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GENERAL INFORMATION

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1. spark plug Eu Fouled spark plug Faulty ignition unit Spark jumps Weak or no spark Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil OFaulty ignition switch Test cylinder compression 1 Starter motor idles but crankshaft does not rotate 2 Valve clearance too small 3 Improper valve and seat contact 4 Worn cylinder and piston rings compression Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing Start engine by follow ing normal starting procedure OFaulty auto bystarter 2 Air leaking through intake pipe Incorrect ignition timing 2 Incorrectly adjusted pilot screw Engine fires but does not start Remove spark plug and inspect again P Dry spark plug OFlooded carburetor Faulty auto bystarter Throttle valve excessively open Wet spark plug 1 51 dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 AFI ENGINE LACKS POWER Probable Cause OClogged air cleaner Restricted fuel flow Start engine and accelerate lightly for NE Engine speed does tank and carburetor not increase 2 exhaust muffler sufficiently 9 Faulty auto bystarter OSplit carburetor vacuum piston Check ignition timing using a timing light O Faulty ignition unit Faulty A C generat
2. VE Co oT 8 PE ec Ier lt ER 5 5 al r3 et e SX 5 E 1 1 L 0 97 Imp qt 1 17 Us qt NO 3 5 e 2 Us qt Liquid cooled Cooling Type XCITING 500 500 1 250 250 ITEM SPECIFICATIONS Air cleaner type amp No Wet paper type element Fuel capacity d 3 Imp gal ga Q mp 0193845 on 30 mm 1 2 in ISTON Type Pall transistor ignition Spark plug DPRTEA 9 Throttle position sensor 0 002 12V10AH Type Dry centrifugal automatic Type Helical gear spur gear Operation Automatic centrifugal vi FR RR tire rolling circumference 10191NQae 94646 uous Lei 3 ga 93 3 ele LA 5 7 Q ru wi J B lt Lo lt 224 1724 1778 mm 69 71 in I DD 2 kg cm 200 28 Tire pressure psi rider only 60 2 5 kg cm 250 kg Rear 36 051 Tuning angle R Brake system Disk brake type Disk brake J J Front SUMON Front Telescopic fork Frame type dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 SPECIFICATIONS XCITING 250 AFI SPECIFICATIONS Name XCITING 250 AFI Overall length 2250 mm 90 in 15 mm 33 in 450 mm 58 in 570 mm 63 in Dissiscement 251 249 1 cm
3. E d bh w r Keke P E kat p II by 1 K m e Wi 52 Be T G CN Ko k Nn WS Ka a VW ag a 3 HIT d ZC ke RT Lin a j 14 K y MTM s s at D AM IL SLT e fe UM RU TT La e LI Air Cleaner Drain Tube T P S Wire Oil Cooler Water Hose AICV Control Valve Water Temperature Sensor Wire Air Cleaner Drain Hose Water Hose HC T PEINE AICV Air Supply Hose Oil Cooler Water Hose Fuel Hose Air Bleed Hose 1 25 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Water Temperature Sensor T P S Automatic Choke Heater Connectors Oil Cooler Water Hose Crankcase Breather Hose Water Temperature Sensor Wire Oil Cooler Water Hose Water Pump Lower Radiator Hose Harness Wire Throttle Cables Water Pipe Upper Radiator Hose AICV Vacuum Hose Water Hose 1 26 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 CABLE amp HARNESS ROUTING XCITING 500 AFI Right Handlebar Switch Left Handlebar Switch LLL Front Brake Hose Combined Brake Hose Harness Wire Meter Connector Front Right Turn Signal Light Connector Tilt Switch Headlight Connector Front Left Turn Signal Light Connector fe d e 4 Front Left Turn Signal Wire LA et Jf eg el Front Right Turn Signal Wire Hea
4. Front Brake Hose Combined Speed Sensor Wire l FA E 8 NW E ue i H L ar A La dii PA Air Bleed Hose 1 18 dO KYMCO 1 GENERAL INFORMATION 500 500 AFI 250 250 AFI Right Handlebar Switch Left Handlebar Switch Combined Brake Hose Harness Wire Meter Connector Front Left Signal Front Right Signal Light Connector Light Connector Headlight Connector Front Left Turn Signal Wire Front Right Turn Signal Wire Headlight Position Light Wire 1 19 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Fuel Filler Cap Lock Cable Left Handlebar Switch Right Handlebar Switch Ignition Switch Fan Motor E M I Fuel Pump Relay Ground Wire Parking Brake Switch Wire Ignition Switch Connector Harness Wire Fan Motor E M I Wire Seat Lock Cable 1 20 500 500 1 250 250 1 GENERAL INFORMATION Front Brake Hose Left Combined Brake Hose Speed Sensor Wire Sei eh b Sx Throttle Cable Mum S HINES TN Na 2 PS fr 74 SEELEY RSS WA 2 c h a 4 SN h e bt 9 2 3 DN i E Z2 P E o I gt e 2 E CS 3 o o LL 9 LL n 5 LL Sea
5. POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Check carburetor pilot Screw adjustment PE AAA AKAA Check intake manifold for air leaks Remove spark plug and install it into spark plug cap to test spark by ee AAA gt connecting it to engine ground Weak or inter Check carburetor air cut off valve 1 53 Probable Cause O Faulty ignition unit Faulty A C generator DMixture too rich turn screw out Mixture too lean turn screw in Damaged insulator rubber 2 Carburetor not securely tightened GFaulty intake manifold gasket Deformed carburetor O ring DFaulty or fouled spark plug Faulty ignition unit 3 Faulty A C generator Faulty ignition coil Broken or shorted high tension wire Faulty ignition switch ODamaged air cut off valve diaphragm Damaged air cut off valve spring 1 GENERAL INFORMATION 500 500 1 250 250 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment M Check ignition timing Check fuel pump for fuel supply gusvasuusuvuaseusuvasuusuvaseucuvavsucuvaveucsvaveueavaveucuvaveueuvavsusavaveuuavavauusvavsuVa wawa Va Va VE VENUE A Check carburetor jets for clogging HOT TETT ETTE LETE VE MEET VEE TTV KN NN NN NN KENNEN Check valve spring tension Probable Cause DFaulty
