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Yingang YG48Q-5A Maintenance Manual

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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 YG48Q-5A 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 YG48Q-5Amotorcycle , 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!
YG48Q-5AMaintenance ManualForeword
Foreword
1

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Summary of Contents for Yingang YG48Q-5A

  • Page 1 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.

  • Page 2: Table Of Contents

    YG48Q-5A Maintenance ManualContents Contents 1-12 Overview 13-23 Lubrication system 24-39 Inspection and adjustment 40-45 Fuel system 46-50 Removal and installation of engine 51-67 Cylinder head, cylinder and piston 68-78 Clutch and Right crankcase cover 79-87 Magneto and starting system 88-104...

  • Page 3: Overview

    YG48Q-5AMaintenanceManualOverview 1、Overview Engine Number Position 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: Frame Number Position: Engine Number Position: Engine Number Frame Number...
  • Page 4 YG48Q-5AMaintenanceManualOverview Maintenance Precautions To disassemble and assemble a motorcycle, Whenever reassembling after being disassembled, special service tools (SST) and general-purpose replace new washers, sealing members, etc. tools must be used in accordance with relevant regulations. While fastening bolts or nuts, proceed in diagonal crossing sequence to gradually screw down to the The specified or equivalent lubricating grease (oil) required torque for 2 to 3 tries.
  • Page 5 YG48Q-5AMaintenanceManualOverview The connector shall be fully inserted in place. For a connector with lock, confirm whether the lock is completely fixed. Make sure the harness is not falling off In case the fuse is blown, check for the causes and, Make sure the plastic jacket of the connector is securely after being repaired, replace corresponding fuse covering the connector without scaling off.
  • Page 6 YG48Q-5AMaintenanceManualOverview In case of a welded clamp, it shall not bite the wire hose or adhesive tape. harness towards the weld mark In case of a wire harness with garland, it shall be reliably The wire harness shall be clamped at the position harnessed.
  • Page 7 YG48Q-5AMaintenanceManualOverview 15. While using the test table, operate according to the maintenance manual after understanding the explanations in the instruction manual. 16. Do not drop or throw the parts and components. Have you learned by heart the method of application? Are the measurement range and polarity in accordance with the instruction manual? 17.
  • Page 8 YG48Q-5AMaintenanceManualOverview Technical Data of Main Performance Item Data Length 1780mm Width 775mm Height 1050mm Wheelbase 1230mm Min. ground clearance 165mm Complete vehicle weight Non-loaded weight: 107kg, Curb weight:157kg, Frame type Cradle type Rake angle 26° Front suspension device spring & hydraulic composite damping Rear suspension device spring &...
  • Page 9 YG48Q-5AMaintenanceManualOverview Clutch Wet clutch, coil clutch, paper friction wafer Clutch operating system Manual mechanical Variable speed gear 4-speed constant mesh 4.059 Primary reduction ratio Ⅰ 3.273 Transmission gear ratio Ⅱ 1.938 Ⅲ 1.350 Ⅳ 1.043 3.846 Final reduction ratio Gear shifting mode Left foot operated to and back type Sequence: I－N－Ⅱ－Ⅲ－Ⅳ...
  • Page 10 YG48Q-5AMaintenanceManualOverview Standard Torque Values ENGINE Thread diameter Item Quantity Torque value (N.m) Thread locker (mm) Cylinder head cover connecting bolt 8～12 40～50 Cylinder bolt 8～12 Valve adjusting screw nut 8～12 Timing driven sprocket bolt 7～11 Rocker-arm shaft cover 24～28 Magneto flywheel fastening nut 38～45 LOCTITE 243 Clutch fastening nut...
  • Page 11 YG48Q-5AMaintenanceManualOverview Name and dimensions Torque value (N.m) 4.5 ～6 5mm bolt & nut 8 ～12 6mm bolt & nut 18 ～25 8mm bolt & nut 30 ～40 10mm bolt & nut 50 ～60 12mm bolt & nut 3.5 ～5 5mm Screw 7 ～11 6mm Screw 10 ～15...
  • Page 12 YG48Q-5AMaintenanceManualOverview Magnetic generator rotor puller: for dismantling Rubber hammer, Iron hammer, Copper hammer magnetic generator rotor Feeler gauge: to measure the clearance of piston, Micrometer: to measure the dimensions of piston, piston cylinder, valve, etc. pin, etc. Dial gauge: to measure the wheel bouncing, cylinder Cylinder barometer: to measure the cylinder pressure inner diameter, etc.
  • Page 13 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 accessories or maintenance ability, it can repair it by itself.
  • Page 14 YG48Q-5AMaintenanceManualOverview YINGANG TECNOLOGY Service Station. Symbol Descriptions Meanings of various symbols in this manual: Explanation Measures to be prompted during operating, inspecting and maintaining. NOTICE: Special instructions or disposal measures given to prevent motorcycle from being damaged. WARNING: Special instructions or measures given to avoid serious damages or personal injuries.

