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Trasmissione X500 250 .pdf



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10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

10
__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

DRIVE AND DRIVEN PULLEY
__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 10- 1
SERVICE INFORMATION------------------------------------------------ 10- 2
TROUBLESHOOTING----------------------------------------------------- 10- 3
LEFT CRANKCASE COVER --------------------------------------------- 10- 4
DRIVE PULLEY ------------------------------------------------------------ 10- 7
CLUTCH/DRIVEN PULLEY---------------------------------------------- 10-14

10
10-0

10. DRIVE AND DRIVEN PULLEY
SCHEMATIC DRAWING

10-1

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

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 (XCITING 500)
Item
Movable driven face bushing I.D.
Driven face collar O.D.
Drive belt width
Clutch lining thickness
Clutch outer I.D.
Drive pulley collar O.D.
Weight roller O.D.

Standard
48 (1.92)~48.025 (1.921)
47.965 (1.9186)~47.985 (1.9194)
28.9 (1.156)
4 (0.16)
160 (6.3)~160.2 (6.31)
28.96 (1.158)~28.974 (1.159)
29.98 (1.1992)~30.08 (1.203)

SPECIFICATIONS (XCITING 250)
Item
Movable driven face bushing I.D.
Driven face collar O.D.
Drive belt width
Clutch lining thickness
Clutch outer I.D.
Drive pulley collar O.D.
Weight roller O.D.

Standard
40 (1.6)~40.025 (1.601)
39.965 (1.5986)~39.985 (1.5994)
23.6 (0.944)~24.4 (0.976)
4 (0.16)
153 (6.12)~153.2 (6.128)
26.96 (1.0784)~26.974 (1.07896)
22.92 (0.9168)~23.08 (0.9232)

Unit: mm (in)
Service Limit
48.06 (1.9224)
47.94 (1.9176)
27.9 (1.116)
1 (0.04)
160.5 (6.32)
28.9 (1.156)
29.5 (1.18)

Unit: mm (in)
Service Limit
40.06 (1.6024)
39.94 (1.5976)
22 (0.88)
1 (0.04)
153.5 (6.14)
26.9 (1.076)
22 (0.88)

10-2

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

TORQUE VALUES (XCITING 500)
Drive face nut
135 N•m (13.5 kgf•m, 97 lbf•ft)
Clutch outer nut
80 N•m (8 kgf•m, 58 lbf•ft)
Clutch drive plate nut
78 N•m (7.8 kgf•m, 56 lbf•ft)

Apply oil to the threads

TORQUE VALUES (XCITING 250)
Drive face nut
93 N•m (9.3 kgf•m, 67 lbf•ft)
Clutch outer nut
54 N•m (5.4 kgf•m, 39 lbf•ft)

Apply oil to the threads

Clutch drive plate nut

54 N•m (5.4 kgf•m, 39 lbf•ft)

SPECIAL TOOLS (XCITING 500)
Universal holder
E017
Clutch spring compressor
E053
Oil seal & bearing install
E014
SPECIAL TOOLS (XCITING 250)
Universal holder
E017
Clutch spring compressor
E034
Oil seal & bearing install
E014

TROUBLESHOOTING
Engine starts but motorcycle won‘t move
• Worn drive belt
• Broken ramp plate
• Worn or damaged clutch lining
• Broken driven face spring
Engine stalls or motorcycle creeps
• Broken clutch weight spring

10-3

Lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight roller
• Faulty driven face

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250
Bolts

LEFT CRANKCASE COVER
REMOVAL (XCITING 500)
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.

Crankcase

10-4

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

Dowel Pins

Remove the dowel pins and gasket.

Gasket

Bolts

REMOVAL (XCITING 250)
Remove the left crankcase cover bolts and
left crankcase covers.

Left Crankcase Cover

Dowel Pins

Remove the seal rubber and dowel pins.

Seal Rubber

10-5

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
DRIVESHAFT BEARING
REPLACEMENT (XCITING 500)
Remove the snap ring.

Clip

Industrial Dryer

Heat the left crankcase cover around the
driveshaft bearing with industrial dryer.
Remove the driveshaft bearing from the left
crankcase cover.

Bearing

Install the new driveshaft bearing into the left
crankcase cover using a special tool.
Special tool:
Oil seal & bearing install

E014

INSTALLATION
Installation is in the reverse order of removal.

* Clean the gasket on the left crankcase

Bearing Install

before installation.

10-6

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
Nut/Washer

DRIVE PULLEY

Drive Pulley Face

REMOVAL
Remove the left crankcase cover (XCITING
500: page 10-4, XCITING 250: 10-5).
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 (XCITING 500)

Clutch Outer

Hold the clutch outer with the special tool as
shown.
Special tool:
Universal holder

E017

Remove the nut, collar (XCITING 500) and
clutch outer.

Universal Holder

Drive Belt

Remove the clutch/driven pulley assembly
and drive belt.

10-7

Clutch/Driven Pulley

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250
Washer (XCITING 500)

Remove the washer (XCITING 500).

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

Drive Face Boss

Movable Drive Face

Remove the washer (XCITING 500).

Washer (XCITING 500)

10-8

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
DISASSEMBLY
Drive pulley
Remove the ramp plate and slide pieces.

Ramp Plate

Slide Pieces

Remove the weight rollers.

Weight Rollers

Drive Face Boss

Remove the drive face boss from the movable
drive face.

