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GENERAL INFORMATION

XCITING 500

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GENERAL INFORMATION
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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-------------------------------------------- 1-12 TROUBLESHOOTING------------------------------------------------------ 1-22

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1. GENERAL INFORMATION
SERIAL NUMBER

XCITING 500

Location of Frame Serial Number

Location of Engine Serial Number

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1. GENERAL INFORMATION
SPECIFICATIONS
ITEM Name Overall length Overall width (mm) Overall height (mm) Wheel base (mm) Engine type Displacement Fuel Used Front wheel Dry weight Rear wheel Total Front wheel Curb weight Rear wheel Total Front wheel Tires Rear wheel Ground clearance
Min. turning radius

XCITING 500

SPECIFICATIONS XCITING 500 2250 mm (90 in) 815 mm (33 in) 1450 mm (58 in) 1570 mm (63 in) O.H.C. 498.5 cm3 (30.4 cu-in)
92# nonleaded gasoline

ITEM SPECIFICATIONS Air cleaner type & No Wet paper type element Fuel capacity Carburetor Ignition System Type Main jet NO. Venturi dia. Throttle type Type Spark plug Ignition timing Spark plug gap 12.8 L (3.38 lmp gal, 2.82 US gal CVK 98 36 mm (1.44 in) PISTON Full transistor digital ignition CR8E Throttle position sensor 0.60.7mm (0.002 0.003 in) 12V12AH Dry, centrifugal automatic
Helical gear/spur gear

Fuel System Electrical Equipment Power Drive System

Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement

83 kg (183 lbs) 132 kg (290 lbs) 215 kg (473 lbs) 90 kg (198 lbs) 141 kg (310 lbs) 231 kg (508 lbs) 120/70-15 150/70-14 150 mm (6 in) 2750 mm (110 in) Electric starter motor

Battery Capacity Type Clutch

Transmis- Reduction sion Gear Ratio

Type Operation Type

Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C., chain drive 92 x 75 mm Bore x stroke (mm) (3.7 x 3 in) Compression ratio 10.5:1 13 kgf/cm (1300kPa, Compression pressure 185 psi) Open 2 BTDC Intake Close 45 ABDC Valve timing Exhaust Open 45 BBDC Close 5 ATDC Valve clearance Intake 0.1 mm (0.004 in) Exhaust 0.1 mm (0.004 in) (cold) Idle speed (rpm) 1400rpm pressure & Lubrication type Forced Wet sump Oil pump type Trochoid Oil filter type Full-flow filtration 2.5 L (2.2 lmp qt, Oil capacity 2.65 Us qt) Final reduction oil 0.55 L (0.5 lmp qt, 0.58 Us qt) capacity Cooling Type Liquid cooled Lubrication System

Automatic centrifugal Type CVT 2.68 1 5.4

1724/1778 mm (69/71 in)

Preliminary Final FR/RR tire rolling circumference Tire pressure Front (rider only/60 kg) Rear Turning angle

Moving Device

2 kg/cm (200 Kpa, 28 psi) 2.5 kg/cm (250 Kpa, 36 psi)

Engine

Brake system type Damping Device Suspension type

Left 40 Right 40 Rear Disk brake Front Disk brake Front Rear Telescopic fork Unit swing Back born

Frame type

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1. GENERAL INFORMATION
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.

XCITING 500

Apply or add designated greases and lubricants to the specified lubrication points.

After reassembly, check all parts for proper tightening and operation. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. When two persons work together, pay attention to the mutual working safety.

Use genuine parts and lubricants. Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface.

When servicing the motorcycle, be sure to use special tools for removal and installation. 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.

After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.

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1. GENERAL INFORMATION
If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.
Confirm Capacity

XCITING 500

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.

After operation, terminal caps shall be installed securely.

Before connecting a terminal, check for damaged terminal cover or loose negative terminal.

When taking out the connector, the lock on the connector shall be released before operation.

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.

Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up.

Check if any connector terminal is bending, protruding or loose.

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.

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1. GENERAL INFORMATION
After clamping, check each wire to make sure it is secure.

XCITING 500

Route harnesses so they are neither pulled tight nor have excessive slack.

Do not pull too tight

Do not squeeze wires against the weld or its clamp.

Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.

After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. 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.
No Contact

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.

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.

When installing other parts, do not press or squeeze the wires.

Do not press or squeeze the i

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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.

Engine Oil

: Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication.

Grease

: Transmission Gear Oil (90#)

Gear Oil

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

: 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

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1. GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES 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 Nm (kgfm, lbfft) 5(0.5, 4) 10 (1, 7) 22 (2.2, 16) 35 (3.5, 25) 55 (5.5, 40) 70 (7, 50) Item 4mm screw 5mm screw 6mm screw, SH bolt 6mm flange bolt and nut 8mm flange bolt and nut 10mm flange bolt and nut

XCITING 500

Torque Nm (kgfm, lbfft) 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 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 Qty 1 1 1 1 1 1 4 1 2 2 3 4 9 4 2 1 2 1 1 Thread dia. (mm) 12 30 20 8 8 10 5 4 16 6 6 10 8 6 6 8 18 18 14 Torque Nm (kgfm, lbfft) 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 oil Remarks

Apply oil

Apply oil Apply oil

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1. GENERAL INFORMATION
ENGINE (Contd) Item 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 Qty 1 1 8 13 2 2 1 Thread dia. (mm) 28 14 8 6 16 8 PT 1/8 Torque Nm (kgfm, lbfft) 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)

XCITING 500

Remarks

Apply oil Apply oil

Apply seal

FRAME Torque Nm (kgfm, lbfft) 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

Item 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 bolt Master cylinder bolt

Qty Thread dia.(mm)

Remarks

4 2 4 1 1 1 1 2 1 4 2 4 2 6 4

8 8 8 22 26 26 18 8 20 10 8 8 8 10 6

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1. GENERAL INFORMATION
FRAME (Contd) Torque Nm (kgfm, lbfft) 50 (5, 36) 80 (8, 58) 80 (8, 58) 35 (3.5, 25) 20 (2, 14) 35 (3.5, 25)

XCITING 500

Item ENGINE HANGER: Engine hanger bolt Engine mounting bolt Engine mounting nut Engine hanger rod nut MUFFLER Exhaust pipe nut Muffler mount bolt

Qty Thread dia.(mm)

Remarks

4 1 1 1 2 3

10 14 14 10 8 10

SPECIAL TOOLS
Tool Name Clutch spring compressor Bearing puller 10,12,15,18mm Valve spring compressor Oil seal & bearing installer Tappet adjuster Flywheel puller Universal holder Oil filter cartridge wrench Flywheel holder Lock nut socket wrench Tool No. E053 E037 E040 E014 E036 E054 E017 E052 E021 F002 Remarks Clutch disassembly Bearing removal Valve removal Oil seal & bearing install Tappet adjustment A.C. generator flywheel removal Holding clutch for removal Cartridge removal or install A.C. generator flywheel holding Steering stem removal or install

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1. GENERAL INFORMATION
LUBRICATION POINTS
ENGINE Lubrication Points 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 surroundings Cylinder 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 Drive gear shaft Countershaft Final gear Final gear shaft Transmission gearshaft bearing part A.C. generator connector Adhesive Lubricant

XCITING 500

Genuine KYMCO Engine Oil (SAE 5W-50) API SJ Engine Oil

Transmission oil: SAE 90

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1. GENERAL INFORMATION
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. abnormal noise and rise the durability of the motorcycle.

