INSPECTION/ADJUSTMENT XCITING 500

INSPECTION/ADJUSTMENT XCITING 500
3. INSPECTION/ADJUSTMENT
XCITING 500
3
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3
__________________________________________________________________________________
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION-------------------------------------------------- 3- 1
MAINTENANCE SCHEDULE---------------------------------------------- 3- 3
FUEL LINE--------------------------------------------------------------------- 3- 5
THROTTLE OPERATION--------------------------------------------------- 3- 5
AIR CLEANER ---------------------------------------------------------------- 3- 6
CRANKCASE BREATHER ------------------------------------------------- 3- 7
SPARK PLUG------------------------------------------------------------------ 3- 7
VALVE CLEARANCE ------------------------------------------------------- 3- 9
ENGINE OIL ------------------------------------------------------------------- 3-10
ENGINE OIL FILTER CARTRIDGE -------------------------------------- 3-13
ENGINE IDLE SPEED ------------------------------------------------------- 3-14
RADIATOR COOLANT ----------------------------------------------------- 3-15
COOLING SYSTEM---------------------------------------------------------- 3-16
SECONDARY AIR SUPPLY SYSTEM ----------------------------------- 3-17
TRANSMISSION OIL -------------------------------------------------------- 3-17
BRAKE FLUED --------------------------------------------------------------- 3-18
BRAKE PAD WEAR --------------------------------------------------------- 3-19
BRAKE SYSTEM ------------------------------------------------------------- 3-19
BRAKE LOCK OPERATION ---------------------------------------------- -3-20
HEADLIGHT AIM ------------------------------------------------------------ -3-21
SIDE STAND---------- -------------------------------------------------------- -3-22
SUSPENSION------------------------------------------------------------------ -3-22
NUTS, BOLTS, FASTENERS----------------------------------------------- -3-23
WHEELS/TIRES--------------------------------------------------------- ----- -3-23
STEERING HEAD BEARINGS--------------------------------------------- -3-24
3-0
3. INSPECTION/ADJUSTMENT
XCITING 500
SERVICE INFORMATION
GENERAL

Place the scooter on al level ground before starting any work.

Gasoline is extremely flammable and is explosive under certain conditions.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where
the gasoline is stored can cause a fire or explosion.
If the engine must be running to do some work, make sure the area is well ventilated. Never run
the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and
may lead to death. Run the engine in an open area or with an exhaust evacuation sustem in and
enclosed area.



SPECIFICATIONS
ITEM
Throttle free play
Spark plug
Spark plug gap
Valve clearance
Engine oil capacity
NGK
IN
EX
At draining
At draining/oil filter change
Total amount
Recommended engine oil
Engine idle speed
Final reduction oil capacity At draining
Total amount
Recommended final reduction oil
Recommended brake fluid
Parking brake lever stroke
Tire size
Solo riding
Tire air pressure
Two up riding
Minimum tire tread depth
3-1
Front
Rear
Front
Rear
Front
Rear
Front
Rear
SPECIFICATIONS
2-6 mm (1/16 – 1/4 in)
CR8E
0.6 – 0.7 mm (0.024 – 0.028 in)
0.1 mm (0.004 in)
0.1 mm (0.004 in)
2.0 liter (2.1 US pt, 1.8 lmp qt)
2.1 liter (2.2 US pt, 1.9 lmp qt)
2.5 liter (2.6 US pt, 2.3 lmp qt)
KYMCO 4-stroke oil or equivalent
motor oil API service classification: SJ
Viscosity: 5W50
1400±100 rpm
0.45 liter (0.48 US pt, 0.4 lmp qt)
0.55 liter (0.57 US pt, 0.5 lmp qt)
SAE 90
DOT 4
3 – 6 notch
120/70-15
150/70-14
200 kPa (2 kgf/cm2, 29 psi)
250 kPa (2.5 kgf/cm2, 36 psi)
225 kPa (2.25 kgf/cm2, 32 psi)
250 kPa (2.5 kgf/cm2, 36 psi)
1.6 mm (0.06 in)
2.0 mm (0.08 in)
3. INSPECTION/ADJUSTMENT
XCITING 500
TORQURE VALUES
Engine oil drain plug
Oil strainer screen cap
Oil filter cartridge
Transmission oil drain bolt
Transmission oil filler bolt
Spark plug
Tappet adjust nut
25 N•m (2.5 kgf•m, 18 lbf•ft)
15 N•m (1.5 kgf•m, 11 lbf•ft)
Apply oil to the threads and seating surface.
