Download - X500 Cap 01 (General Information)
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1. GENERAL INFORMATION
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XCITING 500
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GENERAL INFORMATION__________________________________________________________________________________
SERIAL NUMBER------------------------------------------------------------ 1-1
SPECIFICATIONS ------------------------------------------------------------ 1-2
SERVICE PRECAUTIONS-------------------------------------------------- 1-3
TORQUE VALUES ----------------------------------------------------------- 1-7
SPECIAL TOOLS ------------------------------------------------------------- 1-9
LUBRICATION POINTS ---------------------------------------------------1-10
CABLE & HARNESS ROUTING--------------------------------------------1-12TROUBLESHOOTING------------------------------------------------------1-22
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SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
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SPECIFICATIONS
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)
Front wheel 120/70-15
Rear wheel 150/70-14
Ground clearance 150 mm (6 in)
Min. turning radius 2750 mm (110 in)
Starting system Electric starter motor
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 92 x75 mm(3.7 x3 in)
Compression ratio 10.5:1
Compression pressure13 kgf/cm (1300kPa,185 psi)
Open 2 BTDC
ValveIntake
Close 45 ABDCtiming Open 45 BBDC
Exhaust
Close 5 ATDCValve clearance Intake 0.1 mm (0.004 in)
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed (rpm) 1400rpm
Lubrication typeForced pressure &Wet sump
Oil pump type Trochoid
Oil filter type Full-flow filtration
Oil capacity 2.5 L (2.2 lmp qt,2.65 Us qt)
Final reduction oil
capacity
0.55 L (0.5 lmp qt,0.58 Us qt)
Cooling Type Liquid cooled
ITEM SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel capacity 12.8 L (3.38 lmp gal,
2.82 US gal
Type CVK
Main jet NO. 98
Venturi dia. 36 mm (1.44 in)
Throttle type PISTON
Type Full transistor digital
ignition
Spark plug CR8E
Ignition timing Throttle position sensor
Spark plug gap 0.60.7mm (0.002
0.003 in)
Battery Capacity 12V12AH
ClutchType Dry, centrifugal
automatic
Type Helical gear/spur gear
Operation Automatic centrifugalType
Type CVT
Preliminary 2.68 1
Final 5.4
FR/RR tire rollingcircumference
1724/1778 mm (69/71 in)
Front2 kg/cm (200 Kpa, 28
psi)Tire pressure(rider only/60kg) Rear
2.5 kg/cm (250 Kpa, 36psi)
Turning Left 40
angle
Right 40Brake s stem Rear Disk braketype Front Disk brake
Front Telescopic fork
Suspensiontype Rear Unit swing
Frame type Back born
Tires
FuelSstem
Carburetor
ElectricalEquipment
Inition
Sstem
PowerDriveSys
tem
Transmis-
sionGearRe
duction
Ra
tio
MovingDevice
Damping
Device
Lubrication
Sstem
Engine
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SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.
When tightening bolts or nuts, begin withlarger-diameter to smaller ones at several
times, and tighten to the specified torquediagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure touse special tools for removal andinstallation.
After disassembly, clean removed parts.Lubricate sliding surfaces with engine oil
before reassembly.
Apply or add designated greases andlubricants to the specified lubrication
points.
After reassembly, check all parts for propertightening and operation.
When two persons work together, payattention to the mutual working safety.
Disconnect the battery negative (-) terminalbefore operation.When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.
When connecting the battery, the positive(+) terminal must be connected first.
After connection, apply grease to thebattery terminals. Terminal caps shall be installed securely.
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If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.
After operation, terminal caps shall beinstalled securely.
When taking out the connector, the lock onthe connector shall be released beforeoperation.
Hold the connector body when connectingor disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,protruding or loose.
The connector shall be insertedcompletely.
If the double connector has a lock, lockit at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal.
Check the double connector cover forproper coverage and installation.
Insert the terminal completely.
Check the terminal cover for propercoverage.
Do not make the terminal cover openingface up.
Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only the insulatedsurfaces contact the wire harnesses.
ConfirmCapacity
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After clamping, check each wire to makesure it is secure.
Do not squeeze wires against the weld orits clamp.
