ch9 brakes v1

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  • 9. Brakes XCITING 400i

    91

    Brakes This chapter covers the location and servicing of the brake system components for the KYMCO XCITING 400i models.

    Brake Discs ................................................................... 9-3~9-6

    Front Brake Calipers ................................................... 9-7~9-13

    Master Cylinders ....................................................... 9-14~9-20

    Rear Brake Caliper .................................................... 9-21~9-35

    GENERAL INSTRUCTIONS A contaminated brake disc or pad reduces stopping power. Discard

    contaminated parts and clean a contaminated disc with high quality brake degreasing agent.

    Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced.

    Never allow contamination (dirt, water, etc.) to get into and open brake reservoir.

    Once the hydraulic system has been opened, or if the brake feel spongy, the system must be bled.

    Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible.

    Always check brake operation before riding the vehicle.

    Warning: Frequent inhalation of brake pad dust, regardless of material composition

    could be hazardous to your health. Avoid breathing dust particles.

  • 9. Brakes XCITING 400i

    92

    TROUBLESHOOTING

    Brake lever soft or spongy

    Air in the hydraulic system

    Low brake fluid level

    Clogged fluid passage

    Contaminated brake disc pad

    Warped/deformed brake disc

    Worn brake disc pad

    Sticking worn master cylinder piston

    Contaminated master cylinder

    Contaminated caliper

    Caliper not sliding properly

    Leaking hydraulic system

    Worn caliper piston seal

    Worn master cylinder piston cups

    Bent brake lever

    Brake lever hard

    Clogged restricted brake system

    Sticking/worn caliper piston

    Caliper not sliding properly

    Clogged restricted fluid passage

    Worn caliper piston seal

    Sticking worn master cylinder piston

    Bent brake lever

    Brake drag

    Contaminated brake disc pad

    Worn brake disc pad

    Warped/deformed brake disc

    Caliper not sliding properly

  • 9. Brakes > Disc Brake XCITING 400i

    93

    Disc Brake

    SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

    Inspection

    Measure the thickness of the brake rotor with a micrometer.

    Item Standard mm (in) Service Limited

    Brake disk thickness (rear) 4.8 - 5.2 (0.19 - 0.20) 4 (0.16)

    Brake disk thickness (front) 3.8 - 4.2 (0.15 - 0.17) 3 (0.12)

    Check if the brake rotor runout is within the service limit.

    Measure the runout of the brake disc with a dial gauge. If the reading is out of specification remove the disc from the wheel and recheck.

    Item Standard mm (in) Service Limited

    Brake disc runout 0.03 (0.012)

  • 9. Brakes > Disc Brake XCITING 400i

    94

    Front

    Removal

    Remove the five mounting bolts with a 6 mm Allen.

    To remove the front brake disc take out the five mounting bolts with a 8 mm Allen.

    Remove the front brake discs.

  • 9. Brakes > Disc Brake XCITING 400i

    95

    Installation

    Fit the brake disc into place as shown.

    Coat the threads of the disc bolts in a non-permanent thread locking agent. Thread in the bolts and torque them to specification with an Allen socket.

    Item Qty Thread dia.(mm) Torque

    Nm (kgf-m, ft-lb) Brake disc bolt 5 8 35 (3.5, 25)

    Install the front wheel. See the Front Wheel topic for more information.

    Rear

    Removal

    To remove the rear brake disc take out the five mounting bolts with a 6 mm Allen.

  • 9. Brakes > Disc Brake XCITING 400i

    96

    Lift off the rear brake disc. Installation

    Fit the rear brake disc into place on the wheel as shown.

    Apply a non-permanent thread locking agent to the threads of the rear disc bolts. Insert the bolts and tighten them to specification with a 6 mm Allen.

    Item Qty Thread dia.(mm) Torque

    Nm (kgf-m, ft-lb) Brake disc bolt 5 8 35 (3.5, 25)

  • 9. Brakes > Front Brake Calipers XCITING 400i

    97

    Front Caliper

    SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

    Removal

    Brake Pads

    Push the caliper body inward to push in the pistons. This will allow room to change the brake pads.

