X500_250 Cap 01 (Info Generali)

8/19/2019 X500_250 Cap 01 (Info Generali)

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1. GENERAL INFORMATION

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XCITING 500/250

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GENERAL INFORMATION __________________________________________________________________________________

SERIAL NUMBER-----------------------------------------------------------1 - 1

SPECIFICATIONS (XCITING 500)---------------------------------------1 - 2

SPECIFICATIONS (XCITING 250)---------------------------------------1 - 3

SERVICE PRECAUTIONS -------------------------------------------------1 - 4

TORQUE VALUES ----------------------------------------------------------1 - 8

SPECIAL TOOLS ------------------------------------------------------------1-12

LUBRICATION POINTS ---------------------------------------------------1-13CABLE & HARNESS ROUTING (XCITING 500)------------------------- 1-15

CABLE & HARNESS ROUTING (XCITING 250)------------------------- 1-25

TROUBLESHOOTING------------------------------------------------------1-33

1


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XCITING 500/250

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number


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1-2

XCITING 500/250

SPECIFICATIONS (XCITING 500)

ITEM SPECIFICATIONS

Name XCITING 500

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 498.5 cm3 (30.4 cu-in)

Fuel Used 92# nonleaded gasoline

Front wheel 83 kg (183 lbs)

Dry weight Rear wheel 132 kg (290 lbs)

Total 215 kg (473 lbs)Front wheel 90 kg (198 lbs)

Curb weight Rear wheel 141 kg (310 lbs)

Total 231 kg (508 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 150 mm (6 in)

Min. turning radius 2750 mm (110 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 92 x 75 mm(3.7 x 3 in)

Compression ratio 10.5:1

Compression pressure13 kgf/cm² (1300kPa,185 psi)

Open 2° BTDCIntake valve

Close 45° ABDC

Open 45° BBDCExhaust valve

Close 5° ATDCValve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1400 rpm

Lubrication typeForced pressure &Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 2.5 L (2.2 lmp qt,2.65 Us qt)

Final reduction oil

capacity

0.55 L (0.5 lmp qt,0.58 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 lmp gal,

2.82 US gal

Type CVK

Main jet NO. 98

Venturi dia. φ36 mm (φ1.44 in)

Throttle type PISTON

Type Full transistor ignition

Spark plug CR8E

Ignition timing Throttle position sensor Spark plug gap 0.6～0.7mm (0.002～

0.003 in)

Battery Capacity 12V12AH

Clutch TypeDry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugalType

Type CVT

Preliminary 2.68 – 1Final 5.4

FR/RR tire rollingcircumference

1724/1778 mm (69/71 in)

Front2 kg/cm² (200 Kpa, 28

psi)Tire pressure(rider only/60kg) Rear

2.5 kg/cm² (250 Kpa, 36 psi)

Turning Left 40°

angle Right 40°

Brake s stem Rear Disk braketype Front Disk brake

Front Telescopic fork

Suspensiontype Rear Unit swing

Frame type Back born

Tires

F u e l S s t e m

C a r b ur e t or

E l e c t r i c a l E q ui pm e n t

I ni t i on

S s t e m

P o w e r Dr i v e S y s t e m

T r a n s mi s -

s i on G e a r R e d u

c t i on

R a t i o

M o vi n gD e vi c e

D a m pi n g

D e vi c e

L u b r i c a t i on

S s t e m

E n gi n e


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XCITING 500/250

SPECIFICATIONS (XCITING 250)

ITEM SPECIFICATIONS

Name XCITING 250

Overall length 2250 mm (90 in)

Overall width 815 mm (33 in)

Overall height 1450 mm (58 in)

Wheel base 1570 mm (63 in)

Engine type O.H.C.