6. Probable Cause DWorn or slipping drive belt Broken ramp plate 3 Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot Worn or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings DWorn or slipping drive belt Worn weight rollers 2 Worn or seized driven pulley bearings OOil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings 1 56 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment oe Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight comes on Stoplight does not GFaulty stop switch EE come on Loose or disconnected Check battery circuit connectors by operating turn GO Broken or shorted ignition signals switch wire 5 Faulty side stand switch Signals operate Signals dim remain Check operation of properly on or don t operate DFaulty or weak battery Starter relay by depressing starter button n Relay operates Relay Anes Sai Poor starter bution connection properly operate Open or shorted s
7. 15 3 15 8 cu in Fuel Used 92 nonleaded gasoline 5 kg 165 Ibs Dry weight 10 kg 242 lbs 85 kg 407 Ibs Front wheel 81 kg 178 Ibs Curb weight 19 kg 262 lbs 00 kg 440 Ibs Rear wheel 150 70 14 70 mm 6 8 in 600 mm 104 in Starting system Gasoline 4 stroke ingle cylinder Combustion chambertype Semi sphere O H C chain drive 72 7 X 60 mm 2 908 x 2 4 1n Compression ratio 10 6 1 15 kgf cm 1500kPa Intake valve 409 Exhaust valve Open 42 BEE 7 ATDC Valve clearance 0 1 mm 0 004 in cold Exhaust 0 1 mm 0 004 in Idle speed 600 rpm Forced pressure amp Wet sump Lubrication type Oil pump type Trochoid Oil capacity DI Olm 2 T O ID Bore x stroke Oil filter type _ Full flow filtration 1 1 L 0 97 Imp qt 1 17 Us qt Final reduction oil 0 23 L 0 2 Imp qt capacity 0 24 Us qt Cooling Type Liquid cooled UIDJS G CH 3 e lt ge CH ITEM SPECIFICATIONS Air cleaner type amp No Wet paper type element Fuel capacity 12 8 L 3 38 Imp gal 2 82 US gal Body Venturi Od Type Full transistor ignition Spark plug DPR6EA 9 ECU 0 6 0 7mm 0 002 0 003 in 12V10AH Type Dry centrifugal Ignition timing 91646 uous Spark plug gap juawdmnbq Teua 97546 ond automatic Helical gear spur gear Automatic centrifugal Type FR RR tire rolling circumf
8. compression OTTEN Starter motor idies but crankshaft does not rotate 2 Valve clearance too small 3 Improper valve and seat contact 4 Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing Normal Low or no compression compression 1 62 1 GENERAL INFORMATION ENGINE LACKS POWER Connect the diagnostic tool then check EMS and correct problems Start engine and accelerate lightly for Observation clogging Remove spark plug and inspect KA AAA AAA AAA AA AAA AA AA AA AAA AA AA AA AAA AA Remove oil dipstick and Inspection Adjustment Engine speed Engine speed does increases not increase sufficiently Correct Incorrect Not Clogged Clogged check oil level and condition Plug not fouled or Plug fouled or discolored discolored Remove cylinder head bolts and inspect OO 1 63 Valve train lubricated Valve train not properly lubricated properly Engine does not Engine overheats overheats dO KYMCO XCITING 500 500 1 250 250 AFI Probable Cause OClogged air cleaner Clogged exhaust muffler Faulty spark plug Faulty throttle Faulty fuel pump OFaulty fuel injector Improper valve timing Low or no compression OImproper valve clearance adjustment Worn valve seat valve stem to
9. Front Right Turn Signal Light Connector Headlight Connector Front Left Turn Signal Light Connector Pi CN fad d A A AL Front Left Turn Signal Wire Headlight Position Light Wire 1 39 dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 AFI Battery Positive Cable Seat Lock Light Switch Battery Negative Cable Taillight Connector Hazard Unit Ignition Control Module Wire Hazard Unit Wire RY Sea en AN Vv y NA us M ELE Kee d DIM 2 M SS LG Wo M 4 Wei 5 4 LE NS YA ih ES Taillight Brake light Wire Regulator Rectifier Rear Right Turn Signal Wir Rear Left Turn Signal Wire License Light Wire 1 40 500 500 1 250 250 1 GENERAL INFORMATION Ground Wire Fuel Filler Cap Lock Cable Fuel Filler Hose Fan Motor E M I Wire N I SN M S h 2 SAN VW B AY E E Th E n Ios Leg i un 7 i i Ni 4 SN Fh d d A JE LM E i d Kee d a d PLVS A AA OG WI SE VAAR SE D d d i rad zv C ud TO Bb ES a i du LZ N i E x Right Handlebar Switch Left Handlebar Switch Harness Wire Seat Lock Cable Ignition Switch Connector Throttle Cable 1 4
10. KE HEF a Ff x offi Ground Wire Harness Wire Throttle Cable 1 45 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Battery Positive Cable Seat Lock Light Switch Battery Negative Cable Taillight Connector Taillight Brake light Wire Rear Right Turn Signal Wire Harness Wire Rear Left Turn Signal Wire Starter Motor Wire 1 46 1 GENERAL INFORMATION 500 500 1 250 250 Ignition Coil Fuel Pump Relay Ignition Coil Cable Harness Wire Upper Radiator Hose Rear Brake Hose Radiator Secondary Air Cleaner Lower Radiator Hose Air Bleed Hose 1 47 KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 AFI Positive Termial Lead Starter Motor Cable ositive Termial Lea Seat Lock Cable Center Compartment Light Connector Diagnostic Tool Connector Negative Terminal Lead Taillight Brake Light Turn Signal Light Accessory Socket Seat Connector Air Cleaner Housing Drain Tube Seat Unlock Indicator Connector i a S Crankcase Breather 4 lagen amp Oil Pressure Switch Connector Harness Wire KS ECU Hazard Unit ge zh Oil Pressure Switch Regulator Rectifier Wire Water Hose Lower Radiator Hose Rear Brake Hose 1 48 dO KYMCO 1 GENER