10 N•m (1 kgf•m, 7 lbf•ft)
Apply oil to the threads and seating surface.
24 N•m (2.4 kgf•m, 18 lbf•ft)
24 N•m (2.4 kgf•m, 18 lbf•ft)
12 N•m (1.2 kgf•m, 9 lbf•ft)
9 N•m (0.9 kgf•m, 6 lbf•ft)
SPECIAL TOOLS
Tappet adjuster
Oil filter cartridge wrench
E036
E052
3-2
3. INSPECTION/ADJUSTMENT
XCITING 500
MAINTENANCE SCHEDULE
Perform the pre-ride inspection in the owner’s manual at each scheduled maintenance period.
This interval should be judged by odometer reading or months, whichever comes first.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN
R: REPLACE
A: ADJUST
L: LUBRICATE
3-3
3. INSPECTION/ADJUSTMENT
XCITING 500
NOTE:
1 At higher odometer readings, repeat at the frequency interval established here.
2 Service more frequently if the scooter is ridden in unusually wet or dusty areas.
3 Service more frequently when riding in rain or at full throttle.
4 Inspect every 18000 km (12000 mi) after replacement.
5 Replace every 1 year, or every 10000km (6000mi), whichever comes first.
6 Replace every 2 year, or at indicated odometer interval, whichever comes first.
7 Replace every 2 years. Replacement requires mechanical skill.
3-4
3. INSPECTION/ADJUSTMENT
XCITING 500
Fuel Lines
FUEL LINE
Remove the floorboard. (page 2-6).
Check the fuel lines for deterioration, damage
or leakage. Replace the fuel line if necessary.
* • Do not smoke or allow flames or
sparks in your working area.
FUEL FILTER
Visually check the fuel filter. If accumulation
of sediment or clogging is found, replace the
fuel filter with a new one.
THROTTLE OPERATION
Check for smooth throttle grip full opening
and automatic full closing in all steering
positions.
Check the throttle cables and replace them if
they are deteriorated, kinked or damaged.
Lubricate the throttle cables, if throttle
operation is not smooth.
Measure the throttle grip free play.
Free Play: 2~6 mm (1/16~1/4 in)
Throttle grip free play can be adjusted at
either end of the throttle cable.
Minor adjustment is made with the upper
adjuster.
Slide the rubber sleeve back to expose the
throttle cable adjuster.
Adjust the free play by loosening the lock nut
and turning the adjuster.
3-5
Fuel Filter
3. INSPECTION/ADJUSTMENT
Major adjustments are made with the lower
adjuster.
XCITING 500
Adjust Nut
Remove the seat luggage box (page 2-3).
Adjust the free play by loosening the lock nut
and turning the adjuster.
After adjustment, tighten the lock nut
securely.
Recheck the throttle operation.
Replace any damaged parts, if necessary.
Lock Nut
AIR CLEANER
The air cleaner should be serviced at regular
intervals. Service more frequently when
riding in unusually wet or dusty areas.
Unlock the seat with the ignition key.
Open the seat.
Remove the air cleaner cover.
Air Cleaner Cover
Remove the screws and air cleaner housing
cover
Air Cleaner Housing Cover
3-6
3. INSPECTION/ADJUSTMENT
XCITING 500
Remove the air cleaner element by pull it out.
Discard the air cleaner element.
