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Minimum brake disc thickness
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Front: 3.5 mm (0.14 in)
Rear: 4.5 mm (0.18 in)
Ш Adjust:
brake disc deflection
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X Remove the brake disc.
Y Rotate the brake disc by one bolt hole.
Z Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a crisscross pattern.
T.
R.
Brake disc bolt
18 Nm (1.8 m · kg, 13 ft · lb)
LOCTITE®
Й Measure the brake disc deflection.
Й If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
Й If the brake disc deflection cannot be brought within specification, replace the
brake disc.
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4 - 10
FRONT WHEEL AND BRAKE DISC CHAS
CHECKING THE FRONT WHEEL SENSOR AND SENSOR ROTOR (XP500A)
К Check:
front wheel sensor 1 Cracks/bends/distortion → Replace. Iron powder/dust → Clean.
К Measure:
front wheel sensor resistance
Connect the pocket tester (Ω Ч 1k) to the terminals of the front wheel sensor coupler.
Positive tester probe → Terminal 1 Negative tester probe → Terminal 2
Regulated resistance
1.2 ~ 1.6 k Ω at 20 °C (68 °F)
Out of specification → Replace. 3. Check:
1 • front wheel sensor rotor 1
Cracks/damage → Replace the front wheel assembly.
NOTE:
The wheel sensor rotor of the scooter cannot be replaced as a single unit. To replace the sensor rotor, replace the wheel assembly.
EAS00548
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
Л After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
Л Adjust the front wheel static balance with the brake disc installed.
М Remove:
balancing weight(s)
4 - 11
FRONT WHEEL AND BRAKE DISC CHAS
Н Find:
front wheel’s heavy spot
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О Place the front wheel on a suitable balanc-ing stand.
О Spin the front wheel.
О When the front wheel stops, put an “X1” mark at the bottom of the wheel.
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О Turn the front wheel 90° so that the “X1” mark is positioned as shown.
О Release the front wheel.
О When the front wheel stops, put an “X2” mark at the bottom of the wheel.
О Repeat steps (e) through (g) several times until all the marks come to rest at the same spot.
О The spot where all the marks come to rest
is the front wheel’s heavy spot “X”.
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П Adjust:
front wheel static balance
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Р Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
С Turn the front wheel 90° so that the heavy spot is positioned as shown.
С If the heavy spot does not stay in that posi-tion, install a heavier weight.
С Repeat steps (b) and (c) until the front
wheel is balanced.
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У Check:
front wheel static balance
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Ф Turn the front wheel and make sure that it stays at each position shown.
Ф If the front wheel does not remain stationary
at all of the positions, rebalance it.
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4 - 12
FRONT WHEEL AND BRAKE DISC CHAS
EAS00542
INSTALLING THE FRONT WHEEL (XP500)
Х Lubricate:
oil seal lips
speedometer drive gear
speedometer driven gear
Recommended lubricant
Lithium-soap-based grease
Ш Install:
speed sensor (to front wheel)
NOTE:
Make sure that the speed sensor unit and the wheel hub are installed with the two projec-tions meshed into the two slots respectively.
Щ Install:
front wheel
front wheel axle
front wheel axle pinch bolt
NOTE:
Make sure that the slot a in the speedometer gear unit fits over the stopper b on the front fork outer tube.
Ъ Tighten:
front wheel axle 1
T.
R.
59 Nm (5.9 m · kg, 43 ft · lb)
Use the damper rod holder 2.
• front wheel axle pinch bolt 3
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T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
Damper rod holder (14 mm) 90890-04085
CAUTION:
Before tightening the wheel axle pinch bolt, push down hand on the handlebar several times and check if the front fork rebounds smoothly.
4 - 13
FRONT WHEEL AND BRAKE DISC CHAS
5. Install:
• front brake calipers
1 
WARNING
Make sure that the brake hoses are routed
Properly.
6. Tighten:
• front brake caliper bracket bolt 1
T 40 Nm (4.0 m · kg, 29 ft · lb)
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R.
EAS00542
INSTALLING THE FRONT WHEEL AND
FRONT WHEEL SENSOR (XP500A)
1. Lubricate:
• oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Install:
• front wheel
• front wheel axle
• front wheel axle pinch bolt
NOTE:
Align the slot in the sensor housing with the projection of the front fork before assembly.
CAUTION:
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