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KYMCO Xciting 250/500 Owner`s Manual (pre 2008

1. After refueling be sure to lock the fuel fill cap firmly 30 To lock the fuel fill cap Push fuel fill cap down into place Z WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Refuel only out doors e Wipe up spills immediately Fuel recommendation Use unleaded petrol with a research octane number of 91 or higher Unleaded gasoline can extend spark plug life and exhaust components life Tum the ignition key from to Q position to restarting 31 KYMCO FRONT SMALL BOX To open Insert the ignition key 2 and tum it clockwise To close 1 Holding the front small box lid 2 closed tum the ignition key counterclockwise 2 Remove the key Z WARNING Open the box lid while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the scooter Always keep both hands on the handlebars during operation 32 CENTER SMALL BOX To open the box by pull up the lever 2 of the center small box cover 1 To lock the box cover push down on the box cover until it locks Z WARNING Open the box cover while riding can be hazardous Removing a hand from the handlebars can reduce your ability to control the scooter Always keep both hands on the handlebars during operation 33 KYMCO SEAT To u
2. 0 8 Imp qt 1 1L 1 2US qt 1Imp qt 0 18 L 0 2 US qt 0 16 Imp qt 0 2342 0 25 US qt 0 2 Imp qt 12 8 L 3 38 US gal 2 82 Imp gal 150 kg 330 Ibs dO KYMCO ENGINE Bore and stroke Compression ratio Displacement S park plug Standard XCITING 250 Standard XCITING 250 AFI Idle speed XCITING 250 XCITING 250 AFI CHASSIS TRANSMISSION Tire size front Tire size rear ELECTRICAL Battery Headlight Tail brake light Turn signal light Position light Fuse Main fuse Other fuses 72 7 X60 mm 2 91 X 2 4 in 10 6 1 249 1 cm 15 2 cu in DPR7EA 9 DPR6EA 9 1600 1800min rpm 1500 1700 min rpm 120 70 15 150 70 14 12V 12Ah 12V60W 12V55W LEDX45 12V0 47W LEDX45 12V4 4W 12V10W X4 12V5W front LEDX45 12V0 47W 15A 10A 15A 30A GO KYMCO 5 Stan Perkins Road Spartanburg SC 29307 Telephone 888 235 3417 FAX 864 327 4745
3. 12 11 0 09 09 Center small box 10 Throttle grip 11 Front brake lever 12 Front brake fluid reservoir 13 Rear brake fluid reservoir 14 Rear brake lever 15 Ignition switch 13 13 Tool kit Center compartment Helmet holder Front small box Coolant level Side stand Center stand Left passenger footpeg Air cleaner XCITING 500 AFI XCITING 500 25 Air cleaner XCITING 250 AFI XCITING 250 19 0 21 22 23 24 05 30 29 28 27 26 15 KYMCO 26 Cell phone fixed seat 27 Center compartment light Cell phone socket 28 Seat 29 Adjustable backrest 30 Battery Fuse box Spare fuses 31 Right passenger footpeg 32 Oil filler cap Dipstick 33 Parking brake lever XCITING 500 AFI XCITING 500 KYMCO FRAME NUMBER The read frame number is stamped on right side of the frame Always check that the frame number stamped on your scooter is the same written in document and warranty scooter is the same written in document and warranty card Please write down your frame number in place below FRAME NUMBER 16 ENGINE NUMBER The engine number is stamped on left engine case Please write down your engine number in place below ENGINE NUMBER 17 KYMCO KEY NUMBER The key number 1 will be needed when you order replacement part Record the number for your reference 1 2 1 2 3 4 Ignition key nu
4. 3 remove the left floor mat 4 and remove screw 5 and reserve tank lid 6 and reserve tank cap 7 and add coolant mixture until it reaches the upper level mark 2 Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap If the reserve tank is empty or if coolant loss is excessive check for leaks and see your KYMCO dealer for repair 85 dC KYMCO Coolant replacement Coolant should be replaced by a KYMCO dealer unless the owner has proper tools and service data and is mechanically qualified Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap Z WARNING Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap 86 Coolant recommendation The owner must properly maintain the coolant to prevent freezing overheating and corrosion use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines See antifreeze container label Use only low mineral drinking water or distilled water as a part of the antifreeze solution Water that is high in mineral content or salt may be harmful to the aluminum engine Using coolant with silicate inhibitors may cause premature wear of water pump seals or blo
5. 6 12 18 24 30 PAGE ARCEEANER note A PW SPARKPLUGSm 4 dm R THROTTLE OPERATION 8 VALVE CLEARANCE TAP al a FuELLINE CRANKCASE BREATHER NOTES a cies ENGNEOL Sr TR RRR 8 8679757 ENGINE OIL STRAINER 4 femmer ra le ENGINE IDLE SPEED RADIATOR COOLANT NOTE 6 COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM WHICHEVER COMES FIRST ODOMETER READING NOTE 1 X 1000 km o 3 1 3 5 7 9 11 REFER X 1000 mi 0 2 0 6 1 8 3 42 5 4 66 To INOTE MONTH 3 6 12 18 24 30 PAGE TRANSMISSIONOIL nores Ir Ir Ir 76 TD Feit il i CLUTCHSHOEWEAR r dmi ll BRAKE FLUID feer n BRAKE PADWEAR V E WEZ m WW LOUPE BRAKEsvsEM MWL a li kg BRAKELIGHTSWTCH Og NGT JJ SIDESTAND 4 SUSPENSION Pa HEADLIGHT AIM BOLTS FASTENERS x x WHEELS TIRES STEERING BEARINGS 65 KYMCO TOOL KIT To assist you in the performance of periodic maintenance a tool kit 1 is supplied and located under the seat See page 34 CRANKCASE BREATHER 1 Remove the crankcase breather tube plug 2 from the tube and drain deposits into a suitable container 2 R
6. The battery is in the battery box below seat 1 Open the seat See page 34 2 Remove the screws 1 and battery cover 2 3 Remove the battery retainer 3 4 Disconnect the negative terminal lead 4 from the battery first then disconnect the positive terminal lead 5 5 Pull out the battery from the battery box Battery installation Install in the reverse order of the removal GTX12 BS 0204 4 3 T 93 dO KYMCO FUSE REPLACEMENT When frequent fuse failure occurs it usually indicates a Blown fuse short circuit or an overload in the electrical system See your KY MCO dealer for repair NOTE Never use a fuse with a different rating from that specified Serious damage to the electrical system or a fire may result causing a dangerous loss of lights or engine power Fuse list e 30A CHARGE fuse protects battery charging system e 15A MAIN fuse protects all electrical circuits e 15A HEAD HI LO fuse protects the headlight high lower beam and high beam indicator light e 10A IGNITION fuse protects the ignition system e 10A FAN fuse protects the cooling fan motor 94 Fuse box The fuse box is located left side of the battery in the battery box The specified fuses 2 are 10A 15A 1 Open the seat See page 34 2 Open the battery cover see page 93 3 Open the fuse box cover 1 4 Pull outthe old fuse and install a new fuse The spare fuse 3 are l
7. fuse 0 8A in the cell phone socket To avoid the cell phone overcharged please follow all of the cell phone charger manufacturer s instruments The quality of the cell phone and the cell phone charger is not guaranteed CELL PHONE FIXED SEAT Pressure plate NOTE e The standard accessories of this model don t include the cell phone charger 38 HELMET HOLDERS To use the helmet holders unlock the seat See page 34 hook your helmet fastener ring to the holder and lock the seat securely Z WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause crash in which you can be seriously hurt or killed Use the helmet holder only while parked Do not ride with a helmet secured by the holder 39 dO KYMCO STAND This scooter is equipped with a center stand and side stand Center stand 1 To place the scooter on the center stand place your foot on the stand extension and then rock the scooter to the rear and upward with the passenger hand rail with your right hand while steadying the handlebars with your left hand Side stand 2 An interlock switch is provided to cut off the ignition circuit when the side stand is down The side stand down indicator will light when the side stand left down and ignition switch is ON The side stand ignition interlock switch works as follows e f the side stand is down the engine can not
8. i 8 VAWE CLEARANCE mT l M i i GRANKGASFBREAMER Wore s ENGINEOI QARA R R R 67 75 ENGINEOILFILTER RIS RR ENGINE OIL STRAINER SCREEN ENGINE IDLE SPEED Pf aaron coia hoest SP EE ter en SECONDARY AIR SUPPLY SYSTEM ODOMETER READING NOTE 1 dO KYMCO WHICHEVER COMES FIRST x1000km 1 6 12 15 24 30 36 e ER 1000 0 6 8 12116 20 24 Ecc wonra 18 24 50 e A JNOTES Mm I I DRIVEBELT e CLuICH SHOE WEAR 71 Sy 1 11 R L111 s BRAKEPADWERR 5 TLL erae SYSTEM Sa Dla Tre x BRAKE uen swr Id am erake LOCK OPERATION SL Litani smesa D 4 gt x susenson S m ES x HEADLIGHTAIM Ny m NOT LP NUTS BOLTS Fasteners W r NL NI Dr x waeersmres I MW I LOI bok STEERING BEARINGS I HUL tt hint ODOMETER READING NOTE 1 62 KYMCO MAINTENANCE SCHEDULE XCITING 250AFI XCITING 250 Perform the pre ride inspection see page 44 at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first I INSPECT AND CLEAN ADJ UST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST JL LUBR