Displacement 251/249.1 cm3

(15.3/15.8 cu-in)

Fuel Used 92# nonleaded gasoline


Dry weight Rear wheel 110 kg (242 lbs)Total 185 kg (407 lbs)


Curb weight Rear wheel 119 kg (262 lbs)

Total 200 kg (440 lbs)

Front wheel 120/70-15

Rear wheel 150/70-14

Ground clearance 170 mm (6.8 in)

Min. turning radius 2600 mm (104 in)

Starting system Electric starter motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C., chain drive

Bore x stroke 72.7 x 60 mm(2.908 x 2.4 in)

Compression ratio 10.3:1

Compression pressure15 kgf/cm² (1500kPa,213 psi)

Open 9° BTDCIntake valve

Close 45° ABDC

Open 38° BBDCExhaust valveClose 10° ATDC

Valve clearance Intake 0.1 mm (0.004 in)

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed 1600 rpm

Lubrication typeForced pressure &Wet sump

Oil pump type Trochoid

Oil filter type Full-flow filtration

Oil capacity 1.1 L (0.97 lmp qt,1.17 Us qt)

Final reduction oilcapacity 0.2 L (0.18 lmp qt,0.21 Us qt)

Cooling Type Liquid cooled

ITEM SPECIFICATIONS

Air cleaner type & No Wet paper type element

Fuel capacity 12.8 L (3.38 lmp gal,

2.82 US gal

Type CVK

Main jet NO. 94

Venturi dia. φ30 mm (φ1.2 in)

Throttle type PISTON

Type Full transistor ignition

Spark plug DPR7EA-9

Ignition timing Throttle position sensor Spark plug gap 0.6～0.7mm (0.002～

0.003 in)

Battery Capacity 12V12AH

ClutchType Dry, centrifugal

automatic

Type Helical gear/spur gear

Operation Automatic centrifugalType

Type CVT

Preliminary 0.83 – 2.2Final 8.72

FR/RR tire rollingcircumference

1724/1778 mm (69/71 in)

Front2 kg/cm² (200 Kpa, 28

psi)Tire pressure(rider only/60kg) Rear

2.5 kg/cm² (250 Kpa, 36 psi)

Turning Left 40°

angle Right 40°

Brake s stem Rear Disk braketype Front Disk brake

Front Telescopic fork

Suspensiontype Rear Unit swing

Frame type Back born

Tires

F u e l S s t e m

C a r b ur e t or

E l e c t r i c a l E q ui pm e n t

I ni t i on

S s t e m

P o w e r Dr i v e S y s t e m

T r a n s mi s -

s i on G e a r R e d u

c t i on

R a t i o

M o vi n gD e vi c e

D a m pi n g

D e vi c e

L u b r i c a t i on

S s t e m

E n gi n

e


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SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.

When tightening bolts or nuts, begin withlarger-diameter to smaller ones at several

times, and tighten to the specified torquediagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure touse special tools for removal and installation.

After disassembly, clean removed parts.Lubricate sliding surfaces with engine oil

before reassembly.

Apply or add designated greases and lubricants to the specified lubrication

points.

After reassembly, check all parts for proper tightening and operation.

When two persons work together, payattention to the mutual working safety.

Disconnect the battery negative (-) terminal before operation.When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points, fasteners, and lines for proper connection and installation.

When connecting the battery, the positive(+) terminal must be connected first.

After connection, apply grease to the battery terminals. Terminal caps shall be installed securely.


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If the fuse is burned out, find the cause and repair it. Replace it with a new oneaccording to the specified capacity.

After operation, terminal caps shall beinstalled securely.

When taking out the connector, the lock onthe connector shall be released beforeoperation.

Hold the connector body when connectingor disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending, protruding or loose.

The connector shall be inserted completely.

If the double connector has a lock, lock it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for damaged terminal cover or loose negativeterminal.

Check the double connector cover for proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper coverage.

Do not make the terminal cover openingface up.

Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only the insulated surfaces contact the wire harnesses.

ConfirmCapacity


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XCITING 500/250

After clamping, check each wire to makesure it is secure.

Do not squeeze wires against the weld or its clamp.

After clamping, check each harness tomake sure that it is not interfering with anymoving or sliding parts.

When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends of

bolts and screws.Route wire harnesses passing through the

side of bolts and screws. Avoid the projected ends of bolts and screws.

Route harnesses so they are neither pulled tight nor have excessive slack.

Protect wires and harnesses with electricaltape or tube if they contact a sharp edge or corner.

When rubber protecting cover is used to protect the wire harnesses, it shall beinstalled securely.

Do not break the sheath of wire. If a wire or harness is with a broken sheath,

repair by wrapping it with protective tapeor replace it.

When installing other parts, do not press or squeeze the wires.

Do not pull

too tight

No Contact

Do not press or squeeze the


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XCITING 500/250

After routing, check that the wire harnessesare not twisted or kinked.

