🏷️ Basic Information

Make:

Kymco

Model:

Xciting 500

Product Name:

Kymco Xciting 500 Service Repair Manual ENG

Product Description:

Kymco Xciting 500 Service Manual ENG

👋 Introduction

Segment:

Maxi-scooter, performance scooter

Target Audience:

Owners and independent workshops looking for detailed repair and maintenance information for the Kymco Xciting 500.

Competitors:

Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Scarabeo

Vehicle Appeal:

Sporty handling, comfortable ride for longer distances, powerful engine for its class, good value proposition.

📋 Manual Details

Primary Coverage:

Mechanical, Electrical, Bodywork, Maintenance, Troubleshooting, Repair

Component Coverage:

Engine, Transmission (CVT), Fuel System, Ignition System, Cooling System, Braking System (Front & Rear), Suspension (Front & Rear), Electrical System, Lighting, Frame, Body panels, Wheels, Tires

Estimated Pages:

300-500 (typical for this class of manual)

Type:

Service and Repair Manual

Language:

English (ENG)

Format:

Digital (likely PDF, based on common industry practice for this product type)

📖 Manual Coverage

Engine Systems:

Engine disassembly, assembly, inspection, component replacement (pistons, rings, valves, camshaft, crankshaft), cylinder head, lubrication system, cooling system management.

Drivetrain Systems:

Continuously Variable Transmission (CVT) removal, installation, belt inspection, roller weight analysis, clutch assembly, final drive.

Braking Systems:

Front and rear brake caliper service, brake pad replacement, brake disc inspection and replacement, hydraulic system bleeding, master cylinder service.

Electrical Systems:

Wiring diagrams, lighting system diagnosis and repair, battery maintenance, starter motor, charging system (alternator/stator, regulator/rectifier), ignition system components (spark plug, coil), starter circuits, fuses and relays.

Suspension Steering:

Front fork service (oil replacement, seal replacement), rear shock absorber inspection and replacement, steering head bearing maintenance, wheel bearing inspection.

Fuel Ignition Emissions:

Fuel injection system (throttle body, injectors, fuel pump), fuel filter replacement, ignition timing checks, emissions control systems (if applicable).

Routine Maintenance:

Oil change intervals, oil filter replacement, air filter cleaning/replacement, spark plug replacement, coolant flush and replacement, brake fluid flush and replacement, drive belt inspection and replacement, tire pressure checks, lubrication points.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based fault finding, electrical system diagnostics, engine performance problems, braking issues, starting problems.

Major Repairs:

Engine overhaul procedures, transmission rebuild, suspension component replacement, electrical system component replacement, body panel removal and installation.

Special Tools:

Identification and usage of specific tools required for certain repair procedures (e.g., CVT tool, bearing pullers, torque wrenches).

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, component clearances, and diagnostic flowcharts.

📊 Manual Specifications

Digital Format:

Likely PDF (Portable Document Format), optimized for searchability and viewing on various devices.

Image Resolution:

High-resolution images and diagrams ensuring clarity for component identification and repair steps.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, SOHC

Displacement:

Approximately 493cc (specific to model year variations)

Bore X Stroke:

Specific to model (e.g., ~92mm x 75mm)

Compression Ratio:

Specific to model (e.g., ~10.2:1)

Horsepower:

Typically in the range of 35-40 HP at specified RPM

Torque:

Typically in the range of 40-45 Nm at specified RPM

Fuel Delivery:

Electronic Fuel Injection (EFI) by Keihin or similar manufacturer

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Ignition Type:

CDI (Capacitor Discharge Ignition) with electronic advance

Cooling Method:

Liquid-cooled (radiator, fan, water pump)

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (e.g., Kymco recommends a specific mix or a standard motorcycle coolant)

Oil Type:

SAE 10W-40 or 10W-50, API SG/SH/SJ/SL or JASO MA/MA2 certified motorcycle engine oil

Oil Capacity:

Approx. 1.7 - 1.9 liters (with filter change)

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Drive Type:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

📐 Dimensions

Overall Length:

Approx. 2250 mm

Overall Width:

Approx. 780 mm

Overall Height:

Approx. 1420 mm

Wheelbase:

Approx. 1590 mm

Dry Weight:

Approx. 185 kg

Curb Weight:

Approx. 200 kg (with fluids)

Max Load Capacity:

Specific to owner's manual, typically around 150-170 kg including rider and luggage.

Underseat Storage:

Sufficient for one full-face helmet, possibly two open-face helmets depending on size.

🛡️ Safety Features

Crash Test Ratings:

Not typically subjected to automotive-style crash testing as a motorcycle.

Braking System Type:

Dual disc front brakes, single disc rear brake. ABS (Anti-lock Braking System) available on certain model years/trims.

Lighting:

Halogen headlights, LED taillights and turn signals (depending on year).

Frame Construction:

Steel tube frame for rigidity and strength.

Handlebars:

Ergonomically designed handlebars for rider comfort and control.

💡 Technology Features

Dashboard Display:

Analogue tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, oil pressure warning light.

Lighting Controls:

Headlight switch, turn signal switch, horn, hazard lights (on some models).

ABS:

Available on specific model variants, providing enhanced braking stability.

Charging Port:

Optional 12V accessory socket (DC power outlet) for charging devices.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km or 6 months, whichever comes first.

Oil Filter Replacement:

Every 6,000 km or 12 months (concurrent with oil changes).

Air Filter Inspection:

Every 3,000 km; clean or replace as needed.

Spark Plug Replacement:

Every 6,000 km (specific plug type and gap required).

Drive Belt Inspection:

Every 6,000 km; replace if worn, cracked, or damaged.

Cvt Roller Weight Inspection:

Every 12,000 km for wear and flat spots.

Brake Fluid Flush:

Every 12,000 km or 24 months.

Coolant Replacement:

Every 24,000 km or 24 months.

Engine Oil Specification:

SAE 10W-40 or 10W-50, API SG/SH/SJ/SL, JASO MA/MA2.

Coolant Specification:

Ethylene glycol based, permanent type antifreeze/coolant (e.g., 50/50 mix with distilled water).

Brake Fluid Specification:

DOT 4 (or specified in the owner's manual).

Common Wear Items:

CVT belt, drive rollers, brake pads, tires, battery, spark plug.

Potential Issues:

Occasional electrical connector corrosion, starter motor wear, fuel injector clogging if poor quality fuel is used, regulator/rectifier failure (though less common than on some other brands).

📚 Vehicle History

Manufacturer:

Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer known for producing a wide range of scooters, motorcycles, and ATVs.

Introduction Year:

The Xciting 500 line was introduced around the mid-2000s, evolving from earlier Kymco models.

Key Updates:

Model updates often include styling revisions, engine refinements (e.g., emissions compliance), ABS integration, and improved features.

Manufacturing Location:

Taiwan

🏆 Awards & Recognition

Industry Awards:

While specific awards for the Xciting 500 itself are not widely publicized, Kymco as a brand has received recognition for its scooter technology and value.