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1. GENERAL INFORMATION XCITING 500/250


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GENERAL INFORMATION
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SERIAL NUMBER----------------------------------------------------------- 1 - 1
SPECIFICATIONS (XCITING 500)--------------------------------------- 1 - 2
SPECIFICATIONS (XCITING 250)--------------------------------------- 1 - 3
SERVICE PRECAUTIONS ------------------------------------------------- 1 - 4
TORQUE VALUES ---------------------------------------------------------- 1 - 8
SPECIAL TOOLS ------------------------------------------------------------ 1-12
LUBRICATION POINTS --------------------------------------------------- 1-13
CABLE & HARNESS ROUTING (XCITING 500) ------------------------- 1-15
CABLE & HARNESS ROUTING (XCITING 250) ------------------------- 1-25
TROUBLESHOOTING------------------------------------------------------ 1-33




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1. GENERAL INFORMATION XCITING 500/250


SERIAL NUMBER




Location of Frame Serial Number




Location of Engine Serial Number




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1. GENERAL INFORMATION XCITING 500/250


SPECIFICATIONS (XCITING 500)
ITEM SPECIFICATIONS ITEM SPECIFICATIONS
Name XCITING 500 Air cleaner type & No Wet paper type element
Overall length 2250 mm (90 in) Fuel capacity 12.8 L (3.38 lmp gal,




Fuel System
Overall width 815 mm (33 in) 2.82 US gal




Carburetor
Overall height 1450 mm (58 in) Type CVK
Wheel base 1570 mm (63 in) Main jet NO. 98
Engine type O.H.C. Venturi dia. 36 mm (1.44 in)
Displacement 498.5 cm3 (30.4 cu-in) Throttle type PISTON




Electrical Equipment
Fuel Used 92# nonleaded gasoline Full transistor ignition




Ignition System
Type
Front wheel 83 kg (183 lbs) Spark plug CR8E
Dry weight Rear wheel 132 kg (290 lbs)
Total 215 kg (473 lbs) Ignition timing Throttle position sensor
Front wheel 90 kg (198 lbs) Spark plug gap 0.60.7mm (0.002
Curb weight Rear wheel 141 kg (310 lbs) 0.003 in)
Total 231 kg (508 lbs) Battery Capacity 12V12AH
Tires Front wheel 120/70-15 Dry, centrifugal
Power Drive System




Clutch Type
Rear wheel 150/70-14 automatic
sion Gear Ratio
Transmis- Reduction



Ground clearance 150 mm (6 in) Type Helical gear/spur gear
Min. turning radius 2750 mm (110 in) Automatic centrifugal
Operation
Starting system Electric starter motor Type
Type Gasoline, 4-stroke Type CVT
Cylinder arrangement Single cylinder Preliminary 2.68 1
Combustion chamber type Semi-sphere Final 5.4
Valve arrangement O.H.C., chain drive
FR/RR tire rolling
92 x 75 mm 1724/1778 mm (69/71 in)
Moving Device




Bore x stroke circumference
(3.7 x 3 in)
Compression ratio 10.5:1 2 kg/cm (200 Kpa, 28
Tire pressure Front psi)
Compression pressure 13 kgf/cm (1300kPa,
(rider only/60
185 psi) 2.5 kg/cm (250 Kpa, 36
kg) Rear
Open 2 BTDC psi)
Engine




Intake valve
Close 45 ABDC Turning Left 40
Open 45 BBDC angle Right 40
Exhaust valve
Close 5 ATDC Brake system Rear Disk brake
Valve clearance Intake 0.1 mm (0.004 in) type Front Disk brake
(cold) Exhaust 0.1 mm (0.004 in)
Device
Damping




Front Telescopic fork
Idle speed 1400 rpm
Suspension
Lubrication type Forced pressure &
Wet sump type Rear Unit swing
Oil pump type Trochoid
System
Lubrication




Frame type Back born
Oil filter type Full-flow filtration
Oil capacity 2.5 L (2.2 lmp qt,
2.65 Us qt)
Final reduction oil 0.55 L (0.5 lmp qt,
capacity 0.58 Us qt)
Cooling Type Liquid cooled


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1. GENERAL INFORMATION XCITING 500/250


