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Ch5 final drive

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  • 1. 5. Final Drive XCITING 400i   Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO XCITING 400i. • Final Reduction .................................................................. 5-2 • Final Drive Oil ............................................................. 5-3~5-8 GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. TROUBLESHOOTING Engine starts but motorcycle won't move • Damaged transmission • Seized or burnt transmission Abnormal noise • Worn, seized or chipped gears • Worn bearing Oil leaks • Oil level too high • Worn or damaged oil seal 5‐1     
  • 2. 5. Final Drive > Final Reduction XCITING 400i Final Reduction SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Disassembly Note: Do not remove the transmission case cover except for necessary part replacement. If the drive shaft is replaced, make sure to also replace the bearing and oil seal. There are 8 transmission case cover bolts . 5‐2   
  • 3. 5. Final Drive > Transmission Oil XCITING 400i Final Drive Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Place the scooter on level ground and up on its center stand. The oil drain bolt and oil filler bolt are located on the transmission. Gear oil type: SAE 90 Gear oil capacity: At disassembly 0.23 Liter At change 0.20 Liter 5‐3   
  • 4. 5. Final Drive > Transmission Oil XCITING 400i Inspection Place the vehicle on its center stand on level ground. Remove the transmission oil level check bolt with a 12 mm socket. The oil level is correct when oil flows from the bolt hole. Install the oil level check bolt and tighten it to specification with a 12 mm socket. Torqu Item Qty Thread size (mm) kgf-m Final Drive oil check bolt 1 8 lb-ft 0.8 - 1.2 5.79 - 8.68 If the level is too high allow the oil to flow out of the check hole until the level is even with the bolt hole. If the level is low add more of the same type and brand of oil as shown below. Inspect for leaks. 5‐4   
  • 5. 5. Final Drive > Transmission Oil XCITING 400i Draining Place the vehicle on its center stand on level ground. Place a suitable oil drain pan under the transmission oil drain plug. Place a suitable container under the drain plug to capture the final drive oil. Loosen the oil drain plug with a 12 mm socket. Remove the drain plug and slowly rotate the rear wheel to drain the transmission oil. Inspect the drain plug and washer. 5‐5   
  • 6. 5. Final Drive > Transmission Oil XCITING 400i Install the oil drain plug and washer with a 12 mm socket. Tighten to specification. Torqu Item Qty Thread size (mm) kgf-m Final Drive oil check bolt 1 8 lb-ft 0.8 - 1.2 5.79 - 8.68 5‐6   
  • 7. 5. Final Drive > Transmission Oil XCITING 400i Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole. Gear oil type: SAE 90 Gear oil capacity: At disassembly 0.23 Liter At change 0.20 Liter 5‐7   
  • 8. 5. Final Drive > Transmission Oil XCITING 400i Thread in the final drive oil level check bolt. Install the oil check plug and torque it to specification with a 12 mm socket. Torque Item Qty Thread size (mm) kgf-m Final drive oil check bolt 1 8 lb-ft 0.8 - 1.2 5.79 - 8.68 5‐8