  • Page 15: Lubrication System

    Lubrication system YG48Q-5AMaintenance Manual 2、Lubrication system Maintenance notice Inspection of lubricating oil Troubleshooting Replacement of lubricating oil Lubricating Position of Complete Vehicle Cleaning of Lubricating Oil Strainer Lubrication of Control Lines Cleaning and Replacement of Lubricating Oil Filter Engine Lubrication System Diagram Oil Pump Maintenance notice This section introduces the inspection and replacement method of engine lubricating oil as well as the cleaning method of...
  • Page 16 Lubrication system YG48Q-5AMaintenance Manual Troubleshooting ● ● Lubricating oil contaminated Lubricating oil consumes too fast 1. Fail to replace lubricating oil according to the There is leakage with the engine; maintenance period table; The piston ring is worn. 2. The pouring orifice thread is damaged thus causing The inlet/exhaust valve guide is worn;...
  • Page 17 Lubrication system YG48Q-5AMaintenance Manual Crankshaft oil through Oil injection port Camshaft oil through Oil pump FILTER, OIL Oil outlet...
  • Page 18 Lubrication system YG48Q-5AMaintenance Manual Replacement of lubricating oil While replacing lubricating oil, it shall be carried out before the engine has cooled down. This will ensure quick and complete discharge of the engine oil inside the crankcase. When replacing, unscrew the oil drain plug and discharge the waste engine oil, and then clean the oil drain plug, engine oil strainer, engine oil filter, etc.
  • Page 19 Lubrication system YG48Q-5AMaintenance Manual Flush the strainer with cleaning agent Cleaning of Strainer Cleaning and Replacement of Lubricating Oil Filter Remove the engine oil filter cover to detach the engine oil filter element, clean the filter cover and filter element with cleaning agent, and then mount the clean engine oil element.
  • Page 20 Lubrication system YG48Q-5AMaintenance Manual Loosen the right crankcase cover connecting bolts to detach the right crankcase cover components. Remove the oil pump Use the clutch push rod extractor remove the clutch push rod assembly; use the fixing tool to prevent the clutch and the primary driving gear from rotating;...
  • Page 21 Lubrication system YG48Q-5AMaintenance Manual tightening torque:114N.m -126N.m； 3、Install clutch push rod assembly； 4、 After the right crankcase cover is mounted in place, the angle and position of the clutch operating lever may possibly change; readjustment shall be carried out to accommodate the adjustment of clutch control line； 5、...

  • Page 22: Inspection And Adjustment

    Inspection and adjustment YG48Q-5A Maintenance Manual 3、Inspection and adjustment Maintenance notice Brake system Spark plug Running system Lubricating oil Clutch control line Oil output tank Driving chain Timing phase Battery Checking Cylinder pressure Replacement of Fuse Timing chain tension Brake lamp adjustment...
  • Page 23 Inspection and adjustment YG48Q-5A Maintenance Manual yellow line will be revealed at the crack point. Explanation: Unless expressly stated or indicated in the maintenance period table, check and adjust all parts of the YG48Q-5Amotorcycle according to the contents hereof before using it.
  • Page 24 Inspection and adjustment YG48Q-5A Maintenance Manual Spark Plug Remove the spark plug cap. Remove the spark plug with a socket wrench. Visually check whether there is any damage with the spark plug insulator and ablation with the electrodes. If yes, replace them.
  • Page 25 Inspection and adjustment YG48Q-5A Maintenance Manual While aligning Timing phase It shall be carried out when the vehicle is new or there is any question about the timing phase. Remove the cylinder head cover Turn the crankshaft pulley Counterclockwise to align the scale line “I”...
  • Page 26 Inspection and adjustment YG48Q-5A Maintenance Manual The main reasons for insufficient cylinder pressure care not let the sealing washer and so on fall into the include: crankcase. Insert the tensioner 4locking key into Incorrect valve clearance adjusted the tail end of the newchain tensioner, turn and retract ...
  • Page 27 Inspection and adjustment YG48Q-5A Maintenance Manual Valve clearance the top of the crankcase cover, and both intake and exhaust rock arms do not move but stop at their loosest Notice: While adjusting the valve clearance, the engine shall position, which shows that the piston is in its top dead center position of the compressing stroke.
  • Page 28 Inspection and adjustment YG48Q-5A Maintenance Manual Idle speed Air filter Notice Cleaning and replacement of air filter  Remove the left side covers Handle it carefully to Check and adjust the idle speed after all other items avoid scraping. of the engine have been adjusted to the specified ...
  • Page 29 Inspection and adjustment YG48Q-5A Maintenance Manual throttle control line with throttle valve body and unscrew the retaining nut B to make adjust the free stroke in a larger range. Screw up the retaining but B after the adjustment. Check whether the throttle can turn smoothly from full open to full close at any position.
  • Page 30 Inspection and adjustment YG48Q-5A Maintenance Manual bleed air from the deflating valve of the brake caliper with Actuate the front brake handle a vacuum pump, and then refill brake fluid into the cylinder. When the vacuum pump has fully exhausted the air Min.
  • Page 31 Inspection and adjustment YG48Q-5A Maintenance Manual touch to the side of the brake disc. It shows that the brake shoe has touched the wear limit The brake piece checking （1）Pulling the rear brake, checking the wear and tear of the brake shoe. If the mark "△" on the drum brake cover and also on the brake cam alignment, shows the brake Adjustment nut.
  • Page 32 Inspection and adjustment YG48Q-5A Maintenance Manual specs Clutch control line Front tire Rear tire Clutch is the key part of transmitting power in motorcycle 120/70-12 120/70-12 transmission system，should adjust it according to the Cold tire air Front tire Front tire pressure following overhauling content．The content is the free...
  • Page 33 Inspection and adjustment YG48Q-5A Maintenance Manual turn the clutch operating arm by a proper angle and remount it, and then mount the clutch control line, finally If the chain is too loose or too tight, make adjustment. adjust it to a satisfied free stroke according to the fine Adjusting methods: adjustment.
  • Page 34 Inspection and adjustment YG48Q-5A Maintenance Manual must be consistent with each other. Measure the voltage of the negative pole with a voltmeter; if it is less than 12V, recharge it with a charge power Cleaning and coating oil supply. Seriously corroded conductor connectors of the battery shall be replaced.
  • Page 35 Inspection and adjustment YG48Q-5A Maintenance Manual cause serious hurt to skin and eyes by contact. Replacement of Fuse Set the ignition switch to “OFF” position. The specified In case of contact with it, wash it off for 5 minutes and see a doctor immediately.
  • Page 36 Inspection and adjustment YG48Q-5A Maintenance Manual  Rotating , directly unplugging  Rotating and disassemble the bulb.  Install the new bulb in reverse order Headlight bulb12V35W/35W，12V 1.5W Bulb Front and rear lamp bulb  Loosen the screws, remove the lamp lampshade ...
  • Page 37 Inspection and adjustment YG48Q-5A Maintenance Manual Suspension system Bolts, nuts and fasteners Front suspension All the bolts, nuts and fasteners shall be screwed up as Make the front brake in braking state and press the front per the maintenance period table. And check all the cotter fork bracket for several times, and check the front pins, safety gripping gears, locks, etc.
  • Page 38 YG48Q-5AMaintenance ManualFuel system 4、Fuel system...

  • Page 39: Fuel System

    YG48Q-5AMaintenance ManualFuel system Fuel system Maintenance notice Disassembly and assembly of fuel tank Troubleshooting Removal and installation of air filter Removal and installation of fuel tank Removal and installation of carburetor Maintenance notice This section introduces the knowledge related to the fuel system. CAUTION ...
  • Page 40 YG48Q-5AMaintenance ManualFuel system To avoid fuel line contamination, clog the joint with Removal and installation of fuel tank fireproof fabric after pulling off the fuel tube. Disassemble step Remove the seat Unscrew one connecting bolts Installation steps The installation procedures are the removal procedures in reverse order.
  • Page 41 YG48Q-5AMaintenance ManualFuel system Installation steps： The installation procedures are the removal procedures in reverse order. While installing, the locating slot must be aligned with the locating lobe of throttle body Warning: Remove and installation of carburetor Donot further disassemble the removed throttle body; Disassemble step：...
  • Page 42 YG48Q-5A Maintenance ManualRemoval and installation of engine 5、Removal and installation of engine —...

  • Page 43: Removal And Installation Of Engine

    YG48Q-5A Maintenance ManualRemoval and installation of engine Removal and installation of engine Maintenance notice Installation of engine Removal of engine Maintenance notice It is only necessary to remove the engine from the frame when performing maintenance on the engine’s crankshaft, balancing shaft, driving parts, etc.
  • Page 44 YG48Q-5A Maintenance ManualRemoval and installation of engine Removal of engine Remove the magnetic motor, gear display line and Park the motorcycle on the plane ground, and hit the line wire completely drain the engine lubricating oil. Remove bracket from left and right Remove the left rear cover of the box and the control mechanism of the variable speed pedal..
  • Page 45 YG48Q-5A Maintenance ManualRemoval and installation of engine Removal of engine;  Loosen the nut and remove the lower hanging bolt.  Move the engine slowly from the right. Installation of engine The installation of engine is in the reverse order of removal of engine.
  • Page 46 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston 6、Cylinder head, cylinder and piston Cylinder head cover Cylinder Cylinder head...

  • Page 47: Cylinder Head, Cylinder And Piston

    YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Cylinder head, cylinder and piston Maintenance notice Cylinder head Troubleshooting Cylinder Cylinder head cover Piston Camshaft Maintenance notice The lubrication of the camshaft and rocker arm is implemented by pumping oil by the oil pump through the oil troughs of the cylinder, cylinder head and cylinder head cover;...
  • Page 48 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Top planeness 0.05 φ38.975～φ38.995mm mm φ38.975mm Piston external diameter Fit clearance with 0.01mm～0.04mm 0.04mm cylinder Piston and piston φ12.994mm～φ13mm φ12.994mm Piston pin external diameter φ13.002mm～φ13.010mm φ13.010mm Piston pin hole inside diameter Fit clearance 0.002mm～0.015mm...
  • Page 49 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Troubleshooting  ●Excessive noise Low cylinder pressure Valve: Incorrect valve adjustment; Incorrect valve clearance adjusted; Valve jammed or valve spring broken; Valve ablated or bent; Camshaft worn or damaged; Valve sealing failure; Timing chain too long, worn or damaged;...
  • Page 50 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Cylinder head cover with a valve clearance adjusting tool as required. To remove the cylinder head cover: Mount the valve cover, etc. Remove the lower / upper eyehole covers and turn the crankshaft so that the piston is at the upper dead point of the compression stroke.
  • Page 51 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Camshaft To remove the camshaft: Remove the lower / upper eyehole cover and turn Alignment the crankshaft so that the piston is at the upper dead point of the compression stroke. Strip the timing chain from the timing driven sprocket, Remove the cylinder head cover (See Removal of and remove the timing driven sprocket.
  • Page 52 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Check the camshaft for abrasion, damage, oil through jamming, etc. and check whether the decompressor flying block can rotate and return smoothly. Measure the maximum IN / EX lift. Maintenance limit: IN≥5.56mm, EX ≥5.32mm Max.
  • Page 53 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Pull off the spark plug cap, Installation is in the reverse order of removal. Precautions for installation: Confirm the location pin; clean all parts and components, and check whether the cylinder head oil through is unobstructed, clean and free of leak.
  • Page 54 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Disassembly and assembly of cylinder head Disassemble and assemble the cylinder head according to the following diagram. Use the valve remover / replacerto remove and mount the intake valve and exhaust valve. The spark plug must be tightened to the specified tightening torque of（15～20）N.m for fear of leak.
  • Page 55 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Cylinder head inspection Measure the width of the valve contacting surface. Maintenance limit: ≤1.7mm Check whether the cylinder head is unobstructed, clean and free of leaks; check the cylinder head’s spark plug hole and valve seat for cracks; insert the valve into the...
  • Page 56 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Cylinder inspection Check the cylinder for abrasion or damage, and check the cylinder wall for scratch. Whether the cylinder wall is scratched Notice: Do not drop the location pin into the crankcase. Do not bruise the cylinder wall.
  • Page 57 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Piston Mount the cylinder (See Installation of cylinder). To remove the piston: Mount the cylinder head (See Installation of cylinder Remove the cylinder head cover (See Removal of head); cylinder head cover) Mount the camshaft (See Installation of camshaft).
  • Page 58 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Notice: Do not damage the piston pin and piston ring. Do not reverse the mounting position of the first ring (DY marker) and second ring (D marker). With side with marker face the top of...
  • Page 59 YG48Q-5A Maintenance ManualCylinder Head, Cylinder and Piston Piston inspection Measure the piston pin external diameter. Check the piston for abrasion or damage, cracks, etc. and Clearance gauge Maintenance limit: ≥φ12.994mm check the skirt section for scratch. Measure the piston external diameter at the position Work out the clearance between the cylinder and piston.

  • Page 60: Clutch And Right Crankcase Cover

    YG48Q-5AMaintenance ManualClutch and Right crankcase cover Clutch and Right crankcase cover Clutch Right crankcase cove Engine...
  • Page 61 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Clutch and Right crankcase cover Maintenance notice Clutch Troubleshooting Right crankcase cover Maintenance notice To carry out the maintenance stated herein, it is unnecessary to detach the engine from the frame. However, the engine lubricating oil must be discharged.
  • Page 62 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Troubleshooting  Clutch In case of clutch operation failure, a better correction may usually achieved by adjusting the clutch handle free stroke.  Clutch slipping while accelerating Insufficient free stroke; Clutch disc abrasion; Clutch plate deformed or bent; Clutch spring failure.
  • Page 63 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Right crankcase cover To remove the cylinder head cover: To install the right crankcase cover: Remove the oil drain plug to drain the engine oil Confirm the location pin; clean up the residual inside the crankcase. sealing paper gaskets on the right crankcase and right crankcase cover.
  • Page 64 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Adjust the direction of the clutch operating lever,Mount the clutch operating lever, rear brake return spring, cotter pin, rear brake lamp switch, etc. Refill engine oil. Notice: Do not scrape the crankshaft oil seal. Assemble only when the rack side of the clutch push rod faces the crankshaft.
  • Page 65 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Disassemble and assemble of right crankcase cover Procedure Quantity Remarks Removing order Installation is in the reverse order of removal COVER，CRANRCASE，R GASKET, COVER, CRANKCASE.R 离合器推杆 离合器操纵杆 操纵杆回位弹簧 OIL GAGE OIL SEAL13.7×24×5 FORK PLTAE clutch PLATE clutch OIL-RING OIL SEAL12×21×4 COVER chutch...
  • Page 66 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Clutch To install the clutch: To remove the clutch: Mount the clutch washer with the sabotage side Remove the right crankcase cover (See “Removal facing the main shaft right bearing. of right crankcase cover"). Mount the clutch.
  • Page 67 YG48Q-5AMaintenance ManualClutch and Right crankcase cover Mount the clutch push rod with the clutch push rod assembler . Assemble the right crankcase cover by turning the clutch push rod until its rack side faces the crankshaft. (See “Installation of right crankcase cover").
  • Page 68 YG48Q-5A Maintenance ManualClutch and Right crankcase cover Removal / Installation of Clutch Procedure Quantity Remarks Removing order Installation is in the reverse order of removal CLUTCH DRIVE GEAR, PRIMAR FIXING PLATE CIRCLIP COLLAR SPRING, CAM PLATE, SIDE COVER SPRING PIN KNOCK BEARING 6000 SCREW M5×12...
  • Page 69 YG48Q-5A Maintenance ManualClutch and Right crankcase cover Disassemble and assemble of clutch Disassemble and assemble the clutch according to the following diagram. While removing the clutch lift plate, alternatively loosen the 6connecting bolts to avoid damage of cracking due to uneven force of the clutch spring.
  • Page 70 YG48Q-5A Maintenance ManualClutch and Right crankcase cover SPRING DRIVEN GEAR COLLAR, SHAFT PLATE, UPPER CIRCLIP COLLAR Clutch inspection Check the clutch disc. If there is a scratch or Measure the free length of the clutch spring. Maintenance limit: ≥41.3mm. depigment or a strong scorching smell, replace it.
  • Page 71 YG48Q-5AMaintenance ManualMagneto and starting system 8、Magneto and starting system REF NO DESCRIPTION COVER DRIVE CHAIN，SELF-STARTER PLATE GUIDE, SPROCKET TENTIONER PLATE, SPROCKET, DRIVEN, SELF-STARTER PLATE, FIXED OIL SEAL 30×42×4.5 OIL SEAL 18.9×30×5 OIL-RING OIL SEAL 107×2 BOLT M6×12 OIL-RING OIL SEAL 5.7×1.9 SCREW M6×16...

