6.
16.
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.
16. BRAKE SYSTEM XCITING 500 TORQUE VALUES Master cylinder reservoir cover screw Master cylinder holder bolt Brake lever pivot bolt Brake lever pivot nut Brake light switch screw Brake caliper mounting bolt Brake caliper bleed screw Brake pad pin Front/Rear caliper pad pin plug Brake hose oil bolt Delay valve bleed screw 2 N•m (0.2 kgf•m, 1.4 lbf•ft) 12 N•m (1.2 kgf•m, 9 lbf•ft) 6 N•m (0.6 kgf•m, 4.3 lbf•ft) 6 N•m (0.6 kgf•m, 4.3 lbf•ft) 1 N•m (0.1 kgf•m, 0.7 lbf•ft) 32 N•m (3.
16. BRAKE SYSTEM XCITING 500 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. Place the scooter on a level surface and keep the handlebar straight.
16. BRAKE SYSTEM Connect a clear hose to the left front caliper air bleed screw and insert the other end of the hose into a receptacle. XCITING 500 Clear Hose Left Front Caliper Air Bleed Screw Brake Lever 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.
16. BRAKE SYSTEM 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. XCITING 500 Screws Cap/Diaphragm Specification and classification: DOT 4 Clear Hose 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.
16. BRAKE SYSTEM Step 3: XCITING 500 Rear Caliper Air Bleed Screw 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. Clear Hose BLEEDING THE HYDRAULIC BRAKE SYSTEM ＊ 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.
16. BRAKE SYSTEM XCITING 500 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.
16. BRAKE SYSTEM XCITING 500 Right Front Caliper Air Bleed Screw 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.
16. BRAKE SYSTEM XCITING 500 BRAKE PAD BRAKE PAD REPLACEMENT Front brake: Push the caliper pistons all the way in by pushing the caliper body inward to provide clearance for new pads. ＊ Always replace the brake pads in pairs to ensure even disc pressure. Caliper body Caliper body Remove the pad pin plug and loosen the pad pin. Pad Pin Plug Remove the pad pin and the brake pads. Pad Pin Pad Pin Make sure that the pad spring is installed in original position.
16. BRAKE SYSTEM XCITING 500 Tighten the pad pin to the specified torque. Torque: 18 N•m (1.8 kgf•m, 13 lbf•ft) Install the pad pin plug to the specified torque. Torque: 3 N•m (0.3 kgf•m, 2.2 lbf•ft) Pad Pin Pad Pin Plug Rear/Parking brake: Remove the pad pin plug and loosen the pad pin. ＊ Always replace the brake pads in pairs to ensure even disc pressure. Pad Pin Plug Remove the mount bolts and rear/parking brake caliper from the rear fork. Remove the pad pin and brake pads.
16. BRAKE SYSTEM XCITING 500 Installation steps: Turn the parking brake caliper piston clockwise and push it into the parking brake caliper. Parking Brake Caliper Piston Pin Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper. ＊ Align the pin on the pad with the groove on the parking brake caliper piston. Groove Rear/Parking Caliper Body Bolts Install the rear/parking brake caliper to the rear fork.
16. BRAKE SYSTEM XCITING 500 Tighten the pad pin to the specified torque. Torque: 18 N•m (1.8 kgf•m, 13 lbf•ft) Install the pad pin plug to the specified torque. Torque: 3 N•m (0.3 kgf•m, 2.2 lbf•ft) Pad Pin BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits:Front: 4mm (0.16 in) Rear: 4mm (0.16 in) Replace the brake disc if the smallest measurement is less than the service limit. Measure the brake disc warpage. Service limits:0.
16. BRAKE SYSTEM XCITING 500 Lower Handlebar Cover FRONT MASTER CYLINDER REMOVAL When removing the brake hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Remove the upper handlebar cover (page 25). Drain the front brake hydraulic system (page 16-4). Remove the two screws and lower handlebar cover. Screws Disconnect the brake light connectors from front master cylinder.
. BRAKE SYSTEM Remove the bolts from the master cylinder holder and remove the master cylinder assembly. XCITING 500 Master Cylinder Bolts Holder Nut Brake Lever DISASSEMBLY Remove the brake lever pivot bolt and nut. Remove the brake lever. Pivot Bolt Brake Light Switch Remove the screw and brake light switch.
16. BRAKE SYSTEM XCITING 500 Brake Light Switch ASSEMBLY Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Screw Apply silicone grease to the master piston tip. Install the brake lever. Nut Brake Lever Apply silicone grease to the brake lever pivot bolt sliding surface. Install and tighten the pivot bolt to the specified torque. Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft) Install and tighten the pivot nut to the specified torque.
16. BRAKE SYSTEM XCITING 500 Bolts Install the front master cylinders and holders with the “UP” mark facing up. Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) “UP” Mark Sealing Washers Rest the brake hose eyelet against the stopper. Install the brake hose eyelet with the oil bolt and new sealing washers. Tighten the oil bolt to the specified torque. Torque: 35 N•m (3.
16. BRAKE SYSTEM XCITING 500 Lower Handlebar Cover REAR MASTER CYLINDER REMOVAL When removing the brake hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Remove the upper handlebar cover (page 25). Drain the combination brake hydraulic system (page 16-5). Remove the two screws and lower handlebar cover. Screws Disconnect the brake light switch connectors from master cylinder.
