Kymko Xciting 250-500 Service Manual 2005 Motowiki - by

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

First Edition, May 2005
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4121-LBA2/LDB2-S00
XCITING 500/250
PREFACE
This Service Manual describes the TABLE OF CONTENTS
technical features and servicing
procedures for the KYMCO XCITING GENERAL INFORMATION 1
500/250.
FRAME COVERS /EXHAUST MUFFLER 2
Section 1 contains the precautions for INSPECTION/ADJUSTMENT 3
all operations stated in this manual.
Read them carefully before any LUBRICATION SYSTEM 4
operation is started. FUEL SYSTEM/FUEL PUMP/FUEL
5
TANK/CARBURETOR
Section 2 is the removal/installation COOLING SYSTEM 6
procedures for the frame covers which are
subject to higher removal/installation ENGINE ENGINE REMOVAL/INSTALLATION 7
frequency during maintenance and CYLINDER HEAD/VALVES 8
servicing operations.
CYLINDER/PISTON 9
Section 3 describes the inspection/ DRIVE AND DRIVEN PULLEY 10
adjustment procedures, safety rules and
service information for each part, starting FINAL REDUCTION 11
from periodic maintenance. A.C. GENEARTOR/STARTER CLUTCH 12
Sections 7 through 13 give instructions CRANKCASE/CRANKSHAFT 13

for disassembly, assembly and adjustment STEERING HANDLEBAR/FRONT
14
CHASSIS
of engine parts. Section 14 through 16 is WHEEL/FRONT SHOCK ABSORBER

the removal/ installation of chassis. REAR FORK/REAR WHEEL/REAR
Section 17 through 21 states the testing 15
SHOCK ABSORBER`
and measuring methods of electrical
equipment. BRAKE SYSTEM 16
BATTERY/CHARGING SYSTEM 17
EQUIPMENT
ELECTRICAL
Most sections start with an assembly or IGNITION SYSTEM 18

system illustration and troubleshooting ELECTRIC STARTER 19
for the section. The subsequent pages give
LIGHTS/METERS/SWITCHES 20
detailed procedures for the section.
WIRING DIAGRAMS 21
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
KYMCO reserves the right to make
changes at any time without notice and
without incurring any obligation.
KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
1. GENERAL INFORMATION XCITING 500/250
1 1
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GENERAL INFORMATION
__________________________________________________________________________________
SERIAL NUMBER----------------------------------------------------------- 1 - 1
SPECIFICATIONS (XCITING 500)--------------------------------------- 1 - 2
SPECIFICATIONS (XCITING 250)--------------------------------------- 1 - 3
SERVICE PRECAUTIONS ------------------------------------------------- 1 - 4
TORQUE VALUES ---------------------------------------------------------- 1 - 8
SPECIAL TOOLS ------------------------------------------------------------ 1-12
LUBRICATION POINTS --------------------------------------------------- 1-13
CABLE & HARNESS ROUTING (XCITING 500) ------------------------- 1-15
CABLE & HARNESS ROUTING (XCITING 250) ------------------------- 1-25
TROUBLESHOOTING------------------------------------------------------ 1-33
1-0
SERIAL NUMBER
Location of Frame Serial Number
Location of Engine Serial Number
1-1
SPECIFICATIONS (XCITING 500)

ITEM SPECIFICATIONS ITEM SPECIFICATIONS
Name XCITING 500 Air cleaner type & No Wet paper type element
Overall length 2250 mm (90 in) Fuel capacity 12.8 L (3.38 lmp gal,
Fuel System
Overall width 815 mm (33 in) 2.82 US gal
Carburetor
Overall height 1450 mm (58 in) Type CVK
Wheel base 1570 mm (63 in) Main jet NO. 98
Engine type O.H.C. Venturi dia. φ36 mm (φ1.44 in)
Displacement 498.5 cm3 (30.4 cu-in) Throttle type PISTON
Electrical Equipment
Fuel Used 92# nonleaded gasoline Full transistor ignition
Ignition System
Type
Front wheel 83 kg (183 lbs) Spark plug CR8E
Dry weight Rear wheel 132 kg (290 lbs)
Total 215 kg (473 lbs) Ignition timing Throttle position sensor
Front wheel 90 kg (198 lbs) Spark plug gap 0.6～0.7mm (0.002～
Curb weight Rear wheel 141 kg (310 lbs) 0.003 in)
Total 231 kg (508 lbs) Battery Capacity 12V12AH
Tires Front wheel 120/70-15 Dry, centrifugal
Power Drive System
Clutch Type
Rear wheel 150/70-14 automatic
sion Gear Ratio
Transmis- Reduction
Ground clearance 150 mm (6 in) Type Helical gear/spur gear

Min. turning radius 2750 mm (110 in) Automatic centrifugal
Operation
Starting system Electric starter motor Type
Type Gasoline, 4-stroke Type CVT
Cylinder arrangement Single cylinder Preliminary 2.68 – 1
Combustion chamber type Semi-sphere Final 5.4
Valve arrangement O.H.C., chain drive
FR/RR tire rolling
92 x 75 mm 1724/1778 mm (69/71 in)
Moving Device
Bore x stroke circumference

(3.7 x 3 in)
Compression ratio 10.5:1 2 kg/cm² (200 Kpa, 28
Tire pressure Front psi)
Compression pressure 13 kgf/cm² (1300kPa,
(rider only/60
185 psi) 2.5 kg/cm² (250 Kpa, 36
kg) Rear
Open 2° BTDC psi)
Engine
Intake valve
Close 45° ABDC Turning Left 40°
Open 45° BBDC angle Right 40°
Exhaust valve
Close 5° ATDC Brake system Rear Disk brake
Valve clearance Intake 0.1 mm (0.004 in) type Front Disk brake
(cold) Exhaust 0.1 mm (0.004 in)
Device
Damping
Front Telescopic fork

Idle speed 1400 rpm
Suspension
Lubrication type Forced
Wet sump
pressure &
type Rear Unit swing
Oil pump type Trochoid
System
Lubrication
Frame type Back born

Oil filter type Full-flow filtration
Oil capacity 2.5 L (2.2 lmp qt,
2.65 Us qt)
Final reduction oil 0.55 L (0.5 lmp qt,
capacity 0.58 Us qt)
Cooling Type Liquid cooled
1-2

ITEM SPECIFICATIONS ITEM SPECIFICATIONS
Name XCITING 250 Air cleaner type & No Wet paper type element
Overall length 2250 mm (90 in) 12.8 L (3.38 lmp gal,
Fuel capacity
Fuel System
Overall width 815 mm (33 in) 2.82 US gal
Carburetor
Overall height 1450 mm (58 in) Type CVK
Wheel base 1570 mm (63 in) Main jet NO. 94
Engine type O.H.C. Venturi dia. φ30 mm (φ1.2 in)
Displacement 251/249.1 cm3 Throttle type PISTON
Electrical Equipment
(15.3/15.8 cu-in) Full transistor ignition
Ignition System
Type
Fuel Used 92# nonleaded gasoline Spark plug DPR7EA-9
Front wheel 75 kg (165 lbs)
Dry weight Rear wheel 110 kg (242 lbs) Ignition timing Throttle position sensor
Total 185 kg (407 lbs) Spark plug gap 0.6～0.7mm (0.002～
Front wheel 81 kg (178 lbs) 0.003 in)
Curb weight Rear wheel 119 kg (262 lbs) Battery Capacity 12V12AH
Total 200 kg (440 lbs) Type Dry, centrifugal
Power Drive System
Clutch
Tires Front wheel 120/70-15 automatic
sion Gear Ratio
Transmis- Reduction
Rear wheel 150/70-14 Type Helical gear/spur gear

Ground clearance 170 mm (6.8 in) Automatic centrifugal
Operation
Min. turning radius 2600 mm (104 in) Type
Starting system Electric starter motor Type CVT
Type Gasoline, 4-stroke Preliminary 0.83 – 2.2
Cylinder arrangement Single cylinder Final 8.72
Combustion chamber type Semi-sphere
FR/RR tire rolling
1724/1778 mm (69/71 in)
Moving Device
Valve arrangement O.H.C., chain drive circumference

Bore x stroke 72.7 x 60 mm
(2.908 x 2.4 in) 2 kg/cm² (200 Kpa, 28
Tire pressure Front psi)
Compression ratio 10.3:1 (rider only/60
15 kgf/cm² (1500kPa, 2.5 kg/cm² (250 Kpa, 36
Compression pressure kg) Rear
213 psi) psi)
Open 9° BTDC Turning Left 40°
Engine
Intake valve
Close 45° ABDC angle Right 40°
Open 38° BBDC Brake system Rear Disk brake
Exhaust valve
Close 10° ATDC type Front Disk brake
Valve clearance Intake 0.1 mm (0.004 in)
Device
Damping
Front Telescopic fork

(cold) Exhaust 0.1 mm (0.004 in)
Suspension
Idle speed 1600 rpm
type Rear Unit swing
Forced
Lubrication type Wet sump pressure &
Frame type Back born
Oil pump type Trochoid
System
Lubrication
Oil filter type Full-flow filtration

Oil capacity 1.1 L (0.97 lmp qt,
1.17 Us qt)
Final reduction oil 0.2 L (0.18 lmp qt,
capacity 0.21 Us qt)
Cooling Type Liquid cooled
1-3
SERVICE PRECAUTIONS Apply or add designated greases and

lubricants to the specified lubrication
Make sure to install new gaskets, O-rings, points.
circlips, cotter pins, etc. when
reassembling.
After reassembly, check all parts for proper

tightening and operation.
When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
When two persons work together, pay

attention to the mutual working safety.
Use genuine parts and lubricants.

Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
When servicing the motorcycle, be sure to

use special tools for removal and
installation.
After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After disassembly, clean removed parts. After connection, apply grease to the
Lubricate sliding surfaces with engine oil battery terminals.
before reassembly. Terminal caps shall be installed securely.
1-4
If the fuse is burned out, find the cause and The connector shall be inserted
repair it. Replace it with a new one completely.
according to the specified capacity. If the double connector has a lock, lock
it at the correct position.
Confirm Check if there is any loose wire.
Capacity
Before connecting a terminal, check for

After operation, terminal caps shall be damaged terminal cover or loose negative
installed securely. terminal.
When taking out the connector, the lock on Check the double connector cover for
the connector shall be released before proper coverage and installation.
operation.
Insert the terminal completely.

Hold the connector body when connecting Check the terminal cover for proper
or disconnecting it. coverage.
Do not pull the connector wire.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with

Check if any connector terminal is bending, their respective wire bands at the
protruding or loose. designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
1-5
After clamping, check each wire to make Route harnesses so they are neither
sure it is secure. pulled tight nor have excessive slack.
Do not pull
too tight！
Do not squeeze wires against the weld or

its clamp. Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
After clamping, check each harness to

make sure that it is not interfering with any
moving or sliding parts.
When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.
When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.
Do not break the sheath of wire.
No Contact If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the When installing other parts, do not press or
projected ends of bolts and screws. squeeze the wires.
Do not press or
squeeze the
i
1-6
After routing, check that the wire harnesses Symbols:

are not twisted or kinked. The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the

specified points. (Use
Wire harnesses routed along with
Engine Oil designated engine oil for
handlebar should not be pulled tight, have lubrication.)
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions. : Apply grease for lubrication.
Grease
: Transmission Gear Oil (90#)

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

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

the rust with sand paper or equivalent
before connecting.
Remove Rust！
1-7
TORQUE VALUES
STANDARD TORQUE VALUES
Torque Torque
Item Item
N•m (kgf•m, lbf•ft) N•m (kgf•m, lbf•ft)
5mm bolt and nut 5(0.5, 4) 4mm screw 3 (0.3, 2)
6mm bolt and nut 10 (1, 7) 5mm screw 4 (0.4, 3)
8mm bolt and nut 22 (2.2, 16) 6mm screw, SH bolt 9 (0.9, 6.5)
10mm bolt and nut 35 (3.5, 25) 6mm flange bolt and nut 12 (1.2, 9)
12mm bolt and nut 55 (5.5, 40) 8mm flange bolt and nut 27 (2.7, 20)
14mm bolt and nut 70 (7, 50) 10mm flange bolt and nut 40 (4, 29)
Torque specifications listed below are for important fasteners.
ENGINE (XCITING 500)
Item Q‘ty Thread dia. Torque Remarks

(mm) N•m (kgf•m, lbf•ft)
MAINTENANCE:
Engine oil drain plug 1 12 25 (2.5, 18)
Oil strainer screen cap 1 30 15 (1.5, 11)
Oil filter cartridge 1 20 10 (1, 7)
Transmission oil drain bolt 1 8 20 (2, 15)
Transmission oil filler bolt 1 8 20 (2, 15)
Spark plug 1 10 12 (1.2, 9)
Tappet adjust nut 4 5 9 (0.9, 6)
LUBRICATION SYSTEM:
Oil pump screw 1 4 3 (0.3, 2)
Oil cooler bolt 2 16 35 (3.5, 25) Apply oil
COOLING SYSTEM:
Water pump cover bolt 2 6 13 (1.3, 9)
CYLINDER HEAD:
Breather separator bolt 3 6 13 (1.3, 9) Apply oil
Cylinder head bolt (1 – 4) 4 10 48 (4.8, 35) Apply oil
Cylinder head bolt (5 – 13) 9 8 23 (2.3, 17) Apply oil
Cylinder head cover bolt 4 6 10 (1, 7)
Cam chain tensioner bolt 2 6 12 (1.2, 9)
Tensioner pivot bolt 1 8 10 (1, 7)
Rocker arm shaft 2 18 45 (4.5, 32)
DRIVE/DRIVEN PULLEY:
Drive face nut 1 18 135 (13.5, 97) Apply oil
Clutch out nut 1 14 80 (8, 58) Apply oil
1-8
ENGINE (XCITING 500) (Cont’d)

Drive plate nut 1 28 78 (7.8, 56)
ALTERNATOR
ACG flywheel nut 1 14 55 (5.5, 40)
FINAL REDUCTION:
Transmission cover bolt 8 8 27 (2.7, 20)
CRANKCASE:
Crankcase bolt 13 6 12 (1.2, 9) Apply oil
Oil pipe bolt 2 16 43 (4.3, 31) Apply oil
Cam chain guide 2 8 20 (2, 15)
SWITCH:
Oil pressure switch 1 PT 1/8 22 (2.2, 16) Apply seal
ENGINE (XCITING 250)

Thread Torque
Item Q‘ty Remarks
dia.(mm) N•m (kgf•m, lbf•ft)
MAINTENANCE:
Valve adjusting lock nut 2 5 9 (0.9, 6.5) Apply oil
Spark plug 1 10 12 (1.2, 9)
Transmission oil drain bolt 1 12 20 (2, 15)
Transmission oil check/fill bolt 1 8 20 (2, 15)
Crank case oil drain bolt 1 12 25 (2.5, 18)
Oil filter screen cap 1 30 15 (1.5, 10.8) Apply oil
LUBRICATION SYSTEM:
Oil pump screw 1 3 2 (0.2, 1.4)
COOLING SYSTEM:
Water pump impeller 1 7 12 (1.2, 8.6) Left screw
CYLINDER HEAD:
Cylinder head cap nut 4 8 25 (2.5, 18) Apply oil
Tensioner lifter bolt 1 6 4 (0.4, 3)
Cylinder head cover bolt 4 6 12 (1.2, 8.6)
Cam chain tensioner bolt 2 6 12 (1.2, 8.6)
1-9
ENGINE (XCITING 250) (Cont’d)

DRIVE/DRIVEN PULLEY:
Drive face nut 1 14 93 (9.3, 67) Apply oil
Clutch outer nut 1 12 54 (5.4, 39)
Clutch drive plate nut 1 28 54 (5.4, 39)
Left crankcase cover bolt 6 6 12 (1.2, 8.6)
ALTERNATOR
A.C.G. stator 5 5 9 (0.9, 6.5)
Flywheel nut 1 14 55 (5.5, 40)
FINAL REDUCTION:
Transmission case cover bolt 9 8 20 (2, 14.4)
CRANKCASE:
Cam chain guide bolt 1 6 10 (1, 7)
SWITCH:
Oil pressure switch 1 PT 1/8 22 (2.2, 16) Apply seal
1-10
FRAME
Torque
Item Q‘ty Thread dia.(mm) N•m (kgf•m, Remarks
lbf•ft)
STEERING:
Handlebar bolt 4 8 23 (2.3, 17)
Upper pinch bolt 2 8 23 (2.3, 17)
Lower pinch bolt 4 8 32 (3.2, 23)
Bridge stem nut 1 22 62 (6.2, 45)
Steering stem lock nut 1 25.4 45 (4.5, 32)
Top thread 1 25.4 17 (1.7, 12)
WHEEL:
Front axle bolt 1 18 20 (2, 15)
Front fork bolt 2 8 23 (2.3, 17)
Rear axle nut (XCITING 500) 1 20 180 (18, 130)
Rear axle nut (XCITING 250) 1 16 140 (14, 100)
SUSPENSION:
Rear shock absorber bolt 4 10 40 (4, 29)
Rear fork 2 8 32 (3.2, 23)
BRAKE:
Front caliper mounting bolt 4 8 32 (3.2, 23) Replace a new one
Rear caliper mounting bolt 2 8 32 (3.2, 23) Replace a new one
Brake fluid bolt 6 10 35 (3.5, 25)
Master cylinder bolt 4 6 12 (1.2, 9)
ENGINE HANGER:
Engine hanger bolt 4 10 50 (5, 36)
Engine mounting bolt/nut 1 14 80 (8, 58)
(XCITING 500)
Engine mounting bolt/nut 1 10 50 (5, 36)
(XCINTING 250)
Engine hanger rod nut 1 10 35 (3.5, 25)
MUFFLER
Exhaust pipe nut 2 8 20 (2, 14)
Muffler mount bolt 3 10 35 (3.5, 25)
1-11
SPECIAL TOOLS
XCITING 500
Tool Name Tool No. Remarks

Clutch spring compressor E053 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E054 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Oil filter cartridge wrench E052 Cartridge removal or install
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install
XCITING 250
Tool Name Tool No. Remarks

Clutch spring compressor E034 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E003 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install
1-12
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part •Genuine KYMCO Engine Oil (SAE 5W-50)
Camshaft protruding surface •API SJ Engine Oil
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 Transmission oil: SAE 90
Final gear shaft
Transmission gearshaft bearing part
A.C. generator connector Adhesive
1-13
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Engine Oil Grease

Grease Front/Rear Brake Lever Pivot
Throttle Cable
Seat Lock
Front Wheel Bearing

Rear Wheel Bearing
Grease
Grease
Center Stand/Side Stand Pivot
Grease
1-14
CABLE & HARNESS ROUTING (XCITING 500)
1-15
1-16
1-17
1-18
1-19
1-20
1-21
1-22
1-23
1-24
CABLE & HARNESS ROUTING (XCITING 250)
1-25
1-26
1-27
1-28
1-29
1-30
1-31
1-32
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment Symptom Probable Cause
Check if fuel reaches

carburetor by loosening
drain screw cEmpty fuel tank
dClogged carburetor fuel inlet
tube, vacuum tube or fuel tube
eClogged auto fuel valve
Fuel reaches Fuel does not fClogged float oil passage
carburetor reach carburetor gClogged fuel tank cap
breather hole
hClogged fuel strainer
Remove spark plug and iClogged fuel filter
install it into spark plug jFaulty fuel pump
cap to test spark by
connecting it to engine cFaulty spark plug
ground dFouled spark plug
eFaulty ignition unit
Spark jumps Weak or no spark fFaulty A.C. generator
gBroken or shorted ignition coil
hBroken or shorted exciter coil
iFaulty ignition switch
Test cylinder cStarter motor idles but

compression crankshaft does not rotate
dValve clearance too small
eImproper valve and seat contact
Normal Low or no fWorn cylinder and piston rings
compression compression gBlown cylinder head gasket
hFlaws in cylinder head
iSeized valve
jImproper valve timing
Start engine by follow-
ing normal starting
procedure
cFaulty auto bystarter
Engine does not Engine fires but dAir leaking through intake
fire does not start pipe
eIncorrect ignition timing
fIncorrectly adjusted pilot screw
Remove spark plug and

inspect again
cFlooded carburetor
Dry spark plug Wet spark plug dFaulty auto bystarter
eThrottle valve excessively
open
1-33
ENGINE LACKS POWER

Start engine and
accelerate lightly for cClogged air cleaner
dRestricted fuel flow
observation eClogged fuel line between fuel
Engine speed Engine speed does tank and carburetor
increases not increase fClogged exhaust muffler
sufficiently gFaulty auto bystarter
Check ignition timing hSplit carburetor vacuum piston
(using a timing light) diaphragm
Correct timing Incorrect timing cFaulty ignition unit

dFaulty A.C. generator
Check valve clearance
cImproper valve clearance
Correct Incorrect adjustment
dWorn valve seat (valve stem too
protruding
Test cylinder compression
cImproper valve and seat contact
Normal Abnormal dWorn cylinder and piston rings
compression compression eBlown cylinder head gasket
fFlaws in cylinder head
Check carburetor for gImproper valve timing
clogging
Not Clogged Clogged cClogged carburetor jets
Remove spark plug and

inspect
Plug not fouled or Plug fouled or cFouled spark plug
discolored discolored dIncorrect heat range plug
Remove oil dipstick and
check oil level and condition
cOil level too high
Correct and not Incorrect or dOil level too low
contaminated contaminated eOil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train lubricated Valve train not cClogged oil pipe
properly lubricated properly dFaulty oil pump
cInsufficient coolant
Check if engine overheats dFaulty thermostat
eWorn cylinder and piston rings
fMixture too lean
Engine does not Engine overheats gPoor quality fuel
overheats hExcessive carbon buildup in
combustion chamber
iIgnition timing too early
Rapidly accelerate or run jAir in cooling system
at high speed
cExcessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks dPoor quality fuel
eClutch slipping
fMixture too lean
g Ignition timing too early
1-34
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Check ignition timing
cFaulty ignition unit

Correct timing Incorrect timing
Check carburetor pilot

screw adjustment
cMixture too rich (turn screw

Correctly adjusted Incorrectly adjusted out)
dMixture too lean (turn screw
in)
Check carburetor gasket

for air leaks
cDamaged insulator rubber

No air leak Air leaks dCarburetor not securely
tightened
eFaulty intake manifold gasket
Remove spark plug and fDeformed carburetor O-ring
install it into spark plug
cap to test spark by
connecting it to engine
ground
cFaulty or fouled spark plug
dFaulty ignition unit
Weak or inter- eFaulty A.C. generator
Good spark mittent spark fFaulty ignition coil
gBroken or shorted high
tension wire
Check carburetor air hFaulty ignition switch
cut-off valve
cDamaged air cut-off valve

Good Faulty diaphragm
dDamaged air cut-off valve
spring
1-35
POOR PERFORMANCE (AT HIGH SPEED)
Check ignition timing
cFaulty ignition unit

Correct timing Incorrect timing
Check valve clearance
cImproperly adjusted valve

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

fuel supply
cEmpty fuel tank

Fuel flows freely Fuel flow restricted dClogged fuel tube or filter
eFaulty fuel pump
fCracked fuel pump vacuum
tube
Check carburetor jets
for clogging
Not clogged Clogged cClean and unclog
Check valve timing
Correct Incorrect cCam timing gear aligning

marks not aligned
Check valve spring

tension
Not weakened Weak spring cFaulty spring
1-36
ENGINE NOISE
Symptom Probable Cause
cValve clearance too large

Valve noise
dWorn camshaft lobe
cWorn piston rings

Piston noise dWorn piston pin and connecting rod small
end
eExcessive carbon build-up in combustion
chamber
cDamaged cam chain tensioner

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

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

Gear noise
dWorn final reduction gear shaft splines
1-37
CLUTCH, DRIVE AND DRIVEN PULLEYS
cWorn or slipping drive belt

dBroken ramp plate
eBroken drive face spring
Engine starts but motor-
cycle does not move fSeparated clutch lining
gDamaged driven pulley shaft splines
hDamaged final gear
iSeized final gear
Motorcycle creeps or cBroken shoe spring

engine starts but soon
stops or seems to rush dClutch outer and clutch weight stuck
out (Rear wheel rotates
when engine idles) eSeized pivot

Engine lacks power at dWorn weight rollers
start of a grade(poor eSeized drive pulley bearings
slope performance) fWeak driven face spring
gWorn or seized driven pulley bearings

Engine lacks power at
high speed dWorn weight rollers
eWorn or seized driven pulley bearings
cOil or grease fouled drive belt

There is abnormal noise dWorn drive belt
or smell while running eWeak driven face spring
fWorn or seized driven pulley bearings
1-38
STARTER MOTOR
1. Starter motor won‘t turn
Check operation of
stop switch by cBurned out fuse
applying brake dWeak or dead battery
Stoplight comes on Stoplight does not eFaulty stop switch
come on fLoose or disconnected
Check battery circuit connectors
by operating turn gBroken or shorted ignition
signals switch wire
Signals operate Signals dim, remain
properly on or don‘t operate cFaulty or weak battery
Check operation of
starter relay by
depressing starter
button
Relay operates Relay does not cPoor starter button connection
properly operate dOpen or shorted starter relay
eLoose or disconnected
Connect starter connectors
motor directly to
battery cWorn brushes
Starter motor turns Starter does not turn dOpen or shorted wires or rotor
eOpen starter motor cable
fLoose connectors
cOpen wire harness
2. Starter motor turns slowly or idles
Check battery circuit
by operating turn
signals
Signals operate Signals dim, remain
properly on or don‘t operate cWeak or dead battery
Connect starter
motor directly to
battery
Starter motor Starter motor cLoose connector or terminal
turns slowly turns normally dPoor contact in starter relay
eFaulty starter clutch
Rotate crankshaft
Turns easily Hard to turn cSeized cylinder
cBroken or shorted starter

motor cable
3. Starter motor does not stop turning
Turn ignition switch

OFF
Not stopped Stopped cFaulty starter pinion

cStarter relay shorted or stuck
closed
1-39
NO SPARK AT SPARK PLUG
Replace with a new

spark plug and inspect
again
Weak or no spark Good spark cFaulty spark plug
Check spark plug cap

and high-tension wire
for looseness
Not loose Loose cFaulty spark plug
Check ignition unit

coupler for looseness
Good Good cPoorly connected coupler
Measure resistance
between terminals of
ignition unit coupler
Normal Abnormal
Check related parts
cFaulty ignition switch

Normal Abnormal dFaulty exciter coil
eFaulty pulser coil
fFaulty ignition coil
cBroken wire harness
dPoorly connected coupler
Check ignition unit

with a ignition unit
tester
Normal Abnormal cFaulty ignition unit
Check ignition coil with

a ignition unit tester
Abnormal cFaulty ignition coil
1-40
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging
Start engine and test

limit voltage of battery
terminals
Voltage does not cFaulty AC generator

Normal voltage increase dFaulty regulator/rectifier
eFaulty battery
Measure resistance
between AC generator
coil terminals
Normal Resistance too low cShorted AC generator coil

dOpen circuit between AC
generator 3 yellow wires
Test output voltage of

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

voltage with an electric
tester
cFaulty battery
Normal Abnormal dFaulty regulator/rectifier
eBroken or poorly connected
regulator/rectifier black wire
Check resistance
between regulator/
rectifier terminals
Normal Abnormal cLimit voltage too high
1-41
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Check battery circuit by

operating turn signals
cBurned out fuse
dWeak or dead battery
Signals operate Signals dim, remain eFaulty ignition switch
properly on or don‘t operate fLoose or disconnected
Remove fuel unit and
check operation of connectors
pointer by moving float gBroken wire harness
up and down
Float up: Full Pointer does not
Float down: Empty Pointer moves cFaulty float
move
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire harness
side Pointer does not Pointer moves cBroken or shorted fuel unit
move wire
Check connectors for
proper connection
cDisconnected connector
Good Faulty dIncorrectly connected
connector
eBroken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)
Check battery circuit by

operating turn signals
and horn cBurned out fuse
dWeak or dead battery
Signals operate Signals dim, remain eFaulty ignition switch
properly on or don‘t operate fLoose or disconnected
Remove fuel unit and
check operation of connector
pointer by moving float gBroken wire harness
up and down
Pointer moves Pointer does not cPoor contact in fuel unit
move
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer
Pointer moves in Pointer does not
accordance with move in accord- cInsufficient damping oil in
float ance with float fuel gauge
Check connectors for
proper connection.
Good Faulty cLoose or disconnected

connector
cBroken or shorted wire in
fuel gauge
1-42
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)
Steering is heavy cSteering stem nut too tight
dBroken steering steel balls
Front or rear wheel is cExcessive wheel bearing play

wobbling dBent rim
eLoose axle nut
Steering handlebar pulls cMisaligned front and rear wheels

to one side dBent front fork
POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)
cWeak shock spring
Suspension is too soft dExcessive load
eShock damper oil leaking
Suspension is too hard cBent fork tube or shock rod
cFork tube and slider binding
dFork spring and slider binding
Suspension is noisy eDamaged shock stopper rubber
fLoose steering stem nut
POOR BRAKE PERFORMANCE
cWorn brake linings

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

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

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

dForeign matter on brake linings
cSluggish or elongated brake cables
Brake squeaks dBrake shoes improperly contact
eWater and mud in brake system
fOil or grease on brake linings
1-43
2. FRAME COVERS/ EXHAUST MUFFLER XCITING 500/250
2
__________________________________________________________________________________
__________________________________________________________________________________
2
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
FRAME COVERS/EXHAUST MUFFLER

__________________________________________________________________________________
SCHEMATIC DRAWING ------------------------------------------------- 2- 1

SERVICE INFORMATION------------------------------------------------ 2- 2
TROUBLESHOOTING----------------------------------------------------- 2- 2
FRAME COVERS REMOVAL ------------------------------------------- 2- 3
EXHAUST MUFFLER ----------------------------------------------------- 2-16
2-0
2. EXHAUST MUFFLER/FRAME COVERS XCITING 500/250
SCHEMATIC DRAWING
2-1
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use care not to pull them by force because the cover joint claws
may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Muffler mount bolt 35 N•m (3.5 kgf•m, 25 lbf•ft)
Exhaust pipe joint nut 20 N•m (2 kgf•m, 14 lbf•ft)
Exhaust pipe band bolt 21 N•m (2.1 kgf•m, 15 lbf•ft)
TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
2-2
Nuts Damper Unit

FRAME COVERS REMOVAL
SEAT
REMOVAL
Unlock the seat with the ignition key.
Open the seat.
Remove the two nuts and seat damper unit.
Remove the two nuts and the seat.
INSTALLATION
Installation is in the reverse order of the
removal. Nuts
After installation, check the seat installation

by moving the seat.
Nuts Screws
LUGGAGE BOX
REMOVAL
Remove the seat (page 2-3).
Remove the four screws and three nuts.
Luggage Box Light Connector

Raise the luggage box, disconnect the
luggage box light and accessory socket
connectors.
INSTALLATION
Installation is in the reverse order of removal.
Accessory Socket Connector
2-3
Bolt
SPARK PLUG MAINTENANCE LID
REMOVAL
Remove the bolt and lid.
INSTALLATION
Spark Plug Maintenance Lid
Rubber Cap
REAR SPOILER
REMOVAL
Open the seat.
Remove the rubber cap.
Remove four bolts and rear spoiler.

