KYMCO XCITING 500 Service Manual Download Page 288

Page: 288 / 349

. BRAKE SYSTEM

16-18

XCITING 500

REAR MASTER CYLINDER

REMOVAL

When removing the brake hose bolt, cover

the end of the hose to prevent contamination.

Secure the hose to prevent fluid from leaking

out.

Remove the upper handlebar cover (page 2-

5).
Drain the combination brake hydraulic

system (page 16-5).

Remove the two screws and lower handlebar

cover.

Disconnect the brake light switch connectors

from master cylinder.

Remove the brake hose oil bolt, sealing

washers and brake hose eyelet.

Screws

Lower Handlebar Cover

Brake Hose Bolt

Sealing Washers

Brake Light Switch Connectors

Summary of Contents for XCITING 500

Page 1: ...500 By KWANG YANG Motor Co Ltd First Edition Feb 2005 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4121 L...

Page 2: ...mbly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION...

Page 3: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL I...

Page 4: ...1 GENERAL INFORMATION 1 1 XCITING 500 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number...

Page 5: ...speed rpm 1400rpm Lubrication type Forced pressure Wet sump Oil pump type Trochoid Oil filter type Full flow filtration Oil capacity 2 5 L 2 2 lmp qt 2 65 Us qt Final reduction oil capacity 0 55 L 0 5...

Page 6: ...engine oil before reassembly Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation When two persons wo...

Page 7: ...protruding or loose The connector shall be inserted completely If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check fo...

Page 8: ...ews Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wir...

Page 9: ...operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before...

Page 10: ...NANCE Engine oil drain plug Oil strainer screen cap Oil filter cartridge Transmission oil drain bolt Transmission oil filler bolt Spark plug Tappet adjust nut LUBRICATION SYSTEM Oil pump screw Oil coo...

Page 11: ...E Item Q ty Thread dia mm Torque N m kgf m lbf ft Remarks STEERING Handlebar bolt Upper pinch bolt Lower pinch bolt Bridge stem nut Steering stem lock nut Top thread WHEEL Front axle bolt Front fork b...

Page 12: ...Tool Name Tool No Remarks Clutch spring compressor E053 Clutch disassembly Bearing puller 10 12 15 18mm E037 Bearing removal Valve spring compressor E040 Valve removal Oil seal bearing installer E014...

Page 13: ...ton ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft Balancer shaft Crankshaft one way clutch movable part Oil pump drive chai...

Page 14: ...rts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Seat Lock Grease Throttle Cable Engin...

Page 15: ...1 GENERAL INFORMATION 1 12 XCITING 500 CABLE HARNESS ROUTING...

Page 16: ...1 GENERAL INFORMATION 1 13 XCITING 500...

Page 17: ...1 GENERAL INFORMATION 1 14 XCITING 500...

Page 18: ...1 GENERAL INFORMATION 1 15 XCITING 500...

Page 19: ...1 GENERAL INFORMATION 1 16 XCITING 500...

Page 20: ...1 GENERAL INFORMATION 1 17 XCITING 500...

Page 21: ...1 GENERAL INFORMATION 1 18 XCITING 500...

Page 22: ...1 GENERAL INFORMATION 1 19 XCITING 500...

Page 23: ...1 GENERAL INFORMATION 1 20 XCITING 500...

Page 24: ...1 GENERAL INFORMATION 1 21 XCITING 500...

Page 25: ...nd piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing cFaulty auto bystarter dAir leaking through intake pipe eIncorrect ignition timing fIncorrectly...

Page 26: ...gnition timing too early jAir in cooling system cExcessive carbon build up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean g Ignition timing too early Start engine and acce...

Page 27: ...rator fFaulty ignition coil gBroken or shorted high tension wire hFaulty ignition switch cDamaged air cut off valve diaphragm dDamaged air cut off valve spring Remove spark plug and install it into sp...

Page 28: ...tube cClean and unclog cCam timing gear aligning marks not aligned cFaulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump...

Page 29: ...xcessive carbon build up in combustion chamber cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain cFaulty crankshaft bearing dWorn crank pin bearing cWorn...

Page 30: ...arings fWeak driven face spring gWorn or seized driven pulley bearings cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings cOil or grease fouled drive belt dWorn d...

Page 31: ...starter pinion cStarter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of stop switch by applying brake Stoplig...

Page 32: ...nition coil Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abnor...

Page 33: ...gulator rectifier eBroken or poorly connected regulator rectifier black wire cLimit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an elec...

Page 34: ...om Symptom Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim...

Page 35: ...g stem nut POOR BRAKE PERFORMANCE cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dForeign matter on brake linings eRough brake drum contacti...

Page 36: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

Page 37: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 XCITING 500 SCHEMATIC DRAWING...

Page 38: ...o route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Muffler mount bolt 35 N m 3 5 kgf m 25 lbf ft Exhaust pipe joint nut 20 N m 2 kgf m 14 lbf ft Exhaust pipe band bolt 2...

Page 39: ...ion is in the reverse order of the removal After installation check the seat installation by moving the seat LUGGAGE BOX REMOVAL Remove the seat page 2 3 Remove the four screws and three nuts Raise th...

Page 40: ...REAR SPOILER REMOVAL Unlock the seat with the ignition key Open the seat Remove the rubber cap Remove four bolts and rear spoiler INSTALLATION Installation is in the reverse order of removal FRONT FEN...

Page 41: ...rse order of removal RIGHT LEFT CENTER BODY COVER REMOVAL Remove the two bolts and right left center body cover INSTALLATION Installation is in the reverse order of removal RIGHT LEFT FLOOR SKIRT REMO...

Page 42: ...rse order of removal FLOORBOARD REMOVAL Remove right and left center body cover page 2 5 Remove the right and left floor skirt page 2 5 Remove the luggage box page 2 3 Remove six bolts four screws and...

Page 43: ...ense light connector and remove the license light INSTALLATION Installation is in the reverse order of removal REAR FENDER REMOVAL Remove the licence light page 2 7 Remove two screws Remove two nuts a...

Page 44: ...taillight rear turn signal light connector and remove the side body cover INSTALLATINON Installation is in the reverse order of removal REAR BODY COVER REMOVAL Remove the luggage box page 2 3 Remove t...

Page 45: ...8 Remove eight screw and taillight rear turn signal light INSTALLATION Installation is in the reverse order of removal REAR LOWER COVER REMOVAL Remove the side body cover page 2 8 Remove the rear low...

Page 46: ...is in the reverse order of removal WINDSHIELD REMOVAL Remove four screws and windshield garnish Remove four bolts and windshield INSTALLATION Installation is in the reverse order of removal Rearview M...

Page 47: ...ove the rearview mirrors page 2 9 Remove six screws Remove two screws Remove one screw Disconnect headlight and turn signal light connectors INSTALLATION Installation is in the reverse order of remova...

Page 48: ...n the reverse order of removal TURN SIGNAL LIGHT REMOVAL Remove the front cover page 2 11 Remove three screws and turn signal light INSTALLATION Installation is in the reverse order of removal FRONT M...

Page 49: ...ion is in the reverse order of removal MEER PANEL REMOVAL Remove the front cover page 2 11 Remove the front meter visor page 2 12 Remove four screws Disconnect the speedometer connector and remove met...

Page 50: ...meter INNER COVER REMOVAL Remove the front cover page 2 11 Remove the floorboard page 2 6 Remove the meter panel page 2 13 Remove the shutter screw and shutter Turn the fuel fill cap garnish counterc...

Page 51: ...ION Installation is in the reverse order of removal FRONT LOWER COVER REMOVAL Remove the front cover page 2 11 Remove the right and left floor skirt page 2 5 Remove two bolts and front lower cover EXH...

