2007 Xciting 500 Maintenance.

[500Scoot - Cape Town]

Hi Guys

Happy 2026 to all and may you all have safe km on your Scooters or bikes.

Ruffus, it took some time but I got the spares I ordered, after the scooter overheated.

New Thermostat, Fan Switch that screws into the radiator, new radiator cap.

Drained old fluid from cooling system.
took out thermostat and flushed cooling system with water hose till only clear water came out.

Radiator cap off, and reservoir empty, filled radiator till it reached the top and started overflowing into the reservoir.

started the scooter and when coolant dropped I switched off the scooter and filled the radiator again.

Started again and waited for the radiator to overflow.

Cap on and started it and drove it, temp go to normal, but fan does not come on, not during driving or standing and idling in the garage.
When you put power to the fan it runs, when in the normal state (everything installed and plugged in, fan not coming on.

Any suggestions?

I am going through the manual to look for a fuse or relay.

even when idling the temp go to normal, and stay there, no bubbles in radiator after starting, only overflowing with cap off.

Regards

Gerhard

[500Scoot - Cape Town]

Another observation.

When running the scooter and coolant starts overflowing, it seems nothing is moving down to the reservoir.

But when manually filling the radiator slowly, it will go down to the reservoir.

Is this normal, I understood the reservoir should get some liquid during this de-airing stage as the radiator overflows.

Regards

Gerhard

[Ruffus]

Well done so far! Congrats!
As for the temp:
 it takes around 90° C to open the  thermostate AND to show one more bar on your dashboard. It takes a while to reach that.

Overflow tank:
there should be to start with, fluid until lower bar (seen from aside)
It will not overflow until  95 to 100° C into this tank under your footrest. It needs pressure to work against the coilspring to flow down.

To be sure check all connectors and cables for shave offs on the thermostate side.

Fuse or more serious I doubt, would draw a failure code.

[500Scoot - Cape Town]

Dear Ruffus

Thank you again for the reply

I traced the wire from the fan to a relay and then it go into the loom.

I had a guy test it and seems the relay is faulty.

When filling the tank to the low mark, and system is de-aired, should I put the radiator cap back on and then run it, this will create pressure if I am correct.

I will check connectors as well, as suggested.

I do not know how to draw a failure code from the scoot unfortunately.

Regards

Gerhard

[Ruffus]

The scoots display would start blinkung in a certain manner = failure code.

Yes, overflow to -MIN- cap on, at temp of 90 to 100°C it evolves enough pressure.

Relay might be faulty, will not draw a code. To test change relays with each other, there are four same of them under your front.
If one is faulty change all four.

[500Scoot - Cape Town]

The one I took from the fan looks different, its a sealed unit with 2wires coming from it.
Kymco
D-421
TA Young
2006 02

Thats all thats written on it.

The other 2 looks like the ones you showed.

The 4th one also looks different.

It is a 2007 carb model, dont know if it will be different.

Pictures wont upload as they are too big, will try again from PC.
Regards

Gerhard

[Ruffus]

Maybe carb model had different relays or were changed once for reason.
Last one I saw was an i model and had four same pieces.

[500Scoot - Cape Town]

Hi Ruffus

I will let you know what I find.

Do you know what the compression should be on the motor when we do a compression test?

I would like to test that and we got a camera to look at the inside of the motor to see what the cylinder looks like.

Regards

Gerhard

[Ruffus]

According to KYMCOs workshop manual 13 bar, though I might say after thousands of km it should not be under 11.5 bar throttle completely open.

[500Scoot - Cape Town]

Update:

Cooling system seems sorted.

Fan comes on and coolant seems normal and full al the time.
Temp stays normal.

After this was sorted I had to know if there was any other damage after the overheating problem.

We did a compression test, throttle open and motor turned about 5 times.

First test we got 13bar resetted the gauge and got 14bar on the second run.

 Any comments on this will be appreciated.

Another question, what is normal oil consumption to expect, driving conditions in South Africa is good, we had a few 30°C + days in Cape Town.

Riding 80-100km/h on 20w-50 oil what should be considered as normal oil consumption? 

Looking forward to the replies.

Regards

Gerhard

[Ruffus]

Well done!
It cools, fan kicks in 👍
 KYMCO liquid cooled scoots take usage in hot environment pretty well, didn't see a temp gauge within red under well maintained circumstances.

For compression values:
13-14 bar is like new, WOT though 👍 2nd is higher because you got some fuel injected, which seals rings partially.
..having this, your scoot should NOT consume more than 100ml per 1000 kms.

Anyway it has two liters and a bit for the filter, so even it takes 125ml is nothing to worry.
Will highly depend on your throttle use during warm up phase.

[500Scoot - Cape Town]

Dear Ruffus

Thank you, I will have a look at the oil usage, to me it feels as if more is being used than described, but will monitor first and then confirm.

Am I correct in saying the motor should be at temp, then wait 2-3minutes and then take oil reading?
Thats what I got from the manual, or should I take oil reading before starting?

Regards

Gerhard

[Ruffus]

Oil readings:
-most accurate at cold engine on mainstand
-warm engine, let it sit for a few minutes to collect oil in the sump to have +- 50ml readings.

[500Scoot - Cape Town]

Dear Ruffus

What donuou mean by +-50ml readings.

Am I correct in saying, if cold engin reading is fine, I will be fine for driving?

I am thinking of doing a valve clearance check / adjustment.
I am hearing a ticking nouse when riding and to be honest the power has been feeling a bit down for some time now.

Regards

Gerhard

[Ruffus]

Yes, you are on the safe side with a cold reading.
Then don't be surprised if it reads a bit less with a warm/hot engine.

A valve job on a XC 500 consists of lifting the engine (lowering the body) by unfastening both rear shocks, to be able to remove valve cover. Consider this.