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Proper brake hose routing is essential to insure safe scooter operation. Refer to “CABLE ROUTING” in chapter 2.
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NOTE:
20 While holding the brake hose, tighten the union bolt as shown.
21 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.
4 - 43
FRONT AND REAR BRAKES CHAS
O Fill:
brake master cylinder reservoir
(with the specified amount of the recom-mended brake fluid)
Recommended brake fluid
DOT 4
WARNING
X Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Y 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.
Z 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.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately.
10. Bleed:
brake system
Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (XP500)” and “BLEED-ING THE BRAKE SYSTEM (XP500A)” in chapter 3.
11. 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.
12. 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.
4 - 44
FRONT AND REAR BRAKES CHAS
FRONT BRAKE CALIPER
10 9
New
| LS |
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
| R. | 30 Nm (3.0 m | • | kg, 22 ft | • | Ib) |
| T. | |||||
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
| Order | Job/Part | Q’ty | Remarks | ||
| Removing the front brake caliper | Remove the parts in the order listed. | ||||
| Brake fluid | Drain. | ||||
| Union bolt | Refer to “DISASSEMBLING THE | ||||
| Copper washer | FRONT BRAKE CALIPER” and | ||||
| Brake hose | “ASSEMBLING AND INSTALLING THE | ||||
| FRONT BRAKE CALIPER”. | |||||
| Front brake caliper retaining bolt | |||||
| (lower) | |||||
| Front brake caliper retaining bolt | |||||
| (upper) | Refer to “ASSEMBLING AND INSTALL- | ||||
| Brake caliper | |||||
| ING THE FRONT BRAKE CALIPER”. | |||||
| Brake pad | |||||
| Brake pad shim | |||||
| Brake pad spring | |||||
| Brake pad spring | |||||
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4 - 45
FRONT AND REAR BRAKES CHAS
10 9
New
| LS |
T.
R.
27 Nm (2.7 m • kg, 19 ft • Ib)
| R. | 30 Nm (3.0 m | • | kg, 22 ft | • | Ib) |
| T. | |||||
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
| Order | Job/Part | Q’ty | Remarks | ||
| Front brake caliper bracket bolt 2 | Refer to “ASSEMBLING AND INSTALL- | ||||
| Brake caliper bracket | ING THE FRONT BRAKE CALIPER”. | ||||
| For installation, reverse the removal pro- | |||||
| cedure. | |||||
4 - 46
FRONT AND REAR BRAKES CHAS
EAS00614
| Order | Job/Part | Q’ty | Remarks | ||
| Disassembling the front brake cali- | Remove the parts in the order listed. | ||||
| per | |||||
| Bleed screw | |||||
| Dust seal | Refer to “DISASSEMBLING THE | ||||
| Brake caliper piston seal | FRONT BRAKE CALIPER” and | ||||
| Brake caliper piston | “ASSEMBLING AND INSTALLING THE | ||||
| FRONT BRAKE CALIPER”. | |||||
| Brake caliper body | |||||
| For assembly, reverse the disassembly | |||||
| procedure. | |||||
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4 - 47
FRONT AND REAR BRAKES CHAS
REAR BRAKE CALIPER
| Order | Job/Part | Q’ty | Remarks | ||
| Removing the rear brake caliper | Remove the parts in the order listed. | ||||
| Brake fluid | Drain. | ||||
| Nut | |||||
| Rear brake lock lever cable | Refer to “DISASSEMBLING THE REAR | ||||
| Pin | BRAKE CALIPER”. | ||||
| Spring | |||||
| Union bolt | Refer to “DISASSEMBLING THE REAR | ||||
| Copper washer | BRAKE CALIPER” and “ASSEMBLING | ||||
| Brake hose | AND INSTALLING THE REAR BRAKE | ||||
| CALIPER”. | |||||
| Rear brake caliper retaining bolt | Refer to “ASSEMBLING AND INSTALL- | ||||
| Brake caliper | |||||
| ING THE REAR BRAKE CALIPER”. | |||||
| Brake pad | |||||
4 - 48
FRONT AND REAR BRAKES CHAS
| Order | Job/Part | Q’ty | Remarks | ||
| Brake pad spring | Refer to “ASSEMBLING AND INSTALL- | ||||
| Rear brake caliper bracket bolt | |||||
| ING THE REAR BRAKE CALIPER”. | |||||
| Brake caliper bracket | |||||
| For installation, reverse the removal pro- | |||||
| cedure. | |||||
4 - 49
FRONT AND REAR BRAKES CHAS
T.
R.
2 New
6 Nm (0.6 m • kg, 4.3 ft • Ib)
3 New
| Order | Job/Part | Q’ty | Remarks | ||
| Disassembling the rear brake cali- | Remove the parts in the order listed. | ||||
| per | |||||
| Brake caliper piston | Refer to “DISASSEMBLING THE REAR | ||||
| Dust seal | BRAKE CALIPER” and “ASSEMBLING | ||||
| Piston seal | AND INSTALLING THE REAR BRAKE | ||||
| CALIPER”. | |||||
| Bleed screw | |||||
| Brake caliper body | |||||
| For assembly, reverse the disassembly | |||||
| procedure. | |||||
4 - 50
FRONT AND REAR BRAKES CHAS
a
EAS00619
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