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5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 FUEL SYSTEM The fuel pump is operated by an electromagnetic force and its electrical energy is supplied from the battery. The fuel sent under pressure by the fuel pump flows into the float chamber when the float of the carburetor has dropped and the needle valve is open.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly. • Before float chamber disassembly, drain the residual gasoline from the float chamber. • Do not try to disassemble the automatic choke. • When assembling the vacuum chamber and air cut-off valve, be careful not to damage the diaphragms.
. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 TROUBLESHOOTING Engine does not start • No fuel in tank • Restricted fuel line • Too much fuel getting to cylinder • Clogged air cleaner • Contaminated fuel • Faulty fuel pump Engine idles roughly, stalls or runs poorly • Incorrect idle speed • Rich mixture • Lean mixture • Clogged air cleaner • Intake air leak • Contaminated fuel • Faulty air-cut off valve • Damaged vacuum tube and connectors • Damaged carburetor insulator Throttle does not ope
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Carburetor Clamp Screw CARBURETOR REMOVAL Remove the luggage box (page 2-3) Loosen the air cleaner clamp screw. Loosen the carburetor clamp screw. Disconnect the vacuum hose from the carburetor. Pull the carburetor out from the air cleaner and intake manifold. . Air Cleaner Clamp Screw Disconnect the fuel hose from the carburetor. Disconnect the carburetor heater connector. Vacuum Hose Fuel Hose Carburetor Heater Connector T.P.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR DISASSEMBLY With the automatic choke cover removed, remove the screw and automatic choke assembly. XCITING 500 Automatic Choke Assembly ＊ The automatic choke assembly is a nondisassemblable type Automatic Choke Cover Screw Carburetor Heater Remove the carburetor heater. Top Cap Remove the four screws and top cap.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR Remove the spring , spring retainer, jet needle and throttle valve. XCITING 500 Throttle Valve Spring Retainer Jet Needle Remove the two screws and casting enrichment valve cover and then take out the spring. Spring Casting Enrichment Valve Cover Screws Remove the casting enrichment valve and Oring.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR Remove the three screws and accelerating pump cover. XCITING 500 Screws Accelerating Pump Cover Remove the accelerating pump diaphragm and O-ring. O-ring Accelerating Pump Diaphragm Float Chamber Remove the four screws and float chamber.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Float Pull float pin outs, then remove the float and float valve. Float Valve Float Pin Main Jet Remove the slow jet. Remove the main jet. Needle Jet Holder Remove the needle jet holder.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Remove the needle jet. Needle Jet Pilot Screw Remove the pilot screw, spring, washer and O-ring. ＊ Before pilot screw removal, slowly turn the pilot screw clockwise and count the number of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset correctly. Float FLOAT/FLOAT VALVE INSPECTION Inspect the float for deformation or damage.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination. Check the operation of the float valve. CARBURETOR BODY/JETS INSPECTION AND CLEANING Check carburetor body and each jet for wear or damage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Pilot Screw O-ring PILOT SCREW INSPECTION Remove the O-ring from the pilot screw. Check the pilot screw for wear or damage. ＊ The pilot screw is factory pre-set and should not be removed unless the carburetor is overhauled. Damage to the pilot screw is tightened against the seat. Wash Spring Throttle Valve THROTTLE VALVE/JET NEEDLE INSPECTION Check the throttle valve and jet needle for scratches, wear or damage.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 FLOAT LEVEL INSPECTION Check the float level after checking the float valve, valve seat and float. (A) Set the carburetor so that the float valve end just contacts the float arm lip. Make sure the float valve tip is securely in contact with the valve seat. Measure the float level with the float level gauge. Float level (A): 18.5mm (0.74 in) The float level cannot be adjusted.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Carburetor Heater Connect the positive (+) terminal of a 12 V battery to the terminal of the carburetor heater and the battery negative (-) terminal to the terminal. Check that the heater section is heated in 5 minutes after the battery has been connected. REASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 O-ring Assemble the accelerating pump diaphragm and new O-ring. Small Convex ＊ Install the accelerating pump diaphragm with the small convex facing up. Accelerating Pump Diaphragm Assemble the coasting enrichment valve and new O-ring. O-ring Assemble the jet needle, spring retainer, spring and throttle valve Apply thermo-grease to the threads and tighten the carburetor heater securely.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Fuel Filter Arrow Mark FUEL FILTER/FUEL PUMP FUEL FILTER INSPECTION Visually check the fuel filter. If accumulation of sediment or clogging is found, replace the fuel filter with a new one. Install the fuel filter with the arrow mark facing forward. Fuel Pump Coupler FUEL PUMP INSPECTION Measure resistance between the terminals of fuel pump lead wire coupler. If the measurement is out of specification replace the fuel pump.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR REMOVAL Remove the floorboard (page 2-6) XCITING 500 Fuel Pump Connector Fuel Hoses Disconnect the fuel hoses. Disconnect the fuel pump connector. Remove the fuel pump and filter. “Arrow” Mark INSTALLATION Installation is in the reverse order of removal. ＊ ● Install the fuel pump with the arrow mark facing up. ● Connect the fuel inlet hose between the inlet duct of the fuel pump and fuel filter.
5. FUEL SYSTEM/FUEL PUMP /FUEL TANK/CARBURETOR Disconnect the fuel unit connector. XCITING 500 Fuel Unit Connector Remove the four nuts from the fuel tank. Nuts Ground Wire Connector Disconnect the ground wire connector. Disconnect the fuel filler cap open cable. Fuel Filler Cap Open Cable Remove the two nuts and left floorboard set holder from the frame. Remove the AICV control solenoid valve from the left floorboard set holder.
5. FUEL SYSTEM /FUEL PUMP /FUEL TANK/CARBURETOR XCITING 500 Remove the fuel tank from the frame left side. Fuel Tank Fuel Tank Fuel Tank INSTALLATION Installation is in the reverse order of removal.
