Shineray XY400-A Maintenance Manual
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Shineray XY400-A Maintenance Manual

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XY400 –A Maintenance Manual
With the ever increasing varieties of motorcycles, new structures and new techniques have increasingly been applied. To
help shineray users and maintenance personnel better understand the maintenance, adjustment and repair techniques of
XY400-A motorcycle, we prepared this maintenance manual. This manual is expected to facilitate the SHINERAY users and
maintenance personnel and provide technical guidance for them.
The masterstroke of the manual is the XY400-A motorcycle , and the contents in Chapter 1-Chapter 3 are applicable to the
adjustment of various parts of the motorcycle. Chapter 4-18 describes various constituting parts of the motorcycle respectively.
Chapter 19 contains the electrical system diagram.
The standard maintenance procedures, maintenance precautions and general maintenance knowledge are not covered in
this manual. Any user or maintenance personnel who needs the above information may refer to the related materials
All materials, charts and various data, as well as performance indices referenced herein, are for the latest model in our product
family at the date this manual is printed. Shineray Co., Ltd. Shall have the right to, at any time, amend this manual without prior
notice. The copyright of all parts of this manual belongs to China shineray Co., Ltd. and no units or individuals are allowed to
reprint it the without consent of our company.
We hope you will enjoy the comfort and pleasure it brings to you during your driving!
Foreword
1
Foreword

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Summary of Contents for Shineray XY400-A

  • Page 1 All materials, charts and various data, as well as performance indices referenced herein, are for the latest model in our product family at the date this manual is printed. Shineray Co., Ltd. Shall have the right to, at any time, amend this manual without prior notice.

  • Page 2: Table Of Contents

    XY400 –A Maintenance Manual Contents Contents 1-12 Overview 13-20 Lubrication system 21-39 Inspection and adjustment 40-44 Fuel system 45-49 Removal and installation of engine 50-63 Cylinder head, cylinder and piston 64-74 Clutch and Right crankcase cover 75-83 Magneto and starting system 84-99 Crankcase, crankshaft and Shift mechanism 101-107...

  • Page 3: Overview

    XY400-A 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:...
  • Page 4 XY400-A Maintenance Manual Overview Maintenance Precautions used in accordance with relevant regulations. Whenever reassembling after being disassembled, replace new washers, sealing members, etc. The specified or equivalent lubricating grease (oil) must be applied to or refilled into the specified locations.
  • Page 5 XY400-A Maintenance Manual Overview Make sure the plastic jacket of the connector is securely covering the connector without scaling off. In case the fuse is blown, check for the causes and, after being repaired, replace corresponding fuse as per the Crackle specified capacity.
  • Page 6 XY400-A Maintenance Manual Overview towards the weld mark Do not damage the garnish of the wire harness. The wire harness shall be clamped at the position without Once the wire harness is damaged, repair it by coiling with contacting a rotating part or a removing element.
  • Page 7 XY400-A Maintenance Manual Overview Have you learned by heart the method of application? Are the measurement range and polarity in accordance with the instruction manual? 17. In case of rust on the terminals, carry out connection operation after disposing it with abrasive paper, etc.
  • Page 8 XY400-A Maintenance Manual Overview Technical Data of Main Performance Item Data Length 2105mm Width 760mm Height 1130mm Wheelbase 1420mm Min. ground clearance 160mm Complete vehicle weight Non-loaded weight: 155kg, Curb weight: 160kg, Frame type Cradle type Rake angle 28° Front suspension device spring &...
  • Page 9 XY400-A Maintenance Manual Overview Clutch Wet clutch, coil clutch, paper friction wafer Clutch operating system Manual mechanical Variable speed gear 5-speed constant mesh Primary reduction ratio 2.666 Transmission gear ratio Ⅰ 2.615 Ⅱ 1.789 Ⅲ 1.350 Ⅳ 1.120 0.892 Final reduction ratio 2.533...
  • Page 10 XY400-A Maintenance Manual Overview Standard Torque Values ENGINE Thread diameter Item Quantity Torque value (N.m) Thread locker (mm) Cylinder head cover connecting bolt 8～12 40～50 Cylinder bolt 8～12 Valve adjusting screw nut 8～12 Timing driven sprocket bolt 7～11 Rocker-arm shaft cover 24～28...
  • Page 11 XY400-A Maintenance Manual Overview Name and dimensions Torque value (N.m) 5mm bolt & nut 4.5 ～6 6mm bolt & nut 8 ～12 8mm bolt & nut 18 ～25 10mm bolt & nut 30 ～40 12mm bolt & nut 50 ～60 5mm Screw 3.5 ～5...
  • Page 12 XY400-A Maintenance Manual Overview Magnetic generator rotor puller: for dismantling magnetic Rubber hanner, Iron hammer, Copper hammer generator rotor Feeler gauge: to measure the clearance of piston, cylinder, Micrometer: to measure the dimensions of piston, valve, etc. piston pin, etc.
  • Page 13 I:Carry out inspection, cleaning, adjustment, lubrication or replacement. C: Cleaning. R: Replacement. A: Adjustment. L: Lubrication. * This item is subject to maintenance by persons from SHINERAY Service Station. If the user has special service tools, maintenance accessories or maintenance ability, it can repair it by itself.
  • Page 14 XY400-A Maintenance Manual Overview Symbol Descriptions Meanings of various symbols in this manual: Explanation Measures to be prompted during operating, inspecting and maintaining. NOTICE: Special instructions or disposal measures given to prevent motorcycle from being damaged. WARNING: Special instructions or measures given to avoid serious damages or personal injuries.

  • Page 15: Lubrication System

    XY400-A Maintenance Manual Lubrication system 2. Lubrication system Maintenance notice Inspection of lubricating oil Troubleshooting Replacement of lubricating oil Lubricating Position of Complete Vehicle Cleaning of Lubricating Oil Strainer Lubrication of Control Lines Cleaning and Replacement of Lubricating Oil Filter...
  • Page 16 XY400-A Maintenance Manual Lubrication system Troubleshooting Lubricating oil contaminated Lubricating oil consumes too fast ● ● 1. Fail to replace lubricating oil according to the There is leakage with the engine; maintenance period table; The piston ring is worn. 2. The pouring orifice thread is damaged thus causing The inlet/exhaust valve guide is worn;...
  • Page 17 XY400-A Maintenance Manual Lubrication system Engine Lubrication System Diagram Cylinder head oil through Crankshaft oil through Cylinder oil through Oil filter Camshaft Spindle oil through Oil pump Oil strainer Countershaft oil through Right crankcase body oil through Right crankcase cover oil through...
  • Page 18 XY400-A Maintenance Manual Lubrication system Left crankcase body oil through Cylinder block, cylinder head, camshaft bearing seat and a camshaft oil through Inspection of lubricating oil Park the motorcycle on a flat surface， look over the engine oil dipstick on the oil pot， if the engine oil level is under the lower scale line, refill the recommended lubricating oil until the oil level reaches the upper-middle limit。...
  • Page 19 XY400-A Maintenance Manual Lubrication system Refilling method: Remove the oil filler plug, refill the engine oil slowly with a funnel until the oil level in the engine oil dipstick reaches the upper-middle limit. Then insert the oil filter plug and screw it up.
  • Page 20 XY400-A Maintenance Manual Lubrication system CAUTION Application of 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 lubricating oil.
  • Page 21 XY400-A Maintenance Manual Lubrication system Oil Pump Use the clutch push rod extractor to remove In case of failure, the oil pump needs to be removed for the clutch push rod assembly; use the fixing tool repair or replacement. to prevent the clutch and the primary This section includes the following contents: driving gear from rotating;...
  • Page 22 XY400-A Maintenance Manual Lubrication system Steps for oil pump installation: The installation procedures are the removal procedures in reverse order. Pay attention to the following points during the installation: 1、 The spare parts shall be clean and intact； 2、Install clutch assembly, and the retaining nut M18 shall be coated with thread retaining adhesive LOCTITE243; tightening torque: 114N.m -126N.m；...

