication pressure 1. Oil level too low 2. Clogged filter or oil passages 3. No use the specified oil Cylinder Head, Camshaft, and Valves • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained.
Page 81 4. Engine XCITING 400i/XCITING S 400 Compression too high • Excessive carbon build-up in combustion chamber Abnormal noise • Incorrect valve clearance adjustment • Sticking valve or broken valve spring • Damaged or worn camshaft • Worn cam chain tensioner •...
Page 82 XCITING 400i 3. Engine > Engine Removal Engine Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal.
Page 83 3. Engine > Engine Removal The regulator/rectifier is located on the right side of the vehicle. Disconnect the generator 3-pin connector. Disconnect the crank position sensor wire coupler. Remove the bolts. And remove the oil catcher.( Xciting S 400) 4‐5...
Page 84 XCITING 400i 3. Engine > Engine Removal Unplug the water temperature sensor. Pull back the rubber starter motor lead cover. 4‐6...
Page 85 XCITING 400i 3. Engine > Engine Removal Remove the starter motor lead nut with a 10 mm wrench. Free the cable lead from the starter motor. Thread the nut back on to keep track of it. Loosen the fuel hose stay bolt with an 8 mm socket. Free the fuel hose stay from the cylinder head cover.
Page 86 XCITING 400i 3. Engine > Engine Removal Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container. Loosen the thermostat hose clamp with a #2 Phillips screwdriver.
Page 87 XCITING 400i 3. Engine > Engine Removal Disconnect the main engine ground wire. Free the engine ground from the left side of the engine. Unplug the oil pressure switch wire at the bullet connector. The oil pressure switch is located below the cylinder. Free the wiring harness from its guide above the intake pipe.
Page 88 XCITING 400i 3. Engine > Engine Removal Support the engine with a suitable jack or stand. Remove the rear shock absorbers. Loosen the engine mounting bracket damper nut with a 14 mm socket. Remove the nut and washer. Hold the engine mounting bolts with a 14 mm wrench and loosen the nuts with a 19 mm socket.
Page 89 XCITING 400i 3. Engine > Engine Removal Remove the engine mounting nuts and bolts from both sides. Loosen the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt. Remove the engine mounting bracket damper bolt and nut.
Page 90 XCITING 400i 3. Engine > Engine Removal Remove the engine mounting bracket. Remove the engine mounting bracket damper assembly. Carefully move the engine back and separate it from the chassis. 3‐12...
Page 91 3. Engine > Cylinder Head Cover XCITING 400i Cylinder Head Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Squeeze the breather hose clamp with needle nose pliers and slide if back. Remove the breather hose from the cylinder head cover. 3‐13...
Page 92 3. Engine > Cylinder Head Cover XCITING 400i Free the fuel hose stay from the cylinder head cover. Loosen the four cylinder head cover bolts with a 10 mm socket. Remove the cylinder head cover bolts with washers and grommets. Note the gold colored and longer bolts are on the right side.
Page 93 3. Engine > Cylinder Head Cover XCITING 400i Installation Fit the cylinder head cover gasket onto the cylinder head. Make sure the projection fits into the groove in front of the camshaft sprocket correctly. Install the cylinder head cover over the gasket. Make sure the ridge on the gasket fits into the groove on the cylinder head cover correctly.
Page 94 3. Engine > Cylinder Head Cover XCITING 400i Coat the cylinder head cover bolt seals in fresh engine oil. Insert the cylinder head cover bolts with grommet seals and washers. Note the gold colored and longer bolts go on the right side.
Page 95 3. Engine > Cylinder Head Cover XCITING 400i Fit the fuel stay into place. Tighten the stay bolt securely with an 8 mm socket. Install the breather hose to the cylinder head cover. Secure the hose with the clamp. 3‐17...
Page 96 XCITING 400i 3. Engine > Camshaft Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal The crankshaft must be rotate (clockwise) until the piston is at top dead center (TDC) on the compression stroke. Turn crankshaft clockwise until the "T" mark aligns with the index notch in the timing inspection hole.
Page 97 XCITING 400i 3. Engine > Camshaft The piston should now be at TDC on the compression stroke. You can make sure that it is on the compression stroke by checking that there is some slack in the rocker arms. If the rocker arms are rigid, rotate the crankshaft 360°...
Page 98 XCITING 400i 3. Engine > Camshaft Remove the cam chain tensioner cap bolt with a 8 mm socket. Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket. Lift the cam chain tensioner out of the cylinder. Remove the cam chain tensioner gasket.
Page 99 XCITING 400i 3. Engine > Camshaft Use a 5 mm Allen wrench to remove the camshaft sprocket bolts. Remove the camshaft sprocket as shown. Support the chain so it does not fall into the cylinder head. Thread a bolt into the rocker arm shafts and pull the shafts out. 3‐21...
Page 100 XCITING 400i 3. Engine > Camshaft Lift out the rocker arms as the shafts are removed. Remove the camshaft from the cylinder head. 3‐22...
Page 101 XCITING 400i 3. Engine > Camshaft Inspection Inspect the camshaft cam heights for the intake and exhaust lobes. Inspect the camshaft bearings for excessive play or roughness. Replace the entire camshaft assembly if the bearings are rough or have excessive play. Inspect the rocker arm shaft outer diameter for the intake and exhaust valves.
Page 102 XCITING 400i 3. Engine > Camshaft Inspect the rocker arm bearings for excessive play or roughness. Replace the entire rocker arm assembly if the bearings are rough or have excessive play. Inspect the camshaft bearing journals for scoring or scratches. 3‐24...
Page 103 XCITING 400i 3. Engine > Camshaft Inspect the camshaft sprocket for worn teeth or other signs of wear or damage. 3‐25...
Page 104 XCITING 400i 3. Engine > Camshaft Camshaft Installation Clear out the cylinder head oil passages with compressed air. Make sure all cylinder head oil passages are free of clogs. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else. Position the piston at top dead center as above.
Page 105 XCITING 400i 3. Engine > Camshaft Insert the camshaft into the camshaft holders with the lobes facing down. Lubricate the inside diameter of the rocker arms and the roller with fresh engine oil. Position the rocker arms to accept the rocker arm shafts.
Page 106 XCITING 400i 3. Engine > Camshaft Wipe the rocker arm shafts clean. Insert the rocker arm shafts through the camshaft holders and rocker arms. Install the rocker arm shafts so that the end sits as shown. Install the camshaft set plate so it fits into the groove on the camshaft and between the projections on the rocker arm shafts.
Page 107 XCITING 400i 3. Engine > Camshaft Torque Thread size Item (mm) kgf-m lb-ft Camshaft set plate bolt Install the camshaft sprocket onto the camshaft so the camshaft sprocket boss fits into the appropriate hole on the camshaft sprocket. Make sure the camshaft sprocket boss is facing up so it is visible above the edge of the cylinder head as shown.
Page 108 XCITING 400i 3. Engine > Camshaft Apply a small amount of blue Loctite (non-permanent) to the threads of the camshaft sprocket bolts. Thread in the camshaft sprocket bolts and tighten to specification using a 5 mm Allen socket. Torque Thread Item size (mm) kgf-m...
Page 109 XCITING 400i 3. Engine > Camshaft Rotate the crankshaft 360° clockwise and check the engine timing one more time. Make sure the cam chain tensioner cap bolt washer is in good condition. Install the washer and cam chain tensioner cap bolt. Tighten the bolt to securely with a 10 mm socket.
Page 110 XCITING 400i 3. Engine > Camshaft Make sure the O-ring on the timing plugs are in good condition. Replace it as needed. Install the timing inspection cap to the right side of the engine. Tighten the cap securely but not overly with a large flat blade screwdriver.
Page 111 3. Engine > Valves XCITING 400i Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal IMPORTANT: Record the position of all parts so they can be returned to their proper place during reassembly. Push down the valve springs with a valve spring compressor. Special Tool- Valve Spring Compressor: A120E00063 Remove the two nuts and washers on the top with a 14mm socket.
Page 112 3. Engine > Valves XCITING 400i Remove the two nuts and washers on the left side with a 14mm socket. Remove the two bolts on the right side with a 8mm socket. Remove the nut on the inlet pipe side with a 10mm socket. 3‐34...
Page 113 3. Engine > Valves XCITING 400i Remove the nut on the exhaust pipe side with a 10mm socket. Remove the cylinder head assy and gasket. Remove the split keepers. There are two per valve. 3‐35...
Page 114 3. Engine > Valves XCITING 400i Remove the spring retainer. Remove the valve springs. 3‐36...
Page 115 3. Engine > Valves XCITING 400i Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head. Rotate the valve as it is removed. Remove the valve seal from the valve guide. The valve seals should be replaced if they are removed or you are going to install new valves.
Page 116 3. Engine > Valves XCITING 400i Remove the spring seat. Inspection Inspect the valve springs for fatigue and damage. Replace the valve springs as needed or if the valve is also to be replaced. 3‐38...
Page 117 3. Engine > Valves XCITING 400i Inspect the valves for damage and burning. Measure the valve stem diameter in several places where the valve makes contact with the guide. If the measurement is below specification replace the valve. Item Standard (mm) 4.75 - 4.99 Valve stem O.D.
Page 118 3. Engine > Valves XCITING 400i Inspect the valve seat and the valve seat width. The valve seat should be centered on the valve face. If the seat is pitted, worn out, or fits poorly on the valve face the valve seat must be resurfaced. Item Standard (mm) 1.7±0.1...
Page 119 3. Engine > Valves XCITING 400i Item Standard (mm) 5.00 - 5.012 Valve guide I.D 9.990 – 10.015 0.010 - 0.037 Valve stem-to-guide clearance 0.030 - 0.057 Installation Clean the cylinder head components thoroughly with a high flash-point solvent and compressed air. Return the components to their original locations.
Page 120 3. Engine > Valves XCITING 400i Coat the valve stem in fresh engine oil and insert the valve into the valve guide and through the seal. Turn the valve slowly as it is inserted. If you are installing a new valve you must ream the valve guide first. Make sure the valve will move smoothly in the valve guide without wobble.
Page 121 3. Engine > Valves XCITING 400i Place the spring retainer on top of the spring. Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers. The valve cotter installer tool can also be used to install the split keepers. Special Tool- Valve Spring Compressor: A120E00063 3‐43...
