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16. BRAKE SYSTEM

XCITING 500/250

16
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BRAKE SYSTEM
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SCHEMATIC DRAWING ------------------------------------------------- 16- 1
SERVICE INFORMATION ----------------------------------------------- 16- 2

16

TROUBLESHOOTING----------------------------------------------------- 16- 3
BRAKE FLUID -------------------------------------------------------------- 16- 4
BRAKE PAD----------------------------------------------------------------- 16-10
BRAKE DISC INSPECTION---------------------------------------------- 16-13
FRONT MASTER CYLINDER ------------------------------------------- 16-14
REAR MASTER CYLINDER --------------------------------------------- 16-18
DELAY VALVE------------------------------------------------------------- 16-22
FRONT BRAKE CALIPER------------------------------------------------ 16-24
REAR/PARKING BRAKE CALIPER ----------------------------------- 16-26
PARKING BRAKE LEVER LINK (XCITING 500) ------------------- 16-31

16-0

16. BRAKE SYSTEM
SCHEMATIC DRAWING

16-1

XCITING 500/250

16. BRAKE SYSTEM

XCITING 500/250

SERVICE INFORMATION
GENERAL

＊

Frequent inhalation of brake pad dust, regardless of material composition could be hazardous
to your health.
Avoid breathing dust particles.

• 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.
• This section covers maintenance of the front and rear hydraulic brake system.
• Never allow contamination (dirt, water, etc.) to get into and open 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.
SPECIFICATIONS
ITEM
Front Specified brake fluid
Brake disc thickness
Brake disc runout
Rear Specified brake fluid
Brake disc thickness
Brake disc warpage

STANDARD
DOT 4
4.8 – 5.2 (0.19 – 0.20)
⎯
DOT 4
4.8 – 5.2 (0.19 – 0.20)
⎯

Unit: mm (in)
SERVICE LIMIT
⎯
4 (0.16)
0.03 (0.012)
⎯
4 (0.16)
0.03 (0.012)

16-2

16. BRAKE SYSTEM

XCITING 500/250

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

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)

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

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

16. BRAKE SYSTEM

XCITING 500/250

BRAKE FLUID
Check
Brake fluid: (page 3-24)
Brake hose:
Cracks/wear/damage → Replace.
Apply the brake lever several times.
Fluid leakage → Replace.
Brake hose clamp:
Loosen → Tighten

FLUID REPLACEMENT
Front brake

＊ Avoid spilling brake fluid on painted,

plastic or rubber parts and so on. Place a
rag over these parts whenever the system
is serviced.

Place the scooter on a level surface and keep
the handlebar straight.
Screws

Cap/Diaphragm

Remove the master cylinder reservoir cap and
diaphragm.
Suck up the old brake fluid as much as
possible.
Fill the reservoir with new brake fluid.
Specification and classification: DOT 4

16-4

16. BRAKE SYSTEM
Connect a clear hose to the left front caliper
air bleed screw and insert the other end of the
hose into a receptacle.

XCITING 500/250
Clear Hose

Left Front Caliper Air Bleed Screw
Brake Lever

Loosen the air bleed screw and pump the
brake lever until the old brake fluid is
completely out of the brake system.
Close the air bleed screw and disconnect the
clear hose. Fill the reservoir with new brake
fluid to the upper end of the inspection
window.
Tighten the bleed screw to the specified
torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

Combination brake

＊ Avoid spilling brake fluid on painted,

plastic or rubber parts and so on. Place a
rag over these parts whenever the system
is serviced.

Place the scooter on a level surface and keep
the handlebar straight.

16-5

16. BRAKE SYSTEM
Remove the master cylinder reservoir cap and
diaphragm.
Suck up the old brake fluid as much as
possible.
Fill the reservoir with new brake fluid.

XCITING 500/250
Screws

Cap/Diaphragm

Specification and classification: DOT 4

Clear Hose

Step 1:
Connect a clear hose to the delay valve air
bleed screw and insert the other end of the
hose into a receptacle.
Loosen the air bleed screw and pump the
brake lever until the old brake fluid is
completely out of the brake system. Close
the air bleed screw and disconnect the clear
hose. Fill the reservoir with new brake fluid
to the upper end of the inspection window.

Relay Valve Air Bleed Screw

Step 2:
Connect a clear hose to the right front
caliper air bleed screw. The right brake fluid
replacement is the same way as that of the
step 1.

