Manual de Taller Xciting 500ri LER PDF

XCITING 500/500 AFI/250/300 AFI
By KWANG YANG Motor Co., Ltd.

First Edition, Apr 2006
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-SB30AA-A1
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO XCITING
500/500 AFI /250/300 AFI.
TABLE OF CONTENTS
Section 1 contains the precautions for

all operations stated in this manual.
Read them carefully before any
operation is started.
Section 3 describes the inspection/

adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
The information and contents included in

this manual may be different from the
motorcycle in case specifications are
changed.
KYMCO reserves the right to make
changes at any time without notice and
without incurring any obligation.
KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE DEPARTMENT
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.
FRAME COVERS /EXHAUST MUFFLER
INSPECTION/ADJUSTMENT
LUBRICATION SYSTEM
FUEL SYSTEM/FUEL PUMP/FUEL

TANK/CARBURETOR
AFI (AUTOMATIC FUEL INJECTION)
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
CYLINDER HEAD/VALVES
CYLINDER/PISTON
10
DRIVE AND DRIVEN PULLEY
11
FINAL REDUCTION
12
A.C. GENEARTOR/STARTER CLUTCH 13
CHASSIS
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.
ENGINE
Section 2 is the removal/installation

procedures for the frame covers which are
subject to higher removal/installation
frequency during maintenance and
servicing operations.
GENERAL INFORMATION
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
1. GENERAL INFORMATION
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
1-0
SERIAL NUMBER
Location of Frame Serial Number
Location of Engine Serial Number
1-1
SPECIFICATIONS (XCITING 500)

ITEM
Starting system
Type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Moving Device
Engine
12.8 L (3.38 Imp gal,

2.82 US gal
CVK
98
36 mm (1.44 in)
PISTON
Full transistor ignition
CR8E
Ignition timing
Throttle position sensor
Spark plug gap
0.60.7mm (0.002
0.003 in)
12V12AH
Dry, centrifugal
automatic
Battery Capacity
Clutch Type
Type
Helical gear/spur gear
Operation
Automatic centrifugal
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Tire pressure Front
(rider only/60
kg)
Rear
Turning
angle
Brake system
type
Damping
Device
Lubrication
System
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
92
x 75 mm
Bore x stroke
(3.7 x 3 in)
Compression ratio
10.5:1
13 kgf/cm (1300kPa,
Compression pressure
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)
Exhaust 0.1 mm (0.004 in)
(cold)
Idle speed
1400 rpm
pressure &
Lubrication type Forced
Wet sump
Oil pump type
Trochoid
Oil filter type
Full-flow filtration
2.5
L (2.2 Imp qt,
Oil capacity
2.65 Us qt)
Final reduction oil 0.55 L (0.5 Imp qt,
0.58 Us qt)
capacity
Cooling Type
Liquid cooled
Type
Spark plug
Transmis- Reduction
sion Gear Ratio
Min. turning radius
Ignition System
Ground clearance
Type
Main jet NO.
Venturi dia.
Throttle type
Power Drive System
Tires
Carburetor
Curb weight
83 kg (183 lbs)
132 kg (290 lbs)
215 kg (473 lbs)
90 kg (198 lbs)
141 kg (310 lbs)
231 kg (508 lbs)
120/70-15
150/70-14
150 mm (6 in)
2750 mm (110 in)
Electric starter motor
Fuel capacity
Electrical Equipment
Dry weight
92# nonleaded gasoline
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
ITEM
SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel System
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
Displacement
Fuel Used
SPECIFICATIONS
XCITING 500
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
498.5 cm3 (30.4 cu-in)
Suspension
type
Frame type
2.68 1
5.4
1724/1778 mm (69/71 in)
2 kg/cm (200 Kpa, 28

psi)
2.5 kg/cm (250 Kpa,

36
psi)
Left
40
Right 40
Rear Disk brake
Front Disk brake
Front
Telescopic fork
Rear
Unit swing
Back born
1-2
SPECIFICATIONS (XCITING 500 AFI)

ITEM
Dry weight
Ground clearance
Min. turning radius
Engine
1-3
Throttle Body Venturi

40 mm (1.6 in)
dia
Type
Spark plug
CR7E
Ignition timing
ECU
Spark plug gap
Battery Capacity
Clutch Type
Operation
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Tire pressure Front
(rider only/60
kg)
Rear
Brake system
type
Suspension
type
Frame type
0.60.7mm (0.002
0.003 in)
12V12AH
Dry, centrifugal
automatic
Type
Turning
angle
Damping
Device
Lubrication
System
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
92
x 75 mm
Bore x stroke
(3.7 x 3 in)
Compression ratio
10.5:1
13
kgf/cm (1300kPa,
185 psi)
Open 5 BTDC
Intake valve
Close 45 ABDC
Open 45 BBDC
Exhaust valve
Close 5 ATDC
0.1 mm (0.004 in)
(cold)
Idle speed
1400 rpm
Forced
pressure &
Lubrication type Wet sump
Oil pump type
Trochoid
Oil filter type
2.5 L (2.2 Imp qt,
Oil capacity
2.65 Us qt)
0.58 Us qt)
capacity
Cooling Type
Liquid cooled
Moving Device
Starting system
Type
Valve arrangement
12.8 L (3.38 Imp gal,

