Kymco XCITING 500 - Service Manual > Camshaft Removal

Cylinder Head/Valves / Camshaft Removal

Remove the cylinder head cover.

Turn the crankshaft clockwise and align the "T" mark on the flywheel with the index mark on the right crankcase cover.

Remove the cam chain tensioner lifter sealing bolt, spring and sealing washer.

Cylinder Head/Valves

Remove the two bolts, cam chain tensioner and gasket.

Cylinder Head/Valves

Remove the two bolts and cam chain guide.

Cylinder Head/Valves

Loosen and remove the twelve camshaft holder bolts in a crisscross pattern in several steps, then remove the camshaft holders.

Suspend the cam chain with a piece of wire to prevent the chain from falling into the crankcase.

Cylinder Head/Valves

Remove the camshafts

Cylinder Head/Valves

INSPECTION

Cam chain guide

Inspect the am chain slipper surface of the cam chain guide for wear or damage.

Cylinder Head/Valves

Camshaft holder

Inspect the bearing surface of each camshaft holder for scoring, scratches, or evidence of insufficient lubrication.

Cylinder Head/Valves

Check the stop pin spring on the exhaust camshaft holder for damage.

Replace the stop pin assembly with a new one if the spring is damage.

Cylinder Head/Valves

Camshaft

Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial gauge.

Service limit: 0.05 mm (0.002 in)

Cylinder Head/Valves

Inspect camshaft lobes for pitting/scratches/blue discoloration.

Measure the cam lobe height.

Service Limits:
  IN : 37.11 mm (1.4844 in)
  EX: 36.86 mm (1.4744 in)

If any defects are found, replace the camshaft with a new one, then inspect lubrication system.

Cylinder Head/Valves

Check the decompression system by turning the decompressor cam on the exhaust camshaft.

You should be able to turn the decompressor cam clockwise smoothly, but the decompressor should not turn counterclockwise.

Cylinder Head/Valves

Cam chain tensioner

Check the one-way cam operation (tensioner) Unsmooth operation → Replace.

Cylinder Head/Valves

ROCKER ARMS REMOVAL

Remove the camshaft.

Remove the rocker arm shafts and washers, then remove the rocker arms.

Cylinder Head/Valves

INSPECTION

Rocker arm shaft

Inspect the rocker arm shaft for blue discoloration or grooves.

If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.

Measure each rocker arm shaft O.D.

Measure the I.D. of each rocker arm.

Measure arm to shaft clearance.

Replace as a set if out of specification.

Service limits: 0.1 mm (0.004 in)

Cylinder Head/Valves

Inspect the rocker arm bore, cam lobe contact surface and adjuster surface for wear/pitting/scratches/blue discoloration.

If any defects are found, replace the rocker arm shaft with a new one, then inspect lubrication system.

Measure each rocker arm shaft O.D.

Measure the I.D. of each rocker arm.

Measure arm to shaft clearance.

Replace as a set if out of specification.

Service limits: 0.1 mm (0.004 in)

Cylinder Head/Valves

See also:

 Kymco XCITING 500 - Service Manual > Cylinder Compression Test, Cylinder Head Cover

CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug.

 Kymco XCITING 500 - Service Manual > Cylinder Head Removal

Remove the rock arms. Remove the two bolts, intake pipe and insulator. Remove the two bolts, two nuts, pair reed valve and gasket.