Xingyue XY260T-4 User manual

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

CHASSIS BOLTS AND NUTS···························11
2. ENGINE SERVINCE
3-1 ENGINE REMOVAL·····························12
3-2 ENGINE REINSTALLATION······················12
3-3 ENGINE DISASSEMBLY··························12
3-4 ENGINE COMPONENTS INSPECTION AND SERVICING16
3-5 ENGINE REASSEMBLY·························22
4. FUELAND LUBRICATION SYSTEM
4-1 FUEL TANK AND FUEL COCK····················25
4-2 CARBUTETOR···································26
4-3 OIL PUMP·······································29
5. ELECTRICAL SYSTEM
5-1 IGNITION SYSTEM·······························30
5-2 CHARGING AND LIGHTING SYSTEM··············31
5-3 STARTER SYSTEM·······························33
5-4 BATTERY·······································35
5-5 COIL TYPE FUEL GAUGE·························36
5-6 OIL LEVEL GAUGE······························38
5-7OIL LEVEL GAUGE······························38
6 CHASSIS
6-1 FRONT WHEELAND BRAKE······················39
6-2 FRONT FORK····································40

6-3 STEERING····································42
6-4 REAR WHEEL·································43
7. SERVINCE INFORMATION
7-1 TROUBLESHOOTING··························45
7-2 TIGHTENING TORQUE························52

1. GENERAL INFORMATION
1-1 MODELIDENTIFICATION
1. The frame number (VIN) and the engine number is printed on the position as Fig1 indicated.
Position of frame numbe
r
Position of engine number
1-2 SPECIFICATIONS
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1-3 FUELAND OILRECOMMENDATIONS
Be sure to use the specified fuel and oils. The followings are the specifications.
Fuel tank
FUEl
Gasoline used should be graded 90 octane or
higher. An unleader or low-lead gasoline type
is recommended.
Engine oil hole
FINAL GERA OIL
Use a good quality SAE85W/140 multi-grade
motor oil.
1-4 BREAKING-IN PROCEDURE
During manufacture only the best possible materials are used and all machined parts are finished to
a very high standard but it is still necessary to allow the moving parts to “break-in” before
subjecting the engine to maximum stresses. The future performance and reliability of the engine
depends on the care and restraint exercised during its early life. The general rules are follows.
 Keep to these breaking-in speed limit:
Up to 1000km less than 4/5 throtle
 Upon reaching an odometer reading of 1000km ,you can subject the motorcycle to full throttle
operation.
 Do not maintain constant engine speed for an extended time period during any porion of the
breaking-in. Try to vary the throttle position.
1-5 PRECAUTIONS AND GENERAL INSTRUCTION
Observe the following items without fail when disassembling and reassembling motorcyles.
 Do not run engine indoors with little or no ventilation.
 Be sure to replace packings, gaskets, circlips, O rings and cotter pins with new ones.
Caution:
Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a new
circlip must be installed.
When installing a new circlip, care must be taken mot to expand the end gap larger than required to
slip the circling over shaft.
After installing a circlip, always insure that it is completely seated in its grooves and securely and
securely fitted.
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 Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with
smaller diameter and from inside to outside diagonally, to the specified tightening torque.
 Use special tools where specified.
 Use genuine parts and recommended oils.
 When 2 or more persons work together, pay attention to the safety of each other.
 After the reassembly, check parts for tightness and operation.
 Treat gasoline which is extremely flammable and highly explosive, with greatest care. Never
use gasoline as cleaning solvent.
Warning , caution and note included in this manual occasionally, describing the following contents.
Warning: when personal safety of the rider is involved, disregard of the information could result
in injury.
Caution: for the protection of the motorcycle, the instruction or rule must be strictly adhere to.
Note: advice calculated to faciliate the use of the motorcycle is given under this heading.
1-6 USE OF GENUINE PARTS
To replace any part of the machine, use a genuine replacemen part. If imitation parts or parts
supplied from any other source are used, the machine’s performance would be worse and even
induce costly mechanical troubles.
1-7 POWER TRANSMISSION
The power transmission is discribed as follows:
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A mechanism employing a drive belt and using the centrifugal force for automatic speed change, a
clutch mechanism for control of transimission of drive power to the rear wheel, and a mechanism
with a series of reduction gears for reduction of the drive power from the clutch and transmission of
the power to the rear wheel are installed in the left-side crankcase.
