1 - T-com

Transcription

1 - T-com

1. GENERAL INFORMATION
XCITING 500/250
1
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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 --------------------------------------------------- 1-13
CABLE & HARNESS ROUTING (XCITING 500) ------------------------- 1-15
CABLE & HARNESS ROUTING (XCITING 250) ------------------------- 1-25
TROUBLESHOOTING------------------------------------------------------ 1-33
1-0
XCITING 500/250
SERIAL NUMBER
Location of Frame Serial Number
Location of Engine Serial Number
1-1
XCITING 500/250
SPECIFICATIONS (XCITING 500)
ITEM
Starting system
Type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Moving Device
Engine
12.8 L (3.38 lmp gal,
2.82 US gal
CVK
98
φ36 mm (φ1.44 in)
PISTON
Full transistor ignition
CR8E
Ignition timing
Throttle position sensor
Spark plug gap
0.6～0.7mm (0.002～
0.003 in)
12V12AH
Dry, centrifugal
automatic
Battery Capacity
Clutch Type
Type
Helical gear/spur gear
Operation
Automatic centrifugal
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Tire pressure Front
(rider only/60
kg)
Rear
Turning
angle
Brake system
type
Damping
Device
Lubrication
System
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
92
x 75 mm
Bore x stroke
(3.7 x 3 in)
Compression ratio
10.5:1
13 kgf/cm² (1300kPa,
Compression pressure
185 psi)
Open 2° BTDC
Intake valve
Close 45° ABDC
Open 45° BBDC
Exhaust valve
Close 5° ATDC
Valve clearance Intake
0.1 mm (0.004 in)
Exhaust 0.1 mm (0.004 in)
(cold)
Idle speed
1400 rpm
pressure &
Lubrication type Forced
Wet sump
Oil pump type
Trochoid
Oil filter type
Full-flow filtration
2.5
L (2.2 lmp qt,
Oil capacity
2.65 Us qt)
Final reduction oil 0.55 L (0.5 lmp qt,
0.58 Us qt)
capacity
Cooling Type
Liquid cooled
Type
Spark plug
Transmis- Reduction
sion Gear Ratio
Min. turning radius
Ignition System
Ground clearance
Type
Main jet NO.
Venturi dia.
Throttle type
Power Drive System
Tires
Carburetor
Curb weight
83 kg (183 lbs)
132 kg (290 lbs)
215 kg (473 lbs)
90 kg (198 lbs)
141 kg (310 lbs)
231 kg (508 lbs)
120/70-15
150/70-14
150 mm (6 in)
2750 mm (110 in)
Electric starter motor
Fuel capacity
Electrical Equipment
Dry weight
92# nonleaded gasoline
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
ITEM
SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel System
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
Displacement
Fuel Used
SPECIFICATIONS
XCITING 500
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
498.5 cm3 (30.4 cu-in)
Suspension
type
Frame type
2.68 – 1
5.4
1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28
psi)
2.5 kg/cm² (250 Kpa, 36
psi)
Left
40°
Right 40°
Rear Disk brake
Front Disk brake
Front
Telescopic fork
Rear
Unit swing
Back born
1-2
XCITING 500/250
SPECIFICATIONS (XCITING 250)
ITEM
Curb weight
Min. turning radius
Engine
1-3
Ignition timing
Throttle position sensor
Spark plug gap
0.6～0.7mm (0.002～
0.003 in)
12V12AH
Dry, centrifugal
automatic
Battery Capacity
Type
Clutch
Type
Helical gear/spur gear
Operation
Automatic centrifugal
Type
Type
CVT
Preliminary
Final
FR/RR tire rolling
circumference
Tire pressure Front
(rider only/60
kg)
Rear
Turning
angle
Brake system
type
Damping
Device
Lubrication
System
Gasoline, 4-stroke
Single cylinder
Semi-sphere
O.H.C., chain drive
72.7
x 60 mm
Bore x stroke
(2.908 x 2.4 in)
Compression ratio
10.3:1
15
kgf/cm² (1500kPa,
Compression pressure
213 psi)
Open 9° BTDC
Intake valve
Close 45° ABDC
Open 38° BBDC
Exhaust valve
Close 10° ATDC
Valve clearance Intake
0.1 mm (0.004 in)
Exhaust 0.1 mm (0.004 in)
(cold)
Idle speed
1600 rpm
Forced
pressure &
Lubrication type Wet sump
Oil pump type
Trochoid
Oil filter type
Full-flow filtration
1.1 L (0.97 lmp qt,
Oil capacity
1.17 Us qt)
Final reduction oil 0.2 L (0.18 lmp qt,
0.21 Us qt)
capacity
Cooling Type
Liquid cooled
Moving Device
Starting system
Type
Cylinder arrangement
Combustion chamber type
Valve arrangement
12.8 L (3.38 lmp gal,
2.82 US gal
CVK
94
φ30 mm (φ1.2 in)
PISTON
Full transistor ignition
DPR7EA-9
Transmis- Reduction
sion Gear Ratio
Ground clearance
75 kg (165 lbs)
110 kg (242 lbs)
185 kg (407 lbs)
81 kg (178 lbs)
119 kg (262 lbs)
200 kg (440 lbs)
120/70-15
150/70-14
170 mm (6.8 in)
2600 mm (104 in)
Electric starter motor
Type
Spark plug
Power Drive System
Tires
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Type
Main jet NO.
