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KYMCO ADG5, Manual

Get your hands on the KYMCO ADG5 user manual for free download. This manual provides detailed instructions on how to operate and maintain your ADG5 scooter. Access the manual from manualshive.com and ensure you have all the information you need to get the most out of your KYMCO ADG5.

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10..Brake System

 

                                                 

XCITING S 400

 

 

TROUBLESHOOTING 

Brake lever soft or spongy

 

• Air in the hydraulic system 
• Low brake fluid level 
• Clogged fluid passage 
• Contaminated brake disc pad 
• Warped/deformed brake disc 
• Worn brake disc pad 
• Sticking worn master cylinder piston 
• Contaminated master cylinder 
• Contaminated caliper 
• Caliper not sliding properly 
• Leaking hydraulic system 
• Worn caliper piston seal 
• Worn master cylinder piston cups 
• Bent brake lever 

 

Brake lever hard

 

• Clogged restricted brake system 
• Sticking/worn caliper piston 
• Caliper not sliding properly 
• Clogged restricted fluid passage 
• Worn caliper piston seal 
• Sticking worn master cylinder piston 
• Bent brake lever 

 

Brake drag

 

• Contaminated brake disc pad 
• Worn brake disc pad 
• Warped/deformed brake disc 
• Caliper not sliding properly 

 

 

10-2 

 

Summary of Contents for ADG5

Page 1: ...chapter provides a quick reference source of technical specifications and information for KYMCO XCITING S 400 model Component Location 1 2 Special Tools 1 5 Specifications 1 6 Torque Specifications 1...

Page 2: ...ectifier Hazard Controller ECU Ignition Coil Coolant Reserve Tank Ignition Switch Radiator Fuel Tank Air Cleaner Element Canister Muffler Front Wheel Speed Sensor Connector Horn FUSE BOX O2 Sensor Sid...

Page 3: ...Reference XCITING S 400 1 3 Component Location Throttle Body Fuel Pump Winker Relay Turn Signal Tilt Switch Diagnostic Tool Connector Battery Fuel Cap ABS ECU Meter Instrument Couplers Fuse Box Batte...

Page 4: ...4 Component Location Fuel Pump MAP Sensor ISC Idle Speed Controller Throttle Body TPS Throttle Position Sensor Seat Open Motor Relay Starter Relay Fuel Pump Relay ECU Relay Fan Relay The location refe...

Page 5: ...LLER A120E00093 GeneralPullerSet VALVE CLEAN TOOL SET A120E00096 Valve Valveseatcleaning FLYWHEEL PULLER A120E00097 Flywheel removal STEERINGSTEMLOCKNUTWRENCH 32mm A120F00002 Steeringstemremoval insta...

Page 6: ...nce m 12 3m 50km hr Min turning radius 2500mm Engine Starting system Starting motor Type Gasoline 4 stroke Cylinderarrangement SINGLECYLINDER Combustion chamber type Semi sphere Valvearrangement O H C...

Page 7: ...ubeless Wheel material Aluminum Tire pressure Front 2 0 28 4 Rear 2 25 32 Handle turning angle L R Left 40 Right 40 Brake system type Front Dual Disc brake Rear Single Disc brake Damping Device Suspen...

Page 8: ...C Full open 80 C Valve lift 3 5 4 5 mm Coolant capacity Total1700cc Radiator 1450 cc Reserve tank 250 cc COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing Point Mixing Rate KYMCO SIGMA...

Page 9: ...064 1 062 45 1 080 1 078 1 076 1 074 1 072 1 069 50 1 086 1 084 1 082 1 080 1 077 1 074 55 1 095 1 093 1 091 1 088 1 085 1 082 60 1 100 1 098 1 095 1 092 1 089 1 086 Temp C Coolant 30 35 40 45 50 5 1...

Page 10: ...9 0 3 Fuel pump standard pressure at 40L Hr 294 6kPa 3Bar Water temperature sensor resistance 2 076K 10 25 C Intakepressuresensor MAP pressure at1 4 2V 34 40kpa Inductive ignition coil Primary 3 57 4...

Page 11: ...4 0 16 Brakedisk runout 0 03 0 012 Brake master cylinder I D 12 7 12 74 0 508 0 5096 Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 Front brake caliper cylinder I D 25 4 1 0 Brake lining t...

Page 12: ...1 Quick Reference XCITING S 400 1 12 Torque Engine Specifications...

Page 13: ...1 Quick Reference XCITING S 400 1 13 Torque Frame Specifications...

Page 14: ...5 4 34 6mmbolt nut 0 8 1 2 5 79 8 68 8mmbolt nut 1 8 2 5 13 02 18 08 10mmbolt nut 3 0 4 0 21 70 28 93 12mmbolt nut 5 0 6 0 36 17 43 40 5 mm screw 0 45 0 6 3 25 4 34 6mmscrew SHbolt 0 7 1 1 5 06 7 96 6...

Page 15: ...th Fuel Pump Fuel Pump Relay It will turn off automatically in 5 10 seconds 3 Key On to check for any failure lamp light up on dashboard See theSelf Diagnosis topic for more information 4 Is the Idle...

Page 16: ...1 Quick Reference XCITING S 400 1 16 General Troubleshooting...

Page 17: ...1 Quick Reference XCITING S 400 1 17...

Page 18: ...1 Quick Reference XCITING S 400 1 18...

Page 19: ...1 Quick Reference XCITING S 400 1 19...

Page 20: ...1 Quick Reference XCITING S 400 1 20 VIN and Engine Number Location...

Page 21: ...st 2 27 Steering Inspection 2 28 Throttle Free Play 2 29 Parking Brake 2 30 Tires 2 31 Valve Clearance Adjustment 2 32 WARNING Before running the engine make sure that the working area is well ventila...

Page 22: ...fies the maintenance required to keep your XCITING S 400 scooter in peak operating condition Maintenance work should be performed in accordance with KYMCO standards and specifications by properly trai...

Page 23: ...2 Periodic Maintenance XCITING S 400 9 3...

Page 24: ...move Air Filter Cover 3 Loosen Air Filter Cover Fixing Screw and take out the element Precautions on replacing Filter Element 1 Make sure the Air Filter element is positioned correctly in the casing 2...

Page 25: ...RST Protective gloves and eyewear are recommended at this point Checking Front Brake Fluid 1 Straighten the Handlebar check brake fluid in the Right Reservoir Keep the level between the Upper Mark and...

Page 26: ...oir with recommended DOT 4 Brake Fluid to the Upper Scale Replace Reservoir Cover and tighten 2 fixing screws 3 Replace Brake Fluid every 10000km or 1 year WARNING Mixed use of Brake Fluids of differe...

Page 27: ...t any remaining brake fluid Clean and inspect the rubber diaphragm for tears or other damage Replace as necessary Pull off the rubber cap over the bleeder valve and crack open the bleeder valve on the...

Page 28: ...k the master cylinder reservoir occasionally to make sure the reservoir doesn t run dry Add more brake fluid as necessary Continue this process until clean brake fluid comes out of the bleeder valve a...

Page 29: ...he lever forward and turn the adjuster knob to align the number with the arrow mark on the lever holder Check and Adjust Brakes 1 Adjust brake lever clearance using adjustment knob totally 4 adjustmen...

Page 30: ...ve Verify braking effect of front and rear brakes in low speed Caliper SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Brake Pads Push the caliper body inward to push...

Page 31: ...ove the two caliper mounting bolts with a 12 mm socket Discard the brake caliper mounting bolts Remove the front brake caliper The brake calipers are each mounted to the front fork with two bolts Remo...

Page 32: ...ree the brake pads from the pad retainer Remove the brake pads Remove the brake pad Clips with a splcier Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Al...

Page 33: ...banjo bolt that holds the brake hose to the caliper using a 12 mm socket Discard the two sealing washers The brake calipers are each mounted to the front fork with two bolts Remove the two caliper mou...

Page 34: ...It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads Install the front caliper Guide the brake disc...

Page 35: ...heck water level after the engine cools down Inclined vehicle may cause false reading of Cooling Water level 3 Check level of Cooling Water via viewing window on the water preserving tank Make sure th...

Page 36: ...lity cooling water may shorten the service life of water tank Please be careful Replace cooling water in the tank every 10000km Add proper amount of water tank additives to ensure performance of the c...

Page 37: ...istilled water and KYMCO SIGMA Coolant Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Use coolant of specified mixing rate The mixing rate of KY...

Page 38: ...ooling system Place the vehicle on its center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles s...

Page 39: ...on Hot engine oil can burn Avoid letting used motor oil contact exposed skin TROUBLESHOOTING Oil level too low 1 Natural oil consumption 2 Oil leaks 3 Worn or poorly installed piston rings 4 Worn valv...

Page 40: ...ed Insert the dipstick in without threading it in Remove the dipstick and check the oil level The level must be maintained between the upper and lower level marks on the oil filler cap dipstick If the...

Page 41: ...ause damage to the engine Applicable Temperature of Engine Oil NOTICE To avoid using poor quality oil please go to a KYMCO dealer for oil change Oil Change Method 1 Remove Oil Scale Remove Drain Cock...

Page 42: ...kin Precautions on Oil Change Excessive and insufficient oil amount can both affect engine performance Excessive Oil Increased friction resistance of moving parts in the engine which lowers output pow...

Page 43: ...this point The frame lubrication points are listed below Use general purpose grease Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and incre...

Page 44: ...when the side stand is down Perform the following side stand inspection Place the vehicle on the center stand Unplug the three pin side stand switch connector Use a digital multimeter to check for co...

Page 45: ...ve the ignition coil Clean off the area surrounding the spark plug with compressed air or a shop towel to make sure debris doesn t get into the combustion chamber when the spark plug is removed NOTE A...

Page 46: ...e the spark plug Always check the gap of the spark plug before installation Inspect the color of the porcelain nose of the spark plug The color of the spark plug can indicate how the mixture is burnin...

Page 47: ...emove the spark plug See the Spark Plug topic for more information Thread a compression tester into the spark plug hole hand tight Hold the throttle all the way open Crank the engine with the starter...

Page 48: ...ly If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing See the Steering Stem Removal topic for more information Front Suspension Inspection Check the action...

Page 49: ...side to side if the engine rpm changes either the free play is too small or the throttle cables are not routed properly Check and correct the cause Adjustments of the throttle free play can be made wi...

Page 50: ...Maintenance XCITING S 400 Parking Brake Adjustment Release the fixed nut and rotate the adjust nut to adjust the parking brake Note Do not use the rear brake lock lever while driving Fixed nut Adjust...

Page 51: ...oints due to uneven wear Replace the tire if any of the measurements is lower than the service limit Make sure the wheel is properly balanced when a new tire is replaced Service Limits Front Wheel 1 6...

Page 52: ...e engine is cold Inspection Remove the timing inspection cap from the left side of the engine And rotate the crankshaft from the right side of the engine When installation inspect the O ring on the ca...

Page 53: ...ng surface at the same time the T mark is lined up with the with the index notch in the timing inspection hole Also the camshaft sprocket mounting boss should be visible above the cylinder head surfac...

Page 54: ...t adjusting screw and the valve stem The clearance is correct when there is a light drag on the feeler gauge The clearance is the same for the exhaust and intake valves If the clearance is out of spec...

Page 55: ...the adjusting screw until there is a light drag on the feeler gauge Hold the adjusting screw locknut in place with the wrench to make sure it doesn t interfere with the adjustment Lubricate the tappet...

Page 56: ...400 Make sure the O rings on the timing plugs are in good condition Replace it as needed Install the timing inspection to the right side of the engine Tighten the caps securely but not overly with a l...

Page 57: ...er Set 3 5 Back Mirror Mats Of Floor Side Cover Set 3 6 Under Cowl Under Cover Panel Floor 3 7 Center Cover Set Side Board Set Meter Cover Set 3 8 Leg Shield Assy 3 9 Up And Low Handle Cover 3 9 Front...

Page 58: ...CITING S 400 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 Ca...

Page 59: ...e dismantled order as below illustration Assembly is reverse of dismantled order Note When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make su...

Page 60: ...G S 400 Windscreen Cover Removal Remove four fasteners and remove the windscreen covers Windscreen Removal Remove four bolts and remove the windscreen Front Meter Cover Removal Remove screws and remov...

Page 61: ...rnal Components XCITING S 400 Leg Shield Lid Removal Remove two fasteners and remove the right and left leg shield lids Front Cover Set Removal Remove nuts screws and coupler remove the front cover se...

Page 62: ...CITING S 400 Back Mirror Removal Remove four bolts and remove the back mirrors Mats Of Floor Removal Remove four mats of floor Side Cover Set Removal Remove screws fasteners and remove the left and ri...

Page 63: ...Cowl Removal Remove 4 screws 6 small fasteners and remove the left and right side skirts set Under Cover Removal Remove the 4 bolts and remove the under cover Panel Floor Removal Remove screws bolts...

Page 64: ...e fuel cap lid and remove screws and remove the center cover set Side Board Set Removal Remove fasteners screws and couplers and remove the right and left side boards Meter Cover Set Removal Remove co...

Page 65: ...3 External Components XCITING S 400 Leg Shield Assy Removal Remove the screw rotate and remove the main switch plate 3 9...

Page 66: ...ING S 400 Up And Low Handle Cover Removal Remove the top handle cover Remove the bolts screws and remove the up handle cover Remove the bolts screws Remove throttle and parking brake cables and remove...

Page 67: ...nal Components XCITING S 400 Front Inner Fender Removal Remove screws and remove the front inner fender Front Fender Assy Removal Remove the bolts plates and reflectors Remove the front fender assembl...

Page 68: ...3 External Components XCITING S 400 Seat Removal Turn the ignition switch counter clockwise to open the seat Lift up the seat and remove 2 nuts and remove the seat 3 12...

Page 69: ...S 400 Battery Cover Removal Remove screws nuts remove the battery cover Back Carriers Removal Remove 4 bolts and remove the right and left back carriers Rear Seat Removal Remove 4 bolts and remove the...

Page 70: ...3 External Components XCITING S 400 Luggage Box Removal Remove screws bolts and couplers then remove the luggage box Rear Center Cover Removal Remove fasteners and remove the rear center cover 3 14...

Page 71: ...3 External Components XCITING S 400 Body Cover Set Removal Remove fasteners bolts screws coupler and remove the body cover set 3 15...

Page 72: ...3 External Components XCITING S 400 Heat Shield Removal Remove bolts and remove the heat shields 3 16...

Page 73: ...ETY FIRST Protective gloves and eyewear are recommended at this point Troubleshooting Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler...

Page 74: ...3 External Components XCITING S 400 Muffler Removal Remove bolts of the muffler Remove the muffler Replace the new exhaust pipe gasket 18391 when installation 3 18...

Page 75: ...ternal Components XCITING S 400 Exhaust Pipe Removal Unplug the O2 sensor connector Remove nuts of the exhaust pipe Remove the exhaust pipe Replace the new exhaust pipe gasket 18291 when installation...

Page 76: ...wrench Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperature Use a digital multimeter...

Page 77: ...3 External Components XCITING S 400 Side Stand Removal Unplug the three pin side stand switch connector Remove the spring side stand bolt switch and side stand 3 21...

Page 78: ...External Components XCITING S 400 Center Stand Removal Lift up the vehicle by a jack carefully Remove the center stand spring with a spring puller Remove the nuts and bolts Remove the center stand 3 2...

Page 79: ...7 4 115 GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine installed in the frame Use care when removing and installing the oil pump not to...

Page 80: ...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 mar...

Page 81: ...rviced with the engine installed in the frame After disassembly clean the removed parts and dry them with compressed air before inspection If replacing the piston or cylinder they must be changed as a...

Page 82: ...ired to support and maneuver the engine Be careful not to damage the scooter body cables and wires during engine removal Use shop towels to protect the scooter body during engine removal Place the sco...

Page 83: ...NG 400i The regulator rectifier is located on the right side of the vehicle Disconnect the generator 3 pin connector Disconnect the crank position sensor wire coupler Remove the bolts And remove the o...

Page 84: ...3 Engine EngineRemoval XCITING 400i Unplug the water temperature sensor Pull back the rubber starter motor lead cover 4 6...

Page 85: ...the starter motor lead nut with a 10 mm wrench Free the cable lead from the starter motor Thread the nut back on to keep track of it Loosen the fuel hose stay bolt with an 8 mm socket Free the fuel h...

Page 86: ...remaining coolant to drain into a suitable container Loosen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Allow any remaining...

Page 87: ...engine ground wire Free the engine ground from the left side of the engine Unplug the oil pressure switch wire at the bullet connector The oil pressure switch is located below the cylinder Free the w...

Page 88: ...ne with a suitable jack or stand Remove the rear shock absorbers Loosen the engine mounting bracket damper nut with a 14 mm socket Remove the nut and washer Hold the engine mounting bolts with a 14 mm...

Page 89: ...Remove the engine mounting nuts and bolts from both sides Loosen the engine mounting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt Remove the engine mount...

Page 90: ...3 Engine EngineRemoval XCITING 400i Remove the engine mounting bracket Remove the engine mounting bracket damper assembly Carefully move the engine back and separate it from the chassis 3 12...

Page 91: ...0i Cylinder Head Cover SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Squeeze the breather hose clamp with needle nose pliers and slide if back Remove the breather ho...

Page 92: ...sen the four cylinder head cover bolts with a 10 mm socket Remove the cylinder head cover bolts with washers and grommets Note the gold colored and longer bolts are on the right side Remove the cylind...

Page 93: ...to the cylinder head Make sure the projection fits into the groove in front of the camshaft sprocket correctly Install the cylinder head cover over the gasket Make sure the ridge on the gasket fits in...

Page 94: ...lt seals in fresh engine oil Insert the cylinder head cover bolts with grommet seals and washers Note the gold colored and longer bolts go on the right side Tighten the cylinder head cover bolts secur...

Page 95: ...gine CylinderHeadCover XCITING 400i Fit the fuel stay into place Tighten the stay bolt securely with an 8 mm socket Install the breather hose to the cylinder head cover Secure the hose with the clamp...

Page 96: ...es and eyewear are recommended at this point Removal The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Turn crankshaft clockwise until the T...

Page 97: ...sure that it is on the compression stroke by checking that there is some slack in the rocker arms If the rocker arms are rigid rotate the crankshaft 360 clockwise until the T mark is once again aligne...

Page 98: ...aft Remove the cam chain tensioner cap bolt with a 8 mm socket Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket Lift the cam chain tensioner out of the cylinder Remove the cam...

Page 99: ...Use a 5 mm Allen wrench to remove the camshaft sprocket bolts Remove the camshaft sprocket as shown Support the chain so it does not fall into the cylinder head Thread a bolt into the rocker arm shaft...

Page 100: ...XCITING 400i 3 Engine Camshaft Lift out the rocker arms as the shafts are removed Remove the camshaft from the cylinder head 3 22...

Page 101: ...haust lobes Inspect the camshaft bearings for excessive play or roughness Replace the entire camshaft assembly if the bearings are rough or have excessive play Inspect the rocker arm shaft outer diame...

Page 102: ...shaft Inspect the rocker arm bearings for excessive play or roughness Replace the entire rocker arm assembly if the bearings are rough or have excessive play Inspect the camshaft bearing journals for...

Page 103: ...XCITING 400i 3 Engine Camshaft Inspect the camshaft sprocket for worn teeth or other signs of wear or damage 3 25...

Page 104: ...s wear safety glasses when using compressed air and never point it directly at yourself or anyone else Position the piston at top dead center as above The T mark should be aligned with the index notch...

Page 105: ...haft Insert the camshaft into the camshaft holders with the lobes facing down Lubricate the inside diameter of the rocker arms and the roller with fresh engine oil Position the rocker arms to accept t...

Page 106: ...he rocker arm shafts so that the end sits as shown Install the camshaft set plate so it fits into the groove on the camshaft and between the projections on the rocker arm shafts Apply a small amount o...

Page 107: ...visible above the edge of the cylinder head as shown Align the horizontal marks on the camshaft sprocket with the top edge of the cylinder head as shown Fit the cam chain over the camshaft sprocket F...

Page 108: ...a 5 mm Allen socket Item Qty Thread size mm Torque kgf m lb ft Cam sprocket bolt 2 6 1 0 1 4 7 23 10 13 Install the cam chain tensioner with a new gasket Insert the mounting bolts and tighten them ev...

Page 109: ...clockwise and check the engine timing one more time Make sure the cam chain tensioner cap bolt washer is in good condition Install the washer and cam chain tensioner cap bolt Tighten the bolt to secu...

Page 110: ...Make sure the O ring on the timing plugs are in good condition Replace it as needed Install the timing inspection cap to the right side of the engine Tighten the cap securely but not overly with a lar...

Page 111: ...his point Removal IMPORTANT Record the position of all parts so they can be returned to their proper place during reassembly Push down the valve springs with a valve spring compressor Special Tool Val...

Page 112: ...Valves XCITING 400i Remove the two nuts and washers on the left side with a 14mm socket Remove the two bolts on the right side with a 8mm socket Remove the nut on the inlet pipe side with a 10mm sock...

Page 113: ...3 Engine Valves XCITING 400i Remove the nut on the exhaust pipe side with a 10mm socket Remove the cylinder head assy and gasket Remove the split keepers There are two per valve 3 35...

Page 114: ...3 Engine Valves XCITING 400i Remove the spring retainer Remove the valve springs 3 36...

Page 115: ...n and remove the valve from the combustion chamber side of the cylinder head Rotate the valve as it is removed Remove the valve seal from the valve guide The valve seals should be replaced if they are...

Page 116: ...3 Engine Valves XCITING 400i Remove the spring seat Inspection Inspect the valve springs for fatigue and damage Replace the valve springs as needed or if the valve is also to be replaced 3 38...

Page 117: ...lves for damage and burning Measure the valve stem diameter in several places where the valve makes contact with the guide If the measurement is below specification replace the valve Item Standard mm...

Page 118: ...n out or fits poorly on the valve face the valve seat must be resurfaced Item Standard mm Valveseatwidth IN 1 7 0 1 EX 1 7 0 1 Measure the inside diameter of the valve guides Replace the guides if the...

Page 119: ...ean the cylinder head components thoroughly with a high flash point solvent and compressed air Return the components to their original locations NOTE Always wear safety glasses when using compressed a...

Page 120: ...e and through the seal Turn the valve slowly as it is inserted If you are installing a new valve you must ream the valve guide first Make sure the valve will move smoothly in the valve guide without w...

Page 121: ...top of the spring Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers The valve cotter installer tool can also be used to install the split kee...

Page 122: ...e keeper in the grease on the screwdriver and insert it onto the valve stem Repeat this with the other keeper After the valves have been reassemble place a clean shop towel under the cylinder head in...

Page 123: ...tective gloves and eyewear are recommended at this point CylinderBlock Removal Slide out the lower cam chain guide Inspect the guide for excessive wear and damage Replace the guide as needed Remove tw...

Page 124: ...3 Engine CylindersandPistons Slide the cylinder off of the studs and piston Guide the cam chain through its opening and do not allow if to fall into the crankcase Remove the cylinder Remove the base...

Page 125: ...ylinder dowel pins from the left studs Place a clean shop towel under and around the base of the piston to prevent any parts or debris falling into the crankcase Remove the piston pin clips with a pic...

Page 126: ...n and the piston Clean off the cylinder mating surface but take care to keep debris from falling into the crankcase Spread the piston rings and lift them off opposite the gap Spread the rings the mini...

Page 127: ...e two upper rings are each a single piece of metal The oil ring consists of an expander ring and two side rails Clean the carbon build up off of the piston with a stiff bristled plastic brush or rag N...

Page 128: ...build up in the grooves Inspection The cylinder and piston must be replaced as a set There are two sets of cylinder and piston combinations Make sure to have a No 1 cylinder with an A piston or a No 2...

Page 129: ...XCITING 400i 3 Engine CylindersandPistons Inspect the cylinder bore for damage and abnormal wear Measure the cylinder diameter as described below with a telescoping gauge 3 51...

Page 130: ...D mm 1 A 84 00 84 01 2 B 84 01 84 02 Calculate the cylinder taper The taper is the maximum difference between either yellow and brown or blue and green Item Limit mm Cylinder Taper 0 05 Calculate the...

Page 131: ...cylinder to calculate the piston to cylinder clearance Replace the piston and cylinder as needed to achieve a correct piston to cylinder clearance Item Standard mm Piston to cylinder clearance 0 010...

Page 132: ...he small end of the connecting rod with vernier calipers Item Standard mm Connectingrodsmall endI D Bore 20 Measure the ring groove width and the ring to groove clearance with feeler gauges Item Stand...

Page 133: ...ring in the cylinder about an inch Use the piston to push in the ring to keep it square with the cylinder Measure the ring gap with a feeler gauge Repeat this procedure with second ring and the oil si...

Page 134: ...andPistons Check the oil jet for clogs Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings Spread the rings the minimum amount possible to install them Do not try and...

Page 135: ...ring end gaps line up with the piston pin or perpendicular to the piston pin The rings should turn easily on the piston without sticking or roughness Install the oil expander ring so that the ends ar...

Page 136: ...XCITING 400i 3 Engine CylindersandPistons The IN mark should face the intake side rear of the engine Place the piston over the connecting rod Insert the piston pin into the piston and rod 3 58...

Page 137: ...CylindersandPistons Install new piston pin clips securely into their grooves Turn the gap in the clips away from the access gap Make sure the cylinder head mating surface is clean Install the two dow...

Page 138: ...nside of the cylinder piston rings and piston in fresh engine oil Lower the cylinder over the studs and guide the piston into the cylinder while you are compressing the rings with your fingers Be care...

Page 139: ...XCITING 400i 3 Engine CylindersandPistons Thread in the two cylinder bolts on the right side of the engine Insert the lower cam chain guide and make sure it is seated correctly 3 61...

Page 140: ...ves and eyewear are recommended at this point Removal Generator Cover Remove the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot Skirt Dis...

Page 141: ...nd free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the right crankcase coolant hose clamp with a 8mm socket Slide up the clamp and free...

Page 142: ...3 Engine Generator XCITING 400i Remove the 12 generator cover bolts with an 8 mm socket Note the upper bolt holds a wire stay Remove the generator cover 3 64...

Page 143: ...3 Engine Generator XCITING 400i Remove the generator cover gasket Remove the two dowel pins 3 65...

Page 144: ...e Generator XCITING 400i Remove the oil release valve Inspect the O ring and replace it as needed Stator and Pulsar Coil Crank Position Sensor Free the rubber wire grommet from the right crankcase cov...

Page 145: ...move the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket Remove the stator and the crank position sensor together Flywheel To remove the fly wheel two special t...

Page 146: ...3 Engine Generator XCITING 400i ITEM TOOL NO FLYWHEEL PULLER A120E00097 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket 3 68...

Page 147: ...0i Remove the flywheel nut and washer Apply a protect stay to the threads of the crankshaft before using it Hold the tool with a large wrench and turn in the bolt until the pressure separates the flyw...

Page 148: ...3 Engine Generator XCITING 400i Remove the flywheel from the crankshaft Slide the starter driven gear off of the crankshaft 3 70...

Page 149: ...3 Engine Generator XCITING 400i Remove the woodruff key from the crankshaft Starter Clutch Remove the starter idle gear and shaft from the crankcase 3 71...

Page 150: ...amage Replace the idle gear and shaft as needed Inspect the starter driven gear for wear and damage Measure the inside and outside diameter of the starter driven gear and replace it as needed Item Sta...

Page 151: ...s turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced Remove the three starter clutch mounting bolts with a 6 mm Allen socket Install...

Page 152: ...unting bolts to specification with a 6 mm Allen socket Item Qty Thread size mm Torque kgf m lb ft Onewayclutchbolt 3 8 0 8 1 2 5 76 8 64 Lubricate the starter idle gear shaft with fresh engine oil Ins...

Page 153: ...kshaft Lubricate the inside of the starter driven gear with fresh engine oil Slide the starter driven gear onto the flywheel as shown Clean off the tapered end of the crankshaft where the flywheel wil...

Page 154: ...TING 400i Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft Guide the starter driven gear into the starter clutch on the back of the flywheel Install the washer...

Page 155: ...the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket Item Qty Thread size mm Torque kgf m lb ft ACG flywheel nut 1 14 5 5 6 5 39 78 47 01 ITEM TOOL...

Page 156: ...generator cover together as shown Insert the two crank position sensor mounting bolts and the three stator mounting bolts Tighten the bolts securely with an 8 mm socket Coat the rubber grommet in sil...

Page 157: ...3 Engine Generator XCITING 400i Generator Cover Make sure the generator cover mating surface is clean Install the two dowel pins and a new generator cover gasket Install a new gasket 3 79...

Page 158: ...ine Generator XCITING 400i Make sure the oil release valve is in place and in good condition Fit the generator cover into place Make sure the water pump shaft engages correctly with the oil pump shaft...

Page 159: ...bolts Note the upper bolt holds a wire stay Tighten the bolts securely in a with an 8 mm socket Fit the coolant hose to the right crankcase cover pipe Secure the hose with the clamp and tighten the c...

Page 160: ...coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Plug in the regulator rectifier 3 pin connector Plug in the crank position sensor wire c...

Page 161: ...dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is ins...

Page 162: ...3 Engine OilPump XCITING 400i Oil Pump Removal The oil pump is driven by a chain off of the crankshaft Loosen the two oil pump cover bolts with an 8 mm socket 3 84...

Page 163: ...ine OilPump XCITING 400i Remove the two oil pump cover bolts and the oil pump cover Remove the snap ring on the oil pump shaft with snap ring pliers Remove the oil pump drive chain and driven sprocket...

Page 164: ...ine OilPump XCITING 400i Inspect the oil pump drive chain and sprocket for signs of wear and damage Replace the parts as needed Remove the three oil pump screws with an 8mm socket Remove the oil pump...

Page 165: ...oil pump shaft by hand and make sure it turns smoothly If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit Oil Pump Installation Fit the oil pump into place...

Page 166: ...screws and tighten them securely with an 8mm socket Fit the oil pump driven sprocket into the drive chain Install the gear onto the oil pump shaft and fit the chain onto its teeth on the crankshaft In...

Page 167: ...3 Engine OilPump XCITING 400i Install the oil pump cover and its two mounting bolts Tighten the two oil pump cover bolts securely with an 8 mm socket 3 89...

Page 168: ...rankcase XCITING 400i Crankcase SAFETY FIRST Protective gloves and eyewear are recommended at this point Splitting Remove the upper cam chain guide bolt with an 8 mm Allen Remove the upper cam chain g...

Page 169: ...400i Inspect the cam chain guides for damage and excessive wear Replace the guides as needed Remove the cam chain from the crankshaft and crankcase Inspect the cam chain for wear and damage Replace th...

Page 170: ...3 Engine Crankcase XCITING 400i Remove the six bolts mounting the left crankcase cover protector XCITING 400I XCITING S 400 Remove the left crankcase cover protector 3 92...

Page 171: ...ne Crankcase XCITING 400i Remove the nine bolts mounting the left crankcase cover Remove the two bolts mounting the element duct left crankcase cover XCITING 400I XCITING S 400 Remove the element duct...

Page 172: ...3 Engine Crankcase XCITING 400i Remove the M14 nut mounting the clutch outer Remove the M18 nut mounting the drive face Remove the left crankcase cover XCITING 400I XCITING S 400 3 94...

Page 173: ...400i There are 12 crankcase bolts Loosen the 12 crankcase bolts in a crisscross pattern with an 8 mm socket Remove the crankcase bolts from the left side of the engine Remove the plate with the botto...

Page 174: ...ITING 400i Set the crankcases on the right side Separate the halves of the crankcase If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet Lift the right crankcase...

Page 175: ...3 Engine Crankcase XCITING 400i Remove the two dowel pins from the crankcase Inspect the O ring and replace it as needed 3 97...

Page 176: ...3 Engine Crankcase XCITING 400i Replace the left crankshaft seal if the crankcases are separated Remove the seal with a seal pick 3 98...

Page 177: ...The driver should have the same outside diameter as the seal Lubricate the new crankshaft seal lips with fresh engine oil Assembly Thoroughly clean the crankcase mating surface Apply sealant uniforml...

Page 178: ...3 Engine Crankcase XCITING 400i Set the right case half down on top of the left Install the engine mount spacer Insert the 12 crankcase bolts The plate goes on with the bottom two bolts 3 100...

Page 179: ...3 Engine Crankcase XCITING 400i Tighten the bolts securely and evenly in a crisscross pattern with an 8mm socket Install the cam chain around the timing sprocket teeth on the crankshaft 3 101...

Page 180: ...he upper cam chain guide into place Insert the upper cam chain guide mounting bolt and tighten it to specification with an 8 mm Allen socket Item Qty Thread Size mm Torque kgf m lb ft Cam chain tensio...

Page 181: ...3 Engine Crankshaft XCITING 400i Crankshaft SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Lift the crankshaft out of the left crankcase half 3 103...

Page 182: ...XCITING 400i CrankshaftInspection Check the side clearance of the big end of the connecting rod with a feeler gauge Item Standard mm Service Limit mm Crankshaft Connecting rod big end side clearance...

Page 183: ...push the rod down towards the crank weights If there is definite play between the connecting rod and crank the crankshaft should be replaced Crankshaft Bearings Inspect the crankshaft bearings for sig...

Page 184: ...t be replaced also replace both crank bearings according to the chart below Crankcase Crankshaft Bearing Crankcas e mark Crankshaft mark A B A BL ACK GREEN B GREEN RED Installation Lubricate the conne...

Page 185: ...n XCITING 400i Engine Installation SAFETY FIRST Protective gloves and eyewear are recommended at this point Set the chassis on its center stand Use a jack to support the engine Guide the engine into t...

Page 186: ...nting bracket and damper assembly into place Install the two engine mounting bracket to frame mounting bolts and nuts Insert the bolts from the outside of the frame Insert the engine mounting bracket...

Page 187: ...mounting bracket damper washer and nut Hold the engine mounting bolts with a 14 mm wrench and torque the nuts to specification with a 19 mm socket Item Qty Thread size mm Torque Remarks kgf m lb ft En...

Page 188: ...nting bracket damper bolt and nut with a 17 mm wrench for the nut and a 14 mm socket for the bolt Item Qty Thread size mm Torque Remarks kgf m lb ft Engine hanger Engine side 1 10 4 5 5 5 32 55 39 78...

Page 189: ...3 Engine EngineInstallation XCITING 400i Route the wiring harness through its guide above the intake pipe Plug in the oil pressure switch bullet connector 3 111...

Page 190: ...3 Engine EngineInstallation XCITING 400i Route the starter motor lead to the starter motor and secure it in the stay on the right crankcase cover 3 112...

Page 191: ...stallation XCITING 400i Fit the starter motor cable lead onto the terminal and thread on the nut Tighten the starter motor lead nut securely with a 10 mm wrench Fit the rubber starter motor lead cover...

Page 192: ...ngine Tighten the main engine ground bolt securely with an 8 mm socket Install air bleed hose and secure it with the clamp Connect the coolant hose to the thermostat Move the clamp into place and tigh...

Page 193: ...ions XCITING 400i Connect the coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Fit the fuel stay into place Tighten the stay bolt securely...

Page 194: ...ng the engine Other cooling system service can be done with the engine installed in the frame The engine must be cool before servicing the cooling system When the coolant temperature is over 100 never...

Page 195: ...tat Insufficient coolant Passages blocked in hoses or water jacket Clogged radiator fins Passages blocked in radiator Faulty water pump Temperature gauge shows the wrong temperature Faulty temperature...

Page 196: ...ck water level after the engine cools down Inclined vehicle may cause false reading of Cooling Water level 3 Check level of Cooling Water via viewing window on the water preserving tank Make sure the...

Page 197: ...y cooling water may shorten the service life of water tank Please be careful Replace cooling water in the tank every 10000km Add proper amount of water tank additives to ensure performance of the cool...

Page 198: ...tilled water and KYMCO SIGMA Coolant Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Use coolant of specified mixing rate The mixing rate of KYMC...

Page 199: ...ing system Place the vehicle on its center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles stop...

Page 200: ...th an appropriate suction device If a suction device is unavailable remove the reserve tank and poor it out See the Radiator topic for more information When the coolant has fished draining return the...

Page 201: ...t mix coolant concentrate of different brands Do not drink the coolant which is poisonous COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing Point Mixing Rate Coolant Concentrate Distil...

Page 202: ...he cooling system with a mix of distilled water and Coolant Concentrate Continue filling until the coolant until it reaches the bottom of the filler neck as shown Add coolant to the reserve tank until...

Page 203: ...center stand and start the engine Let it run for several minutes This will purge any air out of the cooling system Check for coolant leaks When the air bubbles stop coming up turn off the engine and...

Page 204: ...diator cap in two stages Allow any built up pressure to vent and then open the cap all the way and remove it When checking the cooling system for leaks you will need a pressure tester Remove the radia...

Page 205: ...when the engine is hot Wet the seal on the radiator cap and install it to the pressure tester Replace the cap if it does not relieve the pressure as specified Radiator cap relief pressure 0 9 0 15 kg...

Page 206: ...runs to the filler neck and cap The top right hose runs to the thermostat on the cylinder head The bottom left hose runs to the water pump Loosen the coolant hose clamps with a 2 Phillips screwdriver...

Page 207: ...ith a 10 mm socket Clean out the fins with low pressure compressed air and water NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else Check...

Page 208: ...5 Cooling System XCITING S 400 Jump a 12 volt battery to the fan connector and make sure the radiator fan operates 5 15...

Page 209: ...perature Sensor and Thermostat SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Water Temperature Sensor WTS Unplug the water temperature sensor Use a 17 mm wrench to r...

Page 210: ...ew item Thermostat Loosen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Squeeze the air bleed hose clamp with needle nose pli...

Page 211: ...5 Cooling System XCITING S 400 Remove the two thermostat mounting bolts with an 8mm socket Lift off the thermostat cover 5 18...

Page 212: ...e thermostat Remove the thermostat O ring and discard it Inspection Water Temperature Sensor Inspect the WTS in a similar manner as the thermosensor Measure the resistance between the WTS terminals an...

Page 213: ...ouching the pot Bring the temperature up to the specification slowly and check the operation of the thermostat The valve should begin to open around 71 C 160 F The valve should lift 3 5 4 5 mm 0 14 0...

Page 214: ...400 model GENERAL INSTRUCTIONS 6 2 TROUBLESHOOTING 6 3 COMPONENT LOCATION 6 4 ECU 6 7 IGNITION COIL 6 9 SPARK PLUG 6 12 CRANK POSITION SENSOR 6 14 O2 SENSOR 6 15 RELAYS 6 16 FUEL TANK 6 17 THROTTLE BO...

Page 215: ...d idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed D...

Page 216: ...pump operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Backfiring or misfiring during acceleration Ignition system malfunction Engine stall hard to s...

Page 217: ...tifier Hazard Controller ECU Ignition Coil Coolant Reserve Tank Ignition Switch Radiator Fuel Tank Air Cleaner Element Canister Muffler Front Wheel Speed Sensor Connector Horn FUSE BOX O2 Sensor Side...

Page 218: ...l System XCITING S 400 6 5 Component Location Throttle Body Fuel Pump Winker Relay Turn Signal Tilt Switch Diagnostic Tool Connector Battery Fuel Cap ABS ECU Meter Instrument Couplers Fuse Box Battery...

Page 219: ...Component Location Fuel Pump MAP Sensor ISC Idle Speed Controller Throttle Body TPS Throttle Position Sensor Seat Open Motor Relay Starter Relay Fuel Pump Relay ECU Relay Fan Relay The location refer...

Page 220: ...d be damaged if dropped or the connector is disconnected when the key is on The excessive voltage may damage the ECU Always turn off the ignition switch before servicing Press the tab and disconnect t...

Page 221: ...nspection Check for continuity between pin 9 and 10 of the ECU side connector There should be continuity at all times Check for continuity between each pins 2 4 and 23 of the ECU side connector There...

Page 222: ...set at the factory and is not adjustable Perform the following checks Before performing any tests make sure the electrical connections are not loose or corroded Ignition Coil Remove the connectors Re...

Page 223: ...he ignition coil terminals as shown Measure the resistance Secondary With Plug Cap Check the secondary resistance between the ignition coil terminal and the spark plug cap Touch the negative meter lea...

Page 224: ...p Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap Touch the negative meter lead to the terminal and the positive meter lead to the spark plug...

Page 225: ...r spark plug wire while cranking or running the engine as this can result in a severe shock Remove the spark plug with a spark plug with a 5 8 in socket Spark plug NGKCR7E Check the spark plug to see...

Page 226: ...the spark plug The color of the spark plug can indicate how the mixture is burning A white colored plug shows a lean mixture where a dark plug shows a rich mixture Do not hesitate to replace a spark p...

Page 227: ...nspection Crank Position Sensor Inspection Note This test is performed with the stator installed in the engine Disconnect the crank position sensor wire coupler Measure the resistance between L Y and...

Page 228: ...wrench Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperature Use a digital multimete...

Page 229: ...t 12 V battery with the fuel cut off relay connector There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is connected replace the relay Seat Op...

Page 230: ...uel System XCITING S 400 6 17 Fuel Tank SAFETY FIRST Protective gloves and eyewear are recommended at this point Warning Gas is extremely flammable Do not work around an open flame or a source of spar...

Page 231: ...ipe and release the fuel pressure unplug the fuel pump connecter Start the engine and let it run until it dies of fuel starvation Turn the ignition switch off Disconnect the coupler Clamp the fuel hos...

Page 232: ...up any remaining fuel immediately Note When slide back the fuel hose carefully not to damage the fuel pump pipe and replace the clamp with a new one when installation Remove the fuel pump mounting bo...

Page 233: ...6 Fuel System XCITING S 400 6 20 Remove the radiator Remove the fuel tank mounting nuts and remove the fuel tank from the frame...

Page 234: ...commended at this point Warning Gas is extremely flammable Do not work around an open flame or a source of sparks Input Voltage Inspection Turn the ignition switch off Place the scooter on its main st...

Page 235: ...ess side of the fuel pump connector with the positive lead touching the red black wire terminal and the negative lead touching the green wire terminal Turn the ignition switch on The battery voltage s...

Page 236: ...eplace the O ring with new item and apply a small amount of fresh engine oil to the new O ring Fuel Level Gauge Inspection Using a digital multi meter set to ohms of resistance measure the resistance...

Page 237: ...6 Fuel System XCITING S 400 6 24 Fuel Level Float Position Resistance Full 1100 33 Empty 100 3 Replace the fuel level float unit with a new part if the resistance is out of specification...

Page 238: ...as shown To separate the fuel hose from the fuel pump pipe Clean up any remaining fuel immediately Disconnect the fuel hose from the fuel injector Connect the fuel pressure gauge Remove the fuel hose...

Page 239: ...re is less than 3 0 bar may fail to start the engine or in trouble in case of riding Turn the key to the OFF position and use the fuel hose clamp to block the fuel hose Return the fuel line to the inj...

Page 240: ...Do not damage the throttle body it may cause the throttle and idle valve to fail synchronization The throttle body is preset in KYMCO factory do not disassemble it incorrectly Do not loosen or tighte...

Page 241: ...ge outputs to the MAP between the following terminals of the MAP connector Terminal Normal Violet Red Green Pink 5 V TPS Inspection Support the scooter on a level surface Put the side stand up and eng...

Page 242: ...el System XCITING S 400 6 29 Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal Violet Red Green Pink 5 V Throttle Position Sensor TPS 3500...

Page 243: ...6 Fuel System XCITING S 400 6 30 Removal Throttle Cables Free the throttle cables from the throttle drum...

Page 244: ...lame or a source of sparks In order to release fuel pressure from the fuel pipe when removing the fuel injector unplug the fuel pump connecter Start the engine and let it run until it dies of fuel sta...

Page 245: ...Inspect the fuel hose for signs of deterioration or damaged Replace the fuel hose as needed Remove the fuel injector mounting bolt with a 10 mm socket Unplug the fuel injector connector Lift the fuel...

Page 246: ...al multi meter is needed to test the fuel injector Measure the resistance between the fuel injector terminals ITEM SPECIFICATIONS Fuel injector resistance at 20 C 68 F 9 9 13 5 Check for signs of clog...

Page 247: ...em XCITING S 400 6 34 When installation Apply a light coat of fresh engine oil to a new fuel injector O ring Fit the fuel injector pipe onto the top of the injector The tab on the injector must fit in...

Page 248: ...ose clamp screw at the throttle body with a 2 Phillips Loosen the intake hose clamp screw at the throttle body with a flat blade screwdriver Remove the sensor couplers remove the throttle out of the a...

Page 249: ...System XCITING S 400 6 36 ThrottleBody Disassembly The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the throttle body MAP TPS ISC or ECU have been reinstalled MAP...

Page 250: ...p and engine stop switch on RUN Turn the ignition switch to OFF Note Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged Place the tilt switch v...

Page 251: ...as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 3 7 4 4 V Note Repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON Discon...

Page 252: ...Diagnosis Note No matter when the CELP illuminated while riding condition should find out the cause of the problem as soon as possible If the ECM connectors or battery leads are disconnected the store...

Page 253: ...YMCO and for KYMCO vehicles only The tool software can be updated for new models with a computer via the USB cable Please refer to the specifications when serving this vehicle This tool does not have...

Page 254: ...CITING S 400 6 41 The diagnostic tool is located under the seat Remove the protective rubber cover Use the Sub cord OBD diagnostics connecter part number 36205 LGC6 E00 to connect between vehicle and...

Page 255: ...e side stand up prior to using the diagnostic tool The functions of the diagnostic tool include ECU version model name data analysis and reset ECU version includes model name ECU number identification...

Page 256: ...l display when the tool is powered on The model name will show ADG5 for the XCITING S 400 Pressing the enter button on the ECU version will show model name ECU number identifications number and softwa...

Page 257: ...0 6 44 DTC Diagnostic Trouble Code INSPECTION PROCEDURE Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring...

Page 258: ...down button to select the load DTC option Press the enter button on the Load DTC item to display the DTC options Move the selector to the Current option and press enter to display current DTC The dia...

Page 259: ...Sensor malfunction or Voltage Low B0 P0121 Throttle position sensor adaptation is out of range B1 P0122 Throttle Position Sensor Voltage Low B2 P0123 Throttle Position Sensor Voltage High B3 P0124 Di...

Page 260: ...Vehicle Speed Sensor malfunction DA P0201 Injection valve malfunction DB P0412 Secondary air injection system malfunction DC P0603 ECU memory error DD P1205 MAP sensor malfunction DE P0500 Vehicle Sp...

Page 261: ...m XCITING S 400 6 48 DTC Clear Procedure Press the down button right to move the item selector down to the DTC Inspect item Pressing the enter button on the DTC Inspect item will bring up the options...

Page 262: ...NG S 400 6 49 Move the selector down to the Clear DTC option and press enter The diagnostic tool will show when the DTC in memory are cleared Also the DTC indicator light between the center and right...

Page 263: ...8 12 BTDC Battery Voltage V 12 V O2 Sensor Voltage V 0 05 0 90 V Engine speed target rpm 1420 rpm 90 15 IDLE CO 0 3 1 5 Before muffler CO Set 0 Suggestion Value 5 5 Engine speed rpm 1420 100 rpm Inta...

Page 264: ...h 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...

Page 265: ...ETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot S...

Page 266: ...nsmission Belt Case XCITING 400i Remove 2 the air cleaner bolts with an 8 mm socket Remove 6 the belt case plastic cover bolts with an 8 mm socket XCITING 400I XCITING S 400 Remove the belt case prote...

Page 267: ...VT Transmission Belt Case XCITING 400i XCITING 400I XCITING S 400 Remove 11 the belt case cover bolts with an 8 mm socket XCITING 400I XCITING S 400 Remove 2 the air filter bolts with an 8 mm socket 7...

Page 268: ...on Belt Case XCITING 400i Remove the drive pulley nut with a 24mm socket Remove the driven pulley nut with a 24mm socket XCITING 400I XCITING S 400 Remove the belt case cover and gasket Remove the two...

Page 269: ...Transmission Belt Case XCITING 400i Inspection Inspect the drive belt for cracks or excessive wear Inspect the belt case bearing by turning it with a finger Replace the bearing if it is rough or nois...

Page 270: ...7 CVT Transmission Belt Case XCITING 400i Remove the bearing fixed plate with a 5 mm Allen Remove two bearing collar Remove the bearing with a suitable bearing puller Tool number A12E00093 7 7...

Page 271: ...Case XCITING 400i Drive in a new bearing with a suitable bearing driver that has the same outside diameter as the bearing Tool number A12E00014 Install two bearing collar Install the bearing fixed pla...

Page 272: ...Case XCITING 400i Installation Install the two dowel pins into the belt case Install a new gasket with the belt case cover Install the driven pulley nut with a 24mm socket Install the drive pulley nut...

Page 273: ...ransmission Belt Case XCITING 400i Install 2 the air filter bolts with an 8 mm socket Install the belt case cover bolts and tighten them securely with an 8 mm socket Install the belt case plastic cove...

Page 274: ...n Belt Case XCITING 400i Insert the plastic cover bolts and tighten them securely with an 8 mm socket Install 2 the air cleaner bolts with an 8 mm socket Fit the drain hose to the plastic belt case co...

Page 275: ...0i CVT Removal SAFETY FIRST Protective gloves and eyewear are recommended at this point Remove the belt case See the Belt Case topic for more information Pulleys and Belt Remove the left face of the d...

Page 276: ...T Transmission CVT Removal XCITING 400i XCITING 400I XCITING S 400 Slide the driven pulley off of the shaft Remove the belt from the driven pulley Inspect the drive belt for cracks or excessive wear 4...

Page 277: ...lide the bushing out of the movable drive face Drive Pulley Disassembly Inspect the faces of the drive pulley Clean away any grease from the faces Inspect the oil seal of the drive pulley for broken o...

Page 278: ...re 6 weight rollers in the back of the right face of the drive pulley Remove the rollers and check them for excessive or uneven wear Measure the weight of the rollers Replace the weight rollers as nee...

Page 279: ...bushing for wear and damage Replace the parts as needed Clutch Disassembly Lift the clutch outer off of the centrifugal clutch Inspect the inside of the clutch outer for excessive wear and damage Meas...

Page 280: ...mit Item Standard mm Service Limit mm Clutchliningthickness 4 0 2 0 To disassemble the clutch and driven pulley set the clutch fitting tool to onto the clutch ITEM TOOLNO DESCRIPTION 46 NUT AND FITTIN...

Page 281: ...CITING 400i Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Loosen the clutch drive plate nut with the special socket that comes with the fitting tool Remove...

Page 282: ...T Removal XCITING 400i Inspect the left side bearing by turning it with a finger If the bearing is rough turning or noisy it should be replaced Remove the clutch spring compressor tool Lift off the ce...

Page 283: ...7 CVT Transmission CVT Removal XCITING 400i Remove the collars and spring Measure the free length of the clutch spring Replace the spring if the measurement fails to meet the service limit 4 20...

Page 284: ...7 CVT Transmission CVT Removal XCITING 400i Remove the three circlips from the clutch pivot pins with a small flat bladescrewdriver Lift off the plate 4 21...

Page 285: ...7 CVT Transmission CVT Removal XCITING 400i Slide the clutch shoes off of the pivots on the drive plate Inspect the clutch shoe bumpers and replace them as needed 4 22...

Page 286: ...ansmission CVT Removal XCITING 400i Driven Pulley Disassembly Remove the clutch as shown above Remove the four guide rollers with guide roller pins Separate the left and right faces of the driven pull...

Page 287: ...CVT Transmission CVT Removal XCITING 400i Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides Remove the seals from the left face of the driven pulley 4 2...

Page 288: ...ver with the same outside diameter as the seal Remove the O rings on the left face Clean the left face and roller pins with a high flash point solvent and compressedair NOTE Always wear safety glasses...

Page 289: ...7 CVT Transmission CVT Removal XCITING 400i Bearing Replacement Inspect the bearings in the right face of the driven pulley Remove the needle bearing with a suitable puller 4 26...

Page 290: ...E Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else Drive in the new baring so the sealed side face out towards the clutch Install the snap ri...

Page 291: ...7 CVT Transmission CVT Removal XCITING 400i Lubricate the bearings in the right face of the driven pulley with grease 4 28...

Page 292: ...ation SAFETY FIRST Protective gloves and eyewear are recommended at this point Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease Drive in the new seals with a sui...

Page 293: ...NERALINSTRUCTIONS 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 TRO...

Page 294: ...ve gloves and eyewear are recommended at this point Disassembly Note Do not remove the transmission case cover except for necessary part replacement If the drive shaft is replaced make sure to also re...

Page 295: ...oves and eyewear are recommended at this point Place the scooter on level ground and up on its center stand The oil drain bolt and oil filler bolt are located on the transmission XCITING S 400 Gear oi...

Page 296: ...s from the bolt hole Install the oil level check bolt and tighten it to specification with a 12 mm socket Item Qty Thread size mm Torqu kgf m lb ft Final Drive oil check bolt 1 8 0 8 1 2 5 79 8 68 If...

Page 297: ...a suitable oil drain pan under the transmission oil drain plug Place a suitable container under the drain plug to capture the final drive oil Loosen the oil drain plug with a 12 mm socket Remove the d...

Page 298: ...rive XCITING 400i XCITING S 400 Install the oil drain plug and washer with a 12 mm socket Tighten to specification Item Qty Thread size mm Torqu kgf m lb ft Final Drive oil check bolt 1 8 0 8 1 2 5 79...

Page 299: ...TING 400i XCITING S 400 Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole Gear oil type SAE 90 Gear oil capacity At disassembly 0 23 Liter At chan...

Page 300: ...ING S 400 Thread in the final drive oil level check bolt Install the oil check plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil check...

Page 301: ...s 9 26 Switches 9 27 Luggage Box Light 9 28 Tilt Switch 9 30 Handlebar Switch 9 32 Side Stand Switch 9 34 Horn 9 35 Meter Instrument 9 36 USB Power Socket 9 37 GENERAL INSTRUCTIONS The battery can be...

Page 302: ...insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the pow...

Page 303: ...mittent power Loose battery cable connection Loose charging system connection Loose connection or short circuit in the ignition system Low power Weak battery Loose battery connection Charging system f...

Page 304: ...factory The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn...

Page 305: ...round wire of the ignition control module Faulty crank position sensor Faulty ignition control module Peak voltage is normal but no spark jumps at the plug Faulty spark plug or leaking ignition coil s...

Page 306: ...otor Starter motor rotates but engine does not start Faulty starter pinion Starter motor rotates in reverse Weak battery Lights Switches AND Fuel Pump GENERAL INSTRUCTIONS Note the following when repl...

Page 307: ...each component TROUBLESHOOTING Lights do not come on when ignition switch is ON Burned bulb Faulty switch Poorly connected broken or shorted wire Temperature gauge does not register correctly Faulty...

Page 308: ...Rectifier Hazard Controller ECU Ignition Coil Coolant Reserve Tank Ignition Switch Radiator Fuel Tank Air Cleaner Element Canister Muffler Front Wheel Speed Sensor Connector Horn FUSE BOX O2 Sensor Si...

Page 309: ...ical Systems XCITING S 400 9 9 Component Location Throttle Body Fuel Pump Winker Relay Turn Signal Tilt Switch Diagnostic Tool Connector Battery Fuel Cap ABS ECU Meter Instrument Couplers Fuse Box Bat...

Page 310: ...10 Component Location Fuel Pump MAP Sensor ISC Idle Speed Controller Throttle Body TPS Throttle Position Sensor Seat Open Motor Relay Starter Relay Fuel Pump Relay ECU Relay Fan Relay The location re...

Page 311: ...to access the fuses FUSE A 15A Winker FR RR Stop Horn Meter Starter Position Phone FUSE B 15A Ignition IGN Coil Fuel Pump Angle Detector Sensor Fan Motor FUSE C 30A Charging FUSE D 25A ABS Motor FUSE...

Page 312: ...ernal topic for more information Note The ECU could be damaged if dropped or the connector is disconnected when the key is on The excessive voltage may damage the ECU Always turn off the ignition swit...

Page 313: ...e Check for continuity between pin 9 and 10 of the ECU side connector There should be continuity at all times Check for continuity between each pins 2 4 and 23 of the ECU side connector There should b...

Page 314: ...on timing is set at the factory and is not adjustable Perform the following checks Before performing any tests make sure the electrical connections are not loose or corroded Ignition Coil Remove the c...

Page 315: ...o the ignition coil terminals as shown Measure the resistance Secondary With Plug Cap Check the secondary resistance between the ignition coil terminal and the spark plug cap Touch the negative meter...

Page 316: ...Cap Check the secondary resistance between the ignition coil terminal and the spark plug wire without the cap Touch the negative meter lead to the terminal and the positive meter lead to the spark plu...

Page 317: ...g or spark plug wire while cranking or running the engine as this can result in a severe shock Remove the spark plug with a spark plug with a 5 8 in socket Spark plug NGKCR7E Check the spark plug to s...