9. Items after riding Be sure to park the motorcycle in Brake Performance tires engine oil level place not easily touched by people lights horn and instrument panel e Forriding safety and good performance do not violate the law to modify the motorcycle KWANG YANG MOTOR CO LTD e Please read the User s Manual carefully to secure driving safely CAUTIONS Tire Size Front 120 70 15 Rear 150 70 14 One Rider Front 2 00kgf cm Rear 2 50kgf cm Two Rider Front 2 25kgf cm Rear 2 50kgf cm Load Capacity Shield1 5kg Clip assy center 3kg As per KYMCO standard specification Note The tire pressure must not overpass 2 50kgf cm e Check the motor oil level with the dipstick after refilling motor oil 10 KYMCO CAUTION Mobile phone charge only Use other appliance may cause damage 7 DA 3 WF H C CAUTION DON T WIPE WITH ORGANIC SOLVENT EX GAS THINNER ETC USE NEUTRAL SOAP TO CLEAN WINDSHIELD 11 dO KYMCO PARTS LOCATION 04 06 05 03 02 12 01 Fuel fill cap 02 Right rearview mirror 03 Hazard switch Engine stop switch Headlight switch Start button 04 Instruments Indicators 05 Passing switch Headlight dimmer switch Turn signal switch Horn button 06 Left rearview mirror 07 Left rear suspension spring preload adjuster 08 Right rear suspension spring preload adjuster KYMCO
10. RIDING Allow the engine oil to circulate before riding Allow sufficient idling time after warm or cold engine start up before applying load or revving the engine This allows time for the lubricating oil to reach all critical engine components Review scooter safety page 1 7 before you ride Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when riding idling or parking your scooter 1 Make sure the throttle is closed and the parking brake XCITING 500 AFI XCITING 500 is locked before moving the scooter off the center stand The rear wheel must be locked when moving the scooter off the center stand or loss of control may result 50 KYMCO 2 HH 72 59 J U 5 0 9 0 2 N f g E E O E 3 Mount the scooter from the left side keeping at least one foot on the ground to steady the scooter 51 KYMCO 4 Unlock the rear wheel by releasing the parking brake lever XCITING 500 AFI XCITING 500 5 Before starting off indicate your direction with the tum signals and check for safe traffic conditions Grasp the handlebars firmly with both hands Never attempt one handed operation loss of vehicle control could result 52 6 To accelerate open the throttle gradually the scooter will move forw
11. SPARK PLUG Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine Readjust the spark plug gap to specified limit by using a spark plug gap thickness gauge The spark plug should be replaced periodically Whenever removing the carbon deposits be sure to observe the operational color of the spark plug s porcelain tip This color tells you whether or not the standard spark plug is suitable for your type of usage A normal operating spark plug should be light brown or tan color If the spark plug is very white or glazed appearing then it has been operating much too hot This spark plug should be replaced with the colder plug CAUTION An improper spark plug may have an incorrect fit or heat XCITING 500 500 range for your engine This may cause severe engine 0 6 0 7 mm damage which will not be covered under warranty 0 024 0 028 in Never use a Spark plug with an improper heat range XEITING 250 25 0 8 0 9 mm Severe engine damage could result 0 032 0 036 in Recommended plug XCITING 500 AFI CR7E XCITING 500 CR8E XCITING 250 DPR7EA 9 XCITING 250 AFI DPR6EA 9 84 COOLANT Inspection The reserve tank is under footboard left Check the coolant level through the inspection window 1 at the left side skirt while the engine is at the normal operating temperature with the scooter in an upright position If the coolant level is below the LOWER level mark
12. care and restraint exercised during the break in period It is especially important that you avoid operating the engine in a manner which could expose the engine parts to excessive heat The following guidelines explain proper break in procedures Maximum throttle operation recommendation The maximum recommended throttle operation during the break in period Initial 800 km 500 miles less than 1 2 throttle Up to 1600 km 1000 miles less than 3 4 throttle 57 KYMCO Vary the engine speed The engine speed should be varied and not held at a constant speed This allows the parts to be loaded with pressure and then unloaded allowing the parts to cool This aids the mating process of the parts It is essential that some stress be placed on the engine components during break in to ensure this mating process Do not though apply excessive load on the engine Avoid constant low speed Operating the engine at constant low speed light load can cause parts to glaze and not seat in Allow the engine to accelerate freely through the gears without exceeding the recommended maximum limits Do not however use full throttle for the first 1600 km 1000 miles dO KYMCO Breaking in the new tires New tires need proper break in to assure maximum performance just as the engine does Wear in the tread surface by gradually increasing your comering lean angles over the first 160 km 100 miles before attempting maximum pe
13. combinations of all the available accessories however your dealer can assist you in selecting quality accessories and installing them correctly Use extreme caution when selecting and installing the accessories for your scooter Z WARNING Improper accessories or modifications can make your scooter unsafe and can lead to an accident Never modify this scooter through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this scooter and should be installed and used according to instruction If you have question consult an authorized KYMCO dealer No modifications We strongly advise you not to remove any original equipment or modify your scooter in any way that would change its design or operation dO KYMCO LOCATION OF THE WARNING AND SPECIFICATION LABELS CAUTIONS Before starting the engine the side stand shall be kicked up to secure safety KYMCO 2 XCITING 500 AFI XCITING 500 CAUTIONS Every 6000 kmrun should exchange the filter CAUTIONS Never put any article between the rear side cover and the engine to avoid interference of riding e Be sure to wear a safety helmet when riding e Make sure to perform the periodic maintenance Do not exceed the speed specified by law when and preride inspection riding The exhaust muffler temperature is very high Preride Inspection
14. may work loose as aresult of the cornering forces experienced in a scooter tire e After repairing a tire do not exceed 80 km h 50 mph for the first 24 hours 130 km h 80 mph thereafter This is to avoid excessive heat build up which could result in a tire repair failure and tire deflation e Replace the tire if it is punctured in the sidewall area or if a puncture the tread area is larger than 6 mm 3 16 in These punctures cannot be repaired adequately 100 KYMCO CLEANING Clean your scooter regularly to protect the surface finishes and inspect for damage wear and oil coolant or brake fluid leakage Avoid cleaning products that are not specifically designed for scooter or automobile surfaces They may contain harsh detergents or chemical solvents that could damage the metal paint and plastic on your scooter If your scooter is still warm form recent operation give the engine and exhaust system time to cool off We recommend avoiding the use of high pressure water spray typical in coin operated car washes NOTE High pressure water or air can damage certain parts of the scooter Washing the scooter 1 Rinse the scooter thoroughly with cool water to remove loose dirt 2 Clean the scooter with a sponge or soft cloth using cool water Avoid directing water to muffler outlets and electrical parts 101 dO KYMCO 3 Clean the plastic parts using a cloth or sponge dampened with a solution of mild
15. oil filler cap dipstick 1 from the right crankcase cover 2 Place a container under the left crankcase 69 KYMCO 3 Remove the oil drain plug 2 to drain the oil 4 Reinstall the drain plug and tighten the drain plug to specification Oil drain plug torque 25 2 5 kgf m 18Ibf ft 5 Fill the engine with oil and install the oil fill cap Oil capacity after draining XCITING 500 AFI XCITING 500 2 0 liter 2 1 US qt 1 8 Imp 40 XCITING 250 AFI XCITING 250 0 9 liter 0 95 US qt 0 8 Imp 40 6 Start the engine and let it idle for 2 3 minutes 7 Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks NOTE e Running the engine with insufficient oil pressure may cause serious engine damage e Let the engine and exhaust system cool before working in those areas 70 Oil filter cartridge 500 AFI XCITING 500 and Oil strainer screen Changing the oil filter cartridge requires a special oil filter cartridge tool and a torque wrench If you do not have these tools and the necessary skill we recommend that you have your KY MCO dealer perform this service If a torque wrench is not used for this installation see your KY MCO dealer as soon as possible to verify proper assembly Change the engine oil with the engine at normal operating temperature and the
