MiniTrike

Installation Manual Kymco xciting 500

Limited Warranty

TOW-PAC, INC. warrants to the first end user purchaser that this product MiniTrike when purchased will be free from defective workmanship and materials, and agrees that it will, at its option, either repair the defect or replace the defective Product for the period of one year from date of original purchase. This warranty does not apply to tires or to the appearance of any item which has been damaged, defaced, been subjected to misuse, or which has been altered or modified in design or construction. Neither the sales personnel of the seller nor any other person is authorized to make any warranties other than those described above or to extent the duration of any warranties beyond the time period described above on behalf of TOW-PAC, INC.
NOTICE OF LIMITED LIABILITY
Tow-Pac, Inc. warrants only components supplied by TowPac, Inc. Tow-Pac, Inc. cannot be responsible for any components on owners motorcycle including frames, hardware, aftermarket accessories, etc. Owner is solely responsible for ensuring motorcycle is in sound mechanical order. Tow-Pac, Inc cannot be responsible for any damage due to improper installation of Tow-Pac components or use of any hardware (bolts, nuts, etc) on Tow-Pac components not supplied directly by Tow-Pac, Inc. Owner is solely responsible for installation of Tow-Pac components. Please refer to limited warranty for warranty details.

Notice

After your MiniTrike is installed, take some time to get used to Trike handling characteristics. On a Trike you will steer rather than lean as you would on a conventional two wheel motorcycle. Take corners very slowly until you get used to the feel of cornering on a Trike. Remember to use your front brake in tandem with your rear break. This will greatly increase your stopping power when in Trike configuration. With MiniTrike installed remember the outrigger wheels. Use caution not to run them into objects. Keep your feet up at all times.

Important Notices

MiniTrike is designed for use on paved surfaces only. Use of MiniTrike on unpaved terrain may void warranty. When installing MiniTrike attach all bolts and brackets loosely. After all bolts and brackets are in place tighten all bolts.

MiniTrike Installation

NOTE: Install all bolts loosely until all brackets are in place. Tighten bolts only after all brackets and bolts are in place Refer to diagram for bracket identification
1. 2. Place scooter in a secure upright position. Remove center stand and underseat storage compartment
3. Attach bracket E to center stand mounting brackets using new bolts provided
4. Use jack underneath scooter to support scooter weight and remove left rear shock bolts.
5. Attach bracket C (left) to top of left rear shock tower using new bolt provided. Insert bolt through bracket, top of rear shock, and thread into shock tower. Reattach left lower shock bolt and tighten at this time. 6. Remove right rear shock bolts and attach bracket D (right) to top of right rear shock tower using new bolt provided. Insert bolt through bracket, top of rear shock, and thread into shock tower. Reattach right lower shock bolt and tighten at this time.
Ensure shock bolts are replaced and remove jack from step 4.
8. Attach wheels and axles to MiniTrike frame and carefully position in proper relation behind scooter. 9. Attach bottom of brackets C/D to rear mounting plate on MiniTrike frame
10. Attach brackets A (left) / B (right) to forward mounting points on MiniTrike frame.
Attach forward portion of brackets A/B to top of bracket E
12. Tighten all bolts. Use care to ensure MiniTrike frame is square with scooter when tightening bolts. 13. 14. Replace underseat storage compartment at this time. Align MiniTrike wheels

