OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. XCITING 500 AFI XCITING 500 XCITING 250 AFI XCITING 250 Issued: 15.02.
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 a long, 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.
READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this scooter should carefully read 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.
CONTENTS Page Page BRAKES.........................................28 SCOOTER SAFETY........................1 FUEL FILL CAP................................30 FRONT SMALL BOX.........................32 CENTER SMALL BOX......................33 SEAT..............................................34 ADJUSTABLE BACKREST...............35 CENTER COMPARTMENT...............36 CENTER COMPARTMENT LIGHT.....37 CELL PHONE SOCKET & CELL PHONE FIXED SEAT.......................37 HELMET HOLDERS........................
Page Page PARKING........................................55 BREAK-IN (RUNNING IN)................57 COOLANT.......................................85 FRONT AND REAR SUSPENSION INSPECTION..................................87 SIDE STAND...................................88 BRAKE LEVER ADJUSTER.............89 BRAKE FLUID................................89 BRAKE PAD WEAR........................90 PARKING BRAKE OPERATION (XCITING 500 AFI/XCITING 500).......91 BATTERY........................................
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.
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 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.
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. A helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and help your vision.
(1) (2) (3) (4) (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. WARNING Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you and your passenger always wear an approved motorcycle helmet that fits properly.
LOAD LIMITS AND GUIDELINES These general guidelines may help you decide whether or how to equip your scooter and how to load it safely. Center small box weight limit: 3 kg (6.6 lbs) 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.
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: 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 Place cargo weight as close to the center of the scooter as possible. Balance cargo weight evenly on both sides.
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 combinations of all the available accessories; however, your dealer can assist you in selecting quality accessories and installing them correctly.
LOCATION OF THE WARNING AND SPECIFICATION LABELS (1) CAUTIONS Before starting the engine, the side stand shall be kicked up to secure safety.
(2): XCITING 500 AFI/XCITING 500 CAUTIONS Every 6000 km run should exchange the filter. (3) CAUTIONS Never put any article between the rear side cover and the engine to avoid interference of riding.
(4) (5) (4) ! Be sure to wear a safety helmet when riding. ! Do not exceed the speed specified by law when riding. ! The exhaust muffler temperature is very high after riding. Be sure to park the motorcycle in a place not easily touched by people. ! For riding safety and good performance do not violate the law to modify the motorcycle. ! Make sure to perform the periodic maintenance and preride inspection.
(7) (6) (6) CAUTION Mobile phone charge only, Use other appliance may cause damage. (7) CAUTION ! ! 11 DON'T WIPE WITH ORGANIC SOLVENT (EX: GAS, THINNER...ETC). USE NEUTRAL SOAP TO CLEAN WINDSHIELD.
PARTS LOCATION (06) (05) (04) (03) (02) (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 (01) (07) (08) 12
(12) (11) (10) (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) (14) (15) 13
(18) (17) (16) (16) Tool kit (17) Center compartment (18) Helmet holder (19) Front small box (20) Coolant level (21) Side stand (22) Center stand (23) Left passenger footpeg (24) Air cleaner (XCITING 500 AFI/ XCITING 500) (25) Air cleaner (XCITING 250 AFI/ XCITING 250) (19) (20) (21) (22) (23) (24) 14 (25)
(30) (29) (28) (27) (26) (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) (31) (32) (33) 15
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.
ENGINE NUMBER The engine number is stamped on left engine case. Please write down your engine number in place below.
KEY NUMBER The key number (1) will be needed when you order replacement part. Record the number for your reference.
CONTROLS KEYS This scooter has two ignition switch keys and shutter keys. OPEN OPEN 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. OPEN 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.
Function “ " 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. “ " 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. “ " Position: To open the fuel fill cap, turn the key to the " " position.
INSTRUMENT AND INDICATORS (3) (2) (4) (5) (5) (6) (7) (8) (9) (1) Oil Service Mode (21) (20) H (19) (18) (17) (10) M (16) (15) (14) (13) (12) (11) NOTE: The indicator 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
(1) Oil pressure warning indicator" " Lights when the engine oil pressure is below normal operating range, should light when ignition switch is ON " " and engine is not running. Should go out when the engine starts, except for occasional flickering at or near idling speed when engine is warm. (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).
