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Table of Contents
XCITING 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-LBA2-S00

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Table of Contents

   Summary of Contents for KYMCO XCITING 500

  • Page 1 XCITING 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-LBA2-S00...
  • Page 2: Table Of Contents

    The information and contents included in this manual may be different from the motorcycle in case specifications are changed. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation. KWANG YANG MOTOR CO., LTD.
  • Page 3: General Information

    . GENERAL INFORMATION XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER------------------------------------------------------------ 1-1 SPECIFICATIONS ------------------------------------------------------------ 1-2 SERVICE PRECAUTIONS -------------------------------------------------- 1-3 TORQUE VALUES ----------------------------------------------------------- 1-7 SPECIAL TOOLS ------------------------------------------------------------- 1-9 LUBRICATION POINTS --------------------------------------------------- 1-10 CABLE & HARNESS ROUTING-------------------------------------------- 1-12...
  • Page 4: Serial Number

    . GENERAL INFORMATION XCITING 500 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...
  • Page 5: Specifications

    . GENERAL INFORMATION XCITING 500 SPECIFICATIONS ITEM SPECIFICATIONS ITEM SPECIFICATIONS Name XCITING 500 Air cleaner type & No Wet paper type element Overall length 2250 mm (90 in) Fuel capacity 12.8 L (3.38 lmp gal, Overall width (mm) 815 mm (33 in) 2.82 US gal...
  • Page 6: Service Precautions

    . GENERAL INFORMATION XCITING 500 Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. After reassembly, check all parts for proper tightening and operation.
  • Page 7 . GENERAL INFORMATION XCITING 500 If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.
  • Page 8 . GENERAL INFORMATION XCITING 500 After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight! Do not squeeze wires against the weld or its clamp.
  • Page 9 . GENERAL INFORMATION XCITING 500 After routing, check that the wire harnesses are not twisted or kinked. Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the Wire harnesses routed along with specified points.
  • Page 10: Torque Values

    . GENERAL INFORMATION XCITING 500 TORQUE VALUES STANDARD TORQUE VALUES Torque Torque Item Item N•m (kgf•m, lbf•ft) N•m (kgf•m, lbf•ft) 5mm bolt and nut 5(0.5, 4) 4mm screw 3 (0.3, 2) 6mm bolt and nut 10 (1, 7) 4 (0.4, 3)
  • Page 11 . GENERAL INFORMATION XCITING 500 ENGINE (Cont’d) Thread dia. Torque Item Q‘ty Remarks (mm) N•m (kgf•m, lbf•ft) Drive plate nut 78 (7.8, 56) ALTERNATOR ACG flywheel nut 55 (5.5, 40) FINAL REDUCTION: Transmission cover bolt 27 (2.7, 20) CRANKCASE: Crankcase bolt 12 (1.2, 9)
  • Page 12: Special Tools

    . GENERAL INFORMATION XCITING 500 FRAME (Cont’d) Torque N•m (kgf•m, Item Q‘ty Thread dia.(mm) Remarks lbf•ft) ENGINE HANGER: Engine hanger bolt 50 (5, 36) Engine mounting bolt 80 (8, 58) Engine mounting nut 80 (8, 58) Engine hanger rod nut 35 (3.5, 25)
  • Page 13: Lubrication Points

    . GENERAL INFORMATION XCITING 500 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE 5W-50) Valve guide/valve stem movable part •API SJ Engine Oil Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut...
  • Page 14 . GENERAL INFORMATION XCITING 500 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts 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.
  • Page 15: Cable & Harness Routing

    . GENERAL INFORMATION XCITING 500 CABLE & HARNESS ROUTING 1-12...
  • Page 16 . GENERAL INFORMATION XCITING 500 1-13...
  • Page 17 . GENERAL INFORMATION XCITING 500 1-14...
  • Page 18 . GENERAL INFORMATION XCITING 500 1-15...
  • Page 19 . GENERAL INFORMATION XCITING 500 1-16...
  • Page 20 . GENERAL INFORMATION XCITING 500 1-17...
  • Page 21 . GENERAL INFORMATION XCITING 500 1-18...
  • Page 22 . GENERAL INFORMATION XCITING 500 1-19...
  • Page 23 . GENERAL INFORMATION XCITING 500 1-20...
  • Page 24 . GENERAL INFORMATION XCITING 500 1-21...
  • Page 25: Troubleshooting

    . GENERAL INFORMATION XCITING 500 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged carburetor fuel inlet tube, vacuum tube or fuel tube...
  • Page 26 . GENERAL INFORMATION XCITING 500 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel line between fuel tank and carburetor Engine speed does Engine speed Clogged exhaust muffler...
  • Page 27 . GENERAL INFORMATION XCITING 500 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too rich (turn screw...
  • Page 28 . GENERAL INFORMATION XCITING 500 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Correct timing Incorrect timing Faulty A.C. generator Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...
  • Page 29 . GENERAL INFORMATION XCITING 500 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Worn piston pin and connecting rod small Piston noise Excessive carbon build-up in combustion chamber Damaged cam chain tensioner...
  • Page 30 . GENERAL INFORMATION XCITING 500 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Engine starts but motor- Separated clutch lining cycle does not move Damaged driven pulley shaft splines...
  • Page 31 . GENERAL INFORMATION XCITING 500 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight does not Faulty stop switch Stoplight comes on...
  • Page 32 . GENERAL INFORMATION XCITING 500 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness...
  • Page 33 . GENERAL INFORMATION XCITING 500 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Faulty AC generator Voltage does not Normal voltage Faulty regulator/rectifier increase Faulty battery Measure resistance...
  • Page 34 . GENERAL INFORMATION XCITING 500 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate...
  • Page 35 . GENERAL INFORMATION XCITING 500 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play Front or rear wheel is...
  • Page 36: Frame Covers /exhaust Muffler

    . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS/EXHAUST MUFFLER __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 2- 1 SERVICE INFORMATION------------------------------------------------ 2- 2 TROUBLESHOOTING----------------------------------------------------- 2- 2 FRAME COVERS REMOVAL ------------------------------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-15...
  • Page 37: Schematic Drawing

    . EXHAUST MUFFLER/FRAME COVERS XCITING 500 SCHEMATIC DRAWING...
  • Page 38: Service Information

    . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.
  • Page 39: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS XCITING 500 Damper Unit Nuts FRAME COVERS REMOVAL SEAT REMOVAL Unlock the seat with the ignition key. Open the seat. Remove the two nuts and seat damper unit. Remove the two nuts and the seat. INSTALLATION Installation is in the reverse order of the removal.
  • Page 40 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Bolt SPARK PLUG MAINTENANCE LID REMOVAL Remove the bolt and lid. INSTALLATION Installation is in the reverse order of removal. Spark Plug Maintenance Lid Rubber Cap REAR SPOILER REMOVAL Unlock the seat with the ignition key.
  • Page 41 . EXHAUST MUFFLER/FRAME COVERS XCITING 500 UPPER HANDLEBAR COVER REMOVAL Remove four screws and upper handlebar cover. INSTALLATION Installation is in the reverse order of removal. Screws Bolts RIGHT/LEFT CENTER BODY COVER REMOVAL Remove the two bolts and right/left center body cover.
  • Page 42 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Screws Remove the seven screws. Screws Remove two screws. Remove the floor skirt. * Be careful not to damage the tabs on the floor skirt. INSTALLATION Installation is in the reverse order of removal.
  • Page 43 . EXHAUST MUFFLER/FRAME COVERS XCITING 500 LICENCE LIGHT REMOVAL Remove two screws. Disconnect the license light connector and remove the license light. INSTALLATION Installation is in the reverse order of removal. Screws Connector REAR FENDER REMOVAL Remove the licence light (page 2-7).
  • Page 44 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 RIGHT/LEFT SIDE BODY COVER REMOVAL Remove the luggage box (page 2-3). Remove the floorboard (page 2-6). Remove the rear spoiler (page 2-4). Remove two bolts. Bolts Raise the side body cover, disconnect the taillight/rear turn signal light connector and remove the side body cover.
  • Page 45 . EXHAUST MUFFLER/FRAME COVERS XCITING 500 Screws TAILIGHT/REAR TURN SIGNAL LIGHT REMOVAL Remove the side and rear body cover (page 2- Remove eight screw and taillight/rear turn signal light. INSTALLATION Installation is in the reverse order of removal. Screws REAR LOWER COVER REMOVAL Remove the side body cover (page 2-8).
  • Page 46 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Rearview Mirror Holder Remove the two bolts, rearview mirror holder and seat. INSTALLATION Installation is in the reverse order of removal Bolts Holder Seat Screws WINDSHIELD REMOVAL Remove four screws and windshield garnish.
  • Page 47 . EXHAUST MUFFLER/FRAME COVERS XCITING 500 Screws FRONT COVER REMOVAL Remove the rearview mirrors (page 2-9). Remove six screws. Screws Remove two screws. Turn Signal Light Connectors Remove one screw. Disconnect headlight and turn signal light connectors. INSTALLATION Installation is in the reverse order of removal.
  • Page 48 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Screws HEADLIGHT REMOVAL Remove the front cover (page 2-11). Remove six screws and headlight. INSTALLATION Installation is in the reverse order of removal. TURN SIGNAL LIGHT REMOVAL Remove the front cover (page 2-11).
  • Page 49 . EXHAUST MUFFLER/FRAME COVERS XCITING 500 Remove two screws and front meter visor. INSTALLATION Installation is in the reverse order of removal. Screw MEER PANEL REMOVAL Remove the front cover (page 2-11). Remove the front meter visor (page 2-12). Remove four screws.
  • Page 50 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Screws METER REMOVAL Remove the meter panel (page 2-13). Remove two screws and meter. Shutter INNER COVER REMOVAL Remove the front cover (page 2-11). Remove the floorboard (page 2-6). Remove the meter panel (page 2-13).
  • Page 51: Exhaust Muffler

    . EXHAUST MUFFLER/FRAME COVERS XCITING 500 Remove four fasteners. Remove the inner cover. INSTALLATION Installation is in the reverse order of removal. Fasteners FRONT LOWER COVER REMOVAL Remove the front cover (page 2-11). Remove the right and left floor skirt (page 2- Remove two bolts and front lower cover.
  • Page 52 . FRAME COVERS/ EXHAUST MUFFLER XCITING 500 Loosen the exhaust pipe band bolt. Remove three muffler mount bolts and muffler from the exhaust pipe. Band Bolt Mount bolts Remove the exhaust pipe joint nuts and exhaust pipe. Joint Nuts Remove the gaskets.
  • Page 53: Inspection/adjustment