Venturi dia.
Throttle type
Ignition System
Dry weight
92# nonleaded gasoline
Carburetor
Fuel Used
Fuel capacity
Electrical Equipment
Displacement
ITEM
SPECIFICATIONS
Air cleaner type & No Wet paper type element
Fuel System
Name
Overall length
Overall width
Overall height
Wheel base
Engine type
SPECIFICATIONS
XCITING 250
2250 mm (90 in)
815 mm (33 in)
1450 mm (58 in)
1570 mm (63 in)
O.H.C.
251/249.1 cm3
(15.3/15.8 cu-in)
Suspension
type
Frame type
0.83 – 2.2
8.72
1724/1778 mm (69/71 in)
2 kg/cm² (200 Kpa, 28
psi)
2.5 kg/cm² (250 Kpa, 36
psi)
Left
40°
Right 40°
Rear Disk brake
Front Disk brake
Front
Telescopic fork
Rear
Unit swing
Back born
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
XCITING 500/250
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
When two persons work together, pay
attention to the mutual working safety.
Use genuine parts and lubricants.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
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.
1-4
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
Confirm
Capacity
XCITING 500/250
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.
After operation, terminal caps shall be
installed securely.
Before connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
When taking out the connector, the lock on
the connector shall be released before
operation.
Check the double connector cover for
proper coverage and installation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Check if any connector terminal is bending,
protruding or loose.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
1-5
After clamping, check each wire to make
sure it is secure.
XCITING 500/250
Route harnesses so they are neither
pulled tight nor have excessive slack.
Do not pull
too tight！
Do not squeeze wires against the weld or
its clamp.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
No Contact
Route wire harnesses to avoid sharp edges
or 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.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not press or
squeeze the
i
1-6
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
XCITING 500/250
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
Engine Oil
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
Grease
: Transmission Gear Oil (90#)
Gear Oil
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Do you understand
the instrument？
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Remove Rust！
1-7
＊
: Note
XCITING 500/250
TORQUE VALUES
STANDARD TORQUE VALUES
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)
Item
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
Torque
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
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
Q‘ty
Thread dia.
(mm)
Torque
1
1
1
1
1
1
4
12
30
20
8
8
10
5
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)
1
2
4
16
3 (0.3, 2)
35 (3.5, 25)
2
6
13 (1.3, 9)
3
4
9
4
2
1
2
6
10
8
6
6
8
18
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)
Apply oil
Apply oil
Apply oil
1
1
18
14
135 (13.5, 97)
80 (8, 58)
Apply oil
Apply oil
Remarks
Apply oil
1-8
XCITING 500/250
Item
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
(Cont’d)
1
Thread dia.