Right Front Caliper Air Bleed Screw

Clear Hose

16-6

16. BRAKE SYSTEM
Step 3:

XCITING 500/250
Rear Caliper Air Bleed Screw

Connect a clear hose to the rear caliper air
bleed screw. The rear brake fluid
replacement is the same way as that of the
step 1.

Clear Hose

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

＊ Bleed the brake fluid circuit:
● The system has been disassembled.
● A brake hose or brake pipe have been
loosened or removed.
● The brake fluid has been very low.
● The brake operation has been faulty.
A loss of braking performance may occur
if the brake system is not properly bled.
Air bleeding steps (Front brake):
1.Add the proper brake fluid to the reservoir.
2.Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
3.Connect the clear plastic hose tightly to the
left front caliper air bleed screw.
4.Place the other end of the hose into a
container.
5.Slowly apply the brake lever several times.
6.Pull the lever in and hold it.
7. Loosen the bleed screw and allow the
lever to travel towards its limit.

Clear Hose

Left Front Caliper Air Bleed Screw

16-7

16. BRAKE SYSTEM

XCITING 500/250

8.Tighten the bleed screw when the lever
limit has been reached, then release the
lever.
9.Repeat steps (5) to (7) until all the air
bubbles have disappeared from the fluid.
10.Tighten the bleed screw.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

＊ If bleeding is difficult, it may be

necessary to let the brake fluid settle for
a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the system have
disappeared.

12.Add brake fluid to the proper level and
install the master cylinder reservoir cap
and diaphragm.

＊ Check the operation of the brake after
bleeding the brake system.

Rear Caliper Air Bleed Screw

Air bleeding steps (combination brake):
The combination brake system air bleeding is
the same manner as that of the front brake
one.
Bleed the air from the rear side (rear caliper)
and then the front side (right front caliper and
delay valve).
Tighten the bleed screw.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

＊ If bleeding is difficult, it may be

Clear Hose

necessary to let the brake fluid settle for
a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the system have
disappeared.

16-8

16. BRAKE SYSTEM

XCITING 500/250
Right Front Caliper Air Bleed Screw

Add brake fluid to the proper level.

＊ Check the operation of the brake after
bleeding the brake system.

Install the master cylinder reservoir cap and
diaphragm.

Clear Hose

Clear Hose

Relay Valve Air Bleed Screw

16-9

16. BRAKE SYSTEM

XCITING 500/250

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.

Caliper body

Remove the pad pin plug and loosen the pad
pin.

Pad Pin Plug

Remove the pad pin and the brake pads.

Pad Pin

Pad Pin

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.

Brake Pads

16-10

16. BRAKE SYSTEM

XCITING 500/250

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)

Pad Pin

Pad Pin Plug

Rear/Parking brake (XCITING 500):
Remove the pad pin plug and loosen the pad
pin.

＊ Always replace the brake pads in pairs to
ensure even disc pressure.

Pad Pin Plug

Remove the mount bolts and rear/parking
brake caliper from the rear fork.
Remove the pad pin and brake pads.

16-11

Rear/Parking Caliper Body

Pad Pin
Bolts

16. BRAKE SYSTEM

XCITING 500/250

Installation steps:
Turn the parking brake caliper piston
clockwise and push it into the parking brake
caliper.

Parking Brake Caliper Piston
Pin

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.

Groove
Rear/Parking Caliper Body

Bolts

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)

16-12

16. BRAKE SYSTEM

XCITING 500/250

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 brake (XCITING 250):
The rear brake pads and front brake pads
replacement are all the same.

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:0.3 mm (0.012 in)

16-13

Pad Pin

Pad Pin Plug

16. BRAKE SYSTEM

XCITING 500/250
Lower Handlebar Cover

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 (page 25).
Drain the front brake hydraulic system (page
16-4).
Remove the two screws and lower handlebar
cover.

Screws

Disconnect the brake light connectors from
front master cylinder.

Brake Light Switch Connectors
Sealing Washers

Remove the brake hose oil bolt, sealing
washers and brake hose eyelet.

Bolt

Brake Hose

16-14

16. BRAKE SYSTEM
Remove the bolts from the master cylinder
holder and remove the master cylinder
assembly.

XCITING 500/250
Master Cylinder

Bolts

Holder
Nut

Brake Lever

DISASSEMBLY
Remove the brake lever pivot bolt and nut.
Remove the brake lever.

Pivot Bolt
Brake Light Switch

Remove the screw and brake light switch.

