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[DISCLAIMER:  I'm just an untrained monkey. What do I know?]

This is meant to be done in conjunction with the KYMCO Diagnostic PDA.  However, who as that?  No one.  As long as you haven't messed with the sensors and throttle, I would perform steps in the Service Manual ( Note: Obviously for AFI )

TPS/ISC RESET PROCEDURE
1. Put the side stand up and engine stop switch is at “RUN”. 2. Turn the ignition switch to “OFF”. 3. Open and hold the throttle fully. 4. Turn the ignition switch to “ON”, after 8 seconds close the throttle fully. 5. Turn the ignition switch to “OFF”. 6. When turn the ignition switch to “ON” again, the TPS and ISC have been reset.

Hello All,

It came time to perform some maintenance on my rear caliper, and part of my inspection revealed that the large rubber boot had split and required replacement.  I did enquire about genuine parts, and of course they wasn't any in stock anywhere in the country and that they would need to be ordered in from the Taiwanese factory.  Completely unsatisfactory right?

I did my research and looked far and wide.  Turns out that the caliper parts are very common.  Which makes sense, because if you're a manufacturer, you're not going to reinvent the wheel and start tooling up a completely custom parts that requires specialised rubber components. You would use off the shelf parts, or you would commission another manufacturer to produce the product for you.

I could be wrong, but I believe that the Kymco Xciting 500iR Rear Caliper is a Nissin caliper.  Therefore, it will be using common parts that are already available.  Nissin make calipers for many different bikes.

As dealers all do, they force you to provide some part number so they can look it up on the system, so I looked for a well known brand till I found the same part.

So for the rear caliper large rubber boot, I ordered the Honda Part 45132-166-016.  The Kymco part is 45132-1F66 ( Notice the similarity in part number )  As I have the part in my hand as I'm writing this, I can confirm that the differences are miniscule.

For the smaller boot I ordered the Honda part 45133-MA3-006.  This part appears to be identical.

I have also notice the the Triumph Tiger uses a front caliper that has the same pad retaining clip.
From the forum
http://www.triumphrat.net/twins-technical-talk/103656-standard-brake-pad-replacement.html
http://i291.photobucket.com/albums/ll286/propforward/Triumph/Brake%20pad%20replacement/IMG_1241Medium.jpg

Yes, zombie.  I've seen that clip before.

The one YouTube Channel I've found indispensable is https://www.youtube.com/channel/UCOXDrrwQRZqOQ3iUCXN12rw

There are many great videos there. He has a Triumph Tiger which has a very similar caliper to the Xciting 500 Rear caliper.



 

Thank you all.  ( Sorry for late reply )

Update:  Couldn't be bothered going 30 rounds with the heavy weights ( Dealer + KYMCO ).  They were willing to fix the issue if I produced receipts for all my parts that I have been servicing the bike with.

Are you really going to keep a receipt for a spark plug or Oil filter?   So, in short I let the matter go.


Cheers!

Thanks winginman,

Much appreciated.  Nice work.  So, I'm guess you were talking about drilling a hole into the riser because of the pins on the stock one?

I was considering changing my handle bars until I saw the pin in the upper holders.  Didn't feel comfortable drilling holes into a new bar.  One could grind off the pins, but then you bars may turn in the holders. If you had an accident, your insurance company may look at it and say that was the cause of the accident and not pay out.

All mods suffer form this.

Cheers!

I raised the handlebars on my 09 using a set of risers for a Honda 600

Honda 600 What exactly?

Cheers!

I'm contemplating using that hole for a 12V inlet to attach a Battery Charger.  A quick way to trickle charge the batter, without having the seat up.