6. COOLING SYSTEM

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COOLING SYSTEM__________________________________________________________________________________

SYSTEM FLOW PATTERN (XCITING 500) -------------------------- 6- 1SYSTEM FLOW PATTERN (XCITING 250) -------------------------- 6- 2SERVICE INFORMATION------------------------------------------------ 6- 3TROUBLESHOOTING----------------------------------------------------- 6- 6COOLING SYSTEM TESTING------------------------------------------- 6- 7COOLANT REPLACEMENT --------------------------------------------- 6- 7THERMOSTAT-------------------------------------------------------------- 6-10WATER PUMP -------------------------------------------------------------- 6-15RADIATOR ------------------------------------------------------------------ 6-23FAN MOTOR SWITCH ---------------------------------------------------- 6-26

WATER TEMPERATURE SENSOR ------------------------------------ 6-27RAIDATOR RESERVE TANK ------------------------------------------- 6-29

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6. COOLING SYSTEM

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SYSTEM FLOW PATTERN (XCITING 500)

6. COOLING SYSTEM

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SYSTEM FLOW PATTERN (XCITING 250)

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SERVICE INFORMATION

GENERAL INSTRUCTIONS

WARING:Removing the radiator cap while the engine is hot can allow the coolant to spray out,seriously scalding you. Always let the engine and radiator cool down before removing theradiator cap.

CAUTION:Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes.

• If any coolant gets in your eyes, rinse them with water and consult a physician immediately.• If any coolant in swallowed, induce vomiting, gargle and consult a physician immediately.• If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water.

NOTE:Use coolant with silicate inhibitors may cause premature wear of water pump seals or blockage ofradiator passages. Using tap water may cause engine damage.

• This section covers service of the cooling system.• These services can be done with the engine installed in the frame.• Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the

system.• All cooling system services can be done with the engine in the frame.• Avoid spilling coolant on painted surfaces.• After servicing the system, check for leaks with a cooling system tester.

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SPECIFICATIONS (XCITING 500)ITEM SPECIFICATIONS (XCITING 500)

Radiator and engine 2 liter (2.1 US qt, 1.76 lmp qt)Coolant capacity Reserve tank 0.37 liter (0.4 US qt, 0.33 lmp qt)

Radiator cap relief pressure 90 kPa (0.9 kgf/cm2, 12.8 psi)Begin to open 80 - 84°C (176 - 183°F)Fully open 95°C (203°F)

Thermostat

Valve lift 8 mm (0.3 in) minimumStandard coolant concentration 1:1 mixture with soft water

SPECIFICATIONS (XCITING 250)ITEM SPECIFICATIONS (XCITING 250)

Radiator and engine 1 liter (1.1 US qt, 0.88 lmp qt)Coolant capacity Reserve tank 0.37 liter (0.4 US qt, 0.33 lmp qt)

Radiator cap relief pressure 90 kPa (0.9 kgf/cm2, 12.8 psi)Begin to open 80 - 82°C (176 - 180°F)Fully open 90°C (198°F)

Thermostat

Valve lift 3.5 mm (0.14 in) minimumStandard coolant concentration 1:1 mixture with soft water

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COOLANT GRAVITY CHARTTemp.

Coolantconcentration

0 5 10 15 20 25 30 35 40 45 50

5% 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.99710% 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.00515% 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.01220% 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.01925% 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.02530% 1.053 1.051 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.03235% 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.04040% 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.04745% 1.080 1.078 1.076 1.074 1.072 1.069 1.056 1.063 1.062 1.057 1.05450% 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.05955% 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.06760% 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071

COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS)Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water

-9 20% -15 30% 425cc 975cc -25 40% -37 50% -44.5 55%

Cautions for Using Coolant:• Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant

concentrate + 975cc distilled water is 30%.)• Do not mix coolant concentrate of different brands.• Do not drink the coolant which is poisonous.• The freezing point of coolant mixture shall be 5lower than the freezing point of the riding

area.