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V-belt drive mechanism
This is composed of a pair of drive faces transimitting the drive power from the crankshaft to the
V-belt and a pair of driven faces for transimission of the drive power from the V-belt to the drive
shaft.
Rollers are installed in the movable drive face, and when the crankshaft rotation speed increase, the
centrifugal force acts onto the rollers and the rollera pushes the movable drive face to the L-side.
Then the clearance between the fixed drive face and the movable drive face becomes smaller and
the V-belt is pushed out torwards the circumference.
When the V-belt rotation radius on the side of the drive faces becomes larger, the radius on the side
of the driven faces becomes small,and as the ratio of driven is changed by this in the range from
2.559 to 0.853, smooth acceleration is obtained from start to high speed.
Clutch mechanism
The clutch components are the clutch shoes, the weights, the return springs and the drum. The
clutch shoes always rotate together with the fixed driven face.
The clutch shoe is installed at the tip of the weight, and the weight is pulled by the return spring
towards the shaft side. When the engine speed increase, the centrifugal force acts onto the weights,
and the shoes overcome the return spring force and come into contact with drum. The power
rotating the fixed driven face is transmitted to the clutch drum via the clutch shoes.
Reduction gears
As the clutch drum is fixed on the drive shaft, the drive shaft also rotates when the clutch drum
rotates, and the power is trasmitted via drive shaft, idle gears, and final drive gear to the rear axle
shaft. The respective speeds are reduced by the reduction gears, and the clutch drum drive power is
transmitted to the rear axle shaft with the final gear ratio of 10.607.
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2. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURETHE
2-1 PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommend intervals for all the required periodic service work necessary
to keep the motorcycle operating at peak performance and economy. Mileages are expressed in
terms of kilometers.
Note:
More frequent servcing may be performed an motorcycle that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Miles 600 2000 4000
Km 1000 3000 6000
INTERVAL: this interval should
be judged by odometer reading or
month, which comes first. Months 2 6 12
Battey -- I I
Air cleaner -- C C
Cylinder head nuts and exhaust pipe bolts T T T
Cylinder head, cylinder and muffler -- C C
Spark plug C C R
Carburetor I I I
I I IFuel line
Replace every 4 years
Gear oil R -- R
Brake I I I
Steering I I I
Front fork I I I
Rear suspension I -- --
Tire I I I
Chassis bolts and nuts T T T
Note: C=clean , I=inspect, R=replace, T=tighten
LUBRICATION POINTS
Warning :
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings, brakes
slippage will result.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions.
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt or grime.
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2-2 MAINTENANCE AND TUNE-UP PROCEDURE
This section describes the servicing procedures for each items of the periodic maintenance
requirments.
BATTERY
Inspect every 3000 km (6 months)
 The battery must be removed to check the
electrolyte lecel and specific gravity.
 Remove the battery ○
一and ○ +leads at the
battery terminals.
 Remove the battery from the frame.
 Check electrolyte for level and specific
gravity. Add distilled water, as necessary,
to keep the surface of eletrolyte above MIN.
level line but not above the MAX. level line.
For checking specific gravity, use a hydrometer
to determin the charged condition.the standard
specific gravity is 1.28 at 20℃for 12V type.
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An S.G. reading of 1.22(at 20℃) or under means
that the battery needs recharging off machine:
take it off and charge it from a recharger. Charging
the battery in place can lead to failure of the
regulator/rectifier.
 To install the battery, reverse the procedure
described above.
Caution:
When installing the battery lead wires, fix
the ○
+lead first and ○ 一lead last.
AIR CLEANER
Clean every 3000 km (6 months)
If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in
output and an increase in fuel consumption. Check and clean the element in the following manner.
 Remove the air cleaner left cover.
 Take out the air cleaner elements.
 Take off the air cleaner coil.
 Fill a washing pan of a proper size with
nonflammable cleaning solvent. Immerse
the coil in the cleaning solvent and wash
them clean.
 Squeeze the cleaning solvent out of the
washed coil by pressing it between the
palms of both hands: do not twist or wring
the coil or it will develop ters.