16. BRAKE SYSTEM Remove the bolts from the master cylinder holder and remove the master cylinder assembly. XCITING 500 Holder Master Cylinder Bolt Brake Lever Nut DISASSEMBLY Remove the brake lever pivot bolt and nut. Remove the brake lever. Pivot Bolt Remove the screw and brake light switch.
16. BRAKE SYSTEM XCITING 500 Screw ASSEMBLY Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Brake Light Switch Apply silicone grease to the master piston tip. Install the brake lever. Brake Lever Nut Apply silicone grease to the brake lever pivot bolt sliding surface. Install and tighten the pivot bolt to the specified torque. Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft) Install and tighten the pivot nut to the specified torque.
16. BRAKE SYSTEM XCITING 500 “UP” Mark Master Cylinder Install the rear master cylinders and holders with the “UP” mark facing up. Install the bolts and tighten the upper bolt first then tighten the lower bolt to the specified torque. Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Bolt Rest the brake hose eyelet against the stopper. Install the brake hose eyelet with the oil bolt and new sealing washers. Tighten the oil bolt to the specified torque. Sealing Washers Torque: 35 N•m (3.
16. BRAKE SYSTEM XCITING 500 Sealing Washers DELAY VAVLE Sealing Washers REMOVAL When removing the brake hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Remove the front cover (page 2-11). Drain the combination brake hydraulic system (page 16-5). Remove the brake hose oil bolt, sealing washers and brake hose eyelets. Bolts Brake Hose Nuts Remove the two nuts and delay valve.
16. BRAKE SYSTEM XCITING 500 Nuts INSTALLATION Install the delay valve and tighten the nuts securely. Delay Valve Sealing Washers Install the brake hose eyelets and new sealing washers. Tighten the brake hose bolt to the specified torque while rest the brake hose eyelet against the stopper on the delay valve. Sealing Washers Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft) Fill the reservoir to the upper level and bleed the brake system (page 16-8).
16. BRAKE SYSTEM XCITING 500 Brake Hose FRONT BRAKE CALIPER REMOVAL Drain the front brake hydraulic system (left front brake caliper: page 16-4) or combination brake hydraulic system (right front brake caliper: page 16-5). Remove the brake pads (page 16-10). Remove the oil bolts, sealing washers and brake hose from the brake caliper. Bolts Sealing Washers Bolts Remove the mount bolts and front brake caliper.
16. BRAKE SYSTEM XCITING 500 Boots Remove the caliper bracket from the caliper body. Bracket ＊ Do not remove the caliper and bracket pins unless replacement. ASSEMBLY Apply silicone grease to the boots inside. Install the caliper bracket to the caliper. Bolts Brake Hose Pad Spring Install the pad spring into the caliper body as shown. Bolts Brake Hose Bolts INSTALLATION Install the front caliper onto the fork leg. Install and tighten the new front caliper mount bolts to the specified torque.
16. BRAKE SYSTEM XCITING 500 Brake Hose Install the brake hose eyelet to the caliper body with new sealing washers and oil bolts. Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolts to the specified torque. Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft) Install the brake pads (page 16-10). Fill and bleed the hydraulic system (page 167 or page 16-8). REAR/PARKING BRAKE CALIPER Bolts Sealing Washers REMOVAL Remove the muffler (page 2-15).
16. BRAKE SYSTEM Remove the mount bolts and rear/parking brake caliper from the rear fork. XCITING 500 Rear/Parking Brake Caliper Bolts Brake Hose DISASSEMBLY (REAR BRAKE) Remove the pad spring from the caliper body. ＊ Do not remove the retainer from the bracket unless replacement. Pad Spring Retainer Bracket Remove the caliper bracket from the caliper body. ＊ Do not remove the caliper and bracket pins unless replacement. ASSEMBLY (REAR BRAKE) Apply silicone grease to the boot inside.
16. BRAKE SYSTEM XCITING 500 Install the pad spring into the caliper body as shown. Pad Spring Brake Arm DISASSEMBLY (PARKING BRAKE) Remove the lock nut and parking brake arm. Lock Nut Brake Shaft Push Rod Remove the parking brake shaft and push rod.
16. BRAKE SYSTEM Removed the two bolts, gasket and parking brake bracket. XCITING 500 Bolts Bracket Gasket ASSEMBLY (PARKING BRAKE) Install the gasket. Brake Shaft Install the parking brake bracket and tighten the bolts to the specified torque. Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft) Apply silicone grease to the parking brake shaft rolling surface. Install the parking brake shaft.
16. BRAKE SYSTEM XCITING 500 Brake Arm Temporarily install the brake arm and the lock nut. Lock Nut Rear/Parking Brake Caliper Bolts INSTALLATION Install the brake pads (page 16-12). Install the rear/parking brake caliper to the rear fork and tighten the new mount bolts to specified torque. Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft) Brake Hose Install the brake hose eyelet to the caliper body with new sealing washers and oil bolts.
16. BRAKE SYSTEM XCITING 500 Arm Connect the parking brake cable. Adjust the parking brake (page 3- 21). Brake Cable Brake Cable PARKING BRAKE LEVER LINK REMOVAL Remove the inner cover (page 2-14). Loosen the lock nut and disconnect the parking brake cable from the parking braking brake lever link. Lock Nut Disconnect the parking brake switch connector.
16. BRAKE SYSTEM Remove the two nuts and parking brake lever link. XCITING 500 Parking Brake Lever Link Nuts Parking Brake Switch DISASSEMBLY Remove the two screws and parking brake switch. ASSEMBLY Assembly is in the reverse order of disassembly. Screw INSTALLATION Installation is in the reverse order of removal.
