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Cyclone Owners Manual (ZS250G)

1. B Chapter 2 Maintenance Knowledge Section 1 Attention Items of Maintenance When there are some problems with motorcycle you can have it repaired at Zongshen after service station or professional maintenance station Meanwhile you also can refer to this maintenance manual Parts on the motorcycle will be worn or loose during riding Lack of regular maintenance can affect the safety and reliability of your motorcycle and shorten the service life So a regular maintenance will help to keep your new motorcycle operating at peak performance l When motorcycle is being repaired please use the components accessories luboil and other accessorial materials which produced or recommended by our company you use the components which are not suitable for this motorcycle it will influence the motivity reliability stability and comfort of motorcycle Seriously the motorcycle will be destroyed 2 After disassembly and reinstallment please replace new gasket sealed components and open pin 3 When tightening bolts and nuts you should do with the principle of diagonal crossover and completely tighten to the standard torque value during 2 or 3 times 4 When cleaning the components please adopt non burning cleaning fluid Paint some luboil on the moving parts of components before installation 5 After installation check whether components are installed correctly Check methods are circumrotate movement operation and inspection 6 When disassem
2. Keep the rearview mirror clean and dustless Adjust it to its best angle before riding 2 Check whether side stand is bend or distorted Repair or replace it if bend or distorted m a a B 3 Check all the covers of motorcycle Re place them if damaged gt Replace the covers if damaged 4 Check whether the seat is damaged Re place it if damaged EOE gt Replace seat if damaged b Check whether the rubber cover of front pedal is damaged Replace it if damaged EXIT gt Replace rubber cover of front pedal if damaged 6 Check whether rear armrest is broken Repalce or repair them if is gt Replace rear armrest if it parts a D FONG FEE 3 The cause trouble description and repair method of frame and accessories Table4 5 Maintenance of Frame and Accessories component trouble description of trouble description of repair method Se eee Frame is infuenced by The jointing of frame Motorcycle shakes or road and is shaken breaks off oen normally Joint frame SCAN Motorcycle makes sound Side stand is distorted Side stand cannot d i uring running and park Correct or replace side or parts return normally ing ke Midi stand i Motorcycle makes sound Returning spring loses SUE during funning andpark Replace returning springiness ing is influenced Spring side stand left cover Bee
3. G dva LEFT TURNING LAMP tear licence plate lamp rit BL BL G R IR BLN y 0 Gr LB W BL Y BL B G P B LG LGG YW G qe WB clutch switeh HORN fuetsensor IUUD NACNETO SWITCH TURNING Headlight switch E diode BR BY G G BY ignition coil piston i ignitor starting motor RELAY grounding ENGLISH Copyright reserved by Zongshen group Formatl60mm x 230mm The 1st edition Aug 2013 The 1st print Aug 2013 ZS ZONGSHEN ZONGSHEN MOTORCYCLE CHONGQING ZONGSHEN MOTORCYCLE INDUSTRY MANUFACTURE CO LTD BADDRESS CHAOYOUCHANG BANAN DISTRICT CHONGQING CHINA HOTLINE 4007003088 ae e ait 222 OQ etas SOE rae B NES me id 9 9 Rae lt 09 4 ee 65000 AA
4. Wheel rotates freely Wheel rotates hardly 1 Check whether brake is dead 2 Check whether the axle of wheel is damaged or worn 3 Check whether the insulator between the wheel The pressure is normal Dismantle spark plug and put your fi on the screw thread hole of spark plug then press down the starting button or rapidly step the starting lever Check the pressure of tire The pressure is too low Check whether the valve element of wheel has leakage and whether wheel is broken off Finger cannot feel strong gas rush outward and the compressing pres sure of cylinder is not enough Finger can feel strong gas rush outward Meanwhile there is sound of flop flop The compressing pressure The compressing pres 5 not enough sure 15 normal Start engine and gently tum throttle con Check whether the outer connection of engine has leakage trol grip inward Observe the rev change Check whether the valve ia timing of engine Check whether the valve clearance is too small Check whether the seal between valve and valve holder is good Check whether piston ring breaks off or is dead or whether its lasticity is not enough The engine rev will en The engine rev won t en hance when the gun is hance MEER stepping on the 6 Check the abrasion of piston ring and cylinder bigger accelerator Check whether engine ignition Is ti
5. for Leftcoverisdamaged Appearance is influenced or repair left i Right cover is damaged Appearance is influenced Front tender gets strike Front fender is dis Motorcycle makes Replace front Mund torted or damaged sound during running fender Front fender gets strike Rear fender is dis Motorcycle makes Seat cover is damaged The comfort of riding pe Front pedal is dis Riding safety is Replace front pedal Rear pedal is dis Comfort for rider declines starting lever Starting lever is dis starting performance Replace starting torted or damaged is influenced lever rear view Rear view mirrior gets Rear view mirrior is Riding safety is Replace rear view mirrior strike or shake distorted or damaged influenced mirrior Rear carrier gets strike Rear carrier is distorted Setting of loads is Woint or replace rear u a B ZUNE SEHEN Section 6 Steering System The direction of motorcycle is operated by steering handlebar The steering handlebar connects with direction pole It sees the frame as the center and run the front shock absorber and operate the front wheel through the rotation of direction pole 1 The Structure and Working Principle of Steering System 1 Steering handlebar The right steering handlebar of motorcycle is the throttle control grip Control oil flow rate The right holding lever is the front brake lever Also there are left and right controlling switches rear view
6. MOTORCYCLE MAINTENANCE MANUAL ZS250GY 3 EFI state i UP ae a 466 0 M I i i a alg a s a a ac d R b b h m 4 re b a ues AT XC PURUS SCELERE EE E 20D mre e e e o a TauTa a a a aute _ PR aad th aad a gE 8 4 b bob Wo b ww b b B A CR RE MM e e a a 4 4 9 4 e a EN Ww x _ _ eh CN ob ob 5b b o BR B B Bo B B B Nm m wm LN NN LN M MN E Pu eee ee ee eee ee d LN MN p LA CHONGQING ZONGSHEN MOTORCYCLE INDUSTRY MANUFACTURE CO LTD ZS250GY 3 SERVICE MANUAL THE FIRST EDITION Aug 2013 Zongshen industrial group reserves all rights of this service manual The specifications and pictures in this manual are only for reference D A INTRODUCTIONS The manual intruduces the structure woking principle disassembly and inspection fault diagnosis and elimination Also this includes technical specifications performance parameter and maintenance data With both the descriptions and pictures you may have a comprehensive understanding of the conf
7. fuel tank without repair 4 Check the fuel pipe for fuel leakage or aging Check filter for block repair or replace it if blocked b If the fuel pipe has fuel leakage or aging replace it Before replacing the fuel pipe or filter Shut up ignition switch to stop the fuel pump and avoid the fuel flow out of the fuel tank rm Z G m gt PENDS HE 5 First of all dismantle the left and right side cover and seat Then remove fixed bolt and take out the fuel tank Keep the oil away from fire when dumping the oil 6 Remove the six fixed bolt M5 X 16 of fuel pump by hexagon wrench TS gt Please dump oil first and keep away from the fire when dismantling the pump 7 out the pump and then clean the oil sludge and water in the tank with oil sludge ESI 7 c M fuel pump p After cleaning the fuel tank could be used when drying out 8 Check the pump seal ring for aging breaking or oil leakage Replace it if necessary rm c G m IL X a 9 Check the motor of fuel pump for running And clean or replace the fuel strainer Replace the fuel filter when the motorcycle drives about 8000 10000Km eck the uel pump 3 The cause trouble description and repair method of fuel supply system Tab
8. spark plug dielectric is brown Theratioof Combustible mixed gas is normal Combustible mixed gas is thick Check whether cylinder ex Check lubricating system haust port and exhaust muffler are blocked with car bon deposite Combustible mixed gas 15 too thin Check whether fuel filter is blocked Check whether fuel nozzle is blocked 3 Check the oxygen sensor is working well Check whether air filter is blocked Check whether oxygen sensor is work ing well 3 Check fuel nozzle is in working order LI 1 Check whether the oil volume in crankcase insufficient M nh Check whether the oil in crankcase is dirty ts mucosity is too bad Check whether oil cleaner is blocked whether oil pump Is in good working ndition Check whether lubricating way is blocked LLL GS RBS Ne Z Co I 60 ZONGSHEN 1 5 Analysis of over consumption of engine fuel Engine fuel exceeds consumptive standard Check whether the operation is correct Yes No Support vehicle with side stand and rotate 1 Check whether motorcycle runs with loads or without wheel with hands economical speed or with low speed 2 Check whether the oil no is correct Wheel turns hard Wheel tums normally 1 Check whether brake is blocked 2 Check whether the axle is worn 3 Check whether the clapboard of w
9. has short circuit nition system has thing wrong with or open circuit short circuit or CDI device circ The cylinder open circuit pressure is Sufficient ON The cylinder ressure is D Check whether venthole of fuel necting point tank cap is blocked 2 Check whether fuel filter is blocked 1 Check whether the outer connection of engine has leakage 3 Check whether fuel nozzle is 1 Check whether igni 2 Check whether valve is timing blocked Check whether fuel tube tion coil has short circuit 3 Check whether valve clearance is too small l is broken or open circuit whether the seal of valve and valve holder is good 6 Check whether connector of fuel 2 Check whether trig 3 EUR whether piston ring breaks off or is dead or has insufficient nozzle and fuel pump assembly is loose gering coil has short cir L CE Deck the abrasion of piston ring and cylinder cult or open circuit Dismantle spark plu and check it dod The electrode of spark plug is wet Check whether air filter is blocked Dip a little gas in cylinder and try to start The running time is too Enginecancontinue shortorenginehasflame working after out after starting starting Check with fault di Check with fault diagnosis agnosis tester tester The electrode of spark plug is dry Z Co I 08 1 4 Analysis of engine overheatin
10. me All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1487149 Y MER AI rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 3448029 Xf same All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 3448027 t i All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1613961 All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1000532 NES All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 2020397 All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 3448028 All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1767202 All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 3580941 zesrz9 rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1767247 nzm All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china is 1767201 Al rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china 15 5574
11. a D PONDA HEN Section 3 Inlet and Exhaust System The inlet system of engine mainly consists of air cleaner and inlet pipe The main function of which is to guide and filtrate air reduce inlet noise and control the volume of mixed gas which is going to engine The exhaust system mainly consists of exhaust pipe and muffler The main function of which is to transfer the exhaust gas to atmosphere reduce the noise when exhausting and the temperature of exhaust gas and eliminate the spark in exhaust gas A good exhaust system can advance the inlet and exhaust system increase engine power and reduce the fuel consumption so it 1 also called exhaust muffler 1 The Structure of Inlet System 1 The Structure and Working Principle of Air Cleaner Air cleaner is the important component of inlet system The function of which is to filtrate purify the air entering into cylinder avoid dust sand entering into cylinder so that it will reduce the abrasion of cylinder piston and piston ring Its performance has a big effect on the motivity of engine noise of inlet and service lifetime Experiences indicate the abrasion of cylinder will increase 8 times the abrasion of piston will increase 3 times and the abrasion of piston ring will increase 9 times if air cleaner is not installed In this way the reliability of engine will reduce and the service lifetime will be shortened Therefore motor cycle must be installed with air cleaner The requirement of air cleaner is not only
12. electrochemistry The plate is divided into anode plate and cathode plate The active substance on anode plate is PbO2 and on cathode plate is Pb Electrolyte is liquid mixed vitriol with distilled water The temperature of electrolyte density for stan dard measurement is 20 C When battery is at the standard temperature in full charge condition its density is between 1 24 1 29g cm In each independent part of battery body there is a set of plates and electrolyte installed inside Each set of plates respectively does the chemistry with electrolyte and makes up of an independent battery Its voltage is about 2V 3 or 6 batteries are series wound and come into being a storage battery with the 6V or 12V voltage The battery cover is made of high insulative hard rubber and hard plastic which forms an integrated inner space with battery body 2 Co I 40 ZONGSHEN 1 Remove fuse tube and check whether it melts down Replace it with the same Fuse tube type 12V 20A CU When fuse tube is damaged replace it with the same type 2 Remove storage battery and measure whether its voltage is above 12V When it s lower than 12V remove and charge it A TOMO gt Screw down connecting bolt of storage battery when it is loose gt Add distilled water when the electrolyte level of storage battery is lower than the lower limit mark Keep away from fire while battery is charging Because it
13. horn sound is normal After adjustment electric horn still cannot make sound Electric horn is damaged Electric horn is adjusted unproperly Z Co I 68 D ZONES HEM 2 10 Analysis of brake light Brake light doesn t illuminate Dismantle the cover of brake light and check whether its bulb is burned out Yes Replace the bulb of brake light No With a lead make short circuit between two oe end of brake light switch or two ead end After short circuit brake light After shortcircuit brake light still doesn t illuminate can illuminate Y The switch of brake light is ad justed unproperly or the inner con necting point has bad connection Rub the power lead of brake light switch with cathode wire with a screwdriver or a lead Check the spark NO When rubbing there When rubbing 5 spark there is no Spa The lead between brake light The Don lead between ignition switch and brake light has short switch and brake light switch has circuit or open short circuit or open circuit 2 11 Analysis of ignition system Engine starts hard Dismantle high voltage wire and check whether there is spark spurt No fire Cut off the connecion of charging coil of generator and triggering coil and respectively measure the voltage Spark plug is dagmaged Repair or replace it Reconnect it Turn off the
14. 1 1 of coal oil and luboil Pull the steel wire to make mixed oil flow into the hose 3 Remove operating steel wire and clean the mixed oil outside Injection Lubrication Operate as follows 1 Enlace the end of metal spring plastic hose of operat ing steel wire with transparent adhesive tape Make it as a pipe as the picture 2 Raise the end with adhesive tape and pull out of steel head 3 Dip luboil in the hose with oil kettle until there is oil dripping from the lower steel wire metal hose wire head steel wire adhesive tape The cause trouble description and repair method of operation system Table4 7 Maintenance of Operation System component trouble description of trouble description of component motorcycle repair handlebar Handlebar is Handlebar is distorted Motorcyclerunstowardsoneside Correct or replace distorted handlebar Steel wire cannot Clutch handlebar is hard Clean lubricate or re oe flexibly pulled to be operated or cannot place operating steel steel cab outside the cable returned well cable Steel wire breaks off Clutch cannot disen Replace operating gage completely steel cable The free stroke 15 Rear brake pedal cannot nal place ee stroke 15 Rear brake loses control Readjust the free stroke lt a a B UNDE SEN Section 8 Shock Absorber Front shock absorber is the spring connecting part between front wheel and ve