Page 52: ...e joint nuts and exhaust pipe Remove the gaskets INSTALLATION Replace the gaskets with new ones Install the exhaust pipe and tighten the joint nuts Torque 20 N m 2 kgf m 14 lbf ft Install the muffler...

Page 53: ...______________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 3 FUEL LINE 3 5 THROTTLE OPERATION 3 5 AIR CLEANER 3 6 CRANKCASE BREATHER 3 7 SPARK PLUG 3 7 VALVE CLEARANCE 3 9 ENGINE OI...

Page 54: ...6 1 4 in Spark plug NGK CR8E Spark plug gap 0 6 0 7 mm 0 024 0 028 in IN 0 1 mm 0 004 in Valve clearance EX 0 1 mm 0 004 in At draining 2 0 liter 2 1 US pt 1 8 lmp qt At draining oil filter change 2 1...

Page 55: ...reads and seating surface Oil filter cartridge 10 N m 1 kgf m 7 lbf ft Apply oil to the threads and seating surface Transmission oil drain bolt 24 N m 2 4 kgf m 18 lbf ft Transmission oil filler bolt...

Page 56: ...m the pre ride inspection in the owner s manual at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first I INSPECT AND CLEAN ADJUST LUBRI...

Page 57: ...ridden in unusually wet or dusty areas 3 Service more frequently when riding in rain or at full throttle 4 Inspect every 18000 km 12000 mi after replacement 5 Replace every 1 year or every 10000km 60...

Page 58: ...g in all steering positions Check the throttle cables and replace them if they are deteriorated kinked or damaged Lubricate the throttle cables if throttle operation is not smooth Measure the throttle...

Page 59: ...n the lock nut securely Recheck the throttle operation Replace any damaged parts if necessary AIR CLEANER The air cleaner should be serviced at regular intervals Service more frequently when riding in...

Page 60: ...val CRANKCASE BREATHER Remove the crankcase breather tube plug from the tube and drain deposits into a suitable container Reinstall the crankcase breather tube plug Service more frequently when riding...

Page 61: ...plug is suitable for your type of usage A normal operating spark plug should be light brown or tan color If the spark plug is very white or glazed appearing then it has been operating much too hot Th...

Page 62: ...align the T mark on the flywheel with the index mark on the right crankcase cover The punch marks on the camshaft should face upward as shown If the punch marks on the camshaft are facing downward tur...

Page 63: ...er tightening the lock nut recheck the valve clearance Install the removed parts in the reverse order of removal ENGINE OIL OIL LEVEL INSPECTION Start the engine and let it idle for 2 3 minutes Turn o...

Page 64: ...ation for reclamation Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Alth...

Page 65: ...he oil strainer screen After draining the oil completely install the strainer screen and setting spring into the engine Apply clean engine oil to the strainer cap threads flange surface and a new O ri...

Page 66: ...1 9 lmp qt at oil filter cartridge change Install the oil filler cap dipstick 1 Check the engine oil level page 3 11 Make sure there are no oil leaks ENGINE OIL FILTER CARTRIDGE REPLACEMENT Drain the...

Page 67: ...il page 3 13 ENGINE IDLE SPEED Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specification The engine must be warm for accurate idle spe...

Page 68: ...the F and L level surface If the level is low remove the reserve tank cap and fill the tank to the F level line with 1 1 mixture of distilled water and antifreeze coolant mixture preparation page 6 5...

Page 69: ...Remove the floorboard page 2 6 Check for any coolant leakage from the water pump radiator hoses and hose joints Check the radiator hoses for cracks or deterioration and replace if necessary Check tha...

Page 70: ...arbon dioxide and water Check the AICV air injection control valve hoses between the AICV control solenoid valve and cylinder head cover for deterioration damage or loose connections Make sure the hos...

Page 71: ...If the brake pads are not worn and the fluid level is low check the entire system for leaks FRONT BRAKE Turn the handlebar so the reservoir is level and check the front brake fluid reservoir level If...

Page 72: ...T BRAKE Check the cutout in each pad If either pad is worn to the cutout replace both pads as a set REAR BRAKE Check the cutout in each pad If either pad is worn to the cutout replace both pads as a s...

Page 73: ...perated bleed the air from the system Inspect the brake hose and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE LOCK OPE...

Page 74: ...slowly and check the lever stroke Standard 3 6 notches All stroke 9 notches If there is out of specification adjust again HEADLIGHT AIM Place the scooter on a level surface Adjust the headlight beam...

Page 75: ...e engine 9 Fully lower the side stand while running the engine 9 The engine should stop as the side stand is lowered If there is a problem with the system check the side stand switch page 20 15 SUSPEN...

Page 76: ...mage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque...

Page 77: ...s when the tread depth reaches the following limits Minimum tread depth Front 1 6 mm 0 06 in Rear 2 0 mm 0 08 in STEERING HEAD BEARINGS Check that the control cables do not interfere with handlebar ro...

Page 78: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBR...

Page 79: ...4 LUBRICATION SYSTEM 4 1 XCITING 500 LUBRICATION SYSTEM DIAGRAM...

Page 80: ...2 0 liter 2 1 US qt 1 8 lmp qt At disassembly 2 5 liter 2 7 US qt 2 2 lmp qt Engine oil capacity At oil filter change 2 1 liter 2 2 US qt 1 9 lmp qt Recommended engine oil KYMCO 4 stroke oil or equiv...

Page 81: ...il used Faulty head gasket Water leak in crankcase Oil contamination Deteriorated oil No oil pressure Faulty oil filter Oil level too low Worn piston ring White appearance with water or Oil pump drive...

Page 82: ...IL PRESSURE RELIEF VALVE REMOVAL Remove the right crankcase cover page 12 3 Remove the pressure relief valve and O ring from the right crankcase INSPECTION Check the operation of the pressure relief v...

Page 83: ...ve the attaching bolt and oil separator cover Remove snap ring Remove the oil pump driven gear then remove the oil pump drive chain Oil Separator Cover Bolts Drive Chain Driven Gear Snap Ring When rem...

Page 84: ...pump bolts to remove the oil pump DISASSEMBLY Remove the screw and oil pump cover Remove the dowel pin oil pump shaft oil pump outer rotor and inner rotor Bolts Oil Pump Screw Oil Pump Cover Outer Ro...

Page 85: ...into the oil pump body Measure the tip clearance Service limit 0 2 mm 0 008 in Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feele...

Page 86: ...dowel pin onto the oil pump body Install the oil pump cover onto the oil pump body by aligning the dowel pin Install and tighten the screw to the specified torque Torqur 3 N m 0 3kgf m 2 lbf ft INSTAL...

Page 87: ...CITING 500 Install the oil pump driven sprocket and drive chain Install the snap ring Install the oil separator cover properly and tighten two bolts securely as shown Snap Ring Drive Chain Driven Gear...

Page 88: ...er cartridge page 3 13 Drain the coolant from the system page 6 6 Loosen the hose bands and disconnect the oil cooler water hoses from the cooler Remove the oil cooler mounting bolts washers oil coole...

Page 89: ...the oil cooler bolts to the specified torque Torque 35 N m 3 5 kgf m 25 lbf ft Connect the oil cooler water hoses tighten the hose band securely Install the oil filter cartridge and fill the crankcase...

Page 90: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYST...

Page 91: ...5 FUELSYSTEM FUELPUMP FUEL TANK CARBURETOR 5 1 XCITING 500 SCHEMATIC DRAWING...

Page 92: ...ed the operation of the fuel pump is stopped by the fuel pressure to prevent excessive supply FUEL PUMP CONSTRUCTION When voltage is applied between the fuel pump terminals current flows into the sole...

Page 93: ...r and air cut off valve be careful not to damage the diaphragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away...

Page 94: ...Damaged vacuum piston diaphragm Automatic valve opens excessively Clogged diaphragm hole Faulty float valve Float level too high Lean mixture Clogged air jets Clogged fuel jets Automatic choke valve...

Page 95: ...l the carburetor out from the air cleaner and intake manifold Disconnect the fuel hose from the carburetor Disconnect the carburetor heater connector Disconnect the throttle cables Disconnect the auto...

Page 96: ...tomatic choke cover removed remove the screw and automatic choke assembly Remove the carburetor heater Remove the four screws and top cap The automatic choke assembly is a non disassemblable type Auto...

Page 97: ...ainer jet needle and throttle valve Remove the two screws and casting enrichment valve cover and then take out the spring Remove the casting enrichment valve and O ring Throttle Valve Spring Retainer...

Page 98: ...8 XCITING 500 Remove the three screws and accelerating pump cover Remove the accelerating pump diaphragm and O ring Remove the four screws and float chamber Screws Accelerating Pump Cover Float Chamb...

Page 99: ...L TANK CARBURETOR 5 9 XCITING 500 Pull float pin outs then remove the float and float valve Remove the slow jet Remove the main jet Remove the needle jet holder Float Float Valve Float Pin Needle Jet...

Page 100: ...and O ring FLOAT FLOAT VALVE INSPECTION Inspect the float for deformation or damage Needle Jet Pilot Screw Float Before pilot screw removal slowly turn the pilot screw clockwise and count the number...

Page 101: ...th a spray type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish Blow the body dry using compressed air After cleaning reassemble the carburetor with new seals Main Jet N...

Page 102: ...RATINGPUMP DIAPHRAGMINSPECTION Check the casting enrichment valve accelerating pump diaphragm for damage and clogging If any abnormal condition is found wash the part clean If damage or clogging is fo...

Page 103: ...the float level is out of specification AUTO BYSTARTER INSPECTION Disconnect the connector Remove the automatic choke cover Connect the positive terminal of a 12 V battery to Yellow lead and the nega...

Page 104: ...the heater section is heated in 5 minutes after the battery has been connected REASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly When reassembling carefully observ...

Page 105: ...the original setting by turn the screw in until it lightly seats and then backing it out the same number of turns counted during disassembly After the assembly and installation on the engine have been...

Page 106: ...uel pump lead wire coupler If the measurement is out of specification replace the fuel pump Fuel pump resistance 1 2 5 As shown in the right illustration connect the battery to the fuel pump and measu...

Page 107: ...oorboard page 2 6 Remove the inner cover page 2 14 Remove the front lower cover page 2 15 Remove the fuel pump and fuel filter page 5 17 Remove the front heat insulation cover Heat Insulation Cover Ar...

Page 108: ...ank Disconnect the ground wire connector Disconnect the fuel filler cap open cable Remove the two nuts and left floorboard set holder from the frame Remove the AICV control solenoid valve from the lef...

Page 109: ...5 FUELSYSTEM FUELPUMP FUEL TANK CARBURETOR 5 19 XCITING 500 Remove the fuel tank from the frame left side INSTALLATION Installation is in the reverse order of removal Fuel Tank Fuel Tank Fuel Tank...

Page 110: ...______________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM _______________________________...

Page 111: ...6 COOLING SYSTEM 6 1 XCITING 500 SCHEMATIC DRAWING...

Page 112: ...argle 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...

Page 113: ...8 1 025 30 1 053 1 051 1 051 1 049 1 047 1 045 1 043 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 0...

Page 114: ...sensor 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 temperatu...

Page 115: ...f the system will not hold the specified pressure for at least six seconds COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rest or if there is a change...

Page 116: ...ator cap Disconnect the water lower hose and drain the coolant from the system Remove the floor mat Remove the screw and reserve tank lid Radiator Cap When filling the system or reserve tank with cool...

Page 117: ...rve tank Reconnect the water lower hose securely Place the scooter on its center stand on a flat level surface Fill the reserve tank to the upper level line Fill the system with the recommended coolan...

Page 118: ...dd coolant to the proper level if necessary Reinstall the radiator cap 4 Check the level of coolant in the reserve tank and fill to the upper level if it is low THERMOSTAT REMOVAL Remove the floorboar...

Page 119: ...tat in heated water to check its operation Replace the thermostat if the valve stays open at room temperature or if it respond at temperatures other than those specified Thermostat begin to open 80 84...

Page 120: ...the housing cover and housing stay to the housing Tighten the bolts securely Install the housing stay to the frame Tighten the nut securely Fill the system with recommended coolant and bleed the air p...

Page 121: ...age 2 15 Drain the coolant page 6 6 Loosen the hose bands and disconnect the water hoses and bypass hose from the water pump Remove he bolts and water pump cover Remove the O ring from the water pump...

Page 122: ...with oil pump shaft end Align the mounting bolt holes in the water pump and crankcase and make sure the water pump is securely installed Install a new O ring into the groove in the water pump cover In...

Page 123: ...e inner cover page 2 14 Remove the front lower cover page 2 15 Disconnect the fan motor connector Loosen the hose band and disconnect the radiator lower hose from the radiator Loosen the hose band and...

Page 124: ...nnectors Disconnect the air bleed hose Remove the four nuts and radiator from the frame Loosen the hose band and disconnect the radiator upper hose from the radiator Be careful not to damage the radia...

Page 125: ...four bolts and fan motor shroud assembly Check the fan motor to operate using an available battery ASSEMBLY Install the fan motor shroud assembly to the radiator with the fan motor wire facing up Ins...

Page 126: ...switch operating temperature is not within the specified range replace the switch with a new one OFF ON Over 88 92 C ON OFF Lower 88 92 C INSTALLATION Fit the O ring Tighten the cooling fan motor swi...

Page 127: ...f the resistance measured is out of specification replace the temperature gauge with a new one Temperature Standard resistance 50 140 310 115 24 1 28 2 After the water temperature sensor has been inst...

Page 128: ...wo nuts and radiator reserve tank from the frame Open the reserve tank cap and drain the coolant from the reserve tank Disconnect the siphon hose INSTALLATION Installation is in the reverse order of r...

Page 129: ..._____________________________________________________________________________ __________________________________________________________________________________ _______________________________________...

Page 130: ...er clutch Section 12 The following components require engine removal for service Crankshaft Crankcase Balancer Section 13 SPECIFICATIONS ITEM SPECIFICATIONS Engine dry weight 66 kg 145 2 lbs At draini...

Page 131: ...ge 2 7 Side rear body cover page 2 8 Exhaust muffler page 2 15 Drain the coolant from the system page 6 6 Support the scooter on its main stand Loosen the air cleaner clamp screw Loosen the carburetor...

Page 132: ...AICV check valve Disconnect the spark plug cap from the cylinder head Disconnect the crankcase breather hose form the cylinder head cover Release the rubber cap and remove the terminal nut to disconne...

Page 133: ...sconnect the air bleed hose and water hose from the water joint Disconnect the outer water hose from the oil cooler Loosen the wire bands and disconnect the alternator connectors Air Bleed Hose Water...

Page 134: ...move the bolt and engine ground cable Loosen the hose bands and disconnect the bypass hose and water hose Disconnect the oil pressure switch connector Engine Ground Cable Bolt Oil Pressure Switch Oil...

Page 135: ...TING 500 Remove the bolts and rear parking brake caliper Remove the brake hose from clamps Disconnect the transmission case breather hose from transmission case Remove the bolts and air cleaner Bolts...

Page 136: ...CITING 500 Remove the rear cushion lower mount bolts Remove the engine mount nut Turn the engine mount bolt counterclockwise and loosen it Pull out the engine mount bolt then removes the engine from t...

Page 137: ...7 ENGINE REMOVAL INSTALLATION 7 8 XCITING 500 At removing the engine be careful not to catch your hand or finger between the engine hanger and crankcase...

Page 138: ...7 ENGINE REMOVAL INSTALLATION 7 9 XCITING 500 Remove the collar Collar...

Page 139: ...rake hoses and wires properly page 1 12 INSPECTION Inspect the bearing Bearings allow play in the right eft crankcase or the bearing turns roughly Replace Inspect the engine mount bolt Band Damage Rep...

Page 140: ...nger mount bolts and outer collars Remove the engine hanger and inner collars Remove the nut washers rubber washers and engine hanger rod INSTALLATION Installation is in the reverse order of removal T...

Page 141: ...REMOVAL INSTALLATION 7 12 XCITING 500 INSPECTION Inspect the bearing Bearings allow play in the engine hanger or the bearing turns roughly Replace Inspect the bush Wear Damage Replace Outer Inner Bear...

Page 142: ...________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES _______________________________________________________________...

Page 143: ...8 CYLINDER HEAD VALVES 8 1 XCITING 500 SCHEMATIC DRAWING...

Page 144: ...4905 37 11 1 4844 EX 37 0084 1 4803 36 86 1 4744 IN 10 0 4 10 015 0 4006 10 1 0 404 EX 10 0 4 10 015 0 4006 10 1 0 404 Valve rocker arm shaft IN 9 975 0 399 9 99 0 3996 9 9 0 396 O D EX 9 975 0 399 9...

Page 145: ...stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve...

Page 146: ...ith the starter motor until the gauge reading stops rising The maximum reading is usually reached 4 7 seconds Compression pressure 13 kg cm2 185 psi 1300 kPa Low compression can be caused by Blown cyl...

Page 147: ...ge 2 6 Remove the spark plug caps page 8 4 Disconnect the crankcase breather hose from the cylinder head cover page 7 3 Remove the four bolts and head cover Remove the cylinder head cover packing Remo...

Page 148: ...CAMSHAFT REMOVAL Remove the cylinder head cover page 8 5 Turn the crankshaft clockwise and align the T mark on the flywheel with the index mark on the right crankcase cover page 3 9 Remove the cam ch...

Page 149: ...nd remove the twelve camshaft holder bolts in a crisscross pattern in several steps then remove the camshaft holders Remove the camshafts Camshaft Holders Bolts Cam Chain Guide Bolts Camshafts Suspend...

Page 150: ...n guide for wear or damage Camshaft holder Inspect the bearing surface of each camshaft holder for scoring scratches or evidence of insufficient lubrication Check the stop pin spring on the exhaust ca...

Page 151: ...atches blue discoloration Measure the cam lobe height Service Limits IN 37 11 mm 1 4844 in EX 36 86 mm 1 4744 in If any defects are found replace the camshaft with a new one then inspect lubrication s...

Page 152: ...e rocker arms INSPECTION Rocker arm shaft Inspect the rocker arm shaft for blue discoloration or grooves If any defects are found replace the rocker arm shaft with a new one then inspect lubrication s...

Page 153: ...e then inspect lubrication system Measure each rocker arm shaft O D Measure the I D of each rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 1 mm 0 0...

Page 154: ...500 Remove the two bolts water joint gasket and water stop collar Remove the three bolts and cylinder head Remove the dowel pins and cylinder head gasket Water Joint Gasket Water Stop Collar Bolts Ga...

Page 155: ...spring seats oil seals and valves using a valve spring compressor Special tool Valve Spring Compressor E040 Be sure to compress the valve springs with a valve spring compressor Mark all disassembled...

Page 156: ...onding guide I D to obtain the stem to guide clearance Service limits IN 0 08 mm 0 0032 in EX 0 1 mm 0 004 in CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks Check the cyl...

Page 157: ...l Lubricate each valve with engine oil and insert the valves into the valve guides Install the valve springs with the small pitch portion 1 facing cylinder head 2 Large pitch portion Put on the valve...

Page 158: ...EAD INSTALLATION Install the dowel pins and new cylinder head gasket as shown Install the cylinder head Apply engine oil to the cylinder head bolt 9 threads Install the two cylinder bolts and cylinder...

Page 159: ...tighten the two bolts to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install gasket and pair reed valve Install and tighten the four bolts securely Install the new O rings onto the insulato...

Page 160: ...nd tighten the two bolts securely ROCKER ARM INSTALLATION Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms rocker arm shafts and washers Tighten the rocker arm shaft t...

Page 161: ...mshaft holder Apply molybdenum disulfide oil to the camshaft journals of the cylinder head Install the cam chain over the cam sprockets and then install the intake and exhaust camshafts Timing Marks P...

Page 162: ...tighten the holder bolts No 1 9 in a crisscross pattern in four steps to the specified torque as follow diagram Stop Pin Exhaust Camshaft Holder Tighten the bolts to the specified torque in sequence N...

Page 163: ...isscross pattern in four steps to the specified torque as follow diagram Tighten the two cylinder bolts to the specified torque Torque 10 N m 1 kgf m 7 lbf ft Tighten the bolts to the specified torque...

Page 164: ...r rod all the way in Install the tensioner with a new gasket onto the cylinder Install and tighten the tensioner bolts to specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Install the spring washer an...

Page 165: ...ll the cylinder head packing into the groove of the cylinder head cover Install the cylinder head cover onto the cylinder head and tighten the cylinder head cover bolts to the specified torque Torque...

Page 166: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 167: ...9 CYLINDER PISTON 9 1 XCITING 500 SCHEMATIC DRAWING...

Page 168: ...91 98 3 6793 91 9 3 676 Piston O D measuring position 10 mm from bottom of skirt Piston to cylinder clearance 0 01 0 0004 0 045 0 0018 0 1 0 004 Piston pin hole I D 22 002 0 8801 22 008 0 8803 22 04 0...

Page 169: ...he two cylinder bolts Remove the cylinder and gasket Remove the dowel pins Remove the piston pin clip Press the piston pin out of the piston and remove the piston Dowel Pins Dowel Pins Water Hose Bolt...

Page 170: ...thout catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Service Limits Top 0 08 mm 0 003 in 2nd 0 065 mm 0 0026...

Page 171: ...in Calculate the cylinder to piston clearance cylinder I D page 9 6 Measure the piston pin hole Take the maximum reading to determine the I D Service Limit 22 04 mm 0 8826 in Measure the piston pin O...

Page 172: ...and Y axis Take the maximum reading to determine the cylinder wear Service Limit 92 1 mm 3 684 in Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Refer to...

Page 173: ...ISTON INSTALLATION PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring...

Page 174: ...end and piston pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase Install the new...

Page 175: ...es Pass the cam chain through the cylinder and install the cylinder over the piston Install and tighten the two cylinder bolts to specified torque Torque 10 N m 1 kgf m 7 lbf ft Install the block pin...

Page 176: ..._______________________________________ __________________________________________________________________________________ _____________________________________________________________________________...

Page 177: ...10 DRIVE AND DRIVEN PULLEY 10 1 XCITING 500 SCHEMATIC DRAWING...

Page 178: ...elt width 28 9 1 156 27 9 1 116 Clutch lining thickness 4 0 16 1 0 04 Clutch outer I D 160 6 3 160 2 6 31 160 5 6 32 Drive pulley collar O D 28 96 1 158 28 974 1 159 28 9 1 156 Weight roller O D 29 98...

Page 179: ...E COVER REMOVAL Remove the left center body cover page 2 5 Remove the three bolts and the left front cover Remove the two bolts and left rear cover Remove the eight bolts and left crankcase cover Left...