Screw

16-15

16. BRAKE SYSTEM

XCITING 500/250
Brake Light Switch

ASSEMBLY
Install the brake light switch and tighten the
screw to the specified torque.
Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft)

Screw

Apply silicone grease to the master piston tip.
Install the brake lever.

Nut

Brake Lever

Apply silicone grease to the brake lever pivot
bolt sliding surface.
Install and tighten the pivot bolt to the
specified torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Install and tighten the pivot nut to the
specified torque.
Pivot Bolt

Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

INSTALLATION
Align the pin on the master cylinder holder
with the hole on the handlebar.

Pin

Hole

16-16

16. BRAKE SYSTEM

XCITING 500/250
Bolts

Install the front master cylinders and holders
with the “UP” mark facing up.
Install the bolts and tighten the upper bolt
first then tighten the lower bolt to the
specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

“UP” Mark
Sealing Washers

Rest the brake hose eyelet against the stopper.
Install the brake hose eyelet with the oil bolt
and new sealing washers.
Tighten the oil bolt to the specified torque.
Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft)

Bolt

Brake Hose

Connect the brake light switch connectors.
Fill the reservoir to the upper level and bleed
the brake system (page 16-7).

Brake Light Switch Connectors

16-17

16. BRAKE SYSTEM

XCITING 500/250
Lower Handlebar Cover

REAR 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 (page 25).
Drain the combination brake hydraulic
system (page 16-5).
Remove the two screws and lower handlebar
cover.

Screws

Disconnect the brake light switch connectors
from master cylinder.

Brake Light Switch Connectors
Sealing Washers

Remove the brake hose oil bolt, sealing
washers and brake hose eyelet.

Brake Hose

Bolt

16-18

16. BRAKE SYSTEM
Remove the bolts from the master cylinder
holder and remove the master cylinder
assembly.

XCITING 500/250
Holder

Master Cylinder

Bolt
Brake Lever

Nut

DISASSEMBLY
Remove the brake lever pivot bolt and nut.
Remove the brake lever.

Pivot Bolt

Remove the screw and brake light switch.

Screw

Brake Light Switch

16-19

16. BRAKE SYSTEM

XCITING 500/250
Screw

ASSEMBLY
Install the brake light switch and tighten the
screw to the specified torque.
Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft)

Brake Light Switch

Apply silicone grease to the master piston tip.
Install the brake lever.

Brake Lever

Nut

Apply silicone grease to the brake lever pivot
bolt sliding surface.
Install and tighten the pivot bolt to the
specified torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Install and tighten the pivot nut to the
specified torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)

Pivot Bolt

INSTALLATION
Align the pin on the master cylinder holder
with the hole on the handlebar.

Hole

Pin

16-20

16. BRAKE SYSTEM

XCITING 500/250
“UP” Mark

Master Cylinder

Install the rear master cylinders and holders
with the “UP” mark facing up.
Install the bolts and tighten the upper bolt
first then tighten the lower bolt to the
specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

Bolt

Rest the brake hose eyelet against the stopper.
Install the brake hose eyelet with the oil bolt
and new sealing washers.
Tighten the oil bolt to the specified torque.

Sealing Washers

Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft)

Brake Hose

Bolt

Connect the brake light switch connectors.
Fill the reservoir to the upper level and bleed
the brake system (page 16-8).

Brake Light Switch Connectors

16-21

16. BRAKE SYSTEM

XCITING 500/250
Sealing Washers

DELAY VAVLE

Sealing Washers

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 front cover (page 2-11).
Drain the combination brake hydraulic
system (page 16-5).
Remove the brake hose oil bolt, sealing
washers and brake hose eyelets.
Bolts

Brake Hose
Nuts

Remove the two nuts and delay valve.

Delay Valve

16-22

16. BRAKE SYSTEM

XCITING 500/250
Nuts

INSTALLATION
Install the delay valve and tighten the nuts
securely.

Delay Valve
Sealing Washers

Install the brake hose eyelets and new sealing
washers.
Tighten the brake hose bolt to the specified
torque while rest the brake hose eyelet
against the stopper on the delay valve.

Sealing Washers

Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft)
Fill the reservoir to the upper level and bleed
the brake system (page 16-8).

Bolts

16-23

Brake Hose

16. BRAKE SYSTEM

XCITING 500/250
Brake Hose

FRONT BRAKE CALIPER
REMOVAL
Drain the front brake hydraulic system (left
front brake caliper: page 16-4) or
combination brake hydraulic system (right
front brake caliper: page 16-5).
Remove the brake pads (page 16-10).
Remove the oil bolts, sealing washers and
brake hose from the brake caliper.

