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10. DRIVE AND DRIVEN PULLEY XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. • Do not apply grease to the movable drive face and weight rollers. SPECIFICATIONS Unit: mm (in) Item Movable driven face bushing I.D. Driven face collar O.D.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Bolts LEFT CRANKCASE COVER REMOVAL Remove the left center body cover (page 2-5). Remove the three bolts and the left front cover. Left Front Cover . Remove the two bolts and left rear cover Bolts Left Rear Cover Bolts Remove the eight bolts and left crankcase cover.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Dowel Pins Remove the dowel pins and gasket. Gasket DRIVESHAFT BEARING REPLACEMENT Remove the snap ring. Clip Heat the left crankcase cover around the driveshaft bearing with industrial dryer. Remove the driveshaft bearing from the left crankcase cover.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Install the new driveshaft bearing into the left crankcase cover using a special tool. Special tool: Oil seal & bearing install E014 Bearing Install INSTALLATION Installation is in the reverse order of removal. ＊ Clean the gasket on the left crankcase before installation. Nut/Washer DRIVE PULLEY Drive Pulley Face REMOVAL Remove the left crankcase cover (page 10-3). Hold the drive pulley face with the special tool and loosen the drive pulley face nut.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Clutch Outer Nut/Collar Hold the clutch outer with the special tool as shown. Special tool: Universal holder E017 Remove the nut, collar and clutch outer. Universal Holder Drive Belt Clutch/Driven Pulley Remove the clutch/driven pulley assembly and drive belt. Washer Remove the washer.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Drive Face Boss Remove the movable drive face assembly while holding the back of the face (ramp plate). Movable Drive Face Washer Remove the washer. Ramp Plate DISASSEMBLY Drive pulley Remove the ramp plate and slide pieces.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Remove the weight rollers. Weight Rollers Drive Face Boss Remove the drive face boss from the movable drive face. INSPECTION Movable Drive Face Check the drive face boss for wear or damage. Measure the boss O.D.. Service limit: 28.9 mm (1.156 in) Measure the face bushing I.D.. Service limit: 29.1 mm (1.
. DRIVE AND DRIVEN PULLEY XCITING 500 Weight Roller Check each roller for wear or damage. Measure the weight roller O.D.. Service limit: 29.5 mm (1.18 in) Dust Seal Movable Drive Face Check the dust seal for wear or damage. Drive Face Boss ASSEMBLY Clean any oil and grease from the pulley faces and weight rollers. Install the drive face boss into the movable drive face.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Weight Rollers Install the weight rollers to the movable drive face. ＊ The direction of all weight rolls is the same. The thin side is towards to clockwise. Thin Side Ramp Plate Install the slide pieces to ramp plate. Install the ramp plate to the movable drive face. Slide Pieces Inner Indentation Side INSTALLATION Install the washer. ＊ The inner indentation side on the washer faces the left crankcase.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Washer Clean any oil and grease from the pulley faces and the drive belt. Install the movable drive face assembly onto the crankshaft while holding the ramp plate. Install the washer. Movable Drive Face Assembly Drive Belt Install the drive belt and clutch/driven pulley assembly. ＊ Install the drive belt with the arrow mark facing up and towards to clockwise.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Washer/Nut Drive Pulley Face Install the drive pulley face and washer. Apply oil to the drive pulley face nut threads and seating surface and install the nut. Hold the drive face with the special tool and tighten the bolt to the specified torque. Special tool: Universal holder E017 Torque: 135 N•m (13.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Nut/Washer Drive Pulley Face CLUTCH/DRIVEN PULLEY REMOVAL Remove the left crankcase cover (page 10-3). Hold the drive pulley face with the special tool and loosen the drive pulley face nut. Special tool: Universal holder E017 Remove the nut, washer and drive pulley face. Universal Holder Nut/Collar Clutch Outer Hold the clutch outer with the special tool as shown. Special tool: Universal holder E017 Remove the nut, collar and clutch outer.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Lock Nut Wrench DISASSEMBLY Clutch/Driven Pulley Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor E053 Set the tool in a vise and remove the clutch drive plate nut. .
10. DRIVE AND DRIVEN PULLEY XCITING 500 Movable Driven Face Remove the guide roller pins, guide rollers and the movable driven face. Guide Roller Pins/Guide Rollers Oil Seals Remove the O-rings and oil seals from the movable driven face. O-rings Snap Ring Driven Face Bearing Replacement Remove the driven face needle bearing. Remove the snap ring, then remove the ball bearing. Apply grease to new ball bearing. Install the ball bearing into the driven face.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Needle Bearing Filling 25 g of grease to the driven face inner surface. Apply grease to new needle bearing. Press the needle bearing into the driven. Grease INSPECTION Clutch Outer Check the clutch outer for wear or damage. Measure the clutch outer I.D.. Service limit: 160.5 mm (6.32 in) Clutch Shoe Lining Check the clutch shoe for wear or damage. Measure the thickness of each shoe. Service limit: 1 mm (0.
10. DRIVE AND DRIVEN PULLEY Driven Face Spring Measure the driven face spring free length. Service limit: 100.7 mm (4.028 in) Driven Face Check the driven face for scratches, scoring or damage. Measure the driven face boss O.D.. Service limit: 47.94 mm (1.887 in) Movable Driven Face Check the movable driven face for scratches, scoring or damage. Check the guide grooves for stepped wear or damage. Measure the movable driven face I.D.. Service limit: 48.06 mm (1.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Drive Belt Check the drive belt for cracks, separation or abnormal or excessive wear. Attach the suitable plates ad shown. Measure the drive belt width. Service limit: 27.9 mm (1.116 in) Remove the clutch/driven pulley, then replace the drive belt if necessary. Oil Seals ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease to new oil seal lips and install into the movable driven face.
10. DRIVE AND DRIVEN PULLEY XCITING 500 Install the movable driven face onto the driven face. Install the guide rollers and guide roller pins. Filling 8 g of grease to each guide groove. Grease Driven Face Spring Install the seal collar. Install spring collar. Install washer. Install driven face spring. Washer Lock Nut Wrench Install the drive belt into the driven pulley. Squeeze and hold the drive belt your hand.
10. DRIVE AND DRIVEN PULLEY ＊ Install the drive belt with the arrow mark XCITING 500 Drive Belt facing up and towards to clockwise. Install the drive belt and clutch/driven pulley assembly. Clutch/Driven Pulley Assembly Nut/Collar Clutch Outer Hold the clutch outer with the special tool as shown. Special tool: Universal holder E017 Install the collar and nut. Tighten the nut to the specified torque.