11. ignition unit 2 Faulty A C generator DImproperly adjusted valve clearance Worn valve seat DEmpty fuel tank Fuel flows freely Fuel flow restricted 2 e Io or filter 4 Cracked fuel pump vacuum tube Not clogged Clogged MClean and unclog Incorrect OCam timing gear aligning marks not aligned Weak spring O Faulty spring Not weakened 1 54 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Q Worn camshaft lobe DWorn piston rings Piston noise Worn piston and connecting rod small end 9 Excessive carbon build up in combustion chamber 0 Damaged cam chain tensioner 2Worn cam gear teeth Cam chain noise Worn or damaged cam chain 2 Extended cam chain OFaulty crankshaft bearing Crankshaft noise Worn crank pin bearing DWorn or damaged final reduction gears Gear noise 2Worn final reduction gear shaft splines 1 55 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS Symptom Engine starts but motor cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There 15 abnormal noise or smell while running dO KYMCO XCITING 500 500 1 250 250
12. limit VO tage of battery terminals O Faulty AC generator Normal voltage Faulty regulator rectifier Faulty battery Mn between AC generator coil terminals Resistance too low DShorted AC generator coil Q Open circuit between AC generator 3 yellow wires Test output voltage of FEE regulator rectifier coupler red wire DFaulty regulator rectifier Faulty AC 2 Normal voltage G Loose regulator rectifier coupler Limit voltage too high Overcharging Inspection Adjustment Probable Cause aea aa A NARGI 9 Measure battery limit voltage with an electric tester O Faulty battery Faulty regulator rectifier 3 Broken or poorly connected regulator rectifier black wire Check resistance between regulator rectifier terminals OM Limit voltage too high 1 71 dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 AFI FUEL GAUGE 1 Pointer does not correctly Ignition switch ON Inspection Adjustment Probable Cause D Check battery circuit by operating turn signals gt FN Burned out fuse Siona Weak or dead battery Signals dim remain Q Faulty ignition switch eee ae He properl y on or don t operate Loose disconnected check operation of P gt roken wire harness pointer by moving float up and down p Float
13. nut 25 2 5 18 Tensioner lifter bolt 4 0 4 3 Cylinder head cover bolt 12 1 2 8 6 Cam chain tensioner bolt 12 1 2 8 6 1 11 1 GENERAL INFORMATION 500 500 AFI 250 250 ENGINE XCITING 250 XCITING 250 AFI Cont d Thread dia Torque It t R k mm Nem kgfm bff 777 DRIVE DRIVEN PULLEY Drive face nut 93 9 3 67 Clutch outer nut 54 5 4 39 Clutch drive plate nut 54 5 4 39 Left crankcase cover bolt 12 1 2 8 6 ALTERNATOR A C G stator 2 9 0 9 6 5 Flywheel nut 55 5 5 40 FINAL REDUCTION Transmission case cover bolt 20 2 14 4 CRANKCASE Cam chain guide bolt 10 1 7 SWITCH Oil pressure switch 22 2 2 16 1 12 dO KYMCO 1 GENERAL INFORMATION 500 500 AFI 250 250 AFI FRAME STEERING Handlebar bolt Upper pinch bolt Lower pinch bolt Bridge stem nut Steering stem lock nut Rear axle nut XCITING 500 Rear axle nut XCITING 250 SUSPENSION Rear shock absorber bolt 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 Q ty Thread dia mm lorque Nem kgfem Ibfeft 23 2 3 17 23 2 3 17 82122220 62 6 2 45 55 5 5 40 20 2 15 20 2 15 23 2 3 17 180 18 130 14
14. out fuse Weak or dead battery Faulty ignition switch 2 Loose or disconnected connector Broken wire harness Poor contact in fuel unit Pointer does not move Pointer does not move in accord OlInsufficient damping oil in ance with float fuel gauge Loose or disconnected connector OM Broken or shorted wire fuel gauge 1 60 1 GENERAL INFORMATION dO KYMCO XCITING 500 500 1 250 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Steering is heavy Front or rear wheel is wobbling Steering handlebar pulls to one side LN POOR SUSPENSION PERFORMANCE Symptom Suspension is too soft Suspension is too hard Suspension is noisy VAN POOR BRAKE PERFORMANCE Symptom Soft brake lever Hard brake lever Hard to brake Poor brake performance Brake squeaks 1 61 Probable Cause Front and rear tire pressures are normal DSteering stem nut too tight 2 Broken steering steel balls DExcessive wheel bearing play Bent rim 3 Loose axle nut Misaligned front and rear wheels Bent front fork Probable Cause Front and rear tire pressures are normal O Weak shock spring Excessive load Q Shock damper oil leaking OM Bent fork tube or shock rod O Fork tube and slider binding Fork spring and slider binding 2 Damaged shock stopper rubber Loose steering stem nut Probable Cause DWorn brake linings Foreign matter on brake l
15. 0 14 100 40 4 29 32 3 2 23 32 3 2 23 32 3 2 23 35 3 5 25 12 1 2 9 50 5 36 80 8 58 50 5 36 35 3 5 25 20 2 14 35 3 5 25 Remarks Replace a new one Replace a new one 1 GENERAL INFORMATION SPECIAL TOOLS XCITING 500 XCITING 500 AFI Oil seal amp 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 Lock nut socket wrench Steering stem top thread wrench A120E00014 A120E00015 A120E00017 A120E00021 A120E00036 A120E00037 A120E00040 A120E00052 A120E00053 A120E00054 A120F00007 A120F00023 XCITING 250 XCITING 250 AFI Flywheel puller Oil seal amp bearing installers Lock nut socket wrench Universal holder Flywheel holder Clutch spring compressor Tappet adjuster Bearing pullers Valve spring compressor Lock nut socket wrench Steering stem top thread wrench dO KYMCO XCITING 500 500 1 250 250 Oil seal amp 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 Steering stem removal or install Steering stem removal or install A120E00003 A120E00014 A120E00015 A120E00017 A120E00021 A120E
