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Yingang YG125-30B Manual Download Page 93

YG125-30B Maintenance Manual

Crankcase, crankshaft and Shift mechanism

99

Disassemble and assemble the balance shaft according to the following diagram.

Notice:

Always align the markers while assembling the balance shaft.

No.

Procedure

Quantity

Remarks

Sequence of disassembling

Assembling

is

in

the

reverse

order

of

disassembling.

1

Balance shaft

1

Apply engine oil while assembling

2

Driving gear

1

Apply engine oil while assembling

3

Pad

1

Apply engine oil while assembling

4

Driven plate

1

5

Buffer rubber

1

Apply engine oil while assembling

6

Driven gear

1

Apply engine oil while assembling

7

Spring

1

Apply engine oil while assembling

8

WASHER

1

Apply engine oil while assembling

9

WASHER

1

Apply engine oil while assembling

10

WASHER

1

Apply engine oil while assembling

11

RACE

1

Apply engine oil while assembling

12

Pad

1

Apply engine oil while assembling

13

Nut M14*1.25

1

14

bear

1

Apply engine oil while assembling

Summary of Contents for YG125-30B

Page 1: ...8 describes various constituting parts of the motorcycle respectively Chapter 19 contains the electrical system diagram The standard maintenance procedures maintenance precautions and general maintena...

Page 2: ...ystem 79 87 9 Crankcase crankshaft and Shift mechanism 88 104 10 Frame and exhaust system 105 109 11 Front wheel front overhang and steering stem 110 121 12 Rear wheel and rear overhang 122 127 13 Gen...

Page 3: ...ition Bar Tool About Motorcycle Maintenance Maintenance Period Table Technical Data of Main Performance Symbol Descriptions Standard Torque Values Engine Number Position Photo of Complete Vehicle Fram...

Page 4: ...and components After reassembling check whether all the spare parts are mounted properly by means of turning moving and operating them 4 To disassemble and assemble a motorcycle special service tools...

Page 5: ...bending Make sure the terminals are not too long or are falling off The connector shall be fully inserted in place For a connector with lock confirm whether the lock is completely fixed Make sure the...

Page 6: ...he vehicle body The wire harness shall be incapable of passing through the position contacting a bolt a screw head or any front part The wire harness shall not be slackened or be forcibly pulled If th...

Page 7: ...enance manual after understanding the explanations in the instruction manual 16 Do not drop or throw the parts and components 17 In case of rust on the terminals carry out connection operation after d...

Page 8: ...urb weight 136kg Vehicle body Frame type Rake angle Front suspension device Rear suspension device Front Tire size Rear Tire size Front wheel pressure Rear wheel pressure Front brake Rear brake Fuel t...

Page 9: ...bore Stroke Cylinder displacement Compression ratio Max power Max torque Valve clearance cold Valve driving gear Air filter Cooling method Lubrication method Engine oil grade Engine oil charge volume...

Page 10: ...15A 10A CPR8EA 9 0 7 0 9mm Open magnetic circuit Electronically injection ECU control EMS EMS EMS 12V 35W 35W Front 12V10W Rear 12V10W 12V21W 5W Standard Torque Values ENGINE Item Quantity Thread dia...

Page 11: ...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 Rea...

Page 12: ...ic special tool for cross hexagon gun tip Valve adjusting socket for valve clearance adjustment Socket for mantling dismantling nuts and bolts Cutting plier Nipper plier expansion plier for mantling d...

Page 13: ...iod Odometer km Remark 2 1000 k m 4 000 km 8 000 km 12 000 km Remarks Fuel system passage I I I Throttle operating system I I I I Throttle valve body I I I I Air filter element Remark 1 C C Replace ev...

Page 14: ...ent C Cleaning R Replacement A Adjustment L Lubrication This item is subject to maintenance by persons from YINGANG TECNOLOGY Service Station If the user has special service tools maintenance accessor...

Page 15: ...N m Use suggested engine oil Use the mixtures of engine oil and molybdenum disulfide Use thread locker Use sealant Use lithium base grease 1 Measures to be prompted during operating inspecting and ma...

Page 16: ...il its quality scale must reach Grade SG and its viscosity shall be selected according to the accompanying diagram depending upon region and air temperature changes While replacing lubricating oil ful...