Periodically check all bolts for tightness
MiniTrike Bracket Diagram

Wheel Alignment

Wheel alignment is critical for proper tire wear and handling.
With MiniTrike installed measure A and B. Loosen axle plates and align wheel so A and B are equal to within 1/16th of an inch. Tighten axle bolts and torque to 45 pounds. Repeat for C and D. NOTE: The measurement of A and B may not be the same as C and D. This is normal and presents no difficulty.
Wheel Height / Traction Adjuster
The wheel height/traction adjuster (right and left side) allows you to selectively adjust the position of your trike wheels in order to customize ride, handling, level, and traction characteristics. Your trike is shipped with the adjuster preset to an optimum position for your model of motorcycle however you can make whatever adjustments necessary to customize to your bike and personal preference. Shortening the adjuster arm raises the trike wheels and places more of the weight of your motorcycle on the motorcycle wheel. This increases motorcycle traction and gives a generally softer ride.
1) Loosen jam nuts 2) Shorten adjuster arm by turning adjuster nut A toward bolt C desired amount. 3) Turn adjuster nut B until it tightens against adjuster bracket and adjuster nut A 4) Tighten nuts A and B and jam nuts
Lengthening the adjuster arm lowers the trike wheels and places more of the weight of your motorcycle on the trike wheels. This gives a firmer ride and increases handling/cornering.
1) Loosen jam nuts 2) Lengthen adjuster arm by turning adjuster nut B toward bolt D desired amount. 3) Turn adjuster nut A until it tightens against adjuster bracket and adjuster nut B 4) Tighten nuts A and B and jam nuts
If necessary the pivot bolt and bolts C and D and be loosened for adjustment Be certain to retighten all bolts after adjustment.
NOTICE: Check all bolts and nuts periodically for tightness NOTICE: Be sure motorcycle is level after adjustment.
Fender Installation Instructions

2) 3) 4) 5) 6)

(12 Inch wheel only)
1) Attach fender brackets to trike frame with spacer BETWEEN fender bracket and frame. Tighten.
NOTE: Leave fender bolts loose until all bolts are inserted.

Place gray plastic washers between fender and trike frame/fender bracket. (4 washers each side) Place fender on frame. Carefully align mounting holes. Insert long bolts first. (2 each side) Insert short bolts second. (3 each side) Carefully tighten bolts. Use care not to over tighten.
Reflector Mounting Instructions
1) 2) Be sure fender is clean and free from dust Do not apply reflectors in direct sunlight or on a hot surface Remove backing from reflector and carefully position on fender. See Diagram Below
Lightly spraying back of reflectors with a mild solution of water or Windex will allow easier positioning. Allow reflectors at least one hour to dry before riding if using this method.

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.
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.
LOCATION OF THE WARNING AND SPECIFICATION LABELS

CAUTIONS

Before starting the engine, the side stand shall be kicked up to secure safety.
(2): XCITING 500 AFI/XCITING 500
Every 6000 km run should exchange the filter.
Never put any article between the rear side cover and the engine to avoid interference of riding.
! 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.
Tire Size (One Rider) (Two Rider) Load Capacity : Front 120/70-15 Rear 150/70-2 : Front 2.00kgf/cm Rear 2.50kgf/cm : 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.

(6) (6)

CAUTION
Mobile phone charge only, Use other appliance may cause damage.
DON'T WIPE WITH ORGANIC SOLVENT (EX: GAS, THINNER.ETC). USE NEUTRAL SOAP TO CLEAN WINDSHIELD.
PARTS LOCATION (06) (05) (04) (03) (02) (01) Fuel fill cap (02) Right rearview mirror (03) Hazard switch/Engine stop switch/Headlight switch/Start button (04) Instruments/Indicators (05) Passing switch/Headlight dimmer switch/Turn signal switch/Horn button (06) Left rearview mirror (07) Left rear suspension spring preload adjuster (08) Right rear suspension spring preload adjuster
(09) Center small box (10) Throttle grip (11) Front brake lever (12) Front brake fluid reservoir (13) Rear brake fluid reservoir (14) Rear brake lever (15) Ignition switch
(16) (16) Tool kit (17) Center compartment (18) Helmet holder (19) Front small box (20) Coolant level (21) Side stand (22) Center stand (23) Left passenger footpeg (24) Air cleaner (XCITING 500 AFI/ XCITING 500) (25) Air cleaner (XCITING 250 AFI/ XCITING 250)

(21) (22)

(30) (29) (28)

(27) (26)