    . INSPECTION/ADJUSTMENT XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ 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...
  • Page 54: Inspection/adjustment

    At draining/oil filter change 2.1 liter (2.2 US pt, 1.9 lmp qt) Total amount 2.5 liter (2.6 US pt, 2.3 lmp qt) KYMCO 4-stroke oil or equivalent motor oil API service classification: SJ Recommended engine oil Viscosity: 5W50 Engine idle speed 1400±100 rpm...
  • Page 55 . INSPECTION/ADJUSTMENT XCITING 500 TORQURE VALUES Engine oil drain plug 25 N•m (2.5 kgf•m, 18 lbf•ft) Oil strainer screen cap 15 N•m (1.5 kgf•m, 11 lbf•ft) Apply oil to the threads and seating surface. Oil filter cartridge 10 N•m (1 kgf•m, 7 lbf•ft) Apply oil to the threads and seating surface.
  • Page 56: Maintenance Schedule

    . INSPECTION/ADJUSTMENT XCITING 500 MAINTENANCE SCHEDULE Perform 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, LUBRICATE OR REPLACE IF NECESSARY...
  • Page 57 . INSPECTION/ADJUSTMENT XCITING 500 NOTE: 1 At higher odometer readings, repeat at the frequency interval established here. 2 Service more frequently if the scooter is ridden in unusually wet or dusty areas. 3 Service more frequently when riding in rain or at full throttle.
  • Page 58: Fuel Line

    . INSPECTION/ADJUSTMENT XCITING 500 Fuel Lines FUEL LINE Remove the floorboard. ( page 2-6 ). Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. * • Do not smoke or allow flames or sparks in your working area.
  • Page 59: Air Cleaner

    . INSPECTION/ADJUSTMENT XCITING 500 Adjust Nut Major adjustments are made with the lower adjuster. Remove the seat luggage box (page 2-3). Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely.
  • Page 60: Crankcase Breather

    Remove the air cleaner element by pull it out. Discard the air cleaner element. Install a new air cleaner element. Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong. KYMCO air...
  • Page 61 . INSPECTION/ADJUSTMENT XCITING 500 Remove the spark plug using a equipped spark plug wrench or an equivalent tool. Inspect or replace as described in the maintenance schedule. Spark Plug Cap INSPECTION Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine.
  • Page 62: Valve Clearance

    . INSPECTION/ADJUSTMENT XCITING 500 Timing Hole Cap/ring VALVE CLEARANCE * Inspect and adjust the valve clearance while the engine is cold (Below 35°C/95°F). Remove the floorboard (page 2-6). Remove the cylinder head cover (page 8-5). Remove the timing hole cap and O-ring.
  • Page 63: Engine Oil

    . INSPECTION/ADJUSTMENT XCITING 500 Lock Nut Thickness Gauge Adjust by loosening the valve adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge. Valve clearance (when cold): IN.: 0.1 mm (0.004 in) EX.: 0.1 mm (0.004 in)
  • Page 64 . INSPECTION/ADJUSTMENT XCITING 500 Recommended engine oil: KYMCO 4-stroke oil or equivalent motor oil API service classification: SJ Viscosity: SAE 5W50 * Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.
  • Page 65 . INSPECTION/ADJUSTMENT XCITING 500 Strainer Screen Place a drain pan under the crankcase and remove the oil strainer cap. The setting spring and oil strainer screen will come out when the oil strainer cap is removed. Setting Spring O-ring Strainer Cap Oil Strainer Screen Clean the oil strainer screen.
  • Page 66: Engine Oil Filter Cartridge

    . INSPECTION/ADJUSTMENT XCITING 500 Fill the crankcase with the recommended engine oil. Oil capacity: 2.0 liter (2.1 US qt, 1.8 lmp qt) at draining 2.1 liter (2.2 US qt, 1.9 lmp qt) at oil filter cartridge change Install the oil filler cap/dipstick (1).
  • Page 67: Engine Idle Speed

    . INSPECTION/ADJUSTMENT XCITING 500 Apply clean engine oil to the new oil filter O-ring cartridge threads, flange surface and a new O- ring. Install the new oil filter cartridge and tighten it to the specified torque. Tool: Oil filter cartridge wrench E052 Torque: 10N•m (1 kgf•m, 7 lbf•ft)
  • Page 68: Radiator Coolant

    . INSPECTION/ADJUSTMENT XCITING 500 RADIATOR COOLANT Place the scooter on its center stand. Check the coolant level through the inspection window at the left floor skirt while the engine is at the normal operating temperature. The level should be between the “F” and “L”...
  • Page 69: Cooling System

    . INSPECTION/ADJUSTMENT XCITING 500 Reserve Tank Cap Remove reserve tank cap. Check to see if there are any coolant leaks when the coolant level decrease very rapidly. If reserve tank becomes completely empty, there is a possibility of air getting into the cooling system.
  • Page 70: Secondary Air Supply System

    . INSPECTION/ADJUSTMENT XCITING 500 SECONDARY AIR SUPPLY SYSTEM This model is equipped with a built-in secondary air supply system. The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system.
  • Page 71: Brake Fluid

    . INSPECTION/ADJUSTMENT XCITING 500 Fill the transmission case with recommended oil. Recommended transmission oil: SAE 90 Oil capacity (at draining): 0.45 liter (0.48 US qt, 0.4 lmp qt) Install the transmission oil filler bolt with a new sealing washer and tighten it.
  • Page 72: Brake Pad Wear

    . INSPECTION/ADJUSTMENT XCITING 500 BRAKE PAD WEAR Brake pad wear depends upon the severity of usage, the type of riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval.
  • Page 73: Brake Lock Operation

    . INSPECTION/ADJUSTMENT XCITING 500 Operate the rear brake lever. Make sure the front wheel does not turn while the rear brake lever is operated. Firmly apply the brake lever and check that no air has entered the system. If the lever feels soft or spongy when operated, bleed the air from the system.
  • Page 74: Headlight Aim

    . INSPECTION/ADJUSTMENT XCITING 500 ADJUSTMENT Place the scooter on its center stand. Release the parking brake lever lock. Pull up the parking brake lever until 1 notch. Loosen the lock nut. Turn the adjust bolt until you feel resistance when turn the rear wheel by your hand.
  • Page 75: Side Stand

    . INSPECTION/ADJUSTMENT XCITING 500 SIDE STAND Support the scooter on a level surface. Check the side stand spring for fatigue or damage. Check the side stand assembly for smooth movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: Start the engine.
  • Page 76: Nuts, Bolts, Fasteners

    . INSPECTION/ADJUSTMENT XCITING 500 REAR SUSPENSION INSPECTION Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired.
  • Page 77: Steering Head Bearings

    . INSPECTION/ADJUSTMENT XCITING 500 Recommended tire size: Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness. Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits.
  • Page 78: Lubrication System

    . LUBRICATION SYSTEM XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM ---------------------------------- 4-1 SERVICE INFORMATION------------------------------------------------ 4-2 TROUBLESHOOTING----------------------------------------------------- 4-3 OIL PRESSURE SWITCH ------------------------------------------------- 4-4 OIL PRESSURE RELIEF VALVE---------------------------------------- 4-4 OIL PUMP -------------------------------------------------------------------- 4-5 OIL COOLER --------------------------------------------------------------- 4-10...
  • Page 79: Lubrication System Diagram

    . LUBRICATION SYSTEM XCITING 500 LUBRICATION SYSTEM DIAGRAM...
  • Page 80: Service Information

    2.5 liter (2.7 US qt, 2.2 lmp qt) ⎯ At oil filter change 2.1 liter (2.2 US qt, 1.9 lmp qt) Recommended engine oil KYMCO 4-stroke oil or equivalent motor oil API service classification SJ ⎯ Viscosity: SAE 5W-50 Oil pump rotor Tip clearance 0.15 (0.006) max...
  • Page 81: Troubleshooting

    . LUBRICATION SYSTEM XCITING 500 TROUBLESHOOTING Oil level low High oil pressure • Oil consumption • Pressure relief valve stuck closed • External oil leak • Plugged oil filter, gallery, or metering orifice • Worn piston ring • Faulty oil pump •...
  • Page 82: Oil Pressure Switch

    . LUBRICATION SYSTEM XCITING 500 Dust Cover OIL PRESSURE SWITCH CHECK Start the engine. Check the oil pressure indicator goes out after one or two seconds. If the oil pressure indicator stay on, stop the engine immediately and determine the cause (section 20).
  • Page 83: Oil Pump

    . LUBRICATION SYSTEM XCITING 500 Bolts OIL PUMP REMOVAL Remove the flywheel (page 12-4). Remove the attaching bolt and oil separator cover. * When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine..
  • Page 84 . LUBRICATION SYSTEM XCITING 500 Oil Pump Remove the two oil pump bolts to remove the oil pump. Bolts Oil Pump Cover DISASSEMBLY Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump shaft, oil pump outer rotor and inner rotor.
  • Page 85 . LUBRICATION SYSTEM XCITING 500 INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) * Measure at several points and use the largest reading to compare the service limit.
  • Page 86 . LUBRICATION SYSTEM XCITING 500 Dowel Pin Oil Pump Cover ASSEMBLY Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft.
  • Page 87 . LUBRICATION SYSTEM XCITING 500 Drive Chain Driven Gear Install the oil pump driven sprocket and drive chain. Install the snap ring. Snap Ring Bolts Install the oil separator cover properly and tighten two bolts securely as shown. Oil Separator Cover...
  • Page 88: Oil Cooler

    . LUBRICATION SYSTEM XCITING 500 OIL COOLER REMOVAL Drain the engine oil and remove the oil filter 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.
  • Page 89 . LUBRICATION SYSTEM XCITING 500 Gasket Bolts INSTALLATION Install the gasket and oil cooler. Install the washers and tighten 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.
  • Page 90: Fuel System/fuel Pump/fuel Tank/carburetor

    . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/FUEL PUMP/ FUEL TANK/CARBURETOR __________________________________________________________________________________ SCHEMATIC DRAWING-------------------------------------------------- 5- 1 FUEL SYSTEM -------------------------------------------------------------- 5- 2 FUEL PUMP CONSTRUCTION ------------------------------------------ 5- 2 SERVICE INFORMATION ------------------------------------------------ 5- 3 TROUBLESHOOTING ----------------------------------------------------- 5- 4...
  • Page 91: Schematic Drawing

    5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 SCHEMATIC DRAWING...
  • Page 92: Fuel System

    . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 FUEL SYSTEM The fuel pump is operated by an electromagnetic force and its electrical energy is supplied from the battery. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.
  • Page 93: Service Information