Page 17: ...in the above diagram besides applying dedicated lubricating oil for chain to the driving chain apply lithium base grease to all other positions All lubricating oils not specified for use in this manu...

Page 18: ...l Lubrication system 16 Engine Lubrication System Diagram Crankshaft oil through Spindle oil through Countershaft oil through Camshaft oil through Cylinder head oil through Cylinder oil through Oil fi...

Page 19: ...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 r...

Page 20: ...g 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 th...

Page 21: ...embly and assembly of oil pump etc Steps for oil pump removal 1 Remove the oil drain plug to drain the engine oil inside the crankcase 2 Loosen the right crankcase cover connecting bolts to detach the...

Page 22: ...be replaced with new ones 6 Remember to refill engine oil after all these are completed CAUTION The clutch retaining nut must be screwed up to the specified tightening torque must be applied to preve...

Page 23: ...to the sense organs of human being The way is simple and easy to use it is used wide in motorcycle maintenance Testing examination method This way is a way that test the size of part and change of ge...

Page 24: ...rcycle according to the contents hereof before using it Technical specifications Throttle bar free stroke 1 3mm Recommended spark plug CPR8EA 9 Spark plug gap 0 7 0 9mm Valve clearance cold IN 0 06 0...

Page 25: ...ket is in good condition To 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 Lubricating oil Park the motorcycle on a flat...

Page 26: ...is abnormal should check electronic ignition high voltage coil charging on the generator and trigger coil etc After properly timing pull off the tensioner locking key and coat the mixture of engine o...

Page 27: ...ng sound Dah Dah it indicates insufficient tension of the chain tensioner replace it with a new one To replace the chain tensioner Unscrew the 2 M6 16 socket cap screw to remove the sealing washer and...

Page 28: ...tion 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...

Page 29: ...olled 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...

Page 30: ...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 retainin...

Page 31: ...fluid is pumped out firmly nip the handle or completely push down quickly screw the deflating valve bolt with the torque being 7 9 N m 6 Mount the brake cylinder cover with the sealing gasket flattene...

Page 32: ...to be changed Please go to the designated special maintenance station And it is better to use the parts from our company Caution Please change the brake shoe in time if it has been touched the wear l...

Page 33: ...should adjust it according to the following overhauling content The content is the free stroke of clutch control handle general is 10 20mm some venial need adjust the adjusting screw of declutch mecha...

Page 34: ...ion 10 20mm If the chain is too loose or too tight make adjustment Adjusting methods Unscrew the rear wheel spindle nut and turn the adjusting bolt on the chain adjuster until the specified tension is...

Page 35: ...s than 12V recharge it with a charge power supply Seriously corroded conductor connectors of the battery shall be replaced Installation of accumulator Installation is in the reverse order of removal W...

Page 36: ...e 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...

Page 37: ...rotate in counter clockwise l Install new bulb in opposite order as below Taillight bulb 12V 9W 3W Front and rear lamp bulb l Loosen the screws remove the lamp lampshade l Lightly press bulb rotate in...

Page 38: ...up to the specified torques Rear suspension Forcibly press the rear end of the seat cushion with the rear suspension and check the rear fork spindle sleeve for abrasion or damage If it is damaged rep...

Page 39: ...YG125 30B Maintenance Manual Fuel system 41 4 Fuel system Fuel tank Throttle valve body Air filter Fuel pump Inlet pipe...

Page 40: ...ng position of such sealing members as the O ring while removing various parts of the fuel system While reassembling always use new sealing members such as an O ring Technical specifications Throat op...

Page 41: ...nstallation procedures are the removal procedures in reverse order While installing note that the wiring of the fuel pump control wire shall be in strict accordance with the wiring diagram Avoid fuel...

Page 42: ...move throttle body including the fuel injector Installation steps The installation procedures are the removal procedures in reverse order While installing the locating slot must be aligned with the lo...

Page 43: ...much dust deposit on the filtering element The engine is difficult to start Insufficient engine output Poor performance of engine during idle run Excessive fuel consumption The exhaust muffler pipe fu...

Page 44: ...YG125 30B Maintenance Manual Removal and installation of engine 46 5 Removal and installation of engine...

Page 45: ...ing oil To maintain the heat engine parts including cylinder head cylinder body piston etc it is necessary to remove the coverings fuel tank throttle body air filter assembly etc To remove the engine...

Page 46: ...de cover seat and fuel tank 3 Remove muffler 4 Remove engine cycle tube 5 Remove Left Right cylinder head connecting pipe 6 Detach the earth wire from the negative pole of the battery 7 Remove clutch...

Page 47: ...the drive chain l Remove the rear absorber and rear fork connecting bolt l Unscrew the nut and take out the rear fork shaft l Take out the rear fork backwards l Loosen the nut and remove the lower han...

Page 48: ...YG125 30B Maintenance Manual Removal and installation of engine 50 Remove the drive chain Move the engine slowly from the right...

Page 49: ...YG125 30B Maintenance Manual Cylinder Head Cylinder and Piston 52 6 Cylinder head cylinder and piston Cylinder head cover Cylinder head Cylinder...

Page 50: ...While assembling coat engine oil and molybdenum disulfide lubricant on the protruding surface of the camshaft for preliminary lubrication Be careful not to damage the cylinder wall and piston Technic...

Page 51: ...necting rod small end Internal diameter 13 013mm 13 028mm 13 028mm Clearance with piston pin 0 013mm 0 033mm 0 033mm Piston ring First ring gap clearance 0 015mm 0 05mm 0 05mm Second ring gap clearanc...

Page 52: ...er piston ring worn l Black smoke from exhaust 1 Valve guide worn 2 Oil shield leaked or damaged 3 Cylinder piston piston ring worn 4 Piston ring clearance too big 5 Piston ring incorrectly installed...

Page 53: ...drop the location pin into the crankcase To mount the cylinder head cover 1 Turn the crankshaft so that the piston is at the upper dead point of the compression stroke 2 Remember to confirm the locati...

Page 54: ...pins 6 Remove the camshaft bearings 7 Strip the timing chain from the timing driven sprocket and remove the timing driven sprocket 8 Remove the camshaft Caution Do not drop the timing chain into the...

Page 55: ...st the valve clearance 7 Connect the phase sensor and mount the eyehole cover and upper eyehole cover in turn Caution When the tensioner is not tensioned never turn the crankshaft for fear of interloc...

Page 56: ...recautions for installation 1 Confirm the location pin clean all parts and components and check whether the cylinder head oil through is unobstructed clean and free of leak 2 Replace new cylinder head...

Page 57: ...ocedure Quantity Remarks 1 cylinder block 1 2 Cylinder head gasket 1 Coat the mixture of engine oil and molybdenum disulfide on the stem while assembling 3 Cylinder body gasket 1 Coat the mixture of e...

Page 58: ...e Maintenance limit 4 53mm Measure the valve stem diameter Maintenance limit IN 5 15mm EX 5 15mm Measure the width of the valve contacting surface Maintenance limit 1 7mm Measure the free length of th...

Page 59: ...the piston slide gage seat Cylinder inspection Check the cylinder for abrasion or damage and check the cylinder wall for scratch Check the cylinder wall for deformation and use the edge ruler and clea...

Page 60: ...amshaft See Installation of camshaft 6 Mount the cylinder head cover See Installation of cylinder head cover Notice Assemble the piston with the top side with the marker facing exhaust side Do not dro...

Page 61: ...t reverse the mounting position of the first ring ATG marker and second ring A marker No Procedure Quantity Remarks Sequence of disassembling Assembling is in the reverse order of disassembling 1 Cran...

Page 62: ...m Measure the clearance between the piston ring and the piston groove before removing the piston ring Maintenance limit First ring Second ring 0 12mm Oil ring 0 40mm Mount the piston rings into the cy...

Page 63: ...YG125 30B Maintenance Manual Clutch and Right crankcase cover 70 Clutch and Right crankcase cover Clutch Right crankcase cove Engine...

Page 64: ...arts and components with cleaning agent and dry them with compressed air To assemble the clutch loosen the clutch spring and coat engine oil on the clutch disc in case of replacing new clutch the clut...

Page 65: ...le pressure 1 Clutch cable galling damaged or dirty 2 Clutch push rod damaged or jammed l Hard clutch operation There is burr on clutch housing chute l Shift lever can t return 1 Return spring cracked...