INSTALLATION
Bolts
FRONT FENDER
RE MOVAL
Remove the six bolts and front fender.
INSTALLATION
Bolts
2-4
UPPER HANDLEBAR COVER

REMOVAL
Remove four screws and upper handlebar
cover.
INSTALLATION
Screws
Bolts
RIGHT/LEFT CENTER BODY COVER
REMOVAL
Remove the two bolts and right/left center
body cover.
＊ Be careful not to damage the tabs on the
center body cover.
INSTALLATION
Center Body Cover
Floor Mat
RIGHT/LEFT FLOOR SKIRT
REMOVAL
Remove the floor mat.
Remove the right and left center body cover
(page 2-5).
2-5
Screws
Remove the seven screws.
Screws
Remove two screws.
Remove the floor skirt.

floor skirt.
INSTALLATION
Bolts
FLOORBOARD
REMOVAL
Remove right and left center body cover
(page 2-5).
Remove the right and left floor skirt (page 2-
5).
Remove the luggage box (page 2-3).
Remove six bolts, four screws and

floorboard.
INSTALLATION Screws
2-6
LICENCE LIGHT
REMOVAL
Remove two screws.
Disconnect the license light connector and
remove the license light.
INSTALLATION
Screws Connector
REAR FENDER
REMOVAL
Remove the licence light (page 2-7).
Remove two screws.
Screws
Remove two nuts and rear fender.
INSTALLATION
Nuts
2-7
RIGHT/LEFT SIDE BODY COVER

REMOVAL
Remove the rear spoiler (page 2-4).
Remove two bolts.
Bolts
Raise the side body cover, disconnect the

taillight/rear turn signal light connector and
remove the side body cover.
INSTALLATINON
Installation is in the reverse order of removal
Taillight/Rear Turn Signal Light Connector
Screws
REAR BODY COVER
REMOVAL
Remove the rear spoiler (page 2-4).
Remove two screws and rear body cover.

rear body cover.
INSTALLATION
2-8
Screws
TAILIGHT/REAR TURN SIGNAL
LIGHT
REMOVAL
Remove the side and rear body cover (page 2-
8).
Remove eight screw and taillight/rear turn

signal light.
INSTALLATION
Screws
REAR LOWER COVER

REMOVAL
Remove the side body cover (page 2-8).
Remove the rear lower cover.
Rear Lower Cover
REARVIEW MIRROR
REMOVAL
Remove bolts lid.
Remove three bolts and rearview mirror.
Lid Bolts
2-9
Rearview Mirror Holder

Remove the two bolts, rearview mirror holder
and seat.
INSTALLATION
Installation is in the reverse order of removal
Bolts Holder Seat
Screws
WINDSHIELD
REMOVAL
Remove four screws and windshield garnish.
Windshield Garnish
Windshield
Remove four bolts and windshield.
＊ Be careful not to scratch or damage the
windshield surface.
INSTALLATION
2-10
Screws
FRONT COVER
REMOVAL
Remove the rearview mirrors (page 2-9).
Remove six screws.
Screws
Remove two screws.
Turn Signal Light Connectors

Remove one screw.
Disconnect headlight and turn signal light
connectors.
INSTALLATION
Screw Headlight Connector
2-11
Screws
HEADLIGHT
REMOVAL
Remove the front cover (page 2-11).
Remove six screws and headlight.
INSTALLATION
TURN SIGNAL LIGHT

REMOVAL
Remove three screws and turn signal light.
INSTALLATION
Screws
Windshield Holder
FRONT METER VISOR
REMOVAL
Remove the windshield (page 2-10).
Remove four bolts and windshield holder.
Bolts
2-12
Remove two screws and front meter visor.
INSTALLATION
Screw
MEER PANEL
REMOVAL
Remove the front meter visor (page 2-12).
Remove four screws.
Screws
Speedometer Connector
Disconnect the speedometer connector and
remove meter panel.
INSTALLATION
Bolts
2-13
Screws
METER
REMOVAL
Remove the meter panel (page 2-13).
Remove two screws and meter.
Shutter
INNER COVER
REMOVAL
Remove the floorboard (page 2-6).
Remove the shutter screw and shutter.
Screw
Cap Garnish
Turn the fuel fill cap garnish
counterclockwise and remove it.
Remove three screws and disconnect the fuel
fill duct.
Screws
2-14
Remove four fasteners (XCITING 500).

Remove the inner cover.
INSTALLATION
Fasteners
FRONT LOWER COVER

REMOVAL
Remove the right and left floor skirt (page 2-
5).
Remove two bolts and front lower cover.
Bolts
2-15
EXHAUST MUFFLER
REMOVAL
Loosen the exhaust pipe band bolt.
Remove three muffler mount bolts and
muffler from the exhaust pipe.
Band Bolt Mount bolts
Remove the exhaust pipe joint nuts and

exhaust pipe.
Remove the gaskets.
Joint Nuts
INSTALLATION
Replace the gaskets with new ones.
Install the exhaust pipe and tighten the joint
nuts.
Torque: 20 N•m (2 kgf•m, 14 lbf•ft)
Install the muffler and tighten the mount

bolts.
Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft)
Install and tighten the band bolts.

Torque: 21 N•m (2.1 kgf•m, 15 lbf•ft) Gaskets
2-16
3. INSPECTION/ADJUSTMENT XCITING 500/250
3
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________ 3
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION-------------------------------------------------- 3- 1
MAINTENANCE SCHEDULE (XCITING 500) ------------------------- 3- 3
MAINTENANCE SCHEDULE (XCITING 250) ------------------------- 3- 5
FUEL LINE--------------------------------------------------------------------- 3- 6
THROTTLE OPERATION--------------------------------------------------- 3- 6
AIR CLEANER ---------------------------------------------------------------- 3- 8
CRANKCASE BREATHER ------------------------------------------------- 3-10
SPARK PLUG------------------------------------------------------------------ 3-10
VALVE CLEARANCE ------------------------------------------------------- 3-12
ENGINE OIL ------------------------------------------------------------------- 3-14
ENGINE OIL FILTER CARTRIDGE (XCITING 500) ------------------ 3-17
ENGINE IDLE SPEED ------------------------------------------------------- 3-18
RADIATOR COOLANT ----------------------------------------------------- 3-19
COOLING SYSTEM---------------------------------------------------------- 3-20
SECONDARY AIR SUPPLY SYSTEM ----------------------------------- 3-21
TRANSMISSION OIL -------------------------------------------------------- 3-22
BRAKE FLUED --------------------------------------------------------------- 3-24
BRAKE PAD WEAR --------------------------------------------------------- 3-25
BRAKE SYSTEM ------------------------------------------------------------- 3-25
BRAKE LOCK OPERATION (XCITING 500) --------------------------- -3-26
HEADLIGHT AIM ------------------------------------------------------------ -3-27
SIDE STAND---------- -------------------------------------------------------- -3-28
SUSPENSION------------------------------------------------------------------ -3-28
NUTS, BOLTS, FASTENERS----------------------------------------------- -3-29
WHEELS/TIRES--------------------------------------------------------- ----- -3-29
STEERING HEAD BEARINGS--------------------------------------------- -3-30
3-0
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.
ITEM SPECIFICATIONS
Throttle free play 2-6 mm (1/16 – 1/4 in)
Spark plug NGK CR8E
Spark plug gap 0.6 – 0.7 mm (0.024 – 0.028 in)
Valve clearance IN 0.1 mm (0.004 in)
EX 0.1 mm (0.004 in)
At draining 2.0 liter (2.1 US pt, 1.8 lmp qt)
Engine oil capacity At draining/oil filter change 2.1 liter (2.2 US pt, 1.9 lmp qt)
Total amount 2.5 liter (2.6 US pt, 2.3 lmp qt)
KYMCO 4-stroke oil or equivalent
Recommended engine oil motor oil API service classification: SJ
Viscosity: 5W50
Engine idle speed 1400±100 rpm
Final reduction oil capacity At draining 0.45 liter (0.48 US pt, 0.4 lmp qt)
Recommended final reduction oil SAE 90
Recommended brake fluid DOT 4
Parking brake lever stroke 3 – 6 notch
Front 120/70-15
Tire size
Rear 150/70-14
Front 200 kPa (2 kgf/cm2, 29 psi)
Solo riding
Tire air pressure Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Two up riding Front 225 kPa (2.25 kgf/cm2, 32 psi)
Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Front 1.6 mm (0.06 in)
Minimum tire tread depth
Rear 2.0 mm (0.08 in)
3-1
ITEM SPECIFICATIONS
Throttle free play 2-6 mm (1/16 – 1/4 in)
Spark plug NGK DPR7EA-9
Spark plug gap 0.6 – 0.7 mm (0.024 – 0.028 in)
Valve clearance IN 0.1 mm (0.004 in)
EX 0.1 mm (0.004 in)
At draining 0.9 liter (0.95 US pt, 0.8 lmp qt)
Engine oil capacity
KYMCO 4-stroke oil or equivalent
Recommended engine oil motor oil API service classification: SJ
Viscosity: 5W50
Engine idle speed 1600±100 rpm
Final reduction oil capacity At draining 0.18 liter (0.19 US pt, 0.16 lmp qt)
Recommended final reduction oil SAE 90
Recommended brake fluid DOT 4
Front 120/70-15
Tire size
Rear 150/70-14
Front 200 kPa (2 kgf/cm2, 29 psi)
Solo riding
Tire air pressure Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Front 225 kPa (2.25 kgf/cm2, 32 psi)
Two up riding
Rear 250 kPa (2.5 kgf/cm2, 36 psi)
Front 1.6 mm (0.06 in)
Minimum tire tread depth
Rear 2.0 mm (0.08 in)
TORQURE VALUES
Engine oil drain plug 25 N•m (2.5 kgf•m, 18 lbf•ft)

Oil strainer screen cap 15 N•m (1.5 kgf•m, 11 lbf•ft)
Apply oil to the threads and seating surface.
Oil filter cartridge 10 N•m (1 kgf•m, 7 lbf•ft)
(XCITING 500) Apply oil to the threads and seating surface.
Transmission oil drain bolt 20 N•m (2 kgf•m, 15 lbf•ft)

Transmission oil filler bolt 20 N•m (2 kgf•m, 15 lbf•ft)
Spark plug 12 N•m (1.2 kgf•m, 9 lbf•ft)
Tappet adjust nut 9 N•m (0.9 kgf•m, 6 lbf•ft)
SPECIAL TOOLS
Tappet adjuster E036

Oil filter cartridge wrench E052 (XCITING 500)
3-2
MAINTENANCE SCHEDULE (XCITING 500)

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
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
MAINTENANCE SCHEDULE (XCITING 250)

Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T: Tighten
Regular Service Mileage (km)
Whichever
Frequency comes
first Ö
Item
Ø
1000 2000 4000 6000 8000 10000
R New
Engine oil scooter
R R R R R
300km
Engine oil filter C C
screen
Fuel filter Replace at every 6000km
R New
Gear oil Note 3 scooter
R R
300km
Valve clearance A A A
Carburetor I I
Air Cleaner Note 2,3 I R R
Spark plug Clean at every 3000km and replace if necessary
Brake system I I I I I I
Drive belt I
Suspension I I
Nut, bolt, fastener I
Tire I I
Steering head bearing I I I
Brake fluid Perform pre-ride inspection daily
Radiator coolant Replace every year or at every 10000km (R)
Radiator core I I
Radiator cap I I
Brake lever I I
Brake shoe wear I I
Shock absorber I I
• In the interest of safety, we recommend these items be serviced only by an authorized KYMCO
motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in dusty or rainy areas.
3. Service more frequently when riding in rain or at full throttle.
3-5
Fuel Lines
FUEL LINE XCITING 500
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. Fuel Filter
Fuel Lines
XCITING 250
Fuel Filter
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)
3-6
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.
Adjust Nut
Major adjustments are made with the lower XCITING 500
adjuster.
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
XCITING 250
Lock Nut Adjust Nut
3-7
AIR CLEANER
The air cleaner should be serviced at regular
intervals. Service more frequently when
riding in unusually wet or dusty areas.
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.
Air cleaner element removal/installation

(XCITING 500):

Open the seat.
Remove the air cleaner cover.
Air Cleaner Cover
Remove the screws and air cleaner housing

cover
Air Cleaner Housing Cover
3-8
Remove the air cleaner element by pull it out.

Discard the air cleaner element.
Install the removed parts in the reverse order

of removal.
Screws
Air Cleaner Element
Air cleaner element removal/installation

(XCITING 250):
Remove the six screws and air cleaner cover.
Air Cleaner Cover
Screws
Remove the four screws and air cleaner

element from air cleaner cover.
Discard the air cleaner element.
Air Cleaner Element
3-9

of removal
Tighten the screws using a diagonal pattern.
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 Spark Plug Cap
be seen in the transparent section of the drain
tube.
SPARK PLUG
REMOVAL
Remove the spark plug maintenance lid
(XCITING 500) (page 2-4).
Remove the luggage box (XCITING 250)
(page 2-3)
Disconnect the spark plug cap and clean

around the spark plug
＊ Clean around the spark plug base with
compressed air before removing, and be
sure that no debris is allowed to enter the Spark Plug Cap
combustion chamber.
3-10
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
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:

XCITING 500: NGK: CR8E
XCITING 250: NGK: DPR7EA-9
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.
of removal.
3-11
Timing Hole Cap/O-ring

VALVE CLEARANCE
＊
Inspect and adjust the valve clearance
while the engine is cold (Below
35°C/95°F).
To adjust (XCITING 500):

Remove the cylinder head cover (page 8-7).
Remove the timing hole cap and O-ring. Crankshaft Hole Cap/O-ring
Remove the crankshaft hole cap and 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.
3-12
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 lock-

nut threads and seating surface.
Hold the adjusting screw and tighten the lock
nut.
Valve Adjusting Wrench/Adjusting Screw
Special tool:
Valve adjusting wrench E012
Torque: 9N•m (0.9 kgf•m, 6 lbf•ft)
After tightening the lock nut, recheck the

valve clearance.

of removal.
Index Mark
To adjust (XCITING 250):

Remove the timing hole cap and O-ring.

Remove the crankshaft hole cap and O-ring.

“T” mark on the flywheel with the index “T” Mark Punch Mark
mark on the right crankcase cover.
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.
3-13
Adjust by loosening the valve adjusting screw Valve Wrench

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 lock-

nut threads and seating surface.
Hold the adjusting screw and tighten the lock
nut.
Special tool:
Valve adjusting wrench E012
After tightening the lock nut, recheck the

valve clearance.

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
Oil Filler Cap/Dipstick
recommended engine oil until the oil level is
to the upper level line (2)
3-14
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.
3-15
Place a drain pan under the crankcase and Strainer Screen

remove the oil strainer cap.
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 Strainer Screen

threads, flange surface and a new O-ring.
Install and tighten the strainer cap with a new
O-ring.
Setting Spring
O-ring
Strainer Cap
3-16
Fill the crankcase with the recommended

engine oil.
Oil capacity (XCITING 500):

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
Oil capacity (XCITING 250):

at draining
Install the oil filler cap/dipstick (1).

Check the engine oil level (page 3-14).
Make sure there are no oil leaks
.
ENGINE OIL FILTER

CARTRIDGE (XCITING 500)
REPLACEMENT
Drain the engine oil (page 3-15).
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
3-17
Apply clean engine oil to the new oil filter

cartridge threads, flange surface and a new O- O-ring
ring.
Install the new oil filter cartridge and tighten
it to the specified torque.
Tool:
Oil filter cartridge wrench E052
Torque: 10N•m (1 kgf•m, 7 lbf•ft)
Refill the engine oil (page 3-15)
(1)
ENGINE IDLE SPEED
Inspect and adjust the idle speed after all

other engine maintenance items have been
performed and are within specification.
The engine must be warm for accurate idle
speed inspection and adjustment.
Warm up the engine.

Place the scooter on its center stand.

Open the seat and remove carburetor cover
(1).
Turn the throttle stop screw (2) as required to

obtain the specified idle speed.
Idle speed (XCITING 500): 1400±100 rpm
3-18
Idle speed (XCITING 250): 1600±100 rpm
RADIATOR COOLANT
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 6-7)
＊ 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.
3-19
Reserve Tank Lid Screw

Remove the left floor mat and remove screw
and reserve tank lid.
Left Floor Mat
Reserve Tank Cap

Remove 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 6-8).
Reinstall the filler cap.
COOLING SYSTEM
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
3-20
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.
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) XCITING 500
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
3-21
AICV Reed Valve

XCITING 250
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.
3-22
Fill the transmission case with recommended

oil.
Recommended transmission oil: SAE 90
Oil capacity (at draining):

XCITING 500:
XCITING 500:
0.18 liter (0.19 US qt, 0.16 lmp qt)
Install the transmission oil filler bolt with a

new sealing washer and tighten it.
3-23
BRAKE FLUID
＊ Do not mix different type of fluid, as
they are not compatible with each
other.
Do not allow foreign material to enter
the system when filling the reservoir.
Avoid 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.
3-24
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 Rear Brake Lever
INSPECTION
This model equipped with a linked brake

system.
Check the rear brake operation as follows:

Jack-up the scooter to raise the front wheel
off the ground.
＊ Do not use the oil filter as a jack point.
3-25
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

(XCITING 500)
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.
3-26
ADJUSTMENT

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.
Vertically Adjusting Screw
＊ Adjust the headlight beam as specified
by local laws and regulations.
3-27
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.
3-28
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
1-8).
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:
3-29
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.
3-30
4. LUBRICATION SYSTEM XCITING 500/250
4
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
4
__________________________________________________________________________________
LUBRICATION SYSTEM
__________________________________________________________________________________
LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1

SERVICE INFORMATION----------------------------------------------- 4- 3
TROUBLESHOOTING---------------------------------------------------- 4- 5
OIL PRESSURE SWITCH ------------------------------------------------ 4- 6
OIL PRESSURE RELIEF VALVE (XCITING 500) ------------------ 4- 6
OIL PUMP ------------------------------------------------------------------- 4- 7
OIL COOLER (XCITING 500) ------------------------------------------- 4-12
4-0
LUBRICATION SYSTEM DIAGRAM

XCITING 500
4-1
XCITING 250
Rocker Arm Shaft
Crankshaft
Oil Filter Screen Oil Pump
4-2
SERVICE INFORMATION
• The oil pump service may be done with the engine installed in the frame.
• When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as
an assembly.
• After the engine has been installed check that there are no oil leaks and that oil pressure is
correct.
• For oil pressure indicator inspection, refer to section 20 of this manual.
SPECIFICATIONS (XCITING 500) Unit: mm (in)

ITEM STANDARD SERVICE LIMIT
At draining 2.0 liter (2.1 US qt, 1.8 lmp qt) ⎯
Engine oil At disassembly 2.5 liter (2.7 US qt, 2.2 lmp qt) ⎯
capacity
At oil filter change 2.1 liter (2.2 US qt, 1.9 lmp qt) ⎯
KYMCO 4-stroke oil or
equivalent motor oil
Recommended engine oil
API service classification SJ ⎯
Viscosity: SAE 5W-50
Tip clearance 0.15 (0.006) max 0.2 (0.008)
Oil pump rotor Body clearance 0.15 – 0.2 (0.006 – 0.008) 0.25 (0.01)
Side clearance 0.04 – 0.09 (0.0016 – 0.0036) 0.12 (0.0048)

Engine oil At draining 0.9 liter (0.95 US qt, 0.8 lmp qt) ⎯
capacity
At disassembly 1.1 liter (1.17 US qt, 1 lmp qt) ⎯
KYMCO 4-stroke oil or
equivalent motor oil
Recommended engine oil ⎯
API service classification SJ
Viscosity: SAE 5W-50
Tip clearance 0.15 (0.006) max 0.2 (0.008)
Oil pump rotor Body clearance 0.15 – 0.2 (0.006 – 0.008) 0.25 (0.01)
Side clearance 0.04 – 0.09 (0.0016 – 0.0036) 0.12 (0.0048)
4-3
TORQUE VALUES (XCITING 500)
Oil pump screw 3 N•m (0.3kgf•m, 2 lbf•ft)

Oil cooler bolt 35 N•m (3.5 kgf•m, 25 lbf•ft)
Oil pressure switch 22 N•m (2.2 kgf•m, 16 lbf•ft) Apply sealant to threads.
Oil filter cartridge 10 N•m (1 kgf•m, 7 lbf•ft)
Oil pump screw 3 N•m (0.3kgf•m, 2 lbf•ft)

Oil pressure switch 22 N•m (2.2 kgf•m, 16 lbf•ft) Apply sealant to threads.
TOOLS
Oil filter wrench E052
4-4
TROUBLESHOOTING
Oil level low High oil pressure
• Oil consumption • Pressure relief valve stuck closed
• External oil leak • Plugged oil filter, gallery, or metering orifice
• Worn piston ring • Faulty oil pump
• Incorrect piston ring installation
• Worn valve guide or seal Seized engine
• No or low oil pressure
Oil contamination (White appearance) • Clogged oil orifice/passage
• From coolant mixing with oil • Internal oil leak
─ Faulty water pump mechanical seal • Non-recommended oil used
─ Faulty head gasket
─ Water leak in crankcase Oil contamination
• Deteriorated oil
No oil pressure • Faulty oil filter
• Oil level too low • Worn piston ring (White appearance with water or
• Oil pump drive chain broken moisture)
• Oil pump drive sprocket broken ─ Damaged water pump mechanical seal
• Oil pump damaged (pump shaft) ─ Damaged head gasket
• Internal oil leak ─ Oil relief not frequent enough
Low oil pressure Oil pressure warning indicator does not work
• Pressure relief valve stuck open • Faulty oil pressure switch
• Clogged oil filter and strainer screen • Short circuit in the indicator wire
• Oil pump worn or damaged • Low or no oil pressure
• Internal oil leak
• Incorrect oil being used
• Oil level too low
4-5
OIL PRESSURE SWITCH Dust Cover

CHECK
Start the engine.
Check the oil pressure indicator goes out after
one or two seconds. If the oil pressure
indicator stay on, stop the engine
immediately and determine the cause (section
20).
Oil Pressure Relief Valve
OIL PRESSURE RELIEF VALVE

(XCITING 500)
REMOVAL
Remove the right crankcase cover (page 12-
3).
Remove the pressure relief valve and O-ring

from the right crankcase
O-ring
Piston
PUSH
INSPECTION
Check the operation of the pressure relief
valve buy pushing on the piston.
INSTALLATION
Apply oil to a new O-ring and install the
pressure relief valve groove, and install the
relief valve to the right crankcase. Oil Pressure Relief Valve
4-6
Bolts
OIL PUMP
REMOVAL
Remove the flywheel (page 12-5).
Remove the attaching bolt and oil separator

cover.
＊ When removing and installing the oil
pump, use care not to allow dust or dirt
to enter the engine..
Oil Separator Cover
Remove snap ring.
Snap Ring
Drive Chain Driven Gear
Remove the oil pump driven gear, then

remove the oil pump drive chain.
4-7
Oil Pump
Remove the two oil pump bolts to remove the
oil pump.
Bolts
Oil Pump Cover

DISASSEMBLY
Remove the screw and oil pump cover.
Screw
Oil Pump Body Dowel Pin Inner Rotor

Remove the dowel pin, oil pump shaft, oil
pump outer rotor and inner rotor.
Outer Rotor Oil Pump Shaft
4-8
INSPECTION
Temporarily install the oil pump shaft.
Install the outer and inner rotors into the oil
pump body.
Measure the tip clearance.
Service limit: 0.2 mm (0.008 in)

＊ Measure at several points and use the
largest reading to compare the service
limit.
Measure the pump body clearance.
Measure the side clearance with the straight

edge and feeler gauge.
4-9
Dowel Pin Oil Pump Cover

ASSEMBLY
Dip all parts in clean engine oil.
Install the outer rotor into the oil pump body.