(mm)
28
Torque
78 (7.8, 56)
1
14
55 (5.5, 40)
8
8
27 (2.7, 20)
13
2
2
6
16
8
12 (1.2, 9)
43 (4.3, 31)
20 (2, 15)
Apply oil
Apply oil
1
PT 1/8
22 (2.2, 16)
Apply seal
Q‘ty
Thread
dia.(mm)
Torque
2
1
1
1
1
1
5
10
12
8
12
30
9 (0.9, 6.5)
12 (1.2, 9)
20 (2, 15)
20 (2, 15)
25 (2.5, 18)
15 (1.5, 10.8)
1
3
2 (0.2, 1.4)
1
7
12 (1.2, 8.6)
Left screw
4
1
4
2
8
6
6
6
25 (2.5, 18)
4 (0.4, 3)
12 (1.2, 8.6)
12 (1.2, 8.6)
Apply oil
Q‘ty
Remarks
Item
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 screw
COOLING SYSTEM:
Water pump impeller
CYLINDER HEAD:
Cylinder head cap nut
Tensioner lifter bolt
Cylinder head cover bolt
Cam chain tensioner bolt
1-9
Remarks
Apply oil
Apply oil
XCITING 500/250
Item
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
(Cont’d)
Q‘ty
Thread dia.
(mm)
Torque
1
1
1
6
14
12
28
6
93 (9.3, 67)
54 (5.4, 39)
54 (5.4, 39)
12 (1.2, 8.6)
5
1
5
14
9 (0.9, 6.5)
55 (5.5, 40)
9
8
20 (2, 14.4)
1
6
10 (1, 7)
1
PT 1/8
22 (2.2, 16)
Remarks
Apply oil
Apply seal
1-10
XCITING 500/250
FRAME
Item
STEERING:
Handlebar bolt
Upper pinch bolt
Lower pinch bolt
Bridge stem nut
Steering stem lock nut
Top thread
WHEEL:
Front axle bolt
Front 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
1-11
Q‘ty Thread dia.(mm)
Torque
N•m (kgf•m,
lbf•ft)
4
2
4
1
1
1
8
8
8
22
25.4
25.4
23 (2.3, 17)
23 (2.3, 17)
32 (3.2, 23)
62 (6.2, 45)
45 (4.5, 32)
17 (1.7, 12)
1
2
1
1
18
8
20
16
20 (2, 15)
23 (2.3, 17)
180 (18, 130)
140 (14, 100)
4
2
10
8
40 (4, 29)
32 (3.2, 23)
4
2
6
4
8
8
10
6
32 (3.2, 23)
32 (3.2, 23)
35 (3.5, 25)
12 (1.2, 9)
4
1
10
14
50 (5, 36)
80 (8, 58)
1
10
50 (5, 36)
1
10
35 (3.5, 25)
2
3
8
10
20 (2, 14)
35 (3.5, 25)
Remarks
Replace a new one
Replace a new one
XCITING 500/250
SPECIAL TOOLS
XCITING 500
Tool Name
Clutch spring compressor
Bearing puller 10,12,15,18mm
Valve spring compressor
Oil seal & bearing installer
Tappet adjuster
Flywheel puller
Universal holder
Oil filter cartridge wrench
Flywheel holder
Lock nut socket wrench
Tool No.
E053
E037
E040
E014
E036
E054
E017
E052
E021
F002
Remarks
Clutch disassembly
Bearing removal
Valve removal
Oil seal & bearing install
Tappet adjustment
A.C. generator flywheel removal
Holding clutch for removal
Cartridge removal or install
A.C. generator flywheel holding
Steering stem removal or install
XCITING 250
Tool Name
Clutch spring compressor
Bearing puller 10,12,15,18mm
Valve spring compressor
Oil seal & bearing installer
Tappet adjuster
Flywheel puller
Universal holder
Flywheel holder
Lock nut socket wrench
Tool No.
E034
E037
E040
E014
E036
E003
E017
E021
F002
Remarks
Clutch disassembly
Bearing removal
Valve removal
Oil seal & bearing install
Tappet adjustment
A.C. generator flywheel removal
Holding clutch for removal
A.C. generator flywheel holding
Steering stem removal or install
1-12
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 oil: SAE 90
Transmission gearshaft bearing part
A.C. generator connector
1-13
Adhesive
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.
