🏷️ Basic Information

Make:

KYMCO

Model:

XCITING 500

Model Variant:

500cc (Likely represents different engine options within the 500cc class, e.g., carburetor vs. fuel injection variants)

Model Code Range:

05-ON (Indicates coverage for models from the 2005 model year onwards)

👋 Introduction

Segment:

Maxi-scooter (High-performance, comfortable touring scooter designed for longer distances and highway use.)

Competitors:

Yamaha TMAX 500/530, Suzuki Burgman 400/650, Honda Forza 300/500 (though historically some of these might be slightly different displacement classes, they compete in the maxi-scooter market).

Features:

Powerful engine for its class, comfortable ergonomics for rider and passenger, ample storage, aerodynamic bodywork, capable of highway speeds, suitable for commuting and touring.

Value:

Offers a blend of performance, comfort, and practicality, aiming to compete with established Japanese maxi-scooter brands at a potentially competitive price point.

📋 Manual Details

Geographical Coverage:

Global (Assuming the manual covers models sold internationally, typical for major manufacturers like KYMCO)

Market Coverage:

All markets where the XCITING 500 was sold

Pages:

Hundreds (Specific number not provided, but indicates a comprehensive document)

Type:

Service Repair Manual

Language:

English (Presumed, as product information is in English. Official KYMCO manuals may exist in multiple languages.)

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, component diagnostics, fuel system (carburetor/injection), ignition system, cooling system, lubrication system, exhaust system, engine management systems (ECU/sensors).

Transmission:

Automatic CVT (Continuously Variable Transmission) disassembly, inspection, repair, clutch system, drive belts, gear oil specifications and replacement.

Chassis:

Frame inspection and repair, suspension (front forks, rear shock absorbers) overhaul and adjustment, steering system components, wheel bearings, linkage systems.

Brakes:

Hydraulic brake systems (front and rear), disc brake caliper service, brake pad replacement, brake fluid type and bleeding procedures, master cylinder overhaul, parking brake mechanism.

Electrical:

Wiring diagrams, battery system, charging system (alternator/stator), starting system (starter motor, solenoid), lighting (headlights, taillights, indicators), horn, fuses, relays, switches, instrument cluster, ECU diagnostics, sensor testing.

Bodywork:

Fairing removal and installation, seat assembly, fuel tank servicing, storage compartment access, panel fasteners, cosmetic repairs, lighting and accessory fitment.

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter replacement, spark plug inspection and replacement, coolant checks and changes, brake fluid flushes, drive belt inspection and replacement, tire pressure checks and adjustments.

Troubleshooting:

Diagnostic flowcharts for common issues, fault code interpretation (if applicable), symptom-based troubleshooting guides for engine, electrical, and mechanical problems.

Repair:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major systems. Torque specifications for critical fasteners.

Rebuilding:

Detailed procedures for engine component rebuilding (pistons, rings, valves, crankshaft, etc.), transmission component servicing, carburetor/fuel injector cleaning and rebuilding.

Depth:

Comprehensive (Covers everything from basic maintenance to complete engine and component overhauls, advanced diagnostics and repair procedures.)

📊 Manual Specifications

Quality:

High-resolution PDF, likely with searchable text for efficient information retrieval. Clear diagrams and illustrations.

Printability:

Printable (Users can print specific sections or the entire manual for hands-on use in a workshop setting.)

Binding:

N/A (PDF format, not physically bound.)

Paper:

N/A (PDF format, not printed on paper.)

⚙️ Engine Specifications

Engine Type:

4-stroke, Single Cylinder, SOHC, 4-valve (Typical configuration for this model, though some earlier versions might have different valve counts. Specifics may vary by sub-model.)

Displacement:

Approx. 499cc - 500cc (Exact displacement may vary slightly based on specific model year and international market variations.)

Bore X Stroke:

Varies by specific model, but common for 500cc class is around 92mm x 75mm or similar.

Cooling System:

Liquid-cooled

Horsepower:

Approx. 35-40 HP (Estimated peak horsepower for a 500cc scooter of this era. Official figures may vary.)

Torque:

Approx. 40-45 Nm (Estimated peak torque. Official figures may vary.)

Fuel Delivery:

Fuel Injection (FI) for later models, Carburetor for earlier models (The '05-ON' implies potential transition or multiple variants. Manual would detail both if applicable.)

Fuel Type:

Unleaded Gasoline (Octane rating typically 91 or higher, refer to manual for exact specification).

Ignition System:

Electronic Ignition (CDI/ECU controlled).

Oil Type:

High-quality motorcycle engine oil, SAE 10W-40 or 10W-50 often recommended for 4-stroke scooters (Specific API/JASO rating required, e.g., JASO MA/MA2).