Install the inner rotor into the outer rotor.
Install the oil pump shaft.
Install the dowel pin onto the oil pump body.
Install the oil pump cover onto the oil pump
body by aligning the dowel pin.
Oil Pump Cover

Install and tighten the screw to the specified
torque.
Torqur: 3 N•m (0.3kgf•m, 2 lbf•ft)
Screw
Oil Pump Arrow Mark

INSTALLATION
Install the oil pump and tighten the two bolts
securely.
＊ Make sure the pump shaft rotates freely
and arrow on the oil pump is upside.
Bolts
4-10
Drive Chain Driven Gear

Install the oil pump driven sprocket and drive
chain.
Install the snap ring.
Snap Ring
Bolts
Install the oil separator cover properly and
tighten two bolts securely as shown.
Oil Separator Cover
4-11
OIL COOLER (XCITING 500)

REMOVAL
Drain the engine oil and remove the oil filter
cartridge (page 3-17).
Drain the coolant from the system (page 6-8).
Loosen the hose bands and disconnect the oil

cooler water hoses from the cooler.
Water Hose
Oil Cooler/Gasket
Remove the oil cooler mounting bolts,
washers, oil cooler and gasket.
Bolts/Washers
Cooler
INSPECTION
Check the cooler for damage.
4-12
Gasket Bolts
INSTALLATION
Install the gasket and oil cooler.
Install the washers and tighten the oil cooler
bolts to the specified torque.
Connect the oil cooler water hoses, tighten

the hose band securely.
Install the oil filter cartridge and fill the

crankcase with recommended engine oil
(page 3-14). Oil Cooler Washers
Fill the cooling system and bleed air (page 6-
8).
4-13
5. FUEL SYSTEM/FUEL PUMP
/FUEL TANK/CARBURETOR XCITING 500/250
5
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
FUEL SYSTEM/FUEL PUMP/ 5

FUEL TANK/CARBURETOR
__________________________________________________________________________________
SCHEMATIC DRAWING-------------------------------------------------- 5- 1
FUEL SYSTEM (XCITING 500) ------------------------------------------ 5- 2
FUEL PUMP (XCITING 250) --------------------------------------------- 5- 3
SERVICE INFORMATION ------------------------------------------------ 5- 4
TROUBLESHOOTING ----------------------------------------------------- 5- 5
CARBURETOR -------------------------------------------------------------- 5- 6
FUEL FILTER/FUEL PUMP----------------------------------------------- 5-23
FUEL TANK------------------------------------------------------------------ 5-25
5-0
5. FUEL SYSTEM /FUEL PUMP
SCHEMATIC DRAWING
5-1
FUEL SYSTEM (XCITING 500)

The fuel pump is operated by an electromagnetic force and its electrical energy is supplied from the
battery. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of
the carburetor has dropped and the needle valve is open. When the needle valve closes, the pressure of
the fuel in the hose connecting the carburetor and the fuel pump increases, and when the set pressure
is reached, the operation of the fuel pump is stopped by the fuel pressure to prevent excessive supply.
FUEL PUMP CONSTRUCTION

When voltage is applied between the fuel pump terminals, current flows into the solenoid coil which
then pulls up the plunger together with the diaphragm allowing fuel to be drawn into the pump. At this
time, the contact which is linked with the plunger opens and interrupts current causing the coil to be
de-energized. This allows the diaphragm to go down by the spring force, thereby pressurizing and
delivering fuel to the outlet. When the fuel pressure builds up and overcomes the spring force, the
plunger stops at pulled up position with the contact in open position.
5-2
FUEL PUMP (XCITING 250)

CONSTRUCTION:
The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and
negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms
and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.
FUEL PUMP CONSTRUCTION
Pulsating Pressure
Outlet from Crankcase
Inlet
5-3
SERVICE INFORMATION
• When working with gasoline, keep away from sparks and flames.
• Note the locations of O-rings when disassembling and replace them with new ones during
assembly.
• Before float chamber disassembly, drain the residual gasoline from the float chamber.
• Do not try to disassemble the automatic choke.
• When assembling the vacuum chamber and air cut-off valve, be careful not to damage the
diaphragms.
• All cables, fuel lines and wires must be routed and secured at correct locations.
• When removing the fuel tank, keep sparks and flames away from the working area.
• When removing the fuel tank, the remaining fuel in the tank must be lower than 1/2 of the fuel
tank capacity to avoid gasoline overflowing.
• Fuel tank capacity: 12.8 liters
SPECIFICATIONS
XCITING 500 XCITING 250
Type CVK CVK
Carburetor identification number 15F8 SD8 LDB2
Size of bore (mm) Ø36 Ø30
Main jet #108 KY94
Slow jet #38 KY035
Idle speed 1400±100 1600±100
Pilot screw opening 3½ ± ½ turns out 2½ ± ½ turns out
Fuel pump flow (at 12V): ml (US oz, lmp oz)/min 370 (12.6 , 13) －
Fuel pump flow (at 12V): cc/rpm/Seconds － 40/1700/10
5-4
TROUBLESHOOTING
Engine does not start Engine idles roughly, stalls or runs poorly
• No fuel in tank • Incorrect idle speed
• Restricted fuel line • Rich mixture
• Too much fuel getting to cylinder • Lean mixture
• Clogged air cleaner • Clogged air cleaner
• Contaminated fuel • Intake air leak
• Faulty fuel pump • Contaminated fuel
• Faulty air-cut off valve
• Damaged vacuum tube and connectors
• Damaged carburetor insulator
Throttle does not open fully, so engine stalls Rich mixture

• Damaged vacuum piston diaphragm • Automatic valve opens excessively
• Clogged diaphragm hole • Faulty float valve
• Float level too high
Lean mixture • Clogged air jets
• Clogged fuel jets • Automatic choke valve set plate installed in
• Clogged fuel tank cap breather hole the wrong groove
• Clogged fuel filter •Clogged air cleaner
• Bent, kinked or restricted fuel line
• Faulty float valve
• Float level too low
• Faulty fuel pump or insufficient output
Engine is hard to start

• No fuel in tank
• Restricted fuel line
• Clogged fuel strainer
• Faulty fuel pump
• Broken or clogged vacuum tube
• Faulty or clogged charcoal canister
Lean mixture
• Clogged charcoal canister
• Bent, kinked or restricted fuel line
• Clogged fuel strainer
• Float level too low
5-5
Carburetor Clamp Screw

CARBURETOR
REMOVAL/INSTALLATION
(XCITING 500)
Remove the luggage box (page 2-3)
Loosen the air cleaner clamp screw.

Loosen the carburetor clamp screw.
Disconnect the vacuum hose from the
carburetor.
Pull the carburetor out from the air cleaner
and intake manifold.
.
Air Cleaner Clamp Screw Vacuum Hose
Fuel Hose
Disconnect the fuel hose from the
carburetor.
Disconnect the carburetor heater connector.
Carburetor Heater Connector
T.P.S Connector Throttle Cables
Disconnect the throttle cables.

Disconnect the automatic choke connector.
Disconnect the T.P.S connector.
Remove the carburetor.
Installation is in the reverse order of the

removal.
Automatic Choke Connector
5-6
(XCITING 250)
Remove the luggage box (page 2-3)
Disconnect the throttle cables.
Throttle Cables
Air Cleaner Clamp Screw

Pull the carburetor out from the air cleaner

and intake manifold.
Carburetor Heater Connector Fuel Hose
Disconnect the fuel hose from the

carburetor.
Disconnect the carburetor heater connector.
Disconnect the automatic choke connector.
Disconnect the T.P.S connector.
Installation is in the reverse order of

removal.
T.P.S Connector Automatic Choke Connector
5-7
Automatic Choke Assembly

DISASSEMBLY (XCITING 500)
With the automatic choke cover removed,

remove the screw and automatic choke
assembly.
＊ The automatic choke assembly is a non-
disassemblable type
Automatic Choke Cover Screw
Carburetor Heater
Loosen the drain screw and drain the fuel
from the float chamber.
Remove the carburetor heater.
Drain Screw
Top Cap
Remove the four screws and top cap.
Screws
5-8
Throttle Valve Spring Retainer

Remove the spring , spring retainer, jet needle
and throttle valve.
Jet Needle Spring
Casting Enrichment Valve Cover

Remove the two screws and casting
enrichment valve cover and then take out the
spring.
Screws
Remove the casting enrichment valve and O- O-ring

ring.
Casting Enrichment Valve
5-9
Screws
Remove the three screws and accelerating
pump cover.
Accelerating Pump Cover
O-ring
Remove the accelerating pump diaphragm
and O-ring.
Accelerating Pump Diaphragm
Float Chamber
Remove the four screws and float chamber.
Screws
5-10
Float Float Valve

Pull float pin outs, then remove the float and
float valve.
Float Pin
Main Jet Slow Jet

Remove the slow jet.
Remove the main jet.
Needle Jet Holder

Remove the needle jet holder.
5-11
Remove the needle jet.
Needle Jet
Pilot Screw
Remove the pilot screw, spring, washer and

O-ring.
＊ Before pilot screw removal, slowly turn
the pilot screw clockwise and count the
number of turns until the screw is lightly
seated. Make a note of how many turns
were made so the screw can be reset
correctly.
Drain Screw
Loosen the drain screw and drain the fuel

from the float chamber.
5-12
Automatic Choke Cap Automatic Choke

With the automatic choke cover removed,
remove the screw and automatic choke
assembly.
＊ The automatic choke assembly is a non-
disassemblable type
Screw
Screws
Remove the two screws and top cap.
Top Cap
Spring Jet Needle

Remove the spring and throttle valve.
Remove the spring retainer/spring and jet
needle from throttle valve.
Retainer/Spring Throttle Valve
5-13
Screws Screws
Remove the two screws and throttle cable
holder.
Remove the two screws and casting

enrichment valve cover.
Throttle Cable Holder Casting Enrichment

Valve Cover
Spring O-ring
Remove the spring, casting enrichment valve
and O-ring.
Remove the two screws and accelerating Accelerating Pump Cover O-ring
pump cover.
Remove the spring, accelerating pump
diaphragm and O-ring
Screws Accelerating Pump Diaphragm Spring
5-14
Float Chamber/O-ring
Remove the three screws, then remove the
float chamber and O-ring.
Screws
Float Valve Float

Pull float pin outs, then remove the float and
float valve.
Float Pin
Main Jet Needle Jet Holder

Remove the slow jet.
Remove the main jet, then remove the
needle jet holder.
Slow Jet
5-15
Needle Jet
Remove the needle jet.
Pilot screw
Remove the pilot screw, spring, washer and

O-ring.
＊ Before pilot screw removal, slowly turn
the pilot screw clockwise and count the
number of turns until the screw is lightly
seated. Make a note of how many turns
were made so the screw can be reset
correctly.
Pilot Screw/Spring/Washer/O-ring
O-ring Spring
Washer Pilot Screw
5-16
Float
FLOAT/FLOAT VALVE INSPECTION
Inspect the float for deformation or damage.
Check the float valve and valve seat for

foreign substance, clogging or damage.
Check the tip of the float valve, where it
contacts the valve seat, for stepped wear or
contamination.
Check the operation of the float valve.
5-17
Main Jet/Needle Jet Holder/Needle Jet

CARBURETOR BODY/JETS
INSPECTION AND CLEANING
Check carburetor body and each jet for wear
or damage.
Clean all jets with a spray-type carburetor

cleaner and dry them using compressed air.
Clean all circuits of the carburetor
thoroughly-not just the perceived problem
area.
Clean the circuits in the carburetor body

with a spray-type cleaner and allow each
circuit to soak, if necessary, to loosen dirt Slow Jet
and varnish. Blow the body dry using
compressed air.
＊ ● Some carburetor cleaning chemicals ,

especially dip type soaking solutions,
are very corrosive and must be handled
carefully. Always follow the chemical
manufacturer’s instructions on proper
use, handling and storage.
● Do not use a wire to clean the jets or
passageways. A wire can damage the
jets and passageways. If the
components cannot be cleaned with a
spray cleaner it may be necessary to
use a dip-type cleaning solution and
allow them to soak. Always follow the
chemical manufacturer’s instructions
for proper use and cleaning of the
carburetor components.
After cleaning, reassemble the carburetor

with new seals.
5-18
Pilot Screw O-ring

PILOT SCREW INSPECTION
Remove the O-ring from the pilot screw.
Check the pilot screw for wear or damage.

＊
The pilot screw is factory pre-set and
should not be removed unless the
carburetor is overhauled.
Damage to the pilot screw is tightened
against the seat.
Wash Spring
Throttle Valve
THROTTLE VALVE/JET NEEDLE
INSPECTION
Check the throttle valve and jet needle for
scratches, wear or damage.
Jet Needle
CASTING ENRICHMENT
VALVE/ACCELERATING PUMP
DIAPHRAGM INSPECTION
Check the casting enrichment
valve/accelerating pump diaphragm for
damage and clogging.
If any abnormal condition is found, wash the
part clean. If damage or clogging is found,
replace the part with a new one.
5-19
FLOAT LEVEL INSPECTION

Check the float level after checking the float
valve, valve seat and float. (A)
Set the carburetor so that the float valve end
just contacts the float arm lip. Make sure the
float valve tip is securely in contact with the
valve seat.
Measure the float level with the float level
gauge.
Float level (A):
XCITING 500: 18.5 mm (0.74 in)
XCITING 250: 18 mm (0.72 in)
The float level cannot be adjusted.

Replace the float assembly if the float level
is out of specification.
Automatic Choke
AUTO-BYSTARTER INSPECTION
Disconnect the connector.
Remove the automatic choke cover.
Connect the positive (+) terminal of a 12 V

battery to Black/White lead and the negative
(-) terminal to the Green/Black lead.
Check that the automatic choke section is
heated in 5 minutes after the battery has
been connected.
To inspect the function, check for change of
temperature from the cold condition.
＊
Do not attempt to disassemble the
automatic choke for the purpose of
checking temperature. Carburetor Heater
CARBURETOR HEATER INSPECTION

Disconnect the carburetor heater terminal
leads.
Carburetor Heater Terminal Leads
5-20
Carburetor Heater
Connect the positive (+) terminal of a 12 V
battery to the terminal of the carburetor
heater and the battery negative (-) terminal
to the terminal.
Check that the heater section is heated in 5
minutes after the battery has been connected.
REASSEMBLY
Carburetor reassembly can be performed in
the reverse order of disassembly. When
reassembling, carefully observe the
following instructions.
＊
● Assemble the parts taking
consideration of their function.
● Replace O-rings and seals with new
ones.
O-ring
Fit a new O-ring in to the float chamber

groove securely.
5-21
O-ring Small Convex

Assemble the accelerating pump diaphragm
and new O-ring.
＊ Install the accelerating pump diaphragm
with the small convex facing up.
O-ring
Assemble the coasting enrichment valve and
new O-ring.
Assemble the jet needle, spring retainer,

spring and throttle valve

Apply thermo-grease to the threads and
tighten the carburetor heater securely.
After cleaning, reinstall the pilot screw to

the original setting by turn the screw in until
it lightly seats, and then backing it out the
same number of turns counted during
disassembly.
＊ Replace the O-ring with a new one.

After the assembly and installation on the
engine have been completed, perform the
following adjustment.
Throttle cable adjustment (page 3-6)
Idle speed adjustment (page 3-18)
5-22
Fuel Filter Arrow Mark

FUEL FILTER/FUEL PUMP
FUEL FILTER INSPECTION
Visually check the fuel filter. If

accumulation of sediment or clogging is
found, replace the fuel filter with a new one.
Install the fuel filter with the arrow mark

facing forward.
Fuel Pump Coupler

FUEL PUMP INSPECTION (XCITING
500)
Measure resistance between the terminals of

fuel pump lead wire coupler.
If the measurement is out of specification
replace the fuel pump.
Fuel pump resistance: 1－2.5Ω
Fuel Pump
As shown in the right illustration, connect

the battery to the fuel pump and measure the
pump discharge amount per minute using
kerosene.
Battery (+) to Black/Red
Battery (-) to Green
Discharge amount per minute:
370 ml (12.6 US oz, 13 lmp oz)
If the measurement is less than the standard

value, replace the fuel pump with a new one.
＊ Do not use gasoline in this test as its is
highly combustible.
5-23
Fuel Pump Connector Fuel Hoses

FUEL PUMP
(XCITING 500)
Disconnect the fuel hoses.

Disconnect the fuel pump connector.
Remove the fuel pump and filter.
“Arrow” Mark Inlet Duct

removal.
＊ ● Install the fuel pump with the arrow
mark facing up.
● Connect the fuel inlet hose between the
inlet duct of the fuel pump and fuel
filter.
● Connect the fuel outlet hose between
the outlet duct of the fuel pump and
carburetor.
Outlet Duct
Nut Fuel Outlet Hose Vacuum Hose
FUEL PUMP
(XCITING 250)
Disconnect the fuel pump inlet, outlet and

vacuum hose from fuel pump.
Remove the nut and fuel pump.
Fuel Inlet Hose
5-24
Inlet Duct
removal.
＊ ● Connect the vacuum hose between the

vacuum duct of the fuel pump and inlet
pipe.
● Connect the fuel inlet hose between the
inlet duct of the fuel pump and fuel
filter.
● Connect the fuel outlet hose between
the outlet duct of the fuel pump and
carburetor. Vacuum Duct Outlet Duct
FUEL TANK
REMOVAL

Remove the inner cover (page 2-14).
Remove the fuel pump and fuel filter (page
5-24).
Remove the radiator (page 6-23).
Remove the front heat insulation cover.
Heat Insulation Cover
5-25
Disconnect the fuel unit connector. Fuel Unit Connector
Remove the four nuts from the fuel tank.
Nuts
Ground Wire Connector

Disconnect the ground wire connector.
Disconnect the fuel filler cap open cable.
Fuel Filler Cap Open Cable

Remove the two nuts and left floorboard set
holder from the frame.
Remove the AICV control solenoid valve
from the left floorboard set holder.
Nuts
5-26
Remove the fuel tank from the frame left

side.
Fuel Tank
Fuel Tank
Fuel Tank
INSTALLATION
removal.
5-27
6. COOLING SYSTEM XCITING 500/250
6
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
COOLING SYSTEM
__________________________________________________________________________________
SYSTEM FLOW PATTERN (XCITING 500) -------------------------- 6- 1 6

SYSTEM FLOW PATTERN (XCITING 250) -------------------------- 6- 2
COOLING SYSTEM TESTING------------------------------------------- 6- 7
COOLANT REPLACEMENT --------------------------------------------- 6- 7
THERMOSTAT-------------------------------------------------------------- 6-10
WATER PUMP -------------------------------------------------------------- 6-15
RADIATOR ------------------------------------------------------------------ 6-23
FAN MOTOR SWITCH ---------------------------------------------------- 6-26
WATER TEMPERATURE SENSOR ------------------------------------ 6-27
RAIDATOR RESERVE TANK ------------------------------------------- 6-29
6-0
SYSTEM FLOW PATTERN (XCITING 500)
6-1
SYSTEM FLOW PATTERN (XCITING 250)
6-2
SERVICE INFORMATION
WARING:
Removing the radiator cap while the engine is hot can allow the coolant to spray out,
seriously scalding you. Always let the engine and radiator cool down before removing the
radiator cap.
CAUTION:
Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.
• If any coolant gets in your eyes, rinse them with water and consult a physician immediately.
• If any coolant in swallowed, induce vomiting, gargle and consult a physician immediately.
• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.
NOTE:
Use coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of
radiator passages. Using tap water may cause engine damage.
• This section covers service of the cooling system.

• These services can be done with the engine installed in the frame.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the
system.
• All cooling system services can be done with the engine in the frame.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
6-3

ITEM SPECIFICATIONS (XCITING 500)
Coolant capacity Radiator and engine 2 liter (2.1 US qt, 1.76 lmp qt)
Reserve tank 0.37 liter (0.4 US qt, 0.33 lmp qt)
Radiator cap relief pressure 90 kPa (0.9 kgf/cm2, 12.8 psi)
Thermostat Begin to open 80 - 84°C (176 - 183°F)
Fully open 95°C (203°F)
Valve lift 8 mm (0.3 in) minimum
Standard coolant concentration 1:1 mixture with soft water

ITEM SPECIFICATIONS (XCITING 250)
Coolant capacity Radiator and engine 1 liter (1.1 US qt, 0.88 lmp qt)
Reserve tank 0.37 liter (0.4 US qt, 0.33 lmp qt)
Radiator cap relief pressure 90 kPa (0.9 kgf/cm2, 12.8 psi)
Thermostat Begin to open 80 - 82°C (176 - 180°F)
Fully open 90°C (198°F)
Valve lift 3.5 mm (0.14 in) minimum
Standard coolant concentration 1:1 mixture with soft water
6-4
COOLANT GRAVITY CHART

Temp. ℃
Coolant 0 5 10 15 20 25 30 35 40 45 50
concentration
5% 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.997
10% 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.005
15% 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20% 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25% 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30% 1.053 1.051 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032
35% 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40% 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45% 1.080 1.078 1.076 1.074 1.072 1.069 1.056 1.063 1.062 1.057 1.054
50% 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55% 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60% 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS)

Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water
-9℃ 20%
-15℃ 30% 425cc 975cc
-25℃ 40%
-37℃ 50%
-44.5℃ 55%
Cautions for Using Coolant:

• Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant
concentrate + 975cc distilled water is 30%.)
• Do not mix coolant concentrate of different brands.
• Do not drink the coolant which is poisonous.
• The freezing point of coolant mixture shall be 5℃lower than the freezing point of the riding
area.
6-5
TORQUE VALUES
Water pump cover bolt (XCITING 500) 13 N•m (1.3 kgf•m, 9 lbf•ft)
Water pump cover bolt (XCITING 250) 10 N•m (1 kgf•m, 7 lbf•ft)
Fan motor bolt 5 N•m (0.53 kgf•m, 3.8 lbf•ft)
Radiator shroud mounting nut 9 N•m (0.9 kgf•m, 6.5 lbf•ft)
Water pump impeller (XCITING 250) 12 N•m (1.2 kgf•m, 8.6 lbf•ft) (Left screw)
TROUBLESHOOTING
Engine temperature too high

• Faulty radiator cap
• Faulty temperature gauge or thermosensor
• Air in system
• Thermostat stuck closed
• Insufficient coolant
• Passages blocked in radiator, hoses or water jacket
• Faulty cooling fan motor
• Faulty fan motor switch
• Faulty water pump
Engine temperature too low

• Faulty temperature gauge or thermosensor
• Thermostat stuck open
• Faulty fan motor switch
Coolant leak
• Faulty water pump mechanical seal
• Deteriorated O-rings
• Faulty radiator cap
• Damaged or deteriorated cylinder head gasket
• Loose hose connection or clamp
• Damaged or deteriorated hoses
6-6
COOLING SYSTEM TESTING

RADIATOR CAP INSPECTION
Cap Tester
Remove the radiator cap (page 6-8).
Pressure test the radiator cap.

Replace the radiator cap if it does not hold
pressure, or if relief pressure is too high or
too low.
It must hold the specified pressure for at
least six seconds.
Radiator Cap
＊ Before installing the cap in the tester,
wet the sealing surface.
Radiator Cap Relief Pressure:

90 kPa (0.9 kg/cm², 12.8 psi)
Pressurize the radiator, engine and hoses, Cap Tester

and check for leaks.
＊ Excessive pressure can damage the
cooling system components.
Do not exceed 105 kPa (1.05 kg/cm²,
14.9 psi).
Repair or replace components if the system

will not hold the specified pressure for at
least six seconds.
COOLANT REPLACEMENT
PREPARATION
● The effectiveness of coolant decreases
with the accumulation of rest or if there is
a change in the mixing proportion during
usage. Therefore, for best performance
change the coolant regularly as specified
in he maintenance schedule.
● Mix only distilled, low mineral water
with the antifreeze.
Recommended mixture:
1:1 (Distilled water and antifreeze)
6-7
Radiator Cap
REPLACEMENT/AIR BLEEDING
＊ When filling the system or reserve tank
with coolant (checking the coolant
level), place the scooter in a vertical
position on a flat, level surface.
Remove the radiator cap.
Disconnect the water lower hose and drain

the coolant from the system.
＊ XCITING 250:
Remove the water drain bolt and drain
the coolant from the system (page 6-17).
Water Lower Hose
Reserve Tank Lid Screw
Remove the floor mat.

Remove the screw and reserve tank lid.
Floor Mat
6-8
Reserve Tank Cap

Remove the reserve tank cap and drain the
coolant from the reserve tank.
Reconnect the water lower hose securely.
Place the scooter on its center stand on a

flat, level surface.
Fill the reserve tank to the upper level line.
Upper Level Line
Filler Neck
Fill the system with the recommended
coolant through the filler opening up to the
filler neck.
6-9
Bleed air from the system as follow:

1. Start the engine and let it idle for 2−3
minutes.
2. Snap the throttle three to four times to
bleed air from the system.
3. Stop the engine and add coolant to the
proper level if necessary. Reinstall the
radiator cap.
4. Check the level of coolant in the reserve
tank and fill to the upper level if it is
low.
Nut
THERMOSTAT
REMOVAL (XCITING 500)

Remove the ignition coil (page 18-5).
Remove the nut and thermostat housing

stay from the frame.
Housing stay
Housing Stay Housing Cover

Remove the bolts, housing stay and
thermostat housing cover.
Bolts
6-10
Thermostat
Remove the O-ring from the housing cover.
Remove the thermostat.
O-ring
Thermostat
Bolt Air Bleed Hose Water Hose


Drain the coolant (page 6-17).
Disconnect the water temperature sensor

connectors from the sensor.
Disconnect the water hose from the
thermostat housing.
Disconnect the air bleed hose from the
thermostat housing.
Remove the mounting bolt and the
thermostat housing from the cylinder head.
Water Temperature Thermostat Housing
Sensor Connectors
6-11
Bolts
Remove the two bolts and thermostat
housing cover.
Thermostat Housing
Thermostat
Remove the thermostat from the thermostat
housing.
6-12
INSPECTION
Visually inspect the thermostat for damage.
Thermostat
Heat the water with an electric heating
element to operating temperature for five Thermometer
minutes.
Suspend the thermostat in heated water to
check its operation.
＊ ● Keep flammable materials away from
the electric heating element.
● Do not let the thermostat or
thermometer touch the pan, or you will
get false readings.
Replace the thermostat if the valve stays

open at room temperature, or if it respond at
temperatures other than those specified.
Thermostat begin to open:

XCITING 500: 80−84°C (176−183°F)
XCITING 250: 80−82°C (176−180°F)
Valve lift:
XCITING 500:
8 mm (0.3 in) minimum at 95°C (203°F)
XCITING 250:
3.5 mm (0.14 in) minimum at 90°C
(198°F)
6-13
Air Bleed Hole

INSTALLATION (XCITING 500)
Install the thermostat into the housing with

its air bleed hole facing up and aligning
bleed hole with the tab in the housing.
Tab Align
Install a new O-ring into the housing cover

groove.
Install the housing cover and housing stay

to the housing.
Tighten the bolts securely.
Install the housing stay to the frame.