Engine Oil
Grease
Seat Lock
Throttle Cable
Grease
Front/Rear Brake Lever Pivot
Front Wheel Bearing
Rear Wheel Bearing
Grease
Grease
Center Stand/Side Stand Pivot
Grease
1-14
CABLE & HARNESS ROUTING (XCITING 500)
1-15
XCITING 500/250
XCITING 500/250
1-16
1-17
XCITING 500/250
XCITING 500/250
1-18
1-19
XCITING 500/250
XCITING 500/250
1-20
1-21
XCITING 500/250
XCITING 500/250
1-22
1-23
XCITING 500/250
XCITING 500/250
1-24
CABLE & HARNESS ROUTING (XCITING 250)
1-25
XCITING 500/250
XCITING 500/250
1-26
1-27
XCITING 500/250
XCITING 500/250
1-28
1-29
XCITING 500/250
XCITING 500/250
1-30
1-31
XCITING 500/250
XCITING 500/250
1-32
XCITING 500/250
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment
Probable Cause
Symptom
Check if fuel reaches
carburetor by loosening
drain screw
Fuel reaches
carburetor
Fuel does not
reach carburetor
cEmpty fuel tank
dClogged carburetor fuel inlet
tube, vacuum tube or fuel tube
eClogged auto fuel valve
fClogged float oil passage
gClogged fuel tank cap
breather hole
hClogged fuel strainer
iClogged fuel filter
jFaulty fuel pump
Weak or no spark
cFaulty spark plug
dFouled spark plug
eFaulty ignition unit
fFaulty A.C. generator
gBroken or shorted ignition coil
hBroken or shorted exciter coil
iFaulty ignition switch
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Spark jumps
Test cylinder
compression
Normal
compression
Low or no
compression
cStarter motor idles but
crankshaft does not rotate
dValve clearance too small
eImproper valve and seat contact
fWorn cylinder and piston rings
gBlown cylinder head gasket
hFlaws in cylinder head
iSeized valve
jImproper valve timing
Start engine by following normal starting
procedure
Engine does not
fire
Engine fires but
does not start
Dry spark plug
Wet spark plug
cFaulty auto bystarter
dAir leaking through intake
pipe
eIncorrect ignition timing
fIncorrectly adjusted pilot screw
inspect again
1-33
cFlooded carburetor
dFaulty auto bystarter
eThrottle valve excessively
open
XCITING 500/250
ENGINE LACKS POWER
Probable Cause
Symptom
Start engine and
accelerate lightly for
observation
Engine speed
increases
Engine speed does
not increase
sufficiently
Check ignition timing
(using a timing light)
cClogged air cleaner
dRestricted fuel flow
eClogged fuel line between fuel
tank and carburetor
fClogged exhaust muffler
gFaulty auto bystarter
hSplit carburetor vacuum piston
diaphragm
cFaulty ignition unit
dFaulty A.C. generator
Correct timing
Incorrect timing
Correct
Incorrect
cImproper valve clearance
adjustment
dWorn valve seat (valve stem too
protruding
Normal
compression
Abnormal
compression
cImproper valve and seat contact
dWorn cylinder and piston rings
eBlown cylinder head gasket
fFlaws in cylinder head
gImproper valve timing
Check valve clearance
Test cylinder compression
Check carburetor for
clogging
Not Clogged
Clogged
cClogged carburetor jets
inspect
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not
contaminated
Incorrect or
contaminated
Remove oil dipstick and
check oil level and condition
cFouled spark plug
dIncorrect heat range plug
cOil level too high
dOil level too low
eOil not changed
Remove cylinder head oil
pipe bolt and inspect
Valve train lubricated
properly
Valve train not
lubricated properly
Check if engine overheats
Engine does not
overheats
Engine overheats
Rapidly accelerate or run
at high speed
Engine does not knock
Engine knocks
cClogged oil pipe
dFaulty oil pump
cInsufficient coolant
dFaulty thermostat
eWorn cylinder and piston rings
fMixture too lean
gPoor quality fuel
hExcessive carbon buildup in
combustion chamber
iIgnition timing too early
jAir in cooling system
cExcessive carbon build-up in
combustion chamber
dPoor quality fuel
eClutch slipping
fMixture too lean
g Ignition timing too early
1-34
XCITING 500/250
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Symptom
Probable Cause
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
cMixture too rich (turn screw
out)
dMixture too lean (turn screw
in)
Air leaks
cDamaged insulator rubber
dCarburetor not securely
tightened
eFaulty intake manifold gasket
fDeformed carburetor O-ring
Check carburetor pilot
