Kymco XCITING 500 - Service Manual > Steering Handlebar
REMOVAL
Remove the front cover.
Remove the upper handlebar cover.
Remove the band bolt and disconnect the left handlebar switch connector.
Remove the two screws and lower handlebar cover.
Remove the bolts, master cylinder holders and rear master cylinders.
Disconnect the left brake light switch connectors.
NOTE: Keep the master cylinder upright to prevent air from entering the hydraulic system.
Remove the bolts, master cylinder holders and front master cylinders.
NOTE: Keep the master cylinder upright to prevent air from entering the hydraulic system.
Remove the screws and right handlebar switch housing.
Remove the bolt/right handlebar weight.
Remove the bolts and upper holders.
Remove the handlebar from the handlebar post and right handlebar switch housing.
INSTALLATION
Pass the handlebar through the right handlebar switch housing.
Align the holes on the handlebar with the pins on the handle post.
Install the handlebar to the handle post.
Install the upper holders with its punch marks facing toward.
Install the upper holder bolts.
Tighten the front bolts first, then tighten the rear bolts.
Torque: 23 N*m (2.3 kgf*m, 17 lbf*ft)
Install the throttle grip and bolt/right handlebar weight and tighten the bolt.
Align the pin on the right handlebar switch housing with the hole on the steering handle.
Install the screws and tighten the forward screw first, then tighten the rear screw.
Align the pin on the rear master cylinder holder with the hole on the handlebar.
Install the front master cylinders and holder with the "UP" mark facing up.
Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque.
Torque: 12 N*m (1.2 kgf*m, 9 lbf*ft)
Align the pin on the rear master cylinder holder with the hole on the handlebar.
Install the rear master cylinders and holder with the "UP" mark facing up.
Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque.
Torque: 12 N*m (1.2 kgf*m, 9 lbf*ft)
Connect the brake light switch connectors.
Connect the left handlebar switch connector and tighten the band bolt.
See also:
Kymco XCITING 500 - Service Manual > Fork
REMOVAL Remove the front wheel. Remove the front fender. Remove the bolt and hose clamp. Remove the bolt and speed sensor (only right fork). Remove the upper fork pinch bolt.
Kymco XCITING 500 - Service Manual > Steering Stem
REMOVAL Remove the front fork. Remove the steering handle. Remove the bolts and brake hoses clamp.
