KYMCO XCITING 500 Manuel utilisateur

XCITING 500/500 AFI/250/300 AFI

By KWANG YANG Motor Co., Ltd.

First Edition, Apr 2006

unauthorized use without the written permission of

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100-SB30AA-A1

XCITING 500/500 AFI/250/300 AFI

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO XCITING

500/500 AFI /250/300 AFI.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which are

subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 8 through 14 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 15 through 17 is

the removal/ installation of chassis.

Section 18 through 22 states the testing

and measuring methods of electrical

equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages give

detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE DEPARTMENT

TABLE OF CONTENTS

GENERAL INFORMATION 1

FRAME COVERS /EXHAUST MUFFLER 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

FUEL SYSTEM/FUEL PUMP/FUEL

TANK/CARBURETOR 5

AFI (AUTOMATIC FUEL INJECTION) 6

COOLING SYSTEM 7

ENGINE REMOVAL/INSTALLATION 8

CYLINDER HEAD/VALVES 9

CYLINDER/PISTON 10

DRIVE AND DRIVEN PULLEY 11

FINAL REDUCTION 12

A.C. GENEARTOR/STARTER CLUTCH 13

CRANKCASE/CRANKSHAFT 14

STEERING HANDLEBAR/FRONT

WHEEL/FRONT SHOCK ABSORBER 15

REAR FORK/REAR WHEEL/REAR

SHOCK ABSORBER` 16

BRAKE SYSTEM 17

BATTERY/CHARGING SYSTEM 18

IGNITION SYSTEM 19

ELECTRIC STARTER 20

LIGHTS/METERS/SWITCHES 21

WIRING DIAGRAMS 22

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

KYMCO reserves the right to make

changes at any time without notice and

without incurring any obligation.

CHASSIS ELECTRICAL

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

XCITING 500/500 AFI/250/300 AFI

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

SERIAL NUMBER-----------------------------------------------------------1 - 1

SPECIFICATIONS (XCITING 500)---------------------------------------1 - 2

SPECIFICATIONS (XCITING 500 AFI) ---------------------------------1 - 3

SPECIFICATIONS (XCITING 250)---------------------------------------1 - 4

SPECIFICATIONS (XCITING 300 AFI) ---------------------------------1 - 5

SERVICE PRECAUTIONS-------------------------------------------------1 - 6

TORQUE VALUES ----------------------------------------------------------1-10

SPECIAL TOOLS ------------------------------------------------------------1-14

LUBRICATION POINTS ---------------------------------------------------1-15

CABLE & HARNESS ROUTING (XCITING 500)-------------------------1-17

CABLE & HARNESS ROUTING (XCITING 500 AFI)--------------------1-27

CABLE & HARNESS ROUTING (XCITING 250)-------------------------1-35

CABLE & HARNESS ROUTING (XCITING 300 AFI)--------------------1-43

TROUBLESHOOTING (XCITING 500/250) ----------------------------1-51

TROUBLESHOOTING (XCITING 500 AFI/300 AFI)-----------------1-62

1. GENERAL INFORMATION

1-1

XCITING 500/500 AFI/250/300 AFI

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

1. GENERAL INFORMATION

1-2

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 500)

ITEM SPECIFICATIONS

Name XCITING 500

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 498.5 cm3 (30.4 cu-in)

Fuel Used 92# nonleaded gasoline

Front wheel 83 kg (183 lbs)

Dry weight Rear wheel 132 kg (290 lbs)

Total 215 kg (473 lbs)

Front wheel 90 kg (198 lbs)

Curb weight Rear wheel 141 kg (310 lbs)

Total 231 kg (508 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 150 mm (6 in)

Min. turning radius 2750 mm (110 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 92 x75 mm

(3.7 x3 in)

Compression ratio 10.5:1

Compression pressure 13 kgf/cm²(1300kPa,

185 psi)

Open 2°BTDC

Intake valve Close 45°ABDC

Open 45°BBDC

Exhaust valve Close 5°ATDC

Valve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1400 rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 2.5 L (2.2 Imp qt,

2.65 Us qt)

Final reduction oil

capacity 0.55 L (0.5 Imp qt,

0.58 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 Imp gal,

2.82 US gal

Type CVK

Main jet NO. 98

Venturi dia. φ36 mm (φ1.44 in)

Throttle type PISTON

Type Full transistor ignition

Spark plug CR8E

Ignition timing Throttle position sensor

Spark plug gap 0.6～0.7mm (0.002～

0.003 in)

Battery Capacity 12V12AH

Clutch Type Dry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugal

Type

Type CVT

Preliminary 2.68 – 1

Final 5.4

FR/RR tire rolling

circumference 1724/1778 mm (69/71 in)

