Kymco MO X500 Service Manual - chap 16 (imp frenante)

16. BRAKE SYSTEM

XCITING 500

__________________________________________________________________________________

BRAKE SYSTEM

__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 16- 1

SERVICE INFORMATION------------------------------------------------ 16- 2

TROUBLESHOOTING----------------------------------------------------- 16- 3

BRAKE FLUID -------------------------------------------------------------- 16- 4

BRAKE PAD ----------------------------------------------------------------- 16-10

BRAKE DISC INSPECTION ---------------------------------------------- 16-13

FRONT MASTER CYLINDER ------------------------------------------- 16-14

REAR MASTER CYLINDER --------------------------------------------- 16-18

DELAY VALVE------------------------------------------------------------- 16-22

FRONT BRAKE CALIPER ------------------------------------------------ 16-24

REAR/PARKING BRAKE CALIPER------------------------------------ 16-26

PARKING BRAKE LEVER LINK --------------------------------------- 16-31

16-0

16. BRAKE SYSTEM

SCHEMATIC DRAWING

XCITING 500

16-1

16. BRAKE SYSTEM

XCITING 500

SERVICE INFORMATION

GENERAL

＊

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health.

Avoid breathing dust particles.

• A contaminated brake disc or pad reduces stopping power. Discard contaminated parts and clean a contaminated disc with high quality brake degreasing agent.

• Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.

• This section covers maintenance of the front and rear hydraulic brake system.

• Never allow contamination (dirt, water, etc.) to get into and open reservoir.

• Once the hydraulic system has been opened, or if the brake feel spongy, the system must be bled.

• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not

mix different types of fluid as they may not be compatible.

• Always check brake operation before riding the vehicle.

SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT

Front

Rea

Specified brake fluid DOT 4 ⎯ Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4 (0.16) Brake disc runout ⎯ 0.03 (0.012) Specified brake fluid DOT 4 ⎯ Brake disc thickness 4.8 – 5.2 (0.19 – 0.20) 4 (0.16) Brake disc warpage ⎯ 0.03 (0.012)

Unit: mm (in)

16-2

16. BRAKE SYSTEM

TORQUE VALUES

Master cylinder reservoir cover screw 2 N•m (0.2 kgf•m, 1.4 lbf•ft)

Master cylinder holder bolt 12 N•m (1.2 kgf•m, 9 lbf•ft)

Brake lever pivot bolt 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

Brake lever pivot nut 6 N•m (0.6 kgf•m, 4.3 lbf•ft) Brake light switch screw 1 N•m (0.1 kgf•m, 0.7 lbf•ft)

Brake caliper mounting bolt 32 N•m (3.2 kgf•m, 23 lbf•ft)

ALOC bolt: replace with a new one.

Brake caliper bleed screw 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

Brake pad pin 18 N•m (1.8 kgf•m, 13 lbf•ft)

Front/Rear caliper pad pin plug 2 N•m (0.2 kgf•m, 1.4 lbf•ft) Brake hose oil bolt 35 N•m (3.5 kgf•m, 25 lbf•ft) Delay valve bleed screw 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

TROUBLESHOOTING

XCITING 500

Brake lever soft or spongy Brake lever hard

• Air in the hydraulic system • Clogged/restricted brake system

• Low brake fluid level • Sticking/worn caliper piston

• Clogged fluid passage • Caliper not sliding properly

• Contaminated brake disc/pad • Clogged/restricted fluid passage

• Warped/deformed brake disc • Worn caliper piston seal

• Worn brake disc/pad • Sticking/worn master cylinder piston

• Sticking/worn master cylinder piston • Bent brake lever

• Contaminated master cylinder

• Contaminated caliper Brake drag

• Caliper not sliding properly • Contaminated brake disc/pad

• Leaking hydraulic system • Worn brake disc/pad

• Worn caliper piston seal • Warped/deformed brake disc

• Worn master cylinder piston cups • Caliper not sliding properly

• Bent brake lever

16-3

16. BRAKE SYSTEM

BRAKE FLUID

Check

Brake fluid: (page 3-18) Brake hose: Cracks/wear/damage → Replace. Apply the brake lever several times. Fluid leakage → Replace. Brake hose clamp: Loosen → Tighten

FLUID REPLACEMENT Front brake

＊

Avoid spilling brake fluid on painted, plastic or rubber parts and so on. Place a rag over these parts whenever the system is serviced.

