Mash XY400B Operational Instructions

XY400B

OPERATIONAL INSTRUCTION

1

Important Information

Please read the user’s manual carefully before going on the first riding. This manual contains a large amount of information of operation
and cautions, which will help you to handle and control of the motorcycle with 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 mentioned-below information may cause the damage of motorcycle with sidecar parts or it may compromise the
driving safety of the motorcycle itself.

Please fill in the blank with the serial Nos. of the motorcycle,

Frame No.：

Engine No.：

Distributor：

Index

I、Technical Data of Main Performance…….……………………1-3
II、Safe drive……………………………………………………………4

Important safety information………….……………….………....…4

Wear protective……………………………………………………...4
Do not ride while under the influence……………………..…..…4
Safe riding principles……………………………………...………5

Being seen……………………....……………………………....….5

How to keep your motorcycle safe………………………………...6
Loading& Carrying passengers………………………………...….6
Gasoline and exhaust fumes………………….…….……..…..…..7

Modifications……………………….….......................…..…..…..7

Flue-Saving tips………………………………….….……..…..….8

III、Parts’ position……………...............................…………...…9-10

Meter reading & usage……………………………………...…11-12

IV、Switch operation…………………….....................…......…….13

Switch instruction……………………………………… ..….…….13

Switches on right handlebar……………………..…..………14

Switches on left handlebar...................................................14-15

Fuel filling………………………….…………………..…......15

Gear Shift …………………………...……………………….……..16

Blind spot mirrors……………………………………….….....…...16

Clutch lever…………………………………...…………….….......17

Throttle… … … ……… … …………… … ………….. … … ........17

Brake usage…………………………………….…………………..17

Parking lever……………………………………………………..18
Seat belt………………………………………….…………… .. 18

Oil output tank………………………………………….…………..19

V、Basic operation and riding………………………….…………..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 clearance……………………………..…………………..…30

Check-up, cleaning of air filter…………………………….....…31

Idle speed……………………………..……..……………….……32
Throttle control…………………………………….………………33
Brake system……………………………………………..……34-36
Running system…………………………………………….………37

Clutch control line………………………………..............……37-38

Driving chain…………………………………………..………38-39

Battery checking……………….....................................……40-41

Replacement of Fuse……………………………….……………41

Brake lamp adjustment………………………………………..…42
Illumination signal system…………………………………..…42-43
Bolts, nuts and fasteners……………………………….………43

Vehicle washing………………………………………………43-44
Maintenance in non -use time…………………………….……44
Resumption of Service……………………………………………45

Special notice………………………………………………………45
Driving…………………………………………………………….…45

VII、Engine management system…………………….…….…46
OBD Service $01………………………………………………….50
OBD Service $02………………………………………………….51
OBD Service $03………………………………………………52-53
OBD Service $04…………………………………………………54
OBD Service $07………………………………………………….55
Service $09 (Request Vehicle Information) -PIDs supported…55
Standard torque values…………………………………………...56
VII、Electrical system diagram……….…….………………………58

1

I、 Technical Data of Main Performance

Item

Data

Dimension & Weight

Length
Width
Height
Wheelbase
Wheelbase sidecar
Min. ground clearance
Complete vehicle weight

2160mm
1610mm
1125mm
1420mm
1170mm
160mm
Non-loaded weight: 260kg,
Max loading 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
Fuel grade

Cradle type
28°
spring & hydraulic composite damping
spring & hydraulic composite damping
100/90-19/ 280 kPa
130/80-18/ 280 kPa
100/90-19/ 280 kPa
Single disc type ModelΦ276
Single disc type ModelΦ160
Single disc type ModelΦ276
13L
93#

2

Engine

Mode
Cylinder bore × Stroke
Cylinder displacement
Compression ratio
Max. power
Max. torque
Valve clearance (cold)
Valve driving gear
Air filter
Cooling method
Lubrication method
Engine oil charge volume
Engine oil filter element
Electric motor starting
Idle speed

Single-cylinder Oil –cooling 4-stroke engine

85.0mm × 70.0mm
397cc

8.8±0.2:1

20.4kw/6500rpm

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

Driving system

Clutch
Clutch operating system
Variable speed gear
Primary reduction ratio
Transmission gear ratio
Final reduction ratio
Gear shifting mode

Wet clutch, coil clutch, paper friction wafer
Manual mechanical
5-speed constant mesh +1- reverse

2.666
R：2.428；Ⅰ：2.727 ； Ⅱ： 1.789；Ⅲ ：1.363 ：Ⅳ： 1.080； V ： 0.925

3.000
Left foot operated to and back type；
Sequence: R－I－N－Ⅱ－Ⅲ－Ⅳ-V

3

Electrical system

Electric generator
Accumulator capacity
Power supply system

Fusible cutout
Spark plug
Spark plug gap
Ignition coil type
Fuel supply mode
Ignition mode
Ignition advance angle
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
accumulator
15A/10A
DPR8Z

0.6-0.7mm
Open magnetic circuit
Electronically injection, ECU control
EMS
EMS
EMS
12V/55W/60W
Front: 12V10W Rear: 12V10W
12V21W/5W
Front: 12V5W Rear: 12V5W Sidecar: 12V5W

4

II、Safe drive

Important safety information

Your safety is very important. Your motorcycle can provide
many years of service and pleasure, if you take responsibility for
your own safety and understand the challenges while riding. There is
much you can do to protect yourself when you ride.
Please read through the following instructions before riding your bike
the first time.

• Be sure you read this owner’s manual completely and

understand all operating features.

• Take sufficient time training with safe and proper riding

technique.

• Practice until you are knowledgeable and comfortable with

your motorcycle, and knowledgeable with all road signs.
Failure to follow any safety instructions could cause severe injury or
even death to the motorcycle operator, passenger or bystander.
Before riding each time, make sure of the following:

Wear protective

Riding a motorcycle leaves the rider exposed. Therefore,
wearing appropriate protective wear can prevent or diminish injuries
from accidents.

• Helmet – The majority of 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 Protection – A plastic face shield can help
prevent accidents by guarding the face and eyes from debris,
allowing the rider to devote full attention to the road. Goggles or
glasses can protect the eyes in the same manner.

• Clothing – Bright clothing should be worn by the driver so
as to be seen easily by other motorists. Avoid loose clothing that
could catch on the levers, chain or wheels which could result in an
accident. Gloves give you a better grip and help protect your hands
from the elements.

Caution

·Do not take on the helmet which is easily increase hurt or
death probability when accident.

·Make sure passenger always wear helmet to protect eyes,
and dress protecting clothes when driving.

Do not ride while under the influence

Before getting on your bike, make sure:

• You have not consumed alcohol or taken drugs.

• You are in good physical and mental condition.

• You have done the recommended per ride inspection.

• Start the engine in a well-ventilated area.

The exhaust emits toxic and poisonous carbon monoxide.

5

Caution

Operating this motorcycle after consuming alcohol or drugs.
could seriously affect your judgment. could cause you to react
more slowly. Could affect your balance and perception. Could
result in an accident.

Safe riding principles

• Keep enough distance with the other vehicles around you as

this gives you time to react.

• Always observe the rules of the road. Observe the posted

speed limit, and signal your turns well in advance.

• Know your limits. Do not go faster than you are able to control.
Always travel at a peed that is proper for the operating conditions,
your ability and experience.

• Always inspect your motorcycle each time you use it to make

sure it is in safe operating condition.

• Always follow the inspection and scheduled maintenance

procedures described in this manual.

• Test your brakes after operating in wet conditions.

• Never attempt wheelies, jumps and other stunts, as these could

cause damage to the motorcycle and cause loss of control.

