Kymco XCITING 500 - Service Manual > Drive Pulley

REMOVAL

Remove the left crankcase cover.

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.

Drive and Driven Pulley

Hold the clutch outer with the special tool as shown.

Special tool: Universal holder E017

Remove the nut, collar and clutch outer.

Drive and Driven Pulley

Remove the clutch/driven pulley assembly and drive belt.

Drive and Driven Pulley

Remove the washer.

Drive and Driven Pulley

Remove the movable drive face assembly while holding the back of the face (ramp plate).

Drive and Driven Pulley

Remove the washer.

Drive and Driven Pulley

DISASSEMBLY

Drive pulley

Remove the ramp plate and slide pieces.

Drive and Driven Pulley

Remove the weight rollers.

Drive and Driven Pulley

Remove the drive face boss from the movable drive face.

Drive and Driven Pulley

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 (1.164 in)

Drive and Driven Pulley

Weight Roller

Check each roller for wear or damage.

Measure the weight roller O.D..

Service limit: 29.5 mm (1.18 in)

Drive and Driven Pulley

Movable Drive Face

Check the dust seal for wear or damage.

Drive and Driven Pulley

ASSEMBLY

Clean any oil and grease from the pulley faces and weight rollers.

Install the drive face boss into the movable drive face.

Drive and Driven Pulley

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.

Drive and Driven Pulley

Install the slide pieces to ramp plate.

Install the ramp plate to the movable drive face.

Drive and Driven Pulley

INSTALLATION

Install the washer.

The inner indentation side on the washer faces the left crankcase.

Drive and Driven Pulley

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.

Drive and Driven Pulley

Install the drive belt and clutch/driven pulley assembly.

Install the drive belt with the arrow mark facing up and towards to clockwise.

Drive and Driven Pulley

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.

Torque: 80 N*m (8 kgf*m, 58 lbf*ft)

Drive and Driven Pulley

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 (13.5 kgf*m, 97 lbf*ft)

Drive and Driven Pulley

See also:

 Kymco XCITING 500 - Service Manual > Left Crankcase Cover

REMOVAL Remove the left center body cover. Remove the three bolts and the left front cover.

 Kymco XCITING 500 - Service Manual > Clutch/driven Pulley

REMOVAL Remove the left crankcase cover. Hold the drive pulley face with the special tool and loosen the drive pulley face nut. Special tool: Universal holder E017