(26) Cell phone fixed seat (27) Center compartment light/Cell phone socket (28) Seat (29) Adjustable backrest (30) Battery/Fuse box/Spare fuses (31) Right passenger footpeg (32) Oil filler cap/Dipstick (33) Parking brake lever (XCITING 500 AFI/ XCITING 500)
FRAME NUMBER The read frame number is stamped on right side of the frame. Always check that the frame number stamped on your scooter is the same written in document and warranty scooter is the same written in document and warranty card. Please write down your frame number in place below. FRAME NUMBER:
ENGINE NUMBER The engine number is stamped on left engine case. Please write down your engine number in place below. ENGINE NUMBER:
KEY NUMBER The key number (1) will be needed when you order replacement part. Record the number for your reference. IGNITION KEY NUMBER:

SHUTTER KEY NUMBER:

(1) Ignition key number (2) Ignition key (3) Shutter key number (4) Shutter key 18

CONTROLS

KEYS This scooter has two ignition switch keys and shutter keys. IGNITION SWITCH To open the ignition key-hole shutter with shutter key: Select the shutter key "OPEN" side upward and insert the shutter key into the hole at the ignition switch.
To shut the ignition key-hole shutter with shutter key: Select the shutter key "SHUT" side upward and insert the shutter key into the hole at the ignition switch. NOTE: Apply anti-freeze chemicals when atmospheric Temperature becomes less than freezing point to avoid ignition key-hole shutter freezing.

Function " Position: All electrical circuits are cut off. The engine will not start. " " Position: The ignition circuit is completed and engine can now be started. The key cannot be removed from the ignition switch. " Position: To lock the steering, turn the handlebar all the way to the left. Push down and turn the key to the " " position and remove the key. All electrical circuits are cut off. " Position: To open the fuel fill cap, turn the key to the " " position. Make sure that the key is at the " " position when Starting the engine. " " Position: To open the seat, turn the key to the " " position.
INSTRUMENT AND INDICATORS (2) (1)

(7) (8) (9)

Oil Service

(14) (13) (12)

NOTE: The indicator of multi-metee will run from zero to maxi limit then zero when connecting the battery (at the state of ignition switch turn on ) and resetting the position of pointer (if the position of pointer is confused)
(1) Oil pressure warning indicator" " Lights when the engine oil pressure is below normal operating range, should light when ignition switch is ON " " and engine is not running. Should go out when the engine starts, except for occasional flickering at or near idling speed when engine is warm. NOTE: Running the engine with insufficient oil pressure may cause serious engine damage. (2) Mode button The button is used to select the trip meter, the odometer or reset trip meter.
(3) Battery charge telltale If the telltale comes on while driving, this indicates the battery voltage is below 11V. (4) Tachometer Shows engine revolutions per minute (rpm). (5) Right/Left turn signal indicator " " Flashes when the right/left turn signal operates. (6) Speedometer Shows riding speed. (7) Fuel gauge Shows approximate fuel supply available.
(8) Fuel refill Indicator" " Lights when the fuel tank is empty or nearly so and you should refill the tank as soon as possible. (9) Oil service indicator reset button The oil service indicator can be reset by pressing the button when the engine oil has been changed. (10) Seat unlock indicator "MET-IN" Lights when the seat is not locked fully. (11) Side stand down indicator Lights when side stand is left down. (12) High beam indicator Lights when the headlight high beam is turned on.

(13) Cell phone socket indicator Lights when the cell phone socket is used. (14) Coolant temperature gauge The coolant temperature gauge indicates engine coolant temperature when the ignition switch is in the " " position. (15) Minute adjust button Push this button to adjust the minute display. (16) Trip meter/Odometer The display in the speedometer has two functions, trip meter and odometer. The trip meter can register the trip distance. The odometer registers the total distance that the scooter has been ridden. By pressing "(2) Mode button" to select the trip meter (mile or km)or odometer (mile or km). The trip counter can be rest by keeping the button pressed down for more than 2 seconds when the trip counter value is displayed.
(17) Clock Show hour and minute. (18) Hour adjust button Push this button to adjust the hour display. (19) Oil service indicator If the oil service indicator comes on while driving, this indicates that the engine oil should be changed at each maintenance interval. NOTE: The oil service indicator comes on when the vehicle's ignition is turned on and must come off when the engine is running.
(20) CELP: Check engine lamp (XCITING 500 AFI/XCITING 250 AFI) Flashes when there is any abnormality in the CELP system. If it comes on at any other time, reduce speed and take the motorcycle to your KYMCO dealer as soom as possible. NOTE: Turn the ignition switch ON with no engine speed when the side stand is put up and the engine stop switch is at (RUN), the CELP will light for two second then off. It shows the lamp work normal. (21) Parking brake indicator (XCITING 500 AFI/XCITING 500) Lights when the parking brake is applied.
RIGHT HANDLEBAR SWITCH Headlight switch (1) " " position The headlight and taillight turn on. " " position The position light and taillight turn on. " " position The headlight and taillight turn off.