Page 180: ...l pins and gasket DRIVESHAFT BEARING REPLACEMENT Remove the snap ring Heat the left crankcase cover around the driveshaft bearing with industrial dryer Remove the driveshaft bearing from the left cran...

Page 181: ...llation is in the reverse order of removal DRIVE PULLEY REMOVAL Remove the left crankcase cover page 10 3 Hold the drive pulley face with the special tool and loosen the drive pulley face nut Special...

Page 182: ...ter with the special tool as shown Special tool Universal holder E017 Remove the nut collar and clutch outer Remove the clutch driven pulley assembly and drive belt Remove the washer Universal Holder...

Page 183: ...G 500 Remove the movable drive face assembly while holding the back of the face ramp plate Remove the washer DISASSEMBLY Drive pulley Remove the ramp plate and slide pieces Movable Drive Face Drive Fa...

Page 184: ...he drive face boss from the movable drive face INSPECTION Movable Drive Face Check the drive face boss for wear or damage Measure the boss O D Service limit 28 9 mm 1 156 in Measure the face bushing I...

Page 185: ...or damage Measure the weight roller O D Service limit 29 5 mm 1 18 in Movable Drive Face Check the dust seal for wear or damage ASSEMBLY Clean any oil and grease from the pulley faces and weight rolle...

Page 186: ...to ramp plate Install the ramp plate to the movable drive face INSTALLATION Install the washer Thin Side Weight Rollers Washer Inner Indentation Side Slide Pieces Ramp Plate The direction of all weigh...

Page 187: ...e drive belt and clutch driven pulley assembly Hold the clutch outer with the special tool as shown Special tool Universal holder E017 Install the collar and nut Tighten the nut to the specified torqu...

Page 188: ...ply oil to the drive pulley face nut threads and seating surface and install the nut Hold the drive face with the special tool and tighten the bolt to the specified torque Special tool Universal holde...

Page 189: ...y face nut Special tool Universal holder E017 Remove the nut washer and drive pulley face Hold the clutch outer with the special tool as shown Special tool Universal holder E017 Remove the nut collar...

Page 190: ...Set the tool in a vise and remove the clutch drive plate nut Remove the spring compressor and disassemble the following Clutch assembly Driven face spring Driven pulley Remove the washer Remove the s...

Page 191: ...face Driven Face Bearing Replacement Remove the driven face needle bearing Remove the snap ring then remove the ball bearing Apply grease to new ball bearing Install the ball bearing into the driven...

Page 192: ...edle bearing Press the needle bearing into the driven INSPECTION Clutch Outer Check the clutch outer for wear or damage Measure the clutch outer I D Service limit 160 5 mm 6 32 in Clutch Shoe Lining C...

Page 193: ...in Driven Face Check the driven face for scratches scoring or damage Measure the driven face boss O D Service limit 47 94 mm 1 887 in Movable Driven Face Check the movable driven face for scratches s...

Page 194: ...drive belt width Service limit 27 9 mm 1 116 in Remove the clutch driven pulley then replace the drive belt if necessary ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face...

Page 195: ...ace spring Install the drive belt into the driven pulley Squeeze and hold the drive belt your hand Set the clutch spring compressor over the clutch driven pulley assembly and hold the spring compresso...

Page 196: ...nstall the drive pulley face and washer Apply oil to the drive pulley face nut threads and seating surface and install the nut Hold the drive face with the special tool and tighten the bolt to the spe...

Page 197: ...___________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL...

Page 198: ...11 FINAL REDUCTION 11 1 XCITING 500 SCHEMATIC DRAWING...

Page 199: ...nge 0 45 L 0 48 US qt 0 4 Imp qt TORQUE VALUES Transmission case cover bolt 27 N m 2 7 kgf m 20 lbf ft Oil drain bolt 24 N m 2 4 kgf m 18 lbf ft Oil filler bolt 24 N m 2 4 kgf m 18 lbf ft SPECIAL TOOL...

Page 200: ...26 Remove the right rear shock absorber page 15 10 Remove the rear fork page 15 4 Remove the rear wheel page 15 4 Drain the transmission gear oil into a clean container Remove the eight bolts and tra...

Page 201: ...1 4 XCITING 500 Remove the countershaft Remove the final gear Remove the driven pulley page 10 13 Press the driveshaft out or the left crankcase Check the drive shaft for wear or damage Final Gear Dri...

Page 202: ...g is left on the driveshaft remove it with the special tool Special tool Universal bearing puller E030 FINAL REDUCTION INSPECTION Check the driveshaft countershaft final gear and final gear shaft for...

Page 203: ...aft bearing using the special tool Special tool Bearing puller E037 Apply engine oil to new bearings cavities Drive new bearings into the transmission case Special tool Oil seal bearing driver E014 BE...

Page 204: ...ve the bearing snap ring Remove the final gear shaft bearing Remove the countershaft or drive shaft bearing using the special tool Special tool Bearing puller E037 Snap Ring Final Gear Shaft Bearing D...

Page 205: ...to the transmission cover Special tool Oil seal bearing driver E014 Apply engine oil to new final gear shaft bearing cavity Drive new bearing into the transmission cover Special tool Oil seal bearing...

Page 206: ...a new final gear shaft oil seal lip and outer surface Install the final gear shaft oil seal FINAL REDUCTION ASSEMBLY Install the final gear to the transmission case Install the countershaft to the tr...

Page 207: ...faces of the left crankcase and transmission cover Install the new gasket Install the transmission cover and tighten the eight bolts in a crisscross pattern in 2 3 steps to the specified torque Torque...

Page 208: ..._________________________________________________ __________________________________________________________________________________ ___________________________________________________________________...

Page 209: ...12 A C GENERATOR STARTER CLUTCH 12 1 XCITING 500 SCHEMATIC DRAWING...

Page 210: ...g the right crankcase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket Refer to section 17 for alternator inspect...

Page 211: ...INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Apply sealant to the grommet seating surface and install it to the cover gr...

Page 212: ...Hold the flywheel with the special tool and loosen the flywheel nut Special tool Flywheel holder E021 Remove the flywheel nut and washer Remove the flywheel starter driven gear assembly using the spe...

Page 213: ...n the driven gear clockwise smoothly but the gear should not turn counterclockwise Remove the starter driven gear by turning the driven gear Check the starter driven gear teeth for wear or damage Meas...

Page 214: ...r wear or damage Apply oil to the starter reduction gear Install the starter reduction gear to the right crankcase Apply molybdenum oil solution to the starter driven gear bushing Install the starter...

Page 215: ...Install the flywheel driven gear onto the crankshaft aligning the key way with woodruff key Apply oil to the washer and flywheel nut threads and seating surface Install the washer and flywheel nut to...

Page 216: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRA...

Page 217: ...13 CRANKCASE CRANKSHAFT 13 1 XCITING 500 SCHEMATIC DRAWING...

Page 218: ...nder head section 8 Cylinder piston section 9 Drive and driven pulley section 10 A C generator starter clutch section 12 Starter motor section 19 Oil pump section 4 SPECIFICATIONS Unit mm in Item Stan...

Page 219: ...r driven gear page 12 4 Remove the cylinder page 9 3 Remove the cam chain from the right crankcase Remove the bolts and cam chain guides INSPECTION Cam chain guide Inspect the cam chain slipper surfac...

Page 220: ...2 Remove the twelve bolts from left crankcase Remove the bolt from right crankcase Place the crankcase assembly with the left side down and separate the right crankcase from the left crankcase Bolt Bo...

Page 221: ...rings from the left crankcase Clean of the sealant from the left and right crankcase mating surfaces Remove the washer from the crankshaft Remove the balancer shaft from the left crankcase Remove the...

