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42 

14.  Brake lamp adjustment 

If the rear brakes lamps abnormally light up and go out, adjust 

it by turning the adjusting nut. If the rear brake lamp switch is 

broken, replace it immediately.   

Pull down the right side cover 

Pull out and pull off the patch plug of the rear brake lamp 

switch, and carefully pull out the rear brake lamp switch wire and 

remove the rear brake spring. Replace with new rear brake lamp 

switch and mount it in the reverse order. 

While installing, the wiring of the rear brake lamp shall be in 

strict accordance with the wiring diagram, and replace the buckle 

strip   

While installing, the rear brake spring shall be reliably hooked 

with the pin hole on the rear brake lamp switch.   

After replacement, adjustment shall still be carried out to the 

rear brake lamp switch.   

 
 
 
 
 
 
 
 

15.  Illumination signal system 
Head lamp   

Before driving, check the brightness, direction, etc. of the 

headlamp.   

The adjustment can be made to the headlamp in the left / right and 

vertical directions. 

 
 
 
 
 

 

 

Loose the screw to disassemble the headlight. 

 

Rotating , directly unplugging 

 

Rotating and disassemble the bulb. 

 

Install the new bulb in reverse order 

Headlamp bulb specifications:12V55W/60W 

Position lamp   

 

Unplugging the sidelight seat 

 

Unplugging the sidelight bulb 

Position lamp bulb specifications: :12V5W 
 

 

Adjusting nut 

Rear brake switch 

Adjusting bolt 

Содержание XY400B

Страница 1: ...XY400B OPERATIONAL INSTRUCTION...

Страница 2: ...h sidecar 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 the men...

Страница 3: ...iding 20 Engine startin 20 Run in of engine 20 22 Operation 22 24 VI Inspection and adjustment 25 Maintenance period table 25 Check up of spark plug 27 Timing phase 27 Machine oil checking 28 29 Valve...

Страница 4: ...g weight 485kg Vehicle body Frame type Rake angle Front suspension device Rear suspension device Front wheel type Rear wheel type Side wheel type Front brake Rear brake Side brake Fuel tank volume Fue...

Страница 5: ...30 6N m 5000rpm IN 0 07 0 10 EX 0 08 0 12 Chain drive Oilpaper filter Oil cooling Please apply Shell 15W 40 SF engine oil in summer and 10W 30 SF in winter 2 2L Oilpaper filter Electric 1600 100r min...

Страница 6: ...ngle Ignition timing Front lamp Turn lamp Taillight Brake signal light Position indicator permanent magnet DC magneto 12V9A h DC power supply and the electric generator is only used to recharge the ac...

Страница 7: ...f serious motorcycle injuries and deaths are direct result of a head injury Therefore drivers and passengers should always wear a helmet to prevent or reduce the chance of head injury Eye and Face Pro...

Страница 8: ...s keep both hands on the handlebar and feet on the foot pegs during operation Never consume alcohol or drugs before or while riding your motorcycle Limit the travel distance to avoid fatigue that can...

Страница 9: ...ossible Make sure the load does not interfere with any moving parts Make sure the load does not interfere with your ability to move around in order to maintain proper equilibrium Put the load as close...

Страница 10: ...es see a doctor immediately or go to the nearest hospital If you spill gasoline on your clothes change and wash the affected area immediately with soap Caution To avoid scalding by muffler do not park...

Страница 11: ...than a few minutes Do not fill up fuel tank above cap neck This instruction book illustrates the notes for the standard and safe operation method and basic maintenance To ensure your comfortable and...

Страница 12: ...ition Left rear view mirror Meter Ignition Steer switch Right rear view mirror Left handlebar Clutch lever Switches on left handlebar Throttle twist grip Front brake lever Switches on right handlebar...

Страница 13: ...10 Rear shock absorber Seat assy Front wheel Front shock absorber Gearshift pedal Front turn light Rear turn light Muffler Pedal rear brake...

Страница 14: ...11 Speedometer Odometer Trip mileage meter Tachometer EFI Indicator Meter reading and usage Fuel gauge High beam indicator Neutral indicator Turn indicator...

Страница 15: ...indicator light on when Far light is switched on 5 Neutral indicator It is lit up when in the neutral position 6 Tachometer It shows the speed rpm of the engine 7 Low fuel indication To refuel in near...

Страница 16: ...ic system will out of Action So during riding do not move the main switch Key in case of accident If it s necessary rider should stop the motorcycle before taking out the key Before take out from moto...