10-9

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

INSPECTION
Movable Drive Face
Check the drive face boss for wear or
damage.
Measure the boss O.D..
Service limit:
XCITING 500: 28.9 mm (1.156 in)
XCITING 250: 26.9 mm (1.076 in)
Measure the face bushing I.D..
Service limit:
XCITING 500: 29.1 mm (1.164 in)
XCITING 250: 27.13 mm (1.058 in)

Weight Roller
Check each roller for wear or damage.
Measure the weight roller O.D..
Service limit:
XCITING 500: 29.5 mm (1.18 in)
XCITING 250: 22 mm (0.888 in)

Dust Seal

Movable Drive Face
Check the dust seal (XCITING 500) for wear
or damage.

10-10

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

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.

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

10-11

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
INSTALLATION
Install the washer (XCITING 500).

Inner Indentation Side (XCITING 500)

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

Washer

Washer (XCITING 500)

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 (XCITING 500).

Movable Drive Face Assembly

Drive Belt

Install the drive belt and clutch/driven pulley
assembly.



Install the drive belt with the arrow mark
facing the direction of travel.

Clutch/Driven Pulley Assembly

10-12

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
Clutch Outer

Collar (XCITING 500)/Nut

Hold the clutch outer with the special tool as
shown.
Special tool:
Universal holder

E017

Install the collar (XCITING 500) and nut.
Tighten the nut to the specified torque.
Torque:
XCITING 500: 80 N•m (8 kgf•m, 58 lbf•ft)
XCITING 250:
54 N•m (5.4 kgf•m, 36 lbf•ft)

Install the drive pulley face and washer.
Apply oil to the drive pulley face nut threads
and seating surface and install the nut.

Universal Holder

Washer/Nut

Drive Pulley Face

Hold the drive face with the special tool and
tighten the bolt to the specified torque.
Special tool:
Universal holder

E017

Torque:
XCITING 500:
135 N•m (13.5 kgf•m, 97 lbf•ft)
XCITING 250:
93 N•m (9.3 kgf•m, 67 lbf•ft)

10-13

Universal Holder

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
Nut/Washer

Drive Pulley Face

CLUTCH/DRIVEN PULLEY
REMOVAL
Remove the left crankcase cover (XCITING
500: page 10-4, XCITING 250: 10-5).
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 (XCITING 500)

Clutch Outer

Hold the clutch outer with the special tool as
shown.
Special tool:
Universal holder

E017

Remove the nut, collar (XCITING 500) and
clutch outer.

Universal Holder

Remove the clutch/driven pulley assembly
and drive belt.

Drive Belt

Clutch/Driven Pulley

10-14

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

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:
XCITING 500:
Clutch Spring Compressor
XCITING 250:
Clutch Spring Compressor

E053
E034

Set the tool in a vise and remove the clutch
drive plate nut.

Remove the spring compressor and
disassemble the following:
- Clutch assembly
- Driven face spring
- Driven pulley

Clutch spring compressor

Driven Face Spring

Remove the washer (XCITING 500).

Washer (XCITING 500)

Remove the spring collar (XCITING 500).
Remove the seal collar.

Spring Collar (XCITING 500)

10-15

Seal Collar

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

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

Needle Bearing

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.
Install the snap ring to groove in the driven
face securely.

Ball Bearing

10-16

10. DRIVE AND DRIVEN PULLEY

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:
XCITING 500: 160.5 mm (6.32 in)
XCITING 250: 153.5 mm (6.14 in)

Clutch Shoe Lining
Check the clutch shoe for wear or damage.
Measure the thickness of each shoe.
Service limit: 1 mm (0.04 in)

10-17

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

Driven Face Spring
Measure the driven face spring free length.
Service limit:
XCITING 500: 100.7 mm (4.028 in)
XCITING 250: 130.5 mm (5.22 in)

Driven Face
Check the driven face for scratches, scoring
or damage.
Measure the driven face boss O.D..
Service limit:
XCITING 500: 47.94 mm (1.9176 in)
XCITING 250: 39.94 mm (1.5976 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:
XCITING 500: 48.06 mm (1.9224 in)
XCITING 250:40.06 mm (1.6024 in)

10-18

10. DRIVE AND DRIVEN PULLEY

XCITING 500/250

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:
XCITING 500: 27.9 mm (1.116 in)
XCITING 250: 22 mm (0.88 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.
Coat new O-rings with grease and install
them into the movable driven face grooves.

O-rings

10-19

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
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 (XCITING 500).
Install washer (XCITING 500).
Install driven face spring.

Install the drive belt into the driven pulley.
Squeeze and hold the drive belt by your hand.
Set the clutch spring compressor over the
clutch/driven pulley assembly and hold the
spring compressor in a vice.
Special tool:
XCITING 500:
Clutch Spring Compressor
XCITING 500:
Clutch Spring Compressor

Washer
Lock Nut Wrench

E053
E034

Compress the driven face spring.
Install and tighten the clutch drive plate nut
to the specified torque.
Torque:
XCITING 500:
78 N•m (7.8 kgf•m, 56 lbf•ft)
XCITING 250:
54 N•m (5.4 kgf•m, 39 lbf•ft)

Clutch spring compressor

10-20

XCITING 500/250

10. DRIVE AND DRIVEN PULLEY
* Install the drive belt with the arrow mark

Drive Belt

facing the direction of travel.
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.
Torque:
XCITING 500: 80 N•m (8 kgf•m, 58 lbf•ft)
XCITING 250:
54 N•m (5.4 kgf•m, 39 lbf•ft)
Install the drive pulley face and washer.
Apply oil to the drive pulley face nut threads
and seating surface and install the nut.

Universal Holder

Washer/Nut

Drive Pulley Face

Hold the drive face with the special tool and
tighten the bolt to the specified torque.
Special tool:
Universal holder

E017

Torque:
XCITING 500:
135 N•m (13.5 kgf•m, 97 lbf•ft)
XCITING 250:
93 N•m (9.3 kgf•m, 67 lbf•ft)

10-21

Universal Holder


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