Tighten the nut securely.
Fill the system with recommended coolant

and bleed the air (page 6-8).
O-ring
O-ring
The installation sequence is the reverse of

removal.
＊ Replace the O-ring with a new one and
apply grease to it.
Water Temperature Sensor
6-14
WATER PUMP
MECHANICAL SEAL INSPECTION XCITING 500

Inspect the telltale hole for sign of coolant
leakage.
If there is leakage, the mechanical seal is
defective, and water pump should be
replaced
Telltale Hole
XCITING 250
Water Pump Telltale Hole
REMOVAL (XCITING 500) Water Hoses

Remove the exhaust muffler (page 2-16)
Loosen the hose bands and disconnect the

water hoses and bypass hose from the water
pump.
Bypass Hose Bolts
6-15
Water Pump Cover

Remove the bolts and water pump cover.
Bolts
Water Pump Cover

Remove the O-ring from the water pump
cover.
O-ring
Water Pump Body

Remove the water pump body from the
crankcase.
6-16
Align
Apply engine oil to a new O-ring and install
it onto the stepped portion of the water
pump.
Install the water pump into the crankcase

while aligning the water pump shaft groove
with oil pump shaft end.
O-ring
Align the mounting bolt holes in the water

pump and crankcase and make sure the
water pump is securely installed.
Install a new O-ring into the groove in the

water pump cover.
Install the water pump cover and tighten the

bolts to the specified toque.
Connect the water hoses and bypass hose,

then tighten the hose bands.
Fill the system with recommended coolant

and bleed the air (page 6-8).
Bolts Band Screw

Remove the drain bolt to drain coolant.
Loosen the hose band screw and disconnect

the water hoses from the water pump.
Remove the four bolts and the water pump

cover, gasket and 2 dowel pins.
Drain Bolt Water Pump Cover
6-17
Remove the water pump impeller. Impeller (Left Hand Threads)

＊ The impeller has left hand threads.
Inspect the mechanical (water) seal and seal Mechanical Seal

washer for wear or damage.
＊ The mechanical seal and seal washer
must be replace as a set.
Impeller Seal Washer (Porcelain)
Disconnect the water hose from the right

crankcase cover. Bolts
Remove the eight bolts attaching the right
crankcase cover.
Water Pump Assembly
6-18
Water Pump Assembly Inner Bearing

Remove the water pump bearing snap ring
from the water pump assembly.
Remove the water pump shaft and inner
bearing.
Snap Ring Water Pump Shaft
Remove the water pump shaft outer

bearing.
Inner Bearing
Water Pump Assembly

Drive the mechanical seal out of the water
pump assembly from the inside.
Mechanical Seal (Water Seal)
6-19
Mechanical Seal Driver

Drive in a new mechanical seal using a
mechanical seal driver.
＊ Apply sealant to the right crankcase
cover fitting surface of a new mechanical
seal and then drive in the mechanical
seal.
Outer Bearing
Drive a new water pump shaft outer bearing
into the water pump assembly from the
inside.
Water Pump Assembly
Install the water pump shaft and shaft inner Snap Ring Water Pump Shaft
bearing into the waster pump assembly.
Install the snap ring to secure the inner
bearing properly.
Inner Bearing
6-20
Install the dowel pins and a new gasket and Bolts

then install the water pump assembly to the
right crankcase cover.
Tighten the eight bolts to secure the right
crankcase cover.
＊ When installing the water pump
assembly, aligning the groove on the
water pump shaft with the tab on the oil
pump shaft.
Water Pump Assembly
Mechanical Seal
When the mechanical seal is replaced, a
new seal washer must be installed to the
impeller.
Impeller Seal Washer (Porcelain)
Install the impeller onto the water pump Impeller (Left Hand Threads)
shaft.
Torque:
12 N•m (1.2 kgf•m, 8.6 lbf•ft) (Left
screw)
＊ The impeller has left hand threads.
6-21
Dowel Pins
Install the two dowel pins and a new gasket.
Water Pump Cover

Install the water pump cover and tighten the
4 bolts.
Bolt
6-22
RADIATOR
REMOVAL
Remove the front lower cover (page 2-15)
Disconnect the fan motor connector.
Fan Motor Connector
Loosen the hose band and disconnect the

radiator lower hose from the radiator.
Lower Hose
Filler Hose
coolant filler hose from the radiator.
6-23
Fan Motor Switch Connectors

Disconnect the fan motor switch
connectors.
Disconnect the air bleed hose.
Air Bleed Hose
Remove the four nuts and radiator from the

frame.
＊ Be careful not to damage the radiator
core.
Nuts
Upper Hose
radiator upper hose from the radiator.
6-24
DISSASSEMBLY
Remove the four bolts and fan
motor/shroud assembly.
Bolts
Check the fan motor to operate using an

available battery.
Fan Motor Wire

ASSEMBLY
Install the fan motor/shroud assembly to the
radiator with the fan motor wire facing up.
Install and tighten the bolts securely.
6-25
FAN MOTOR SWITCH

REMOVAL
Disconnect the fan motor switch connector
(page 6-24).
Remove the fan motor switch.
Fan Motor Switch
INSPECTION
Place the fan motor switch in oil contained
in a pan as shown and raise the oil
temperature gradually to check for the
temperature at which the switch starts to
operate.
If the switch operating temperature is not
within the specified range, replace the
switch with a new one.
OFF→ON Over 88−92°C
ON→OFF Lower 88−92°C
＊ ● Handle the cooling fan motor switch
carefully as it is vulnerable to impact.
● Do not allow the cooling fan motor
switch Îand the thermometer Ïto
come in contact with the bottom of the
pan.
O-ring
INSTALLATION
Fit the O-ring.
Tighten the cooling fan motor switch to
specified torque.
＊ ● Replace the O-ring a new one.
● Do not coat grease to the O-ring.
6-26
Water joint
WATER TEMPERATURE
SENSOR

Remove the side body cover (page 2-8)

connector.
Remove the water temperature sensor from
the water joint.


connectors.
Remove the water temperature sensor from
the thermostat housing.
Water Temperature Thermostat Housing

Sensor Connectors
6-27
INSPECTION
Connect the water temperature sensor to the Water Temperature Sensor
ohmmeter and dip it in oil contained in a
pan which is placed on an electric heater.
Gradually raise oil temperature while
reading the thermometer in the pan and the
ohmmeter connected. If the resistance
measured is out of specification, replace the
temperature gauge with a new one.
Temperature Standard resistance Thermometer
50℃ 140–310Ω
115℃ 24.1–28.2Ω
＊ ● Handle the water temperature sensor

carefully as it is vulnerable to impact.
● Do not allow the water temperature
sensor and the thermometer to come in
contact with the bottom of the pan.
After the water temperature sensor has been

installed, fill coolant and perform air
bleeding (page 6-8).
INSTALLATION
With thread lock applied to the threaded
part, tighten the water temperature sensor.
Torque: 8 N•m (0.8 kgf•m, 5.8 lbf•ft)
6-28
RADIATOR RESERVE TANK

REMOVAL
Remove the two nuts and radiator reserve

tank from the frame.
Nuts
Open the reserve tank cap and drain the

coolant from the reserve tank.
Disconnect the siphon hose.
INSTALLATION
removal.
Pour the recommended coolant to the upper

level line with the center stand applied
Siphon Hose
6-29
7. ENGINE REMOVAL/INSTALLATION XCITING 500/250
7
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ENGINE REMOVAL/INSTALLATION
__________________________________________________________________________________
ENGINE REMOVAL (XCITING 500) ----------------------------------- 7- 2
ENGINE REMOVAL (XCITING 250) ----------------------------------- 7-11
ENGINE HANGER --------------------------------------------------------- 7-16 7
7-0
SERVICE INFORMATION
• During engine removal and installation, support the scooter on its main stand.
• Support the frame using a jack or other adjustable support to ease of engine hanger bolt removal.
• The following components require engine removal for serviced with the engine installed in the
frame.
ä Oil pump (Section 4)
ä Water pump (Section 6)
ä Cylinder head (Section 8)
ä Cylinder/Piston (Section 9)
ä Drive and driven pulleys/clutch (Section 10)
ä Final reduction (Section 11)
ä Alternator/Starter clutch (Section 12)
• The following components require engine removal for service.
ä Crankshaft/Crankcase/Balancer (Section 13)
SPECIFICATIONS
ITEM SPECIFICATIONS
XCITING 500 66 kg (145.2 lbs)
Engine dry weight
XCITING 250 37.5 kg (82.5 lbs)
XCITING 500 2 liter (2.1 US qt, 1.8 lmp qt)
At draining
XCITING 250 0.9 liter (0.95 US qt, 0.8 lmp qt)
Engine oil XCITING 500 2.5 liter (2.7 US qt, 2.2 lmp qt)
capacity At disassembly
XCITING 250 1.1 liter (0.97 US qt, 1.17 lmp qt)
At oil filter cartridge change (XCITING 500) 2.1 liter (2.2 US qt, 1.9 lmp qt)
TORQURE VALUES
Engine mounting bolt/nut (XCITING 500) 80 N•m (8 kgf•m, 58 lbf•ft)

Engine mounting bolt/nut (XCITING 250) 50 N•m (5 kgf•m, 36 lbf•ft)
Rear shock absorber lower mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Rear/parking brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
ALOCK bolt: replace with a new one
Engine hanger mounting bolt 50 N•m (5 kgf•m, 36 lbf•ft)
Engine hanger rod nut 35 N•m (3.5 kgf•m, 25 lbf•ft)
7-1
ENGINE REMOVAL (XCITING

500)
Remove the following:
Luggage box (page 2-3)
Floorboard (page 2-6)
Rear fender (page 2-7)
Side/rear body cover (page 2-8)
Exhaust muffler (page 2-16)
Support the scooter on its main stand.
Air Cleaner Clamp Screw

Fuel Hose
Disconnect the fuel hose from the carburetor.
7-2
Disconnect the water temperature sensor AICV air Supply Hose

connector.
Disconnect AICV air supply hose from the
AICV check valve.
Water Temperature Sensor Connector
Crankcase Breather Hose

Disconnect the spark plug cap from the
cylinder head.
Disconnect the crankcase breather hose form
the cylinder head cover.
Spark Plug Cap
Rubber Cap
Release the rubber cap and remove the
terminal nut to disconnect the starter motor
cable.
Nut
7-3
Air Bleed Hose

Disconnect the air bleed hose and water hose
from the water joint.
Water Hose
Outer Water Hose

Disconnect the outer water hose from the oil
cooler.
Alternator Connectors
Loosen the wire bands and disconnect the
alternator connectors.
7-4
Engine Ground Cable

Remove the bolt and engine ground cable.
.
Bolt
Bypass Hose
Loosen the hose bands and disconnect the
bypass hose and water hose
Water Hose
Oil Pressure Switch

Disconnect the oil pressure switch connector.
Oil Pressure Switch Connector
7-5
Bolts
Remove the bolts and rear/parking brake
caliper.
Remove the brake hose from clamps.
Disconnect the transmission case breather

hose from transmission case.
Transmission Case Breather Hose
Bolts
Remove the bolts and air cleaner.
7-6
Remove the rear cushion lower mount bolts
Lower Mount Bolts
Nut
Remove the engine mount nut.
Bolt
Turn the engine mount bolt counterclockwise
and loosen it.
Pull out the engine mount bolt then removes
the engine from the frame.
7-7
＊ At removing the engine, be careful not to

catch your hand or finger between the
engine hanger and crankcase.
7-8
Remove the collar.
Collar
7-9
Long Engine Collar

Pull out the long engine collar.
INSTALLATION
＊ ● At installing the engine, be careful not
to catch your hand or finger between
the engine hanger and crankcase.
● Check for leakage of the engine oil and
engine coolant.
Torque:
Engine mounting bolt/nut:
80 N•m (8 kgf•m, 58 lbf•ft)
Route the brake hoses and wires properly

(page 1-15).
7-10
Crankcase Breather Hose

ENGINE REMOVAL (XCITING
250)
Remove the following:
Luggage box (page 2-3)
Floorboard (page 2-6)
Rear fender (page 2-7)
Side/rear body cover (page 2-8)
Exhaust muffler (page 2-16)
Carburetor (page 5-6)
Support the scooter on its main stand.

AICV Air Supply Hose
Disconnect the crankcase breather and AICV
air supply hoses from the cylinder head
cover. Fuel Pump Vacuum Hose
Disconnect the fuel pump and AICV vacuum

hoses from the inlet pipe.
AICV Vacuum Hose

Air Cleaner
Remove the two air cleaner mounting bolts

and disconnect the transmission case breather
hose from air cleaner case, then remove the
air cleaner.
Bolts Transmission Case Breather Hose
7-11
Rubber Cap Start Motor

Remove the bolt and thermostat housing.
Release the rubber cap and remove the

terminal nut to disconnect the starter motor
cable.
Thermostat Housing Bolt Nut
Disconnect the alternator connectors.
Alternator Connectors
Engine Ground Cable Water Hose

Remove the bolt and disconnect the engine
ground cable from the right crankcase cover.
Loosen the band screw and disconnect the

water hose from the water pump.
Bolt Screw
7-12
Bolts Bolts/Bands
Remove the two rear brake caliper mounting
bolts and three rear brake hose bands/bolts
from rear fork, then remove the rear brake
caliper.
Bolt/Band Rear Brake Caliper
Oil Pressure Switch Connector
Disconnect the oil pressure switch connector .
Remove the spark plug cap.
Spark Plug Cap
Remove the rear cushion lower mounting

bolts.
Bolts
7-13
Remove the nut.

Pull out the engine mounting bolt, then
removes the engine from the frame.
Nut Bolt
＊ At removing the engine, be careful not to

catch your hand or finger between the
engine hanger and crankcase.
INSTALLATION
＊ ● At installing the engine, be careful not
to catch your hand or finger between
the engine hanger and crankcase.
● Check for leakage of the engine oil and
engine coolant.
Torque:
Engine mounting bolt/nut:
Route the brake hoses and wires properly

(page 1-25).
7-14
INSPECTION
Inspect the bearing (XCITING 500):
Bearings allow play in the right/left crankcase
or the bearing turns roughly → Replace.
Bearing
O-rings
Inspect the bushes (XCITING 250):

Bushes allow play in the right/left crankcase
or the wear/damage → Replace.
Inspect the inner collars (XCITING 250):

Wear/Damage → Replace.
Replace the new O-rings and apply grease to

the inner collars outside when the inner
collars are installation.
Bush Inner Collar Bush
Inspect the engine mount bolt:

Band/Damage → Replace
＊ Do not attempt to straighten a bent
engine mount bolt.
7-15
Bolts
ENGINE HANGER
REMOVAL
Loosen and remove the engine mount nut
(page 7-7).
Loosen and remove the engine mount bolt
(page 7-7).
Remove the engine hanger mount bolts.

Remove the outer collars (XCITING 500).
Outer Collars (XCITING 500)
Inner Collars
Remove the engine hanger
Remove the inner collars.
Nut Washers
Remove the nut, washers, rubber washers and
engine hanger rod.
INSTALLATION
Torque:
Engine hanger mounting bolt:
Engine hanger rod nut:
35 N•m (3.5 kgf•m, 25 lbf•ft) Rubber Washers Engine Hanger rod
7-16
INSPECTION Outer/Inner Bearings

Inspect the bearings in the engine hanger
(XCITING 500):
Bearings allow play in the engine hanger or
the bearing turns roughly → Replace.
Inspect the bushes in the engine hanger

(XCITING 250):
Bushes
Bush
Inspect the bush in the engine hanger rod:

7-17
8. CYLINDER HEAD/VALVES XCITING 500/250
8.
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CYLINDER HEAD/VALVES
__________________________________________________________________________________
SCHEMATIC DRAWING (XCITING 500) ----------------------------- 8- 1

CYLINDER COMPRESSION TEST ------------------------------------- 8- 6
CYLINDER HEAD COVER (XCITING 500)--------------------------- 8- 7
CYLINDER HEAD COVER (XCITING 250)--------------------------- 8- 8 8
CAMSHAFT (XCITING 500) --------------------------------------------- 8- 9
CAMSHAFT (XCITING 250) --------------------------------------------- 8-14
ROCKER ARMS (XCITING 500) ---------------------------------------- 8-17
ROCKER ARMS (XCITING 250) ---------------------------------------- 8-18
CYLINDER HEAD---------------------------------------------------------- 8-19
8-0
SCHEMATIC DRAWING (XCITING 500)
8-1
8-2
SERVICE INFORMATION
• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator
and water jacket must be drained first.
• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable
parts and valve arm sliding surfaces for initial lubrication.
• The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages.
Clean and unclog the oil passages before assembling the cylinder head.
• After disassembly, clean the removed parts and dry them with compressed air before inspection.
• After removal, mark and arrange the removed parts in order. When assembling, install them in
the reverse order of removal.

Item Standard Service Limit
IN 0.1 mm (0.004 in) ⎯
Valve clearance (cold)
EX 0.1 mm (0.004 in) ⎯
Cylinder head compression pressure 13 kg/cm2 (185 psi, 1300 kPa) ⎯
Cylinder head warpage ⎯ 0.05 (0.002)
IN 37.2614 (1.4905) 37.11 (1.4844)
Camshaft cam height
EX 37.0084 (1.4803) 36.86 (1.4744)
IN 10 (0.4)～10.015 (0.4006) 10.1 (0.404)
Valve rocker arm I.D.
EX 10 (0.4)～10.015 (0.4006) 10.1 (0.404)
Valve rocker arm shaft IN 9.975 (0.399)～9.99 (0.3996) 9.9 (0.396)
O.D. EX 9.975 (0.399)～9.99 (0.3996) 9.9 (0.396)
IN 4.975 (0.199)～4.99 (0.1996) 4.925 (0.197)
Valve stem O.D.
EX 4.955 (0.1982)～4.97 (0.1988) 4.915 (0.1966)
IN 5 (0.2)～5.015 (0.2006) 5.03 (0.2012)
Valve guide I.D.
EX 5 (0.2)～5.015 (0.2006) 5.03 (0.2012)
Valve stem-to-guide IN 0.01 (0.004)～0.037 (0.0015) 0.08 (0.0032)
clearance EX 0.03 (0.0012)～0.057 (0.0023) 0.1 (0.004)
8-3

IN 0.1 mm (0.004 in) ⎯
Valve clearance (cold)
EX 0.1 mm (0.004 in) ⎯
Cylinder head compression pressure 15 kg/cm2 (213 psi, 1500 kPa) ⎯
Cylinder head warpage ⎯ 0.05 (0.002)
IN 34.2987 (1.371948) 34.14 (1.3656)
Camshaft cam height
EX 34.1721 (1.366884) 34.02 (1.3608)
IN 10 (0.4)～10.015 (0.4006) 10.1 (0.404)
Valve rocker arm I.D.
EX 10 (0.4)～10.015 (0.4006) 10.1 (0.404)
Valve rocker arm shaft IN 9.972 (0.399)～9.987 (0.3995) 9.9 (0.396)
O.D. EX 9.972 (0.399)～9.987 (0.3995) 9.9 (0.396)
IN 4.975 (0.199)～4.99 (0.1996) 4.925 (0.197)
Valve stem O.D.
EX 4.955 (0.1982)～4.97 (0.1988) 4.915 (0.1966)
IN 5 (0.2)～5.012 (0.2005) 5.03 (0.2012)
Valve guide I.D.
EX 5 (0.2)～5.012 (0.2005) 5.03 (0.2012)
Valve stem-to-guide IN 0.01 (0.004)～0.037 (0.0015) 0.08 (0.0032)
clearance EX 0.03 (0.0012)～0.057 (0.0023) 0.1 (0.004)

Cylinder head bolt (13) 13 N•m (1.3 kgf•m, 9 lbf•ft) Apply engine oil to threads
Cylinder head bolt (1 – 4) 48 N•m (4.8 kgf•m, 35 lbf•ft) Apply engine oil to threads
Cylinder head bolt (5 – 12) 23 N•m (2.3 kgf•m, 17 lbf•ft) Apply engine oil to threads
Cylinder head cover bolt 10 N•m (1 kgf•m, 7 lbf•ft)
Cylinder head cover bolt 10 N•m (1 kgf•m, 7 lbf•ft)
Breather separator bolt 13 N•m (1.3 kgf•m, 9 lbf•ft)
Cam chain tensioner bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Tensioner pivot bolt 10 N•m (1 kgf•m, 7 lbf•ft)
Rocker arm shaft 45 N•m (4.5 kgf•m, 32 lbf•ft)

Cylinder head cap nut 25 N•m (2.5 kgf•m, 18 lbf•ft) Apply engine oil to threads
Valve clearance adjusting nut 9 N•m (0.9 kgf•m, 6.5 lbf•ft) Apply engine oil to threads
Cylinder head cover bolt 12 N•m (1.2 kgf•m, 8.6 lbf•ft)
SPECIAL TOOLS
Valve spring compressor E040
8-4
TROUBLESHOOTING
• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine
top-end noises.
Poor performance at idle speed White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide
• Damaged valve stem oil seal
Compression too low
• Incorrect valve clearance adjustment Abnormal noise
• Burned or bend valves • Incorrect valve clearance adjustment
• Incorrect valve timing • Sticking valve or broken valve spring
• Broken valve spring • Damaged or worn camshaft
• Poor valve and seat contact • Worn cam chain tensioner
• Leaking cylinder head gasket • Worn camshaft and rocker arm
• Warped or cracked cylinder head
• Poorly installed spark plug
Compression too high

• Excessive carbon build-up in combustion
chamber
8-5
CYLINDER COMPRESSION TEST

Warm up the engine to normal operating
temperature.
Stop the engine and remove the spark plug
cap and remove the spark plug (page 3-10).
Park Plug Cap
Compression Gauge
Install a compression gauge into the spark
plug hole.
Open the throttle all the way and crank the

engine with the starter motor until the gauge
reading stops rising.
The maximum reading is usually reached 4 –
7 seconds.
＊ To avoid discharging the battery, do not
operate the starter motor for more than
seven seconds.
Compression pressure:
XCITING 500:
13 kg/cm2 (185 psi, 1300 kPa)
XCITING 250:
15 kg/cm2 (213 psi, 1500 kPa)
Low compression can be caused by:

Blown cylinder head gasket
Improper valve adjustment
Valve leakage
Worn piston ring or cylinder
High compression can be caused by:

Carbon deposits in combustion chamber or
on piston head
8-6
Bolts
CYLINDER HEAD COVER
(XCITING 500)
DISASSEMBLY
Remove the spark plug caps (page 8-6)
Disconnect the crankcase breather hose from
the cylinder head cover (page 7-3).
Remove the four bolts and cylinder head

cover.
Cylinder Head Cover
Cylinder Head Cover Packing

Remove the cylinder head cover packing.
Bolts
Remove the bolts and breather separator.
8-7
Gasket
Remove the gasket.
ASSEMBLY
Assembly is in the reverse order of
disassembly.
Torque:
Breather separator bolt:
13 N•m (1.3 kgf•m, 9 lbf•ft)
Cylinder Head Cover Bolts

CYLINDER HEAD COVER
(XCITING 250)
DISASSEMBLY
Disconnect the crankcase breather hose from
the cylinder head cover (page 7-11).
Remove the four bolts and two nuts, then

remove cylinder head cover.
Nuts Crankcase Breather Hose
Remove the cylinder head cover O-ring.
O-ring
8-8
Bolt Washer
CAMSHAFT (XCITING 500)
REMOVAL
“T” mark on the flywheel with the index
mark on the right crankcase cover (page 3-
12).
Remove the cam chain tensioner lifter sealing

bolt, spring and sealing washer.
Spring
Cam Chain Tensioner/Gasket

Remove the two bolts, cam chain tensioner
and gasket.
Bolts
Bolts
Remove the two bolts and cam chain guide.
Cam Chain Guide
8-9
Camshaft Holders Bolts

Loosen and remove the twelve camshaft
holder bolts in a crisscross pattern in several
steps, then remove the camshaft holders.
＊ Suspend the cam chain with a piece of
wire to prevent the chain from falling
into the crankcase.
Camshafts
Remove the camshafts.
Refer to the page 8-28 to install the

camshafts.
8-10
INSPECTION
Cam chain guide
Inspect the am chain slipper surface of the
cam chain guide for wear or damage.
Camshaft Holder
Camshaft holder
＊ Always replace the camshaft holder and

cylinder head in pairs
Inspect the bearing surface of each camshaft

holder for scoring, scratches, or evidence of
insufficient lubrication.
Stop Pin
Check the stop pin spring on the exhaust
camshaft holder for damage.
Replace the stop pin assembly with a new one
if the spring is damage.
8-11
Camshaft
Support both ends of the camshaft with V-
blocks and check the camshaft runout with a
dial gauge.
Inspect camshaft lobes for

pitting/scratches/blue discoloration.
Measure the cam lobe height.

Service Limits: IN : 37.11 mm (1.4844 in)
EX: 36.86 mm (1.4744 in)
If any defects are found, replace the camshaft

with a new one, then inspect lubrication
system.
Check the decompression system by turning

the decompressor cam on the exhaust
camshaft.
You should be able to turn the decompressor
cam clockwise smoothly, but the
decompressor should not turn
counterclockwise.
8-12
Cam chain tensioner

Check the one-way cam operation (tensioner)
Unsmooth operation → Replace.
8-13
CAMSHAFT (XCITING 250)
REMOVAL
Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the
index mark on the right crankcase cover
(page 3-13).
Hold the round hole on the camshaft gear
facing up and the location is the top dead
center on the compression stroke.
Remove the cam chain tensioner lifter sealing
bolt. Cam Chain Tensioner Round Hole
Tensioner Screw
Turn the cam chain tensioner screw
clockwise to pull the tensioner rod all the way
in.
Camshaft Holder
Remove the four cap nuts attaching the

camshaft holder.
＊ • Diagonally loosen the cylinder head
cap nuts in 2 or 3 times.
Cap Nuts
8-14
Camshaft Holder/Dowel Pins

Remove the camshaft holder and dowel pins.
Remove the camshaft gear from the cam Cam Chain

chain to remove the camshaft.
Camshaft Gear
8-15
INSPECTION
Camshaft
Check each cam lobe for wear or damage.
Measure the cam lobe height.
Service Limits: IN : 34.14 mm (1.3656 in)
EX: 34.02 mm (1.3608 in)
Camshaft Bearings
Check each camshaft bearing for play or
damage. Replace the camshaft assembly with
a new one if the bearings are noisy or have
excessive play.
8-16
Rocker Arms
ROCKER ARMS (XCITING 500)
REMOVAL
Remove the camshaft (page 8-9).
Remove the rocker arm shafts and washers,

then remove the rocker arms.
Refer to page 8-27 to install the rocker arms.

Rocker Arm Shafts/Washers
Rocker Arm Shaft

INSPECTION
Rocker arm shaft
Inspect the rocker arm shaft for blue
discoloration or grooves.
If any defects are found, replace the rocker
arm shaft with a new one, then inspect
lubrication system.
Measure each rocker arm shaft O.D.

Measure the I.D. of each rocker arm.
Measure arm to shaft clearance.
Replace as a set if out of specification.
Service limits: 0.1 mm (0.004 in)
Rock Arm
Inspect the rocker arm bore, cam lobe contact
surface and adjuster surface for
wear/pitting/scratches/blue discoloration.
lubrication system.

8-17
Valve Rocker Arms

ROCKER ARMS (XCITING 250)
REMOVAL
Remove the camshaft (page 8-14).
Remove the rocker arm shafts and then

remove the rocker arms.
Rocker Arm Shafts

INSPECTION
Camshaft holder
Inspect the bearing surface of camshaft Camshaft Holder
holder for scoring, scratches, or evidence of
insufficient lubrication.
Rocker arm shaft

Inspect the rocker arm shaft for blue
discoloration or grooves.
lubrication system.
Rocker Arm Shafts
Inspect the rocker arm bore, cam lobe contact

surface and adjuster surface for
wear/pitting/scratches/blue discoloration.
lubrication system.