15. close of one way valve which causes a big resistance so that it reduces the shake of front shock absorber spring 2 Rear Shock Absorber The rear shock absorber of this motorcycle adopts compound of hydraulic pressure and spring It mainly consists of upper tie in rubber cover gasket rear shock absorber spring rear shock absorber lever piston damper and lower tie in Rear shock absorber mainly gets the axial pressure of rear wheel When the rear wheel gets the strike or shake for the road condition rear shock absorber will compress and expand The hydraulic pressure oil of damper is forced to flow through the damping hole so it reduces the shake of rear shock absorber spring 2 Disassembly and Maintenance of Front Shock Absorber 1 Check the effective stroke and performance of front shock absorber and check whether there is leakage from front shock absorber gt Maintain front shock absorber in time if it has some problems in order to ensure the riding safety 2 Dismantle four fixed bolt of front shock absorber and remove the front shock absorber bolt ot front ron shock absorber 3 Dismantle bolt of front shock absorber and drain front shock absorber oil Check whether the oil is bad Replace it if bad 4 Remove the oil seal and spring clamp of front Shock absorber and check whether the edge of oil seal is worn Replace it if necessary 5 Dismantle front shock absorber pole and lower pipe Check the
16. force must be overcome When moving the positive charge the work for conquering the force between electric charge is called potential The differential potential between any two points is called voltage We use U to stand for and its unit is V When electric current flows in a substance the substance will produce a resistance which is called electric resistance We use to stand for its unit is Different substance has different resistance For example the resistance of copper iron aluminium is small which is called conductor However the resistance of wood china plastic is big which is called dielectric Also there are some other substances such as silicon whose electric performance is between conductor and dielectric which is called semiconductor 2 Ohm s Law Ohm s law indicates the relationship among voltage resistance and electric current Viz Electric current I and voltage U have direct proportion and electric current I and resistance R have inverse proportion Its formula is U Also UZIR R U I 3 Electric apparatus direct current DC alternating current AC and electrical source Electric apparatus is usually called load which is an equipment that can consume electric power and transfer the power to other kind of power The device which offers power to electric apparatus is called electrical source or power supply The electric current what electrical source offers to electric equipment has two types One type whose intensity and di
17. frame Secondly install front fork assembly handlebar assembly front and rear fender assembly shock absorber assembly carrier assembly front and rear wheel assembly fuel tank assembly and seat assembly Thirdly install headlight taillight steering indicator horn and battery assembly The fourth connect all electric circuit and control cables The fifth install driving chain dentiform belt wind shield and chain cover or belt cover Last lubricate the whole motorcycle 6 Consult the following reference about disassembly installation and inspection if there is any assembly se quence difference which is caused by different type and structure 7 Pay attention to the following Choose a clean and wide place strictly follow the assembly requirements parts connecting should accord with specification avoid misfitting and leaving out of any gaskets cotter pin and fixing clip 3 Adjustment after Repair The interconnection of parts have been affected in some extent after repair To recover the performance of motorcycle adjust them according to the specification of user smanual adjust as follows z G 42 LL 7 2 G 42 Ai 8 PENDS 1 Ignition Time Adjustment If there is a wrong ignition advance angle it will cause a series of problems such as hard engine starting power decrease high fuel consumption engine overheating uncomplete fuel burning exhaust value overrun Short service lifetime and s
18. generator AC magnet rotor generator and AC three phase generator Like DC generator it also works according to the principle of electromagnetism induction But it doesn t produce electric current through the method that lead plumbs magnetic wire and moves in the well proportional magnetic field It produces inductive AC through the method that the rotor which made of permanent magnet rotates continously and comes into being a rotating magnetic field then makes magnetic wire continously and alternately pass the fixed coil 3 The Structure and Working Principle of Storage Battery This kind of storage battery has light weight small bulk good seal and shockproof performance and the plumbum acid storage battery has small inner resistance and stable voltage It mainly consists of battery body cover plate electrolyte and clapboard The battery body is made of hard rubber or plastic which is acidproof heat resistant and shock proof The battery is divided into or 6 unattached parts according to the different stated voltage There must be marked two marks outside the battery body The upper mark is H and the lower one is L which respectively indicate the upper limit and lower limit Meanwhile there are anode and cathode marked on battery is anode and is cathode Plate is the main substance where storage battery does chemistry of charging and discharging It is made of plumbum antimony alloy pieces which are painted active substance and processed through
19. has a same axle with throttle lever and throttle valve The structure is a linear variable resistor and its sliding terminal is drived by throttle axle Resistance signal which is passed to the ECU through this sensor depends on the opening of throttle EFI could judge the real time load of engine and dynamic variation according to the signal and its rate of changes which output from the sensor sensor of intake air temperature is installed on the pipe of intake system The function of it is to test air temperature enter into the engine It also use thermistor of NTC coefficient as a sensing element The change of gas temperature directly affects its density fluctuation therefore intake air temperature is one of the importance parameters for computing actual amount of air which enters into the cylinder Nozzle is an electromagnetic switch device Two poles elicite from coil connect with ECU through engine wires Voltage is applied to coil under the control of ECU and the coil produces magnetic force to overcome spring force fuel pressures and a vacuum suction of intake manifold suck up iron core that could enables fuel to traverse the seal surface of ball valve which is the one with the iron core then the fuel sprays from nozzle and forms a mist spray After interruption of power supply magnetic disappears and nozzle shuts The top of fuel injector adopts rubber sealing for forming a reliable leakproofness of fuel pressure with the port of fuel c
20. illuminate AC power supply illumi natingsystem Remove the connecting component between the lead bundle of generator and vehicle cable Check whether there is Pone export from the export lead of illuminating coil with a bulb The bulb doesn t illuminate Thebulbilluminates Replace rectifier The the illuminating coil of generator or its export lead has open circuit or short circuit Illuminating light still cannotilluminate Illuminating light can illuminate The inner of rectifier has short circuit Disassemble head light assembly and check whether its bulb 1 burned out Check whetherthere is power export from the powerimport lead of illuminatingswitch with the method of connecting a bulb Yes Replace the bulb of head light and check whether other bulbs are burned out Yes Generator or the circuit between igni tion switch and illuminating switch has open circuit or short circuit With a lead make short circuit be tween electric source lead of illumi nating switch and export lead Yes After short circuit connecting After short circuit connecting illumi illuminating light will illuminate nating light still doesn t illuminate The connecting point of The circuit between illuminating inner illuminating switch switch and illuminating light has has bad connection open circuit or short circuit Z Co I 66 3
21. to the following introduction of disassembly installation and maintenance The basic principle of disassembly of Engine and other components is the same as principle of whole motorcycle The order and method of disassembly is different because of different structure and character istic of different component Pay more attention to the store environment and order for all disassembled parts are components Pay attention to the following items when disassembling motorcycle and components 1 The components which have high requirement for position should check its position mark first when disassembling If the mark is not clear please re make a mark 2 When dismantling the components which are too tight please use the special tools If you have none special tools support the motorcycle with some wooden or soft metal then hammer the right place with gluey hammer to avoid component damage 3 When dismantling the assembly of front rear shock absorber and front rear wheel support motor cycle with main stand Avoid motorcycle falling down to hurt people or damage the components A Put the components which are dismantled in order Do not put those components directly on the ground Such as spray components chromeplate components and high precision components 5 The nuts and bolts which are dismantled should be stored carefully which also can be installed on the original place but don t tighten them 6 The components which are only dismantled by special to
22. will diffuse combustible and explosive gas during charging 3 Dismantle the socket of charging coil of generator and measure the charging coil with multimeter Check whether the coil has short circuit Replace it if short circuit 4 Remove left cover of engine and the stator generator Measure the resistance of generator stator with multimeter and check whether the resistance has short circuit or open circuit Replace it if short or open circuit Resistance Value Check fuse ZONGESHEN 5 Check whether the magnetic cylinder of gen erator rotor fades magnet Replace magnetic cyl inder if fades Check magnetic cylinder 3 The cause trouble description and repair method of power supply part Table5 1 Maintenance of Power Supply Part componen ipti rouble description o i description u of motorcycle repair method Headlight cannot illuminate Engine 5 hard to be started i short circuit Battery has poor power PARNEGA Replace charging coil open circuit Climit There is no spark spurt be Engine cannot be started value tween piston electrode Engine is hard to be started or distorted no ee rrent apm or tbe SEE rted edu export of generator ugh B cannot work fades magnet no electric current export of Engine cannot be started generator Headlight cannot illuminate generator rotor Replace generator rotor Storing time is 100 Electric power is not
23. 208 All rights of this trademark reserved by Zongshen Industrial Group trademark registration number in china 15 5335140 Zongshen Industrial Group are applying this trademark 89 3 E 1 A piaggio This Logo is the combination of registration trademark of Zongshen Industrial Group and registration trademark of w T PIAGGIO amp C S P A All rights reserved by ZONGSHEN PIAGGIO FOSHAN MOTORCYCLE CO LTD 57 This trademark was registered by Zongshen Industrial Group in more than 20 countries such as Nigeria Argent ina and Vietnam etc This trademark was registered by Zongshen Industrial Group in more than 90 countries such as Japan New Ze aland Germany Canada etc LP STAR This trademark was registered by Zongshen Industrial Group in more than 90 countries such as Germany Camb odia and France etc LIMITED Without written permission by Zongshen Industrial Group no company and individual is allowed to copy duplicate and use above trademarks and logos catalogue INTRODUCTION CATALOGUE CHAPTER 1 GENERALE INFORMATION duc boul ues ripae 1 SECTION JI VERO CE OE dus uu Pa vu exon entrar artes 1 SOCOM 2 SUC Eu 2 CHAPTER 2 MAINTENANCE KNOWLEDGE 4 section 1 Attention Tremssor Maimiemanee 4 Section 2 General knowledge of Malnte riariQes
24. Basic Knowledge In order to get a further understanding of structure and working principle of motorcycle electrical system you should have a general conception about basic knowledge of electrics firstly Electricity electric current voltage and resistance The basic component of any substance is atom There exists electropositive atomic nucleus and electronegative electron inside the atom The quantity of nucleus is the same as electron so which makes the positive electricity counteract the negative electricity and causes atom to be neutral lf the substance is influenced for friction or magnetic field this balance will be broken So the electron will increase or decrease because of moving At that time the substance has electric charge because the atom is not neutral The electric charge of substance has the relationship with the increasing and decreasing of atom When the atom increases the substance will be electronegative When the atom decreases the substance will have positive electricity Electric charge moves regularly in conductor along a stated direction which is called electric current The quantity of electric charge per second is used to scale the strength of electric current In electrics we use to stand for electric current Its strength unit is Amp A Normally the stated direction of electric current is from the anode of battery to the cathode There is an interaction force between electric charge In order to make electric charge move such
25. Front shock absorber The comfort stability pap front shock ing h lasticitvlis soft or makes and safety of ridin ce oe OM Motorcycle runs to Correct and replace Front shock absorber Left pole and right pole side andi front shock absorber pole is distorted are not at the same comfort stability and front shock ab level safety are influenced sorber pole The surface of front The oil seal of frontshock The comfort stability Replace front shock shock absorber 1 lansorber pole hagand safety of riding absorber or its pole damaged leakage decline The chromeplating tier Viotorcycle runs to of front shock The oil seal of front wards side Replace front shock is worn so that the shock absorber pole comfort stability and absorber or its pole frontshock metal part appears leakage safety are influenced i Motorcycle runs to absorber The lower pipe of front Front shock absorber wards d side and Replace front shock ab shock absorber is worn leakage comfort stabilt St y and sorber or its lower pipe or breaks safety are influenced P Piston lever is worn Front shock absorber The comfort stability Replacefrontshock ab or damaged 00501 and safety of riding sorber or piston lever decline Piston ring is wornor Front shock ab 198 Replace frontshock ab damaged sorber is too soft Soren OE piston ring decline The edg
26. S ZONGESHEN 2 6 Analysis of illuminating light bulb The bulb of illuminating light is easy to burn out Replace rectifier Short circuit or tanct is not good Rectifier has trouble 2 7 Analysis of illuminating light Illuminating lamplight is weak AC supply illuminating system Replace rectifier Illuminating lamplight is still weak Illuminating lamplight becomes normal Check whether the charging coil and ne system of magneto is short Circuit Rectifier is bad ZONES HEM 2 8 Analysis of turning light Tuming light doesn tilluminate All turning light of one side Some turning lights of one side 05 t illuminate don t illuminate All turning light don t illuminate Remove the cover of turning light Press horn button and check and check whether of turning electric horn light is burned out Electric horn makes no sound or Remove the connecting compo is barbarous nent of turning switch Mea sure the turning light switch with ohmic meter and check whether its problem is solved Remove the cover of turning light and check whether of turning light is burned out Yes Replace Measure the voltage of turning light connecting point of light holder power wire to the groundwith voltagemeter Yes Replace of turning light Thevo
