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SANYANG INDUSTRY CO. XS125-K User Manual

SANYANG INDUSTRY CO. XS125-K
122 pages
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SERVICE MANUAL
XS 125-K
DK Version 1.0 2009

Table of Contents

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SANYANG INDUSTRY CO. XS125-K Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke, air-cooled
Displacement124.6 cc
Fuel SystemCarburetor
IgnitionCDI
Starting SystemElectric & Kick
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Ground Clearance160 mm
Rear SuspensionDual shock

Summary

Preface

General Information and Specifications

Service Rules

Outlines essential guidelines and practices for servicing the motorcycle.

Specifications

Detailed technical specifications for the motorcycle model.

Torque Values

Specifies torque settings for various engine and frame components.

Troubleshooting

Guides for diagnosing and resolving common engine starting and running issues.

Inspection and Adjustment Procedures

Engine Inspections and Adjustments

Covers maintenance schedule, oil, spark plug, compression, and valve clearance.

Frame Inspections and Adjustments

Includes air cleaner, clutch, brakes, drive chain, wheels, suspension, and steering.

Oil and Oil Filter Maintenance

Procedures for checking and replacing engine oil and filter.

Spark Plug Inspection and Gap Adjustment

Guidance on inspecting and adjusting the spark plug for optimal performance.

Compression Test Procedure

Steps for performing a compression test and identifying causes of low/high compression.

Valve Clearance Inspection and Adjustment

Detailed steps for checking and adjusting valve clearances.

Ignition Timing Inspection

Procedure for checking and verifying ignition timing.

Throttle Grip and Idling Speed Adjustment

Instructions for adjusting throttle grip free play and engine idling speed.

Brake and Drive Chain Adjustments

Covers adjustments for front/rear brakes and drive chain slack.

Suspension Checks

Guidance on inspecting front and rear suspension components.

Steering and Battery Maintenance

Procedures for inspecting steering head and battery fluid levels.

Lubrication System

Lubrication System Troubleshooting

Diagnosing and resolving issues related to oil level, contamination, and pressure.

Lubrication System Service Information

Provides service notes, oil specifications, and pump delivery data.

Engine Removal and Installation

Engine Service Information and Torque Values

General instructions for engine service and torque specs for mounting.

Engine Removal Procedures

Step-by-step guide to safely remove the engine from the motorcycle.

Engine Installation Procedures

Guidance for reinstalling the engine, including post-installation checks.

Cylinder Head and Valve System

Cylinder Head and Valve Troubleshooting

Diagnosing issues like low compression, high compression, and abnormal noise.

Camshaft, Rocker Arm, and Shaft Inspection

Procedures for inspecting camshaft lobes, rocker arms, and shafts for wear.

Cylinder Head Disassembly and Inspection

Steps to disassemble the cylinder head and check for cracks or warpage.

Valve and Valve Guide Inspection

Checking valve stem condition, movement, and stem-to-guide clearance.

Valve Seat Inspection and Refacing

Procedures for inspecting valve seats and refacing them for proper sealing.

Valve Seat Grinding and Lapping

Instructions for grinding valve seats using specific cutters and lapping valves.

Cylinder Head Assembly

Steps for assembling the cylinder head with valves, springs, and retainers.

Cylinder Head Installation

Procedure for installing the cylinder head, camshaft, and camsprocket.

Cylinder and Piston Service

Cylinder and Piston Troubleshooting

Diagnosing issues like low compression, excessive smoke, overheating, and noise.

Cylinder Removal and Inspection

Steps for removing the cylinder and inspecting its bore for wear or damage.

Piston and Piston Ring Inspection

Procedures for measuring piston ring clearance, end gap, and checking for wear.

Piston Ring Installation

Guidelines for correctly installing piston rings, ensuring proper gap spacing.

Piston and Cylinder Installation

Steps for installing the piston and cylinder, including lubrication.

Clutch, Oil Pump, and Gear Shift Systems

Clutch System Troubleshooting

Diagnosing issues with clutch operation, engagement, and lever pressure.

Clutch Component Removal and Inspection

Steps for removing clutch parts and inspecting friction discs, plates, and springs.

Oil Pump Service and Inspection

Procedures for removing, disassembling, inspecting, and assembling the oil pump.

Gearshift Linkage Assembly

Instructions for assembling the gearshift linkage components correctly.

A.C. Generator and Starter Motor

AC Generator and Starter Motor Service Info

General instructions, special tools, and torque values for AC generator service.

