OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. XCITING 500 AFI XCITING 500 XCITING 250 AFI XCITING 250 Issued: 15.02.2006 FOREWORD Thank you for purchasing this KYMCO scooter and welcome to the family of KYMCO scooter riders. Please read this owner's manual carefully before riding so that you will be thoroughly familiar with the proper operation of your scooter controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for your scooter, give it the proper care and maintenance described in this manual. For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards. Keep this owner's manual aboard your scooter at all time so that you can refer to it whenever you need information. This manual should be considered a permanent part of the scooter and should remain with the scooter when it is sold. All information, illustrations, photographs and specifications contained in this manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepancies in this manual. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. A READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this scooter should carefully read and understand the contents of this manual before riding the scooter. SPECIAL MESSAGES Please read this manual and follow its instructions carefully. To emphasize special information the words WARNING , CAUTION and Note carry special meanings and should be carefully reviewed. WARNING Indicates a strong possibility that serious injury or death may result if instructions are not followed. Indicates a possibility that equipment or property damage could result if instructions are not followed. Gives helpful information CAUTION NOTE: The Owner's Manual should be considered a permanent part of your scooter. It should remain with the vehicle at all times and stay with the scooter if it is sold. ON-ROAD USE This scooter is designed to be used only on the road. B CONTENTS Page Page BRAKES.........................................28 SCOOTER SAFETY........................1 IMPORTANT SAFETY INFORMATION................................1 PROTECTIVE APPAREL...................3 LOAD LIMITS AND GUIDELINES.......5 LOCATION OF THE WARNING AND SPECIFICATION LABELS..................8 FUEL FILL CAP................................30 FRONT SMALL BOX.........................32 CENTER SMALL BOX......................33 SEAT..............................................34 ADJUSTABLE BACKREST...............35 CENTER COMPARTMENT...............36 CENTER COMPARTMENT LIGHT.....37 CELL PHONE SOCKET & CELL PHONE FIXED SEAT.......................37 HELMET HOLDERS........................39 STAND...........................................40 SUSPENSION.................................42 DIAGNOSTIC TOOL CONNECTOR (XCITING 500 AFI/XCITING 250 AFI)..43 PARTS LOCATION........................12 FRAME NUMBER............................16 ENGINE NUMBER...........................17 KEY NUMBER.................................18 CONTROLS..................................19 KEYS.............................................19 IGNITION SWITCH..........................19 INSTRUMENT AND INDICATORS....21 RIGHT HANDLEBAR SWITCH..........25 LEFT HANDLEBAR SWITCH............27 PRE-RIDE INSPECTION...............44 OPERATION.................................45 STARTING THE ENGINE.................45 RIDING...........................................50 (Cont'd) C Page PARKING........................................55 BREAK-IN (RUNNING IN)................57 Page COOLANT.......................................85 FRONT AND REAR SUSPENSION INSPECTION..................................87 SIDE STAND...................................88 BRAKE LEVER ADJUSTER.............89 BRAKE FLUID................................89 BRAKE PAD WEAR........................90 PARKING BRAKE OPERATION (XCITING 500 AFI/XCITING 500).......91 BATTERY........................................92 FUSE REPLACEMENT....................94 TIRES............................................97 INSPECTION AND MAINTENANCE............................59 THE IMPORTANCE OF MAINTENANCE..............................59 MAINTENANCE SCHEDULE (XCITING 500 AFI/XCITING 500).......60 MAINTENANCE SCHEDULE (XCITING 250AFI/XCITING 250 )......63 TOOL KIT.......................................66 CRANKCASE BREATHER...............66 ENGINE OIL...................................67 TRANSMISSION OIL.......................76 AIR CLEANER................................78 THROTTLE OPERATION.................81 IDLE SPEED...................................82 SPARK PLUG..................................84 D CLEANING.................................101 STORAGE GUIDE.......................106 SPECIFICATIONS (XCITING 500 AFI/XCITING 500)...109 SPECIFICATIONS (XCITING 250AFI/XCITING 250)....111 SCOOTER SAFETY IMPORTANT SAFETY INFORMATION Your scooter can provide many years of service and pleasure, if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You will find many helpful recommendations throughout this manual. Following are a few that we consider most important. Wear a helmet Scooter safety equipment starts with a quality helmet. One of the most serious injuries that can happen is a head injury. Always wear a properly approved helmet. You should also wear suitable eye protection. Make yourself easy to see To make yourself more visible, wear bright reflective clothing, position yourself so other drivers can see you, signal before turning or changing lanes, and use your horn when it will help others notice you. Know your limits Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you to avoid accidents. 1 Keep your scooter in safe condition For safe riding, it's important to inspect your scooter before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by KYMCO for this scooter. Inspection before riding Do not forget to perform an entire safety inspection to ensure the safety of the rider. Be extra safety conscious on bad weather days Riding on bad weather days, especially wet ones, requires extra caution. Braking distance double on a rainy day. Stay off of the painted surface marks, manhole covers and greasy appearing areas as they can be especially slippery. Use extreme caution at railway crossings and on metal gratings and bridges. Whenever in doubt about road conditions, slow down. M odification Modification of the scooter, or removal of original equipment may render the vehicle unsafe or illegal. Obey all applicable equipment regulations in your area. 2 PROTECTIVE APPAREL For your safety, we strongly recommend that you always wear an approved scooter helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride. Helmets and protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and help your vision. Additional riding gear In addition to a helmet and eye protection, we also recommend: Sturdy boots with non-slip soles to help protect your feet and ankles. Leather gloves to keep your hands warm and help prevent blisters, cuts, burns and bruises. A scooter riding suit or jacket for comfort as well as protection. Bright-colored and reflective clothing can help make you more noticeable in traffic. Be sure to avoid loose clothes that could get caught on any part of your scooter. 3 (1) (2) (3) (4) (1)Wear gloves. (2)Clothes should be close-fitting. (3)Always wear an helmet. You should also wear a face shield or goggles. (4)Wear bright or reflective clothing. (5)Shoes should be close-fitting, have low heels and offer ankle protection. WARNING Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you and your passenger always wear an approved motorcycle helmet that fits properly. You should also wear eye protection and other protective apparel when you ride. 4 (5) LOAD LIMITS AND GUIDELINES These general guidelines may help you decide whether or how to equip your scooter and how to load it safely. Load limits Following are the load limits for your scooter: Center small box weight limit: 3 kg (6.6 lbs) Center compartment weight limit:10 kg (22 lbs) Rear carrier weight limit:5 kg (11 lbs) Maximum weight capacity (Includes the weight of the rider, passenger, all cargo and All accessories.): 150 kg (330 lbs) Maximum cargo weight: 19 kg (42 lbs) Overloading the individual storage compartments can also affect stability and handling. So be sure to stay within the limits given below: Maximum weight: In center compartment In front small box In center small box On rear carrier 10 kg (22 lbs) 1.5 kg (3.3 lbs) 3 kg (6.6 lbs) 5kg (11 lbs) 5 Front small box weight limit: 1.5 kg (3.3 lbs) Loading guidelines Improperly loading your scooter can affect its stability and handling. You should ride at reduced speeds whenever carrying cargo. Follow these guidelines whenever you carry a passenger or cargo: Check that both tires are properly inflated. To prevent loose items from creating a hazard, make sure that all cargo is securely tied down before you ride away Place cargo weight as close to the center of the scooter as possible. Balance cargo weight evenly on both sides. WARNING Overloading or improper loading can cause changes in vehicle handling, stability and braking which could lead to an accident. Never exceed the stated load capacity for this scooter. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo. Allow greater distance for braking. 6 Accessories and Modification There are great variety of accessories available to KYMCO owners. KYMCO cannot have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for KYMCO to test each accessory on the market or combinations of all the available accessories; however, your dealer can assist you in selecting quality accessories and installing them correctly. Use extreme caution when selecting and installing the accessories for your scooter. WARNING Improper accessories or modifications can make your scooter unsafe and can lead to an accident. Never modify this scooter through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this scooter and should be installed and used according to instruction. If you have question, consult an authorized KYMCO dealer. No modifications We strongly advise you not to remove any original equipment or modify your scooter in any way that would change its design or operation. 7 LOCATION OF THE WARNING AND SPECIFICATION LABELS (1) CAUTIONS Before starting the engine, the side stand shall be kicked up to secure safety. (1) 8 (2): XCITING 500 AFI/XCITING 500 CAUTIONS Every 6000 km run should exchange the filter. (3) CAUTIONS Never put any article between the rear side cover and the engine to avoid interference of riding. (2) (3) 9 (4) (5) (4) ! Be sure to wear a safety helmet when riding. ! Do not exceed the speed specified by law when riding. ! The exhaust muffler temperature is very high after riding. Be sure to park the motorcycle in a place not easily touched by people. ! For riding safety and good performance do not violate the law to modify the motorcycle. ! Make sure to perform the periodic maintenance and preride inspection. ! Preride Inspection Items Brake Performance, tires, engine oil level, lights, horn, and instrument panel. KWANG YANG MOTOR CO., LTD ! Please read the User's Manual carefully to secure driving safely. (5) CAUTIONS Tire Size (One Rider) (Two Rider) Load Capacity : Front 120/70-15 Rear 150/70-14 2 2 : Front 2.00kgf/cm Rear 2.50kgf/cm 2 2 : Front 2.25kgf/cm Rear 2.50kgf/cm : Shield 1.5kg Clip assy center 3kg (As per KYMCO standard specification) 2 (Note: The tire pressure must not overpass 2.50kgf/cm ! Check the motor oil level with the dipstick after refilling motor oil. 10 (7) (6) (6) CAUTION Mobile phone charge only, Use other appliance may cause damage. (7) CAUTION ! ! DON'T WIPE WITH ORGANIC SOLVENT (EX: GAS, THINNER...ETC). USE NEUTRAL SOAP TO CLEAN WINDSHIELD. 11 PARTS LOCATION (06) (05) (04) (03 ...