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Xingyue XY260T-4 Service Manual

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1. GENERAL INFORMATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1
1-1 MODEL IDENTIFICATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1
1-2 Specifications・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 1
1-3 FUEL AND OIL RECOMMENDATIONS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・2
1-4 BREAKING-IN PROCEDURE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・2
1-5 PRECAUTIONS AND GENERAL INSTRUCTION・ ・ ・ ・ ・ ・ ・ ・ ・ ・2
1-6 Use OF GENUINE PARTS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・3
1-7 POWER TRANSMISSION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・3
2． PERIODIC MAINTENANCE AND TUNE-UP PROCEDURETHE・ 6
2-1 PERIODIC MAINTENANCE SCHEDULE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・6
2-2 Maintenance And Tune-Up Procedure・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 7
Battery・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 7
AIR CLEANER・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・8
CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS・ ・ ・ ・8
SPARK PLUG・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・9
Carburetor・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・9
FUEL LINE・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10
GEAR OIL・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10
STEERING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10
FRONT FORK・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10
REAR SUSPENSION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・10
・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11
TIRE

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  • Page 1 1. GENERAL INFORMATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 1-1 MODEL IDENTIFICATION・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・1 1-2 SPECIFICATIONS・...
  • Page 2 CHASSIS BOLTS AND NUTS・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・11 2. ENGINE SERVINCE 3-1 ENGINE REMOVAL・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・12 3-2 ENGINE REINSTALLATION・...
  • Page 3 6-3 STEERING・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・42 6-4 REAR WHEEL・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・43 7.
  • Page 4 1. GENERAL INFORMATION 1-1 MODEL IDENTIFICATION 1. The frame number (VIN) and the engine number is printed on the position as Fig1 indicated. Position of frame number Position of engine number 1-2 SPECIFICATIONS - 1 -...

  • Page 5: Fuel And Oil Recommendations

    1-3 FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oils. The followings are the specifications. FUEl Fuel tank Gasoline used should be graded 90 octane or higher. An unleader or low-lead gasoline type is recommended. FINAL GERA OIL Use a good quality SAE85W/140 multi-grade motor oil.

  • Page 6: Power Transmission

    Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter and from inside to outside diagonally, to the specified tightening torque. Use special tools where specified. Use genuine parts and recommended oils. When 2 or more persons work together, pay attention to the safety of each other. After the reassembly, check parts for tightness and operation.
  • Page 7 A mechanism employing a drive belt and using the centrifugal force for automatic speed change, a clutch mechanism for control of transimission of drive power to the rear wheel, and a mechanism with a series of reduction gears for reduction of the drive power from the clutch and transmission of the power to the rear wheel are installed in the left-side crankcase.
  • Page 8 V-belt drive mechanism This is composed of a pair of drive faces transimitting the drive power from the crankshaft to the V-belt and a pair of driven faces for transimission of the drive power from the V-belt to the drive shaft.