Page 222: ...Y Remove the two bolts outer washer oil pipe and inner washers RIGHT CRANKCASE ASSEMBLY Install the inner washers onto the right crankcase Install the oil pipe with the thick side face upward Inner Wa...

Page 223: ...color code green brown or yellow Record the right or left crankcase main journal I D code A or B If the crankcase and or crankshaft are replaced select them with the following fitting table The U mark...

Page 224: ...e the oil clearance by subtracting the journal O D from bearing I D Standard 0 025 0 041 mm 0 001 0 0016 in Service limit 0 07 mm 0 003 in Replace the crankcase if the service limit is exceeded Select...

Page 225: ...smoothly and quietly Also check that the bearing outer race fits tightly in the crankcase Replace the bearings if the races does not turn smoothly and quietly or if they fit loosely in the crankcase...

Page 226: ...ncer shaft bearing from the right crankcase Install the snap ring into the right crankcase Install the new bearings to the right and left crankcase using special tool Special tool Oil seal bearing dri...

Page 227: ...RANKCASE ASSEMBLY Install the crankshaft to the left crankcase Install the balancer shaft to align the punch mark with the O mark on the crankshaft Install the washer onto the crankshaft Crankshaft Le...

Page 228: ...mating surfaces except the oil passage area Install the right crankcase over the left crankcase Install and turn in the right crankcase bolt but do not tighten it Install and tighten the left crankca...

Page 229: ...AFT 13 13 XCITING 500 Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque Torque 20 N m 2 kgf m 15 lbf ft Install the cam chain to right crankcase Cam Cha...

Page 230: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

Page 231: ...14 STEERING HANDLEBAR FRONT WHEEL FRONT SHOCK ABSORBER 14 1 XCITING 500 SCHEMATIC DRAWING...

Page 232: ...rmation SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 6 0 06 Driver only 200 kPa 2 00 kgf cm2 29 psi Cold tire pressure Driver and passenger 225 kPa 2 25kgf cm2 32 p...

Page 233: ...es not track straight Deteriorated fork fluid Damaged or loose steering bearings Incorrect fork fluid weight Bent fork Low tire pressure Bent front axle wheel installed incorrectly Bent frame Hard sus...

Page 234: ...xle bolt Support the scooter securely using a hoist or equivalent and raise the front wheel off the ground Remove the right and left mount bolts and front brake calipers Pull off the front axle out an...

Page 235: ...blocks and measure the runout Actual runout is 1 2 the total indicator reading Service limit 0 20 mm 0 008 in Wheel Check the rim runout by placing the wheel in a truing stand Spin the wheel slowly a...

Page 236: ...inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub DIASSEMBLY Remove the right and left disc bolts...

Page 237: ...eel hub Remove the distance collar and drive out the other bearing Special tool Bearing remover E037 NOTE Replace the wheel bearings in pairs Do not reuse old bearings ASSEMBLY Pack a new bearing cavi...

Page 238: ...ng cavities with grease Drive the new right bearing squarely with the sealed side facing up until it is fully seated Special tool Oil seal bearing install driver E014 Apply grease to the new dust seal...

Page 239: ...late blots and tighten them to the specified torque Torque 10 N m 1 0 kgf m 7 lbf ft Install the brake discs into wheel hub Install new disc bolts and tighten them to the specified torque Torque 42 N...

Page 240: ...he axle bolt to the specified torque Torque 55 N m 5 5 kgf m 40 lbf ft Tighten the front axle holder to the specified torque Torque 23 N m 2 3 kgf m 17 lbf ft Install the right and left front calipers...

Page 241: ...d pump the fork up and down several times to seat the axle and check brake operation Check the brake operation by applying the brake lever Measure the speed sensor to speed sensor guide clearance Stan...

Page 242: ...er fork pinch bolt Remove the lower fork pinch bolts Remove the fork from the handlebar post and steering stem INSTALLATION Install the fork tube into steering stem and handlebar post and align the ma...

Page 243: ...kgf m 17 lbf ft Install the brake caliper onto the fork leg with new mount bolts Torque 32 N m 3 2 kgf m 23 lbf ft Install the brake hose clamp onto the fork leg with the bolt Install the speed sensor...

Page 244: ...bolt and disconnect the left handlebar switch connector Remove the two screws and lower handlebar cover Remove the bolts master cylinder holders and rear master cylinders Disconnect the left brake li...

Page 245: ...he bolts master cylinder holders and front master cylinders NOTE Keep the master cylinder upright to prevent air from entering the hydraulic system Remove the screws and right handlebar switch housing...

Page 246: ...ABSORBER 14 16 XCITING 500 Remove the bolts and upper holders Remove the handlebar from the handlebar post and right handlebar switch housing INSTALLATION Pass the handlebar through the right handleb...

Page 247: ...dlebar to the handle post Install the upper holders with its punch marks facing toward Install the upper holder bolts Tighten the front bolts first then tighten the rear bolts Torque 23 N m 2 3 kgf m...

Page 248: ...d tighten the forward screw first then tighten the rear screw Align the pin on the rear master cylinder holder with the hole on the handlebar Install the front master cylinders and holder with the UP...

Page 249: ...ylinders and holder with the UP mark facing up Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Connect the brake...

Page 250: ...STEM REMOVAL Remove the front fork page 14 12 Remove the steering handle page 14 14 Remove the bolts and brake hoses clamp Remove the nut washer and handle post Special tool Long socket wrench E015 Re...

Page 251: ...OCK ABSORBER 14 21 XCITING 500 Remove the steering stem lock nut Special tool Long socket wrench F007 Remove the lock washer Loosen the steering top thread Hold the steering stem and remove the steeri...

Page 252: ...emove the steering stem and lower bearing Remove the dust seal upper inner race and upper bearing BEARING REPLACEMENT Remove the upper bearing outer race NOTE Always replace the bearings and races as...

Page 253: ...SHOCK ABSORBER 14 23 XCITING 500 Remove the lower bearing outer race Drive a new upper bearing race into the steering head pipe Drive a new lower bearing race into the steering head pipe Lower Outer...

Page 254: ...ing stem Remove the lower bearing inner race with a chisel or equivalent tool being careful not to damage the steering stem Remove the dust seal Install the dust seal Apply grease to a new lower beari...

Page 255: ...en it to the specified torque Torque 17 N m 1 7 kgf m 12 lbf ft Turn the steering stem lock to lock several times to seat the bearings Temporarily loosen the steering stem top thread Install the fork...

Page 256: ...Long socket wrench F007 Torque 45 N m 4 5 kgf m 32 lbf ft Make sure that the steering stem moves smoothly without play or binding Install the handle post to the steering stem and front forks Install t...

Page 257: ...___________________________________________________ __________________________________________________________________________________ _________________________________________________________________...

Page 258: ...15 REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 XCITING 500 SCHEMATIC DRAWING...

Page 259: ...s for all suspension pivots and mounting points Refer to section 16 for brake system information SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Rider only Cold...

Page 260: ...tire pressure Engine mount bolt not tightened properly Loose or worn final gear shaft bearing Rear suspension noisy Insufficient tire pressure Loose mounting fasteners Unbalanced tire and wheel Fault...

Page 261: ...ing brake caliper page 16 26 Loosen the rear axle nut Support the scooter securely on its main stand Remove the bolts and brake hose cable clamps from the rear fork Remove the rear shock absorber lowe...

Page 262: ...G 500 Remove the inner side collar Remove the rear wheel INSTECTION Wheel Check the wheel rim runout using dial indicator Actual urnout is 1 2 the total indicator reading Service Limits Radial 2 0mm 0...