Page 318: ...of the spark plug The color of the spark plug can indicate how the mixture is burning A white colored plug shows a lean mixture where a dark plug shows a rich mixture Do not hesitate to replace a spar...

Page 319: ...or Inspection Crank Position Sensor Inspection Note This test is performed with the stator installed in the engine Disconnect the crank position sensor wire coupler Measure the resistance between L Y...

Page 320: ...o making charging system checks 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 preven...

Page 321: ...the generator 3 pin connector Check the connectors for loose contacts or corroded terminals Measure the resistance between each Yellow wire terminals Check for continuity between each yellow wire term...

Page 322: ...othing In case of contact flush with water and get prompt medical attention Removal The battery is located in the front of the vehicle Remove the windscreen and meter cover See the external topic for...

Page 323: ...attery Voltage 20 C 68 F Fully Charged 13 0 13 2 V Battery Charging Charge the battery with a motorcycle specific battery charger at the specified rate Connect the charger leads to their appropriate b...

Page 324: ...or continuity and inspect the wire Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery acro...

Page 325: ...ITING S 400 9 25 Starter Motor Pull back the rubber starter motor lead cover and remove the nut Remove two starter motor mounting bolts and remove the starter motor Inspect the starter motor O ring an...

Page 326: ...nect 12 V battery with the fuel cut off relay connector There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is connected replace the relay Seat...

Page 327: ...tion switch connectors Use a digital multimeter to check for continuity to inspect the ignition switches Continuity should exist between the wires as indicated To remove the anti tamper bolts use a pu...

Page 328: ...ith light sensing switch in case the user forgets to close the Seat Pad or the Pad fails to fully close up system will cut the power automatically after a set time preventing any power loss of battery...

Page 329: ...9 Electrical Systems XCITING S 400 9 29 Check the circuit with the wire...

Page 330: ...nd up and engine stop switch on RUN Turn the ignition switch to OFF Note Do not disconnect the tilt switch connector during inspection The capacity of battery must be fully charged Place the tilt swit...

Page 331: ...tage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 3 7 4 4 V Note Repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON Di...

Page 332: ...ternal topic for more information Unplug the black connector for the left handlebar switches Unplug the green connector for the right handlebar switches Use a digital multimeter to check for continuit...

Page 333: ...9 Electrical Systems XCITING S 400 9 33 Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indicated...

Page 334: ...pin side stand switch connector Use a digital multimeter to check for continuity With the side stand retracted there should be continuity between the yellow green wire and the green wire terminals Wi...

Page 335: ...move the front cover See the external topic for more information 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...

Page 336: ...9 Electrical Systems XCITING S 400 9 36 Meter Instrument Remove couplers Check the wiring diagram to inspect circuit...

Page 337: ...while the engine is running WARNING To avoid electrocution or short circuit make sure to cover up the protection cap after using the USB Power Socket To prevent any accident from occurring park your M...

Page 338: ...c 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 Never allow contamination dirt wat...

Page 339: ...ontaminated caliper Caliper not sliding properly Leaking hydraulic system Worn caliper piston seal Worn master cylinder piston cups Bent brake lever Brake lever hard Clogged restricted brake system St...

Page 340: ...10 Brake System XCITING S 400 Diagram 10 3...

Page 341: ...rd mm in Service Limited Brake disk thickness rear 4 8 5 2 0 19 0 20 4 0 16 Brake disk thickness front 3 8 4 2 0 15 0 17 3 0 12 Check if the brake rotor runout is within the service limit Measure the...

Page 342: ...rake System XCITING S 400 Front Removal Remove the five mounting bolts with a 6 mm Allen To remove the front brake disc take out the five mounting bolts with a 8 mm Allen Remove the front brake discs...

Page 343: ...read locking agent Thread in the bolts and torque them to specification with an Allen socket Item Qty Thread dia mm Torque Nm kgf m ft lb Brake disc bolt 5 8 35 3 5 25 Install the front wheel See the...

Page 344: ...rear brake disc into place on the wheel as shown Apply a non permanent thread locking agent to the threads of the rear disc bolts Insert the bolts and tighten them to specification with a 6 mm Allen...

Page 345: ...moval Brake Pads Push the caliper body inward to push in the pistons This will allow room to change the brake pads Remove the two caliper mounting bolts with a 12 mm socket Discard the brake caliper m...

Page 346: ...th a 6mm Allen Free the brake pads from the pad retainer Remove the brake pads Remove the brake pad Clips with a splcier Replace the pads if the brake wear exceeds the wear indicator lines or if the w...

Page 347: ...the banjo bolt that holds the brake hose to the caliper using a 12 mm socket Discard the two sealing washers The brake calipers are each mounted to the front fork with two bolts Remove the two calipe...

Page 348: ...ew caliper bracket mounting bolts Tighten the mounting bolts to specification Item Q ty Thread dia mm Torque Remarks Nm kgf m ft lb Front caliper mounting bolt 4 10 35 3 5 25 Replace a new one Install...

Page 349: ...d pin It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads Install the front caliper Guide the brake...

Page 350: ...up any spills immediately Removal Place a suitable container under the banjo bolt to catch any remaining brake fluid Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socke...

Page 351: ...ven Always replace brake pads as a set When installation Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring It may be necessary to rotate the piston and...

Page 352: ...ster Cylinders Up And Low Handle Cover Removal Remove the top handle cover Remove the bolts screws and remove the up handle cover Remove the bolts screws Remove throttle and parking brake cables and r...

Page 353: ...bber accordion diaphragm Pour out any remaining brake fluid Clean and inspect the rubber diaphragm for tears or other damage Replace as necessary Pull off the rubber cap over the bleeder valve and cra...

Page 354: ...e master cylinder reservoir occasionally to make sure the reservoir doesn t run dry Add more brake fluid as necessary Continue this process until clean brake fluid comes out of the bleeder valve and t...

Page 355: ...ng Brake Adjustment Release the fixed nut and rotate the adjust nut to adjust the parking brake Note Do not use the rear brake lock lever while driving Note Do not use the rear brake lock lever while...

Page 356: ...ecommended at this point ABS Component Location 1 Front Wheel speed Sensor 2 Front Wheel speed Sensor Rotor 3 Rear Wheel speed Sensor 4 Rear Wheel speed Sensor Rotor 5 ABS Indicator Light 6 ABS Hydrau...

Page 357: ...er having ridden on wet roads or similar situations o ABS can not compensate for adverse road conditions misjudgment or improper application of brakes You must take the same care as with vehicle not e...

Page 358: ...lt Always use the standard tires for this vehicle Notice o When the ABS is functioning you may feel a pulsing in the brake lever This is normal you need not suspend applying the brakes o ABS does not...

Page 359: ...rs are disconnected The ABS hydraulic unit memorizes service codes Do not spray water on the electrical parts ABS parts connectors leads and wiring Whenever the ABS electrical connections are to be di...

Page 360: ...ervice codes detected once by the ABS hydraulic unit will be memorized in the ABS hydraulic unit Therefore after maintenance work is finished be sure to erase the service codes Do not erase the servic...

Page 361: ...ferent in size from the standard size is being used Replace with standard size When the wheel is deformed Replace the wheel Much of the ABS troubleshooting work consists of confirming continuity of th...

Page 362: ...10 Brake System XCITING S 400 Pre diagnosis Inspection Chart 1 10 25...

Page 363: ...10 Brake System XCITING S 400 Pre diagnosis Inspection Chart 2 10 26...

Page 364: ...hen the ignition switch is turned on and goes off shortly after the vehicle starts moving The light stays off as long as the system is ok If something is wrong with the ABS the indicator comes on and...

Page 365: ...ect the meter connector Check for continuity between the ABS signal wire Pink lead terminal of the main harness side connector and ground If there is the continuity in the lead replace or repair the m...

Page 366: ...replace the ABS hydraulic unit If there is not the continuity in the lead replace or repair the main harness Solenoid Valve Inspection Service Code 13 14 17 18 1st step test Recheck the service code i...

Page 367: ...Deformation of the wheel or tire 4 Sensor rotor for missing teeth and clogging with foreign matter If the all parts are correct move on to the 2nd step 2nd step test Recheck the service code indicati...

Page 368: ...sensor rotor Standard 1 mm 0 04 in If the measurement is over standard check each part for deformation and looseness and correct accordingly Recheck the clearance Check that there is iron or other ma...

Page 369: ...d replace the rear wheel rotation sensor Rear Wheel Rotation Sensor Wiring Inspection service code 44 1st step test Measure the clearance between the rear wheel rotation sensor and sensor rotor Standa...

Page 370: ...and rear wheel sensor connector Short the light blue brown and black red lead terminals of the main harness side connector with a jumper lead and check for continuity between the light blue brown and...

Page 371: ...ery terminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 9 6V or more 3rd step test Inspect the following parts Batt...

Page 372: ...ry terminal voltage connect the diagnosis tool to the ABS diagnosis connector Turn the ignition switch ON Battery terminal voltage Standard 16 6V or less 3rd step test Inspect the following parts Batt...

Page 373: ...service code perform the pre diagnosis inspection 1 and 2 and retrieve the service code If the ABS indicator light lit faulty ECU in the ABS hydraulic unit Replace the ABS hydraulic unit If the ABS in...

Page 374: ...lfunction AV 05 5019 Valve Relay malfunction Failsafe relay 06 5025 Deviation between Wheel speeds WSS_GENERIC 07 5035 Pump Motor Malfunction 08 5042 Front wheel speed sensor malfunction Plausibility...

Page 375: ...tem the front and rear wheel speed sensors should show speed when the wheels are rotated Inspect the wheel speed sensors rotors wires and connectors if the speed doesn t show correctly Check the speed...

Page 376: ...nit for the brake Front F and Rear R brake hose positions Do not attempt to disassemble the ABS unit If the ABS unit must be replaced the new unit should come filled with brake fluid Install the new c...