16. only use accessories that have been approved by KYMCO for this scooter Inspection before riding Do not forget to perform an entire safety inspection to ensure the safety of the rider Be extra safety conscious on bad weather days Riding on bad weather days especially wet ones requires extra caution Braking distance double on arainy day Stay off of the painted surface marks manhole covers and greasy appearing areas as they can be especially slippery Use extreme caution at railway crossings and on metal gratings and bridges Whenever in doubt about road conditions slow down Modification Modification of the scooter or removal of original equipment may render the vehicle unsafe or illegal Obey all applicable equipment regulations in your area KYMCO PROTECTIVE APPAREL For your safety we strongly recommend that you always wear an approved scooter helmet eye protection boots gloves long pants and a long sleeved shirt or jacket whenever you ride Helmets and protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries Ahelmet should fit your head comfortably and securely Always wear a face shield or goggles to protect your eyes and help your vision Additional riding gear In addition to a helmet and eye protection we also recommend Sturdy boots with non slip soles to help protect your feet and ankles e Leather gloves to keep your hands warm and
17. scooter on its center stand to assure complete and rapid draining NOTE e Running the engine with insufficient oil pressure may cause serious engine damage e Lettne engine and exhaust system cool before working in those areas 1 Remove the oil filler cap dipstick 1 from the right crankcase cover 71 KYMCO 2 Place a drain pan under the crankcase and remove the oil strainer screen cap 2 The spring 3 and oil strainer screen 4 will come out when the drain plug is removed 3 Clean the oil strainer screen 4 Check that the oil strainer screen sealing rubber and drain plug O ring are in good condition 72 5 XCITING 500 AFI XCITING 500 Remove the rubber sleeve 5 by removing the clip 6 6 XCITING 500 AFI XCITING 500 Remove the oil filter cartridge 7 with a filter wrench and let the remaining oil drain out Discard the oil filter cartridge 73 dO KYMCO 7 XCITING 500 AFI XCITING 500 XCITING 500 AFI XCITING 500 Apply a thin coat of engine oil to the new oil filter cartridge rubber seal 8 8 XCITING 500 AFI XCITING 500 Using a special tool and a torque wrench install the new oil filter cartridge and tighten to a torque of 12 N m 1 2 kgf m 8 Ibf ft Use only the KYMCO genuine oil filter cartridge or a filter cartridge of equivalent quality specified for your model Using the wrong KY MCO filter cartridge or a non KY MCO filter cartridge which is not of equivalen
18. ICATE The following maintenance schedule specifies all maintenance required to keep your scooter in peak operating condition Maintenance work should be performed in accordance with standards and specifications of KY MCO by properly trained and equipped technicians Your KYMCO dealer meets all of these requirements Should be serviced by yourKY MCO dealer unless the owner has the propertools and service data andis mechanically qualified 1 the interest of safety we recommend these items be serviced only by your KYMCO dealer KYMCO recommends thatyour KY MCO dealershould road testyour scooterafter each periodic maintenance is carried out NOTE 1 At higher odometer readings repeat at the frequency interval established here 2 Service more frequently if the scooter is ridden in unusually Wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Clean every 2000 km 1200 mi after replacement and replace every 5000 km 3000 mi 5 Replace every 1 year or every 4000km 2400mi whichever comes first Replacement requires mechanical skill 6 Replace every 10000 km 6000 mi or once a year it at every 5000 km 3000 mi Replacement requires mechanical skill 7 Replace every 2 years Replacement requires mechanical skill 63 dO KYMCO WHICHEVER COMES FIRST ODOMETER READING NOTE 1 gt X1000km0 3 1 315 719 11 refer x 1000 mi 0 2 0 6 1 8 3 42 5 4 66 TO INOTE amontH 3
19. OWNER S MANUAL XCITING 500 AFI XCITING 500 XCITING 250 AFI XCITING 250 Issued 15 02 2006 FOREWORD Thank you for purchasing this KYMCO scooter and welcome to the family of KYMCO scooter riders Please read this owner s manual carefully before riding so that you will be thoroughly familiar with the proper operation of your scooter controls its features capabilities and limitations To ensure along trouble free life for your scooter give it the proper care and maintenance described in this manual For replacement parts and accessories we recommend genuine KYMCO products They ve been specially designed for your vehicle and manufactured to meet KYMCO s demanding standards Keep this owner s manual aboard your scooter at all time so that you can refer to it whenever you need information This manual should be considered a permanent part of the scooter and should remain with the scooter when itis sold All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual KYMCO reserves the right to make changes at any time without notice and without incurring any obligation READ THIS MANUAL CAREFULLY Your Owner s Manual contains important information on safety operation and maintenance Any one who operates this scooter should carefully rea
20. TIONS THROTTLE 81 XCITING 500 AFI XCITING 500 109 IDLE 5 4 82 SPECIFICATIONS SPARK 84 XCITING250AFI XCITING 250 111 KYMCO SCOOTER SAFETY IMPORTANT SAFETY INFORMATION Your scooter can provide many years of service and pleasure if you take responsibility for your own Safety and understand the challenges that you can meet on the road There is much that you can do to protect yourself when you ride You will find many helpful recommendations throughout this manual Following are a few that we consider most important Wear a helmet Scooter safety equipment starts with a quality helmet One of the most serious injuries that can happen is a head injury Always wear a properly approved helmet You should also wear Suitable eye protection Make yourself easy to see To make yourself more visible wear bright reflective clothing position yourself so other drivers can see you signal before turning or changing lanes and use your horn when it will help others notice you Know your limits Ride within the boundaries of your own skill at all times Knowing these limits and staying within them will help you to avoid accidents KYMCO Keep your scooter in safe condition For safe riding it s important to inspect your scooter before every ride and perform all recommended maintenance Never exceed load limits and
21. all the transmission oil filler bolt with a new sealing washer and tighten it Torque 20 N m 2 kgf m 15 Ibf ft TT KYMCO AIR CLEANER The air cleaner should be serviced at regular intervals Service more frequently when riding in unusually wet or dusty areas Air cleaner element XCITING 500 AFI XCITING 500 1 Open seat See page 34 2 Remove air cleaner cover 1 3 Remove the screws and air cleaner case cover 2 78 Remove the air cleaner element 3 by pull it out Discard the air cleaner element Install a new air cleaner element Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong KY MCO air cleaner element or a non KY MCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems Install the removed parts in the reverse order of removal 79 dO KYMCO Air cleaner element XCITING 250 XCITING 250 AFI The air cleaner element 1 should be replaced by a KYMCO dealer unless the owner has proper tools and service data and is mechanically qualified 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 KY MCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems 80 THROTTLE OPERATION 1 Check for
22. ard Do not BLIP the throttle open and close rapidly as the scooter will move forward suddenly causing possible loss of control 7 To decelerate close throttle 8 When slowing down the scooter coordination of the throttle and front and rear brakes is most important Both front and rear brakes should be applied together Independent use of only the front or rear brake reduces stopping performance Excessive brake application may cause either wheel to lock reducing control of the scooter a 7 Ne 53 KYMCO 9 When approaching a corner or turn close the throttle fully and slow the scooter down by applying both front and rear brakes at the same time 10 After completing the tum open the throttle gradually to accelerate the scooter 11 When descending a steep grade close the throttle fully and apply both brakes to slow the scooter Avoid continuous use of the brakes which may result in overheating and reduction of braking efficiency 54 12 When riding on wet or loose surfaces be especially cautious When riding in wet or rainy conditions or on loose surfaces the ability to maneuver and stop will be reduced For your safety e Exercise extreme caution when braking accelerating or turning e Ride at slower speeds and allow for extra stopping distance e Keep the scooter as upright as possible e Use extreme caution when riding over slippery surfaces such as railroad track