Page 263: ...R 15 6 XCITING 500 DISASSEMBLY Wheel Remove the brake disc bolts and rear brake disc REAR FORK BEARING REPLACEMENT Remove the outer side collar from the rear fork Remove the dust seal from the rear fo...

Page 264: ...race fits tightly in the rear fork Remove and discard the bearing if the race does not turn smoothly and quietly or if it fits loosely in the rear fork Remove the bearing from the rear fork Drive in...

Page 265: ...new dust seal lip and install it to the rear fork Check the bushing for wear or damage ASSEMBLY Wheel Install the brake disc onto the wheel hub Install the new brake disc bolts and tighten them to th...

Page 266: ...the rear wheel onto the final gear shaft aligning the spline Install the inner side collar Apply grease to the final gear shaft Install the rear fork and tighten the bolts to the specified torque Tor...

Page 267: ...securely Release the main stand and support the scooter securely on its side stand Tighten the rear axle nut to the specified torque Torque 180 N m 18 kgf m 130 lbf ft Install the rear parking brake c...

Page 268: ...ION Check the damper unit for leakage or other damage Check the upper joint bushing for wear or damage Replace the shock absorber assembly if necessary INSTALLATION Install the rear shock absorber tig...

Page 269: ...15 REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 12 XCITING 500 Install and tighten the lower mount bolt to the specified torque Torque 40 N m 4 kgf m 29 lbf ft Lower Mount Bolt...

Page 270: ...______________________________________________ __________________________________________________________________________________ BRAKESYSTEM __________________________________________________________...

Page 271: ...16 BRAKE SYSTEM 16 1 XCITING 500 SCHEMATIC DRAWING...

Page 272: ...draulic system has been opened or if the brake feel spongy the system must be bled Always use fresh DOT 4 brake fluid from a sealed container when servicing the system Do not mix different types of fl...

Page 273: ...lbf ft Delay valve bleed screw 6 N m 0 6 kgf m 4 3 lbf ft TROUBLESHOOTING Brake lever soft or spongy Brake lever hard Air in the hydraulic system Clogged restricted brake system Low brake fluid level...

Page 274: ...Front brake Place the scooter on a level surface and keep the handlebar straight Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reserv...

Page 275: ...isconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window Tighten the bleed screw to the specified torque Torque 6 N m 0 6 kgf m 4 3 lbf ft Combination...

Page 276: ...o a receptacle Loosen the air bleed screw and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleed screw and disconnect the clear hose Fill the rese...

Page 277: ...tightly to the left front caliper air bleed screw 4 Place the other end of the hose into a container 5 Slowly apply the brake lever several times 6 Pull the lever in and hold it 7 Loosen the bleed scr...

Page 278: ...nner as that of the front brake one Bleed the air from the rear side rear caliper and then the front side right front caliper and delay valve Tighten the bleed screw Torque 6 N m 0 6 kgf m 4 3 lbf ft...

Page 279: ...rake fluid to the proper level Install the master cylinder reservoir cap and diaphragm Check the operation of the brake after bleeding the brake system Right Front Caliper Air Bleed Screw Clear Hose C...

Page 280: ...move the pad pin and the brake pads Make sure that the pad spring is installed in original position Install new pads so that the their ends rest on the pad retainer on the bracket properly Install the...

Page 281: ...orque Torque 3 N m 0 3 kgf m 2 2 lbf ft Rear Parking brake Remove the pad pin plug and loosen the pad pin Remove the mount bolts and rear parking brake caliper from the rear fork Remove the pad pin an...

Page 282: ...pad spring to align the pad pin holes in the pads and caliper Install the rear parking brake caliper to the rear fork Install and tighten the new rear parking brake caliper mounting blots to the spec...

Page 283: ...e Torque 3 N m 0 3 kgf m 2 2 lbf ft BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness Service limits Front 4mm 0 16 in Rear 4mm 0 16 in Replac...

Page 284: ...from leaking out Remove the upper handlebar cover page 2 5 Drain the front brake hydraulic system page 16 4 Remove the two screws and lower handlebar cover Disconnect the brake light connectors from...

Page 285: ...master cylinder holder and remove the master cylinder assembly DISASSEMBLY Remove the brake lever pivot bolt and nut Remove the brake lever Remove the screw and brake light switch Holder Master Cylind...

Page 286: ...brake lever Apply silicone grease to the brake lever pivot bolt sliding surface Install and tighten the pivot bolt to the specified torque Torque 6 N m 0 6 kgf m 4 3 lbf ft Install and tighten the piv...

Page 287: ...12 N m 1 2 kgf m 9 lbf ft Rest the brake hose eyelet against the stopper Install the brake hose eyelet with the oil bolt and new sealing washers Tighten the oil bolt to the specified torque Torque 35...

Page 288: ...m leaking out Remove the upper handlebar cover page 2 5 Drain the combination brake hydraulic system page 16 5 Remove the two screws and lower handlebar cover Disconnect the brake light switch connect...

Page 289: ...master cylinder holder and remove the master cylinder assembly DISASSEMBLY Remove the brake lever pivot bolt and nut Remove the brake lever Remove the screw and brake light switch Bolt Holder Master C...

Page 290: ...brake lever Apply silicone grease to the brake lever pivot bolt sliding surface Install and tighten the pivot bolt to the specified torque Torque 6 N m 0 6 kgf m 4 3 lbf ft Install and tighten the piv...

Page 291: ...1 2 kgf m 9 lbf ft Rest the brake hose eyelet against the stopper Install the brake hose eyelet with the oil bolt and new sealing washers Tighten the oil bolt to the specified torque Torque 35 N m 3 5...

Page 292: ...contamination Secure the hose to prevent fluid from leaking out Remove the front cover page 2 11 Drain the combination brake hydraulic system page 16 5 Remove the brake hose oil bolt sealing washers...

Page 293: ...lets and new sealing washers Tighten the brake hose bolt to the specified torque while rest the brake hose eyelet against the stopper on the delay valve Torque 35 N m 3 5 kgf m 25 lbf ft Fill the rese...

Page 294: ...caliper page 16 5 Remove the brake pads page 16 10 Remove the oil bolts sealing washers and brake hose from the brake caliper Remove the mount bolts and front brake caliper DISASSEMBLY Remove pad spri...

Page 295: ...aliper Install the pad spring into the caliper body as shown INSTALLATION Install the front caliper onto the fork leg Install and tighten the new front caliper mount bolts to the specified torque Torq...

Page 296: ...ake pads page 16 10 Fill and bleed the hydraulic system page 16 7 or page 16 8 REAR PARKING BRAKE CALIPER REMOVAL Remove the muffler page 2 15 Drain the rear brake hydraulic system page 16 5 Disconnec...

Page 297: ...caliper bracket from the caliper body ASSEMBLY REAR BRAKE Apply silicone grease to the boot inside Apply silicone grease to the boot inside Install the caliper bracket to the caliper Rear Parking Brak...

Page 298: ...TING 500 Install the pad spring into the caliper body as shown DISASSEMBLY PARKING BRAKE Remove the lock nut and parking brake arm Remove the parking brake shaft and push rod Pad Spring Brake Shaft Pu...

Page 299: ...t ASSEMBLY PARKING BRAKE Install the gasket Install the parking brake bracket and tighten the bolts to the specified torque Torque 32 N m 3 2 kgf m 23 lbf ft Apply silicone grease to the parking brake...

Page 300: ...s to specified torque Torque 32 N m 3 2 kgf m 23 lbf ft Install the brake hose eyelet to the caliper body with new sealing washers and oil bolts Push the brake hose eyelet to the stopper on the calipe...

Page 301: ...page 3 21 PARKING BRAKE LEVER LINK REMOVAL Remove the inner cover page 2 14 Loosen the lock nut and disconnect the parking brake cable from the parking braking brake lever link Disconnect the parking...