  • Page 23: Inspection And Adjustment

    XY400 –A Maintenance Manual Inspection and adjustment 3. Inspection and adjustment Maintenance notice Running system Check-up of spark plug Clutch control line Machine oil checking Driving chain Oil output tank Battery Checking Timing phase Replacement of Fuse Cylinder pressure Brake lamp adjustment Timing chain tension Headlamp dimming Valve clearance...
  • Page 24 XY400 –A Maintenance Manual Inspection and adjustment Explanation: Unless expressly stated or indicated in the maintenance period table, check and adjust all parts of the XY400-C motorcycle according to the contents hereof before using it. Technical specifications ● Throttle bar free stroke： 2-6mm ●...
  • Page 25 XY400 –A Maintenance Manual Inspection and adjustment Check-up of spark plug Machine oil checking For some maintenance operations, one or both the side ①Remove the spark plug cap. Remove the spark plug with panels need to be removed. a socket wrench. Visually check whether there is any To remove the left- and right-hand side panels, operate as follows: damage with the spark plug insulator and ablation with the...
  • Page 26 XY400 –A Maintenance Manual Inspection and adjustment drain the waste engine oil, and flush the strainer with cleaning agent; place the motorcycle side down to facilitate cleaning as required. Then insert the oil drain plug, and proceed with the remaining steps according to the method of “Replacement of lubricating oil".
  • Page 27 XY400 –A Maintenance Manual Inspection and adjustment Oil output tank Adjustment of Ignition Time Oil pot total volume 2.2L, intermediate position oil That the ignition lead angle is not correct will cause a series dipstick oil pot on the line for 1.8L。 of problem that engine is difficult to start，power decrease，...
  • Page 28 XY400 –A Maintenance Manual Inspection and adjustment possible faults have been excluded, check the cylinder Test cylinder pressure. Cylinder pressure: ≥0.8MPa/300r/min. While testing, remove the spark plug and mount a pressure gauge at the position where the spark plug is mounted; fully open the throttle bar and electronically start the engine, and Timing chain tension then check all connecting points of the pressure gauge for...
  • Page 29 XY400 –A Maintenance Manual Inspection and adjustment Upper eyehole cover Old tensioner Eyehole cover Tensioner locking key Confirm the upper dead point Valve clearance Turn the nut of the flywheel clockwise until the engraved Notice: “T” mark on the flywheel aligns with the engraved line on While adjusting the valve clearance, the engine shall be the top of the crankcase cover, and both intake and cold.
  • Page 30 XY400 –A Maintenance Manual Inspection and adjustment Air filter on the rock arm, turn the adjusting nut till a slight Cleaning and replacement of air filter resistance is felt on the inserted right clearance gage. Remove the left side covers Handle it carefully to ...
  • Page 31 XY400 –A Maintenance Manual Inspection and adjustment Idle speed Notice Check and adjust the idle speed after all other items of the engine have been adjusted to the specified ranges. For this model, the idle speed is controlled by an ECU. Since the intake flow at idle speed has been properly Maintaining &...
  • Page 32 If the brake lever feels mushy when pulled, there may be air in the brake lines or the brake may be defective. Since it is dangerous to operate the motorcycle under such conditions, have the brake system immediately checked by the SHINERAY Dealer.
  • Page 33 XY400 –A Maintenance Manual Inspection and adjustment CAUTION Actuate the front brake handle Do not spill brake fluid onto any painted surface or light lens. Do not mix two brands of fluid. Completely change the brake fluid in the brake system if you wish to switch to another fluid When the vacuum pump has fully exhausted the air inside the brake caliper, after the brake fluid is pumped...
  • Page 34 Inspection and adjustment the braking system may cause failure in extreme Caution conditions. Contact an SHINERAY dealer to have the brake pads replaced. WARNING: After the brake pads have been replaced, ride carefully and brake gradually in order to allow the brake pads to properly run in/couple to the relative discs.
  • Page 35 XY400 –A Maintenance Manual Inspection and adjustment If any spoke is broken or cracked, replace it as soon as Coarse adjustment: possible Remove the clutch control line on the handle end, and then remove the clutch operating arm on the engine end; turn the clutch operating arm by a proper angle and remount it, and then mount the clutch control line, finally adjust it to a satisfied free stroke according to the fine...
  • Page 36 XY400 –A Maintenance Manual Inspection and adjustment 12. Driving chain Adjusting bolt Driving chain tension inspection Park the motorcycle on level ground with main stand, and shift the transmission to the neutral position. Check the driving chain tension. Press the chain with a finger up and down to check the amount of movement of the lower chain.
  • Page 37 When electrolyte leaks, or other failure of the electrical washing oil shall be in corrosive to the oil seal; while system is detected, apply to the SHINERAY Dealer. assembling the chain, the locking piece coupling If the vehicle remains unused for long periods, it is...
  • Page 38 XY400 –A Maintenance Manual Inspection and adjustment Caution In this model, both the startup and EMS system are completely powered with accumulator. Therefore, it is quite important to ensure sufficient electric quantity of accumulator, otherwise, startup is impossible. Never fill in tap water, because this will shorten the accumulator’s life span.
  • Page 39 XY400 –A Maintenance Manual Inspection and adjustment 14. Replacement of Fuse Set the ignition switch to “OFF” position. The specified fuse tube of 15A/10A should be used for main fuse replacement, and a 10A fuse tube for FAI injection nozzle. Open the left side cover, remove the fuse holder on the side of the battery and replace the fuse tube.
  • Page 40 XY400 –A Maintenance Manual Inspection and adjustment 16. ABS (Anti-locked Braking System) Anti lock braking system (antilock brake system) ABS. Role is in the motorcycle braking, automatic control brake force size, the wheels cannot be locked, is in a state of piping side the slip (slip rate at around 20%), to ensure that the wheels and the ground adhesion at the maximum value Turn signal light...
  • Page 41 XY400 –A Maintenance Manual Inspection and adjustment 18. Suspension system Front suspension Make the front brake in braking state and press the front fork bracket for several times, and check the front suspension for normal operation. If abnormal noise or “Crack” sound is heard, check all the fasteners and screw them up to the specified torques.