(1) (2)

Electric starter button " " (2) Push in the electric starter button to rotate the starter motor. NOTE: ! If the brake lever is not squeezed, the starter motor will not rotate. ! This scooter is equipped with interlock switches for the ignition circuit and the starter circuit. The engine can only be started if the side stand is fully up. 25
To prevent electrical system damage, do not operate the starter motor more than five seconds at a time.
Engine stop switch (3) " " position The ignition circuit is off. The engine cannot start or run. " " position The ignition circuit is on and the engine can run. Hazard switch " "(4) " "At this position, the right and left turn signal lights wink together. "OFF"At this position, the right and left turn signal lights go out together.

Do not overfill the tank. There should be no fuel in the filler neck (2). After refueling, be sure to lock the fuel fill cap firmly.
To lock the fuel fill cap: Push fuel fill cap down into place.
Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel.
! Stop the engine and keep heat, sparks, and ! Refuel only out doors. ! Wipe up spills immediately.
Fuel recommendation Use unleaded petrol with a research octane number of 91 or higher. Unleaded gasoline can extend spark plug life and exhaust components life. Turn the ignition key from " restarting. " to " " position to flame away.
FRONT SMALL BOX To open: Insert the ignition key (2) and turn it clockwise. To close: 1. Holding the front small box lid (2) closed, turn the ignition key counterclockwise. 2. Remove the key.

To open

Open the box lid while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the scooter. Always keep both hands on the handlebars during operation.

To close

CENTER SMALL BOX To open the box by pull up the lever (2) of the center small box cover (1). To lock the box cover , push down on the box cover until it locks.
Open the box cover while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the scooter. Always keep both hands on the handlebars during operation.
SEAT To unlock the seat " ": (1) Ignition key at the " " position (The engine is running.): Push the key and turn it counterclockwise from " to " " position.

(3) (2) "

(2) Ignition key at the " " position (The engine is stopped.): Turn it counterclockwise from " " to " " position. (3) Ignition key at the " " position (The steering is locked.): Turn it counterclockwise from " " to " " position. Pull the seat up to lift the seat. To lock seat: Lower and push down on the reverse side of the hooks of the seat until it locks. Make sure the seat is secure before riding. NOTE: The lamplight and "MET-IN" indicator light will come on while the seat is unlock, make sure the seat is locked. 34
ADJUSTABLE BACKREST The seat is equipped with a backrest (1) which allows the seat to be adjusted according to the riders preference or physical condition. To adjust: Open the seat (see page 34), Pull the locking lever (2) left on the back and move the backrest back and forth according to the riders preference or physical condition. After cleaning or running in the rain, wipe off water collected under the backrest before the scooter again. (1)

CENTER COMPARTMENT The center compartment is below the seat. Opening and closing: See "SEAT" (page 34). MAXIMUM WEIGHT LIMIT: 10kg (22 lbs)
Never exceed the maximum weight limit; handling and stability may be severely affected. The center compartment may become heated by the engine. Do not store food and other articles which are flammable or susceptible to heat damage in this compartment. Do not direct water under pressure against the center compartment as water will be forced into the compartment.
CENTER COMPARTMENT LIGHT The center compartment light (1) will be turned ON automatically when the seat is opened. Kept ON as long as the seat is opened regardless of the position of the main switch.
CELL PHONE SOCKET & CELL PHONE FIXED SEAT Pull socket cap (2) out and inserting the cell phone charger into the socket. The charging indicator light of instrument will become to red. The socket's rated capacity is DC 12V, 10Watts (0.8A) or less. When you have done using cell phone, unplug it, and cover the socket with cap. This scooter is equipped a cell phone fixed seat (3) which puts the cell phone down at proper position. 37