Install a new air cleaner element. Use the
KYMCO genuine air cleaner element or an
equivalent air cleaner element specified for
your model. Using the wrong. KYMCO air
cleaner element or a non-KYMCO air cleaner
which is not of equivalent quality may cause
premature engine wear or performance
problems.
Screws
Install the removed parts in the reverse order
of removal.
Air Cleaner Element
CRANKCASE BREATHER
Remove the crankcase breather tube plug
from the tube and drain deposits into a
suitable container.
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.
SPARK PLUG
REMOVAL
Remove the spark plug maintenance lid (page
2-4).
Disconnect the spark plug cap and clean
around the spark plug base.
* Clean around the spark plug base with
compressed air before removing, and be
sure that no debris is allowed to enter the
combustion chamber.
3-7
Spark Plug Cap
3. INSPECTION/ADJUSTMENT
XCITING 500
Remove the spark plug using a equipped
spark plug wrench or an equivalent tool.
Inspect or replace as described in the
maintenance schedule.
Spark Plug Cap
INSPECTION
Remove the carbon deposits from the spark
plug with a small wire brush or a spark plug
cleaning machine.
The spark plug should be replaced
periodically. Whenever removing the carbon
deposits, be sure to observe the operational
color of the spark plug's porcelain tip. This
color tells you whether or not the standard
spark plug is suitable for your type of usage.
A normal operating spark plug should be
light brown or tan color. If the spark plug is
very white or glazed appearing, then it has
been operating much too hot. This spark plug
should be replaced with the colder plug.
Recommended spark plug: NGK: CR8E
Measure the spark plug gap between the
center and side electrodes with the feeler
gauge.
If necessary, adjust the gap by bending the
side electrode carefully.
Spark plug gap:
0.6-0.7 mm (0.024-0.028 in)
Install the spark plug in the cylinder head and
hand tighten, then torque to the specification.
Torque: 12 N•m (1.2kgf•m, 9 lbf•ft)
Install the spark plug cap.
Install the removed parts in the reverse order
of removal.
3-8
3. INSPECTION/ADJUSTMENT
XCITING 500
Timing Hole Cap/ring
VALVE CLEARANCE
*
Inspect and adjust the valve clearance
while the engine is cold (Below
35°C/95°F).
Remove the floorboard (page 2-6).
Remove the cylinder head cover (page 8-5).
Remove the timing hole cap and O-ring.
Remove the crankshaft hole cap and O-ring.
Crankshaft Hole Cap/O-ring
“T” Mark
Turn the crankshaft clockwise and align the
“T” mark on the flywheel with the index
mark on the right crankcase cover.
Index Mark
Punch Marks
The punch marks on the camshaft should face
upward as shown.
If the punch marks on the camshaft are facing
downward, turn the crankshaft clockwise one
full turn (360°) and the punch marks are
facing upward.
3-9
3. INSPECTION/ADJUSTMENT
XCITING 500
Lock Nut
Thickness Gauge
Adjust by loosening the valve adjusting screw
lock-nut and turning the adjusting screw until
there is a slight drag on the thickness gauge.
Valve clearance (when cold):
IN.: 0.1 mm (0.004 in)
EX.: 0.1 mm (0.004 in)
Apply oil to the valve adjusting screw locknut threads and seating surface.
Hold the adjusting screw and tighten the lock
nut.
Special tool:
Valve adjusting wrench
Valve Adjusting Wrench/Adjusting Screw
E012
Torque: 9N•m (0.9 kgf•m, 6 lbf•ft)
After tightening the lock nut, recheck the
valve clearance.
Install the removed parts in the reverse order
of removal.
ENGINE OIL
OIL LEVEL INSPECTION
Start the engine and let it idle for 2-3
minutes.
Turn off the engine and support the scooter
level surface.
Remove the oil filler cap/dipstick and wipe
the oil from the dipstick with a clean cloth.
Insert the dipstick into the oil filler hole
without screwing it in.