2.82 US gal
Fuel capacity
Transmis- Reduction
sion Gear Ratio
Tires
83 kg (183 lbs)
132 kg (290 lbs)
215 kg (473 lbs)
90 kg (198 lbs)
141 kg (310 lbs)
231 kg (508 lbs)
120/70-15
150/70-14
150 mm (6 in)
2750 mm (110 in)
Power Drive System
Curb weight
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
ITEM
SPECIFICATIONS
Ignition System
Fuel Used
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
Fuel System Electrical Equipment
Displacement
SPECIFICATIONS
XCITING 500 AFI
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
498.5 cm3 (30.4 cu-in)
2.68 1
5.4
1724/1778 mm (69/71 in)
2 kg/cm (200 Kpa, 28

psi)
2.5 kg/cm (250 Kpa,

36
psi)
Left
40
Right 40
Rear Disk brake
Front Disk brake
Front
Telescopic fork
Rear
Unit swing
Back born
SPECIFICATIONS (XCITING 250)

ITEM
Curb weight
Min. turning radius
Engine
Ignition timing
Throttle position sensor
Spark plug gap
0.60.7mm (0.002
0.003 in)
12V10AH
Dry, centrifugal
automatic
Battery Capacity
Clutch Type
Type
Operation
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Tire pressure Front
(rider only/60
kg)
Rear
Turning
angle
Brake system
type
Damping
Device
Lubrication
System
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
72.7
x 60 mm
Bore x stroke
(2.908 x 2.4 in)
Compression ratio
10.3:1
15
kgf/cm (1500kPa,
213 psi)
Open 9 BTDC
Intake valve
Close 45 ABDC
Open 38 BBDC
Exhaust valve
Close 10 ATDC
0.1 mm (0.004 in)
(cold)
Idle speed
1600 rpm
Forced
pressure &
Oil pump type
Trochoid
Oil filter type
1.1 L (0.97 Imp qt,
Oil capacity
1.17 Us qt)
0.21 Us qt)
capacity
Cooling Type
Liquid cooled
Moving Device
Starting system
Type
Valve arrangement
12.8 L (3.38 Imp gal,

2.82 US gal
CVK
94
30 mm (1.2 in)
PISTON
DPR7EA-9
Transmis- Reduction
sion Gear Ratio
Ground clearance
75 kg (165 lbs)
110 kg (242 lbs)
185 kg (407 lbs)
81 kg (178 lbs)
119 kg (262 lbs)
200 kg (440 lbs)
120/70-15
150/70-14
170 mm (6.8 in)
2600 mm (104 in)
Type
Spark plug
Power Drive System
Tires
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Type
Main jet NO.
Venturi dia.
Throttle type
Ignition System
Dry weight
Carburetor
Fuel Used
Fuel capacity
Electrical Equipment
Displacement
ITEM
SPECIFICATIONS
Fuel System
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
SPECIFICATIONS
XCITING 250
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
251/249.1 cm3
(15.3/15.8 cu-in)
Suspension
type
Frame type
0.83 2.2
8.72
1724/1778 mm (69/71 in)
2 kg/cm (200 Kpa, 28

psi)
2.5 kg/cm (250 Kpa,

36
psi)
Left
40
Right 40
Rear Disk brake
Front Disk brake
Front
Telescopic fork
Rear
Unit swing
Back born
1-4
SPECIFICATIONS (XCITING 300 AFI)

ITEM
Fuel Used
Dry weight
Ground clearance
Min. turning radius
Starting system
Type
Valve arrangement
75 kg (165 lbs)
110 kg (242 lbs)
185 kg (407 lbs)
81 kg (178 lbs)
119 kg (262 lbs)
200 kg (440 lbs)
120/70-15
150/70-14
170 mm (6.8 in)
2600 mm (104 in)
Throttle Body Venturi

32 mm (1.2 in)
dia
Type
Spark plug
DPR6EA-9
Ignition timing
ECU
Spark plug gap
Battery Capacity
Clutch Type
0.80.9mm (0.002
0.003 in)
12V12AH
Dry, centrifugal
automatic
Type
Operation
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Moving Device
Engine
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
Tire pressure
72.7
x
65.2
mm
(rider only/60
Bore x stroke
(2.908 x 2.4 in)
kg)
Compression ratio
10.6:1
15
kgf/cm (1500kPa,
Turning
213 psi)
angle
Open 9 BTDC
Intake valve
Brake system
Close 40 ABDC
type
Open 42 BBDC
Exhaust valve
Close 7 ATDC
Suspension
0.1 mm (0.004 in)
type
(cold)
Idle speed
1600 rpm
Frame type
Forced
pressure &
Oil pump type
Trochoid
Oil filter type
1.1 L/0.9L (0.97 Imp qt,
Oil capacity
1.17 Us qt)
Final reduction oil 0.23 L/0.18L (0.2 Imp qt,
0.24 Us qt)
capacity
Cooling Type
Liquid cooled
Damping
Device
Lubrication
System
1-5
12.8 L (3.38 Imp gal,

2.82 US gal
Fuel capacity
Transmis- Reduction
sion Gear Ratio
Tires
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Power Drive System
Curb weight
9 nonleaded gasoline
ITEM
SPECIFICATIONS
Ignition System
Displacement
Fuel System Electrical Equipment
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
SPECIFICATIONS
XCITING 300 AFI
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
270 cm3
(15.3/15.8 cu-in)
Front
0.83 2.2
8.26
1724/1778 mm (69/71 in)
2 kg/cm (200 Kpa, 28

psi)
2.5 kg/cm (250 Kpa,

36
psi)
Left
40
Right 40
Rear Disk brake
Front Disk brake
Rear
Front
Telescopic fork
Rear
Unit swing
Back born
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
Apply or add designated greases and

lubricants to the specified lubrication
points.
After reassembly, check all parts for proper

tightening and operation.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
When two persons work together, pay
attention to the mutual working safety.
Use genuine parts and lubricants.

Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
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.
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.
1-6
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
Confirm
Capacity
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.
After operation, terminal caps shall be

installed securely.
Before connecting a terminal, check for

damaged terminal cover or loose negative
terminal.
When taking out the connector, the lock on

the connector shall be released before
operation.
Check the double connector cover for

proper coverage and installation.
Hold the connector body when connecting

or disconnecting it.
Do not pull the connector wire.
Insert the terminal completely.

Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Check if any connector terminal is bending,

protruding or loose.
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.
1-7
After clamping, check each wire to make
sure it is secure.
Route harnesses so they are neither

pulled tight nor have excessive slack.
Do not pull
too tight
Do not squeeze wires against the weld or

its clamp.
Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or
corner.
After clamping, check each harness to

make sure that it is not interfering with any
moving or sliding parts.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.
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.
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.
When installing other parts, do not press or

squeeze the wires.
Do not press or
squeeze the wire
1-8
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.
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
Engine Oil
: Apply engine oil to the

specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
Grease
: Transmission Gear Oil (90#)

Gear Oil
When a testing device is used, make sure to

understand the operating methods
thoroughly and operate according to the
operating instructions.
Do you understand
the instrument
Be careful not to drop any parts.
When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.
Remove Rust
1-9
: Note
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque
Nm (kgfm, lbfft)
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)
Item
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
Torque
Nm (kgfm, lbfft)
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/XCITING 500 AFI)

Item
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
Qty
Thread dia.
(mm)
Torque
Nm (kgfm, lbfft)
1
1
1
1
1
1
4
12
30
20
8
8
10
5
25 (2.5, 18)
15 (1.5, 11)
10 (1, 7)
20 (2, 15)
20 (2, 15)
12 (1.2, 9)
9 (0.9, 6)
1
2
4
16
3 (0.3, 2)
35 (3.5, 25)
13 (1.3, 9)
3
4
9
4
2
1
2
6
10
8
6
6
8
18
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)
Apply oil
Apply oil
Apply oil
1
1
18
14
135 (13.5, 97)

80 (8, 58)
Apply oil
Apply oil
Remarks
Apply oil
1-10

Item
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
(Contd)
Thread dia.
(mm)
28
Torque
Nm (kgfm, lbfft)
78 (7.8, 56)
14
55 (5.5, 40)
27 (2.7, 20)
13
2
2
6
16
8
12 (1.2, 9)
43 (4.3, 31)
20 (2, 15)
Apply oil
Apply oil
PT 1/8
22 (2.2, 16)
Apply seal
Qty
Remarks

Item
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
1-11
Qty
Thread
dia.(mm)
Torque
Nm (kgfm, lbfft)
2
1
1
1
1
1
5
10
12
8
12
30
9 (0.9, 6.5)
12 (1.2, 9)
20 (2, 15)
20 (2, 15)
25 (2.5, 18)
15 (1.5, 10.8)
2 (0.2, 1.4)
12 (1.2, 8.6)
Left screw
4
1
4
2
8
6
6
6
25 (2.5, 18)
4 (0.4, 3)
12 (1.2, 8.6)
12 (1.2, 8.6)
Apply oil
Remarks
Apply oil
Apply oil

Item
DRIVE/DRIVEN PULLEY:
Drive face nut
Clutch outer nut
Clutch drive plate nut
Left crankcase cover bolt
ALTERNATOR
A.C.G. stator
Flywheel nut
FINAL REDUCTION:
Transmission case cover bolt
CRANKCASE:
Cam chain guide bolt
SWITCH:
Oil pressure switch
(Contd)
Qty
Thread dia.
(mm)
Torque
Nm (kgfm, lbfft)
1
1
1
6
14
12
28
6
93 (9.3, 67)
54 (5.4, 39)
54 (5.4, 39)
12 (1.2, 8.6)
5
1
5
14
9 (0.9, 6.5)
55 (5.5, 40)
20 (2, 14.4)
10 (1, 7)
PT 1/8
22 (2.2, 16)
Remarks
Apply oil
Apply seal
1-12
FRAME
Item
STEERING:
Handlebar bolt
Upper pinch bolt
Lower pinch bolt
Bridge stem nut
Steering stem lock nut
Top thread
WHEEL:
Front axle bolt
Front fork bolt
Rear axle nut (XCITING 500)
Rear axle nut (XCITING 250)
SUSPENSION:
Rear shock absorber bolt
Rear fork
BRAKE:
Front caliper mounting bolt
Rear caliper mounting bolt
Brake fluid bolt
Master cylinder bolt
ENGINE HANGER:
Engine hanger bolt
Engine mounting bolt/nut
(XCITING 500)
Engine mounting bolt/nut
(XCINTING 250)
Engine hanger rod nut
MUFFLER
Exhaust pipe nut
Muffler mount bolt
1-13
Qty Thread dia.(mm)
Torque
Nm (kgfm,
lbfft)
4
2
4
1
1
1
8
8
8
22
25.4
25.4
23 (2.3, 17)
23 (2.3, 17)
32 (3.2, 23)
62 (6.2, 45)
55 (5.5, 40)
20 (2, 15)
1
2
1
1
18
8
20
16
20 (2, 15)
23 (2.3, 17)
180 (18, 130)
140 (14, 100)
4
2
10
8
40 (4, 29)
32 (3.2, 23)
4
2
6
4
8
8
10
6
32 (3.2, 23)
32 (3.2, 23)
35 (3.5, 25)
12 (1.2, 9)
4
1
10
14
50 (5, 36)
80 (8, 58)
10
50 (5, 36)
10
35 (3.5, 25)
2
3
8
10
20 (2, 14)
35 (3.5, 25)
Remarks
Replace a new one