23. assumption that the scooter will be used exclusively for its designed purpose Sustained high speed operation or operation in unusually wet or dusty conditions will require more frequent service than specified in the maintenance schedule Consult your KYMCO dealer for recommendations applicable to your individual needs and use If your overturns or becomes involved a crash be sure your KY MCO dealer inspects all major parts even if you are able to make some repairs KYMCO Z WARNING Improperly maintaining this scooter or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed Always follow the inspection and maintenance recommendations and schedules in this owner s manual Z WARNING Running the engine indoors orina garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Only run the engine outdoors where there is fresh air 59 dO KYMCO MAINTENANCE SCHEDULE XCITING 500 AFI XCITING 500 Perform the pre ride inspection see page 44 at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first I INSPECT AND CEEAN ADJ UST LUBRICATE OR REPLACE IF NECESSARY C CLEAN REPLACE A ADJUST L LUBRICATE The following maintenance schedule specifies all maintenance required to keep your scooter in peak operating conditi
24. be started e f the engine is running and the side stand is put down the engine will stop running 40 KYMCO Z WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left e Check operation of the side stand ignition interlock system before riding e Always retract the side stand completely before starting off CAUTION Park the scooter on firm level ground to help prevent it from falling over If you must park on an incline aim the front of the scooter uphill and place the scooter on the center stand or the scooter on the side stand may roll off use the parking brake XCITING 500AFI XCITING 500 when the scooter is parked with the side stand 41 KYMCO SUSPENSION Each shock absorber 1 has 5 adjustment positions for different load or riding conditions Use a pin spanner 2 to adjust the rear shocks Always adjust the shock absorber position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber Position 1 is for light loads and smooth road conditions Positions 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooter is heavily loaded Be certain to adjust both shock absorbers to the same position Standard position 3 42 DIAGNOSTIC TOOL CONNECTOR XCITING 500 250 AFI The diagnostic tool connector 1 located r
25. bnormality in the CELP system If it comes at any other time reduce speed and take the motorcycle to your KY MCO dealer as soom as possible NOTE Turn the ignition switch ON with no engine speed when the side stand is put up and the engine stop switch is at RUN the CELP will light for two second then off It shows the lamp work normal 21 Parking brake indicator XCITING 500 AFI XCITING 500 Lights when the parking brake is applied RIGHT HANDLEBAR SWITCH Headlight switch 1 38 position The headlight and taillight turn on zoaz position The position light and taillight tum on e position The headlight and taillight tum off Electric starter button 2 Push in the electric starter button to rotate the starter motor NOTE e If the brake lever is not squeezed the starter motor will not rotate e This scooter is equipped with interlock switches for the ignition circuit and the starter circuit The engine can only be started if the side stand is fully up 25 CAUTION To prevent electrical system damage do not operate the starter motor more than five seconds at a time KYMCO Engine stop switch 3 63r position The ignition circuit is off The engine cannot start or run position The ignition circuit is on and the engine can run Hazard switch A 4 AV Atthis position the right and left turn signal lights wink together OFF Atthis p
26. carrier 5kg 11 Ibs KYMCO Center small box weight limit 3 kg 6 6 Ibs Center compartment weight limit 10 kg 22 Ibs Rear carrier weight limit 5 kg 11 Ibs Front small box weight limit 1 5 kg 3 3 Ibs KYMCO Loading guidelines Improperly loading your scooter can affect its stability and handling You should ride at reduced speeds whenever carrying cargo Follow these guidelines whenever you carry a passenger or cargo e Check that both tires are properly inflated To prevent loose items from creating a hazard make sure that all cargo is securely tied down before you ride away e Place cargo weight as close to the center of the scooter as possible Balance cargo weight evenly on both sides Z WARNING Overloading or improper loading can cause changes in vehicle handling stability and braking which could lead to an accident Never exceed the stated load capacity for this scooter Cargo should be properly distributed and securely attached Reduce speed when carrying cargo Allow greater distance for braking KYMCO Accessories and Modification There are great variety of accessories available to KYMCO owners KYMCO cannot have direct control over the quality or suitability of accessories you may wish to purchase The addition of unsuitable accessories can lead to unsafe operating conditions It is not possible for KYMCO to test each accessory on the market or
27. ce interval Front right left brake Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your KY MCO dealer for this service Rear brake Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set See your KY MCO dealer for this service 90 PARKING BRAKE OPERATION XCITING 500 AFI XCITING 500 Parking brake inspection 1 Stop the engine and put the scooter on its center stand on level ground 2 Pull the parking brake lever slowly and check the lever stroke Standard 3 6 notches If adjustment is necessary have the brake adjusted by our KYMCO dealer for this service 91 dO KYMCO BATTERY Itis not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance free Sealed type If your battery seems weak and or is leaking electrolyte causing hard starting or other electrical troubles contact your KYMCO dealer NOTE Your battery is a maintenance free type and can be permanently damaged if the cap strip is removed 92 Z WARNING The battery gives off explosive hydrogen gas during normal operation A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you Wear protective clothing and a face shield or have a skilled mechanic do the battery maintenance Battery removal Always keep ignition switch is OFF
28. ckage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and distilled water in this scooter This coolant solution is recommended for most operating temperatures and provides good corrosion protection A higher concentration of antifreeze decreases the cooling system performance and is recommended only when additional protection against freezing is needed A concentration of less than 40 60 40 antifreeze will not provide proper corrosion protection During freezing temperatures check the cooling system frequently and add higher concentrations of antifreeze up to a maximum of 60 antifreeze if required 87 KYMCO FRONT AND REAR SUSPENSION INSPECTION 1 Check the fork assembly by locking the front brake and pumping the fork up and down vigorously Suspension action should be smooth and there must be no oil leakage 2 Swing arm bearings should be checked by pushing hard against the side of the rear wheel while the scooter is on the center stand Free play indicates wom bearings 3 Carefully inspect all front and rear suspension fasteners for tightness KYMCO SIDE STAND Perform the following maintenance in accordance with the maintenance schedule Functional check e Check the spring for damage or loss of tension and the side stand assembly for freedom of movement e Check the side stand ignition cut off system 1 Place the scooter on it
29. d and understand the contents of this manual before riding the scooter SPECIAL MESSAGES Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAUTION and Note carry special meanings and should be carefully reviewed Indicates a strong possibility that serious injury or death may result if instructions are not followed CAUTION Indicates a possibility that equipment or property damage could result if instructions are not followed NOTE Gives helpful information The Owner s Manual should be considered a permanent part of your scooter It should remain with the vehicle at all times and stay with the scooter if it is sold ON ROAD USE This scooter is designed to be used only on the road CONTENTS Page SCOOTER 1 IMPORTANT SAFETY INFORMATION vy 22 299 9329229222332 1 PROTECTIVE 3 LOAD LIMITS AND GUIDELINEG 5 LOCATION OF THE WARNING AND SPECIFICATION EABELS iaces 8 PARTS LOGATION 2 nnus 12 FRAME 16 ENGINE NUMBER Inge 17 KEY NUMBER i per 18 DONO BER 19 r A a 19 IGNITION SWIUTPGE anri rrt rn 19 INSTRUMENT AND INDICATORS 21 RIGHT HANDLEBAR SWITCH 25 LEFT HANDLEBAR SWITCH 27 Page BEARES FRETI 28 FUELTILE GAP