    5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly.
  • Page 94: Troubleshooting

    . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly • No fuel in tank • Incorrect idle speed • Restricted fuel line • Rich mixture • Too much fuel getting to cylinder •...
  • Page 95: Carburetor

    5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Carburetor Clamp Screw CARBURETOR REMOVAL Remove the luggage box (page 2-3) Loosen the air cleaner clamp screw. Loosen the carburetor clamp screw. Disconnect the vacuum hose from the carburetor. Pull the carburetor out from the air cleaner and intake manifold.
  • Page 96 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Automatic Choke Assembly DISASSEMBLY With the automatic choke cover removed, remove the screw and automatic choke assembly. * The automatic choke assembly is a non- disassemblable type Automatic Choke Cover Screw Carburetor Heater Remove the carburetor heater.
  • Page 97 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Throttle Valve Spring Retainer Remove the spring , spring retainer, jet needle and throttle valve. Jet Needle Spring Casting Enrichment Valve Cover Remove the two screws and casting enrichment valve cover and then take out the spring.
  • Page 98 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Screws Remove the three screws and accelerating pump cover. Accelerating Pump Cover O-ring Remove the accelerating pump diaphragm and O-ring. Accelerating Pump Diaphragm Float Chamber Remove the four screws and float chamber.
  • Page 99 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Float Float Valve Pull float pin outs, then remove the float and float valve. Float Pin Main Jet Slow Jet Remove the slow jet. Remove the main jet. Needle Jet Holder...
  • Page 100 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Remove the needle jet. Needle Jet Pilot Screw Remove the pilot screw, spring, washer and O-ring. * Before pilot screw removal, slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated.
  • Page 101 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
  • Page 102 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Pilot Screw O-ring PILOT SCREW INSPECTION Remove the O-ring from the pilot screw. Check the pilot screw for wear or damage. * The pilot screw is factory pre-set and should not be removed unless the carburetor is overhauled.
  • Page 103 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 FLOAT LEVEL INSPECTION Check the float level after checking the float valve, valve seat and float. Set the carburetor so that the float valve end just contacts the float arm lip. Make sure the float valve tip is securely in contact with the valve seat.
  • Page 104 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Carburetor Heater Connect the positive (+) terminal of a 12 V battery to the terminal of the carburetor heater and the battery negative (-) terminal to the terminal. Check that the heater section is heated in 5 minutes after the battery has been connected.
  • Page 105 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 O-ring Small Convex Assemble the accelerating pump diaphragm and new O-ring. * Install the accelerating pump diaphragm with the small convex facing up. Accelerating Pump Diaphragm O-ring Assemble the coasting enrichment valve and new O-ring.
  • Page 106: Fuel Filter/fuel Pump

    . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Fuel Filter Arrow Mark FUEL FILTER/FUEL PUMP FUEL FILTER INSPECTION Visually check the fuel filter. If accumulation of sediment or clogging is found, replace the fuel filter with a new one. Install the fuel filter with the arrow mark facing forward.
  • Page 107: Fuel Tank

    5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Fuel Pump Connector Fuel Hoses REMOVAL Remove the floorboard (page 2-6) Disconnect the fuel hoses. Disconnect the fuel pump connector. Remove the fuel pump and filter. “Arrow” Mark Inlet Duct INSTALLATION Installation is in the reverse order of removal.
  • Page 108 . FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Fuel Unit Connector Disconnect the fuel unit connector. Remove the four nuts from the fuel tank. Nuts Ground Wire Connector Disconnect the ground wire connector. Disconnect the fuel filler cap open cable.
  • Page 109 5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Remove the fuel tank from the frame left side. Fuel Tank Fuel Tank Fuel Tank INSTALLATION Installation is in the reverse order of removal. 5-19...
  • Page 110: Cooling System

    . COOLING SYSTEM XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SYSTEM FLOW PATTERN----------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 4 COOLING SYSTEM TESTING------------------------------------------- 6- 5 COOLANT REPLACEMENT --------------------------------------------- 6- 5 THERMOSTAT-------------------------------------------------------------- 6- 8 WATER PUMP -------------------------------------------------------------- 6-10...
  • Page 111 . COOLING SYSTEM XCITING 500 SCHEMATIC DRAWING...
  • Page 112: Service Information

    . COOLING SYSTEM XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS WARING: Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
  • Page 113 -37℃ -44.5℃ Cautions for Using Coolant: • Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30%.) • Do not mix coolant concentrate of different brands. • Do not drink the coolant which is poisonous.
  • Page 114: Troubleshooting

    . COOLING SYSTEM XCITING 500 TORQUE VALUES Water pump cover bolt 13 N•m (1.3 kgf•m, 9 lbf•ft) Fan motor bolt 5 N•m (0.53 kgf•m, 3.8 lbf•ft) Radiator shroud mounting nut 9 N•m (0.9 kgf•m, 6.5 lbf•ft) TROUBLESHOOTING Engine temperature too high •...
  • Page 115: Cooling System Testing

    . COOLING SYSTEM XCITING 500 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Cap Tester Remove the radiator cap (page 6-6). Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.
  • Page 116 . COOLING SYSTEM XCITING 500 Radiator Cap REPLACEMENT/AIR BLEEDING Remove the front cover (page 2-11). Remove the front lower cover (page 2-15). * When filling the system or reserve tank with coolant (checking the coolant level), place the scooter in a vertical position on a flat, level surface.
  • Page 117 . COOLING SYSTEM XCITING 500 Reserve Tank Cap Remove the reserve tank cap and drain the coolant from the reserve 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.
  • Page 118: Thermostat

    . COOLING SYSTEM XCITING 500 Bleed air from the system as follow: 1. Start the engine and let it idle for 2−3 minutes. 2. Snap the throttle three to four times to bleed air from the system. 3. Stop the engine and add coolant to the proper level if necessary.
  • Page 119 . COOLING SYSTEM XCITING 500 Thermostat Remove the O-ring from the housing cover. Remove the thermostat. O-ring Thermostat INSPECTION Visually inspect the thermostat for damage. Heat the water with an electric heating element to operating temperature for five minutes. Suspend the thermostat in heated water to check its operation.
  • Page 120: Water Pump

    . COOLING SYSTEM XCITING 500 Air Bleed Hole INSTALLATION Install the thermostat into the housing with its air bleed hole facing up and aligning bleed hole with the tab in the housing. Align Install a new O-ring into the housing cover groove.
  • Page 121 . COOLING SYSTEM XCITING 500 Water Hoses REMOVAL Remove the exhaust muffler (page 2-15) Drain the coolant (page 6-6). Loosen the hose bands and disconnect the water hoses and bypass hose from the water pump. Bypass Hose Bolts Water Pump Cover Remove he bolts and water pump cover.
  • Page 122 . COOLING SYSTEM XCITING 500 Water Pump Body Remove the water pump body from the crankcase. Align INSTALLATION Apply engine oil to a new O-ring and install it onto the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with oil pump shaft end.
  • Page 123: Radiator

    . COOLING SYSTEM XCITING 500 RADIATOR REMOVAL Drain the coolant (page 6-6). Remove the inner cover (page 2-14). Remove the front lower cover (page 2-15) Disconnect the fan motor connector. Fan Motor Loosen the hose band and disconnect the radiator lower hose from the radiator.
  • Page 124 . COOLING SYSTEM XCITING 500 Fan Motor Switch Connectors Disconnect the fan motor switch connectors. Disconnect the air bleed hose. Air Bleed Hose Remove the four nuts and radiator from the frame. * Be careful not to damage the radiator core.
  • Page 125 . COOLING SYSTEM XCITING 500 DISSASSEMBLY Remove the four bolts and fan motor/shroud assembly. Bolts Check the fan motor to operate using an available battery. Fan Motor Wire ASSEMBLY Install the fan motor/shroud assembly to the radiator with the fan motor wire facing up.
  • Page 126: Fan Motor Switch

    . COOLING SYSTEM XCITING 500 FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connector (page 6-14). Remove the fan motor switch. Fan Motor Wire INSPECTION Place the fan motor switch in oil contained in a pan as shown and raise the oil...
  • Page 127: Water Temperature Sensor

    . COOLING SYSTEM XCITING 500 WATER TEMPERATURE SENSOR REMOVAL Remove the side body cover (page 2-8) Disconnect the water temperature sensor connector. Remove the water temperature sensor. Water Temperature Sensor Water Temperature Sensor INSPECTION Connect the water temperature sensor to the ohmmeter and dip it in oil contained in a pan which is placed on an electric heater.
  • Page 128: Raidator Reserve Tank

    . COOLING SYSTEM XCITING 500 RADIATOR RESERVE TANK REMOVAL Remove the floorboard (page 2-6). Remove the two nuts and radiator reserve tank from the frame. Nuts Open the reserve tank cap and drain the coolant from the reserve tank. Disconnect the siphon hose.
  • Page 129: Engine Removal/installation

    7. ENGINE REMOVAL/INSTALLATION XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 7- 1 ENGINE REMOVAL ------------------------------------------------------- 7- 2 ENGINE HANGER --------------------------------------------------------- 7-11...
  • Page 130 7. ENGINE REMOVAL/INSTALLATION 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.
  • Page 131 7. ENGINE REMOVAL/INSTALLATION XCITING 500 ENGINE REMOVAL Remove the following: Luggage box (page 2-3) Floorboard (page 2-6) Rear fender (page 2-7) Side/rear body cover (page 2-8) Exhaust muffler (page 2-15) Drain the coolant from the system (page 6-6). Support the scooter on its main stand.
  • Page 132 7. ENGINE REMOVAL/INSTALLATION XCITING 500 AICV air Supply Hose Disconnect the water temperature sensor connector. Disconnect AICV air supply hose from the AICV check valve. Water Temperature Sensor Connector Crankcase Breather Hose Disconnect the spark plug cap from the cylinder head.
  • Page 133 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Air Bleed Hose Disconnect the air bleed hose and water hose from the water joint. Water Hose Outer Water Hose Disconnect the outer water hose from the oil cooler. Alternator Connectors Loosen the wire bands and disconnect the...
  • Page 134 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Engine Ground Cable Remove the bolt and engine ground cable. Bolt Bypass Hose Loosen the hose bands and disconnect the bypass hose and water hose Water Hose Oil Pressure Switch Disconnect the oil pressure switch connector.
  • Page 135 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Bolts Remove the bolts and rear/parking brake caliper. Remove the brake hose from clamps. Disconnect the transmission case breather hose from transmission case. Transmission Case Breather Hose Bolts Remove the bolts and air cleaner.
  • Page 136 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Remove the rear cushion lower mount bolts Lower Mount Bolts Remove the engine mount nut. Bolt Turn the engine mount bolt counterclockwise and loosen it. Pull out the engine mount bolt then removes the engine from the frame.
  • Page 137 7. ENGINE REMOVAL/INSTALLATION 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 XCITING 500 Remove the collar. Collar...
  • Page 139 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Long Engine Collar Pull out the long engine collar. INSTALLATION Installation is in the reverse order of removal. * ● At installing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
  • Page 140 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Bolts/Outer Collars ENGINE HANGER REMOVAL Loosen and remove the engine mount nut (page 7-7). Loosen and remove the engine mount bolt (page 7-7). Remove the engine hanger mount bolts and outer collars. Inner Collars Remove the engine hanger and inner collars.
  • Page 141 7. ENGINE REMOVAL/INSTALLATION XCITING 500 Outer/Inner Bearings INSPECTION Inspect the bearing: Bearings allow play in the engine hanger or the bearing turns roughly → Replace. Bush Inspect the bush: Wear/Damage → Replace. 7-12...
  • Page 142: Cylinder Head/valves