16. 00034 A120E00036 A120E00037 A120E00040 A120F00007 A120F00023 A C generator flywheel removal Oil seal amp bearing install Steering stem removal or install Holding clutch for removal A C generator flywheel holding Clutch disassembly Tappet adjustment Bearing removal Valve removal Steering stem removal or install Steering stem removal or install 1 14 1 GENERAL INFORMATION LUBRICATION POINTS ENGINE dO KYMCO XCITING 500 500 1 250 250 AFI 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 Drive gear shaft Countershaft Final gear Final gear shaft Transmission gearshaft bearing part eGenuine KYMCO Engine Oil SAE 5W 50 eAPI SJ Engine Oil Transmission oil SAE 90 1 15 1 GENERAL INFORMATION 500 500 1 250 250 FRAME The following 15 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 t
17. 1 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 Fuel Filler Cap Lock Cable Combined Brake Hose Throttle Cable Ground Wire Fuel Tank Breather Hose Speed Sensor Wire Seat Lock Cable Front Right Brake Hose Rear Brake Hose 1 42 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 CABLE amp HARNESS ROUTING XCITING 250 AFI Right Handlebar Switch Left Handlebar Switch LLL Front Brake Hose Combined Brake Hose Harness Wire Meter Connector Front Right Turn Signal Light Connector Tilt Switch Headlight Connector Front Left Turn Signal Light Connector fe d e 4 Front Left Turn Signal Wire LA et Jf eg el Front Right Turn Signal Wire Headlight Position Light Wire 1 43 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 Fuel Filler Cap Lock Cable Combined Brake Hose Front Left Brake Hose Tilt Switch Throttle Cable Ground Wire Fuel Tank Breather Hose Speed Sensor Wire Seat Lock Cable Front Right Brake Hose Rear Brake Hose 1 44 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Fuel Filler Cap Lock Cable Left Handlebar Switch Right Handlebar Switch ZI NA y Ya A am E Ge P L ON Kb H i fnm A NE f sal gu HN Seat Lock Cable LN
18. AL INFORMATION XCITING 500 500 AFI 250 250 Fan Motor Switch Leads Upper Radiator Hose Fuel Pump Harness Wire Side Stand Switch Wire Fuel Pump Relay Ignition Coil Fuel Injector Fuel Hose EXAI ECT Sensor Air Cleaner Housing Drain Tube Ce MAP Sensor _ 5 DE ISC Crankcase Breather Hose Harness Wire Throttle Cable 1 49 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Regulator Rectifier Wire Positive Termial Lead Pulser Connector Engine Ground Cable Negative Terminal Lead Harness Wire Fuel Injector Ignition Coil Fuel Hose Fuel Pump Reserve TankN Ignition Coil Cable Overflow Hose Side Stand Switch Siphon Hose 1 50 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 TROUBLESHOOTING XCITING 500 250 ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment carburetor by MEN Check if fuel reaches drain screw Fuel reaches carburetor Probable Cause Empty fuel tank Q Clogged carburetor fuel inlet tube vacuum tube or fuel tube GClogged auto fuel valve Clogged float oil passage GClogged Ge tank cap breather hole Fuel does not reach carburetor Clogged fuel strainer i M MClo ged fuel filter Remove spark plug and OFaulty fuel pump install it into spark plug cap to test spark by connecting 1t to engine
19. G XCITING 250 Seat Lock Cable A C Generator Wire Wire Fuel Hose Fuel Pump Oil Pressure Vacuum Hose Switch Control Fuel Unit eyo AICV Vacuum Hose Throttle Cable M Ignition Coil Cable AICV Air Supply Hose Secondary Air Supply Hose Side Stand Switch Wire Siphon Hose Fan Motor Water Fill Hose Switch Wire Front Brake Hose 1 35 1 GENERAL INFORMATION 500 500 1 250 250 Harness Wire Fuel Pump Vacuum Hose Fuel Hose Lower Radiator Hose Fuel Hose Speed Sensor Wire Front Brake Hose Combined 1 36 dO KYMCO 1 GENERAL INFORMATION 500 500 AFI 250 250 AFI Crankcase Breather Hose Throttle Cable Harness Wire Automatic Choke T P S Connector Secondary Air Heater Wire Supply Hose AICV Vacuum Hose AICV Air Supply Hose Fuel Hose 1 37 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Fuel Pump Vacuum Hose Throttle Cable Fuel Hose Crankcase Breather Hose g s AN AICV Vacuum Hose Air Bleed Hose AICV Air Supply Hose Lower Radiator Hose 1 38 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Right Handlebar Switch Left Handlebar Switch Front Brake Hose Combined Brake Hose AM Harness Wire Let e NN xig TS Meter Connector
20. 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 lorque Nem kgfem Ibf 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 3 0 3 2 35 3 5 25 13 1 3 9 13 1 3 9 48 4 8 35 23 2 3 17 10 1 7 12 1 2 9 10 1 7 45 4 5 32 135 13 5 97 80 8 58 ft 1 10 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 ENGINE XCITING 500 XCITING 500 AFI Cont d Thread dia Torque Item t Remark mn Drive plate nut 78 7 8 56 ALTERNATOR flywheel nut 55 5 5 40 FINAL REDUCTION Transmission cover bolt 27 2 7 20 CRANKCASE Crankcase bolt 12 1 2 9 Oil pipe bolt 43 4 3 31 Cam chain guide 20 2 15 SWITCH Oil pressure switch 22 2 2 16 ENGINE XCITING 250 XCITING 250 AFI Thread Torgue MAINTENANCE Valve adjusting lock nut 9 0 9 6 5 Spark plug 12 1 2 9 Transmission oil drain bolt 20 2 15 Transmission oil check fill bolt 20 2 15 Crank case oil drain bolt 25 2 5 18 Oil filter screen 15 1 5 10 8 LUBRICATION SYSTEM Oil pump screw 2 0 2 1 4 COOLING SYSTEM Water pump impeller 12 1 2 8 6 CYLINDER HEAD Cylinder head cap
21. amp No Wet paper type element Fuel capacity 12 8 L 3 38 Imp gal 2 82 US gal Body Venturi pamm Type Full transistor ignition Spark plug CR7E ECU 0 6 0 7mm 0 002 0 003 in Ignition timing 91646 uous Spark plug gap 12V12AH Dry centrifugal automatic Helical gear spur gear Automatic centrifugal Type FR RR tire rolling circumference 9 6 6 JOMOd STUISUBL L uononpoy 1724 1778 mm 69 71 in 2 kg cm 200 28 Tire pressure psi rider only 60 2 5 kg cm 250 Kpa kg Rear 4g osi DT Telescopic fork Front SUMON Brake system Front 1 GENERAL INFORMATION SPECIFICATIONS XCITING 250 15 3 15 8 cu in Front wheel 120 70 15 Rear wheel ngine type Displacement Ee z Z oa te ken ila la EAE E erem 2 5 lo EEE 15151 s juowdnbq Tenga uel Used _ z lt p lt SIS e Cylinder arrangement single cylinder Combustion chamber type 2 908 x 2 4 in 213 psi Close Open Valve clearance Intake 0 1 mm 0 004 in cold Exhaust 0 1 mm 0 004 in Idle speed 1600 rpm Forced pressure amp Wet sump Full flow filtration 0 Starting system Bore x stroke Compression ratio Compression pressure Valve arrangement Q C 5 Exhaust valve ourguq 5 e e i E ES c Si e c 3 e lt go C UIDJIS G