Front 2 kg/cm²(200 Kpa, 28

psi)

Tire pressure

(rider only/60

kg) Rear 2.5 kg/cm²(250 Kpa,

psi)

Turning Left 40°

angle Right 40°

Brake systemRearDisk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel System

Carburetor

Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

System

Engine

1. GENERAL INFORMATION

1-3

XCITING 500/500 AFI/250/300 AFI

ITEM SPECIFICATIONS

Name XCITING 500 AFI

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 498.5 cm3 (30.4 cu-in)

Fuel Used 92# nonleaded gasoline

Front wheel 83 kg (183 lbs)

Dry weight Rear wheel 132 kg (290 lbs)

Total 215 kg (473 lbs)

Front wheel 90 kg (198 lbs)

Curb weight Rear wheel 141 kg (310 lbs)

Total 231 kg (508 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 150 mm (6 in)

Min. turning radius 2750 mm (110 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 92 x75 mm

(3.7 x3 in)

Compression ratio 10.5:1

Compression pressure 13 kgf/cm²(1300kPa,

185 psi)

Open 5°BTDC

Intake valve Close 45°ABDC

Open 45°BBDC

Exhaust valve Close 5°ATDC

Valve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1400 rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 2.5 L (2.2 Imp qt,

2.65 Us qt)

Final reduction oil

capacity 0.55 L (0.5 Imp qt,

0.58 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 Imp gal,

2.82 US gal

Throttle Body Venturi

dia φ40 mm (φ1.6 in)

Type Full transistor ignition

Spark plug CR7E

Ignition timing ECU

Spark plug gap 0.6～0.7mm (0.002～

0.003 in)

Battery Capacity 12V12AH

Clutch Type Dry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugal

Type

Type CVT

Preliminary 2.68 – 1

Final 5.4

FR/RR tire rolling

circumference 1724/1778 mm (69/71 in)

Front 2 kg/cm²(200 Kpa, 28

psi)

Tire pressure

(rider only/60

kg) Rear 2.5 kg/cm²(250 Kpa,

psi)

Turning Left 40°

angle Right 40°

Brake systemRearDisk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel System Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

System

Engine

SPECIFICATIONS (XCITING 500 AFI)

1. GENERAL INFORMATION

1-4

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 250)

ITEM SPECIFICATIONS

Name XCITING 250

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 251/249.1 cm3

(15.3/15.8 cu-in)

Fuel Used 92# nonleaded gasoline

Front wheel 75 kg (165 lbs)

Dry weight Rear wheel 110 kg (242 lbs)

Total 185 kg (407 lbs)

Front wheel 81 kg (178 lbs)

Curb weight Rear wheel 119 kg (262 lbs)

Total 200 kg (440 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 170 mm (6.8 in)

Min. turning radius 2600 mm (104 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 72.7 x60 mm

(2.908 x2.4 in)

Compression ratio 10.3:1

Compression pressure 15 kgf/cm²(1500kPa,

213 psi)

Open 9°BTDC

Intake valve Close 45°ABDC

Open 38°BBDC

Exhaust valve Close 10°ATDC

Valve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1600 rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 1.1 L (0.97 Imp qt,

1.17 Us qt)

Final reduction oil

capacity 0.2 L (0.18 Imp qt,

0.21 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 Imp gal,

2.82 US gal

Type CVK

Main jet NO. 94

Venturi dia. φ30 mm (φ1.2 in)

Throttle type PISTON

Type Full transistor ignition

Spark plug DPR7EA-9

Ignition timing Throttle position sensor

Spark plug gap 0.6～0.7mm (0.002～

0.003 in)

Battery Capacity 12V10AH

Clutch Type Dry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugal

Type

Type CVT

Preliminary 0.83 – 2.2

Final 8.72

FR/RR tire rolling

circumference 1724/1778 mm (69/71 in)

Front 2 kg/cm²(200 Kpa, 28

psi)

Tire pressure

(rider only/60

kg) Rear 2.5 kg/cm²(250 Kpa,

psi)

Turning Left 40°

angle Right 40°

Brake systemRearDisk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel System

Carburetor

Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

System

Engine

1. GENERAL INFORMATION

1-5

XCITING 500/500 AFI/250/300 AFI

ITEM SPECIFICATIONS

Name XCITING 300 AFI

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 270 cm3

(15.3/15.8 cu-in)

Fuel Used 9nonleaded gasoline

Front wheel 75 kg (165 lbs)

Dry weight Rear wheel 110 kg (242 lbs)

Total 185 kg (407 lbs)

Front wheel 81 kg (178 lbs)

Curb weight Rear wheel 119 kg (262 lbs)