SPECIFICATIONS (XCITING 250)
ITEM SPECIFICATIONS ITEM SPECIFICATIONS
Name XCITING 250 Air cleaner type & No Wet paper type element
Overall length 2250 mm (90 in) 12.8 L (3.38 lmp gal,
Fuel capacity




Fuel System
Overall width 815 mm (33 in) 2.82 US gal




Carburetor
Overall height 1450 mm (58 in) Type CVK
Wheel base 1570 mm (63 in) Main jet NO. 94
Engine type O.H.C. Venturi dia. 30 mm (1.2 in)
Displacement 251/249.1 cm3 Throttle type PISTON




Electrical Equipment
(15.3/15.8 cu-in) Full transistor ignition




Ignition System
Type
Fuel Used 92# nonleaded gasoline Spark plug DPR7EA-9
Front wheel 75 kg (165 lbs)
Dry weight Rear wheel 110 kg (242 lbs) Ignition timing Throttle position sensor
Total 185 kg (407 lbs) Spark plug gap 0.60.7mm (0.002
Front wheel 81 kg (178 lbs) 0.003 in)
Curb weight Rear wheel 119 kg (262 lbs) Battery Capacity 12V12AH
Total 200 kg (440 lbs) Type Dry, centrifugal
Power Drive System



Clutch
Tires Front wheel 120/70-15 automatic
sion Gear Ratio
Transmis- Reduction


Rear wheel 150/70-14 Type Helical gear/spur gear
Ground clearance 170 mm (6.8 in) Automatic centrifugal
Operation
Min. turning radius 2600 mm (104 in) Type
Starting system Electric starter motor Type CVT
Type Gasoline, 4-stroke Preliminary 0.83 2.2
Cylinder arrangement Single cylinder Final 8.72
Combustion chamber type Semi-sphere
FR/RR tire rolling
1724/1778 mm (69/71 in)
Moving Device




Valve arrangement O.H.C., chain drive circumference
Bore x stroke 72.7 x 60 mm
(2.908 x 2.4 in) 2 kg/cm (200 Kpa, 28
Tire pressure Front psi)
Compression ratio 10.3:1 (rider only/60
15 kgf/cm (1500kPa, 2.5 kg/cm (250 Kpa, 36
Compression pressure kg) Rear
213 psi) psi)
Open 9 BTDC Turning Left 40
Engine




Intake valve
Close 45 ABDC angle Right 40
Open 38 BBDC Brake system Rear Disk brake
Exhaust valve
Close 10 ATDC type Front Disk brake
Valve clearance Intake 0.1 mm (0.004 in)
Device
Damping




Front Telescopic fork
(cold) Exhaust 0.1 mm (0.004 in)
Suspension
Idle speed 1600 rpm
type Rear Unit swing
Forced pressure &
Lubrication type Wet sump
Frame type Back born
Oil pump type Trochoid
System
Lubrication




Oil filter type Full-flow filtration
Oil capacity 1.1 L (0.97 lmp qt,
1.17 Us qt)
Final reduction oil 0.2 L (0.18 lmp qt,
capacity 0.21 Us qt)
Cooling Type Liquid cooled
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1. GENERAL INFORMATION XCITING 500/250


SERVICE PRECAUTIONS Apply or add designated greases and
lubricants to the specified lubrication
Make sure to install new gaskets, O-rings, points.
circlips, cotter pins, etc. when
reassembling.



After reassembly, check all parts for proper
tightening and operation.


When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

When two persons work together, pay
attention to the mutual working safety.




Use genuine parts and lubricants.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.



When servicing the motorcycle, be sure to
use special tools for removal and
installation.

After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After disassembly, clean removed parts. After connection, apply grease to the
Lubricate sliding surfaces with engine oil battery terminals.
before reassembly. Terminal caps shall be installed securely.




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1. GENERAL INFORMATION XCITING 500/250


If the fuse is burned out, find the cause and The connector shall be inserted
repair it. Replace it with a new one completely.
according to the specified capacity. If the double connector has a lock, lock
it at the correct position.
Confirm Check if there is any loose wire.
Capacity




Before connecting a terminal, check for
After operation, terminal caps shall be damaged terminal cover or loose negative
installed securely. terminal.