8-18
Intake Pipe/Insulator
CYLINDER HEAD

＊ Always replace the camshaft holder and
cylinder head in pairs
Remove the rock arms (page 8-17).
Remove the two bolts, intake pipe and

insulator.
Bolts
Remove the two bolts, two nuts, pair reed Pair Reed Valve Gasket
valve and gasket.
Nuts
Bolts
Remove the two bolts, water joint, gasket and
water stop collar.
Water Joint/Gasket/Water Stop Collar
8-19
Cylinder Head
Remove the three bolts and cylinder head.
Bolts
Dowel Pins
Remove the dowel pins and cylinder head
gasket.
Gasket
8-20

First drain the coolant from the radiator and
water jacket, then remove the thermostat
water hose.
Remove the camshaft. (page 8-14).
Remove the carburetor and intake pipe.
Remove the two cylinder bolts.
Cylinder Bolts
Remove the bolt attaching the thermostat

housing and the thermostat housing.
Remove the cylinder head.
Bolt
Cylinder Head Gasket

Remove the dowel pins and cylinder head
gasket.
Remove the cam chain guide.
Remove all gasket material from the cylinder
head mating surface.
＊ Be careful not to drop any gasket
material into the engine.
Cylinder Cam Chain Tensioner Slipper
8-21
Valve Spring Compressor

CYLINDER HEAD DISASSEMBLY
Remove the valve spring cotters, retainers,

springs, spring seats, oil seals and valves
using a valve spring compressor.
＊ • Be sure to compress the valve springs
with a valve spring compressor.
• Mark all disassembled parts to ensure
correct reassembly.
Special tool:
Valve Spring Compressor E040
Valve Spring Cotters Retainers Valves
Springs Spring Seats Oil Seals
8-22
VALVE /VALVE GUIDE INSPECTION

Inspect each valve for bending, burning,
scratches or abnormal stem wear.
If any defects are found, replace the valve
with a new one.
Check valve movement in the guide.

Measure each valve stem O.D.
Measure each valve guide I.D.
Subtract each valve stem O.D. from the
corresponding guide I.D. to obtain the stem-
to-guide clearance.
Service limits:
IN: 0.08 mm (0.0032 in)
EX: 0.1 mm (0.004 in)
＊ If the stem-to-guide clearance exceeds
the service limits, replace the cylinder
head is necessary.
CYLINDER HEAD INPECTION

Check the spark plug hole and valve areas for
cracks.
Check the cylinder head for warpage with a

straight edge and feeler gauge.
Service Limit: 0.05 mm (0.002 in)
VALVE SPRING INSPECTION

Measure the free length of the inner and outer
valve springs.
Service Limit:
XCITING 500: Inner: 33.4 mm (1.336 in)
Outer: 38 mm (1.52 in)
XCITING 250: Inner: 29.1 mm (1.164 in)
Outer: 39.2 mm (1.568 in)
8-23
Measure compressed force (valve spring) and

installed length.
Replace if out of specification.
Standard (XCITING 500):

Inner: 3.5 kg (at 28.7 mm, 1.148 in)
Outer: 13 kg (at 31.43 mm, 1.2572 in)

Inner: 2.95 kg (at 26.6 mm, 1.064 in)
Outer: 10.45 kg (at 29.6 mm, 1.184 in)
Measure the spring tilt.

Replace if out of specification.

Inner: 1.2 mm (0.048)
Outer: 1.2 mm (0.048)

Inner: 0.81 mm (0.0324 in)
Outer: 1.07 mm (0.0428 in)
ASSEMBLY
Install the valve spring seats and oil seal.
Valve Spring Compressor
＊ Be sure to install new oil seal.
Lubricate each valve with engine oil and

insert the valves into the valve guides.
Install the valve springs and retainers.
Compress the valve springs using the valve
spring compressor, then install the valve
cotters.
＊ • When assembling, a valve spring

compressor must be used.
• Install the cotters with the pointed ends
facing down from the upper side of the
cylinder head.
Special tool:
Valve Spring Compressor E040
8-24
Tap the valve stems gently with a plastic

hammer for 2～3 times to firmly seat the
cotters.
＊ Be careful not to damage the valves.
Dowel Pins
Install the dowel pins and new cylinder head
gasket as shown.
Gasket
Cylinder Bolts Cylinder Head

Install the cylinder head.
Apply engine oil to the cylinder head bolt (9)

threads.
Install the two cylinder bolts and cylinder
head bolt (9) but do not tighten them.
Cylinder Head Bolt (9)
8-25
Bolts Water Stop Collar Gasket

Install the water stop collar, gasket and water
joint.
Install and tighten the two bolts to the
specified torque.
Water Joint
. Pair Reed Valve Gasket

Install gasket and pair reed valve.
Install and tighten the four bolts securely.
Bolts
O-ring O-ring
Install the new O-rings onto the insulator and
intake pipe.
8-26
Insulator
Install the insulator with the O-ring face the
cylinder head.
O-ring
Intake Pipe
Install the intake pipe and tighten the two
bolts securely.
Bolts
Rocker Arm Washer

ROCKER ARM INSTALLATION
(XCITING 500)
Apply engine oil to the rocker arms and
rocker arm shafts
Install the rocker arms, rocker arm shafts and

washers.
Tighten the rocker arm shaft to the specified
torque.

Rocker Arm Shaft
8-27
CAMSHAFT INSTALLATION
(XCITING 500)
Turn the crankshaft clockwise, align the “T”
mark on the flywheel with the index mark on
the right crankcase cover (page 3-12).
Apply molybdenum disulfide oil to the

camshaft journals of the camshaft holder.
Apply molybdenum disulfide oil to the

camshaft journals of the cylinder head.
Punch Marks
Install the cam chain over the cam sprockets
and then install the intake and exhaust
camshafts.
＊ Install each camshafts to the correct
locations.
“IN”: no decompressor cam
“EX”: has a decompressor cam (page 8-
12)
Make sure the timing marks on the cam
sprockets are flush with the cylinder Timing Marks
head upper surface and punch marks
face upward as shown.
8-28
Install intake and exhaust camshaft holders to

the correct locations.
＊
Install each camshaft holders to the
correct locations.
“IN”: no stop pin.
“EX”: has a stop pin.
Apply engine oil to cylinder head bolt (No.
1 – 9) threads.
Install and tighten the holder bolts (No. 1 – 9)

in a crisscross pattern in four steps to the Stop Pin Exhaust Camshaft Holder
specified torque as follow diagram.
Tighten the bolts to the specified torque in sequence

N•m (kgf•m, lbf•ft)
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Step 1 18 (1.8, 13) ← ← ← 12 (1.2, 9) ← ← ← ←
Step 2 48 (4.8, 35) ← ← ← 23 (2.3, 17) ← ← ← ←
8-29
Install the common camshaft holder by arrow

mark facing outside.
Install and tighten the holder bolts (No. 10 –

13) in a crisscross pattern in four steps to the ＊
specified torque as follow diagram. Apply engine oil to cylinder head bolt
(No. 10 – 13) threads.
Tighten the bolts to the specified torque in sequence

N•m (kgf•m, lbf•ft)
(10) (11) (12) (13)
Step 1 12 (1.2, 9) ← ← ←
Step 2 23 (2.3, 17) ← ← ←
“Arrow” Mark
Tighten the two cylinder bolts to the specified

torque.
Cylinder Bolts
8-30
Bolts
Install the cam chain guide and tighten the
two bolts securely.
Cam Chain Guide
Release the timing chain tensioner one-way

cam and push the tensioner rod all the way in.
Install the tensioner with a new gasket onto Cap Bolt Washer
the cylinder.
Install and tighten the tensioner bolts to
specified torque.
Install the spring, washer and timing chain

tensioner cap bolt to specified torqur.
Torque: 10 N•m (1 kgf•m, 9 lbf•ft) Spring Bolts
Adjust the valve clearance (page 3-12).
8-31
Cylinder Head Cover Packing

Install the cylinder head packing into the
groove of the cylinder head cover.
Install the cylinder head cover onto the

Bolts
cylinder head and tighten the cylinder head
cover bolts to the specified torque.
Cylinder Head Cover
8-32
Gasket
Install the cam chain guide.
Install the dowel pins and a new cylinder
head gasket.
Cam Chain Guide Dowel Pins
Cam Chain
Install the cylinder head and take out the cam
chain
Assemble the camshaft holder. Valve Rocker Arms

First install the intake and exhaust valve
rocker arms; then install the rocker arm shafts.
＊ • Install the exhaust valve rocker arm
shaft on the “EX” side of the camshaft
holder and the exhaust rocker arm shaft
is shorter.
• Clean the intake valve rocker arm shaft
off any grease before installation.
• Align the cutout on the exhaust valve
rocker arm shaft with the bolt of the
camshaft holder. Camshaft Holder
8-33
Punch Marks
Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the
index mark on the right crankcase cover.
Keep the round hole on the camshaft gear
facing up and align the punch marks on the
camshaft gear with the cylinder head surface
(Position the intake and exhaust cam lobes
down.) and install the cam chain over the
camshaft gear.
Round Hole Cam Chain

Install the dowel pins.
Dowel Pins
Camshaft Holder/Dowel Pins
Install the camshaft holder, washers and nuts
on the cylinder head.
Tighten the four cylinder head cap nuts and
two cylinder bolts to the specified torque.
Torque:
Cylinder head cap nut:
25 N•m (2.5 kgf•m, 18 lbf•ft)
Apply engine oil to threads
Cylinder bolt: 10 N•m (1 kgf•m, 7 lbf•ft)

“EX” Mark
＊ • Install the camshaft holder with the Washer

“EX” mark face exhaust valve side.
• Apply engine oil to the threads of the
cylinder head cap nuts.
• Diagonally tighten the cylinder head
cap nuts in 2～3 times.
• First tighten the cylinder head cap nuts
and then tighten the cylinder bolts to
avoid cracks.
Bolts Nut
8-34
Tensioner Screw
Turn the cam chain tension screw
counterclockwise to release it.
O-ring
Apply engine oil to a new O-ring and install
it.
Tighten the cam chain tension cap screw.
＊ Be sure to install the gasket into the

groove properly.
Cylinder Head Cover

Adjust the valve clearance. (page 3-13).
Install a new cylinder head cover O-ring and

install the cylinder head cover.
＊ Be sure to install the O-ring into the
groove properly.
Install and tighten the cylinder head cover
bolts.
O-ring
8-35
9. CYLINDER/PISTON XCITING 500/250
9
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CYLINDER/PISTON
__________________________________________________________________________________
SCHEMATIC DRAWING ------------------------------------------------- 9-1

SERVICE INFORMATION------------------------------------------------ 9-2
TROUBLESHOOTING----------------------------------------------------- 9-3
CYLINDER/PISTON ------------------------------------------------------- 9-4
9-0
SCHEMATIC DRAWING
9-1
SERVICE INFORMATION
• The cylinder and piston can be serviced with the engine installed in the frame.
• When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are
correctly installed.
• After disassembly, clean the removed parts and dry them with compressed air before inspection.

I.D. 92.005 (3.6802)～92.015 (3.6806) 92.1 (3.684)
Warpage 0.01 (0.0004) 0.05 (0.002)
Cylinder
Cylindricity 0.01 (0.0004) 0.1 (0.004)
True roundness 0.01 (0.0004) 0.1 (0.004)
Ring-to-groove top 0.03 (0.0012)～0.065 (0.0026) 0.08 (0.003)
clearance Second 0.015 (0.0006)～0.05 (0.002) 0.65 (0.0026)
top 0.15 (0.006)～0.3 (0.012) 0.5 (0.02)
Piston, Ring end gap Second 0.03 (0.012)～0.45 (0.018) 0.65 (0.026)
piston ring Oil side rail 0.2 (0.008)～0.7 (0.028) 1 (0.04)
Piston O.D. 91.96 (3.6784)～91.98 (3.6793) 91.9 (3.676)
Piston O.D. measuring position 10 mm from bottom of skirt －
. Piston-to-cylinder clearance 0.01 (0.0004)～0.045 (0.0018) 0.1 (0.004)
Piston pin hole I.D. 22.002 (0.8801)～22.008 (0.8803) 22.04 (0.8816)
Piston pin O.D 21.994 (0.8798)～22 (0.88) 21.96 (0.8784)
Piston-to-piston pin clearance 0.002 (0.0001)～0.014 (0.0006) 0.02 (0.001)
Connecting rod small end I.D. bore 22.016 (0.8806)～22.034 (0.8814) 22.06 (0.8824)
9-2

I.D. 72.75 (2.91)～72.7015 (2.90806) 72.8 (2.912)
Warpage 0.01 (0.0004) 0.05 (0.002)
Cylinder
Cylindricity 0.01 (0.0004) 0.1 (0.004)
True roundness 0.01 (0.0004) 0.1 (0.004)
Ring-to-groove top 0.03 (0.0012)～0.065 (0.0026) 0.08 (0.003)
clearance Second 0.015 (0.0006)～0.05 (0.002) 0.65 (0.0026)
top 0.15 (0.006)～0.3 (0.012) 0.5 (0.02)
Piston, Ring end gap Second 0.03 (0.012)～0.45 (0.018) 0.65 (0.026)
piston ring Oil side rail 0.2 (0.008)～0.7 (0.028) 1 (0.04)
Piston O.D. 72.67 (2.9068)～72.69 (2.9076) 72.6 (2.904)
Piston O.D. measuring position 9 mm from bottom of skirt －
. Piston-to-cylinder clearance 0.01 (0.0004)～0.045 (0.0018) 0.1 (0.004)
Piston pin hole I.D. 17.002 (0.68008)～17.008 (0.68032) 17.04 (0.6816)
Piston pin O.D 16.994 (0.67976)～17 (0.68) 16.96 (0.6784)
Piston-to-piston pin clearance 0.002 (0.0001)～0.014 (0.0006) 0.02 (0.001)
Connecting rod small end I.D. bore 17.016 (0.68064)～17.034 (0.68136) 17.06 (0.6824)
TROUBLESHOOTING
• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven

compression Excessive smoke from exhaust muffler
• Worn or damaged cylinder and piston rings • Worn or damaged piston rings
• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin
• Incorrectly installed piston
9-3
Bolts Cylinder/Gasket Block Pin

CYLINDER/PISTON
Remove the cylinder head (page 8-19).
Take the block pin out.

Remove the water hose from the cylinder.
Remove the two cylinder bolts.
Remove the cylinder and gasket.
Water Hose
Dowel Pins
Remove the dowel pins
Piston Pin Clip

Remove the piston pin clip.
＊ Place a clean shop towel in the crankcase
to keep the piston pin clip from falling
into the crankcase.
Press the piston pin out of the piston and

remove the piston.
Piston Piston Pin
9-4
REMOVAL (XCITING 250) Dowel Pins

Remove the cylinder head (page 8-21).
Remove the water hose from the cylinder.

Remove the cylinder head gasket and dowel
pine.
Water Hose Gasket

Cylinder
Remove the cam chain guide.
Remove the cylinder.
Cam Chain Guide
Gasket
Remove the cylinder gasket and dowel pins.
Clean any gasket material from the cylinder
surface.
Dowel Pins
Remove the piston pin clip. Shop Towel
＊ Place a clean shop towel in the crankcase

to keep the piston pin clip from falling
into the crankcase.
Press the piston pin out of the piston and

remove the piston.
Piston Pin Piston

9-5
PISTON RING REMOVAL
Spread each piston ring and remove it by

lifting up at a point opposite the gap
＊ Do not damage the piston ring by
spreading the ends too far.
Clean carbon deposits from the piston ring

grooves.
INSPECTION
Piston ring
Inspect the piston rings for movement by
rotating the rings. The rings should be able to
move in their grooves without catching.
Push the ring until the outer surface of the

piston ring is nearly flush with the piston and
measure the ring-to-groove clearance.
Service Limits: Top: 0.08 mm (0.003 in)

2nd: 0.065 mm (0.0026 in)
Insert each piston ring into the bottom of the

cylinder squarely.
＊ Use the piston head to push each piston
ring into the cylinder.
Measure the piston ring end gap.
Service Limit:
Top: 0.5 mm (0.02 in)
2nd: 0.65 mm (0.026 in)
Oil ring: 1 mm (0.04 in)
9-6
Piston/Piston pin
Measure the piston O.D. at the point (A) from
the bottom and 90° to the piston pin hole.
(A)
10 mm
Service Limit (XCITING 500):
91.9 mm (3.676 in) at (A): 10 mm
Service Limit (XCITING 250):
72.6 mm (2.904 in) at (A): 9 mm
Calculate the cylinder-to-piston clearance

(cylinder I.D.: page 9-6)
Measure the piston pin hole. Take the

maximum reading to determine the I.D..
Service Limit:
XCITING 500: 22.04 mm (0.8816 in)
XCITING 250: 17.04 mm (0.6816 in)
Measure the piston pin O.D. at piston and

connecting rod sliding areas.
Service Limit:
XCITING 500:21.96 mm (0.8784 in)
XCITING 250:16.96 mm (0.6784 in)
Measure the piston-to-piston pin clearance.
9-7
Cylinder
Check the cylinder for warpage with a
straight edge and feeler gauge in the
directions shown.
Check the cylinder wall for wear or damage.

Measure and record the cylinder I.D. at three
levels in an X and Y axis. Take the maximum TOP
reading to determine the cylinder wear.
MIDDLE
Service Limit:
XCITING 500: 92.1 mm (3.684 in) BOTTOM
XCITING 250: 72.8 mm (2.912 in)
Calculate the piston-to-cylinder clearance.

Take a maximum reading to determine the
clearance. Refer to page 9-7 for measurement
of the piston O.D..
Calculate the taper and out-of-round at three

levels in an X and Y axis. Take the maximum
reading to determine them.
Service Limit:
Taper: 0.1 mm (0.004 in)
Out-of-round: 0. 1 mm (0.004 in)
9-8
Measure the connecting rod small end I.D..
Service Limit:
XCITING 500: 22.06 mm (0.8824 in)
XCITING 250: 17.06 mm (0.6824 in)
Calculate the connecting rod-to-piston pin

clearance.
PISTON RING INSTALLATION

Carefully install the piston rings into the
piston ring grooves with the markings facing
up.
＊ Be careful not to damage the piston and

rings.
Do not confuse the top and second rings.

To install the oil ring, install the oil ring,
then install the side rails.
Stagger the piston ring end gaps 120° degrees

apart from each other.
Stagger the side rail end gaps as shown.
9-9
Piston “IN” Mark

CYLINDER/PISTON INSTALLATION
(XCITING 500)
Clean any gasket material from the cylinder
mating surfaces of the crankcase and oil
passage.
Apply engine oil to the piston pin.

Apply engine oil to the connecting rod small
end and piston pin hole.
Install the piston with the “IN” mark face

intake side and piston pin.
Piston Pin
Piston Pin Clip
Place a clean shop towel over the crankcase

prevent the clip from falling into the
crankcase.
Install the new pin clip.

＊ Make sure that the piston pin clips are
seated securely.
Do not align the piston pin clip end gap
with the piston cut-out
Piston Piston Pin
Dowel Pins
9-10
Bolts Cylinder/Gasket Block Pin

Install the gasket.
Apply engine oil to the cylinder wall, piston

and piston ring outer surfaces.
Pass the cam chain through the cylinder and

install the cylinder over the piston.
＊ Be careful not to damage the piston rings
and cylinder walls.
Install the two cylinder bolts and after the

cylinder head and holders has installed (page Water Hose
8-25), then tighten the two cylinder bolts to
specified torque.
Install the block pin.

Connect the water hose.
9-11
CYLINDER/PISTON INSTALLATION
(XCITING 250)
Remove any gasket material from the
crankcase surface.
＊ • Be careful not to drop foreign matters
into the crankcase.
“IN” Mark Piston
Install the piston, piston pin and a new piston

pin clip.
＊ • Position the piston “IN” mark on the
intake valve side.
• Place a clean shop towel in the
crankcase to keep the piston pin clip
from falling into the crankcase.
Piston Pin Clip Piston Pin

Dowel Pin
Install the dowel pins and a new cylinder
gasket on the crankcase.
Gasket
Coat the cylinder bore, piston and piston Cylinder

rings with clean engine oil.
Carefully lower the cylinder over the piston
by compressing the piston rings.
＊ • Be careful not to damage or break the
piston rings.
• The piston ring end gaps should not be
parallel with or at 90° to the piston pin.
9-12
Install the cam chain guide.

＊ • Insert the tab on the cam chain guide
into the cylinder groove.
Cam Chain Guide
Dowel Pins
Install the cylinder gasket and dowel pins.
Connect the water hose to the cylinder.
Gasket
9-13
10. DRIVE AND DRIVEN PULLEY XCITING 500/250
10
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
DRIVE AND DRIVEN PULLEY

__________________________________________________________________________________

LEFT CRANKCASE COVER --------------------------------------------- 10- 4
DRIVE PULLEY ------------------------------------------------------------ 10- 7
CLUTCH/DRIVEN PULLEY---------------------------------------------- 10-14
10
10-0
SCHEMATIC DRAWING
10-1
SERVICE INFORMATION
• The drive pulley, clutch and driven pulley can be serviced with the engine installed.
• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from
them to minimize the slipping of drive belt and drive pulley.
• Do not apply grease to the movable drive face and weight rollers.

Movable driven face bushing I.D. 48 (1.92)～48.025 (1.921) 48.06 (1.9224)
Driven face collar O.D. 47.965 (1.9186)～47.985 (1.9194) 47.94 (1.9176)
Drive belt width 28.9 (1.156) 27.9 (1.116)
Clutch lining thickness 4 (0.16) 1 (0.04)
Clutch outer I.D. 160 (6.3)～160.2 (6.31) 160.5 (6.32)
Drive pulley collar O.D. 28.96 (1.158)～28.974 (1.159) 28.9 (1.156)
Weight roller O.D. 29.98 (1.1992)～30.08 (1.203) 29.5 (1.18)

Movable driven face bushing I.D. 40 (1.6)～40.025 (1.601) 40.06 (1.6024)
Driven face collar O.D. 39.965 (1.5986)～39.985 (1.5994) 39.94 (1.5976)
Drive belt width 23.6 (0.944)～24.4 (0.976) 22 (0.88)
Clutch lining thickness 4 (0.16) 1 (0.04)
Clutch outer I.D. 153 (6.12)～153.2 (6.128) 153.5 (6.14)
Drive pulley collar O.D. 26.96 (1.0784)～26.974 (1.07896) 26.9 (1.076)
Weight roller O.D. 22.92 (0.9168)～23.08 (0.9232) 22 (0.88)
10-2

Drive face nut 135 N•m (13.5 kgf•m, 97 lbf•ft) Apply oil to the threads
Clutch outer nut 80 N•m (8 kgf•m, 58 lbf•ft)
Clutch drive plate nut 78 N•m (7.8 kgf•m, 56 lbf•ft)

Drive face nut 93 N•m (9.3 kgf•m, 67 lbf•ft) Apply oil to the threads
Clutch outer nut 54 N•m (5.4 kgf•m, 39 lbf•ft)
Clutch drive plate nut 54 N•m (5.4 kgf•m, 39 lbf•ft)
SPECIAL TOOLS (XCITING 500)

Universal holder E017
Clutch spring compressor E053
Oil seal & bearing install E014

Clutch spring compressor E034
TROUBLESHOOTING
Engine starts but motorcycle won‘t move Lack of power
• Worn drive belt • Worn drive belt
• Broken ramp plate • Weak driven face spring
• Worn or damaged clutch lining • Worn weight roller
• Broken driven face spring • Faulty driven face
Engine stalls or motorcycle creeps

• Broken clutch weight spring
10-3
Bolts
LEFT CRANKCASE COVER
Remove the left center body cover (page 2-5).
Remove the three bolts and the left front

cover.
Left Front Cover

.
Bolts
Remove the two bolts and left rear cover
Left Rear Cover
Bolts
Remove the eight bolts and left crankcase
cover.
Crankcase
10-4
Dowel Pins
Remove the dowel pins and gasket.
Gasket
Bolts
Remove the left crankcase cover bolts and
left crankcase covers.
Left Crankcase Cover
Dowel Pins
Remove the seal rubber and dowel pins.
Seal Rubber
10-5
DRIVESHAFT BEARING
REPLACEMENT (XCITING 500)
Remove the snap ring.
Clip
Industrial Dryer
Heat the left crankcase cover around the
driveshaft bearing with industrial dryer.
Remove the driveshaft bearing from the left
crankcase cover.
Bearing
Install the new driveshaft bearing into the left

crankcase cover using a special tool.
Special tool:
INSTALLATION
＊ Clean the gasket on the left crankcase Bearing Install
before installation.
10-6
Nut/Washer Drive Pulley Face

DRIVE PULLEY
REMOVAL
Remove the left crankcase cover (XCITING
500: page 10-4, XCITING 250: 10-5).
Hold the drive pulley face with the special

tool and loosen the drive pulley face nut.
Special tool:
Remove the nut, washer and drive pulley Universal Holder

face.
Nut/Collar (XCITING 500) Clutch Outer
Hold the clutch outer with the special tool as

shown.
Special tool:
Remove the nut, collar (XCITING 500) and

clutch outer.
Universal Holder
Drive Belt Clutch/Driven Pulley
Remove the clutch/driven pulley assembly

and drive belt.
10-7
Washer (XCITING 500)

Remove the washer (XCITING 500).
Drive Face Boss

Remove the movable drive face assembly
while holding the back of the face (ramp
plate).
Movable Drive Face
Remove the washer (XCITING 500). Washer (XCITING 500)
10-8
Ramp Plate
DISASSEMBLY
Drive pulley
Remove the ramp plate and slide pieces.
Slide Pieces
Remove the weight rollers.
Weight Rollers
Drive Face Boss

Remove the drive face boss from the movable
drive face.
10-9
INSPECTION
Movable Drive Face
Check the drive face boss for wear or
damage.
Measure the boss O.D..
Service limit:
XCITING 500: 28.9 mm (1.156 in)
XCITING 250: 26.9 mm (1.076 in)
Measure the face bushing I.D..
Service limit:
XCITING 500: 29.1 mm (1.164 in)
XCITING 250: 27.13 mm (1.058 in)
Weight Roller
Check each roller for wear or damage.
Measure the weight roller O.D..
Service limit:
XCITING 500: 29.5 mm (1.18 in)
XCITING 250: 22 mm (0.888 in)
Dust Seal
Movable Drive Face

Check the dust seal (XCITING 500) for wear
or damage.
10-10
Drive Face Boss

ASSEMBLY
Clean any oil and grease from the pulley
faces and weight rollers.
Install the drive face boss into the movable

drive face.
Weight Rollers
Install the weight rollers to the movable drive
face.
＊ The direction of all weight rolls is the
same. The thin side is towards to
clockwise.
Thin Side
Ramp Plate
Install the slide pieces to ramp plate.
Install the ramp plate to the movable drive
face.
Slide Pieces
10-11
Inner Indentation Side (XCITING 500)

INSTALLATION
Install the washer (XCITING 500).
＊ The inner indentation side on the washer
faces the left crankcase.
Washer

Clean any oil and grease from the pulley
faces and the drive belt.
Install the movable drive face assembly onto

the crankshaft while holding the ramp plate.
Install the washer (XCITING 500).
Movable Drive Face Assembly
Drive Belt
Install the drive belt and clutch/driven pulley

assembly.
＊
Install the drive belt with the arrow mark
facing the direction of travel.
Clutch/Driven Pulley Assembly
10-12
Clutch Outer Collar (XCITING 500)/Nut

shown.
Special tool:
Install the collar (XCITING 500) and nut.