27. The comfort stability Joint rear fork rear wheel is too big fork Bede off n safety of riding ecline The road is bad and the The dust seal of bear The seal of bearing Replace dust seal of strike and shake to rear ing cover of rear fork cover bearing of rear fork bearing wheel are too big is worn rear fork is bad PENDS HE Section 10 Wheel Front rear wheel is the running component of motorcycle It supports the weight of whole motorcycle and ensures a friction made by wheel and road to make wheel avoid sliding Wheel can reduce and absorb the strike and shake caused by the road The front wheel cooperates with operating part which fixes on the direction of running The rear wheel is transferred power by engine which drives motorcycle to run Wheel mainly consists of outer tire inner tire aluminium tire tire hub bearing bush oil seal and axle The Structure and Working Principle of Wheel 1 Tire The tire of motorcycle is the important component of riding system Its function is to touch road surface directly support the weight of whole motorcycle reduce strike and shake during running with its elasticity ensure balanced motorcycle running and avoid sliding Tire consists of outer tire inner tire and gasket Outer Tire Outer tire consists of tire surface tire body gasket and tire ring The surface of outer tire directly touches road surface There are different thread on tire surface which helps motor
28. aming is a fine finish by reamer which can increase the precision degree of holes on parts and decrease the roughness improves the match precision between hole and shaft and the precision can reach grade 6 to grade 8 The basic tool for reaming is a reamer such as fixed reamer adjustable reamer conical reamer and so on Before reaming we need to drill a bottom hole in advance which is for the precision requirement of hole shaped and making room for reaming procedure 5 Tapping and thread die cutting Tapping is to Process internal thread with screw tap and thread die cutting is to process external thread with threading die The essential tools for tapping is screw tap Generally screw tap consist of master tap and plug tap The difference between these Two kinds of tap is that master tap adopt a slight bevel angle on cutting part instead plug tap adopt a steeply bevel angle After tapping we should drill a bottom hole with chamfer Please refer to the specialized list or the following formula for the bit diameter of bottom hole Diameter of drilling hole outside diameter of screw thread 1 1mm X screw pitch appropriate for iron and Copper Diameter of drilling hole outside diameter of screw thread 1 2mm X screw pitch appropriate for steel and brass When cutting inside threads turn master tap into the chamfer angle hole then take out and use plug tap to shape the threads The tool for outside screw threads cutting is screw plate Scr
29. and turning and bearing is too handlebar shakes dur loose Ing running wheel hub is worn The axial and radial clearance of inner Replace bearing and outer bearing Is too big or its rotation IS not flexible running and it is har front wheel Tire 5 worn Replace outer tire to avoid side sliding Gear is damaged Speedometer finger Replace the gear box of cannot swing speedometer The transmission ring of Speedometer finger Replace the ROT box gear wheel is damaged cannot swing Table4 10 component description Replace front wheel front wheel Bearing is worn or damaged Motorcycle runs to wards one side and handlebar shakes during running It is easy to slide PUEDE gear box of speedometer r ete Motorcycle runs to bearing is too loose wards one side and rear wheel shakes during running The axial and radial clearance of inner and outer bearing is too big or its rotation is not flexible Bearing is worn or damaged of speedom Rear wheel is distorted Rear aluminium wheel is distorted rear wheel Rear wheel is damaged The bearing hole of The match of bearin wheel hub 1 worn hole of wheel hub an It is easy to slide during running and it is nard to avoid Side sliding rear tire Rear tire is worn Replace bearing Replace outer tire a B Section 11 Brake Motorcycle usually needs to decelerate and stop duri
30. at the muffler tail Clean it muffler tail 5 The cause trouble description and repair method of inlet and exhaust system Table4 3 Maintenance of Inlet and Exhaust System component trouble description of description of h description component motorcycle repair method Engine is hard to be started or cannot be started poor Clean or replace Element is dusty SUE ST unstable idle element speed high fuel consump inlet system tion and Black smoke from exhaust muffler The body of air The noise of engine in ae air cleaner cleaner is broken let is big leakage at vent of The noise of engine exhaust Replace seal gasket exhaust pipe becomes louder of exhaust pipe The body of ex The noise of engine ex Replace exhaust haust muffler is haust becomes louder muffler broken exhaust system rm 2 m e EE CO PENDS HE Section 4 Rear Transmission Device Because the export torque of engine is small and its rev is fast it only can enhance the torque of engine to ensure the good working condition of motorcycle by 3 time deceleration The first time is through the drive and driven gear of cluth The second time is through the drive and driven bearing of derailleur The third time is through the drive and driven gear of rear transmission that the export power and rev of engine can economically and properly be used 1 The Structure and Working Principle of Rear T
31. bling motorcycle normally please use appropriative maintenance tools Please repair motorcycle with flameout If the motorcycle needs to be repaired while engine is working please do it at a well ventilated place because the exhaust gas from motorcycle contains poisonous CO 8 Gas is easy to burn or explode so do not smoke or ignite at maintenance place 9 The electrolyte of battery consists of vitriol If eyes skin and clothes are spattered with electrolyte completely clean it with water Seriously please go to hospital 1O There is hydric gas from battery which is flammable and explosive so do not smoke ignite fire near battery Especially when it is charging Statement in this manual preceded by the following words are of special significance Indicates a potential hazardous situation which if not avoid may cause people hurt or death Indicates a potential hazardous situation which if not avoid may damage your bike N Bites gt Indicates special information to make maintenance easier or instructions clearer d ZUND SEE Section 2 General knowledge of Maintenance 1 Classification of Maintenance Maintenance can be divided into 4 parts according to the range and interval period 4 parts contains major repair medium repair minor repair and assembly repair 1 Major repair is a thorough repair which needs to make motorcycle completely disassembled cleaned measured inspected adjusted an
32. ch the higher mark on board Meanwhile the rotating main axle drives counter through whirlpool lever Therefore the total mileage of motorcycle is indicated by the counter Maintain speedom eter once a year Add luboil to where it needs 2 Fuel Meter Fuel meter is to indicate the fuel volume in fuel tank It guides the resistance changes in sensor which caused by the change of fuel level to fuel volume indicator and indicates the change of fuel volume through fuel volume indicator 2 Disassembly and Maintenance of Meter 1 When fingers of meter don t work dismantle speed ometer and check it 3 Check whether the connection of speedometer is looseness lt a 3 The cause trouble description and repair method of meter 12 Maintenance of Meter component cause trouble description of trouble description of i description method Out The filament of indi The filament of indicator Indicator doesn t work Replace bulb of indicator cator is burned out is burned ou meter The filament Thefilamentofmeterhead headlamp the bulb of assembly meter head lamp lamp is burned out doesn t work meter indicator is burned out Speedometer 19 Speedometer is damaged Speedometer doesn speedometer damaged work Z Co I 46 ZONGSHEN CHAPTER 4 ELECTRICAL SYSTEM Part 1
33. chine such as the bonding of handlebar and steering head bonding of plastic label and spay paint metal parts bonding of brake disc and brake pads There are various adhesive such as epoxy adhesive phenol formaldehyde adhesive and so on 5 Motorcycle assembly The last procedure in repair is assembly which is a key to ensure the good quality of motorcycle 1 Assembly includes module assembly parts assembly and overall assembly In the process of assembly we should abide by the principle that assemble module first then parts and the overall finally The sequence of assembly 15 opposite to disassembly which is to first assemble the last disassembled components and to last assemble the first disassembled components 2 Module assembly is the first stage in whole process which makes the parts into a single module such as the combination of front brake drum cover the combination of brake pads the combination of wheel 3 Parts assembly is based upon module assembly which assembles the parts and module as a whole such as front and rear wheel assembly front fork assembly shock absorber assembly and so on 4 Overall assembly is the last procedure to complete the whole working process which connects parts and modules with frame according to installation sequence by all means 5 The sequences of overall assembly are similar The operation is as following Firstly finish all modules assembly and parts assembly then install engine assembly and gearbox assembly on
34. cuit between ignition switch and ing light has open cir flasher or between flasher and turning light cult or short circuit switch has open circuit or short circuit ZONGSHEN 2 9 Analysis of electric horn Electric horn can not make sound Tum on ignition switch tum on off tuming light switch and check the turning light Turning light cannot illuminate illuminatedimly Tuminglightcan illuminate brightly The power of Sl battery is not enough or the circuit between storage battery and switch has open circuit or short circuit Power supply of storage battery is normal Remove the power lead from the power connection of electric horn then rub the power lead with cathode wire Check the spark or measure the voltage with multimeter When rubbing there is spark or the When rubbing there is no spark or the voltage is normal voltage is not normal The power wire between ignition switch and electric horn has open circuit Connect the power lead of electric horn Connect the non power connection of electric horn connection of button with the cathode wire After connection the electric After connection the electric horn can make sound horn still cannot make sound The inner connecting point of horn Adjust the volume and has bad connection or the lead be tone of electric horn tween electric horn and button has open After adjustment the
35. cycle avoid sliding on different road The tire body has a certain intensity but in order to emit heat it had better not be too thick The tire ring is packed by the edge of curtain and steel ring which makes outer tire fix on the rim If the perimeter of tire ring is too short which will make the disassembly of outer tire more difficult and if the perimeter is too long which will make outer tire spring out The curtain tier is the framework of outer tire But the curtain tier of outer tire crosses with the transect of tire which makes an angle But the curtain tier of meridian tire arrays as the direction of earth meridian The meridian tire has the good characters of reducing power consumption fuel consumption and prolonging service lifetime Inner tire and Gasket Inner tire is made of rubber It is a circle There is a valve on it which can adjust the pressure of inner tire The main requirement of inner tire is seal The pressure of inner tire is the main reason of influencing the usage of wheel and tire The gasket is a round rubber cincture which separates inner tire and rim protects the seal of inner tire and prevents the break caused by the spiculate thing 2 Rim Rim is the framework for supporting and fixing the tire The rim of this motorcycle has two types die casting rim and spoked rim The former is made from aluminum alloy which integrates the rim and hub by casting and then machining This kind of rim has high intensity simple arts and crafts con
36. d or make poor sound Turning light illuminates dimly Electric horn makes rotund sound Turning light illuminates brightly The power of storage battery 15 Press a button and the not or the connecting stor sound at the beginning of elec age battery lead has poor tric starting can be heard connection Press startin sound at the tric starting cannot Mad and the of elec e heard Make short circuit of the connnection of battery on starting relay and the connection of starting motor with screwdriver and thick lead Remove the connecting component of starting relay from vehicle cable Connect the anode cathode of storage battery with two down leads of start ing relay coil with two leads After connection starting motor still cannot run and the sound at the beginning of electric starting cannot be heard The coil of starting relay has open circuit or short circult 1 Check whether the connecting point of inner clutch switch has bad connection 2 Check whether the connecting point of starting button has bad connection After short circuit connection starting motor can run normally After short circuit connection starting motor still cannot run After connection starting motor can run normally heck the circuit of electric con trol system The connecting point of start Disassemble starting moto
37. d right adjuster Rear wheel inclines break off left mark the same as the right mark djuster is damaged an uster cannot be Drive chain is easy to Replace adjuster da ed break off rubber Rubber cushion is cushion is strange sound from Replace rubber cushion worn damaged rear wheel cushion PENDS HE Section 5 Frame and Accessaries Frame is the supporting framework of motorcycle t is the main supporting of motorcycle Because motorcycle should bear mighty shake during running its component and structure must have high intensity and the frame is required to be light In this way it is good for motorcycle to have a high speed running Structure and Working Principle of Frame and Accessaries The frame of this motorcycle adopts pipe joint ing and crooked girder It has high intensity good firmness and good suitability It mainly consists of head pipe main frame tail pipe rear supporting pipe low bending pipe lt is made through the meth ods of jointing riveting and so on Frame is used to support engine transmission system operation system seat fuel tank brake sys tem and so on Meanwhile it also offers the install ing point for other 1 makes motorcycle as an integrated part 2 Disassembly and Maintenance of Frame and Accessories 1 Check rearview mirror for looseness and damage Fasten or repair it if loose or damaged Check rearview mirror
38. d so on After the major repair motorcycle can reach the standard of origi nal motivity economy stability and safety performance 2 Medium repair is to repair and adjust some parts which influence the performance of motorcycle Medium repair can eliminate potentially hazardous avoid deterioration of problems and keep a good running condition 3 Minor repair is a running repair which is mainly focus on elimination of some temporary problems or partial hurts during running 4 Assembly repair is a separate repair for assembly which is caused when the requirement of a certain assembly or hurt abrasion or distortion of a certain component influence the performance of motorcycle 2 Repair Technics 1 Disassembly of Motorcycle Disassembly is a very important part during repair The method of disassembly will directly influence the quality and efficiency of repair If components broken or blocked caused by unproper disassembly it will not only expand the repair range but also will delay the repair period Seriously it will lead to the disassembly stop The basic principle of disassembly is the order and direction opposite to those of installation Normally the order is from outside to inside from up to down from big to small When disassembling pay attention to the store environment and order to avoid damnification and confusion The order and method of disassembly is not absolute Different motorcycle has different order and method of disassembly You can refer
