TECHNICAL TRAINING MATERIALS

Xciting Series
Specification Xciting 500i

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KEIHIN SYSTEM

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 XCITING 300i/500i FI PARTS LOCATION

ECU---300i ROLL Sensor

※500i ECU is located under the front cover

CPS O2 sensor

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FUEL PUMP AISV WTS MAP SENSOR

IGNITION COIL INJECTOR TPS ISC

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 SELF-DIAGNOSTIC PROCEDURE
Turn the ignition switch
“ON” without start the
engine , The CELP lamp
will light for two second
then off. It shows the lamp
work normal.

XCITING Check Engine Lamp PEOPLE S Check Engine Lamp

(CELP) (CELP)

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SELF-DIAGNOSIS CELP FAILURE CODES

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DTC LIST FOR KEIHIN

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 FAILURE CODES CLEARED
1. Turn the key to the ON position and wait for ten seconds.
2. Fully open the throttle and wait for ten seconds.
3. Release the throttle.
4. The indicator will blink twice (0.5 second) quickly.

NOTE: The self-diagnosis could not be reset if there’s still trouble in Fi system.

Throttle
opened fully

10 s 10 s 5s
KEY ON

Throttle Throttle
closed closed

Indicator blinks twice continuously

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 TPS/ISC RESET

1. Turn the key to the OFF position.

2. Fully open the throttle .
3. Turn the key to the ON position.
4. Release the throttle after waiting for 8 seconds.
5. Turn the key to the OFF position.
6. Turn the key to the ON position.
7. TPS and ISC have been reset successfully.

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 KYMCO Fi Diagnostic tool

Model No.

ECU Version

DTC Inspect
LEA7

DATA Analyze

CO Adjust

UP Button
Down Button

Power indicator Enter or Exit DTC indicator(Failure codes)

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 RECHECK TPS/ISC WITH Fi DIAGNOSTIC TOOL

1. Turn to page 02 on Fi diagnostic tool

2. Release the throttle
3. Refer to standard specifications as below,
“ Throttle position ” : 1% below
“ Throttle position sensor output voltage ” : 0.5 ± 0.10 Volt.

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RECHECK TPS/ISC WITH Fi DIAGNOSTIC TOOL

1. Fully open the throttle.

2. Refer to standard specifications as below,
“Throttle position (TP) ”: 94% over
“Throttle position sensor output voltage ”: >3.78 Volt.

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 Fi DIAGNOSTIC TOOL CONNECTION

1. Upward the side stand

2. Turn the engine stop switch to the “RUN” position

RUN

Upward side stand

Diagnostic Tool Connector

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DTC inspection

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DTC cleared

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Data Analysis

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 ISC

The (TPS) and (ISC) have to reset, when

the throttle body MAP, TPS, ISC or ECU
has been reinstalled .

Remove the screw, then remove the ISC

and set plate.
ISC/Set
Plate
Install the ISC and set plate onto the
throttle body(Apply oil to new O-ring). Be
careful not damage O-ring.

ISC O-ring

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 MAP
REMOVAL / INSTALLATION
MAP
Remove the screw of the MAP.
Carefully install the MAP into the
hole of throttle body after using
the engine oil onto the O-ring.

INSPECTION

O-ring

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 TPS

INSPECTION

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THROTTLE BODY CLEANING

1. Remove the throttle body.

2. Use the carburetor cleaner to clean the
throttle body’s butterfly valve.
3. Waiting for ten minutes.
4. Blow the throttle body with a air gun.
5. Install the throttle body.

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 FUEL PUMP RELAY

INSPECTION

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FUEL PUMP REMOVAL / INSTALLATION Hose band

REMOVAL
Disconnect the fuel pump connector and fuel
hose from fuel pump.
Remove the six screws, then remove the
fuel pump and O-ring.

Fuel pump connector Screw

INSTALLATION

Place a new O-ring onto fuel tank.

Be careful not damage the fuel pump wire and

make sure of the connector rearward.

Install and tighten the screws

Torque: 0.35 kgf-m (3.5 N-m, 2.5 lbf-ft)

O-ring
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 FUEL OUTPUT PRESSURE INSPECTION

1. Turn the key to the OFF position.

2. Use the fuel hose clamp.
3. Disconnect the fuel hose from the fuel injector.
4. Connect the fuel pressure gauge.
5. Turn the key to the ON position.
5. Check the fuel pressure. Standard:3.0 Bar

Caution！
If the fuel output pressure is less than
3.0 bar, may fail to start the engine or in
trouble in case of riding.