Page 377: ...odel TROUBLESHOOTING 11 1 Handlebar 11 2 Switch Housings and Throttle 11 3 Grips 11 6 Steering stem 11 7 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken st...

Page 378: ...r are recommended at this point Removal Bar Ends Remove the bar ends with a 6 mm Allen XCITING 400i XCITING S 400 Switch Housings Remove the wire and cable guide bolts with an 8 mm socket Remove the w...

Page 379: ...he black connector for the left handlebar switches XCITING 400i XCITING S 400 Unplug the green connectors for the right handlebar switches XCITING 400i XCITING S 400 Remove the right switch housing mo...

Page 380: ...11 Steering XCITING 400i XCITING S 400 Separate the switch housing The right switch housing has wires on both sides so it cannot be completely opened XCITING 400i XCITING S 400 11 4...

Page 381: ...0i XCITING S 400 Handlebar SAFETY FIRST Protective gloves and eyewear are recommended at this point Loosen the four handlebar bolts with a 12 mm socket Remove the handlebar holders and bolts XCITING 4...

Page 382: ...lationship between the angle of the grip and the throttle tube so that the new grip can be installed with the correct angle NOTE Always wear safety glasses when using compressed air and never point it...

Page 383: ...need to be adjusted The KYMCO XCITING 400i XCITING S 400 use ball bearings in the steering Always replace the races at the same time as the bearings Remove these components Windshield Windshield Front...

Page 384: ...11 Steering XCITING 400i XCITING S 400 Remove the bridge stem nut and washer Lift off the upper fork clamp Special tool A120F00002 XCITING 400i XCITING S 400 11 8...

Page 385: ...ocket Wrench A120F00007 A special lock nut wrench is needed to loosen the steering stem lock nut Remove the steering stem lock nut Special Tool Long Socket Wrench A120F00007 Slide off the lock washer...

Page 386: ...Remove the inner race for the upper bearing Lower the lower fork clamp and steering stem out of the frame Lift out the upper ball bearings And slide the lower ball bearings up and off of the steering...

Page 387: ...damage Replace them as needed Use a chisel and hammer to drive out the bearing races Do not damage the frame pipe and steering stem Have the drift set against the lip of the race and work around the r...

Page 388: ...e front fork components for the KYMCO XCITING S 400 model TROUBLESHOOTING 12 1 Front Fender Assy Removal 12 2 Front Fork Removal 12 3 TROUBLESHOOTING Soft front shock absorber Weak shock springs Insuf...

Page 389: ...12 Front Suspension XCITING S 400 Front Fender Assy Removal Remove the bolts plates and reflectors Remove the front fender assembly 12 2...

Page 390: ...0 Front Fork Removal Loosen the front axle pinch bolt with a 6 mm Allen Loosen the front axle with an 24 mm socket Lift the front end of the vehicle with a suitable stand or jack so that the front whe...

Page 391: ...and slide the front axle out from the left side Guide the front wheel out from the fork legs Remove the collars from each side of the wheel Inspect the bearing seals and the O rings seals on the coll...

Page 392: ...ove the front wheel speed sensor mounting bolt with an 8 mm socket Free the front wheel speed sensor from the right fork Loosen the top fork clamp bolts with a 6 mm Allen If the fork is to be disassem...

Page 393: ...gs down and out of the fork clamp using a twisting motion Installation Slide the fork legs up into fork clamp using a twisting motion Fit the fork into place so that the mark on the top of the fork tu...

Page 394: ...m Q ty Thread dia mm Torque Nm kgf m ft lb Lower pinch bolt 4 8 32 3 2 23 Tighten the fork caps securely with a 30 mm socket Tighten the upper fork clamp bolts to specification with a 6 mm Allen socke...

Page 395: ...12 Front Suspension XCITING S 400 Check the speed sensor to rotor clearance with a feeler gauge and make sure that it is 0 3 1 2 mm 0 0012 0 048 in 12 8...

Page 396: ...s chapter provides information on the rear suspension components of the KYMCO XCITING 400i XCITING S 400 model TROUBLESHOOTING 13 1 Rear Fork 13 2 Installation 13 6 Shock Absorbers 13 8 TROUBLESHOOTIN...

Page 397: ...s stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk Remove these components Muffler Exhaust Sys...

Page 398: ...ove the rear wheel hose clamp bolts with an 8 mm socket Place the scooter on its center stand so that the rear wheel is off the ground Remove the two rear fork bolts with a 12 mm socket Remove the rea...

Page 399: ...e wheel bearing by turning it with a finger Replace the bearing and seal as needed Remove the seal and snap ring Drive the bearing out from the inside out Drive in the new bearing with a suitable driv...

Page 400: ...the snap ring into the groove Apply grease to the lips of the new seal and drive it into place in the same manner as the bearing Inspect the shock absorber bushing and replace it as needed Inspect th...

Page 401: ...rease to the lips of the dust seal and install the collar into the rear fork Fit the rear fork into place Install the two rear fork bolts and tighten them to specification with a 12 mm socket Item Q t...

Page 402: ...400 Install the rear wheel speed sensor and hose clamp bolts with an 8 mm socket Install the rear axle nut and tighten it to specification with a 24 mm socket Item Q ty Thread dia mm Torque Nm kgf m f...

Page 403: ...preload for stiffer rear suspension and can be used when the scooters heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions Use a pin spanner to adjust the rea...

Page 404: ...e these components Seat Seat Luggage Box Luggage Box Support the engine with a suitable hoist or jack Remove the rear shock mounting bolts with a 14 mm socket Remove the shock absorbers Inspect the sh...

Page 405: ...assemble the shock absorber Installation Fit the shock absorber into place Make sure the preload arrow indicator faces out from the lower mount Install the upper shock absorbers Insert the upper mount...

Page 406: ...nstall the lower shock absorber mounting bolts and torque them to specification with a 14 mm socket Item Q ty Thread dia mm Torque Nm kgf m ft lb Rear shock absorber bolt 4 10 40 4 29 Remove these com...

Page 407: ...Bearing Replacement 14 2 Front Wheel 14 5 Tire Inspection 14 10 Wheel Inspection 14 22 Troubleshooting Front wheel wobbling Bent rim Loose front axle Faulty tire Improperly tightened axle nut Rear whe...

Page 408: ...e you plan to install them Do not let the wheel rest on its brake discs or wheel speed sensor rotor Front Wheel Remove the dust seals from the each side of the front wheel using a seal pick or large f...

Page 409: ...Remove one of the bearings with a bearing puller Special Tools Bearing Remover A120E00093 Remove the distance collar Repeat the procedure and remove the other bearing and seal The seal should be repla...

Page 410: ...ng is fully seated and the marked side is facing out Special Tools Bearing Installer A120E00014 Insert the distance collar into the hub Drive in the other bearing The bearing should fit against the di...

Page 411: ...es and eyewear are recommended at this point Removal Loosen the front axle pinch bolt with a 6 mm Allen Loosen the front axle with an 24 mm socket Lift the front end of the vehicle with a suitable sta...

Page 412: ...slide the front axle out from the left side Guide the front wheel out from the fork legs Remove the collars from each side of the wheel Inspect the bearing seals and the O rings seals on the collars R...

Page 413: ...em or are rough replace all the bearings for that wheel To remove the speed sensor rotor take out the five bolts Installation Install the front wheel speed sensor rotor Tighten the five bolts securely...

Page 414: ...the front wheel into the fork Apply a light coat of grease to the front axle Insert the axle from the left side Set the front wheel on the ground Pump the front suspension up and down several times t...

Page 415: ...Allen Item Q ty Thread dia mm Torque Nm kgf m ft lb Front fork pinch bolt 2 8 23 2 3 17 Pump the front brake lever to establish pressure and to seat the pads against the disc If the brakes do not pump...

Page 416: ...to uneven wear Replace the tire if any of the measurements is lower than the service limit Make sure the wheel is properly balanced when a new tire is replaced Service Limits Front Wheel 1 6 mm Rear W...

Page 417: ...the Wheel Bearing Replacement topic for more information Place the wheel on a truing stand and use a dial indicator to check if the rim is out of true The specifications for the front and rear wheels...

Page 418: ...Canister 15 6 Oxygen Sensor 15 9 WARNING Before running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxi...

Page 419: ...gas from spreading to the atmosphere Exhaust Emission Control System The exhaust emission from the scooter is controlled by combustion management fuel delivery ignition setting and exhaust system The...

Page 420: ...t condition Sending the mixture condition info to ECU by voltage signal ECU control the fuel injection to meet the emission regulation Catalyst To reduce the emission of HC CO and NOx produced from th...

Page 421: ...element set installation is in the reverse order of removal Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong KYMCO air cleaner el...

Page 422: ...should be installed tightly The leakage hole should be installed downward Tool Vacuum pump Pressure pump Maintenance standard Emission vacuum standard 45m mHg Capacity of canister 90cc Install angle...

Page 423: ...ve control valve If the pressure will be kept without change obviously in one minute that means the valve are with good condition otherwise the valve malfunction a new canister should be replaced Conn...

Page 424: ...if the flow rate above 9 4 litters per minute that means the valve is in good condition otherwise the canister should be replaced NOTE Always using the pump by manual do not apply high pressure for t...

Page 425: ...gine reach above 80 C This model equipped the catalyst in the muffler to reduce the pollution emission Inspection Of Catalyst Converter Inspection of catalyst converter efficiency at idle speed Warm u...

Page 426: ...n Sensor to work normally In normal hours the impedance of heater is 7 7 1 2 ohm and can be told with multimeter Output of sensor after the engine is warmed up is A F 14 7 mixing ratio too thick 0 7V...

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