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KYMCO Xciting 500i User Manual

KYMCO Xciting 500i
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TECHNICAL TRAINING MATERIALS
TECHNICAL TRAINING MATERIALS
Xciting
Xciting
Series
Series
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KYMCO Xciting 500i Specifications

General IconGeneral
Fuel SystemElectronic Fuel Injection
Front SuspensionTelescopic fork
Rear BrakeSingle disc
ABSYes
Width800 mm
Seat Height800 mm
Wheelbase1, 580 mm
Fuel Capacity12.8 liters
Top Speed160 km/h
Engine TypeLiquid-cooled, 4-stroke, 4-valve, SOHC
Displacement499cc
TransmissionCVT
Rear SuspensionDouble swing
Front BrakeDual Discs

Summary

Xciting 500i Specifications

Engine Specifications

Details on bore, stroke, compression, displacement, spark plug, and idle speed.

Chassis & Transmission Specifications

Tire sizes for front and rear.

Electrical Specifications

Details on battery, headlights, tail/brake lights, turn signals, position lights, and fuses.

Keihin Fuel Injection System Overview

System Components and Abbreviations

List of Keihin system components with their full names and abbreviations.

Self-Diagnostic Procedure for CELP Lamp

CELP Lamp Functionality Check

Procedure to verify the Check Engine Lamp (CELP) functionality.

CELP Failure Codes Explained

Interpreting CELP Blink Patterns

Understanding blink counts to identify specific failure codes.

Keihin DTC List and Symptoms

DTCs for TPS, MAP, WTS, Tilt Switch, O2 Sensor, Injector

Diagnostic Trouble Codes (DTCs) related to TPS, MAP, WTS, Tilt Switch, O2 Sensor, and Injector.

DTCs for Ignition Coil, Fuel Pump, O2 Heater, ISC, AICV, CPS

Diagnostic Trouble Codes (DTCs) for ignition coil, fuel pump, O2 heater, ISC, AICV, and CPS.

Clearing Failure Codes

Procedure for Clearing DTCs

Step-by-step instructions to reset diagnostic trouble codes.

TPS/ISC Reset Procedure

Resetting Throttle Position and Idle Speed Control

Steps to reset the TPS and ISC components.

KYMCO Fi Diagnostic Tool Overview

Diagnostic Tool Interface and Buttons

Introduction to the diagnostic tool's screen, buttons, and indicators.

Rechecking TPS/ISC with Diagnostic Tool

TPS/ISC Recheck - Low Throttle Position

Checking TPS/ISC status at closed throttle using the diagnostic tool.

TPS/ISC Recheck - High Throttle Position

Checking TPS/ISC status at fully open throttle using the diagnostic tool.

Fi Diagnostic Tool Connection

Connecting the Diagnostic Tool

Steps for connecting the Fi diagnostic tool to the vehicle.

DTC Inspection Procedure

Connecting Tool and Checking Version

Connecting the diagnostic tool and verifying software version.

Navigating DTC List

Using the diagnostic tool to view and navigate the DTC list.

Viewing Previous DTCs

Accessing and viewing historical diagnostic trouble codes.

Clearing DTCs

Procedure for Clearing DTCs on Tool

Steps to clear diagnostic trouble codes using the tool.

Data Analysis with Fi Tool

Navigating Data Analysis Screens

Exploring different data analysis screens on the diagnostic tool.

Data Analysis Screens (Engine Temp, ISC, Cut Out)

Details on screens showing engine temp, ISC, and cut-out voltage.

Idle Speed Control (ISC) System

ISC Reset and Installation

Procedure for resetting and installing the ISC component.

MAP Sensor

MAP Sensor Removal, Installation, and Inspection

Instructions for MAP sensor removal, installation, and inspection.

Throttle Position Sensor (TPS)

TPS Inspection and Reset Requirement

Inspection of TPS and the need for resetting after component changes.

Throttle Body Cleaning Procedure

Steps for Cleaning Throttle Body

Detailed steps for cleaning the throttle body and its butterfly valve.

Fuel Pump Relay Inspection

Inspecting the Fuel Pump Relay

Procedure for inspecting the fuel pump relay's continuity.

Fuel Pump Removal and Installation

Fuel Pump Component Handling

Instructions for removing and installing the fuel pump and its O-ring.

Fuel Output Pressure Inspection

Checking Fuel Pressure

Procedure to check fuel output pressure and its importance for starting.

Fuel Injector Removal

Steps for Fuel Injector Removal

Detailed procedure for safely removing the fuel injector.

Fuel Injector Installation

Procedure for Fuel Injector Installation

Instructions for installing the fuel injector with proper O-ring and tab alignment.

Fuel Injector Cleaning

Troubleshooting and Cleaning Injector

Procedure to clean fuel injectors, addressing output and injection time issues.

Tilt Switch Inspection

Inspecting Tilt Switch Voltage

Measuring voltage at different tilt angles for the tilt switch.

Water Temperature Sensor Resistance

Water Temp Sensor Resistance Standards

Standard resistance values for the water temperature sensor at various temperatures.

O2 Sensor Inspection

Inspecting O2 Sensor Resistance

Measuring the resistance of the O2 sensor for proper function.

Keihin EMS Parts Specifications

Component Specification Summary

Overview of specifications for various Keihin EMS components like ECU, MAP, TPS, etc.

ABS Indicator Light and System Operation

ABS Indicator Light Location and Function

Location and operational description of the ABS indicator light on the meter.

ABS System Operation and Precautions

Details on ABS operation, limitations, and precautions for safe use.

ABS Parts Location

Identifying Key ABS Components

Visual guide to the location of major ABS system parts.

ABS Component Identification List

Numbered list identifying ABS components shown in the diagram.

Fi Diagnostic Tool Operation

Connecting and Initializing the Fi Tool

Connecting the Fi diagnostic tool and performing initial setup.

Fi Diagnostic Tool Interface and Navigation

Understanding the diagnostic tool's screen layout and navigation menus.

ECU Model and Version Information

Display of ECU model and version details on the diagnostic tool.

DTC Inspection Menu Options

Navigating the DTC Inspection menu for active, occurred, and history codes.

Viewing and Clearing DTCs

Displaying specific DTCs and the procedure to clear them.

Data Analysis Screens (Speed, Voltage, etc.)

Interpreting data from diagnostic tool screens like speed, voltage, and ECU status.

Wheel Speed Sensor Handling

Wheel Speed Sensor Removal and Installation

Procedure for removing and installing front and rear wheel speed sensors.

ABS ECU and Hydraulic Unit Service

Warning on ABS ECU Removal

Caution regarding potential damage to ABS ECU or Hydraulic Unit during removal.

Hydraulic Unit Replacement and Torque Specs

Notes for replacing the Hydraulic Unit and torque specifications for bolts and nuts.

Wheel Speed Sensor Inspection

Inspecting Wheel Speed Sensors

Checking the resistance of front and rear wheel speed sensors.

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