    Remove the two caliper mounting bolts with a 12 mm socket. Discard the brake caliper mounting bolts.

    Remove the front brake caliper. The brake calipers are each mounted to the front fork with two bolts.

  • 9. Brakes > Front Brake Calipers XCITING 400i

    98

    Remove the brake pads with a 6mm Allen.

    Free the brake pads from the pad retainer. Remove the brake pads.

    Remove the brake pad Clips with a splcier.

    Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Always replace brake pads as a set.

  • 9. Brakes > Front Brake Calipers XCITING 400i

    99

    Caliper

    Place a suitable container under the banjo bolt to catch any remaining brake fluid. Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket. Discard the two sealing washers.

    The brake calipers are each mounted to the front fork with two bolts.

    Remove the two caliper mounting bolts with a 12 mm socket. Discard the brake caliper mounting bolts.

    Remove the brake caliper from the fork leg.

  • 9. Brakes > Front Brake Calipers XCITING 400i

    910

    Disassembly

    Remove the pad retainer from the brake caliper bracket if needed.

    Remove the pistons and clean them with steel wool. Clean all of the brake caliper components using aerosol brake cleaner and a lint free cloth. Discard the old seals.

  • 9. Brakes > Front Brake Calipers XCITING 400i

    911

    Inspection

    Inspect the pistons for wear and damage. Inspect the piston bores for wear and damage.

    Assembly

    Lubricate the caliper pistons, the caliper piston bores with DOT 4 brake fluid from a tightly sealed container.

    NOTE: Brake fluid is a corrosive chemical and can damage paints and

    some plastics. Avoid contact with skin. Install the pistons. Push the caliper pistons completely into the caliper closed end first. You can use one of the old brake pads to push in both pistons at the same time.

  • 9. Brakes > Front Brake Calipers XCITING 400i

    912

    Install the brake pad as shown.

    Installation

    Install the front caliper. Guide the brake disc between the pads. Line up the caliper bracket mounts with the fork.

    Install the two new caliper bracket mounting bolts. Tighten the mounting bolts to specification.

    Item Q'ty Thread dia.(mm)Torque Remarks

    Nm (kgf-m, ft-lb)

    Front caliper mounting bolt 4 10 35 (3.5, 25) Replace a new one

  • 9. Brakes > Front Brake Calipers XCITING 400i

    913

    Install the banjo bolt with new sealing washers and tighten to specification with a 12 mm socket.

    Item Q'ty Thread dia.(mm)Torque

    Nm (kgf-m, ft-lb)

    Brake fluid bolt 2 10 35 (3.5, 25)

  • 9. Brakes > Master Cylinders XCITING 400i

    914

    Master Cylinders

    SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

    NOTE: Brake fluid is a corrosive chemical and can damage paints and some plastics.

    Avoid contact with skin.

    Removal

    The master cylinders for the front and rear brakes are essentially the same.

    Remove the brake hose banjo bolt from the master cylinder using a 12 mm socket. Discard the sealing washers.

    Unplug the brake light switch connectors.

  • 9. Brakes > Master Cylinders XCITING 400i

    915

    Remove the two master cylinder mounting bolts with an 8 mm socket.

    Remove the master cylinder clamp.

    Remove the master cylinder.

    Remove the two master cylinder cover screws with a #2 Phillips head screwdriver.

  • 9. Brakes > Master Cylinders XCITING 400i

    916

    Remove the master cylinder cover, plastic piece and rubber accordion diaphragm. Pour out any remaining brake fluid. Disassembly Brake Levers

    Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt with a flat blade screwdriver.

  • 9. Brakes > Master Cylinders XCITING 400i

    917

    Remove the pivot nut and bolt.

    Remove the brake lever.

    Brake Light Switch

    Remove the brake light switch mounting bolt with a #2 Phillips screwdriver. Remove the brake light switch.

  • 9. Brakes > Master