• Always 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 affect

performance and awareness.

• Do not touch the engine or exhaust after riding as they will be

extremely hot right after the engine has been turned off.

• Park the motorcycle away from fuel or flammable materials.

Being seen

Many motorcycle accidents are caused by car drivers who do
not see motorcycle riders on the road. Therefore you need to
follow these guidelines:

• Wear bright clothing to increase visibility. Bright orange,
yellow or green jackets or vests and a brightly colored helmet can
help others see you.

• Always use turn signals when you are planning to turn or

merge to main roads, and turn it off after you have made your turn.

• Flash brake lights whenever you are going to slow down

quickly or where others may not expect you are going to slow
down.

• Stay out of blind spots of other motorists.

• When you come to an intersection, move to the portion of

your lane that will bring you into another driver’s field of sight at the
earliest possible moment.

6

How to keep your motorcycle safe

Get training if you are inexperienced.
Beginners should get training from a certified instructor.

Become familiar with this motorcycle at slow speeds first. Even
if you are an experienced operator, do not attempt to operate at
maximum performance until you are totally

The equilibrium and stability of your motorcycle are affected by
the manner in which you load it. It is very important that you do not
install accessories that change the design and concept of the
motorcycle. Doing so could alter the safety of your motorcycle.

Loading& Carrying passengers

You should avoid carrying passengers or large loads until you
have gained sufficient experience riding alone. Extra weight
changes handling, stability, braking performance, turns, acceleration
and deceleration. The load you carry on the motorcycle has an
important effect on your safety, as well as the life of the motorcycle;
therefore, apart from driver and passenger, it is advised to keep load
to a minimum. If you decide to carry any load, take the following into
account:

• Make sure the load is as light and as small as possible.

• 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 as possible to the center of the

motorcycle.

• Put only light load on rear rack, if installed.

• Do not attach anything to handlebars, steering, headlight or front

forks.

• Strap everything properly.

• Inflate tires properly.

Caution

The design of the motorcycle requires distribution of the
carried goods in certain extent of equilibrium and improper
arrangement of goods will adversely affect the performance
and stability of the vehicle. The manufacturer shall not take
any responsibility due to the reason mentioned above.

• Keep the load low and distribute the load evenly. An uneven

load can cause the motorcycle to drift to one side. Carrying excess
load on your motorcycle can cause an accident or crash resulting
in severe injury or even death to the motorcycle operator,
passenger or bystander. To carry passengers safely, you must
instruct the passenger before you start to:

• Wear a helmet.

• Get on the motorcycle after you have started the engine.

• Sit as far forward as possible without crowding the driver.

• Hold firmly to your waist, hips, belt or passenger handles.

• Keep both feet on the pegs at all time, even when the

7

motorcycle is stopped.

• Keep legs away from hot and moving parts.

• Stay directly behind you, leaning as you lean.

• Avoid any unnecessary motion.

To drive with a passenger safely, you must:

• Go slower.

• Start slowing earlier as you approach a stop.

• Maintain a larger cushion of space ahead and to the sides.

• Wait for larger gaps when you want to cross, enter or merge into

traffic.

Gasoline and exhaust fumes

Gasoline is highly flammable and exhaust fumes are
poisonous:

• Turn off engine before refueling.

• Do not spill any gasoline on the engine, exhaust system or

the plastic parts.

• Do not refuel while smoking or near any open flame.

• Do not operate your motorcycle in a closed area as the

exhaust fumes may cause loss of consciousness or death within a
short time.

• Do not park the motorcycle near a flame source.

• If you swallow gasoline, inhale gasoline vapor or spill

gasoline in your eyes, 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 the vehicle at

the walkway.

Passenger should attention that avoid scalded by the

muffler

Hay or rattan plant will arouse fire if too closed to the

muffler.

Modifications

Any modifications to this motorcycle, removal of original
equipment or use of unapproved accessories, may cause it to be
unsafe for use and may trigger severe accidents. Some
modifications may also make your motorcycle illegal to use on
public roadways, and will void all warranty coverage.

Your dealer is familiar with all recommended accessories for
your motorcycle, and should be consulted before installing any
accessories. The owner of the motorcycle is responsible for the
safety, installation and usage of any accessories not approved by
us.

Before installing new accessories, make sure they do not
interfere with moving parts, reduce ground clearance, and do not
interfere with the operating controls.

8

Flue-Saving tips

The way you drive your motorcycle will have a direct impact on

your fuel consumption.

• Driving at appropriate speed and avoiding sudden
acceleration or braking, is not only important for your safety and fuel
economy, but also to extend the usable life of your motorcycle and to
achieve a smoother operation.

• Driving within allowed limits inside the city will yield
surprising fuel economy.

• Always maintain tires at recommended pressure. Check
pressure weekly.

• Have your motorcycle inspected and serviced according to
the periodic service and maintenance table.

• Check that brakes are not dragging and preventing the
wheels from turning freely. Avoid riding with the rear brake pedal
pressed.

• Turn off the engine if waiting for more 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 safe riding experience, please

read this instruction book carefully.

·The pictures and illustrations in this book may be different

from the actual vehicle, due to the difference of model.

·The vehicle is specifically designed for two people (Including

the rider himself)

Caution

Do not use polluted fuel；

Using polluted fuel may possibly cause stain inside the
fuel tank, which in turn block the fuel line, and occurs failure
when the engine starts, or even cause severe damage to the
engine.

Do not use sub-standard or polluted engine oil 。

Always use decent engine oil, so the engine’s

performance and longevity can be ensured.

If any failure occurs under the inappropriate usage of
polluted oil or petrol, this failure can be worked out through
warranty

9

III、Parts Position

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

10

Rear shock absorber

Seat assy

Front wheel

Front shock absorber

Gearshift pedal

Front turn light

Rear turn light

Muffler

Pedal, rear brake

11

Speedometer

Odometer

Trip mileage meter

Tachometer

EFI Indicator

Meter reading and usage

Fuel gauge
High beam indicator

Neutral indicator

Turn indicator

12

1、Speedometer

Indicate motorcycle speed (Km/h). Do not exceed legal

rate-limiting to assure safe riding.

2、Odometer

Indicate riding distance (Km).

3、Turn indicator

（R）right turn，twinkle when turn to right(Green).
 （L）left turn，twinkle when turn to left(Green).

4、High beam 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 nearest fuel station once indicator turn on.

8、Trip mileage meter

It shows the mileage of trip in kilometers.

9、Zero Knob

Indicate distance from Zero, by rotating Zero Knob to the

Direction of Arrow can return it to Zero.

10、EFI Indicator

Indicating EFI system situation

13

IV、Switch operation

1. Switch instruction

Main Switch used to Start or switch off the engine .

Position

Function

Remarks

To stop the vehicle (switching off all
circuits)

Can

For starting or driving the
vehicle(making all the maincircuits)

Can not
To lock the steering handle

Can

Caution

Do not move the Key position when riding, if the key is on

position during riding, all electric 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 motorcycle, make sure the handle bar

is knocked.

If the engine is not started when the key is put on

position, the battery will discharge.

Do not use the key with other sharp Metal keys or key box

，

in case of scratching the upper board or leads to other kind of
lost（suggest to use cloth or leather made key box）。

Key

The same key will operate the ignition switch, steering lock, fuel

cap.

14

2. Switches on right handlebar

 Electric start button

Push this button, make the engine start.

 Emergency Cut-off Switch

Emergency cut-off switch used to Switch off the motorcycle

by hand; under normal situation, assure it used when position on

, but not .

