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7. ENGINE REMOVAL/INSTALLATION

7-1

XCITING 500

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 6)

Cylinder head (Section 8)

Cylinder/Piston (Section 9)

Drive and driven pulleys/clutch (Section 10)

Final reduction (Section 11)

Alternator/Starter 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 draining

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 cartridge change

2.1 liter (2.2 US qt, 1.9 lmp qt)

TORQURE VALUES

Engine mounting bolt

80 N•m (8 kgf•m, 58 lbf•ft)

Engine mounting nut

80 N•m (8 kgf•m, 58 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)

Содержание XCITING 500

Страница 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...

Страница 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...

Страница 3: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL I...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 36: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 78: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBR...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 90: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYST...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 129: ..._____________________________________________________________________________ __________________________________________________________________________________ _______________________________________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 166: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 176: ..._______________________________________ __________________________________________________________________________________ _____________________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 197: ...___________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 208: ..._________________________________________________ __________________________________________________________________________________ ___________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 216: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRA...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 230: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 257: ...___________________________________________________ __________________________________________________________________________________ _________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 270: ...______________________________________________ __________________________________________________________________________________ BRAKESYSTEM __________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 303: ...______________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHA...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 314: ...___________________________________________ __________________________________________________________________________________ _________________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 321: ...__________________________________________________ __________________________________________________________________________________ __________________________________________________________________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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