 Immerse the coil in CCI or CCI SUPER oil,
and squeeze the oil out of coil leaving it
slightly wet with oil.
 At last reassemble the elements.
A: non-flammable cleaning solvent
B: CCI or CCI SUPER oil
Caution:
Before and during the cleaning operation, inspect the element for tears. A torn element must be
replaced.
Be sure to position the element snugly and correctly, so that no incoming air will bypass it.
Remember, rapid wear of piston rings and cylinder bore is often caused by a defective or poorly
fitted element.
CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS
Tighten initial 1000km(2 months) and every 3000km (6 months)
Cylinder head nuts, when they are not tightened to
the specified torque., may result in leakage of the
compressed mixture and reduce output. First loosen
the nuts and tighten the 4nuts evenly one by one
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in stages untill each one is tightening to the specified torque.Tighten the nuts in the order indicated.
Cylinder head nut tightening torque 8-12N.m
(0.8-1.2kg-m)
SPARK PLUG
clean initial 1000km (2 months) and every 3000km (6 months), replace every 6000km (12 months).
Neglecting the spark plug eventually leads to
difficult starting and poor performance. If
the spark plug is used for a long period, the
electrode gradually burns away and carbon
builds up along the inside part. In accordance
with the periodic inspection chart, the plug
should be removed for inspection, cleaning
and to rest the gap.
 Carbon deposits on the spark plug will
prevent good sparking and cause misfiring.
Clean the deposits off periodically.
 If the center electrode is farily worn down,
the plug should be replaced and the plug gap
set to the specified gap using a thickness gauge.
Spark plug gap 0.6-0.8mm
 Check spark plug for burnt condition. If abnormal, replace it.
 Tighten the spark plug in the cylinder head with the specified toque.
Spark plug tightening torque. 25-30N.m
(2.5-3.0 kg-m)
Note：
To check the spark plug,first make sure that the fuel tank contains unleaded gasoline,and if plug is
either sooty with carbon or burnt white,replace it.
Note:
Confirm the thread size and reach when replacing the plug.
CARBURETOR
ENGINE IDLE R/MIN
Inspect initial 1000km (2 months) and every 3000 km (6 months)
 Adjust the throttle cable play.
 Warm the engine up.
Note: a warm engine means an engine has been run for 10 minutes.
 Remove the right frame cover,
 Adjust the throttle stop screw to obtain the idle r/min as follows.
Fuel cable
screw
Idle r/min 1400±100r/min Fuel line
 Finally adjust the throttle cable play.
THROTTLE CABLE
Loosen the lock nut and adjust the cable play by turning adjuster in or out to obtain the following
cable play.
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After adjusting play, tighten the lock nut.
Cable play 0.5-1.mm
OVERHAULAND CLEANING
Wash the carburetor and component parts in cleaning solvent after disassembly.
Before reassembly, inspect the float level and needle valve. Adjust and replace parts when
necessary.
Then blow compressed air through all jets and passages to make sure they are not clogged. Do not
use wire ,etc. to clean them, as this can damage the parts.
FUEL LINE
Inspect initial 1000km (2 months) and every 3000km (6 months) . repalce every four years.
GEAR OIL
Change initial 1000km (2 months) and every 6000 km (12 months)
After a long period of use, the gear oil qualities will deteriorate and quicken the wear of gear and
bearing surfaces. Replace the gear oil periodically following the procedure below:
Drain plug
 Start the engine to warm up the oil, this will
facilitate draining of oil.
 Unscrew the drain plug and drain the oil completely.
 Supply a good quality SAE 85W/140 multigtade
motor oil through the filler hole untill the oil
flows from the filler hole,
STEERING
Inspect intial 1000(2 months) and every 3000km (6 months)
Steering should be adjusted for smooth manipulation of handlebars and safe running. Too stiff
steering prevents smooth manipulation of handlebars and too loose steering will cause the
handlebars to vibrate. Check to see that there is no play in the front fork andhandlebar fittings. If
any play is found, perform steering bearing adjustment.
FRONT FORK
Inspect initial 1000km(2 months) and every 3000km(6 months)
Inspect the front fork for oil leakage, scoring and scraches on the outer surface of inner tube and
replace the defective parts, if necessary.