Left Crankcase Cover and Flywheel Removal

Steps for removing the left crankcase cover and flywheel assembly.

Stator Coil and Flywheel Installation

Procedures for inspecting stator coils and installing the flywheel.

Starter Motor and Driven Gear Service

Guides for removing and assembling the starter motor and driven gear.

Camshaft, Crankshaft, Crankcase, Transmission, and Kickstarter

Troubleshooting for Transmission and Crankshaft

Diagnosing hard shifting, gear jumping, and noise issues.

Crankcase Separation Procedure

Steps for separating the left and right crankcase halves.

Crankshaft Removal and Inspection

Procedures for removing and inspecting the crankshaft and its bearings.

Transmission Disassembly and Fork Inspection

Steps for disassembling the transmission and inspecting shift forks.

Kick Starter Disassembly and Assembly

Procedures for disassembling and reassembling the kick starter mechanism.

Crankcase Assembly

Instructions for installing the gasket and assembling the crankcase halves.

Carburetor System

Carburetor Troubleshooting

Diagnosing engine starting, rough idle, lean, and rich mixture problems.

Carburetor Removal and Disassembly

Steps for removing the carburetor and disassembling its throttle valve.

Float System Disassembly and Inspection

Procedures for disassembling the float chamber and inspecting the float valve.

Carburetor Jet and Air Screw Service

Instructions for removing and servicing main jet, needle jet, and air screw.

Float Level Adjustment

Guidance on adjusting the float level for optimal fuel delivery.

Carburetor Installation

Steps for reinstalling the carburetor and adjusting throttle cable and idle speed.

Headlight, Steering, Front Wheel, and Front Fork Systems

Front End Troubleshooting

Diagnosing issues like wheel wobbling, hard steering, and suspension problems.

Headlight Service

Procedures for removing, wiring, and installing the headlight assembly.

Meter and Handlebar Service

Steps for removing the meter and handlebar, and installing the handlebar.

Front Wheel Removal and Inspection

Procedures for removing the front wheel and inspecting axle and bearings.

Front Brake System Service

Inspection and disassembly of front brake disc and drum components.

Front Wheel and Fork Assembly

Assembling front wheel components and fork assemblies.

Front Fork Removal and Installation

Steps for removing and installing the front fork assembly.

Steering Stem Service

Procedures for disassembling and assembling the steering stem.

Rear Wheel and Suspension Systems

Rear Wheel and Suspension Troubleshooting

Diagnosing wobble, vibration, soft/hard suspension, and brake performance issues.

Rear Wheel Removal and Axle Inspection

Steps for removing the rear wheel and inspecting the axle runout.

Wheel Bearing and Sprocket Inspection

Checking wheel bearings, rim runout, final driven sprocket, and damper rubbers.

Final Driven Sprocket Assembly

Procedure for installing the drive sprocket and lock plates.

Rear Brake Panel and Shoe Replacement

Inspection and replacement of rear brake shoes and lining.

Shock Absorber Service

Procedures for removing, disassembling, and installing the shock absorber.

Rear Fork Service

Steps for removing, disassembling, and inspecting the rear fork.

Rear Brake Pedal Adjustment

Instructions for adjusting the rear brake pedal and linkage.

Battery and Charging System

Battery and Charging System Troubleshooting

Diagnosing issues with no power, low power, and intermittent power.

Battery Removal, Installation, and Testing

Procedures for battery handling, specific gravity testing, and charging.

Charging System Performance Test

How to test charging output using a voltmeter and ammeter.

Stator Coils and Rectifier Testing

Procedures for testing stator coils and the rectifier for proper function.

Ignition System Service

Ignition System Troubleshooting

Diagnosing no spark, rough running, and ignition timing issues.

Spark Plug and Ignition Timing Specifications

Details on spark plug type, gap, and ignition timing settings.

Ignition Coil Removal and Testing

Steps for removing the ignition coil and performing output tests.

Switches and Horn

Switches and Horn Troubleshooting

Diagnosing issues with lights not coming on, dim lights, and beam shifting.

Electrical Component Specifications

Specifications for headlights, indicators, and pilot lights.

Switch Wiring Diagrams

Wiring schematics for main, dimmer, winker, horn, light, start, and hazard switches.

Brake Light Switch and Horn Testing

Procedures for testing front/rear brake light switches and the horn.

Wiring Diagrams

Electrical Distribution Schematic