  • Page 72: Magneto And Starting System

    YG48Q-5AMaintenance ManualMagneto and starting system Magneto and starting system Maintenance notice Rotor assembly Left front cover Starting motor and starting transmission system Maintenance notice To carry out the maintenance stated herein, and the engine lubricating oil must be drained.。 Before assembling, clean all parts and components with cleaning agent and dry them with compressed air. When mount，...
  • Page 73 YG48Q-5AMaintenance ManualMagneto and starting system Left front cover To remove the left front cover: Remove the gear shift pedal and left rear cover, and separate the magneto lead connector with the main cable. Left rear pla Gear shift pedal Unscrew the oil drain plug to drain the engine lubricating oil inside the engine Remove the double-linked gear cover connecting bolts...
  • Page 74 YG48Q-5AMaintenance ManualMagneto and starting system Disassembly and assembly of left front cover Disassemble and assemble the left front cover according to the following diagram. Use the thread retaining adhesive LOCTITE 648 while assembling the pressure plate bolt. Use the thread retaining adhesive LOCTITE 648 while assembling the magneto stator connecting bolt. In case of O-ring aging, prolonging or deforming, replace it.
  • Page 75 YG48Q-5AMaintenance ManualMagneto and starting system Rotor assembly To remove the clutch: Remove the left front cover (See Removal of left front cover). Remove the positioning pin and seal gasket. bolt 6、Remove the starting sprocket limit plate, remove the transmission chain and drive chain wheel Use the rotor fastening tool to fasten the rotor, and remove the fastening nut M10 and plain washer.
  • Page 76 YG48Q-5AMaintenance ManualMagneto and starting system Disassembly and assembly of rotor assembly Disassemble and assemble the rotor assembly according to the following diagram. （10-14） Use thread retaining adhesive LOCTITE 648 on the screw while assembling, with the tightening torque being Procedure Quantity Remarks Removing order...
  • Page 77 YG48Q-5AMaintenance ManualMagneto and starting system Starting motor and starting Mount the plain washer and apply thread retaining Transmission system adhesive LOCTITE648 to the fastening nut M10; use Remove the live wire and earth wire of the starting motor. the rotor fastening tool to fasten the rotor, and Remove the starting motor connecting bolt M6×25.
  • Page 78 YG48Q-5AMaintenance ManualMagneto and starting system Notice: Never let adhere to the left crank conical surface and rotor tapered surface. The disk gear shall only be capable of rotating clockwise flexibly relative to the rotor. Use the thread retaining adhesive LOCTITE 648 while assembling the pressure plate bolt.
  • Page 79 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism 9、Crankcase, crankshaft and Shift mechanism GASKE CAM SHAFT ASSY COUNTER SHAFT, TRANSMISSION SHAFT, KICK STARTER CRANKSHAF THE MAIN SHAFT, TRANSMISSION CRANKSHAFT, CRANKCASE, L PIN A, KNOCK...