Wire harnesses routed along withhandlebar should not be pulled tight, haveexcessive slack or interfere with adjacentor surrounding parts in all steering

positions.

When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, removethe rust with sand paper or equivalent

before connecting.

Symbols:

The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil for lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Note

Engine Oil

Grease

Gear Oil

Do you understand the instrument

Remove Rust


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XCITING 500/250

TORQUE VALUESSTANDARD TORQUE VALUES

Item Torque N•m (kgf•m, lbf•ft) Item Torque N•m (kgf•m, lbf•ft)

5mm bolt and nut

6mm bolt and nut

8mm bolt and nut

10mm bolt and nut

12mm bolt and nut

14mm bolt and nut

5(0.5, 4)

10 (1, 7)

22 (2.2, 16)

35 (3.5, 25)

55 (5.5, 40)

70 (7, 50)

4mm screw

5mm screw

6mm screw, SH bolt

6mm flange bolt and nut



3 (0.3, 2)

4 (0.4, 3)

9 (0.9, 6.5)

12 (1.2, 9)

27 (2.7, 20)

40 (4, 29)

Torque specifications listed below are for important fasteners.

ENGINE (XCITING 500)

Item Q‘tyThread dia.

(mm)

Torque

N•m (kgf•m, lbf•ft)Remarks

MAINTENANCE:

Engine oil drain plug

Oil strainer screen cap

Oil filter cartridge

Transmission oil drain bolt

Transmission oil filler bolt

Spark plug

Tappet adjust nut

LUBRICATION SYSTEM:

Oil pump screw

Oil cooler bolt

COOLING SYSTEM:

Water pump cover bolt

CYLINDER HEAD:

Breather separator bolt

Cylinder head bolt (1 – 4)Cylinder head bolt (5 – 13)

Cylinder head cover bolt

Cam chain tensioner bolt

Tensioner pivot bolt

Rocker arm shaft

DRIVE/DRIVEN PULLEY:

Drive face nut

Clutch out nut

1

1

1

1

1

1

4

1

2

2

3

49

4

2

1

2

1

1

12

30

20

8

8

10

5

4

16

6

6

108

6

6

8

18

18

14

25 (2.5, 18)

15 (1.5, 11)

10 (1, 7)

20 (2, 15)

20 (2, 15)

12 (1.2, 9)

9 (0.9, 6)

3 (0.3, 2)

35 (3.5, 25)

13 (1.3, 9)

13 (1.3, 9)

48 (4.8, 35)23 (2.3, 17)

10 (1, 7)

12 (1.2, 9)

10 (1, 7)

45 (4.5, 32)

135 (13.5, 97)

80 (8, 58)

Apply oil

Apply oil

Apply oilApply oil

Apply oil

Apply oil


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ENGINE (XCITING 500) (Cont’d)


(mm)

Torque

N•m (kgf•m, lbf•ft)

Remarks

Drive plate nut

ALTERNATOR

ACG flywheel nut

FINAL REDUCTION:

Transmission cover bolt

CRANKCASE:

Crankcase bolt

Oil pipe bolt

Cam chain guide

SWITCH:Oil pressure switch

1

1

8

13

2

2

1

28

14

8

6

16

8

PT 1/8

78 (7.8, 56)

55 (5.5, 40)

27 (2.7, 20)

12 (1.2, 9)

43 (4.3, 31)

20 (2, 15)

22 (2.2, 16)

Apply oil

Apply oil

Apply seal

ENGINE (XCITING 250)

Item Q‘tyThread

dia.(mm)Torque

N•m (kgf•m, lbf•ft)Remarks

MAINTENANCE:

Valve adjusting lock nut

Spark plug

Transmission oil drain bolt

Transmission oil check/fill bolt

Crank case oil drain bolt

Oil filter screen cap

LUBRICATION SYSTEM:

Oil pump screwCOOLING SYSTEM:

Water pump impeller

CYLINDER HEAD:

Cylinder head cap nut

Tensioner lifter bolt

Cylinder head cover bolt

Cam chain tensioner bolt

2

1

1

1

1

1

1

1

4

1

4

2

5

10

12

8

12

30

3

7

8

6

6

6

9 (0.9, 6.5)