Page 66: ...the right crankcase cover connecting bolt 5 Take out the right crankcase cover component 6 Take out the right crankcase cover sealing paper gasket To install the right crankcase cover 1 Confirm the l...

Page 67: ...direction of the clutch operating lever Mount the clutch operating lever rear brake return spring cotter pin rear brake lamp switch etc 6 Refill engine oil Notice Do not scrape the crankshaft oil seal...

Page 68: ...er 1 2 Right crankcase cover sealing paper gasket 2 Replace it with a new one while assembling 3 clutch push rod 1 4 rubber ring 1 5 Oil Level Gauge 1 6 lever return spring 1 7 elastic cylindrical pin...

Page 69: ...sher 4 Remove the clutch 5 Remove the clutch washer To install the clutch 1 Mount the clutch washer with the sabotage side facing the main shaft right bearing 2 Mount the clutch 3 Mount the butterfly...

Page 70: ...er 6 Assemble the right crankcase cover by turning the clutch push rod until its rack side faces the crankshaft See Installation of right crankcase cover Warning Thread retaining adhesive LOCTITE243 m...

Page 71: ...h plate 1 14 Bolt m6 25 4 Disassemble and assemble of clutch Disassemble and assemble the clutch according to the following diagram While removing the clutch lift plate alternatively loosen the 6conne...

Page 72: ...order of removal 1 clutch bush 1 Tightening torque 12N m 2 clutch assembly 1 3 Nut M14 1 1 4 Flat washer 1 5 Deep groove ball bearing 1 Gum base soaking oil while assembling 6 Clutch out cover 1 7 Clu...

Page 73: ...e limit 2 8mm 3 Check the clutch plate for distortion and check the planners with a clearance gauge Maintenance limit 0 20mm 4 Measure the thickness of each clutch plate The thickness is 1 4mm 5 Measu...

Page 74: ...YG125 30B Maintenance Manual Magneto and starting system 79 8 Magneto and starting system Engine Double linked Gear Rotor assembly Left front cover Idle gear Disk gear Double linked gear cover...

Page 75: ...parts coat the mixture of engine oil and molybdenum disulfide onto the left crank journal as the initial lubrication Do not dent the seal surface and do not damage the stator coil Technical specifica...

Page 76: ...rear cover and separate the magneto lead connector with the main cable 2 Unscrew the oil drain plug to drain the engine lubricating oil inside the engine 3 Remove the double linked gear cover connecti...

Page 77: ...8 while assembling the magneto stator connecting bolt In case of O ring aging prolonging or deforming replace it Notice Do not dent the seal surface and do not damage the stator coil No Procedure Quan...

Page 78: ...ouble linked gear etc 3 Use the rotor fastening tool to fasten the rotor and remove the fastening nut M12 and plain washer 4 Use the rotor extractor to extract the rotor 5 Remove the rotor assembly wa...

Page 79: ...der Installation is in the reverse order of removal 1 Screw M8 16 6 Use thread retaining adhesive LOCTITE 648 while assembling with the tightening torque being 25N m 2 One way device outer body 1 3 On...

Page 80: ...linked gear The Washer and the double linked gear is assembled into the left crankcase 5 To install the left front cover Clean the sealing paper gasket remaining on the left crankcase and left front...

Page 81: ...dhesive LOCTITE 648 while assembling the pressure plate bolt Warning Thread retaining adhesive LOCTITE243 must be applied to the rotor retaining nut M12 while assembling with the tightening torque bei...

Page 82: ...YG125 30B Maintenance Manual Magneto and starting system 87 7 Measure the washer thickness the maintenance limit 0 4mm Vernier calipers...

Page 83: ...Maintenance Manual Crankcase crankshaft and Shift mechanism 88 9 Crankcase crankshaft and Shift mechanism Right hand crankcase body Crankshaft Gearshift drum Counter shaft Main shaft Left hand crankc...

Page 84: ...l be removed 1 Right hand crankcase clutch gear shifter 2 Cylinder head cover camshaft cylinder head cylinder and piston See Cylinder head cylinder and piston 3 Left front cover rotor assembly electri...

Page 85: ...1 Shift fork bent or damaged 2 Shift fork shaft bent 3 Gearshift drum badly machined or bearing shifted 4 Driving driven shaft bearings shifted l Gear shift trouble 1 Shift fork bent or damaged 2 Shif...

Page 86: ...ce shaft Notice Do not pry the left right hand crankcase body by inserting such tools as screwdrivers into the mould closing face To mount the crankcase 1 Place the right hand crankcase on the assembl...

Page 87: ...front cover rotor assembly electrical starting transmission system driving drive sprocket etc Refer to the related sections 6 Mount the assembled engine onto the frame and engine oil to complete the...

Page 88: ...1 6 Release oil bolt 1 7 Pad 1 8 Left hand crankcase 1 9 O ring 1 10 Double head bolt 1 11 Main gear plate 1 12 Bolt M6 16 1 13 Pin 10 14 2 14 BOLT FLG M6 40 7 15 BOLT FLG M6 45 1 16 BOLT FLG M6 70 7...

Page 89: ...er of removal 1 Left hand crankcase 1 Apply engine oil while assembling 2 Crankshaft bearing 6203 1 Apply engine oil while assembling 3 Driving shaft bearing 6006 1 Let the oil seal side face inward a...

Page 90: ...rankcase 1 2 Balance shaft bearing 6302 1 Apply engine oil while assembling 3 Driving shaft bearing 62 22 C3 1 Let the oil seal side face inward and apply engine oil while assembling 4 Gear shift shaf...

Page 91: ...ring until the temperature at the inner circle of the bearing reaches 106 and then assemble the crankshaft 2 Use a high power electric drier to heat the right crankcase body balance shaft bearing unti...

Page 92: ...Remarks Removing order Installation is in the reverse order of removal 1 Left hand crankcase 1 2 Crankshaft 1 3 Balance shaft 1 4 Right hand crankcase 1 Disassembly and assembly of crankshaft and bal...

Page 93: ...while assembling 2 Driving gear 1 Apply engine oil while assembling 3 Pad 1 Apply engine oil while assembling 4 Driven plate 1 5 Buffer rubber 1 Apply engine oil while assembling 6 Driven gear 1 Appl...

Page 94: ...0 10mm 3 Measure the connecting rod big end radial clearance Maintenance limit 0 06mm 4 Measure the connecting rod large end side clearance the maintenance limit 0 80mm 5 Measure the left hand crank j...

Page 95: ...the shift fork and check whether the driving driven shaft can rotate freely 5 Mount the shift arm 6 Replace it with a new paper pad assembly one while assembling mount the left hand crankcase See Inst...

Page 96: ...oil while assembling 9 driven shaft 1 Apply engine oil while assembling 10 Warping spring 1 11 Bolt M8 28 1 12 gearshift drum 1 Apply engine oil while assembling 13 Shift plant assm 1 Apply engine oi...

Page 97: ...only remove unloading gear arm is not required to remove unloading gear drum assembly can be directly drawn outward shift arm combination To mount the shift mechanism 1 Mount the gearshift arm combin...

Page 98: ...aintenance Manual Crankcase crankshaft and Shift mechanism 105 Warning Thread retaining adhesive LOCTITE243 must be applied to the rotor retaining nut M12 while assembling with the tightening torque b...

Page 99: ...YG125 30B Maintenance Manual Frame and exhaust system 106 10 Frame and exhaust system...

Page 100: ...tom of component Trouble symptom of motorcycle Repair method Frame The frame is deformed or broken The frame is deformed or broken Running off tracking Calibrate or replace frame Main stand Deformatio...

Page 101: ...patch plug to remove the headlamp l Pull off the left right turn lamp connecting wire from the headlamp bracket l Remove the meter assembly total of 2 connecting bolts To mount the coverings headlamp...

Page 102: ...ght bulb Replacement of turn lamp bulb l Loosen the screws remove the lamp lampshade l Lightly press bulb rotate in counter clockwise l Install new bulb in opposite order as below Front and rear lamp...

Page 103: ...Installation is in the reverse order of removal The muffler seal gasket at the engine s exhaust port shall be replaced with a new one While mounting apply sealants at the joining part of the exhaust...

Page 104: ...YG125 30B Maintenance Manual Front wheel front overhang and steering stem 110 11 Front wheel front suspension device and steering stem...

Page 105: ...e values Front wheel spindle 50N m 60N m Steering handle set bolt 20 30N m Front fork vertical pipe cap nut 50 60N m Upper lower connection plate set bolt 8 12N m Brake disc fastening nut 20 30N m Tro...

Page 106: ...able The steel cable The clutch is slipping or not fully disconnected Replace control steel cable Rear brake pedal The free stroke is over small The clutch is not fully disconnected Readjust the free...

Page 107: ...der Piston rod Over worn or damaged Over soft at front shock cylinder Replace piston rod Piston ring is over worn or damaged Over soft at front shock cylinder Replace piston ring Oil sealing Cut edge...

Page 108: ...e lose effect exhaust front brake oil way oil pipe is broken oil leakage from oil pipe brake lose effect replace oil pipe front brake oil pipe is clogged oil pipe is clogged brake lose effect clean or...

Page 109: ...control line l Remove the right combination switch l Remove the right brake cylinder body l Remove the clutch control line and disassemble the connection of the clutch switch leads and the main cable...

Page 110: ...bolt at the connection board and then the bolt at direction of the tube up to the torque of 20 30N m 4 Do not mount the throttle cable in the opposite direction of the feeder on the right handle other...

Page 111: ...he front wheel spindle on the V holder and measure the deflection of the wheel spindle with a dial gauge if the reading is no less than 0 2mm replace the front wheel spindle Front wheel bearing inspec...

Page 112: ...e installing the front brake caliper apply the thread retaining adhesive LOCTITE 243 with the tightening torque being 20 30N m Check 1 Dismantle oil drain bolt and check bolt whether or not is loose 2...

Page 113: ...it worn 8 Measure free length of absorber spring and check it whether or not is distorted 490mm 9 Check length of return spring to check it whether or not is distored 29mm 10 Fill absorber oil per sta...

Page 114: ...teering stem adjust the adjusting nut and inspect it by turning it left and right and moving it up and down to ensure no vertical play and flexible rotating laterally Tighten the cap nut to the requir...

Page 115: ...drive it after holding and releasing the front brake handle until the brake strip and the brake disc are well engaged Front brake disc inspection Measure the thickness of the brake disc with an outsi...

Page 116: ...YG125 30B Maintenance Manual Rear wheel and rear suspension device 122 12 Rear wheel and rear suspension device...

Page 117: ...r damper reliably stand the motorcycle from under the engine a jack or other supports Key torque values Real wheel spindle nut 60 90 N m Rear fork shaft nut 50 60N m Troubleshooting Rear wheel shimmy...

Page 118: ...scription Damage form Trouble symptom of component Trouble symptom of motorcycle Repair method Sprocket and cam sprocket Gear is over wor Drive chain has abnormal sound drive chain is easy to fall out...

Page 119: ...right scale lines of the chain adjuster are consistent and then fasten the rear wheel spindle nut to the required tightening torque of 60 90N m Warning The rear wheel spindle must be firmly screwed u...

Page 120: ...ecting bolt 4 Take out the rear fork backwards To install the rear fork Installation is in the reverse order of removal While installing the rear fork shaft make sure that the end covers shall be alig...

Page 121: ...the reverse order of removal While installing use the upper hole for the lower installation of the damper Notice Before removing the damper the tightening torque of the bolt connecting the frame is 30...

Page 122: ...here the removal is convenient first following the principle of searching from easy to difficulty Both the parameter detection method and the parts replacement method are acceptable However if the par...

Page 123: ...The main contents include recharging charge storing and discharging YG125 30A power supply features large power supply capacity as high as more than 250W It comprises the following parts and component...

Page 124: ...rt circuit or broken circuit by millimeter 3 Open left cover to check magneto coil whether is burned or loose 4 Dismantle magneto bolt and replace magneto coil 5 Dismantle starting clutch and replace...

Page 125: ...ccumulator s terminal voltage is less then 12V l The vehicle has been stored for too long and the accumulator has discharged automatically l Charging circuit fails in the complete vehicle l Accumulato...

Page 126: ...n to power on the relay start the engine to drive the idle gear and starter gear thus enabling the engine to enter its operating cycle for normal ignition fuel injection and combustion The system cons...