Replace a new one
SPECIAL TOOLS
XCITING 500/XCITING 500 AFI
Tool Name
Tool No.
Oil seal & bearing installers

Lock nut socket wrench
Universal holder
Flywheel holder
Tappet adjuster
Bearing pullers
Valve spring compressor
Oil filter cartridge wrench
Clutch spring compressor
Flywheel puller
Steering stem top thread wrench
A120E00014
A120E00015
A120E00017
A120E00021
A120E00036
A120E00037
A120E00040
A120E00052
A120E00053
A120E00054
A120F00007
A120F00023
Remarks
Oil seal & bearing install
Steering stem removal or install
Holding clutch for removal
A.C. generator flywheel holding
Tappet adjustment
Bearing removal
Valve removal
Cartridge removal or install
Clutch disassembly
A.C. generator flywheel removal
XCITING 250/XCITING 300 AFI

Tool Name
Flywheel puller
Oil seal & bearing installers
Universal holder
Flywheel holder
Clutch spring compressor
Tappet adjuster
Tool No.
A120E00003
A120E00014
A120E00015
A120E00017
A120E00021
A120E00034
A120E00036
Remarks
A.C. generator flywheel removal
Oil seal & bearing install
Holding clutch for removal
A.C. generator flywheel holding
Clutch disassembly
Tappet adjustment
Bearing pullers
A120E00037 Bearing removal
Valve spring compressor
A120E00040 Valve removal
A120F00007 Steering stem removal or install
Steering stem top thread wrench A120F00023 Steering stem removal or install
1-14
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part

Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Balancer shaft
Crankshaft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE 5W-50)

API SJ Engine Oil
Drive gear shaft

Countershaft
Final gear
Final gear shaft
Transmission oil: SAE 90
Transmission gearshaft bearing part

A.C. generator connector
1-15
Adhesive
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Engine Oil
Grease
Seat Lock
Throttle Cable
Grease
Front/Rear Brake Lever Pivot
Front Wheel Bearing
Rear Wheel Bearing
Grease
Grease
Center Stand/Side Stand Pivot
Grease
1-16
CABLE & HARNESS ROUTING (XCITING 500)
1-17
1-18
1-19
1-20
1-21
1-22
1-23
1-24
1-25
1-26
CABLE & HARNESS ROUTING (XCITING 500 AFI)
Tilt Switch
1-27
Tilt Switch
1-28
1-29
1-30
1-31
Revise to front cover

position
Fuel Pump Relay
Rear Brake Hose
1-32
1-33
1-34
CABLE & HARNESS ROUTING (XCITING 250)
1-35
1-36
1-37
1-38
1-39
1-40
1-41
1-42
CABLE & HARNESS ROUTING (XCITING 300 AFI)
Tilt Switch
1-43
Tilt Switch
1-44
1-45
1-46
1-47
300i ECU Location at

rear frame position as
picture.
300Ri ECU Location at
front cover position .
1-48
1-49
1-50
TROUBLESHOOTING (XCITING 500/250)

ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment
Probable Cause
Symptom
Check if fuel reaches

carburetor by loosening
drain screw
Fuel reaches
carburetor
Fuel does not

reach carburetor
cEmpty fuel tank

dClogged carburetor fuel inlet
tube, vacuum tube or fuel tube
eClogged auto fuel valve
fClogged float oil passage
gClogged fuel tank cap
breather hole
hClogged fuel strainer
iClogged fuel filter
jFaulty fuel pump
Weak or no spark
cFaulty spark plug

dFouled spark plug
eFaulty ignition unit
fFaulty A.C. generator
gBroken or shorted ignition coil
hBroken or shorted exciter coil
iFaulty ignition switch
Remove spark plug and

install it into spark plug
cap to test spark by
connecting it to engine
ground
Spark jumps
Test cylinder
compression
Normal
compression
Low or no
compression
cStarter motor idles but

crankshaft does not rotate
dValve clearance too small
eImproper valve and seat contact
fWorn cylinder and piston rings
gBlown cylinder head gasket
hFlaws in cylinder head
iSeized valve
jImproper valve timing
Start engine by following normal starting

procedure
Engine does not
fire
Engine fires but

does not start
Dry spark plug
Wet spark plug
cFaulty auto bystarter

dAir leaking through intake
pipe
eIncorrect ignition timing
fIncorrectly adjusted pilot screw

inspect again
1-51
cFlooded carburetor
dFaulty auto bystarter
eThrottle valve excessively
open
ENGINE LACKS POWER

Probable Cause
Symptom
Start engine and

accelerate lightly for
observation
Engine speed
increases
Engine speed does

not increase
sufficiently
Check ignition timing

(using a timing light)
cClogged air cleaner

dRestricted fuel flow
eClogged fuel line between fuel
tank and carburetor
fClogged exhaust muffler
gFaulty auto bystarter
hSplit carburetor vacuum piston
diaphragm
cFaulty ignition unit
dFaulty A.C. generator
Correct timing
Incorrect timing
Correct
Incorrect
cImproper valve clearance

adjustment
dWorn valve seat (valve stem too
protruding
Normal
compression
Abnormal
compression
cImproper valve and seat contact

dWorn cylinder and piston rings
eBlown cylinder head gasket
fFlaws in cylinder head
gImproper valve timing
Check valve clearance
Test cylinder compression
Check carburetor for

