Shineray XY400-2 Maintenance Manual Download Page 2

XY400-C   Maintenance Manual

 

                                                                                                                                        Contents

 

 

Contents 

1.

 Overview

 

1-12 

 

2.

 Lubrication 

system

 

13-20 

 

3.

 

Inspection and adjustment

 

21-41 

 

4.

 Fuel 

system

 

42-45 

 

5.

 

Removal and installation of engine

 

46-50 

 

6.

 

Cylinder head, cylinder and piston

 

51-64 

 

7.

 

Clutch and Right crankcase cover

 

65-75 

 

8.

 

Magneto and starting system

 

76-84 

 

9.

 

Crankcase, crankshaft and Shift mechanism

 

85-100 

 

10.

  Frame and exhaust system

 

101-109 

 

11.

  Front wheel, front overhang and steering stem

 

110-126 

 

12.

  Rear wheel and rear overhang

 

127-135 

 

13.  General remarks of electrical system 

136-137 

 

14.  Power supply system 

138-140 

 

15. Starting 

system 

141-144 

 

16.  Illumination signal system 

145-151 

 

17.  Electrical starting control system 

152-157 

 

18.  Engine management system 

158-174 

 

19.  Electrical System Diagram 

175 

Engine

 

V

ehic

le

 body

 

Electrical s

yst

em

 

Overview

 

Summary of Contents for XY400-2

Page 1: ...s various constituting parts of the motorcycle respectively Chapter 19 contains the electrical system diagram The standard maintenance procedures maintenance precautions and general maintenance knowle...

Page 2: ...em 76 84 9 Crankcase crankshaft and Shift mechanism 85 100 10 Frame and exhaust system 101 109 11 Front wheel front overhang and steering stem 110 126 12 Rear wheel and rear overhang 127 135 13 Genera...

Page 3: ...tion Bar Tool About Motorcycle Maintenance Maintenance Period Table Technical Data of Main Performance Symbol Descriptions Standard Torque Values Engine Number Position Photo of Complete Vehicle Frame...

Page 4: ...nd components After reassembling check whether all the spare parts are mounted properly by means of turning moving and operating them 4 To disassemble and assemble a motorcycle special service tools S...

Page 5: ...The connector shall be fully inserted in place For a connector with lock confirm whether the lock is completely fixed Make sure the harness is not falling off Make sure the plastic jacket of the conn...

Page 6: ...corner parts the contacting part shall be protected with hose or adhesive tape In case of a wire harness with garland it shall be reliably harnessed Do not damage the garnish of the wire harness Once...

Page 7: ...n operation after disposing it with abrasive paper etc 18 Do not forcibly twist or forcefully bend the cable Because a deformed or damaged cable is the cause of bad operation and damage Have you learn...

Page 8: ...mposite damping 100 90 19 130 70 18 Normally loaded 225 kPa Normally loaded 225 kPa Single disc type Model 276 Drum brake Model 160 13L 93 Engine Mode Cylinder bore Stroke Cylinder displacement Compre...

Page 9: ...and back type Sequence I N V Electrical system Electric generator Accumulator capacity Power supply system Fusible cutout Spark plug Spark plug gap Ignition coil type Fuel supply mode Ignition mode Ig...

Page 10: ...3 6 8 12 LOCTITE 648 Stator leads pressure plate bolt 2 6 8 12 LOCTITE 648 Spark Plug 1 12 18 25 Pensioner plate fastening bolt 1 6 7 10 Vehicle body Item Quantity Thread diameter mm Torque value N m...

Page 11: ...torized gun special power tool for mantling dismantling bolt and nut Pawl socket for mantling dismantling oil filtering element nut and clutch nut A and B bolt socket for mantling dismantling A and B...

Page 12: ...re the clearance of piston cylinder valve etc Micrometer to measure the dimensions of piston piston pin etc Dial gauge to measure the wheel bouncing cylinder inner diameter etc Cylinder barometer to m...