Page 127: ...ether is charged 4 Check rectifier whether is charged 5 Check fuse whether is burned 6 Check positive and negative pole of battery whether contact well 7 Check relay whether is damaged 8 Check magneto...

Page 128: ...shift position switch l Connect the line or replace clutch switch l Connect the line or replace the left switch l Connect the line or replace the left switch l Replace the starting relay l Repair or...

Page 129: ...les and people to dodge by the flash of the turn lamp while driving at night it shall inform of its presence by the tail lamp s front rear position lamp and illuminate the number on the license plate...

Page 130: ...YG125 30B Maintenance Manual Illumination signal system 136 Circuit schematic drawing...

Page 131: ...whether is charged 5 Check fuse whether is burned 6 Take off headlamp switch socket to check whether there is current 7 Dismantle headlamp bolt to check lamp case whether is damaged 8 Take out headlam...

Page 132: ...eck horn button whether is rusted or lose contact Adjust velum of electrical horn to check it whether is damaged 18 Check neutral socket whether contact well 19 Signal lamp control systems Check flash...

Page 133: ...Manual Illumination signal system 139 Major parts and components Head lamp Combined rear position lamp Front brake lamp switch Rear brake lamp switch Horn Right combination switch Left combination swi...

Page 134: ...es of the main cable are open l Connect the fuse or replace it l Repair or replace the left switch l Replace bulb l Re plug l Repair or replace main cable l Brake lamp does not illuminate l Correspond...

Page 135: ...The complete vehicle information the YG125 30A displays include vehicle speed engine speed fuel indicator Neutral indicator turn indication high beam indication total subtotal mileage traveled and EFI...

Page 136: ...turn indicator 3 Meter reading and usage 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...

Page 137: ...lectrical start whether energize 2 Check fuse whether is burned 3 Dismantle headlamp holder to check holder whether there is current 4 Dismantle meter bolt to check it whether is loose or damaged 5 Di...

Page 138: ...ne poorly plugged or open circuit l Meter failed l ECU failed l Re plug or repair l Replace meter l Replace ECU l Fuel level indication failure l No indication while there is fuel l Having indication...

Page 139: ...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 prod...

Page 140: ...Engine management system 146 Major parts and components Intake air pressure sensor Throttle sensor Fuel Injector Idle speed control valve Cylinder Head Temperature Sensor Throttle body Electronic con...

Page 141: ...YG125 30B Maintenance Manual Engine management system 147 Circuit schematic drawing...

Page 142: ...ect 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...

Page 143: ...lant Oil Temperature Sensor Circuit Low Voltage KsDGDM_CoolantShortLow P0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open KsDGDM_CoolantShortHigh Throttle Position Sensor TPS P0122 TPS...

Page 144: ...emperature Yes Setp 5 No Next 3 Remove the connector and use the multimeter to check whether the resistance between pin B and D is reasonable according to the temperature Yes Step 5 No Next 4 Remove t...

Page 145: ...use the multimeter to check whether the resistance between pin A and C of the sensor is reasonable according to the temperature Yes Step 5 No Next 4 Use the multimeter to measure whether the voltage...

Page 146: ...o Next 3 Open the throttle to 100 slowly check whether the data of throttle opening goes to between 90 100 Yes Step 5 No Next 4 Repeat Step 3 check whether the data jumps when open the throttle slowly...

Page 147: ...k whether voltage of the relay feeder ear is about 12V Yes Change the pump No Next 3 Check whether the feeder ear is short to ground or open Yes Harness issue No Help Malfcode P0351 Information Cylind...

Page 148: ...l quality 5 Change the ECU and repeat the test if the issue is gone then the root cause is the ECU Or change the old one back to check the root cause ITEM OPERATION RESULT NEXT STEP Engine cannot star...

Page 149: ...blocked and whether the intake pipe leaks Yes Intake system maintenance No Next Whether there is carbon deposit at the throttle body and bypass channel Yes Clean the TB No Next Check whether the IACV...

Page 150: ...k plug Yes Next No Change the sprk plug Check whether the cylinder pressure is normal Yes Next No Check the engine Check whether the exhaust pipe is blocked or not No help Yes maintenance Backfire Pul...

Page 151: ...YG125 30B Maintenance Manual Electrical System Diagram 157 19 Electrical System Diagram...

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