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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SPECIFICATIONS
XCITING 500
ITEMSPECIFICATIONS
NameXCITING 500
Overall length2250 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 typeO.H.C.
Displacement498.5 cm3 (30.4 cu-in)
Fuel Used92# nonleaded gasoline
Front wheel 83 kg (183 lbs)
Dry weightRear wheel 132 kg (290 lbs)
Total215 kg (473 lbs)
Front wheel 90 kg (198 lbs)
Curb weightRear wheel 141 kg (310 lbs)
Total231 kg (508 lbs)
Tires
Ground clearance150 mm (6 in)
Min. turning radius2750 mm (110 in)
Starting system
TypeGasoline, 4-stroke
Cylinder arrangementSingle cylinder
Combustion chamber type Semi-sphere
Valve arrangementO.H.C., chain drive
Bore x stroke (mm)
Compression ratio10.5:1
Compression pressure
Engine
Valve
timin
Valve clearance
(cold)
Idle speed (rpm)1400rpm
Lubrication
S
stem
Cooling TypeLiquid 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 typeTrochoid
Oil filter typeFull-flow filtration
Oil capacity
Final reduction oil
capacity
Open2° BTDC
Close45° ABDC
Open45° BBDC
Close5° ATDC
Intake0.1 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,
ITEMSPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel S
Fuel capacity12.8 L (3.38 lmp gal,
Carbureto
stem
Electrical Equipment
Power Drive System
Moving Device
Brake syste
type
Damping
Device
Frame typeBack born
TypeCVK
Main jet NO.98
Venturi dia.φ36 mm (φ1.44 in)
Throttle typePISTON
I
Type
nition S
Spark plugCR8E
stem
Ignition timingThrottle position senso
Spark plug gap0.6~0.7mm (0.002~
Battery Capacity12V12AH
Clutch
Ratio
FR/RR tire rolling
circumference
Tire pressure
(rider only/60
kg)
TurningLeft40°
angle
Suspension
type
TypeDry, centrifugal
Transmis-
sion Gear
TypeHelical gear/spur gear
Operation
Reduction
TypeCVT
Preliminary
Final
Front
Rear
Right40°
RearDisk brake
FrontDisk 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
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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
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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.