30. dens 30 FRONT SMALL 32 CENTER SMALL 33 EN NN 34 ADJUSTABLE BACKREST 35 CENTER COMPARTMENT 36 CENTER COMPARTMENT LIGHT 37 CELL PHONE SOCKET amp CELL PHONE FIXED SEAT nnn 37 HELMET HOLDERS pto eRrhS 39 STAND kua 40 SUSPENSION 42 DIAGNOSTIC TOOL CONNECTOR XCITING 500AFI XCITING 250AFI 43 PRE RIDE INSPECTION 44 OPERATION m ictor EE 45 STARTING THE ENGINE 45 50 PARKING ccccccccccceceecscecesceesseeesseeees 55 2 2222 00 0 022 85 BREAK IN RUNNING IN 57 REAR SUSPENSION INSPECTION AND 2 2 00 87 MAINTENANCE essei 59 SIDE 88 THE IMPORTANCE OF BRAKE LEVER ADJUSTER s 89 MAINTENANCE BRAKE FLUID 89 MAINTENANCE SCHEDULE BRAKE PAD 90 XCITING 500AFI XCITING 500 60 PARKING BRAKE OPERATION XCITING 500 AFI XCITING 500 91 XCITING 250AFI XCITING 250 63 BATTERY see 92 OOL KIE 45 PUSE REPLACEMENT 94 CRANKCASE GRENER D m 97 ENGINE OIL e 444 101 TRANSMISSION 76 STORAGE 106 AIR 78 SPECIFICA
31. detergent and water Rub the soiled area gently rinsing it frequently with fresh water Take care to keep brake fluid or chemical solvents off the scooter They will damage the plastic and painted surfaces The inside of the headlight lens may be clouded immediately after washing the scooter Moisture condensation inside the headlight lens will disappear gradually by lighting the headlight in high beam Run the engine while keeping the headlight on 4 After cleaning rinse the scooter thoroughly with plenty of clean water Strong detergent residue can corrode alloy parts 5 Dry the scooter start the engine and letit run for several minutes 102 6 Test the brakes before riding the scooter Several applications may be necessary to restore normal braking performance Braking efficiency may be temporarily impaired immediately after washing the scooter Anticipate longer stopping distance to avoid a possible 8 ZA accident FE EN MN Ml Finishing touches After washing your scooter consider using a commercially available spray cleaner polish or quality liquid or paste waxto finish the job Use only a non abrasive polish or wax made specifically for scooter or automobiles Apply the polish or wax according to the instructions on the container 103 dO KYMCO Removing road salt The salt contained in the road surface freezing prevention medicine which a road was sprayed with in winter and the seawater becomes the ca
32. e tread condition at the periodic inspection For maximum Safety and good tire life the tire pressures should be inspected more often dO KYMCO Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter Under inflated tires make smooth comering difficult and overinflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control Be sure that the tire pressure is within the specified limits at all times Tire pressure should only be adjusted when the tires are cold Cold inflation tire pressure EN Solo riding Two up riding 200 kpa 225 kpa 2 kgf cm 2 25 kgf cm 29 psi 32 psi 250 kpa 250 kpa 2 5 kgf cm 2 5 kgficm 36 psi 36 psi 98 Tire tread condition Proper tire condition and proper tire type affect vehicle performance Cuts or cracks in the tires can lead to tire failure and loss of vehicle control tires are susceptible to puncture failures and subsequent loss of vehicle control Tire wear also affects the tire profile changing vehicle handling characteristics Check tire uuu io cau uay you ride Replace tires if tires show visual evidence of damage such as cracks or cuts or if tread depth is less than 1 6 mm 0 06 in front 2 0 mm 0 08 in rear NOTE These wear limits will be reached before the wear bars molded into the tire make con
33. eated by the engine Do not store food and other articles which are flammable or susceptible to heat damage in this compartment Do not direct water under pressure against the center compartment as water will be forced into the compartment 36 CENTER COMPARTMENT LIGHT The center compartment light 1 will be turned ON automatically when the seat is opened Kept ON as long as the seat is opened regardless of the position of the main switch CELL PHONE SOCKET amp CELL PHONE FIXED SEAT Pull socket cap 2 out and inserting the cell phone charger into the socket The charging indicator light of instrument will become to red The sockets rated capacity is DC 12V 10Watts 0 8A or less When you have done using cell phone unplug it and cover the socket with cap This scooter is equipped a cell phone fixed seat 3 which puts the cell phone down at proper position 37 dO KYMCO Operation method Take the fasten band off then pressing the button to make the pressure plate sprang open Put the cell phone at proper position on the cell phone fixed seat then push the pressure plate left Banding the fasten band then insert the cell phone charger into the socket CAUTION e Donot plug in any heat generating accessory such as an automobile cigarette lighter because it can damage the socket Do not add electrical equipment that will exceed the accessory socket capacity otherwise you may blow the Sprang open
34. einstall the crankcase breather tube plug Service more frequently when riding in rain at full throttle or after the scooter is washed or overturned Service if the deposit level can be seen in the transparent section of the drain tube 66 KYMCO ENGINE OIL OIL VISCOSITIES Engine oil recommendation Use a premium quality 4 stroke motor oil to 10W en ensure longer service life of your scooter Use only oils which are rated SJ under the API service classification The recommended Single viscosity is SAE 5W 50 If a SAE 5W 50 Garde motor oil is not available select an altemative according to the right chart Oil capacity see page 109 or 111 Ls 15W 40 15W 50 D 10 0 10 20 30 40 C 20 40 60 80 100 F 67 KYMCO Engine oil level check Check the engine oil level each day before riding the scooter The level must be maintained between the upper 1 and lower level 2 marks on the oil filler cap dipstick 1 Start the engine and let it idle for a few minutes Make sure the red low oil pressure indicator goes off If the light remains on stop the engine immediately 2 Stop the engine and put the scooter on its center stand on level ground 3 After a few minutes remove the oil filler cap dipstick wipe it clean and reinsert the oil filler cap dipstick without screwing it in Remove the oil filler cap dipstick The oi
35. help prevent blisters cuts burns and bruises Ascooter riding suit or jacket for comfort as well as protection Bright colored and reflective clothing can help make you more noticeable in traffic Be sure to avoid loose clothes that could get caught on any part of your scooter 1 Wear gloves 2 Clothes should be close fitting 3 Always wear an helmet You should also wear a face shield or goggles 4 Wear bright or reflective clothing 5 Shoes should be close fitting have low heels and offer ankle protection Z WARNING Not wearing a helmet increases the chance of serious injury or death ina crash Be sure you and your passenger always wear an approved motorcycle helmet that fits properly You should also wear eye protection and other protective apparel when you ride LOAD LIMITS AND GUIDELINES These general guidelines may help you decide whether or how to equip your scooter and how to load it safely Load limits Following are the load limits for your scooter Maximum weight capacity Includes the weight of the rider passenger all cargo and All accessories 150 kg 330 Ibs Maximum cargo weight 19 kg 42 Ibs Overloading the individual storage compartments can also affect stability and handling So be sure to stay within the limits given below Maximum weight In center compartment 10 kg 22 Ibs In front small box 1 5 kg 3 3 Ibs In center small box 3 kg 6 6 Ibs On rear
36. icator of multi metee will run from zero to maxi limit then zero when connecting the battery at the state of ignition switch turn on and resetting the position of pointer if the position of pointer is confused 21 dC KYMCO 1 Oil pressure warning indicator Lights when the engine oil pressure is below normal operating range should light when ignition switch is ON engine is not running Should go out when the engine starts except for occasional flickering at or near idling speed when engine is warm NOTE Running the engine with insufficient oil pressure may cause serious engine damage 2 Mode button The button is used to select the trip meter the odometer or reset trip meter 22 3 Battery charge telltale If the telltale comes on while driving this indicates the battery voltage is below 11V 4 Tachometer Shows engine revolutions per minute rpm 5 Right Left turn signal indicator Flashes when the right left turn signal operates 6 Speedometer Shows riding speed 7 Fuel gauge Shows approximate fuel supply available 8 Fuel refill Indicator Lights when the fuel tank is empty or nearly so and you should refill the tank as soon as possible 9 Oil service indicator reset button The oil service indicator can be reset by pressing the button when the engine oil has been changed 10 Seat unlock indicator MET IN Lights when the seat is no