Page 122 3. Engine > Valves XCITING 400i Apply grease to the inside of the split keepers. Apply a dab of grease to the end of a flat blade screwdriver. Set the keeper in the grease on the screwdriver and insert it onto the valve stem. Repeat this with the other keeper.
Page 123 XCITING 400i 3. Engine > Cylinders and Pistons Cylinders and Pistons SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Cylinder Block Removal Slide out the lower cam chain guide. Inspect the guide for excessive wear and damage. Replace the guide as needed. Remove two towel pins Remove the two cylinder bolts on the right side of the engine.
Page 124 XCITING 400i 3. Engine > Cylinders and Pistons Slide the cylinder off of the studs and piston. Guide the cam chain through its opening and do not allow if to fall into the crankcase. Remove the cylinder. Remove the base gasket. 3‐46...
Page 125 XCITING 400i 3. Engine > Cylinders and Pistons Remove the two cylinder dowel pins from the left studs. Place a clean shop towel under and around the base of the piston to prevent any parts or debris falling into the crankcase. Remove the piston pin clips with a pick or needle nose pliers.
Page 126 XCITING 400i 3. Engine > Cylinders and Pistons Remove the piston pin and the piston. Clean off the cylinder mating surface, but take care to keep debris from falling into the crankcase. Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal.
Page 127 XCITING 400i 3. Engine > Cylinders and Pistons The two upper rings are each a single piece of metal. The oil ring consists of an expander ring and two side rails. Clean the carbon build up off of the piston with a stiff bristled plastic brush or rag.
Page 128 XCITING 400i 3. Engine > Cylinders and Pistons Also clean out the ring grooves. You can use an old ring to scrape out any carbon build up in the grooves. Inspection The cylinder and piston must be replaced as a set. There are two sets of cylinder and piston combinations.
Page 129 XCITING 400i 3. Engine > Cylinders and Pistons Inspect the cylinder bore for damage and abnormal wear Measure the cylinder diameter as described below with a telescoping gauge. 3‐51...
Page 130 XCITING 400i 3. Engine > Cylinders and Pistons Inspect the cylinder front to back and side to side at three different height levels with a dial bore gauge. Mark Cylinder I.D. (mm) 84.00 – 84.01 84.01 – 84.02 Calculate the cylinder taper. The taper is the maximum difference between either yellow and brown or blue and green.
Page 131 XCITING 400i 3. Engine > Cylinders and Pistons Measure the outside diameter of the piston at 9 mm up from the bottom of the skirt at a 90° angle to the piston pin. Measure the piston with vernier calipers or a micrometer. Check the piston for wear, damage, and extreme discoloration.
Page 132 XCITING 400i 3. Engine > Cylinders and Pistons Measure the inside diameter of the small end of the connecting rod with vernier calipers. Item Standard (mm) Connecting rod small end I.D. Bore Measure the ring groove width and the ring-to-groove clearance with feeler gauges.
Page 133 XCITING 400i 3. Engine > Cylinders and Pistons Insert the top ring into the cylinder. Push the top ring in the cylinder about an inch. Use the piston to push in the ring to keep it square with the cylinder. Measure the ring gap with a feeler gauge.
Page 134 XCITING 400i 3. Engine > Cylinders and Pistons Check the oil jet for clogs. Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Do not try and force them on the piston. 3‐56...
Page 135 XCITING 400i 3. Engine > Cylinders and Pistons Install the top and second rings with their markings facing up. Install the rings to the piston as shown above so that no ring end gaps line up with the piston pin or perpendicular to the piston pin. The rings should turn easily on the piston without sticking or roughness.
Page 136 XCITING 400i 3. Engine > Cylinders and Pistons The "IN" mark should face the intake side (rear) of the engine. Place the piston over the connecting rod. Insert the piston pin into the piston and rod. 3‐58...
Page 137 XCITING 400i 3. Engine > Cylinders and Pistons Install new piston pin clips securely into their grooves. Turn the gap in the clips away from the access gap. Make sure the cylinder head mating surface is clean. Install the two dowel pins as shown. 3‐59...
Page 138 XCITING 400i 3. Engine > Cylinders and Pistons Install the new base gasket onto the crankcase. Coat the inside of the cylinder, piston rings, and piston in fresh engine oil. Lower the cylinder over the studs and guide the piston into the cylinder while you are compressing the rings with your fingers.
Page 139 XCITING 400i 3. Engine > Cylinders and Pistons Thread in the two cylinder bolts on the right side of the engine. Insert the lower cam chain guide and make sure it is seated correctly. 3‐61...
Page 140 XCITING 400i 3. Engine > Generator A.C. Generator and Starter clutch SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Generator Cover Remove the following components - # Seat # Luggage Box # Center Cover # Rear Carrier # Body Cover # Front Cover # Front Lower Cover...
Page 141 XCITING 400i 3. Engine > Generator Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container. Loosen the right crankcase coolant hose clamp with a 8mm socket.
Page 142 XCITING 400i 3. Engine > Generator Remove the 12 generator cover bolts with an 8 mm socket. Note the upper bolt holds a wire stay. Remove the generator cover. 3‐64...
Page 143 XCITING 400i 3. Engine > Generator Remove the generator cover gasket. Remove the two dowel pins. 3‐65...
Page 144 XCITING 400i 3. Engine > Generator Remove the oil release valve. Inspect the O-ring and replace it as needed. Stator and Pulsar Coil/Crank Position Sensor Free the rubber wire grommet from the right crankcase cover. 3‐66...
Page 145 XCITING 400i 3. Engine > Generator XCITING 400I XCITING S 400 Remove the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket. Remove the stator and the crank position sensor together. Flywheel To remove the fly wheel two special tools are needed.
Page 146 XCITING 400i 3. Engine > Generator ITEM TOOL NO. FLYWHEEL PULLER A120E00097 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket. 3‐68...
Page 147 XCITING 400i 3. Engine > Generator Remove the flywheel nut and washer. Apply a protect stay to the threads of the crankshaft before using it. Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the crankshaft. 3‐69...
Page 148 XCITING 400i 3. Engine > Generator Remove the flywheel from the crankshaft. Slide the starter driven gear off of the crankshaft. 3‐70...
Page 149 XCITING 400i 3. Engine > Generator Remove the woodruff key from the crankshaft. Starter Clutch Remove the starter idle gear and shaft from the crankcase. 3‐71...
Page 150 XCITING 400i 3. Engine > Generator Inspect the starter idle gear and shaft for wear and damage. Replace the idle gear and shaft as needed. Inspect the starter driven gear for wear and damage. Measure the inside and outside diameter of the starter driven gear and replace it as needed. Item Standard (mm) Starter drive gear I.D.
Page 151 XCITING 400i 3. Engine > Generator Fit the boss of the starter driven gear into the starter clutch. The starter clutch should only allow the driven gear to turn in one direction. If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced.
Page 152 XCITING 400i 3. Engine > Generator Tighten the starter clutch mounting bolts to specification with a 6 mm Allen socket. Torque Thread Item size (mm) kgf-m lb-ft Oneway clutch bolt 0.8 -1.2 5.76 – 8.64 Lubricate the starter idle gear shaft with fresh engine oil. Install the starter idle gear and shaft into the crankcase.
Page 153 XCITING 400i 3. Engine > Generator Flywheel Install the woodruff key into its slot on the end of the crankshaft. Lubricate the inside of the starter driven gear with fresh engine oil. Slide the starter driven gear onto the flywheel as shown. Clean off the tapered end of the crankshaft where the flywheel will ride and make sure the inside of the flywheel is oil free where it will contact the crankshaft.
Page 154 XCITING 400i 3. Engine > Generator Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft. Guide the starter driven gear into the starter clutch on the back of the flywheel. Install the washer and flywheel nut. 3‐76...
Page 155 XCITING 400i 3. Engine > Generator Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket. Torque Thread Item kgf-m lb-ft size (mm) ACG flywheel nut 5.5-6.5 39.78-47.01 ITEM TOOL NO. UNIVERSAL HOLDER A120E00097 3‐77...
Page 156 XCITING 400i 3. Engine > Generator Stator and Crank Position Sensor Fit the stator and the crankshaft position sensor into the generator cover together as shown. Insert the two crank position sensor mounting bolts and the three stator mounting bolts. Tighten the bolts securely with an 8 mm socket. Coat the rubber grommet in silicone sealant where it contacts the generator cover.
Page 157 XCITING 400i 3. Engine > Generator Generator Cover Make sure the generator cover mating surface is clean. Install the two dowel pins and a new generator cover gasket. Install a new gasket. 3‐79...
Page 158 XCITING 400i 3. Engine > Generator Make sure the oil release valve is in place and in good condition. Fit the generator cover into place. Make sure the water pump shaft engages correctly with the oil pump shaft. 3‐80...
Page 159 XCITING 400i 3. Engine > Generator Insert the 12 generator cover bolts. Note the upper bolt holds a wire stay. Tighten the bolts securely in a with an 8 mm socket. Fit the coolant hose to the right crankcase cover pipe. Secure the hose with the clamp and tighten the coolant hose clamp securely with a #2 Phillips screwdriver.
Page 160 XCITING 400i 3. Engine > Generator Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver. Plug in the regulator/rectifier 3-pin connector. Plug in the crank position sensor wire coupler on the right side of the frame.
Page 161 3. Engine > Oil Pump XCITING 400i Oil Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 162 3. Engine > Oil Pump XCITING 400i Oil Pump Removal The oil pump is driven by a chain off of the crankshaft. Loosen the two oil pump cover bolts with an 8 mm socket. 3‐84...
Page 163 3. Engine > Oil Pump XCITING 400i Remove the two oil pump cover bolts and the oil pump cover. Remove the snap ring on the oil pump shaft with snap ring pliers. Remove the oil pump drive chain and driven sprocket. 3‐85...
Page 164 3. Engine > Oil Pump XCITING 400i Inspect the oil pump drive chain and sprocket for signs of wear and damage. Replace the parts as needed. Remove the three oil pump screws with an 8mm socket. Remove the oil pump. 3‐86...
Page 165 3. Engine > Oil Pump XCITING 400i Turn the oil pump shaft by hand and make sure it turns smoothly. If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit. Oil Pump Installation Fit the oil pump into place so that the arrow is pointing up.
Page 166 3. Engine > Oil Pump XCITING 400i Insert the three oil pump mounting screws and tighten them securely with an 8mm socket. Fit the oil pump driven sprocket into the drive chain. Install the gear onto the oil pump shaft and fit the chain onto its teeth on the crankshaft.