(8) Fuel refill Indicator" " Lights when the fuel tank is empty or nearly so and you should refill the tank as soon as possible. (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 " " position. (9) Oil service indicator reset button The oil service indicator can be reset by pressing the button when the engine oil has been changed.
(17) Clock Show hour and minute. (20) CELP: Check engine lamp (XCITING 500 AFI/XCITING 250 AFI) Flashes when there is any abnormality in the CELP system. If it comes on at any other time, reduce speed and take the motorcycle to your KYMCO dealer as soom as possible. (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.
RIGHT HANDLEBAR SWITCH Headlight switch (1) " " position The headlight and taillight turn on. " " position The position light and taillight turn on. (1) " " position The headlight and taillight turn off. (2) Electric starter button " " (2) Push in the electric starter button to rotate the starter motor. NOTE: ! If the brake lever is not squeezed, the starter motor will not rotate. ! This scooter is equipped with interlock switches for the ignition circuit and the starter circuit.
Engine stop switch (3) " " position The ignition circuit is off. The engine cannot start or run. (4) " " position The ignition circuit is on and the engine can run. Hazard switch " "(4) " "At this position, the right and left turn signal lights wink together. "OFF"At this position, the right and left turn signal lights go out together. (3) CAUTION ! Turn on hazard switch when parking or there is a special condition. ! After the hazard switch is turned on, it will not reset automatically.
(1) LEFT HANDLEBAR SWITCH Turn signal switch (1) Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will wink when the switch is operated, " " For turning to the "left". " "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. (2) Horn button " " (2) Press the button to sound the horn.
BRAKES Combination brake lever (Left handlebar) The front and 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.
Parking brake (XCITING 500 AFI/XCITING 500) To apply the parking brake: Pull in the parking brake lever (1) to lock the rear wheel. To apply 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.
FUEL FILL CAP To open the fuel fill cap: Insert the ignition key in the ignition switch and turn it to the " " 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). After refueling, be sure to lock the fuel fill cap firmly.
To lock the fuel fill cap: Push fuel fill cap down into place. WARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. ! Stop the engine and keep heat, sparks, and flame away. ! Refuel only out doors. ! 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. Turn the ignition key from " restarting.
FRONT SMALL BOX To open To open: Insert the ignition key (2) and turn it clockwise. To close: 1. Holding the front small box lid (2) closed, turn the ignition key counterclockwise. 2. Remove the key. (1) WARNING Open the box lid while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the scooter. To close Always keep both hands on the handlebars during operation.
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. (1) Pull WARNING Open the box cover while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the scooter. Pu sh Always keep both hands on the handlebars during operation.
SEAT To unlock the seat " ": (1) Ignition key at the " " position (The engine is running.): Push the key and turn it counterclockwise from " to " " position. (3) (2) " (2) Ignition key at the " " position (The engine is stopped.): Turn it counterclockwise from " " to " " position. (3) Ignition key at the " " position (The steering is locked.): Turn it counterclockwise from " " to " " position. Pull the seat up to lift the seat.
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. (1) 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.
CENTER COMPARTMENT The center compartment is below the seat. Opening and closing: See "SEAT" (page 34). MAXIMUM WEIGHT LIMIT: 10kg (22 lbs) CAUTION Never exceed the maximum weight limit; handling and stability may be severely affected. The center compartment may become heated 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.
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. (1) CELL PHONE SOCKET & 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 socket's rated capacity is DC 12V, 10Watts (0.8A) or less.
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 ! Do not plug in any heat-generating accessory such as an automobile cigarette lighter because it can damage the socket.
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. WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a 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.
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. (1) Side stand (2) An interlock switch is provided to cut off the ignition circuit when the side stand is down.
WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left. ! Check operation of the side stand/ignition interlock system before riding. ! Always retract the side stand completely before starting off. CAUTION Park the scooter on firm, level ground to help prevent it from falling over.
SUSPENSION (1) 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.
DIAGNOSTIC TOOL CONNECTOR (XCITING 500 AFI/XCITING 250 AFI) The diagnostic tool connector (1) located right 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.
PRE-RIDE INSPECTION 3. Coolant level: add coolant if required. Check for leaks (page 85). 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. 4. Front and rear brakes: check operation; make sure there is no brake fluid leakage (page 89). 5. Tires: check condition and pressure (page 97).