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 FUEL INJECTOR
REMOVAL
1. Disconnect the connector from the fuel injector.
2. Remove the bolt of the fuel injector.
3. Take out of the fuel pipe and fuel injector from the
Inlet pipe.
4. Remove the fuel injector from the fuel pipe
Connector Bolt

Caution
Ensure the fuel pipe without any pressure, then remove
the fuel injector.
STEP 1 : Disconnect the fuel pump relay or fuel pump
connecter.
STEP 2: Turn the key to the ON position. Starting the
engine till the engine stop working.
O-ring Fuel Injector

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 FUEL INJECTOR REMOVAL / INSTALLATION
Groove
INSTALLATION
1. Apply the engine oil to a new O-ring.
2. Install the fuel injector into the fuel pipe.
3. Ensure the tab of the fuel injector inserted into the
groove of the fuel pipe.

Tab

4. Install the fuel pipe into the intake manifold by

aligning the dowel pin.
5. Be careful not to damage the O-ring.
6. Tighten the fuel pipe mounting bolt.

O-ring Dowel pin

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 FUEL INJECTOR CLEANING
Battery
Problem:
1. Fuel Injector cannot output the fuel.
2. The Injector injection time (ms) is shorter or
longer.
Fuel Injector
Standard: < 1.6ms
Analysis:
Injector block (With some carbons).
Troubleshooting:
1. Use the specified injector cleaner.
2. Pouring the liquid of carburetor cleaner until
half container .
3. Connect the battery as picture.
4. The injector cleaner with the flash relay.
Container
5. Keeping the fuel Injector operation.
6. Waiting for 20~30 minutes.
7. Cleaning the carbons completely. Flash relay

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 TILT SWITCH

INSPECTION

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 WATER TEMPERATURE SENSOR

RESISTANCE

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O2 SENSOR

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 Specification for Keihin EMS Parts
NO. Item Photo Tool Specification

1. Check the label

2. Check if the connector is loosen
1. 39200-LDF2-8000 (ECU) D
3. Check if the voltage is within 5V±0.1V
4. Check the MAP version

1610K-LDF2-8000
2. D According to the diagnosis report
(IDLE AIR BYPASS VALVE /ISC)

3 MAP SENSOR D 13.332kpaABS(1V) ~ 119.990kpaABS(4.2V)

IDLE opening: 0.5V±0.1V

4 THROTTLE POSITION SENSOR/TPS D
WOT opening: > 3.78V

1. To hear if any noisy

5. FUEL PUMP D,M
2. FUEL LEVEL F:7Ω±3 E:95Ω±5

6. FUEL INJECTOR D,M 10.17~12.43Ω

~ 18.8KΩ when temperature -20℃

WATER TEMPERATURE
7. D,M ~ 1.136KΩ when temperature 40℃
SENSOR/WTS
~ 0.1553KΩ when temperature 100℃

Primary coil: 3.57 ~ 4.83Ω

8. INDUCTIVE IGNITION COIL D,M
Secondary coil: 10.42 ~ 14.49KΩ

1. Heater : 6.7Ω~9.5Ω
9. OXYGEN SENSOR D,M 2. A/F: <14.7 Voltage: >0.8V (Mixture is rich)
A/F: >14.7 Voltage: <0.18V (Mixture is lean)

10. CRANK POSITION SENSOR/CPS D,M 100 ~ 130Ω

AIR INJECTION SOLENIO

11. D,M 27.75Ω±1.8Ω
VALVE/AISV

Normal position = 0.4V ~ 1.4V

12. TILT SWITCH D,M
Fall down = 3.7V ~ 4.4V
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XCITING 500Ri ABS

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 Anti-Lock Brake System(ABS) Indicator Light

• Meter instruments(For models equipped with ABS)

• The ABS indicator light in the meter position .This light will comes on when the ignition
switch is turned on and goes off shortly after the vehicle starts moving.it stays off.
• If something is wrong with the ABS,the indicator comes on and remains it. When the
indicator light is on,the ABS doesn’t function but if the ABS fails,the conventional brake
system will still work normally.

