manual de taller xciting 500ri LER.pdf
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XCITING 500/500 AFI/250/300 AFI
By KWANG YANG Motor Co., Ltd. First Edition, Apr 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-SB30AA-A1
XCITING 500/500 AFI/250/300 AFI
PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO XCITING 500/500 AFI /250/300 AFI.
TABLE OF CONTENTS
Section 1 contains the precautions for all operations stated in this manual. Read them carefully before any operation is started.
Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.
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 DEPARTMENT
ELECTRICAL EQUIPMENT
Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section.
1
FRAME COVERS /EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
FUEL SYSTEM/FUEL PUMP/FUEL TANK/CARBURETOR
5
AFI (AUTOMATIC FUEL INJECTION)
6
COOLING SYSTEM
7
ENGINE REMOVAL/INSTALLATION
8
CYLINDER HEAD/VALVES
9
CYLINDER/PISTON
10
DRIVE AND DRIVEN PULLEY
11
FINAL REDUCTION
12
A.C. GENEARTOR/STARTER CLUTCH 13
CHASSIS
Sections 8 through 14 give instructions for disassembly, assembly and adjustment of engine parts. Section 15 through 17 is the removal/ installation of chassis. Section 18 through 22 states the testing and measuring methods of electrical equipment.
ENGINE
Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations.
GENERAL INFORMATION
CRANKCASE/CRANKSHAFT
14
STEERING HANDLEBAR/FRONT WHEEL/FRONT SHOCK ABSORBER
15
REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER`
16
BRAKE SYSTEM
17
BATTERY/CHARGING SYSTEM
18
IGNITION SYSTEM
19
ELECTRIC STARTER
20
LIGHTS/METERS/SWITCHES
21
WIRING DIAGRAMS
22
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
1
1
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GENERAL INFORMATION __________________________________________________________________________________
SERIAL NUMBER----------------------------------------------------------- 1 - 1 SPECIFICATIONS (XCITING 500)--------------------------------------- 1 - 2 SPECIFICATIONS (XCITING 500 AFI) --------------------------------- 1 - 3 SPECIFICATIONS (XCITING 250)--------------------------------------- 1 - 4 SPECIFICATIONS (XCITING 300 AFI) --------------------------------- 1 - 5 SERVICE PRECAUTIONS ------------------------------------------------- 1 - 6 TORQUE VALUES ---------------------------------------------------------- 1-10 SPECIAL TOOLS ------------------------------------------------------------ 1-14 LUBRICATION POINTS --------------------------------------------------- 1-15 CABLE & HARNESS ROUTING (XCITING 500) ------------------------- 1-17 CABLE & HARNESS ROUTING (XCITING 500 AFI)-------------------- 1-27 CABLE & HARNESS ROUTING (XCITING 250) ------------------------- 1-35 CABLE & HARNESS ROUTING (XCITING 300 AFI)-------------------- 1-43 TROUBLESHOOTING (XCITING 500/250) ---------------------------- 1-51 TROUBLESHOOTING (XCITING 500 AFI/300 AFI) ----------------- 1-62
1-0
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SERIAL NUMBER
Location of Frame Serial Number
Location of Engine Serial Number
1-1
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SPECIFICATIONS (XCITING 500) ITEM
Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement
Moving Device
Engine
12.8 L (3.38 Imp gal, 2.82 US gal CVK 98 φ36 mm (φ1.44 in) PISTON Full transistor ignition CR8E
Ignition timing
Throttle position sensor
Spark plug gap
0.6～0.7mm (0.002～ 0.003 in) 12V12AH Dry, centrifugal automatic
Battery Capacity Clutch Type Type
Helical gear/spur gear
Operation
Automatic centrifugal Type
Type
CVT
Preliminary Final FR/RR tire rolling circumference Tire pressure Front (rider only/60 kg) Rear Turning angle
Brake system type Damping Device
Lubrication System
Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C., chain drive 92 x 75 mm Bore x stroke (3.7 x 3 in) Compression ratio 10.5:1 13 kgf/cm² (1300kPa, Compression pressure 185 psi) Open 2° BTDC Intake valve Close 45° ABDC Open 45° BBDC Exhaust valve Close 5° ATDC Valve clearance Intake 0.1 mm (0.004 in) Exhaust 0.1 mm (0.004 in) (cold) Idle speed 1400 rpm pressure & Lubrication type Forced Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 2.5 L (2.2 Imp qt, Oil capacity 2.65 Us qt) Final reduction oil 0.55 L (0.5 Imp qt, 0.58 Us qt) capacity Cooling Type Liquid cooled
Type Spark plug
Transmis- Reduction sion Gear Ratio
Min. turning radius
Ignition System
Ground clearance
Type Main jet NO. Venturi dia. Throttle type
Power Drive System
Tires
Carburetor
Curb weight
83 kg (183 lbs) 132 kg (290 lbs) 215 kg (473 lbs) 90 kg (198 lbs) 141 kg (310 lbs) 231 kg (508 lbs) 120/70-15 150/70-14 150 mm (6 in) 2750 mm (110 in) Electric starter motor
Fuel capacity
Electrical Equipment
Dry weight
92# nonleaded gasoline
Front wheel Rear wheel Total Front wheel Rear wheel Total Front wheel Rear wheel
ITEM SPECIFICATIONS Air cleaner type & No Wet paper type element Fuel System