When taking out the connector, the lock on Check the double connector cover for
the connector shall be released before proper coverage and installation.
operation.




Insert the terminal completely.
Hold the connector body when connecting Check the terminal cover for proper
or disconnecting it. coverage.
Do not pull the connector wire.
Do not make the terminal cover opening
face up.




Secure wire harnesses to the frame with
Check if any connector terminal is bending, their respective wire bands at the
protruding or loose. designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.




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1. GENERAL INFORMATION XCITING 500/250


After clamping, check each wire to make Route harnesses so they are neither
sure it is secure. pulled tight nor have excessive slack.


Do not pull
too tight




Do not squeeze wires against the weld or
its clamp. Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.




After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.

When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.




When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Do not break the sheath of wire.
No Contact If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.




Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the When installing other parts, do not press or
projected ends of bolts and screws. squeeze the wires.
Do not press or
squeeze the
i




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1. GENERAL INFORMATION XCITING 500/250


After routing, check that the wire harnesses Symbols:
are not twisted or kinked. The following symbols represent the
servicing methods and cautions included in
this service manual.




: Apply engine oil to the
specified points. (Use
Wire harnesses routed along with
Engine Oil designated engine oil for
handlebar should not be pulled tight, have lubrication.)
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions. : Apply grease for lubrication.
Grease



: Transmission Gear Oil (90#)
Gear Oil




: Note
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Do you understand
the instrument




Be careful not to drop any parts.




When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Remove Rust




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1. GENERAL INFORMATION XCITING 500/250


TORQUE VALUES
STANDARD TORQUE VALUES
Torque Torque
Item Item
Nm (kgfm, lbfft) Nm (kgfm, lbfft)
5mm bolt and nut 5(0.5, 4) 4mm screw 3 (0.3, 2)
6mm bolt and nut 10 (1, 7) 5mm screw 4 (0.4, 3)
8mm bolt and nut 22 (2.2, 16) 6mm screw, SH bolt 9 (0.9, 6.5)
10mm bolt and nut 35 (3.5, 25) 6mm flange bolt and nut 12 (1.2, 9)
12mm bolt and nut 55 (5.5, 40) 8mm flange bolt and nut 27 (2.7, 20)
14mm bolt and nut 70 (7, 50) 10mm flange bolt and nut 40 (4, 29)
Torque specifications listed below are for important fasteners.


ENGINE (XCITING 500)

Item Q`ty Thread dia. Torque Remarks
(mm) Nm (kgfm, lbfft)
MAINTENANCE:
Engine oil drain plug 1 12 25 (2.5, 18)
Oil strainer screen cap 1 30 15 (1.5, 11)
Oil filter cartridge 1 20 10 (1, 7)
Transmission oil drain bolt 1 8 20 (2, 15)
Transmission oil filler bolt 1 8 20 (2, 15)
Spark plug 1 10 12 (1.2, 9)
Tappet adjust nut 4 5 9 (0.9, 6)
LUBRICATION SYSTEM:
Oil pump screw 1 4 3 (0.3, 2)
Oil cooler bolt 2 16 35 (3.5, 25) Apply oil
COOLING SYSTEM:
Water pump cover bolt 2 6 13 (1.3, 9)
CYLINDER HEAD:
Breather separator bolt 3 6 13 (1.3, 9) Apply oil
Cylinder head bolt (1 4) 4 10 48 (4.8, 35) Apply oil
Cylinder head bolt (5 13) 9 8 23 (2.3, 17) Apply oil
Cylinder head cover bolt 4 6 10 (1, 7)
Cam chain tensioner bolt 2 6 12 (1.2, 9)
Tensioner pivot bolt 1 8 10 (1, 7)
Rocker arm shaft 2 18 45 (4.5, 32)
DRIVE/DRIVEN PULLEY:
Drive face nut 1 18 135 (13.5, 97) Apply oil
Clutch out nut 1 14 80 (8, 58) Apply oil




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1. GENERAL INFORMATION XCITING 500/250


ENGINE (XCITING 500) (Cont'd)