ABS Indicator Light Location

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• ABS is designed to help prevent the wheels from locking up when the brakes are applied hard
while running straight. The ABS automatically regulates brake force. Intermittently gaining
gripping force and braking force helps prevent wheel lock-up and allows stable steering control
while stopping. Brake control function is identical to that of conventional vehicle .The brake
lever is used for the front brake and rear brake. Although the ABS provides stability while
stopping by preventing wheel lock-up, remember the following characteristics:
• ABS can not compensate for adverse road conditions,misjudgment or improper application of
brakes.You must take the same care as with vehicle not equipped with ABS.
• ABS isn’t designed to shorten the braking distance. On loose,uneven or downhill surfaces, the
stopping distance of a vehicle with ABS may be longer than that of an equivalent vehicle
without ABS.Use special caution in such areas.
• ABS will help prevent wheel lock-up when braking in straight line but it cannot control wheel
slip which may caused by braking during cornering.When turning a corner, it is better to limit
braking to the light application of both brakes or not to brake at all.Reduce your speed before
you get into the corner.

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• The computers intergrade in the ABS compare vehicle speed with wheel speed. Since non-
recommended tires can affect wheel speed, they may confuse,Which can extend distance.

•※CAUTION
•Use of non- recommended tires may cause malfunctioning of ABS and lead to extended
braking distance.The rider could have an accident as a result. Always use standard for this
recommended vehicle .

• NOTICE:
• When the ABS is functioning,you may feel a pulsing in the brake lever.this is normal.
• You need not suspend applying brakes.

• ABS does not function at speeds of approx. 10 km/h or below.

• ABS does not function if battery is discharged or battery power supply malfunction. Light will
come on

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 ABS Parts Location
(5)
(6)
(7)

(3) (1)

(2)

(4)

1. Front Wheel speed Sensor

2. Front Wheel speed Sensor Rotor
3. Rear Wheel speed Sensor
4. Rear Wheel speed Sensor Rotor
5. ABS Indicator Light
6. ABS Hydraulic Unit
7. ABS diagnosis tool Connector (Near battery position)

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 DIAGNOSTIC PROCEDURE

1.Connect the KYMCO Fi Diagnostic tool

2.Put the side stand and engine stop switch is at “RUN”
position.
3.Connect the diagnostic tool connector

Diagnostic tool connector

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 Fi Diagnostic Tool Vehicle’s Model
(R&D Drawing NO.)
ECU Version

DTC Inspect

DATA Analyze

Adjust

UP Button
Down Button

Power Enter or Exit DTC

(Failure codes)

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<Picture 1>

<Picture 3>

<Picture 2>

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 <Picture 6>

<Picture 4>

<Picture 7>

<Picture 5>
<Picture 8>

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<Picture 9> <Picture 11>

<Picture 12>

<Picture 10>

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<Picture 13> <Picture 15>
The adjust is without function
KYMCO Diagnosis 01
Fr Speed 5 km/hr
Re Speed 5 km/hr
Battery Volt 12.6V
<Picture 14>
Battery volt: 9.6~16.7V keep function

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 Wheel Speed Sensor Removal And Installation

Remove the screw for front wheel Remove the screw for rear wheel

Disconnect the connector Disconnect the connector

for front wheel for rear wheel
Standard clearance between Sensor and Rotor: 0.8 ~ 1.0mm
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ABS ECU& Hydraulic Unit

Warning :
I f remove the ABS ECU screws cause to
damage the ECU or Hydraulic Unit parts.
Kymco do not guarantee the parts.

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 (1)

NOTE :
Do not drain brake oil when
replacing the new Hydraulic Unit.
Because brake oil is fully inside.
(2)

TORQUE:
(1) Oil bolts *4: 35.0N.m (3.5kgf.m)
(2) Nut *2 : 8.0N.m (0.8 kgf.m)

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 WHEEL SPEED SENSOR INSPECTION

Front wheel speed Rear wheel speed sensors

Standard: 3500~6500

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 FI Diagnostic Software For PC Version
Ver 2.18
Double click to
change the serial port.

To close this basic

display.

To change language

Connect ECU to begin

diagnosis

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 Function Introduction
Start to diagnosis Command message Throttle Position ECU version
Exit software Change port

RPM condition

Failure code list

Automatically
detect and show
the model photo

Failure item

Showing failure part location

photo automatically
Vehicle running
condition signal showing
Show how to figure out the failure
code and possible defect cause

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