If the oil level is below or near the lower
level line (1) he dipstick, add the
recommended engine oil until the oil level is
to the upper level line (2)
Oil Filler Cap/Dipstick
3-10
3. INSPECTION/ADJUSTMENT
Recommended engine oil:
KYMCO 4-stroke oil or equivalent motor
oil API service classification: SJ
Viscosity: SAE 5W50
* Other viscosities shown in the chart may
be used when the average temperature in
your riding area is within the indicated
range.
Reinstall the filler cap/dipstick.
ENGINE OIL & STARINER SCREEN
When running in very dusty conditions, oil
changes should be performed more frequently
than specified in the maintenance schedule.
Please dispose of used engine oil in a manner
that is compatible with the environment. We
suggest you take it in a sealed container to
your local recycling center or service station
for reclamation. Do not throw it in the trash
or pour it on the ground or down a drain.
Used engine oil may cause skin cancer if
repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it
is still advisable to thoroughly wash your
hands with soap and water as soon as possible
after handling used oil.
Change the engine oil with the engine at
normal operating temperature and the scooter
on its center stand to assure complete and
rapid draining.
Remove the oil filler cap/dipstick (1) from
the right crankcase cover.
3-11
XCITING 500
3. INSPECTION/ADJUSTMENT
Place a drain pan under the crankcase and
remove the oil strainer cap.
XCITING 500
Strainer Screen
The setting spring and oil strainer screen will
come out when the oil strainer cap is
removed.
Setting Spring
O-ring
Strainer Cap
Oil Strainer Screen
Clean the oil strainer screen.
After draining the oil completely, install the
strainer screen and setting spring into the
engine.
Apply clean engine oil to the strainer cap
threads, flange surface and a new O-ring.
Install and tighten the strainer cap with a new
O-ring.
Strainer Screen
Torque: 15N•m (1.5 kgf•m, 11 lbf•ft)
Setting Spring
O-ring
Strainer Cap
3-12
3. INSPECTION/ADJUSTMENT
Fill the crankcase with the recommended
engine oil.
Oil capacity:
2.0 liter (2.1 US qt, 1.8 lmp qt) at draining
2.1 liter (2.2 US qt, 1.9 lmp qt)
at oil filter cartridge change
Install the oil filler cap/dipstick (1).
Check the engine oil level (page 3-11).
Make sure there are no oil leaks.
ENGINE OIL FILTER
CARTRIDGE
REPLACEMENT
Drain the engine oil (page 3-11).
Remove the rubber sleeve (2) by removing
the clip (1).
Remove and discard the oil filter cartridge (3)
using the special tool.
Tool:
Oil filter wrench: E052
3-13
XCITING 500
3. INSPECTION/ADJUSTMENT
Apply clean engine oil to the new oil filter
cartridge threads, flange surface and a new Oring.
Install the new oil filter cartridge and tighten
it to the specified torque.
Tool:
Oil filter cartridge wrench
XCITING 500
O-ring
E052
Torque: 10N•m (1 kgf•m, 7 lbf•ft)
Refill the engine oil (page 3-13)
O-ring
ENGINE IDLE SPEED
ΠInspect and adjust the idle speed after all
other engine maintenance items have been
performed and are within specification.
ΠThe engine must be warm for accurate idle
speed inspection and adjustment.
Warm up the engine.
Place the scooter on its center stand.
Unlock the seat with the ignition key.
Open the seat and remove carburetor cover.
Turn the throttle stop screw as required to
obtain the specified idle speed.
Idle speed: 1400±100 rpm
Throttle Stop Screw
3-14
3. INSPECTION/ADJUSTMENT
XCITING 500
RADIATOR COOLANT
Place the scooter on its center stand.
Check the coolant level through the
inspection window at the left floor skirt while
the engine is at the normal operating
temperature.
The level should be between the “F” and “L”
level surface.
If the level is low, remove the reserve tank
cap and fill the tank to the “F” level line with
1:1 mixture of distilled water and antifreeze
(coolant mixture preparation: page 6-5)
* Using coolant with silicate inhibitors
may cause premature wear of water
pump seals or blockage of radiator
passages. Using tap water may cause
engine damage.