39. e of oil seal 15 01 seal has leakage The comfort stability Replace oil seal of worn or damaged Front shock absorber and safety of riding front shock absorber is too soft decline The oil of front shock Front shock absorber The comfort stability Add or replace front absorber is not enough becomes soft and safety of riding shock absorber oil ac or bad decline cording to the stated i Motorcycle runs to Dn Rear shock absorber wards one side and Replace rear shock is too soft comfort stability and absorber has poor elasticity safety are influenced Rear damper Rear shock absorber The comfort stability Replace rear shock leakage is too soft ang Sately OT absorber rear shock ecline absorber The piston lever of rear Motorcycle runs to damper is distorted or Rear shock absorber ane Pun di St absorber breaks 5 distorted safety are influenced The upper and lower Rear shock ab The comfort stability Replace upper and connecting rubber cover sorber is distorted and safety of riding lower connecting are worn or have aging or makes sound decline rubber cover u a B ZUNE SEHEN Section 9 Rear Fork The rear fork connects rear wheel with frame It makes rear wheel rotate around a fixed pointthrough rear shock absorber to reduce the strike and shake of rear wheel The Structure and Working Principle of Rear Fork Because rear fork gets big st
40. ector Fuel injector injects the proper amount of atomized fuel into the intake pipe of engine by ECU thus the atomized fuel can participate in the combustion process in the cylinder 4 Fuel Filter Fuel filter connects with the oil way between the electric fuel pump and fuel rail This system adopts the dedicated filter for EFI to make impurities not block the nozzle The housing of filter has enough intensity and it never break due to the fuel pressure 5 Fuel Pipe The pressure of the fuel supply system is 250 Its selection must have enough safety factor for security rm 2 G m L EEN C lt a a B 2 Disassembly and Maintenance of Fuel System 1 The capacity of the fuel tank is 16L When refueling please keep air circulation and keep away from sparks and flame gt Fuel is highly combustible Smoking and getting close to the fire are strictly forbidden gt Switch off the motorcycle and operate in an airy place 2 Check the fuel tank cap for fuel leakage Replace the sealing ring of cap if necessary TIGHT gt The brand of oil allowed is 937 Do not using other type of oil 3 Check the fuel tank for fuel leakage Replace or repair it if necassery A If the fuel tank 15 deformed by the collision of OT checkfueltank external force repair it to original condition with wooden hammer If the fuel tank has cracks replace
41. enough Starting motor doesn t Charge or replace run or runs feebly storage battery and voltage 1 too low Signal system is deviant Storage battery Starting motor doesn t Add distilled water or ECT IS not Electric power is not enough run or runs feebly replace storage battery ne and voltage is too low Signal system is deviant fuse tube To no power Starting motor doesn 1 Replace fuse tube Z Co I 50 ZONGSHEN Section Control Part 1 Composing and Function of Control Part In electrical system of motorcycle control part is to ensure the good working condition of power supply part and power consumption part and ensure their can make rider control the electrical system momentarily Control part mainly consists of adjuster rectifier flash relay starting relay fuse tube control switch and cable assembly 1 Adjuster Adjuster is the important component of power supply part of motorcycle electrical system It can be divided into DC generator adjuster and AC generator adjuster according to the engine type 1 DC generator adjuster Because the voltage export of DC generator adjuster and the rev has direct proportion it will bring some problems A When motorcycle runs with high speed the engine rev is very fast and the voltage export of DC generator is very high which will easily make the electro equipment burn out and make the storage battery over charge B When mo
42. ers let magnetic line plumb and get through the center of palm and make four fingers towards the direction of electric current At this time the direction which thumb points to is the direction of magnetic field power which is called left hand rule Unwind the thumb of right hand hold coil along the direction of electric current with the other four fingers At this time the direction which the thumb points to is the direction of magnetic wire which coil produces magnetic field which is called right hand rule Electrical system is an important part of motorcycle lts structure and function directly influence the performance and riding comfort of motorcycle The electric system is divided into three parts power supply control and power consumption Because the ignition system of electrical system is the core of motorcycle it is described in the engine part During the common usage you should maintain the electrical system frequently The common trouble of electrical system of motorcycle can be looked up through the circuit diagram so the circuit diagram is attached both in user s manual and mainienace manua ZONES HEM Section 2 Power Supply 1 The structure and working principle of power supply Power supply part mainly consists of generator and battery lts function is in the closed circuit of motorcycle generator and battery has parallel connection and offers electric current to the electro equipment in electrical system then stores the rest p
43. ew plate includes fixed screw plate adjustable screw plate and active screw plate Usually we use fixed screw plate i e round screw plate When cutting outside screw threads choose screw plate and diameter of club shaped material according the required material diameter of screw thread and screw pitch To make proper choice please refer to the specialized list or the following formula Diameter of club shaped materialoutside diameter of screw thread 0 13mm X screw pitch Bevel the end of club shaped material in 15 20 angle before cutting outside screw threads To ensure easy operation the screw plate and club shaped material should be in vertical therefore the minimum diameter of cone angle should less than inside diameter of screw thread 6 Rectification The operation that eliminates the unevenness of plane shaped bar shaped and column shaped parts is called rectification Rectification can reshape the parts The rectification depends on the flexibility of metal parts Therefore metal parts with good flexibility can be rectified directly such as soft steel and red cooper metal parts with less flexibility need to anneal before rectification The ways for rectification are torsion extension bending and expansion 7 Bonding Bonding is widely used in manufacture and repairs because it operates easily and can be done without special equipment and expensive materials In addition the bonding parts don t need to be processed by high precision ma
44. ey are damaged or have short circuit Repair or replace them if have problems AN CAUTION gt Check whether front rear brake switches are in good working condition Readjust or replace them if they are not in good working condition gt If front rear brake light do not shine when braking then there is no electric power to start 5 Remove fuse tube and check whether it melts Replace it with the same type Fuse tube type 12V 20A CAUTION Replace fuse tube with the same type when it is damaged m Z e BE ZONGSHEN 6 Check whether the main cable is damaged Bundle the leads in time if the insulative rubber ized fabric is damaged 3 The cause trouble description and method repair of control part Table 5 2 Maintenance of Control Part pone trouble description of trouble description of repair method description component motorcycle s otorage battery cannot be Rectifier has short circuit or charged llluminating open circuit light illuminates dimly Replace rectifier or cannot illuminate and Is easy to be burned out starting Starting motor doesn twork Motorcycle cannot be relay circuit o with electric Replace starting relay Starting motor runs feebly Inner connectin Motorcyclecannotbe started i Starting motor doesn Replace button starting pont oonneos bad ok with a starter een Inner connectin Motorcycle cannot be started po
45. f parts gently with a small hammer In this way the knock can produce vibration and oil that has remained in crack will splash for vibration The splashed oil will dye the talcum powder yellow so we can easily find a yellow mark in crack place Cleaning methods for non metal parts differ in different materials The best detergent for rubber parts is alcohol Do not use coal oil or gasoline to clean rubber parts because they can cause inflation and deformity of rubber parts Gasoline is suitable for clutch disc and brake pads friction disc while aqueous alkali is forbidden 4 Repair methods and skills After disassembly cleaning and inspection the following is the principal stage Mastering the basic skill well is the key to ensure a good quality of maintenance The skills for maintenance are as following 1 Chiseling filing and scraping Chiseling is to process metal parts by hammer and chisel The functions are cutting and parting Filing is to rasp off the surface of parts by a file It includes rasp and delicate filing Teeth of a file directly decide the roughness degree when filing metal parts The operation of file is different because of different shape surface of parts Scraping is a process which scrapes off a thin layer from the surface of parts It is a delicate work so we should scrape the parts bit by bit with great care Usually scraping off 0 005 0 01 each time Before scraping we need to spread red lead on the surface of parts Then
46. fi petes perds 5 sections JAdiustine Data of Maintenance ek bes EO EXPECT oce vede ovas 8 CHAPTER 3 dee eati our Suse is ibat mee chard Tende NC 10 section L FHel SuDDIV SS 10 SECTION EFI Sy atat Eo toa 13 SECTION Intake and Exhabst Sys etis eec 20 Section 4 Rear ransmissioh DEVICE Ga a beet e eean ha dede 24 SecHonm o Flee aM ACCO SONS e etna naa A 28 Section 6 Steene System 31 SE ON COntrol Steel able 32 section 8 SHOCK ADSOFDGOE Aaaeeeaa e atas ee eee eben adre b Puno Av en en de Bo SOC PR aaa UU FECE 37 AO pote c 38 fs lt rete ter td kee ene See Cae Sn tta 42 SecHomd2 MOOT oe ee ee 48 CHAPTER 4 ELECTRICAL 50 SECTION 50 ee 5l Gone Dec T 5A Sections sac Ricca dace pente 57 5 TROUBLESHOOTING 60 APPENDIX CIRCUIT Serin aea n eo br me 74 23 PENDA PEE d CHAPTER 1 GENERAL INFORMATION section 1 vehicle introduction ZS250GY 3 is designed for use on road With futu
47. friction pieces are worn 5 Check whether the driven pieces of clutch are distorted 6 Check whether the operation components of clutch separatory cam separatory handspike and so on are worn D ZONES HEM Section 2 Analysis of electrical part 2 1 Analysis of battery Battery cannot be charged Remove the connecting part between the generator lead and vehicle cable Measure the resistance with ohmic meter and check whether the resistance between export lead of charging coil accords with the standard value Resistance value is smaller than standard value Resistance value accords with standard value arging coil has Short circuit Resistancevalueis infinite Install the connecting component between generator Charging coil or other ex lead and vehicle cable Remove rectifier or the connect port lead has open circuit in between commutated adjuster and vehicle cable Measure the resistance between the export lead of charg ing coil with ohmic meter Check whether the resistance accords with the own resistance of charging coil Yes Set multimeter to 0 20 DC voltage Measure the volta e between the lead ends from the connecting No battery normally it s red wire and ground circuit from generator to rectifier or etween commutated adjuster has open circuit or bad connection There is no voltage show There is voltage show The lead t
48. function of electrical system is to offer electric power to the starting and running of motorcycle and to send sound or light signals so that the running safety can be ensured The electrical system mainly contains the part of electric power supply electric power consumption and electric power control 1 Electric Supply The part of electric supply mainly consists of generator and battery When generator reaches a certain rev driven by engine generator will export eletric power which not only offers the power to electric setup but also to the battery so that it can be charged The battery can transfer chemical power to electric power which can support starting illumination and signal setup 2 Electric Consumption The function of electric consumption part is to offer several kinds of sound or light signals to ensure running safety meanwhile it can start engine conveniently and fast It mainly consists of illuminating signal device and electric starter device 3 Control Part The function of control part is to ensure and adjust electric supply and electric consumption It mainly consists of ECU rectifier starter relay fuse control switch and main wire 5 Engine Engine is a device which is to make fuel burn in the cylinder and to transfer heat to mechanical power it is the power producer of motocycle the maintenance of engine please refer to the engine service manual 2 G 42 LL z G 42 4 X ZONE
49. g Engine overheats Check whether the operation is correct No 1 Check whether the gas no is correct or has stored for a long time Check cooling system 2 Check whether engine always runs with the high speed or with loads liquid cooled engine Check whether there is sand or smeary deposit on radiator Yes No Check whether there is sand or smeary deposit on radiator Check whether there is enough fluid in the channel Yes Supply the same type of liquid Check whether the con necting pipe is loose or damaged Ye 5 Tighten or replace No Check whether the pum Is damaged ulla Check whether the chan nel is unblocked No Check whether the engine ignition is timing Yes Yes Check whether clutch slips Clutch slides Refer to 1 6 Dismantle piston and check the color of piston dielectric Estimate the mixed ratio of mixed gas according to all kinds of exceptional phenomena No 1 Check whether CDI device has problems 2 Check whether the flywheel of generator and triggering coil are loose Spark plug dielectric is white When accelerating engine has intermission The engine power is insufficient Spark plug dielectric is dark black Exhaust muf fler emits black smoke when engine runs with the medium low speed The accelerating perfor mance is bad and idle speed is unstable But it is normal when with high speed
50. hannel The bottom of it adopts rubber sealing for forming a aeroseal with engine intake manifold Nozzle spray the fuel as mist into the inlet valve Throttle body is installed in the front of the intake manifold It consists of valve body throttle position sensor and ISCV The main function is to control air inflow when engine is working Oxygen sensor is installed on the exhaust pipe of engine It is a important part of closed loop fuel control system The main sensitive materials of oxygen sensor is zirconia Zirconia is heated to 300 C by exhaust and is activated then oxygen ion traverses the zirconia part and gets to its external electrode Ultimately Zirconia part induct content of oxygen from engine exhaust emission and change the output voltage value Oxygen sensor adopts Teflon insulated wires and stainless steel materials of component Air for refer ence is imported through wire so it is non blocking When AFR becomes thin oxygen content of exhaust increases and the output voltage of oxygen sensor reduces Otherwise the output voltage valve rises it provide feedback of the real time condition of AFR to ECU rm 2 G m L D a B 2 Disassembly and Maintenance of EFI system The EFI of motorcycle has been calibrated before leaving the factory When EFI system has failure adjust idle screw of throttle voluntarily and replace or adjust parts of are strictly prohibited Please go to our se