  • Page 80: Crankcase, Crankshaft And Shift Mechanism

    YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Crankcase, crankshaft and Shift mechanism Maintenance notice Crankshaft and balance shaft Troubleshooting Variable transmission system Crankcase Maintenance notice To carry out the maintenance stated herein, the engine must be removed from the frame. To repair the crankshaft, balance shaft or variable transmission system, the left hand crankcase and the right hand crankcase must be separated, which is known as crankcase dissection.
  • Page 81 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Crankshaft bearing worn; Connecting rod big end bearing worn; Driving/driven shaft bearings worn; Balance shaft supplementary tooth spring failure.  Driving/driven shaft gears engaged badly Shift fork bent or damaged; Shift fork shaft bent; Gearshift drum badly machined or bearing shifted;...
  • Page 82 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Crankcase To remove the crankcase: Notice Remove the engine from the frame (engine oil fully Do not pry the left/right hand crankcase body by drained) and put it on the assembly operating table. inserting such tools as screwdrivers into the mould Remove such parts and components as right hand closing face.
  • Page 83 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Mount other parts and components of engine, mainly include right hand crankcase cover, clutch, gear Notice: shifter, cylinder head cover, camshaft, cylinder head, To close the crankcase, use your hand(s) to gently cylinder, piston, left front cover, rotor assembly, press it in place, or use a Bakelite hammer to strike it electrical starting transmission system, driving drive gently.
  • Page 84 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Removal and installation of crankcase Procedure Quantity Remarks Removing order Installation is in the reverse order of removal R.CRANKCASE GASKET CRANKSHAFT, CRANKCASE, L BOLT A, CYLINDER STUD （A） BOLT B, CYLINDER STUD (B) PIN A, KNOCK92401-10014 WASHER PIN A, KNOCK92401-10014 CLAMP, OVER FLOW PIPE...
  • Page 85 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Do not remove breather pipe joint, otherwise damage will be caused. Generally, do not remove the bearing; if it is removed, coat engine oil on surfaces of spare parts while pressing it in; mount it with SST and confirm the press-in depth of the bearing.
  • Page 86 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Generally, do not remove the bearing; if it is removed, coat engine oil on surfaces of spare parts while pressing it in; mount it with SST and confirm the press-in depth of the bearing. Assemble the driven shaft bearing with the with oil seal facing inwards.
  • Page 87 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Removal and installation of crankshaft and balance shaft Procedure Quantity Remarks Removing order Installation is in the reverse order of removal Left hand crankcase Crankshaft Knock pin GASKET Disassembly and assembly of crankshaft and balance shaft Do not further disassemble the crankshaft, otherwise the spar parts may be damaged.
  • Page 88 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Procedure Quantity Remarks Sequence of disassembling Assembling reverse order disassembling. KICK-START SYSTEM CIRCLIP 17，1 PLATE, RACHET, GUIDE BOLT M6×20 RACHET, KICK STARTER GEAR, KICK STARTER SPRING SUPPORT, SPRING, RACHET SPRING SUPPORT, SPRING, START WASHER 17 WASHER 20 SHAFT, KICK STARTER CIRCLIP 20.2×1×27...
  • Page 89 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Suppo Dial gauge Driving shaft Gearshift drum Measure the connecting rod large end side Counter shaft To mount the variable transmission system: clearance, the maintenance limit: ≤0.80mm. Place the right hand crankcase assembled with Clearance gauge crankshaft and balance shaft on the assembly operating table, and the driving/driven shaft and...
  • Page 90 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Removal and installation of driving shaft and driven shaft and gearshift drumand shifting shaft Attention: the washer, retainer, etc. must be assembled in place at the correct positions, the spare parts 8apply lubricating oil.while assembling Procedure Quantity Remarks...
  • Page 91 YG48Q-5AMaintenance ManualCrankcase, crankshaft and Shift mechanism Check Check the driving/driven shaft gears for serious abrasion and pit corrosion; check whether the shift fork is bent and whether the gearshift drum guiding slot is damaged. Driving/driven shaft inspection Warning Thread retaining adhesive LOCTITE243 must be applied to the rotor retaining nut M12 while assembling, with the tightening torque being 45N.m.
  • Page 92 YG48Q-5AMaintenance ManualFrame and exhaust system 10、Frame and exhaust system...

  • Page 93: Frame And Exhaust System

    YG48Q-5AMaintenance ManualFrame and exhaust system Frame and exhaust system Maintenance notice Removal and installation of rear mudguard Troubleshooting Removal / installation of exhaust muffler Coverings, headlamp and meter Rear position lamp assembly Maintenance notice To carry out the maintenance stated herein, take special care of the scratches and damages to the coverings, meter and light fittings.
  • Page 94 YG48Q-5A Maintenance ManualFrame and exhaust system Instrument Side cover and seat  Remove the meter assembly (total of 3 connecting bolts),  Remove the two nut, remove the seat. And remove the connection cable. Remove 3 hole covers keyhole Remove the left and right support ...
  • Page 95 YG48Q-5A Maintenance ManualFrame and exhaust system Headlamp dimming Front and rear lamp bulb12V1.5W Before driving, check the brightness, direction, etc. of the headlamp. BULB The adjustment can be made to the headlamp in the left / right and vertical directions.
  • Page 96 YG48Q-5A Maintenance ManualFrame and exhaust system  Dismantle the suspension bolt on the muffler. Connecting bolt  Dismantle muffler connecting nut.  Dismantle the muffler. To mount the exhaust muffler: 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.