screw adjustment
Check carburetor gasket
for air leaks
No air leak
install it into spark plug
cap to test spark by
connecting it to engine
ground
Good spark
Weak or intermittent spark
cFaulty or fouled spark plug
dFaulty ignition unit
eFaulty A.C. generator
fFaulty ignition coil
gBroken or shorted high
tension wire
hFaulty ignition switch
Good
Faulty
cDamaged air cut-off valve
diaphragm
dDamaged air cut-off valve
spring
Check carburetor air
cut-off valve
1-35
XCITING 500/250
POOR PERFORMANCE (AT HIGH SPEED)
Symptom
Probable Cause
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
cImproperly adjusted valve
clearance
dWorn valve seat
Fuel flows freely
Fuel flow restricted
cEmpty fuel tank
dClogged fuel tube or filter
eFaulty fuel pump
fCracked fuel pump vacuum
tube
Not clogged
Clogged
cClean and unclog
Correct
Incorrect
cCam timing gear aligning
marks not aligned
Not weakened
Weak spring
Check valve clearance
Check fuel pump for
fuel supply
Check carburetor jets
for clogging
Check valve timing
Check valve spring
tension
cFaulty spring
1-36
XCITING 500/250
ENGINE NOISE
Symptom
Valve noise
Probable Cause
cValve clearance too large
dWorn camshaft lobe
cWorn piston rings
Piston noise
Cam chain noise
Crankshaft noise
dWorn piston pin and connecting rod small
end
eExcessive carbon build-up in combustion
chamber
cDamaged cam chain tensioner
dWorn cam gear teeth
eWorn or damaged cam chain
fExtended cam chain
cFaulty crankshaft bearing
dWorn crank pin bearing
Gear noise
cWorn or damaged final reduction gears
dWorn final reduction gear shaft splines
1-37
XCITING 500/250
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Engine starts but motorcycle does not move
Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)
Probable Cause
cWorn or slipping drive belt
dBroken ramp plate
eBroken drive face spring
fSeparated clutch lining
gDamaged driven pulley shaft splines
hDamaged final gear
iSeized final gear
cBroken shoe spring
dClutch outer and clutch weight stuck
eSeized pivot
Engine lacks power at
start of a grade(poor
slope performance)
dWorn weight rollers
eSeized drive pulley bearings
fWeak driven face spring
gWorn or seized driven pulley bearings
Engine lacks power at
high speed
dWorn weight rollers
eWorn or seized driven pulley bearings
There is abnormal noise
or smell while running
cOil or grease fouled drive belt
dWorn drive belt
eWeak driven face spring
fWorn or seized driven pulley bearings
1-38
XCITING 500/250
STARTER MOTOR
1. Starter motor won‘t turn
Symptom
Probable Cause
Check operation of
stop switch by
applying brake
Stoplight comes on
Stoplight does not
come on
cBurned out fuse
dWeak or dead battery
eFaulty stop switch
fLoose or disconnected
connectors
gBroken or shorted ignition
switch wire
Signals operate
properly
Signals dim, remain
on or don‘t operate
cFaulty or weak battery
Relay operates
properly
Relay does not
operate
Starter motor turns
Starter does not turn
Check battery circuit
by operating turn
signals
Check operation of
starter relay by
depressing starter
button
Connect starter
motor directly to
battery
cPoor starter button connection
dOpen or shorted starter relay
eLoose or disconnected
connectors
cWorn brushes
dOpen or shorted wires or rotor
eOpen starter motor cable
fLoose connectors
cOpen wire harness
2. Starter motor turns slowly or idles
Symptom
Probable Cause
Check battery circuit
by operating turn
signals
Signals operate
properly
Signals dim, remain
Starter motor
turns slowly
Starter motor
turns normally
cWeak or dead battery
Connect starter
motor directly to
battery
cLoose connector or terminal
dPoor contact in starter relay
eFaulty starter clutch
Rotate crankshaft
Hard to turn
Turns easily
cSeized cylinder
cBroken or shorted starter
motor cable
3. Starter motor does not stop turning
Symptom
Probable Cause
Turn ignition switch
OFF
Not stopped
1-39
Stopped
cFaulty starter pinion
cStarter relay shorted or stuck
closed
XCITING 500/250
NO SPARK AT SPARK PLUG
Symptom
Probable Cause
Replace with a new
spark plug and inspect
again
Good spark
cFaulty spark plug
Not loose
Loose
cFaulty spark plug
Good
Good
cPoorly connected coupler
Normal