51. he main function of glass cover is to diffuse the beam of light which reflected by spotlight mirrior and ensure front road to have enough area to be illuminated It avoids making the coming drivers have the feeling of swimming Bulb is divided to single filament and double filament Bulb holder is made of galvanizing sheet iron after pressing lt is cylindrical There are uneven bulge at the edge of holder and there is a hole which lead can get through Lampshade and cover make up of a complete space which contains the other parts of headlight 2 Taillight and Brake Light Taillight is used to indicate the position of motorcycle to the back vehicles when running at night and make the registration mark seen clearly Taillight mainly consists of lampshade cover lamp holder and bulb The lampshade is made of red organic glass There is transparent organic glass window embeded at lower part so that the registration mark can be illuminated The light cover is made of plastic There are two side stands with holes at the buttom The lampshade and light cover can be connected by screw 3 Horn During motorcycle running rider can let horn make sound and make motorcycle noticed by passer by and other vehicles to ensure running safety According to the different way of power supply electric horn can be divided into AC electric horn and DC electric horn This motorcycle adopts DC electric horn 4 Turning Light When motorcycle needs to turn turning light wil
52. heel hub has installed or is too short Pressure is too low Inflate according to the stated standard Pressure is normal Check whether fuel tank fuel tube is leakage and hoop of tube is fastened es No Check the mixed ratio of combus tible mixed gas Deal with it according to the actual situation The mixed ratio of combustible Combustible mixed gas mixed gas is normal is too thick Combustible mixed gas is too thin Check whether the rev of engine is DCheck whether air filter is blocked 2 Check wheher oxygen sensor is work WETS ing well iis No whether fuel nozzle is in work WORMER Check whether gine ignition is timing Accordingto 1 1 ing order Check whether oxygen sensor is working well Check ignition system D ZONES HEM 1 6 Analysis of exhaust muffler of 4 stroke engine The exhaust muffler of 4 stroke engine emits blue and white thick smoke Check whether the oil levelofcrank case exceeds the upper mark Ye The oil in crankcase is too much The redundant oil Should be discharged and let the oil level not exceed the upper mark No Start engine When it runs with high speed remove ruler and check whether the oil adding hole emits smoke vy Check whetherthe match clear ance of valve and
53. hicle body Rear shock absorber mainly bear axial pressure of rear wheel Both of them support the weight of the whole vehicle body During motorcycle running it reduces the concussion and shake for motorcycle and rider reduces the pressure for components prolongs the service lifetime of motorcycle and enhances the comfort operation and stability for rider The Structure and Working principle of Front Rear Shock Absorber 1 Front Shock Absorber The front shock absorber of this motorcycle adopts compound of hydraulic pressure and spring It mainly consists of front shock absorber spring seal ring dustproof cover piston ring front shock absorber pole piston lever buffer spring one way valve spring socket one way valve spring one way valve one way valve socket front shock absorber pipe and piston lever socket When the front wheel of motorcycle gets strike and shake the front shock absorber pipe rises the damping oil flows up through the one way valve and small holes on piston lever The resistance power is small at this time When absorber pipe continues going up the clearance between one way valve socket and the cone shaped surface of piston lever becomes smaller and smaller so that the resistance becomes bigger which avoids the bump of front shock absorber pipe and front shock absorber When front shock absorber pipe goes down for the returning of front shock absorber spring the damping oil only can flow from the small holes of piston lever because of the
54. ift The clutch of this motorcycle adopts automatic wet and multiple 3 Gearshift The function of gearshift is to change the rev and drive torque of motorcycle transmission and to ensure proper pull and speed of motorcycle so that it can adapt the changable running condition The gearshift of this motorcycle adopts gradational gearshift d 4 Rear transmission device The function of rear transmission device 1 to transmit the engine power to transmission device so that the rev is reduced and the torque is augmented Then transmit the power to rear wheel to drive motorcycle run The transmission of this motorcycle is chain transmission 5 Intake and Exhaust System The function of inlet system is to guide and filtrate air to control the volume of mixed gas flowing into cylinder according to the needs of working condition It mainly consists of inlet pipe and air cleaner The function of exhaust system is to vent the exhaust gas in cylinder and to reduce the noise during exhausting It mainly consists of exhaust pipe and muffler 6 Fuel Supply System The function of fuel supplying system is to confect clean gas and air into mixed gas with proper proportion according to the working condition of engine and to offer the mixed gas timely and quantificationally to burning chamber to keep burning The fuel supply system mainly consists of fuel tank fuel pump fuel injector fuel filter and fuel pipe 4 Electrical System The
55. ignition switch and observe the high voltage coil Measure the DC resistance of two coils Switch is amaged The flywheel rotor of gen erator loses magnetism seriously Charging and triggering coil have short circuit or open circuit Cut off the power export end of igni tion and measure the voltage has voltage no voltage Electronic ignitor is damaged Replace it Ignition coil has open circuit or short circuit Adi Tem Or re Repair or replace it place it Replace it 00 switch illuminator erbali flashing relay sita leftfan wate temperatura is ee PAT TET Er BLY B Gr B BBL BBL Wi IGNITION KEY engine switch RIGHT TURNING LAMP FRONT apo LB pes 2 a Bri tachomeder 1 LL YW RIGHT TURNING LANP REAR gt FUEL GAUGE 0 6 mena SSS 0 reat larnp assembly Tv ZONES HEM APPENDIX CIRCUIT DIAGRAM vehicle speed sensor BIR 6 POSITION LAMP FT 12V 1W 6 HEADLIGHT T2V35Wi 35w EL LEFT TURNING LAMP FRONT 124 1 3W Oe l1 1 p p D d I PARE 6 4oV SW 0
56. iguration as well as the service and repair skill We hope it can bring technical support and guide to all the users and after service staffs Technical specifications performance parameter and maintenance data mentioned in manual are base upon the latest design features of your motorcycle Chongqing Zongshen Automobile Industry Co Ltd reserves the right to make changes to the specifications of its vehicles without notification We sincerely hope you can give us your suggestions about the design manufacture and quality of this type of motorcycle so that we can do the improvement in time Thank you for your support and co operation All the specifications diagram data and performance index in this manual end in the print of this book Our companyreserves the right to change the book without any notification All rights are reserved by Zongshen Any people or companies won t copy it if there is no permission Otherwise we will go behind the criminal and legal responsiblity In this book we take ZS250GY 3 for example to explain the detail of the disassembly installation inspection and troubleshooting of this series models Due to our limited knowledge it is very possible to have mistakes or omissions in this book And we welcome your comments Chongqing Zongshen Automobile Industry Co Ltd Address CHAOYOUCHANG BANAN DISTRICT CHONGQING CHINA service hotline 400 7003088 For more information visit our website www zongshenmotor com Editor Aug 2013
57. ing nut is too tight the turning resistance of steer ing handlebar will be too big so that the steering handlebar will be locked which is hard to be operated or cannot be operated Therefore it influences riding safety Support motorcycle with main stand and make front wheel off the ground Rotate the front fork and front shock absorber and check whether the bearing is loose Turn the steering handlebar and check whether the bearing 15 flexible Adjust it if the bearing is too loose or tight First unscrew the locknut of direction pole rotate adjusting nut and check the tightness of bearing Re tighten the locknut until the bearing is normal The cause trouble description and repair method of direction pole Table 4 6 Maintenance of direction pole component trouble description trouble description of The match clear l Adjust nut with lock Adjusting nut is too ance of bearing oe NC until the tight and bearing ring is handlebar is flexible bearing too small and there is no bear ring ing rolling between direction pole and frame pipe Bearing ring is too worn or damaged and has pit pres mark and spit Bearing is worn Turning handlebar is not bearing distorted flexible and shakes dur Wholly replacebali bearing damaged ing running direction Direction pole is Direction pole is Turning handlebar is Correct or replace di pole distorted distorted flexible rection pole Turning handlebar is Wh
58. ir abrasion Replace them if worn 6 Remove the returning spring of shock absorber pole and check its abrasion and distortion Replace it if distorted Y Spring clamp b Shock absorber spring a pegs 7 Measure the inner diameter of lower pipe of front shock absorber with callipers Check whether it exceeds the limit value of maintenance Replace it if exceeds 8 Remove the returning spring of front shock absorber and check its abrasion Replace it if worn jp RS Nl 9 When installing front shock absorber add front shock phock 7 absorber oil according to the stated The standard volume et P of front shock absorber is 330 5 mL t Lower pipe of shock a pea 1 Check whether the spring of rear shock absorber becomes soft and its damper has leakage Replace shock absorber assembly if the rear damper has leakage shock absorber rm Z G m IL gt a D PENDS HE 2 Check whether the left one has the same length as the right one and check whether the spring surface of shock absorber is damaged Replace it if damaged Rear shock absorber AN Kerne gt When rubber components have abrasion or aging replace them 4 The cause trouble description and repair method of front rear shock absorber Table 4 8 Maintenance of Front Rear Shock Absorber component trouble description of trouble description of The front shock absorber
59. is 20mm 30mm the free stroke of rear brake pedal cannot reach the standard value readjust the nut of rear brake rod AlRegulate adjusting nut of rear brake and adjust the free stroke of rear brake pedal to 20mm 30mm B Step rear brake pedal for several times and re lease it Rotate the rear wheel assembly and check the rear wheel for free rotation d L 41 PENDS HE 11 Disassemble the nut of rear wheel axle and remove the wheel axle and rear wheel assembly 12 Remove friction lining and Measure the thick ness of it with the limit value of repair is 2 0mm Check the piston of brake caliper If it cannot run normally fix or replace hydraulic brake 13 Disassemble the fixed bolt of brake disc and remove it Please smear glue on the bolt before installing the rear brake disc to avoid bolt looseness 14 Check the wear for bake disc measure the inner diameter by callipers The limit value of repair is 131 0mm A gt If the value of inner diameter exceed the limit value replace it measure the thickness a a B UNE SEN 15 Measure the run out of brake disc by dial indicator and the limit value is 0 3mm AC gt Ifthe value of run out exceed the limit value replace it 3 The cause trouble description and repair method of front rear brake see Table 3 13 Table 3 11 Maintenance of Front Rear Brake Trouble description Trouble descrip
60. l send out yellow flash signal through flash relay to make other people notice this motorcycle is going to turn Normally the turning light consists of cover holder bulb and lampshade 2 Disassembly and Maintenance of light Signalling Device 1 Dismantle the cover of headlight and check whether the holder and bulb are in good working condition Remove the bulb and check whether it is burned out Replace it with the same type if burned out Bulb type HS1 12V 35 35W P M E AJ Bulb of SN headtignt ri Z Co I 54 ZONGSHEN A Check whether the taillight is burned out Re place it with the same type if burned out 3 Check whether the turning light is burned out Replace it with the same type if burned out 4 Check whether the bulb of meter indicator is burned out Replace it if burned out Bulb of gear Indicator 5 When the sound of electric horn is hoarse and electric horn has no sound adjust the horn volume acccording to the actual situation or replace the horn with the same type 3 The caus Table5 3 component description headlight assembly taillight brake light turning light gear Indicator electric horn gt e trouble description and repair method of power consumption part Maintenance of Power Consumption Part cause trouble description of trouble description repair method component of motorcycle The adj
61. le 4 1 Maintenance of Fuel Supply System component trouble description trouble description of repair method description of componen motorcycle Fuel tank body is broken leakage of fuel tank Repair or replace fuel tank Unblock the venthole of fuel tank uic UR orca Fuel supply is notgood Motorcycle cannot start m tank cap is The appearance of or replace fuel Fuel tank is deformed Fueltank is accidented fore PE pr e p u oifiter screen is dirty Motorcycle is hard to be started or cannot be pr smal are Fuel supply is not good started The engine power is not enough and the Clean oil filter screen idle speed is not stable fuel pump pump body IS Fuelsupplyis notgood Motorcycle cannot be Cleanor replace fuel pump The motor of fuel pum ied Motorcycle cannot be does not run started Replace the motor Fuel pressure regula Fuel can not be back Oil duct is cracked tor Is blocked Motorcycle is hard to be Clean or replace the od uen The pressure of oil Started or cannot be pump assembly m Pd O m supply is low started The engine power e is not enough and the idle speed is not stable Se zs a D PENDS HE Section 2 EFI system The main effect of EFI system is to convert the fuel which is supplied from fuel tank into a mist then mixture of the mist and air import into the combustion chamber 1 The Structure and Working Principle of EFI s
62. ltage is nor mal and there is voltage display The voltage 15 not nor mal andthere isnovolt age display The power wire of holder has open circuit j The inner connecting point of tuming lightswitch has bad or the light holder has oonnecuon bad connection Remove the cover of turning lightand check whether light is burned out Yes No Tum om ot tumin lieht switch of turning light Make short circuit for two ends check whether the com of flasher with a lead or a mutated adjuster works screwdriver well The connection of light holder is bad or the con nection between direc tion indicator light bulb and holder is bad Yes NO After short circuit turning Aftershortcircuit tuming light light still cannot illuminate can illuminate Remove the connecting component of turning lights Flasher is damaged With a lead make short circuit from the power import of Wr Ing light switch to the power lead of left right turning ight No After short circuit turning light still cannot illuminate The inner connecting point of turning light switch has bad connection Yes After short circuit turning light will illuminate Check whether the power import lead of mS switch has power export with a method of connecting a bulb Yes No The bulb can The bulb can illuminate not illuminate The power lead of turn Ihe cir