Page 167 3. Engine > Oil Pump XCITING 400i Install the oil pump cover and its two mounting bolts. Tighten the two oil pump cover bolts securely with an 8 mm socket. 3‐89...
Page 168 XCITING 400i 3. Engine > Crankcase Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Splitting Remove the upper cam chain guide bolt with an 8 mm Allen. Remove the upper cam chain guide. 3‐90...
Page 169 XCITING 400i 3. Engine > Crankcase Inspect the cam chain guides for damage and excessive wear. Replace the guides as needed. Remove the cam chain from the crankshaft and crankcase. Inspect the cam chain for wear and damage. Replace the cam chain as needed. 3‐91...
Page 170 XCITING 400i 3. Engine > Crankcase Remove the six bolts mounting the left crankcase cover protector. XCITING 400I XCITING S 400 Remove the left crankcase cover protector. 3‐92...
Page 171 XCITING 400i 3. Engine > Crankcase Remove the nine bolts mounting the left crankcase cover. Remove the two bolts mounting the element duct left crankcase cover. XCITING 400I XCITING S 400 Remove the element duct. 3‐93...
Page 172 XCITING 400i 3. Engine > Crankcase Remove the #M14 nut mounting the clutch outer. Remove the #M18 nut mounting the drive face. Remove the left crankcase cover. XCITING 400I XCITING S 400 3‐94...
Page 173 XCITING 400i 3. Engine > Crankcase There are 12 crankcase bolts. Loosen the 12 crankcase bolts in a crisscross pattern with an 8 mm socket. Remove the crankcase bolts from the left side of the engine. Remove the plate with the bottom two crankcase bolts. 3‐95...
Page 174 XCITING 400i 3. Engine > Crankcase Set the crankcases on the right side. Separate the halves of the crankcase. If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet. Lift the right crankcase off of the left. 3‐96...
Page 175 XCITING 400i 3. Engine > Crankcase Remove the two dowel pins from the crankcase. Inspect the O-ring and replace it as needed. 3‐97...
Page 176 XCITING 400i 3. Engine > Crankcase Replace the left crankshaft seal if the crankcases are separated. Remove the seal with a seal pick. 3‐98...
Page 177 XCITING 400i 3. Engine > Crankcase Drive the new seal into the left crankcase from the outside with a suitable driver. The driver should have the same outside diameter as the seal. Lubricate the new crankshaft seal lips with fresh engine oil. Assembly Thoroughly clean the crankcase mating surface.
Page 178 XCITING 400i 3. Engine > Crankcase Set the right case half down on top of the left. Install the engine mount spacer. Insert the 12 crankcase bolts. The plate goes on with the bottom two bolts. 3‐100...
Page 179 XCITING 400i 3. Engine > Crankcase Tighten the bolts securely and evenly in a crisscross pattern with an 8mm socket. Install the cam chain around the timing sprocket teeth on the crankshaft. 3‐101...
Page 180 XCITING 400i 3. Engine > Crankcase Fit the upper cam chain guide into place. Insert the upper cam chain guide mounting bolt and tighten it to specification with an 8 mm Allen socket. Thread Torque Item Size(mm) kgf-m lb-ft Cam chain tensioner pivot 0.8-1.2 5.79 - 8.68 3‐102...
Page 181 XCITING 400i 3. Engine > Crankshaft Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Lift the crankshaft out of the left crankcase half. 3‐103...
Page 182 XCITING 400i 3. Engine > Crankshaft Crankshaft Inspection Check the side clearance of the big end of the connecting rod with a feeler gauge. Item Standard (mm) Service Limit (mm) Connecting rod big Crankshaft 0.15 - 0.35 end side clearance 3‐104...
Page 183 XCITING 400i 3. Engine > Crankshaft Grip the small end of the connecting rod and try and push the rod down towards the crank weights. If there is definite play between the connecting rod and crank the crankshaft should be replaced.
Page 184 XCITING 400i 3. Engine > Crankshaft Note the bearing color code and crankcase code. The crank weights are also marked with a size code. When the crankshaft and or crankcases must be replaced also replace both crank bearings according to the chart below. Crankcase C ran k c as e m a rk Bearing...
Page 185 3. Engine > Engine Installation XCITING 400i Engine Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Set the chassis on its center stand. Use a jack to support the engine. Guide the engine into the back of the frame. 3‐107...
Page 186 3. Engine > Engine Installation XCITING 400i Fit the engine mounting bracket and damper assembly into place. Install the two engine mounting bracket to frame mounting bolts and nuts. Insert the bolts from the outside of the frame. Insert the engine mounting bracket and damper bolt from the right side. Thread on the nut.
Page 187 3. Engine > Engine Installation XCITING 400i Install the engine mounting bracket damper washer and nut. Hold the engine mounting bolts with a 14 mm wrench and torque the nuts to specification with a 19 mm socket. Torque Thread Item Remarks size (mm) kgf-m...
Page 188 3. Engine > Engine Installation XCITING 400i Tighten the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt. Torque Thread Item Remarks size(mm) kgf-m lb-ft Engine hanger: Engine side 4.5-5.5 32.55-39.78 U-nut...
Page 189 3. Engine > Engine Installation XCITING 400i Route the wiring harness through its guide above the intake pipe. Plug in the oil pressure switch bullet connector. 3‐111...
Page 190 3. Engine > Engine Installation XCITING 400i Route the starter motor lead to the starter motor and secure it in the stay on the right crankcase cover. 3‐112...
Page 191 3. Engine > Engine Installation XCITING 400i Fit the starter motor cable lead onto the terminal and thread on the nut. Tighten the starter motor lead nut securely with a 10 mm wrench. Fit the rubber starter motor lead cover into place. 3‐113...
Page 192 3. Engine > Engine Installation XCITING 400i Install the main engine ground to the right side of the engine. Tighten the main engine ground bolt securely with an 8 mm socket. Install air bleed hose and secure it with the clamp. Connect the coolant hose to the thermostat.
Page 193 3. Quick Reference > Specifications XCITING 400i Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver. Fit the fuel stay into place. Tighten the stay bolt securely with an 8 mm socket.
Page 194 5. Cooling System XCITING S 400 5.Cooling System This chapter covers the location and servicing of the cooling system components for the KYMCO XCITING S 400 model. General Instructions ..............5-1 Troubleshooting ................5-2 Coolant ..................5-3 Radiator ..................5-11 Water Temperature Sensor (WTS) ..........
Page 195 5. Cooling System XCITING S 400 TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or sensor • Faulty radiator cap • Faulty thermostat • Insufficient coolant • Passages blocked in hoses or water jacket • Clogged radiator fins • Passages blocked in radiator •...
Page 196 5. Cooling System XCITING S 400 Coolant For the sake of safety, check level of cooling water before riding the vehicle. Replace the cooling liquid as specified in Regular Maintenance Schedule. Check Level of Cooling Water 1. Park the vehicle on level ground and brace it up with Main Stand.
Page 197 In case of fault of vehicle: Go to a KYMCO dealer for check and repair if any fault occurs when riding the vehicle. Use only original parts for replacement. Check following items if engine does not start or engine stops when riding the vehicle: ◆...
Page 198 When the coolant has fished draining return the drain bolt to the water pump with a new sealing washer. Tighten the drain bolt securely with an socket. Fill the cooling system with a mix of distilled water and KYMCO SIGMA Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown.
Page 199 5. Cooling System XCITING S 400 Add coolant to the reserve tank until it reaches the upper level mark. Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes.
Page 200 5. Cooling System XCITING S 400 Open the coolant reserve tank lid. Siphon the coolant out of the reserve tank with an appropriate suction device. If a suction device is unavailable remove the reserve tank and poor it out. See the Radiator topic for more information.
Page 201 5. Cooling System XCITING S 400 Filling Coolant capacity Radiator 1450cc Reserve tank 250cc Total capacity 1700cc • Use coolant of specified mixing rate. (The mixing rate of 860cc coolant concentrate + 859cc distilled water is 50%.) • Do not mix coolant concentrate of different brands.
Page 202 5. Cooling System XCITING S 400 Fill the cooling system with a mix of distilled water and Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown. Add coolant to the reserve tank until it reaches the upper level...
Page 203 5. Cooling System XCITING S 400 Gently rock the vehicle side-to-side to release any air bubbles trapped in the cooling system. Place the vehicle on its center stand and start the engine. Let it run for several minutes. This will purge any air out of the cooling system.
Page 204 5. Cooling System XCITING S 400 Radiator SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. Pressure Testing Remove the radiator coolant panel screws with a #2 Phillips screwdriver.
Page 205 5. Cooling System XCITING S 400 CAUTION: Never remove the radiator cap when the engine is hot. Wet the seal on the radiator cap and install it to the pressure tester. Replace the cap if it does not relieve the pressure as specified.
Page 206 5. Cooling System XCITING S 400 There are two coolant hoses that connect to the radiator. The top left hose runs to the filler neck and cap. The top right hose runs to the thermostat on the cylinder head. The bottom left hose runs to the water pump.
Page 207 5. Cooling System XCITING S 400 Inspection Inspect the radiator fins for damage and clogging. To remove the fan be taken out the four mounting bolts with a 10 mm socket. Clean out the fins with low pressure compressed air and water.
Page 208 5. Cooling System XCITING S 400 Jump a 12 volt battery to the fan connector and make sure the radiator fan operates. 5-15...
Page 209 5. Cooling System XCITING S 400 Water Temperature Sensor and Thermostat SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Water Temperature Sensor (WTS) Unplug the water temperature sensor. Use a 17 mm wrench to remove the water temperature sensor.
Page 210 5. Cooling System XCITING S 400 Discard the WTS O-ring and replace it with a new item. Thermostat Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the thermostat.
Page 211 5. Cooling System XCITING S 400 Remove the two thermostat mounting bolts with an 8mm socket. Lift off the thermostat cover. 5-18...
Page 212 5. Cooling System XCITING S 400 Lift out the thermostat. Remove the thermostat O-ring and discard it. Inspection Water Temperature Sensor Inspect the WTS in a similar manner as the thermosensor. Measure the resistance between the WTS terminals and compare this to the specifications.
Page 213 5. Cooling System XCITING S 400 Thermostat The thermostat should be closed at room temperature. Suspend the thermostat and a thermometer in a pot of water with string. Make sure the thermostat and the thermometer are not touching the pot.