22. cording to the operating ons Do you understan the instrument B When rust 1s found on a terminal remove the rust with sand paper or equivalent before connecting Remove Rust 1 9 dO KYMCO XCITING 500 500 AFI 250 250 AFI Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use E gine Oil designated engine oil for lubrication BT Apply grease for lubrication Grease m Transmission Gear Oil 907 Gear Oil Note 1 GENERAL INFORMATION 500 500 AFI 250 250 TORQUE VALUES STANDARD TORQUE VALUES Torque 5mm bolt and nut 5 0 5 4 4mm screw 6mm bolt and nut 10 1 7 8mm bolt and nut 22 2 2 16 10mm bolt and nut 35 3 5 25 12mm bolt and nut 55 5 5 40 70 7 50 lorque Nem kgfem Ibfeft 3 0 3 2 4 0 4 3 9 0 9 6 5 12 1 2 9 27 2 7 20 40 4 29 5mm screw 6mm screw SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 14mm bolt and nut 10mm flange bolt and nut Torque specifications listed below are for important fasteners ENGINE XCITING 500 XCITING 500 AFI Q ty Thread dia mm MAINTENANCE Engine oil drain plug Oil strainer screen Oil filter cartridge Transmission oil drain bolt Transmission oil filler bolt Spark plug Tappet adjust nut LUBRICATION SYSTEM Oil pump screw
23. cumference 2 kg cm 200 28 psi 2 5 kg cm 250 Rear 36 051 Turning angle R Brake system Disk brake type Disk brake QU Tire pressure Front rider only 60 kg Front Telescopic fork Frame type dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 SPECIFICATIONS XCITING 500 AFI SPECIFICATIONS Name XCITING 500 AFI Overall length 2250 mm 90 in 15 mm 33 in 450 mm 58 in 570 mm 63 in Engine type O H C 498 5 cm 30 4 cu in yusuidinby Teua 97546 ond Displacement Fuel Used 92 nonleaded gasoline 3 kg 183 Ibs Dry weight 32 kg 290 Ibs 15 kg 473 Ibs Front wheel 90 kg 198 Ibs Curb weight 41 kg 310 Ibs 31 kg 508 lbs Rear wheel 150 70 14 50 mm 6 in 750 mm 110 in Starting system Electric starter motor Type Gasoline 4 stroke Single cylinder Combustion chambertype Semi sphere Am Compression ratio 10 5 1 Compression pressure 13 kgf cm 1300kPa 185 psi Intake valve gt BIDC Close 45 ABDC Exhaust valve Open 45 BBDC 5 ATDC Valve clearance 0 1 mm 0 004 in cold Exhaust 0 1 mm 0 004 in Idle speed 1400 rpm ubrication type Sr amp il pump type L Trochoid Oil filter type Full flow filtration Oil capacity 5 qt UIDJIS G Final reduction oil 0 55 L 0 5 Imp qt capacity 0 58 Us qt Cooling Type Liquid cooled ITEM SPECIFICATIONS Air cleaner type
24. d spark Check spark plug cap and high tension wire for looseness O Faulty spark plug Check ignition unit coupler for looseness Measure resistance between terminals of ignition unit coupler O Faulty ignition switch Faulty exciter coil Q Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler OFaulty ignition unit 1 58 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause 22 22220 54 Start engine and test limit voltage of battery terminals DFaulty AC generator Normal voltage Faulty regulator rectifier Faulty battery between AC generator NN coil terminals Resistance too low DShorted AC generator coil Q Open circuit between generator 3 yellow wires Test output voltage of regulator rectifier coupler red wire DFaulty regulator rectifier Faulty ae bead Normal voltage G Loose regulator rectifier coupler OLimit voltage too high Overcharging Inspection Adjustment Probable Cause 9 Measure battery limit Voltage with an electric tester O Faulty battery Faulty regulator rectifier 3 Broken or poorly connected regulator rectifier black wire Check resistance bet
25. dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment oe Probable Cause Check operation of stop switch by OBurned out fuse applying brake Weak or dead battery Stoplight comes on Stoplight does not GFaulty stop switch formen come on Loose or isconnected Check battery circuit connectors by operating turn A GO Broken or po ignition signals switch wir E E Faulty MER stand switch Signals operate Signals dim remain Check operation of properly on or don t operate Faulty or weak battery Starter relay by depressing starter button Relay operates Relay Tm em DPoor Ste button connsction properly operate Open or shorted starter relay GLoose Of disconnected i connectors motor directly to ge battery Worn brushes Open starter motor cable Loose connectors Open wire harness 2 Starter motor turns lt a idles Inspection Adjustment Probable Cause Q S Check battery circuit turn REREN signals Signals operate Signals dim remain men Gre don t operate DWeak or dead battery Connect starter motor directly to gt battery DLoose connector or terminal 2Poor contact in starter relay Faulty starte
26. dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 AFI GENERAL INFORMATION 1 1 SPECIFICATIONS XCITING 500 1 2 SPECIFICATIONS XCITING 500 AFI 1 3 SPECIFICATIONS XCITING 250 1 4 SPECIFICATIONS XCITING 250 AFT 1 5 SEP VICE DIGG ONE 1 6 IOROUE 1 10 SPECTAT TOUS 1 14 1 15 CABLE amp HARNESS ROUTING XCITING 500 1 17 CABLE amp HARNESS ROUTING XCITING 500 AFI po CABLE amp HARNESS ROUTING XCITING 250 1 35 CABLE amp HARNESS ROUTING XCITING 250 AFI 1 43 TROUBLESHOOTING XCITING 500 250 1 51 TROUBLESHOOTING XCITING 500 AFI 250 AFI 1 62 1 0 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number 1 1 1 GENERAL INFORMATION SPECIFICATIONS XCITING 500 SPECIFICATIONS Name XCITING 500 Overall length 7 2250 mm 90 in 15 mm 33 in 450 mm 58 in 570 mm 63 in Displacement 498 5 em 304 cu in 924 nonleaded gasoline Front wheel 83 kg 183 Ibs Dry weight Rear wheel 132 kg 290 Ibs Total 15 kg 473 lbs Front whee Cu