clogging
Not Clogged
Clogged
cClogged carburetor jets

inspect
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not

contaminated
Incorrect or
contaminated
Remove oil dipstick and

check oil level and condition
cFouled spark plug

dIncorrect heat range plug
cOil level too high
dOil level too low
eOil not changed
Remove cylinder head

bolts and inspect
Valve train lubricated
properly
Valve train not

lubricated properly
Check if engine overheats

Engine does not
overheats
Engine overheats
Rapidly accelerate or run

at high speed
Engine does not knock
Engine knocks
cFaulty oil pump

cInsufficient coolant
dFaulty thermostat
eWorn cylinder and piston rings
fMixture too lean
gPoor quality fuel
hExcessive carbon buildup in
combustion chamber
iIgnition timing too early
jAir in cooling system
cExcessive carbon build-up in
combustion chamber
dPoor quality fuel
eClutch slipping
fMixture too lean
g Ignition timing too early
1-52
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Symptom
Probable Cause

Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
cMixture too rich (turn screw

out)
dMixture too lean (turn screw
in)
Air leaks
cDamaged insulator rubber

dCarburetor not securely
tightened
eFaulty intake manifold gasket
fDeformed carburetor O-ring
Check carburetor pilot

screw adjustment
Check intake manifold

for air leaks
No air leak
ground
Good spark
Weak or intermittent spark
cFaulty or fouled spark plug

dFaulty ignition unit
eFaulty A.C. generator
fFaulty ignition coil
gBroken or shorted high
tension wire
hFaulty ignition switch
Good
Faulty
cDamaged air cut-off valve

diaphragm
dDamaged air cut-off valve
spring
Check carburetor air

cut-off valve
1-53
POOR PERFORMANCE (AT HIGH SPEED)
Symptom
Probable Cause

Correct timing
Incorrect timing
Correctly adjusted
cImproperly adjusted valve

clearance
dWorn valve seat
Fuel flows freely
Fuel flow restricted
cEmpty fuel tank

dClogged fuel tube or filter
eFaulty fuel pump
fCracked fuel pump vacuum
tube
Not clogged
Clogged
cClean and unclog
Correct
Incorrect
cCam timing gear aligning

marks not aligned
Not weakened
Weak spring
Check fuel pump for

fuel supply
Check carburetor jets

for clogging
Check valve timing
Check valve spring

tension
cFaulty spring
1-54
ENGINE NOISE
Symptom
Valve noise
Probable Cause
cValve clearance too large

dWorn camshaft lobe
cWorn piston rings

Piston noise
Cam chain noise
Crankshaft noise
dWorn piston pin and connecting rod small

end
eExcessive carbon build-up in combustion
chamber
cDamaged cam chain tensioner

dWorn cam gear teeth
eWorn or damaged cam chain
fExtended cam chain
cFaulty crankshaft bearing

dWorn crank pin bearing
Gear noise
cWorn or damaged final reduction gears

dWorn final reduction gear shaft splines
1-55
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Engine starts but motorcycle does not move
Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)
Probable Cause
cWorn or slipping drive belt
dBroken ramp plate
eBroken drive face spring
fSeparated clutch lining
gDamaged driven pulley shaft splines
hDamaged final gear
iSeized final gear
cBroken shoe spring

dClutch outer and clutch weight stuck
eSeized pivot
Engine lacks power at

start of a grade(poor
slope performance)

dWorn weight rollers
eSeized drive pulley bearings
fWeak driven face spring
gWorn or seized driven pulley bearings

high speed

eWorn or seized driven pulley bearings
There is abnormal noise

or smell while running
cOil or grease fouled drive belt

dWorn drive belt
eWeak driven face spring
fWorn or seized driven pulley bearings
1-56
STARTER MOTOR
1. Starter motor wont turn
Symptom
Probable Cause
Check operation of
stop switch by
applying brake
Stoplight comes on
Stoplight does not

come on
Signals operate
properly
Signals dim, remain

on or dont operate
Relay operates
properly
Relay does not

operate
Starter motor turns
Starter does not turn
Check battery circuit

by operating turn
signals
Check operation of
starter relay by
depressing starter
button
Connect starter
motor directly to
battery
cBurned out fuse

dWeak or dead battery
eFaulty stop switch
fLoose or disconnected
connectors
gBroken or shorted ignition
switch wire
hFaulty side stand switch
cFaulty or weak battery
cPoor starter button connection

dOpen or shorted starter relay
eLoose or disconnected
connectors
cWorn brushes
dOpen or shorted wires or rotor
eOpen starter motor cable
fLoose connectors
cOpen wire harness
2. Starter motor turns slowly or idles

Symptom
Probable Cause

by operating turn
signals
Signals operate
properly
Signals dim, remain

on or dont operate
Starter motor
turns slowly
Starter motor
turns normally
cWeak or dead battery
Connect starter
motor directly to
battery
cLoose connector or terminal
dPoor contact in starter relay
eFaulty starter clutch
Rotate crankshaft
Hard to turn
Turns easily
cSeized cylinder
cBroken or shorted starter
motor cable
3. Starter motor does not stop turning