Caution

Emergency cut-off switch only used under urgent

situation.

During riding, turn the switch from to

will cause

dangers, and damage the engine.

Use Emergency cut-off switch to stop the engine should
make sure that the Main Switch on position; if on
position and engine powered off , the battery discharged.

If put the Switch on

position, the engine cannot be

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 Near Light Lamp Instruction
Press the button, the use of far and near light switch can control

the distance light

（ ）headlight on full beam
（ ）headlight on lower beam

 Directional switch
Use indication switch when turning Left and right.
If put main Switch on“ ” position, the indicator will wrinkle.
Slide Direction indicator can stop the turning signal Operation.
（R）Turn Right
 （L）Turn Left

Caution

when finished turning, the direction indicator switch will not

be back to original position automatically, please switch it
manually.

Driving with light on will obstruct traffic.

Electric Start Button

Emergency Cut-off Switch

15

 Horn button

When the main switch at “ ”, press horn button , it will

make a sound.

 Overtaking lamp switch

According to Ultra Lights, headlights flashing, to indicate the

vehicle in front to overtake.

4. Fuel filling

The capacity of the fuel tank is 13L. Lead free gasoline of
No.93III(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
tank by the cover and take out the key.

Caution

To ensure the engine is stopped and far away from fire

before adding fuel.

Fuel will spill if the fuel is up to the underline of level card .

Horn

Light changing switch

Overtaking lamp switch

Directional Switch

Fuel tank cover

16

5. Gear shift

①When you ride on the motorcycle and the engine is idling,
disengage the clutch and push the gear shifting pedal down
by left foot fingers to change the gear from neutral to 1st gear
position.

②Gradually turn the throttle twist grip to increase the speed
of the engine to about 3000 r/min, and slowly release the
clutch lever until the motorcycle start to move, with a good
coordination between the two operations of throttle and clutch
to ensure a natural riding start.

③When the motorcycle reaches a balanced state of
running, return back the throttle twist grip and disengage the
clutch again, and then push up the shifting pedal to change
the gear to the 2nd position.

④The gear can be shifted up to 3rd-5th gear position in the
same way.

⑤If you push down the shifting pedal instead of push up,
you can change down the gear position.

Gear down operation

If you want to speed up drastically, for example, when
passing another motorcycle, gearing down can provide faster
acceleration, but if the speed gets too high, damage for the
engine may be caused by over-speed.

6. Blind spot mirrors

Blind spot collisions are one of the principal causes of accidents

in high density traffic. To help broaden visibility,

Fashionable designed mirrors with built-in blind spot windows.

They provide extra range so riders can change lanes with confidence.

5
4
3
2
N
1
R

Shifting forward
Shifting backward

Blind spot collisions

17

7. Clutch lever

The clutch lever located on the left side is used to
disengage the transmission when vehicle is not moving, and for
shifting gears. Pull lever in completely before shifting. Once gear
has been engaged, slowly release the lever.

8. Throttle

The throttle controls engine rpm (speed). To increase
engine rpm, rotate the grip toward you. To reduce engine rpm,
rotate the grip away from you. The throttle will automatically
return to the closed position (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

slide down。

When riding in rainy day or on wet road, when brake
suddenly, accidents will occur, so please speed down and use
the brake properly。

Avoid repeat brakes and overheat the brake, which will
cause the brake lose effect.

Front brake lever

The front brake lever located on the right hand side is used to

slow down or stop the vehicle.

Rear brake pedal

The rear brake pedal is used to slow down or stop the vehicle.

Clutch lever

Throttle

Front brake lever

18

10. Parking lever

Turn the parking lever to the left side tightly.
How to release it:
Pull parking lever to the right side, it will return automatic to its
position, the front brake will be relieved at the same time.

Caution

When starting the engine or parking the motorcycle,
apply the parking lever to lock the front wheels to prevent
the motorcycle from moving and causing the risk of hazard.

If the play of the brake handle 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. Replace the damaged seat

belt immediately.
＊ Do not use the seat belt if the motorcycle does not have the safety
frame.
To fasten:
Connect both segments of the belt with the buckle.
To unfasten:
Press the red button on the buckle to release the seat belt.
Connect both segments of the belt with the buckle, being careful to
avoid twisting of the belt, adjust the belt length, being suitable for the
operator.

Rear brake pedal

Parking lever

19

Engine cycle tube

Oil-out line

12. Oil output tank

1、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 shall be installed
in the face of location of the wind。

20

V、Basic operation and riding

Before riding your motorcycle, please revise the safety
messages given in the first pages of this manual.
In this section, we will describe important notes and techniques
in order for you to safely ride this motorcycle. Please read this
manual thoroughly and spend some time practicing on your new
motorcycle. Pay attention on your safety and that of others.

Engine starting

Set the key of the ignition switch to “ ”position.
Set the emergency stop switch to “ ” position.
Ascertain the gear is in neutral position by checking the

neutral position lamp is lighted.

Ascertain the fuel level in the tank.

To start engine :

Start the engine by the electric cell motor. Each time you
push down the start button, it is recommended that you stop
pushing when firing sound of the engine combustion is heard and
the engine is fired and running. If the engine is not firing, please
stop pushing down the start button in 5 seconds, and wait for
more than 5 seconds before next start.

Slightly turn 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 engine running at a higher speed so as to
warm up the engine for about 10 seconds or more.

Caution

The engine can only be started when the gear is in neutral

position or clutch is OFF. Otherwise accident may happen.

Unnecessary long time idle running (especially at a high

speed) may be harmful to the engine.

To stop engine running:

You can also stop the engine running by turn the ignition key to

“

” position to cut off all electrical power.

If the start fails

If the engine can’t be started, or the motorcycle is not moving,

the points below should be checked：

·If there is fuel in the tank

·If the motorcycle is properly operated according to the

instruction book shows

·If the fuse is melted

·If the engine start button is working properly

·If the battery is finished with power which cause the engine

start button not working, please try the kick start

Run-in of engine

Run-in of the engine is very important. Any operation without
run-in (or improper operation) will cause serious damages or failures
of function

21

A. Engine without run-in and the one have been run in have

big difference in their power and torque performance.

B. The well run-in engine: the initial wear-out of the parts is
well renewed, which eases the damage to the parts in fierce
movements, and extend the service life of the engine.

C. Requirements

1). Never fully open the throttle when the new motorcycle

has not been ridden for more than 350km.

2). When riding in each gear, the speed should less than
80% of its allowed speed (the opening of the throttle should be
less than 80%), and shift the gear in time.

3). Do not let your engine bear too much load in the first
350km.

Maintenance of the engine:
A. When the engine has run in for 800-1000km, a duly

check should be taken.

1). Replace the engine oil (the capacity of the engine oil is

1.8L)

2). The adjustment of the valve clearance inside cylinder
head is allowed

B. After finishing 800-1000km run-in, please activate

ordinary maintenance.

1). Check the spark 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 must be checked and

maintained on time.

Please make sure thorough inspection for the vehicle is finished

each time before you ride.

1、Engine oil level checking: Insufficient engine oil will cause

earlier abrasion, and damages.

2、Fuel level checking, tighten up the fuel tank cap, and check if

the fuel pipe is twisted.

3、Transmission chain checking, loosen chain will fall out of the
sprocket, severely worn out chain may break, insufficient lubrication
may cause the abrasion to the chain and sprocket, and if the chain is
getting too tight, then the transmission system will be suffering extra
burden, which in turn abase the chain or break the transmission.

4、Check the tire, to see if the tire is under abrasion, tire with
scratch or grooves abnormal should be replaced, the tire treads
depth should meets the legal regulation, moreover, tire pressure
inspection is also crucial. Both factors mentioned above is key to the
motorcycle performance and safety.