27. dlight Position Light Wire 1 27 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 Fuel Filler Cap Lock Cable Combined Brake Hose Front Left Brake Hose Tilt Switch Throttle Cable Ground Wire Fuel Tank Breather Hose Speed Sensor Wire Seat Lock Cable Front Right Brake Hose Rear Brake Hose 1 28 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Fuel Filler Cap Lock Cable Left Handlebar Switch Right Handlebar Switch ZI NA y Ya A am E Ge P L ON Kb H i fnm A NE f sal gu HN Seat Lock Cable LN KE HEF a Ff x offi Ground Wire Harness Wire Throttle Cable 1 29 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Battery Positive Cable Seat Lock Light Switch Battery Negative Cable Taillight Connector Taillight Brake light Wire Rear Right Turn Signal Wire Harness Wire Rear Left Turn Signal Wire Starter Motor Wire 1 30 1 GENERAL INFORMATION 500 500 AFI 250 250 Ignition Coil Fuel Pump Relay Harness Wire Upper Radiator Hose Rear Brake Hose Radiator Secondary Air Cleaner Lower Radiator Hose Air Bleed Hose 1 31 1 GENERAL INFORMATION 500 500 1 250 250 Starter Moto
28. erence 9 6 6 JOMOd SIUISUPI L uononpoy 1724 1778 mm 69 71 in 2 kg cm 200 28 Tire pressure psi rider only 60 2 5 kg cm 250 Kpa kg Rear 4g osi DT Telescopic fork Front a 5 ga J e Brake system Front 1 GENERAL INFORMATION SERVICE PRECAUTIONS Bi Make sure to install new gaskets O rings circlips cotter pins etc when reassembling o B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants p B When servicing the motorcycle be sure to use special tools for removal and installation B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly KYMCO XCITING 500 500 1 250 250 E Apply or add designated greases lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation E When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation E When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive term
29. he motorcycle Hn Engine Oil STE Grease Front Rear Brake Lever Pivot WT Grease Seat Lock Throttle Cable Front Wheel Bearing BT Grease Rear Wheel Bearing WT Grease Center Stand Side Stand Pivot BT 1 16 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 CABLE amp HARNESS ROUTING XCITING 500 Heater Control Wire Starter Motor Cable Throttle Cable Upper Radiator Hose Stator Wire Water Hose Fuel Hose Fuel Filter Fuel Pump Air Bleed Hose N Radiator Siphon Hose Water Reserve Tank Water Filler Hose Front Brake Hose 1 17 1 GENERAL INFORMATION XCITING 500 500 1 250 250 AFI Harness Wire ll OG L gt Wir e A d e j a Po HELF ir I fi al VW a M S d E Luef TE TEL F Va Carburetor Parking Brake Cable a 3 j e _ ba D gt Ke 5 E A E ls te zm F UA m aet Ula Es 7 J Thermostat SL m d d Water Hose hl _ Se n ama GE 8 I 151 i 2 ART es MI E Pi Harness Wire Ke A AC 129 n ei Throt e Cable Ee m Lower Radiator Hose Rear Brake Hose
30. inal must be connected first After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 6 1 GENERAL INFORMATION B If the fuse is burned out find the cause and repair it Replace it with a new one B After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation B Hold the connector body when connecting or disconnecting it Do not pull the connector wire BREN PUN E Check if any connector terminal is bending protruding or loose KYMCO XCITING 500 500 1 250 250 B The connector shall be inserted completely B If the double connector has a lock lock it at the correct position B Check if there is any loose wire CD Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation B Insert the terminal completely Check the terminal cover for proper coverage B Do not make the terminal cover opening face up Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses O x X 1 GENERAL INFORMATION XCITING 500 500 1 250 250 B After clamping check each wire to make sure
31. inings Rough brake drum contacting area DWorn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings Worn brake cam contacting area on Worn brake linings Foreign matter on brake linings OSluggish or elongated brake cables Brake shoes improperly contact Water and mud in brake system 9 or grease on brake linings dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 TROUBLESHOOTING XCITING 500 AFI 250 ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Make sure engine stop switch is ON Put the side stand up Connect the diagnostic tool then check EMS and correct problems Empty fuel tank OQ Clogged fuel pump Fuel reaches fuel Fuel does not reach ilter injector fuel injector Faulty fuel pump amp Faulty fuel cut off e 1 Remove spark plug and G Cracked fuel hose install it into spark plug cap to test spark by connecting it to engine gt ground OFaulty spark plug Lob M Fouled spark plug Faulty ignition coil Broken or shorted ignition coil 9 Broken or shorted CPS OFaulty ignition switch Remove the fuel injector start the starter motor to check fuel gt injector operation EE Fuel SC No fuel supply O Clogged fuel d ector 3 Faulty Test cylinder
