User Guide

ManualsBrandsKymco ManualsOtherMO X500

13. CRANKCASE/CRANKSHAFT

13-0

XCITING 500

__________________________________________________________________________________

CRANKCASE/CRANKSHAFT

__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 13- 1

SERVICE INFORMATION------------------------------------------------ 13- 2

TROUBLESHOOTING----------------------------------------------------- 13- 2

CAM CHAIN/CAM CHAIN GUIDE REMOVAL --------------------- 13- 3

CRANKCASE SEPARATION -------------------------------------------- 13- 4

CRANKCASE ASSEMBLY ----------------------------------------------- 13-11

Summary of content (14 pages)

PAGE 1
3.
PAGE 2
13.
PAGE 3
13. CRANKCASE/CRANKSHAFT XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft and balancer. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces. • When installing the crankcase, do not use an iron hammer to tap it. • The following parts must be removed before separating the crankcase.
PAGE 4
13. CRANKCASE/CRANKSHAFT XCITING 500 CAM CHAIN/CAM CHAIN GUIDE REMOVAL Remove the starter driven gear (page 12-4). Remove the cylinder (page 9-3). Remove the cam chain from the right crankcase. Cam Chain Cam Chain Guides Remove the bolts and cam chain guides. Bolts INSPECTION Cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage.
PAGE 5
13. CRANKCASE/CRANKSHAFT XCITING 500 Cam chain Inspect the cam chain for cracks or stiff. Bolts CRANKCASE SEPARATION Remove the parts required for crankcase separation (page 13-2). Remove the twelve bolts from left crankcase. ＊ Loosen the bolts in a crisscross pattern in several steps. Bolt Remove the bolt from right crankcase. Place the crankcase assembly with the left side down and separate the right crankcase from the left crankcase.
PAGE 6
13. CRANKCASE/CRANKSHAFT XCITING 500 Dowel Pins Remove the dowel pins and O-ring. Remove the oil collar and O-rings from the left crankcase. Clean of the sealant from the left and right crankcase mating surfaces. Oil Collar/O-rings Dowel Pin/O-ring Washer Remove the washer from the crankshaft. Remove the balancer shaft from the left crankcase. Crankshaft Remove the crankshaft from the left crankcase.
PAGE 7
13. CRANKCASE/CRANKSHAFT XCITING 500 Bolts/Outer Washer RIGHT CRANKCASE DISASSEMBLY Remove the two bolts, outer washer, oil pipe and inner washers. Oil Pipe/Inner Washers Inner Washers RIGHT CRANKCASE ASSEMBLY Install the inner washers onto the right crankcase. Thick Side Install the oil pipe with the thick side face upward.
PAGE 8
13. CRANKCASE/CRANKSHAFT XCITING 500 Bolts/Outer Washer Install the outer washers and two bolts. Tighten the two bolts to the specified torque. Torque: 43 N•m (4.3 kgf•m, 31 lbf•ft) Main Journal Bearing I.D. Color Code CRANKSHAFT/CRANKCASE SELECTION Crankcase and crankshaft are select fitted. Record the main journal O.D. code (－ or ＋) Record the main journal bearing I.D. color code (green, brown or yellow). Record the right or left crankcase main journal I.D. code (A or B). Main Journal O.D.
PAGE 9
13. CRANKCASE/CRANKSHAFT XCITING 500 MAIN BEARING INSPECTION Inspect the bearing inserts for unusual wear, damage or peeling and replace the crankcase if necessary. Main bearing oil clearance Clean off any oil from the main bearing inserts and crankshaft journals. Measure and record the crankshaft main journal O.D.. Measure and record the main bearing I.D.. Calculate the oil clearance by subtracting the journal O.D. from bearing I.D.. Bearing Standard: 0.025 – 0.041 mm (0.001 – 0.
PAGE 10
13. CRANKCASE/CRANKSHAFT XCITING 500 BALANCER SHAFT BEARING REPLACMENT Remove the crankshaft and balancer shaft (page 13-4). Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Replace the bearings if the races does not turn smoothly and quietly, or if they fit loosely in the crankcase. Bearing Puller Remove the balancer shaft bearing from the left crankcase using the special tool.
PAGE 11
13. CRANKCASE/CRANKSHAFT XCITING 500 Remove the balancer shaft bearing from the right crankcase. Bearing Snap Ring Install the snap ring into the right crankcase. Oil Seal & Bring Driver Install the new bearings to the right and left crankcase using special tool.
PAGE 12
13. CRANKCASE/CRANKSHAFT XCITING 500 Crankshaft CRANKCASE ASSEMBLY Install the crankshaft to the left crankcase. Align Install the balancer shaft to align the punch mark with the “O” mark on the crankshaft. Left Front Cover Washer Install the washer onto the crankshaft.
PAGE 13
. CRANKCASE/CRANKSHAFT XCITING 500 Dowel Pins Install the oil collar and O-rings Clean the right and left crankcase mating surface thoroughly, being careful not to damage them. Install the dowel pins and O-ring. Oil Collar/O-rings Dowel Pin/O-ring Bolt Apply a light but through coating of sealant (Threebond 1215 or equivalent) to all crankcase mating surfaces except the oil passage area. Install the right crankcase over the left crankcase.
PAGE 14
13. CRANKCASE/CRANKSHAFT Install the cam chain guides to the right crankcase and tighten the bolts to the specified torque. XCITING 500 Cam Chain Guides Torque: 20 N•m (2 kgf•m, 15 lbf•ft) Install the cam chain to right crankcase.