Kymco MO X500 Service Manual - chap 01 (info generali)

1. GENERAL INFORMATION
XCITING 500
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
1
__________________________________________________________________________________
SERIAL NUMBER------------------------------------------------------------ 1-1 SPECIFICATIONS------------------------------------------------------------ 1-2 SERVICE PRECAUTIONS-------------------------------------------------- 1-3 TORQUE VALUES ----------------------------------------------------------- 1-7 SPECIAL TOOLS ------------------------------------------------------------- 1-9 LUBRICATION POINTS ---------------------------------------------------1-10 CA B L E & HA R N E S S R O UTI N G--------------------------------------------1-12 TROUBLESHOOTING------------------------------------------------------1-22
1-0
1. GENERAL INFORMATION
r
r
SERIAL NUMBER
XCITING 500
Location of Frame Serial Numbe
Location of Engine Serial Numbe
1-1
1. GENERAL INFORMATION
r
m
g
r
m
m
y
r
g
y
y
SPECIFICATIONS
XCITING 500
ITEM SPECIFICATIONS
Name XCITING 500 Overall length 2250 mm (90 in) Overall width (mm) 815 mm (33 in) Overall height (mm) 1450 mm (58 in) Wheel base (mm) 1570 mm (63 in) Engine type O.H.C. Displacement 498.5 cm3 (30.4 cu-in) Fuel Used 92# nonleaded gasoline
Front wheel 83 kg (183 lbs)
Dry weight Rear wheel 132 kg (290 lbs)
Total 215 kg (473 lbs)
Front wheel 90 kg (198 lbs)
Curb weight Rear wheel 141 kg (310 lbs)
Total 231 kg (508 lbs)
Tires
Ground clearance 150 mm (6 in)
Min. turning radius 2750 mm (110 in)
Starting system Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive
Bore x stroke (mm) Compression ratio 10.5:1
Compression pressure
Engine
Valve timin
Valve clearance (cold)
Idle speed (rpm) 1400rpm
Lubrication
S stem
Cooling Type Liquid cooled
Front wheel 120/70-15
Rear wheel 150/70-14
Electric starter moto
92 x 75 mm (3.7 x 3 in)
13 kgf/c 185 psi)
Intake
Exhaust
Lubrication type Oil pump type Trochoid
Oil filter type Full-flow filtration Oil capacity
Final reduction oil capacity
Open 2° BTDC Close 45° ABDC Open 45° BBDC
Close 5° ATDC Intake 0.1 mm (0.004 in) Exhaust 0.1 mm (0.004 in)
Forced pressure & Wet sump
2.5 L (2.2 lmp qt,
2.65 Us qt)
0.55 L (0.5 lmp qt,
0.58 Us qt)
² (1300kPa,
ITEM SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel S
Fuel capacity 12.8 L (3.38 lmp gal,
Carbureto
stem
Electrical Equipment
Power Drive System
Moving Device
Brake syste type
Damping
Device
Frame type Back born
Type CVK Main jet NO. 98 Venturi dia. φ36 mm (φ1.44 in) Throttle type PISTON
I
Type
nition S
Spark plug CR8E
stem
Ignition timing Throttle position senso Spark plug gap 0.60.7mm (0.002
Battery Capacity 12V12AH Clutch
Ratio
FR/RR tire rolling circumference
Tire pressure (rider only/60 kg)
Turning Left 40° angle
Suspension type
Type Dry, centrifugal
Transmis-
sion Gear
Type Helical gear/spur gear Operation
Reduction
Type CVT Preliminary
Final
Front
Rear
Right 40° RearDisk brake
Front Disk brake Front
Rear
2.82 US gal
Full transistor digital ignition
0.003 in)
automatic
Automatic centrifugal Type
2.68 – 1
5.4
1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28 psi)
2.5 kg/c psi)
Telescopic fork
Unit swing
² (250 Kpa, 36
1-2
1. GENERAL INFORMATION
XCITING 500
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Apply or add designated greases and
lubricants to the specified lubrication points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil before reassembly.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting
points, fasteners, and lines for proper connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
1-3
1. GENERAL INFORMATION
m
XCITING 500
If the fuse is burned out, find the cause and
repair it. Replace it with a new one according to the specified capacity.
Confir Capacity
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before operation.
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose negative terminal.
Check the double connector cover for
proper coverage and installation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Insert the terminal completely.Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses.
1-4
1. GENERAL INFORMATION
N
t
XCITING 500
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any moving or sliding parts.
Route harnesses so they are neither
pulled tight nor have excessive slack.
Do not pull too tight
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be installed securely.
When fixing the wire harnesses, do not
make it contact the parts which will generate high heat.
o Contac
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the projected ends of bolts and screws.
Do not break the sheath of wire.If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not press or squeeze the
1-5
1. GENERAL INFORMATION
After routing, check that the wire harnesses
are not twisted or kinked.
XCITING 500
Symbols:
The following symbols represent the servicing methods and cautions included in this service manual.
Wire harnesses routed along with
handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
When a testing device is used, make sure to
understand the operating methods thoroughly and operate according to the operating instructions.
Do you understand the instrument
Engine Oil
Grease
Gear Oil
: Apply engine oil to the
specified points. (Use designated engine oil for lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Note
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent before connecting.