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TORQUE VALUES

Water pump cover bolt (XCITING 500) 13 N•m (1.3 kgf•m, 9 lbf•ft)Water pump cover bolt (XCITING 250) 10 N•m (1 kgf•m, 7 lbf•ft)Fan motor bolt 5 N•m (0.53 kgf•m, 3.8 lbf•ft)Radiator shroud mounting nut 9 N•m (0.9 kgf•m, 6.5 lbf•ft)Water pump impeller (XCITING 250) 12 N•m (1.2 kgf•m, 8.6 lbf•ft) (Left screw)

TROUBLESHOOTING

Engine temperature too high• Faulty radiator cap• Faulty temperature gauge or thermosensor• Air in system• Thermostat stuck closed• Insufficient coolant• Passages blocked in radiator, hoses or water jacket• Faulty cooling fan motor• Faulty fan motor switch• Faulty water pump

Engine temperature too low• Faulty temperature gauge or thermosensor• Thermostat stuck open• Faulty fan motor switch

Coolant leak• Faulty water pump mechanical seal• Deteriorated O-rings• Faulty radiator cap• Damaged or deteriorated cylinder head gasket• Loose hose connection or clamp• Damaged or deteriorated hoses

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COOLING SYSTEM TESTINGRADIATOR CAP INSPECTIONRemove the radiator cap (page 6-8).

Pressure test the radiator cap.Replace the radiator cap if it does not holdpressure, or if relief pressure is too high ortoo low.It must hold the specified pressure for atleast six seconds.

Radiator Cap Relief Pressure: 90 kPa (0.9 kg/cm², 12.8 psi)

Pressurize the radiator, engine and hoses,and check for leaks.

Repair or replace components if the systemwill not hold the specified pressure for atleast six seconds.

COOLANT REPLACEMENTPREPARATION The effectiveness of coolant decreases

with the accumulation of rest or if there isa change in the mixing proportion duringusage. Therefore, for best performancechange the coolant regularly as specifiedin he maintenance schedule.

Mix only distilled, low mineral waterwith the antifreeze.

Recommended mixture:1:1 (Distilled water and antifreeze)

Excessive pressure can damage thecooling system components.Do not exceed 105 kPa (1.05 kg/cm²,14.9 psi).

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Radiator Cap

Cap Tester

Before installing the cap in the tester,wet the sealing surface.

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Cap Tester

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REPLACEMENT/AIR BLEEDINGRemove the front cover (page 2-11).

Remove the front lower cover (page 2-15).

Remove the radiator cap.

Disconnect the water lower hose and drainthe coolant from the system.

Remove the floor mat.Remove the screw and reserve tank lid.

Radiator Cap

When filling the system or reserve tankwith coolant (checking the coolantlevel), place the scooter in a verticalposition on a flat, level surface.

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Reserve Tank Lid Screw

Floor Mat

Water Lower Hose

XCITING 250:

Remove the water drain bolt and drainthe coolant from the system (page 6-17).

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Remove the reserve tank cap and drain thecoolant from the reserve tank.

Reconnect the water lower hose securely.

Place the scooter on its center stand on aflat, level surface.Fill the reserve tank to the upper level line.

Fill the system with the recommendedcoolant through the filler opening up to thefiller neck.

Reserve Tank Cap

Upper Level Line

Filler Neck

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Bleed air from the system as follow:1. Start the engine and let it idle for 2−3

minutes.2. Snap the throttle three to four times to

bleed air from the system.3. Stop the engine and add coolant to the

proper level if necessary. Reinstall theradiator cap.

4. Check the level of coolant in the reservetank and fill to the upper level if it islow.

THERMOSTATREMOVAL (XCITING 500)

Remove the floorboard (page 2-6).Remove the ignition coil (page 18-5).

Remove the nut and thermostat housingstay from the frame.

Remove the bolts, housing stay andthermostat housing cover.

Nut

Housing stay

Housing Stay Housing Cover

Bolts

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Remove the O-ring from the housing cover.Remove the thermostat.

REMOVAL (XCITING 250)

Remove the luggage box (page 2-3).Drain the coolant (page 6-17).

Disconnect the water temperature sensorconnectors from the sensor.Disconnect the water hose from thethermostat housing.Disconnect the air bleed hose from thethermostat housing.Remove the mounting bolt and thethermostat housing from the cylinder head.

Thermostat

O-ring

Thermostat

Thermostat Housing

Water HoseAir Bleed HoseBolt

Water TemperatureSensor Connectors

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Remove the two bolts and thermostathousing cover.

Remove the thermostat from the thermostathousing.

Thermostat

Bolts

Thermostat Housing

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INSPECTIONVisually inspect the thermostat for damage.

Heat the water with an electric heatingelement to operating temperature for fiveminutes.Suspend the thermostat in heated water tocheck its operation.

Replace the thermostat if the valve staysopen at room temperature, or if it respond attemperatures other than those specified.