Page 214 6.Fuel System XCITING S 400 6.Fuel Injection System This chapter covers the location and servicing of the fuel system components for the KYMCO XCITING S 400 model. GENERAL INSTRUCTIONS ............6-2 TROUBLESHOOTING ..............6-3 COMPONENT LOCATION ............. 6-4 ECU ....................6-7 IGNITION COIL ................
Page 215 6.Fuel System XCITING S 400 GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
Page 216 6.Fuel System XCITING S 400 TROUBLESHOOTING Engine fail to start • Intake manifold air leak • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Faulty fuel pump • Clogged fuel filter, throttle body • Sticking fuel injector needle • Faulty fuel pump operating system •...
Page 217 6.Fuel System XCITING S 400 Component Location Regulator/Rectifier Air Cleaner/Element Seat Open Motor Spark Plug Fuel Tank Ignition Coil Horn Side Standard Switch Coolant Reserve Tank Hazard Controller Ignition Switch Front Wheel Speed Canister Sensor Connector Starter Relay Battery FUSE BOX...
Page 218 6.Fuel System XCITING S 400 Component Location Meter Instrument Couplers Winker Relay (Turn Signal) Battery Tilt Switch ABS ECU Fuel Cap Battery Box Fuse Box Fuel Pump Throttle Body Diagnostic Tool Connector...
Page 219 6.Fuel System XCITING S 400 Component Location MAP Sensor Throttle Body ISC (Idle Speed Controller) 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)
Page 220 6.Fuel System XCITING S 400 Note: The ECU could be damaged if dropped or the connector is disconnected when the key is on. The excessive voltage may damage the ECU. Always turn off the ignition switch before servicing. Press the tab and disconnect the ECU coupler.
Page 221 6.Fuel System XCITING S 400 Inspection Check for continuity between pin 9 and 10 of the ECU side connector. There should be continuity at all times. Check for continuity between each pins 2,4 and 23 of the ECU side connector.
Page 222 6.Fuel System XCITING S 400 Ignition System The ignition timing is set at the factory and is not adjustable. Perform the following checks. Before performing any tests make sure the electrical connections are not loose or corroded. Ignition Coil Remove the connectors.
Page 223 6.Fuel System XCITING S 400 Ignition Coil Resistance Primary Set the multimeter to read ohms of resistance (Ω). Touch the positive and negative meter leads to the ignition coil terminals as shown. Measure the resistance. Ignition Coil Primary Resistance 3.57 - 4.83 Ω...
Page 224 6.Fuel System XCITING S 400 Secondary Without Plug Cap Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap. Touch the negative meter lead to the terminal and the positive meter lead to the spark plug wire as shown.
Page 225 6.Fuel System XCITING S 400 Spark Plug Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
Page 226 6.Fuel System XCITING S 400 Measure the gap with a wire-type thickness gauge. If the gap is incorrect, replace the spark plug. Always check the gap of the spark plug before installation. Inspect the color of the porcelain nose of the spark plug. The color of the spark plug can indicate how the mixture is burning.
Page 227 6.Fuel System XCITING S 400 AC Generator Inspection Crank Position Sensor Inspection Note: This test is performed with the stator installed in the engine. Disconnect the crank position sensor wire coupler. Measure the resistance between L/Y and G/GR wire terminals.
Page 228 6.Fuel System XCITING S 400 O2 Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. Installation torque: 2~3 kgf-m (20~30 N-m) 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.
Page 229 6.Fuel System XCITING S 400 Relays Seat Open Motor Relay/ Starter Relay/ Fuel Pump Relay/ ECU Relay/ Fan Relay (The location refer to the wiring diagram wire color) Relays Inspection Use a digital multimeter to inspect the relay. Relay Connect 12 V battery with the fuel cut-off relay connector.
Page 230 6.Fuel System XCITING S 400 Fuel Tank SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. 6-17...
Page 231 6.Fuel System XCITING S 400 Fuel Tank Removal In order to drain the fuel from the fuel pipe and release the fuel pressure unplug the fuel pump connecter. Start the engine and let it run until it dies of fuel starvation.
Page 232 6.Fuel System XCITING S 400 Clean up any remaining fuel immediately. Note: When slide back the fuel hose carefully not to damage the fuel pump pipe, and replace the clamp with a new one when installation. Remove the fuel pump mounting bolts. And remove the fuel pump assembly.
Page 233 6.Fuel System XCITING S 400 Remove the radiator. Remove the fuel tank mounting nuts and remove the fuel tank from the frame. 6-20...
Page 234 6.Fuel System XCITING S 400 Fuel Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. Input Voltage Inspection Turn the ignition switch off.
Page 235 6.Fuel System XCITING S 400 Set the engine stop switch to the “RUN” position. Unplug the fuel pump connecter. Set the multi meter to read battery voltage. Touch the multi meter leads to the harness side of the fuel pump connector, with the positive lead touching the red/black wire terminal and the negative lead touching the green wire terminal.
Page 236 6.Fuel System XCITING S 400 Fuel Pump Lift the fuel pump out of the tank. Discard the fuel pump O-ring, and when installation, replace the O-ring with new item and apply a small amount of fresh engine oil to the new O-ring.
Page 237 6.Fuel System XCITING S 400 Fuel Level Float Position Resistance Full 1100Ω± 33Ω Empty 100Ω± 3Ω Replace the fuel level float unit with a new part if the resistance is out of specification. 6-24...
Page 238 6.Fuel System XCITING S 400 Fuel Pump Output Pressure Turn the key to the OFF position. Use a fuel hose clamp as shown. To separate the fuel hose from the fuel pump pipe. Clean up any remaining fuel immediately. Disconnect the fuel hose from the fuel injector.
Page 239 6.Fuel System XCITING S 400 If the fuel output pressure is less than 3.0 bar, may fail to start the engine or in trouble in case of riding. Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose.
Page 240 ● Do not damage the throttle body, it may cause the throttle and idle valve to fail synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it incorrectly. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
Page 241 6.Fuel System XCITING S 400 Measure if the ECU voltage outputs to the MAP between the following terminals of the MAP connector. Terminal Normal Violet/Red (+) – Green/Pink (-) TPS Inspection Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “ON”.
Page 242 6.Fuel System XCITING S 400 Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector. Terminal Normal Violet/Red (+) – Green/Pink (-) Throttle Position Sensor (TPS) 3500 - 6500 Ω 6-29...
Page 243 6.Fuel System XCITING S 400 Removal Throttle Cables Free the throttle cables from the throttle drum. 6-30...
Page 244 6.Fuel System XCITING S 400 Fuel Injector Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Gas is extremely flammable! Do not work around an open flame or a source of sparks. In order to release fuel pressure from the fuel pipe when removing the fuel injector, unplug the fuel pump connecter.
Page 245 6.Fuel System XCITING S 400 Slide back the clamp and free the injector fuel pipe from the fuel hose. Inspect the fuel hose for signs of deterioration or damaged. Replace the fuel hose as needed. Remove the fuel injector mounting bolt with a 10 mm socket. Unplug the fuel injector connector.
Page 246 6.Fuel System XCITING S 400 Inspection A digital multi meter is needed to test the fuel injector. Measure the resistance between the fuel injector terminals. ITEM SPECIFICATIONS Fuel injector resistance (at 20°C/68°F) 9.9 – 13.5 Ω Check for signs of clogging.
Page 247 6.Fuel System XCITING S 400 When installation: Apply a light coat of fresh engine oil to a new fuel injector O-ring. Fit the fuel injector pipe onto the top of the injector. The tab on the injector must fit into the pipe.
Page 248 6.Fuel System XCITING S 400 Loosen the air box hose clamp screw at the throttle body with a #2 Phillips. Loosen the intake hose clamp screw at the throttle body with a flat blade screwdriver. Remove the sensor couplers, remove the throttle out of the air box and intake boots, then remove the throttle body.
Page 249 6.Fuel System XCITING S 400 Throttle Body Disassembly The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU have been reinstalled. MAP Sensor 6-36...
Page 250 6.Fuel System XCITING S 400 Tilt Switch Remove the front cover. See the external topic for more information. Support the scooter level surface. Put the side stand up and engine stop switch on “RUN”. Turn the ignition switch to “OFF”.
Page 251 6.Fuel System XCITING S 400 Incline the tilt switch 65±10 degrees to the left or right at the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage) Black/Blue (+) ~ Green/Pink (-) 3.7 - 4.4 V...
Page 252 6.Fuel System XCITING S 400 Self-Diagnosis Note: No matter when the CELP illuminated while riding condition, should find out the cause of the problem as soon as possible. CELP If the ECM connectors, or battery leads are disconnected the stored malfunction codes will be lost.
Page 253 Fuel Injection Diagnostic Tool OPERATION INSTRUCTIONS Diagnostic tool Part Number: 3620A-LEB2-E00 This tool has been developed by KYMCO and for KYMCO vehicles only. The tool software can be updated for new models with a computer via the USB cable. Please refer to the specifications when serving this vehicle.
Page 254 6.Fuel System XCITING S 400 The diagnostic tool is located under the seat. Remove the protective rubber cover. Use the Sub cord, OBD diagnostics connecter (part number:36205-LGC6-E00) to connect between vehicle and diagnostic tool. 6-41...
Page 255 6.Fuel System XCITING S 400 Plug in the tool to the ECU connector and turn on the ignition switch to send power to the tool. Place the scooter on its main stand and put the side stand up prior to using the diagnostic tool.
Page 256 ECU Version The four functions will display when the tool is powered on. The model name will show ADG5 for the XCITING S 400. Pressing the enter button on the ECU version will show model name, ECU number, identifications number and software version.
Page 257 6.Fuel System XCITING S 400 DTC (Diagnostic Trouble Code) INSPECTION PROCEDURE Press the down button (right) to move the item selector down to the DTC Inspect item. Pressing the enter button on the DTC Inspect item will bring up the options shown above.
Page 258 6.Fuel System XCITING S 400 Press the down button to select the load DTC option. Press the enter button on the Load DTC item to display the DTC options. Move the selector to the Current option and press enter to display current DTC.
Page 259 6.Fuel System XCITING S 400 Fuel Injection System Failure Code Pcode A1 P0030 O2 sensor heater malfunction A2 P0031 O2 sensor heater Voltage Low A3 P0032 Lambda sensor heater Voltage High A4 P0105 MAP sensor malfunction A5 P0107 MAP sensor Voltage Low...