REAR SUSPENSION
Inspect initial 1000km (2 months) and every 6000km(12 months)
Inspect the rear shock absorbor and engine mounting portions for oil leakage and wear of mounting
damper rubbers. Replace the defective part if necessary.
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TIRE
inspect initial 1000km (2 months) and every 3000km (6 months)
TIRE PRESSURE
If the tire pressure is too high, the motorcycle will tend to
ride stiffly, have poor traction. Coversely, if the tire
pressure is too low., stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
roadability and to prolong tire life,
Caution :
The standard tire fitted on this motorcycle is 130/60-13
for front and rear. The use of a tire other than the standard
may cause handling instability.
Cold inflation tire pressure
Front rear
196kpa(1.96kg/m2) 221kpa(2.21kg/m2)
TIRE TREAD CONDITION
Operating the motorcycle with the excessively worn tires will decress riding stability and
consequently invite a dangerous situation. It is highly recommemded to replace the tire when the
remaining depth of tire tread reaches the following.
CHASSIS BOLTS AND NUTS
Tighten initial 1000km(2 months) and every 3000km (6 months)
These bolts and nuts listed below are important safety parts. They must be loosened first and
retightened, to the specified torque with a torque wrench.
NO. DESCRIPTION N.m Kg.m
1 Rear axle nut 80 -100 8.0-10.0
2 Rear shock absorber nuts 25-35 2.5-3.5
3 Steering stem lock nut 65-75 6.5-7.5
4 Handlebar clamp nut 30-40 3.0-4.0
5 Front shock absorber nuts 30-40 3.0-4.0
6 Hunger nuts 30-40 3.0-4.0
7 Front axle nut 50-60 5.0-6.0
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3. ENGINE SERVINCE
3-1 ENGINE REMOVAL
Before taking the engine out of the frame, wash engine. The procedure of engine removal is
sequentially explained in the following steps, and engine reinstallation is effected by reversing the
removal procedure.
 Open the seat and disconnect the battery and lead wires from the battery terminals.
 Remove the frame covers
 Remove the rear brake assy.
 Disconnect the oil hose from oil pump.
 Loosen the air intake pipe clamp screw and remove the carburetor cap from the carburetor.
 Remove the engine ground wire and disconnect the starter motor lead.
 Disconnect the magneto lead wire coupler
 Remover the two hoses from the carburetor
 Remove the spark plug cap
 Unclamp the battery breather pipe from the carburetor.
 Remove the engine mounting bracket bolt and rear shock absorber lower bolt.
 Separate the engine assembly from the frame.
3-2 ENGINE REINSTALLATION
For remounting engine, reverse the order of engine removal and take the following additional steps.
 Install the engine mounting bracket bolt and tighten it.
 Tighten the rear shock absorber upper and lower bolt to the specified torque.
N.m Kg.m
Rear shock absorber nuts 25-35 2.5-3.5
 Install final gear oil multi-grade motor oil when engine is overhauled.
 Route the battery breather pipe properly.
 After remounting the engine, route wiring harness and cables properly by referring to the
section, wire routing and cable routing, and adjust the following items to the specification.
3-3 ENGINE DISASSEMBLY
The procedure for engine disassembly is sequentially explained in the following steps.
 Remove the exhaust pipe nuts and muffler mounting bolt.
 Remove the cylinder head cover and air cleaner case.
 Remove the VTV from carburetor.
 Remove the carburetor assembly.
 Remove the oil pump.
 Remove the left crankcase cover.
 Remove the engine mounting bolt and bracket.
This bolt is inserted from the left side.
 Remove the clutch drum from the drive shaft by
using the special tool.
 Remove the cylinder head and cylinder.
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 Place a cloth beneath the piston and remove the
circlipe with pliers
Draw out piston pin.
Note: when reinstalling the piston, face the arrow on the piston top to the exhaust port side.
 Remove the oil pump drive piece○
1by using screwdriver.
 Using the conrod holder remove the nut, washer, and
fixed drive face.
Tightening torque 40-60N.m
(4.0-6.0 kg .m )
 Remove the clutch shoe assembly, drive belt and driven
wheel assembly.
 Using the impact driver remove the final gear box cover.
 Remove the idler drive gear, bushing and drive shaft.
 After removing drive shaft and gears as shown in the photo,
remove the rear axle nut and cotter pin.