  • Page 42: Fuel System

    XY400 –A Maintenance Manual Fuel system 4. Fuel system Air filter Fuel tank Throttle valve body Inlet pipe Fuel pump...
  • Page 43 XY400 –A Maintenance Manual Fuel system Fuel system Maintenance notice Disassembly and assembly of fuel tank Troubleshooting Removal and installation of air filter Removal and installation of fuel tank Removal and installation of carburetor Maintenance notice This section introduces the knowledge related to the fuel system. CAUTION Pay special attention to fire prevention while dealing with gasoline! ...
  • Page 44 XY400 –A Maintenance Manual Fuel system Removal and installation of fuel tank Installation steps Disassemble step The installation procedures are the removal procedures in Take off fuel tank lock to check it whether is reverse order. damaged. While installing, note that the wiring of the fuel pump control Remove the seat。...
  • Page 45 XY400 –A Maintenance Manual Fuel system Remove and installation of throttle body aligned with the locating lobe of throttle body Disassemble step： Warning: Removal of rear wheel Do not further disassemble the removed throttle body; in case several sensors on it need to be changed, proceed under the instruction of an EMS system technician.
  • Page 46 XY400 –A Maintenance Manual Fuel system Aintenance of Air Cleaner Component Damage form Trouble symptom of motorcycle Repair method description The engine is difficult to start．Insufficient engine C1ean the filtering Too much dust deposit output；Poor performance of engine during idle element．c1ean on the filtering element．...

  • Page 47: Removal And Installation Of Engine

    XY400–A Maintenance Manual Removal and installation of engine 5. Removal and installation of engine...
  • Page 48 XY400–A Maintenance Manual Removal and installation of engine Removal and installation of engine Maintenance notice Installation of engine Removal of engine Maintenance notice It is only necessary to remove the engine from the frame when performing maintenance on the engine’s crankshaft, balancing shaft, driving parts, etc.
  • Page 49 XY400–A Maintenance Manual Removal and installation of engine Removal of engine Remove the exhaust pipe  Park the motorcycle on the plane ground, and completely drain the engine lubricating oil. Screw plug for oil draining Remove engine cycle tube Remove oil -out line and oil -in line Remove side cover, seat and fuel tank Remove Left /Right cylinder head connecting pipe Remove muffler...
  • Page 50 XY400–A Maintenance Manual Removal and installation of engine Remove the starting motor wire. 15. Remove the inlet pipe connected to the engine bolt starting motor wire 10. Remove the high voltage wire 16. Remove the engine hanging plate. Upper suspension ...
  • Page 51 XY400–A Maintenance Manual Removal and installation of engine  Take out the rear fork backwards Loosen the nut and remove the lower hanging bolt.  Move the engine slowly from the right.  Installation of engine The installation of engine is in the reverse order of removal of engine.
  • Page 52 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston 6. Cylinder head, cylinder and piston Cylinder head cover Cylinder head Cylinder...

  • Page 53: Cylinder Head, Cylinder And Piston

    XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Cylinder head, cylinder and piston Maintenance notice Cylinder head Troubleshooting Cylinder Cylinder head cover Piston Camshaft Maintenance notice The lubrication of the camshaft and rocker arm is implemented by pumping oil by the oil pump through the oil troughs of the cylinder, cylinder head and cylinder head cover;...
  • Page 54 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Top planeness 0.05 Piston external φ84.937mm～φ84.927mm φ84.92mm diameter Fit clearance with 0.01mm～0.45mm 0.1mm cylinder Piston and piston Piston pin external φ20mm～φ19.994mm φ19.98mm diameter Piston pin hole φ20.002mm～φ20.010mm φ20.05mm inside diameter Fit clearance 0.002mm～0.018mm 0.05mm Internal diameter...
  • Page 55 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Troubleshooting Low cylinder pressure  ● Excessive noise Valve: Incorrect valve adjustment; --Incorrect valve clearance adjusted; Valve jammed or valve spring broken; --Valve ablated or bent; Camshaft worn or damaged; --Valve sealing failure; Timing chain too long, worn or damaged;...
  • Page 56 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston with a valve clearance adjusting tool as required. Cylinder head cover Mount the valve cover, etc To remove the cylinder head cover: Remove the lower / upper eyehole covers and turn the crankshaft so that the piston is at the upper dead point of the compression stroke.
  • Page 57 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Camshaft Strip the timing chain from the timing driven sprocket, To remove the camshaft: and remove the timing driven sprocket. Remove the lower / upper eyehole cover and turn the Remove the camshaft crankshaft so that the piston is at the upper dead point of the compression stroke.
  • Page 58 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Camshaft inspection Engine oil and molybdenum disulfide Check the camshaft for abrasion, damage, oil through jamming, etc. and check whether the decompressor flying block can rotate and return smoothly. Measure the maximum IN / EX lift. Maintenance limit: IN≥≥5.5057mm, EX ≥...
  • Page 59 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Caution Remove Left /Right cylinder head connecting pipe Do not drop the location pin into the crankcase. To mount the cylinder head: Installation is in the reverse order of removal. Precautions for installation: Confirm the location pin;...
  • Page 60 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Disassembly and assembly of cylinder head Disassemble and assemble the cylinder head according to the following diagram. Use the valve remover / replacer to remove and mount the intake valve and exhaust valve. The spark plug must be tightened to the specified tightening torque of 15～20N.m for fear of leak.
  • Page 61 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Cylinder head inspection Check whether the cylinder head is unobstructed, clean and free of leaks; check the cylinder head’s spark plug Outside micrometer hole and valve seat for cracks; insert the valve into the Measure the width of the valve contacting surface.
  • Page 62 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Cylinder inspection Check the cylinder for abrasion or damage, and check the Chain slide cylinder wall for scratch. Whether the cylinder wall is scratched Check the cylinder wall for deformation, and use the edge ruler and clearance gauge to inspect the planeness of the Notice: cylinder’s joining surface.
  • Page 63 XY400–A Maintenance Manual Cylinder Head, Cylinder and Piston Piston Mount the cylinder (See Installation of cylinder). To remove the piston: Mount the cylinder head (See Installation of cylinder Remove the cylinder head cover (See Removal of head); cylinder head cover) Mount the camshaft (See Installation of camshaft).
  • Page 64 Notice: Do not damage the piston pin and piston ring. Do not reverse the mounting position of the first ring (ATG marker) and second ring (A marker). With side with marker face the top of Procedure Quantity Remarks Sequence of disassembling Assembling is in the reverse order of disassembling.
  • Page 65 Piston inspection Check the piston for abrasion or damage, cracks, etc. and Measure the piston pin external diameter. check the skirt section for scratch. Clearance gauge Measure the piston external diameter at the position 10mm Maintenance limit: ≥φ19.98mm above the piston skirt. Work out the clearance between the cylinder and piston.
  • Page 66 XY400–A Maintenance Manual Clutch and Right crankcase cover 7. Clutch and Right crankcase cover Clutch Engine Right crankcase cove...

  • Page 67: Clutch And Right Crankcase Cover

    XY400–A Maintenance Manual Clutch and Right crankcase cover Clutch and Right crankcase cover Maintenance notice Clutch Troubleshooting Right crankcase cover Maintenance notice To carry out the maintenance stated herein, it is unnecessary to detach the engine from the frame. However, the engine lubricating oil must be discharged.
  • Page 68 XY400–A Maintenance Manual Clutch and Right crankcase cover Troubleshooting  Clutch In case of clutch operation failure, a better correction may usually achieved by adjusting the clutch handle free stroke. Clutch slipping while accelerating  Insufficient free stroke; Clutch disc abrasion; Clutch plate deformed or bent;...
  • Page 69 XY400–A Maintenance Manual Clutch and Right crankcase cover Right crankcase cover Right crankcase cover To remove the cylinder head cover: Loosen the right shaft axle box cover external tubing bolt To install the right crankcase cover: Confirm the location pin; clean up the residual sealing paper gaskets on the right crankcase and right Remove the oil drain plug to drain the engine oil inside crankcase cover.
  • Page 70 XY400–A Maintenance Manual Clutch and Right crankcase cover Mount the right shaft axle box cover external tubing bolt Adjust the direction of the clutch operating lever, Mount the clutch operating lever, rear brake return spring, cotter pin, rear brake lamp switch, etc. Refill engine oil.
  • Page 71 XY400–A Maintenance Manual Clutch and Right crankcase cover Disassemble and assemble of right crankcase cover Procedure Quantity Remarks Removing order Installation is in the reverse order of removal The positioning pin Right crankcase cover sealing paper gasket Replace it with a new one while assembling Right crankcase cover Bolt M6*28 Bolt M6*45...
  • Page 72 XY400–A Maintenance Manual Clutch and Right crankcase cover Clutch To install the clutch: To remove the clutch: Mount the clutch washer with the sabotage side facing Remove the right crankcase cover (See “Removal of the main shaft right bearing. right crankcase cover"). Mount the clutch.
  • Page 73 XY400–A Maintenance Manual Clutch and Right crankcase cover Mount the clutch push rod with the clutch push rod assembler Assemble the right crankcase cover by turning the clutch push rod until its rack side faces the crankshaft. (See “Installation of right crankcase cover"). Right crankcase cover Warning Thread retaining adhesive LOCTITE243 must be...
  • Page 74 XY400–A Maintenance Manual Clutch and Right crankcase cover Removal / Installation of Clutch Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Primary driving gear Oil pump drive gear Oil pump driving gear Bushing Clutch housing Do not further disassemble Clutch washer 22x35x2 Assemble with the sub stage side facing inwards...
  • Page 75 XY400–A Maintenance Manual Clutch and Right crankcase cover . Assemble with While mounting the clutch lift plate, alternatively loosen the 6 connecting bolts to the specified torque protruding side of the butterfly washer facing the plain washer While assembling, the clutch disc must be coated with lubricating oil; in case of replacing new clutch disc, it must be soaked in oil for over 24 hours before being assembled.
  • Page 76 XY400–A Maintenance Manual Clutch and Right crankcase cover Clutch inspection Measure the free length of the clutch spring. Check whether the housing splice has scars or cuts Maintenance limit: ≥41.3mm. due to the collision of clutch disc. Clutch spring free length measurement Inspection Vernier calipers Are there scars or cuts?
  • Page 77 XY400–A Maintenance Manual Magneto and starting system 8. Magneto and starting system Idle gear Double-linked gear cover Left front cover Rotor assembly Double-linked Gear Disk gear Engine...

  • Page 78: Magneto And Starting System

    XY400–A Maintenance Manual Magneto and starting system Magneto and starting system Maintenance notice Rotor assembly Left front cover Starting motor and starting transmission system Maintenance notice To carry out the maintenance stated herein, and the engine lubricating oil must be drained.。 Before assembling, clean all parts and components with cleaning agent and dry them with compressed air.
  • Page 79 XY400–A Maintenance Manual Magneto and starting system Left front cover Remove the left front cover. To remove the left front cover: gasket Left front cover sealing paper Remove the gear shift pedal and left rear cover, and separate the magneto lead connector with the main cable.
  • Page 80 XY400–A Maintenance Manual Magneto and starting system Disassembly and assembly of left front cover Disassemble and assemble the left front cover according to the following diagram. Use the thread retaining adhesive LOCTITE 648 while assembling the pressure plate bolt. Use the thread retaining adhesive LOCTITE 648 while assembling the magneto stator connecting bolt. ...
  • Page 81 XY400–A Maintenance Manual Magneto and starting system Rotor assembly To remove the clutch: Notice: Remove the left front cover (See Removal of left front Do not let the semicircular key drop into the crankcase. cover). Remove the starting idle gear, double-linked gear, etc Double-linked Gear Use the rotor fastening tool to fasten the rotor,...
  • Page 82 XY400–A Maintenance Manual Magneto and starting system Disassembly and assembly of rotor assembly Disassemble and assemble the rotor assembly according to the following diagram. Use thread retaining adhesive LOCTITE 648 on the screw while assembling, with the tightening torque being 10-14N.m Armature One-way device One-way device outer body...
  • Page 83 XY400–A Maintenance Manual Magneto and starting system Starting motor and starting Mount the plain washer and apply thread retaining Transmission system adhesive LOCTITE648 to the fastening nut M12; use the Remove the live wire and earth wire of the starting rotor fastening tool to fasten the rotor, and motor.
  • Page 84 XY400–A Maintenance Manual Magneto and starting system ⑹ Put on the oil drain plug and refill engine lubricating oil. to the rotor retaining nut M12 while assembling, with the tightening torque being 45N.m. Left front cover Check Check the spline gear of output shaft of the starting motor for defect, squeezing, deforming, etc.
  • Page 85 XY400–A Maintenance Manual Magneto and starting system Measure the disk gear diameter, the maintenance limit: ≥φ42.084mm Outside micrometer Measure the washer thickness, the maintenance limit: ≥0.4mm Vernier calipers...
  • Page 86 XY400–A Maintenance Manual Magneto and starting system 9. Crankcase, crankshaft and Shift mechanism Right hand crankcase body Gearshift drum Crankshaft Main shaft Counter shaft Left hand crankcase body...

