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KYMCO XCITING S 400 User Manual

KYMCO XCITING S 400
426 pages
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1.Quick Reference
XCITING S 400
1-1
1. Quick Reference
This chapter provides a quick reference source of technical specifications and
information for KYMCO XCITING S 400 model.
Component Location ........................................................ 1-2
Special Tools ..................................................................... 1-5
Specifications .................................................................... 1-6
Torque Specifications ....................................................... 1-12
Troubleshooting ................................................................ 1-15
VIN and Engine Number Location .................................... 1-20

Table of Contents

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KYMCO XCITING S 400 Specifications

General IconGeneral
Displacement399 cc
Fuel SystemElectronic Fuel Injection
Cooling SystemLiquid cooled
TransmissionCVT
Front SuspensionTelescopic fork
Tires (Front)120/70-15
Tires (Rear)150/70-14
Width800 mm
Fuel Capacity12.5 liters
Max Power25.0 kW @ 7, 500 rpm
Max Torque37.7 Nm @ 6000 rpm
Rear BrakeSingle disc, 240 mm
Wheelbase1, 565 mm
Weight213 kg
Rear SuspensionDual shock absorbers
Length2, 200 mm

Summary

1. Quick Reference

Component Location

Identifies key components on the motorcycle with visual aids.

Special Tools

Lists specialized tools required for maintenance tasks.

General Information

Provides overall technical specifications and data for the model.

Torque Specifications

Details critical torque values for engine and frame fasteners.

Troubleshooting Guide

Offers solutions for common operational problems and malfunctions.

VIN and Engine Number Location

Shows the specific locations of the Vehicle Identification Number and engine number.

2. Periodic Maintenance

Maintenance Schedule

Outlines recommended service intervals based on mileage or time.

Air Filter Servicing

Provides instructions for inspecting and replacing the air filter element.

Brake Fluid Service

Covers checking, replenishing, and replacing brake fluid.

Brake Inspection and Adjustment

Details procedures for checking brake levers, pads, and adjusters.

Caliper and Brake Pad Service

Explains how to remove, inspect, and install brake calipers and pads.

Coolant System Maintenance

Covers checking, filling, and servicing the cooling system components.

Engine Oil Service

Provides steps for checking, changing, and inspecting engine oil levels and periods.

General Lubrication Points

Identifies frame lubrication points for regular maintenance.

Side Stand Inspection

Details how to inspect the side stand interlock function for safety.

Spark Plug Service

Covers spark plug removal, inspection, gapping, and replacement procedures.

Engine Compression Test

Outlines the procedure for testing engine cylinder compression for performance issues.

Steering Inspection

Describes how to inspect steering head bearings for smooth operation.

Throttle Free Play Inspection

Explains how to check and adjust throttle grip free play for proper response.

Parking Brake Adjustment

Provides instructions for adjusting the parking brake mechanism.

Tire Inspection and Service

Covers checking tire pressure, tread wear, and dimensions.

Valve Clearance Adjustment

Details the procedure for measuring and adjusting valve clearances.

3. External Components

General Instructions

Provides general guidelines for servicing external motorcycle components.

Front Bodywork and Covers Removal

Covers removal of windscreen, meter cover, leg shields, and front covers.

Side Panels and Seat Removal

Details removal of side covers, floor mats, back mirrors, and seats.

Exhaust System Components

Covers exhaust system service, including muffler and pipe removal.

Chassis Mounted Components Removal

Covers removal of side stand and center stand components.

4. Engine

Engine Removal

Step-by-step guide for removing the engine from the motorcycle chassis.

Cylinder Head and Component Service

Covers servicing of the cylinder head, camshaft, and valves.

Cylinder and Piston Service

Details inspection and replacement of cylinder and piston components.

Generator, Oil Pump, and Crankcase Service

Covers servicing of the generator, oil pump, and crankcase assemblies.

Crankshaft and Engine Installation

Covers crankshaft service and the process of reinstalling the engine.