63. maintainence limit value 3 Before dismantling front wheel fix the bike first and leave the wheel of ground then take off tighting nut of front wheel shaft M14 and take out front wheel shaft and front wheel assembly 41 out front wheel shaft bush to check whether it was abraded If it was worse replace it Add grease when assembling the bush 5 Take out the oil seal to check whether the blade is abraded Replace it when needed a PENDS HE 6 Put front wheel on rectification desk and rotate itin high speed to check the abrasion condition and free strock if it is abraded dismantle it and replace A Check aN wheel shaft ENG gt When there is noise or free strock turn wide replace it with new beering And assemble beering with the oil seal inside 7 front wheel shaft abrade badly knock it out by using shaft disassembling tools and replace it with the new one a di TETT A dis 8 fron shaft gt When assembling front wheel shaft add grease on it and assemble beering with the oil seal inside gt 8 Put front wheel on rectification desk to check the vibration of it Rotate it with hand and use dial indicator to test the value and read the value Maintainance limit value Radial 2 0mm Axial 2 0mm measure the vibration of KOUN lt front wheel Ifthe vibration value is over maintainance li
64. match the parts with standard one The unmatched parts are the aim of scraping After several match and scraping the contact surface of parts is bigger So it reaches the requirement and achieves the purpose 2 Rubbing Rubbing is to rub out a thin layer from the surface of parts by grinder and crocus This is a fine finish for the surface of parts which can provide a precise size exact geometrical shape and the lowest degree of roughness lt includes flat rubbing internal rubbing and external rubbing The rubbing tool for flat rubbing is a plane plate while internal rubbing tool is a pestle During maintenance rubbing methods are usually used for rubbing the flat of crankcase and internal hole of connecting rod 3 Rivet joint and welding Rivet joint is a process which can join two parts or more together with rivets Ilt is widely used in maintenance such as rivet joint of clutch disc and so on Classified by its function rivet joint can be divided into fixed rivet joint active rivet joint and seal rivet joint Welding is a process which can bring into close union of two metal parts with welding tool and solder It is also widely used in maintenance such as repairing the crack of frame and other metal parts 4 Drilling and Reaming Drilling is a process which drills holes on parts or materials with drill bit The drilling tools mainly include beam drill bench drill electric hand drill rotary hand drill drill bit and clamp d a 5 FUND SHE Re
65. ming Yes No 1 Check whether oil supplying is blocked and 1 Check whether there is something wrong with CDI oil pressure value is between 240 250KPa 2 Check whether the flywheel of generator and trigering 2 Check whether fuel filter filter and muffler coil are loose are blocked ZONGSHEN 1 3 Analysis of Engine Start Engine cannot be started or is hard to be started Checkignitionsystem Remove piston and check whether there Is carbon deposit between the electrode of spark plug No Yes Check whether there is spark spurt Clean out car between the electrode of spark plug bon deposit poor spark or no spark between electrode There is strong blue and blue purple spark spurt be tween electrode Unscrew the cap of piston and check whether Check whether the engine igni there is spark spurt with high voltage coil tion is timing No Yes i oor spark or no 5 S park j 1 Checkwhetherthereissome Pull out fuel injector start thing wrong with CDI device check whether fuel 2 Check whether the flywheel spurted is atomised of generator and triggering coil Check whetherthere is some are loose thing wrong with spark plug and spark plug cap Yes Check the compressin Check whether of cylinder wit there is gas in fuel rometer tank Check whether Checkwhetherthe Check whether the ignition coil circuit of ig there is some
66. mirrior and choke switch respectively installed on the left and right handlebar 2 Direction pole assembly Direction pole assembly is the important part of steering system It mainly consists of direction pole lower connecting board bearing and bearing ring Normally the direction pole 1 jointed with lower board wholly called direction pole and installed within the frame pipe The weight of motorcycle and rider transfers to front wheel through the direction pole However the weight caused by the strike of road for the front wheel transfers to motorcycle body through the direction pole Therefore direction pole not only must bear the big loads strike but also ensure the flexible turning during running 2 Disassembly and Maintenance of Steering System In order to make motorcycle keep a good operation you should maintain the steering system termly For the first time disassemble vehicle after 1500km and then disassemble it every 600km Check the abrasion of inner and outer bearing and H ball Replace them if necessary When replacing rolling ball you must replace it completely Don t mix the new parts with the old ones The maintenance of direction pole should stress on bearing If the bearing is always lack of lubrication and adjusting nut is loose the clearance of bearing will be too big so that the steering handle bar will shake during running which influences the stability and safety of motorcycle On the other hand if the bearing is damaged or adjust
67. mit value above rectify or replace it 9 Check the abrasion of front outer tyre The maintainance limit value of front outer tyre thread is 2 00mm If the pressure of front wheel is insufficient check whether inner tyre valve core has leakage then check whether in ner tyre has leakage ENTE If inner tyre valve core has leakage repair or replace the core If inner tyre has leakage fix or Q inner oue replace inner tyre E ye e a a B 10 Dismantle the locknut of rear axle Remove rear axle and rear wheel assembly 11 Dismantle rear wheel and check whether rear wheel hub is damaged Replace it if damaged 12 Check whether rear axle is worn Replace it if worn EN gt Smear lubricant when installing di Y E heck rear s axle a gt 13 Check whether the front and rear rim distorted Correct or replace them in time Check whether the outer tire thread of rear wheel is worn Replace outer tire if the abrasion value exceeds 2mm zs PENDS HE 3 The cause trouble description and repair method of wheel Maintenance of Wheel cause trouble description of trouble description Front wheel is distorted Front wheel 15 Motorcyclerunstowardsone distorted side and tuming handlebar shakes during running The bearing hole of The match of bearing Motorcycle runs towards hole of wheel hub one side
68. nerally fuse is composed of plastic fuse boxes fitted up with the fuse tube 6 Control Switch The control switches of electrical system are centralized on the left and right handlebar Normally from up to down there are switches of high low beam light turning light and horn on the left handlebar Also from up to down there are switches of position light headlight and electric starter on the right handlebar The general electrical switch is in the middle of handlebar 7 Main Cable Each part of electrical system of motorcycle is connected by lead In order to avoid leads in a mess and be propitious to arrange on the frame leads with the same direction are usually bound by insulative rubberized fabric This is cable assembly 2 Disassembly and Maintenance of Control Part 1 Measure the voltage export of relay with multimeter and check whether it is within 13 0V 14 0V Re place the voltage adjusting relay when the voltage export is lower than 13 0V Joint of voltage adjusting relay A CUN Replace the rectifier when the cooling fins of it are broken ZONESHEN 2 Remove the flasher socket of signal system and measure the flasher with multimeter Check whether it has short circuit Replace it if short circuit 3 Check whether starting relay is in good working condition Replace it with the same type if it is not in good working condition 4 Dismantle the switches of left and right controls Check whether th
69. ng riding so brake is used to make resistance to wheel to achieve that purpose For normal motorcycles front brake is operated by right hand and rear brake is operated by right foot However among some motorcycles with automatic clutch such moped or scooter the rear brake can be operated by left hand The brake of motorcycle consists of drum brake and disc brake This motorcycle adopts front disc brake and rear drum brake 1 Structure and working principle of brake Disc brake consists of mechanism type and hydraulic type At present hydraulic brake is in common use motorcycle The hydraulic brake normally consists of brake handle brake pedal main oil reservoir reserve oil reservoir The reserve oil reservoir and main reservoir are usually integrated brake caliper brake disc and brake oil pipe When operating brake brake handle compresses the main oil reservoir which enhances the pressure in hydraulic pressure system drives the main piston in brake caliper and tighten the friction pieces on brake disc Therefore the brake disc fixed on wheel can get the braking power The characters of disc brake is soft working automatic cleaning and hard to lose control Structure drawing of disc brake 2 Disassembly and maintenance of brake 1 Hold front brake control with right hand to check the Check brake handle brake performance of front brake The standard free stroke is LOmm 20mm AN je Ye gt If front brake control can no
70. ntisbumed out Starting motor doesn t work wth electe sate Check storage battery rectifier damaged fuse tube Fuse tube is dam Starting motorcannotrun Replace fuse tube aged or melts down illuminating Inner connectin Illuminating light is notin Repair or replace illu ight i Int connects bad Inner connecting point con iti inatino light 5r Is damaged nects bad or is damaged Boe oie CMON OF Direction indi Inner connecting Inner connecting point con Direction indicator lamp Repair or replace direc cator switch point connects bad nects bad or is cH doesn t illuminate tion indicator lamp he inner flasher is The inner flasher is burned out Direction indicator lamp Replace flasher burned out doesn t illuminate The inner con ere iii brake light _ Brake light illuminates for a Repair or replace brake switch pe FE time or doesn t light switch is damaged illuminate r Inner con Inner connecting pointof hom Electric horn doesn t wo rk horn button point connects bad button connects bad or is lor its sound is not normal Repair or replace horn or is damaged damaged button o HSI TONSA ZONESHEN Section 4 Power Consumption Part The power consumption part of electrical system of motorcycle consists of following 1 Light signalling Device Illuminating signal device consists of headlight positi
71. o on Therefore adjust ingiton advance angle firstly If ignition system cannot work well check electrical ignition device high voltage coil ignition coil and triggering loop of magneto and so on 2 Carburetor Adjustment Carburetor adjustment is very important which directly decides the performance of engine so maintain it as the following Before carburetor adjustment make sure the operation temperature of engine is in order open choke valve check whether the valve clearance and ignition timing are right and ensure no leakage or block of engine and carburetor Carburetor adjustment includes idle adjustment and fluid level adjustment of float chamber The adjustment can make the operation of engine idle stabler and avoid poor or rich oil in carburetor 3 Clutch Adjustment Clutch is used to transfer power so it plays an important role in transmission system Adjust the free stroke of clutch operation grip within 10mm and 20mm For some motorcycles there is a need to adjust adjust ing bolts of disengagement parts Section 3 Adjusting Data of Maintenance Table 2 1 operation brake shock absorber wheel terns Standard Value mm Free stroke of front brake lever 1020 Free stroke of rear brake pedal 030 Depth of flower pattern on tire surface 2 Stroke of front shock absorber 2 Free stroke of throttle control grip J 1 Stroke of rear shock absorber 2 Sub 4 0 Free length of front shock absorber spring 425 45 35 Free length of
72. of drive chain Remove tie in of drive chain and drive chain Check the abrasion of the tie in of drive chain and replace it if necessary A gt When installing the open end of spring clamp of chain tie in should be opposite to the running direction of chain 6 Check the abrasion and distortion of drive chain Wholly replace the big and small sprocket wheel and drive chain if necessary rm Z G m gt a D PENDS HE 7 Remove left gasket of rear wheel and check its abrasion Dismantle the locknut of rear axle then take rear wheel off 8 Remove the oil seal of cushion body of rear drive sprocket wheel and check its abrasion 9 Remove the rear drive sprocket and check it for wear A EUN gt When both big and small drive sprocket wheel are worn wholly replace them including big and small drive sprocket and drive chain 10 Remove the gasket of rear drive sprocket wheel and check the abrasion of rear drive sprocket wheel axle Replace it if necessary otherwise it will influ ence the working of transmission system gt When rear drive sprocket wheel axle is worn replace it in time otherwise it will lead to a big swing of rear wheel and a dead rear wheel sprocket wheel a 3 The cause trouble description and repair method of rear transmission device Table 4 4 Maintenance of Rear Transmission Device component t
73. olly replace bear flexible and shakes dur ing ring ing running PENDS HE Section 7 Operating Steel Wire 1 Structure and Working Principle of Operating Steel Wire Operating steel wire mainly consists of steel wire wire head and metal spring plastic hose The steel wire should be soft so that it doesn t break off easily and it can bear big pressure lt is normally made of several thin wires which ensure the intensity of steel wire and make it soft The wire hsead is connected with steel wire through the method of stannum jointing zins alloy die casting and so on The outside of metal spring plastic hose is plastic and inside is a spring hose made of steel wire which can bear any bending and won t change the length when suffers axial pressure There is a nylon bushing between the steel spring plastic hose and steel wire which avoids the direct friction of steel wire and spring hose 2 Maintenance of Operating Steel Wire In order to keep operating steel wire working well and prolong its sevice lifetme termly cleaning and lubricat ing is necessary For the first time you can do it after 1500km and then every 3000km Here are two meth ods for lubrication one is dip in the other is injection Dip In Lubrication Operate as follows 1 Dip the whole steel wire in coal oil for 5 1Omin Pull the steel wire to clean out the deposit in hose 2 Dip the whole steel wire in the mixed oil which has persentage of
74. ols please operate as regulation Please energize equally and pay attention to the direction When dismantling components please choose suitable tools energize equally and pay attention to direction to avoid component damage 8 The brake pads which are dismantled should be stored separately which are also forbidden to contact luboil otherwise it will lead to brake failure 9 When there are some difficulties to dismantle because of the rust of screw thread components you can dip the components in gas for several minutes then dismantle them 10 When dismantling gaskets you should be much careful to avoid damage 2 Cleaning of Components After the components are dismantled they must be adhibited some oil or carbon deposit Clean them to help maintenance and installation You can choose gas coal oil and cleaning liquid to clean The cleaning method is adopted according to the speciality of components 1 Oil Stain Cleaning Cool cleaning and heat cleaning are two methods for metal parts Use gasoline or coal oil as detergent put the metal parts into detergent and scrub them by brush which is called cool cleaning Use aqueous alkali as detergent put metal parts into detergent heat up to 7 9 C 90 C and immerse for 1O0min 15min then take out the metal parts and clean which is called heat cleaning z 42 L 2 CD L 6 HEM 2 Carbon Deposit Removing To remove the carbon depo