XCITING 500

Place the scooter on a level surface and keep the handlebar straight.

Remove the master cylinder reservoir cap and diaphragm.

Suck up the old brake fluid as much as possible.

Fill the reservoir with new brake fluid.

Specification and classification: DOT 4

Screws Cap/Diaphrag

16-4

16. BRAKE SYSTEM

XCITING 500

Connect a clear hose to the left front caliper air bleed screw and insert the other end of the hose into a receptacle.

Loosen the air bleed screw and pump the brake lever until the old brake fluid is completely out of the brake system.

Clear Hose

Left Front Caliper Air Bleed Screw

Brake Leve

Close the air bleed screw and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.

Tighten the bleed screw to the specified torque.

Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

Combination brake

＊

Avoid spilling brake fluid on painted, plastic or rubber parts and so on. Place a rag over these parts whenever the system is serviced.

Place the scooter on a level surface and keep the handlebar straight.

Shock Absorber Lower Mount Bol

16-5

16. BRAKE SYSTEM

XCITING 500

Remove the master cylinder reservoir cap and diaphragm.

Suck up the old brake fluid as much as possible.

Fill the reservoir with new brake fluid.

Specification and classification: DOT 4

Step 1:

Connect a clear hose to the delay valve air bleed screw and insert the other end of the hose into a receptacle.

Loosen the air bleed screw and pump the brake lever until the old brake fluid is completely out of the brake system. Close the air bleed screw and disconnect the clear hose. Fill the reservoir with new brake fluid to the upper end of the inspection window.

Screws Cap/Diaphrag

Clear Hose

Step 2:

Connect a clear hose to the right front caliper air bleed screw. The right brake fluid replacement is the same way as that of the step 1.

Relay Valve Air Bleed Screw

Right Front Caliper Air Bleed Screw

Clear Hose

16-6

16. BRAKE SYSTEM

XCITING 500

Step 3:

Connect a clear hose to the rear caliper air bleed screw. The rear brake fluid replacement is the same way as that of the step 1.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

Rear Caliper Air Bleed Screw

Clear Hose

＊

Bleed the brake fluid circuit:

● The system has been disassembled.

● A brake hose or brake pipe have been

loosened or removed.

● The brake fluid has been very low.

● The brake operation has been faulty.

A loss of braking performance may occur if the brake system is not properly bled.

Air bleeding steps (Front brake):

1. Add the proper brake fluid to the reservoir.

2. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.

3. Connect the clear plastic hose tightly to the

left front caliper air bleed screw.

4. Place the other end of the hose into a

container.

5. Slowly apply the brake lever several times.

6. Pull the lever in and hold it.

7. Loosen the bleed screw and allow the

lever to travel towards its limit.

Clear Hose

Left Front Caliper Air Bleed Screw

16-7

16. BRAKE SYSTEM

8. Tighten the bleed screw when the lever

limit has been reached, then release the lever.

9. Repeat steps (5) to (7) until all the air

bubbles have disappeared from the fluid.

10. Tighten the bleed screw.

Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

＊

If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

12. Add brake fluid to the proper level and

install the master cylinder reservoir cap and diaphragm.

XCITING 500

＊

Check the operation of the brake after bleeding the brake system.

Air bleeding steps (combination brake):

The combination brake system air bleeding is the same manner as that of the front brake one. Bleed the air from the rear side (rear caliper) and then the front side (right front caliper and delay valve).

Tighten the bleed screw.

Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

＊

If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

Rear Caliper Air Bleed Screw

Clear Hose

16-8

16. BRAKE SYSTEM

Add brake fluid to the proper level.

＊

Check the operation of the brake after bleeding the brake system.

Install the master cylinder reservoir cap and diaphragm.

XCITING 500

Right Front Caliper Air Bleed Screw

Clear Hose

16-9

Relay Valve Air Bleed Screw

+ 23 hidden pages

Kymco MO X500 Service Manual - chap 16 (imp frenante)

Specifications and Main Features

Frequently Asked Questions

User Manual