Kymco XCITING 500 - Service Manual > Steering Stem

REMOVAL

Remove the front fork.

Remove the steering handle.

Remove the bolts and brake hoses clamp.

Remove the nut, washer and handle post.

Special tool: Long socket wrench E015

Remove the brake hoses from the clamps on the steering stem.

Remove the steering stem lock nut.

Special tool: Long socket wrench F007

Remove the lock washer.

Loosen the steering top thread.

Hold the steering stem and remove the steering stem top thread.

Remove the steering stem and lower bearing.

Remove the dust seal, upper inner race and upper bearing.

BEARING REPLACEMENT

Remove the upper bearing outer race.

NOTE: Always replace the bearings and races as a set.

Remove the lower bearing outer race.

Drive a new upper bearing race into the steering head pipe.

Drive a new lower bearing race into the steering head pipe.

Install the steering stem lock nut onto the steering to prevent the threads from being damaged when removing the lower bearing inner race from the steering stem.

Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the steering stem.

Remove the dust seal.

Install the dust seal.

Apply grease to a new lower bearing inner race using a hydraulic press.

INSTALLATION

Apply grease to each new bearings and inner races.

Install the upper bearing, upper inner race and dust seal.

Install the lower bearing onto the stem.

Insert the steering stem into the steering head pipe.

Install the steering top thread and tighten it to the specified torque.

Torque: 17 N*m (1.7 kgf*m, 12 lbf*ft)

Turn the steering stem lock-to-lock several times to seat the bearings.

Temporarily loosen the steering stem top thread.

Install the fork.

Install the front wheel.

Install the steering top thread to the specified torque with the front wheel is grounded.

Torque: 17 N*m (1.7 kgf*m, 12 lbf*ft)

Install the lock washer aligning its tab into the groove on the steering stem.

Install the steering stem lock nut.

Hold the steering stem top thread and tighten the steering stem lock nut to the specified torque.

Special tool: Long socket wrench F007

Torque: 45 N*m (4.5 kgf*m, 32 lbf*ft)

Make sure that the steering stem moves smoothly without play or binding.

Install the handle post to the steering stem and front forks.

Install the washer and nut.

Tighten the handle post nut to the specified torque.

Special tool: Long socket wrench E015

Torque: 62 N*m (6.2 kgf*m, 45 lbf*ft)

Install the brake hose clamp and tighten the bolts securely.

Route the brake hoses and wires properly.

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