32. it is secure X Do not squeeze wires against the weld or its clamp B After clamping check each harness to make sure that it 1s not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp edges corners Avoid the projected ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover 15 used to protect the wire harnesses it shall be installed securely B Do not break the sheath of wire B If wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires Do not Dress Daa 1 8 1 GENERAL INFORMATION B After routing check that the wire harnesses are not twisted or kinked B 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 B When a testing device 1s used make sure to understand the operating methods thoroughly and operate ac
33. lever Hard brake lever Hard to brake Poor brake performance Brake squeaks 1 73 Probable Cause Front and rear tire pressures are normal DSteering stem nut too tight 2 Broken steering steel balls DExcessive wheel bearing play Bent rim Loose axle nut OM Misaligned front and rear wheels Bent front fork Probable Cause Front and rear tire pressures are normal DWeak shock spring 2 Excessive load Shock damper oil leaking Bent fork tube or shock rod O Fork tube and slider binding Fork spring and slider binding 2 Damaged shock stopper rubber Loose steering stem nut Probable Cause DWorn brake linings Foreign matter on brake linings Rough brake drum contacting area DWorn brake linings Foreign matter on brake linings Rough brake drum contacting area O Worn brake linings Worn brake cam contacting area on DWorn brake linings Foreign matter on brake linings OSluggish or elongated brake cables Brake shoes improperly contact Water and mud in brake system Oil or grease on brake linings
34. nto spark plug cap to test spark by lt connecting it to engine ground abc O Faulty CPS Faulty ignition coil Weak or Broken or shorted Good Good spark intermittent spark high tension wire amp Faulty spark plug Fouled throttle body Faulty TPI reset 1 65 1 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Connect the diagnostic tool then check EMS and correct problems AKAA AHAA KHAAA RAMA AAA BAA AAAH ABAKA MABAKA MAHAKA MAHAKA MAHAKA MAMAA MAMAA MAANA AMKANA MAANA Incorrect timing NTG OG EO Correctly adjusted Incorrectly adjusted Check fuel pump for Seem Chek toe by or Gere eee a iii Check valve spring tension dO KYMCO XCITING 500 500 1 250 250 AFI Probable Cause D Faulty spark plug Faulty ignition coil Faulty CPS QImproperly adjusted valve clearance Worn valve seat O Empty fuel tank Clogged fuel hose or filter 3 Faulty fuel pump Clogged fuel injector Clean and unclog 0 timing gear aligning marks not aligned O Faulty spring 1 66 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Q Worn camshaft lobe DWorn piston rings Piston noise 2Worn piston and connecting rod small end Excessive carbon build u
35. o protruding OImproper valve and seat contact 2 Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head Improper valve timing Fouled fuel injector OFouled spark plug Incorrect heat range plug level too high Oil level too low not changed O Faulty oil pump O Insufficient coolant 2 Faulty thermostat Worn cylinder and piston rings Mixture too lean Poor quality fuel 5 Excessive carbon buildup in combustion chamber Ignition timing too early Air in cooling system 1 GENERAL INFORMATION 500 500 1 250 250 DExcessive carbon build up in combustion chamber Engine does not knock Engine knocks Cle alpine amp Ignition timing too early 1 64 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Connect the J tool then check EMS and correct problems NN Check ignition timing D Faulty ignition coil Faulty CPS GFaulty ECU Correct timing Incorrect timing SS clogging Not Clogged Clogged O Fouled fuel injector Faulty fuel pump E Check intake manifold for air leaks Damage insulator rubber Throttle body not securely Q Faulty intake manifold Remove spark plug and O ring install it i
36. or OImproper valve clearance Worn valve seat valve stem too protruding OImproper valve and seat contact Normal Abnormal 2 Worn cylinder and piston rings compression compression GBlown cylinder head gasket Flaws in cylinder head Check carburetor for GImproper valve timing clogging Not Clogged Clogged Clogged carburetor jets Remove spark plug and 7 Plug not fouled Plug fouled or DFouled spark plug discolored discolored 2 Incorrect heat range plug Remove oil dipstickand ITS check oil level and condition level too high contaminated contaminated not changed Remove cylinder head bolts and inspect AA AAA AWA Valve train lubricated Valve train not DFaulty oil pump properly lubricated properly n DInsufficient coolant i Check if engine overheats ZE 2 Faulty thermostat Worn cylinder and piston rings Mixture too lean Engine does not Poor quality fuel overheats 5 Excessive carbon buildup in combustion chamber Ignition timing too early Air in cooling system Rapidly accelerate or run at high speed Engine does not knock DExcessive carbon build up in combustion chamber Poor quality fuel OG Clutch slipping 0 Mixture too lean Ignition timing too early Engine knocks 1 52 1 GENERAL INFORMATION dO KYMCO XCITING 500 500 1 250 250
37. p in combustion chamber 0 Damaged cam chain tensioner Worn cam gear teeth Cam chain noise Worn or damaged cam chain Extended cam chain OFaulty crankshaft bearing Crankshaft noise Worn crank pin bearing Worn damaged final reduction gears Gear noise 2Worn final reduction gear shaft splines 1 67 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS Symptom Engine starts but motor cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of grade poor slope performance Engine lacks power at high speed There is abnormal noise or smell while running dO KYMCO XCITING 500 500 1 250 250 Probable Cause DWorn or slipping drive belt 2 Broken ramp plate 9 Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot DWorn or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings D Worn or slipping drive belt Worn weight rollers 2 Worn or seized driven pulley bearings OOil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings 1 68