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.
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.
3. Open the ignition key-hole shutter and make sure the engine stop switch is at " " (RUN). 4. Turn the ignition switch to " " (ON) Confirm 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.
6. With the throttle closed, push the starter button. Release the starter button as soon as the engine starts. Pu 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.
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 turn 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 turn the ignition switch to the OFF position and then back to ON.
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.
2. Stand on the left side of the scooter and push it forward and off the center stand. 3. Mount the scooter from the left side keeping at least one foot on the ground to steady the scooter.
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 turn signals, and check for safe traffic conditions. Grasp the handlebars firmly with both hands. Never attempt onehanded operation; loss of vehicle control could result.
6. To accelerate, open the throttle gradually; the scooter will move forward. Do not "BLIP" the throttle (open and close rapidly) as the scooter will move forward suddenly, causing possible loss of control. Clos e 7. To decelerate, close throttle. Open 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.
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. 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 10. After completing the turn, open the throttle gradually to accelerate the scooter.
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: ! Exercise extreme caution when braking, accelerating or turning. ! Ride at slower speeds and allow for extra stopping distance. ! Keep the scooter as upright as possible. ! Use extreme caution when riding over slippery surfaces such as railroad tracks, iron plates, manhole covers, painted lines, etc. PARKING 1.
3. Lock the steering ( see page 20) to help prevent theft. WARNING The exhaust pipe and muffler become very hot during operation and remain sufficiently hot to inflict burns if touched even after shutting off the engine. A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your scooter.
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 care and restraint exercised during the break-in period.
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.
INSPECTION AND MAINTENANCE WARNING THE IMPORTANCE OF MAINTENANCE A well-maintained scooter is essential for safe, economical and trouble-free riding. It will also help reduce air pollution. 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. To help you properly care for your scooter, the following pages include a maintenance schedule for regularly scheduled maintenance.
MAINTENANCE SCHEDULE (XCITING 500 AFI/XCITING 500) Perform the pre-ride inspection (see page 44) at each scheduled maintenance period. This interval val should be b judged by odometer reading or months, whichever comes first. I: INSPECT ADJUST, LUBRICATE OR REPLACE IF NECESSARY CT AND CLEAN, CL C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE N REP The following wing maintenance mainte ntenance ce schedule sch c edu e specifies all maintenance required to keep your scooter in peak operating ating condition.
FREQUENCY ITEM AIR CLEANER SPARK PLUGS ＊ THROTTLE OPERATION ＊ VALVE CLEARANCE ＊ FUEL LINE CRANKCASE BREATHER ENGINE OIL ENGINE OIL FILTER ＊ ENGINE OIL STRAINER SCREEN ＊ ENGINE IDLE SPEED RADIATOR COOLANT ＊ COOLING SYSTEM ＊ SECONDARY AIR SUPPLY SYSTEM WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 1 6 12 18 24 30 36 REFER X 1000 mi 0.
FREQUENCY ITEM ＊ TRANSMISSION OIL ＊ DRIVE BELT ＊＊ CLUTCH SHOE WEAR BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM ＊ BRAKE LIGHT SWITCH ＊ BRAKE LOCK OPERATION SIDE STAND ＊ SUSPENSION ＊ HEADLIGHT AIM ＊ NUTS, BOLTS, FASTENERS ＊＊ WHEELS/TIRES ＊＊ STEERING BEARINGS WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 1 6 12 18 24 30 36 REFER X 1000 mi 0.
MAINTENANCE SCHEDULE CHEDULE (XCITING 250AFI/XCITING 250) Perform the pre-ride e inspection inspectio (see page 44) at each scheduled maintenance period. This interval should d be judged judge reading or months, whichever comes first.
FREQUENCY ITEM ＊ AIR CLEANER SPARK PLUGS ＊ THROTTLE OPERATION ＊ VALVE CLEARANCE ＊ FUEL LINE CRANKCASE BREATHER ENGINE OIL ＊ ENGINE OIL STRAINER SCREEN ＊ ENGINE IDLE SPEED RADIATOR COOLANT ＊ COOLING SYSTEM ＊ SECONDARY AIR SUPPLY SYSTEM WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 0.3 1 3 5 7 9 11 REFER X 1000 mi 0.2 0.6 1.8 3 4.2 5.4 6.