Name Overall length Overall width Overall height Wheel base Engine type Displacement Fuel Used
SPECIFICATIONS XCITING 500 2250 mm (90 in) 815 mm (33 in) 1450 mm (58 in) 1570 mm (63 in) O.H.C. 498.5 cm3 (30.4 cu-in)
Suspension type
Frame type
2.68 – 1 5.4 1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28 psi)
2.5 kg/cm² (250 Kpa, 36 psi) Left 40° Right 40° Rear Disk brake Front Disk brake Front
Telescopic fork
Rear
Unit swing Back born
1-2
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SPECIFICATIONS (XCITING 500 AFI) ITEM
92# nonleaded gasoline
Dry weight
Ground clearance Min. turning radius
Engine
1-3
Throttle Body Venturi φ40 mm (φ1.6 in) dia Full transistor ignition Type Spark plug
CR7E
Ignition timing
ECU
Spark plug gap
Battery Capacity Clutch Type
Helical gear/spur gear
Operation
Automatic centrifugal Type
Type
CVT
Preliminary Final FR/RR tire rolling circumference Tire pressure Front (rider only/60 kg) Rear
Brake system type Suspension type
Frame type
0.6～0.7mm (0.002～ 0.003 in) 12V12AH Dry, centrifugal automatic
Type
Turning angle
Damping Device
Lubrication System
Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C., chain drive 92 x 75 mm Bore x stroke (3.7 x 3 in) Compression ratio 10.5:1 13 kgf/cm² (1300kPa, Compression pressure 185 psi) Open 5° BTDC Intake valve Close 45° ABDC Open 45° BBDC Exhaust valve Close 5° ATDC Valve clearance Intake 0.1 mm (0.004 in) Exhaust 0.1 mm (0.004 in) (cold) Idle speed 1400 rpm Forced pressure & Lubrication type Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 2.5 L (2.2 Imp qt, Oil capacity 2.65 Us qt) Final reduction oil 0.55 L (0.5 Imp qt, 0.58 Us qt) capacity Cooling Type Liquid cooled
Moving Device
Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement
12.8 L (3.38 Imp gal, 2.82 US gal
Fuel capacity
Transmis- Reduction sion Gear Ratio
Tires
83 kg (183 lbs) 132 kg (290 lbs) 215 kg (473 lbs) 90 kg (198 lbs) 141 kg (310 lbs) 231 kg (508 lbs) 120/70-15 150/70-14 150 mm (6 in) 2750 mm (110 in) Electric starter motor
Power Drive System
Curb weight
Front wheel Rear wheel Total Front wheel Rear wheel Total Front wheel Rear wheel
ITEM SPECIFICATIONS Air cleaner type & No Wet paper type element
Ignition System
Fuel Used
Name Overall length Overall width Overall height Wheel base Engine type
Fuel System Electrical Equipment
Displacement
SPECIFICATIONS XCITING 500 AFI 2250 mm (90 in) 815 mm (33 in) 1450 mm (58 in) 1570 mm (63 in) O.H.C. 498.5 cm3 (30.4 cu-in)
2.68 – 1 5.4 1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28 psi)
2.5 kg/cm² (250 Kpa, 36 psi) Left 40° Right 40° Rear Disk brake Front Disk brake Front
Telescopic fork
Rear
Unit swing Back born
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SPECIFICATIONS (XCITING 250) ITEM
Curb weight
Min. turning radius
Engine
Ignition timing
Throttle position sensor
Spark plug gap
0.6～0.7mm (0.002～ 0.003 in) 12V10AH Dry, centrifugal automatic
Battery Capacity Clutch Type Type
Helical gear/spur gear
Operation
Automatic centrifugal Type
Type
CVT
Preliminary Final FR/RR tire rolling circumference Tire pressure Front (rider only/60 kg) Rear Turning angle
Brake system type Damping Device
Lubrication System
Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C., chain drive 72.7 x 60 mm Bore x stroke (2.908 x 2.4 in) Compression ratio 10.3:1 15 kgf/cm² (1500kPa, Compression pressure 213 psi) Open 9° BTDC Intake valve Close 45° ABDC Open 38° BBDC Exhaust valve Close 10° ATDC Valve clearance Intake 0.1 mm (0.004 in) Exhaust 0.1 mm (0.004 in) (cold) Idle speed 1600 rpm Forced pressure & Lubrication type Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 1.1 L (0.97 Imp qt, Oil capacity 1.17 Us qt) Final reduction oil 0.2 L (0.18 Imp qt, 0.21 Us qt) capacity Cooling Type Liquid cooled
Moving Device
Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement
12.8 L (3.38 Imp gal, 2.82 US gal CVK 94 φ30 mm (φ1.2 in) PISTON Full transistor ignition DPR7EA-9
Transmis- Reduction sion Gear Ratio
Ground clearance
75 kg (165 lbs) 110 kg (242 lbs) 185 kg (407 lbs) 81 kg (178 lbs) 119 kg (262 lbs) 200 kg (440 lbs) 120/70-15 150/70-14 170 mm (6.8 in) 2600 mm (104 in) Electric starter motor
Type Spark plug
Power Drive System
Tires
Front wheel Rear wheel Total Front wheel Rear wheel Total Front wheel Rear wheel
Type Main jet NO. Venturi dia. Throttle type
Ignition System
Dry weight
92# nonleaded gasoline
Carburetor
Fuel Used
Fuel capacity
Electrical Equipment
Displacement
ITEM SPECIFICATIONS Air cleaner type & No Wet paper type element Fuel System
Name Overall length Overall width Overall height Wheel base Engine type
SPECIFICATIONS XCITING 250 2250 mm (90 in) 815 mm (33 in) 1450 mm (58 in) 1570 mm (63 in) O.H.C. 251/249.1 cm3 (15.3/15.8 cu-in)
Suspension type
Frame type
0.83 – 2.2 8.72 1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28 psi)
2.5 kg/cm² (250 Kpa, 36 psi) Left 40° Right 40° Rear Disk brake Front Disk brake Front