XCITING 500

This will avoid

Engine Oil Grease Seat Lock Throttle Cable

Grease Front/Rear Brake Lever Pivot

Rear Wheel Bearing Grease Center Stand/Side Stand Pivot Grease

Front Wheel Bearing Grease

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1. GENERAL INFORMATION
CABLE & HARNESS ROUTING

XCITING 500

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1. GENERAL INFORMATION
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment
Check if fuel reaches carburetor by loosening drain screw

XCITING 500

Symptom

Probable Cause

Fuel reaches carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps

Fuel does not reach carburetor

cEmpty fuel tank dClogged carburetor fuel inlet tube, vacuum tube or fuel tube eClogged auto fuel valve fClogged float oil passage gClogged fuel tank cap breather hole hClogged fuel strainer iClogged fuel filter jFaulty fuel pump cFaulty spark plug dFouled spark plug eFaulty ignition unit fFaulty A.C. generator gBroken or shorted ignition coil hBroken or shorted exciter coil iFaulty ignition switch cStarter motor idles but crankshaft does not rotate dValve clearance too small eImproper valve and seat contact fWorn cylinder and piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing

Weak or no spark

Test cylinder compression Normal compression Low or no compression

Start engine by following normal starting procedure Engine does not fire Engine fires but does not start cFaulty auto bystarter dAir leaking through intake pipe eIncorrect ignition timing fIncorrectly adjusted pilot screw

Remove spark plug and inspect again Dry spark plug Wet spark plug cFlooded carburetor dFaulty auto bystarter eThrottle valve excessively open

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1. GENERAL INFORMATION
ENGINE LACKS POWER Inspection/Adjustment
Start engine and accelerate lightly for observation Engine speed increases Check ignition timing (using a timing light) Correct timing Check valve clearance Correct Test cylinder compression Normal compression Check carburetor for clogging Not Clogged Remove spark plug and inspect Plug not fouled or discolored Remove oil dipstick and check oil level and condition Correct and not contaminated Remove cylinder head oil pipe bolt and inspect Valve train lubricated properly Check if engine overheats Engine does not overheats Rapidly accelerate or run at high speed Engine does not knock Engine knocks Engine overheats Valve train not lubricated properly Incorrect or contaminated Plug fouled or discolored Clogged Abnormal compression Incorrect Incorrect timing Engine speed does not increase sufficiently

XCITING 500

Symptom

Probable Cause
cClogged air cleaner dRestricted fuel flow eClogged fuel line between fuel tank and carburetor fClogged exhaust muffler gFaulty auto bystarter hSplit carburetor vacuum piston diaphragm cFaulty ignition unit dFaulty A.C. generator cImproper valve clearance adjustment dWorn valve seat (valve stem too protruding cImproper valve and seat contact dWorn cylinder and piston rings eBlown cylinder head gasket fFlaws in cylinder head gImproper valve timing cClogged carburetor jets

cFouled spark plug dIncorrect heat range plug cOil level too high dOil level too low eOil not changed

cClogged oil pipe dFaulty oil pump cInsufficient coolant dFaulty thermostat eWorn cylinder and piston rings fMixture too lean gPoor quality fuel hExcessive carbon buildup in combustion chamber iIgnition timing too early jAir in cooling system cExcessive carbon build-up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean g Ignition timing too early

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1. GENERAL INFORMATION
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

XCITING 500

Inspection/Adjustment
Check ignition timing

Symptom

Probable Cause

Correct timing

Incorrect timing

cFaulty ignition unit dFaulty A.C. generator

Check carburetor pilot screw adjustment cMixture too rich (turn screw out) dMixture too lean (turn screw in)

Correctly adjusted

Incorrectly adjusted

Check carburetor gasket for air leaks cDamaged insulator rubber dCarburetor not securely tightened eFaulty intake manifold gasket fDeformed carburetor O-ring

No air leak Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark Check carburetor air cut-off valve

Air leaks

Weak or intermittent spark

cFaulty or fouled spark plug dFaulty ignition unit eFaulty A.C. generator fFaulty ignition coil gBroken or shorted high tension wire hFaulty ignition switch