Page 260 6.Fuel System XCITING S 400 C7 P0562 Battery voltage VBK too Low C8 P0563 Battery voltage VBK too High C9 P0650 MIL Voltage High CA P0700 Engine overspeed detected CB P1110 Roll sensor Voltage High CC P1111 Roll sensor malfunction or Voltage Low...
Page 261 6.Fuel System XCITING S 400 DTC Clear Procedure Press the down button (right) to move the item selector down to the DTC Inspect item. Pressing the enter button on the DTC Inspect item will bring up the options shown above.
Page 262 6.Fuel System XCITING S 400 Move the selector down to the Clear DTC option and press enter. The diagnostic tool will show when the DTC in memory are cleared. Also, the DTC indicator light between the center and right buttons will be off.
Page 263 6.Fuel System XCITING S 400 ADG5 SF : Customer : Eng. No: Service Production Date : Mileage : Date : Reason of repair: □ maintenance □ breakdown Item Date Reference Memo ECU No 39200-LKF5-E000 Hardware Ver Software Ver Calibration Ver...
Page 264 7. CVT Continuously Variable Transmission CVT Continuously Variable Transmission This chapter covers the location and servicing of the CVT components for the KYMCO XCITING 400i/XCITING S 400. • Belt Case ..............7-2~7-11 • CVT Removal ............7-12~7-28 • CVT Installation ............. 7-29 GENERAL INSTRUCTIONS •...
Page 265 7. CVT Transmission > Belt Case XCITING 400i Belt Case SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the following components - ◦ Seat ◦ Luggage Box ◦ Center Cover ◦ Rear Carrier ◦ Body Cover ◦...
Page 266 7. CVT Transmission > Belt Case XCITING 400i Remove 2 the air cleaner bolts with an 8 mm socket. Remove 6 the belt case plastic cover bolts with an 8 mm socket. XCITING 400I XCITING S 400 Remove the belt case protector. 7‐3...
Page 267 4. CVT Transmission > Belt Case XCITING 400i XCITING 400I XCITING S 400 Remove 11 the belt case cover bolts with an 8 mm socket. XCITING 400I XCITING S 400 Remove 2 the air filter bolts with an 8 mm socket.
Page 268 7. CVT Transmission > Belt Case XCITING 400i Remove the drive pulley nut with a 24mm socket. Remove the driven pulley nut with a 24mm socket. XCITING 400I XCITING S 400 Remove the belt case cover and gasket. Remove the two dowel pins. 7‐5...
Page 269 4. CVT Transmission > Belt Case XCITING 400i Inspection Inspect the drive belt for cracks or excessive wear. Inspect the belt case bearing by turning it with a finger. Replace the bearing if it is rough or noisy. 7‐6...
Page 270 7. CVT Transmission > Belt Case XCITING 400i Remove the bearing fixed plate with a 5 mm Allen. Remove two bearing collar. Remove the bearing with a suitable bearing puller. Tool number: A12E00093 7‐7...
Page 271 4. CVT Transmission > Belt Case XCITING 400i Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing. Tool number: A12E00014 Install two bearing collar. Install the bearing fixed plate with a 5 mm Allen 7‐8...
Page 272 7. CVT Transmission > Belt Case XCITING 400i Installation Install the two dowel pins into the belt case. Install a new gasket with the belt case cover. Install the driven pulley nut with a 24mm socket. Install the drive pulley nut with a 24mm socket. 7‐9...
Page 273 4. CVT Transmission > Belt Case XCITING 400i Install 2 the air filter bolts with an 8 mm socket. Install the belt case cover bolts and tighten them securely with an 8 mm socket. Install the belt case plastic cover. 4‐10...
Page 274 7. CVT Transmission > Belt Case XCITING 400i Insert the plastic cover bolts and tighten them securely with an 8 mm socket. Install 2 the air cleaner bolts with an 8 mm socket. Fit the drain hose to the plastic belt case cover as shown. 4‐11...
Page 275 7. CVT Transmission > CVT Removal XCITING 400i CVT Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the belt case. See the Belt Case topic for more information. Pulleys and Belt Remove the left face of the drive pulley. Remove the outer clutch.
Page 276 7. CVT Transmission > CVT Removal XCITING 400i XCITING 400I XCITING S 400 Slide the driven pulley off of the shaft. Remove the belt from the driven pulley. Inspect the drive belt for cracks or excessive wear. 4‐13...
Page 277 Inspect the faces of the drive pulley. Clean away any grease from the faces. Inspect the oil seal of the drive pulley for broken or excessive wear. XCITING 400I XCITING S 400 Lift the ramp plate out of the back of the left drive pulley face. 4‐14...
Page 278 There are 6 weight rollers in the back of the right face of the drive pulley. Remove the rollers and check them for excessive or uneven wear. Measure the weight of the rollers. Replace the weight rollers as needed. Weight roller (Drive Pulley) XCITING 400I: 17±0.3g XCITING S 400: 11±0.3g 4‐15...
Page 279 7. CVT Transmission > CVT Removal XCITING 400i Inspect the movable drive face and bushing for wear and damage. Replace the parts as needed. Clutch Disassembly Lift the clutch outer off of the centrifugal clutch. Inspect the inside of the clutch outer for excessive wear and damage. Measure the inside diameter of the clutch outer and replace the part as needed.
Page 280 7. CVT Transmission > CVT Removal XCITING 400i XCITING 400I XCITING S 400 Inspect the clutch shoe lining thickness. Replace the shoes if the wear is below the service limit. Item Standard (mm) Service Limit (mm) Clutch lining thickness To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch.
Page 281 7. CVT Transmission > CVT Removal XCITING 400i Use the clutch spring compressor tool to compress the spring in the driven pulley assembly. Loosen the clutch drive plate nut with the special socket that comes with the fitting tool. Remove the clutch drive plate nut. 4‐18...
Page 282 7. CVT Transmission > CVT Removal XCITING 400i Inspect the left side bearing by turning it with a finger. If the bearing is rough turning or noisy it should be replaced. Remove the clutch spring compressor tool. Lift off the centrifugal clutch. 4‐19...
Page 283 7. CVT Transmission > CVT Removal XCITING 400i Remove the collars and spring. Measure the free length of the clutch spring. Replace the spring if the measurement fails to meet the service limit. 4‐20...
Page 284 7. CVT Transmission > CVT Removal XCITING 400i Remove the three circlips from the clutch pivot pins with a small flat blade screwdriver. Lift off the plate. 4‐21...
Page 285 7. CVT Transmission > CVT Removal XCITING 400i Slide the clutch shoes off of the pivots on the drive plate. Inspect the clutch shoe bumpers and replace them as needed. 4‐22...
Page 286 7. CVT Transmission > CVT Removal XCITING 400i Driven Pulley Disassembly Remove the clutch as shown above. Remove the four guide rollers with guide roller pins. Separate the left and right faces of the driven pulley. 4‐23...
Page 287 7. CVT Transmission > CVT Removal XCITING 400i Inspect the faces of the driven pulley. Clean away any grease from the faces where the belt rides. Remove the seals from the left face of the driven pulley. 4‐24...
Page 288 7. CVT Transmission > CVT Removal XCITING 400i Drive in the new seals with a suitable driver with the same outside diameter as the seal. Remove the O-rings on the left face. Clean the left face and roller pins with a high flash point solvent and compressed air.
Page 289 7. CVT Transmission > CVT Removal XCITING 400i Bearing Replacement Inspect the bearings in the right face of the driven pulley. Remove the needle bearing with a suitable puller. 4‐26...
Page 290 7. CVT Transmission > CVT Removal XCITING 400i Remove the collar, snap ring, and bearing from the right face of the driven pulley. Clean the right face with a high flash point solvent and compressed air. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 291 7. CVT Transmission > CVT Removal XCITING 400i Lubricate the bearings in the right face of the driven pulley with grease 4‐28...
Page 292 7. CVT Transmission > CVT Installation XCITING 400i CVT Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease. Drive in the new seals with a suitable driver with the same outside diameter as the seal.
Page 293 XCITING 400i / XCITING S 400 Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO XCITING 400i / XCITING S 400. • Final Reduction ..............8-2 • Final Drive Oil............. 8-3~8-8 GENERAL INSTRUCTIONS •...
Page 294 XCITING 400i / XCITING S 400 8. Final Drive Final Reduction SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Disassembly Note: Do not remove the transmission case cover except for necessary part replacement. If the drive shaft is replaced, make sure to also replace the bearing and oil seal.
Page 295 XCITING 400i / XCITING S 400 8. Final Drive Final Drive Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Place the scooter on level ground and up on its center stand. The oil drain bolt and oil filler bolt are located on the transmission.
Page 296 XCITING 400i / XCITING S 400 8. Final Drive Inspection Place the vehicle on its center stand on level ground. Remove the transmission oil level check bolt with a 12 mm socket. The oil level is correct when oil flows from the bolt hole.
Page 297 XCITING 400i / XCITING S 400 8. Final Drive Draining Place the vehicle on its center stand on level ground. Place a suitable oil drain pan under the transmission oil drain plug. Place a suitable container under the drain plug to capture the final drive oil.
Page 298 XCITING 400i / XCITING S 400 8. Final Drive Install the oil drain plug and washer with a 12 mm socket. Tighten to specification. Torqu Item Thread size (mm) kgf-m lb-ft Final Drive oil 0.8 - 1.2 5.79 - 8.68 check bolt 8‐6...
Page 299 XCITING 400i / XCITING S 400 8. Final Drive Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole. Gear oil type: SAE 90 Gear oil capacity: At disassembly 0.23 Liter At change 0.20 Liter...
Page 300 XCITING 400i / XCITING S 400 8. Final Drive Thread in the final drive oil level check bolt. Install the oil check plug and torque it to specification with a 12 mm socket. Torque Item Thread size (mm) kgf-m lb-ft Final drive oil 0.8 - 1.2...
Page 301 9.Electrical Systems XCITING S 400 9.Electrical Systems This chapter covers the location and servicing of the electrical systems for the KYMCO XCITING S 400 model. General Instructions ............... 9-1 Troubleshooting ................9-3 Component Location ..............9-8 Fuses ..................... 9-11 ....................9-12 Ignition System ................
