8.

ENGINE REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

8
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ENGINE REMOVAL/INSTALLATION
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SERVICE INFORMATION------------------------------------------------ 8- 1
ENGINE REMOVAL (XCITING 500/500 AFI) ------------------------ 8- 2
ENGINE REMOVAL (XCITING 250/300 AFI) ------------------------ 8-11 8
ENGINE HANGER --------------------------------------------------------- 8-16

8-0
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

SERVICE INFORMATION

GENERAL INSTRUCTIONS
• During engine removal and installation, support the scooter on its main stand.
• Support the frame using a jack or other adjustable support to ease of engine hanger bolt removal.
• The following components require engine removal for serviced with the engine installed in the
frame.
™ Oil pump (Section 4)
™ Water pump (Section 7)
™ Cylinder head (Section 9)
™ Cylinder/Piston (Section 10)
™ Drive and driven pulleys/clutch (Section 11)
™ Final reduction (Section 12)
™ Alternator/Starter clutch (Section 13)
• The following components require engine removal for service.
™ Crankshaft/Crankcase/Balancer (Section 14)

SPECIFICATIONS
ITEM SPECIFICATIONS
XCITING 500/500 AFI 66 kg (145.2 lbs)
Engine dry weight
XCITING 250/300 AFI 37.5 kg (82.5 lbs)
XCITING 500/500 AFI 2 liter (2.1 US qt, 1.8 lmp qt)
At draining
XCITING 250/300 AFI 0.9 liter (0.95 US qt, 0.8 lmp qt)
Engine oil XCITING 500/500 AFI 2.5 liter (2.7 US qt, 2.2 lmp qt)
capacity At disassembly
XCITING 250/300 AFI 1.1 liter (0.97 US qt, 1.17 lmp qt)
At oil filter cartridge change 2.1 liter (2.2 US qt, 1.9 lmp qt)
(XCITING 500/500 AFI)

TORQURE VALUES

Engine mounting bolt/nut (XCITING 500/500 AFI) 80 N•m (8 kgf•m, 58 lbf•ft)

Engine mounting bolt/nut (XCITING 250/300 AFI) 50 N•m (5 kgf•m, 36 lbf•ft)
Rear shock absorber lower mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Rear/parking brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
ALOCK bolt: replace with a new one
Engine hanger mounting bolt 50 N•m (5 kgf•m, 36 lbf•ft)
Engine hanger rod nut 35 N•m (3.5 kgf•m, 25 lbf•ft)

8-1
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

ENGINE REMOVAL (XCITING

500/500 AFI)
Remove the following:
Luggage box (page 2-3)
Floorboard (page 2-6)
Rear fender (page 2-7)
Side/rear body cover (page 2-8)
Exhaust muffler (page 2-16)

Drain the coolant from the system (page 7-8).

Support the scooter on its main stand.

Air Cleaner Clamp Screw

Loosen the air cleaner clamp screw.

Loosen the carburetor clamp screw.

Remove the carburetor.

Throttle body (page 6-42)

Carburetor Clamp Screw

Fuel Hose
Disconnect the fuel hose from the carburetor.
Remove fuel injector pipe and disconnect the
fuel injector connector (page 6-36).

8-2
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Disconnect the water temperature sensor AICV air Supply Hose

connector.
Disconnect AICV air supply hose from the
AICV check valve.

Water Temperature Sensor Connector

Crankcase Breather Hose

Disconnect the spark plug cap from the
cylinder head.
Disconnect the crankcase breather hose form
the cylinder head cover.

Spark Plug Cap

Rubber Cap
Release the rubber cap and remove the
terminal nut to disconnect the starter motor
cable.

Nut
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INSTALLATION XCITING 500/500 AFI/250/300 AFI

Air Bleed Hose

Disconnect the air bleed hose and water hose
from the water joint.

Water Hose

Outer Water Hose

Disconnect the outer water hose from the oil
cooler.

Alternator Connectors
Loosen the wire bands and disconnect the
alternator connectors.

8-4
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Engine Ground Cable

Remove the bolt and engine ground cable.

.
Bolt

Bypass Hose
Loosen the hose bands and disconnect the
bypass hose and water hose

Water Hose

Oil Pressure Switch

Disconnect the oil pressure switch connector.

Oil Pressure Switch Connector

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[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Bolts
Remove the bolts and rear/parking brake
caliper.
Remove the brake hose from clamps.

Disconnect the transmission case breather

hose from transmission case.

Transmission Case Breather Hose

Bolts
Remove the bolts and air cleaner.

8-6
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Remove the rear cushion lower mount bolts

Lower Mount Bolts

Nut

Remove the engine mount nut.

Bolt
Turn the engine mount bolt counterclockwise
and loosen it.
Pull out the engine mount bolt then removes
the engine from the frame.

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INSTALLATION XCITING 500/500 AFI/250/300 AFI

At removing the engine, be careful not to

catch your hand or finger between the
engine hanger and crankcase.

8-8
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Remove the collar.

Collar
8-9
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INSTALLATION XCITING 500/500 AFI/250/300 AFI

Long Engine Collar

Pull out the long engine collar.

