SHAD K0XC55ST Top Master Fitting Kit Instruction Manual

1. Introduction

This instruction manual provides detailed guidance for the proper installation and maintenance of the SHAD K0XC55ST Top Master fitting kit. This kit is specifically designed to enable the secure mounting of a SHAD top case onto compatible motorcycles, enhancing your vehicle's luggage capacity.

The SHAD K0XC55ST is engineered for KYMCO XCITING 500 and KYMCO XCITING 500R models from 2005 to 2010. Please read all instructions carefully before beginning installation to ensure safety and correct assembly.

2. Safety Information

• Always ensure the motorcycle is stable and on a level surface before starting any installation.
• Use appropriate tools for each step. Incorrect tools can damage components or cause injury.
• Do not overtighten fasteners. Refer to your motorcycle's service manual for specific torque values if available, or tighten securely without excessive force.
• After installation, verify that all components are securely fastened and that the top case is properly attached and locked.
• Regularly check the fitting kit and top case for any signs of wear, damage, or loose fasteners, especially after long rides or off-road use.
• Distribute weight evenly within the top case and adhere to the maximum load capacity specified by SHAD for your top case model.

3. Package Contents

The SHAD K0XC55ST Top Master fitting kit package includes the following components:

• SHAD K0XC55ST Top Master support structure (main frame)
• Mounting hardware (bolts, washers, spacers, etc.)
• Instruction leaflet (if included separately)

Please verify all components are present and undamaged before proceeding with installation. If any parts are missing or damaged, contact your retailer or SHAD support.

Figure 1: Overview of the SHAD K0XC55ST Top Master fitting kit. This image displays the black support structure and the base plate where a top case would attach.

4. Setup and Installation

The SHAD K0XC55ST Top Master fitting kit is designed for vehicle-specific installation on KYMCO XCITING 500 / 500R (2005-2010) motorcycles. It is compatible with a universal mounting plate, which is typically supplied with SHAD top cases.

1. Prepare the Motorcycle: Ensure the motorcycle is turned off, on its center stand or a stable paddock stand. Remove any existing rear rack or passenger grab handles as instructed by your motorcycle's service manual, if necessary, to access the mounting points.
2. Identify Mounting Points: Locate the designated mounting points on the rear of your KYMCO XCITING 500 / 500R. These are typically existing bolt holes on the subframe or rear fender area.
3. Position the Support Structure: Carefully place the SHAD K0XC55ST support structure onto the identified mounting points. Align the holes on the fitting kit with the motorcycle's mounting points.
4. Attach with Hardware: Use the provided mounting hardware (bolts, washers, spacers) to secure the fitting kit to the motorcycle. Start all bolts by hand to ensure proper thread engagement before tightening.
5. Tighten Fasteners: Gradually tighten all bolts using appropriate tools. Ensure even tightening across all mounting points. Do not overtighten.
6. Install Universal Plate (if applicable): If your SHAD top case came with a universal mounting plate, attach it to the newly installed K0XC55ST fitting kit according to the top case's specific instructions. This usually involves securing the plate to the fitting kit's base using screws and nuts.
7. Final Check: Once installed, gently shake the fitting kit to ensure it is firmly attached and does not wobble. Double-check all bolts for tightness.

Note on Compatibility: While this kit is designed for specific models, some motorcycle variations or aftermarket accessories may require minor adjustments or professional installation. If you encounter difficulties in aligning the fitting kit, consult a qualified mechanic or SHAD support.

5. Operating Instructions (with Top Case)

Once the SHAD K0XC55ST Top Master fitting kit and the universal mounting plate are securely installed, you can attach your SHAD top case.

1. Attaching the Top Case: Align the bottom of your SHAD top case with the universal mounting plate. Push the top case down and forward until it clicks securely into place. Ensure the locking mechanism engages.
2. Verifying Security: Gently pull upwards on the top case to confirm it is firmly locked to the plate. If it moves or feels loose, re-engage the locking mechanism.
3. Removing the Top Case: To remove, insert your key into the top case lock, turn it to the unlock position, and press the release button (location varies by top case model). Lift the top case upwards and backwards to detach it from the plate.
4. Loading the Top Case: Distribute the weight of contents evenly. Do not exceed the maximum load capacity specified for your SHAD top case model. Overloading can affect motorcycle handling and stability.

6. Maintenance

Proper maintenance ensures the longevity and safe operation of your SHAD K0XC55ST fitting kit.

• Regular Inspection: Periodically inspect all bolts and fasteners for tightness. Vibrations from riding can cause them to loosen over time.
• Cleanliness: Clean the fitting kit with mild soap and water. Avoid harsh chemicals or abrasive cleaners that could damage the finish or material.
• Check for Damage: Inspect the ABS material for cracks, deformities, or other signs of damage, especially after impacts or heavy use. Replace damaged components immediately.
• Lubrication: If any moving parts or locking mechanisms on your top case feel stiff, apply a small amount of silicone-based lubricant.

7. Troubleshooting

This section addresses common issues you might encounter during installation or use.

8. Specifications

9. Warranty and Support

For warranty information, technical support, or to purchase replacement parts, please contact SHAD directly or refer to their official website. Keep your proof of purchase for warranty claims.

SHAD Official Website: www.shad.es (This is a general placeholder, actual link might vary by region)