Page 1
15. REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
XCITING 500
15
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REAR FORK/REAR WHEEL/
15
REAR SHOCK ABSORBER
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SCHEMATIC DRAWING ------------------------------------------------- 15- 1
SERVICE INFORMATION------------------------------------------------ 15- 2
TROUBLESHOOTING----------------------------------------------------- 15- 3
REAR WHEEL/REAR FORK --------------------------------------------- 15- 4
REAR SHOCK ABSORBER ---------------------------------------------- 15-10
15-0
Page 2
15. REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
SCHEMATIC DRAWING
XCITING 500
15-1
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15. REAR FORK/REAR WHEEL/
⎯
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y
⎯
r
⎯
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REAR SHOCK ABSORBER
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean
a contaminated disc with a high quality brake degreasing agent.
• Riding on damaged rims impairs safe operation of the vehicle.
• This section covers of the rear wheel and rear suspension.
• 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.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth
Cold tire pressure
Wheel rim runout
Rider onl
Rider and passenge
Radial
Axial
250 kPa (2.50 kgf/cm2, 36 psi)
XCITING 500
Unit: mm (in)
2.0 (0.08
2.0 (0.08
2.0 (0.08
TORQUE VALUES
Rear brake disc bolt 42 N•m (4.3 kgf•m, 31 lbf•ft)
ALOC bolt: replace with a new one.
Rear axle nut 180 N•m (18 kgf•m, 130 lbf•ft)
Rear shock absorber upper mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Rear shock absorber lower mounting bolt 40 N•m (4 kgf•m, 29 lbf•ft)
Final shaft holder bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
Right/parking brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)
ALOC bolt: replace with a new one.
15-2
Page 4
15. REAR FORK/REAR WHEEL/
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
• Engine mount bolt not tightened properly
• Loose or worn final gear shaft bearing Rear suspension noisy
• Insufficient tire pressure • Loose mounting fasteners
• Unbalanced tire and wheel • Faulty shock absorber
• Weak rear suspension mount bushings
Soft suspension
• Weak rear shock absorber spring
• Oil leakage from damper unit
Rear wheel noise
• Worn rear wheel axle bearings
• Worn rear fork bearings
• Deformed rear fork
XCITING 500
15-3
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15. REAR FORK/REAR WHEEL/
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t
REAR SHOCK ABSORBER
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.
Remove the bolts and brake hose/cable
clamps from the rear fork.
Remove the rear shock absorber lower mount
bolt.
Remove the rear axle nut.
XCITING 500
Axle Nu
Bolts/Clamps
Remove the rear fork mount bolts and rear
fork.
Mount Bol
Mount Bolts
Rear Fork
15-4
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15. REAR FORK/REAR WHEEL/
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REAR SHOCK ABSORBER
Remove the inner side collar.
Remove the rear wheel.
XCITING 500
Inner Side Colla
INSTECTION
Wheel
Check the wheel rim runout using dial
indicator.
Actual urnout is 1/2 the total indicator
reading.
Service Limits:
Radial: 2.0mm (0.08 in)
Axial: 2.0mm (0.08 in)
15-5
Rear Wheel
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15. REAR FORK/REAR WHEEL/
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REAR SHOCK ABSORBER
DISASSEMBLY
Wheel
Remove the brake disc bolts and rear brake
disc.
REAR FORK BEARING
REPLACEMENT
XCITING 500
Brake Disc
Outer Side Colla
Remove the outer side collar from the rear
fork.
Remove the dust seal from the rear fork.
Dust Seal
15-6
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15. REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
XCITING 500
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.
Remove and discard the bearing if the race
does not turn smoothly and quietly, or if it fits
loosely in the rear fork.
Remove the bearing from the rear fork.
Drive in a new bearing squarely until it is
fully seated, using the special tools.
Special tool:
Oil seal & bearing installE014
Bearing Snap Ring
Install the snap ring to the groove of the rear
fork securely.
15-7
Bearing Snap Ring
Page 9
15. REAR FORK/REAR WHEEL/
REAR SHOCK ABSORBER
Apply grease to the new dust seal lip and
install it to the rear fork.
Dust Seal
Check the bushing for wear or damage.
XCITING 500
Busing
ASSEMBLY
Wheel
Install the brake disc onto the wheel hub.
Install the new brake disc bolts and tighten
them to the specified torque.
Torque: 42 N•m (4.3 kgf•m, 31 lbf•ft)
Brake Disc
15-8
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15. REAR FORK/REAR WHEEL/
r
REAR SHOCK ABSORBER
INSTALLATION
Install the rear wheel onto the final gear shaft,
aligning the spline.
Rear Wheel
XCITING 500
Install the inner side collar.
Apply grease to the final gear shaft.
Install the rear fork and tighten the bolts to
the specified torque.
Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft)
Inner Side Colla
Mount Bolts
15-9
Rear Fork
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15. REAR FORK/REAR WHEEL/
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REAR SHOCK ABSORBER
XCITING 500
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.
Release the main stand and support the
scooter securely on its side stand.
Bolts/Clamps
Mount Bol
Axle Nu
Tighten the rear axle nut to the specified
torque.
Torque: 180 N•m (18 kgf•m, 130 lbf•ft)
Install the rear/parking brake caliper (page
16-30).
Install the muffler (page 2-16).
REAR SHOCK ABSORBER
REMOVAL
Remove he luggage box (page 2-3).
Support the scooter securely on its center
stand.
Support the engine securely with a hoist or
equivalent.
Lower Mount Bol
Remove the rear shock absorber lower mount
bolt.
15-10
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15. REAR FORK/REAR WHEEL/
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REAR SHOCK ABSORBER
XCITING 500
Remove the rear shock absorber upper mount
bolt and shock absorber.
INSTECTION
Check the damper unit for leakage or other
damage.
Check the upper joint bushing for wear or
damage.
Upper Mount Bol
Bushing
Replace the shock absorber assembly if
necessary.
INSTALLATION
Install the rear shock absorber tighten the
upper mount bolt to the specified torque.
Torque: 40 N•m (4 kgf•m, 29 lbf•ft)
Damper Uni
Upper Mount Bol
15-11
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15. REAR FORK/REAR WHEEL/
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REAR SHOCK ABSORBER
XCITING 500
Install and tighten the lower mount bolt to the
specified torque.
Torque: 40 N•m (4 kgf•m, 29 lbf•ft)
Lower Mount Bol
15-12
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