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Removing the front wheel (xp500)
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1. Stand the scooter on a level surface.
WARNING
Securely support the so that there is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
8. Remove:
front brake calipers
NOTE:
Do not squeeze the brake lever when remov-ing the brake caliper.
9. Loosen:
front wheel axle pinch bolt 1
front wheel axle 2
Use the damper rod holder 3.
Damper rod holder (14 mm) 90890-04085
9. Elevate:
front wheel
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
EAS00520
REMOVING THE FRONT WHEEL AND
FRONT WHEEL SENSOR (XP500A)
ABS wheel sensor and sensor rotor
CAUTION:
Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub-ject them to shocks.
The ABS wheel sensor cannot be disas-sembled. Do not attempt to disassemble it. If faulty, replace with a new one.
4 - 6
FRONT WHEEL AND BRAKE DISC CHAS
1. Stand the scooter on a level surface.
WARNING
Securely support the so that there is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
7. Remove:
• plastic clamp 1
• front wheel sensor lead guide 2
• front wheel sensor 3
CAUTION:
Be sure not to contact the sensor elec-trode to any metal part when removing the front wheel sensor from the sensor housing.
Do not operate the brake lever when removing the brake caliper.
10. Remove:
• front brake calipers
NOTE:
Do not squeeze the brake lever when remov-ing the brake caliper.
• Loosen:
wheel axle pinch bolt 1
front wheel axle 2
Use the damper rod holder 3.
Damper rod holder (14 mm) 90890-04085
• Elevate:
front wheel
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
4 - 7
FRONT WHEEL AND BRAKE DISC CHAS
EAS00525
CHECKING THE FRONT WHEEL
Й Check:
wheel axle
Roll the wheel axle on a flat surface. Bends → Replace.
WARNING
Do not attempt to straighten a bent wheel axle.
К Check:
tire
front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3.
К Measure:
front wheel radial runout 1
front wheel lateral runout 2
Over the specified limits → Replace.
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Front wheel radial runout limit 1 mm (0.04 in)
Front wheel lateral runout limit 0.5 mm (0.02 in)
Л Check:
wheel bearings
Front wheel turns roughly or is loose → Replace the wheel bearings.
oil seals
Damage/wear → Replace.
4 - 8
FRONT WHEEL AND BRAKE DISC CHAS
5. Replace:
• wheel bearings New
• oil seals New
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П Clean the outside of the front wheel hub.
П Remove the oil seals 1 with a flat-head screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel sur-face.
Т Remove the wheel bearings 3 with a gen-eral bearing puller.
Т Install the new wheel bearings and oil seals in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center race 4 or balls 5. Contact should be made only with the outer race 6.
NOTE:
Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal.
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EAS00528
CHECKING THE BRAKE DISC
The following procedure applies to all of the brake discs.
У Check:
brake disc
Damage/galling → Replace.
У Measure:
brake disc deflection
Out of specification → Correct the brake disc deflection or replace the brake disc.
Maximum brake disc deflection
Front: 0.12 mm (0.0047 in)
Rear: 0.15 mm (0.0059 in)
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Ф Place the scooter on a suitable stand so that the front wheel is elevated.
4 - 9
FRONT WHEEL AND BRAKE DISC CHAS
Х Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is sta-tionary.
Х Remove the brake caliper.
Х Hold the dial gauge at a right angle against the brake disc surface.
Х Measure the deflection 1.5 mm (0.06 in)
below the edge of the brake disc.
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Ч Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
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