Kymco XCITING 500 - Service Manual > Camshaft Removal

Remove the cylinder head cover.

Turn the crankshaft clockwise and align the "T" mark on the flywheel with the index mark on the right crankcase cover.

Remove the cam chain tensioner lifter sealing bolt, spring and sealing washer.

Remove the two bolts, cam chain tensioner and gasket.

Remove the two bolts and cam chain guide.

Loosen and remove the twelve camshaft holder bolts in a crisscross pattern in several steps, then remove the camshaft holders.

Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase.

Remove the camshafts

INSPECTION

Cam chain guide

Inspect the am chain slipper surface of the cam chain guide for wear or damage.

Camshaft holder

Inspect the bearing surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication.

Check the stop pin spring on the exhaust camshaft holder for damage.

Replace the stop pin assembly with a new one if the spring is damage.

Camshaft

Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial gauge.

Service limit: 0.05 mm (0.002 in)

Inspect camshaft lobes for pitting/scratches/blue discoloration.

Measure the cam lobe height.

Service Limits:
  IN : 37.11 mm (1.4844 in)
  EX: 36.86 mm (1.4744 in)

If any defects are found, replace the camshaft with a new one, then inspect lubrication system.

Check the decompression system by turning the decompressor cam on the exhaust camshaft.

You should be able to turn the decompressor cam clockwise smoothly, but the decompressor should not turn counterclockwise.

Cam chain tensioner

Check the one-way cam operation (tensioner) Unsmooth operation → Replace.

ROCKER ARMS REMOVAL

Remove the camshaft.

Remove the rocker arm shafts and washers, then remove the rocker arms.

INSPECTION

Rocker arm shaft

Inspect the rocker arm shaft for blue discoloration or grooves.

If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.

Measure each rocker arm shaft O.D.

Measure the I.D. of each rocker arm.

Measure arm to shaft clearance.

Replace as a set if out of specification.

Service limits: 0.1 mm (0.004 in)

Inspect the rocker arm bore, cam lobe contact surface and adjuster surface for wear/pitting/scratches/blue discoloration.

If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.

Measure each rocker arm shaft O.D.

Measure the I.D. of each rocker arm.

Measure arm to shaft clearance.

Replace as a set if out of specification.

Service limits: 0.1 mm (0.004 in)

See also: