Kymco XCITING 500 - Service Manual > Drive Pulley

REMOVAL

Remove the left crankcase cover.

Hold the drive pulley face with the special tool and loosen the drive pulley face nut.

Special tool: Universal holder E017

Remove the nut, washer and drive pulley face.

Hold the clutch outer with the special tool as shown.

Special tool: Universal holder E017

Remove the nut, collar and clutch outer.

Remove the clutch/driven pulley assembly and drive belt.

Remove the washer.

Remove the movable drive face assembly while holding the back of the face (ramp plate).

Remove the washer.

DISASSEMBLY

Drive pulley

Remove the ramp plate and slide pieces.

Remove the weight rollers.

Remove the drive face boss from the movable drive face.

INSPECTION

Movable Drive Face

Check the drive face boss for wear or damage.

Measure the boss O.D..

Service limit: 28.9 mm (1.156 in)

Measure the face bushing I.D..

Service limit: 29.1 mm (1.164 in)

Weight Roller

Check each roller for wear or damage.

Measure the weight roller O.D..

Service limit: 29.5 mm (1.18 in)

Movable Drive Face

Check the dust seal for wear or damage.

ASSEMBLY

Clean any oil and grease from the pulley faces and weight rollers.

Install the drive face boss into the movable drive face.

Install the weight rollers to the movable drive face.

The direction of all weight rolls is the same. The thin side is towards to clockwise.

Install the slide pieces to ramp plate.

Install the ramp plate to the movable drive face.

INSTALLATION

Install the washer.

The inner indentation side on the washer faces the left crankcase.

Clean any oil and grease from the pulley faces and the drive belt.

Install the movable drive face assembly onto the crankshaft while holding the ramp plate.

Install the washer.

Install the drive belt and clutch/driven pulley assembly.

Install the drive belt with the arrow mark facing up and towards to clockwise.

Hold the clutch outer with the special tool as shown.

Special tool: Universal holder E017

Install the collar and nut.

Tighten the nut to the specified torque.

Torque: 80 N*m (8 kgf*m, 58 lbf*ft)

Install the drive pulley face and washer.

Apply oil to the drive pulley face nut threads and seating surface and install the nut.

Hold the drive face with the special tool and tighten the bolt to the specified torque.

Special tool: Universal holder E017

Torque: 135 N*m (13.5 kgf*m, 97 lbf*ft)

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