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Kymco Xciting 500 2004-2008 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kymco Model: Xciting 500 Model Year: 2004-2008 Generation Generation: First Generation (2004-2008) Codes Engine Codes: Likely follows Kymco's internal alphanumeric coding for the 500cc engine;...
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厂商:
斯库: 454148
Kymco Xciting 500 2004-2008 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kymco
Model:
Xciting 500
Model Year:
2004-2008
Generation
Generation:
First Generation (2004-2008)
Codes
Engine Codes:
Likely follows Kymco's internal alphanumeric coding for the 500cc engine; specific codes would be detailed within the manual.
👋 Introduction
Market Position
Market Position:
The Kymco Xciting 500 was positioned as a premium, large-displacement maxi-scooter, competing in a segment typically dominated by European and Japanese manufacturers, offering a blend of performance, comfort, and touring capability.
Competitive Analysis
Competitive Analysis:
Competed with scooters like the Yamaha TMAX, Suzuki Burgman 400/650, and BMW C series models, aiming to provide a strong value proposition with comparable performance and features.
Key Features
Key Features:
Powerful 500cc engine, comfortable ergonomics for long-distance riding, ample storage, advanced braking systems (often with ABS as an option), and a sophisticated design.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive repair and maintenance for the Kymco Xciting 500 (2004-2008 models).
Page Count
Page Count:
348
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, starting, charging, exhaust systems.
Transmission:
Automatic CVT (Continuously Variable Transmission) operation, maintenance, and repair.
Chassis:
Frame, suspension (front and rear), steering, wheels, tires, braking system (front and rear).
Electrical:
Wiring diagrams, lighting, instrumentation, battery, starting and charging systems, ignition system, accessories.
Body:
Body panels, fairings, seats, storage, controls.
Procedures Included
Procedures Included:
Routine maintenance, troubleshooting, disassembly, assembly, repair, adjustment, inspection, diagnostic procedures, specifications.
Troubleshooting Procedures:
Detailed diagnostic charts and step-by-step troubleshooting guides for various systems, aiding in identifying and resolving common and uncommon faults.
Removal And Installation:
Complete instructions for the removal and installation of all major components and sub-assemblies, including specialized tools required.
Technical Depth
Technical Depth:
Detailed step-by-step procedures with explanations, pictorial diagrams, illustrations, exploded views, photos, and torque specifications. Covers everything from basic checks to complete component overhauls.
Special Tools Reference:
References specific Kymco service tools and their usage for various repair and adjustment procedures.
Pictorial Diagrams:
Extensive use of clear, detailed diagrams, exploded views, and photographs to illustrate procedures and component relationships.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Printable pages, high resolution for clarity.
Binding Type
Binding Type:
N/A (Digital Download - PDF)
Paper Type
Paper Type:
N/A (Digital Download - PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, SOHC, 4-valve
Displacement:
498.8 cc
Bore X Stroke:
Approximately 92.0 mm x 75.0 mm (specific values to be confirmed in manual).
Cooling System:
Liquid-cooled
Compression Ratio:
Typically around 10.0:1 to 10.5:1 (specific value in manual).
Valve Actuation:
Single Overhead Camshaft (SOHC) with 4 valves per cylinder.
Performance
Horsepower:
Around 33-36 HP (at crank, specific value in manual).
Torque:
Around 40-44 Nm (at crank, specific value in manual).
Fuel System
Fuel Delivery:
Fuel Injection (EFI) - specific injector details and pressures in manual.
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic advance.
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Optional
Optional Transmission:
N/A (CVT is standard for this model)
Features
Clutch Type:
Automatic centrifugal clutch.
Final Drive:
Belt drive to rear wheel via CVT and reduction gear.
📐 Dimensions
Exterior
Overall Length:
Approx. 2235 mm (specific value in manual).
Overall Width:
Approx. 800 mm (specific value in manual).
Overall Height:
Approx. 1400 mm (specific value in manual).
Wheelbase:
Approx. 1590 mm (specific value in manual).
Weights
Dry Weight:
Approx. 220 kg (specific value in manual).
Fuel Tank Capacity:
Approx. 14 liters (specific value in manual).
🛡️ Safety Features
Ratings
Safety Ratings:
Not typically rated by organizations like NHTSA or IIHS as it's a scooter; safety relies on adherence to manual's procedures and standard road safety practices.
Active Features
Active Safety Features:
Disc brakes (front and rear), optional ABS (Anti-lock Braking System) on some models/regions. Effective lighting systems.
Passive Features
Passive Safety Features:
Robust chassis and frame construction, bodywork for rider protection, rider footrests.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation including speedometer, tachometer, fuel gauge, odometer, trip meter, and indicator lights. No advanced infotainment systems typical of modern vehicles.
Driver Assistance
Driver Assistance Features:
Optional ABS on some models. Focus on reliable mechanical and electrical systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months, depending on usage (specific interval in manual).
Valve Clearance Check:
Usually recommended every 10,000-15,000 km (specific interval in manual).
Cvt Belt Inspection:
Regular inspection for wear and damage, replacement typically around 20,000-30,000 km (specific interval in manual).
Air Filter Replacement:
Typically every 5,000-10,000 km or as needed based on operating conditions (specific interval in manual).
Spark Plug Replacement:
Recommended replacement interval typically between 10,000-20,000 km, depending on plug type and condition (specific interval in manual).
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher (specific viscosity and API rating in manual).
Engine Oil Capacity:
Approx. 1.6-1.8 liters with filter change (specific capacity in manual).
Coolant Type:
Ethylene glycol-based antifreeze/coolant (specific mix ratio and type in manual).
Brake Fluid Type:
DOT 4 (specific type and specifications in manual).
Gear Oil Type:
SAE 80W-90 API GL-4 or GL-5 hypoid gear oil (specific type and capacity in manual).
Known Issues
Known Issues:
Potential for CVT belt wear/slippage, some electrical component reliability concerns, and general wear and tear typical for a vehicle of this age. Specific common issues and troubleshooting tips will be detailed in the manual.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Kymco (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer renowned for its scooters, motorcycles, and ATVs, often recognized for producing high-quality, reliable, and value-driven vehicles.
Model Evolution
Model Evolution:
The Xciting line was introduced to cater to the growing demand for maxi-scooters. The 500cc model represented Kymco's ambition to compete in the higher-displacement segment, offering a comfortable and powerful touring experience.
Production
Production Period:
2004-2008 (for this specific manual coverage).
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards are not readily documented for this model, Kymco has received numerous accolades for product quality and value in the scooter market globally.
Ratings
Owner Satisfaction Ratings:
Owner satisfaction varied, with many praising its power and comfort for the price point, while some experienced reliability issues common in early generations of advanced models.
Certifications
Certifications:
Compliant with relevant emissions and safety standards for its respective market at the time of manufacture.
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