  • Page 9: Periodic Maintenance Schedule

    2. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURETHE 2-1 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommend intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometers. Note: More frequent servcing may be performed an motorcycle that are used under severe conditions.
  • Page 10 2-2 MAINTENANCE AND TUNE-UP PROCEDURE This section describes the servicing procedures for each items of the periodic maintenance requirments. BATTERY Inspect every 3000 km (6 months) The battery must be removed to check the electrolyte lecel and specific gravity. Remove the battery ○ and ○...
  • Page 11 An S.G. reading of 1.22(at 20℃) or under means that the battery needs recharging off machine: take it off and charge it from a recharger. Charging the battery in place can lead to failure of the regulator/rectifier. To install the battery, reverse the procedure described above.
  • Page 12 in stages untill each one is tightening to the specified torque.Tighten the nuts in the order indicated. Cylinder head nut tightening torque 8-12N.m (0.8-1.2kg-m) SPARK PLUG clean initial 1000km (2 months) and every 3000km (6 months), replace every 6000km (12 months). Neglecting the spark plug eventually leads to difficult starting and poor performance.
  • Page 13 After adjusting play, tighten the lock nut. Cable play 0.5-1.mm OVERHAUL AND CLEANING Wash the carburetor and component parts in cleaning solvent after disassembly. Before reassembly, inspect the float level and needle valve. Adjust and replace parts when necessary. Then blow compressed air through all jets and passages to make sure they are not clogged. Do not use wire ,etc.
  • Page 14 TIRE inspect initial 1000km (2 months) and every 3000km (6 months) TIRE PRESSURE If the tire pressure is too high, the motorcycle will tend to ride stiffly, have poor traction. Coversely, if the tire pressure is too low., stability will be adversely affected. Therefore, maintain the correct tire pressure for good roadability and to prolong tire life, Caution :...
  • Page 15 3. ENGINE SERVINCE 3-1 ENGINE REMOVAL Before taking the engine out of the frame, wash engine. The procedure of engine removal is sequentially explained in the following steps, and engine reinstallation is effected by reversing the removal procedure. Open the seat and disconnect the battery and lead wires from the battery terminals. Remove the frame covers Remove the rear brake assy.
  • Page 16 Place a cloth beneath the piston and remove the circlipe with pliers Draw out piston pin. Note: when reinstalling the piston, face the arrow on the piston top to the exhaust port side. Remove the oil pump drive piece○ by using screwdriver. Using the conrod holder remove the nut, washer, and fixed drive face.
  • Page 17 Caution: Once remove the movable drive face, rollers provided inside he drive face may be dislocated and disassembly of the drive face be needed. Remove the starter driven gear and key. Note: When reinstalling the starter driven gear, align the key groove with the key.
  • Page 18 Remove the oil pump driver gear. Remove the movable drive face cover. Remove the movable drive face plate and O-ring. Remove the 6 pcs of rollers Note: when reinstalling rollers, apply grease to sliding surface of rollers. Using the special tool, remove the clutch shoe nut by turning it clockwise.
  • Page 19 Using the sliding hammer and attachment,remove the bearing. Caution:The removed bearing should be replaced with a new one. Remove the fixed driven face bearings in the same manner. When removing the inner bearing,remove the cir clip by using the snap ring pliers. Remove the oil seal with screw driver.
  • Page 20 CRANKSHAFT CRANKSHAFT RUNOUT Support crankshaft by”V”blocks ○ ,with the dial gauge ○ rigged to read the runout as shown. Service limit 0.05mm Excessive crankshaft runout is often responsible for abnormal engine vibration.such vibration shortens engine life. CONDITION OF BIG END BEARING Turn the crankshaft with the connecting rod to feel the smoothness of rotary motion in the big end.move the rod up and down while holding the crankshaft rigidly to be sure that...
  • Page 21 B .CLUTCH”LOCK-UP”INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping. ● Warm the engine to normal operating temperatures. ● Connect an electric tachometer to the engine. ● Apply the rear brake as firm as possible. ●...
  • Page 22 DRIVE FACE Inspect the belt contact surface of the drive faces for wear, scratches or any abnormality .if there is something unusual, replace the drive face with a new one. ROLLER AND SLIDING SURFACE Inspect each roller and sliding surface for wear or damage. DRIVEN FACE SPRING Measure the free length of the driven face spring.if the length is shorter than the service limit, replace the spring...
  • Page 23 fuel consumption. Service limit 0.05mm CYLINDER Decarbon the exhaust port and the upper part of the cylinder. taking care not to damage the cylinder wall surface. The wear of the cylinder wall is determined form diameter reading taken at 20mm from the top of the cylinder with a cylinder gauge.if the wear thus determined exceeds the limit indicated below,rework the bore to the bore to the next oversize by using a boring machine or replace the cylinder with a new...
  • Page 24 rings and rotate them in their respective grooves to be sure that they move smoothly. Carbon in groove is liable to cause the piston ring to get stuck in the groove.and this condition will lead to reduced engine power output. A piston whose sliding surface is badly grooved or scuffed due to overheating must be replaced.
  • Page 25 3-5 ENGINE REASSEMBLY Reassembly is generally performed in the reverse order to disassembly.but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis.these steps will be taken up for respective parst and components. BEARINGS Insert the bearings into the crankshaft and drive-shaft using the special tool ,after the bearing is installed.be sure to lubricate to prevent initial wear.
  • Page 26 CRANKCASE Wipe the crankcase mating surfaces (both surfaces)with cleaning solvent and coat one of a pairin the usual manner. just before assembling the crankcase. Set the two positioning pins to the crankcase. OIL PUMP DRIVE GEAR Apply grease to the oil pump drive gear and install the oil pump drive gear to the left crankcase cover.
  • Page 27 between the drive faces. When installing the belt,pull the movable driven face out. Arrow mark on the drive belt indicates the turning direction. FIXED DRIVE FACE Install the fixed drive face with spring washer and secure the nut. After installing the drive face.turn the movable driven face and take up the belt play.
  • Page 28 4. FUEL AND LUBRICATION SYSTEM 4-1 FUEL TANK AND FUEL COCK When the engine has started. a negative pressure(vacuum pressure)is generated at the intake port.the negative pressure acts upon the diaphragm of the fuel cock and it presses down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor.
  • Page 29 4-2 CARBUTETOR FLOAT HEIGHT ADJUSTMENT To check the float height,invert the carburetor body,holding the float arm pin so that the pin will not slip off.with the float arm kept free.measure the height ○ A While float arm is just in contact with needle valve by using the caliper.bend the tongue ○...
  • Page 30 NEEDLE VALVE INSPECTION If foreing matter is caught between the valve seat and the needle.the gasoline will continue flowing and casue it to overflow.if the seat and needle are worn out beyond the permissible limits.similar trouble will occur.conversely. if the needle sticks.the gasoline will not flow into the float chamber.remove the carburetor.float chamber and floats.
  • Page 31 CARBURETION Adequate carburetion is determined according to the results of various tests.mainly concerning engine power.fuel consumption and cooling effect of fuel on engine.and jet settings are made so as to satisfy and balance all of these conditions.therefore.the jet should not be replaced with a size other than the original.and the positions of adjustable parts should not be changed except when compensating for the mixture ratio due to altitude defferences or other climatic conditions.when adjustment is necessary.refer to the following.
  • Page 32 4-3 OIL PUMP CHECKING OIL PUMP Use the special tool.to check the pump for capacity by measuring the amount of oil the pump draws during the specified interval. ● Remove the frame covers. ● Have the tool filled with CCI SUPER OIL and connect it to the suction side of the pump. ●...
  • Page 33 5. ELECTRICAL SYSTEM 5-1 IGNITION SYSTEM The ignition system consists of a flywheel magneto, a CDI & ignition coil unit and a spark plug. As the rotor rotates, an AC current is induced in the coil. The current in induced in the○ direction charges up the capacitor.
  • Page 34 a “x1k” ohm range. Inspect the CDI & ignition coil unit for continuity between plug cap and ground. If the tester reading shows 4-10kΩ, secondary winding are in proper condition. Ignition coil secondary resistance 4-10kΩ Caution : As the diode, condenser and SCR are provided in the primary circuit, the primary circuit cannot be checked by using an ohmmeter.
  • Page 35 Start the engine and turn the lighting switch ON. Check that the proper charging occurs at the specified engine speeds shown in the following table. (values in the table indicate minimum limit. Therefore , they should be more than indicated under normal condition.) Note: Be sure to use a battery which is completely charged.
  • Page 36 Charging coil W/R-ground(stator base) 0.7±20%Ω Lighting coil Y/R –ground(stator base) 0.45±20%Ω 5-3 STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. Depressing the starter button (on the right handlebar switch box) while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starter motor to the battery.
  • Page 37 STARTER MOTOR INSPECTION STARTER PINION Inspect the pinion gear for smooth operation. While holding the starter motor housing, the pinion gear should turn freely, and not turn in the opposite direction. If the pinion gear turns both directions or is locked on the shaft, replace the starter pinion assembly with a new one.
  • Page 38 5-4 BATTERY In fitting the battery to the motorcycle, connect the breather tube to the battery vent. INTIAL CHARGING FILLING ELECTROLYTE Remove short sealed cap before filling electrolyte. Fill battery with electrolyte(dilute sulfuric cid) solution with acid concentration of 35.0% by weight, having a specific grvity of 1.28 at 20℃ up to indicated MAX.LEVEL.
  • Page 39 rate of 0.4 ampers (which is a tenth of the capacity of the present battery) Be carefull not to permit the electrolyte temperature to exceed 45℃, at any time, during the recharging operation. Interrupt the operation, as necessary, to let the electrolye cool down. Recharging the battery to the specification.