75. on light taillight and meter indicator Its main function is when motorcycle runs at night they illuminate and have motorcycle noticed by other vehicles in order to ensure the riding safety signal device consists of turning indicator horn gear indicator and brake light It is used to indicate the running condition of motorcycle and express the operation of rider through sound and light signal 2 Electric Starter Device Electric starter device consists of starting motor and mesh setup lt is mainly used to start engine for the details please refer to section 7 chapter 2 Light signalling Device 1 Headlight and Position Light Headlight illuminates the front road for rider It makes rider see the road condition and other running vehicles and also it can send signal to the coming people and vehicles lts flash can make the front vehicles noticed its overtaking intention When motorcycle runs a fog day headlight is also usually opened to ensure its riding safety Position light is used to indicate the position of motorcycle and make motorcycle noticed by other people at a district where the illuminating condition is good or motorcycle passes other vehicles at night It is usually installed in headlight assembly Headlight mainly consists of focus lamp glass cover bulb lamp holder and cover The function of focus lamp is to make the light from bulb gather into a bright beam of light Its material is aluminum board which is made through pressing T
76. ower in battery According to the character of electric current export generator can be divided into DC generator and AC generator According to the different structure the AC generator can be divided into AC flywheel generator AC magnet rotor generator and AC three phase generator magnetic pole of first two has permanent magnet so it is also called AC permanent magnet generator However the last one produces magnetic pole through electricfying the coil so it is called AC excitation generator Usually the generator we talk about is AC flywheel generator According to the different rated voltage of battery it can be divided into 6V battery and 12V battery If the rated voltage is the same according to the different volume it can be divided into big and small According to the different structure it can be divided into plumbum acid battery and complete seal and maintenance free battery 1 The Structure and Working Principle of DC Generator DC generator works according to the principle of electromagnetism induction Viz when lead plumbs magnetic wire and moves in the well proportioned magnetic field there is inductive electromotive force produced in the lead If the lead forms a closed circuit with other outer circuit there is inductive electric current produced in the lead The direction of this electric current can be estimated through right hand rule 2 The Structure and Working Principle of AC Generator AC generator mainly consists of AC flywheel
77. pping 208 and whether valve spring iS 1 whether the flywheel motor returns of generator and the triggering coil are loose The idle speed of en gine is unstable Noidlespeed of engine Check the compressing pressure of cylinder Check whether engine ignition is timing The comprssing pressure of cylin derisnotenough The comprssing pressure of cylin der is normal Check by fault diagnosis 1 Check whether the outer connection part of tester if idling is still high No engine has leakage ee l 2 Check whether valve timing is normal Check the mixed ratio of combus 3 Check whether the valve clearance is too narrow tible mixed gas 4 Check whether the seal between valve and valve seat is good mM 5 Check whether the piston ring is broken off or dead or has poor elasticity 6 Check the abrasion of piston ring and cylinder Check air passage of throttle valve Air passage has carbon depo sition seriously Clean the passage There is no idling output after cleaning Check it by using fault di agnosis tester Check whetherthe elec trodeclearance of spark plug is too small Yes Adjust electrode clearance D ZONES HEM 1 2 Analysis of Insufficient Engine Power Engine power is insufficient Support motorcycle with main stand make it off the ground and rotate wheel with hands
78. r and check as follows 1 Check whether carbon brush is worn 2 Check whether the spring of carbon brush breaks off or its elasticity is poor whether armature comb is worn Check whether armature coil has open circuit or short circuit Ing relay is dam 3 Check whether the circuit of inner electric starting system has open circuit or aged or ablates short circuit 2 4 Analysis of starting motor e running starting motor is weak Turn on ignition switch and press horn button or turn on off turning light switch Electric horn cannot make sound or make weak sound Electric horn makes rotund sound Turning light illuminates brightly Turning light illuminates dimly Check PUES the lead end from starting relay to starting motor has poor connection enone or the lead of connecting stor Yes age battery has poor connection Dismantle the connecting lead of starting motor from starting CUR relay and the connecting lead of storage battery Press start ing button When starting relay makes sound measure the resis tance between the battery connection of starting relay and connection of Se motor with ohmic meter Check whether the resistance gets through Yes No Measure the resistance of motor with Pu CE point of starting re ohmic meter and check whether it gets lay is damaged or ablates D ZONES HEM 2 5 Analysis of illuminating light All illuminating light t
79. ramic appearance and easy operation It adopt single cylinder 4 stroke air cooling engine This type of engine has the advantages of good cooling powerful and good acceleration The frame is pipe joint which has high tensity and good rigidity The brake system adopts the combination of front and rear disc so that it could ensure the stabilization and safety And rim type wheel has good appearance and function of anti abrasion FIGURE 1 1 Left view of motorcycle l Front fender 2 Front shock absorber 3 Steering 4 Fuel tank 5 Rear armrest 6 Front wheel 71 brake 8 Gearshift pedal 9 Side stand 10 Rear wheel fh fed ae Ee TT T3 FIGURE 1 2 Right view of motorcycle 1 Taillight assembly 2 Muffler 3 Seat 4 lgnition lock 5 Headlight 6 Rear brake 7 Rear pedal 8 Front pedal 9 rear brake es Z G I Z 42 ER 2 D FONG FEE PN Chapter 2 Structure This motorcycle mainly consists of riding system operation system brake system transmission system fuel supply system electrical system and engine Refer to Diagram 1 3 Diagram 1 3 structure Riding system 2 Electrical system 3JOperation and brake system 4 Fuel supply system 5 Engine 6 Transmission system 1 Riding System The basic function of riding system 1 Make motorcycle in a whole and support whole motorcycle 2 Receive the torque from
80. ransmission Device The rear transmission device of this motorcycle adopts chain It mainly consists of drive gear driven gear drive chain chain tie in drive chain box chain adjuster and rubber dead block First it exports power through the end of countershaft C of engine derailleur power exporting bearing then trans i Xm fers the power to driven chain through drive chain and SEE axo CO makes 3 time deceleration The driven chain is fastened on the cushion body by bolts The cushion body con nects with rear hub through rubber dead block So when changing the speed during running power is transferred flexibly through rubber cushion so it avoids the abrasion of parts and enhances the comfort and stability of motorcycle 2 Disassembly and Maintenance of Rear Transmission Device 1 Dismantle the fixed bolt of gearshift pedal and remove the gearshift pedal pomum c 2 Dismantle bolts of left rear cover of left crankcaseand remove left rear cover of left crankcase rear cover o left crankcase Small drive sprocket GRE Sew as Ta iS ME Gig X9 OD SOO e INO drive chain a a B 3 Check the abrasion of small drive chain and replace the chain assembly if necessary 4 Dismantle fixed bolt of chain box and remove the chain b Dismantle the spring clamp
81. rear shock absorber spring axial Wheel hub runout Axle runout rear 22 we Table 2 2 Maintenance Cycle Items 4000km 8000km 12000km e ooo 101 A Ri Rl RAI 1 1 1 Chokevavecable 1 1 1 Aircleanerelement R R sekpuggp Vaveclearance 1 1 1 bDhvngchin im UL m ML Bay L 1 1 L huw 1 1 1 1 1 1 1 173 j Beelgnswih 1 1 1 f Headightadusing Mamsdesand 1 1 1 1 1 1 1 Outer tire of front and rear wheel eoo ee ee steering system bearing Maintain the motorcycle according to the period that is listed above Each capital letter on the list stands for as follows L lubricate I inspect clean adjust lubricate or replace indicates that maintaining this item by service center of our company If maintain it by yourself please consult this maintenance manual indicates that maintaining this item only by service center of our company To ensure riding safety please follow our advice A Shorten the main
82. rection don t change according to the change of time is called direct current DC The other whose intensity and direction change periodically according to the change of time is called alternating current AC 4 Circuit series circuit and parallel circuit The closed circuit which is made up of electrical source electric apparatus and connecting lead is called circuit The circuit is divided into two basic types series circuit and parallel circuit In series circuit several electric apparatuses connect with each other and there is no cut in the middle At this time the electric current which is through each electric apparatus is the same But in parallel circuit the beginning and the end of each equipment connects between the two points and the voltage of two end is the same In the complicated circuit of motorcycle both series circuit and parallel circuit coexist 5 Short circuit and open circuit In a normal circuit if two leads of which electrical source passes electric apparatus don t pass electric appara tus and connect with each other which is called short circuit In the circuit which is made up of electrical source electric apparatus and connecting lead because of the cut of lead it makes electric current not form a closed circuit which is called open circuit 6 Left hand rule and right hand rule In the magnetic field which can produce electromagnetism induction stretch out the left hand make palm flat make thumb plumb the other four fing
83. rike and shake the requirement on material and jointing is very high It is made through the method of jointing and so on It mainly consists of rear fork dust seal dustproof seal cover and rear cover of bearing In order to keep rear fork rotating up and down around the vehicle body there is bearing shaft or bearing installed at the connection of rear fork and vehicle body When rear fork rotates will make rear wheel more flexibly and more stably 2 Disassembly and Maintenance of Rear Fork 1 Check whether rear fork is distorted or crakes because of the outside force whether the match clearance of each component of rear fork becomes big and whether the rotating times of rear fork is too much A Check rear fork gt Replace or maintain rear fork in time if it has the problems above to ensure the comfort and safety of riding 3 The cause trouble description and repair method of rear fork Table4 9 Maintenance of Rear Fork component trouble description trouble description of repair method description of component motorcycle Motorcycle runs to Correct or replace Rear wheel gets strike Rear fork is distorted Wards one side and rear fork comfort stability and safety are influenced EXER falls down M breaks off cannot run Joint or replace rear and EXER breaks usd ormally fork rearfork strike and shake to The jointing of Rear
84. rom con Measure the rectifier and com nectingcomponentto battery has open mutated adjuster with ohmic meter Check whether they have problems circuit 2 2 Analysis of battery Battery cannot be full charged Check whether brake light al ways illuminates Yes Adjust or replace brake switch Set ignition switch to OFF position Remove cathode wire from storage battery Connect the cathode end of current meter to the cathode of stora Be battery and anode end to the anode of storage battery Check the leakage of electric current The value of electric current leakage is smaller than the stated value The value of electric current leakage is bigger than the stated value Normally the electric current is required to be below 1mA Check whether the charging coil of generator has short circuit Thecircuitfrom rectifier or Yes commutated adjuster or 1 Check whether the electrolyte of storage battery is enough whether the electrolyte density of storage battery Is too small storage battery to ignition illuminat Switch has short circuit ing coil JCheck whether plate of storage battery has too much pbso or has short circuit Z Co I 64 ZONGESHEN 2 3 Analysis of starting motor Starting motor doesn trun Turn on ignition switch and press the horn button or turn on off turning light switch Eletric horn cannot make soun
85. rouble eee of trouble description of description noorde method Gear teeth are worn ae ae drive sprocket easy to break off wheel and drive chain wheel inner teeth of gear strange sound from Drive chain is easy to replace drive are worn drive chain break off ven sprocket wheel and drive chain Drive chain disen Drive chain has Wholly replace drive COPIE AGANO gages from gear strange sound and 15 and driven sprocket easy to break off wheel and drive chain sprocket wheel The inner teeth of gear strange sound from chain is easy to ay replace drive and driven sprocket are worn drive chain break off wheel and drive chain Drive chain 1 too dirty Drive chain has strange Clean and lubricate or has bad lubrication sound h Drive chain is too improper tightening Drive chain has Adjust the tightness tight adjustment of chain strange sound to improper tightening Drive chain has Adjust the tightness drive chain Drive chain is too Tee cate Dan strange sound or is of drive chain to loose easy to break off 15mm 25mm Drive chain disen Drive 2 is easy Wholly replace drive Chain is worn and driven sprocket gages from gear break off wheel and drive chain drive chain Drive chain box 15 sound from drive chain drive chain box damaged box b Readjust left and right improper adjustment of Drive chain is easy 10 adjuster and keep the adjuster an
86. rvice station to maintain for any queries EFI failure indicator is equipped in the meter When ignition system is opened indicater lights up when the indicator does not light up that means there is failure When engine starts the indicator puts out When the indicator keeps the light on or flashing that means there is failure idle air control valve throttle position sensor 18 ez ay crankshaftposition sensor NCC crankshaft throttle body position LSH j ERGUN MODULE igniton coil engine temperature M sensor engine 5 inlett E trol module nlet tempera ture pressuremillllibs sensor M3 5 nozzle neutral switch 5 WCPR fuel i fault diagnosis dumping switch switch SCI ignition switch p fuel pump fault jndi highTempera rev signal Ve batte m cau ngiamp ture indicator of engine y 1 of engine catalytic converter optional for metal carrier Structural drawing of system 3 The trouble description of system Check the EFI system by the test instrument If it has fault replace homologous component of EFI If not please check the system as following 1 Check the line connection 2 Check whether or not the voltage reaches 9V 3 Check the vehicle and EFI safe system 4 Check whether the oil ways are blocked extruded or broken rm Z G m X C1
87. sit on component we can use mechanical method or chemical method Mechanical method 1 that scrape deposit with bamboo scraper or spade and clean them with gasoline Immerse the component brush the carbon deposit off and clean them with hot water which is called chemical method 3 Parts Inspection Inspect the parts after cleaning The purpose for inspection is to check whether the parts need to be repaired or replaced There are three methods i e direct inspection instrument inspection and troubleshooting 1 Direct Inspection Direct inspection is to check and judge the condition of parts by individual sensation instead of instrument It is a simple and feasible method which is widely used for maintenance 2 Instrument Inspection Instrument inspection is to measure the size and geometry shape of parts by gauge and apparatus then compare the measured value with limiting value to figure out the condition of parts This method can get an accurate judgement but it needs careful inspection for the precision of instrument and reasonable selection of parts 3 Troubleshooting To find the latent fault of parts we can apply troubleshooting Usually we adopt the method of oil immersion and knock during maintenance The process of this method is as following First immerse the parts into coal oil or diesel oil for several minutes Second take out and wipe the parts Third spread talcum powder on the surface of parts Finally knock the non working surface o