  • Page 87: Crankcase, Crankshaft And Shift Mechanism

    XY400–A Maintenance Manual Magneto and starting system Crankcase, crankshaft and Shift mechanism Maintenance notice Crankshaft and balance shaft Troubleshooting Variable transmission system Crankcase Maintenance notice To carry out the maintenance stated herein, the engine must be removed from the frame. To repair the crankshaft, balance shaft or variable transmission system, the left hand crankcase and the right hand crankcase must be separated, which is known as crankcase dissection.
  • Page 88 XY400–A Maintenance Manual Magneto and starting system Troubleshooting Noise from engine  Crankshaft bearing worn; Connecting rod big end bearing worn; Driving/driven shaft bearings worn; Balance shaft supplementary tooth spring failure. Driving/driven shaft gears engaged badly  Shift fork bent or damaged; Shift fork shaft bent;...
  • Page 89 XY400–A Maintenance Manual Magneto and starting system Crankcase Notice To remove the crankcase: Do not pry the left/right hand crankcase body by Remove the engine from the frame (engine oil fully inserting such tools as screwdrivers into the mould drained) and put it on the assembly operating table. closing face.
  • Page 90 XY400–A Maintenance Manual Magneto and starting system Mount the mould closing bolt and fasten it. Mount other parts and components of engine, mainly include right hand crankcase cover, clutch, gear shifter, cylinder head cover, camshaft, cylinder head, cylinder, piston, left front cover, rotor assembly, electrical starting transmission system, driving drive sprocket, etc.
  • Page 91 XY400–A Maintenance Manual Magneto and starting system Removal and installation of crankcase Knock pin Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Mould closing bolt (big pan head) Mould closing bolt (small pan head) Left hand crankcase Use the oil seal guide to protect the oil seal during removal and installation Shift arm combination...
  • Page 92 XY400–A Maintenance Manual Magneto and starting system Notice: Do not dent the sealing surface, and assemble the driving shaft bearing with the side with oil seal facing inwards. Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Left hand crankcase Apply engine oil while assembling Crankshaft bearing 6203...
  • Page 93 XY400–A Maintenance Manual Magneto and starting system Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Right hand crankcase Balance shaft bearing 6302 Apply engine oil while assembling Driving shaft bearing 62/22/C3 Let the oil seal side face inward and apply engine oil while assembling Gear shift shaft oil seal 18x34x5 Apply engine oil while assembling...
  • Page 94 XY400–A Maintenance Manual Magneto and starting system Crankshaft and balance shaft crankcase body balance shaft bearing until the To remove the crankshaft and balance shaft: temperature at the inner circle of the bearing reaches Remove the (left hand) crankcase (See “Removal of left 106℃, and then assemble the balance shaft.
  • Page 95 XY400–A Maintenance Manual Magneto and starting system Removal and installation of crankshaft and balance shaft Knock Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Left hand crankcase Crankshaft Balance shaft Right hand crankcase...
  • Page 96 XY400–A Maintenance Manual Magneto and starting system Disassembly and assembly of crankshaft and balance shaft Do not further disassemble the crank shaft, otherwise the spar parts may be damaged. Disassemble and assemble the balance shaft according to the following diagram. Notice: Always align the markers while assembling the balance shaft.
  • Page 97 XY400–A Maintenance Manual Magneto and starting system Crankshaft and balance shaft inspection Measure the connecting rod large end side clearance, Check whether the crankshaft journals are abnormally the maintenance limit: ≤0.80mm. worn, whether the connecting rod can rotate flexibly and Clearance gauge whether there is significant noise while rotating.
  • Page 98 XY400–A Maintenance Manual Magneto and starting system Variable transmission system Mount the shift arm To remove the variable transmission system: Driving shaft Shift arm Remove the (left hand) crankcase (See “Removal of left hand crankcase"). Remove the shift fork shaft. Remove the gearshift drum.
  • Page 99 XY400–A Maintenance Manual Magneto and starting system Removal and installation of driving shaft and driven shaft and gearshift drum and shifting shaft Attention: the washer, retainer, etc. must be assembled in place at the correct positions, the spare parts 8 apply lubricating oil. while assembling Procedure Quantity...
  • Page 100 XY400–A Maintenance Manual Magneto and starting system Check Shift mechanism Check the driving/driven shaft gears for serious abrasion To remove the shift mechanism and pit corrosion; check whether the shift fork is bent and Removal of left hand crankcase cover(See “Removal whether the gearshift drum guiding slot is damaged.
  • Page 101 XY400–A Maintenance Manual Magneto and starting system Mount the left crankcase body combination（Use oil seal guide to protect oil seal） Mount the rotor assembly(See “Mount of left hand crankcase cover "). Mount the left hand crankcase cover(See “Mount of right crankcase cover "). Warning Thread retaining adhesive LOCTITE243 must be applied to the rotor retaining nut M12 while...

  • Page 102: Frame And Exhaust System

    XY400–A Maintenance Manual Frame and exhaust system 10. Frame and exhaust system Covering Rear mudguard Frame weld assembly...
  • Page 103 XY400–A Maintenance Manual Frame and exhaust system Frame and exhaust system Maintenance notice Removal and installation of rear mudguard Troubleshooting Removal / installation of exhaust muffler Coverings, headlamp and meter Rear position lamp assembly Maintenance notice To carry out the maintenance stated herein, take special care of the scratches and damages to the coverings, meter and light fittings.
  • Page 104 XY400–A Maintenance Manual Frame and exhaust system Fender Damaged Broken Effects of fender effect Replace the fender Seat Broken Broken Decrease of the Replace the seat comfortable Footrest Broken and Broken and deformation Replace the footrest deformation Maintenance of Exhaust Muffler Component Damage form Trouble symptom of...
  • Page 105 XY400–A Maintenance Manual Frame and exhaust system Maintenance of Frame and Accessories Check front fender whether is damaged.  Overall structure of frame is shown in fig. check  welding part whether is come off and frame is distorted. Overall structure of side stand is shown in fig and ...
  • Page 106 XY400–A Maintenance Manual Frame and exhaust system Side cover 、 seat and front fairing Remove the seven nut, remove the block wind plank.  Remove the four nut, remove the seat.  Remove the eleven nut, remove the front fairing. ...
  • Page 107 XY400–A Maintenance Manual Frame and exhaust system Remove the headlamp To mount the related sections, headlamp: Remove the front fairing.(Refer to the related sections)  The installation of the related sections and headlamp is in Pull off the headlamp patch plug to remove the related the reverse order of removal.
  • Page 108 XY400–A Maintenance Manual Frame and exhaust system Combined rear position lamp Dismantle the suspension bolt on the muffler, check  - Undo the two screws and remove the tail-lamp.  whether it is sliding.  - Taillights are for LED without maintenance。 Dismantle muffler connecting nut, check whether the ...
  • Page 109 XY400–A Maintenance Manual Frame and exhaust system Maintenance of Control System Dismantle clutch cable. Disassemble, assemble and check control Check cable whether is flexible. Dismantle right handle bar switch and check throttle handle whether is damaged then fill lubrication oil Adjust clutch and check clutch whether it declutch.
  • Page 110 XY400–A Maintenance Manual Front wheel, front overhang and steering stem 11. Front wheel, front suspension device and steering stem Control component Upper connect plate Front fork assembly Front wheel assembly...
  • Page 111 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Front wheel, front suspension device and steering stem Maintenance notice Front suspension device Troubleshooting Front brake Control subassembly Steering stem Front wheel Maintenance notice This section introduces the removal, installation and maintenance of the front wheel, front suspension device (front fork), front brake and steering stem.
  • Page 112 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Front wheel run out  Rim bent or deformed Wheel bearing worn Wheel spoke deformed or slacked Front wheel spindle slacked Tire damaged Wheel hard to rotate  Wheel bearing or bush damaged Adjusting nut over-fastened Tire pressure insufficient Shift fork bent or damaged.