12 (1.2, 9)

20 (2, 15)

20 (2, 15)

25 (2.5, 18)

15 (1.5, 10.8)

2 (0.2, 1.4)

12 (1.2, 8.6)

25 (2.5, 18)

4 (0.4, 3)

12 (1.2, 8.6)

12 (1.2, 8.6)

Apply oil

Apply oil

Left screw

Apply oil


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XCITING 500/250

ENGINE (XCITING 250) (Cont’d)


(mm)

Torque

N•m (kgf•m, lbf•ft)

Remarks

DRIVE/DRIVEN PULLEY:

Drive face nut

Clutch outer nut

Clutch drive plate nut

Left crankcase cover bolt

ALTERNATOR

A.C.G. stator

Flywheel nut

FINAL REDUCTION:Transmission case cover bolt

CRANKCASE:

Cam chain guide bolt

SWITCH:

Oil pressure switch

1

1

1

6

5

1

9

1

1

14

12

28

6

5

14

8

6

PT 1/8

93 (9.3, 67)

54 (5.4, 39)

54 (5.4, 39)

12 (1.2, 8.6)

9 (0.9, 6.5)

55 (5.5, 40)

20 (2, 14.4)

10 (1, 7)

22 (2.2, 16)

Apply oil

Apply seal


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XCITING 500/250

FRAME

Item Q‘ty Thread dia.(mm)

Torque

N•m (kgf•m,

lbf•ft)Remarks

STEERING:

Handlebar bolt

Upper pinch bolt

Lower pinch bolt

Bridge stem nut

Steering stem lock nut

Top thread

WHEEL:

Front axle boltFront fork bolt

Rear axle nut (XCITING 500)

Rear axle nut (XCITING 250)

SUSPENSION:

Rear shock absorber bolt

Rear fork

BRAKE:

Front caliper mounting bolt

Rear caliper mounting bolt

Brake fluid bolt

Master cylinder bolt

ENGINE HANGER:

Engine hanger bolt

Engine mounting bolt/nut

(XCITING 500)

Engine mounting bolt/nut

(XCINTING 250)

Engine hanger rod nut

MUFFLER

Exhaust pipe nut

Muffler mount bolt

4

2

4

1

1

1

12

1

1

4

2

4

2

6

4

4

1

1

1

2

3

8

8

8

22

25.4

25.4

188

20

16

10

8

8

8

10

6

10

14

10

10

8

10

23 (2.3, 17)

23 (2.3, 17)

32 (3.2, 23)

62 (6.2, 45)

45 (4.5, 32)

17 (1.7, 12)

20 (2, 15)23 (2.3, 17)

180 (18, 130)

140 (14, 100)

40 (4, 29)

32 (3.2, 23)

32 (3.2, 23)

32 (3.2, 23)

35 (3.5, 25)

12 (1.2, 9)

50 (5, 36)

80 (8, 58)

50 (5, 36)

35 (3.5, 25)

20 (2, 14)

35 (3.5, 25)

Replace a new one

Replace a new one


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XCITING 500/250

SPECIAL TOOLS

XCITING 500

Tool Name Tool No. Remarks

Clutch spring compressor E053 Clutch disassembly

Bearing puller 10,12,15,18mm E037 Bearing removal

Valve spring compressor E040 Valve removal

Oil seal & bearing installer E014 Oil seal & bearing install

Tappet adjuster E036 Tappet adjustment

Flywheel puller E054 A.C. generator flywheel removal

Universal holder E017 Holding clutch for removal

Oil filter cartridge wrench E052 Cartridge removal or install

Flywheel holder E021 A.C. generator flywheel holdingLock nut socket wrench F002 Steering stem removal or install

XCITING 250

Tool Name Tool No. Remarks

Clutch spring compressor E034 Clutch disassemblyBearing puller 10,12,15,18mm E037 Bearing removal

Valve spring compressor E040 Valve removal

Oil seal & bearing installer E014 Oil seal & bearing install

Tappet adjuster E036 Tappet adjustment

Flywheel puller E003 A.C. generator flywheel removal

Universal holder E017 Holding clutch for removal

Flywheel holder E021 A.C. generator flywheel holding

Lock nut socket wrench F002 Steering stem removal or install


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XCITING 500/250

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part

Camshaft protruding surface

Valve rocker arm friction surface

Camshaft drive chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings Cylinder inside wall