    8. CYLINDER HEAD/VALVES XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 CYLINDER COMPRESSION TEST ------------------------------------- 8- 4 CYLINDER HEAD COVER----------------------------------------------- 8- 5 CAMSHAFT REMOVAL -------------------------------------------------- 8- 6...
  • Page 143 8. CYLINDER HEAD/VALVES XCITING 500 SCHEMATIC DRAWING...
  • Page 144: Cylinder Head/valves

    8. CYLINDER HEAD/VALVES XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
  • Page 145: Troubleshooting

    8. CYLINDER HEAD/VALVES XCITING 500 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low • Worn valve stem or valve guide •...
  • Page 146: Cylinder Compression Test

    8. CYLINDER HEAD/VALVES XCITING 500 CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug (page 3-7). Park Plug Cap Compression Gauge Install a compression gauge into the spark plug hole.
  • Page 147: Cylinder Head Cover

    8. CYLINDER HEAD/VALVES XCITING 500 Bolts CYLINDER HEAD COVER DISASSEMBLY Remove the floorboard (page 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.
  • Page 148: Camshaft Removal

    8. CYLINDER HEAD/VALVES XCITING 500 Gasket Remove the gasket. ASSEMBLY Assembly is in the reverse order of disassembly. Torque: Breather separator bolt: 13 N•m (1.3 kgf•m, 9 lbf•ft) Bolt Washer CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-5). Turn the crankshaft clockwise and align the “T”...
  • Page 149 8. CYLINDER HEAD/VALVES XCITING 500 Bolts Remove the two bolts and cam chain guide. Cam Chain Guide Camshaft Holders Bolts Loosen and remove the twelve camshaft holder bolts in a crisscross pattern in several steps, then remove the camshaft holders.
  • Page 150 8. CYLINDER HEAD/VALVES XCITING 500 INSPECTION Cam chain guide Inspect the am chain slipper surface of the cam chain guide for wear or damage. Spark Plug Cap Camshaft holder Inspect the bearing surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication.
  • Page 151 8. CYLINDER HEAD/VALVES XCITING 500 Camshaft Support both ends of the camshaft with V- blocks and check the camshaft runout with a dial gauge. Service limit: 0.05 mm (0.002 in) Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height.
  • Page 152: Rocker Arm Removal

    8. CYLINDER HEAD/VALVES XCITING 500 Cam chain tensioner Check the one-way cam operation (tensioner) Unsmooth operation → Replace. Rocker Arms ROCKER ARMS REMOVA Remove the camshaft (page 8-6) Remove the rocker arm shafts and washers, then remove the rocker arms.
  • Page 153: Cylinder Head Removal

    8. CYLINDER HEAD/VALVES XCITING 500 Rock Arm Inspect the rocker arm bore, cam lobe contact surface and adjuster surface for wear/pitting/scratches/blue discoloration. If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.
  • Page 154 8. CYLINDER HEAD/VALVES XCITING 500 Bolts Remove the two bolts, water joint, gasket and water stop collar. Water Joint/Gasket/Water Stop Collar Cylinder Head Remove the three bolts and cylinder head. Bolts Dowel Pins Remove the dowel pins and cylinder head gasket.
  • Page 155 8. CYLINDER HEAD/VALVES XCITING 500 Valve Spring Compressor DISSASEMBLY CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. * • Be sure to compress the valve springs with a valve spring compressor.
  • Page 156 8. CYLINDER HEAD/VALVES XCITING 500 VALVE /VALVE GUIDE INSPECTION Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D.
  • Page 157 8. CYLINDER HEAD/VALVES XCITING 500 Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 3.5 kg (at 28.7 mm, 1.148 in) Outer: 13 kg (at 31.43 mm, 1.2572 in) Measure the spring tilt. Replace if out of specification.
  • Page 158: Cylinder Head Installation

    8. CYLINDER HEAD/VALVES XCITING 500 Tap the valve stems gently with a plastic hammer for 2~3 times to firmly seat the cotters. * Be careful not to damage the valves. Dowel Pins CYLINDER HEAD INSTALLATION Install the dowel pins and new cylinder head gasket as shown.
  • Page 159 8. CYLINDER HEAD/VALVES XCITING 500 Bolts Water Stop Collar Gasket Install the water stop collar, gasket and water joint. Install and tighten the two bolts to the specified torque. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Water Joint Pair Reed Valve Gasket Install gasket and pair reed valve.
  • Page 160: Rocker Arm Installation

    8. CYLINDER HEAD/VALVES XCITING 500 Insulator Install the insulator with the O-ring face the cylinder head. O-ring Intake Pipe Install the intake pipe and tighten the two bolts securely. Bolts Rocker Arm Washer ROCKER ARM INSTALLATION Apply engine oil to the rocker arms and...
  • Page 161: Camshaft Installation

    8. CYLINDER HEAD/VALVES XCITING 500 CAMSHAFT INSTALLATION Turn the crankshaft clockwise, align the “T” mark on the flywheel with the index mark on the right crankcase cover (page 3-9). Apply molybdenum disulfide oil to the camshaft journals of the camshaft holder.
  • Page 162 8. CYLINDER HEAD/VALVES XCITING 500 Install intake and exhaust camshaft holders to the correct locations. * Install each camshaft holders to the correct locations. “IN”: no stop pin. “EX”: has a stop pin. Apply engine oil to cylinder head bolt (No.
  • Page 163 8. CYLINDER HEAD/VALVES XCITING 500 Install the common camshaft holder by arrow mark facing outside. Install and tighten the holder bolts (No. 10 – * 13) in a crisscross pattern in four steps to the Apply engine oil to cylinder head bolt specified torque as follow diagram.
  • Page 164 8. CYLINDER HEAD/VALVES XCITING 500 Bolts Install the cam chain guide and tighten the two bolts securely. Cam Chain Guide Release the timing chain tensioner one-way cam and push the tensioner rod all the way in. Cap Bolt Washer Install the tensioner with a new gasket onto the cylinder.
  • Page 165: Cylinder Head Cover Installation

    8. CYLINDER HEAD/VALVES XCITING 500 Cylinder Head Cover Packing CYLINDER HEAD COVER INSTALLATION Install the cylinder head packing into the groove of the cylinder head cover. Bolts Install the cylinder head cover onto the cylinder head and tighten the cylinder head cover bolts to the specified torque.
  • Page 166: Cylinder/piston

    9. CYLINDER/PISTON XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 CYLINDER/PISTON REMOVAL ---------------------------------------- 9-3 CYLINDER/PISTON INSTALLATION --------------------------------- 9-7...
  • Page 167 9. CYLINDER/PISTON XCITING 500 SCHEMATIC DRAWING...
  • Page 168: Cylinder/piston

    9. CYLINDER/PISTON XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
  • Page 169: Cylinder/piston Removal

    9. CYLINDER/PISTON XCITING 500 Bolts Cylinder/Gasket Block Pin CYLINDER/PISTON REMOVAL Remove the cylinder head (page 8-11). Take the block pin out. Remove the water hose from the cylinder. Remove the two cylinder bolts. Remove the cylinder and gasket. Water Hose...
  • Page 170 9. CYLINDER/PISTON XCITING 500 Spread each piston ring and remove it by lifting up at a point opposite the gap * Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
  • Page 171 9. CYLINDER/PISTON XCITING 500 Piston/Piston pin Measure the piston O.D. at the point 10 mm 10 mm from the bottom and 90° to the piston pin 10 mm hole. Service Limit: 91.9 mm (3.676 in) Calculate the cylinder-to-piston clearance (cylinder I.D.: page 9-6) Measure the piston pin hole.
  • Page 172 9. CYLINDER/PISTON XCITING 500 Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
  • Page 173: Cylinder/piston Installation

    9. CYLINDER/PISTON XCITING 500 Measure the connecting rod small end I.D.. Service Limit: 22.06 mm (0.8824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing *...
  • Page 174 9. CYLINDER/PISTON XCITING 500 Piston “IN” Mark CYLINDER/PISTON INSTALLATION Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
  • Page 175 9. CYLINDER/PISTON XCITING 500 Bolts Cylinder/Gasket Block Pin Install the gasket. Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. * Be careful not to damage the piston rings and cylinder walls.
  • Page 176: Drive And Driven Pulley

    . DRIVE AND DRIVEN PULLEY XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEY __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10- 1 SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 2 LEFT CRANKCASE COVER --------------------------------------------- 10- 3 DRIVE PULLEY ------------------------------------------------------------ 10- 5...
  • Page 177: Drive And Driven Pulley

    10. DRIVE AND DRIVEN PULLEY XCITING 500 SCHEMATIC DRAWING 10-1...
  • Page 178: Service Information

    . DRIVE AND DRIVEN PULLEY XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
  • Page 179: Left Crankcase Cover

    10. DRIVE AND DRIVEN PULLEY XCITING 500 Bolts LEFT CRANKCASE COVER REMOVAL Remove the left center body cover (page 2-5). Remove the three bolts and the left front cover. Left Front Cover Bolts Remove the two bolts and left rear cover...
  • Page 180 . DRIVE AND DRIVEN PULLEY XCITING 500 Dowel Pins Remove the dowel pins and gasket. Gasket DRIVESHAFT BEARING REPLACEMENT Remove the snap ring. Clip Industrial Dryer Heat the left crankcase cover around the driveshaft bearing with industrial dryer. Remove the driveshaft bearing from the left crankcase cover.
  • Page 181: Drive Pulley