  • Page 113: Front Wheel, Front Overhang And Steering Stem

    XY400–A Maintenance Manual Front wheel, front overhang and steering stem Maintenance of Control system Component Damage form Trouble symptom of Trouble symptom of Repair method description component motorcycle Steering The steering handle The steering handle is bent Correct or replace Off-tracking in running.
  • Page 114 XY400–A Maintenance Manual Front wheel, front overhang and steering stem The tire is over worn(the tire vein It is possible to slip and has a Replace outer tire depth is less than poor slip proof function 2mm) Gear is damaged． Speedometer Replace The indicator of the...
  • Page 115 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Maintenance of Steering Post Component Damage form Trouble symptom Trouble symptom of Repair method description of component motorcycle Steel ball Adjust the steering post socket screw by tighten wrench till Too small gap the steering post moves left Over tight of steering...
  • Page 116 XY400–A Maintenance Manual Front wheel, front overhang and steering stem clogged wall is broken or cocked brake lose effect replace front brake caliper wall is over worn brake lose effect replace front brake caliper oil leakage from front front brake caliper is lose effect replace front break caliper broken...
  • Page 117 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Control subassembly Loosen the retaining bolt and remove the clutch Remove the left/right balance weight. handle holder. Pull off the left handle. Remove the right handle and right combination switch Brake switch Remove the clutch control line and disassemble the connection of the clutch switch leads and the main...
  • Page 118 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Remove the right brake cylinder body. While installing, the clutch handle holder and the front  brake cylinder body notch shall be aligned with the mark point of the grip tube, and the pins of left/right combination switch shall be blocked into the pin holes of the grip tube.
  • Page 119 XY400–A Maintenance Manual Front wheel, front overhang and steering stem To mount of the front wheel Front wheel spindle inspection While installing, fasten the front wheel spindle nut to the Dismantle front wheel axle nut and take out rear wheel axle required torque of 50-60N.m to check it whether is distored.
  • Page 120 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Disassemble, assemble and check front Unscrew the upper / lower connection plate bolt  absorber Front suspension device Park the motorcycle on the plane ground, and remove  the coverings of the whole vehicle (See Removal of coverings) and front wheels (See Removal of front wheel) To install the front fork:...
  • Page 121 XY400–A Maintenance Manual Front wheel, front overhang and steering stem Take off dust sleeve, circlip and oil seal to check edge Measure internal diameter to check whether or not is it whether or not is worn and circlip is distorted. worn.
  • Page 122 XY400–A Maintenance Manual Front wheel, front overhang and steering stem 10) Fill absorber oil per standard. Lower steering stem Oiling quantity: 250 ± 2ml/, the brand is CN1# shock Dismantle and mount outer seat ring of vertical pipe absorber oil, injected before the strict filtering, does not and check outer seat ring whether is worn.
  • Page 123 XY400–A Maintenance Manual Front wheel, front overhang and steering stem the brake shoe has touched the wear limit. Brake shoe Hitch pin The fluid level in the pump reservoir may never drop below the minimum notch (LOWER) shown on the clear reservoir Spring compression Warning: When it is replaced with a new brake strip or brake disc,...
  • Page 124 Principle of the braking system XY400-A(390K), with the front is disc while the rear is drum braking system, which defines that only the front wheel braking system has the function of ABS. In normal operation mode, the function of braking system equipped with ABS is same as none ABS braking system.
  • Page 125 2 seconds, then the Disable ABS ABS is enabled. The warning lamp is no longer blinking, but Customers may do not want the ABS function, but SHINERAY goes out. suggests the ABS function is always enabled。 In the above item 1、2,” timing from the lights blinking, toggle the switch to in 2 seconds”, without operation...
  • Page 126 Warning may cannot be in the best function, except this changes are approved or recommended by To ensure safety, this item is only subject to maintenance SHINERAY。 by persons from SHINERAY Service Statio...
  • Page 127 XY400–A Maintenance Manual Rear wheel and rear suspension device 12. Rear wheel and rear suspension device Rear wheel assembly Rear brake caliper Rear damper component Rear fork assembly Chain cover sheet...
  • Page 128 XY400–A Maintenance Manual Rear wheel and rear suspension device Rear wheel and rear suspension device Maintenance notice Rear fork Troubleshooting Rear shock absorber Rear wheel Maintenance of Rear Transmission Maint nance notice This section introduces the removal, installation and maintenance of the rear wheel, rear brake, rear fork and rear damper .While repairing the rear wheel and rear damper, reliably stand the motorcycle from under the engine a jack or other supports.
  • Page 129 XY400–A Maintenance Manual Rear wheel and rear suspension device For the damage form, fault symptom and repair method of rear wheels Component Damage form Trouble symptom of Trouble symptom of Repair method description component motorcycle Rear rim is twisted Rear rim is twisted and Off racking in running．rear Replace rear rim and deformed．...
  • Page 130 XY400–A Maintenance Manual Rear wheel and rear suspension device Maintenance of Rear Suspension Component Damage form Trouble symptom of Trouble symptom of Repair method description component motorcycle Rear shock Rear shock absorber spring is absorber spring is broken or Rear shock absorber is over Replace rear shock broken or with with insufficient...
  • Page 131 XY400–A Maintenance Manual Rear wheel and rear suspension device clogged wall is broken or cocked brake lose effect replace Rear brake caliper wall is over worn brake lose effect replace Rear brake caliper oil leakage from Rear Rear brake caliper is lose effect replace Rear break caliper broken...
  • Page 132 XY400–A Maintenance Manual Rear wheel and rear suspension device Rear wheel To remove the rear wheel. 1) Stand the motorcycle with a jack to lift the rear wheel above the ground. 2) Remove the chain set. Remove the lock clip in this direction 1) Take out the rear wheel assembly and the spindle bush.
  • Page 133 XY400–A Maintenance Manual Rear wheel and rear suspension device Rear wheel spindle inspection whether are damaged. Dismantle front wheel axle nut and take out rear wheel axle to check it whether is distorted. Place the rear wheel spindle on the V-holder, and measure the deflection of the wheel spindle with a dial gauge;...
  • Page 134 XY400–A Maintenance Manual Rear wheel and rear suspension device Take out bush and dismantle bolt of rear driven chain disc. 3、Remove the rear shock absorber and rear fork connecting bolt. Bolt Normal tooth shape Check rear driven chain disc whether it is exceed limit value.
  • Page 135 XY400–A Maintenance Manual Rear wheel and rear suspension device Rear fork bearing inspection - Using an appropriate spanner, turn the ring nut (2) Replace the removed seal ring and needle bearing with new positioning the adjuster (3) in correspondence to the catch ones.
  • Page 136  below the minimum notch (LOWER) shown on the clear reservoir Caution Contact an SHINERAY dealer to have the brake pads replaced. Warning: After the brake pads have been replaced, ride carefully and brake gradually in order to allow the brake pads to...
  • Page 137 XY400–A Maintenance Manual Rear wheel and rear suspension device Rear brake disc inspection Measure the thickness of the brake disc with an outside micrometer; if the thickness is no more than 3mm, replace the rear brake disc. Outside micrometer Measure the runout of the brake disc with a dial gauge; if the runout is no less than 0.2mm, replace the rear brake disc.