(3) (2)

Operation method Take the fasten band off, then pressing the button to make the pressure plate sprang open. Put the cell phone at proper position on the cell phone fixed seat, then push the pressure plate left. Banding the fasten band, then insert the cell phone charger into the socket.
CAUTION ! Do not plug in any heat-generating
accessory such as an automobile cigarette lighter because it can damage the socket. ! Do not add electrical equipment that will exceed the accessory socket capacity, otherwise you may blow the fuse (0.8A) in the cell phone socket. ! To avoid the cell phone overcharged, please follow all of the cell phone charger manufacturer's instruments. The quality of the cell phone and the cell phone charger is not guaranteed. NOTE: ! The standard accessories of this model don't include the cell phone charger. 38

(CELL PHONE FIXED SEAT)

HELMET HOLDERS To use the helmet holders, unlock the seat (see page 34), hook your helmet fastener ring to the holder and lock the seat securely.
Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed. Use the helmet holder only while parked. Do not ride with a helmet secured by the holder.
STAND This scooter is equipped with a center stand and side stand. Center stand (1) To place the scooter on the center stand, place your foot on the stand extension and then rock the scooter to the rear and upward with the passenger hand rail with your right hand, while steadying the handlebars with your left hand. Side stand (2) An interlock switch is provided to cut off the ignition circuit when the side stand is down. The side stand down indicator will light when the side stand left down and ignition switch is ON ( ) The side stand/ignition interlock switch works as follows: ! If the side stand is down, the engine can not be started. ! If the engine is running and the side stand is put down, the engine will stop running.

OPERATION

STARTING THE ENGINE Always follow the proper starting procedure described below. This scooter is equipped with a side stand ignition cut-off system. The engine cannot be started if the side stand is down. A running engine will shut off if the side stand is lowered. To protect the catalytic converter in your scooter's exhaust system, avoid extending idling and the use of leaded petrol. Your scooter's exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door closed. Even with the door open, run the engine only long enough to move your scooter out of the garage. Do not use the electric starter for more than 5 seconds at a time. Release the starter button for approximately 10 seconds before pressing it again.
1. Place the scooter on its center stand and make sure to put the side stand up. 2. Lock the rear wheel by applying the parking brake lever (XCITING 500 AFI/XCITING 500).
Contact with the spinning rear wheel can cause you to be hurt. Set the parking brake (XCITING 500 AFI/XCITING 500) when the scooter is on its center stand.
3. Open the ignition key-hole shutter and make sure the engine stop switch is at " " (RUN). 4. Turn the ignition switch to " " (ON)
Confirm the red low oil pressure indicator is ON. The low oil pressure indicator should go off a few seconds after the engine starts. If the light stays on, stop the engine immediately and check the engine oil level. NOTE: Operating the engine with insufficient oil pressure can cause serious engine damage. 5. Squeeze the rear brake lever. The electric starter will only work when the rear brake lever is squeezed and the side stand is up.
6. With the throttle closed, push the starter button. Release the starter button as soon as the engine starts.
7. Be sure to keep the throttle closed and the parking brake locked (XCITING 500 AFI/XCITING 500) while warming up the engine. 8. Allow the engine to warm up before riding. Do not "BLIP" the throttle (open and close rapidly) as the scooter will move forward suddenly. Do not leave the scooter unattended while the engine is warming up. Close