22

5、Brake system checking, to see if the brake system is
working normally. Brake fluid amount and the state of the brake
shoe should be checked. The brake fluid checking should be
done before the engine started, if the level of the fluid is lower
than the minimum level line, the cause maybe leaking or the
abrasion of the brake shoe. To avoid the utter incompetence of
the brake system. Please go to SHINERAY’s technician for
professional inspection and suggestions, we will also help you to
check the condition of the brake pipe, disk and brake shoe, also
the distance of the brake lever and pedal.

6、Cable checking, Please check if all the cable for control
is correctly installed, and moves smoothly.

7、Throttle checking, check the throttle grip, throttle cable to
see if there is enough gap, and if the acceleration process is
smooth, and turning off process is fast and clear.

8、Clutch checking, the cable should have enough gap to
move, and can move smoothly.

9、Lights and horn checking, please kindly check if the
illumination and the horn 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、Steering bar adjusting, sit vertically on the seat, check if

the steering bar is at the best position for your safe and comfortable
operation, also without the tangle of cables..

Caution

When you check, please make sure your conformity to the

safety rules and law.

The exhaustion contains harmful gas, like CO, so please
make sure when you make the checking with the engine started,
and keep it in ventilated place.

The checking should be launched in flat and hard ground,
with stable support.

Watch out for fire when the engine is just switched off,
because the engine and muffler are still quite hot then.

Before you repair or mend, the engine should be switched
off and the key should be pulled out.

If the problems still exist after calibration, please
immediately get contact with our authorized workshops, dealers
or appointed repair shops.

Operation

•Shift the gear properly according to the motor speed,

•In order to keep the fuel consumption at a lower state, and

also to ensure the longevity, please do not accelerate or decelerate
too drastically。

23

Running in

Make 1000km running in at the speed of 6000rpm, this can

provide better longevity

Caution

Always start the vehicle from gear I, and make the

starting process as slow and carefully as possible.

During the riding, if there is any abnormal noise, please
contact the authorized distributors for inspection, and take
necessary step.

Keep the speed under the legal limit.

Looking at the terrain

＊ Watch your speed and control technique when you ride
on excessively flat, loose and rough surface, and keep an eye on
any potential hazards such as pits, water puddles, rocks, root
blocks, etc to avoid the risk of an accident.

＊ Driving forward out of ditch or muddy conditions, or up
a steep slope, could cause the motorcycle to up over backward.
If the mud is deep enough it will keep the wheels from turning.
Then, the motorcycle will rotate up and back around the axle very
quickly. When stuck in muddy conditions, do not remove the
implement or ballast weight. Always back out.

Avoid tipping over

＊ When starting the motorcycle on an uphill slope, shift
to as 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 over,
especially on hillsides or steep slopes.

＊ When operating the motorcycle on a slope, set the wheel
tread as wide as possible for maximum stability, reduce the engines
speed and avoid quick application of the brakes or sharp turns.

＊ Stay off hills and slopes which are too steep.

＊ When operating on slopes or rough uneven ground, it is

important to have as much distance as possible between the wheels.
Operate the motorcycle carefully at the lowest speed.

＊ When riding with poor visibility, e.g. riding at night, turn on
the headlight and slow down your speed to ensure safety.

Making turns

When you approach a turn, first slow down and smoothly turn the
handlebars to the direction you are going. Also, move your gravity to
the outer floor panel and tilt your upper body to the inner side of the
turn, which enables your control at the turn to be smoother and safer.

Warning

Do not make a sharp turn at high speed. Drive motorcycle

with care especially when turning at high speed.

Going downhill

Place your gravity as backward as possible and straighten

24

both of your arms. Keep the motorcycle in balance and apply the
rear brake to slow down your speed.

Unless otherwise necessary, do not press the accelerator

lever.

Do not apply only the front brake to avoid the motorcycle

flipping over.

Do not allow the motorcycle to coast downhill with the gear

shift in neutral.

Going uphill

When going uphill, move your gravity as forward as
possible. Also, sit in the front part of the seat and bend your
upper body forward. Keep a steady speed in the uphill process
and keep the motorcycle balanced.

Caution

If the slope is too high to proceed and the motorcycle is
moving backward, apply the front brake to slow down and
carefully control the motorcycle to slip down. If it is beyond
control, the rider should immediately get off from the left
side to avoid the risk of being 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 water current and its depth if riding through
water is necessary. If water flows very fast or is deep, the
performance of the motorcycle will be affected, which may cause
unsafely to the rider.

Warning

Do not ride across a river with fast current or great depth
to avoid loss of control of the motorcycle and cause risk of
hazard to the rider.

After crossing the water area, you should check that the
brake function is normal. If it is not, slow down your speed and
also intermittently apply both front and rear brakes to restore
the brake function.

If it takes a long period of time to ride through the water
area and the brake system submerges in water too long, it will
lead to loss of brake function. Do not ride this motorcycle any
longer and take it to the nearest service center for inspection
and servicing.

25

VI、Inspection and adjustment

Maintenance Period Table

Maintenance times

Maintenance Items

Period

Odometer km (Remark 2)

2000

k m

4,000

km

8,000

km

12,000

km

Remarks

* Fuel system passage

I I I

** Fuel precision filter

Replace for every 15000km driving

* Throttle operating system

I I I I

* Throttle valve body

I I I I

Air filter element

Remark 1

C C R

Replace every 8,000km driving

Oil catcher

C C

C

Clean for every 5,000km driving

Spark Plug

I I

I

Replace every 15000km driving

Engine lubricant 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 intake and exhaust

Remark 3 I Check every 8,000km driving

Clutch

I I I I

* Driving chain

Proceed with I and L for every 500km driving

** Front and rear brake system

I I I I

** Brake Pad

I I I I

** Brake fluid

Change every 2 years

* Front and rear brake lamp switch

I I I I

* Accumulator

Monthly

I I I

I

* Suspension system

I I I I

* Nut and 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

26

Maintenance shall be carried out to the motorcycle in a specified period. The meanings of various symbols in the list are as follows:

I: Carry out inspection, cleaning, adjustment, lubrication or replacement.
C: Cleaning. R: Replacement.
A: Adjustment.
L: Lubrication.

Caution

It is mandatory to replace parts and lubricants according to the maintenance table.

Periodic maintenance is a combination of verification and service operations performed through Approved Service Center network, to
properly maintain your motorcycle. It is normal 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 the motorcycle. These
interventions do not constitute flaws in the motorcycle; on the contrary, their purpose is to prevent any problems for your motorcycle to
continue operating properly.

This section introduces the inspection and adjustment of various parts of the motorcycle. It also introduces the technical requirements for
the inspection and adjustment.

Unless expressly stated or indicated in the maintenance period table, check and adjust all parts of the XY400 motorcycle
according to the contents hereof before using it.

27

1. Check-up of spark plug

①Remove the spark plug cap. Remove the spark plug with a
socket wrench. Visually check whether there is any damage with
the spark plug insulator and ablation with the electrodes. If yes,
replace them.

②Check the spark plug electrode gap with a plug gauge.
Spark plug electrode gap 0.6 -0.7mm. Carefully adjust the electrode
gap. Then clear away the accumulated carbon and contaminants
with a spark plug cleaner or string wire. Check that the spark plug
sealing gasket is in good condition.

③To mount the spark plug, manually screw up the spark plug
first, and then tighten it with a socket wrench. Put on the spark plug
cap.

The 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 and the upper eyehole

cover.