Telescopic fork
Rear
Unit swing Back born
1-4
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SPECIFICATIONS (XCITING 300 AFI) ITEM
Fuel Used Dry weight
Ground clearance Min. turning radius
Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement
75 kg (165 lbs) 110 kg (242 lbs) 185 kg (407 lbs) 81 kg (178 lbs) 119 kg (262 lbs) 200 kg (440 lbs) 120/70-15 150/70-14 170 mm (6.8 in) 2600 mm (104 in) Electric starter motor
Throttle Body Venturi φ32 mm (φ1.2 in) dia Full transistor ignition Type Spark plug
DPR6EA-9
Ignition timing
ECU
Spark plug gap
Battery Capacity Clutch Type
0.8～0.9mm (0.002～ 0.003 in) 12V12AH Dry, centrifugal automatic
Type
Helical gear/spur gear
Operation
Automatic centrifugal Type
Type
CVT
Preliminary Final FR/RR tire rolling circumference
Moving Device
Engine
Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C., chain drive Tire pressure 72.7 x 65.2 mm (rider only/60 Bore x stroke (2.908 x 2.4 in) kg) Compression ratio 10.6:1 15 kgf/cm² (1500kPa, Compression pressure Turning 213 psi) angle Open 9° BTDC Intake valve Brake system Close 40° ABDC type Open 42° BBDC Exhaust valve Close 7° ATDC Valve clearance Intake Suspension 0.1 mm (0.004 in) type Exhaust 0.1 mm (0.004 in) (cold) Idle speed 1600 rpm Frame type Forced pressure & Lubrication type Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 1.1 L/0.9L (0.97 Imp qt, Oil capacity 1.17 Us qt) Final reduction oil 0.23 L/0.18L (0.2 Imp qt, 0.24 Us qt) capacity Cooling Type Liquid cooled Damping Device
Lubrication System
1-5
12.8 L (3.38 Imp gal, 2.82 US gal
Fuel capacity
Transmis- Reduction sion Gear Ratio
Tires
Front wheel Rear wheel Total Front wheel Rear wheel Total Front wheel Rear wheel
Power Drive System
Curb weight
9 nonleaded gasoline
ITEM SPECIFICATIONS Air cleaner type & No Wet paper type element
Ignition System
Displacement
Fuel System Electrical Equipment
Name Overall length Overall width Overall height Wheel base Engine type
SPECIFICATIONS XCITING 300 AFI 2250 mm (90 in) 815 mm (33 in) 1450 mm (58 in) 1570 mm (63 in) O.H.C. 270 cm3 (15.3/15.8 cu-in)
Front
0.83 – 2.2 8.26 1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28 psi)
2.5 kg/cm² (250 Kpa, 36 psi) Left 40° Right 40° Rear Disk brake Front Disk brake Rear
Front
Telescopic fork
Rear
Unit swing Back born
1. GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.
XCITING 500/500 AFI/250/300 AFI
Apply or add designated greases and lubricants to the specified lubrication points.
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 disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.
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 connection, apply grease to the battery terminals. Terminal caps shall be installed securely.
1-6
1. GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity
XCITING 500/500 AFI/250/300 AFI
The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Check if there is any loose wire.
After operation, terminal caps shall be installed securely.
Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
When taking out the connector, the lock on the connector shall be released before operation.
Check the double connector cover for proper coverage and installation.
Hold the connector body when connecting or disconnecting it. Do not pull the connector wire.
Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up.
Check if any connector terminal is bending, protruding or loose.
Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses.
1-7
1. GENERAL INFORMATION After clamping, check each wire to make sure it is secure.
XCITING 500/500 AFI/250/300 AFI
Route harnesses so they are neither 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. 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 projected ends of bolts and screws.
When installing other parts, do not press or squeeze the wires. Do not press or squeeze the wire
1-8
1. GENERAL INFORMATION After routing, check that the wire harnesses are not twisted or kinked.
Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
XCITING 500/500 AFI/250/300 AFI
Symbols: The following symbols represent the servicing methods and cautions included in this service manual.
Engine Oil
: Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication.
Grease
: Transmission Gear Oil (90#) Gear Oil
When a testing device is used, make sure to 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！
1-9
＊
: Note
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
TORQUE VALUES STANDARD TORQUE VALUES Item
Torque N•m (kgf•m, lbf•ft)
5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 14mm bolt and nut
5(0.5, 4) 10 (1, 7) 22 (2.2, 16) 35 (3.5, 25) 55 (5.5, 40) 70 (7, 50)
Item 4mm screw 5mm screw 6mm screw, SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange bolt and nut
Torque N•m (kgf•m, lbf•ft) 3 (0.3, 2) 4 (0.4, 3) 9 (0.9, 6.5) 12 (1.2, 9) 27 (2.7, 20) 40 (4, 29)
Torque specifications listed below are for important fasteners.
