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

1. GENERAL INFORMATION

XCITING 500

1

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GENERAL INFORMATION

1

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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

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SERIAL NUMBER

XCITING 500

Location of Frame Serial Numbe

Location of Engine Serial Numbe

1-1

1. GENERAL INFORMATION

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m

g

r

m

m

y

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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 0.6～0.7mm (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

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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