    10. DRIVE AND DRIVEN PULLEY XCITING 500 Install the new driveshaft bearing into the left crankcase cover using a special tool. Special tool: Oil seal & bearing install E014 Bearing Install INSTALLATION Installation is in the reverse order of removal.
  • Page 182 . DRIVE AND DRIVEN PULLEY XCITING 500 Nut/Collar Clutch Outer Hold the clutch outer with the special tool as shown. Special tool: Universal holder E017 Remove the nut, collar and clutch outer. Universal Holder Drive Belt Clutch/Driven Pulley Remove the clutch/driven pulley assembly and drive belt.
  • Page 183 10. DRIVE AND DRIVEN PULLEY XCITING 500 Drive Face Boss Remove the movable drive face assembly while holding the back of the face (ramp plate). Movable Drive Face Washer Remove the washer. Ramp Plate DISASSEMBLY Drive pulley Remove the ramp plate and slide pieces.
  • Page 184 . DRIVE AND DRIVEN PULLEY XCITING 500 Remove the weight rollers. Weight Rollers Drive Face Boss Remove the 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..
  • Page 185 10. DRIVE AND DRIVEN PULLEY XCITING 500 Weight Roller Check each roller for wear or damage. Measure the weight roller O.D.. Service limit: 29.5 mm (1.18 in) Dust Seal Movable Drive Face Check the dust seal for wear or damage.
  • Page 186 . DRIVE AND DRIVEN PULLEY XCITING 500 Weight Rollers Install the weight rollers to the movable drive face. * The direction of all weight rolls is the same. The thin side is towards to clockwise. Thin Side Ramp Plate Install the slide pieces to ramp plate.
  • Page 187 10. DRIVE AND DRIVEN PULLEY XCITING 500 Washer Clean any oil and grease from the pulley faces and the drive belt. Install the movable drive face assembly onto the crankshaft while holding the ramp plate. Install the washer. Movable Drive Face Assembly...
  • Page 188 . DRIVE AND DRIVEN PULLEY XCITING 500 Washer/Nut Drive Pulley Face Install 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 specified torque.
  • Page 189: Clutch/driven Pulley

    10. DRIVE AND DRIVEN PULLEY XCITING 500 Nut/Washer Drive Pulley Face CLUTCH/DRIVEN 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 tool: Universal holder...
  • Page 190 . DRIVE AND DRIVEN PULLEY XCITING 500 Lock Nut Wrench DISASSEMBLY Clutch/Driven Pulley Hold the clutch/driven pulley assembly with the clutch spring compressor. * Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor...
  • Page 191 10. DRIVE AND DRIVEN PULLEY XCITING 500 Movable Driven Face Remove the guide roller pins, guide rollers and the movable driven face. Guide Roller Pins/Guide Rollers Oil Seals Remove the O-rings and oil seals from the movable driven face. O-rings...
  • Page 192 . DRIVE AND DRIVEN PULLEY XCITING 500 Needle Bearing Filling 25 g of grease to the driven face inner surface. Apply grease to new needle bearing. Press the needle bearing into the driven. Grease INSPECTION Clutch Outer Check the clutch outer for wear or damage.
  • Page 193 10. DRIVE AND DRIVEN PULLEY XCITING 500 Driven Face Spring Measure the driven face spring free length. Service limit: 100.7 mm (4.028 in) Driven Face Check the driven face for scratches, scoring or damage. Measure the driven face boss O.D..
  • Page 194 . DRIVE AND DRIVEN PULLEY XCITING 500 Drive Belt Check the drive belt for cracks, separation or abnormal or excessive wear. Attach the suitable plates ad shown. Measure the drive belt width. Service limit: 27.9 mm (1.116 in) Remove the clutch/driven pulley, then replace the drive belt if necessary.
  • Page 195 10. DRIVE AND DRIVEN PULLEY XCITING 500 Install the movable driven face onto the driven face. Install the guide rollers and guide roller pins. Grease Filling 8 g of grease to each guide groove. Driven Face Spring Install the seal collar.
  • Page 196 . DRIVE AND DRIVEN PULLEY XCITING 500 Drive Belt * Install the drive belt with the arrow mark facing up and towards to clockwise. Install the drive belt and clutch/driven pulley assembly. Clutch/Driven Pulley Assembly Nut/Collar Clutch Outer Hold the clutch outer with the special tool as shown.
  • Page 197: 11. Final Reduction

    11. FINAL REDUCTION XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION------------------------------------------------ 11-2 TROUBLESHOOTING----------------------------------------------------- 11-2 FINAL REDUCTION DISASSEMBLY --------------------------------- 11-3 FINAL REDUCTION INSPECTION------------------------------------- 11-5 FINAL REDUCTION ASSEMBLY -------------------------------------- 11-9 11-0...
  • Page 198 11. FINAL REDUCTION XCITING 500 SCHEMATIC DRAWING 11-1...
  • Page 199 11. FINAL REDUCTION XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
  • Page 200 11. FINAL REDUCTION XCITING 500 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler (page 2-15). Remove the rear brake caliper (page 16-26). Remove the right rear shock absorber (page 15-10). Remove the rear fork (page 15-4). Remove the rear wheel (page 15-4).
  • Page 201 11. FINAL REDUCTION XCITING 500 Countershaft Remove the countershaft Final Gear Remove the final gear. Driveshaft Remove the driven pulley (page 10-13). Press the driveshaft out or the left crankcase. Check the drive shaft for wear or damage. 11-4...
  • Page 202 11. FINAL REDUCTION XCITING 500 Oil Seal Remove the driveshaft oil seal and bearing from the transmission case. Driveshaft Bearing If the bearing is left on the driveshaft, remove it with the special tool. Special tool: Universal bearing puller E030...
  • Page 203 11. FINAL REDUCTION XCITING 500 Driveshaft Bearing Bearing Puller Check the oil seal and bearings in the left crankcase for wear or damage. BEARING REPLACEMENT (TRANSMISSION CASE) Remove the countershaft or final gear shaft bearing using the special tool. Special tool:...
  • Page 204 11. FINAL REDUCTION XCITING 500 Snap Ring Remove the bearing snap ring. Final Gear Shaft Bearing Remove the final gear shaft bearing. Countershaft Bearing Remove the countershaft or drive shaft bearing using the special tool. Special tool: Bearing puller E037...
  • Page 205 11. FINAL REDUCTION XCITING 500 Oil Seal & Bearing Driver Apply engine oil to new bearings cavities. Drive new bearings into the transmission cover. Special tool: Oil seal & bearing driver E014 Apply engine oil to new final gear shaft bearing cavity.
  • Page 206 11. FINAL REDUCTION XCITING 500 Oil Seal Apply oil to a new final gear shaft oil seal lip and outer surface. Install the final gear shaft oil seal. Final Gear FINAL REDUCTION ASSEMBLY Install the final gear to the transmission case.
  • Page 207 11. FINAL REDUCTION XCITING 500 Final Gear Shaft Gasket Install the final gear shaft to transmission case. Install the dowel pins. Clean the mating surfaces of the left crankcase and transmission cover. Install the new gasket. Dowel Pins Bolts Install the transmission cover and tighten the eight bolts in a crisscross pattern in 2 –...
  • Page 208 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 12-1 SERVICE INFORMATION------------------------------------------------ 12-2 TROUBLESHOOTING----------------------------------------------------- 12-2 ALTERANTOR STATOR-------------------------------------------------- 12-3 FLYWHEEL/STARTER CLUTCH --------------------------------------- 12-4 12-0...
  • Page 209 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 SCHEMATIC DRAWING 12-1...
  • Page 210 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
  • Page 211 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 Right Crankcase Cover ALTERNATOR STATOR REMOVAL Remove the right center body cover (page 2- Remove the exhaust muffler (page 2-15). Remove water pump (page 6-10). Remove the fifteen bolts and right crankcase cover, dowel pins and gasket.
  • Page 212 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 Flywheel Holder Nut/Washer FLYWHEEL/STARTER CLUTCH REMOVAL Remove the right crankcase cover (page 12- Hold the flywheel with the special tool and loosen the flywheel nut. Special tool: Flywheel holder E021 Remove the flywheel nut and washer.
  • Page 213 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 Reduction Gear Remove the reduction gear. Driven gear INSPECTION Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise.
  • Page 214 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 Reduction Gear Check the starter reduction gear teeth and shaft for wear or damage. Reduction Gear Apply oil to the starter reduction gear. Install the starter reduction gear to the right crankcase. Driven gear Apply molybdenum oil solution to the starter driven gear bushing.
  • Page 215 . A.C. GENERATOR/STARTER CLUTCH XCITING 500 Clean any oil from tapered portion of the crankshaft. Install the woodruff key in the crankshaft key groove. Woodruff Key Flywheel Holder Nut/Washer Clean any oil from the tappered portion of the flywheel I.D..
  • Page 216: Crankcase/crankshaft