Turn the crankshaft pulley Counterclockwise to align the scale

line “I” with the indication mark “ ” on the front-left cover.

Caution

At this point, the piston must be at the upper dead point
of the compression stroke other than that of the exhaust
stroke.

Remove the cam phase sensor on the right of the cylinder
head, and check whether the boss of the driven sprocket is in the
center of the cam phase sensor hole. If observation is difficult due
to the narrow space, use a small reflective mirror to help
observation.

Upon completion of inspection, mount the cam phase sensor,
eyehole cover and upper eyehole cover in turn.

28

3. 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 more than 3

minutes, otherwise level may not be accurate.

• 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。

Change engine oil every 2000 Km at an Approved Service
Center. Recommended oil: high quality 4-stroke machine oil ,as
Class SAE 10W40 or 15W40 API SF / SG, JASO MA. in viscosity
will help maintain a long service life of the engine .In case those are
not available ,a substitute suitable 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 the oil level in the engine oil dipstick
reaches the upper-middle limit. Then insert the oil filter plug and
screw it up.

Replacement of lubricating oil

While replacing lubricating oil, it shall be carried out before the
engine has cooled down. This will ensure quick and complete
discharge 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. Finally, insert the oil drain plug.
Unscrew the oil filter plug and slowly refill 1.8L new engine oil of the
specified trademark into the crankcase, then insert the oil filter plug.

Upper scale line

Lower scale line

Engine oil level is between the upper and lower
scale lines

29

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.

While cleaning, you should unscrew the oil drain plug to 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".

Cleaning and Replacement of Lubricating Oil Filter

Remove the engine oil filter cover to detach the engine oil
filter element, clean the filter cover and filter element with cleaning
agent, and then mount the clean engine oil element. Replace with a

new one as required.

Check for damage of the engine oil filter cover and its

O-shaped sealing ring; replace with a new one as required.

Mount the engine oil filter cover and screw up the bolt to the

specified torque.

Notice

Before the crankcase is refilled with fresh engine oil, the

engine oil filter must be cleaned.

Screw plug for oil draining

Remove oil filter cover

Oil filter

30

4. Valve clearance

Noise will stem from too big valve clearance. However if

there is too small gap or even no gap at all, closing of 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 adjusted on a
cold engine by the following procedures:

Remove the caps of the central hole and the ignition timing
observation hole on the left crankcase cover.

Remove the caps of the two air valves on the cylinder head.

Turn the nut of the flywheel clockwise until the engraved “T”
mark on the flywheel aligns with the engraved line on the top of the
crankcase cover, and both intake and exhaust rock arms do not
move but stop at their loosest position, which shows that the piston
is in its top dead 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 stroke but exhaust/intake stroke. In this case,
continuously turn the flywheel clockwise for 360 degrees to the top
dead center position of the compressing stroke, where the valve
clearance can be adjusted. Afterwards, check the valve clearance
by inserting a clearance gage into the gap between adjusting screw
and the end of the valve.

The specified valve clearance is : 0.07-0.10mm for intake

valve and 0.08-0.12mm for exhaust valve respectively.

If clearance adjustment is needed, loosen the locking nut on
the rock arm, turn the adjusting nut till a slight resistance is felt on
the inserted right clearance gage.

At the end of the adjustment, tighten the “Locking out ”to
prevent loosening and another check to make sure that the valve
clearance is OK before all those dismounted caps are refitted on.

Eyehole cover

Upper eyehole cover

31

5. Check-up, cleaning of air filter

Take out the air filter and check if it is contaminated.

Dismounting:

Open and remove the right side cover,
Remove 4 screws, remove Air filter cover

Cleaning:

Wash the filter in clean washing oil and wipe it dry with dry
cloth. Soak the filter element in clean engine lub oil. Squeeze it dry
and fit 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 element for use must be intact or the
engine will suck in dust and dirt, resulting a shorter service life
of the engine.

Water should be prevented from entering into the filter
in washing the vehicle.

The filter shall never be cleaned with gasoline or any
other agent of a low ignition point.

Air cleaner cover

Air cleaner element

32

6. Idle speed

Caution

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 adjusted upon
delivery, do not adjust the idle speed adjusting screw as desired. In
case the idle speed is unsteady, zero or too high, find out the
possible causes with the troubleshooting method for the EMS
system and eliminate the trouble.

Under the monitoring of the maintaining and 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,

and at this point, the idle speed is unstable 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 above two cases, unscrew
the retaining nut and adjust the idle speed adjusting screw to let the
intake flow reach the specified flow.

Idle speed 1500 r/min ± 150 r/min.

After adjusting toe-in, remember to screw up the retaining nut.

Adjusting screw

Maintaining & diagnostic instrument

33

7. Throttle control

First, check whether the throttle control line is deformed,
twisted or damaged.

Then, measure the throttle bar free stroke. Turn the bar to
lean it against one side of the free stroke, and draw a straight line
between the bar and the balance weight with a mark pen, and then
turn the bar to lean it against the other side of the free stroke;
measure the distance the straight line staggers, i.e. the throttle bar
free stroke.

Free stroke 2-6mm.

If the free stroke is insufficient or too big, make adjustment.

Adjusting methods:

Fine adjustment:

Pull open the rubber lagging, 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 the fine adjustment is not satisfying, separate the throttle
control line with throttle valve body and unscrew the retaining nut B
to make adjust the free stroke in a larger range. Screw up the
retaining but B after the adjustment.

Check whether the throttle can turn smoothly from full open to
full close at any position. If there is clogging, adjust or replace it.

Warning

Use not full throttle to the free stroke motorcycle is a
dangerous operation, rotating the handle, not full throttle to
the free stroke can make the engine speed increases suddenly.

Retaining nut A

Retaining nut B

34

8. Brake system

The front brake and the rear brake and the side brake is disk
type, due to the abrasion of the brake shoes, the brake fluid will be
getting less as time goes by.

The performance can’t be adjusted, but the brake fluid level
and brake shoe abrasion are the two most important factors, that
need to be checked on time.

The brake system should be checked frequently, to ensure
there is no leaking.
Front Brake

Good and bad of brake function concern the move ment
security，that adjust the brake correctly is very important．

Check the front brake handle free stroke.

The brake handle free stroke 10-20mm

Warning

brake fluid will arouse inflammation , should avoid being
touched with skin & eyes. Once touched, should clean clearly
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 the
level is too low but not emptied, directly refill brake fluid (DOT 4
brake fluid).

If the brake fluid inside the cylinder is found cloudy, impure or
smelt, Drain and refill the brake fluid.

If the brake fluid in both the front and the rear cylinders is
drained, bleed air from the deflating valve of the brake caliper with a
vacuum pump, and then refill brake fluid into the cylinder. This
model has total of 3 brake calipers, wherein, the rear brake caliper
interlocks with the side brake rear caliper (controlled by rear brake
pedal), therefore, the vacuuming process shall be carried out
simultaneously for the front brake caliper and side brake front
caliper and for the rear brake caliper and the side brake rear caliper.

10 – 20mm

35

Brake fluid vacuum filling method:

This method is only applicable to refilling brake fluid for new

vehicles or when the brake fluid in the cylinder is drained.

Open the cover of brake cylinder cover and refill brake fluid.
Actuate the brake handle or pedal, exhaust the air in the dead

corner of the brake caliper.

When the vacuum pump has fully exhausted the air inside the
brake caliper, after the brake fluid is pumped out, firmly nip the
handle or completely push down the pedal and quickly screw the
deflating valve bolt, with the torque being 7-9 N.m.

Mount the brake cylinder cover with the sealing

gasket flattened, and replace with new sealing gasket as
required.