  • Page 97: Front Wheel, Front Overhang And Steering Stem

    YG48Q-5A Maintenance ManualFront wheel, front overhang and steering stem 11、Front wheel, front suspension device and steering stem...
  • Page 98 YG48Q-5A Maintenance ManualFront wheel, front overhang and steering stem Front wheel, front suspension device and steering stem Maintenance notice Front suspension device Troubleshooting Front brake Control subassembly Steering stem Front wheel Maintenance notice This section introduces the removal, installation and maintenance of the front wheel, front suspension device (front fork), front brake and steering stem.
  • Page 99 YG48Q-5A Maintenance ManualFront wheel, front overhang and steering stem Tire pressure insufficient Shift fork bent or damaged.  Insufficient suspension device rigidity Insufficient front fork spring Insufficient hydraulic oil refilled in the front fork  Poor brake performance The brake is not adjusted as per regulations...
  • Page 100 YG48Q-5A Maintenance ManualFront wheel, front overhang and steering stem depth is less than 2mm) Gear is damaged． Speedometer Replace The indicator of the speedometer gear The gear drive speedometer fails to move gear box ring is damaged． Maintenance of Front Shock Absorber...
  • Page 101 YG48Q-5A Maintenance ManualFront wheel, front overhang and steering stem deformed deformed. deformed. stem For the damage form, fault symptom and repair method of front brake Item Damage form Trouble symptom Trouble symptom of Repair method ofcomponent motorcycle brake 1iquid is...
  • Page 102 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem  Control subassembly Remove the right brake cylinder body. 1、Remove the left/right balance weight. Remove the right brake cylinder body 2、Remove handle and combination switch  Pull off the brake switch leads ...
  • Page 103 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem To install the control subassembly Installation is in the reverse order of removal. While installing the brake cylinder body, make sure the cylinder is in the same height as the original...
  • Page 104 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem Disassembly and assembly of front wheel Dial indicator Disassemble and assemble the front wheel according to the following diagam. After the bearing is removed, replace with a new bearing along with dust seal.
  • Page 105 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem Unscrew the upper / lower connection plate bolt and. the Oil seal assembly: in primary lip and the dust lip direction of the tube bolt between coated with lubricating grease, oil seal...
  • Page 106 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem Check length of return spring to check it whether or To mount of steering stem Installation is in the reverse order of removal not is distored.29mm While installing the steering stem, adjust the adjusting nut...
  • Page 107 YG48Q-5A Maintenance ManualFront wheel, front suspension device and steering stem Warning: When it is replaced with a new brake strip or brake disc, do not drive it immediately; instead, drive it after holding and releasing the front brake handle until the brake strip and the brake disc are well engaged.
  • Page 108  YG48Q-5A Maintenance ManualRear wheel and rear suspension device 12、Rear wheel and rear suspension device...
  • Page 109  YG48Q-5A Maintenance ManualRear wheel and rear suspension device 12、Rear wheel and rear suspension device Maintenance notice Rear fork Troubleshooting Rearshock absorber Rear wheel Maintenance notice This section introduces the removal, installation and maintenance of the rear wheel, rear brake, rear fork and rear damper .While repairing the rear wheel andrear damper, reliably stand the motorcycle from under the engine a jack or...
  • Page 110  YG48Q-5A Maintenance ManualRear wheel and rear suspension device For the damage form, fault symptom and repair method of rear wheels Component Damage form Trouble symptom Trouble symptom of Repair method description ofcomponent motorcycle Off racking in Rear rim is twisted Rear rim is twisted and running．rearwheelwobbles...
  • Page 111  YG48Q-5A Maintenance ManualRear wheel and rear suspension device Rear wheel properly adjust the chain adjuster to ensure that the chain To remove the rear wheel slack is between 20mm and 30mm and that the left and Stand the motorcycle with a jack to lift the rear right scale lines of the chain adjuster are consistent, and wheel above the ground.
  • Page 112  YG48Q-5A Maintenance ManualRear wheel and rear suspension device 3、Remove the rear damper and rear fork connecting bolt. Take out bush and dismantle bolt of rear driven chain disc. Check rear driven chain disc whether it is exceed limit value.
  • Page 113  YG48Q-5A Maintenance ManualRear wheel and rear suspension device Rear fork bearing inspection 1. Dismantle rear brake caliper bolt Replace the inner shaft and coat of the bearing。face and apply lithium base grease on the bearing. After the installation is complete, check whether the bearing can rotate.
  • Page 114  YG48Q-5A Maintenance ManualRear wheel and rear suspension device Warning: When it is replaced with a new brake strip or brake disc, do not drive it immediately; instead, drive it after holding and releasing the front brake handle until the brake strip and the brake disc are well engaged.

  • Page 115: General Remarks Of Electrical System

    The development of electronics will especially influence the motorcycle’s electrical system significantly. YG48Q-5A’s electrical system uses a lot of advanced vehicle electronics technologies that are much more complicated then the traditional motorcycle. It comprises the following sub-systems: •...
  • Page 116 Power supply system is the precondition for a complete vehicle to operate, capable of providing sufficient electric energy for other electrical systems. The main contents include recharging, charge storing and discharging. YG48Q-5A power supply features large power supply capacity as high as more than 250W. It comprises the following parts and components: •...
  • Page 117 YG48Q-5A Maintenance ManualPower supply system Maintenance of Charging System Disassemble. assemble and check charging system Check socket whether contact well. Check plate electrode whether is damaged Dismantle rectifier bolt and measure two yellow wire whether is short circuit or broken circuit by millimeter.
  • Page 118 YG48Q-5A Maintenance ManualPower supply system Major faults diagnosis Phenomenon Possible causes Solutions    No electricity in the complete Main fuse is blown; Replace main fuse   vehicle: Main fuse circuits contact poorly; Re-plug.   Accumulator’s positive and ...
  • Page 119 When the engine starts to work, an exogenous action is needed to help it run, thus entering the ignition & fuel supply procedure to enable the internal combustion engine to combust repeatedly and work steadily. YG48Q-5A motorcycle is only equipped with electric controlled starting. First, release it from the protection of shift position switch, side stand switch and clutch switch;...
  • Page 120 YG48Q-5A Maintenance ManualStarting system Maintenance of starting system Disassemble, assemble and maintain Turn on ignition switch and flameout switch to check electrical start whether energize. Check magneto coil whether contact well. Check plate electrode whether is damaged Check electrical starting switch whether contact well.
  • Page 121 YG48Q-5A Maintenance ManualStarting system Major faults diagnosis Phenomenon Possible causes Solutions    Starting relay Accumulator voltage too low; Recharge the accumulator; doesn’t attract;   Corresponding fuse is not connected or is Connect the fuse or replace it;...
  • Page 122 YG48Q-5A Maintenance ManualIllumination signal system 16、Illumination signal system Overview Major parts and components Circuit schematic drawing Major faults diagnosis Overview Illumination signal system is an important guaranty for the safe driving of the vehicle. It includes the headlamp illumination system, signal lamp control system and horn system.
  • Page 123 YG48Q-5A Maintenance ManualIllumination signal system Circuit schematic drawing...
  • Page 124 YG48Q-5A Maintenance ManualIllumination signal system Maintenance of illumination system Take off headlamp switch socket to check whether Turn on ignition switch and flameout switch to check there is current electrical start whether energize. Dismantle headlamp bolt to check lamp case whether is damaged.
  • Page 125 YG48Q-5A Maintenance ManualIllumination signal system 17. Signal lamp control systems 12. Take off ignition switch socket to check whether Check flasher whether is burned or plug is loose. current input headlamp switch Turn on signal indication switch left handle to check switch whether is rusted or lose contact.
  • Page 126 YG48Q-5A Maintenance ManualIllumination signal system...
  • Page 127 Maintenance ManualIllumination signal system YG48Q-5A Major faults diagnosis Phenomenon Possible causes Solutions    Headlamp does not Accumulator voltage too low; Recharge the accumulator;   illuminate; Corresponding fuse is not connected or is Connect the fuse or replace it;...