37. ight of the battery in the battery box We recommend this item be serviced only by your KYMCO dealer This scooter apply this connector for fuel system condition inspection Check the fuel system condition using the recommended fuel system tester 43 dO KYMCO PRE RIDE INSPECTION For your safety it is very important to take a few moments before each ride to walk around your scooter and check its condition If you detect any problem be sure you take care of it or have it corrected by your KYMCO dealer Z WARNING Improperly maintaining this scooter or failing to correct a problem before riding can cause a crash in which you can be seriously hurt or killed Always perform a pre ride inspection before every ride and correct any problems 1 Engine oil level add engine oil if required page 68 Check for leaks 2 Fuel level fill fuel tank when necessary page 30 Check for leaks 44 3 Coolant level add coolant if required Check for leaks page 85 4 Front and rear brakes check operation make sure there is no brake fluid leakage page 89 Tires check condition and pressure page 97 Throttle check for smooth opening and full closing in all steering positions Lights and hom check that headlight tail brake light tum signals indicators and hom function properly Engine stop switch check for proper function page 26 Side stand ignition cut off system check for
38. l level should be between the upper and lower marks on the oil filler cap dipstick 4 If required add the specified oil see page 67 up to the upper level mark Do not overfill 5 Reinstall the oil filler cap dipstick Check for oil leaks NOTE e Running the engine with insufficient oil pressure may Cause serious engine damage e Lettne engine and exhaust system cool before working in those areas 68 C KYMCO Engine oil replacement Engine oil quality is the chief factor affecting engine service life Change the engine oil as specified in the maintenance schedule see page 60 or 63 When running in very dusty conditions oil changes should be performed more frequently than specified in the maintenance schedule Please dispose of used engine oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining 1 Remove the
39. mber Ignition key Shutter key number Shutter key 2 18 CONTROLS KEYS This scooter has two ignition switch keys and shutter keys IGNITION SWITCH To open the ignition key hole shutter with shutter key Select the shutter key OPEN side upward and insert the shutter key into the hole at the ignition switch To shut the ignition key hole shutter with shutter key Select the shutter key SHUT side upward and insert the shutter key into the hole at the ignition switch NOTE Apply anti freeze chemicals when atmospheric Temperature becomes less than freezing point to avoid ignition key hole shutter freezing 19 dO KYMCO Function 31 Position All electrical circuits are cut off The engine will not start Position The ignition circuit is completed and engine can now be started The key cannot be removed from the ignition switch e Position To lock the steering turn the handlebar all the way to the left Push down and turn the key to the position and remove the key All electrical circuits are cut off Y PR Position To open the fuel fill cap turn the key to the PR position Make sure that the key is at the position when Starting the engine Position To open the seat turn the key to the Z position 20 INSTRUMENT AND INDICATORS 11 20 19 18 17 16 15 14 13 12 17 NOTE The ind
40. nd rear brakes are applied by squeezing the combination brake lever gently towards the grip The brake light will be lit when the lever is squeezed inward Front brake lever Right handlebar The brake is applied by squeezing the front brake lever gently towards the grip The brake light will be lit when the lever is squeezed inward 28 Parking brake XCITING 500 AFI XCITING 500 To apply the parking brake Pull in the parking brake lever 1 to lock the rear wheel D To release the parking brake To release the parking brake lever while light pulling in the lever and pushing the release knob 2 Before riding check that the parking brake indicator is turned OFF and make sure that the rear brake is fully released so there is no drag on the rear wheel Z WARNING Riding the scooter with the parking brake lever will be hazardous The rear brake will overheat and it will reduce braking performance To release gt 2 mhia Operating the parking brake lever while riding can cause rear wheel skid and loss of control Use the parking brake lever only when parking and release lever before riding 29 KYMCO FUEL FILL CAP To open the fuel fill cap Insert the ignition key in the ignition switch and turn it to the 5 position the key can not remove Rotate the key clockwise to the position and open the fuel fill cap 1 Do not overfill the tank There should be no fuel in the filler neck 2
41. ne oil After draining After draining and oil filter change After disassembly Transmission oil After draining After disassembly Fuel tank Maximum weight capacity 2250 mm 90 in 815 mm 32 6 in 1450 mm 58 in 1570 mm 62 8 in 215kg 473 16 2 0L 2 T US qt 1 8 Imp qt 2 11 2 2US qt 1 9Imp qt 2 5L 2 7 US qt 2 2 Impqt 0 45 L 0 48 US qt 0 4 Imp qt 0 55 L 0 57 US at 0 5 Imp qt 12 81 3 38 US gal 2 82 Imp gal 150 kg 330 Ibs KYMCO ENGINE Bore and stroke Compression ratio Displacement S park plug Standard XGiT ING 500 AFI Standard XCITING 500 Idle speed CHASSIS TRANSMISSION Tire size front Tire size rear ELECTRICAL Battery Headlight Tail brake light Turn signal light Position light Fuse Main fuse Otherfuses 92 X75 mm 3 68 X 3 in 10 5 1 498 5 30 4 cu in CR7E 1300 1500min rpm 120 70 15 150 70 14 12V 12Ah 12V60W 12V55W LEDX45 12V0 47W LEDX45 12V4 4W 12V10W 4 12V5W front LEDX45 12V0 47W 15A 10A 15A 30A KYMCO SPECIFICATIONS XCITING 250 XCITING 250 AFI DIMENSIONS Overall length Overall width Overall height Wheel base WEIGHT Dry weight CAPACITIES Engine oil After draining After disassembly Transmission oil After draining After disassembly Fuel tank Maximum weight capacity 111 2250 mm 90 in 815 mm 32 6 in 1450 mm 58 in 1570 mm 62 8 in 185 kg 407 Ibs 0 9 L 0 95 US qt
42. nlock the seat 1 Ignition key at the Q position The engine is running Push the key and tum it counterclockwise from Q to A position 2 Ignition key atthe P3 position The engine is stopped Turn it counterclockwise from to er position 3 Ignition key atthe position The steering is locked Turn it counterclockwise from Q to position Pull the seat up to lift the seat To lock seat Lower and push down on the reverse side of the hooks of the seat until it locks Make sure the seat is secure before riding NOTE The lamplight and MET IN indicator light will come on while the seat is unlock make sure the seat is locked 34 ADJUSTABLE BACKREST The seat is equipped with a backrest 1 which allows the seat to be adjusted according to the riders preference or physical condition To adjust Open the seat See page 34 Pull the locking lever 2 left on the back and move the backrest back and forth according to the riders preference or physical condition After cleaning or running in the rain wipe off water collected under the backrest before the scooter again 35 dO KYMCO CENTER COMPARTMENT The center compartment is below the seat Opening and closing See SEAT page 34 MAXIMUM WEIGHT LIMIT 10kg 22 Ibs CAUTION Never exceed the maximum weight limit handling and stability may be severely affected The center compartment may become h
43. ocated in the battery retainer 5 Close the fuse box covers and seat 95 KYMCO Charge fuse The charge fuse is located right side of the battery in the battery box The specified fuses 2 are 30A 1 Open the seat See page 34 2 Remove the battery See page 93 3 Disconnect the wire connector 1 of the starter magnetic switch 4 Pull out the old fuse and install a new fuse The spare fuse are located in the battery retainer 5 Reconnect the connector 96 TIRES N WARNING Failure to follow these warnings may result in an accident due to tire failure The tires on your scooter form the crucial link between your scooter and the road Follow these instructions e Checktire condition and pressure and adjust pressure before each ride e Avoid overloading your scooter e Replace a tire when worn to the specified limit or if you find damage such as cuts or cracks e Always use the size and type of tires specified in this owner s manual e Balance the wheel after tire installation e Read this section of owner s manual carefully 97 KYMCO Z WARNING Failure to perform break in of the tires could cause tire slip and loss of control Use extra care when riding on new tires Perform proper break in of the tires referring to the break in section and avoid hard acceleration hard cornering and hard braking for the first Check the tire inflation pressure and tir
44. on Maintenance work should be performed in accordance with standards and specifications of KYMCO by properly trained and equipped technicians Your KYMCO dealer meets all of these requirements Should be serviced by yourKY MCO dealer unless the owner has the propertools and service data and is mechanically qualified the interest of safety we recommend these items be serviced only by your KYMCO dealer KYMCO recommends thatyour KY MCO dealershould road test your scooteraftereach periodic maintenance is carried out NOTE 1 At higher odometer readings repeat at the frequency interval established here 2 Service more frequently if the scooter is ridden in unusually wet or dusty areas Service more frequently when riding in rain or at full throttle 4 Inspect every 18000 km 12000 mi after replacement 5 Replace every 1 year or every 10000km 6000mi whichever comes first Replacement requires mechanical skill 6 Replace every 2 year or at indicated odometer interval whichever comes first Replacement requires mechanical skill 7 Replace every 2 years Replacement requires mechanical skill 60 KYMCO WHICHEVER COMES FIRST T gt km 1 6 12118 2 30 36 reFer x 1000 mi 0 6 4 8 12 16 20 24 Nore MONTH 6 12 18 24 30 36 PAGE AIRCLEANER jJNOTE2 78 79 5 GJ m 1 R R THROTTLE OPERATION 854