Note: final driven gear is press-fitted on the rear axle.
 Remove the rear wheel assembly.
 Reinstall the rear axle nut and lightly tap the rear axle.
Remove the rear axle from the crankcase.
 Remove the movable drive face and spacer.
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Caution:
Once remove the movable drive face, rollers provided inside he drive face may be dislocated and
disassembly of the drive face be needed.
 Remove the starter driven gear and key.
Note:
When reinstalling the starter driven gear, align the key groove
with the key.
 Using the rotor holder, remove the rotor securing nut.
Tightening torque 35-43N.m
(3.5-4.3 kg .m )
 using the crankcase separating tool, remove the rotor from
the crankshaft.
 Remove the red valve assembly
 Remove the crankcase securing screws.
 Using the crankcase separating tool and attachment, remove
the right crankcase from the left one.
 Tap the left end of the crankshaft with plastic hammer and
remove the crankshaft from the left grankcase.
 Remove the oil pump driven gear and thrust washer
- 14 -

 Remove the oil pump driver gear.
 Remove the movable drive face cover.
 Remove the movable drive face plate and O-ring.
 Remove the 6 pcs of rollers
Note: when reinstalling rollers, apply grease to sliding
surface of rollers.
 Using the special tool, remove the clutch shoe nut
by turning it clockwise.
 Using screw driver remove the movable driven face seat.
Caution: when reinstalling the driven face seat, degrease the
outer surface of the driven face seat completely.
 Remove the three pins from the fixed driven face.
Note:
Apply grease to the sliding surface between fixed driven face
and movable driven face.
When reinstalling the movable face to fixed face, make sure
that oil seal should be positioned properly.
- 15 -

 Using the sliding hammer and attachment,remove the bearing.
Caution:The removed bearing should be replaced with a new one.
 Remove the fixed driven face bearings in the same manner.
When removing the inner bearing,remove the cir clip by using
the snap ring pliers.
 Remove the oil seal with screw driver.
Caution: The removed oil seal should be replaced with a new one.
 Remove the rear axleshaft oil seal with screw driver.
3-4 ENGINE COMPONENTS INSPECTION AND SERVICING
BEARINGS
Wash the bearing with cleaning solvent and lubricate with
motor oil before inspecting.
Turn the inner race and check to see that the inner race
turns smoothly,of if noise is heard,the bearing is defective
and must be replaced with a new one.
OIL SEALS
Damage to the lip ○
1of the oil seal may result in leakage
of the fuel-air mixture or oil.inspect for damage and be
sure to replace damaged parts if there are any.
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CRANKSHAFT
CRANKSHAFT RUNOUT
Support crankshaft by”V”blocks ○
2,with the dial gauge ○ 3
rigged to read the runout as shown.
Service limit 0.05mm
Excessive crankshaft runout is often responsible for abnormal
engine vibration.such vibration shortens engine life.
CONDITION OF BIG END BEARING
Turn the crankshaft with the connecting rod to feel the
smoothness of rotary motion in the big end.move the rod up
and down while holding the crankshaft rigidly to be sure that
there is no rattle in the big end.
CON-ROD DEFLECTION
Wear on the big end of the connecting rod can be estimated
by checking the movement of the small end of the rod.this
method can also check the extent of wear on the parts of the
connecting rod,crank pin and crank pin bearing should all be
replaced.
Service limit 3.0mm
CON-ROD SMALL END BORE I.D.
Using a caliper gauge,measure the con-rod small end diameter.
Service limit 14.040mm
AUTOMATIC CLUTCH INSPECTION
The engine is equipped with an automatic clutch and variable ratio belt drive transmission.the
engagement of the clutchs governed by enging RPMs and a centrifugal mechanism located in the
clutch.
To insure proper performance and longevity of the clutch assembly it is essential that the clutch
engages smoothly and gradually.two inspection checks must be performed to thoroughlt check the
operation of the drivetrain.follow the procedures listed.
A .INITIAL ENGAGEMENT INSPECTION
●Warm the motorcycle up to normal operating temperature.
●Connect an electric tachometer to the engine.
●Seated on the motorcycle with the motorcycle on level ground,increase the engine RPMs slowly
and note the RPM at which the motorcycle begins to move forward.
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