ENGINE (XCITING 500/XCITING 500 AFI) Item MAINTENANCE: Engine oil drain plug Oil strainer screen cap Oil filter cartridge Transmission oil drain bolt Transmission oil filler bolt Spark plug Tappet adjust nut LUBRICATION SYSTEM: Oil pump screw Oil cooler bolt COOLING SYSTEM: Water pump cover bolt CYLINDER HEAD: Breather separator bolt Cylinder head bolt (1 – 4) Cylinder head bolt (5 – 13) Cylinder head cover bolt Cam chain tensioner bolt Tensioner pivot bolt Rocker arm shaft DRIVE/DRIVEN PULLEY: Drive face nut Clutch out nut
Q‘ty
Thread dia. (mm)
Torque N•m (kgf•m, lbf•ft)
1 1 1 1 1 1 4
12 30 20 8 8 10 5
25 (2.5, 18) 15 (1.5, 11) 10 (1, 7) 20 (2, 15) 20 (2, 15) 12 (1.2, 9) 9 (0.9, 6)
1 2
4 16
3 (0.3, 2) 35 (3.5, 25)
2
6
13 (1.3, 9)
3 4 9 4 2 1 2
6 10 8 6 6 8 18
13 (1.3, 9) 48 (4.8, 35) 23 (2.3, 17) 10 (1, 7) 12 (1.2, 9) 10 (1, 7) 45 (4.5, 32)
Apply oil Apply oil Apply oil
1 1
18 14
135 (13.5, 97) 80 (8, 58)
Apply oil Apply oil
Remarks
Apply oil
1-10
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE (XCITING 500/XCITING 500 AFI) Item Drive plate nut ALTERNATOR ACG flywheel nut FINAL REDUCTION: Transmission cover bolt CRANKCASE: Crankcase bolt Oil pipe bolt Cam chain guide SWITCH: Oil pressure switch
(Cont’d)
1
Thread dia. (mm) 28
Torque N•m (kgf•m, lbf•ft) 78 (7.8, 56)
1
14
55 (5.5, 40)
8
8
27 (2.7, 20)
13 2 2
6 16 8
12 (1.2, 9) 43 (4.3, 31) 20 (2, 15)
Apply oil Apply oil
1
PT 1/8
22 (2.2, 16)
Apply seal
Q‘ty
Remarks
ENGINE (XCITING 250/XCITING 300 AFI) Item MAINTENANCE: Valve adjusting lock nut Spark plug Transmission oil drain bolt Transmission oil check/fill bolt Crank case oil drain bolt Oil filter screen cap LUBRICATION SYSTEM: Oil pump screw COOLING SYSTEM: Water pump impeller CYLINDER HEAD: Cylinder head cap nut Tensioner lifter bolt Cylinder head cover bolt Cam chain tensioner bolt
1-11
Q‘ty
Thread dia.(mm)
Torque N•m (kgf•m, lbf•ft)
2 1 1 1 1 1
5 10 12 8 12 30
9 (0.9, 6.5) 12 (1.2, 9) 20 (2, 15) 20 (2, 15) 25 (2.5, 18) 15 (1.5, 10.8)
1
3
2 (0.2, 1.4)
1
7
12 (1.2, 8.6)
Left screw
4 1 4 2
8 6 6 6
25 (2.5, 18) 4 (0.4, 3) 12 (1.2, 8.6) 12 (1.2, 8.6)
Apply oil
Remarks
Apply oil
Apply oil
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE (XCITING 250/XCITING 300 AFI) Item DRIVE/DRIVEN PULLEY: Drive face nut Clutch outer nut Clutch drive plate nut Left crankcase cover bolt ALTERNATOR A.C.G. stator Flywheel nut FINAL REDUCTION: Transmission case cover bolt CRANKCASE: Cam chain guide bolt SWITCH: Oil pressure switch
(Cont’d)
Q‘ty
Thread dia. (mm)
Torque N•m (kgf•m, lbf•ft)
1 1 1 6
14 12 28 6
93 (9.3, 67) 54 (5.4, 39) 54 (5.4, 39) 12 (1.2, 8.6)
5 1
5 14
9 (0.9, 6.5) 55 (5.5, 40)
9
8
20 (2, 14.4)
1
6
10 (1, 7)
1
PT 1/8
22 (2.2, 16)
Remarks Apply oil
Apply seal
1-12
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
FRAME
Item STEERING: Handlebar bolt Upper pinch bolt Lower pinch bolt Bridge stem nut Steering stem lock nut Top thread WHEEL: Front axle bolt Front fork bolt Rear axle nut (XCITING 500) Rear axle nut (XCITING 250) SUSPENSION: Rear shock absorber bolt Rear fork BRAKE: Front caliper mounting bolt Rear caliper mounting bolt Brake fluid bolt Master cylinder bolt ENGINE HANGER: Engine hanger bolt Engine mounting bolt/nut (XCITING 500) Engine mounting bolt/nut (XCINTING 250) Engine hanger rod nut MUFFLER Exhaust pipe nut Muffler mount bolt
1-13
Q‘ty Thread dia.(mm)
Torque N•m (kgf•m, lbf•ft)
4 2 4 1 1 1
8 8 8 22 25.4 25.4
23 (2.3, 17) 23 (2.3, 17) 32 (3.2, 23) 62 (6.2, 45) 55 (5.5, 40) 20 (2, 15)
1 2 1 1
18 8 20 16
20 (2, 15) 23 (2.3, 17) 180 (18, 130) 140 (14, 100)
4 2
10 8
40 (4, 29) 32 (3.2, 23)
4 2 6 4
8 8 10 6
32 (3.2, 23) 32 (3.2, 23) 35 (3.5, 25) 12 (1.2, 9)
4 1
10 14
50 (5, 36) 80 (8, 58)
1
10
50 (5, 36)
1
10
35 (3.5, 25)
2 3
8 10
20 (2, 14) 35 (3.5, 25)
Remarks
Replace a new one Replace a new one
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
SPECIAL TOOLS XCITING 500/XCITING 500 AFI Tool Name
Tool No.
