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14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 SERVICE INFORMATION GENERAL INSTRUCTIONS • A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with a high quality brake degreasing agent. • This section covers of the front wheel , fork, handlebar, and steering. • A jack or other support is required to support the vehicle. • Do not twist or bend the brake hose and pipe when servicing.
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14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER FRONT WHEEL XCITING 500 Holder bolt REMOVAL Loosen the front axle holder bolt. Front Axle Loosen the front axle bolt. Support the scooter securely using a hoist or equivalent and raise the front wheel off the ground. Remove the right and left mount bolts and front brake calipers. Bolts Pull off the front axle out and remove the front wheel. NOTE: Do not operate the front and rear brake lever after removing the front wheel.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Side Collar Remove the right and left side collar from the wheel hub. INSTECTION Axle Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. Service limit: 0.20 mm (0.008 in) Wheel Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. Service limit: Radial: 0.20 mm (0.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Wheel Bearing 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 hub. DIASSEMBLY Remove the right and left disc bolts and brake discs. Discs Remove the bolts and speed sensor guide.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Remove the dust seals Dust Seals Install the bearing remover into the bearing. Drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. Special tool: Bearing remover E037 NOTE: Replace the wheel bearings in pairs. Do not reuse old bearings. ASSEMBLY Pack a new bearing cavities with grease. Drive the new left bearing squarely with the sealed side facing up until it is fully seated.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Distance Collar Install the distance collar. Pack a new bearing cavities with grease. Drive the new right bearing squarely with the sealed side facing up until it is fully seated. Special tool: Oil seal & bearing install driver E014 Dust Seals Apply grease to the new dust seal lips. Install the dust seals into the wheel hub until there are flush with the wheel hubs.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Install the speed sensor guide. Install the plate blots and tighten them to the specified torque. XCITING 500 Speed sensor guide Torque: 10 N•m (1.0 kgf•m, 7 lbf•ft) Install the brake discs into wheel hub. Install new disc bolts and tighten them to the specified torque. Torque: 42 N•m (4.3 kgf•m, 31 lbf•ft) Discs Side Collar INSTALLATION Install the side collars into the wheel hub.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Install the front wheel between the fork leg. Install the front axle front left side. Tighten the axle bolt to the specified torque. XCITING 500 Front Axle Torque: 55 N•m (5.5 kgf•m, 40 lbf•ft) Tighten the front axle holder to the specified torque. Dowel Pin Torque: 23 N•m (2.3 kgf•m, 17 lbf•ft) Install the right and left front calipers onto the fork leg. Install and tighten the new front caliper mount blots to the specified torque.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 With the front brake applied, pump the fork up and down several times to seat the axle and check brake operation. Check the brake operation by applying the brake lever. Speed Sensor Measure the speed sensor to speed sensor guide clearance. Standard (A): 0.3 – 1.2 mm (0.0012 – 0.048 in) Adjust it if necessary (page 20-5).
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER FORK XCITING 500 Upper Pinch Bolt REMOVAL Remove the front wheel (page 14-4). Remove the front fender (page 2-4). Remove the bolt and hose clamp. Remove the bolt and speed sensor (only right fork). Remove the upper fork pinch bolt. Remove the lower fork pinch bolts. Remove the fork from the handlebar post and steering stem.
.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Tighten the lower pinch bolts to specified torque. Torque: 23 N•m (2.3 kgf•m, 17 lbf•ft) Install the brake caliper onto the fork leg with new mount bolts. Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft) Install the brake hose clamp onto the fork leg with the bolt. Install the speed sensor onto the right fork leg and tighten the bolt. Install the front fender. Install the front wheel.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 STEERING HANDLEBAR REMOVAL Remove the front cover (page 2-11). Remove the upper handlebar cover (page 25). Remove the band bolt and disconnect the left handlebar switch connector. Left Handlebar Switch Connector Bolt Remove the two screws and lower handlebar cover. Screws Bolts Remove the bolts, master cylinder holders and rear master cylinders. Disconnect the left brake light switch connectors.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Remove the bolts, master cylinder holders and front master cylinders. XCITING 500 Bolts NOTE: Keep the master cylinder upright to prevent air from entering the hydraulic system. Screws Remove the screws and right handlebar switch housing. Remove the bolt/right handlebar weight.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Remove the bolts and upper holders. XCITING 500 Holder Bolts Switch Housing Remove the handlebar from the handlebar post and right handlebar switch housing. INSTALLATION Pass the handlebar through the right handlebar switch housing.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Holes Align the holes on the handlebar with the pins on the handle post. Pins Install the handlebar to the handle post. Holder Bolts Install the upper holders with its punch marks facing toward. Install the upper holder bolts. Tighten the front bolts first, then tighten the rear bolts. Torque: 23 N•m (2.3 kgf•m, 17 lbf•ft) Throttle Grip Install the throttle grip and bolt/right handlebar weight and tighten the bolt.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Hole Align the pin on the right handlebar switch housing with the hole on the steering handle. Pin Screws Install the screws and tighten the forward screw first, then tighten the rear screw. Pin “UP” Mark Align the pin on the rear master cylinder holder with the hole on the handlebar. Install the front master cylinders and holder with the “UP” mark facing up.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Align the pin on the rear master cylinder holder with the hole on the handlebar. Hole Pin “UP” Mark Install the rear master cylinders and holder with the “UP” mark facing up. Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Connect the brake light switch connectors.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER STEERING STEM XCITING 500 Clamp Bolts REMOVAL Remove the front fork (page 14-12). Remove the steering handle (page 14-14). Remove the bolts and brake hoses clamp. Remove the nut, washer and handle post. Special tool: Long socket wrench E015 Remove the brake hoses from the clamps on the steering stem.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Remove the steering stem lock nut. Special tool: Long socket wrench F007 Lock Washer Remove the lock washer. Top Thread Loosen the steering top thread. Hold the steering stem and remove the steering stem top thread.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Lower Bearing Remove the steering stem and lower bearing. Steering Stem Dust Seal Upper Inner Race Upper Bearing Remove the dust seal, upper inner race and upper bearing BEARING REPLACEMENT Remove the upper bearing outer race. NOTE: Always replace the bearings and races as a set.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Remove the lower bearing outer race. Lower Outer Race Drive a new upper bearing race into the steering head pipe. Upper Outer Race Drive a new lower bearing race into the steering head pipe.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Install the steering stem lock nut onto the steering to prevent the threads from being damaged when removing the lower bearing inner race from the steering stem. XCITING 500 Lower Inner Race Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the steering stem. Remove the dust seal. Dust Seal Install the dust seal. Apply grease to a new lower bearing inner race using a hydraulic press.
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER Install the lower bearing onto the stem. Insert the steering stem into the steering head pipe. XCITING 500 Lower Bearing Steering Stem Top Thread Install the steering top thread and tighten it to the specified torque. Torque: 17 N•m (1.7 kgf•m, 12 lbf•ft) Turn the steering stem lock-to-lock several times to seat the bearings. Temporarily loosen the steering stem top thread. Install the fork (page 14-12). Install the front wheel (page 14-9).
14.STEERING HANDLEBAR/FRONT WHEEL/ FRONT SHOCK ABSORBER XCITING 500 Lock Washer Lock Nut Install the lock washer aligning its tab into the groove on the steering stem. Install the steering stem lock nut. Hold the steering stem top thread and tighten the steering stem lock nut to the specified torque. Special tool: Long socket wrench F007 Torque: 45 N•m (4.5 kgf•m, 32 lbf•ft) Make sure that the steering stem moves smoothly without play or binding.