Page 302 9.Electrical Systems XCITING S 400 • When a battery is overcharged, some symptoms can be found. If there is a short circuit inside the battery, no voltage is produced on the battery terminals. If the rectifier won‘t operate, the voltage will become too high and shorten the battery service life.
Page 303 9.Electrical Systems XCITING S 400 TROUBLESHOOTING No power • Dead battery • Disconnected battery cable • Fuse burned out • Faulty ignition switch Intermittent power • Loose battery cable connection • Loose charging system connection • Loose connection or short circuit in the ignition system Low power •...
Page 304 9.Electrical Systems XCITING S 400 Ignition System GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page above.
Page 305 9.Electrical Systems XCITING S 400 TROUBLESHOOTING No peak voltage • Short circuit in engine stop switch or ignition switch wire. • Faulty engine stop switch or ignition switch. • Loose or poorly connected ignition control module connectors. • Open circuit or poor connection in ground wire of the ignition control module.
Page 306 9.Electrical Systems XCITING S 400 TROUBLESHOOTING Starter motor will not turn • Fuse burned out • Weak battery • Faulty ignition switch • Faulty starter clutch or gear • Faulty front or rear stop switch • Faulty starter relay • Poorly connected, broken or shorted wire •...
Page 307 9.Electrical Systems XCITING S 400 • Check the battery condition before performing any inspection that requires proper battery voltage. • A continuity test can be made with the switches installed on the scooter. • Route the wires and cables properly after servicing each component.
Page 308 9.Electrical Systems XCITING S 400 Component Location Regulator/Rectifier Air Cleaner/Element Seat Open Motor Spark Plug Fuel Tank Ignition Coil Horn Side Standard Switch Coolant Reserve Tank Hazard Controller Ignition Switch Front Wheel Speed Canister Sensor Connector Starter Relay Battery FUSE BOX...
Page 309 9.Electrical Systems XCITING S 400 Component Location Meter Instrument Couplers Winker Relay (Turn Signal) Battery Tilt Switch ABS ECU Fuel Cap Battery Box Fuse Box Fuel Pump Throttle Body Diagnostic Tool Connector...
Page 310 9.Electrical Systems XCITING S 400 Component Location MAP Sensor Throttle Body ISC (Idle Speed Controller) 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)
Page 311 9.Electrical Systems XCITING S 400 Fuses Fuse Box The fuse box is located on top of the battery. Open the covers to access the fuses. FUSE A: 15A (Winker, FR/RR Stop Horn, Meter, Starter, Position, Phone) FUSE B: 15A (Ignition, IGN Coil, Fuel Pump, Angle Detector Sensor, Fan Motor)
Page 312 9.Electrical Systems XCITING S 400 Remove the luggage box, body cover and external covers. See the external topic for more information. Note: The ECU could be damaged if dropped or the connector is disconnected when the key is on. The excessive voltage may damage the ECU. Always turn off the ignition switch before servicing.
Page 313 9.Electrical Systems XCITING S 400 Inspection Disconnect and remove the ECU from the frame. Check for continuity between pin 9 and 10 of the ECU side connector. There should be continuity at all times. Check for continuity between each pins 2, 4 and 23 of the ECU side connector.
Page 314 9.Electrical Systems XCITING S 400 Ignition System Ignition System The ignition timing is set at the factory and is not adjustable. Perform the following checks. Before performing any tests make sure the electrical connections are not loose or corroded. Ignition Coil Remove the connectors.
Page 315 9.Electrical Systems XCITING S 400 Ignition Coil Resistance Primary Set the multimeter to read ohms of resistance (Ω). Touch the positive and negative meter leads to the ignition coil terminals as shown. Measure the resistance. Ignition Coil Primary Resistance 3.57 - 4.83 Ω...
Page 316 9.Electrical Systems XCITING S 400 Secondary Without Plug Cap Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap. Touch the negative meter lead to the terminal and the positive meter lead to the spark plug wire as shown.
Page 317 9.Electrical Systems XCITING S 400 Spark Plug Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
Page 318 9.Electrical Systems XCITING S 400 Measure the gap with a wire-type thickness gauge. If the gap is incorrect, replace the spark plug. Always check the gap of the spark plug before installation. Inspect the color of the porcelain nose of the spark plug. The color of the spark plug can indicate how the mixture is burning.
Page 319 9.Electrical Systems XCITING S 400 AC Generator Inspection Crank Position Sensor Inspection Note: This test is performed with the stator installed in the engine. Disconnect the crank position sensor wire coupler. Measure the resistance between L/Y and G/GR wire terminals.
Page 320 9.Electrical Systems XCITING S 400 Charging System To replace the stator/charging coil see the A.C. Generator and Starter clutch topic. Charging Voltage Inspection Remove the battery cover. See the Battery topic for more information. Note: The battery should be fully charged prior to making charging system checks.
Page 321 9.Electrical Systems XCITING S 400 Charging Coil Wire Disconnect the generator 3-pin connector. Check the connectors for loose contacts or corroded terminals. Measure the resistance between each Yellow wire terminals. Check for continuity between each yellow wire terminal regulator/rectifier side and ground.
Page 322 9.Electrical Systems XCITING S 400 Battery SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention.
Page 323 9.Electrical Systems XCITING S 400 Battery Testing Check the battery voltage with a multi-meter. Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal. If the battery reads under 12.3 V it is undercharged.
Page 324 9.Electrical Systems XCITING S 400 Starting System Starter Relay Inspection Disconnect the starter relay wire connector. And remove the starter relay. Check for continuity between the yellow/red wire and green/yellow wire. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
Page 325 9.Electrical Systems XCITING S 400 Starter Motor Pull back the rubber starter motor lead cover and remove the nut. Remove two starter motor mounting bolts and remove the starter motor. Inspect the starter motor O-ring and replace it as needed.
Page 326 9.Electrical Systems XCITING S 400 Relays Seat Open Motor Relay/ Starter Relay/ Fuel Pump Relay/ ECU Relay/ Fan Relay (The location refer to the wiring diagram wire color) Relays Inspection Use a digital multimeter to inspect the relay. Relay Connect 12 V battery with the fuel cut-off relay connector.
Page 327 9.Electrical Systems XCITING S 400 Switches Ignition Switch Remove the front cover. Unplug the ignition switch connectors. Use a digital multimeter to check for continuity to inspect the ignition switches. Continuity should exist between the wires as indicated. To remove the anti-tamper bolts use a punch and a hammer to strike the bolts so that they rotate loose.
Page 328 9.Electrical Systems XCITING S 400 Luggage Box Light The lamp lights up when Seat Pad is lifted up, goes out when closed. (The Cabinet Light is provided with light-sensing switch; in case the user forgets to close the Seat Pad or the Pad fails to fully close up, system will cut the power automatically after a set time, preventing any power loss of battery.)
Page 329 9.Electrical Systems XCITING S 400 Check the circuit with the wire. 9-29...
Page 330 9.Electrical Systems XCITING S 400 Tilt Switch Remove the front cover. See the external topic for more information. Support the scooter level surface. Put the side stand up and engine stop switch on “RUN”. Turn the ignition switch to “OFF”.
Page 331 9.Electrical Systems XCITING S 400 Incline the tilt switch 65±10 degrees to the left or right at the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-) 5 V (ECU voltage) Black/Blue (+) ~ Green/Pink (-) 3.7 - 4.4 V...
Page 332 9.Electrical Systems XCITING S 400 Handlebar Switch Remove the front cover. See the external topic for more information. Unplug the black connector for the left handlebar switches. Unplug the green connector for the right handlebar switches. Use a digital multimeter to check for continuity to inspect the handlebar switches.
Page 333 9.Electrical Systems XCITING S 400 Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated. 9-33...
Page 334 9.Electrical Systems XCITING S 400 Side Stand Switch Place the vehicle on the center stand. Unplug the three-pin side stand switch connector. Use a digital multimeter to check for continuity. With the side stand retracted there should be continuity between the yellow/green wire and the green wire terminals.
Page 335 9.Electrical Systems XCITING S 400 Horn Remove the front cover. See the external topic for more information. Disconnect the horn connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.
Page 336 9.Electrical Systems XCITING S 400 Meter Instrument Remove couplers. Check the wiring diagram to inspect circuit. 9-36...
Page 337 9.Electrical Systems XCITING S 400 USB Power Socket This vehicle is provided with a USB Power Socket. You may connect a low power consumption product to the Socket, for charging the product while the engine is running. WARNING ◆ To avoid electrocution or short-circuit, make sure to cover-up the protection cap after using the USB Power Socket.
Page 338 10..Brake System XCITING S 400 10.Brakes This chapter covers the location and servicing of the brake system components for the KYMCO XCITING S 400 model. GENERAL INSTRUCTIONS ............10-1 TROUBLESHOOTING ..............10-2 DIAGRAM ..................10-3 DISC BRAKE ................. 10-4 FRONT CALIPER ................10-8 REAR BRAKE PAD .................
Page 339 10..Brake System XCITING S 400 TROUBLESHOOTING Brake lever soft or spongy • Air in the hydraulic system • Low brake fluid level • Clogged fluid passage • Contaminated brake disc pad • Warped/deformed brake disc • Worn brake disc pad •...
Page 340 10..Brake System XCITING S 400 Diagram 10-3...
Page 341 10..Brake System XCITING S 400 Disc Brake SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Measure the thickness of the brake rotor with a micrometer. Item Standard mm (in) Service Limited 4.8 - 5.2 (0.19 - 0.20) 4 (0.16)
Page 342 10..Brake System XCITING S 400 Front Removal Remove the five mounting bolts with a 6 mm Allen. To remove the front brake disc take out the five mounting bolts with a 8 mm Allen. Remove the front brake discs. 10-5...
Page 343 10..Brake System XCITING S 400 Installation Fit the brake disc into place as shown. Coat the threads of the disc bolts in a non-permanent thread locking agent. Thread in the bolts and torque them to specification with an Allen socket.
Page 344 10..Brake System XCITING S 400 Lift off the rear brake disc. Installation Fit the rear brake disc into place on the wheel as shown. Apply a non-permanent thread locking agent to the threads of the rear disc bolts. Insert the bolts and tighten them to specification with a 6 mm Allen.
Page 345 10..Brake System XCITING S 400 Front Caliper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Brake Pads Push the caliper body inward to push in the pistons. This will allow room to change the brake pads.