Tighten the nut to the specified torque.
Torque:
XCITING 500: 80 N•m (8 kgf•m, 58 lbf•ft)
XCITING 250: Universal Holder
54 N•m (5.4 kgf•m, 36 lbf•ft)
Washer/Nut Drive Pulley Face

Install the drive pulley face and washer.
Apply oil to the drive pulley face nut threads
and seating surface and install the nut.
Hold the drive face with the special tool and

tighten the bolt to the specified torque.
Special tool:
Torque:
XCITING 500:
135 N•m (13.5 kgf•m, 97 lbf•ft) Universal Holder
XCITING 250:
93 N•m (9.3 kgf•m, 67 lbf•ft)
10-13
Nut/Washer Drive Pulley Face

CLUTCH/DRIVEN PULLEY
REMOVAL
Remove the left crankcase cover (XCITING
500: page 10-4, XCITING 250: 10-5).
Hold the drive pulley face with the special

tool and loosen the drive pulley face nut.
Special tool:
Remove the nut, washer and drive pulley

face. Universal Holder
Nut/Collar (XCITING 500) Clutch Outer

shown.
Special tool:
Remove the nut, collar (XCITING 500) and

clutch outer.
Universal Holder
Remove the clutch/driven pulley assembly Drive Belt Clutch/Driven Pulley

and drive belt.
10-14
DISASSEMBLY Lock Nut Wrench

Clutch/Driven Pulley
Hold the clutch/driven pulley assembly with
the clutch spring compressor.
＊ Be sure to use a clutch spring compressor
to avoid spring damage.
Special tool:
XCITING 500:
Clutch Spring Compressor E053
XCITING 250:
Set the tool in a vise and remove the clutch Clutch spring compressor
drive plate nut.
Driven Face Spring

Remove the spring compressor and
disassemble the following:
- Clutch assembly
- Driven face spring
- Driven pulley
Remove the washer (XCITING 500).
Remove the spring collar (XCITING 500).
Remove the seal collar.
Spring Collar (XCITING 500) Seal Collar
10-15
Movable Driven Face

Remove the guide roller pins, guide rollers
and the movable driven face.
Guide Roller Pins/Guide Rollers
Oil Seals
Remove the O-rings and oil seals from the
movable driven face.
O-rings
Snap Ring Needle Bearing

Driven Face Bearing Replacement
Remove the driven face needle bearing.
Remove the snap ring, then remove the ball

bearing.
Apply grease to new ball bearing.
Install the ball bearing into the driven face.

Ball Bearing
Install the snap ring to groove in the driven
face securely.
10-16
Needle Bearing
Filling 25 g of grease to the driven face inner
surface.
Apply grease to new needle bearing.

Press the needle bearing into the driven.
Grease
INSPECTION
Clutch Outer
Check the clutch outer for wear or damage.
Measure the clutch outer I.D..
Service limit:
XCITING 500: 160.5 mm (6.32 in)
XCITING 250: 153.5 mm (6.14 in)
Clutch Shoe Lining

Check the clutch shoe for wear or damage.
Measure the thickness of each shoe.
Service limit: 1 mm (0.04 in)
10-17
Driven Face Spring

Measure the driven face spring free length.
Service limit:
XCITING 500: 100.7 mm (4.028 in)
XCITING 250: 130.5 mm (5.22 in)
Driven Face
Check the driven face for scratches, scoring
or damage.
Measure the driven face boss O.D..
Service limit:
XCITING 500: 47.94 mm (1.9176 in)
XCITING 250: 39.94 mm (1.5976 in)
Movable Driven Face

Check the movable driven face for scratches,
scoring or damage.
Check the guide grooves for stepped wear or
damage.
Measure the movable driven face I.D..
Service limit:
XCITING 500: 48.06 mm (1.9224 in)
XCITING 250:40.06 mm (1.6024 in)
10-18
Drive Belt
Check the drive belt for cracks, separation or
abnormal or excessive wear.
Attach the suitable plates ad shown.

Measure the drive belt width.
Service limit:
XCITING 500: 27.9 mm (1.116 in)
XCITING 250: 22 mm (0.88 in)
Remove the clutch/driven pulley, then replace

the drive belt if necessary.
Oil Seals
ASSEMBLY
Clean any oil from the drive belt sliding
surfaces on the driven face.
Apply grease to new oil seal lips and install

into the movable driven face.
Coat new O-rings with grease and install
them into the movable driven face grooves.
O-rings
10-19
Install the movable driven face onto the

driven face.
Install the guide rollers and guide roller pins.
Filling 8 g of grease to each guide groove. Grease
Driven Face Spring

Install the seal collar.
Install spring collar (XCITING 500).
Install washer (XCITING 500).
Install driven face spring.
Install the drive belt into the driven pulley.

Squeeze and hold the drive belt by your hand.
Washer
Set the clutch spring compressor over the Lock Nut Wrench
clutch/driven pulley assembly and hold the
spring compressor in a vice.
Special tool:
XCITING 500:
XCITING 500:
Compress the driven face spring.

Install and tighten the clutch drive plate nut
to the specified torque.
Clutch spring compressor
Torque:
XCITING 500:
78 N•m (7.8 kgf•m, 56 lbf•ft)
XCITING 250:
54 N•m (5.4 kgf•m, 39 lbf•ft)
10-20
Drive Belt
＊ Install the drive belt with the arrow mark
facing the direction of travel.
Install the drive belt and clutch/driven pulley

assembly.
Clutch/Driven Pulley Assembly
Nut/Collar Clutch Outer

shown.
Special tool:
Install the collar and nut.

Tighten the nut to the specified torque.
Torque:
XCITING 500: 80 N•m (8 kgf•m, 58 lbf•ft)
Universal Holder
XCITING 250:
54 N•m (5.4 kgf•m, 39 lbf•ft)
Install the drive pulley face and washer. Washer/Nut Drive Pulley Face
Apply oil to the drive pulley face nut threads
and seating surface and install the nut.
Hold the drive face with the special tool and

tighten the bolt to the specified torque.
Special tool:
Torque:
XCITING 500:
135 N•m (13.5 kgf•m, 97 lbf•ft)
Universal Holder
XCITING 250:
93 N•m (9.3 kgf•m, 67 lbf•ft)
10-21
11. FINAL REDUCTION XCITING 500/250
11 11
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
FINAL REDUCTION
__________________________________________________________________________________

FINAL REDUCTION DISASSEMBLY --------------------------------- 11-3
FINAL REDUCTION INSPECTION------------------------------------- 11-5
FINAL REDUCTION ASSEMBLY -------------------------------------- 11-9
11-0
SCHEMATIC DRAWING
11-1
SERVICE INFORMATION
• The servicing operations of this section can be made with the engine installed.
• When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
SPECIFICATIONS
Specified Oil: SAE 90#
Oil Capacity:
XCITING 500:
At disassembly : 0.55 L (0.57 US qt, 0.5 lmp qt)
At change : 0.45 L (0.48 US qt, 0.4 lmp qt)
XCITING 250:
At disassembly : 0.2 L (0.21 US qt, 0.18 lmp qt)
At change : 0.18 L (0.19 US qt, 0.16 lmp qt)
TORQUE VALUES
Transmission case cover bolt 27 N•m (2.7 kgf•m, 20 lbf•ft)
Oil drain bolt 20 N•m (2 kgf•m, 15 lbf•ft)
Oil filler bolt 20 N•m (2 kgf•m, 15 lbf•ft)
SPECIAL TOOLS
Bearing puller E037
Oil seal & bearing driver E014
Universal bearing puller E030
TROUBLESHOOTING
Engine starts but motorcycle won‘t move
• Damaged transmission
• Seized or burnt transmission
• Faulty drive and driven pulleys/clutch
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase
11-2
Bolts
FINAL REDUCTION DISASSEMBLY
Remove the exhaust muffler (page 2-16).
Remove the rear brake caliper (page 16-26).
Remove the right rear shock absorber (page
15-10).
Remove the rear fork (page 15-4).
Remove the rear wheel (page 15-4).
Drain the transmission gear oil into a clean

container.
Remove the eight bolts and transmission

cover.
Transmission Cover
Gasket
Remove the gasket and dowel pins.
Dowel Pin
Final Gear Shaft

Remove the final gear shaft.
11-3
Countershaft
Remove the countershaft.
Final Gear
Remove the final gear.
Driveshaft
Remove the driven pulley (page 10-14).
Press the driveshaft out or the left

crankcase.
Check the drive shaft for wear or damage.
11-4
Remove the driveshaft oil seal and bearing Oil Seal

from the transmission case.
Driveshaft Bearing
If the bearing is left on the driveshaft,
remove it with the special tool.
Special tool:
Universal bearing puller E030
Universal Bearing Puller
Countershaft Driveshaft
FINAL REDUCTION
INSPECTION
Check the driveshaft, countershaft, final
gear and final gear shaft for wear or
damage.
Final Gear Shaft Final Gear
11-5
Check the oil seal and bearings in the left Driveshaft Bearing Bearing Puller
crankcase for wear or damage.
BEARING REPLACEMENT
(TRANSMISSION CASE)
Remove the countershaft or final gear shaft
bearing using the special tool.
Special tool:
Bearing puller E037
Countershaft Bearing Final Gear Shaft Bearing
Oil Seal & Bearing Driver

Apply engine oil to new bearings cavities.
Drive new bearings into the transmission
case.
Special tool:
Oil Seal
BEARING REPLACEMENT
(TRANSMISSION COVER)
Remove the final gear shaft oil seal.
11-6
Remove the bearing snap ring (XCITING Snap Ring

500).
Final Gear Shaft Bearing

Remove the final gear shaft bearing.
Countershaft Bearing
Remove the countershaft or drive shaft
bearing using the special tool.
Special tool:
Bearing puller E037
Drive Shaft Bearing
11-7

Apply engine oil to new bearings cavities.
Drive new bearings into the transmission
cover.
Special tool:
Apply engine oil to new final gear shaft

bearing cavity.
Drive new bearing into the transmission
cover.
Special tool:
Snap Ring
Install the bearing snap ring.
11-8
Oil Seal
Apply oil to a new final gear shaft oil seal
lip and outer surface.
Install the final gear shaft oil seal.
Final Gear
FINAL REDUCTION ASSEMBLY
Install the final gear to the transmission
case.
Countershaft
Install the countershaft to the transmission

case.
11-9
Final Gear Shaft Gasket

Install the final gear shaft to transmission
case.

Clean the mating surfaces of the left
crankcase and transmission cover.
Install the new gasket.
Dowel Pins
Bolts
Install the transmission cover and tighten

the eight bolts in a crisscross pattern in 2 –
3 steps to the specified torque.
Fill the transmission case with the

recommended oil (page 3-22).
11-10
12. A.C. GENERATOR/STARTER CLUTCH XCITING 500/250
12
__________________________________________________________________________________
12
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
A.C. GENERATOR/STARTER CLUTCH

__________________________________________________________________________________

ALTERANTOR STATOR-------------------------------------------------- 12-3
FLYWHEEL/STARTER CLUTCH --------------------------------------- 12-5
12-0
SCHEMATIC DRAWING
12-1
SERVICE INFORMATION
• All servicing operations and inspections in this section can be made with the engine installed.
• Drain the coolant before removing the right crankcase cover.
• Be careful not to drain the coolant when the engine temperature is high. (Perform this operation
when the engine is cold.)
• Drain the coolant into a clean container.
• Drain the engine oil into a clean container before removing the right crankcase cover.
• When the right crankcase cover is installed, fill with the recommended engine oil and coolant.
Then, bleed air from the water jacket.
• Refer to section 17 for alternator inspection, and to section 18 for ignition pulse generator
inspection.

Starter driven gear I.D. 27.026 (1.081)～27.045 (1.0818) 27.1 (1.084)
Starter driven gear O.D. 45.66 (1.8264)～45.673 (1.8292) 45.6 (1.824)

Starter driven gear I.D. 22.026 (0.88104)～22.045 (0.8818) 22.1 (0.884)
Starter driven gear O.D. 42.195 (1.6878)～42.208 (1.68832) 41.5 (1.66)

Flywheel puller E054
Flywheel holder E021

Flywheel puller E003
TORQUE VALUES
Flywheel nut: 55 N•m (5.5 kgf•m, 40 lbf•ft)
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear
12-2
Right Crankcase Cover

ALTERNATOR STATOR
Remove the right center body cover (page 2-

5).
Remove water pump (page 6-15).
Remove the fifteen bolts and right crankcase

cover, dowel pins and gasket.
Stator Bolts Grommet

Remove the two pulse coil mount bolts.
Remove the three stator mount bolts,
grommet and the stator from the right
crankcase cover.
INSTALLATION
Install the stator and tighten the stator mount
Apply sealant to the grommet seating surface Bolts Pulse Coil

and install it to the cover groove properly.
Install the pulse coil and tighten mount bolts


Dowel Pins Gasket
Clean the mating surfaces of the right
crankcase and cover.
Install the dowel pins and gasket.

Install the right crankcase cover and tighten
the bolts in a crisscross pattern in 2 or 3 steps.
12-3
ALTERNATOR STATOR Bolts Water Inlet Hose

Remove the right center body cover (page 2-

5).
Disconnect the water hoses from the right

crankcase cover.
Remove the nine bolts attaching the right
crankcase cover and the cover.
Water Outlet Hose
A.C. Generator Stator Screws

Remove the two pulse coil mount screws.
Remove the three stator mount bolts,
grommet and the stator from the right
crankcase cover.
Bolts Pulser Coil
Dowel Pins
INSTALLATION
Install the stator and tighten the stator mount
Apply sealant to the grommet seating surface

and install it to the cover groove properly.
Install the pulse coil and tighten mount bolts

Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Gasket
Clean the mating surfaces of the right

crankcase and cover.
Install the dowel pins and gasket.

Install the right crankcase cover and tighten
the bolts in a crisscross pattern in 2 or 3 steps.
12-4
Flywheel Holder Nut/Washer

FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-
3).
Hold the flywheel with the special tool and

loosen the flywheel nut.
Special tool:
Remove the flywheel nut and washer.
Flywheel Puller
Remove the flywheel/starter driven gear
assembly using the special tool.
Special tool:
XCITING 500: Flywheel puller E054
XCITING 250: Flywheel puller E003
Remove the woodruff key.
Woodruff Key
12-5
Reduction Gear
Remove the reduction gear (XCITING 500).
Remove the reduction gear and shaft

(XCITING 250).
Starter Idle Gear
Reduction Gear
Check the starter reduction gear teeth and

shaft for wear or damage (XCITING 500).
12-6
Reduction Gear
Inspect the reduction gear and shaft for wear
or damage (XCITING 250).
Shaft
Driven gear
INSPECTION
Check the operation of the sprag clutch by
turning the driven gear.
You should be able to turn the driven gear
clockwise smoothly, but the gear should not
turn counterclockwise.
Remove the starter driven gear by turning the

driven gear.
Flywheel
Check the starter driven gear teeth for wear or

damage.
Measure the starter driven gear boss O.D..
Service limit:
XCITING 500: 45.6 mm (1.824 in)
XCITING 250: 41.5.6 mm (1.66 in)
Measure the starter driven gear bushing I.D..
Service limit:
XCITING 500: 27.1 mm (1.084 in)
XCITING 250: 22.1 mm (0.884 in)
12-7
Reduction Gear
Apply oil to the starter reduction gear.
Install the starter reduction gear to the right
crankcase.
Reduction Gear Shaft

Apply oil to the starter reduction gear and
shaft (XCITING 250).
Install the starter reduction gear and shaft
(XCITING 250) to the right crankcase.
Reduction Gear
Driven gear
Apply molybdenum oil solution to the

starter driven gear bushing.
Install the starter driven gear by turning the
driven gear clockwise.
Flywheel
12-8
Clean any oil from tapered portion of the

crankshaft.
Install the woodruff key in the crankshaft

key groove.
Woodruff Key
Clean any oil from the tappered portion of Flywheel Holder Nut/Washer
the flywheel I.D..
Install the flywheel/driven gear onto the

crankshaft, aligning the key way with
woodruff key.
Apply oil to the washer and flywheel nut

threads and seating surface.
Install the washer and flywheel nut to the
crankshaft.
Hold the flywheel with the special tool and

tighten the flywheel nut to the specified
torque.
Special tool:
12-9
13. CRANKCASE/CRANKSHAFT XCITING 500/250
13
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________ 13
__________________________________________________________________________________
__________________________________________________________________________________
CRANKCASE/CRANKSHAFT
__________________________________________________________________________________

CAM CHAIN/CAM CHAIN GUIDE ------------------------------------- 13- 5
CRANKCASE---------------------------------------------------------------- 13- 6
CRANKCASE ASSEMBLY (XCITING 500)--------------------------- 13-16
CRANKCASE ASSEMBLY (XCITING 250)--------------------------- 13-18
13-0
13-1
13-2
SERVICE INFORMATION
• This section covers crankcase separation to service the crankshaft and balancer. The engine must
be removed for this operation.
• When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart
forcedly to prevent damaging the mating surfaces.
• When installing the crankcase, do not use an iron hammer to tap it.
• The following parts must be removed before separating the crankcase.
Cylinder head (section 8)
Cylinder/piston (section 9)
Drive and driven pulley (section 10)
A.C. generator/starter clutch (section 12)
Starter motor (section 19)
Oil pump (section 4)

Main bearing oil clearance 0.025 (0.001)～0.041 (0.0016) 0.7 (0.003)
Crankshaft Connecting rod big end side 0.05 (0.002)～0.5 (0.02) 0.8 (0.031)
clearance
Runout ⎯ 0.06 (0.002)

Item Standard Service
Connecting rod big end side
0.15～0.35 (0.006～0.014) 0.6 (0.024)
clearance
Crankshaft Connecting rod big end radial 0.004～0.008 (0.00016～0.0032) 0.05 (0.002)
clearance
Runout ⎯ 0.1 (0.004)
13-3

Crankcase bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Cam chain guide bolt 20 N•m (2 kgf•m, 15 lbf•ft)
Oil pipe bolt 43 N•m (4.3 kgf•m, 31 lbf•ft)

Crankcase bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Cam chain guide bolt 10 N•m (1 kgf•m, 10 lbf•ft)
SPECIAL TOOLS
Bearing puller E037
TROUBLESHOOTING
Excessive engine noise
• Worn connecting to small end
• Worn or damaged crankshaft bearings
13-4
CAM CHAIN/CAM CHAIN GUIDE

Remove the starter driven gear (page 12-5).
Remove the cylinder (page 9-4).
Remove the cam chain from the right

crankcase.
Cam Chain
Cam Chain Guides
Remove the bolts and cam chain guides.
Bolts
Cam Chain Guide

Remove the cam chain guide bolt.
Remove the cam chain guide and cam chain.
Bolt Cam Chain
13-5
INSPECTION
Cam chain guide
Inspect the cam chain slipper surface of the
cam chain guide for wear or damage.
Slipper Surface
Cam chain
Inspect the cam chain for cracks or stiff.
CRANKCASE Bolts
SEPARATION (XCITING 500)
Remove the parts required for crankcase
separation (page 13-3).
Remove the twelve bolts from left crankcase.

＊ Loosen the bolts in a crisscross pattern in
several steps.
13-6
Bolt
Remove the bolt from right crankcase.
Place the crankcase assembly with the left

side down and separate the right crankcase
from the left crankcase.
＊ Separate the right crankcase from the left

crankcase while tapping them at several
locations with a soft hammer.
Dowel Pins
Remove the dowel pins and O-ring.
Remove the oil collar and O-rings from the
left crankcase.
Clean of the sealant from the left and right
crankcase mating surfaces.
Oil Collar/O-rings Dowel Pin/O-ring
Washer
Remove the washer from the crankshaft.
Remove the balancer shaft from the left
crankcase.
＊ Always replace the crankshaft and
balancer shaft in pairs
13-7
Crankshaft
Remove the crankshaft from the left
crankcase.
＊ Always replace the crankshaft and

balancer shaft in pairs
Bolts
SEPARATION (XCITING 250)
Place the crankcase with the left crankcase
down and remove the right crankcase from
the left crankcase.
＊ • Never use a driver to pry the crankcase
mating surfaces apart.
Gasket
Remove the gasket and dowel pins.
Dowel Pins
13-8
Remove the crankshaft from the left Crankshaft

crankcase.
Left Crankcase
Bolts/Outer Washer
RIGHT CRANKCASE DISASSEMBLY
(XCITING 500)
Remove the two bolts, outer washer, oil pipe
and inner washers.
Oil Pipe/Inner Washers
Inner Washers
RIGHT CRANKCASE ASSEMBLY
Install the inner washers onto the right
crankcase.
13-9
Thick Side
Install the oil pipe with the thick side face
upward.
Oil Pipe
Bolts/Outer Washer
Install the outer washers and two bolts.
Tighten the two bolts to the specified torque.
13-10
Main Journal Bearing I.D. Color Code

CRANKSHAFT/CRANKCASE
SELECTION (XCITING 500)
Crankcase and crankshaft are select fitted.
Record the main journal O.D. code (－ or

＋)
Record the main journal bearing I.D. color

code (green, brown or yellow).
Record the right or left crankcase main

journal I.D. code (A or B).
Main Journal O.D. Code
If the crankcase and/or crankshaft are
replaced, select them with the following
fitting table.
The “U” mark in the table indicates that

mating is possible in the crossed code.
Main journal O.D. code

＋－
Main journal bearing I.D. color code
/Crankcase main journal I.D. code
Green/A U
Green/B U
Brown/A U
Yellow/B U
＊ Always replace the crankcase in pairs.

Crankcase Main Journal I.D. Code
13-11
MAIN BEARING INSPECTION

(XCITING 500)
Inspect the bearing inserts for unusual wear,
damage or peeling and replace the crankcase
if necessary.
Main bearing oil clearance

Clean off any oil from the main bearing
inserts and crankshaft journals.
Measure and record the crankshaft main
journal O.D..
Measure and record the main bearing I.D..
Calculate the oil clearance by subtracting the Bearing
journal O.D. from bearing I.D..
Standard:
0.025 – 0.041 mm (0.001 – 0.0016 in)
Replace the crankcase if the service limit is

exceeded. Runout Side Clearance Runout
Select the replacement crankcase (page 13-
11).
CRANKSHAFT INSPECTION (XCITING

500)
Measure the connecting rod big end side
clearance.
Measure the crankshaft runout.

Journals
CRANKSHAFT INSPECTION (XCITING

250)
Measure the crankshaft runout.

13-12
Measure the connecting rod big end side

clearance.
Measure the connecting rod small end I.D.

BALANCER SHAFT INSPECTION

(XCITING 500)
Inspect the balance shaft gear teeth.
Burrs/chips/roughness/wear → Replace.
Balancer Shaft
13-13
BALANCER SHAFT BEARING

REPLACMENT (XCITING 500)
Remove the crankshaft and balancer shaft
(page 13-7).
Turn the inner race of each bearing with your

finger.
The bearings should turn smoothly and
quietly. Also check that the bearing outer race
fits tightly in the crankcase.
Replace the bearings if the races does not turn

smoothly and quietly, or if they fit loosely in
the crankcase.
Bearing Puller
Remove the balancer shaft bearing from the
left crankcase using the special tool.
Special tool: Bearing puller E037
Bearing
Remove the bearing snap ring from right

crankcase.
Snap Ring
13-14
Remove the balancer shaft bearing from the

right crankcase.
Bearing
Snap Ring
Install the snap ring into the right crankcase.

Install the new bearings to the right and left
crankcase using special tool.
Special tool:
Bearing
13-15
Crankshaft
CRANKCASE ASSEMBLY
(XCITING 500)
Install the crankshaft to the left crankcase.
Align Balancer Shaft
Install the balancer shaft to align the punch

mark with the “O” mark on the crankshaft.
Washer
Install the washer onto the crankshaft.
13-16
Dowel Pins
Install the oil collar and O-rings
Clean the right and left crankcase mating

surface thoroughly, being careful not to
damage them.
Install the dowel pins and O-ring.
Oil Collar/O-rings Dowel Pin/O-ring
Bolt
Apply a light but through coating of sealant
(Threebond 1215 or equivalent) to all
crankcase mating surfaces except the oil
passage area.
Install the right crankcase over the left

crankcase.
Install and turn in the right crankcase bolt but
do not tighten it.
Bolts
Install and tighten the left crankcase bolts in a
crisscross pattern in 2 – 3 steps to the
specified torque.
Tighten the right crankcase bolt to the

specified torque.
Make sure that the crankshaft turns smoothly.
13-17
Cam Chain Guides

Install the cam chain guides to the right
crankcase and tighten the bolts to the
specified torque.
Install the cam chain to right crankcase.
Cam Chain
CRANKCASE ASSEMBLY
(XCITING 250)
Clean off all gasket material from the
crankcase mating surfaces.
＊ • Avoid damaging the crankcase mating
surfaces.
Oil Seal
Install a new oil seal into the left crankcase.
Left Crankcase
13-18
Place the left crankcase down and install the

crankshaft into the left crankcase.
＊ • Avoid damaging the oil seal.
• Apply grease to the lip of the oil seal.
Gasket
Install the two dowel pins and a new gasket.
Dowel Pins
Bolts
Place the right crankcase over the crankshaft
and onto the left crankcase.
＊ • Install the right crankcase squarely and
do not tap it with an iron or plastic
hammer.
Install and tighten the right and left crankcase

attaching bolts.
13-19
Cam Chain Tensioner Slipper

Install the cam chain.
Install the cam chain tensioner slipper.
Install and tighten the cam chain tensioner
slipper bolt.
Bolt
13-20
15. REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER XCITING 500/250
15
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
REAR FORK/REAR WHEEL/ 15

REAR SHOCK ABSORBER
__________________________________________________________________________________

REAR WHEEL/REAR FORK --------------------------------------------- 15- 4
REAR SHOCK ABSORBER ---------------------------------------------- 15-10
15-0
SCHEMATIC DRAWING
15-1
SERVICE INFORMATION
• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean
a contaminated disc with a high quality brake degreasing agent.
• Riding on damaged rims impairs safe operation of the vehicle.
• This section covers of the rear wheel and rear suspension.
• A jack or other support is required to support the vehicle.
• Do not twist or bend the brake hose when servicing.
• Use genuine KYMCO replacement bolts and nuts for all suspension pivots and mounting points.
• Refer to section 16 for brake system information.
SPECIFICATIONS
Unit: mm (in)
Minimum tire tread depth ⎯ 2.0 (0.08)
Rider only ⎯
Cold tire pressure 250 kPa (2.5 kgf/cm2, 36 psi)
Rider and passenger ⎯
Wheel rim runout Radial ⎯ 2.0 (0.08)
Axial ⎯ 2.0 (0.08)
TORQUE VALUES
Rear brake disc bolt 42 N•m (4.3 kgf•m, 31 lbf•ft)
ALOC bolt: replace with a new one.
Rear axle nut (XCITING 500) 180 N•m (18 kgf•m, 130 lbf•ft)
Rear axle nut (XCITING 250) 140 N•m (14 kgf•m, 100 lbf•ft)
Rear shock absorber upper mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Rear shock absorber lower mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Final shaft holder bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
Right/parking brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
15-2
TROUBLESHOOTING
Rear wheel wobbling Hard suspension
• Bent rim • Bent damper rod
• Faulty tire • Worn or damaged engine mount bushings
• Axle not tightened properly • High tire pressure
• Engine mount bolt not tightened properly
• Loose or worn final gear shaft bearing Rear suspension noisy
• Insufficient tire pressure • Loose mounting fasteners
• Unbalanced tire and wheel • Faulty shock absorber
• Weak rear suspension mount bushings
Soft suspension
• Weak rear shock absorber spring
• Oil leakage from damper unit
Rear wheel noise

• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork
15-3
Axle Nut
REAR WHEEL/REAR FORK
REMOVAL
Remove the muffler (page 2-16).

Remove the rear/parking brake caliper (page
16-26).
Loosen the rear axle nut.