FREQUENCY ITEM ＊ TRANSMISSION OIL ＊ DRIVE BELT ＊＊ CLUTCH SHOE WEAR BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM ＊ BRAKE LIGHT SWITCH SIDE STAND ＊ SUSPENSION ＊ HEADLIGHT AIM ＊ NUTS, BOLTS, FASTENERS ＊＊ WHEELS/TIRES ＊＊ STEERING BEARINGS WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 0.3 1 3 5 7 9 11 REFER X 1000 mi 0.2 0.6 1.8 3 4.2 5.4 6.
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). (1) CRANKCASE BREATHER 1. Remove the crankcase breather tube plug (2) from the tube and drain deposits into a suitable container. 2. Reinstall 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.
ENGINE OIL Engine oil recommendation Use a premium quality 4-stroke motor oil to ensure longer service life of your scooter. Use only oils which are rated, SJ under the API service classification. The recommended viscosity is SAE 5W-50. If a SAE 5W-50 motor oil is not available, select an alternative according to the right chart.
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.
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.
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 N-m (2.5 kgf-m, 18lbf-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 lmp qt) XCITING 250 AFI/XCITING 250: 0.9 liter (0.95 US qt, 0.8 lmp qt) 6. Start the engine and let it idle for 2－3 minutes. 7.
Oil filter cartridge (XCITING 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 KYMCO dealer perform this service. If a torque wrench is not used for this installation, see your KYMCO dealer as soon as possible to verify proper assembly.
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.
5. XCITING 500 AFI/XCITING 500: Remove the rubber sleeve (5) by removing the clip (6). XCITING 500 AFI/XCITING 500 (5) 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.
7. 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 lbf-ft) Use only the KYMCO genuine oil filter cartridge or a filter cartridge of equivalent quality specified for your model.
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 lbf-ft) 10. Fill the crankcase with the recommended grade oil (see page 67). Oil capacity (after draining and oil filter change): XCITING 500 AFI/XCITING 500: 2.1 liter (2.2 US qt, 1.9 lmp qt) XCITING 250 AFI/XCITING 250: 0.9 liter (0.95 US qt, 0.8 lmp qt) 11. Install the oil filler cap/dipstick. 12. Start the engine and let it idle for 2－3 minutes. 13.
TRANSMISSION OIL Oil change XCITING 500 AFI/XCITING 500 1. Place the scooter in its center stand. 2. Remove the transmission oil drain bolt (1).
3. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil. After draining the oil completely, install the oil drain bolt with a new sealing washer and tighten it. XCITING 500 AFI/XCITING 500 Torque: 20 N-m (2 kgf-m, 15 lbf-ft) 4. Fill the transmission case with recommended oil. (2) Recommended transmission oil: SAE 90 Oil capacity (at draining): XCITING 500 AFI/XCITING 500: 0.45 liter (0.48 US qt, 0.4 lmp qt) XCITING 250 AFI/XCITING 250: 0.18 liter (0.2 US qt, 0.
AIR CLEANER The air cleaner should be serviced at regular intervals. Service more frequently when riding in unusually wet or dusty areas. Push Air cleaner element (XCITING 500 AFI/XCITING 500): 1. Open seat (see page 34) 2. Remove air cleaner cover (1). (1) 3.
4. Remove the air cleaner element (3) by pull it out. 5. Discard the air cleaner element. 6. 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 KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems. 7. Install the removed parts in the reverse order of removal.
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-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.
THROTTLE OPERATION 1. Check for 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) 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.
IDLE SPEED The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-andgo 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).
4. Adjust idle speed with the throttle stop screw (2). XCITING 500 Idle speed: XCITING 500: 1400 100 rpm XCITING 250: 1700 100 rpm NOTE: It is 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 KYMCO dealer.
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.
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 (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.
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.
FRONT AND REAR SUSPENSION INSPECTION 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. 1.
SIDE STAND Perform the following maintenance in accordance with the maintenance schedule. Functional check: ! Check the spring for damage or loss of tension and the side stand assembly for freedom of movement. ! Check the side stand ignition cut-off system: 1. Place the scooter on its center stand. Side stand up 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.
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. (3) Push the lever (1) forward and turn 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 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 maintenance 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 KYMCO 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.