Bolts

Sealing Washers
Bolts

Remove the mount bolts and front brake
caliper.

Brake Caliper

DISASSEMBLY
Remove pad spring from the caliper body.

＊ Do not remove the retainer from the
bracket unless replacement.

Pad Spring

Retainer

16-24

16. BRAKE SYSTEM

XCITING 500/250
Boots

Remove the caliper bracket from the caliper
body.

Bracket

＊ 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.

Pad Spring

Install the pad spring into the caliper body as
shown.

Bolts

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)

Brake Caliper

16-25

16. BRAKE SYSTEM

XCITING 500/250
Brake Hose

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 (page 16-10).
Fill and bleed the hydraulic system (page 167 or page 16-8).

REAR/PARKING BRAKE
CALIPER

Bolts

Sealing Washers

REMOVAL (XCITING 500)
Remove the muffler (page 2-16).
Drain the rear brake hydraulic system (page
16-5).
Disconnect the parking brake cable from the
brake arm.

Remove the pad pin plug and loosen the pad
pin.
Remove the brake pad (XCITING 500: page
16-11, XCITING 250: page 16-13).
Arm

Brake Cable
Brake Hose

Remove the oil bolt, sealing washers and
brake hose from the brake caliper.

Bolts

Sealing Washers

16-26

16. BRAKE SYSTEM
Remove the mount bolts and rear/parking
brake caliper from the rear fork.

XCITING 500/250
Rear/Parking Brake Caliper

Bolts

DISASSEMBLY (XCITING 500)
Remove the pad spring from the caliper body.

＊ Do not remove the retainer from the
bracket unless replacement.

Pad Spring

Retainer
Bracket

Remove the caliper bracket from the caliper
body.

＊ Do not remove the caliper and bracket
pins unless replacement.

ASSEMBLY (XCITING 500)
Apply silicone grease to the boot inside.
Apply silicone grease to the boot inside.
Install the caliper bracket to the caliper.

Boots

16-27

16. BRAKE SYSTEM

XCITING 500/250

Install the pad spring into the caliper body as
shown.

Pad Spring
Brake Arm

PARKING BRAKE DISASSEMBLY
(XCITING 500)
Remove the lock nut and parking brake arm.

Lock Nut
Brake Shaft

Push Rod

Remove the parking brake shaft and push rod.

16-28

16. BRAKE SYSTEM
Removed the two bolts, gasket and parking
brake bracket.

XCITING 500/250
Bolts

Bracket
Gasket

PARKING BRAKE ASSEMBLY
(XCITING 500)
Install the gasket.

Brake Shaft

Install the parking brake bracket and tighten
the bolts to the specified torque.
Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft)
Apply silicone grease to the parking brake
shaft rolling surface.
Install the parking brake shaft.

16-29

16. BRAKE SYSTEM

XCITING 500/250
Brake Arm

Temporarily install the brake arm and the
lock nut.

Lock Nut
Rear/Parking Brake Caliper

Bolts

INSTALLATION (XCITING 500)
Install the brake pads (page 16-12).
Install the rear/parking brake caliper to the
rear fork and tighten the new mount bolts to
specified torque.
Torque: 32 N•m (3.2 kgf•m, 23 lbf•ft)

Brake Hose

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)
Fill and bleed the hydraulic system (page 168).

Bolts

Sealing Washers

16-30

16. BRAKE SYSTEM

XCITING 500/250
Arm

Connect the parking brake cable.
Adjust the parking brake (page 3- 26).

REMOVAL/INSTALLATION/
DISASSEMBLY/ASSEMBLY (XCITING
250)
The rear caliper and front caliper
removal/installation/disassembly/assembly
are all the same.
Brake Cable
Brake Cable

PARKING BRAKE LEVER LINK
(XCITING 500)
REMOVAL
Remove the inner cover (page 2-14).
Loosen the lock nut and disconnect the
parking brake cable from the parking braking
brake lever link.

Lock Nut

Disconnect the parking brake switch
connector.

Parking Brake Switch Connector

16-31

16. BRAKE SYSTEM
Remove the two nuts and parking brake lever
link.

XCITING 500/250
Parking Brake Lever Link

Nuts
Parking Brake Switch

DISASSEMBLY
Remove the two screws and parking brake
switch.

ASSEMBLY
Assembly is in the reverse order of
disassembly.

Screw

INSTALLATION
Installation is in the reverse order of removal.

16-32