9. When approaching a corner or turn, close the throttle fully and slow the scooter down by applying both front and rear brakes at the same time. 10. After completing the turn, open the throttle gradually to accelerate the scooter.
11. When descending a steep grade, close the throttle fully and apply both brakes to slow the scooter. Avoid continuous use of the brakes, which may result in overheating and reduction of braking efficiency.
12. When riding on wet or loose surfaces, be especially cautious. When riding in wet or rainy conditions or on loose surfaces, the ability to maneuver and stop will be reduced. For your safety: ! Exercise extreme caution when braking, accelerating or turning. ! Ride at slower speeds and allow for extra stopping distance. ! Keep the scooter as upright as possible. ! Use extreme caution when riding over slippery surfaces such as railroad tracks, iron plates, manhole covers, painted lines, etc.
PARKING 1. After stopping the scooter turn the ignition switch counterclockwise to the " " (OFF) position and remove the key. 2. Use the center stand to support the scooter while parked. Park the scooter on firm, level ground to prevent it from falling over. If you must park on a slight incline, aim the front of the scooter uphill to reduce the possibility of rolling off the center stand or overturning.
3. Lock the steering ( see page 20) to help prevent theft. The exhaust pipe and muffler become very hot during operation and remain sufficiently hot to inflict burns if touched even after shutting off the engine. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your scooter.
A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine. Park the scooter where pedestrians or children are not likely to touch the muffler.

To lock

To unlock
BREAK-IN (RUNNING-IN) The first 1600 km (1000 miles) are the most important in the life of your scooter. Proper break-in operation during this time will help ensure maximum life and performance from your new scooter. Proper break-in operation allows the machined surfaces to polish each other and mate smoothly. Scooter reliability and performance depend on special care and restraint exercised during the break-in period. It is especially important that you avoid operating the engine in a manner which could expose the engine parts to excessive heat. The following guidelines explain proper break-in procedures. Maximum throttle operation recommendation The maximum recommended throttle operation during the break-in period: Initial 800 km (500 miles): less than 1/2 throttle Up to 1600 km (1000 miles): less than 3/4 throttle 57

Engine oil replacement Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule (see page 60 or 63). When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation. Do not throw it in the trash or pour it on the ground or down a drain. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. 1. Remove the oil filler cap/dipstick (1) from the right crankcase cover. 2. Place a container under the left crankcase.
3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification. Oil drain plug torque: 25 N-m (2.5 kgf-m, 18lbf-ft) 5. Fill the engine with oil and install the oil fill cap. Oil capacity (after draining): XCITING 500 AFI/XCITING 500: 2.0 liter (2.1 US qt, 1.8 lmp qt) XCITING 250 AFI/XCITING 250: 0.9 liter (0.95 US qt, 0.8 lmp qt) 6. Start the engine and let it idle for 23 minutes. 7. Stop the engine and check that the oil level is at the upper level mark on the oil filler cap/dipstick with the scooter upright on firm, level ground. Make sure there are no oil leaks.
! Running the engine with insufficient oil pressure may ! Let the engine and exhaust system cool before working
in those areas. (2) 70 cause serious engine damage.
Oil filter cartridge (XCITING 500 AFI/XCITING 500)and Oil strainer screen Changing the oil filter cartridge requires a special oil filter cartridge tool and a torque wrench. If you do not have these tools and the necessary skill, we recommend that you have your KYMCO dealer perform this service. If a torque wrench is not used for this installation, see your KYMCO dealer as soon as possible to verify proper assembly.
Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. NOTE: ! Running the engine with insufficient oil pressure may cause serious engine damage. ! Let the engine and exhaust system cool before working in those areas. 1. Remove the oil filler cap/dipstick (1) from the right crankcase cover. 71
2. Place a drain pan under the crankcase and remove the oil strainer screen cap (2). The spring (3) and oil strainer screen (4) will come out when the drain plug is removed. 3. Clean the oil strainer screen. 4. Check that the oil strainer screen, sealing rubber and drain plug O-ring are in good condition. (2)