Reserve Tank Lid
Remove the left floor mat and remove screw
and reserve tank lid.
Left Floor Mat
3-15
Screw
3. INSPECTION/ADJUSTMENT
Remove reserve tank cap.
XCITING 500
Reserve Tank Cap
Check to see if there are any coolant leaks
when the coolant level decrease very rapidly.
If reserve tank becomes completely empty,
there is a possibility of air getting into the
cooling system.
Be sure to remove all air from the cooling
system (page 6-6).
Reinstall the filler cap.
COOLING SYSTEM
Remove the floorboard (page 2-6).
Check for any coolant leakage from the water
pump, radiator hoses and hose joints.
Check the radiator hoses for cracks or
deterioration and replace if necessary.
Check that all hose clamps are tight.
Remove the front lower cover (page 2-15).
Radiator Hose
Check the radiator air passages for clogs or
damage.
Straighten any bent fins, and remove insects,
mud or other obstructions with compressed
air or low water pressure.
Replace the radiator if the air flow is
restricted over more than 20% of the
radiating surface.
3-16
3. INSPECTION/ADJUSTMENT
XCITING 500
SECONDARY AIR SUPPLY
SYSTEM
This model is equipped with a built-in
secondary air supply system.
The secondary air supply system introduces
filtered air into exhaust gases in the exhaust
port. The secondary air is drawn into the
exhaust port whenever there is negative
pressure pulse in the exhaust system. This
charged secondary air promotes burning of
the unburned exhaust gases and changes a
considerable amount of hydrocarbons and
carbon monoxide into relatively harmless
carbon dioxide and water.
Air Supply Hose
AICV Reed Valve
Check the AICV (air injection control valve)
hoses between the AICV control solenoid
valve and cylinder head cover for
deterioration, damage or loose connections.
Make sure the hoses are not cracked.
If the hoses show any signs of heat damage,
inspect the AICV check valve in the AICV
reed valve cover damage.
AICV Control Solenoid Valve
TRANSMISSION OIL
OIL CHANGE
Place the scooter in its center stand.
Remove the transmission oil drain bolt (1)
and 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.
Torque: 24 N•m (2.4 kgf•m, 18 lbf•ft)
3-17
3. INSPECTION/ADJUSTMENT
XCITING 500
Fill the transmission case with recommended
oil.
Recommended transmission oil: SAE 90
Oil capacity (at draining):
0.45 liter (0.48 US qt, 0.4 lmp qt)
Install the transmission oil filler bolt with a
new sealing washer and tighten it.
Torque: 24 N•m (2.4 kgf•m, 18 lbf•ft)
BRAKE FLUID
*
ΠDo not mix different type of fluid, as
they are not compatible with each
other.
ΠDo not allow foreign material to enter
the system when filling the reservoir.
ŒAvoid spilling fluid on painted, plastic
or rubber parts. Place a rag over these
parts whenever the system is serviced.
When the fluid level is low, check the brake
pads for wear. A low fluid level may be due
to wear of the brake pads. If the brake pads
are worn, the caliper piston is pushed out, and
this accounts for a low reservoir level. If the
brake pads are not worn and the fluid level is
low, check the entire system for leaks.
FRONT BRAKE
Turn the handlebar so the reservoir is level
and check the front brake fluid reservoir
level.
If the level is near the lower level line “L”,
check brake pad wear.
REAR BRAKE
Place the scooter on a level surface and
support it in an upright position.
Check the rear brake fluid reservoir level.
If the level is near the lower level line“L”,
check brake pad wear.
3-18
3. INSPECTION/ADJUSTMENT
XCITING 500
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.
REAR BRAKE
Check the cutout in each pad.
If either pad is worn to the cutout, replace
both pads as a set.
BRAKE SYSTEM
INSPECTION
This model equipped with a linked brake
system.
Check the rear brake operation as follows:
Place the scooter on its center stand.