Connecting rod/piston pin hole

Connecting rod big end

Crankshaft

Balancer shaft

Crankshaft one-way clutch movable part

Oil pump drive chain

Starter reduction gear engaging part

O-ring face

Oil seal lip

•Genuine KYMCO Engine Oil (SAE 5W-50)

•API SJ Engine Oil

Drive gear shaft

Countershaft

Final gear

Final gear shaft

Transmission gearshaft bearing part

Transmission oil: SAE 90

A.C. generator connector Adhesive


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XCITING 500/250

FRAME

The following is the lubrication points for the frame.

Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

Seat Lock

Grease

Throttle Cable

Engine Oil

Grease

Grease

Front/Rear Brake Lever Pivot

Grease

Grease

Rear Wheel BearingFront Wheel Bearing

Center Stand/Side Stand Pivot


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TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank Clogged carburetor fuel inlet

tube, vacuum tube or fuel tubeClogged auto fuel valveClogged float oil passageClogged fuel tank cap

breather holeClogged fuel strainer Clogged fuel filter Faulty fuel pump

Faulty spark plugFouled spark plugFaulty ignition unitFaulty A.C. generator Broken or shorted ignition coilBroken or shorted exciter coilFaulty ignition switch

Starter motor idles butcrankshaft does not rotate

Valve clearance too smallImproper valve and seat contactWorn cylinder and piston ringsBlown cylinder head gasketFlaws in cylinder head Seized valveImproper valve timing

Faulty auto bystarter Air leaking through intake

pipeIncorrect ignition timingIncorrectly adjusted pilot screw

Flooded carburetor Faulty auto bystarter Throttle valve excessively

open

Check if fuel reachescarburetor by looseningdrain screw

Remove spark plug and install it into spark plugcap to test spark byconnecting it to engineground

Inspection/Adjustment Probable Cause

Spark jumps

Normal compression

Engine does not

fire

Weak or no spark

Low or no compression

Engine fires but

does not start

Test cylinder

compression

Start engine by follow-ing normal starting

procedure

Remove spark plug and inspect again

Symptom

Fuel reaches carburetor

Fuel does not reach carburetor

Wet spark plugDry spark plug


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XCITING 500/250

ENGINE LACKS POWER

Clogged air cleaner Restricted fuel flowClogged fuel line between fuel

tank and carburetor Clogged exhaust muffler Faulty auto bystarter Split carburetor vacuum piston

diaphragm

Faulty ignition unitFaulty A.C. generator

Improper valve clearanceadjustmentWorn valve seat (valve stem too

protruding

Improper valve and seat contactWorn cylinder and piston ringsBlown cylinder head gasketFlaws in cylinder head Improper valve timing

Clogged carburetor jets

Fouled spark plugIncorrect heat range plug

Oil level too highOil level too lowOil not changed

Clogged oil pipeFaulty oil pump

Insufficient coolantFaulty thermostatWorn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup in

combustion chamber Ignition timing too earlyAir in cooling system

Excessive carbon build-up incombustion chamber Poor quality fuel

Clutch slippingMixture too lean Ignition timing too early

Start engine and accelerate lightly for observation

Inspection/Adjustment Symptom Probable Cause

Engine speed increases

Correct timing

Engine speed does not increasesufficiently

Incorrect timing

Check ignition timing(using a timing light)

Test cylinder compression

Check carburetor for clogging

Rapidly accelerate or runat high speed

Remove spark plug and ins ect

Check if engine overheats

Check valve clearance

Correct Incorrect

Normal compression

Abnormal compression

Not Clogged Clogged

Remove oil dipstick and check oil level and condition

Remove cylinder head oili e bolt and ins ect

Engine overheatsEngine does not overheats

Plug not fouled or discolored

Plug fouled or discolored

Correct and notcontaminated

Incorrect or contaminated

Valve train lubricated properly Valve train notlubricated properly

Engine does not knock Engine knocks


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XCITING 500/250

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty ignition unit

Faulty A.C. generator

Mixture too rich (turn screwout)

Mixture too lean (turn screwin)