Page 13: ...nd bolt fastening I I I I Wheel tire I I I I Steering column bearing I I I I Steering backstay cable Inspect every 5000km driving and replace every 10000km driving Maintenance shall be carried out to...

Page 14: ...ose tools Tightening torque of 50 N m Use suggested engine oil Use the mixtures of engine oil and molybdenum disulfide Use thread locker Use sealant Use lithium base grease Measures to be prompted dur...

Page 15: ...its quality scale must reach Grade SG and its viscosity shall be selected according to the accompanying diagram depending upon region and air temperature changes While replacing lubricating oil fully...

Page 16: ...in the above diagram besides applying dedicated lubricating oil for chain to the driving chain apply lithium base grease to all other positions All lubricating oils not specified for use in this manua...

Page 17: ...rication System Diagram Right crankcase body oil through Right crankcase cover oil through Crankshaft oil through Spindle oil through Countershaft oil through Camshaft oil through Cylinder head oil th...

Page 18: ...ommended lubricating oil until the oil level reaches the upper middle limit Refilling method Remove the oil filler plug refill the engine oil slowly with a funnel until the oil level in the engine oil...

Page 19: ...ge of the engine oil inside the crankcase When replacing unscrew the oil drain plug and discharge the waste engine oil and then clean the oil drain plug engine oil strainer engine oil filter etc Final...

Page 20: ...steps according to the method of Replacement of Lubricating Oil Cleaning and Replacement of Lubricating Oil Filter Remove the engine oil filter cover to detach the engine oil filter element clean the...

Page 21: ...mbly and assembly of oil pump etc Steps for oil pump removal 1 Remove the oil drain plug to drain the engine oil inside the crankcase 2 Loosen the right crankcase cover connecting bolts to detach the...

Page 22: ...be replaced with new ones 6 Remember to refill engine oil after all these are completed CAUTION The clutch retaining nut must be screwed up to the specified tightening torque must be applied to preven...

Page 23: ...ust according to the sense organs of human being The way is simple and easy to use it is used wide in motorcycle maintenance Testing examination method This way is a way that test the size of part and...

Page 24: ...ording to the contents hereof before using it Technical specifications Throttle bar free stroke 2 6mm Recommended spark plug DPR8Z Spark plug gap 0 6 0 7mm Valve clearance cold IN 0 07 0 10mm EX 0 08...

Page 25: ...should be used 2 Machine oil checking Check oil level weekly Always keep oil level between the HI and LO mark Add oil when necessary To check oil level Make sure engine is has been turned off for mor...

Page 26: ...engine oil of poor quality will have an impact on the functional performance and life span of the motorcycle engine Cleaning of Lubricating Oil Strainer It shall be carried out while replacing lubrica...

Page 27: ...piston is at the upper dead point the scale line on the camshaft is at the same level with the Notice At this point the piston must be at the upper dead point of the compression stroke other than that...

Page 28: ...essure Upon completion of testing mount the spark plug to its original position The main reasons for insufficient cylinder pressure include Incorrect valve clearance adjusted Valve leakage Cylinder he...

Page 29: ...the valve will be hindered which will cause many problems such as engine stall power loss etc Therefore the valve clearance must be checked periodically The valve clearance should be inspected and ad...

Page 30: ...e clearance is OK before all those dismounted caps are refitted on While adjusting unscrew the retaining nut and then turn the adjusting screw until you feel that the clearance gauge is slightly pulle...

Page 31: ...e or null if the ignition advance angle is less than 0 it indicates the intake flow at idle speed is too big and at this point the idle speed is often as high as more than 1800 r min Only under the ab...

Page 32: ...stroke can make the engine speed increases suddenly 9 Brake system Check the front brake handle free stroke The brake handle free stroke 10 20mm Brake fluid level inspection Check the brake fluid leve...

Page 33: ...um base brake fluid 2 The brake fluid can t be mixed with other Impurities otherwise the braking performance shall be reduced due to chemical change Caution The brake fluid is strongly corrosive never...

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