3. Remove the screws and air cleaner case cover (2)

(2) 78

4. Remove the air cleaner element (3) by pull it out. 5. Discard the air cleaner element. 6. Install a new air cleaner element. Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems. 7. Install the removed parts in the reverse order of removal.
Air cleaner element (XCITING 250/XCITING 250 AFI): The air cleaner element (1) should be replaced by a KYMCO dealer, unless the owner has proper tools and service data and is mechanically qualified. Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.
THROTTLE OPERATION 1. Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. 2. Measure the throttle grip free play at the throttle grip flange. The standaard free play should approximately: 26 mm (0.080.24 in)

26 mm (0.080.24 in)

To adjust the free play: 1. Slide the rubber sleeve (1) back to expose the throttle cable adjuster (2). 2. Loosen the lock nut (3), then turn the adjuster to obtain the correct free play. 3. Tighten the lock nut and reinstall the sleeve.

(3) (2) (1)

IDLE SPEED The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-andgo riding is sufficient. 1. Warm up the engine place the scooter on its center stand. 2. Open the seat (see page 34). 3. Open the carburetor cover (1).
4. Adjust idle speed with the throttle stop screw (2). Idle speed: XCITING 500: rpm XCITING 250: rpm NOTE: It is not necessary to adjust idle speed for XCITING 250 AFI. The throttle body is factory pre-set, do not loosen or tighten the painted bolts and screws of the throttle body. Lossening or tightening them can cause throttle and idle valve synchronization failure. We recommend the AFI (automatic fuel injection) system be serviced only by your KYMCO dealer. Idle speed: XCITING 500 AFI: rpm XCITING 250 AFI: rpm

XCITING 500

XCITING 250
SPARK PLUG Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine. Readjust the spark plug gap to specified limit by using a spark plug gap thickness gauge. The spark plug should be replaced periodically. Whenever removing the carbon deposits, be sure to observe the operational color of the spark plug's porcelain tip. This color tells you whether or not the standard spark plug is suitable for your type of usage. A normal operating spark plug should be light brown or tan color. If the spark plug is very white or glazed appearing, then it has been operating much too hot. This spark plug should be replaced with the colder plug.

An improper spark plug may have an incorrect fit or heat range for your engine. This may cause severe engine damage which will not be covered under warranty. Never use a spark plug with an improper heat range. Severe engine damage could result. Recommended plug: XCITING 500 AFI: CR7E XCITING 500: CR8E XCITING 250: DPR7EA-9 XCITING 250 AFI: DPR6EA-9 84
XCITING 500 AF/500: 0.6 - 0.7 mm (0.024 - 0.028 in) XCITING 250 AFI/250: 0.8 - 0.9 mm (0.032 - 0.036 in)
COOLANT Inspection The reserve tank is under footboard left. Check the coolant level through the inspection window (1) at the left side skirt while the engine is at the normal operating temperature with the scooter in an upright position. If the coolant level is below the LOWER level mark (3), remove the left floor mat (4) and remove screw (5) and reserve tank lid (6) and reserve tank cap (7) and add coolant mixture until it reaches the upper level mark (2). Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. (6) (5)
(4) If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. 85
Coolant replacement Coolant should be replaced by a KYMCO dealer, unless the owner has proper tools and service data and is mechanically qualified. Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap.
Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Coolant recommendation The owner must properly maintain the coolant to prevent freezing, overheating, and corrosion, use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines.(See antifreeze container label.) Use only low-mineral drinking water or distilled water as a part of the antifreeze solution. Water that is high in mineral content or salt may be harmful to the aluminum engine. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. The factory provides a 50:50 solution of antifreeze and distilled water in this scooter. This coolant solution is recommended for most operating temperatures and provides good corrosion protection.