Total 200 kg (440 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 170 mm (6.8 in)

Min. turning radius 2600 mm (104 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 72.7 x65.2 mm

(2.908 x2.4 in)

Compression ratio 10.6:1

Compression pressure 15 kgf/cm²(1500kPa,

213 psi)

Open 9°BTDC

Intake valve Close 40°ABDC

Open 42°BBDC

Exhaust valve Close 7°ATDC

Valve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1600 rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 1.1 L/0.9L (0.97 Imp qt,

1.17 Us qt)

Final reduction oil

capacity 0.23 L/0.18L (0.2 Imp qt,

0.24 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 Imp gal,

2.82 US gal

Throttle Body Venturi

dia φ32mm (φ1.2 in)

Type Full transistor ignition

Spark plug DPR6EA-9

Ignition timing ECU

Spark plug gap 0.8～0.9mm (0.002～

0.003 in)

Battery Capacity 12V12AH

Clutch Type Dry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugal

Type

Type CVT

Preliminary 0.83 – 2.2

Final 8.26

FR/RR tire rolling

circumference 1724/1778 mm (69/71 in)

Front 2 kg/cm²(200 Kpa, 28

psi)

Tire pressure

(rider only/60

kg) Rear 2.5 kg/cm²(250 Kpa,

psi)

Turning Left 40°

angle Right 40°

Brake systemRearDisk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel System Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

System

Engine

SPECIFICATIONS (XCITING 300 AFI)

1. GENERAL INFORMATION

1-6

XCITING 500/500 AFI/250/300 AFI

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for proper

tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-7

XCITING 500/500 AFI/250/300 AFI

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

Confir

Capacity

Autres manuels pour XCITING 500

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels KYMCO Moto

KYMCO

KYMCO XCITING S 400 Manuel utilisateur

KYMCO

KYMCO DOWNTOWN 300i 2011 Manuel utilisateur

KYMCO

KYMCO VISA R 110 Manuel utilisateur

KYMCO

KYMCO PEOPLE S 50 Manuel utilisateur

KYMCO

KYMCO K-XCT 125i Manuel utilisateur

KYMCO

KYMCO Venox 250 Manuel utilisateur

KYMCO

KYMCO Downtown 350i Mode d'emploi

KYMCO

KYMCO MXU 500 IRS Manuel utilisateur

KYMCO

KYMCO Quannon 125 Note de version

KYMCO

KYMCO 125 ZING II QE - Manuel utilisateur

KYMCO

KYMCO Dink-R 150 Manuel utilisateur

KYMCO

KYMCO Stryker 125 Manuel utilisateur

KYMCO

KYMCO AGILITY300 Manuel utilisateur

KYMCO

KYMCO Dink 50 Note de version

KYMCO

KYMCO K-PIPE 125 Manuel utilisateur

KYMCO

KYMCO G-Dink 125i Manuel utilisateur

KYMCO

KYMCO CV3 Series Manuel utilisateur

KYMCO

KYMCO Dink 50 Manuel utilisateur

KYMCO

KYMCO Venox 250 Note de version

KYMCO

KYMCO 125 ZING II QE - Manuel utilisateur

KYMCO

KYMCO PEOPLE S 125 Manuel utilisateur

KYMCO

KYMCO X-Town CT125 Manuel utilisateur

KYMCO

KYMCO AHG5 Manuel utilisateur

KYMCO

KYMCO DINK50 Manuel utilisateur

Manuels Moto populaires d'autres marques

OHVALE

OHVALE GP-0 Manuel de la liste des pièces

Yamaha

Yamaha Star XV19CTSZ 2009 Manuel utilisateur

KTM

KTM 350 XCF-W USA Manuel utilisateur

HYOSUNG

HYOSUNG ST7 Manuel utilisateur

Husqvarna

Husqvarna FC 250 2016 Manuel utilisateur

Ducati

Ducati SCRAMBLER 800 Manuel d'instructions

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Manuel utilisateur

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Manuel utilisateur

Yamaha

Yamaha 2006 YZF-R1V Manuel utilisateur

KTM

KTM Freeride E-XC 2021 Manuel utilisateur

Fantic

Fantic Enduro 125 Manuel utilisateur

Ducati

Ducati Supersport 750 desmodue Manuel utilisateur

MV Agusta

MV Agusta 2008 F4 312RR 1078 Manuel d'instructions

Yamaha

Yamaha XVS650A Manuel utilisateur

Yamaha

Yamaha YZF-R6T(C) Manuel

Ducati

Ducati 748 monoposto strada Manuel utilisateur

ATK

ATK 1988 250 Manuel utilisateur

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Manuel utilisateur