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Yingang YG125-30A User Manual

Yingang YG125-30A
151 pages
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YG125-30B MaintenanceManual Foreword
1
Foreword
Withtheeverincreasingvarietiesofmotorcycles,newstructuresandnewtechniqueshaveincreasinglybeenapplied.
TohelpYINGANGTECHNOLOGYCo.,Ltdusersandmaintenancepersonnelbetterunderstandthemaintenance,
adjustmentandrepairtechniquesofYG125-30Amotorcycle,wepreparedthismaintenancemanual.Thismanualis
expectedtofacilitatetheYINGANGTECHNOLOGYCo.,Ltdusersandmaintenancepersonnelandprovidetechnical
guidanceforthem.
ThemasterstrokeofthemanualistheYG125-30Amotorcycle,andthecontentsinChapter1-Chapter3areapplicable
totheadjustmentofvariouspartsofthemotorcycle.Chapter4-18describesvariousconstitutingpartsofthemotorcycle
respectively.Chapter19containstheelectricalsystemdiagram.
Thestandardmaintenanceprocedures,maintenanceprecautionsandgeneralmaintenanceknowledgearenot
coveredinthismanual.Anyuserormaintenancepersonnelwhoneedstheaboveinformationmayrefertotherelated
materials
Allmaterials,chartsandvariousdata,aswellasperformanceindicesreferencedherein,areforthelatestmodelinour
productfamilyatthedatethismanualisprinted.YINGANGTECHNOLOGYCo.,Ltd. shallhavetheright to,atanytime,
amendthismanualwithoutpriornotice.ThecopyrightofallpartsofthismanualbelongstoChinaYINGANG
TECHNOLOGYCo.,Ltd. andnounitsorindividualsareallowedtoreprintitthewithoutconsentofourcompany.
Wehopeyouwillenjoythecomfortandpleasureitbringstoyouduringyourdriving!

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Yingang YG125-30A Specifications

General IconGeneral
CoolingAir-cooled
Ignition SystemCDI
Transmission5-speed manual
Fuel SupplyCarburetor
Front SuspensionTelescopic fork
Rear SuspensionDual shock absorbers
Front BrakeDisc
Rear BrakeDrum
Front Tire2.75-18
Rear Tire3.00-18
Wheelbase1280 mm
Seat Height760 mm
Ground Clearance160 mm
Curb Weight120 kg
Engine TypeAir-cooled
Starting SystemElectric and kick
Fuel Tank Capacity12 L
EngineSingle cylinder, 4-stroke
Displacement124.6 cc

Summary

Foreword

1. Overview

Engine Number Position

Identifies the location of the engine number on the motorcycle.

About Motorcycle Maintenance

General information about motorcycle maintenance procedures.

Technical Data of Main Performance

Key specifications and performance data of the motorcycle.

Standard Torque Values

Specifies torque settings for various fasteners and components.

Maintenance Precautions

2. Lubrication System

Maintenance Notice

General note regarding lubrication system maintenance.

Troubleshooting Lubrication System

Common problems and solutions for the lubrication system.

Lubricating Positions

Identifies lubrication points on the complete vehicle.

Lubrication of Control Lines

Procedure for lubricating clutch, throttle, and steering cables.

Engine Lubrication System Diagram

Diagram illustrating the engine's oil flow paths and components.

3. Inspection and Adjustment

Spark Plug Inspection and Adjustment

Procedure for inspecting and adjusting the spark plug.

Lubricating Oil Check

Checking and maintaining the engine's lubricating oil level.

Timing Phase and Chain Tension

Checking engine timing phase and adjusting timing chain tension.

Cylinder Pressure and Valve Clearance

Testing cylinder pressure and adjusting valve clearance.

Air Filter and Idle Speed Maintenance

Maintaining air filter and adjusting engine idle speed.

Throttle Control and Brake System

Inspecting throttle control and front brake system components.

Brake Fluid and Piece Inspection

Checking brake fluid level and inspecting brake shoe wear.

4. Fuel System

Maintenance Notice

General note regarding fuel system maintenance.

Troubleshooting Fuel System

Common problems and solutions for the fuel system.

Fuel Tank Removal and Installation

Procedures for removing and installing the fuel tank.

Air Filter Removal and Installation

Procedures for removing and installing the air filter.

Carburetor Removal and Installation

Procedures for removing and installing the carburetor.

5. Engine Removal and Installation

Maintenance Notice

General note regarding engine removal and installation.

Engine Installation

Procedures for installing the engine back into the frame.

Engine Removal

Step-by-step guide for removing the engine from the motorcycle frame.

6. Cylinder Head, Cylinder, and Piston

Maintenance Notice

General note regarding cylinder head, cylinder, and piston maintenance.