45. osition the right and left turn signal lights go outtogether CAUTION e Turn on hazard switch when parking or there is a special condition After the hazard switch is turned on it will not reset automatically Be sure to reset it after use to avoid affecting the traffic safety e When the signal lights are winking the hazard switch does not work When the ignition switch is OFF the hazard light will still work e If you leave the switch on for a long time the battery may become totally discharged So be careful not to use the hazard lights for more than 30 minutes 26 LEFT HANDLEBAR SWITCH Turn signal switch 1 Use the tum signal switch while turning to another direction or shifting to another lane The turn signal light will wink when tne switch is operated e For turning to the left c For turning to the right The instrument turn signal indicator light will also wink when the switch is operated Push the switch and it will release Horn button 2 Press the button to sound the hom Dimmer switch 3 D position The headlight low beam and taillight turn on ED position The headlight high beam and taillight tum on The high beam indicator light also tums on Passing light control switch 4 When this switch is pressed the headlight flashes on to signal approaching cars or when passing 27 dO KYMCO BRAKES Combination brake lever Left handlebar The front a
46. proper function page 88 10 Steering check for condition and smoothness KYMCO OPERATION STARTING THE ENGINE Always follow the proper starting procedure described below This scooter is equipped with a side stand ignition cut off system The engine cannot be started if the side stand is down A running engine will shut off if the side stand is lowered To protect the catalytic converter in your scooter s exhaust system avoid extending idling and the use of leaded petrol Your scooter s exhaust contains poisonous carbon monoxide gas High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage Do not run the engine with the garage door closed Even with the door open run the engine only long enough to move your scooter out of the garage Do not use the electric starter for more than 5 seconds at a time Release the starter button for approximately 10 seconds before pressing it again 45 KYMCO 1 Place the scooter on its center stand and make sure to put the side stand up 2 Lock the rear wheel by applying the parking brake lever XCITING 500 AFI XCITING 500 CAUTION Contact with the spinning rear wheel can cause you to be hurt Set the parking brake XCITING 500 AFI XCITING 500 when the scooter is on its center stand 46 3 Open the ignition key hole_shutter and make sure the engine stop switch is at Q RUN 4 Tum the ignition switch to ON Confirm
47. rformance Avoid hard acceleration hard comering and hard braking for the first 160 km 100 miles Z WARNING Failure to perform break in of the tires could cause tire slip and loss of control Use extra care when riding on newtires Perform proper break in of the tires as described in this section and avoid hard acceleration hard cornering and hard braking for the first 160 km 100 miles 58 Observe your first and most critical service The 1000 km 600 miles service is the most important service your scooter will receive During break in all of the engine components will have worn in and all of the other parts will have seated in All adjustments will be restored all fasteners will be tightened and the dirty oil will be replaced Timely performance of the 1000 km 600 miles service will ensure optimum service life and performance from the engine NOTE The 1000 km 600 miles service should be performed as outlined in the maintenance schedule section of this owner s manual Pay particular attention to the caution and waming in maintenance schedule section INSPECTION AND MAINTENANCE THE IMPORTANCE OF MAINTENANCE A well maintained scooter is essential for safe economical and trouble free riding It will also help reduce air pollution To help you properly care for your scooter the following pages include a maintenance schedule for regularly scheduled maintenance These instructions are based on the
48. s iron plates manhole covers painted lines etc KYMCO PARKING 1 After stopping the scooter tum the ignition switch counterclockwise to the KX OFF position and remove the key 2 Use the center stand to support the scooter while parked Park the scooter on firm level ground to prevent it from falling over If you must park on a slight incline aim the front of the scooter uphill to reduce the possibility of rolling off tne center stand or overtuming dO KYMCO 3 Lock the steering see page 20 to help prevent theft WARNING The exhaust pipe and muffler become very hot during A hot muffler can burn you operation and remain sufficiently hot to inflict burns if The muffler will be hot touched even after shutting off the engine enough to burn you for some time after stopping the Make sure flammable materials such as dry grass or engine leaves do not come in contact with the exhaust system when parking your scooter Park the scooter where pedestrians or children are not likely to touch the muffler To lock To unlock 56 BREAK IN RUNNING IN The first 1600 km 1000 miles are the most important in the life of your scooter Proper break in operation during this time will help ensure maximum life and performance from your new scooter Proper break in operation allows the machined surfaces to polish each other and mate smoothly Scooter reliability and performance depend on special
49. s center stand 2 Put the side stand up and start the engine 3 Lower the side stand The engine should stop as you put the side stand down If the side stand system does not operate as described see your KY MCO dealer for service 88 Side stand up BRAKE LEVER ADJUSTER There is an adjuster on both the brake levers Each adjuster has 4 positions so that the released lever position can be adjusted to suit the operator s hands Push the lever 1 forward and tum the adjuster 2 to align the number with the arrow mark 3 on the lever holder The distance from the grip to the released lever is minimum at number 4 and maximum at number 1 BRAKE FLUID Brake fluid level With the scooter in an upright position check the front and rear fluid level It should be above the lower level mark If the level is at or below the lower level mark L check the brake pads for wear see page 90 Worn pads should be replaced If the pads are not worn have your brake system inspected for leaks The recommended brake fluid is DOT 4 brake fluid from a sealed container or an equivalent Other checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings 89 KYMCO BRAKE PAD WEAR Brake pad wear depends upon the severity of usage the type of riding and road conditions Generally the pads will wear faster on wet and dirty roads Inspect the pads at each regular maintenan
50. smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions 2 Measure the throttle grip free play at the throttle grip flange The standaard free play should approximately 2 6 mm 0 08 0 24 in To adjust the free play 1 Slide the rubber sleeve 1 back to expose the throttle cable adjuster 2 2 Loosen the lock nut 3 then turn the adjuster to obtain the correct free play 3 Tighten the lock nut and reinstall the sleeve 81 KYMCO 2 6mm 0 08 0 24 in KYMCO IDLE SPEED The engine must be at normal operating temperature for accurate idle speed adjustment Ten minutes of stop and go riding is sufficient 1 Warm up the engine place the scooter on its center stand 2 Open the seat see page 34 3 Open the carburetor cover 1 82 4 Adjust idle speed with the throttle stop screw 2 Idle speed XCITING 500 1400 100 rpm XCITING 250 1700 100 rpm NOTE Itis not necessary to adjust idle speed for XCITING 250 AFI The throttle body is factory pre set do not loosen or tighten the painted bolts and screws of the throttle body Lossening or tightening them can cause throttle and idle valve synchronization failure We recommend the AFI automatic fuel injection system be serviced only by your KY MCO dealer Idle speed XCITING 500 AFI 1400 100 rpm XCITING 250 AFI 1600 100 rpm 83 KYMCO