INSTALLATION
Installation is in the reverse order of removal.

● At installing the engine, be careful not

to catch your hand or finger between
the engine hanger and crankcase.
● Check for leakage of the engine oil and
engine coolant.

Torque:
Engine mounting bolt/nut:
80 N•m (8 kgf•m, 58 lbf•ft)

Route the brake hoses and wires properly

(page 1-16).

8-10
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Crankcase Breather Hose

ENGINE REMOVAL (XCITING
250/250 AFI)
Remove the following:
Luggage box (page 2-3)
Floorboard (page 2-6)
Rear fender (page 2-7)
Side/rear body cover (page 2-8)
Exhaust muffler (page 2-16)
Carburetor (page 5-6) (XCITING 250)
Throttle body (page 6-42)

Drain the coolant from the system (page 7-8). AICV Air Supply Hose
Support the scooter on its main stand.
Disconnect the crankcase breather and AICV
air supply hoses from the cylinder head
cover. Fuel Pump Vacuum Hose

Disconnect the fuel pump and AICV vacuum

hoses from the inlet pipe (XCITING 250).

Remove fuel injector pipe and disconnect the

fuel injector connector (page 6-36).

AICV Vacuum Hose

Air Cleaner

Remove the two air cleaner mounting bolts

and disconnect the transmission case breather
hose from air cleaner case, then remove the
air cleaner.

Bolts Transmission Case Breather Hose

8-11
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Rubber Cap Start Motor

Disconnect the ECT sensor connector (page
6-39). (XCITING 250 AFI)

Remove the bolt and thermostat housing.

Release the rubber cap and remove the

terminal nut to disconnect the starter motor
cable.

Thermostat Housing Bolt Nut

Disconnect the alternator connectors.

Alternator Connectors

Engine Ground Cable Water Hose

Remove the bolt and disconnect the engine
ground cable from the right crankcase cover.

Loosen the band screw and disconnect the

water hose from the water pump.

Bolt Screw
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INSTALLATION XCITING 500/500 AFI/250/300 AFI

Bolts Bolts/Bands
Remove the two rear brake caliper mounting
bolts and three rear brake hose bands/bolts
from rear fork, then remove the rear brake
caliper.

Bolt/Band Rear Brake Caliper

Oil Pressure Switch Connector

Disconnect the oil pressure switch connector .

Remove the spark plug cap.

Spark Plug Cap

Remove the rear cushion lower mounting

bolts.

Bolts
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[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Remove the nut.

Pull out the engine mounting bolt, then
removes the engine from the frame.

Nut Bolt

At removing the engine, be careful not to

catch your hand or finger between the
engine hanger and crankcase.

INSTALLATION
Installation is in the reverse order of removal.

● At installing the engine, be careful not

to catch your hand or finger between
the engine hanger and crankcase.
● Check for leakage of the engine oil and
engine coolant.

Torque:
Engine mounting bolt/nut:
50 N•m (5 kgf•m, 36 lbf•ft)

Route the brake hoses and wires properly

(XCITING 250: page 1-26/XCITING 250
AFI: page 1-34).

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[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

INSPECTION
Inspect the bearing (XCITING 500/500 AFI):
Bearings allow play in the right/left crankcase
or the bearing turns roughly → Replace.

Bearing

O-rings

Inspect the bushes (XCITING 250/250 AFI):

Bushes allow play in the right/left crankcase
or the wear/damage → Replace.

Inspect the inner collars (XCITING 250/250

AFI):
Wear/Damage → Replace.

Replace the new O-rings and apply grease to

the inner collars outside when the inner
collars are installation.

Bush Inner Collar Bush

Inspect the engine mount bolt:

Band/Damage → Replace

Do not attempt to straighten a bent

engine mount bolt.

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[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

Bolts
ENGINE HANGER
REMOVAL
Loosen and remove the engine mount nut
(page 8-7).
Loosen and remove the engine mount bolt
(page 8-7).

Remove the engine hanger mount bolts.

Remove the outer collars (XCITING 500/500
AFI).

Outer Collars (XCITING 500)

Inner Collars

Remove the engine hanger

Remove the inner collars.

Nut Washers

Remove the nut, washers, rubber washers

and engine hanger rod.

INSTALLATION
Installation is in the reverse order of removal.

Torque:
Engine hanger mounting bolt:
50 N•m (5 kgf•m, 36 lbf•ft)
Engine hanger rod nut:
Rubber Washers Engine Hanger rod
35 N•m (3.5 kgf•m, 25 lbf•ft)
8-16
[Link] REMOVAL/
INSTALLATION XCITING 500/500 AFI/250/300 AFI

INSPECTION Outer/Inner Bearings

Inspect the bearings in the engine hanger
(XCITING 500/500 AFI):
Bearings allow play in the engine hanger or
the bearing turns roughly → Replace.

Inspect the bushes in the engine hanger

(XCITING 250/250 AFI):
Wear/Damage → Replace.

Bushes

Bush

Inspect the bush in the engine hanger rod:

Wear/Damage → Replace.

8-17