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XY400-C Maintenance Manual Overview

1. Overview

Engine Number Position

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 Number Position:

Engine Number Position:

Engine Number

Frame Number

Содержание XY400-2

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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