After clamping, check each harness tomake sure that it is not interfering with anymoving or sliding parts.
When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.
Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends of
bolts and screws.Route wire harnesses passing through the
side of bolts and screws. Avoid theprojected ends of bolts and screws.
Route harnesses so they are neitherpulled tight nor have excessive slack.
Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.
When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.
Do not break the sheath of wire. If a wire or harness is with a broken sheath,
repair by wrapping it with protective tapeor replace it.
When installing other parts, do not press orsqueeze the wires.
Do not pulltoo tight
No Contact
Do not press orsqueeze the
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After routing, check that the wire harnessesare not twisted or kinked.
Wire harnesses routed along withhandlebar should not be pulled tight, haveexcessive slack or interfere with adjacentor surrounding parts in all steering
positions.
When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, removethe rust with sand paper or equivalent
before connecting.
Symbols:
The following symbols represent theservicing methods and cautions included inthis service manual.
: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Note
Engine Oil
Grease
Gear Oil
Do you understandthe instrument
Remove Rust
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TORQUE VALUESSTANDARD TORQUE VALUES
Item TorqueNm (kgfm, lbfft) Item TorqueNm (kgfm, lbfft)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
5(0.5, 4)
10 (1, 7)
22 (2.2, 16)
35 (3.5, 25)
55 (5.5, 40)
70 (7, 50)
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
3 (0.3, 2)
4 (0.4, 3)
9 (0.9, 6.5)
12 (1.2, 9)
27 (2.7, 20)
40 (4, 29)
Torque specifications listed below are for important fasteners.
ENGINE
Item QtyThread dia.
(mm)
Torque
Nm (kgfm, lbfft)Remarks
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
1
1
1
1
1
1
4
1
2
2
3
49
4
2
1
2
1
1
12
30
20
8
8
10
5
4
16
6
6
108
6
6
8
18
18
14
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)
Apply oil
Apply oil
Apply oilApply oil
Apply oil
Apply oil
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ENGINE (Contd)
Item QtyThread dia.
(mm)
Torque
Nm (kgfm, lbfft)
Remarks
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
1
1
8
13
2
2
1
28
14
8
6
16
8
PT 1/8
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)
Apply oil
Apply oil
Apply seal
FRAME
Item Qty Thread dia.(mm)
Torque
Nm (kgfm,
lbfft)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
Brake fluid boltMaster cylinder bolt
4
2
4
1
1
1
1
2
1
4
2
4
2
64
8
8
8
22
26
26
18
8
20
10
8
8
8
106
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)
35 (3.5, 25)12 (1.2, 9)
Replace a new one
Replace a new one
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FRAME (Contd)
Item Qty Thread dia.(mm)
Torque
Nm (kgfm,
lbfft)Remarks
ENGINE HANGER:
Engine hanger bolt
Engine mounting bolt
Engine mounting nut
Engine hanger rod nut
MUFFLER
Exhaust pipe nutMuffler mount bolt
4
1
1
1
23
10
14
14
10
810
50 (5, 36)
80 (8, 58)
80 (8, 58)
35 (3.5, 25)
20 (2, 14)35 (3.5, 25)
SPECIAL TOOLS
Tool Name Tool No. Remarks
Clutch spring compressor E053 Clutch disassembly
Bearing puller 10,12,15,18mm E037 Bearing removal
Valve spring compressor E040 Valve removal
Oil seal & bearing installer E014 Oil seal & bearing install
Tappet adjuster E036 Tappet adjustment
Flywheel puller E054 A.C. generator flywheel removal
Universal holder E017 Holding clutch for removal
Oil filter cartridge wrench E052 Cartridge removal or install
Flywheel holder E021 A.C. generator flywheel holding
Lock nut socket wrench F002 Steering stem removal or install
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LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundingsCylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Balancer shaft
Crankshaft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE 5W-50)
API SJ Engine Oil
Drive gear shaft
Countershaft
Final gear
Final gear shaft
Transmission gearshaft bearing part
Transmission oil: SAE 90
A.C. generator connector Adhesive
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FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified. This will avoidabnormal noise and rise the durability of the motorcycle.