Page 302: ...parking brake lever link DISASSEMBLY Remove the two screws and parking brake switch ASSEMBLY Assembly is in the reverse order of disassembly INSTALLATION Installation is in the reverse order of remova...

Page 303: ...______________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHA...

Page 304: ...17 BATTERY CHARGING SYSTEM 17 1 XCITING 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT...

Page 305: ...cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level goes down quickly Before troubleshoot...

Page 306: ...e seals again For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery SPECIFICATIONS ITE...

Page 307: ...stall the battery Check the battery current leakage Specified current leakage 0 5 Ma max Check the alternator charging coil Standard 0 1 0 5 20 C 68 F Measure and record the battery voltage using a di...

Page 308: ...t then disconnect the positive terminal lead Pull out the battery from the battery box Installation is in the reverse order of removal After connecting the battery cables coat the terminals with greas...

Page 309: ...EAKAGE TEST Turn the ignition switch OFF disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe to the battery terminal With the ignition...

Page 310: ...terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000 min 1 rpm Standard Measured battery...

Page 311: ...fication or if any wire has continuity to ground Refer to section 12 for alternator stator replacement REGULATOR RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box page 2 3 Disconnect the regula...

Page 312: ...inuity at all times Charging coil line Measure the resistance between each Yellow wire terminals Standard 0 1 0 5 20 C 68 F Check for continuity between each Yellow wire terminal and ground There shou...

Page 313: ...500 REMOVAL INSTALLATION Remove the side body cover page 2 8 Disconnect the regulator rectifier connectors Remove the two bolts regulator rectifier and stay Installation is in the reverse order of rem...

Page 314: ...___________________________________________ __________________________________________________________________________________ _________________________________________________________________________...

Page 315: ...18 IGNITION SYSTEM 18 1 XCITING 500 IGNITION SYSTEM LAYOUT IGNITION CIRCUIT...

Page 316: ...weak battery results in a slower engine cranking speed as well as no spark at the spark plug Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the eng...

Page 317: ...18 IGNITION SYSTEM 18 3 XCITING 500 PEAK VOLTAGE IS NORMAL BUT NO SPARK JUMPS AT THE PLUG Faulty spark plug or leaking ignition coil secondary current Faulty ignition coil...

Page 318: ...plug Connect known good spark plug to the spark plug cap and ground the spark plugs to the cylinder as done in the spark test Turn the ignition switch to ON and engine stop switch ON Connect the multi...

Page 319: ...Remove the floorboard page 2 6 Disconnect the spark plug cap from the spark plug page 18 4 Disconnect the ignition coil primary connectors Remove the two nuts and the ignition coil Installation is in...

Page 320: ...96M 14 88M 15 02M 14 74M 3 35M 14 7M G B G 44 3K 44 9K 6 62M 6 63M 3 54K 103 9K 12 51M 3 54K V R 47 5K 48 4K 6 62M 6 63M 3 53K 100 2K 3 54K 12 51M 1 99K V B 148 5K 149 4K 6 75M 6 76M 102 8K 99 3K 102...

Page 321: ...__________________________________________________ __________________________________________________________________________________ __________________________________________________________________...

Page 322: ...19 ELECTRIC STARTER 19 1 XCITING 500 STARTING SYSTEM LAYOUT STARTING CIRCUIT...

Page 323: ...is not cranking over the starter motor may be damaged See section 12 for starter clutch servicing See section 20 for following components Ignition switch Starter switch Brake light switch TROUBLESHOO...

Page 324: ...age Abnormal Starter motor does not turn Normal Abnormal Normal Check for loose or poorly connected starter relay switch terminals Abnormal Check for loose or poorly connected or broken starter motor...

Page 325: ...ty starter switch Loose or poor contact of connector Open circuit in wire harness Faulty starter relay Loose or poor starter relay connector contact Battery voltage registers No voltage Check the star...

Page 326: ...rter motor cable directly to the battery positive terminal If the starter motor does not turn the starter motor is faulty REMOVAL Remove the carburetor page 5 5 Turn the ignition switch turned to OFF...

Page 327: ...oil and install it into the starter motor groove Install the starter motor into the crankcase Install the two bolts and tighten them securely Connect the starter motor cable to motor terminal with the...

Page 328: ...the procedure below GROUND LINE INSPECTION Disconnect the starter relay switch connector Check for continuity between the Green wire terminal and ground There should be continuity VOLTAGE INSPECTION...

Page 329: ...cables Connect a fully charged 12 V battery positive wire to the relay switch Yellow Red wire terminal and negative wire to the Green wire terminal There should be continuity between the cable termin...

Page 330: ..._____________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES ________________________________________________________...

Page 331: ...an it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that requ...

Page 332: ...over properly on to the headlight and connect the headlight connector POSITION LIGHT Remove the front cover page 2 11 Remove the bulb socket and position light bulb Remove the bulb and replace with a...

Page 333: ...erclockwise to remove it Remove the bulb and replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL Remove the six screws and lens Taillight Brak...

Page 334: ...the reverse order of removal Rear turn signal Remove the screw and bulb cap Remove the bulb and replace with a new one Installation is in the reverse order of removal LICENSE LIGHT Remove two screws D...

Page 335: ...l SPEED SENSOR REMOVAL INSTALLATION Remove the front cover page 2 11 Disconnect the speed sensor connector Remove the bolt and speed sensor Installation is in the reverse order of removal INSPECTION M...

Page 336: ...TING 500 ADJUSTMENT Remove the bolt and speed sensor Remove the speed sensor cap Loosen the lock screws and adjust speed sensor to the standard clearance Standard 0 3 1 2 mm 0 0012 0 048 in Cap Lock S...

Page 337: ...continuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front cover page 2 11 Disc...

Page 338: ...e front cover page 2 11 Right handlebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color cod...

Page 339: ...ar switch Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Turn Signal Switch...

Page 340: ...2 3 Disconnect the luggage box light switch connector and check for continuity between the switch terminals There should be no continuity with the luggage box light switch pushed and there should be c...

Page 341: ...on switch is ON If the light does not comes on check the fuse and wires for a loose connection or an open circuit Start the engine and make sure that the light goes out If the light does not go out ch...

Page 342: ...ressure switch threads as shown Install the oil pressure switch onto the crankcase tighten it to the specified torque Torque 22 N m 2 2 kgf m 16 lbf ft Connect the oil pressure switch terminal to the...

Page 343: ...UNIT REMOVAL Remove the floorboard page 2 6 Disconnect the fuel unit connector Turn the fuel unit retainer counterclockwise and remove it Remove the fuel unit Retainer Fuel Unit Be careful not to bend...

Page 344: ...er Less Empty Wire Terminals Display Free From Much to Less Apply From Less to Much The fuel meter is normal if it operates as above indicated If not check for poorly connected terminals or shorted wi...

Page 345: ...w Green and Green with the side stand retracted There should be continuity between the Yellow Black and Green with the side stand applied REMOVAL Remove the left floor skirt page 2 5 Disconnect the si...

Page 346: ...e front cover page 2 11 Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is connected across the horn ter...

Page 347: ...minals of the bank angle sensor connector with the connector connected TERMINAL STANDARD Black Blue Battery voltage Black White Battery voltage 0 1 V The engine should stop as you incline the bank ang...

Page 348: ...after keeping the temperature under 10 4 3 Check if the yellow wire of heater controller unit has output voltage Start engine and if the temperature of heater controller unit is under 10 4 Check if t...

Page 349: ...21 WIRING DIAGRAMS 21 0 XCITING 500 21 21...

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KYMCO XCITING 500, Service Manual

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