Troubleshooting - KYMCO XCITING 500 Service Manual

16
. BRAKE SYSTEM
TORQUE VALUES
Master cylinder reservoir cover screw
Master cylinder holder bolt
Brake lever pivot bolt
Brake lever pivot nut
Brake light switch screw
Brake caliper mounting bolt
Brake caliper bleed screw
Brake pad pin
Front/Rear caliper pad pin plug
Brake hose oil bolt
Delay valve bleed screw

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
16-3
2 N•m (0.2 kgf•m, 1.4 lbf•ft)
12 N•m (1.2 kgf•m, 9 lbf•ft)
6 N•m (0.6 kgf•m, 4.3 lbf•ft)
6 N•m (0.6 kgf•m, 4.3 lbf•ft)
1 N•m (0.1 kgf•m, 0.7 lbf•ft)
32 N•m (3.2 kgf•m, 23 lbf•ft)
ALOC bolt: replace with a new one.
6 N•m (0.6 kgf•m, 4.3 lbf•ft)
18 N•m (1.8 kgf•m, 13 lbf•ft)
2 N•m (0.2 kgf•m, 1.4 lbf•ft)
35 N•m (3.5 kgf•m, 25 lbf•ft)
6 N•m (0.6 kgf•m, 4.3 lbf•ft)
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
XCITING 500