Oil seal & bearing installers Lock nut socket wrench Universal holder Flywheel holder Tappet adjuster Bearing pullers Valve spring compressor Oil filter cartridge wrench Clutch spring compressor Flywheel puller Lock nut socket wrench Steering stem top thread wrench
A120E00014 A120E00015 A120E00017 A120E00021 A120E00036 A120E00037 A120E00040 A120E00052 A120E00053 A120E00054 A120F00007 A120F00023
Remarks Oil seal & bearing install Steering stem removal or install Holding clutch for removal A.C. generator flywheel holding Tappet adjustment Bearing removal Valve removal Cartridge removal or install Clutch disassembly A.C. generator flywheel removal Steering stem removal or install Steering stem removal or install
XCITING 250/XCITING 300 AFI Tool Name Flywheel puller Oil seal & bearing installers Lock nut socket wrench Universal holder Flywheel holder Clutch spring compressor Tappet adjuster
Tool No. A120E00003 A120E00014 A120E00015 A120E00017 A120E00021 A120E00034 A120E00036
Remarks A.C. generator flywheel removal Oil seal & bearing install Steering stem removal or install Holding clutch for removal A.C. generator flywheel holding Clutch disassembly Tappet adjustment
Bearing pullers A120E00037 Bearing removal Valve spring compressor A120E00040 Valve removal Lock nut socket wrench A120F00007 Steering stem removal or install Steering stem top thread wrench A120F00023 Steering stem removal or install
1-14
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
LUBRICATION POINTS ENGINE Lubrication Points
Lubricant
Valve guide/valve stem movable part Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft Balancer shaft Crankshaft one-way clutch movable part Oil pump drive chain Starter reduction gear engaging part O-ring face Oil seal lip
•Genuine KYMCO Engine Oil (SAE 5W-50) •API SJ Engine Oil
Drive gear shaft Countershaft Final gear Final gear shaft
Transmission oil: SAE 90
Transmission gearshaft bearing part A.C. generator connector
1-15
Adhesive
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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 Seat Lock
Throttle Cable
Grease Front/Rear Brake Lever Pivot
Front Wheel Bearing
Rear Wheel Bearing
Grease Grease Center Stand/Side Stand Pivot Grease
1-16
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CABLE & HARNESS ROUTING (XCITING 500)
1-17
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
1-18
1. GENERAL INFORMATION
1-19
XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
1-20
1. GENERAL INFORMATION
1-21
XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CABLE & HARNESS ROUTING (XCITING 500 AFI)
Tilt Switch
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
Tilt Switch
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
Revise to front cover position
Fuel Pump Relay
Rear Brake Hose
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CABLE & HARNESS ROUTING (XCITING 250)
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CABLE & HARNESS ROUTING (XCITING 300 AFI)
Tilt Switch
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
Tilt Switch
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
300i ECU Location at rear frame position as picture. 300Ri ECU Location at front cover position .
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1. GENERAL INFORMATION
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XCITING 500/500 AFI/250/300 AFI
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
TROUBLESHOOTING (XCITING 500/250) ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment
Probable Cause
Symptom
Check if fuel reaches carburetor by loosening drain screw
Fuel reaches carburetor
Fuel does not reach carburetor
cEmpty fuel tank dClogged carburetor fuel inlet tube, vacuum tube or fuel tube eClogged auto fuel valve fClogged float oil passage gClogged fuel tank cap breather hole hClogged fuel strainer iClogged fuel filter jFaulty fuel pump
Weak or no spark
cFaulty spark plug dFouled spark plug eFaulty ignition unit fFaulty A.C. generator gBroken or shorted ignition coil hBroken or shorted exciter coil iFaulty ignition switch
Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps
Test cylinder compression Normal compression
Low or no compression
cStarter motor idles but crankshaft does not rotate dValve clearance too small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing
Start engine by following normal starting procedure Engine does not fire
Engine fires but does not start
Dry spark plug
Wet spark plug
cFaulty auto bystarter dAir leaking through intake pipe eIncorrect ignition timing fIncorrectly adjusted pilot screw
Remove spark plug and inspect again
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cFlooded carburetor dFaulty auto bystarter eThrottle valve excessively open
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE LACKS POWER Inspection/Adjustment
Probable Cause
Symptom
Start engine and accelerate lightly for observation Engine speed increases
Engine speed does not increase sufficiently
Check ignition timing (using a timing light)
cClogged air cleaner dRestricted fuel flow eClogged fuel line between fuel tank and carburetor fClogged exhaust muffler gFaulty auto bystarter hSplit carburetor vacuum piston diaphragm cFaulty ignition unit dFaulty A.C. generator
Correct timing
Incorrect timing
Correct
Incorrect
cImproper valve clearance adjustment dWorn valve seat (valve stem too protruding
Normal compression
Abnormal compression
cImproper valve and seat contact dWorn cylinder and piston rings eBlown cylinder head gasket fFlaws in cylinder head gImproper valve timing
Check valve clearance
Test cylinder compression
Check carburetor for clogging Not Clogged
Clogged
cClogged carburetor jets
Remove spark plug and inspect Plug not fouled or discolored
Plug fouled or discolored
Correct and not contaminated
Incorrect or contaminated
Remove oil dipstick and check oil level and condition
cFouled spark plug dIncorrect heat range plug cOil level too high dOil level too low eOil not changed
Remove cylinder head bolts and inspect Valve train lubricated properly
Valve train not lubricated properly
Check if engine overheats Engine does not overheats
Engine overheats
Rapidly accelerate or run at high speed Engine does not knock
Engine knocks
cFaulty oil pump cInsufficient coolant dFaulty thermostat eWorn cylinder and piston rings fMixture too lean gPoor quality fuel hExcessive carbon buildup in combustion chamber iIgnition timing too early jAir in cooling system cExcessive carbon build-up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean g Ignition timing too early
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
cFaulty ignition unit dFaulty A.C. generator
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
cMixture too rich (turn screw out) dMixture too lean (turn screw in)
Air leaks
cDamaged insulator rubber dCarburetor not securely tightened eFaulty intake manifold gasket fDeformed carburetor O-ring
Check carburetor pilot screw adjustment
Check intake manifold for air leaks
No air leak Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark
Weak or intermittent spark
cFaulty or fouled spark plug dFaulty ignition unit eFaulty A.C. generator fFaulty ignition coil gBroken or shorted high tension wire hFaulty ignition switch
Good
Faulty
cDamaged air cut-off valve diaphragm dDamaged air cut-off valve spring
Check carburetor air cut-off valve
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
cFaulty ignition unit dFaulty A.C. generator
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
cImproperly adjusted valve clearance dWorn valve seat
Fuel flows freely
Fuel flow restricted
cEmpty fuel tank dClogged fuel tube or filter eFaulty fuel pump fCracked fuel pump vacuum tube
Not clogged
Clogged
cClean and unclog
Correct
Incorrect
cCam timing gear aligning marks not aligned
Not weakened
Weak spring
Check valve clearance
Check fuel pump for fuel supply
Check carburetor jets for clogging
Check valve timing
Check valve spring tension
cFaulty spring
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE NOISE
Symptom
Valve noise
Probable Cause
cValve clearance too large dWorn camshaft lobe
cWorn piston rings Piston noise
Cam chain noise
Crankshaft noise
dWorn piston pin and connecting rod small end eExcessive carbon build-up in combustion chamber
cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain
cFaulty crankshaft bearing dWorn crank pin bearing
Gear noise
cWorn or damaged final reduction gears dWorn final reduction gear shaft splines
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Engine starts but motorcycle does not move
Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)
Probable Cause cWorn or slipping drive belt dBroken ramp plate eBroken drive face spring fSeparated clutch lining gDamaged driven pulley shaft splines hDamaged final gear iSeized final gear
cBroken shoe spring dClutch outer and clutch weight stuck eSeized pivot
Engine lacks power at start of a grade(poor slope performance)
cWorn or slipping drive belt dWorn weight rollers eSeized drive pulley bearings fWeak driven face spring gWorn or seized driven pulley bearings
Engine lacks power at high speed
cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings
There is abnormal noise or smell while running
cOil or grease fouled drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
STARTER MOTOR 1. Starter motor won‘t turn Symptom
Inspection/Adjustment
Probable Cause
Check operation of stop switch by applying brake Stoplight comes on
Stoplight does not come on
Signals operate properly
Signals dim, remain on or don‘t operate
Relay operates properly
Relay does not operate
Starter motor turns
Starter does not turn
Check battery circuit by operating turn signals Check operation of starter relay by depressing starter button Connect starter motor directly to battery
cBurned out fuse dWeak or dead battery eFaulty stop switch fLoose or disconnected connectors gBroken or shorted ignition switch wire hFaulty side stand switch cFaulty or weak battery
cPoor starter button connection dOpen or shorted starter relay eLoose or disconnected connectors cWorn brushes dOpen or shorted wires or rotor eOpen starter motor cable fLoose connectors cOpen wire harness
2. Starter motor turns slowly or idles Symptom
Inspection/Adjustment
Probable Cause
Check battery circuit by operating turn signals Signals operate properly
Signals dim, remain on or don‘t operate
Starter motor turns slowly
Starter motor turns normally
cWeak or dead battery
Connect starter motor directly to battery cLoose connector or terminal dPoor contact in starter relay eFaulty starter clutch
Rotate crankshaft Hard to turn
Turns easily
cSeized cylinder cBroken or shorted starter motor cable
3. Starter motor does not stop turning Symptom
Inspection/Adjustment
Probable Cause
Turn ignition switch OFF Not stopped
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Stopped
cFaulty starter pinion cStarter relay shorted or stuck closed
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
NO SPARK AT SPARK PLUG Inspection/Adjustment
Symptom
Probable Cause
Replace with a new spark plug and inspect again Good spark
cFaulty spark plug
Not loose
Loose
cFaulty spark plug
Good
Good
cPoorly connected coupler
Normal
Abnormal
Normal
Abnormal
Weak or no spark Check spark plug cap and high-tension wire for looseness
Check ignition unit coupler for looseness
Measure resistance between terminals of ignition unit coupler
Check related parts cFaulty ignition switch dFaulty exciter coil eFaulty pulser coil fFaulty ignition coil cBroken wire harness dPoorly connected coupler Check ignition unit Abnormal
cFaulty ignition unit
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment
Symptom
Probable Cause
Start engine and test limit voltage of battery terminals Normal voltage
Voltage does not increase
Normal
Resistance too low
cFaulty AC generator dFaulty regulator/rectifier eFaulty battery
Measure resistance between AC generator coil terminals cShorted AC generator coil dOpen circuit between AC generator 3 yellow wires
Test output voltage of regulator/rectifier coupler red wire Normal voltage
No voltage
cFaulty regulator/rectifier dFaulty AC generator eLoose regulator/rectifier coupler fLimit voltage too high
Overcharging Inspection/Adjustment
Symptom
Probable Cause
Measure battery limit voltage with an electric tester Normal
Abnormal
cFaulty battery dFaulty regulator/rectifier eBroken or poorly connected regulator/rectifier black wire
Abnormal
cLimit voltage too high
Check resistance between regulator/ rectifier terminals Normal
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Symptom
Inspection/Adjustment
Probable Cause
Check battery circuit by operating turn signals
Remove fuel unit and check operation of pointer by moving float up and down Float up: Full Float down: Empty Check operation of pointer by opening and shorting fuel unit terminal on wire harness side
cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connectors gBroken wire harness
Signals operate properly
Signals dim, remain on or don‘t operate
Pointer does not move
Pointer moves
cFaulty float
Pointer moves
cBroken or shorted fuel unit wire
Pointer does not move
Check connectors for proper connection Faulty
Good
cDisconnected connector dIncorrectly connected connector eBroken or shorted wire in fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON) Inspection/Adjustment
Probable Cause
Symptom
Check battery circuit by operating turn signals and horn Remove fuel unit and check operation of pointer by moving float up and down Move float up and down rapidly (1 round /sec.) to check the operation of pointer
Signals operate properly
Signals dim, remain on or don‘t operate
Pointer moves
Pointer does not move
Pointer moves in accordance with float
Pointer does not move in accordance with float
cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connector gBroken wire harness cPoor contact in fuel unit
cInsufficient damping oil in fuel gauge
Check connectors for proper connection. Good
Faulty
cLoose or disconnected connector cBroken or shorted wire in fuel gauge
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom
Probable Cause (Front and rear tire pressures are normal)
Steering is heavy
cSteering stem nut too tight dBroken steering steel balls
Front or rear wheel is wobbling
cExcessive wheel bearing play dBent rim eLoose axle nut
Steering handlebar pulls to one side
cMisaligned front and rear wheels dBent front fork
POOR SUSPENSION PERFORMANCE Symptom
Suspension is too soft
Probable Cause (Front and rear tire pressures are normal) cWeak shock spring dExcessive load eShock damper oil leaking
Suspension is too hard
cBent fork tube or shock rod
Suspension is noisy
cFork tube and slider binding dFork spring and slider binding eDamaged shock stopper rubber fLoose steering stem nut
POOR BRAKE PERFORMANCE Symptom
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Probable Cause
Soft brake lever
cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area
Hard brake lever
cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area
Hard to brake
cWorn brake linings dWorn brake cam contacting area on
Poor brake performance
cWorn brake linings dForeign matter on brake linings
Brake squeaks
cSluggish or elongated brake cables dBrake shoes improperly contact eWater and mud in brake system fOil or grease on brake linings
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
TROUBLESHOOTING (XCITING 500 AFI/300 AFI) ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment
Probable Cause
Symptom
1. Make sure engine stop switch is ON. 2. Put the side stand up. 3. Connect the diagnostic tool, then check EMS and correct problems.
Fuel reaches fuel injector
Fuel does not reach fuel injector
cEmpty fuel tank dClogged fuel pump filter eFaulty fuel pump fFaulty fuel cut-off relay gCracked fuel hose
Weak or no spark
cFaulty spark plug dFouled spark plug eFaulty ignition coil fFaulty CPS gBroken or shorted ignition coil hBroken or shorted CPS iFaulty ignition switch
No fuel supply
cFaulty fuel injector dClogged fuel injector eFaulty ECU
Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps
Remove the fuel injector, start the starter motor to check fuel injector operation. Fuel supply
Test cylinder compression
Normal compression
Low or no compression
cStarter motor idles but crankshaft does not rotate dValve clearance too small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE LACKS POWER Inspection/Adjustment
Probable Cause
Symptom
Connect the diagnostic tool, then check EMS and correct problems. Start engine and accelerate lightly for observation Engine speed increases Check ignition timing
Engine speed does not increase sufficiently
cClogged air cleaner dClogged exhaust muffler eFaulty spark plug fFaulty throttle gFaulty fuel pump hFaulty fuel injector
iImproper valve timing jLow or no compression cFaulty ECU dFaulty CPS
Correct timing
Incorrect timing
Correct
Incorrect
cImproper valve clearance adjustment dWorn valve seat (valve stem too protruding
Normal compression
Abnormal compression
cImproper valve and seat contact dWorn cylinder and piston rings eBlown cylinder head gasket fFlaws in cylinder head gImproper valve timing
Check valve clearance
Test cylinder compression
Check fuel injector for clogging Not Clogged
Clogged
cFouled fuel injector
Remove spark plug and inspect Plug not fouled or discolored
Plug fouled or discolored
Correct and not contaminated
Incorrect or contaminated
Remove oil dipstick and check oil level and condition
cFouled spark plug dIncorrect heat range plug cOil level too high dOil level too low eOil not changed
Remove cylinder head bolts and inspect Valve train lubricated properly
Valve train not lubricated properly
Check if engine overheats Engine does not overheats
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Engine overheats
cFaulty oil pump cInsufficient coolant dFaulty thermostat eWorn cylinder and piston rings fMixture too lean gPoor quality fuel hExcessive carbon buildup in combustion chamber iIgnition timing too early jAir in cooling system
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
Rapidly accelerate or run at high speed Engine does not knock
Engine knocks
cExcessive carbon build-up in combustion chamber dPoor quality fuel eClutch slipping fIgnition timing too early
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment
Symptom
Probable Cause
Connect the diagnostic tool, then check EMS and correct problems.
Check ignition timing
Correct timing
Incorrect timing
Not Clogged
Clogged
cFaulty ignition coil dFaulty CPS eFaulty ECU
Check fuel injector for clogging
cFouled fuel injector dFaulty fuel pump
Check intake manifold for air leaks
No air leak
Air leaks
cDamage insulator rubber dThrottle body not securely
tighten eFaulty intake manifold
O-ring
Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark
Weak or intermittent spark
cFaulty CPS dFaulty ignition coil eBroken or shorted
high tension wire fFaulty spark plug
Check throttle body
Good
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Faulty
cFouled throttle body dFaulty TPI reset
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment
Symptom
Probable Cause
Connect the diagnostic tool, then check EMS and correct problems.
