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11. FINAL REDUCTION
XCITING 500
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FINAL REDUCTION
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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
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11. FINAL REDUCTION
SCHEMATIC DRAWING
XCITING 500
11-1
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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.
SPECIFICATIONS
Specified Oil: SAE 90#
Oil Capacity:
At disassembly : 0.55 L (0.57 US qt, 0.5 Imp qt)
At change : 0.45 L (0.48 US qt, 0.4 Imp qt)
TORQUE VALUES
Transmission case cover bolt 27 N•m (2.7 kgf•m, 20 lbf•ft)
Oil drain bolt 24 N•m (2.4 kgf•m, 18 lbf•ft)
Oil filler bolt 24 N•m (2.4 kgf•m, 18 lbf•ft)
SPECIAL TOOLS
Bearing puller E037
Oil seal & bearing driver E014
Universal bearing puller E030
TROUBLESHOOTING
Engine starts but motorcycle won‘t move
• Damaged transmission
• Seized or burnt transmission
• Faulty drive and driven pulleys/clutch
Abnormal noise
• Worn, seized or chipped gears
• Worn bearing
Oil leaks
• Oil level too high
• Worn or damaged oil seal
• Cracked crankcase
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11. FINAL REDUCTION
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XCITING 500
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).
Drain the transmission gear oil into a clean
container.
Remove the eight bolts and transmission
cover.
Remove the gasket and dowel pins.
Bolts
Transmission Cove
Gaske
Remove the final gear shaft.
11-3
Dowel Pin
Final Gear Shaf
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XCITING 500
Remove the countershaft.
Remove the final gear.
Countershaf
Final Gea
Remove the driven pulley (page 10-13).
Press the driveshaft out or the left
crankcase.
Check the drive shaft for wear or damage.
Driveshaf
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11. FINAL REDUCTION
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Remove the driveshaft oil seal and bearing
from the transmission case.
If the bearing is left on the driveshaft,
remove it with the special tool.
Special tool:
Universal bearing puller E030
Oil Seal
Driveshaf
Bearing
FINAL REDUCTION
INSPECTION
Check the driveshaft, countershaft, final
gear and final gear shaft for wear or
damage.
11-5
Universal Bearing Pulle
Countershaft Driveshaf
Final Gear Shaft Final Gea
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XCITING 500
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:
Bearing puller E037
Apply engine oil to new bearings cavities.
Drive new bearings into the transmission
case.
Driveshaft Bearing Bearing Pulle
Countershaft Bearing Final Gear Shaft Bearing
Oil Seal & Bearing Drive
Special tool:
Oil seal & bearing driver E014
BEARING REPLACEMENT
(TRANSMISSION COVER)
Remove the final gear shaft oil seal.
Oil Seal
11-6
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11. FINAL REDUCTION
XCITING 500
Remove the bearing snap ring.
Remove the final gear shaft bearing.
Snap Ring
Final Gear Shaft Bearing
Remove the countershaft or drive shaft
bearing using the special tool.
Special tool:
Bearing puller E037
11-7
Countershaft Bearing
Drive Shaft Bearing
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11. FINAL REDUCTION
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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.
Drive new bearing into the transmission
cover.
XCITING 500
Oil Seal & Bearing Drive
Special tool:
Oil seal & bearing driver E014
Install the bearing snap ring.
Oil Seal & Bearing Drive
Snap Ring
11-8
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Apply oil to a new final gear shaft oil seal
lip and outer surface.
Install the final gear shaft oil seal.
FINAL REDUCTION ASSEMBLY
Install the final gear to the transmission
case.
XCITING 500
Oil Seal
Final Gea
Install the countershaft to the transmission
case.
11-9
Countershaf
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11. FINAL REDUCTION
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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.
XCITING 500
Final Gear Shaft Gaske
Dowel Pins
Bolts
Install the transmission cover and tighten
the eight bolts in a crisscross pattern in 2 –
3 steps to the specified torque.
Torque: 27 N•m (2.7 kgf•m, 20 lbf•ft)
Fill the transmission case with the
recommended oil (page 3-17).
11-10
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