Jack-up the scooter to raise the front wheel
off the ground.
* Do not use the oil filter as a jack point.
3-19
Rear Brake Lever
3. INSPECTION/ADJUSTMENT
XCITING 500
Operate the rear brake lever.
Make sure the front wheel does not turn while
the rear brake lever is operated.
Firmly apply the brake lever and check that
no air has entered the system.
If the lever feels soft or spongy when
operated, bleed the air from the system.
Inspect the brake hose and fittings for
deterioration, cracks and signs of leakage.
Tighten any loose fittings.
Replace hoses and fittings as required.
BRAKE LOCK OPERATION
INSPECTION
Stop the engine and put the scooter on its
center stand on level ground.
Pull up the parking brake lever slowly and
check the parking brake lever stroke.
Parking brake lever stroke: 3-6 notches
If out of specification, adjust the parking
brake lever.
3-20
3. INSPECTION/ADJUSTMENT
XCITING 500
ADJUSTMENT
Place the scooter on its center stand.
Release the parking brake lever lock.
Pull up the parking brake lever until 1 notch.
Loosen the lock nut.
Turn the adjust bolt until you feel resistance
when turn the rear wheel by your hand.
Hold the adjust bolt and tighten the lock nut
securely.
Lock Nut
Adjust Bolt
Release the parking brake lever.
Make sure the rear wheel turns smoothly.
Pull the parking brake lever slowly and check
the lever stroke.
Standard: 3-6 notches
All stroke: 9 notches
If there is out of specification, adjust again.
HEADLIGHT AIM
Horizontally Adjusting Screw
Place the scooter on a level surface.
Adjust the headlight beam vertically by
turning the vertical beam adjuster.
A clockwise rotation moves the beam up and
counterclockwise rotation moves the beam
down.
Adjust the headlight beam horizontally by
turning the horizontal beam adjuster.
A clockwise rotation moves the beam toward
the right side of the rider.
* Adjust the headlight beam as specified
by local laws and regulations.
3-21
Vertically Adjusting Screw
3. INSPECTION/ADJUSTMENT
XCITING 500
SIDE STAND
Support the scooter on a level surface.
Check the side stand spring for fatigue or
damage.
Check the side stand assembly for smooth
movement and lubricate the side stand pivot
if necessary.
Check the side stand ignition cut-off system:
9 Start the engine.
9 Fully lower the side stand while running
the engine.
9 The engine should stop as the side stand is
lowered.
If there is a problem with the system, check
the side stand switch (page 20-15).
SUSPENSION
FRONT SUSPENSION INSPECTION
Check the action of the forks by operating the
front brakes and compressing the front
suspension several times.
Check the entire assembly for signs of leaks,
damage or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.
3-22
3. INSPECTION/ADJUSTMENT
REAR SUSPENSION INSPECTION
Check the action of the shock absorber by
compressing it several times.
Check the entire shock absorber assembly for
signs of leaks, damage or loose fasteners.
Replace damaged components which cannot
be repaired.
Tighten all nuts and bolts.
NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are
tightened to their correct torque values (page
1-7).
Check that all safety clips, hose clamps and
cable stays are in place and properly secured.
WHEELES/TIRES
Tire pressure should be checked when the
tires are cold.
Recommended tire pressure:
3-23
XCITING 500
3. INSPECTION/ADJUSTMENT
XCITING 500
Recommended tire size:
Check the tires for cuts, embedded nails, or
other damage.
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the
tires.
Replace the tires when the tread depth
reaches the following limits.
Minimum tread depth:
Front: 1.6 mm (0.06 in)
Rear: 2.0 mm (0.08 in)
STEERING HEAD BEARINGS
Check that the control cables do not interfere
with handlebar rotation.
Support the scooter securely and raise the
front wheel off the ground.
Check that the handlebar moves freely from
side to side.
If the handlebar moves unevenly, binds, or
has vertical movement, inspect the steering
head bearings.
3-24
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