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XY400GY

                                                                                                                                                                                   

 

-29- 

with  the  brake  discs.  Consequently,  the  braking 

performance would be influenced and it will damage 

the discs.

 

 

Substitution of rear brake pads 

Push the brake caliper towards the chain wheel to move the 

brake piston back into its initial position. Remove the clip

1

,  pull  out  screw

2

and  remove  the  brake  pads. 

Thoroughly clean the brake caliper with compressed air and 

check the sleeves of the guiding bolts for damage. Insert the 

left  brake  pad  into  the  caliper  and  securest  with  the  bolt. 

Insert the right brake pad and push the screw into the brake 

caliper down to the bottom. Reassemble the clip

1

 

Warning 

-It is very important to keep the brake discs away from 

oil or any fatty materials. Otherwise, the braking effect 

would be largely reduced 

After  installation,  please  check  whether  if  the  circlips 

have been fitted correctly 

After  assembling  the  braking  system,  please  always 

actuate the hand brake lever or foot brake pedal to check 

respectively  whether  or  not  the  pads  are  properly 

installed and pressure point is established. 

 

10.

 

Examination of chain tension 

Jack up the motorcycle so that the rear wheel can not reach 

the  ground.  Press  the  end  of  the  chain  sliding  component 

chain  upward.  The  distance  between  the  chain  and  the 

swing arm should be approx.8-10mm. In the course of this 

procedure,  the  upper  chain  portion

A

will  get  tight.  If 

necessary, correct the chain tension. 

 

Warning 

The  excessive  tightness  of  the  chain  will  put 

additional load on the components of  the secondary 

drive train  (chain, bearings of transmission and rear 

wheel).  Aside  from  the  consequence  of  premature 

wear-out, If it’s getting worse, the chain may rapture 

or the countershaft of the transmission may break up. 

The  over  looseness  of  the  chain,  in  another  aspect, 

may result in the jump-off of the chain from the chain 

wheel. If this happens, the chain could also block the 

rear wheel or damage the engine. 

-In both cases mentioned above, the rider is likely to 

lose the control of the motorcycle. 

 

Adjustment of chain tension 

Loosen collar nut

1

,and tighten lock nut

2

. Screw 

right and left adjusting screws equally. To ensure the rear 

wheel is correctly assembled, the labels on the right and 

left  chain  adjusters  must  be  positioned  identically  in 

relation  to  the  reference  labels

B

.  Tighten  the 

adjusting  bolt  and  nut.  Clean  and  lubricate  the  bolt 

regularly.  Before  tightning  the  collar  nut,  please  verify 

that  the  chain  adjusters

4

are  setting  close  to  the 

adjusting screws and that the rear wheel has been aligned 

with  the  front  wheel.  Then  tighten  collar  nut

1

to 

80Nm 

Summary of Contents for Adventure 400cc

Page 1: ......

Page 2: ...of the motorcycle For your safety please pay a great importance to the cautions as follows Warning Any ignorance of the mentioned below information may lead to safety problems Caution Any ignorance of...

Page 3: ...itch 11 Fuel system 11 Operation of the engine 12 Switches on handlebar 13 Gear Shift 15 The use of clutch 15 Brake 15 Air filter installation 15 Rearview mirror 16 Oil cooler installation 16 Check up...

Page 4: ...during riding their new motorcycles while they become arrogant when they feel familiar with their motorcycle and the arrogance often bring dangers To avoid it happen to you please always keep in mind...

Page 5: ...loading capacity seriously Loading of goods The design of the motorcycle requires distribution of the carried goods in certain extent of equilibrium and improper arrangement of goods will adversely af...

Page 6: ...re is sufficient fuel in the tank when closing the filler cap make sure that the tank vent pipe is free of kink 3 Check the chain A loose chain may fall off the chain wheels an extremely worn chain ma...

Page 7: ...ome other outside parts and jointing position are easily rust Operation turning Turning basic principle is combine the centrifugal force and gravitation well to get balance result Turning method Turni...

Page 8: ...ce system Lubrication method Fuel pump type Engine oil grade Engine oil charge volume Engine oil filter element Electric motor starting Idle speed Single cylinder water cooling 4 valve top mounted cam...

Page 9: ...gnition coil type Fuel supply mode Front lamp Turn lamp Stop Rear position lamp permanent magnet AC magneto 12V 11 2A h DC power supply and the electric generator is only used to recharge the accumula...

Page 10: ...Ignition Steer switch lock Clutch lever Left handlebar Horn switches Fuel tank lock Front brake lever Throttle twist grip Engine starter switches Rear goods basket jonting assy Seat assy Front wheel...

Page 11: ...ADVENTURE 400cc 10 Front shockabsorber Side stand Real shockabsorber Gearshift pedal Rear turn light...

Page 12: ...L left turn twinkle when turn to left Green Low oil alarm indication lamp The fuel tank is near empty low fuel warning light lights up at this time should be added the fuel as soon as possible Far and...

Page 13: ...he meter clock shows the use of 12H system Time display format AM 12 05 00 PM 1 56 00 Stopwatch The meter stopwatch with digital display display the time format is 00 00 00 The maximum time for 23 99...