Item Q`ty Thread dia. Torque Remarks
(mm) Nm (kgfm, lbfft)
Drive plate nut 1 28 78 (7.8, 56)
ALTERNATOR
ACG flywheel nut 1 14 55 (5.5, 40)
FINAL REDUCTION:
Transmission cover bolt 8 8 27 (2.7, 20)
CRANKCASE:
Crankcase bolt 13 6 12 (1.2, 9) Apply oil
Oil pipe bolt 2 16 43 (4.3, 31) Apply oil
Cam chain guide 2 8 20 (2, 15)
SWITCH:
Oil pressure switch 1 PT 1/8 22 (2.2, 16) Apply seal




ENGINE (XCITING 250)
Thread Torque
Item Q`ty Remarks
dia.(mm) Nm (kgfm, lbfft)
MAINTENANCE:
Valve adjusting lock nut 2 5 9 (0.9, 6.5) Apply oil
Spark plug 1 10 12 (1.2, 9)
Transmission oil drain bolt 1 12 20 (2, 15)
Transmission oil check/fill bolt 1 8 20 (2, 15)
Crank case oil drain bolt 1 12 25 (2.5, 18)
Oil filter screen cap 1 30 15 (1.5, 10.8) Apply oil
LUBRICATION SYSTEM:
Oil pump screw 1 3 2 (0.2, 1.4)
COOLING SYSTEM:
Water pump impeller 1 7 12 (1.2, 8.6) Left screw
CYLINDER HEAD:
Cylinder head cap nut 4 8 25 (2.5, 18) Apply oil
Tensioner lifter bolt 1 6 4 (0.4, 3)
Cylinder head cover bolt 4 6 12 (1.2, 8.6)
Cam chain tensioner bolt 2 6 12 (1.2, 8.6)




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1. GENERAL INFORMATION XCITING 500/250


ENGINE (XCITING 250) (Cont'd)

Item Q`ty Thread dia. Torque Remarks
(mm) Nm (kgfm, lbfft)
DRIVE/DRIVEN PULLEY:
Drive face nut 1 14 93 (9.3, 67) Apply oil
Clutch outer nut 1 12 54 (5.4, 39)
Clutch drive plate nut 1 28 54 (5.4, 39)
Left crankcase cover bolt 6 6 12 (1.2, 8.6)
ALTERNATOR
A.C.G. stator 5 5 9 (0.9, 6.5)
Flywheel nut 1 14 55 (5.5, 40)
FINAL REDUCTION:
Transmission case cover bolt 9 8 20 (2, 14.4)
CRANKCASE:
Cam chain guide bolt 1 6 10 (1, 7)
SWITCH:
Oil pressure switch 1 PT 1/8 22 (2.2, 16) Apply seal




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1. GENERAL INFORMATION XCITING 500/250


FRAME
Torque
Item Q`ty Thread dia.(mm) Nm (kgfm, Remarks
lbfft)
STEERING:
Handlebar bolt 4 8 23 (2.3, 17)
Upper pinch bolt 2 8 23 (2.3, 17)
Lower pinch bolt 4 8 32 (3.2, 23)
Bridge stem nut 1 22 62 (6.2, 45)
Steering stem lock nut 1 25.4 45 (4.5, 32)
Top thread 1 25.4 17 (1.7, 12)
WHEEL:
Front axle bolt 1 18 20 (2, 15)
Front fork bolt 2 8 23 (2.3, 17)
Rear axle nut (XCITING 500) 1 20 180 (18, 130)
Rear axle nut (XCITING 250) 1 16 140 (14, 100)
SUSPENSION:
Rear shock absorber bolt 4 10 40 (4, 29)
Rear fork 2 8 32 (3.2, 23)
BRAKE:
Front caliper mounting bolt 4 8 32 (3.2, 23) Replace a new one
Rear caliper mounting bolt 2 8 32 (3.2, 23) Replace a new one
Brake fluid bolt 6 10 35 (3.5, 25)
Master cylinder bolt 4 6 12 (1.2, 9)
ENGINE HANGER:
Engine hanger bolt 4 10 50 (5, 36)
Engine mounting bolt/nut 1 14 80 (8, 58)
(XCITING 500)
Engine mounting bolt/nut 1 10 50 (5, 36)
(XCINTING 250)
Engine hanger rod nut 1 10 35 (3.5, 25)
MUFFLER
Exhaust pipe nut 2 8 20 (2, 14)
Muffler mount bolt 3 10 35 (3.5, 25)