  • Page 138: General Remarks Of Electrical System

    The development of electronics will especially influence the motorcycle’s electrical system significantly. XY400-A’s electrical system uses a lot of advanced vehicle electronics technologies that are much more complicated then the traditional motorcycle. It comprises the following sub-systems: •...
  • Page 139 XY400–2A Maintenance Manual Power supply system • Information display system We shall give detailed explanations separately in the following sections...

  • Page 140: Power Supply System

    Power supply system is the precondition for a complete vehicle to operate, capable of providing sufficient electric energy for other electrical systems. The main contents include recharging, charge storing and discharging. XY400-A power supply features large power supply capacity as high as more than 250W. It comprises the following parts and components: •...
  • Page 141 XY400–A Maintenance Manual Power supply system Maintenance of Charging System Check plate electrode whether is damaged Disassemble. assemble and check charging system Check socket whether contact well. Socket check connector socket of rectifier and measure output Dismantle rectifier bolt and measure two yellow wire voltage by multimeter to (13.0-13.3)v whether is short circuit or broken circuit by millimeter.
  • Page 142 XY400–A Maintenance Manual Power supply system Major faults diagnosis Phenomenon Possible causes Solutions No electricity in the complete Main fuse is blown; Replace main fuse    vehicle: Main fuse circuits contact poorly; Re-plug.   Replace main fuse; Accumulator’s positive and negative Reconnect;...

  • Page 143: Starting System

    When the engine starts to work, an exogenous action is needed to help it run, thus entering the ignition & fuel supply procedure to enable the internal combustion engine to combust repeatedly and work steadily. XY400-A motorcycle is only equipped with electric controlled starting.
  • Page 144 XY400–A Maintenance Manual Starting system Maintenance of starting system Check fuse whether is burned. Fuse whether Disassemble, assemble and maintain Turn on ignition switch and flameout switch to check electrical start whether energize. Check positive and negative pole of battery whether contact well Battery Check plate electrode whether is damaged...
  • Page 145 XY400–A Maintenance Manual Starting system 10. Turn on electrical starting button to check whether is rusted or energize. 11. Turn on flameout switch to check it whether is rusted or loose 12. Check switch plug of relay whether is loose. 13.
  • Page 146 XY400–A Maintenance Manual Starting system Major faults diagnosis Phenomenon Possible causes Solutions Starting relay Accumulator voltage too low; Recharge the accumulator;    doesn’t attract; Corresponding fuse is not connected or is Connect the fuse or replace it;  ...

  • Page 147: Illumination Signal System

    XY400–A Maintenance Manual Illumination signal system 16. Illumination signal system Overview Major parts and components Circuit schematic drawing Major faults diagnosis Overview Illumination signal system is an important guaranty for the safe driving of the vehicle. It includes the headlamp illumination system, signal lamp control system and horn system.
  • Page 148 XY400–A Maintenance Manual Illumination signal system Circuit schematic drawing...
  • Page 149 XY400–A Maintenance Manual Illumination signal system Maintenance of illumination system Turn on ignition switch and flameout switch to check Take off headlamp switch socket to check whether there electrical start whether energize. is current Head lamp Open battery to check electrode plate whether is burned or electrolyte is little.
  • Page 150 XY400–A Maintenance Manual Illumination signal system Tail lights Dismantle taillight bolt to check lamp case whether is damaged. Take off ignition switch socket to check whether current input headlamp switch Brake lamp switch Check tail lamp and brake lamp socket whether lose Dismantle after brake lamp switch to check it whether lose contact or bulb is burned contact.
  • Page 151 XY400–A Maintenance Manual Illumination signal system Horn Check horn button whether is rusted or lose contact Adjust velum of electrical horn to check it whether is damaged. Horn button Check neutral socket whether contact well. Fuel level sensor Check fuel sensor failed or float is blocked; Line poorly plugged, open or short circuit.
  • Page 152 XY400–A Maintenance Manual Illumination signal system Major faults diagnosis Phenomenon Possible causes Solutions Headlamp does not Accumulator voltage too low; Recharge the accumulator;    illuminate; Corresponding fuse is not connected or is Connect the fuse or replace it; ...
  • Page 153 XY400–A Maintenance Manual Illumination signal system Line failure  Horn does not sound Corresponding fuse is not connected or is Connect the fuse or replace it;    blown; Repair or replace the left switch;  Horn button failed; Adjust or replace horn;...