Abnormal
Normal
Abnormal
Weak or no spark
Check spark plug cap
and high-tension wire
for looseness
Check ignition unit
coupler for looseness
Measure resistance
between terminals of
ignition unit coupler
Check related parts
cFaulty ignition switch
dFaulty exciter coil
eFaulty pulser coil
fFaulty ignition coil
cBroken wire harness
dPoorly connected coupler
Check ignition unit
with a ignition unit
tester
Normal
Abnormal
Check ignition coil with
a ignition unit tester
Abnormal
cFaulty ignition coil
1-40
XCITING 500/250
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Symptom
Probable Cause
Start engine and test
limit voltage of battery
terminals
Normal voltage
Voltage does not
increase
Normal
Resistance too low
cFaulty AC generator
dFaulty regulator/rectifier
eFaulty battery
Measure resistance
between AC generator
coil terminals
cShorted AC generator coil
dOpen circuit between AC
generator 3 yellow wires
Test output voltage of
regulator/rectifier
coupler red wire
Normal voltage
No voltage
cFaulty regulator/rectifier
dFaulty AC generator
eLoose regulator/rectifier
coupler
fLimit voltage too high
Overcharging
Symptom
Probable Cause
Measure battery limit
voltage with an electric
tester
Normal
Abnormal
cFaulty battery
dFaulty regulator/rectifier
eBroken or poorly connected
regulator/rectifier black wire
Abnormal
cLimit voltage too high
Check resistance
between regulator/
rectifier terminals
Normal
1-41
XCITING 500/250
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Probable Cause
Symptom
Check battery circuit by
operating turn signals
Remove fuel unit and
check operation of
pointer by moving float
up and down
Float up: Full
Float down: Empty
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire harness
side
cBurned out fuse
eFaulty ignition switch
connectors
gBroken wire harness
Signals operate
properly
Signals dim, remain
Pointer does not
move
Pointer moves
cFaulty float
Pointer moves
cBroken or shorted fuel unit
wire
Pointer does not
move
Check connectors for
proper connection
Faulty
Good
cDisconnected connector
dIncorrectly connected
connector
eBroken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)
Probable Cause
Symptom
Check battery circuit by
operating turn signals
and horn
Remove fuel unit and
check operation of
pointer by moving float
up and down
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer
Signals operate
properly
Signals dim, remain
Pointer moves
Pointer does not
move
Pointer moves in
accordance with
float
Pointer does not
move in accordance with float
cBurned out fuse
eFaulty ignition switch
connector
gBroken wire harness
cPoor contact in fuel unit
cInsufficient damping oil in
fuel gauge
Check connectors for
proper connection.
Good
Faulty
cLoose or disconnected
connector
cBroken or shorted wire in
fuel gauge
1-42
XCITING 500/250
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
Symptom
Probable Cause
(Front and rear tire pressures are normal)
Steering is heavy
cSteering stem nut too tight
dBroken steering steel balls
Front or rear wheel is
wobbling
cExcessive wheel bearing play
dBent rim
eLoose axle nut
Steering handlebar pulls
to one side
cMisaligned front and rear wheels
dBent front fork
POOR SUSPENSION PERFORMANCE
Symptom
Suspension is too soft
Probable Cause
(Front and rear tire pressures are normal)
cWeak shock spring
dExcessive load
eShock damper oil leaking
Suspension is too hard
cBent fork tube or shock rod
Suspension is noisy
cFork tube and slider binding
dFork spring and slider binding
eDamaged shock stopper rubber
fLoose steering stem nut
POOR BRAKE PERFORMANCE
Symptom
1-43
Probable Cause
Soft brake lever
cWorn brake linings
dForeign matter on brake linings
eRough brake drum contacting area
Hard brake lever
cWorn brake linings
eRough brake drum contacting area
Hard to brake
cWorn brake linings
dWorn brake cam contacting area on
Poor brake performance
cWorn brake linings
Brake squeaks
cSluggish or elongated brake cables
dBrake shoes improperly contact
eWater and mud in brake system
fOil or grease on brake linings

1 - T-com

Transcription

Similar documents

Kymco ZX/Scout - 49ccScoot.Com

Installations-Anleitung