Symptom
Probable Cause
Turn ignition switch

OFF
Not stopped
1-57
Stopped
cFaulty starter pinion

cStarter relay shorted or stuck
closed
NO SPARK AT SPARK PLUG

Symptom
Probable Cause
Replace with a new

spark plug and inspect
again
Good spark
cFaulty spark plug
Not loose
Loose
cFaulty spark plug
Good
Good
cPoorly connected coupler
Normal
Abnormal
Normal
Abnormal
Weak or no spark
Check spark plug cap
and high-tension wire
for looseness
Check ignition unit

coupler for looseness
Measure resistance
between terminals of
ignition unit coupler
Check related parts

cFaulty ignition switch
dFaulty exciter coil
eFaulty pulser coil
fFaulty ignition coil
cBroken wire harness
dPoorly connected coupler
Check ignition unit
Abnormal
1-58
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging
Symptom
Probable Cause
Start engine and test

limit voltage of battery
terminals
Normal voltage
Voltage does not

increase
Normal
Resistance too low
cFaulty AC generator
dFaulty regulator/rectifier
eFaulty battery
Measure resistance
between AC generator
coil terminals
cShorted AC generator coil
dOpen circuit between AC
generator 3 yellow wires
Test output voltage of

regulator/rectifier
coupler red wire
Normal voltage
No voltage
cFaulty regulator/rectifier
dFaulty AC generator
eLoose regulator/rectifier
coupler
fLimit voltage too high
Overcharging
Symptom
Probable Cause
Measure battery limit

voltage with an electric
tester
Normal
Abnormal
cFaulty battery
eBroken or poorly connected
regulator/rectifier black wire
Abnormal
cLimit voltage too high
Check resistance
between regulator/
rectifier terminals
Normal
1-59
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Symptom
Probable Cause
Check battery circuit by

operating turn signals
Remove fuel unit and

check operation of
pointer by moving float
up and down
Float up: Full
Float down: Empty
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire harness
side
cBurned out fuse

eFaulty ignition switch
connectors
gBroken wire harness
Signals operate
properly
Signals dim, remain

on or dont operate
Pointer does not

move
Pointer moves
cFaulty float
Pointer moves
cBroken or shorted fuel unit

wire
Pointer does not

move
Check connectors for

proper connection
Faulty
Good
cDisconnected connector
dIncorrectly connected
connector
eBroken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)

Probable Cause
Symptom

and horn
check operation of
up and down
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer
Signals operate
properly
Signals dim, remain

on or dont operate
Pointer moves
Pointer does not

move
Pointer moves in
accordance with
float
Pointer does not

move in accordance with float
cBurned out fuse

connector
cPoor contact in fuel unit
cInsufficient damping oil in

fuel gauge

proper connection.
Good
Faulty
cLoose or disconnected
connector
cBroken or shorted wire in
fuel gauge
1-60
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

Symptom
Probable Cause
(Front and rear tire pressures are normal)
Steering is heavy
cSteering stem nut too tight

dBroken steering steel balls
Front or rear wheel is

wobbling
cExcessive wheel bearing play

dBent rim
eLoose axle nut
Steering handlebar pulls

to one side
cMisaligned front and rear wheels

dBent front fork
POOR SUSPENSION PERFORMANCE

Symptom
Suspension is too soft
Probable Cause
cWeak shock spring
dExcessive load
eShock damper oil leaking
Suspension is too hard
cBent fork tube or shock rod
Suspension is noisy
cFork tube and slider binding

dFork spring and slider binding
eDamaged shock stopper rubber
fLoose steering stem nut
POOR BRAKE PERFORMANCE

Symptom
1-61
Probable Cause
Soft brake lever
cWorn brake linings

dForeign matter on brake linings
eRough brake drum contacting area
Hard brake lever
cWorn brake linings

Hard to brake
cWorn brake linings

dWorn brake cam contacting area on
Poor brake performance
cWorn brake linings

Brake squeaks
cSluggish or elongated brake cables

dBrake shoes improperly contact
eWater and mud in brake system
fOil or grease on brake linings
TROUBLESHOOTING (XCITING 500 AFI/300 AFI)

ENGINE WILL NOT START OR IS HARD TO START
Probable Cause
Symptom
1. Make sure engine stop switch

is ON.
2. Put the side stand up.
3. Connect the diagnostic tool,
then check EMS and correct
problems.
Fuel reaches fuel

injector
Fuel does not reach

fuel injector
cEmpty fuel tank

dClogged fuel pump
filter
eFaulty fuel pump
fFaulty fuel cut-off
relay
gCracked fuel hose
Weak or no spark
cFaulty spark plug

dFouled spark plug
eFaulty ignition coil
fFaulty CPS
gBroken or shorted ignition coil
hBroken or shorted CPS
iFaulty ignition switch
No fuel supply
cFaulty fuel injector

dClogged fuel injector
eFaulty ECU

ground
Spark jumps
Remove the fuel injector, start

the starter motor to check fuel
injector operation.
Fuel supply
Test cylinder
compression
Normal
compression
Low or no
compression
cStarter motor idles but

crankshaft does not rotate
dValve clearance too small
eImproper valve and seat contact
fWorn cylinder and piston rings
gBlown cylinder head gasket
hFlaws in cylinder head
iSeized valve
jImproper valve timing
1-62
ENGINE LACKS POWER

Probable Cause
Symptom
Connect the diagnostic

tool, then check EMS and
correct problems.
Start engine and
accelerate lightly for
observation
Engine speed
increases
Engine speed does

not increase
sufficiently
cClogged air cleaner

dClogged exhaust muffler
eFaulty spark plug
fFaulty throttle
gFaulty fuel pump
hFaulty fuel injector
iImproper valve timing

jLow or no compression
cFaulty ECU
dFaulty CPS
Correct timing
Incorrect timing
Correct
Incorrect
cImproper valve clearance

adjustment
dWorn valve seat (valve stem too
protruding
Normal
compression
Abnormal
compression
cImproper valve and seat contact

dWorn cylinder and piston rings
eBlown cylinder head gasket
fFlaws in cylinder head
gImproper valve timing
Test cylinder compression
Check fuel injector for

clogging
Not Clogged
Clogged
cFouled fuel injector

inspect
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not

contaminated
Incorrect or
contaminated
Remove oil dipstick and

check oil level and condition
cFouled spark plug

dIncorrect heat range plug
cOil level too high
dOil level too low
eOil not changed
Remove cylinder head

bolts and inspect
Valve train lubricated
properly
Valve train not

lubricated properly
Check if engine overheats

Engine does not
overheats
1-63
Engine overheats
cFaulty oil pump

cInsufficient coolant
dFaulty thermostat
eWorn cylinder and piston rings
fMixture too lean
gPoor quality fuel
hExcessive carbon buildup in
combustion chamber
iIgnition timing too early
jAir in cooling system
Rapidly accelerate or run

at high speed
Engine does not knock
Engine knocks
cExcessive carbon build-up in

combustion chamber
dPoor quality fuel
eClutch slipping
fIgnition timing too early
1-64
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Symptom
Probable Cause

correct problems.
Correct timing
Incorrect timing
Not Clogged
Clogged
cFaulty ignition coil

dFaulty CPS
eFaulty ECU
Check fuel injector for

clogging
cFouled fuel injector

dFaulty fuel pump
Check intake manifold

for air leaks
No air leak
Air leaks
cDamage insulator rubber

dThrottle body not securely
tighten
eFaulty intake manifold
O-ring

ground
Good spark
Weak or
intermittent spark
cFaulty CPS
dFaulty ignition coil
eBroken or shorted
high tension wire

fFaulty spark plug
Check throttle body
Good
1-65
Faulty
cFouled throttle body

dFaulty TPI reset
POOR PERFORMANCE (AT HIGH SPEED)
Symptom
Probable Cause

correct problems.
Correct timing
Incorrect timing
cFaulty spark plug

dFaulty ignition coil
eFaulty CPS

cImproperly adjusted valve
Correctly adjusted
clearance
dWorn valve seat
Check fuel pump for

fuel supply
Fuel flows freely
Fuel flow restricted
Not clogged
Clogged
Correct
Incorrect
Not weakened
Weak spring
cEmpty fuel tank

dClogged fuel hose or filter
eFaulty fuel pump
fClogged fuel injector
Check throttle body or

air cleaner for clogging
cClean and unclog
Check valve timing

cCam timing gear aligning
marks not aligned
Check valve spring

tension
cFaulty spring
1-66
ENGINE NOISE
Symptom
Valve noise
Probable Cause
cValve clearance too large

dWorn camshaft lobe
cWorn piston rings

Piston noise
Cam chain noise
Crankshaft noise
dWorn piston pin and connecting rod small

end
eExcessive carbon build-up in combustion
chamber
cDamaged cam chain tensioner

dWorn cam gear teeth
eWorn or damaged cam chain
fExtended cam chain
cFaulty crankshaft bearing

dWorn crank pin bearing
Gear noise
cWorn or damaged final reduction gears

dWorn final reduction gear shaft splines
1-67
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Engine starts but motorcycle does not move
Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)
Probable Cause
dBroken ramp plate
eBroken drive face spring
fSeparated clutch lining
gDamaged driven pulley shaft splines
hDamaged final gear
iSeized final gear
cBroken shoe spring

dClutch outer and clutch weight stuck
eSeized pivot

start of a grade(poor
slope performance)

eSeized drive pulley bearings
fWeak driven face spring
gWorn or seized driven pulley bearings

high speed

eWorn or seized driven pulley bearings
There is abnormal noise

or smell while running
cOil or grease fouled drive belt

dWorn drive belt
eWeak driven face spring
fWorn or seized driven pulley bearings
1-68
STARTER MOTOR
1. Starter motor wont turn
Symptom
Probable Cause
Check operation of
stop switch by
applying brake
Stoplight comes on
Stoplight does not

come on
Signals operate
properly
Signals dim, remain

on or dont operate
Relay operates
properly
Relay does not

operate
Starter motor turns
Starter does not turn

by operating turn
signals
Check operation of
starter relay by
depressing starter
button
Connect starter
motor directly to
battery
cBurned out fuse

eFaulty stop switch
connectors
gBroken or shorted ignition
switch wire
hFaulty side stand switch
cFaulty or weak battery
cPoor starter button connection

dOpen or shorted starter relay
eLoose or disconnected
connectors
cWorn brushes
dOpen or shorted wires or rotor
eOpen starter motor cable
fLoose connectors
cOpen wire harness
2. Starter motor turns slowly or idles

Symptom
Probable Cause

by operating turn
signals
Signals operate
properly
Signals dim, remain

on or dont operate
Starter motor
turns slowly
Starter motor
turns normally
cWeak or dead battery
Connect starter
motor directly to
battery
cLoose connector or terminal
dPoor contact in starter relay
eFaulty starter clutch
Rotate crankshaft
Hard to turn
Turns easily
cSeized cylinder
cBroken or shorted starter
motor cable
3. Starter motor does not stop turning