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1. GENERAL INFORMATION XCITING 500/250


SPECIAL TOOLS
XCITING 500

Tool Name Tool No. Remarks
Clutch spring compressor E053 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E054 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Oil filter cartridge wrench E052 Cartridge removal or install
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install


XCITING 250

Tool Name Tool No. Remarks
Clutch spring compressor E034 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E003 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install




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1. GENERAL INFORMATION XCITING 500/250


LUBRICATION POINTS

ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE 5W-50)
Camshaft protruding surface API SJ Engine Oil
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Balancer shaft
Crankshaft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
O-ring face
Oil seal lip
Drive gear shaft
Countershaft
Final gear Transmission oil: SAE 90
Final gear shaft
Transmission gearshaft bearing part
A.C. generator connector Adhesive




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1. GENERAL INFORMATION XCITING 500/250


FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.




Engine Oil Grease
Grease Front/Rear Brake Lever Pivot
Throttle Cable
Seat Lock




Front Wheel Bearing
Rear Wheel Bearing
Grease
Grease

Center Stand/Side Stand Pivot

Grease



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1. GENERAL INFORMATION XCITING 500/250


CABLE & HARNESS ROUTING (XCITING 500)




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1. GENERAL INFORMATION XCITING 500/250

CABLE & HARNESS ROUTING (XCITING 250)




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1. GENERAL INFORMATION XCITING 500/250


TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START


Inspection/Adjustment Symptom Probable Cause

Check if fuel reaches
carburetor by loosening
drain screw Empty fuel tank
Clogged carburetor fuel inlet
tube, vacuum tube or fuel tube
Clogged auto fuel valve
Fuel reaches Fuel does not Clogged float oil passage
carburetor reach carburetor Clogged fuel tank cap
breather hole
Clogged fuel strainer
Remove spark plug and Clogged fuel filter
install it into spark plug Faulty fuel pump
cap to test spark by
connecting it to engine Faulty spark plug
ground Fouled spark plug
Faulty ignition unit
Spark jumps Weak or no spark Faulty A.C. generator
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch

Test cylinder Starter motor idles but
compression crankshaft does not rotate
Valve clearance too small
Improper valve and seat contact
Normal Low or no Worn cylinder and piston rings
compression compression Blown cylinder head gasket
Flaws in cylinder head
Seized valve
Improper valve timing
Start engine by follow-
ing normal starting
procedure
Faulty auto bystarter
Engine does not Engine fires but Air leaking through intake
fire does not start pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw


Remove spark plug and
inspect again

Flooded carburetor
Dry spark plug Wet spark plug Faulty auto bystarter
Throttle valve excessively
open




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1. GENERAL INFORMATION XCITING 500/250


ENGINE LACKS POWER

Inspection/Adjustment Symptom Probable Cause
Start engine and
accelerate lightly for Clogged air cleaner
Restricted fuel flow
observation Clogged fuel line between fuel
Engine speed Engine speed does tank and carburetor
increases not increase Clogged exhaust muffler
sufficiently Faulty auto bystarter
Check ignition timing Split carburetor vacuum piston
(using a timing light) diaphragm

Correct timing Incorrect timing Faulty ignition unit
Faulty A.C. generator
Check valve clearance
Improper valve clearance
Correct Incorrect adjustment
Worn valve seat (valve stem too
protruding
Test cylinder compression
Improper valve and seat contact
Normal Abnormal Worn cylinder and piston rings
compression compression Blown cylinder head gasket
Flaws in cylinder head
Check carburetor for Improper valve timing
clogging

Not Clogged Clogged Clogged carburetor jets

Remove spark plug and
inspect
Plug not fouled or Plug fouled or Fouled spark plug
discolored discolored Incorrect heat range plug
Remove oil dipstick and
check oil level and condition
Oil level too high
Correct and not Incorrect or Oil level too low
contaminated contaminated Oil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train lubricated Valve train not Clogged oil pipe
properly lubricated properly Faulty oil pump
Insufficient coolant
Check if engine overheats Faulty thermostat
Worn cylinder and piston rings
Mixture too lean
Engine does not Engine overheats Poor quality fuel
overheats Excessive carbon buildup in
combustion chamber
Ignition timing too early
Rapidly accelerate or run Air in cooling system
at high speed
Excessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early