  • Page 128: Electrical Starting Control System

    YG48Q-5A Maintenance ManualElectrical starting control system 17、Electrical starting control system Overview Major parts and components Circuit schematic drawing Major faults diagnosis Overview The information display system displays the dynamic and static information of the complete vehicle on the instrument panel for the driver’s safe operation.
  • Page 129 YG48Q-5A Maintenance ManualElectrical starting control system Line color function corresponding table COLOUR FUNCTION COLOUR FUNCTION Black Power Supply(+) Green/Red Neutral indicator The rotational speed signal green Power Supply(-) Black/ Yellow Fuel oil signal Brown Instrument lighting Yellow / white Battery power supply（+）...
  • Page 130 YG48Q-5A Maintenance ManualElectrical starting control system Dismantle headlamp holder to check holder whether there is current. Dismantle meter bolt to check it whether is loose or damaged. Dismantle meter bolt and odometer cable to check bolt whether is damaged or loose.
  • Page 131 YG48Q-5A Maintenance ManualElectrical starting control system Major faults diagnosis Phenomenon Possible causes Solutions    Winker indicator is out of The winker indicator filament is burnt Replace winker indicator bulb work    Meter dial illuminator is out...
  • Page 132 YG48Q-5A Maintenance ManualEngine management system 18、Engine management system System Overview Tools Major parts and components Maintenance depending on the malfcode Maintenance depending on the performance Circuit schematic drawing Maintenance of Engine management system System Overview Components of system and Operating principle...
  • Page 133 YG48Q-5A Maintenance ManualEngine management system Major parts and components...
  • Page 134 YG48Q-5A Maintenance ManualEngine management system...
  • Page 135 YG48Q-5A Maintenance ManualEngine management system ITEM PIN No. DESCRIBE ITEM PIN No. DESCRIBE J1-1 IACAHi J2-1 COILA J1-2 MAGNETO CUT RELAY J2-2 J1-3 J2-3 KW2000 J1-4 J2-4 CRANK HI J1-5 J2-5 INJA J1-6 TACH J2-6 J1-7 CANLo J2-7 O2AHTR J1-8...
  • Page 136 YG48Q-5A Maintenance ManualEngine management system Oil pressure garge: messure the fuel pressure. Cylinder pressure garge: messure the pressure garge. Maintenance depending on the malfcode. Description If the issure cannot repeat, the issure analysis may be wrong. The multimeter below means the digital type. Pointer-type is forbidden.
  • Page 137 YG48Q-5A Maintenance ManualEngine management system P1693 Tachometer Circuit Low Voltage KsDGDM_TAC_Circuit_Low Tachometer P1694 Tachometer Circuit High Voltage KsDGDM_TAC_Circuit_High Malfcode：P0107 Information：MAP Circuit Low Voltage or Open ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next Check the data of ‘BARO’. Make sure whether it is about 100kPa...
  • Page 138 YG48Q-5A Maintenance ManualEngine management system Malfcode：P0113 Information：IAT Circuit High Voltage ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on. Next check whether the data of ‘intake air temperature’ equals to the real intake Setp 5 air temperature.
  • Page 139 YG48Q-5A Maintenance ManualEngine management system check whether the following pins are short to battery or open: J2-10, J2-14 Harness issue of the ECU and pin C and D of the sensor. Next crank the engine and stay idle. Check whether the ‘engine temperture’ goes Help high when engine get warm.
  • Page 140 YG48Q-5A Maintenance ManualEngine management system B、Injector: leakage or not maintenance Change sensor C、Fuel pressure too big or not D、 Valve clearance is to small or not Malfcode：P0201 Information：Injector 1 Circuit Malfunction ITEM OPERATION RESULT NEXT STEP Connect the diagnostic tool, and ignition on.
  • Page 141 YG48Q-5A Maintenance ManualEngine management system Remove the connector. Use multimeter to check whether the resistance Next between pin A and pin D, pin B and pin C is about 53±5.3Ω Change stepper motor Check whether the 4 wires are short to battery/ground or open.
  • Page 142 YG48Q-5A Maintenance ManualEngine management system Check the pump. Check whether the ‘RMP’ data on the diagnostic tool shows the Next real engine RPM. Check the crank sensor. Next Pull out the spark plug, check whether the spark over is normal.
  • Page 143 YG48Q-5A Maintenance ManualEngine management system Next Change the TB Check whether the idle pintle has been adjusted Next Maintenance Check wehtherther is any leakage of the intake pipe. Next Next Check whether the IACV works well Change IACV Help Remove the engine temperature sensor and check whether the...

  • Page 144: Electrical System Diagram

    Maintenance ManualElectrical System Diagram YG48Q-5A 19、Electrical System Diagram...

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