Page 14: ...and trouble solutions Code Description Diagnosis Name Trouble shooting level 1 Engine over temperature diagnosis TCO_OVER_TEMP 2 2 Crank wrong tooth number diagnosis TOOTH_NR 1 3 Throttle position ada...

Page 15: ...le bruises or scratch motorcycle surface recommended the use of cloth or leather Keychain Do not throw the keys or articles with heavy Do not the key grinding drilling or otherwise change the key to i...

Page 16: ...grip 1 8 press electric starting switch 8 When the engine is started turn the throttle grip until the engine is hot Close the chock if too heat and the chock need time do not close all the chock keep...

Page 17: ...be noted that the lasting operating time of the E start must not exceed 15 seconds If the battery is low lower than 10 5 V you just need to ride for a few kilometers and charge the battery The correct...

Page 18: ...fic Horn Button When the main switch at press horn button it will make a sound horn button Throttle button By adjusting the door switch open or close the choke Electric Start Button Push this button m...

Page 19: ...herwise it will cause the brake temperature rise to unusually high Brake shoe brake disc excessive wear and increases the braking distance 9 Air filter installation Air filter installed in proper posi...

Page 20: ...I I I I I Brake system I I I I I Brake block converters I I I I I Headlight adjustment I I I I I Suspension I I I I Clutch I I I I I Side stand I I I I bolts nuts fasteners I I I I I Rims tires I I I...

Page 21: ...igh level of security reliability and performance of emission control Based on this description assumes the motorcycles used for design purposes sustained high speed action or in abnormal operation of...

Page 22: ...adjust this screw at your will or it will affect the stability of the engine idling speed Basic information about carburetor wear out Because of the vibration of the engine the wear out of the thrott...

Page 23: ...oline on any other agent of a low ignition point The filter core fo the air cleaner must be installed completely and unbrokenly or the dust and dirts would get into the engine to reduce the life lengt...

Page 24: ...te the T wrench for 360 degree clockwise to make the mark aligned with and then adjust the valve Insert the feeler between the valve adjusting screw and valve end to check the valve clearance The stan...

Page 25: ...ne oil Clean the filter and then install Fill with 1 1L new engine oil Start the engine for idle running with 2 3 minutes Check whether or not the engine oil level is among the lowest and highest leve...

Page 26: ...vice life The type of these bushes is stated on the back of the brake pads and also recorded in the homologation papers Other brake pads are applicable for racing games Brake discs Brake discs worn ou...

Page 27: ...spilled or overflowing brake fluid with water Warning Never use DOT5 brake fluid Store the brake fluid out the reach of kids Brake fluid can cause skin irritation Please avoid any contact with skin an...

Page 28: ...uced After installation please check whether if the circlips have been fitted correctly After assembling the braking system please always actuate the hand brake lever or foot brake pedal to check resp...

Page 29: ...bolt Spilled brake fluid must be rinsed off with water Warning Never use DOT5 brake fluid Store the brake fluid out the reach of kids Brake fluid can cause skin irritation Please avoid any contact wit...

Page 30: ...ing component chain upward The distance between the chain and the swing arm should be approx 8 10mm In the course of this procedure the upper chain portion A will get tight If necessary correct the ch...

Page 31: ...d be largely reduced and the motorcycle could easily lose control Caution When mounting the chain masterlink clip the closed side of the masterlink clip must point in running direction Meanwhile check...

Page 32: ...damping values decrease range Check the basic setup of the telescopic front shock absorber The precise riding sag level of the telescopic shock absorber cannot be determined for various reasons Simil...

Page 33: ...compression lever 1 adjusting the compression damping force to adjust and compression damping force increases gradually at the end of valve end cover to the outside of the adjusting compression dampi...

Page 34: ...ure spray directly at the pivot of bearing 12 Tire Tire pressure checking Check the appropriate pressure degree through checking the inspection tire touchdown level Using the tire gauge to inspect tir...

Page 35: ...s 1 Remove the battery and replace with a new one of the same type and specification then connect the positive pole first and the negative pole last Caution Never remove the cover 2 or the battery wil...

Page 36: ...ect the positive pole first and the negative pole last Please avoid the positive pole getting touch with the motorcycle s frame When charging connect the battery before switching on the charging devic...

Page 37: ...ble A loose shaft may cause instability when riding After the installation of front wheel please operate the front brake lever continuously until the pressure is back to normal It is very important to...

Page 38: ...ressure When you are going to ride your motorcycle to somewhere please check your motorcycle tyres including the factors of type condition and pressure etc The size of the tyre can be found in the tec...

Page 39: ...XY400GY 38 the connector is lubricating or not...

Page 40: ...our electronic system When washing the motorcycle please remove the air cleaner cover and filter core and using foam or cotton yarn to protect the intake channel When washing please block up the muffl...

Page 41: ...professional stuff please have your sump cleaned at the authorized service station Specifications of torsional moment of fasteners Ref No Position Spec N m Ref No Position Spec N m 1 Fastening nut Fr...

Page 42: ...XY400GY 41 VIII ELECTRICAL DIAGRAM...

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