5. Cooling System

General Instructions and Troubleshooting

Provides safety guidelines and troubleshooting for cooling system issues.

Coolant System Service

Covers checking, filling, and servicing the cooling system components.

Radiator Service

Details inspection and pressure testing of the radiator for leaks.

Water Temperature Sensor and Thermostat Service

Covers removal, inspection, and installation of the WTS and thermostat.

6. Fuel Injection System

General Instructions and Troubleshooting

Provides guidelines and common issues for the fuel injection system.

Component Locations

Illustrates the placement of key fuel injection system parts.

ECU, Ignition, and Spark Plug Service

Covers servicing procedures for the ECU, ignition coil, and spark plug.

Fuel Tank and Fuel Injector Service

Covers removal and service of the fuel tank and injector components.

Throttle Body and Sensor Service

Details servicing of the throttle body, MAP, ISC, and TPS sensors.

Diagnostic Tool Operation and Codes

Explains how to use the diagnostic tool and interpret failure codes.

7. CVT Continuously Variable Transmission

General Instructions and Troubleshooting

Provides guidelines and common issues for the CVT system.

Belt Case Service

Covers removal, inspection, and installation of the CVT belt case.

CVT Removal and Disassembly

Details the process of removing and disassembling CVT pulleys and belt.

CVT Installation

Covers the reassembly and installation of CVT components.

8. Final Drive

General Instructions and Troubleshooting

Provides guidelines and common issues for the final drive system.

Final Reduction Service

Covers servicing procedures for the final reduction gear unit.

Final Drive Oil Service

Details checking, draining, and filling the final drive oil.

9. Electrical Systems

General Information and Troubleshooting

Covers basic electrical system information and common problems.

Component Locations

Illustrates the location of major electrical system components.

ECU, Ignition, and Spark Plug Service

Details servicing procedures for ECU, ignition system, and spark plug.

Charging, Battery, and Starting Systems

Covers maintenance of charging, battery, and starting systems.

Switches, Relays, and Accessories

Covers service of various switches, relays, horn, meter, and USB socket.

10. Brakes

General Instructions and Troubleshooting

Provides guidelines and common issues for the brake system.

Disc Brake and Caliper Service

Covers inspection and service of brake discs, calipers, and pads.

Master Cylinders and Parking Brake

Details servicing of master cylinders and parking brake adjustment.

ABS System Service and Troubleshooting

Covers ABS system introduction, components, and troubleshooting procedures.

11. Steering

Troubleshooting

Addresses steering-related issues like hard steering and tracking problems.

Handlebar and Switch Housing Service

Covers removal and service of handlebar components and switch housings.

Grips Service

Provides instructions for replacing or installing handlebar grips.

Steering Stem Removal and Service

Details the process of removing and servicing the steering stem assembly.

12. Front Suspension

Troubleshooting

Addresses front suspension issues like soft forks and shock absorber noise.

Front Fender Assembly Removal

Covers the removal of the front fender assembly.

Front Fork Removal and Installation

Provides steps for removing and reinstalling the front fork assembly.

13. Rear Suspension

Troubleshooting

Addresses rear suspension issues like soft rear cushion and damper oil leaks.

Rear Fork Service

Details the removal and service of the rear fork components.

Shock Absorbers Service

Covers adjusting and replacing rear shock absorbers for proper ride.

14. Wheels

Troubleshooting

Addresses wheel-related issues like wobbling and noise.

Wheel Bearing Replacement

Provides instructions for replacing wheel bearings for smooth rotation.

Front Wheel Service

Covers removal and installation of the front wheel assembly.

Tire and Wheel Inspection

Details inspection of tire pressure, tread wear, and wheel runout.

15. EEC SYSTEM

Introduction and Troubleshooting

Introduces the EEC system and covers related troubleshooting.

System Components Service

Covers servicing of air filter, canister, and oxygen sensor.

Maintenance Information

Provides maintenance standards and leakage checking procedures for the EEC system.

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