KYMCO AHG5, Service Manual

Page: 272 / 363

14. FRONT ASSEMBLY
DT X360
14-10
Loosen the bleed valve and pump the brake
lever.
Stop operating the brake when no more fluid
flows out of the bleed valve.
Brake Fluid Filling/Air Bleeding 4.4.

Do not mix different types of fluid since they are not compatible.
Fill the master cylinder with DOT 4 brake fluid to the upper level.
Connect a commercially available brake bleeder to the front caliper bleed valve.
Check the fluid level often while bleeding the brake to prevent air from being pumped into
the system.
When using a brake bleeding tool, follow the manufacturer’s operating instructions.

If air enters the bleeder from around the bleed valve threads, seal the threads
with teflon tape.
Pump the brake bleeder and loosen the front caliper bleed valve. Add fluid when the fluid
level in the master cylinder is low to prevent drawing air into the system.
Repeat the above procedures until no air bubbles appear in the plastic hose.
Close the front caliper bleed valve and operate the front brake lever.
If it still spongy, bleed the system again.
If the brake bleeder is not available, perform the following procedure.
Pump up the system pressure with the brake lever until these are not air bubbles in the fluid
flowing out of the reservoir small hole and lever resistance is felt.
1. Pump the brake lever several times, then squeeze the brake lever all the way and
loosen the bleed valve 1/4 turn. Wait several seconds and close the bleed valve

If air enters the bleeder from around the bleed valve threads, seal the threads
with teflon tape.
2. Release the brake lever slowly until the bleed valve has been closed. Add fluid when
the fluid level in the master cylinder is low to prevent drawing air into the system.
3. Repeat the steps 1 - 2 until there are no air bubbles in the bleed hose.
After bleeding air completely, tighten the bleed valve to the specified torque.
Torque: 6 N•m (0.6 kgf•m, 4.3 lbf•ft)
Fill the reservoir to the casting ledge with DOT 4 brake fluid to the upper level.
Install the diaphragm, set plate and reservoir cover and tighten the screws to the specified
torque.
Torque: 2 N•m (0.2 kgf•m, 1.1 lbf•ft)