Страница 17: ...started 3 Switches on left handlebar Light changing switch Position indicator shows its position to the nearby Vehicles and reminding other vehicles when wait at crossroad to avoid Confusion Far and N...

Страница 18: ...RON 93 or above is required for the motorcycle To fuel the vehicle support it by the main stand open the lock cover of the fuel tank by the key and fill fuel through the opening and then close the tan...

Страница 19: ...and then push up the shifting pedal to change the gear to the 2nd position The gear can be shifted up to 3rd 5th gear position in the same way If you push down the shifting pedal instead of push up y...

Страница 20: ...ition engine idle when you remove your hand 9 Brake usage Use front and rear brake simultaneously Avoid unnecessary sudden brake Caution If You only use the front or rear brake the motorcycle may slid...

Страница 21: ...level is incorrect the front wheels may not be locked which may cause the risk of a hazard 11 Seat belt Always fasten seat belt while operating the motorcycle Check the seat belt for any damage Repla...

Страница 22: ...Oil pot total volume 2 2L intermediate position oil dipstick oil pot on the line for 1 8L 2 Pot plus external pipe and radiator total volume loading was 2 3 0 05L Filling volume for 2 2L Oil radiator...

Страница 23: ...n the throttle twist grip by about 1 8 turn but never over 1 4 turn to increase intake air and restart the engine again if the engine started but stalled during idling in cold seasons and keep the eng...

Страница 24: ...park plug adjust the clearance and clean up the carbon deposit 2 Replace the engine oil 3 Tighten each fastener 4 Clean the air cleaner Checking before Operations In order to ensure safety vehicles mu...

Страница 25: ...are working normally 10 Rear view mirror checking sit on the vehicle and keep your body vertical to the ground see if you get a clear view of the world behind you from the rear view mirror 11 Steerin...

Страница 26: ...s low a gear possible and reduce the engine speed to avoid tipping over backward Do not drive near the edge of a gully or steep embankment Avoid holes ditches etc which may cause the motorcycle to tip...

Страница 27: ...ing crushed by the motorcycle once it turns over Do not apply only the rear brake to avoid the motorcycle flipping over Do not abruptly apply the accelerator Riding through water Watch the speed of wa...

Страница 28: ...ubricant oil For a motorcycle change every 500km 1200km and 2000km respectively and then change it every 3000km driving Oil filter R Replace every 12 000km driving Tensioner Remark 3 I I I I both inta...

Страница 29: ...l during these operations that some parts may be replaced components are inspected for adjustment variations from their original settings as a result of normal wear and tear of the parts and usage of...

Страница 30: ...e spark plug of the designated type should be used 2 Timing phase It shall be carried out when the vehicle is new or there is any question about the timing phase Remove the eyehole cover on the left a...

Страница 31: ...for the ambient temperature of application should be selected according to the table on the table below Refilling method Remove the oil filler plug refill the engine oil slowly with a funnel until th...

Страница 32: ...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...

Страница 33: ...ead center position of the compressing stroke If the T mark is near its right position but rock arms will move apparently when flywheel rotate a small angle the flywheel is not in the compressing stro...

Страница 34: ...t it back to position The engine s operating efficiency and prolong its life span After cleaning or replacing filter element reassemble the complete vehicle in the reverse order Caution The air filter...

Страница 35: ...diagnostic instrument check whether the ignition advance angle is between 0 15 If the ignition advance angle is more than 15 it indicates the throttle valve s intake flow at idle speed is insufficient...

Страница 36: ...g unscrew the retaining nut A and turn the adjusting solenoid to adjust to a satisfied free stroke And then screw up the retaining nut A and mount the protective rubber lagging Coarse adjustment If th...

Страница 37: ...rly with water furthermore if touched with eyes must go to hospital storing in the area where child cannot touch Brake fluid level inspection Check the brake fluid level in the front brake cylinder if...

Страница 38: ...d foreign matters from pump cylinder Loosen the screw of cover then take out the diaphragm Add the recommended brake fluid into the upper position of cylinder then tighten the cover with special atten...

Страница 39: ...strip and the brake disc are well engaged Rear brake Pushing the brake pedal by hand checking the resistance to confirm the move of the brake pedal weather is good If not it could be adjusted by adjus...

Страница 40: ...Check the wheel for loosened or broken spokes Screw the loosened spokes to the specified torque with a spoke nut fastening tool The spoke nut torque 2 45 4 9N m If any spoke is broken or cracked repl...