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1. GENERAL INFORMATION XCITING 500/250


POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)



Inspection/Adjustment Symptom Probable Cause


Check ignition timing



Faulty ignition unit
Correct timing Incorrect timing
Faulty A.C. generator

Check carburetor pilot
screw adjustment

Mixture too rich (turn screw
Correctly adjusted Incorrectly adjusted out)
Mixture too lean (turn screw
in)

Check carburetor gasket
for air leaks

Damaged insulator rubber
No air leak Air leaks Carburetor not securely
tightened
Faulty intake manifold gasket
Remove spark plug and Deformed carburetor O-ring
install it into spark plug
cap to test spark by
connecting it to engine
ground
Faulty or fouled spark plug
Faulty ignition unit
Weak or inter- Faulty A.C. generator
Good spark mittent spark Faulty ignition coil
Broken or shorted high
tension wire
Check carburetor air Faulty ignition switch
cut-off valve



Damaged air cut-off valve
Good Faulty diaphragm
Damaged air cut-off valve
spring




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1. GENERAL INFORMATION XCITING 500/250


POOR PERFORMANCE (AT HIGH SPEED)



Inspection/Adjustment Symptom Probable Cause


Check ignition timing



Faulty ignition unit
Correct timing Incorrect timing
Faulty A.C. generator


Check valve clearance


Improperly adjusted valve
Correctly adjusted Incorrectly adjusted clearance
Worn valve seat


Check fuel pump for
fuel supply

Empty fuel tank
Fuel flows freely Fuel flow restricted Clogged fuel tube or filter
Faulty fuel pump
Cracked fuel pump vacuum
tube
Check carburetor jets
for clogging


Not clogged Clogged Clean and unclog



Check valve timing


Correct Incorrect Cam timing gear aligning
marks not aligned

Check valve spring
tension


Not weakened Weak spring Faulty spring




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1. GENERAL INFORMATION XCITING 500/250


ENGINE NOISE


Symptom Probable Cause



Valve clearance too large
Valve noise
Worn camshaft lobe



Worn piston rings
Piston noise Worn piston pin and connecting rod small
end
Excessive carbon build-up in combustion
chamber




Damaged cam chain tensioner
Cam chain noise Worn cam gear teeth
Worn or damaged cam chain
Extended cam chain




Faulty crankshaft bearing
Crankshaft noise
Worn crank pin bearing




Worn or damaged final reduction gears
Gear noise
Worn final reduction gear shaft splines




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CLUTCH, DRIVE AND DRIVEN PULLEYS


Symptom Probable Cause


Worn or slipping drive belt
Broken ramp plate
Broken drive face spring
Engine starts but motor-
cycle does not move Separated clutch lining
Damaged driven pulley shaft splines
Damaged final gear
Seized final gear




Motorcycle creeps or Broken shoe spring
engine starts but soon
stops or seems to rush Clutch outer and clutch weight stuck
out (Rear wheel rotates
when engine idles) Seized pivot




Worn or slipping drive belt
Engine lacks power at Worn weight rollers
start of a grade(poor Seized drive pulley bearings
slope performance) Weak driven face spring
Worn or seized driven pulley bearings




Worn or slipping drive belt
Engine lacks power at
high speed Worn weight rollers
Worn or seized driven pulley bearings




Oil or grease fouled drive belt
There is abnormal noise Worn drive belt
or smell while running Weak driven face spring
Worn or seized driven pulley bearings




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1. GENERAL INFORMATION XCITING 500/250