Support the scooter securely on its main
stand.
Bolts/Clamps
Remove the bolts and brake hose/cable
clamps from the rear fork.
Remove the rear shock absorber lower mount
bolt.
Remove the rear axle nut.
Mount Bolt
Mount Bolts
Remove the rear fork mount bolts and rear
fork.
Rear Fork
15-4
Remove the inner side collar.
Inner Side Collar
Remove the rear wheel.
Rear Wheel
INSTECTION
Wheel
Check the wheel rim runout using dial
indicator.
Actual urnout is 1/2 the total indicator
reading.
Service Limits:
Radial: 2.0mm (0.08 in)
Axial: 2.0mm (0.08 in)
15-5
Brake Disc
DISASSEMBLY
Wheel
Remove the brake disc bolts and rear brake
disc.
Outer Side Collar

REAR FORK BEARING
REPLACEMENT
Remove the outer side collar from the rear

fork.
Remove the dust seal from the rear fork.
Dust Seal
15-6
Bearing Snap Ring

Remove the snap ring.
Turn the inner race of the bearing with your

finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer race fits
tightly in the rear fork.
Remove and discard the bearing if the race

does not turn smoothly and quietly, or if it fits
loosely in the rear fork.
Remove the bearing from the rear fork.
Drive in a new bearing squarely until it is

fully seated, using the special tools.
Special tool:
Oil seal & bearing installE014
Install the snap ring to the groove of the rear Bearing Snap Ring
fork securely.
15-7
Apply grease to the new dust seal lip and

install it to the rear fork.
Dust Seal
Busing
Check the bushing for wear or damage.
Brake Disc
ASSEMBLY
Wheel
Install the brake disc onto the wheel hub.
Install the new brake disc bolts and tighten

them to the specified torque.
15-8
INSTALLATION
Install the rear wheel onto the final gear shaft,

aligning the spline.
Rear Wheel
Install the inner side collar.

Apply grease to the final gear shaft.
Inner Side Collar
Mount Bolts
Install the rear fork and tighten the bolts to

the specified torque.
Rear Fork
15-9
Bolts/Clamps
Install and tighten the rear axle nut to
temporarily.
Install and tighten the rear shock absorber
lower mount bolt to the specified torque.
Install the brake hose/cable clamps to the rear

fork and tighten the bolts securely.
Mount Bolt
Release the main stand and support the Axle Nut

scooter securely on its side stand.
Tighten the rear axle nut to the specified

torque.
Torque:
XCITING 500:
180 N•m (18 kgf•m, 130 lbf•ft)
XCITING 250:
140 N•m (14 kgf•m, 100 lbf•ft)
Install the rear/parking brake caliper (page

16-30).
Install the muffler (page 2-16).
Lower Mount Bolt
REAR SHOCK ABSORBER
REMOVAL
Remove he luggage box (page 2-3).
Support the scooter securely on its center

stand.
Support the engine securely with a hoist or
equivalent.
Remove the rear shock absorber lower mount

bolt.
15-10
Upper Mount Bolt

Remove the rear shock absorber upper mount
bolt and shock absorber.
Bushing
INSTECTION
Check the damper unit for leakage or other

damage.
Check the upper joint bushing for wear or
damage.
Replace the shock absorber assembly if

necessary.
Damper Unit
Upper Mount Bolt

INSTALLATION
Install the rear shock absorber tighten the

upper mount bolt to the specified torque.
15-11
Lower Mount Bolt

Install and tighten the lower mount bolt to the
specified torque.
15-12
16. BRAKE SYSTEM XCITING 500/250
16
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
BRAKE SYSTEM
__________________________________________________________________________________

SERVICE INFORMATION ----------------------------------------------- 16- 2
16
BRAKE FLUID -------------------------------------------------------------- 16- 4
BRAKE PAD----------------------------------------------------------------- 16-10
BRAKE DISC INSPECTION---------------------------------------------- 16-13
FRONT MASTER CYLINDER ------------------------------------------- 16-14
REAR MASTER CYLINDER --------------------------------------------- 16-18
DELAY VALVE------------------------------------------------------------- 16-22
FRONT BRAKE CALIPER------------------------------------------------ 16-24
REAR/PARKING BRAKE CALIPER ----------------------------------- 16-26
PARKING BRAKE LEVER LINK (XCITING 500) ------------------- 16-31
16-0
SCHEMATIC DRAWING
16-1
SERVICE INFORMATION
GENERAL
＊ Frequent inhalation of brake pad dust, regardless of material composition could be hazardous
to your health.
Avoid breathing dust particles.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and
clean a contaminated disc with high quality brake degreasing agent.
• Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag over these parts
whenever the system is serviced.
• This section covers maintenance of the front and rear hydraulic brake system.
• Never allow contamination (dirt, water, etc.) to get into and open reservoir.
• Once the hydraulic system has been opened, or if the brake feel spongy, the system must be
bled.
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not
mix different types of fluid as they may not be compatible.
• Always check brake operation before riding the vehicle.
SPECIFICATIONS
Unit: mm (in)
Front Specified brake fluid DOT 4 ⎯
Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4 (0.16)
Brake disc runout ⎯ 0.03 (0.012)
Rear Specified brake fluid DOT 4 ⎯
Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4 (0.16)
Brake disc warpage ⎯ 0.03 (0.012)
16-2
TORQUE VALUES
Master cylinder reservoir cover screw 2 N•m (0.2 kgf•m, 1.4 lbf•ft)
Master cylinder holder bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)
Brake lever pivot bolt 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Brake lever pivot nut 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Brake light switch screw 1 N•m (0.1 kgf•m, 0.7 lbf•ft)
Brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
Brake caliper bleed screw 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Brake pad pin 18 N•m (1.8 kgf•m, 13 lbf•ft)
Front/Rear caliper pad pin plug 2 N•m (0.2 kgf•m, 1.4 lbf•ft)
Brake hose oil bolt 35 N•m (3.5 kgf•m, 25 lbf•ft)
Delay valve bleed screw 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
TROUBLESHOOTING
Brake lever soft or spongy Brake lever hard
• Air in the hydraulic system • Clogged/restricted brake system
• Low brake fluid level • Sticking/worn caliper piston
• Clogged fluid passage • Caliper not sliding properly
• Contaminated brake disc/pad • Clogged/restricted fluid passage
• Warped/deformed brake disc • Worn caliper piston seal
• Worn brake disc/pad • Sticking/worn master cylinder piston
• Sticking/worn master cylinder piston • Bent brake lever
• Contaminated master cylinder
• Contaminated caliper Brake drag
• Caliper not sliding properly • Contaminated brake disc/pad
• Leaking hydraulic system • Worn brake disc/pad
• Worn caliper piston seal • Warped/deformed brake disc
• Worn master cylinder piston cups • Caliper not sliding properly
• Bent brake lever
16-3
BRAKE FLUID
Check
Brake fluid: (page 3-24)
Brake hose:
Cracks/wear/damage → Replace.
Apply the brake lever several times.
Fluid leakage → Replace.
Brake hose clamp:
Loosen → Tighten
FLUID REPLACEMENT
Front brake
＊ Avoid spilling brake fluid on painted,
plastic or rubber parts and so on. Place a
rag over these parts whenever the system
is serviced.
Place the scooter on a level surface and keep

the handlebar straight.
Screws Cap/Diaphragm
Remove the master cylinder reservoir cap and
diaphragm.
Suck up the old brake fluid as much as
possible.
Fill the reservoir with new brake fluid.
Specification and classification: DOT 4
16-4
Connect a clear hose to the left front caliper Clear Hose

air bleed screw and insert the other end of the
hose into a receptacle.
Left Front Caliper Air Bleed Screw
Brake Lever
Loosen the air bleed screw and pump the
brake lever until the old brake fluid is
completely out of the brake system.
Close the air bleed screw and disconnect the

clear hose. Fill the reservoir with new brake
fluid to the upper end of the inspection
window.
Tighten the bleed screw to the specified

torque.
Combination brake
＊ Avoid spilling brake fluid on painted,

plastic or rubber parts and so on. Place a
rag over these parts whenever the system
is serviced.
Place the scooter on a level surface and keep

the handlebar straight.
16-5
Screws Cap/Diaphragm
Remove the master cylinder reservoir cap and
diaphragm.
Suck up the old brake fluid as much as
possible.
Fill the reservoir with new brake fluid.
Specification and classification: DOT 4
Clear Hose
Step 1:
Connect a clear hose to the delay valve air
bleed screw and insert the other end of the
hose into a receptacle.
Loosen the air bleed screw and pump the
brake lever until the old brake fluid is
completely out of the brake system. Close
the air bleed screw and disconnect the clear
hose. Fill the reservoir with new brake fluid
to the upper end of the inspection window.
Relay Valve Air Bleed Screw
Right Front Caliper Air Bleed Screw

Step 2:
Connect a clear hose to the right front
caliper air bleed screw. The right brake fluid
replacement is the same way as that of the
step 1.
Clear Hose
16-6
Rear Caliper Air Bleed Screw

Step 3:
Connect a clear hose to the rear caliper air
bleed screw. The rear brake fluid
replacement is the same way as that of the
step 1.
Clear Hose
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
＊ Bleed the brake fluid circuit:
● The system has been disassembled.
● A brake hose or brake pipe have been
loosened or removed.
● The brake fluid has been very low.
● The brake operation has been faulty.
A loss of braking performance may occur
if the brake system is not properly bled.
Air bleeding steps (Front brake): Clear Hose

1.Add the proper brake fluid to the reservoir.
2.Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
3.Connect the clear plastic hose tightly to the
left front caliper air bleed screw.
4.Place the other end of the hose into a
container.
5.Slowly apply the brake lever several times.
6.Pull the lever in and hold it.
7. Loosen the bleed screw and allow the
lever to travel towards its limit.
Left Front Caliper Air Bleed Screw
16-7
8.Tighten the bleed screw when the lever

limit has been reached, then release the
lever.
9.Repeat steps (5) to (7) until all the air
bubbles have disappeared from the fluid.
10.Tighten the bleed screw.
＊ If bleeding is difficult, it may be

necessary to let the brake fluid settle for
a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the system have
disappeared.
12.Add brake fluid to the proper level and

install the master cylinder reservoir cap
and diaphragm.
＊ Check the operation of the brake after
bleeding the brake system.
Rear Caliper Air Bleed Screw

Air bleeding steps (combination brake):
The combination brake system air bleeding is
the same manner as that of the front brake
one.
Bleed the air from the rear side (rear caliper)
and then the front side (right front caliper and
delay valve).
Tighten the bleed screw.

＊ If bleeding is difficult, it may be Clear Hose
necessary to let the brake fluid settle for
a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the system have
disappeared.
16-8
Right Front Caliper Air Bleed Screw

Add brake fluid to the proper level.
＊ Check the operation of the brake after
bleeding the brake system.
Install the master cylinder reservoir cap and

diaphragm.
Clear Hose
Clear Hose
Relay Valve Air Bleed Screw
16-9
BRAKE PAD
BRAKE PAD REPLACEMENT
Front brake:
Push the caliper pistons all the way in by
pushing the caliper body inward to provide
clearance for new pads.
＊ Always replace the brake pads in pairs to
ensure even disc pressure.
Caliper body
Remove the pad pin plug and loosen the pad

pin.
Pad Pin Plug Pad Pin
Remove the pad pin and the brake pads. Pad Pin
Make sure that the pad spring is installed in

original position.
Install new pads so that the their ends rest on
the pad retainer on the bracket properly.
Install the pad pin by pushing the pads

against the pad spring to align the pad pin
holes in the pads and caliper.
Brake Pads
16-10
Tighten the pad pin to the specified torque.
Install the pad pin plug to the specified

torque.
Pad Pin Pad Pin Plug
Rear/Parking brake (XCITING 500):

pin.
＊ Always replace the brake pads in pairs to
ensure even disc pressure.
Pad Pin Plug Pad Pin
Rear/Parking Caliper Body Bolts

Remove the mount bolts and rear/parking
brake caliper from the rear fork.
Remove the pad pin and brake pads.
16-11
Installation steps:
Turn the parking brake caliper piston
clockwise and push it into the parking brake
caliper.
Parking Brake Caliper Piston
Pin
Install the pad pin by pushing the pads
against the pad spring to align the pad pin
holes in the pads and caliper.
＊ Align the pin on the pad with the groove
on the parking brake caliper piston.
Groove
Rear/Parking Caliper Body Bolts

Install the rear/parking brake caliper to the
rear fork.
Install and tighten the new rear/parking brake
caliper mounting blots to the specified torque.
16-12
Tighten the pad pin to the specified torque.
Install the pad pin plug to the specified

torque.
Rear brake (XCITING 250):
Pad Pin Pad Pin Plug

The rear brake pads and front brake pads
replacement are all the same.
BRAKE DISC INSPECTION
Visually inspect the brake disc for damage or

cracks.
Measure the brake disc thickness.
Service limits:Front: 4mm (0.16 in)

Rear: 4mm (0.16 in)
Replace the brake disc if the smallest

measurement is less than the service limit.
Measure the brake disc warpage.
Service limits:0.3 mm (0.012 in)
16-13
Lower Handlebar Cover

FRONT MASTER CYLINDER
REMOVAL
When removing the brake hose bolt, cover
the end of the hose to prevent contamination.
Secure the hose to prevent fluid from leaking
out.
Remove the upper handlebar cover (page 2-

5).
Drain the front brake hydraulic system (page
16-4).
Remove the two screws and lower handlebar

cover.
Screws
Disconnect the brake light connectors from

front master cylinder.
Brake Light Switch Connectors
Sealing Washers
Remove the brake hose oil bolt, sealing
washers and brake hose eyelet.
Bolt Brake Hose
16-14
Master Cylinder Bolts

Remove the bolts from the master cylinder
holder and remove the master cylinder
assembly.
Holder
Nut Brake Lever
DISASSEMBLY
Remove the brake lever pivot bolt and nut.
Remove the brake lever.
Pivot Bolt
Brake Light Switch

Remove the screw and brake light switch.
Screw
16-15
Brake Light Switch

ASSEMBLY
Install the brake light switch and tighten the

screw to the specified torque.
Screw
Nut Brake Lever

Apply silicone grease to the master piston tip.
Install the brake lever.
Apply silicone grease to the brake lever pivot

bolt sliding surface.
Install and tighten the pivot bolt to the
specified torque.
Install and tighten the pivot nut to the

specified torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft) Pivot Bolt
INSTALLATION
Align the pin on the master cylinder holder
with the hole on the handlebar.
Pin Hole
16-16
Bolts
Install the front master cylinders and holders
with the “UP” mark facing up.
Install the bolts and tighten the upper bolt
first then tighten the lower bolt to the
specified torque.
“UP” Mark
Sealing Washers
Rest the brake hose eyelet against the stopper.
Install the brake hose eyelet with the oil bolt
and new sealing washers.
Tighten the oil bolt to the specified torque.
Bolt Brake Hose
Connect the brake light switch connectors.
Fill the reservoir to the upper level and bleed

the brake system (page 16-7).
16-17
Lower Handlebar Cover

REAR MASTER CYLINDER
REMOVAL
out.
Remove the upper handlebar cover (page 2-

5).
Drain the combination brake hydraulic
system (page 16-5).
Remove the two screws and lower handlebar

cover. Screws
Disconnect the brake light switch connectors

from master cylinder.
Sealing Washers
washers and brake hose eyelet.
Brake Hose Bolt
16-18
Holder Master Cylinder

Remove the bolts from the master cylinder
holder and remove the master cylinder
assembly.
Bolt
Brake Lever Nut

DISASSEMBLY
Remove the brake lever pivot bolt and nut.
Remove the brake lever.
Pivot Bolt
Screw
Remove the screw and brake light switch.
Brake Light Switch
16-19
Screw
ASSEMBLY
Install the brake light switch and tighten the
screw to the specified torque.
Brake Light Switch
Apply silicone grease to the master piston tip. Brake Lever Nut
Install the brake lever.
Apply silicone grease to the brake lever pivot

bolt sliding surface.
Install and tighten the pivot bolt to the
specified torque.
Install and tighten the pivot nut to the

specified torque.

Pivot Bolt
INSTALLATION
Align the pin on the master cylinder holder
with the hole on the handlebar.
Hole Pin
16-20
“UP” Mark Master Cylinder

Install the rear master cylinders and holders
with the “UP” mark facing up.
Install the bolts and tighten the upper bolt
first then tighten the lower bolt to the
specified torque.
Bolt
Sealing Washers
Rest the brake hose eyelet against the stopper.
Install the brake hose eyelet with the oil bolt
and new sealing washers.
Tighten the oil bolt to the specified torque.
Brake Hose Bolt
Connect the brake light switch connectors.

16-21
Sealing Washers Sealing Washers

DELAY VAVLE
REMOVAL
out.

Drain the combination brake hydraulic
system (page 16-5).

washers and brake hose eyelets.
Bolts Brake Hose
Nuts
Remove the two nuts and delay valve.
Delay Valve
16-22
Nuts
INSTALLATION
Install the delay valve and tighten the nuts
securely.
Delay Valve
Sealing Washers Sealing Washers

Install the brake hose eyelets and new sealing
washers.
Tighten the brake hose bolt to the specified
torque while rest the brake hose eyelet
against the stopper on the delay valve.

Bolts Brake Hose
16-23
Brake Hose
FRONT BRAKE CALIPER
REMOVAL
Drain the front brake hydraulic system (left
front brake caliper: page 16-4) or
combination brake hydraulic system (right
front brake caliper: page 16-5).
Remove the brake pads (page 16-10).
Remove the oil bolts, sealing washers and

brake hose from the brake caliper.
Bolts Sealing Washers
Bolts
Remove the mount bolts and front brake
caliper.
Brake Caliper
DISASSEMBLY
Remove pad spring from the caliper body.
＊ Do not remove the retainer from the
bracket unless replacement.
Pad Spring Retainer
16-24
Boots Bracket
Remove the caliper bracket from the caliper
body.
＊ Do not remove the caliper and bracket
pins unless replacement.
ASSEMBLY
Apply silicone grease to the boots inside.
Install the caliper bracket to the caliper.
Pad Spring
Install the pad spring into the caliper body as
shown.
Bolts
INSTALLATION
Install the front caliper onto the fork leg.
Install and tighten the new front caliper
mount bolts to the specified torque.
Brake Caliper
16-25
Brake Hose
Install the brake hose eyelet to the caliper
body with new sealing washers and oil bolts.
Push the brake hose eyelet to the stopper on
the caliper, then tighten the oil bolts to the
specified torque.
Install the brake pads (page 16-10).

Fill and bleed the hydraulic system (page 16-
7 or page 16-8).

REAR/PARKING BRAKE
CALIPER
Remove the muffler (page 2-16).
Drain the rear brake hydraulic system (page
16-5).
Disconnect the parking brake cable from the

brake arm.

pin.
Remove the brake pad (XCITING 500: page
16-11, XCITING 250: page 16-13).
Arm Brake Cable
Brake Hose
Remove the oil bolt, sealing washers and

brake hose from the brake caliper.
16-26
Rear/Parking Brake Caliper Bolts

Remove the mount bolts and rear/parking
brake caliper from the rear fork.

Remove the pad spring from the caliper body.
＊ Do not remove the retainer from the
bracket unless replacement.
Pad Spring Retainer
Remove the caliper bracket from the caliper Bracket

body.
＊ Do not remove the caliper and bracket
pins unless replacement.
ASSEMBLY (XCITING 500)

Apply silicone grease to the boot inside.
Apply silicone grease to the boot inside.
Install the caliper bracket to the caliper.
Boots
16-27
Install the pad spring into the caliper body as

shown.
Pad Spring
Brake Arm
PARKING BRAKE DISASSEMBLY

(XCITING 500)
Remove the lock nut and parking brake arm.
Lock Nut
Brake Shaft Push Rod

Remove the parking brake shaft and push rod.
16-28
Bolts
Removed the two bolts, gasket and parking
brake bracket.
Bracket
Gasket
PARKING BRAKE ASSEMBLY

(XCITING 500)
Install the gasket.
Brake Shaft
Install the parking brake bracket and tighten

the bolts to the specified torque.
Apply silicone grease to the parking brake

shaft rolling surface.
Install the parking brake shaft.
16-29
Brake Arm
Temporarily install the brake arm and the
lock nut.
Lock Nut
Rear/Parking Brake Caliper Bolts

Install the brake pads (page 16-12).
Install the rear/parking brake caliper to the

rear fork and tighten the new mount bolts to
specified torque.
Brake Hose
Install the brake hose eyelet to the caliper
body with new sealing washers and oil bolts.
Push the brake hose eyelet to the stopper on
the caliper, then tighten the oil bolts to the
specified torque.
Fill and bleed the hydraulic system (page 16-

8).
16-30
Arm
Connect the parking brake cable.
Adjust the parking brake (page 3- 26).
REMOVAL/INSTALLATION/
DISASSEMBLY/ASSEMBLY (XCITING
250)
The rear caliper and front caliper

removal/installation/disassembly/assembly
are all the same.
Brake Cable
Brake Cable
PARKING BRAKE LEVER LINK
(XCITING 500)
REMOVAL
Loosen the lock nut and disconnect the

parking brake cable from the parking braking
brake lever link.
Lock Nut
Disconnect the parking brake switch

connector.
Parking Brake Switch Connector
16-31
Parking Brake Lever Link

Remove the two nuts and parking brake lever
link.
Nuts
Parking Brake Switch
DISASSEMBLY
Remove the two screws and parking brake
switch.
ASSEMBLY
Assembly is in the reverse order of
disassembly.
Screw
INSTALLATION
16-32
17. BATTERY/CHARGING SYSTEM XCITING 500/250
17
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
BATTERY/CHARGING SYSTEM
__________________________________________________________________________________
CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1

BATTERY -------------------------------------------------------------------- 17-5 17
CHARGING SYSTEM INSPECTION ----------------------------------- 17-6
ALTERNATOR CHARGING COIL-------------------------------------- 17-7
REGULATOR/RECTIFIER------------------------------------------------ 17-8
17-0
CHARGING SYSTEM LAYOUT
CHARGING CIRCUIT
17-1
SERVICE INFORMATION
GENERAL
CAUTION
• The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide
adequate ventilation when charging.
• The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe
burns. Wear protective clothing and a face shield.
─ If electrolyte gets on your skin, flush with water.
─ If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician
immediately.
• Electrolyte is poisonous.
─ If swallowed, drink large quantities of water or milk and call your local Poison Control
Center or physician immediately, KEEP OUT OF REACH OF CHILDREN.
• Always turn off the ignition switch before disconnecting any electrical component.
• Some electrical components may be damaged if terminals or connectors are connected or
disconnected while the ignition switch is turned to “ON” and current is present.
• For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.
• For a battery remaining in a shorted vehicle, disconnect the negative battery cable from the battery.
• The battery caps should not be removed. Attempting to remove the sealing caps from the cells
may damage the battery.
• The maintenance free battery must be replaced when it reaches the end of its service life.
• The battery can be damaged if overcharged or undercharged, or if left to discharge for long
period. These same conditions contribute to shortening the “life span” of the battery. Even under
normal use, the performance of the battery deteriorates after 2-3 years.
• Battery voltage may recover after battery charging, but under heavy load, the battery voltage will
drop quickly and eventually die out. For this reason, the charging system is often suspected as the
problem. Battery overcharge often results from problems in the battery itself, which may appear
to be an overcharging symptom. If one of the battery cells is shorted and battery voltage does not
increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the
electrolyte level goes down quickly.
• Before troubleshooting the charging system, check for proper use and maintenance of the battery.
Check if the battery is frequently under heavy load, such as having the headlight and taillight on
for long periods of time without riding the vehicle.
• The battery self-discharge when the vehicle is not in use, for this reason, charge the battery every
2 weeks to prevent sulfate from occurring.
• Filling a new battery with electrolyte will produce some voltage, but in order to achieve its
maximum performance, always charge the battery. Also, the battery life is lengthened when it is
initially charged.
• When checking the charging system, always follow the steps in the troubleshooting flow chart
(page 17-4)
• For alternator service, refer to section 12
17-2
BATTERY CHARGING
• This model comes with a maintenance free (MF) battery. Remember the following about MF
batteries.
─ Use only the electrolyte that comes with the battery.
─ Use all of the electrolyte
─ Seal the battery properly
─ Never open the seals again
• For battery charging, do not exceed the charging current and time specified on the battery. Using
excessive current or extending the charging time may damage the battery.
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12V – 12 Ah
Current leakage 0.5 Ma max.
Voltage (20°C/68°F) Full charged 13.0 – 13.2 V
Needs charging Below 12.3 V
Charging current Normal 1.4 A/5 – 10 h
Quick 5.5 A/0.5 h
Alternator Capacity 240 W/5000 rpm
Charging coil resistance (20°C/68°F) 0.1 – 0.5Ω
17-3
TROUBLESHOOTING
Battery is damaged or weak
Remove the battery.
Check the battery condition. Incorrect •Faulty battery
Correct
Incorrect Disconnect the regulator/rectifier

Install the battery. connectors and recheck the battery
Check the battery current leakage. current leakage.
Specified current leakage: 0.5 Ma Incorrect Correct

max
•Faulty regulator/rectifier.
Correct
•Shorted wire harness.
•Faulty ignition switch.
Check the alternator charging coil.
Incorrect •Faulty charging coil.
Standard: 0.1 – 0.5 Ω (20°C/68°F)
Correct
Correct •Faulty battery.

Measure and record the battery
voltage using a digital multimeter.
Start the engine.
Measure the charging voltage.
Compare the measurements to result
of the following calculation.
Measured voltage < measured

charging voltage < 15.5 V
Incorrect
Perform the regulator/rectifier wire Incorrect •Open circuit in related wire.

harness inspection.
•Loose or poor contacts of related
terminal.
Correct •Shorted wire harness
•Faulty regulator/rectifier
17-4
Screws
BATTERY
Unlock and open the seat (page 2-3).
Turn ignition switch OFF.
Remove the screws and battery box cover.
Battery Box Cover
Positive Terminal Negative Terminal

Remove the battery retainer.
With the ignition switch to “OFF” disconnect
the negative (-) terminal lead from the battery
first, then disconnect the positive (+) terminal
lead.
Pull out the battery from the battery box.
After connecting the battery cables, coat the

terminals with grease.
Battery Battery Retainer
VOLTAGE INSPECTION
Remove the battery cover (see above).
Measure the battery voltage using a

commercially available digital multimeter.
Voltage (20ºC/68ºC):
Fully charged: 13.0－13.2 V
Under charged: below 12.3 V
17-5
BATTERY CHARGING
Remove the battery (page 17-5).
Connect the charger positive (+) cable to the

battery positive (+) terminal.
Connect the charger negative (-) cable to the
battery negative (-) terminal.
＊ Turn the power ON/OFF at the chatger,
not at the battery terminals.
Charging current time:
Standard: 1.4 A/5－10 hours
Quick: 5.5 A/0.5 hours
Quick charging should only be done in an

emergency; slow charging is preferred.
For battery charging, do not exceed the
charging current and time specified on the
battery. Using excessive current or extending
the charging time may damage the battery.
CHARGING SYSTEM
INSPECTION
Remove the battery cover (page 17-5).
CURRENT LEAKAGE TEST

Turn the ignition switch OFF, disconnect the
negative (-) cable from the battery.
Connect the ammeter (+) probe to the
negative (-) cable and the ammeter (-) probe
to the battery (-) terminal.
With the ignition switch OFF, check for
current leakage.
When measuring current using a tester, set it
to a high range, and then bring the range
down to an appropriate level. Current flow
higher than the range selected may blow out
the fuse in the tester.
While measuring current, do not turn the
ignition switch ON. A sudden surge of
current may blow out the fuse in the tester.
Specified current leakage: 0.5 Ma max.
If current leakage exceeds the specified value,

a shorted circuit is likely.
Locate the short by disconnecting
connections one by one and measuring the
current.
17-6
CHARGING VOLTAGE INSPECTION

Be sure that the battery is in good condition
before performing this test.
＊ Do not disconnect the battery or any

cable in the charging system without first
switching off the ignition switch. Failure
to follow this precaution can damage the
tester or electrical components.
Start the engine and warm it up to the

operating temperature; stop the engine.
Connect the multimeter between the positive
and negative terminals of the battery.
To prevent short, make absolutely certain

which are the positive and negative terminals
or cable.
With the headlight on and turned to the high
beam position, restart the engine.
Measure the voltage on the multimeter when
the engine runs at 5000 min-1 (rpm).
Standard:
Measured battery voltage (page 17-5) <
Measure charging voltage (see above)
<15.5 V
Alternator Connector
ALTERNATOR CHARGING COIL
INSPECTION
Disconnect the alternator connector.
17-7
Measure the resistance between each Yellow

wire terminals.
Standard: 0.1－0.5 Ω (20ºC/68ºF)
Check for continuity between each Yellow

wire terminal of the alternator side connector
and ground.
There should be continuity.
Replace the alternator stator if resistance is

out of specification, or if any wire has
continuity to ground.
Alternator Connector
Refer to section 12 for alternator stator
replacement.
REGULATOR/RECTIFIER Regulator/Rectifier
WIRE HARNESS INSPECTION
Disconnect the regulator/rectifier connectors.