38. r Cable poses e enna hese YA Seat Lock Cable Diagnostic Connector Center Compartment Light Connector Negative Terminal Lead Taillight Brake Light Turn Signal Light Accessory Socket Seat Connector Seat Unlock Indicator Connector Air Cleaner Housing Drain Tube Crankcase Breather Hose gt So J m Oil Pressure 9 Ns Switch Connector Harness Wire PEAS se A Se j E 1725 y ECU amv 02 02 HT Sensor Switch Oil Pressure Switch Water Hose Lower Radiator Hose Rear Brake Hose 1 32 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Fan Motor Switch Leads Upper Radiator Hose Fuel Pump Harness Wire Side Stand Switch Wire Frere EXAI Ignition Coil Fuel Hose Fuel Injector ECT Sensor Air Cleaner Housing Drain Tube MAP Sensor np ISC Crankcase Breather Hose Harness Wire Throttle Cable 1 33 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Regulator Rectifier Wire Positive Termial Lead Pulser Connector Engine Ground Cable Negative Terminal Lead Harness Wire Fuel Injector Ignition Coil Fuel Hose Fuel Pump Reserve TankN Ignition Coil Cable Overflow Hose Side Stand Switch Siphon Hose 1 34 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 AFI CABLE amp HARNESS ROUTIN
39. r clutch Starter motor turns normally Hard to turn d OSeized cylinder Broken or shorted starter motor cable 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Tum ignition switch OFF Not stopped M n Stopped OFaulty starter pinion OStarter relay shorted or stuck closed dO KYMCO 1 GENERAL INFORMATION 500 500 1 250 250 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Connect the diagnostic tool then check EMS and correct problems ee rr s spark plug and inspect again O Faulty spark plug and high tension wire for looseness O Faulty spark plug RERRSRRRRSRSRERRSRSRERRSKRANARSXRAERRRARARRARXRARRARKSARRARASARRARASAERARANAERARARAERRANAERARANARESRASAEESRKRANESEKEA Check ignition unit coupler for looseness Measure resistance between terminals of ignition unit coupler PETE EEE EEE EEE O Faulty ignition switch Faulty CPS Faulty ignition coil Broken wire harness Poorly connected coupler P D Faulty ignition coil 1 70 dO KYMCO 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause Start engine and test
40. rb weight Rear whee Total Front whee Rear whee 0 kg 198 Ibs 4 kg 310 Ibs 3 kg 508 Ibs Electric starter motor 0193845 on am 20 70 15 50 70 14 50 mm 6 in 750 mm 110 in Type Gasoline 4 stroke Un ingle cylinder un emi sphere Valve arrangement OC chain drive wem Dim Compression ratio 10 5 1 HS Intake valve Open p BTDC Close 45 ABDC Exhaust valve Open 45 BBDC ATDC Valve clearance 0 1 mm 0 004 in cold Exhaust 0 1 mm 0 004 in LA 09 gt AN LA c 2 SUMON 11 1 go un un k Ve dle speed Lubrication type Oil pump type Oil capacity 400 rpm Wet sump Oil filter type Full flow filtration M 2 UIDJS G uoneormqnT UA ON tA c C gt a e we a Sja Nes TE e Final reduction oil 0 55 L 0 5 Imp qt capacity Cooling Type Liquid cooled XCITING 500 500 1 250 250 AFI ITEM SPECIFICATIONS Air cleaner type amp No Wet paper type element Fuel capacity 12 8 L 3 38 Imp gal 2 82 US gal Main jet NO 98 Ignition timing Throttle position sensor 0 6 0 7mm 0 002 0 003 in 2 2 Dry centrifugal automatic Helical gear spur gear 1724 1778 mm 69 71 in JOJD JNJE juowdnbq Teua UWOJS SG uous UIDIS G IOMOd FR RR tire rolling cir
41. t Lock Cable Front Brake Hose Combined Rear Brake Hose 1 21 1 GENERAL INFORMATION 500 500 1 250 250 Side Stand Switch Prepare Connector Ignition Coil Fuel Unit Wire Harness Wire Fuel Hose Fuel Pump Wire Side Stand Switch Side Stand Switch Wire 1 22 dO KYMCO 1 GENERAL INFORMATION 500 500 AFI 250 250 AFI AICV Vacuum Hose Transmission Case Breather Hose Crankcase Breather Hose Fuel Hose Oil Cooler Water Hose Water Hose Upper Radiator Hose Air Cleaner Drain Tube Oil Cooler Water Hose AICV Air Hose Air Cleaner Drain Hose AICV Air Hose Side Stand Switch Wire Fuel Hose Side Stand Switch 1 23 1 GENERAL INFORMATION 500 500 1 250 250 Taillight Brake light Wire Rear Right Turn Signal Wi rat Rear Loft Turn Signal Wire 9 9 Battery Positive Cable FAG D Battery Negative Cable Seat Lock Light Switch License Light Wira Taillight Connector Ignition Control Module Wire Hazard Unit Wire Harness Wire Frame Ground Cable Starter Motor Cable Ignition Control Module Ground Wire Regulator Rectifier Wire Regulator Rectifier 1 24 1 GENERAL INFORMATION XCITING 500 500 AFI 250 250 Transmission Case Breather Hose Heater Wire Automatic Choke Wire AICV Vacuum Hose Upper Radiator Hose 7 4
42. tarter relay AAA Aa uu GLoose disconnected connectors motor directly to H U battery OWorn brushes ERE TPE Starter does not turn OQ Open Of shorted wires or rotor Open starter motor cable Loose connectors Open wire harness 2 Starter motor turns lt a idles Inspection Adjustment Probable Cause Check battery circuit turn i m signals NM A Smale nee Signals dim remain properly on or don t operate DWeak or dead battery Connect starter motor directly to 65 gt battery Ge Loose connector or terminal 2Poor contact in starter relay Faulty starter clutch Starter motor turns normally Hard to turn e n OSeized cylinder Broken or shorted starter motor cable 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Tum ignition switch Sg gt OFF Not stopped e OFaulty starter pinion Starter relay shorted or stuck closed 1 57 1 GENERAL INFORMATION 500 500 1 250 250 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Replace with a new spark plug and inspect again Weak or no spark O Faulty spark plug Goo