2005-2006 KYMCO XCITING 500/250 Service Manual (420 P.)
Service guide for all XCITING 500/250 configurations with engine, fuel system, cooling, and transmission specs. Includes valve clearance 0.1mm, spark plugs CR8E/DPR7EA-9, torque specifications, and complete diagnostics procedures.
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Sample pages from the 2005-2006 KYMCO XCITING 500/250 Service Manual (420 P.) manual
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Kymco Models Covered & Key Technical Specifications
Models: KYMCO XCITING 500, KYMCO XCITING 250
Sub-models / Variants: 500, 250
Trade Names: XCITING
Build Years: 2005–2006
Serial Numbers: Frame serial number located on frame, Engine serial number located on crankcase
Technical Data:
- Engine displacement: 498.5 cm³ (XCITING 500), 251/249.1 cm³ (XCITING 250)
- Engine configuration: O.H.C. Single cylinder, 4-stroke
- Cooling system: Liquid cooled
- Starting system: Electric starter motor
- Idle speed: 1400±100 rpm (XCITING 500), 1600±100 rpm (XCITING 250)
- Valve clearance (cold): 0.1 mm (intake and exhaust)
- Spark plug (XCITING 500): NGK CR8E
- Spark plug (XCITING 250): NGK DPR7EA-9
- Transmission type: CVT (Automatic centrifugal)
- Drive system: Rear unit swing
Kymco Manual Features & Content Preview
2005–2006 KYMCO XCITING 500/250 Technical Documentation
- Covers 2005–2006 KYMCO XCITING 500 and XCITING 250 maxi-scooters, providing technical specifications for engine, chassis, and electrical system diagnostics
- Official OEM publication with 420 pages, documenting complete disassembly and assembly sequences for engine, drivetrain, and frame components
- Includes 21 detailed technical sections, comprehensive wiring diagrams, and torque specification tables for critical fasteners
- No shipping wait — the PDF is available immediately after purchase
- Indexed PDF search covers every chapter and appendix
- Contains 420 pages of structured technical data, including service limits and lubricant application charts
- This 420-page factory manual serves as the primary technical reference for the 2005–2006 KYMCO XCITING 500/250 production series.
Documented Systems and Chapters
The KYMCO XCITING 500/250 service manual documents the technical architecture of both displacement variants through a structured 21-section layout. The engine section provides data on head/valve assembly, cylinder/piston tolerances, pulley drive systems, and final reduction gear settings. Chassis documentation captures front-end steering, shock absorber, and braking system service information.
The electrical equipment section includes detailed wiring diagrams and system testing data for charging, ignition, and starter circuits. Each section starts with system illustrations, diagnostic logic for common symptoms, and removal/installation sequences for peripheral components like frame covers, body panels, and exhaust hardware.
Specification Highlights
Torque values are documented for all major engine and chassis fasteners, such as the 135 Nm drive face nut for the 500cc model and 93 Nm for the 250cc variant. Coolant capacities and fluid specifications for engine and final reduction gears are listed alongside valve clearance values set at 0.1 mm cold. Intake valve clearance for the 2005 KYMCO XCITING 500 is specified at 0.1 mm. Compression pressure for the 2005 XCITING 250 is documented at 15 kgf/cm². Spark plug gap for both variants is specified at 0.6–0.7 mm. All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work.
This 420-page KYMCO OEM factory manual documents the engine, chassis, electrical, and fuel systems for the 2005–2006 KYMCO XCITING 500/250 model series.
Document Reference: Kwang Yang Motor Co., Ltd. Overseas Service Section
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