Good

Faulty

cDamaged air cut-off valve diaphragm dDamaged air cut-off valve spring

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1. GENERAL INFORMATION
POOR PERFORMANCE (AT HIGH SPEED)

XCITING 500

Inspection/Adjustment
Check ignition timing

Symptom

Probable Cause

Correct timing

Incorrect timing

cFaulty ignition unit dFaulty A.C. generator

Check valve clearance cImproperly adjusted valve clearance dWorn valve seat

Correctly adjusted

Incorrectly adjusted

Check fuel pump for fuel supply cEmpty fuel tank dClogged fuel tube or filter eFaulty fuel pump fCracked fuel pump vacuum tube

Fuel flows freely

Fuel flow restricted

Check carburetor jets for clogging cClean and unclog

Not clogged

Clogged

Check valve timing cCam timing gear aligning marks not aligned

Correct Check valve spring tension

Incorrect

Not weakened

Weak spring

cFaulty spring

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1. GENERAL INFORMATION
ENGINE NOISE

XCITING 500

Symptom

Probable Cause

Valve noise

cValve clearance too large dWorn camshaft lobe

cWorn piston rings Piston noise dWorn piston pin and connecting rod small end eExcessive carbon build-up in combustion chamber

Cam chain noise

cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain

Crankshaft noise

cFaulty crankshaft bearing dWorn crank pin bearing

Gear noise

cWorn or damaged final reduction gears dWorn final reduction gear shaft splines

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1. GENERAL INFORMATION
CLUTCH, DRIVE AND DRIVEN PULLEYS

XCITING 500

Symptom

Probable Cause
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

Engine starts but motorcycle does not move

Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)

cBroken shoe spring dClutch outer and clutch weight stuck eSeized pivot

Engine lacks power at start of a grade(poor slope performance)

cWorn or slipping drive belt dWorn weight rollers eSeized drive pulley bearings fWeak driven face spring gWorn or seized driven pulley bearings

Engine lacks power at high speed

cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings

There is abnormal noise or smell while running

cOil or grease fouled drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings

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1. GENERAL INFORMATION
STARTER MOTOR 1. Starter motor wont turn
Inspection/Adjustment Check operation of stop switch by applying brake Stoplight comes on Check battery circuit by operating turn signals Check operation of starter relay by depressing starter button Connect starter motor directly to battery Starter motor turns Starter does not turn Signals operate properly Stoplight does not come on Symptom

XCITING 500

Probable Cause cBurned out fuse dWeak or dead battery eFaulty stop switch fLoose or disconnected connectors gBroken or shorted ignition switch wire cFaulty or weak battery

Signals dim, remain on or dont operate

Relay operates properly

Relay does not operate

cPoor starter button connection dOpen or shorted starter relay eLoose or disconnected connectors cWorn brushes dOpen or shorted wires or rotor eOpen starter motor cable fLoose connectors cOpen wire harness

2. Starter motor turns slowly or idles

Inspection/Adjustment Check battery circuit by operating turn signals Signals operate properly Connect starter motor directly to battery Starter motor turns slowly Rotate crankshaft Turns easily Hard to turn cSeized cylinder cBroken or shorted starter motor cable Starter motor turns normally cLoose connector or terminal dPoor contact in starter relay eFaulty starter clutch Signals dim, remain on or dont operate cWeak or dead battery Symptom Probable Cause

3. Starter motor does not stop turning

Inspection/Adjustment Turn ignition switch OFF Not stopped Stopped cFaulty starter pinion cStarter relay shorted or stuck closed Symptom Probable Cause

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1. GENERAL INFORMATION
NO SPARK AT SPARK PLUG Inspection/Adjustment
Replace with a new spark plug and inspect again Weak or no spark Check spark plug cap and high-tension wire for looseness Not loose Check ignition unit coupler for looseness Good Measure resistance between terminals of ignition unit coupler Loose Good spark