  • Page 154: Electrical Starting Control System

    XY400–A Maintenance Manual Engine management system 17. Electrical starting control system Overview Major parts and components Circuit schematic drawing Major faults diagnosis Overview The information display system displays the dynamic and static information of the complete vehicle on the instrument panel for the driver’s safe operation.
  • Page 155 XY400–A Maintenance Manual Engine management system Major parts and components ○ Combination meter Outline drawing Line color function corresponding table COLOUR FUNCTION COLOUR FUNCTION Black Power Supply(+) Black/ Yellow The rotational speed signal green Power Supply(-) Yellow / white Fuel oil signal Brown Instrument lighting Battery power supply（+）...
  • Page 156 XY400–A Maintenance Manual Engine management system Meter reading and usage Odometer Speedometer Indicate riding distance (Km). Indicate motorcycle speed (Km/h). Do not exceed legal Tachometer rate-limiting to assure safe riding. It shows the speed(rpm) of the engine. Turning indicator light Trip meter （R）right turn，twinkle when turn to right(Green).
  • Page 157 XY400–A Maintenance Manual Engine management system Maintenance of electrical starting control system Dismantle meter bolt to check it whether is loose or Turn on ignition switch and flameout switch to check damaged. electrical start whether energize. Dismantle meter bolt and odometer cable to check bolt whether is damaged or loose.
  • Page 158 XY400–A Maintenance Manual Engine management system Major faults diagnosis Phenomenon Possible causes Solutions Winker indicator is out The winker indicator filament is burnt out Replace winker indicator bulb    of work The meter dial illuminator filament is burnt out Replace meter dial illuminator ...
  • Page 159 XY400–A Maintenance Manual Engine management system Turn indicator Line poorly plugged or open circuit; Re-plug or repair;    filament is burnt out Meter failed; Replace meter;   Headlight high-beam  indicator filament is burnt out LCD fails to switch Meter failed Replace meter ...

  • Page 160: Engine Management System

    XY400–A Maintenance Manual Engine management system 18. Engine management system System Overview System Overview Tools Major parts and components Maintenance depending on the malfcode Circuit schematic drawing DTC List Maintenance of Engine management system Maintenance depending on the performance Components of system and Operating principle The Engine Management System(EMS) comprises electronic control unit(ECU), throttle body, Idle speed control valve, fuel pump, fuel injector, ignition coil, O2 sensor, throttle position sensor, T-MAP sensor, cylinder head temperature sensor and so on.
  • Page 161 XY400–A Maintenance Manual Engine management system • Throttle, Idle speed control valve (air intake) Electronic control unit • ECU Major parts and components Fuel pressure regulator Fuel injector Throttle body assembly Electronic control unit( ECU) Temperature sensor Throttle sensor Idle speed control valve Ignition Coil Oxygen sensor Fuel sender assy...
  • Page 162 XY400–A Maintenance Manual Engine management system...
  • Page 163 XY400–A Maintenance Manual Engine management system ITEM PIN No. DESCRIBE ITEM PIN No. DESCRIBE J1-1 IACAHi J2-1 COILA J1-2 MAGNETO CUT RELAY J2-2 J1-3 J2-3 KW2000 J1-4 J2-4 CRANK HI J1-5 J2-5 INJA J1-6 TACH J2-6 J1-7 CANLo J2-7 O2AHTR J1-8 CANHi J2-8...
  • Page 164 XY400–A Maintenance Manual Engine management system 5) When disassmeble the fuel pump from the pump, make sure the power is off. Or it may casue the fire. 6) The fuel pump cannot work in air or water, it will shorten the service life. And the positive and negative connecters cannot be exchanged.
  • Page 165 XY400–A Maintenance Manual Engine management system DTC List System or Component DTC Number DTC Description Related Calibration Manifold Absolute P0107 MAP Circuit Low Voltage or Open KsDGDM_MAP_ShortLow Pressure Sensor (MAP) P0108 MAP Circuit High Voltage KsDGDM_MAP_ShortHigh P0112 IAT Circuit Low Voltage KsDGDM_IAT_ShortLow Intake Air Temperature Sensor (IAT)
  • Page 166 XY400–A Maintenance Manual Engine management system Malfcode：P0107 Information：MAP Circuit Low Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next Step 5 Check the data of ‘BARO’. Make sure whether it is about 100kPa Next (depending on where you are) Remove the connector, and use the multimeter to check whether the...
  • Page 167 XY400–A Maintenance Manual Engine management system Malfcode：P0112 Information：IAT Circuit Low Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next check whether the data of ‘intake air temperature’ equals to the real intake Setp 5 air temperature. Next Remove the connector, and use the multimeter to check whether the Step 5...
  • Page 168 XY400–A Maintenance Manual Engine management system Malfcode：P0117 Information：Coolant/Oil Temperature Sensor Circuit Low Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next check whether the data of ‘engine temperature’ equals to the real Step 5 temperature. Next Remove the connector and use the multimeter to check whether the Step 5...
  • Page 169 XY400–A Maintenance Manual Engine management system Malfcode：P0122 Information：TPS Circuit Low Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next Step 5 Check whether the data of ‘Throttle opening’ is bettwen 0%-1%. Next Step 5 Open the throttle to 100% slowly, check whether the data of ‘throttle opening’...
  • Page 170 XY400–A Maintenance Manual Engine management system Malfcode：P0131/P0132 Information：O2S 1 Circuit Low/High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next Use multimeter to check whether the connection between pin B of the Harness issue oxygen sensor and pin J2-17 of the ECU is open, and whether the pin B of Next sensor is short to pin A.
  • Page 171 XY400–A Maintenance Manual Engine management system Malfcode：P0230/P0232 Information：FPR Coil Circuit Low/High Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition off next Wait about 30s. Remove the fuel pump realy, ignition on. Check whether Change the pump voltage of the relay feeder ear is about 12V Next Check whether the feeder ear is short to ground or open.
  • Page 172 XY400–A Maintenance Manual Engine management system Maintenance depending on the performance. Before issue analysis, please check: The MIL works well. Clear the history malfcode. When the malfcode comes again, note the condictions. Check the appearance Whether there is leakage of the fuel pipe or not. Whether there is block/leakage or damage of the intake pipe.
  • Page 173 XY400–A Maintenance Manual Engine management system ITEM OPERATION RESULT NEXT STEP Next Check whether the voltage of the battery is around 8-12V. Change the battery. Crank the engine, and check whether the voltage is Next above 8V. Change the battery. Next Check whether the start motor working well or not.
  • Page 174 XY400–A Maintenance Manual Engine management system dry the plug and combustion chamber. Pull out the spark plug, check whether it is wet or not Next Engine is good Check whether the cylinder pressure is normal or not Check the engine Check whether the air filter is blocked and whether the Intake system maintenance intake pipe leaks.
  • Page 175 XY400–A Maintenance Manual Engine management system Change IACV Help Remove the engine temperature sensor and check whether the engine works well Change the sensor Check whether the air filter is blocked and whether the Intake system maintenance intake pipe leaks. Next Next Check whether the fuel pressure is about 250kPa.
  • Page 176 XY400–A Maintenance Manual Engine management system Pull out the spark plug, check whether the spark over Next is normal. Check the ignition system Next Check whether the timing is right Adjust the timing Help Check the typ and the clearance of the spark plug. Change the spark plug...

  • Page 177: Electrical System Diagram

    XY400–A Maintenance Manual Engine management system 19. Electrical System Diagram...
  • Page 178 XY400–A Maintenance Manual General remarks of electrical system...

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