Oil Capacity:

Approx. 1.7 - 1.9 Liters (Including oil filter replacement, refer to manual for precise capacity.)

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT) with Dry Clutch

Optional Transmissions:

N/A (CVT is standard for this type of scooter)

Drive System:

Belt drive to rear wheel.

Gear Ratios:

CVT provides infinite gear ratios within its operating range.

Transmission Fluid Type:

Manual would specify any gearbox oil requirements for the final drive (if separate) and potentially specific CVT fluid requirements if not integrated with engine oil.

📐 Dimensions

Length:

Approx. 2,205 mm (Refer to manual for exact specifications)

Width:

Approx. 800 mm (Refer to manual for exact specifications)

Height:

Approx. 1,360 mm (Refer to manual for exact specifications)

Dry Weight:

Approx. 190 - 200 kg (Curb weight will be higher with fluids.)

Curb Weight:

Refer to manual for exact specifications (Typically ~10-15kg more than dry weight).

Storage Capacity:

Under-seat storage capable of holding a full-face helmet and other items. Glove compartment.

🛡️ Safety Features

Crash Test Results:

N/A (Motorcycles and scooters typically do not undergo standardized crash testing like passenger cars. Safety features are analyzed on a component and design basis.)

Braking System:

Dual Hydraulic Disc Brakes (Front and Rear) for enhanced stopping power. Some models may feature ABS (Anti-lock Braking System) as an option or standard on higher trims.

Lighting:

Halogen or LED Headlights for improved visibility, LED taillight and brake light, front and rear turn signals.

Frame Construction:

Robust steel frame designed for stability and handling.

Tires:

Tubeless tires for safety and convenience. Specific tire sizes and recommended pressures will be in the manual.

💡 Technology Features

Instrument Cluster:

Digital and Analog combination display featuring speedometer, tachometer, odometer, trip meters, fuel gauge, coolant temperature gauge, and various indicator lights (e.g., engine check, oil pressure, high beam).

ABS:

Optional or standard on some variants. If equipped, the manual will cover ABS system diagnostics and bleeding procedures.

Charging Port:

Some models may feature a 12V accessory socket for charging electronic devices.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 - 5,000 km or 6 months, whichever comes first (Refer to manual for exact interval and conditions).

Air Filter Maintenance:

Inspection every 5,000 km, cleaning/replacement as needed. Replacement typically every 10,000 - 15,000 km.

Spark Plug Replacement:

Inspection at 5,000 km, replacement typically around 10,000 - 20,000 km depending on plug type (e.g., standard vs. iridium).

Brake Fluid Flush:

Every 2 years or 24,000 km (Due to moisture absorption, regular flushing is critical for brake system performance.)

Drive Belt Inspection:

Inspection at 10,000 km, replacement typically between 20,000 - 30,000 km (Depends heavily on riding style and conditions.)

Engine Oil Specification:

JASO MA/MA2, API SG or higher, SAE 10W-40 or 10W-50 (Exact specification to be confirmed in the manual.)

Coolant Specification:

Ethylene glycol-based antifreeze mixed with distilled water in a 50/50 ratio. Specific coolant type might be recommended by KYMCO.

Brake Fluid Specification:

DOT 4 (Hydraulic brake systems typically use DOT 4 fluid. Refer to manual for confirmation and specific manufacturer recommendation.)

Common Wear Items:

Drive belt, brake pads, tires, suspension bushings, and bearings are common wear items requiring regular inspection and replacement.

Potential Failures:

Older models might experience issues with electrical components, starter motors, or fuel system components if not properly maintained. Overheating due to coolant leaks or blocked radiators can occur.

Service Tips:

Regular cleaning of the CVT cover and inspection of the drive belt are crucial for maintaining performance and preventing premature failure. Ensure proper cooling system maintenance to prevent engine damage.

📚 Vehicle History

Manufacturer:

KYMCO (Kwang Yang Motor Co., Ltd.) is a Taiwanese company known for producing scooters, motorcycles, ATVs, and utility vehicles. It's one of the world's largest scooter manufacturers.

Xciting Lineage:

The XCITING series is KYMCO's flagship maxi-scooter line, known for its performance and comfort. The 500cc model represents a significant displacement within this range, offering more power than smaller scooters.

Manufacturing Origin:

Taiwan (Primary manufacturing location for KYMCO vehicles.)

Model Years Covered:

2005 onwards (Specific sub-models and updates within this range will be detailed in the manual.)

🏆 Awards & Recognition

Industry Accolades:

While specific awards for the XCITING 500 are not detailed in the product information, KYMCO generally receives positive reviews for its maxi-scooters in performance, comfort, and value categories within the powersports industry.

Review Consensus:

Often praised for strong engine performance, stable handling, and comfortable ride quality suitable for touring. Value for money is frequently cited as a key advantage.