KYMCO XCITING 500 Bedienungsanleitung

1. GENERAL INFORMATION

1-0

XCITING 500/250

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

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

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

SPECIFICATIONS (XCITING 250)---------------------------------------1 - 3

SERVICE PRECAUTIONS-------------------------------------------------1 - 4

TORQUE VALUES ----------------------------------------------------------1 - 8

SPECIAL TOOLS ------------------------------------------------------------1-12

LUBRICATION POINTS ---------------------------------------------------1-13

CABLE & HARNESS ROUTING (XCITING 500)-------------------------1-15

CABLE & HARNESS ROUTING (XCITING 250)-------------------------1-25

TROUBLESHOOTING------------------------------------------------------1-33

1. GENERAL INFORMATION

1-1

XCITING 500/250

SERIAL NUMBER

Location of Engine Serial Numbe

Location of Frame Serial Numbe

1. GENERAL INFORMATION

1-2

XCITING 500/250

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 moto

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/c

²(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 lmp qt,

2.65 Us qt)

Final reduction oil

capacity 0.55 L (0.5 lmp 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 lmp 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 senso

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/c

²(250 Kpa, 36

psi)

Turning Left 40°

angle Right 40°

Brake s

ste

Rea

Disk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

stem

Engine

1. GENERAL INFORMATION

1-3

XCITING 500/250

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 moto

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/c

²(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 lmp qt,

1.17 Us qt)

Final reduction oil

capacity 0.2 L (0.18 lmp 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 lmp 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 senso

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 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/c

²(250 Kpa, 36

psi)

Turning Left 40°

angle Right 40°

Brake s

ste

Rea

Disk brake

type Front Disk brake

Front Telescopic fork

Suspension

type Rear Unit swing

Frame type Back born

Tires

Fuel S

stem

Carbureto

Electrical Equipment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Ratio

Moving Device Damping

Device

Lubrication

stem

Engine

1. GENERAL INFORMATION

1-4

XCITING 500/250

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

1-5

XCITING 500/250

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

1. GENERAL INFORMATION

1-6

XCITING 500/250

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

Route harnesses so they are neither

pulled tight nor have excessive slack.

Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

When rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

When installing other parts, do not press or

squeeze the wires.

Do not pull

too tight！

o Contac

Do not press or

squeeze the

1. GENERAL INFORMATION

1-7

XCITING 500/250

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or surrounding parts in all steering

positions.

When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Symbols:

The following symbols represent the

servicing methods and cautions included in

this service manual.

: Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Note

Engine Oil

Grease

Gear Oil

＊

Do you understand

the instrument？

Remove Rust！

1. GENERAL INFORMATION

1-8

XCITING 500/250

TORQUE VALUES

STANDARD TORQUE VALUES

Item Torque

N•m (kgf•m, lbf•ft) Item Torque

N•m (kgf•m, lbf•ft)

5mm bolt and nut

6mm bolt and nut

8mm bolt and nut

10mm bolt and nut

12mm bolt and nut

14mm bolt and nut

5(0.5, 4)

10 (1, 7)

22 (2.2, 16)

35 (3.5, 25)

55 (5.5, 40)

70 (7, 50)

4mm screw

5mm screw

6mm screw, SH bolt

6mm flange bolt and nut

8mm flange bolt and nut

10mm flange bolt and nut

3 (0.3, 2)

4 (0.4, 3)

9 (0.9, 6.5)

12 (1.2, 9)

27 (2.7, 20)

40 (4, 29)

Torque specifications listed below are for important fasteners.

ENGINE (XCITING 500)

Item Q‘ty Thread dia.

(mm) Torque

N•m (kgf•m, lbf•ft) Remarks

MAINTENANCE:

Engine oil drain plug

Oil strainer screen cap

Oil filter cartridge

Transmission oil drain bolt

Transmission oil filler bolt

Spark plug

Tappet adjust nut

LUBRICATION SYSTEM:

Oil pump screw

Oil cooler bolt

COOLING SYSTEM:

Water pump cover bolt

CYLINDER HEAD:

Breather separator bolt

Cylinder head bolt (1 – 4)

Cylinder head bolt (5 – 13)

Cylinder head cover bolt

Cam chain tensioner bolt

Tensioner pivot bolt

Rocker arm shaft

DRIVE/DRIVEN PULLEY:

Drive face nut

Clutch out nut

25 (2.5, 18)

15 (1.5, 11)

10 (1, 7)

20 (2, 15)

12 (1.2, 9)

9 (0.9, 6)

3 (0.3, 2)

35 (3.5, 25)

13 (1.3, 9)

48 (4.8, 35)

23 (2.3, 17)

10 (1, 7)

12 (1.2, 9)

10 (1, 7)

45 (4.5, 32)

135 (13.5, 97)

80 (8, 58)

Apply oil

1. GENERAL INFORMATION

1-9

XCITING 500/250

ENGINE (XCITING 500) (Cont’d)

Item Q‘ty Thread dia.

(mm) Torque

N•m (kgf•m, lbf•ft) Remarks

Drive plate nut

ALTERNATOR

ACG flywheel nut

FINAL REDUCTION:

Transmission cover bolt

CRANKCASE:

Crankcase bolt

Oil pipe bolt

Cam chain guide

SWITCH:

Oil pressure switch

PT 1/8

78 (7.8, 56)

55 (5.5, 40)

27 (2.7, 20)

12 (1.2, 9)

43 (4.3, 31)

20 (2, 15)

22 (2.2, 16)

Apply oil

Apply seal

ENGINE (XCITING 250)

Item Q‘ty Thread

dia.(mm) Torque

N•

(

f•

lbf•ft

)

Remarks

MAINTENANCE:

Valve adjusting lock nut

Spark plug

Transmission oil drain bolt

Transmission oil check/fill bolt

Crank case oil drain bolt

Oil filter screen cap

LUBRICATION SYSTEM:

Oil pump screw

COOLING SYSTEM:

Water pump impeller

CYLINDER HEAD:

Cylinder head cap nut

Tensioner lifter bolt

Cylinder head cover bolt

Cam chain tensioner bolt

9 (0.9, 6.5)

12 (1.2, 9)

20 (2, 15)

25 (2.5, 18)

15 (1.5, 10.8)

2 (0.2, 1.4)

12 (1.2, 8.6)

25 (2.5, 18)

4 (0.4, 3)

12 (1.2, 8.6)

Apply oil

Left screw

Apply oil

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