Kymco XCITING 500 - Service Manual > 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.
Remove the pad pin plug and loosen the pad pin.
Remove the pad pin and the brake pads.
Make sure that the pad spring is installed in original position.
Install new pads so that the their ends rest on the pad retainer on the bracket properly.
Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
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)
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.
Remove the mount bolts and rear/parking brake caliper from the rear fork.
Remove the pad pin and brake pads.
Installation steps:
Turn the parking brake caliper piston clockwise and push it into the parking brake caliper.
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.
Install the rear/parking brake caliper to the rear fork.
Install and tighten the new rear/parking brake caliper mounting blots to the specified torque.
Torque: 32 N*m (3.2 kgf*m, 23 lbf*ft)
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)
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:0.30 mm (0.012 in)
See also:
Kymco XCITING 500 - Service Manual > Brake Fluid
Check Brake fluid Brake hose: Cracks/wear/damage → Replace. Apply the brake lever several times. Fluid leakage → Replace. Brake hose clamp: Loosen → Tighten
Kymco XCITING 500 - Service Manual > 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.