    . CRANKCASE/CRANKSHAFT XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 13- 1 SERVICE INFORMATION------------------------------------------------ 13- 2 TROUBLESHOOTING----------------------------------------------------- 13- 2 CAM CHAIN/CAM CHAIN GUIDE REMOVAL --------------------- 13- 3 CRANKCASE SEPARATION -------------------------------------------- 13- 4 CRANKCASE ASSEMBLY ----------------------------------------------- 13-11...
  • Page 217 . CRANKCASE/CRANKSHAFT XCITING 500 SCHEMATIC DRAWING 13-1...
  • Page 218 . CRANKCASE/CRANKSHAFT XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft and balancer. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
  • Page 219 . CRANKCASE/CRANKSHAFT XCITING 500 CAM CHAIN/CAM CHAIN GUIDE REMOVAL Remove the starter driven gear (page 12-4). Remove the cylinder (page 9-3). Remove the cam chain from the right crankcase. Cam Chain Cam Chain Guides Remove the bolts and cam chain guides.
  • Page 220 . CRANKCASE/CRANKSHAFT XCITING 500 Cam chain Inspect the cam chain for cracks or stiff. Bolts CRANKCASE SEPARATION Remove the parts required for crankcase separation (page 13-2). Remove the twelve bolts from left crankcase. * Loosen the bolts in a crisscross pattern in several steps.
  • Page 221 . CRANKCASE/CRANKSHAFT XCITING 500 Dowel Pins Remove the dowel pins and O-ring. Remove the oil collar and O-rings from the left crankcase. Clean of the sealant from the left and right crankcase mating surfaces. Oil Collar/O-rings Dowel Pin/O-ring Washer Remove the washer from the crankshaft.
  • Page 222 . CRANKCASE/CRANKSHAFT XCITING 500 Bolts/Outer Washer RIGHT CRANKCASE DISASSEMBLY Remove the two bolts, outer washer, oil pipe and inner washers. Oil Pipe/Inner Washers Inner Washers RIGHT CRANKCASE ASSEMBLY Install the inner washers onto the right crankcase. Thick Side Install the oil pipe with the thick side face upward.
  • Page 223 . CRANKCASE/CRANKSHAFT XCITING 500 Bolts/Outer Washer Install the outer washers and two bolts. Tighten the two bolts to the specified torque. Torque: 43 N•m (4.3 kgf•m, 31 lbf•ft) Main Journal Bearing I.D. Color Cod CRANKSHAFT/CRANKCASE SELECTION Crankcase and crankshaft are select fitted.
  • Page 224 . CRANKCASE/CRANKSHAFT XCITING 500 MAIN BEARING INSPECTION Inspect the bearing inserts for unusual wear, damage or peeling and replace the crankcase if necessary. Main bearing oil clearance Clean off any oil from the main bearing inserts and crankshaft journals. Measure and record the crankshaft main journal O.D..
  • Page 225 . CRANKCASE/CRANKSHAFT XCITING 500 BALANCER SHAFT BEARING REPLACMENT Remove the crankshaft and balancer shaft (page 13-4). Turn the 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 crankcase.
  • Page 226 . CRANKCASE/CRANKSHAFT XCITING 500 Remove the balancer shaft bearing from the right crankcase. Bearing Snap Ring Install the snap ring into the right crankcase. Oil Seal & Bring Driver Install the new bearings to the right and left crankcase using special tool.
  • Page 227 . CRANKCASE/CRANKSHAFT XCITING 500 Crankshaft CRANKCASE ASSEMBLY Install the crankshaft to the left crankcase. Align Balancer Shaft Install the balancer shaft to align the punch mark with the “O” mark on the crankshaft. Left Front Cover Washer Install the washer onto the crankshaft.
  • Page 228 . CRANKCASE/CRANKSHAFT XCITING 500 Dowel Pins Install the oil collar and O-rings Clean the right and left crankcase mating surface thoroughly, being careful not to damage them. Install the dowel pins and O-ring. Oil Collar/O-rings Dowel Pin/O-ring Bolt Apply a light but through coating of sealant...
  • Page 229 . CRANKCASE/CRANKSHAFT XCITING 500 Cam Chain Guides 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 Chain...
  • Page 230: Steering Handlebar/front Wheel/front Shock Absorber

    14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 14- 1 SERVICE INFORMATION------------------------------------------------ 14- 2 TROUBLESHOOTING----------------------------------------------------- 14- 3 FRONT WHEEL------------------------------------------------------------- 14- 4 FORK-------------------------------------------------------------------------- 14-12 STEERING HANDLEBAR ------------------------------------------------ 14-14...
  • Page 231 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER SCHEMATIC DRAWING 14-1...
  • Page 232: Front Shock Absorber

    • A jack or other support is required to support the vehicle. • Do not twist or bend the brake hose and pipe when servicing. • Use genuine KYMCO replacement bolts and nuts for all suspension pivots and mounting points • Refer to section 16 for brake system information.
  • Page 233 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER TROUBLESHOOTING Hard steering Wheel turns hard • Steering stem top thread too tight • Faulty front wheel bearings • Worn or damaged steering bearings • Bent front axle • Worn or damaged steering bearing races •...
  • Page 234 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Holder bolt FRONT WHEEL REMOVAL Loosen the front axle holder bolt. Front Axle Loosen the front axle bolt. Support the scooter securely using a hoist or equivalent and raise the front wheel off the ground.
  • Page 235 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Side Collar Remove the right and left side collar from the wheel hub. INSTECTION Axle Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading.
  • Page 236 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Wheel Bearing Turn the 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 and brake discs.
  • Page 237 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Remove the dust seals Dust Seals Install the bearing remover into the bearing. Drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. Special tool: Bearing remover...
  • Page 238 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Distance Collar Install the distance collar. Pack a new bearing cavities with grease. Drive the new right bearing squarely with the sealed side facing up until it is fully seated. Special tool: Oil seal &...
  • Page 239 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Speed sensor guide Install the speed sensor guide. Install the plate 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.
  • Page 240 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Front Axle Install the front wheel between the fork leg. Install the front axle front left side. Tighten the axle bolt to the specified torque. Torque: 55 N•m (5.5 kgf•m, 40 lbf•ft)
  • Page 241 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER With the front brake applied, 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. Speed Sensor Measure the speed sensor to speed sensor guide clearance.
  • Page 242 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Upper Pinch Bolt FORK REMOVAL Remove the front wheel (page 14-4). Remove the front fender (page 2-4). Remove the bolt and hose clamp. Remove the bolt and speed sensor (only right fork).
  • Page 243 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Tighten the lower pinch bolts to specified torque. Torque: 23 N•m (2.3 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.
  • Page 244 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER STEERING HANDLEBAR REMOVAL Remove the front cover (page 2-11). Remove the upper handlebar cover (page 2- Remove the band bolt and disconnect the left handlebar switch connector. Left Handlebar Switch Connector Bolt Remove the two screws and lower handlebar cover.
  • Page 245 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Bolts Remove the bolts, master cylinder holders and front master cylinders. NOTE: Keep the master cylinder upright to prevent air from entering the hydraulic system. Screws Remove the screws and right handlebar switch housing.
  • Page 246 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Holder Bolts Remove the bolts and upper holders. Switch Housing Remove the handlebar from the handlebar post and right handlebar switch housing. INSTALLATION Pass the handlebar through the right handlebar switch housing.
  • Page 247 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Holes Align the holes on the handlebar with the pins on the handle post. Pins Holder Bolts Install the handlebar to the handle post. Install the upper holders with its punch marks facing toward.
  • Page 248 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Hole Align the pin on the right handlebar switch housing with the hole on the steering handle. Screws Install the screws and tighten the forward screw first, then tighten the rear screw.
  • Page 249 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Align the pin on the rear master cylinder holder with the hole on the handlebar. Hole “UP” Mark Install the rear master cylinders 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.
  • Page 250 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Clamp Bolts STEERING 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 Remove the brake hoses from the clamps on the steering stem.
  • Page 251 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Remove the steering stem lock nut. Special tool: Long socket wrench F007 Lock Washer Remove the lock washer. Top Thread Loosen the steering top thread. Hold the steering stem and remove the steering stem top thread.
  • Page 252 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Lower Bearing Remove the steering stem and lower bearing. Steering Stem Dust Seal Upper Inner Race Upper Bearing Remove the dust seal, upper inner race and upper bearing BEARING REPLACEMENT Remove the upper bearing outer race.
  • Page 253 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Remove the lower bearing outer race. Lower Outer Race Drive a new upper bearing race into the steering head pipe. Upper Outer Race Drive a new lower bearing race into the steering head pipe.
  • Page 254 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Lower Inner Race Install the steering stem lock nut onto the steering to prevent the threads from being damaged when removing the lower bearing inner race from the steering stem. Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the steering stem.
  • Page 255 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Lower Bearing Install the lower bearing onto the stem. Insert the steering stem into the steering head pipe. Steering Stem Top Thread Install the steering top thread and tighten it to the specified torque.
  • Page 256 14.STEERING HANDLEBAR/FRONT WHEEL/ XCITING 500 FRONT SHOCK ABSORBER Lock Nut Lock Washer Install the lock washer aligning its tab into the groove on the steering stem. Install the steering stem lock nut. Hold the steering stem top thread and tighten the steering stem lock nut to the specified torque.
  • Page 257: Rear Fork/rear Wheel/rear Shock Absorber

    . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 15- 1 SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 3 REAR WHEEL/REAR FORK --------------------------------------------- 15- 4 REAR SHOCK ABSORBER ---------------------------------------------- 15-10...
  • Page 258 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...
  • Page 259 • A jack or other support is required to support the vehicle. • Do not twist or bend the brake hose when servicing. • Use genuine KYMCO replacement bolts and nuts for all suspension pivots and mounting points. • Refer to section 16 for brake system information.
  • Page 260 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER TROUBLESHOOTING Rear wheel wobbling Hard suspension • Bent rim • Bent damper rod • Faulty tire • Worn or damaged engine mount bushings • Axle not tightened properly • High tire pressure •...
  • Page 261 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Axle Nut REAR WHEEL/REAR FORK REMOVAL Remove the muffler (page 2-15). Remove the rear/parking brake caliper (page 16-26). Loosen the rear axle nut. Support the scooter securely on its main stand.
  • Page 262 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Remove the inner side collar. Inner Side Collar Remove the rear wheel. Rear Wheel INSTECTION Wheel Check the wheel rim runout using dial indicator. Actual urnout is 1/2 the total indicator reading.
  • Page 263 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Brake Disc DISASSEMBLY Wheel Remove the brake disc bolts and rear brake disc. Outer Side Collar REAR FORK BEARING REPLACEMENT Remove the outer side collar from the rear fork. Remove the dust seal from the rear fork.
  • Page 264 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Bearing Snap Ring Remove the snap ring. Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the rear fork.
  • Page 265 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Apply grease to the new dust seal lip and install it to the rear fork. Dust Seal Busing Check the bushing for wear or damage. Brake Disc ASSEMBLY Wheel Install the brake disc onto the wheel hub.
  • Page 266 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER INSTALLATION Install the rear wheel onto the final gear shaft, aligning the spline. Rear Wheel Install the inner side collar. Apply grease to the final gear shaft. Inner Side Collar Mount Bolts Install the rear fork and tighten the bolts to the specified torque.
  • Page 267 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Bolts/Clamps Install and tighten the rear axle nut to temporarily. Install and tighten the rear shock absorber lower mount bolt to the specified torque. Torque: 40 N•m (4.0 kgf•m, 29 lbf•ft) Install the brake hose/cable clamps to the rear fork and tighten the bolts securely.
  • Page 268 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Upper Mount Bolt Remove the rear shock absorber upper mount bolt and shock absorber. Bushing INSTECTION Check the damper unit for leakage or other damage. Check the upper joint bushing for wear or damage.
  • Page 269 . REAR FORK/REAR WHEEL/ XCITING 500 REAR SHOCK ABSORBER Lower Mount Bolt Install and tighten the lower mount bolt to the specified torque. Torque: 40 N•m (4 kgf•m, 29 lbf•ft) 15-12...
  • Page 270: Brake System