  • Page 40 Even when the ignition switch is turned off, the pointer remains in the position where it was when the switch was ON . This function is displayed by using high-viscosity oil and a balanced magnet. FUEL LEVEL SYSTEM The fuel level system can be divided into two section: (1) the fuel meter: located in the instrument cluter (2) the fuel tank float assembly (fuel gauge sending unit) Note: prior to testing the fuel level system, verify that the battery is in a fully charged condition.
  • Page 41 5-6 OIL LEVEL GAUGE INSPECTION Check the oil level switch for continuity between BL/W and B/W lead wires. If the tester does not show the value of 0-1 ohm when the float is in bottom, replace the unit with a new one. 5-7 COMBINATION METER Disassemble combination meter as shown INSPECTION...
  • Page 42 6 CHASSIS 6-1 FRONT WHEEL AND BRAKE INSPECTION AND SERVICING WHEEL BEARINGS Inspect the play of wheel bearing inner race by hand while installed it in the wheel. Rotate the inner race by hand to inspect an abnormal noise and a smooth rotation. Replace the bearing if there is something unusual.
  • Page 43 WHEEL BEARING REMOVAL Drive out the right and left wheel bearing by using the special tool in the following procedures. Insert the adapter into the wheel bearing After inseting the wedge bar from opposite side, lock the wedge bar in the slit of the adapter. Drive out the wheel bearing by knocking the wedge bar.
  • Page 44 Remove the frame head cover Remove the leg shield Remove the axle nut and front wheel Remove the front fender Remove the front fork clamp bolt and draw out the front fork assembly Note: Loosen the front fork cap bolt before loosening the clamp bolt Loosen and remove the cap bolt and spring.
  • Page 45 FORK OIL For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications blow. Hold the front fork vertical and adjust the fork oil level with the special tool. Note : When adjusting oil level, remove the fork spring and compress the inner tube fully. Install the front fork spring and the fork cap bolt.
  • Page 46 INSPECTION Inspect and check the removed parts for the following abnormalities. Bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar REASSEMBLY Reassemble and remount the steering stem and handlebar in the reverse order of disassemble and removal and also carry out the following steps.
  • Page 47 item Kg.m ○ 80-100 8.0-10.0 ○ 0.8-0.8 remove the left frame cover and muffler pull off cotter pin and remove the axle nut remove the rear wheel with brake drum. INSPECTION Inspect the following items referring to the front wheel (the methods are described above). Wheel and wheel base Tire Brake shoe and brake drum...
  • Page 48 7. SERVINCE INFORMATION 7-1 TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will Compression too low not start or is 1.Excessively worn cylinder or piston rings. Replace. hard to star. 2.Stiff piston ring in place. Repair or replace. 3.Gas leaks from the joint in crankcase. cylinder or cylinder head. Repair or replace.
  • Page 49 Complaint Symptom and possible causes Remedy Engine idles 1. Excessively worn cylinder or piston rings. Replace. poorly. 2. Stiff piston ring in place. Replace. 3. Gas leaks from crankshaft oil seal. Replace. 4. Spark plug gaps too wide. Adjust or Replace. 5.
  • Page 50 CARBURETOR Complaint Symptom and possible causes Remedy Trouble with 1. Starter jet is clogged. Clean. starting. 2. Starter pipe is clogged. Clean. 3. Air leaking from a joint between starter body and Check starter body carburetor. cayburetor for tightness and replace gasket.
  • Page 51 ECTRICAL Complaint Symptom and possible causes Remedy No sparking or 1. Defective CDI& ignition coil unit. Replace. poor sparking. 2. Defective spark plug. Replace. 3. Defective stator coil. Replace. 4. Loose connection of lead wire. Connect/tighten. Spark plug soon 1. Mixture too rich. Adjust carburetors.
  • Page 52 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”,acidic 1. Not enough electrolyte. Add distilled water.if the battery has white powdery ont been damaged and “ sulfation” has not substance or spots advanced too far,and recharge. on surfaces of cell 2. Battery case is cracked. Replace the battery.
  • Page 53 CHASSIS Complaint Symptom and possible causes Remedy 1. Steering stem nut overtightened. Adjust. 2. Broken bearing/race in steering stem. Replace. Handling feels too 3. Distorted steering stem. Replace. heavy. 4. Not enough pressure in tires. Adjust. 1. Loss of balance between right and left Adjust or replace.
  • Page 54 BRAKES(DRUM AND DISC BRAKE) Complaint Symptom and possible causes Remedy 1. Leakage of brake fluid from hydraulic system. Repair or replace. 2. Worn pads or shoe. 3. Oil adhesion on engaging surface of pads. Replace. Insufficient 4. Worn disc. Clean disc and pads. brake power.
  • Page 55 7-2 TIGHTENING TORQUE ENGINE ITEM Kg-m Cylinder head nut 8-12 0.8-1.2 Spark plug 25-30 2.5-3.0 Exhaust pipe nut 8-12 0.8-1.2 Engine mounting bracket bolt 25-40 2.5-4.0 Engine mounting bolt 40-60 4.0-6.0 Muffler mounting bolt 18-28 1.8-2.8 Clutch drum nut 40-60 4.0-6.0 Magneto rotor nut 35-43...
  • Page 56 SPECIAL TOOLS PARTNAME PARTNAME “L”type hexagon wrench set Hydrometer Snapring pliers CDI test lead Impact driver set Conrod holder Vernier calipers Univer sal clamp wrench Micrometer(25-50mm) Bearing and oil seal installer Micrometer(0-25mm) Crankcase separation tool Cylinder gauge set 5-mm attachment Dial gauge(1/100mm) Attachment (I.D.12mm) Magnetic stand...
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