Thermostat begin to open:XCITING 500: 80−84°C (176−183°F)XCITING 250: 80−82°C (176−180°F)

Valve lift:XCITING 500:

8 mm (0.3 in) minimum at 95°C (203°F)XCITING 250:3.5 mm (0.14 in) minimum at 90°C

(198°F)

Thermostat

Thermometer

Keep flammable materials away fromthe electric heating element.

Do not let the thermostat orthermometer touch the pan, or you willget false readings.

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INSTALLATION (XCITING 500)

Install the thermostat into the housing withits air bleed hole facing up and aligningbleed hole with the tab in the housing.

Install a new O-ring into the housing covergroove.

Install the housing cover and housing stayto the housing.Tighten the bolts securely.

Install the housing stay to the frame.Tighten the nut securely.

Fill the system with recommended coolantand bleed the air (page 6-8).

INSTALLATION (XCITING 250)

The installation sequence is the reverse ofremoval.

Air Bleed Hole

Tab Align

O-ring

O-ring

Water Temperature Sensor

Replace the O-ring with a new one andapply grease to it.

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WATER PUMP

MECHANICAL SEAL INSPECTIONInspect the telltale hole for sign of coolantleakage.If there is leakage, the mechanical seal isdefective, and water pump should bereplaced

REMOVAL (XCITING 500)Remove the exhaust muffler (page 2-16)

Drain the coolant (page 6-8).

Loosen the hose bands and disconnect thewater hoses and bypass hose from the waterpump.

Telltale Hole

Water Hoses

Bypass Hose Bolts

XCITING 500

Telltale HoleWater Pump

XCITING 250

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Remove the bolts and water pump cover.

Remove the O-ring from the water pumpcover.

Remove the water pump body from thecrankcase.

Water Pump Cover

Bolts

Water Pump Cover

O-ring

Water Pump Body

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INSTALLATION (XCITING 500)Apply engine oil to a new O-ring and installit onto the stepped portion of the waterpump.

Install the water pump into the crankcasewhile aligning the water pump shaft groovewith oil pump shaft end.

Align the mounting bolt holes in the waterpump and crankcase and make sure thewater pump is securely installed.

Install a new O-ring into the groove in thewater pump cover.

Install the water pump cover and tighten thebolts to the specified toque.Torque: 13 N•m (1.3 kgf•m, 9 lbf•ft)

Connect the water hoses and bypass hose,then tighten the hose bands.

Fill the system with recommended coolantand bleed the air (page 6-8).

REMOVAL (XCITING 250)

Remove the drain bolt to drain coolant.

Loosen the hose band screw and disconnectthe water hoses from the water pump.

Remove the four bolts and the water pumpcover, gasket and 2 dowel pins.

Align

O-ring

Water Pump CoverDrain Bolt

Bolts Band Screw

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Remove the water pump impeller.

Inspect the mechanical (water) seal and sealwasher for wear or damage.

Disconnect the water hose from the rightcrankcase cover.Remove the eight bolts attaching the rightcrankcase cover.

The impeller has left hand threads.＊Impeller (Left Hand Threads)

The mechanical seal and seal washermust be replace as a set.

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Mechanical Seal

Seal Washer (Porcelain)Impeller

Water Pump Assembly

Bolts

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Water Pump Assembly

Remove the water pump bearing snap ringfrom the water pump assembly.Remove the water pump shaft and innerbearing.

Remove the water pump shaft outerbearing.

Drive the mechanical seal out of the waterpump assembly from the inside.

Inner Bearing

Snap Ring

Inner Bearing

Water Pump Assembly

Water Pump Shaft

Mechanical Seal (Water Seal)

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Drive in a new mechanical seal using amechanical seal driver.

INSTALLATION (XCITING 250)Drive a new water pump shaft outer bearinginto the water pump assembly from theinside.

Install the water pump shaft and shaft innerbearing into the waster pump assembly.Install the snap ring to secure the innerbearing properly.

Apply sealant to the right crankcasecover fitting surface of a new mechanicalseal and then drive in the mechanicalseal.

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Mechanical Seal Driver

Water Pump Assembly

Outer Bearing

Inner Bearing

Snap Ring Water Pump Shaft

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Install the dowel pins and a new gasket andthen install the water pump assembly to theright crankcase cover.Tighten the eight bolts to secure the rightcrankcase cover.