Seat Lock
Grease
Throttle Cable
Engine Oil
Grease
Grease
Front/Rear Brake Lever Pivot
Grease
Grease
Rear Wheel BearingFront Wheel Bearing
Center Stand/Side Stand Pivot
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CABLE & HARNESS ROUTING
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TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
cEmpty fuel tankdClogged carburetor fuel inlet
tube, vacuum tube or fuel tubeeClogged auto fuel valvefClogged float oil passagegClogged fuel tank cap
breather holehClogged fuel straineriClogged fuel filterjFaulty fuel pump
cFaulty spark plugdFouled spark plugeFaulty ignition unitfFaulty A.C. generatorgBroken or shorted ignition coilhBroken or shorted exciter coiliFaulty ignition switch
cStarter motor idles butcrankshaft does not rotate
dValve clearance too smalleImproper valve and seat contactfWorn cylinder and piston ringsgBlown cylinder head gaskethFlaws in cylinder headiSeized valvejImproper valve timing
cFaulty auto bystarterdAir leaking through intake
pipeeIncorrect ignition timingfIncorrectly adjusted pilot screw
cFlooded carburetordFaulty auto bystartereThrottle valve excessively
open
Check if fuel reachescarburetor by looseningdrain screw
Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground
Inspection/Adjustment Probable Cause
Spark jumps
Normalcompression
Engine does not
fire
Weak or no spark
Low or nocompression
Engine fires but
does not start
Test cylinder
compression
Start engine by follow-ing normal starting
procedure
Remove spark plug andinspect again
Symptom
Fuel reachescarburetor
Fuel does notreach carburetor
Wet spark plugDry spark plug
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ENGINE LACKS POWER
cClogged air cleanerdRestricted fuel floweClogged fuel line between fuel
tank and carburetorfClogged exhaust mufflergFaulty auto bystarterhSplit carburetor vacuum piston
diaphragm
cFaulty ignition unitdFaulty A.C. generator
cImproper valve clearanceadjustmentdWorn valve seat (valve stem too
protruding
cImproper valve and seat contactdWorn cylinder and piston ringseBlown cylinder head gasketfFlaws in cylinder headgImproper valve timing
cClogged carburetor jets
cFouled spark plugdIncorrect heat range plug
cOil level too highdOil level too loweOil not changed
cClogged oil pipedFaulty oil pump
cInsufficient coolantdFaulty thermostateWorn cylinder and piston ringsfMixture too leangPoor quality fuelhExcessive carbon buildup in
combustion chamberiIgnition timing too earlyjAir in cooling system
cExcessive carbon build-up incombustion chamberdPoor quality fuele
Clutch slippingfMixture too leang Ignition timing too early
Start engine andaccelerate lightly forobservation
Inspection/Adjustment Symptom Probable Cause
Engine speedincreases
Correct timing
Engine speed doesnot increasesufficiently
Incorrect timing
Check ignition timing(using a timing light)
Test cylinder compression
Check carburetor forclogging
Rapidly accelerate or runat high speed
Remove spark plug andins ect
Check if engine overheats
Check valve clearance
Correct Incorrect
Normalcompression
Abnormalcompression
Not Clogged Clogged
Remove oil dipstick andcheck oil level and condition
Remove cylinder head oili e bolt and ins ect
Engine overheatsEngine does notoverheats
Plug not fouled ordiscolored
Plug fouled ordiscolored
Correct and notcontaminated
Incorrect orcontaminated
Valve train lubricatedproperly Valve train notlubricated properly
Engine does not knock Engine knocks
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POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
cFaulty ignition unit
dFaulty A.C. generator
cMixture too rich (turn screwout)
dMixture too lean (turn screwin)
cDamaged insulator rubberdCarburetor not securely
tightenedeFaulty intake manifold gasketfDeformed carburetor O-ring
cFaulty or fouled spark plugdFaulty ignition uniteFaulty A.C. generatorfFaulty ignition coilgBroken or shorted high
tension wirehFaulty ignition switch
cDamaged air cut-off valvediaphragm
dDamaged air cut-off valvespring
Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor aircut-off valve
Check carburetor gasketfor air leaks
Check carburetor pilotscrew adjustment
Correct timing Incorrect timing
Correctly adjusted
No air leak Air leaks
Good sparkWeak or inter-mittent spark
Good Faulty
Incorrectly adjusted
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POOR PERFORMANCE (AT HIGH SPEED)
cFaulty ignition unit
dFaulty A.C. generator
cImproperly adjusted valveclearance
dWorn valve seat
cEmpty fuel tankdClogged fuel tube or filter
eFaulty fuel pumpfCrackedfuelpump vacuumtube
cClean and unclog
cCam timing gear aligningmarks not aligned
cFaulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jetsfor clogging
Check fuel pump forfuel supply
Correct timing Incorrect timing
Check valve springtension
Check valve clearance
Fuel flows freely Fuel flow restricted
Correct Incorrect
Not clogged Clogged
Correctly adjusted Incorrectly adjusted
Not weakened Weak spring
Check valve timing
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ENGINE NOISE
cValve clearance too large
dWorn camshaft lobe
cWorn piston rings
dWorn piston pin and connecting rod smallend
eExcessive carbon build-up in combustionchamber
cDamaged cam chain tensioner
dWorn cam gear teeth
eWorn or damaged cam chain
fExtended cam chain
cFaulty crankshaft bearing
dWorn crank pin bearing
cWorn or damaged final reduction gears
dWorn final reduction gear shaft splines
Valve noise
Symptom Probable Cause
Crankshaft noise
Gear noise
Piston noise
Cam chain noise
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CLUTCH, DRIVE AND DRIVEN PULLEYS
cWorn or slipping drive belt
dBroken ramp plate
eBroken drive face spring
fSeparated clutch lining
gDamaged driven pulley shaft splines
hDamaged final gear
iSeized final gear
cBroken shoe spring
dClutch outer and clutch weight stuck
eSeized pivot
cWorn or slipping drive beltdWorn weight rollers
eSeized drive pulley bearings
fWeak driven face spring
gWorn or seized driven pulley bearings
cWorn or slipping drive belt
dWorn weight rollers
eWorn or seized driven pulley bearings
cOil or grease fouled drive belt
dWorn drive belt
eWeak driven face spring
fWorn or seized driven pulley bearings
Engine starts but motor-cycle does not move
Engine lacks power atstart of a grade(poorslope performance)
Symptom Probable Cause
Engine lacks power athigh speed
There is abnormal noiseor smell while running
Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheel rotateswhen engine idles)
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STARTER MOTOR
1. Starter motor wont turn
cBurned out fusedWeak or dead batteryeFaulty stop switchfLoose or disconnected
connectorsgBroken or shorted ignition
switch wire
cFaulty or weak battery
cPoor starter button connectiondOpen or shorted starter relayeLoose or disconnected
connectors
cWorn brushesdOpen or shorted wires or rotoreOpen starter motor cablefLoose connectors
cOpen wire harness
2. Starter motor turns slowly or idles
cWeak or dead battery
cLoose connector or terminaldPoor contact in starter relayeFaulty starter clutch
cSeized cylinder
cBroken or shorted startermotor cable
3. Starter motor does not stop turning
cFaulty starter pinion
cStarter relay shorted or stuckclosed
Inspection/Adjustment
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Symptom
Check operation ofstop switch byapplying brake
Stoplight does notcome on
Stoplight comes on
Check battery circuitby operating turnsignals
Check battery circuitby operating turnsignals
Turn ignition switchOFF
Probable Cause
Probable Cause
Probable Cause
Signals operateproperly
Signals dim, remainon or dont o erateCheck operation of
starter relay bydepressing starter
button
Connect startermotor directly to
battery
Connect startermotor directly to
battery
Starter motorturns slowly
Starter motorturns normally
Signals operatero erl
Signals dim, remainon or dont o erate
Not stopped Stopped
Rotate crankshaft
Starter motor turns Starter does not turn
Relay operatesproperly
Relay does notoperate
Turns easily Hard to turn
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NO SPARK AT SPARK PLUG
cFaulty spark plug
cFaulty spark plug
cPoorly connected coupler
cFaulty ignition switchdFaulty exciter coileFaulty pulser coilfFaulty ignition coil
cBroken wire harnessdPoorly connected coupler
cFaulty ignition unit
cFaulty ignition coil
Replace with a newspark plug and inspectagain
Check ignition unitcoupler for looseness
Inspection/Adjustment Symptom Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal Abnormal
Abnormal
Measure resistancebetween terminals ofignition unit coupler
Check related parts
Check ignition coil witha ignition unit tester
Weak or no spark
Not loose
Good spark
Loose
Good Good
Check spark plug capand high-tension wirefor looseness
Check ignition unitwith a ignition unittester
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POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
cFaulty AC generatordFaulty regulator/rectifiereFaulty battery
cShorted AC generator coildOpen circuit between AC
generator 3 yellow wires
cFaulty regulator/rectifierdFaulty AC generatoreLoose regulator/rectifier
couplerfLimit voltage too high
Overcharging
cFaulty batterydFaulty regulator/rectifiereBroken or poorly connected
regulator/rectifier black wire
cLimit voltage too high
Start engine and testlimit voltage of batteryterminals
Measure battery limitvoltage with an electrictester
Test output voltage ofregulator/rectifiercoupler red wire
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Normal
Normal
Voltage does notincrease
Abnormal
Resistance too low
Normal voltage No voltage
Measure resistancebetween AC generator
coil terminals
Check resistancebetween regulator/rectifier terminals
Normal Abnormal
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1. GENERAL INFORMATION
1-31
XCITING 500
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
cBurned out fusedWeak or dead batteryeFaulty ignition switchfLoose or disconnected
connectorsgBroken wire harness
cFaulty float
cBroken or shorted fuel unitwire
cDisconnectedconnectordIncorrectly connected
connectoreBroken or shorted wire in
fuel gauge2. Pointer fluctuates or swings (Ignition switch ON)
cBurned out fusedWeak or dead batteryeFaulty ignition switchfLoose or disconnected
connectorgBroken wire harness
cPoor contact in fuel unit
cInsufficient damping oil infuel gauge
cLoose or disconnected
connectorcBroken or shorted wire in
fuel gauge
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Remove fuel unit andcheck operation of
pointer by moving floatu and down
Remove fuel unit andcheck operation of
pointer by moving float
up and down
Signals operatero erl
Signals dim, remainon or dont o erate
Signals operatero erl
Signals dim, remainon or dont o erate
Check battery circuit byoperating turn signals
Check battery circuit byoperating turn signalsand horn
Probable Cause
Probable Cause
Pointer does not
move
Pointer moves
Pointer movesPointer does notmove
Check operation ofpointer by opening andshorting fuel unitterminal on wire harnessside
Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer
Pointer does notmove
Pointer moves
Pointer does notmove in accord-ance with float
Pointer moves inaccordance withfloat
Good Faulty
Check connectors forproper connection
Check connectors forproper connection.
Good Faulty
Float up: FullFloat down: Empty
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1. GENERAL INFORMATION XCITING 500
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
(Front and rear tire pressures are normal)
cSteering stem nut too tightdBroken steering steel balls
cExcessive wheel bearing playdBent rimeLoose axle nut
cMisaligned front and rear wheelsdBent front fork
POOR SUSPENSION PERFORMANCE
(Front and rear tire pressures are normal)
cWeak shock springdExcessive loadeShock damper oil leaking
cBent fork tube or shock rod
cFork tube and slider binding
dFork spring and slider bindingeDamaged shock stopper rubberfLoose steering stem nut
POOR BRAKE PERFORMANCE
cWorn brake liningsdForeign matter on brake liningseRough brake drum contacting area
cWorn brake liningsdForeign matter on brake liningseRough brake drum contacting area
cWorn brake liningsdWorn brake cam contacting area on
cWorn brake liningsdForeign matter on brake linings
cSluggish or elongated brake cablesdBrake shoes improperly contacteWater and mud in brake system
fOil or grease on brake linings
Steering is heavy
Suspension is too soft
Soft brake lever
Hard brake lever
Poor brake performance
Front or rear wheel iswobbling
Symptom
Symptom
Symptom
Probable Cause
Probable Cause
Probable Cause
Steering handlebar pullsto one side
Suspension is too hard
Suspension is noisy
Brake squeaks
Hard to brake