PARKING BRAKE OPERATION (XCITING 500 AFI/XCITING 500) Parking brake inspection: 1. Stop the engine and put the scooter on its center stand on level ground. 2. Pull the parking brake lever slowly and check the lever stroke. Standard: 36 notches If adjustment is necessary, have the brake adjusted by our KYMCO dealer for this service.
BATTERY It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your KYMCO dealer. NOTE: Your battery is a maintenance-free type and can be permanently damaged if the cap strip is removed.
The battery gives off explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or seriously hurt you. Wear protective clothing and a face shield, or have a skilled mechanic do the battery maintenance.
Battery removal (Always keep ignition switch is OFF) The battery is in the battery box below seat. 1. Open the seat (see page 34). 2. Remove the screws (1) and battery cover (2).
3. Remove the battery retainer (3). 4. Disconnect the negative (-) terminal lead (4) from the battery first, then disconnect the positive (+) terminal lead (5). 5. Pull out the battery from the battery box. Battery installation: Install in the reverse order of the removal.
FUSE REPLACEMENT When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your KYMCO dealer for repair. NOTE: Never use a fuse with a different rating from that specified. Serious damage to the electrical system or a fire may result, causing a dangerous loss of lights or engine power. Fuse list ! 30A CHARGE fuse protects battery charging system. ! 15A MAIN fuse protects all electrical circuits. ! 15A HEAD-HI/LO fuse protects the headlight high/lower beam and high beam indicator light. ! 10A IGNITION fuse protects the ignition system. ! 10A FAN fuse protects the cooling fan motor.

Blown fuse

Fuse box : The fuse box is located left side of the battery in the battery box. The specified fuses (2) are: 10A, 15A 1. Open the seat (see page 34). 2. Open the battery cover.(see page 93). 3. Open the fuse box cover (1). (1)
4. Pull out the old fuse and install a new fuse. The spare fuse (3) are located in the battery retainer. 5. Close the fuse box covers and seat.
Charge fuse : The charge fuse is located right side of the battery in the battery box. The specified fuses (2) are: 30A 1. Open the seat (see page 34). 2. Remove the battery (see page 93). 3. Disconnect the wire connector (1) of the starter magnetic switch.
4. Pull out the old fuse and install a new fuse. The spare fuse are located in the battery retainer. 5. Reconnect the connector.
Failure to follow these warnings may result in an accident due to tire failure. The tires on your scooter form the crucial link between your scooter and the road. Follow these instructions: ! Check tire condition and pressure, and adjust pressure before each ride. ! Avoid overloading your scooter. ! Replace a tire when worn to the specified limit, or if you find damage such as cuts or cracks. ! Always use the size and type of tires specified in this owner's manual. ! Balance the wheel after tire installation. ! Read this section of owner's manual carefully.

6. Test the brakes before riding the scooter. Several applications may be necessary to restore normal braking performance. Braking efficiency may be temporarily impaired immediately after washing the scooter. Anticipate longer stopping distance to avoid a possible accident.
Finishing touches After washing your scooter, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for scooter or automobiles. Apply the polish or wax according to the instructions on the container.
Removing road salt The salt contained in the road surface freezing prevention medicine which a road was sprayed with in winter, and the seawater becomes the cause which rust occurs in. Wash your scooter by the following point after it runs through such a place. 1. Clean the scooter using cool water (see page 101). Do not use warm water. This worsens the effect of the salt. 2. Dry the scooter and the surface of the metal is protected with the wax. Painted aluminum wheel maintenance Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels after riding through any of these substances, use a wet sponge and mild detergent. Avoid stiff brushes, steel wool, or cleaners containing abrasives or chemical compounds. After washing, rinse with plenty of water and dry with a clean cloth. Apply touch-up paint to the wheels where damage has resulted. Exhaust pipe maintenance The exhaust pipe is stainless steel but may become stained by oil or mud. If necessary, remove heat stains with a liquid kitchen abrasive.
Clean the windshield Using plenty of water, clean the windshield with a soft cloth or sponge. (Avoid using detergents or any kind of chemical cleaner on the windshield.) Dry with a soft, clean cloth. To avoid possible scratching or other damage, use only water and a soft cloth or sponge to clean the windshield. For a dirtier windshield, use a diluted neutral detergent with a sponge and plenty of water. Make sure to wash off all the detergent. (Detergent residue may cause windshield cracks.) Replace the windshield if scratches cannot be removed and they obstruct clear vision. Do not let battery electrolyte, brake fluid or other acid chemicals get on the windshield and screen garnish. They will damage the plastic.