88. t reach the standard value readjust front brake 2 Disassemble the front brake pliers locking bolt remove the front brake caliper Disassemble the front brake caliper PENDA HE 3 Disassemble disc brake friction plate and check the piston of brake caliper for working condition If it cannot work well repair or replace hydraulic brake 4 Disassemble locking nut of front axle and Mile age line then remove the front wheel 5 Remove the speed counter and check the wear breaking of the seal blade Replace it if necessary 6 Remove the front wheel remove the front brake disc fixed bolt remove the front brake disc Please smear glue on the bolt before installing the front brake disc to avoid bolt looseness Remove front brake friction plate Ba locki 2 bh Check the run out eck rear brake arm lt a a B 7 Measure the thickness of front brake disc with micrometer The limit value of repair is 2 0mm CAUTION p If the thickness of brake disc exceeds the limit value of repair 2 0mm replace the brake disc 8 Measure brake disc run out with dial indicator and the limit value of repair is O 3mm p If the run out of brake disc exceeds the limit value of repairO 3mm replace the brake disc 9 Step rear brake pedal by foot check it for performance The standard free stroke of brake pedal
89. tenance period if motorcycle usually runs in dusty region Specification table 2 3 Torque tightening MIO x 1 25 45 55 T 2 G 42 ap 9 PENDS HE Section 1 Fuel Supply System Fuel supply system consists of fuel tank fuel pump injector fuel filter and oil pipe 1 The Structure and Working Principle of Fuel System 1 Fuel Tank Fuel tank is jointed by the armor plate which is normally 0 8mm 1 0mm Some fuel tank is jointed apertured clapboard inside which not only strengthens the fuel tank but also avoids the fuel gurgitation during riding Because of the strong erosion of oil it must be galvanized on the surface of fuel tank There is a fuel adding hole on the top of fuel tank and close the fuel cap which has air hole so that it can avoid fuel leakage during riding and ensure the balanced pressure of inner and outer fuel tank So that fuel can flow out naturally 2 Fuel Pump The fuel pump consists of pump support and oil pressure adjuster Flexible installation can decrease the vibration on the fuel pump The pump installed in the fuel tank is to get a simple construction and non leakage The pump adopts turbo single stage and electric type It is driven by a DC motor with 12V and controlled by ECU through the pump relay There is a one way valve at the exit of the pump which can prevent the oil from flowing back to the bank when engine stops and ensures a good starting performence 3 Fuel Inj
90. tion Friction plates are MEO UR cannot return Replace brake pads as a Set The end of brake pad is Rear brake makes ab worn to a slot normal sound or is out of control Of Brake is out of control Repair or replace fric drum 1 tion plates of brake pads The Brake pads cannot Replace return enough or broken Ne spring Moving parts are rusty The rotation of brake Brake is out of control Clean and lubricate Brake cam 19 have foreign things is not flexible or cannot return brake cam The circle surface of Brake is out of control Replace brake cam brake cam Is worn PENDS HE Section 12 Meter The meter of motorcycle is to indicate the working condition of motorcycle 1 The Structure and Working Principle of Meter 1 Speedometer Speedometer is to indicate the running speed of motorcycle and the total mileage lt is driven by front wheel The rev of front wheel is sent to speedometer through gearshift system and soft axle which makes magnetic cylinder rotate Coil cuts magnetic wire which makes whirlpool and magnetic field to cooperate with the magnetic field of magnetic cylinder makes whirlpool disc get a torque overcomes a resistance and drives the finger to rotate The higher the speed is the stronger the magnetic field of whirlpool disc is The torque is bigger so the angle of finger swing augments and it can rea
91. tioning spring breaks off or its elasticity is insufficient Disassemble crankcase and check whether its mesh of gear is correct according to the standard Yes No The depth of gear The depth of gear mesh mesh is hot Brought is enough Check whether convex pawls of mesh gear are worn to Check whether the fork is wom or distorted cone shaped and whether opposite groove of gear end is worn to be bell mouthed Yes No 1 Check whether fork hole and fork axle orn Check whether the installation of de railleur is correct Rep lace gear Check whether the spline of main and secondary axle and the spline trough of slip gear are worn 1 9 Analysis of slide and uncomplete disengagement of clutch Clutch slides and disengages uncompletely Automatic wet and multiple clutch slides Check whetherthe clutch adjuster is adjusted to the best state No Yes Readjust it Check whether the elasticity of cluth spring is well proportioned NO Yes NO Clean lubricate or re place it Check whether drive and driven Wholly replace cluth spring hub trough are worn to be zigzag Yes Repair or replace 1 Check whether the pressing bolt of clutch spring is them loose 2 Check whether the friction pieces of clutch are worn or ablate 3 Check whether the elasticity of clutch spring is poor 4 Check whether drive hub of clutch and the connecting surface of pressing plate and
92. to filtrate the air but also the resistance of air flowing must be small so that the volume of engine inlet will enhance More require ments are reliable working performance simple structure small dimension of appearance light body and easy to maintain The air cleaner mainly consists of element and sealed box When engine runs air will enter into the front cavity of air cleaner through air pipe then flow into the rear cavity after filtration and finally enter the throttle 2 The Structure and Working Principle of Inlet Pipe Inlet pipe is the important component to con nect throttle and engine inlet Meanwhile it has a function of supporting throttle and has a simple structure Its bending shape depends on posi tion which the throttle should be corresponding to the engine inlet but you should think about the influ ence of inlet resistance If the pipe is long it has advantage of fuel pulverization but air resistance is big If the pipe is short which is not good for fuel pulverization but air resistance is small The mixed gas after pulverization of throttle flows into cylinder through inlet pipe and engine inlet The inlet pipe reduces the heat which engine has transferred to throttle and separates the shake of engine from throttle 2 The Structure and Working Principle of Exhaust System The exhaust pipe in exhaust muffler is made of bending steel pipe It locates between exhaust vent of engine and muffler Its funtion is to guide the e
93. torcycle runs with low speed the engine rev is very low which makes storage battery export power to DC generator with strong electric current so that the DC generator is burned out So it is necessary to make adjuster cooperate with generator 2 AC generator adjuster The motorcycle with generator not only needs the rectifier to transfer the AC to DC but also it needs AC adjuster to stabilize the export of generator At present the AC adjuster which is usually used is AC electronic adjuster AC adjuster mainly consists of transistor diode and thyristor When generator works the lighting and signal coil will produce AC 2 Rectifier Rectifier is normally divided into two types single phase half wave rectifier and full wave bridge rectifier These two rectifiers work as the principle of one way electric character of silicon diode It is like an electronic valve which only allows one side electric current to go through 3 Flash Relay Flash relay is called flasher lt is mainly divided into three types thermal resistance capacitance and transistor 4 Starting Relay When starting electromotor works the electric current will be very strong It can reach tens of amp Starting relay is an electromagnetic switch When pressing the starting switch of right handlebar electric current will connect with the cathode of battery through storage battery battery connection relay coil and connection of starting switch then it will make a closed circuit 5 Tube Ge
94. transmission setup Provide traction for motorcycle running through the contact of wheel and road 3 Endure and transmit road function and endure torque made by the outside force of wheel 4 Absorb and handle the strike and shake produced during motorcycle running Riding system mainly contains frame assembly front rear shock absorber front rear wheel and some other accesories 2 Operation and Brake System The main function of operation system 15 to control running direction running speed brake illumination and signals and to ensure motorcycle running safety The operation and brake system mainly consists of steering setup brake setup and some relative controlling handlebar controlling switch steel cable and accessories 3 Transmission System The basic function of transmission system is to augment torque or reduce transmission speed according to the road condition and running need After that to transmit the result to drive wheel and to make motorcycle run Transmission system mainly consists of starting device clutch gearshift and accessories of rear transmission device 1 Starting Device The function of starting device is to start engine and to make engine automatic running The starting device of motorcycle is divided into two modes One is kick starting and the other is electric starting 2 Clutch The function of clutch is to transmit or cut off the power from engine reliably and softly and to ensure motorcycle 1H stable start and gearsh
95. ustment of The beam of light of headlight is Adjust the beam of light beam of light 15 biog far or too clase of headlight Imporper Thefilamentofhead The filament of headlight is Headlight doesn Replace the bulb of light is bumed out purned out illuminate headlight The filament of The filament of brake light Replace the bulb of brake lightibrake Boke tates eae lene brake light is bumed out brake light brake light ight is bumed out The filament is The filament of tuming light is light doesn t Replace the bulb of turn burned out burned out illuminate Ing light The filament is indi Gear indicator doesn t Replace the bulb of gear burned out pe ee illuminate indicator The inner horn is The inner horn is burned Electrichornhasnosound Replace electric horn ee jout or damaged or the sound is not normal Z Co I 96 ZONGSHEN Chapter 5 Analysis of Motorcycle Troubles Section 1 Analysis of Engine Trouble 1 1 Analysis of Poor Idle Speed of Engine poor idle speed of engine Y The idle speed of en gine is too high Pull the valve of with hands and check whether it is com pletely closed Check it by fault diagnosis tester ves Yes nn Check whether the steel wire of rottle control cable can be flex 105 of downtime pulled outside the cover of Ver ee then restart switch ing i when idling ste
96. valve pipe is too big NO Oil seal of valve is damaged 1 Check whether cylinder piston and piston ring are worn Check whether piston ring has 2 oor elasticity orisdead 3 Check whether the opening of piston ring has 120 to another opening Yes Check whether valve and valve pipe are worn 1 7 Analysis of gearshift Gearshift of derailleu is difficult Start engine and check whether the idle speed of engine 5 too fast No Check whether operation of gearshift is harmonious Check whether cluth disengages Improve operation uncompletely method Yes No Check whether the gearshift axle is distorted or whether gearshift arm is distorted or worn Yes Readjust it 1 Check whether the elasticity of cluth spring is well proportioned 2 Check whether drive or driven hub tooth of clutch is worn Yes tosawtooth 3 Check whether friction steel pieces of clutch are distorted 4 Check whether the components of operation system of clutch are worn Replaceit 1 Check whether camshaft of gearshift or cam trough inside is worn or damaged 2 Check whether the fork is worn Check whether the fork is distorted Check whether the fork axle is distorted or worn m Z e 2 Co I 62 ZONGSHEN 1 8 Analysis of derailleur gearshift derailleur gearshift Check whether the posi
97. venient installation but poor elasticity and cannot be adjusted lf the rim is distorted or damaged you should replace the whole rim The spoked rim is made from steel strip In the wheel rim there is a lot of hole seats in which a spoke and spoke nut are installed The other end of spoke connects the wheel hub Therefore the spoked rim has a good shock resistance adjustable characteristic and convienent maintenance In this part it mainly discusses the die casting rim 3 Wheel Hub The wheel hub of motorcycle is divided into front hub and rear hub The structure of front hub and rear hub is very familiar The rear wheel is drive wheel so there is power transmission device installed on rear hub There are bearing bearing gasket oil seal and axle installed in the front and rear hub which is good for the operation of wheel hub 2 Disassembly and Maintenance of Wheel 1 Check whether tire pressure is within the normal scale Clean out the deposit of outer tire thread Avoid inner and outer tire damaged Che W gt Check abrasion of outer tire Replace it if it exceeds the limit value 2 00mm B UNE SEN 2 If front wheel is deformed by stricking or vibration so that the bike run out of way or steering control trembling or vibrating The wheel need to be re placed or adjusted Check front wheel P C q 1 M N Replace the wheel when it trembling over the
98. xhaust gas from engine to the muffler rm Z G m IL 2 3 Disassembly and Maintenance of Intake System 1 Dismantle suspension bolt of air cleaner and clamp screw of inlet pipe Remove air cleaner assembly 2 Dismantle lock screw of air cleaner element Take out the element of air cleaner and check whether there is too much dust on it Clean it if too much dust 3 Remove filter sieve of air cleaner and check whether itis damaged or dusty Clean the filter sieve rm Z G m IL N PONDA HEN 4 Disassembly and Maintenance of Exhaust System 1 Dismantle the locknut of exhaust pipe of muffler and suspension bolt of muffler Check whether the suspension bracket is broken Re joint it if broken CAUTION gt When the suspension bracket of muffler is broken replace or re joint it 2 Remove muffler and check whether the muffler is broken or damaged Re joint or replace it when bro ken or damaged 3 Remove the seal gasket of muffler and check whether the gasket is damaged Replace it if damaged The seal gasket must be replaced every disassembly of muffler 4 Check whether there is carbon deposit in the muffler pipe Clean it CUN Check Whether muffler is rusty or broken Replace or maintain it if necessary rm Z G m 3r a B b Check whether there is carbon deposit
99. ystem EFI system consists of ECU nozzle throttle valve intake air temperature integrated pressure sensor engine temperature sensor ignition coil CKP pump oxygen sensor EFI system could control the ratio of fuel air mixture which import into the engine cylinder combustion process and exhaust gas conversion accurately So as to optimize engine performance and driveability and control the exhaust emission strictly ECU is a microprocessor as a core of SCM By sensor and working request switch installed in the engine and body of motorcycle ECM could analyse mode of operation and estimate operating conditions Finally controlling engine and relevant mechanisms accurately through actuator in the engine and body of motorcycle The type of engine speed and crankshaft angle sensor is magnetoelectricity The function of this sensor is to determine the position of the rotating and revolving speed for crankshaft Crankshaft angle sensor is installed on the clutch housing and it works with 24x gear ring from flywheel MAP sensor is installed in the intake manifold to measure the pressure so ECU could judge air enter into the engine from this signal MAP sensor consists of an elastic diaphragm seal and a magneticcore Diaphragm seal and magneticcore is placed in the coil accurately When they sense pressure they could produce a 0 bv output signal in direct proportion to input pressure Throttle position sensor is installed on the throttle body and

Cyclone Owners Manual (ZS250G)

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