Damaged insulator rubber Carburetor not securely

tightened Faulty intake manifold gasketDeformed carburetor O-ring

Faulty or fouled spark plugFaulty ignition unitFaulty A.C. generator Faulty ignition coilBroken or shorted high

tension wireFaulty ignition switch

Damaged air cut-off valvediaphragm

Damaged air cut-off valvespring

Remove spark plug and install it into spark plugcap to test spark byconnecting it to engineground


Check ignition timing

Check carburetor air cut-off valve

Check carburetor gasketfor air leaks

Check carburetor pilotscrew adjustment

Correct timing Incorrect timing

Correctly adjusted

No air leak Air leaks

Good spark Weak or inter-

mittent spark

Good Faulty

Incorrectly adjusted


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XCITING 500/250

POOR PERFORMANCE (AT HIGH SPEED)


Faulty A.C. generator

Improperly adjusted valveclearance

Worn valve seat

Empty fuel tank Clogged fuel tube or filter

Faulty fuel pumpCracked fuel pump vacuumtube

Clean and unclog

Cam timing gear aligningmarks not aligned

Faulty spring


Check ignition timing

Check carburetor jetsfor clogging

Check fuel pump for fuel supply

Correct timing Incorrect timing

Check valve springtension

Check valve clearance

Fuel flows freely Fuel flow restricted

Correct Incorrect

Not clogged Clogged

Correctly adjusted Incorrectly adjusted

Not weakened Weak spring

Check valve timing


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XCITING 500/250

ENGINE NOISE

Valve clearance too large

Worn camshaft lobe

Worn piston rings

Worn piston pin and connecting rod smallend

Excessive carbon build-up in combustionchamber

Damaged cam chain tensioner

Worn cam gear teeth

Worn or damaged cam chain

Extended cam chain

Faulty crankshaft bearing

Worn crank pin bearing

Worn or damaged final reduction gears

Worn final reduction gear shaft splines

Valve noise

Symptom Probable Cause

Crankshaft noise

Gear noise

Piston noise

Cam chain noise


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XCITING 500/250

CLUTCH, DRIVE AND DRIVEN PULLEYS

Worn or slipping drive belt

Broken ramp plate

Broken drive face spring

Separated clutch lining

Damaged driven pulley shaft splines

Damaged final gear

Seized final gear

Broken shoe spring

Clutch outer and clutch weight stuck

Seized pivot

Worn or slipping drive beltWorn weight rollers

Seized drive pulley bearings

Weak driven face spring

Worn or seized driven pulley bearings

Worn or slipping drive belt

Worn weight rollers


Oil or grease fouled drive belt

Worn drive belt

Weak driven face spring


Engine starts but motor-cycle does not move

Engine lacks power atstart of a grade(poor slope performance)

Symptom Probable Cause

Engine lacks power athigh speed

There is abnormal noiseor smell while running

Motorcycle creeps or engine starts but soonstops or seems to rushout (Rear wheel rotateswhen engine idles)


40/44


1-39

XCITING 500/250

STARTER MOTOR

1. Starter motor won‘t turn

Burned out fuseWeak or dead batteryFaulty stop switchLoose or disconnected

connectorsBroken or shorted ignition

switch wire

Faulty or weak battery

Poor starter button connectionOpen or shorted starter relayLoose or disconnected

connectors

Worn brushesOpen or shorted wires or rotor Open starter motor cableLoose connectors

