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XCITING500ByKWANGYANGMotorCo.,Ltd.FirstEdition,Feb2005Allrightsreserved.AnyreproductionorunauthorizedusewithoutthewrittenpermissionofKWANGYANGMotorCo.,Ltd.isexpresslyprohibited.4121-LBA2-S00XCITING500PREFACEThisServiceManualdescribesthetechnicalfeaturesandservicingproceduresfortheKYMCOXCITING500.Section1containstheprecautionsforalloperationsstatedinthismanual.Readthemcarefullybeforeanyoperationisstarted.Section2istheremoval/installationproceduresfortheframecoverswhicharesubjecttohigherremoval/installationfrequencyduringmaintenanceandservicingoperations.Section3describestheinspection/adjustmentprocedures,safetyrulesandserviceinformationforeachpart,startingfromperiodicmaintenance.Sections7through13giveinstructionsfordisassembly,assemblyandadjustmentofengineparts.Section14through16istheremoval/installationofchassis.Section17through21statesthetestingandmeasuringmethodsofelectricalequipment.Mostsectionsstartwithanassemblyorsystemillustrationandtroubleshootingforthesection.Thesubsequentpagesgivedetailedproceduresforthesection.KWANGYANGMOTORCO.,LTD.OVERSEASSALESDEPARTMENTOVERSEASSERVICESECTIONTABLEOFCONTENTSGENERALINFORMATION1FRAMECOVERS/EXHAUSTMUFFLER2INSPECTION/ADJUSTMENT3LUBRICATIONSYSTEM4FUELSYSTEM/FUELPUMP/FUELTANK/CARBURETOR5COOLINGSYSTEM6ENGINEREMOVAL/INSTALLATION7CYLINDERHEAD/VALVES8CYLINDER/PISTON9DRIVEANDDRIVENPULLEY10FINALREDUCTION11A.C.GENEARTOR/STARTERCLUTCH12CRANKCASE/CRANKSHAFT13STEERINGHANDLEBAR/FRONTWHEEL/FRONTSHOCKABSORBER14REARFORK/REARWHEEL/REARSHOCKABSORBER`15BRAKESYSTEM16BATTERY/CHARGINGSYSTEM17IGNITIONSYSTEM18ELECTRICSTARTER19LIGHTS/METERS/SWITCHES20WIRINGDIAGRAMS21Theinformationandcontentsincludedinthismanualmaybedifferentfromthemotorcycleincasespecificationsarechanged.KYMCOreservestherighttomakechangesatanytimewithoutnoticeandwithoutincurringanyobligation.CHASSISELECTRICALEQUIPMENTENGINE1.GENERALINFORMATION1-0XCITING5001__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________GENERALINFORMATION__________________________________________________________________________________SERIALNUMBER------------------------------------------------------------1-1SPECIFICATIONS------------------------------------------------------------1-2SERVICEPRECAUTIONS--------------------------------------------------1-3TORQUEVALUES-----------------------------------------------------------1-7SPECIALTOOLS-------------------------------------------------------------1-9LUBRICATIONPOINTS---------------------------------------------------1-10CABLE&HARNESSROUTING--------------------------------------------1-12TROUBLESHOOTING------------------------------------------------------1-2211.GENERALINFORMATION1-1XCITING500SERIALNUMBERLocationofEngineSerialNumberLocationofFrameSerialNumber1.GENERALINFORMATION1-2XCITING500SPECIFICATIONSITEMSPECIFICATIONSNameXCITING500Overalllength2250mm(90in)Overallwidth(mm)815mm(33in)Overallheight(mm)1450mm(58in)Wheelbase(mm)1570mm(63in)EnginetypeO.H.C.Displacement498.5cm3(30.4cu-in)FuelUsed92#nonleadedgasolineFrontwheel83kg(183lbs)DryweightRearwheel132kg(290lbs)Total215kg(473lbs)Frontwheel90kg(198lbs)CurbweightRearwheel141kg(310lbs)Total231kg(508lbs)Frontwheel120/70-15Rearwheel150/70-14Groundclearance150mm(6in)Min.turningradius2750mm(110in)StartingsystemElectricstartermotorTypeGasoline,4-strokeCylinderarrangementSinglecylinderCombustionchambertypeSemi-sphereValvearrangementO.H.C.,chaindriveBorexstroke(mm)92x75mm(3.7x3in)Compressionratio10.5:1Compressionpressure13kgf/cm²(1300kPa,185psi)Open2°BTDCValveIntakeClose45°ABDCtimingOpen45°BBDCExhaustClose5°ATDCValveclearanceIntake0.1mm(0.004in)(cold)Exhaust0.1mm(0.004in)Idlespeed(rpm)1400rpmLubricationtypeForcedpressure&WetsumpOilpumptypeTrochoidOilfiltertypeFull-flowfiltrationOilcapacity2.5L(2.2lmpqt,2.65Usqt)Finalreductionoilcapacity0.55L(0.5lmpqt,0.58Usqt)CoolingTypeLiquidcooledITEMSPECIFICATIONSAircleanertype&NoWetpapertypeelementFuelcapacity12.8L(3.38lmpgal,2.82USgalTypeCVKMainjetNO.98Venturidia.φ36mm(φ1.44in)ThrottletypePISTONTypeFulltransistordigitalignitionSparkplugCR8EIgnitiontimingThrottlepositionsensorSparkpluggap0.6~0.7mm(0.002~0.003in)BatteryCapacity12V12AHClutchTypeDry,centrifugalautomaticTypeHelicalgear/spurgearOperationAutomaticcentrifugalTypeTypeCVTPreliminary2.68–1Final5.4FR/RRtirerollingcircumference1724/1778mm(69/71in)Front2kg/cm²(200Kpa,28psi)Tirepressure(rideronly/60kg)Rear2.5kg/cm²(250Kpa,36psi)TurningLeft40°angleRight40°BrakesystemRearDiskbraketypeFrontDiskbrakeFrontTelescopicforkSuspensiontypeRearUnitswingFrametypeBackbornTiresFuelSystemCarburetorElectricalEquipmentIgnitionSystemPowerDriveSystemTransmis-sionGearReductionRatioMovingDeviceDampingDeviceLubricationSystemEngine1.GENERALINF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