Cylinder Head Procedures

Procedures related to the cylinder head assembly.

Cylinder Procedures

Procedures related to the cylinder component.

Piston Procedures

Procedures related to the piston component.

7. Clutch and Right Crankcase Cover

Maintenance Notice

General note for clutch and right crankcase cover maintenance.

Troubleshooting Clutch and Right Crankcase

Common problems and solutions for the clutch and right crankcase cover.

Clutch Assembly and Maintenance

Maintenance procedures for the clutch assembly.

Right Crankcase Cover Removal and Installation

Procedures for removing and installing the right crankcase cover.

8. Magneto and Starting System

Maintenance Notice

General note for magneto and starting system maintenance.

Left Front Cover Maintenance

Procedures related to the left front cover of the engine.

Rotor Assembly Maintenance

Maintenance and assembly of the rotor assembly.

Starting Motor and Transmission System

Procedures for the starting motor and its transmission system.

9. Crankcase, Crankshaft, and Shift Mechanism

Maintenance Notice

General note for crankcase, crankshaft, and shift mechanism maintenance.

Troubleshooting Crankcase, Crankshaft, Shift

Common problems and solutions for the crankcase, crankshaft, and shift mechanism.

Crankcase Removal and Mounting

Procedures for removing and mounting the crankcase.

Crankshaft and Balance Shaft Procedures

Procedures for removing and mounting the crankshaft and balance shaft.

Variable Transmission System Procedures

Procedures for removing and mounting the variable transmission system.

10. Frame and Exhaust System

Maintenance Notice

General note regarding frame and exhaust system maintenance.

Troubleshooting Frame and Exhaust

Common problems and solutions for the frame and exhaust system.

Frame Maintenance

Procedures for maintaining and repairing the motorcycle frame components.

Exhaust Muffler Maintenance

Procedures for maintaining and repairing the exhaust muffler.

11. Front Wheel, Front Suspension, and Steering Stem

Maintenance Notice

General note for front wheel, suspension, and steering stem maintenance.

Key Torque Values

Important torque values for front wheel and suspension components.

Troubleshooting Front Wheel, Suspension, Steering

Common problems and solutions for the front wheel, suspension, and steering stem.

Front Suspension Device Maintenance

Procedures related to the front suspension components.

Front Brake System Checks

Checks and maintenance for the front brake system.

Steering Stem Maintenance

Procedures for maintaining and adjusting the steering stem.

Front Wheel Maintenance

Procedures for removing and mounting the front wheel.

12. Rear Wheel and Rear Suspension Device

Maintenance Notice

General note for rear wheel and suspension maintenance.

Key Torque Values

Important torque values for rear wheel and suspension components.

Troubleshooting Rear Wheel and Suspension

Common problems and solutions for the rear wheel and suspension device.

Rear Wheel Maintenance

Procedures for removing, installing, and inspecting the rear wheel.

Rear Fork and Suspension Maintenance

Maintenance procedures for the rear fork and shock absorber.

Troubleshooting and Torque Values

Common issues and key torque specifications for rear components.

13. General Remarks of Electrical System

Precautions for Circuit Inspection

Important precautions before performing electrical circuit inspections.

System Principle and Composition

Overview of the electrical system's principles and components.

14. Power Supply System

Power Supply System Overview

General introduction to the power supply system.

Major Parts and Components

Identification of key components in the power supply system.

Circuit Schematic Drawing

Schematic diagram of the power supply system's electrical connections.

Charging System Maintenance

Procedures for maintaining the motorcycle's charging system.

15. Starting System

Starting System Overview

Introduction to the motorcycle's starting system.

Major Parts and Components

Identification of key components within the starting system.

Circuit Schematic Drawing

Electrical schematic for the starting system.

Starting System Maintenance

Procedures for maintaining and troubleshooting the starting system.

16. Illumination and Signal System

Illumination System Overview

Introduction to headlamp, signal lamps, and horn systems.

Headlamp System Maintenance

Maintenance procedures for the headlamp illumination system.

Signal Lamp and Horn Control

Operation and control of signal lamps and the horn system.

Circuit Schematic and Major Components

Electrical schematic and identification of key parts.

17. Electrical Starting Control System

Control System Overview

Introduction to the electrical information display system.

Major Parts and Components

Key components of the information display system.

Circuit Schematic Drawing

Electrical schematic for the control system.

Electrical Starting Control System Maintenance

Procedures for maintaining the electrical starting control system.

18. Engine Management System

EMS System Overview

Introduction to the Engine Management System (EMS).

EMS Components and Operating Principles

Overview of EMS components and their operating principles.

EMS System Composition

Breakdown of EMS sensors and actuators.

Engine Management System Maintenance

Procedures for maintaining the Engine Management System.

19. Electrical System Diagram

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