Kymco Agility 50 - Service manual > Brake master cylinder

Removal

First drain the brake fluid from the hydraulic brake system.

• When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid.

Disassembly

Remove the piston rubber cover and snap ring from the brake master cylinder.

Remove the washer, main piston and spring from the brake master cylinder.

Clean the inside of the master cylinder and brake reservoir with brake fluid.

Inspection

Measure the brake master cylinder I.D.

Service Limit: 12.75mm

Inspect the master cylinder for scratch or crack.

Measure the brake master cylinder piston O.D.

Service Limit: 12.6mm

Before assembly, inspect the lst and 2nd rubber cups for wear.

Assembly

Before assembly, apply brake fluid to all removed parts.

Install the spring together with the 1st rubber cup.

• During assembly, the main piston and spring must be installed as a unit without exchange.
• When assembling the piston, soak the cups in brake fluid for a while.
• Install the cups with the cup lips facing the correct direction.

Install the main piston, spring and snap ring.

Install the rubber cover.

Install the brake lever.

Disassembly

Remove the brake caliper seat from the brake caliper.

Remove the piston from the brake caliper.

If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.

Check the piston cylinder for scratch or wear and replace if necessary.

Push the piston oil seal outward to remove it.

Clean the oil seal groove with brake fluid.

Be careful not to damage the piston surface.

Place the brake master cylinder on the handlebar and install the holder with "up" mark facing up. Be sure to align the punch mark with the holder joint.

First tighten the upper bolt and then tighten the lower bolt.

Torque: 3.0~4.0kgf-m

Install the brake fluid pipe with the attaching bolt and two sealing washers.

Install the handlebar covers. Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 12-10.

BRAKE CALIPER (FRONT)

Removal

Remove the brake caliper.

Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper.

Do not spill brake fluid on any coated surfaces.

Check the piston for scratch or wear.

Measure the piston O.D. with a micrometer.

Service Limit: 26.3mm

Check the caliper cylinder for scratch or wear and measure the cylinder bore.

Service Limit: 26.45mm

Assembly

Clean all removed parts.

Apply silicon grease to the piston and oil seal.

Lubricate the brake caliper cylinder inside wall with brake fluid.

Install the brake caliper piston with grooved side facing out.

Install the piston with its outer end 3-5mm protruding beyond the brake caliper.

Wipe off excessive brake fluid with a clean shop towel. Apply silicon grease to the brake caliper seat pin and caliper inside.

Install the brake caliper seat.

Installation

Install the brake caliper and tighten the two bolts.

Torque: 2.9~3.5kg-m

Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt.

Torque: 2.5~3.5kg-m

Fill the brake reservoir with recommended brake fluid and bleed air from the brake system.

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