Symptom
Probable Cause
Turn ignition switch

OFF
Not stopped
1-69
Stopped
cFaulty starter pinion

cStarter relay shorted or stuck
closed
NO SPARK AT SPARK PLUG

Symptom
Probable Cause

correct problems.
Replace with a new

spark plug and inspect
again
Good spark
cFaulty spark plug
Not loose
Loose
cFaulty spark plug
Good
Good
cPoorly connected coupler
Normal
Abnormal
Normal
Abnormal
Weak or no spark
Check spark plug cap
and high-tension wire
for looseness
Check ignition unit

coupler for looseness
Measure resistance
between terminals of
ignition unit coupler
Check related parts

cFaulty ignition switch
dFaulty CPS
eFaulty ignition coil
cBroken wire harness
dPoorly connected coupler
Check ignition coil
Abnormal
cFaulty ignition coil
1-70
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging
Symptom
Probable Cause
Start engine and test

limit voltage of battery
terminals
Normal voltage
Voltage does not

increase
Normal
Resistance too low
cFaulty AC generator
eFaulty battery
Measure resistance
between AC generator
coil terminals
cShorted AC generator coil
dOpen circuit between AC
generator 3 yellow wires
Test output voltage of

regulator/rectifier
coupler red wire
Normal voltage
No voltage
cFaulty regulator/rectifier
dFaulty AC generator
eLoose regulator/rectifier
coupler
fLimit voltage too high
Overcharging
Symptom
Probable Cause
Measure battery limit

voltage with an electric
tester
Normal
Abnormal
cFaulty battery
eBroken or poorly connected
regulator/rectifier black wire
Abnormal
cLimit voltage too high
Check resistance
between regulator/
rectifier terminals
Normal
1-71
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Probable Cause
Symptom


check operation of
up and down
Float up: Full
Float down: Empty
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire harness
side
cBurned out fuse

connectors
Signals operate
properly
Signals dim, remain

on or dont operate
Pointer does not

move
Pointer moves
cFaulty float
Pointer moves
cBroken or shorted fuel unit

wire
Pointer does not

move

proper connection
Faulty
Good
cDisconnected connector
dIncorrectly connected
connector
eBroken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)

Probable Cause
Symptom
and horn
check operation of
up and down
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer
Signals operate
properly
Signals dim, remain

on or dont operate
Pointer moves
Pointer does not

move
Pointer moves in
accordance with
float
Pointer does not

move in accordance with float
cBurned out fuse

connector
cPoor contact in fuel unit
cInsufficient damping oil in

fuel gauge

proper connection.
Good
Faulty
cLoose or disconnected
connector
cBroken or shorted wire in
fuel gauge
1-72
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

Symptom
Probable Cause
Steering is heavy
cSteering stem nut too tight

dBroken steering steel balls
Front or rear wheel is

wobbling
cExcessive wheel bearing play

dBent rim
eLoose axle nut
Steering handlebar pulls

to one side
cMisaligned front and rear wheels

dBent front fork
POOR SUSPENSION PERFORMANCE

Symptom
Suspension is too soft
Probable Cause
cWeak shock spring
dExcessive load
eShock damper oil leaking
Suspension is too hard
cBent fork tube or shock rod
Suspension is noisy
cFork tube and slider binding

dFork spring and slider binding
eDamaged shock stopper rubber
fLoose steering stem nut
POOR BRAKE PERFORMANCE

Symptom
1-73
Probable Cause
Soft brake lever
cWorn brake linings

Hard brake lever
cWorn brake linings

Hard to brake
cWorn brake linings

dWorn brake cam contacting area on
Poor brake performance
cWorn brake linings

Brake squeaks
cSluggish or elongated brake cables

dBrake shoes improperly contact
eWater and mud in brake system
fOil or grease on brake linings

Manual de Taller Xciting 500ri LER PDF

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Manual de Taller Xciting 500ri LER PDF

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XCITING 500/500 AFI/250/300 AFI

By KWANG YANG Motor Co., Ltd.

XCITING 500/500 AFI/250/300 AFI

Section 1 contains the precautions for

Section 3 describes the inspection/

The information and contents included in

KWANG YANG MOTOR CO., LTD.

Most sections start with an assembly or

FRAME COVERS /EXHAUST MUFFLER

FUEL SYSTEM/FUEL PUMP/FUEL

AFI (AUTOMATIC FUEL INJECTION)

DRIVE AND DRIVEN PULLEY

A.C. GENEARTOR/STARTER CLUTCH 13

Sections 8 through 14 give instructions

Section 2 is the removal/installation

REAR FORK/REAR WHEEL/REAR

XCITING 500/500 AFI/250/300 AFI

XCITING 500/500 AFI/250/300 AFI

Location of Frame Serial Number

Location of Engine Serial Number

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 500)

12.8 L (3.38 Imp gal,

Throttle position sensor

Spark plug gap

Helical gear/spur gear

Min. turning radius

Power Drive System

92# nonleaded gasoline

2 kg/cm (200 Kpa, 28

2.5 kg/cm (250 Kpa,

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 500 AFI)

92# nonleaded gasoline

Throttle Body Venturi

Spark plug gap

Helical gear/spur gear

12.8 L (3.38 Imp gal,

Power Drive System

Fuel System Electrical Equipment

2 kg/cm (200 Kpa, 28

2.5 kg/cm (250 Kpa,

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 250)

Min. turning radius

Throttle position sensor

Spark plug gap

Helical gear/spur gear

12.8 L (3.38 Imp gal,

Power Drive System

92# nonleaded gasoline

2 kg/cm (200 Kpa, 28

2.5 kg/cm (250 Kpa,

XCITING 500/500 AFI/250/300 AFI

SPECIFICATIONS (XCITING 300 AFI)

Throttle Body Venturi

Spark plug gap

Helical gear/spur gear

12.8 L (3.38 Imp gal,

Power Drive System

Fuel System Electrical Equipment

2 kg/cm (200 Kpa, 28

2.5 kg/cm (250 Kpa,