Страница 41: ...handle has the proper free stroke Being too loose will cause a failure of the clutch detachment while being too tight will cause poor clutch engagement thus damaging the clutch 11 Driving chain Drivi...

Страница 42: ...place it in case of damage Remount the chain and coat it with chain specific lubricant while mounting the chain the spring locking pieces shall be in the opposite direction with the chain movement the...

Страница 43: ...st Charging the battery The battery is losing power every day even if it is not used Please disconnect the battery cord and strictly follow the instruction in the operation manual while charging batte...

Страница 44: ...immediately 6 Foreign matter should be prevented from entering into the battery during dismounting and installation 7 The breathing pipe must be kept unblocked 13 Replacement of fuse Set the ignition...

Страница 45: ...lace the buckle strip While installing the rear brake spring shall be reliably hooked with the pin hole on the rear brake lamp switch After replacement adjustment shall still be carried out to the rea...

Страница 46: ...otate in counter clockwise Install new bulb in opposite order as below Turn lamp bulb specifications 12V10W 16 Bolts nuts and fasteners All the bolts nuts and fasteners shall be screwed up as per the...

Страница 47: ...tronic system please protect your 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 was...

Страница 48: ...in braking situation Don t drive too much long distance If find abnormal should stop for checking Wait 2 to 3 minutes after crash and then restart the motorcycle Turn on headlight when drive at night...

Страница 49: ...rred to the ECU with electronic signal The ECU output controlling signals after input signal are handled Through the engine and actuators on the vehicle ignition coil fuel injector Idle speed control...

Страница 50: ...tion Throttle Idle speed control valve air intake 3 Electronic control unit ECU Major parts and components Intake air pressure sensor Throttle sensor Fuel Injector Idle speed control valve Cylinder He...

Страница 51: ...ers needing attention 1 Do not disassemble the components arbitrarily It may damage the components if the warter or the oil seep into the parts 2 Turn the ignition off before connect or disconnect the...

Страница 52: ...he eninge is running 11 Cannot messure the signal by pierce the harness Maintenance depending on the malfcode Description 1 If the issure cannot repeat the issure analysis may be wrong 2 The multimete...

Страница 53: ...5 Engine coolant temperature 1C OBD requirements to which vehicle or engine is certified 06 Short Term Fuel Trim Bank1 20 PIDs 21 to 40 which are supported by the Powertain controller 07 Long term Fue...

Страница 54: ...status 04 Calculated Load Value 05 Engine Coolant Temperature 07 Long term Fuel Trim bank1 09 Long term Fuel Trim bank2 0B Intake manifold absolute pressure 0C Engine RPM 0D Vehicle speed 11 Throttle...

Страница 55: ...TPS_ShortHigh 123 N A Oxygen Sensor P0131 O2S 1 Circuit Low Voltage KsDGDM_O2_1_ShortLow 131 N A P0132 O2S 1 Circuit High Voltage KsDGDM_O2_1_ShortHigh 132 N A Oxygen Sensor Heater P0032 O2S Heater Ci...

Страница 56: ...DM_VSS_NoSignal 500 N A Park Neutral Switch Diag P0850 Park Neutral Switch Error KsDGDM_ParkNeutralSwitch 850 N A CCP P0445 CCP short to high CCP KsDGDM_CCP_CircuitShortHigh 445 N A P0444 CCP short to...

Страница 57: ...with Service 05 Status of system monitoring tests can be read with Service 01 PID 01 On board monitoring test results can be read with Service 06 Distance travelled while MIL is activated can be read...

Страница 58: ...o not necessarily indicate a faulty component system If test results indicate a failure after additional driving then the MIL will be illuminated and a DTC will be set and reported with service 03h in...

Страница 59: ...t 2 7 8 12 Rocker arm shaft cover 2 14 24 28 Magneto flywheel fastening nut 1 12 38 45 Clutch fastening nut 1 18 38 45 Primary driving gear fastening nut 1 18 38 45 Oil drain plug 1 12 38 45 Crankshaf...

Страница 60: ...8 20 30 Steering handle set bolt 4 8 20 30 Front fork vertical pipe cap nut 1 22 60 90 Lower connection plate set bolt 2 10 30 40 Upper connection plate set bolt 2 6 8 12 Rear sprocket nut 6 8 20 30...

Страница 61: ...58 VIII Electrical system diagram...

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