X500 Cap 01 (General Information)

8/22/2019 X500 Cap 01 (General Information)

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1. GENERAL INFORMATION

1-0

XCITING 500

1

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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

1


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1-1

XCITING 500

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number


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1-2

XCITING 500

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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XCITING 500

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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XCITING 500

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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XCITING 500

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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XCITING 500

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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1-7

XCITING 500

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



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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XCITING 500

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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XCITING 500

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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XCITING 500

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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XCITING 500

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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XCITING 500

CABLE & HARNESS ROUTING


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XCITING 500


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XCITING 500


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XCITING 500


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XCITING 500


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XCITING 500

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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XCITING 500

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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XCITING 500

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


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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XCITING 500

POOR PERFORMANCE (AT HIGH SPEED)


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


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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XCITING 500

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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XCITING 500

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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XCITING 500

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



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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1-29

XCITING 500

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 coil

Replace with a newspark plug and inspectagain

Check ignition unitcoupler for looseness


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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XCITING 500

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



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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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



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





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

X500 Cap 01 (General Information)

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Transcript of X500 Cap 01 (General Information)