Kymco XCITING 500 - Service Manual > Schematic Drawing, Service Information

SCHEMATIC DRAWING

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with a high quality brake degreasing agent.
• This section covers of the front wheel , fork, handlebar, and steering.
• A jack or other support is required to support the vehicle.
• Do not twist or bend the brake hose and pipe when servicing.
• Use genuine KYMCO replacement bolts and nuts for all suspension pivots and mounting points
• Refer to section 16 for brake system information.

SPECIFICATIONS

Unit: mm (in)

TORQUE VALUES

Handlebar bolt 23 N*m (2.3 kgf*m, 17 lbf*ft)
Steering stem nut 62 N*m (6.2 kgf*m, 45 lbf*ft)
Steering stem lock nut 45 N*m (4.5 kgf*m, 32 lbf*ft)
Steering top thread 17 N*m (1.7 kgf*m, 12 lbf*ft)
Steering stem pinch bolt 23 N*m (2.3 kgf*m, 17 lbf*ft)
Front axle bolt 55 N*m (5.5 kgf*m, 40 lbf*ft)
Front brake disc bolt 42 N*m (4.3 kgf*m, 31 lbf*ft) Lock bolt: replace with a new one.
Front fork bolt 23 N*m (2.3 kgf*m, 17 lbf*ft)

SPECIAL TOOLS

Long socket wrench E015
Bearing remover E037
Oil seal & bearing install driver E014

TROUBLESHOOTING

Hard steering

• Steering stem top thread too tight
• Worn or damaged steering bearings
• Worn or damaged steering bearing races
• Bent steering stem
• Insufficient tire pressure
• Faulty front tire

Steers to one side or does not track straight

• Damaged or loose steering bearings
• Bent fork
• Bent front axle: wheel installed incorrectly
• Bent frame
• Faulty front tire
• Worn or damaged front wheel bearings
• Worn or damaged engine mounting bushings

Front wheel wobbling

• Bent rim
• Worn or damaged front wheel bearings
• Faulty front tire
• Loose front axle fasteners

Wheel turns hard

• Faulty front wheel bearings
• Bent front axle
• Brake drug

Soft suspension

• Weak fork spring
• Insufficient fluid in fork
• Deteriorated fork fluid
• Incorrect fork fluid weight
• Low tire pressure

Hard suspension

• Bent fork tube
• Too much fluid in fork
• Incorrect fork fluid weight
• Clogged fork fluid passage
• High tire pressure

Front suspension noise

• Worn slider or fork tube bushing
• Insufficient fluid in fork
• Loose fork fastener

See also: