XOD XD-H800 / XD-H880 Hydraulic Disc Brakes User Manual

1. Introduction

Thank you for choosing XOD XD-H800 / XD-H880 Hydraulic Disc Brakes. These high-performance brakes are designed to provide strong and reliable stopping power for your electric scooter or e-bike. Featuring a double-piston hydraulic system and an integrated design, they offer enhanced safety and control. This manual provides essential information for proper installation, operation, and maintenance to ensure optimal performance and longevity of your braking system.

2. Safety Information

• Always wear appropriate safety gear, including a helmet, when operating your electric scooter or e-bike.
• Ensure all components are securely fastened before each ride.
• Regularly inspect your brakes for wear and tear, and replace parts as necessary.
• If you are unsure about any installation or maintenance steps, consult a professional technician.
• Do not modify the braking system, as this may compromise safety and performance.

3. Package Contents

Your XOD Hydraulic Disc Brake set typically includes:

• XOD XD-H800 / XD-H880 Brake Levers (Left and Right)
• XOD XD-H800 / XD-H880 Calipers (Front and Rear specific)
• Hydraulic Oil Pipes (Front and Rear specific lengths)
• Protective Sleeves
• Screws and Copper Sleeves for connection
• Wrench (for installation)
• Screwdriver (for installation)

Note: The product does not include the scooter itself.

Image: Complete set of XOD XD-H800 / XD-H880 Hydraulic Disc Brakes.

4. Specifications

Image: Detailed dimensions and mounting types for XOD XD-H800 and XD-H880 brakes, showing 74mm caliper width, 51mm mounting hole distance, 6mm thickness, and 108mm lever length.

5. Setup and Installation

5.1. Oil Pipe Connection to Brake Lever

The oil pipe needs to be securely connected to the brake lever. Follow these steps carefully:

1. Gather the necessary tools: a wrench (8mm open-end wrench is suitable) and a screwdriver.
2. Identify the components: protective sleeve, screw, and copper sleeve.
3. Thread the protective sleeve, then the screw, and finally the copper sleeve onto the end of the oil pipe.
4. Remove the oil plug from the brake lever.
5. Insert the oil pipe into the brake lever. Ensure the oil pipe is pushed all the way in until the marked line on the pipe is flush with or slightly inside the lever connection point. This is crucial for a secure, leak-free connection.
6. While maintaining firm pressure on the oil pipe to keep it fully seated, use the wrench to tighten the screw. Tighten until snug, approximately 7-9 Nm if using a torque wrench. If not, tighten until the threads are mostly covered, leaving about 2-3 threads visible.
7. Slide the protective sleeve over the tightened connection.

Video: Demonstration of connecting the oil pipe to the brake lever, including threading components and tightening the connection.

5.2. Caliper Mounting

The brake calipers have specific mounting orientations depending on the model (XD-H800 or XD-H880) and whether they are for the front or rear wheel. Pay close attention to the mounting direction.

• For Rear Wheels: XD-H800 calipers are typically mounted on the right side, while XD-H880 calipers are mounted on the left side.
• For Front Wheels: XD-H800 calipers are typically mounted on the left side, while XD-H880 calipers are mounted on the right side.

When installing the brake pump for the hydraulic oil brake, do not add any screw washers. This is important for proper function and fit.

Image: Close-up view of the XD-H880 caliper installation, highlighting that no additional screw washers should be used.

Image: Easy three-step installation guide, showing caliper fixing to the rear wheel, oil pipe connection, and handle angle adjustment.

5.3. Compatibility with Scooter Models

These brakes are compatible with a wide range of electric scooters and e-bikes, including but not limited to:

• KuKirin G1 Pro, G2, G2 Pro, G2 Max, G2 Master, G3, G3 Pro, G4, G4 Max, G5, C1 Pro
• KUGOO G Booster/ ES3
• Dualtron ultra/Dualtron eagle pro/Dualtron 3
• Ultron t10/ultron t11/ultron t108/ultron t128
• FLJT113/vmax r55/xiaomi
• IO Hawk Legend (base: Kaabo Mantis)
• YKAMURA RS/speedway 4/blade 10
• Minimotors Speedway 5/Kaabo Mantis 10/Kaabo Mantis 8
• WEPAD RR/WHITE SIBERIA scooter/king song n12 pro

Refer to the images below for visual guidance on caliper mounting for specific scooter models:

Image: Caliper mounting positions for G2-G2MAX models, showing Left Rear Brake for XD-H880 and Left Front Brake for XD-H800.

Image: Caliper mounting positions for G3PRO and G4 models, showing Right Rear Brake for XD-H800 and Right Front Brake for XD-H880.

Image: Caliper mounting positions for G5 models, showing Right Rear Brake for XD-H800 and Right Front Brake for XD-H800.

Image: Caliper mounting positions for Left Rear H880 and Right Front H880.

6. Operating the Brakes

Once properly installed, operating your XOD hydraulic disc brakes is straightforward:

• Squeeze the brake levers gently to apply braking force. The hydraulic system provides smooth and responsive stopping power.
• Apply both front and rear brakes simultaneously for optimal and balanced braking.
• Avoid sudden, hard braking, especially at high speeds, to prevent skidding and loss of control.
• Familiarize yourself with the brake feel and response in a safe, open area before riding in traffic.

7. Maintenance

Regular maintenance is essential for the safety and performance of your hydraulic disc brakes:

• Brake Pad Inspection: Regularly check the brake pads for wear. Replace them when they are worn down to the minimum thickness indicated by the manufacturer or when braking performance decreases.
• Rotor Inspection: Inspect the brake rotors for any bends, cracks, or excessive wear. Replace damaged rotors immediately.
• Fluid Level Check: While the brakes are typically pre-filled, it's good practice to periodically check for any leaks. If braking feels spongy or weak, the system may need bleeding or a fluid top-up. Consult a professional for hydraulic fluid maintenance.
• Cleaning: Keep the calipers and rotors clean from dirt, oil, and grease. Use a clean cloth and a suitable brake cleaner. Avoid getting oil or grease on the brake pads or rotors, as this will severely reduce braking effectiveness.
• Cable and Hose Inspection: Check the hydraulic hoses for any kinks, cuts, or abrasions. Ensure all connections are secure.

8. Troubleshooting

• Weak or Spongy Brakes: This often indicates air in the hydraulic system or low fluid levels. The system may need to be bled or refilled. Professional assistance is recommended for this.
• Squealing or Grinding Noise: This can be caused by contaminated brake pads/rotors, worn pads, or loose calipers. Clean the brakes, replace pads if worn, and ensure calipers are securely mounted.
• Brake Lever Feels Hard: Check for blockages in the hydraulic line or a seized piston in the caliper.
• Brakes Dragging: This could be due to misaligned calipers, sticky pistons, or an overfilled hydraulic system. Adjust caliper alignment or seek professional help for piston issues.

9. User Tips

• Mounting Direction: Always pay close attention to the left and right mounting options for the brake clamps when purchasing and installing, as they are specific to front and rear wheels and brake models (XD-H800 vs. XD-H880).
• Cable Lengths: The front cable is approximately 1350mm, and the rear cable is approximately 2150mm. Ensure these lengths are suitable for your specific scooter or e-bike model.
• Hydraulic Fluid: The brakes are typically pre-filled with mineral oil. If you experience issues, check for leaks or consider a professional bleed if the braking performance is compromised.
• Visual Guidance: If you are unclear about any installation steps, refer carefully to the provided installation photos and videos.

10. Warranty & Support

For any warranty claims, technical support, or further assistance, please contact your retailer or the XOD customer service department. Keep your proof of purchase for warranty validation.