After refilling, check the oil cup, hydraulic brake hose and all
connecting pieces for leakage.

Make up the brake fluid

·Turn the handle bar and make the pump cylinder be

horizontal with the ground.

·wipe out the dust and 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 attention for diaphragm
to avoid no foreign matters in.

Warning

Brake fluid will arouse inflammation , should avoid being
touched with skin & eyes . Once touched, should clean clearly
with water, furthermore, if touched with eyes , must go to
hospital .

Storing in the area where child cannot touch.

Caution

Brake fluid supplement can not exceed the upper, so
that the liquid outflow.

supplementary brake fluid due to special care, don't let
the dust or water into the cylinder.

If the brake fluid is obviously reduced, is a sign of failure
automatic system.

Avoid chemical reaction, the brake fluid is not available
from different manufacturers.

Do not allow the brake fluid contact vehicle parts, so as
not to damage the painted parts.

Brake piece checking

Operating brake, if the wears limit line of the brake shoe touch
to the side of the brake disc. It shows that the brake shoe has
touched the wear limit.

36

Brake piece checking

Operating brake, if the wears limit line of the brake shoe
touch to the side of the brake disc. It shows that the brake shoe has
touched the wear limit.

Warning

When it is replaced with a new brake strip or brake disc,
do not drive it immediately; instead, drive it after holding and
releasing the front brake handle until the brake 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 adjusting the rear brake adjustment nut. Twirling the
nut to adjust the pedal stroke. Pushing the brake pedal by hand till
feeling resistance . Validation the pedal free stroke whether is in the
scope of regulations.

Brake pedal free stroke：18-25mm

The rear brake caliper interlocks with the side brake rear caliper
(controlled by rear brake pedal)

Adjustment nut.

37

9. Running system

Tire specifications and tire pressure

Check the tire pressure with a tire pressure gauge to see
whether the pressure conforms to the recommended value.

Tire specifications and recommended tire pressure:

If the tire pressure can’t reach the specified requirements,

check the tire for cuts, embedded iron nail or other sharp articles.

Caution

The tire pressure measured when the tire is cooled down
shall be the correct tire pressure.

Spoke

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, replace it as soon as
possible.

10. Clutch control line

Check the clutch operating handle free stroke. Clutch

operating handle free stroke: 10-20mm.

Adjusting methods:

Fine adjustment: Pull open the rubber lagging, unscrew the
retaining nut, and turn the adjusting nut to adjust to a satisfied free
stroke. And then screw up the retaining nut and mount the
protective rubber lagging.

Front wheel tire pressure

Spoke nut fastening tool

10-20mm

Rear wheel tire pressure

38

Coarse adjustment:

If a satisfactory free stroke can't be achieved by fine
adjustment, remove the clutch control line on the handle end to
adjust the engine end.

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 adjustment.

Caution

Always ensure the clutch operating 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

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.

Driving chain tension: 20-30mm.

If the chain is too loose or too tight, make adjustment.

Adjusting methods:

Unscrew the rear wheel spindle nut and turn the adjusting bolt

Adjusting Nut
Retaining nut

Adjusting Nut
Retaining nut

Retaining nut

39

on the chain adjuster until the specified tension is achieved, and
then fasten the rear wheel spindle nut, and check the flexibility for
free rotation of the rear wheel and the consistency of the front and
rear wheels.

Caution

The scale lines of the chain adjuster on both sides must

be consistent with each other.

Warning

The rear wheel spindle nut must be firmly screwed up to

the tightening torque of 50-60N.m.

Clean and inspection of chain

First, remove the chain by detaching the spring locking pieces

and the removable chain plate.

Use cleaning liquid to wash the driving chain and remove dust

and mud, and then air dry it; check the chain for abrasion or
cracking, and replace 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 left and right scale
lines of the chain adjuster shall be consistent and the chain swag
(tension) shall be 20-30mm.

Inspect the abrasion of major / minor sprocket. In case of
serious tooth abrasion, teeth missing or broken teeth, replace it.

Caution

This model uses the oil seal chain, so the selected
washing oil shall be in corrosive to the oil seal; while
assembling the chain, the locking piece coupling spindle shall
be coated with appropriate amount of chain-specific
lubricating oil.

Warning

While mounting the spring locking pieces, its opening
end shall be in the opposite direction with the normal
movement of the driving chain.

Unscrew the rear wheel spindle nut

Adjustment

40

12. Battery checking

Open the left side cover.
Clean away dust and corrosive from the surface of the battery.
Remove the negative, then the positive pole of the

accumulator; unscrew and remove the loosen battery strap

.The battery is free of maintenance. There is no need to check

the electrolyte level. Clean the battery terminals regularly.

The condition of charging will significantly influence the life

length of the battery.

Seriously corroded conductor connectors of the battery shall

be replaced.

To remove the battery

Open the battery box，firstly disconnect the negative pole,
then the positive pole. Remove the battery and replace with a new
one (of the same type and specification), then connect the positive
pole first and the negative pole last.

Installation of accumulator

Installation is in the reverse order of removal. While connecting the
poles, connect the positive pole first.

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 battery.

The charging amperage and time of charging should not
exceed the required standards. Charging at high amperage will
negatively influence the life of the battery.

Please regularly use special charging devices to charge the
maintenance free battery. You can also apply such device to test
overload voltage, the stability of the battery. In addition, this
charging device will avoid overcharging of the battery.

If you find the battery is out of charge when starting the
motorcycle, please charge the battery as soon as possible. Battery
will be damaged if it stands in a status of being uncharged for a long
period.

Caution

1 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.

2 Never fill in tap water, because this will shorten the

41

accumulator’s life span.

3 To dismantle battery ,disconnect the

negative(-)electrode before the positive(+)one, and vice
versa in installation .Ensure against any contact of the
positive(+)electrode with the vehicle body.

4 Never have the electrolyte level come over the upper

mark line when adding distilled water .Otherwise
overflow and corrosion will occur.

5 The electrolyte contains sulfuric acid and will cause

serious hurt to skin and eyes by contact. In case of
contact with it, wash it off for 5 minutes and see a doctor
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 switch to “OFF” position. The specified fuse

tube of 15A 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.
If the new fuse tube is broken again as soon as it is fitted on, it
means that somewhere of the electric parts is shorted
unexpectedly.

Caution

Do not use any fuse over 15A/10A.

Be sure not to wash the battery when washing the
vehicle.

Negative (-) Connector

Positive (+) Connector

Fuse

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

43

Combined rear position lamp

 Loosen the screws, remove the taillight lampshade
 Lightly rotate taillight seat, take out the seat and bulb.
 Lightly press bulb, rotate in counter-clockwise.
 Install new bulb in opposite order as below.

Taillight bulb：12V21/5W

Turn signal light

 Loosen the screws, remove the lamp lampshade
 Lightly press bulb, rotate 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
maintenance period table. And check all the cotter pins, safety
gripping gears, locks, etc.

17. Vehicle washing

Cleaning the motorcycle
To keep a good looking of the covers, please wash your motorcycle
often.
The best way to clean your motorcycle is to use warm water
combining with detergent to mop up the dirt before using water to
clean up.

44

Attention: If you use high-press water to wash the motorcycle,
please do not point the squirt gun at the electrical parts, plug,
cables, bearings and ECU, etc. The high press would let the water
get into the parts and lead to the failure of function and premature
aging.

-Please use ordinary detergent brands to clean your motorcycle, for
the dirtiest places, please use brush to clean.

-Plug up the muffler before cleaning with water to prevent water
getting into the inside muffler.