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.
BATTERY It is 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. WARNING The battery gives off explosive hydrogen gas during normal operation.
Battery removal (Always keep ignition switch is OFF) The battery is in the battery box below seat. (1) 1. Open the seat (see page 34). 2. Remove the screws (1) and battery cover (2). (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.
FUSE REPLACEMENT When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your KYMCO 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 ! 30A CHARGE fuse protects battery charging system. ! 15A MAIN fuse protects all electrical circuits.
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). (1) 3. Open the fuse box cover (1). 4. Pull out the old fuse and install a new fuse. The spare fuse (3) are located in the battery retainer. (3) 5. Close the fuse box covers and seat.
Charge fuse : The charge fuse is located right side of the battery in the battery box . The specified fuses (2) are: 30A (1) 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.
TIRES WARNING WARNING Failure to perform break-in of the tires could cause tire slip and loss of control. 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. Use extra care when riding on new tires.
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. Worn tires are susceptible to puncture failures and subsequent loss of vehicle control. Tire wear also affects the tire profile, changing vehicle handling characteristics. Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.
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. Front Rear Size 120/70-15 150/70-14 Type TUBELESS TUBELESS WARNING An improperly repaired, installed, or balanced tire can cause loss of control or shorten tire life.
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. ! Tubeless tires require an 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.
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.
3. Clean the plastic parts using a cloth or sponge dampened with a solution of mild 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.
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 accident. Finishing touches After washing your scooter, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax to finish the job.
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 cause 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.
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. For a 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.
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.
4. To prevent rusting in the cylinders, perform the following: ．Remove the spark plug caps from the spark plugs, using tape or string, secure the caps to any convenient plastic body part so that they are positioned away from the spark plugs. ．Remove the spark plugs from the engine and store them in a safe place. Do not connect the spark plugs to the spark plug caps. ．Pour a tablespoon (15－20 cc) of clean engine oil into each cylinder and cover the spark plug holes with a piece of cloth.
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. Perform all Pre-ride inspection checks (see page 44) . Test ride the scooter at low speeds in a safe riding area away from traffic.
SPECIFICATIONS NS (XCITING (XCIT 500 AFI/XCITING 500) DIMENSIONS Overall length Overall width Overall height Wheel base 2250 mm (90 in) 815 mm (32.6 in) 1450 mm (58 in) 1570 mm (62.8 in) WEIGHT Dry weight ght 215 2 15 kg (473 lbs) lbs CAPACITIES Engine oil 2.0 L (2.1 .1 US q 1.8 S qt, 1. lmp qt) After draining ing After draining and d oil filter change After disassembly Transmission oil After draining After disassembly Fuel tank Maximum weight capacity 2.1 L (2.2 US qt, 1.9 lmp ( p qt) 2.5 L (2.
ENGINE Bore and stroke e Compression ratio Displacement Spark plug lug ard (XCITING (XCIT Standard 500 AFI) Standard (XCITING 500) ard (XCIT ITING 5 92 X75 mm (3.68 X 3 in) 10.5:1 3 498.5 cm (30.
SPECIFICATIONS NS (XCITING (XCIT 250/XCITING 250 AFI) DIMENSIONS Overall length Overall width Overall height Wheel base 2250 mm (90 in) 815 mm (32.6 in) 1450 mm (58 in) 1570 mm (62.8 in) WEIGHT Dry weight ght 185 kg (407 lbs) lb CAPACITIES Engine oil After draining ing After disassembly mbly y Transmission oil After draining After disassembly Fuel tank Maximum weight capacity 0.9 L (0.95 0.95 US qt, 0.8 0 lmp lm qt) 1.1 L (1.2 US S qt, 1 lmp lm qt) q t) 0.18 L (0.2 US qt, 0.16 lmp qt) ( 0.23 L (0.
ENGINE e Bore and stroke Compression ratio Displacement Spark plug ard (XCIT (XCITING 250) Standard Standard(XCITING ard(XCIT 250 AFI) 72.7 X60 mm (2.91 X 2.4 in) 10.6:1 3 249.1 cm (15.
5 Stan Perkins Road Spartanburg, SC 29307 Telephone: (888) 235-3417 FAX: (864) 327-4745 Prepared: July 2008 T300-KL10SA30SB-US-A5
