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1. E
xt
e
r
na
l
Com
p
one
nt
s
XCITING 400
i
1-1
E
x
t
e
r
n
a
l
C
o
m
pon
e
n
t
s
This chapter covers the location and servicing of the external components for the
KYMCO XCITING 400i.
• Exhaust System 2-11
• Seat 12-13
• Luggage Box 14-16
• Rear Carrier 17-18
• Center Cover 19-20
• Side Covers 21-22
• Body Cover 23-32
• Front Cover 33-45
• Front Cover Meter 46-49
• Inner Cover 50-57
• Front Fender 58-60
• Rear Fender 61-66
• Handlebar Cover 67-71
• Under Cover 72-73
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐2
E
x
h
a
u
s
t
S
ys
t
e
m
S
A
FETY FIRST
:
P
r
o
t
e
c
t
i
v
e
g
l
o
v
e
s
a
nd
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y
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w
ea
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a
r
e
r
e
c
o
mm
e
nd
e
d
a
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t
h
i
s
po
i
n
t
.
Ge
n
e
r
a
l
I
n
s
t
r
u
c
t
i
on
s
• When removing frame covers, use care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
T
r
oub
l
e
s
hoo
t
i
ng
N
o
i
sy
e
x
h
a
u
s
t
m
u
ff
l
e
r
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
L
a
ck
o
f
po
w
e
r
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Re
m
o
v
a
l
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐3
Remove the two exhaust pipe joint nuts with a 12 mm deep well socket.
Unplug the O
2
sensor connector.
Hea
t
S
h
i
e
l
d
s
Remove the four muffler heat shield bolts with a 10 mm socket.
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐4
Remove the heat shield.
To remove the four bolts to free the heat shield on the muffler.
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐5
Remove the three muffler mounting bolts with a 14 mm socket.
Remove the exhaust system.
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐6
Remove the exhaust pipe gasket and discard it.
O
2
Se
n
s
o
r
R
e
m
oval
Remove the O2 sensor with a 17 mm wrench.
Use care not to pinch the wires.
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐7
The O
2
sensor issues signal to ECU when the temperature is over 350°C while the engine
is running.
Test the O
2
sensor at room temperature.
Use a digital multimeter set to ohms of resistance to inspect the O2 sensor.
Measure the resistance between the white wire terminals of the
O
2
sensor connector. Replace the O
2
sensor if the reading is out
of specification.
I
T
E
M
SP
EC
I
F
I
C
A
T
I
O
N
S
O
2
h
ea
t
e
r
s
e
n
s
o
r
r
e
s
i
s
t
a
nc
e
(
a
t
20
°
C
/
68
°
F
)
6.7
-
9.5
Ω
(
e
ng
i
n
e
w
a
r
m
i
ng
cond
i
t
i
on
)
I
n
s
t
a
ll
a
t
i
on
Hea
t
S
h
i
e
l
d
s
Install the heat shields and tighten the bolts securely.
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐8
O
2
Se
n
s
o
r
Apply anti-seize compound to the threads of the O
2
sensor.
Install the O
2
sensor and tighten it to specification with a 17 mm
wrench. Use care not to pinch the wires.
I
t
e
m
T
or
qu
e
N-m
l
b-
ft
O
2
S
e
ns
or
25 18
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐9
E
x
h
a
u
s
t
S
ys
t
e
m
Insert a new exhaust pipe gasket into the exhaust port.
Fit the exhaust system into place
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐10
Install the two exhaust pipe joint nuts with a 12 mm deep well socket.
Do not tighten.
Install the three muffler mounting bolts and tighten to specification
with a
socket.
I
t
e
m
T
or
qu
e
N-m
k
gf
-m
M
uf
f
l
e
r
M
ount
i
ng
Bolt
s
40
4.0
Tighten the two exhaust pipe joint nuts to specification with a 12 mm
deep well socket.
I
t
e
m
T
or
qu
e
N-m
k
gf
-m
E
xha
us
t
P
i
p
e
J
oi
nt
N
ut
s
20 2.0
1.
External components >
E
xha
us
t
S
ys
t
e
m XCITING 400
i
1‐11
If the exhaust pipe and muffler were separated tighten the muffler clamp
securely.
Plug in the O
2
sensor.
1. E
xt
e
r
na
l
Com
p
one
nt
s
>
S
ea
t XCITING 400i
1-12
Sea
t
S
A
FETY FIRST
:
P
r
o
t
e
c
t
i
v
e
g
l
o
v
e
s
a
nd
e
y
e
w
ea
r
a
r
e
r
e
c
o
mm
e
nd
e
d
a
t
t
h
i
s
po
i
n
t
.
Re
m
ov
a
l
Insert the key and turn it counterclockwise .
Remove the two luggage box hinge nuts with a 10 mm socket.
1. E
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Com
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s
>
S
ea
t XCITING 400i
1-13
I
ns
t
a
ll
a
t
i
on
Install the seat with the piston pivot onto the hinge.
Install the
two seat plastic screws from the front of body cover.
Install the two luggage box hinge nuts and tighten securely with a 10 mm socket.
Push down the back of the seat to lock closed.
1. E
xt
e
r
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l
Com
p
one
nt
s
>
L
ugga
ge
B
ox XCITING 400i
1-14
Lugg
a
g
e
B
ox
Re
m
ov
a
l
Remove the four luggage nuts with a 10 mm socket.
Remove the two luggage bolts with a 10 mm socket.
1. E
xt
e
r
na
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Com
p
one
nt
s
>
L
ugga
ge
B
ox XCITING 400i
1-15
Lift up the luggage box to unplug the luggage box light connector.
Remove the luggage box.
I
ns
t
a
ll
a
t
i
on
Plug in the luggage box light connector.
Install the luggage box.
Install the two luggage bolts with a 10 mm socket.
1. E
xt
e
r
na
l
Com
p
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nt
s
>
L
ugga
ge
B
ox XCITING 400i
1-16
Install the four luggage nuts and tighten securely with a 10 mm socket.
1. E
xt
e
r
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l
Com
p
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nt
s
>
R
ea
r
C
a
rr
i
e
r XCITING 400i
1-17
Rea
r
Ca
rr
i
e
r
Re
m
ov
a
l
Remove the four carrier bolts with a 6 mm Allen.
Remove the carrier.
1. E
xt
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r
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l
Com
p
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nt
s
>
R
ea
r
C
a
rr
i
e
r XCITING 400i
1-18
I
ns
t
a
ll
a
t
i
on
Install the carrier.
Install the two upper carrier bolts with a 6 mm Allen.
Install the two carrier bolts on each side with a 6 mm Allen.
1.
E
xt
e
r
na
l
Com
p
one
nt
s
>
C
e
nt
e
r
C
ove
r
XCITING 400i
1-19
Ce
n
t
e
r
C
ov
e
r
Re
m
ov
a
l
Note: Do not force the cover and damage the claws.
Remove the two seat plastic screws from the front of body cover.
Remove the seat with the piston pivot.
Remove the two plastic screws from the front of center cover.
1.
E
xt
e
r
na
l
Com
p
one
nt
s
>
C
e
nt
e
r
C
ove
r
XCITING 400i
1-20
Pull the center cover back and up to free the claws and then
move the cover backward to free it from the scooter.
Remove the center cover.
I
ns
t
a
ll
a
t
i
on
Place the center cover on the scooter.
Push the cover down and forward to lock in the claws.
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