Page 346 10..Brake System XCITING S 400 Remove the brake pads with a 6mm Allen. Free the brake pads from the pad retainer. Remove the brake pads. Remove the brake pad Clips with a splcier. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven.
Page 347 10..Brake System XCITING S 400 Caliper Place a suitable container under the banjo bolt to catch any remaining brake fluid. Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket. Discard the two sealing washers.
Page 348 10..Brake System XCITING S 400 Installation Install the front caliper. Guide the brake disc between the pads. Line up the caliper bracket mounts with the fork. Install the two new caliper bracket mounting bolts. Tighten the mounting bolts to specification.
Page 349 10..Brake System XCITING S 400 When installation: Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.
Page 350 10..Brake System XCITING S 400 Rear Brake Pad Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Brake fluid is very caustic and can damage paint, chrome and plastic. Wipe up any spills immediately. Removal Place a suitable container under the banjo bolt to catch any remaining brake fluid.
Page 351 10..Brake System XCITING S 400 Loosen the brake pad pin with a 5 mm Allen. Remove the brake pad pin with a 5 mm Allen. Free the brake pads from the pad retainer. Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven.
Page 352 10..Brake System XCITING S 400 Master Cylinders Up And Low Handle Cover Removal Remove the top handle cover. Remove the bolts, screws and remove the up handle cover. Remove the bolts, screws. Remove throttle and parking brake cables and remove the low handle cover.
Page 353 10..Brake System XCITING S 400 SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Draining The brake bleeding process is the same for the front and rear brakes. Remove the two master cylinder cover screws with a #2 Phillips head screwdriver.
Page 354 10..Brake System XCITING S 400 Pump the brake lever several times and hold the lever in. While holding the lever in, crack open the bleeder valve. The front brake lever will travel all the way to the grip and brake fluid and/or air will come out of the bleeder valve into the 6 mm hose.
Page 355 10..Brake System XCITING S 400 Parking Brake Adjustment Release the fixed nut, and rotate the adjust nut to adjust the parking brake. Fixed nut Adjust nut Note: Do not use the rear brake lock lever while driving. Note: Do not use the rear brake lock lever while driving.
Page 356 10..Brake System XCITING S 400 SAFETY FIRST: Protective gloves and eyewear are recommended at this point. ABS Component Location 1. Front Wheel speed Sensor 2. Front Wheel speed Sensor Rotor 3. Rear Wheel speed Sensor 4. Rear Wheel speed Sensor Rotor 5.
Page 357 10..Brake System XCITING S 400 Introduction to KYMCO Anti-Lock Brake System ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
Page 358 10..Brake System XCITING S 400 Caution: Use of non-recommended tires may cause malfunctioning of ABS and lead to extended braking distance. The rider could have an accident as a result. Always use the standard tires for this vehicle. Notice: When the ABS is functioning, you may feel a pulsing in the brake lever.
Page 359 10..Brake System XCITING S 400 ABS Servicing Precautions There are a number of important precautions that should be followed servicing the ABS system. □ This ABS system is designed to be used with a 12V sealed battery as its power source.
Page 360 10..Brake System XCITING S 400 Caution If any of the brake line fittings, including the ABS hydraulic unit joint nuts, or the bleed valve are opened at any time, the air must be bled completely from the brake line. Do not ride the scooter with air in the brake line, or the ABS could malfunction.
Page 361 10..Brake System XCITING S 400 ABS Troubleshooting Outline The ABS indicator light lights up to alert the rider when an abnormality is detected by the system. The service codes are stored in the ABS unit memory. The codes will not be erased unless manually cleared. After the fault has been corrected erase the service codes.
Page 362 10..Brake System XCITING S 400 Pre-diagnosis Inspection Chart 1 10-25...
Page 363 10..Brake System XCITING S 400 Pre-diagnosis Inspection Chart 2 10-26...
Page 364 10..Brake System XCITING S 400 Meter Instruments The ABS indicator light is on the left side of the meter. This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving. The light stays off as long as the system is ok.
Page 365 10..Brake System XCITING S 400 ABS Indicator Light Is Unlit (When The Ignition Switch Turned To ON) 1st step test. Disconnect the meter connector. Check the terminal voltage between the ABS signal wire (Pink lead) terminal of the meter connector and ground. Turn the ignition switch ON.
Page 366 10..Brake System XCITING S 400 ABS Indicator Light lights (When the scooter is running, - no service code) 1st step test. Disconnect the ABS hydraulic unit connector and meter connector. Check for continuity between the ABS signal wire (Pink lead) terminal of the meter side connector and the ABS signal wire (Pink lead) terminal of the ABS unit side connector.
Page 367 10..Brake System XCITING S 400 Front, Rear Wheel Rotation Difference Abnormal (service code 25) 1st step test. Check the following and correct the faulty part. 1. Incorrect the tire pressure 2. Tire not recommended for the scooter were installed (incorrect tire size).
Page 368 10..Brake System XCITING S 400 ABS Motor Relay Inspection (service code 35) 1st step test. Check the ABS motor relay fuse (25A). Front Wheel Rotation Sensor Signal Abnormal (service code 42) 1st step test. Measure the clearance between the front wheel rotation sensor and sensor rotor.
Page 369 10..Brake System XCITING S 400 Front Wheel Rotation Sensor Wiring Inspection (service code 43) 1st step test. Disconnect the ABS hydraulic unit connector and front wheel sensor connector. Short the white/brown and red-green lead terminals of the main harness side connector with a jumper lead, and check for continuity between the white/brown and red green lead terminals of the main harness side connector.
Page 370 10..Brake System XCITING S 400 Rear Wheel Rotation Sensor Wiring Inspection (service code 45) 1st step test. Disconnect the ABS hydraulic unit connector and rear wheel sensor connector. Short the light-blue/brown and black/red lead terminals of the main harness side connector with a jumper lead, and check for continuity between the light-blue brown and black/red lead terminals of the main harness side connector.
Page 371 10..Brake System XCITING S 400 Power Supply Voltage Abnormal (under-voltage) (service code 52) 1st step test. Disconnect the ABS diagnosis connector and ABS hydraulic unit connector. Check for continuity for the black lead terminal of the main harness side connector.
Page 372 10..Brake System XCITING S 400 Power Supply Voltage Abnormal (over-voltage) (service code 53) 1st step test. Disconnect the ABS diagnosis connector and ABS hydraulic unit connector. Check for continuity for the black lead terminal of the main harness side connector.
Page 373 10..Brake System XCITING S 400 ECU Inspection (service code 55) 1st step test. Recheck the service code indication; erase the service code, perform the pre-diagnosis inspection 1 and 2, and retrieve the service code. If the ABS indicator light lit. faulty ECU in the ABS hydraulic unit. Replace the ABS hydraulic unit.
Page 374 10..Brake System XCITING S 400 Check and clear the ABS DTCs in the same manner as the fuel injection DTCs. Bosch ABS9m DTC LIST Code NO (Diagnostic Tool description (PDA) 3620A-LEB2-E00) 5013 Rear Inlet Valve malfunction (EV) 5014 Rear Outlet Valve malfunction (AV)
Page 375 10..Brake System XCITING S 400 When using the DATA Analyze feature of the diagnostic tool with the ABS system the front and rear wheel speed sensors should show speed when the wheels are rotated. Inspect the wheel speed sensors, rotors, wires, and connectors if the speed doesn't show correctly.
Page 376 10..Brake System XCITING S 400 ABS Unit Note the markings on the ABS unit for the brake Front (F) and Rear (R) brake hose positions. Do not attempt to disassemble the ABS unit. If the ABS unit must be replaced the new unit should come filled with brake fluid.
Page 377 11.Steering XCITING 400i/XCITING S 400 11.Steering This chapter covers the location and servicing of the steering components for the KYMCO XCITING 400i/XCITING S 400 model. TROUBLESHOOTING ..............11-1 Handlebar ..................11-2 Switch Housings and Throttle ............. 11-3 Grips ....................11-6 Steering stem ................
Page 378 11.Steering XCITING 400i/XCITING S 400 Handlebar SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Bar Ends Remove the bar ends with a 6 mm Allen. XCITING 400i XCITING S 400 Switch Housings Remove the wire and cable guide bolts with an 8 mm socket.
Page 379 11.Steering XCITING 400i/XCITING S 400 Switch Housings and Throttle Unplug the black connector for the left handlebar switches. XCITING 400i XCITING S 400 Unplug the green connectors for the right handlebar switches. XCITING 400i XCITING S 400 Remove the right switch housing mounting screws with a #2 Phillips screwdriver.
Page 380 11.Steering XCITING 400i/XCITING S 400 Separate the switch housing. The right switch housing has wires on both sides so it cannot be completely opened. XCITING 400i XCITING S 400 11-4...
Page 381 11.Steering XCITING 400i/XCITING S 400 Handlebar SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Loosen the four handlebar bolts with a 12 mm socket. Remove the handlebar holders and bolts. XCITING 400i XCITING S 400 11-5...
Page 382 11.Steering XCITING 400i/XCITING S 400 Grips If you plan to replace the grips you can slice them lengthwise with a razor blade and peel them off. To remove the grips without cutting them use a screwdriver to open a gap between the grip and the handlebar.
Page 383 If the movement is to tight or loose the steering stem adjusting nut may need to be adjusted. The KYMCO XCITING 400i/XCITING S 400 use ball bearings in the steering. Always replace the races at the same time as the bearings.
Page 384 11.Steering XCITING 400i/XCITING S 400 Remove the bridge stem nut and washer. Lift off the upper fork clamp. Special tool: A120F00002 XCITING 400i XCITING S 400 11-8...
Page 385 11.Steering XCITING 400i/XCITING S 400 A special lock nut wrench is needed to loosen the steering stem lock nut. Remove the steering stem lock nut. Special Tool - Long Socket Wrench: A120F00007 A special lock nut wrench is needed to loosen the steering stem lock nut. Remove the steering stem lock nut.
Page 386 11.Steering XCITING 400i/XCITING S 400 Remove the inner race for the upper bearing. Lower the lower fork clamp and steering stem out of the frame. Lift out the upper ball bearings. And slide the lower ball bearings up and off of the steering stem.
Page 387 11.Steering XCITING 400i/XCITING S 400 Inspect the bearings and races for wear and damage. Replace them as needed. Use a chisel and hammer to drive out the bearing races. Do not damage the frame pipe and steering stem. Have the drift set against the lip of the race, and work around the race evenly to drive it out.