STARTER MOTOR
1. Starter motor won`t turn
Inspection/Adjustment Symptom Probable Cause
Check operation of
stop switch by Burned out fuse
applying brake Weak or dead battery
Stoplight comes on Stoplight does not Faulty stop switch
come on Loose or disconnected
Check battery circuit connectors
by operating turn Broken or shorted ignition
signals switch wire
Signals operate Signals dim, remain
properly on or don`t operate Faulty or weak battery
Check operation of
starter relay by
depressing starter
button
Relay operates Relay does not Poor starter button connection
properly operate Open or shorted starter relay
Loose or disconnected
Connect starter connectors
motor directly to
battery Worn brushes
Starter motor turns Starter does not turn Open or shorted wires or rotor
Open starter motor cable
Loose connectors
Open wire harness
2. Starter motor turns slowly or idles
Inspection/Adjustment Symptom Probable Cause
Check battery circuit
by operating turn
signals
Signals operate Signals dim, remain
properly on or don`t operate Weak or dead battery
Connect starter
motor directly to
battery
Starter motor Starter motor Loose connector or terminal
turns slowly turns normally Poor contact in starter relay
Faulty starter clutch
Rotate crankshaft

Turns easily Hard to turn Seized cylinder

Broken or shorted starter
motor cable
3. Starter motor does not stop turning
Inspection/Adjustment Symptom Probable Cause

Turn ignition switch
OFF

Not stopped Stopped Faulty starter pinion
Starter relay shorted or stuck
closed

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1. GENERAL INFORMATION XCITING 500/250


NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom Probable Cause

Replace with a new
spark plug and inspect
again

Weak or no spark Good spark Faulty spark plug

Check spark plug cap
and high-tension wire
for looseness

Not loose Loose Faulty spark plug


Check ignition unit
coupler for looseness


Good Good Poorly connected coupler

Measure resistance
between terminals of
ignition unit coupler


Normal Abnormal


Check related parts


Faulty ignition switch
Normal Abnormal Faulty exciter coil
Faulty pulser coil
Faulty ignition coil
Broken wire harness
Poorly connected coupler

Check ignition unit
with a ignition unit
tester

Normal Abnormal Faulty ignition unit


Check ignition coil with
a ignition unit tester
Abnormal Faulty ignition coil


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1. GENERAL INFORMATION XCITING 500/250


POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging

Inspection/Adjustment Symptom Probable Cause

Start engine and test
limit voltage of battery
terminals

Voltage does not Faulty AC generator
Normal voltage increase Faulty regulator/rectifier
Faulty battery
Measure resistance
between AC generator
coil terminals


Normal Resistance too low Shorted AC generator coil
Open circuit between AC
generator 3 yellow wires

Test output voltage of
regulator/rectifier
coupler red wire
Faulty regulator/rectifier
Faulty AC generator
Normal voltage No voltage Loose regulator/rectifier
coupler
Limit voltage too high




Overcharging

Inspection/Adjustment Symptom Probable Cause

Measure battery limit
voltage with an electric
tester
Faulty battery
Normal Abnormal Faulty regulator/rectifier
Broken or poorly connected
regulator/rectifier black wire

Check resistance
between regulator/
rectifier terminals

Normal Abnormal Limit voltage too high




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1. GENERAL INFORMATION XCITING 500/250


FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Inspection/Adjustment Symptom Probable Cause

Check battery circuit by
operating turn signals
Burned out fuse
Weak or dead battery
Signals operate Signals dim, remain Faulty ignition switch
properly on or don`t operate Loose or disconnected
Remove fuel unit and
check operation of connectors
pointer by moving float Broken wire harness
up and down
Float up: Full Pointer does not
Float down: Empty Pointer moves Faulty float
move
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire harness
side Pointer does not Pointer moves Broken or shorted fuel unit
move wire
Check connectors for
proper connection
Disconnected connector
Good Faulty Incorrectly connected
connector
Broken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)
Inspection/Adjustment Symptom Probable Cause

Check battery circuit by
operating turn signals
and horn Burned out fuse
Weak or dead battery
Signals operate Signals dim, remain Faulty ignition switch
properly on or don`t operate Loose or disconnected
Remove fuel unit and
check operation of connector
pointer by moving float Broken wire harness
up and down
Pointer moves Pointer does not Poor contact in fuel unit
move
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer
Pointer moves in Pointer does not
accordance with move in accord- Insufficient damping oil in
float ance with float fuel gauge
Check connectors for
proper connection.

Good Faulty Loose or disconnected
connector
Broken or shorted wire in
fuel gauge

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STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

Symptom Probable Cause
(Front and rear tire pressures are normal)
Steering is heavy Steering stem nut too tight