Open wire harness

2. Starter motor turns slowly or idles

Weak or dead battery

Loose connector or terminalPoor contact in starter relayFaulty starter clutch

Seized cylinder

Broken or shorted starter motor cable

3. Starter motor does not stop turning

Faulty starter pinion

Starter relay shorted or stuck closed

Inspection/Adjustment



Symptom

Symptom

Symptom

Check operation of stop switch byapplying brake

Stoplight does notcome on

Stoplight comes on

Check battery circuit by operating turnsignals

Check battery circuit by operating turnsignals

Turn ignition switchOFF

Probable Cause

Probable Cause

Probable Cause

Signals operate properly

Signals dim, remainon or don‘t o erateCheck operation of

starter relay bydepressing starter

button

Connect starter motor directly to

battery

Connect starter motor directly to

battery

Starter motor turns slowly

Starter motor turns normally

Signals operate ro erl

Signals dim, remainon or don‘t o erate

Not stopped Stopped

Rotate crankshaft

Starter motor turns Starter does not turn

Relay operates properly

Relay does not operate

Turns easily Hard to turn


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1-40

XCITING 500/250

NO SPARK AT SPARK PLUG

Faulty spark plug

Faulty spark plug

Poorly connected coupler

Faulty ignition switchFaulty exciter coilFaulty pulser coilFaulty ignition coil

Broken wire harnessPoorly connected coupler


Faulty ignition coil

Replace with a newspark plug and inspectagain

Check ignition unitcoupler for looseness


Normal

Abnormal

Normal

Abnormal

Normal Abnormal

Abnormal

Measure resistance between terminals of ignition unit coupler

Check related parts

Check ignition coil witha ignition unit tester

Weak or no spark

Not loose

Good spark

Loose

Good Good

Check spark plug capand high-tension wirefor looseness

Check ignition unitwith a ignition unittester


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1-41

XCITING 500/250

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Faulty AC generator Faulty regulator/rectifier Faulty battery

Shorted AC generator coilOpen circuit between AC

generator 3 yellow wires

Faulty regulator/rectifier Faulty AC generator Loose regulator/rectifier

coupler Limit voltage too high

Overcharging

Faulty batteryFaulty regulator/rectifier Broken or poorly connected

regulator/rectifier black wire

Limit voltage too high

Start engine and testlimit voltage of batteryterminals

Measure battery limitvoltage with an electrictester

Test output voltage of regulator/rectifier coupler red wire



Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Normal

Normal

Voltage does notincrease

Abnormal

Resistance too low

Normal voltage No voltage

Measure resistance between AC generator

coil terminals

Check resistance between regulator/rectifier terminals

Normal Abnormal


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1-42

XCITING 500/250

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)

Burned out fuseWeak or dead batteryFaulty ignition switchLoose or disconnected

connectorsBroken wire harness

Faulty float

Broken or shorted fuel unitwire

Disconnected connector Incorrectly connected

connector Broken or shorted wire in

fuel gauge2. Pointer fluctuates or swings (Ignition switch ON)

Burned out fuseWeak or dead batteryFaulty ignition switchLoose or disconnected

connector Broken wire harness

Poor contact in fuel unit

Insufficient damping oil infuel gauge

Loose or disconnected

connector Broken or shorted wire in

fuel gauge



Symptom

Symptom

Remove fuel unit and check operation of

pointer by moving floatu and down

Remove fuel unit and check operation of

pointer by moving float

up and down





Check battery circuit byoperating turn signals

Check battery circuit byoperating turn signalsand horn

Probable Cause

Probable Cause

Pointer does not

move

Pointer moves

Pointer movesPointer does notmove

Check operation of pointer by opening and shorting fuel unitterminal on wire harnessside

Move float up and down rapidly (1 round /sec.) to check theoperation of pointer

Pointer does notmove

Pointer moves

Pointer does notmove in accord-ance with float

Pointer moves inaccordance withfloat

Good Faulty

Check connectors for proper connection

Check connectors for proper connection.

Good Faulty

Float up: FullFloat down: Empty


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1. GENERAL INFORMATION XCITING 500/250

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Steering stem nut too tightBroken steering steel balls

Excessive wheel bearing playBent rimLoose axle nut

Misaligned front and rear wheelsBent front fork

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Weak shock springExcessive load Shock damper oil leaking

Bent fork tube or shock rod

Fork tube and slider binding

Fork spring and slider bindingDamaged shock stopper rubber Loose steering stem nut

POOR BRAKE PERFORMANCE

Worn brake liningsForeign matter on brake liningsRough brake drum contacting area

Worn brake liningsForeign matter on brake liningsRough brake drum contacting area

Worn brake liningsWorn brake cam contacting area on

Worn brake liningsForeign matter on brake linings

Sluggish or elongated brake cablesBrake shoes improperly contactWater and mud in brake system

Steering is heavy

Suspension is too soft

Soft brake lever

Hard brake lever

Poor brake performance

Front or rear wheel iswobbling

Symptom

Symptom

Symptom

Probable Cause

Probable Cause

Probable Cause

Steering handlebar pullsto one side

Suspension is too hard

Suspension is noisy

Brake squeaks

Hard to brake

X500_250 Cap 01 (Info Generali)

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Transcript of X500_250 Cap 01 (Info Generali)