XCITING 500

Symptom

Probable Cause

cFaulty spark plug

cFaulty spark plug

Good

cPoorly connected coupler

Normal Check related parts

Abnormal

Normal

Abnormal

cFaulty ignition switch dFaulty exciter coil eFaulty pulser coil fFaulty ignition coil cBroken wire harness dPoorly connected coupler

Check ignition unit with a ignition unit tester Normal Check ignition coil with a ignition unit tester Abnormal cFaulty ignition coil Abnormal cFaulty ignition unit

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1. GENERAL INFORMATION
Undercharging Inspection/Adjustment
Start engine and test limit voltage of battery terminals Normal voltage Measure resistance between AC generator coil terminals Normal Resistance too low Voltage does not increase

XCITING 500

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Symptom

Probable Cause

cFaulty AC generator dFaulty regulator/rectifier eFaulty battery

cShorted AC generator coil dOpen circuit between AC generator 3 yellow wires

Test output voltage of regulator/rectifier coupler red wire Normal voltage No voltage cFaulty regulator/rectifier dFaulty AC generator eLoose regulator/rectifier coupler fLimit voltage too high

Overcharging Inspection/Adjustment
Measure battery limit voltage with an electric tester Normal Abnormal cFaulty battery dFaulty regulator/rectifier eBroken or poorly connected regulator/rectifier black wire

Symptom

Probable Cause

Check resistance between regulator/ rectifier terminals Normal Abnormal cLimit voltage too high

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1. GENERAL INFORMATION
FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment
Check battery circuit by operating turn signals Signals operate properly Signals dim, remain on or dont operate

XCITING 500

Symptom

Probable Cause

Remove fuel unit and check operation of pointer by moving float up and down Float up: Full Float down: Empty Check operation of pointer by opening and shorting fuel unit terminal on wire harness side Check connectors for proper connection

cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connectors gBroken wire harness

Pointer does not move

Pointer moves

cFaulty float

Pointer does not move

Pointer moves

cBroken or shorted fuel unit wire

Good

Faulty

cDisconnected connector dIncorrectly connected connector eBroken or shorted wire in fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON) Inspection/Adjustment

Check battery circuit by operating turn signals and horn Remove fuel unit and check operation of pointer by moving float up and down Move float up and down rapidly (1 round /sec.) to check the operation of pointer Signals operate properly Signals dim, remain on or dont operate

Symptom

Probable Cause

cBurned out fuse dWeak or dead battery eFaulty ignition switch fLoose or disconnected connector gBroken wire harness cPoor contact in fuel unit

Pointer moves

Pointer does not move

Pointer moves in accordance with float

Pointer does not move in accordance with float

cInsufficient damping oil in fuel gauge

Check connectors for proper connection. Good Faulty cLoose or disconnected connector cBroken or shorted wire in fuel gauge

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1. GENERAL INFORMATION
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause

XCITING 500

(Front and rear tire pressures are normal) Steering is heavy Front or rear wheel is wobbling Steering handlebar pulls to one side cSteering stem nut too tight dBroken steering steel balls cExcessive wheel bearing play dBent rim eLoose axle nut cMisaligned front and rear wheels dBent front fork

POOR SUSPENSION PERFORMANCE Symptom Probable Cause

(Front and rear tire pressures are normal) cWeak shock spring dExcessive load eShock damper oil leaking cBent fork tube or shock rod cFork tube and slider binding dFork spring and slider binding eDamaged shock stopper rubber fLoose steering stem nut

Suspension is too soft Suspension is too hard

Suspension is noisy

POOR BRAKE PERFORMANCE Symptom Probable Cause

cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dWorn brake cam contacting area on cWorn brake linings dForeign matter on brake linings cSluggish or elongated brake cables dBrake shoes improperly contact eWater and mud in brake system fOil or grease on brake linings

Soft brake lever

Hard brake lever

Hard to brake Poor brake performance

Brake squeaks

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