    XCITING 500 . BRAKE SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BRAKE SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 16- 1 SERVICE INFORMATION------------------------------------------------ 16- 2 TROUBLESHOOTING----------------------------------------------------- 16- 3 BRAKE FLUID -------------------------------------------------------------- 16- 4 BRAKE PAD ----------------------------------------------------------------- 16-10 BRAKE DISC INSPECTION ---------------------------------------------- 16-13 FRONT MASTER CYLINDER ------------------------------------------- 16-14...
  • Page 271 XCITING 500 . BRAKE SYSTEM SCHEMATIC DRAWING 16-1...
  • Page 272: Brake System

    XCITING 500 . BRAKE SYSTEM SERVICE INFORMATION GENERAL * Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. Avoid breathing dust particles. • A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with high quality brake degreasing agent.
  • Page 273: Troubleshooting

    XCITING 500 . BRAKE SYSTEM TORQUE VALUES Master cylinder reservoir cover screw 2 N•m (0.2 kgf•m, 1.4 lbf•ft) Master cylinder holder bolt 12 N•m (1.2 kgf•m, 9 lbf•ft) Brake lever pivot bolt 6 N•m (0.6 kgf•m, 4.3 lbf•ft) Brake lever pivot nut 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
  • Page 274: Brake Fluid

    XCITING 500 . BRAKE SYSTEM BRAKE FLUID Check Brake fluid: (page 3-18) Brake hose: Cracks/wear/damage → Replace. Apply the brake lever several times. Fluid leakage → Replace. Brake hose clamp: Loosen → Tighten FLUID REPLACEMENT Front brake * Avoid spilling brake fluid on painted, plastic or rubber parts and so on.
  • Page 275 XCITING 500 . BRAKE SYSTEM Clear Hose Connect a clear hose to the left front caliper air bleed screw and insert the other end of the hose into a receptacle. Left Front Caliper Air Bleed Screw Brake Lever Loosen the air bleed screw and pump the brake lever until the old brake fluid is completely out of the brake system.
  • Page 276 XCITING 500 . BRAKE SYSTEM Screws Cap/Diaphragm Remove the master cylinder reservoir cap and diaphragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid. Specification and classification: DOT 4 Clear Hose Step 1:...
  • Page 277 XCITING 500 . BRAKE SYSTEM Rear Caliper Air Bleed Screw Step 3: Connect a clear hose to the rear caliper air bleed screw. The rear brake fluid replacement is the same way as that of the step 1. Clear Hose...
  • Page 278 XCITING 500 . BRAKE SYSTEM 8. Tighten the bleed screw when the lever limit has been reached, then release the lever. 9. Repeat steps (5) to (7) until all the air bubbles have disappeared from the fluid. 10. Tighten the bleed screw.
  • Page 279 XCITING 500 . BRAKE SYSTEM Right Front Caliper Air Bleed Screw Add brake fluid to the proper level. * Check the operation of the brake after bleeding the brake system. Install the master cylinder reservoir cap and diaphragm. Clear Hose...
  • Page 280: Brake Pad

    XCITING 500 . BRAKE SYSTEM BRAKE PAD BRAKE PAD REPLACEMENT Front brake: Push the caliper pistons all the way in by pushing the caliper body inward to provide clearance for new pads. * Always replace the brake pads in pairs to ensure even disc pressure.
  • Page 281 XCITING 500 . BRAKE SYSTEM Tighten the pad pin to the specified torque. Torque: 18 N•m (1.8 kgf•m, 13 lbf•ft) Install the pad pin plug to the specified torque. Torque: 3 N•m (0.3 kgf•m, 2.2 lbf•ft) Pad Pin Pad Pin Plug...
  • Page 282 XCITING 500 . BRAKE SYSTEM Installation steps: Turn the parking brake caliper piston clockwise and push it into the parking brake caliper. Parking Brake Caliper Piston Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
  • Page 283: Brake Disc Inspection

    XCITING 500 . BRAKE SYSTEM Tighten the pad pin to the specified torque. Torque: 18 N•m (1.8 kgf•m, 13 lbf•ft) Install the pad pin plug to the specified torque. Torque: 3 N•m (0.3 kgf•m, 2.2 lbf•ft) Pad Pin Pad Pin Plug...
  • Page 284: Front Master Cylinder

    XCITING 500 . BRAKE SYSTEM Lower Handlebar Cover FRONT 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- Drain the front brake hydraulic system (page 16-4).
  • Page 285 XCITING 500 . BRAKE SYSTEM Master Cylinder Bolts Remove the bolts from the master cylinder holder and remove the master cylinder assembly. Holder Brake Lever DISASSEMBLY Remove the brake lever pivot bolt and nut. Remove the brake lever. Pivot Bolt Brake Light Switch Remove the screw and brake light switch.
  • Page 286 XCITING 500 . BRAKE SYSTEM Brake Light Switch ASSEMBLY Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Screw Brake Lever Apply silicone grease to the master piston tip.
  • Page 287 XCITING 500 . BRAKE SYSTEM Bolts Install the front master cylinders and holders 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) “UP”...
  • Page 288: Rear Master Cylinder

    XCITING 500 . BRAKE SYSTEM Lower Handlebar Cover 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- Drain the combination brake hydraulic system (page 16-5).
  • Page 289 XCITING 500 . BRAKE SYSTEM Holder Master Cylinder Remove the bolts from the master cylinder holder and remove the master cylinder assembly. Bolt Brake Lever DISASSEMBLY Remove the brake lever pivot bolt and nut. Remove the brake lever. Pivot Bolt Screw Remove the screw and brake light switch.
  • Page 290 XCITING 500 . BRAKE SYSTEM Screw ASSEMBLY Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Brake Light Switch Brake Lever Apply silicone grease to the master piston tip.
  • Page 291 XCITING 500 . BRAKE SYSTEM “UP” Mark Master Cylinder Install the rear master cylinders and holders with the “UP” mark facing up. Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque.
  • Page 292: Delay Valve

    XCITING 500 . BRAKE SYSTEM Sealing Washers Sealing Washers DELAY VAVLE 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 front cover (page 2-11).
  • Page 293 XCITING 500 . BRAKE SYSTEM Nuts INSTALLATION Install the delay valve and tighten the nuts securely. Delay Valve Sealing Washers Sealing Washers Install the brake hose eyelets 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.
  • Page 294: Front Brake Caliper

    XCITING 500 . BRAKE SYSTEM Brake Hose FRONT BRAKE CALIPER REMOVAL Drain the front brake hydraulic system (left front brake caliper: page 16-4) or combination brake hydraulic system (right front brake caliper: page 16-5). Remove the brake pads (page 16-10).
  • Page 295 XCITING 500 . BRAKE SYSTEM Boots Bracket Remove the caliper bracket from the caliper body. * Do not remove the caliper and bracket pins unless replacement. ASSEMBLY Apply silicone grease to the boots inside. Install the caliper bracket to the caliper.
  • Page 296: Rear/parking Brake Caliper

    XCITING 500 . BRAKE SYSTEM Brake Hose 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 caliper, then tighten the oil bolts to the specified torque.
  • Page 297 XCITING 500 . BRAKE SYSTEM Rear/Parking Brake Caliper Bolts Remove the mount bolts and rear/parking brake caliper from the rear fork. Brake Hose DISASSEMBLY (REAR BRAKE) Remove the pad spring from the caliper body. * Do not remove the retainer from the bracket unless replacement.
  • Page 298 XCITING 500 . BRAKE SYSTEM Install the pad spring into the caliper body as shown. Pad Spring Brake Arm DISASSEMBLY (PARKING BRAKE) Remove the lock nut and parking brake arm. Lock Nut Brake Shaft Push Rod Remove the parking brake shaft and push rod.
  • Page 299 XCITING 500 . BRAKE SYSTEM Bolts Removed the two bolts, gasket and parking brake bracket. Bracket Gasket ASSEMBLY (PARKING BRAKE) Install the gasket. Brake Shaft 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 shaft rolling surface.
  • Page 300 XCITING 500 . BRAKE SYSTEM Brake Arm Temporarily install the brake arm and the lock nut. Lock Nut Rear/Parking Brake Caliper Bolts INSTALLATION Install the brake pads (page 16-12). Install the rear/parking brake caliper to the rear fork and tighten the new mount bolts to specified torque.
  • Page 301: Parking Brake Lever Link

    XCITING 500 . BRAKE SYSTEM Connect the parking brake cable. Adjust the parking brake (page 3- 21). Brake Cable Brake Cable 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.
  • Page 302 XCITING 500 . BRAKE SYSTEM Parking Brake Lever Link Remove the two nuts and parking brake lever link. Nuts Parking Brake Switch DISASSEMBLY Remove the two screws and parking brake switch. ASSEMBLY Assembly is in the reverse order of disassembly.
  • Page 303: Battery/charging System

    . BATTERY/CHARGING SYSTEM XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1 SERVICE INFORMATION------------------------------------------------ 17-2 TROUBLESHOOTING----------------------------------------------------- 17-4 BATTERY -------------------------------------------------------------------- 17-5 CHARGING SYSTEM INSPECTION ----------------------------------- 17-6 ALTERNATOR CHARGING COIL-------------------------------------- 17-7 REGULATOR/RECTIFIER------------------------------------------------ 17-8 17-0...
  • Page 304: Charging System Layout

    . BATTERY/CHARGING SYSTEM XCITING 500 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT 17-1...
  • Page 305 . BATTERY/CHARGING SYSTEM XCITING 500 SERVICE INFORMATION GENERAL CAUTION • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns.
  • Page 306 . BATTERY/CHARGING SYSTEM XCITING 500 BATTERY CHARGING • This model comes with a maintenance free (MF) battery. Remember the following about MF batteries. ─ Use only the electrolyte that comes with the battery. ─ Use all of the electrolyte ─ Seal the battery properly ─...
  • Page 307: Troubleshooting

    . BATTERY/CHARGING SYSTEM XCITING 500 TROUBLESHOOTING Battery is damaged or weak Remove the battery. •Faulty battery Incorrect Check the battery condition. Correct Disconnect the regulator/rectifier Incorrect connectors and recheck the battery Install the battery. Check the battery current leakage. current leakage.
  • Page 308: Battery

    . BATTERY/CHARGING SYSTEM XCITING 500 Screws BATTERY REMOVAL/INSTALLATION Unlock and open the seat (page 2-3). Turn ignition switch OFF. Remove the screws and battery box cover. Battery Box Cover Positive Terminal Negative Terminal Remove the battery retainer. With the ignition switch to “OFF” disconnect...
  • Page 309: Charging System Inspection

    . BATTERY/CHARGING SYSTEM XCITING 500 BATTERY CHARGING Remove the battery (page 17-5). Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. * Turn the power ON/OFF at the chatger, not at the battery terminals.
  • Page 310: Alternator Charging Coil