-After cleaning with water, please mop up the motorcycle with
clothing or just dry off. Ride for a distance until the engine has
reached a working temperature; meanwhile apply brake to
evaporate the water left inside the parts.

- Since the motorcycle cools down, please grease all the sliding
parts and bearings with lubricating oil and butter, meanwhile grease
the oil plug with lubricating oil.

- In order to avoid any sundries getting into the electronic 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 washing, please block up the muffler to avoid the water
getting into the muffler and engine.

18. Maintenance in Non-use Time

For the motorcycle to be stored for a long period of time, attention
should be paid to the prevention of moisture, sunshine and rain
attack in order to protect it from unnecessary damage. Special
check-ups should be carried out on those important parts and
subassemblies before storage.

①Change lubricating oil.
②Grease the chain.
③Dismantle the battery and put it in a shady, cool and

well-ventilated place. It is suggested that the battery be charged
once a month to preventing it from over discharged and out of
function.
④Clean the vehicle and apply antirust oil to the part vulnerable to
rust.
⑤Inflate the tyre as required and support the vehicle up with the
main stand.
⑥Take out the ignition key and keep it in your well planned place
for easy resumption of service.
⑦Put the covering over the motorcycle.

45

19. Resumption of service

①Remove the covering and clean the vehicle. Change the
lubricating oil if the vehicle has been off service for over 4 months.

②Charge the battery and remount it.
③Filling new fuel to the required level, or replace in-tank

deteriorated fuel with new fuel if the motorcycle has not been used
for more than 4 months and the engine can not be started.
④Prior to driving, test the vehicle at low speed in a safe place.

20. Special notice

Keep safe distance

Don’t obstruct the traffic.
Don’t drive on footpath.

Overtake from the left side lane.
Make sure brake at anytime
Stop for while should 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.

21. Driving

Before start, look around to avoid accident
Take back the stander, ride on motorcycle
Turn on turning light, release brake, make sure the safe situation
and then drive.

Warning

Put side stander in original position, if not it will cause

accident.

Only drive on vehicle road, if drive on footpath will lead

accident.

Drive on uneven road in high speed, will lead rollover and

hurt.

Don’t drive on grit road, if grit enters in engine or tire, will

cause rollover and hurt.

If possible, don’t drive near seaside or Calcium chloride

road, muffler, some other outside parts, and jointing position
are easily rust.

46

VII、 Engine management system

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. Based on the air flow and engine
speed, the fuel injector and ignition coil are controlled by ECU to get the optimal combustible mixture of fuel and air and Ignition timing which
meet all engine operating conditions. The EMS use sensors to collect parameters such as air flow, temperature of inlet air, cylinder head
temperature, atmospheric pressure and the operation state of engine (rpm, load, acceleration and deceleration). All parameters are
transferred 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 valve and so on), the fuel and fire are exactly controlled and corrected
with closed loop. For production conformity, corrected fuelling in order to match up to the difference of vehicles due to the inconformity of
components.

System composition:

1. Sensor:

• Intake air pressure sensor (load information) intake air temperature and pressure sensors

• Throttle position sensor (load information, load range information, acceleration/deceleration information)

• Engine speed sensor (speed information, crankshaft position)

• Intake air temperature sensor (air density information)

• Oxygen sensor (information of the excess air coefficient is more than 1 or less than 1)

2. Actuator:

• Fuel pump relay,

• Fuel pump

• Fuel injector (fuel supply)

• Ignition coil

47

• High-tension cord

• Spark plug (ignition)

• 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 Head Temperature Sensor

Throttle body

48

Maintenance of Engine management system

Because of the EFI, there are many possibilities for the engine issues. In other word, one issue may be caused by the mechanical problem
or the EFI components. And the diagnostic tools cannot 100% indicate the root cause. So this manual shows the way to dig out the root cause
with the help of the diagnostic tools.

Maintenance matters 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 connectors.

3) Make sure the temperature of the ECU is below 80℃.

4) The fuel pressure is much high ( about 250kPa), so please do not disassemble the fuel pipe arbitrariliy. If have to, pleae release the

pressure at first, and make sure the operation is dilivered in the ventilated environment by the the professional mantenance persons.

Electronic control unit( ECU)

Oxygen sensor

49

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.

7) The ignition system check only could be delivered when it is nessasary. When check the spark plug out of the engine, if start the engine,

please make sure the throttle is closed. Or too much unburned gasoline coming to the catalyst may damage the catalyst.

8) The idle speed is adjusted by the ECU. The idle pintle is not alowed to adjust.

9) The Positive and Negative of the battery cannot be reversed. It may damage the EFI components.

10) It is forbidden to remove the battery when the 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 multimeter below means the digital type. Pointer-type is forbidden.

3) If the malfcode shows the voltage is low, it means maybe the wire is short to ground. If the malfcode shows the voltage is high, it
means maybe the wire is short to battery. If the malfcode shows the components signal abnormal, it means the wire is open or
short to other wires.

Diagnostic help：

1) If the malfcode shows again after clearence, check whether the connector is connected well.

2) Do not ignore the affect of the engine maintenance situation, the cylinder pressure, and the mechanical ignition timing.

3) Change another ECU to do the test. If the malfcode disappears, the root cause is the ECU. If the malfcode is still there, then use
the old ECU to do the test.

50

OBD Service $01

PID

Description

PID

Description

00

Request supported PIDs from PID 0x01-0x20

0E

Ignition Timing Advance for #1 Cylinder

01

01 Monitor status since DTCs cleared

0F

Intake air temperature

03

Fuel system status

11

Absolute throttle position sensor

04

Calculated Load Value

13

Location of oxygen sensors

05

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 Fuel Trim-bank1

21

Distance Travelled with MIL Commanded On

08

Short Term Fuel Trim Bank2

40

Supported PIDs 41h - 60h

09

Long term Fuel Trim-bank2

4D

Engine run time while MIL is

0B

Intake Manifold Absolute Pressure

60

PID used to determine PID support for PIDs 0x61 – 0x80

0C

Engine speed

7F

Engine run time

0D

Vehicle speed

51

OBD Service $02

PID

Description

00

Request supported PIDs from PID 0x01-0x20

02

DTC that caused required freeze frame data storage

03

Fuel system 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 position

20

PIDs $21 to $40 which are supported by the Powertain controller

60

PID used to determine PID support for PIDs 0x61 – 0x80

7F

Engine run time

52

OBD Service $03

System or Component

DTC
Number

DTC Description

Related Calibration

HEX

DEC

Manifold Absolute
Pressure Sensor (MAP)

P0107

MAP Circuit Low Voltage or Open

KsDGDM_MAP_ShortLow

107

#N/A

P0108

MAP Circuit High Voltage

KsDGDM_MAP_ShortHigh

108

#N/A

Intake Air Temperature
Sensor (IAT)

P0112

IAT Circuit Low Voltage

KsDGDM_IAT_ShortLow

112

#N/A

P0113

IAT Circuit High Voltage or Open

KsDGDM_IAT_ShortHigh

113

#N/A

Coolant/Oil Sensor
P0117

Coolant/Oil Temperature Sensor Circuit Low
Voltage

KsDGDM_CoolantShortLow

117

#N/A

P0118

Coolant/Oil Temperature Sensor Circuit High
Voltage or Open

KsDGDM_CoolantShortHigh

118

#N/A

Throttle Position Sensor
(TPS)

P0122

TPS Circuit Low Voltage or Open

KsDGDM_TPS_ShortLow

122

#N/A

P0123

TPS Circuit High Voltage

KsDGDM_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 Circuit High Voltage