Page 388 12.Front Suspension XCITING S 400 12.Front Suspension This chapter covers the location and servicing of the front fork components for the KYMCO XCITING S 400 model. TROUBLESHOOTING ..............12-1 Front Fender Assy. Removal ............12-2 Front Fork Removal ..............12-3...
Page 389 12.Front Suspension XCITING S 400 Front Fender Assy. Removal Remove the bolts, plates and reflectors. Remove the front fender assembly. 12-2...
Page 390 12.Front Suspension XCITING S 400 Front Fork Removal Loosen the front axle pinch bolt with a 6 mm Allen. Loosen the front axle with an 24 mm socket. Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground.
Page 391 12.Front Suspension XCITING S 400 Support the front wheel and slide the front axle out from the left side. Guide the front wheel out from the fork legs. Remove the collars from each side of the wheel. Inspect the bearing seals and the O-rings seals on the collars.
Page 392 12.Front Suspension XCITING S 400 Front Fork Removal and Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the front wheel speed sensor mounting bolt with an 8 mm socket. Free the front wheel speed sensor from the right fork.
Page 393 12.Front Suspension XCITING S 400 Slide the forks legs down and out of the fork clamp using a twisting motion. Installation Slide the fork legs up into fork clamp using a twisting motion. Fit the fork into place so that the mark on the top of the fork tube lines up with the upper fork clamp as shown.
Page 394 12.Front Suspension XCITING S 400 Tighten the lower fork clamp bolts evenly to specification with a 12 mm socket. Torque Item Q'ty Thread dia.(mm) Nm (kgf-m, ft-lb) Lower pinch bolt 32 (3.2, 23) Tighten the fork caps securely with a 30 mm socket. Tighten the upper fork clamp bolts to specification with a 6 mm Allen socket.
Page 395 12.Front Suspension XCITING S 400 Check the speed sensor to rotor clearance with a feeler gauge and make sure that it is 0.3 - 1.2 mm (0.0012 - 0.048 in). 12-8...
Page 396 13.Rear Suspension XCITING 400i/XCITING S 400 13.Rear Suspension This chapter provides information on the rear suspension components of the KYMCO XCITING 400i/XCITING S 400 model. TROUBLESHOOTING ..............13-1 Rear Fork ..................13-2 Installation ..................13-6 Shock Absorbers ................13-8 TROUBLESHOOTING Soft rear cushion •...
Page 397 13.Rear Suspension XCITING 400i/XCITING S 400 Rear Fork SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding.
Page 398 13.Rear Suspension XCITING 400i/XCITING S 400 Remove the rear wheel hose clamp bolts with an 8 mm socket. Place the scooter on its center stand so that the rear wheel is off the ground. Remove the two rear fork bolts with a 12 mm socket.
Page 399 13.Rear Suspension XCITING 400i/XCITING S 400 Inspect the wheel bearing by turning it with a finger. Replace the bearing and seal as needed. Remove the seal and snap ring. Drive the bearing out from the inside out. Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing.
Page 400 13.Rear Suspension XCITING 400i/XCITING S 400 Install the snap ring into the groove. Apply grease to the lips of the new seal and drive it into place in the same manner as the bearing. Inspect the shock absorber bushing and replace it as needed.
Page 401 13.Rear Suspension XCITING 400i/XCITING S 400 Installation Apply grease to the lips of the dust seal and install the collar into the rear fork. Fit the rear fork into place. Install the two rear fork bolts and tighten them to specification with a 12 mm socket.
Page 402 13.Rear Suspension XCITING 400i/XCITING S 400 Install the rear wheel speed sensor and hose clamp bolts with an 8 mm socket. Install the rear axle nut and tighten it to specification with a 24 mm socket. Torque Item Q'ty Thread dia.(mm)
Page 403 13.Rear Suspension XCITING 400i/XCITING S 400 Shock Absorbers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Pre-Load Setting Each shock absorber on the scooter has 5 spring preload adjustment positions for different load or riding conditions. Position 1 is for light loads and smooth road conditions. Position 3 to 5 increase spring preload for stiffer rear suspension and can be used when the scooters heavily loaded.
Page 404 13.Rear Suspension XCITING 400i/XCITING S 400 Removal Place the vehicle on its center stand. Remove these components Seat Seat Luggage Box Luggage Box Support the engine with a suitable hoist or jack. Remove the rear shock mounting bolts with a 14 mm socket.
Page 405 13.Rear Suspension XCITING 400i/XCITING S 400 Check over the shock absorber for damage and oil leaks. Replace the shock absorber if needed. Do not attempt to disassemble the shock absorber. Installation Fit the shock absorber into place. Make sure the preload arrow indicator faces out from the lower mount.
Page 406 13.Rear Suspension XCITING 400i/XCITING S 400 Install the lower shock absorber mounting bolts and torque them to specification with a 14 mm socket. Torque Item Q'ty Thread dia.(mm) Nm (kgf-m, ft-lb) Rear shock absorber bolt 40 (4, 29) Remove these components...
Page 407 14.Wheels XCITING S 400 14.Wheels This chapter covers the location and servicing of the wheels for the KYMCO XCITING S 400 model. Troubleshooting ................14-1 Wheel Bearing Replacement ............14-2 Front Wheel ................... 14-5 Tire Inspection ................14-10 Wheel Inspection ................14-22...
Page 408 14.Wheels XCITING S 400 Wheel Bearing Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace bearings as a set, and do not reuse old bearings. Place the new bearings in the freezer about an hour before you plan to install them.
Page 409 14.Wheels XCITING S 400 Remove one of the bearings with a bearing puller. Special Tools- Bearing Remover: A120E00093 Remove the distance collar. Repeat the procedure and remove the other bearing and seal. The seal should be replaced with a new item.
Page 410 14.Wheels XCITING S 400 Install the left bearing first. Pack the new bearing cavities with grease. Heat the bearing area of the wheel with a heat gun, take the bearing out of the freezer and install it. You can use a bearing installer tool or a socket with the same outside diameter as the bearing.
Page 411 14.Wheels XCITING S 400 Front Wheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the front axle pinch bolt with a 6 mm Allen. Loosen the front axle with an 24 mm socket. Lift the front end of the vehicle with a suitable stand or jack so that the front wheel comes off of the ground.
Page 412 14.Wheels XCITING S 400 Support the front wheel and slide the front axle out from the left side. Guide the front wheel out from the fork legs. Remove the collars from each side of the wheel. Inspect the bearing seals and the O-rings seals on the collars. Replace the seals if they are in poor condition.
Page 413 14.Wheels XCITING S 400 Inspect the wheel bearings by turning them in the hub. If the bearings have play in them or are rough replace all the bearings for that wheel. To remove the speed sensor rotor take out the five bolts.
Page 414 14.Wheels XCITING S 400 Make sure the tire direction of rotation marker is correct. Slide the front wheel into the fork. Apply a light coat of grease to the front axle. Insert the axle from the left side.Set the front wheel on the ground. Pump the front suspension up and down several times to seat the front axle Tighten the front axle to specification with an 24 mm socket.
Page 415 14.Wheels XCITING S 400 Torque Item Q'ty Thread dia.(mm) Nm (kgf-m, ft-lb) Front axle bolt 20 (2, 15) Tighten the front axle pinch bolt securely with a 6 mm Allen. Torque Item Q'ty Thread dia.(mm) Nm (kgf-m, ft-lb) Front fork pinch bolt 23 (2.3, 17)
Page 416 Kymco dealer for replacing with new one. Excessive wear of tire tread pattern will result in widened tread which is more prone to be punctured.
Page 417 14.Wheels XCITING S 400 Wheel Inspection SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub. Replace the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub.
Page 418 15.EEC System XCITING S 400 15.EEC SYSTEM This chapter covers the E.E.C system for the KYMCO XCITING S 400. E.E.C System Introduction ..........15-2 Function ................15-3 Trouble Shooting ............... 15-3 Air Filter Servicing ............15-4 Maintenance Information ..........15-5 Dismantle Of Canister ............
Page 419 15.EEC System XCITING S 400 E.E.C System Introduction: Evaporative Emission Control System The evaporative emission control system is used to prevent gasoline vapors from escaping into the atmosphere from the fuel tank and fuel system. Crankcase Emission Control System The scooter is equipped with a closed crankcase system. Blow-by gas is recycled into the combustion chamber via the intake system.
Page 420 15.EEC System XCITING S 400 Function Item Function Description It is used to prevent gasoline Storage the gasoline vapors to Evaporative vapors from escaping into the canister, conduct the gasoline Emission atmosphere from the fuel tank vapors to engine by vacuum Control Valve and fuel system.
Page 421 Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems..
Page 422 15.EEC System XCITING S 400 Maintenance Information Note of maintenance: Install the tubes in correct position. If the tubes broken should be replaced with a new one. The tubes should be installed tightly. The leakage hole should be installed downward.
Page 423 15.EEC System XCITING S 400 Dismantle of Canister 1.Dismantle the windshield, front cover and head light assembly. 2.Dismantle the canister tube set and canister. Canister Inspection of canister evaporative control valve Connecting a vacuum pump to the tube of canister. (Follow the illustration below.) Applying 250m/mHg pressure to the canister evaporative control valve.
Page 424 15.EEC System XCITING S 400 Inspection of the flow rate of the canister vacuum valve 1. Using a vacuum pump connecting to the vacuum tube of canister and apply 45m/mHg of negative pressure. 2. Apply pressure to the emission control valve of canister, if the flow rate above 9.4 litters per minute that means the valve is in good condition,...
Page 425 15.EEC System XCITING S 400 P.C.V. Dismantle 1.Dismantle the cover of air cleaner. 2.Dismantle the P.C.V cover. 3.P.C.V , if there is oil in the red drain tube, it should be cleaned. Inspection of emission system Clean or replace the air cleaner.
Page 426 15.EEC System XCITING S 400 Oxygen Sensor It uses DC-8-16V Battery Power with 4 pins: one power pin, one heater pin, one signal output pin and one earthing pin. The sensor is installed to the front pipe of exhaust pipe to detect the oxygen concentration of exhaust gas for determining if ECU shall instruct to increase or reduce fuel supply for meeting waste gas emission standard of environment legislation.

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