Kymco XCITING 500 - Service Manual > Front Brake Caliper
REMOVAL
Drain the front brake hydraulic system (left front brake caliper) or combination brake hydraulic system (right front brake caliper).
Remove the brake pads.
Remove the oil bolts, sealing washers and brake hose from the brake caliper.
Remove the mount bolts and front brake caliper.
DISASSEMBLY
Remove pad spring from the caliper body.
Do not remove the retainer from the bracket unless replacement.
Remove the caliper bracket from the caliper body.
Do not remove the caliper and bracket pins unless replacement.
ASSEMBLY
Apply silicone grease to the boots inside.
Install the caliper bracket to the caliper.
Install the pad spring into the caliper body as shown.
INSTALLATION
Install the front caliper onto the fork leg.
Install and tighten the new front caliper mount bolts to the specified torque.
Torque: 32 N*m (3.2 kgf*m, 23 lbf*ft)
Install the brake hose eyelet to the caliper body with new sealing washers and oil bolts.
Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolts to the specified torque.
Torque: 35 N*m (3.5 kgf*m, 25 lbf*ft)
Install the brake pads.
Fill and bleed the hydraulic system.
See also:
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.
Kymco XCITING 500 - Service Manual > Rear/parking brake caliper
REMOVAL Remove the muffler. Drain the rear brake hydraulic system. Disconnect the parking brake cable from the brake arm. Remove the pad pin plug and loosen the pad pin.