When the mechanical seal is replaced, anew seal washer must be installed to theimpeller.

Install the impeller onto the water pumpshaft.Torque:12 N•m (1.2 kgf•m, 8.6 lbf•ft) (Leftscrew)

When installing the water pumpassembly, aligning the groove on thewater pump shaft with the tab on the oilpump shaft.

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Bolts

Water Pump Assembly

Mechanical Seal

Seal Washer (Porcelain)Impeller

The impeller has left hand threads.＊

Impeller (Left Hand Threads)

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Install the two dowel pins and a new gasket.

Install the water pump cover and tighten the4 bolts.Torque: 10 N•m (1 kgf•m, 7 lbf•ft)

Dowel Pins

Water Pump Cover

Bolt

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RADIATORREMOVALDrain the coolant (page 6-8).Remove the inner cover (page 2-14).Remove the front lower cover (page 2-15)

Disconnect the fan motor connector.

Loosen the hose band and disconnect theradiator lower hose from the radiator.

Loosen the hose band and disconnect thecoolant filler hose from the radiator.

Fan Motor Connector

Filler Hose

Lower Hose

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Disconnect the fan motor switchconnectors.Disconnect the air bleed hose.

Remove the four nuts and radiator from theframe.

Loosen the hose band and disconnect theradiator upper hose from the radiator.

Be careful not to damage the radiatorcore.

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Fan Motor Switch Connectors

Air Bleed Hose

Upper Hose

Nuts

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DISSASSEMBLYRemove the four bolts and fanmotor/shroud assembly.

Check the fan motor to operate using anavailable battery.

ASSEMBLYInstall the fan motor/shroud assembly to theradiator with the fan motor wire facing up.Install and tighten the bolts securely.

Bolts

Fan Motor Wire

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FAN MOTOR SWITCHREMOVALDisconnect the fan motor switch connector(page 6-24).

Remove the fan motor switch.

INSPECTIONPlace the fan motor switch in oil containedin a pan as shown and raise the oiltemperature gradually to check for thetemperature at which the switch starts tooperate.If the switch operating temperature is notwithin the specified range, replace theswitch with a new one.OFF→ON Over 88−92°CON→OFF Lower 88−92°C

INSTALLATIONFit the O-ring.Tighten the cooling fan motor switch tospecified torque.Torque: 17 N•m (1.8 kgf•m, 13 lbf•ft)

Fan Motor Switch

O-ring

Handle the cooling fan motor switch

carefully as it is vulnerable to impact. Do not allow the cooling fan motor

switch Îand the thermometer Ïtocome in contact with the bottom of thepan.

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Replace the O-ring a new one. Do not coat grease to the O-ring.

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WATER TEMPERATURESENSOR

REMOVAL (XCITING 500)Remove the side body cover (page 2-8)

Disconnect the water temperature sensorconnector.Remove the water temperature sensor fromthe water joint.

REMOVAL (XCITING 250)Remove the luggage box (page 2-3).

Disconnect the water temperature sensorconnectors.Remove the water temperature sensor fromthe thermostat housing.

Water Temperature Sensor

Water joint

Thermostat HousingWater TemperatureSensor Connectors

Water Temperature Sensor

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INSPECTIONConnect the water temperature sensor to theohmmeter and dip it in oil contained in apan which is placed on an electric heater.Gradually raise oil temperature whilereading the thermometer in the pan and theohmmeter connected. If the resistancemeasured is out of specification, replace thetemperature gauge with a new one.

Temperature Standard resistance50 140–310Ω115 24.1–28.2Ω

After the water temperature sensor has beeninstalled, fill coolant and perform airbleeding (page 6-8).

INSTALLATIONWith thread lock applied to the threadedpart, tighten the water temperature sensor.Torque: 8 N•m (0.8 kgf•m, 5.8 lbf•ft)

Handle the water temperature sensorcarefully as it is vulnerable to impact.

Do not allow the water temperaturesensor and the thermometer to come incontact with the bottom of the pan.

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Water Temperature Sensor

Thermometer

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RADIATOR RESERVE TANKREMOVALRemove the floorboard (page 2-6).

Remove the two nuts and radiator reservetank from the frame.

Open the reserve tank cap and drain thecoolant from the reserve tank.

Disconnect the siphon hose.

INSTALLATIONInstallation is in the reverse order ofremoval.

Pour the recommended coolant to the upperlevel line with the center stand applied

Nuts

Siphon Hose