    . BATTERY/CHARGING SYSTEM XCITING 500 CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. * Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.
  • Page 311: Regulator/rectifier

    . BATTERY/CHARGING SYSTEM XCITING 500 Measure the resistance between each Yellow wire terminals. Standard: 0.1-0.5 Ω (20ºC/68ºF) Check for continuity between each Yellow wire terminal of the alternator side connector and ground. There should be continuity. Replace the alternator stator if resistance is out of specification, or if any wire has continuity to ground.
  • Page 312 . BATTERY/CHARGING SYSTEM XCITING 500 Ground line Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Regulator/Rectifier Connector Charging coil line Measure the resistance between each Yellow wire terminals. Standard: 0.1-0.5 Ω (20ºC/68ºF)
  • Page 313 . BATTERY/CHARGING SYSTEM XCITING 500 Regulator/Rectifier Connector 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 removal. Bolts 17-10...
  • Page 314: Ignition System

    . IGNITION SYSTEM XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT------------------------------------------- 18-1 SERVICE INFORMATION------------------------------------------------ 18-2 TROUBLESHOOTING----------------------------------------------------- 18-2 IGNITION COIL INSPECTION ------------------------------------------ 18-4 IGNITION CONTROL MODULE ---------------------------------------- 18-5 18-0...
  • Page 315 . IGNITION SYSTEM XCITING 500 IGNITION SYSTEM LAYOUT IGNITION CIRCUIT 18-1...
  • Page 316 . IGNITION SYSTEM XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS ● Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● When servicing the ignition system, always follow the steps in the troubleshooting on page ???.
  • Page 317 . IGNITION SYSTEM 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. 18-3...
  • Page 318 . IGNITION SYSTEM XCITING 500 IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the floorboard (page 2-6). Check cylinder compression and check that the spark plugs is installed correctly in the cylinder. Disconnect the spark plug cap from the spark plug.
  • Page 319 . IGNITION SYSTEM XCITING 500 IGNITION PULSE GENERATOR INSPECTION Remove the luggage box (page 2-3). Disconnect the ignition pulse generator connector. Measure the ignition pulse generator resistance between the Green/White wire and Blue/Yellow wire. Standard: 516Ω (20ºC/68ºF) Ignition Pulse Generator Connector...
  • Page 320 . IGNITION SYSTEM XCITING 500 * Due to the semiconductor in circuit, it RESISTANCE INSPECTION is necessary to use a specified tester for Measure the resistance between the terminals. accurate testing. Use of an improper tester in an improper range may give false readings.
  • Page 321: Electric Starter

    . ELECTRIC STARTER XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ELECTRIC STARTER __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19-1 SERVICE INFORMATION------------------------------------------------ 19-2 TROUBLESHOOTING----------------------------------------------------- 19-2 STARTER MOTOR --------------------------------------------------------- 19-5 STARTER RELAY SWITCH---------------------------------------------- 19-7 19-0...
  • Page 322 . ELECTRIC STARTER XCITING 500 STARTING SYSTEM LAYOUT STARTING CIRCUIT 19-1...
  • Page 323 . ELECTRIC STARTER XCITING 500 SERVICE INFORMATION GENERAL • Always turn the ignition switch to “OFF” before servicing the starter motor. The motor could suddenly start, causing serious injury. • The starter motor can be serviced with the engine in the frame.
  • Page 324 . ELECTRIC STARTER XCITING 500 (From previous page) Check for loose or poorly •Poorly connected terminal Abnormal connected starter relay switch terminals. Normal •Poorly connected starter motor cable. Check for loose or poorly Abnormal connected or broken starter •Open circuit in starter motor cable.
  • Page 325 . ELECTRIC STARTER XCITING 500 (From previous page) Check the starter relay voltage •Faulty engine stop switch. No voltage (page 19-7). •Faulty starter switch. •Loose or poor contact of connector. Battery voltage registers •Open circuit in wire harness. Check the starter relay voltage •Faulty starter relay.
  • Page 326 . ELECTRIC STARTER XCITING 500 Starter Motor Cable STARTER MOTOR INSPECTION Remove the luggage box (page 2-3). Disconnect the starter motor cable from the starter relay switch. Turn the ignition switch to “ON”. Connect the starter motor cable directly to the battery positive terminal.
  • Page 327 . ELECTRIC STARTER XCITING 500 O-ring INSTALLATION Coat a new O-ring with engine oil and install it into the starter motor groove. Install the starter motor into the crankcase. Starter Motor Install the two bolts and tighten them securely. Bolts...
  • Page 328 . ELECTRIC STARTER XCITING 500 Starter Relay Switch STARTER RELAY SWITCH INSPECTION Remove the luggage box (page 2-3). Retracted the side stand. Turn the ignition switch to “ON” and engine stop switch on. Squeeze the rear brake lever fully and push the starter switch.
  • Page 329 . ELECTRIC STARTER XCITING 500 Starter Relay Switch CONTINUTY INSPECTION Disconnect the starter relay switch connector and 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.
  • Page 330: Lights/meters/switches

    . LIGHTS/METERS/SWITCHES XCITING 500 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULB REPLACEMENT --------------------------------------------------- 20- 2 SPEED SENSOR ------------------------------------------------------------ 20- 5 BRAKE LIGHT SWITCH-------------------------------------------------- 20- 7 IGNITION SWITCH -------------------------------------------------------- 20- 7 HANDLEBAR SWITCH --------------------------------------------------- 20- 8...
  • Page 331: Lights/meters/switches

    . LIGHTS/METERS/SWITCHES XCITING 500 SERVICE INFORMATION GENERAL * A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
  • Page 332: Bulb Replacement

    . LIGHTS/METERS/SWITCHES XCITING 500 Headlight Connector Dust Cover BULB REPLACEMENT HEADLIGHT * A halogen headlight bulb becomes very hot while the headlight is ON, and remain for a while after it is turned OFF. Be sure to let it cool down before servicing.
  • Page 333 . LIGHTS/METERS/SWITCHES XCITING 500 Socket Bulb FRONT TURN SIGNAL Remove the front cover (page 2-11). Turn the bulb socket counterclockwise to remove it. Remove the bulb and replace with a new one. Installation is in the reverse order of removal.
  • Page 334 . LIGHTS/METERS/SWITCHES XCITING 500 Connectors Disconnect the taillight/brake light connectors. Installation is in the reverse order of removal. Screw 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.
  • Page 335: Speed Sensor

    . LIGHTS/METERS/SWITCHES XCITING 500 Remove the bulb socket and license light bulb. Remove the bulb and replace with a new one. Installation is in the reverse order of removal. Socket Bulb Speed Sensor connector SPEED SENSOR REMOVAL/INSTALLATION Remove the front cover (page 2-11).
  • Page 336 . LIGHTS/METERS/SWITCHES XCITING 500 Speed Sensor ADJUSTMENT Remove the bolt and speed sensor. Bolt Remove the speed sensor cap. Lock Screw Loosen the lock screws and adjust speed sensor to the standard clearance. Standard: 0.3 – 1.2 mm (0.0012 – 0.048 in)
  • Page 337: Brake Light Switch

    . LIGHTS/METERS/SWITCHES XCITING 500 BRAKE LIGHT SWITCH Remove the upper handlebar cover (page 2-5). Disconnect front or rear light switch connector and check for continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.
  • Page 338: Handlebar Switch

    . LIGHTS/METERS/SWITCHES XCITING 500 Light Switch HANDLEBAR SWITCH INSPECTION Remove the 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 code...
  • Page 339 . LIGHTS/METERS/SWITCHES XCITING 500 Turn Signal Switch (Winker Switch) Left handlebar 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: Horn Switch Passing Switch...
  • Page 340: Parking Switch

    . LIGHTS/METERS/SWITCHES XCITING 500 PARKING SWITCH INSPECTION Remove the front cover (page 2-11). Disconnect the parking switch connector and check for continuity between the switch terminals. There should be continuity with the parking lever pull up, and there should be no continuity with the front brake lever is push down.
  • Page 341 . LIGHTS/METERS/SWITCHES XCITING 500 Dust Cover If the indicator does not come on, inspect as follow: Remove the dust cover and disconnect oil pressure switch terminal. Oil Pressure Switch Terminal Short the oil pressure switch wire terminal with the ground using a jumper wire.
  • Page 342 . LIGHTS/METERS/SWITCHES XCITING 500 Apply sealant to the oil pressure 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) Oil Pressure Switch Terminal Connect the oil pressure switch terminal to the switch.
  • Page 343: Fuel Unit

    . LIGHTS/METERS/SWITCHES XCITING 500 Fuel Unit FUEL UNIT REMOVAL Remove the floorboard (page 2-6). Disconnect the fuel unit connector. Fuel Unit Wire Retainer Turn the fuel unit retainer counterclockwise and remove it. Remove the fuel unit. * Be careful not to bend or damage the fuel unit float arm.
  • Page 344 . LIGHTS/METERS/SWITCHES XCITING 500 INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. * Before performing the following test, Upper operate the turn signals to determine that the battery circuit is normal. Check the fuel meter for correct indication by moving the fuel unit float up and down.
  • Page 345: Side Stand Switch

    . LIGHTS/METERS/SWITCHES XCITING 500 Install the fuel unit retainer. * Align the arrow mark on the fuel unit retainer with the arrow mark on the fuel tank. Side Stand Switch Connector SIDE STAND SWITCH INSPECTION Remove the left floor skirt (page 2-5).
  • Page 346: Horn

    . LIGHTS/METERS/SWITCHES XCITING 500 Installs the side stand switch aligning the switch pin with the side stand hole. Install and tighten the side stand switch bolt securely. Hole Connector HORN INSPECTION Remove the front cover (page 2-11) Disconnect the horn connectors from the horn.
  • Page 347: Bank Angle Sensor

    . LIGHTS/METERS/SWITCHES XCITING 500 BANK ANGLE SENSOR INSPECTION Support the scooter level surface. Remove the meter panel (page 2-13). Turn the ignition switch to “ON” and measure the voltage between the following terminals of the bank angle sensor connector with the connector connected.
  • Page 348: Heater Control Unit

    . LIGHTS/METERS/SWITCHES XCITING 500 Installation is in the reverse order of removal. * Install the bank angle sensor with its “UP” mark facing up. Tighten the mounting screws securely. HEATER CONTROL UNIT INSPECTION Heater control unit inspection 1.Open ignition switch to check if the brown /blue wire of it is enough voltage.
  • Page 349: Wiring Diagrams

    . WIRING DIAGRAMS XCITING 500 21-0...

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