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Front brake master cylinder
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WARNING
Ч Before installation, all internal brake com-ponents should be cleaned and lubricated with clean or new brake fluid.
Ч Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
Ш Install:
brake master cylinder kit 1
• circlip 2 New
dust boot 3
Ъ Install:
brake master cylinder 1
brake master cylinder holder 2
| • holder bolts | T.R. | 10 Nm (1.0 m · kg, 7.2 ft · lb) |
NOTE:
Ы • Install the brake master cylinder holder with the “UP” mark facing up a.
Ь • Align the brake master cylinder with the pro-jection b in the handlebar.
First, tighten the upper bolt, then the lower bolt.
4 - 40
FRONT AND REAR BRAKES CHAS
3. Install:
• copper washers 1 New
• brake hose 2
• union bolt 3
WARNING
T.
R.
30 Nm (3.0 m · kg, 22 ft · lb)
Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2.
NOTE:
Э While holding the brake hose, tighten the union bolt as shown.
Э Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.
CAUTION:
When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a on the brake master cylinder.
А Connect:
front brake light switch connector
А Fill:
brake master cylinder reservoir
(with the specified amount of the recom-mended brake fluid)
Recommended brake fluid
DOT 4
WARNING
Б Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Б Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Б When refilling, be careful that water does not enter the reservoir. Water will signifi-cantly lower the boiling point of the brake fluid and could cause vapor lock.
4 - 41
FRONT AND REAR BRAKES CHAS
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
Л Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED-ING THE BRAKE SYSTEM (XP500A)” in chapter 3.
Л Check:
brake fluid level
Below the minimum level mark a → Add the recommended brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3.
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Л Check:
brake lever operation
Soft or spongy feeling → Bleed the brake system.
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED-ING THE BRAKE SYSTEM (XP500A)” in chapter 3.
EAS00600
ASSEMBLING AND INSTALLING THE
REAR BRAKE MASTER CYLINDER
WARNING
М Before installation, all internal brake com-ponents should be cleaned and lubricated with clean or new brake fluid.
М Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
Н Install:
brake master cylinder kit 1
• circlip 2 New
• dust boot 3
4 - 42
a
FRONT AND REAR BRAKES CHAS
| 2. | Install: | |||
| b | • | brake master cylinder 1 | ||
| • brake master cylinder holder 2 | ||||
| • | holder bolts | T.R.10 Nm (1.0 m · kg, 7.2 ft · lb) | ||
| NOTE: | ||||
| UP | • Install the brake master cylinder holder with | |||
| the “UP” mark facing up a. | ||||
| • Align the brake master cylinder with the pro- | ||||
| jection b on the handlebar. | ||||
| • First, tighten the upper bolt, then the lower | ||||
| bolt. |
3. Install:
• copper washer 1 New
15 brake hose 2
16 union bolt 3 
T. 30 Nm (3.0 m · kg, 22 ft · lb)
R.
WARNING
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