Check the connectors for loose contacts of
corroded terminals.
Regulator/Rectifier Connectors
Battery line
Measure the voltage between the Red/White
wire terminal and ground.
There should be battery voltage at all times.
Regulator/Rectifier Connector
17-8
Ground line
Check the continuity between the Green wire
terminal and ground.
There should be continuity at all times.
Charging coil line

Measure the resistance between each Yellow
wire terminals.
Standard: 0.1－0.5 Ω (20ºC/68ºF)
Check for continuity between each Yellow
There should be no continuity.
17-9
Regulator/Rectifier (XCITING 500)

Disconnect the regulator/rectifier connectors.
Remove the two bolts, regulator/rectifier and

stay.
Bolts
Regulator/Rectifier (XCITING 250)
Bolts
17-10
18. IGNITION SYSTEM XCITING 500/250
18
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
IGNITION SYSTEM
__________________________________________________________________________________
IGNITION SYSTEM LAYOUT------------------------------------------- 18-1

IGNITION CIRCUIT (XCITING 500) ----------------------------------- 18-1
IGNITION CIRCUIT (XCITING 250) ----------------------------------- 18-2
IGNITION COIL INSPECTION ------------------------------------------ 18-4
IGNITION CONTROL MODULE ---------------------------------------- 18-5 18
18-0
IGNITION SYSTEM LAYOUT
IGNITION CIRCUIT (XCITING 500)
18-1
IGNITION CIRCUIT (XCITING 250)
SERVICE INFORMATION
● Some electrical components may be damaged if terminals or connectors are connected or
disconnected while the ignition switch is “ON” and current is present.
● When servicing the ignition system, always follow the steps in the troubleshooting on page 18-3.
● The ignition timing cannot be adjusted since the ignition control module is factory preset.
● The ignition control module may be damaged if dropped. Also, if the connector is disconnected
when current is flowing, the excessive voltage may damage the ignition control module. Always
turn off the ignition switch before servicing.
● A faulty ignition system is often related to poor connections. Check those connections before
proceeding.
● Make sure the battery is adequately charged. Using the starter motor with a weak battery results in
a slower engine cranking speed as well as no spark at the spark plug.
● Use a spark plug of the correct heat range. Using spark plug with an incorrect heat range can
damage the engine.
● See section 12 for ignition pulse generator removal/installation.
● See section 20 for following components:
ä Ignition switch
ä Engine stop switch
18-2
SPECIFICATIONS
Item Standard
XCITING 500 NGK-CR8E
Spark plug
XCITING 250 NGK-DPR7EA-9
Spark plug gap 0.7 mm (0.028 in)
Ignition system Full transistor digital ignition
Ignition timing Throttle position sensor
TROUBLESHOOTING
LOW PEAK VOLTAGE
● Cranking speed is too low (battery is undercharged).
● Poorly connected connectors or an open circuit in the ignition system.
● Faulty ignition-coil.
● Faulty ignition control module.
NO PEAK VOLTAGE
● Short circuit in engine stop switch or ignition switch wire.
● Faulty engine stop switch or ignition switch.
● Loose or poorly connected ignition control module connectors.
● Open circuit or poor connection in ground wire of the ignition control module.
● Faulty ignition pulse generator.
Faulty ignition control module.
PEAK VOLTAGE IS NORMAL, BUT NO SPARK JUMPS AT THE PLUG

● Faulty spark plug or leaking ignition coil secondary current.
● Faulty ignition coil.
18-3
IGNITION COIL INSPECTION

IGNITION COIL PRIMARY PEAK
VOLTAGE
Check cylinder compression and check that the

spark plugs is installed correctly in the cylinder.
Disconnect the spark plug cap from the spark
plug.
Spark Plug Cap
Spark Plug
Connect known good spark plug to the spark
plug cap and ground the spark plugs to the
cylinder as done in the spark test.
Spark Plug Cap
Turn the ignition switch to “ON” and engine

stop switch ON.
Connect the multimeter (+) probe to the
Black/White wire and the multimeter (-) to the
body ground.
Check for initial voltage at this time.
The battery voltage should be measured.
If the initial voltage cannot be measured, check
the power supply circuit.
Ignition Coil
18-4
IGNITION PULSE GENERATOR

INSPECTION
Disconnect the ignition pulse generator
connector.
Measure the ignition pulse generator resistance
between the Green/White wire and Blue/Yellow
wire.
Standard: 516Ω (20ºC/68ºF)
Ignition Pulse Generator Connector
IGNITION COIL
Disconnect the spark plug cap from the spark
plug (page 18-4).
Disconnect the ignition coil primary connectors.

Remove the two nuts and the ignition coil.
Ignition Coil
IGNITION CONTROL MODULE Ignition Control Module Connectors

Disconnect the ignition control module

connectors and remove the ignition control
module.
Ignition Control Module
18-5
RESISTANCE INSPECTION
＊ Due to the semiconductor in circuit, it
(XCITING 500) is necessary to use a specified tester for
Measure the resistance between the terminals. accurate testing. Use of an improper
tester in an improper range may give
false readings.
B/W G/B V/B
G/Gr G
V/G
L/Y
G/W B/Y V/R Y/L B/L Y/G

Unit: Ω
(+)
(-) L/Y G/GR G/W B/Y B/W G/B G V/R V/B V/G Y/L B/L Y/G
L/Y 91.6K 6.67M 6.68M 46.2K 49.5K 150K 46.2K 12.59M 49.7K
G/GR 9.5M 9.3M ← ↑ 9.23M 9M 9.16M 8.97M 8.96M ↑
G/W 91.8K 6.67M 6.68M ↑ 47K 50.3K 150.9K 47K 12.59M 50.3K ↑
B/Y 15.96M ↑ 15.6M 994 ↑ 15.33M 14.88M 15.04M 14.74M 3.35M 14.7M ↑
B/W 15.96M ↑ 15.6M 994 ↑ 14.96M 14.88M 15.02M 14.74M 3.35M 14.7M ↑
G/B ↑ ← ← ← ← ← ← ← ← ↑
G 44.3K ↑ 44.9K 6.62M 6.63M ↑ 3.54K 103.9K ∞ 12.51M 3.54K ↑
V/R 47.5K ↑ 48.4K 6.62M 6.63M ↑ 3.53K 100.2K 3.54K 12.51M 1.99K ↑
V/B 148.5K ↑ 149.4K 6.75M 6.76M ↑ 102.8K 99.3K 102.7K 12.67M 101.2K ↑
V/G 44.3K ↑ 44.9K 6.62M 6.63M ↑ ∞ 3.55K 103.9K 12.51M 3.55K ↑
Y/L 8.13M ↑ 8.1M ← ↑ 7.81M 7.77M 7.91M 7.72M 7.72M ↑
B/L 47.5K ↑ 48.4K 6.62M 6.62M ↑ 3.53K 1.99K 102.2K 3.53K 12.51M ↑
Y/G ↑ ← ← ← ← ← ← ← ← ←
18-6
RESISTANCE INSPECTION
(XCITING 250) ＊ Due to the semiconductor in circuit, it
Measure the resistance between the terminals.
is necessary to use a specified tester for
accurate testing. Use of an improper
tester in an improper range may give
false readings.
B/W G/B V/B
G/Gr G
V/G
L/Y
G/W B/Y V/R Y/G

Unit: Ω
(+)
(-) L/Y G/GR G/W B/Y B/W G/B G V/R V/B V/G Y/G
L/Y 91.6K 6.67M 6.68M 46.2K 49.5K 150K 46.2K
G/GR 9.5M 9.3M ← ↑ 9.23M 9M 9.16M 8.97M ↑
G/W 91.8K 6.67M 6.68M ↑ 47K 50.3K 150.9K 47K ↑
B/Y 15.96M ↑ 15.6M 994 ↑ 15.33M 14.88M 15.04M 14.74M ↑
B/W 15.96M ↑ 15.6M 994 ↑ 14.96M 14.88M 15.02M 14.74M ↑
G/B ↑ ← ← ← ← ← ← ↑
G 44.3K ↑ 44.9K 6.62M 6.63M ↑ 3.54K 103.9K ∞ ↑
V/R 47.5K ↑ 48.4K 6.62M 6.63M ↑ 3.53K 100.2K 3.54K ↑
V/B 148.5K ↑ 149.4K 6.75M 6.76M ↑ 102.8K 99.3K 102.7K ↑
V/G 44.3K ↑ 44.9K 6.62M 6.63M ↑ ∞ 3.55K 103.9K ↑
Y/G ↑ ← ← ← ← ← ← ←
18-7
19. ELECTRIC STARTER XCITING 500/250
19
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
ELECTRIC STARTER
__________________________________________________________________________________
STARTING SYSTEM LAYOUT ----------------------------------------- 19-1

STARTER MOTOR --------------------------------------------------------- 19-5
STARTER RELAY SWITCH---------------------------------------------- 19-7
19
19-0
STARTING SYSTEM LAYOUT
STARTING CIRCUIT
19-1
SERVICE INFORMATION
GENERAL
• Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could
suddenly start, causing serious injury.
• The starter motor can be serviced with the engine in the frame.
• When checking the starter system, always follow the steps in the troubleshooting flow chart
(page 19-2).
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate
ignition current.
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking
over, the starter motor may be damaged.
• See section 12 for starter clutch servicing.
• See section 20 for following components:
ä Ignition switch
ä Starter switch
ä Brake light switch
TROUBLESHOOTING
• Check for the following before troubleshooting:

─ Blown main fuse (30A) and sub fuse (10 A)
─ Loose battery and starter motor cable
─ Discharged battery
• The starter motor can turn with the following conditions:
─ Ignition switch ON
─ Engine stop switch in RUN
─ Rear brake lever fully squeezed
─ Side stand retracted
─ Starter switch pushed
Starter motor will not turn

Check for loose or poorly Abnormal •Poorly connected battery terminals.
connected battery terminals
and opened or shorted battery •Open or short circuit in battery.
cable.
Normal
(Go to following page)
19-2
(From previous page)
Check for loose or poorly Abnormal •Poorly connected terminal

connected starter relay switch
terminals.
Normal
Check for loose or poorly Abnormal •Poorly connected starter motor cable.
connected or broken starter •Open circuit in starter motor cable.
motor cable.
Normal
With the ignition switch Clicks Connect the starter motor terminal
turned to “ON”, push the directly to the battery positive
starter switch and check for a terminal (Because a large amount of
click sound from the starter current flows, do not use a thin wire).
relay switch.
Starter motor
No clicks Starter motor turns does not turn
•Faulty starter motor.
•Loose or disconnected starter motor cable.

•Faulty starter relay switch.
Check the starter relay coil Abnormal •Faulty side stand switch.
ground line (page 19-7) •Loose or poor contact of connector.
•Open or short circuit in wire harness.
Normal
(Go to following page)
19-3
(From previous page)
Check the starter relay voltage No voltage •Faulty engine stop switch.
(page 19-7). •Faulty starter switch.
•Loose or poor contact of connector.
Battery voltage registers •Open circuit in wire harness.
Check the starter relay voltage Abnormal •Faulty starter relay.

(page 19-7).
Normal
•Loose or poor starter relay connector contact.
19-4
Starter Motor Cable

STARTER MOTOR
INSPECTION
Disconnect the starter motor cable from the

starter relay switch.
Turn the ignition switch to “ON”.
Connect the starter motor cable directly to the
battery positive terminal.
If the starter motor does not turn, the starter
motor is faulty.
Nut
REMOVAL
Remove the carburetor (page 5-6).
Turn the ignition switch turned to “OFF”
Release the rubber cap and remove the terminal

nut to disconnect the starter motor cable from
the starter motor.
Rubber Cap
Remove the two bolts and starter motor. Starter Motor
Bolts
19-5
O-ring
INSTALLATION
Coat a new O-ring with engine oil and install it
into the starter motor groove.
Install the starter motor into the crankcase.
Starter Motor
Install the two bolts and tighten them securely.
Bolts
Starter Motor Cable

Connect the starter motor cable to motor
terminal with the terminal nut and tighten it.
Nut
19-6
Starter Relay Switch

STARTER RELAY SWITCH
INSPECTION
Retracted the side stand.

Turn the ignition switch to “ON” and engine
stop switch on.
Squeeze the rear brake lever fully and push the
starter switch.
The coil is normal if the starter relay switch
clicks.
If you do not hear the switch click. Inspect the

relay switch using the procedure below.
GROUND LINE INSPECTION

Disconnect the starter relay switch connector.
Check for continuity between the Green wire
terminal and ground.
There should be continuity.
Starter Relay Connector
VOLTAGE INSPECTION
Connect the starter relay switch connector.
Turn the ignition switch ON and engine stop
switch to RUN.
Measure the starter relay switch Yellow/Red

If the battery voltage appears only when the rear

brake lever is squeezed fully and starter switch
is pushed, the circuit is normal.
19-7

CONTINUTY INSPECTION
Disconnect the starter relay switch connector
and cables.
Connect a fully charged 12 V battery positive
wire to the relay switch Yellow/Red wire
terminal and negative wire to the Green wire
terminal.
There should be continuity between the cable

terminals while the battery is connected, and no
continuity when the battery is disconnected.
19-8
20. LIGHTS/METERS/SWITCHES XCITING 500/250
20
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
LIGHTS/METERS/SWITCHES
__________________________________________________________________________________

BULB REPLACEMENT --------------------------------------------------- 20- 2
SPEED SENSOR ------------------------------------------------------------ 20- 5
BRAKE LIGHT SWITCH-------------------------------------------------- 20- 7
IGNITION SWITCH -------------------------------------------------------- 20- 7
HANDLEBAR SWITCH --------------------------------------------------- 20- 8
PARKING SWITCH (XCITING 500) ------------------------------------ 20-10
LUGGAGE BOX LIGHT SWITCH -------------------------------------- 20-10
OIL PRESSURE SWITCH ------------------------------------------------- 20-10
FUEL UNIT ------------------------------------------------------------------ 20-13
SIDE STAND SWITCH ---------------------------------------------------- 20-15
HORN ------------------------------------------------------------------------- 20-16
BANK ANGLE SENSOR (XCITING 500) ------------------------------ 20-17
HEATER CONTROL UNIT ----------------------------------------------- 20-18 20
20-0
SERVICE INFORMATION
GENERAL
＊ A halogen head light bulb becomes very hot while the head light is on, and remains for a while
after it is turned off. Be sure to let it cool down before servicing.
• Note the following when replacing the halogen headlight bulb

ä Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb,
as they may create hot spots on the bulb and cause it to fail.
ä If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to
prevent its early failure.
ä Be sure to install the dust cover after replacing the bulb.
• Check the battery condition before performing any inspection that requires proper battery
voltage.
• A continuity test can be made with the switches installed on the scooter.
• Route the wires and cables properly after servicing each component.
20-1
Headlight Connector Dust Cover

BULB REPLACEMENT
HEADLIGHT
＊ A halogen headlight bulb becomes very
hot while the headlight is ON, and
remain for a while after it is turned OFF.
Be sure to let it cool down before
servicing.
Remove the front cover (page 2-11)
Disconnect the headlight connector from the

headlight bulb and remove the dust cover.
Retainer Bulb
Unhook the retainer and remove the bulb from
the headlight case.
＊ Avoid touching the halogen headlight
bulb. Finger prints can create hot spots
that cause a bulb to break.
Install a new bulb in the headlight case, by

aligning the bulb tab with the case groove.
Hook the retainer.
Install the dust cover properly on to the

headlight and connect the headlight connector
Socket
POSITION LIGHT
Remove the bulb socket and position light bulb.

Remove the bulb and replace with a new one.
Bulb
20-2
FRONT TURN SIGNAL Socket Bulb

Turn the bulb socket counterclockwise to

remove it.
Screws
TAILLIGHT/BRAKE LIGHT, REAR TURN
SIGNAL
Remove the six screws and lens.
Lens
Screws
Taillight/Brake light
Remove the two screws and remove the
taillight/brake light.
Taillight/Brake Light
20-3
Connectors
Disconnect the taillight/brake light connectors.
Screw
Rear turn signal
Remove the screw and bulb cap.
Cap Bulb
LICENSE LIGHT
Remove two screws.
Disconnect the license light connector and
remove the license light.
Screws Connector
20-4
Remove the bulb socket and license light bulb.

Socket Bulb
Speed Sensor connector
SPEED SENSOR
Disconnect the speed sensor connector.

Remove the bolt and speed sensor.
Bolt Speed Sensor
Speed Sensor
INSPECTION
Measure the speed sensor to speed sensor guide
clearance.
Standard (A): 0.3 – 1.2 mm (0.0012 – 0.048 in)
Speed Sensor Guide
20-5
Speed Sensor
ADJUSTMENT
Remove the bolt and speed sensor.
Bolt
Remove the speed sensor cap.
Cap
Lock Screw
Loosen the lock screws and adjust speed sensor
to the standard clearance.
Standard: 0.3 – 1.2 mm (0.0012 – 0.048 in)
Lock Screw
20-6
BRAKE LIGHT SWITCH

Remove the upper handlebar cover (page 2-5).
Disconnect front or rear light switch connector

and check for continuity between the switch
terminals.
There should be continuity with the front or rear

brake lever squeezed, and there should be no
continuity with the front or rear brake lever is
released.
Brake Light Switch
Connector Ignition Switch (Comb Switch)
IGNITION SWITCH
INSPECTION
Disconnect the ignition switch connector and

check for continuity at the switch side connector
terminals.
Continuity should exist between the color code
wires as follows:
20-7
Light Switch
HANDLEBAR SWITCH
INSPECTION
Right handlebar switch

Disconnect the right handlebar switch connector
and check for continuity at switch side connector
terminals.
wires as follows:
Starter Switch
Hazard Switch
Engine Stop Switch
20-8
Turn Signal Switch (Winker Switch)

Left handlebar switch
Disconnect the left handlebar switch connector
and check for continuity at switch side connector
terminals.
wires as follows:
Horn Switch
Passing Switch
Dimmer Switch
20-9
PARKING SWITCH (XCITING 500)

INSPECTION
Disconnect the parking switch connector and

check for continuity between the switch
terminals.
There should be continuity with the parking

lever pull up, and there should be no continuity
with the front brake lever is push down.
Parking Brake Switch Connector
Luggage Box Light Switch
LUGGAGE BOX LIGHT SWITCH

INSPECTION
Disconnect the luggage box light switch

connector and check for continuity between the
switch terminals.
There should be no continuity with the luggage

box light switch pushed, and there should be
continuity with the luggage box light switch is
released.
Luggage Box Light Switch Connector
Oil Pressure Warning Indicator

OIL PRESSURE SWITCH
INSPECTION
If the oil pressure warning indicator stays on
while the engine running, check the engine oil
level before inspection.
Make sure that the oil pressure warning

indicator come on with the ignition switch ON.
20-10
Dust Cover
If the indicator does not come on, inspect as
follow:
Remove the dust cover and disconnect oil

pressure switch terminal.
Oil Pressure Switch Terminal

Short the oil pressure switch wire terminal with
the ground using a jumper wire.
The oil pressure warning indicator comes on
with the ignition switch is ON.
If the light does not comes on, check the fuse
and wires for a loose connection or an open
circuit.
Start the engine and make sure that the light

goes out.
If the light does not go out, check the internal oil
for leak.
If the engine oil does not leak, replace the oil
pressure switch (see below).
Oil Pressure Switch
Remove the dust cover and disconnect oil
pressure switch terminal.
Remove the oil pressure switch from the
crankcase.
20-11
Apply sealant to the oil pressure switch threads

as shown.
Install the oil pressure switch onto the crankcase,

tighten it to the specified torque.
Oil Pressure Switch Terminal

Connect the oil pressure switch terminal to the
switch.
Dust Cover
Install the dust cover.
20-12
Fuel Unit
FUEL UNIT
REMOVAL
Disconnect the fuel unit connector.
Fuel Unit Wire
Retainer
Turn the fuel unit retainer counterclockwise and
remove it.
Remove the fuel unit.

＊ Be careful not to bend or damage the
fuel unit float arm.
20-13
INSPECTION
Connect the fuel unit wire connectors and turn
the ignition switch “ON”.
＊ Before performing the following test,
operate the turn signals to determine that Upper
the battery circuit is normal.
Check the fuel meter for correct indication by

moving the fuel unit float up and down.
Float Position Display
Upper Much (Full)
Lower Less (Empty)
Wire Terminals Display

Free From Much to Less
Apply From Less to Much
The fuel meter is normal if it operates as above
indicated. If not, check for poorly connected
terminals or shorted wires.
Lower
Groove
INSTALLATION
Install the O-ring and fuel unit.
＊Align the groove on the fuel unit with
the flange on the fuel tank.
Flange
20-14
Install the fuel unit retainer.

＊Align the arrow mark on the fuel unit
retainer with the arrow mark on the fuel
tank.
Side Stand Switch Connector

SIDE STAND SWITCH
INSPECTION
Remove the left floor skirt (page 2-5).
Disconnect the side stand switch connector.

There should be continuity between the
Yellow/Green and Green with the side stand
retracted.
There should be continuity between the
Yellow/Black and Green with the side stand
applied.
Luggage Box Light Connector

REMOVAL
Remove the left floor skirt (page 2-5).
Disconnect the side stand switch connector.

Remove the bolt and side stand switch from the
side stand.
Bolt
20-15
Installs the side stand switch aligning the switch

pin with the side stand hole.
Install and tighten the side stand switch bolt

securely.
Hole Pin
Connector
HORN
INSPECTION
Disconnect the horn connectors from the horn.
Connect a 12 V battery to the horn terminals.

The horn is normal if it sounds when the 12 V
battery is connected across the horn terminals.
Horn
Disconnect the horn connectors from the horn.

Remove the nut and horn.
Nut
20-16
BANK ANGLE SENSOR (XCITING

500)
INSPECTION
Support the scooter level surface.
Turn the ignition switch to “ON” and measure

the voltage between the following terminals of
the bank angle sensor connector with the
connector connected.
TERMINAL STANDARD
Black/Blue Battery voltage
Black/White Battery voltage – (0-1 V)
Bank Angle Sensor
The engine should stop as you incline the bank

angle sensor approximately degrees to the left or
right.
Disconnect the bank angle sensor connector.
Remove the two screws, washers and bank angle
sensor.
Bank Angle Sensor Screws/Washers
20-17

＊Install the bank angle sensor with its
“UP” mark facing up.
Tighten the mounting screws securely.
HEATER CONTROL UNIT Nut

INSPECTION
Heater control unit inspection
1.Open ignition switch to check if the brown
/blue wire of it is enough voltage.
2.Put the heater controller unit in refrigerator. Start
engine after keeping the temperature under 10 ±
4℃.
3.Check if the yellow wire of heater controller
unit has output voltage.
Start engine and if the temperature of heater
controller unit is under 10 ± 4℃. Check if the
white/yellow wire of heater controller unit has
output voltage. If it has not any voltage. It is
Heater Control Unit
damaged.
Remove the nut and heater control unit.
20-18
21. WIRE DIAGRAM XCITING 500
21XCITING 500 21
WIRE COLORS
(GROUND/MARKING)
21-0
21. WIRING DIAGRAMS XCITING 500/250
XCITING 250
21-1

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XCITING 500/250

By KWANG YANG Motor Co., Ltd.

Sections 7 through 13 give instructions CRANKCASE/CRANKSHAFT 13

of engine parts. Section 14 through 16 is WHEEL/FRONT SHOCK ABSORBER

Most sections start with an assembly or IGNITION SYSTEM 18

KWANG YANG MOTOR CO., LTD.

Location of Frame Serial Number

Location of Engine Serial Number

SPECIFICATIONS (XCITING 500)

Ground clearance 150 mm (6 in) Type Helical gear/spur gear

Bore x stroke circumference

Front Telescopic fork

Frame type Back born

SPECIFICATIONS (XCITING 250)

Rear wheel 150/70-14 Type Helical gear/spur gear

Valve arrangement O.H.C., chain drive circumference

Front Telescopic fork

Oil filter type Full-flow filtration

SERVICE PRECAUTIONS  Apply or add designated greases and

 After reassembly, check all parts for proper

 When tightening bolts or nuts, begin with

 When two persons work together, pay

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure to

 After operation, check all connecting

 Before connecting a terminal, check for

 Insert the terminal completely.

 Secure wire harnesses to the frame with

 Do not squeeze wires against the weld or

 After clamping, check each harness to

 When rubber protecting cover is used to

 When fixing the wire harnesses, do not

 Route wire harnesses to avoid sharp edges

 After routing, check that the wire harnesses  Symbols:

: Apply engine oil to the

: Transmission Gear Oil (90#)

 When a testing device is used, make sure to ＊ : Note

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

ENGINE (XCITING 500)

Item Q‘ty Thread dia. Torque Remarks

ENGINE (XCITING 500) (Cont’d)

Item Q‘ty Thread dia. Torque Remarks

ENGINE (XCITING 250)

ENGINE (XCITING 250) (Cont’d)

Item Q‘ty Thread dia. Torque Remarks

Tool Name Tool No. Remarks

Tool Name Tool No. Remarks

Engine Oil Grease

Front Wheel Bearing

Center Stand/Side Stand Pivot

CABLE & HARNESS ROUTING (XCITING 500)

CABLE & HARNESS ROUTING (XCITING 250)

ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment Symptom Probable Cause

Check if fuel reaches

Test cylinder cStarter motor idles but

Remove spark plug and

ENGINE LACKS POWER

SERVICE PRECAUTIONS Apply or add designated greases and

After reassembly, check all parts for proper

When tightening bolts or nuts, begin with

When two persons work together, pay

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

After operation, check all connecting

Before connecting a terminal, check for

Insert the terminal completely.

Secure wire harnesses to the frame with

Do not squeeze wires against the weld or

After clamping, check each harness to

When rubber protecting cover is used to

When fixing the wire harnesses, do not

Route wire harnesses to avoid sharp edges

After routing, check that the wire harnesses Symbols:

When a testing device is used, make sure to ＊ : Note

Be careful not to drop any parts.

When rust is found on a terminal, remove