11. Rear Suspension XCITING 400i  

11‐1   

Rear Suspension

This chapter provides information on the rear suspension components of the KYMCO XCITING 400i models.

Shock Absorbers .......................................................................... 11-2~11-7

Rear Fork ................................................................................. 11-8~11-11

GENERAL INFORMATION

• Use genuine KYMCO replacement bolts and nuts for all suspension pivots and mounting points.

TROUBLESHOOTING

Soft rear shock absorber

• Weak shock absorber spring

• Damper oil leaks

Hard suspension

• Bent damper rod

• Worn or damaged engine mount bushings

• High tire pressure

Rear suspension noisy

• Loose mounting fasteners

• Faulty shock absorber

• Weak rear suspension mount bushings

11. Rear Suspension > Rear Fork XCITING 400i  

11‐2  

Rear Fork

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

• When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding.

• During servicing, keep oil or grease off the brake pads and brake disk.

Remove these components

Muffler Exhaust System

Right Rear Shock Absorber Lower Mount Shock Absorbers

Hold the rear brake to keep the rear wheel from turning.

Remove the rear axle nut with a 27 mm socket.

11. Rear Suspension > Rear Fork XCITING 400i  

11‐3  

Remove the rear wheel hose clamp bolts with an 8 mm socket. Place the scooter on its center stand so that the rear wheel is off the ground.

Remove the two rear fork bolts with a 12 mm socket.

Remove the rear fork.

Remove the collar from the rear fork.

11. Rear Suspension > Rear Fork XCITING 400i  

11‐4  

Inspect the wheel bearing by turning it with a finger. Replace the bearing and seal as needed.

Remove the seal and snap ring.

Drive the bearing out from the inside out.

Drive in the new bearing with a suitable driver that is the same outside diameter as the bearing.

11. Rear Suspension > Rear Fork XCITING 400i  

11‐5  

Install the snap ring into the groove.

Apply grease to the lips of the new seal and drive it into place in the same manner as the bearing.

Inspect the shock absorber bushing and replace it as needed. Inspect the rear fork for damage and replace it as needed.

11. Rear Suspension > Rear Fork XCITING 400i  

11‐6  

Installation

Apply grease to the lips of the dust seal and install the collar into the rear fork.

Fit the rear fork into place.

Install the two rear fork bolts and tighten them to specification with a 12 mm socket.

Item Q'ty Thread dia.(mm)Torque

Nm (kgf-m, ft-lb)

Rear fork 2 8 35 (3.5, 25)

11. Rear Suspension > Rear Fork XCITING 400i  

11‐7  

Install the rear wheel speed sensor and hose clamp bolts with an 8 mm socket.

Install the rear axle nut and tighten it to specification with a 24 mm socket.

Item Q'ty Thread dia.(mm)Torque

Nm (kgf-m, ft-lb)

Rear axle nut 1 16 140 (14, 100.8)

11. Rear Suspension > Shock Absorbers XCITING 400i  

11‐8   

Shock Absorbers

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Pre-Load Setting

Each shock absorber on the scooter has 5 spring preload adjustment positions for different load or riding conditions.

Position 1 is for light loads and smooth road conditions. Position 3 to 5 increase spring preload for stiffer rear suspension and can be used when the scooters heavily loaded. Be certain to adjust both shock absorbers to the same spring preload positions.

Use a pin spanner to adjust the rear shock spring preload. The shock absorbers are adjustable for pre-load. There are 5 settings. Position 1 is the softest and 5 is the stiffest.

Caution: Always adjust the shock absorber pre-load position in sequence (1-2-3-4-5 or 5-4-3-2-1). Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber.

(Pre-Load Standard Setting: Position 3)

11. Rear Suspension > Shock Absorbers XCITING 400i  

11‐9   

Removal

Place the vehicle on its center stand.

Remove these components

Seat Seat

Luggage Box Luggage Box

Support the engine with a suitable hoist or jack.

Remove the rear shock mounting bolts with a 14 mm socket.

Remove the shock absorbers.

Inspect the shock absorber bushings for wear and damage. Replace the shock absorbers or bushings as needed.

11. Rear Suspension > Shock Absorbers XCITING 400i  

11‐10   

Check over the shock absorber for damage and oil leaks. Replace the shock absorber if needed. Do not attempt to disassemble the shock absorber.

Installation

Fit the shock absorber into place. Make sure the preload arrow indicator faces out from the lower mount.

Install the upper shock absorbers. Insert the upper mounting bolt first. Tighten the bolts to specification with a 14 mm socket.

Item Q'ty Thread dia.(mm)Torque

Nm (kgf-m, ft-lb)

Rear shock absorber bolt 4 10 40 (4, 29)

11. Rear Suspension > Shock Absorbers XCITING 400i  

11‐11   

Install the lower shock absorber mounting bolts and torque them to specification with a 14 mm socket.

Item Q'ty Thread dia.(mm)Torque

Nm (kgf-m, ft-lb)

Rear shock absorber bolt 4 10 40 (4, 29)

Remove these components

Luggage Box Luggage Box

Seat Seat