Check ignition timing
Correct timing
Incorrect timing
cFaulty spark plug dFaulty ignition coil eFaulty CPS
Check valve clearance cImproperly adjusted valve
Correctly adjusted
Incorrectly adjusted
clearance dWorn valve seat
Check fuel pump for fuel supply
Fuel flows freely
Fuel flow restricted
Not clogged
Clogged
Correct
Incorrect
Not weakened
Weak spring
cEmpty fuel tank dClogged fuel hose or filter eFaulty fuel pump fClogged fuel injector
Check throttle body or air cleaner for clogging cClean and unclog
Check valve timing cCam timing gear aligning
marks not aligned
Check valve spring tension cFaulty spring
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
ENGINE NOISE
Symptom
Valve noise
Probable Cause
cValve clearance too large dWorn camshaft lobe
cWorn piston rings Piston noise
Cam chain noise
Crankshaft noise
dWorn piston pin and connecting rod small end eExcessive carbon build-up in combustion chamber
cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain
cFaulty crankshaft bearing dWorn crank pin bearing
Gear noise
cWorn or damaged final reduction gears dWorn final reduction gear shaft splines
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Engine starts but motorcycle does not move
Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)
Probable Cause cWorn or slipping drive belt dBroken ramp plate eBroken drive face spring fSeparated clutch lining gDamaged driven pulley shaft splines hDamaged final gear iSeized final gear
cBroken shoe spring dClutch outer and clutch weight stuck eSeized pivot
Engine lacks power at start of a grade(poor slope performance)
cWorn or slipping drive belt dWorn weight rollers eSeized drive pulley bearings fWeak driven face spring gWorn or seized driven pulley bearings
Engine lacks power at high speed
cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings
There is abnormal noise or smell while running
cOil or grease fouled drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings
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1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
STARTER MOTOR 1. Starter motor won‘t turn Symptom
Inspection/Adjustment
Probable Cause
Check operation of stop switch by applying brake Stoplight comes on
Stoplight does not come on
Signals operate properly
Signals dim, remain on or don‘t operate
Relay operates properly
Relay does not operate
Starter motor turns
Starter does not turn
Check battery circuit by operating turn signals Check operation of starter relay by depressing starter button Connect starter motor directly to battery
cBurned out fuse dWeak or dead battery eFaulty stop switch fLoose or disconnected connectors gBroken or shorted ignition switch wire hFaulty side stand switch cFaulty or weak battery
cPoor starter button connection dOpen or shorted starter relay eLoose or disconnected connectors cWorn brushes dOpen or shorted wires or rotor eOpen starter motor cable fLoose connectors cOpen wire harness
2. Starter motor turns slowly or idles Symptom
Inspection/Adjustment
Probable Cause
Check battery circuit by operating turn signals Signals operate properly
Signals dim, remain on or don‘t operate
Starter motor turns slowly
Starter motor turns normally
cWeak or dead battery
Connect starter motor directly to battery cLoose connector or terminal dPoor contact in starter relay eFaulty starter clutch
Rotate crankshaft Hard to turn
Turns easily
cSeized cylinder cBroken or shorted starter motor cable
3. Starter motor does not stop turning Symptom
Inspection/Adjustment
Probable Cause
Turn ignition switch OFF Not stopped
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Stopped
cFaulty starter pinion cStarter relay shorted or stuck closed
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
NO SPARK AT SPARK PLUG Inspection/Adjustment
Symptom
Probable Cause
Connect the diagnostic tool, then check EMS and correct problems.
Replace with a new spark plug and inspect again
Good spark
cFaulty spark plug
Not loose
Loose
cFaulty spark plug
Good
Good
cPoorly connected coupler
Normal
Abnormal
Normal
Abnormal
Weak or no spark Check spark plug cap and high-tension wire for looseness
Check ignition unit coupler for looseness
Measure resistance between terminals of ignition unit coupler
Check related parts cFaulty ignition switch dFaulty CPS eFaulty ignition coil cBroken wire harness dPoorly connected coupler Check ignition coil Abnormal
cFaulty ignition coil
1-70
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment
Symptom
Probable Cause
Start engine and test limit voltage of battery terminals Normal voltage
Voltage does not increase
Normal
Resistance too low
cFaulty AC generator dFaulty regulator/rectifier eFaulty battery
Measure resistance between AC generator coil terminals cShorted AC generator coil dOpen circuit between AC generator 3 yellow wires
Test output voltage of regulator/rectifier coupler red wire Normal voltage
No voltage
cFaulty regulator/rectifier dFaulty AC generator eLoose regulator/rectifier coupler fLimit voltage too high
Overcharging Inspection/Adjustment
Symptom
Probable Cause
Measure battery limit voltage with an electric tester Normal
Abnormal
cFaulty battery dFaulty regulator/rectifier eBroken or poorly connected regulator/rectifier black wire
Abnormal
cLimit voltage too high
Check resistance between regulator/ rectifier terminals Normal
1-71
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment
Probable Cause
Symptom
Check battery circuit by operating turn signals
Remove fuel unit and check operation of pointer by moving float up and down Float up: Full Float down: Empty Check operation of pointer by opening and shorting fuel unit terminal on wire harness side
cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connectors gBroken wire harness
Signals operate properly
Signals dim, remain on or don‘t operate
Pointer does not move
Pointer moves
cFaulty float
Pointer moves
cBroken or shorted fuel unit wire
Pointer does not move
Check connectors for proper connection Faulty
Good
cDisconnected connector dIncorrectly connected connector eBroken or shorted wire in fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON) Probable Cause
Symptom
Inspection/Adjustment Check battery circuit by operating turn signals and horn Remove fuel unit and check operation of pointer by moving float up and down Move float up and down rapidly (1 round /sec.) to check the operation of pointer
Signals operate properly
Signals dim, remain on or don‘t operate
Pointer moves
Pointer does not move
Pointer moves in accordance with float
Pointer does not move in accordance with float
cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connector gBroken wire harness cPoor contact in fuel unit
cInsufficient damping oil in fuel gauge
Check connectors for proper connection. Good
Faulty
cLoose or disconnected connector cBroken or shorted wire in fuel gauge
1-72
1. GENERAL INFORMATION
XCITING 500/500 AFI/250/300 AFI
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom
Probable Cause (Front and rear tire pressures are normal)
Steering is heavy
cSteering stem nut too tight dBroken steering steel balls
Front or rear wheel is wobbling
cExcessive wheel bearing play dBent rim eLoose axle nut
Steering handlebar pulls to one side
cMisaligned front and rear wheels dBent front fork
POOR SUSPENSION PERFORMANCE Symptom
Suspension is too soft
Probable Cause (Front and rear tire pressures are normal) cWeak shock spring dExcessive load eShock damper oil leaking
Suspension is too hard
cBent fork tube or shock rod
Suspension is noisy
cFork tube and slider binding dFork spring and slider binding eDamaged shock stopper rubber fLoose steering stem nut
POOR BRAKE PERFORMANCE Symptom
1-73
Probable Cause
Soft brake lever
cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area
Hard brake lever
cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area
Hard to brake
cWorn brake linings dWorn brake cam contacting area on
Poor brake performance
cWorn brake linings dForeign matter on brake linings
Brake squeaks
cSluggish or elongated brake cables dBrake shoes improperly contact eWater and mud in brake system fOil or grease on brake linings
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