51. t quality may cause engine damage 74 KYMCO 9 Install the oil strainer screen spring and oil strainer screen cap Oil strainer screen cap torque 15 N m 1 5 kgf m 11 Ibf ft 10 Fill the crankcase with the recommended grade oil see page 67 Cil capacity after draining and oil filter change XCITING 500 AFI XCITING 500 2 1 liter 2 2 US qt 1 9 Imp qt XCITING 250 AFI XCITING 250 0 9 liter 0 95 US qt 0 8 Imp qt 11 Install the oil filler cap dipstick 12 Start the engine and let it idle for 2 3 minutes 13 Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks 75 KYMCO TRANSMISSION OIL Oil change 1 Place the scooter in its center stand 2 Remove the transmission oil drain bolt 1 76 XCITING 500 AFI XCITING 500 3 Remove the transmission oil filler bolt 2 slowly tum XCITING 500 AFI XCITING 500 the rear wheel and drain the oil EE 7 After draining the oil completely install the oil drain bolt mg with a new sealing washer and tighten it Torque 20 2 kgf m 15 Ibf ft 4 Fill the transmission case with recommended oil Recommended transmission oil SAE 90 Oil capacity at draining XCITING 500 AFI XCITING 500 0 45 liter 0 48 US qt 0 4 Imp qt XCITING 250 AFI XCITING 250 0 18 liter 0 2 US qt 0 16 Imp qt 5 Inst
52. t locked fully 11 Side stand down indicator Lights when side stand is left down 12 High beam indicator Lights when the headlight high beam is tumed on 23 KYMCO 13 Cell phone socket indicator Lights when the cell phone socket is used 14 Coolant temperature gauge The coolant temperature gauge indicates engine coolant temperature when the ignition switch is in the Q position 15 Minute adjust button Push this button to adjust the minute display 16 Trip meter Odometer The display in tne speedometer has two functions trip meter and odometer The trip meter can register the trip distance The odometer registers the total distance that the scooter has been ridden By pressing 2 Mode button to select the trip meter mile or km or odometer mile or km The trip counter can be rest by keeping the button pressed down for more than 2 seconds when the trip counter value is displayed dO KYMCO 17 Clock Show hour and minute 18 Hour adjust button Push this button to adjust the hour display 19 Oil service indicator If the oil service indicator comes on while driving this indicates that the engine oil should be changed at each maintenance interval NOTE The oil service indicator comes on when the vehicle s ignition is tumed on and must come off when the engine is running 24 20 CELP Check engine lamp XCITING 500 250 AFI Flashes when there is any a
53. tact with the road When you replace a tire be sure to replace it with a tire of the size listed below If you use a different size of tire scooter handling may be adversely affected possibly resulting loss of scooter control TUBELESS TUBELESS Be sure to balance the wheel after repairing a puncture or replacing the tire Proper wheel balance is important to avoid variable wheel to road contact and to avoid uneven tire wear 99 KYMCO Z WARNING An improperly repaired installed or balanced tire can cause loss of control or shorten tire life e Ask your KYMCO dealer or qualified mechanic to perform tire repair replacement and balancing because proper tools and experience are required e Install tires according to the rotation direction shown by arrows on the sidewall of each tire dO KYMCO Z WARNING Failure to follow these instructions about tubeless tires may result in an accident due to tire failure Tubeless tires require different service procedures than tube tires e Tubeless tires require air tight seal between the tire bead and wheel rim Special tire irons and rim protectors or a specialized tire mounting machine must be used for removing and installing tires to prevent tire or rim damage which could result in an air leak eRepair puncture in tubeless tires by removing the tire and applying an internal patch eDo not use an external repair plug to repair a puncture since the plug
54. the red low oil pressure indicator is ON The low oil pressure indicator should go off a few seconds after the engine starts If the light stays on stop the engine immediately and check the engine oil level NOTE Operating the engine with insufficient oil pressure can cause serious engine damage 5 Squeeze the rear brake lever The electric starter will only work when the rear brake lever is squeezed and the side stand is up 47 KYMCO 6 With the throttle closed push the starter button Release the starter button as soon as the engine starts 7 Be sure to keep the throttle closed and the parking brake locked XCITING 500 AFI XCITING 500 while warming up the engine 8 Allow the engine to warm up before riding Do not BLIP the throttle open and close rapidly as the scooter will move forward suddenly Do not leave the scooter unattended while the engine is warming up 48 If you cannot restart a warm engine 1 Place the scooter on its center stand and squeeze the rear brake lever 2 Open the throttle 1 8 1 4 tum while starting the engine Ignition cut off XCITING 500 AFI XCITING 250 AFI XCITING 500 AFI XCITING 250 AFI is designed to automatically stop the engine and fuel pump if the scooter is over turned a angle detect sensor cuts off the ignition system Before restarting the engine you must tum the ignition switch to the OFF position and then back to ON 49 KYMCO
55. tthe spark plugs to the spark plug caps Poura tablespoon 15 20 cc of clean engine oil into each cylinder and cover the spark plug holes with a piece of cloth Crankthe engine several times to distribute the oil Reinstall the spark plugs and spark plug caps 5 Remove the battery Store in an area protected from freezing temperatures and direct sunlight Slow charge the battery once a month 6 Wash and dry the scooter Wax all painted surfaces Coat chrome with rustinhibiting oil 7 Inflate the tires to their recommended pressures Place the scooter on blocks to raise both tires off the ground 8 Coverthe scooter don t use plastic or other coated materials and store in an unheated area free of dampness with a minimum of daily temperature variation Do notstore the scooter in direct sunlight 107 dO KYMCO Removal from storage 1 Uncover and clean the scooter 2 Change the engine oil if more than 1 months have passed since the Start of storage 3 Charge the battery as required Install the battery 4 Drain any excess aerosol rust inhibiting oil from the fuel tank Fill the fuel tank with fresh petrol 5 Performall Pre ride inspection checks see page 44 Test ride the scooter at low speeds in a safe riding area away from traffic 108 KYMCO SPECIFICATIONS XCITING 500 AFI XCITING 500 DIMENSIONS Overall length Overall width Overall height Wheel base WEIGHT Dry weight CAPACITIES Engi
56. uct clear vision Do not let battery electrolyte brake fluid or other acid chemicals get on the windshield screen garnish They will damage the plastic 105 KYMCO STORAGE GUIDE Extended storage such as for winter requires that you take certain steps to reduce the effects of deterioration from non use of the scooter In addition necessary repairs should be made before storing the scooter otherwise these repairs may be forgotten by the time the scooter is removed from storage Storage 1 Change the engine oil and filter 2 Make sure the cooling system is filled with a 50 50 antifreeze solution 3 Drain the carburetor and empty the fuel tank into an approved petrol container using a commercially available hand siphon or an equivalent method Spray the inside of the tank with an aerosol rust inhibiting oil Reinstall the fuel fill cap on the tank Z WARNING Petrol is highly flammable and explosive You can be burned or seriously injured when handling fuel e Stop the engine and keep heat sparks and flame away e Refuel only outdoors e Wipe up spills immediately 106 KYMCO 4 To prevent rusting in the cylinders perform the following Remove the spark plug caps fromthe spark plugs using tape or string secure the caps to any convenient plastic body partso thatthey are positioned away fromthe spark plugs Remove the spark plugs from the engine and store them in a safe place Do not connec
57. use which rust occurs in Wash your scooter by the following point after it runs through such a place 1 Clean the scooter using cool water see page 101 Do not use warm water This worsens the effect of the salt 2 Dry the scooter and the surface of the metal is protected with the wax Painted aluminum wheel maintenance Aluminum may corrode from contact with dirt mud or road salt Clean the wheels after riding through any of these substances use a wet sponge and mild detergent Avoid stiff brushes steel wool or cleaners containing abrasives or chemical compounds After washing rinse with plenty of water and dry with a clean cloth Apply touch up paintto the wheels where damage has resulted Exhaust pipe maintenance The exhaust pipe is stainless steel but may become stained by oil or mud If necessary remove heat stains with a liquid kitchen abrasive 104 KYMCO Clean the windshield Using plenty of water clean the windshield with a soft cloth or sponge Avoid using detergents or any kind of chemical cleaner on the windshield Dry with a soft clean cloth To avoid possible scratching or other damage use only water and a soft cloth or sponge to clean the windshield Fora dirtier windshield use a diluted neutral detergent with a sponge and plenty of water Make sure to wash off all the detergent Detergent residue may cause windshield cracks Replace the windshield if scratches cannot be removed and they obstr

KYMCO Xciting 250/500 Owner`s Manual (pre 2008

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