Remove Rust
1-6
1. GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
XCITING 500
Item
5mm bolt and nut 6mm bolt and nut
8mm bolt and nut 10mm bolt and nut 12mm bolt and nut
14mm bolt and nut
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty
MAINTENANCE:
Engine oil drain plug Oil strainer screen cap Oil filter cartridge Transmission oil drain bolt Transmission oil filler bolt Spark plug Tappet adjust nut
LUBRICATION SYSTEM:
Oil pump screw Oil cooler bolt
COOLING SYSTEM:
Water pump cover bolt
CYLINDER HEAD:
Breather separator bolt Cylinder head bolt (1 – 4) Cylinder head bolt (5 – 13) Cylinder head cover bolt Cam chain tensioner bolt Tensioner pivot bolt Rocker arm shaft
DRIVE/DRIVEN PULLEY:
Drive face nut Clutch out nut
Torque
N•m (kgf•m, lbf•ft)
5(0.5, 4) 10 (1, 7) 22 (2.2, 16) 35 (3.5, 25) 55 (5.5, 40)
70 (7, 50)
Thread dia.
1 1 1 1 1 1 4
1 2
2
3 4 9 4 2 1 2
1 1
Item
4mm screw 5mm screw
6mm screw, SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange bolt and nut
(mm)
12 30 20
8 8
10
5
4
16
6
6
10
8 6 6 8
18
18 14
N•m (kgf•m, lbf•ft)
Torque
25 (2.5, 18) 15 (1.5, 11)
10 (1, 7) 24 (2.4, 18) 24 (2.4, 18)
12 (1.2, 9)
9 (0.9, 6)
3 (0.3, 2)
35 (3.5, 25)
13 (1.3, 9)
13 (1.3, 9) 48 (4.8, 35) 23 (2.3, 17)
10 (1, 7)
12 (1.2, 9)
10 (1, 7)
45 (4.5, 32)
135 (13.5, 97)
80 (8, 58)
Torque
N•m (kgf•m, lbf•ft)
3 (0.3, 2) 4 (0.4, 3) 9 (0.9, 6.5) 12 (1.2, 9) 27 (2.7, 20)
40 (4, 29)
Remarks
Apply oil
Apply oil Apply oil Apply oil
Apply oil Apply oil
1-7
1. GENERAL INFORMATION
ENGINE (Cont’d)
XCITING 500
Item Q‘ty
Drive plate nut
ALTERNATOR
ACG flywheel nut
FINAL REDUCTION:
Transmission cover bolt
CRANKCASE:
Crankcase bolt Oil pipe bolt Cam chain guide
SWITCH:
Oil pressure switch
FRAME
Item Q‘ty Thread dia.(mm)
1
1
8
13
2 2
1
Thread dia.
(mm)
28
14
8
6
16
8
PT 1/8
Torque
N•m (kgf•m, lbf•ft)
78 (7.8, 56)
55 (5.5, 40)
27 (2.7, 20)
12 (1.2, 9) 43 (4.3, 31)
20 (2, 15)
22 (2.2, 16)
Torque
N•m (kgf•m,
lbf•ft)
Remarks
Apply oil Apply oil
Apply seal
Remarks
STEERING:
Handlebar bolt Upper pinch bolt Lower pinch bolt Bridge stem nut Steering stem lock nut Top thread
WHEEL:
Front axle bolt Front fork bolt Rear axle nut
SUSPENSION:
Rear shock absorber bolt Rear fork
BRAKE:
Front caliper mounting bolt Rear caliper mounting bolt
4 2 4 1 1 1
1 2 1
4 2
4 2
8 8
8 22 26 26
18
8 20
10
8
8
8
23 (2.3, 17) 23 (2.3, 17) 23 (2.3, 17) 62 (6.2, 45) 45 (4.5, 32) 17 (1.7, 12)
55 (5.5, 40) 23 (2.3, 17)
180 (18, 130)
40 (4, 29)
32 (3.2, 23)
32 (3.2, 23) 32 (3.2, 23)
Replace a new one Replace a new one
Brake fluid bolt Master cylinder bolt
6 4
10
6
35 (3.5, 25)
12 (1.2, 9)
1-8
1. GENERAL INFORMATION
FRAME (Cont’d)
Item Q‘ty Thread dia.(mm)
ENGINE HANGER:
Torque
N•m (kgf•m,
lbf•ft)
XCITING 500
Remarks
Engine hanger bolt Engine mounting bolt Engine mounting nut Engine hanger rod nut
MUFFLER
Exhaust pipe nut Muffler mount bolt
4 1 1 1
2 3
SPECIAL TOOLS
Tool Name Tool No. Remarks
Clutch spring compressor Bearing puller 10,12,15,18mm E037
Valve spring compressor E040 Oil seal & bearing installer E014 Tappet adjuster E036 Flywheel puller E054 Universal holder E017 Oil filter cartridge wrench E052 Flywheel holder E021 Lock nut socket wrench F002
E053 Clutch disassembly
10 14 14 10
8 10
Bearing removal Valve removal Oil seal & bearing install Tappet adjustment A.C. generator flywheel removal Holding clutch for removal Cartridge removal or install A.C. generator flywheel holding Steering stem removal or install
50 (5, 36) 80 (8, 58) 80 (8, 58)
35 (3.5, 25)
20 (2, 14)
35 (3.5, 25)
1-9
Loading...
+ 23 hidden pages