KsDGDM_O2_1_HeaterShortHigh

32

#N/A

P0031

O2S Heater Circuit Low Voltage

KsDGDM_O2_1_HeaterShortLow

31

#N/A

Fuel Injector
P0201

Injector 1 Circuit Malfunction

KsDGDM_INJ_CYL_A_Fault

201

#N/A

P0202

Injector 2 Circuit Malfunction

KsDGDM_INJ_CYL_B_Fault

202

#N/A

Fuel Pump Relay (FPR)
P0230

FPR Coil Circuit Low Voltage or Open FPR

KsDGDM_FPP_CircuitShortLow

230

#N/A

P0232

FPR Coil Circuit High Voltage FPR

KsDGDM_FPP_CircuitShortHigh

232

#N/A

Crankshaft Position
Sensor (CKP)

P0336

CKP Sensor Noisy Signal

KsDGDM_CrankNoisySignal

336

#N/A

P0337

CKP Sensor No Signal

KsDGDM_CrankNoSignal

337

#N/A

Ignition Coil
P0351

Cylinder 1 Ignition Coil Malfunction

KsDGDM_EST_A_Fault

351

#N/A

P0352

Cylinder 2 Ignition Coil Malfunction

KsDGDM_EST_B_Fault

352

#N/A

53

Idle Control System

P0505

Idle Speed Control Error

KsDGDM_IdleControl

505

#N/A

System Voltage
P0562

System Voltage Low

KsDGDM_SysVoltLow

562

#N/A

P0563

System Voltage High

KsDGDM_SysVoltHigh

563

#N/A

MIL

P0650

MIL Circuit Malfunction

KsDGDM_MIL_Circuit

650

#N/A

Tachometer
P1693

Tachometer Circuit Low Voltage

KsDGDM_TAC_Circuit_Low

1693

#N/A

P1694

Tachometer Circuit High Voltage

KsDGDM_TAC_Circuit_High

1694

#N/A

Oxygen Sensor 2
P0137

O2S 2 Circuit Low Voltage

KsDGDM_O2_2_ShortLow

137

#N/A

P0138

O2S 2 Circuit High Voltage

KsDGDM_O2_2_ShortHigh

138

#N/A

Oxygen Sensor Heater
2 or AC clutch

P0038

O2S Heater 2 Circuit High Voltage

KsDGDM_O2_2_HeaterShortHigh

38

#N/A

P0037

O2S Heater 2 Circuit Low Voltage

KsDGDM_O2_2_HeaterShortLow

37

#N/A

Vehicle Speed Sensor

P0500

VSS No Signal

KsDGDM_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 low/open CCP /CAN

KsDGDM_CCP_CircuitShortLow

444

#N/A

BLM MaxAdapt

P0171

BLM Max Adapt(Kohler Special) BLM

KsFDIAG_BLM_MaxAdapt

171

#N/A

BLM MinAdapt

P0172

BLM Min Adapt(Kohler Special) BLM

KsFDIAG_BLM_MinAdapt

172

#N/A

PE system Lean

P0174

PE syst Lean(Kohler Special) PE

KsFDIAG_PESystLean

174

#N/A

Evaporator temperature
sensor

P0537

A/C Evaporator Temperature Sensor Circuit
Low A/C

KsDGDM_EvaporatorShortLow

537

#N/A

P0538

A/C Evaporator Temperature Sensor Circuit
high or open A/C

KsDGDM_EvaporatorShortHigh

538

#N/A

AC Clutch Relay
P0647

A/C clutch Relay Control Circuit High

KsDGDM_O2_2_HeaterShortHigh

647

#N/A

P0646

A/C clutch Relay Control Circuit Low

KsDGDM_O2_2_HeaterShortLow

646

#N/A

ECU diagnostic

P0601

Calibration and software CheckSum fail

KsDGDM_FileROM_Checksum

601

1537

54

OBD Service $04

Functional description

The purpose of this service is to provide a means for the external test equipmentto command ECUs to clear all emission-related
diagnostic information This includes:

• MIL and number of diagnostic trouble codes (can be read with Service $01, PID $01)

• Clear the I/M (Inspection/Maintenance) readiness bits (Service $01, PID $01 )

• Confirmed diagnostic trouble codes (can be read with Service $03)

• Pending diagnostic trouble codes (can be read with Service $07)

• Diagnostic trouble code for freeze frame data (can be read with Service $02, PID $02)

• Freeze frame data (can be read with Service $02)

• Oxygen sensor test data (can be read 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 with Service $01, PID $21)

• Number of warm-ups since DTCs cleared (can be read with Service $01, PID $01)

• Distance travelled since DTCs cleared (can be read with Service $01, PID $01)

• Time run by the engine while MIL is activated (can be read with Service $01, PID $4D)

• Time since diagnostic trouble codes cleared (can be read with Service $01, PID $01)

Other manufacturer-specific “clearing/resetting” actions may also occur in response to this request message.

For safety and/or technical design reasons, some ECUs may not respond to this service under all conditions.

All ECUs shall respond to this service request with the ignition ON and with the engine not running.

55

OBD Service $07

Functional description for ISO 15765-4 or SAE J1979 May 2007

The purpose of this service is to enable the external test equipment to obtain“pending” diagnostic trouble codes detected during current
or last completed driving cycle for emission-related components / systems that are tested or continuously monitored during normal
driving conditions.

Service 07h is required for all DTCs and is independent of Service 03h.

The intended use of this data is to assist the service technician after a vehicle repair, and after clearing diagnostic information, by
reporting test results after a single driving cycle. If the test failed during the driving cycle, the DTC associated with that test will be
reported. Test results reported by this service do 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, indicating a faulty component
/ system. This service can always be used to request the results of the latest test, independent of the setting of a DTC.

Test results for these components / systems are reported in the same format as the DTCs in Service $03 - refer to the functional
description for service $03.

If less than three (3) DTC values are reported for failed tests, the response messages used to report the test results shall be filled with
$00 to fill seven (7) data bytes. This maintains the required fixed message length for all messages.

Service $09 (Request Vehicle Information) -PIDs supported

PID

Description

00

PIDs supported [01 - 20]

02

Vehicle Identification Number

04

Calibration Identifications

06

Calibration Verification Numbers

08

In use Performance tracking

56

Standard Torque Values

ENGINE

Name and dimensions

Torque value (N.m)

Name and dimensions

Torque value (N.m)

Cylinder head connecting nut

13 8 8～12

Cylinder bolt

4

10

40～50

2 6 8～12

Valve adjusting screw nut

4

10

8～12

Timing driven sprocket bolt

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

Crankshaft, main-shaft bearing baffle screw

5

6

8～12

Stud

1

6

8～12

Stud

4

10

40～50

Exhaust valve stud bolt

2 8 10～14

Stator connecting bolt

3 6 8～12

Stator leads pressure plate bolt

2

6

8～12

Spark Plug 1 12

18～25

Pensioner plate fastening bolt

1

6

8～12

57

Name and dimensions

Torque value (N.m)

Name and dimensions

Torque value (N.m)

Front wheel spindle

1

20

100～120

Front vibration damper plate

1

10

30～40

Real wheel spindle nut

1

16

60～90

Rear fork shaft nut

1

14

50～60

Engine hanging bolt

3

10

30～40

4 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

Brake disc fastening nut

17 8 20～30

Brake caliper screw

6 8 20～30

Side wheel set nut 2 20

100～120

While the rocker set nut

1

20

100～120

Side frame, frame joint bolt

2

10

39～49

Stabilizer bar fastening bolts

4

12

45～55

Side damper set nut

2

10

39～49

58

VIII、 Electrical system diagram