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Yingang YG125-25 User Manual

Yingang YG125-25
144 pages
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YG125-25 Maintenance Manual Foreword
Foreword
With the ever increasing varieties of motorcycles, new structures and new techniques have increasingly been applied.
To help YINGANG TECHNOLOGY Co., Ltd users and maintenance personnel better understand the maintenance,
adjustment and repair techniques of YG125-25 motorcycle, we prepared this maintenance manual. This manual is expected
to facilitate the YINGANG TECHNOLOGY Co., Ltd users and maintenance personnel and provide technical guidance for
them.
The masterstroke of the manual is the YG125-25 motorcycle , and the contents in Chapter 1-Chapter 3 are applicable
to the adjustment of various parts of the motorcycle. Chapter 4-18 describes various constituting parts of the motorcycle
respectively. Chapter 19 contains the electrical system diagram.
The standard maintenance procedures, maintenance precautions and general maintenance knowledge are not
covered in this manual. Any user or maintenance personnel who needs the above information may refer to the related
materials
All materials, charts and various data, as well as performance indices referenced herein, are for the latest model in our
product family at the date this manual is printed. YINGANG TECHNOLOGY Co., Ltd. shall have the right to, at any time,
amend this manual without prior notice. The copyright of all parts of this manual belongs to China YINGANG
TECHNOLOGY Co., Ltd. and no units or individuals are allowed to reprint it the without consent of our company.
We hope you will enjoy the comfort and pleasure it brings to you during your driving!
1
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Yingang YG125-25 Specifications

General IconGeneral
CoolingAir-cooled
Starting SystemElectric and kick start
Transmission5-speed manual
Fuel Tank Capacity12 liters
Front SuspensionTelescopic fork
Rear SuspensionDual Shock Absorbers
Front BrakeDisc
Rear BrakeDrum
Ground Clearance160 mm
Seat Height780 mm
EngineSingle cylinder, 4-stroke
Maximum Torque9.5 Nm at 7, 500 rpm
Wheelbase1, 280 mm
Engine Type4-stroke, air-cooled

Summary

Foreword

Overview

Technical Data of Main Performance

Motorcycle specifications and performance data.

Bar Tool

Lists specialized tools for maintenance procedures.

Maintenance Period Table

Schedule for routine maintenance tasks based on mileage.

Lubrication system

Maintenance notice

Important points before performing lubrication tasks.

Inspection and adjustment

Maintenance notice

General guidelines for inspection and adjustment procedures.

Spark Plug

Procedure for checking and adjusting the spark plug.

Valve clearance

Procedure for inspecting and adjusting valve clearance.

Throttle control

Procedures for checking and adjusting throttle free stroke.

Brake system

Inspection and maintenance of the front and rear brake systems.

Battery Checking

Procedures for checking, removing, and installing the battery.

Driving chain

Procedure for inspecting and adjusting drive chain tension.

Steering stem bearing

Procedure for inspecting and adjusting steering stem bearings.

Fuel system

Maintenance Notices and Component Handling

Safety precautions, notices, and troubleshooting for the fuel system.

Fuel Tank, Air Filter, and Throttle Body Service

Procedures for removing and installing key fuel system components.

Removal and installation of engine

Engine Removal and Installation Procedures

Detailed steps for engine removal, installation, torque values, and specifications.

Cylinder head, cylinder and piston

Technical Specifications and Benchmarks

Detailed specifications and maintenance limits for cylinder head, cylinder, and piston.

Component Disassembly and Assembly

Procedures for cylinder head, camshaft, cylinder, and piston disassembly and assembly.

Clutch and Right crankcase cover

Clutch Maintenance and Specifications

Clutch specifications, maintenance, torque values, and troubleshooting.

Right Crankcase Cover Service

Procedures for removing and installing the right crankcase cover.

Magneto and starting system

Technical Specifications and Rotor Assembly

Specs for magneto/starting system, rotor assembly procedures.

Starting Motor System Maintenance

Procedures for maintaining the starting motor and transmission system.

Crankcase, crankshaft and Shift mechanism

Crankcase Maintenance Procedures

Steps for crankcase disassembly, assembly, and related components.

Crankshaft and Balance Shaft Service

Procedures for crankshaft, balance shaft removal, installation, and inspection.

Variable Transmission System Maintenance

Procedures for variable transmission system removal, installation, and checks.

Frame and exhaust system

Frame and Muffler Maintenance

Maintenance details for the frame and exhaust muffler components.

Component Installation

Steps for installing vehicle coverings, headlamp, and meter assembly.

Muffler Removal and Installation

Procedures for removing and installing the exhaust muffler.

Front wheel, front suspension and steering stem

System Overview and Troubleshooting

Overview, specs, torque, and troubleshooting for front wheel, suspension, and steering.

Component Maintenance Procedures

Maintenance for control systems, wheels, shock absorbers, and steering post.

Brake System Maintenance

Procedures for front brake system damage, symptoms, and repair.

Rear wheel and rear suspension device

System Overview and Troubleshooting

Overview, troubleshooting for rear wheel and suspension components.

Rear Wheel and Transmission Maintenance

Maintenance for rear wheels, drive chain, and sprockets.

Rear Suspension and Fork Procedures

Maintenance for rear suspension, shock absorber, and rear fork.

General remarks of electrical system

Precautions for Circuit Inspection

Important safety precautions before inspecting electrical circuits.

System Principle and Composition

Overview of the motorcycle's electrical system principles and components.

Power supply system

System Overview and Schematic

Introduction to the power supply system and its circuit diagram.

Charging System Maintenance

Procedures for maintaining the charging system.

Major Faults Diagnosis

Diagnosing and troubleshooting common power supply faults.

Starting system

System Overview and Schematic

Introduction to the starting system and its circuit diagram.

System Maintenance and Troubleshooting

Procedures for maintaining and troubleshooting the starting system.

Illumination signal system

System Overview and Components

Introduction to illumination system, its components, and functions.

Circuit Schematic and Maintenance

Circuit diagram and maintenance procedures for the illumination system.

Electrical starting control system

System Overview and Components

Overview and components of the information display system.

Meter Reading and Maintenance

How to read and maintain the combination meter.

Fault Diagnosis

Diagnosing and troubleshooting electrical starting control system faults.

Engine management system

System Overview and Composition

Overview and composition of the Engine Management System (EMS).

Component Identification and Maintenance

Visual identification and maintenance of key EMS components.

Troubleshooting Engine Performance Issues

Troubleshooting steps for common EMS-related engine performance problems.

Electrical System Diagram

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