ZONGSHEN ZS250GY-3(EFI) Maintenance Manual Download Page 11 | Manualshive

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ENG
LISH

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.

[1]When motorcycle is being repaired,please use the components,accessories,luboil

and  other  accessorial  materials  which  produced  or  recommended  by  our  company  or.If  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 disassembling motorcycle,normally please use appropriative maintenance tools.
[7]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.

[10]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:

WARNING

CAUTION

ADVICE

I

ndicates a potential hazardous situation, which if not avoid, may cause people hurt or death.

I

ndicates a potential hazardous situation, which if not avoid, may damage your bike.

I

ndicates special information to make maintenance easier or instructions clearer.

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Summary of Contents for ZS250GY-3(EFI)

Page 1: ......

Page 2: ...SH ZS250GY 3 EFI MOTOCYCLE 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 ...

Page 3: ...ENGLISH ...

Page 4: ... Industrial Group in more than 90 countries such as Japan New Ze aland Germany Canada etc This trademark was registered by Zongshen Industrial Group in more than 90 countries such as Germany Camb odia and France etc This trademark was registered by Zongshen Industrial Group in more than 20 countries such as Nigeria Argent ina and Vietnam etc INTRODUCTIONS The manual intruduces the structure woking...

Page 5: ...ENGLISH ...

Page 6: ... 1 Fuel Supply System 10 section 2 EFI System 13 section 3 Intake and Exhaust system 20 section 4 Rear Transmission Device 24 section 5 Frame and Accessories 28 section 6 Steering System 31 section 7 Control Steel Cable 32 section 8 Shock Absorber 33 section 9 Rear Fork 37 section 10 Wheel 38 section 11 Brake 42 section 12 Meter 48 CHAPTER 4 ELECTRICAL 50 section 1 Basic Knowledge 50 section 2 Pow...

Page 7: ...ENGLISH ...

Page 8: ...s designed for use on road With futuramic 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 ...

Page 9: ...ning 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 oth...

Page 10: ... 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 e...

Page 11: ...ring 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 disassembling motorcycle normally please use appropriative maintenance tools 7 Please repair moto...

Page 12: ...nment 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...

Page 13: ...e 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 ...

Page 14: ...ectification 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 machine such as the bonding of handlebar and steering head bonding of plastic label and spay paint metal parts bond...

Page 15: ...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 sta...

Page 16: ... I I I I I R I I I R I I I L I I I I I I I I I I I R I I I R I I I L I I I I I I I I I I I R I I I R I I I L I I I I I I I I I I Shorten the maintenance period if motorcycle usually runs in dusty region 25 35 50 60 70 80 70 80 45 55 45 55 28 32 50 60 55 65 45 5 Torque tighteningCAUTION table 2 3 Motorcycle M24 1 M10 1 25 M14 1 5 M14 1 5 M10 1 25 M10 M8 M12 1 25 M12 1 25 M10 1 25 Locknut of main pi...

Page 17: ...el 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 Injector Fuel supply system consists of ...

Page 18: ...ce the sealing ring of cap if necessary 4 Check the fuel pipe for fuel leakage or aging Check filter for block repair or replace it if blocked 3 Check the fuel tank for fuel leakage Replace or repair it if necassery If the fuel tank is deformed by the collision of external force repair it to original condition with wooden hammer If the fuel tank has cracks replace the fuel tank without repair If t...

Page 19: ...leakage Replace it if necessary 7 Take out the pump and then clean the oil sludge and water in the tank with oil sludge remove the fuel pump 6 Remove the six fixed bolt M5 16 of fuel pump by hexagon wrench Please dump oil first and keep away from the fire when dismantling the pump WARNING After cleaning the fuel tank could be used when drying out CAUTION dismantle the fuel tank dismantle the fuel ...

Page 20: ...uel tank is deformed The appearance of mo torcycle is bad Repair or replace fuel tank Fueltankisaccidented Motorcycle is hard to be started or cannot be started The engine power is not enough and the idle speed is not stable Clean oil filter screen Fuelsupplyisnotgood Cleanorreplacefuelpump Fuelsupplyisnotgood Motorcycle cannot be started The fuel pump body is blocked The motor of fuel pump does n...

Page 21: ...l 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...

Page 22: ...rated before leaving the factory When EFI system has failure adjust idle screw of throttle voluntarily and replace or adjust parts of EFI are strictly prohibited Please go to our service station to maintain for any queries EFI failure indicator is equipped in the meter When ignition system is opened the indicater lights up when the indicator does not light up that means there is failure When engin...

Page 23: ...r cycle must be installed with air cleaner The requirement of air cleaner is not only 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...

Page 24: ...et 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 it is damaged or dusty Clean the filter sieve element filter sieve air cleaner ...

Page 25: ...int 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 When the suspension bracket of muffler is broken replace or re joint it The seal gasket must be replaced every disassembly of muffler CAUTION CAUTION 4 Check whether there is carbon deposit in the muffler pipe Clean it Check Whether muffler is rusty or broken ...

Page 26: ...ment is dusty Clean or replace element The body of air cleaner is broken Engine is hard to be started or cannot be started poor engine power unstable idle speed high fuel consump tion and black smoke from exhaust muffler inlet system The noise of engine in let is big exhaust system Replace air cleaner body The noise of engine exhaust becomes louder leakage at vent of exhaust pipe The body of ex ha...

Page 27: ... the end of countershaft of engine derailleur power exporting bearing then trans fers the power to driven chain through drive chain and 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 a...

Page 28: ...rive chain and drive chain Check the abrasion of the tie in of drive chain and replace it if necessary 6 Check the abrasion and distortion of drive chain Wholly replace the big and small sprocket wheel and drive chain if necessary CAUTION When installing the open end of spring clamp of chain tie in should be opposite to the running direction of chain Small drive sprocket wheel chain box Chain tie ...

Page 29: ...ket wheel are worn wholly replace them including big and small drive sprocket and drive chain CAUTION L e f t gasket Oil seal Rear drive sprocket wheel 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 When rear drive sprocket wheel axle is worn replace i...

Page 30: ...o break off improper tightening adjustment of chain Drive chain is too loose Chain is worn Drive chain is easy to break off Drive chain disen gages from gear drive chain box adjuster rubber cushion Drive chain box is damaged sound from drive chain box improper adjustment of left and right adjuster Rear wheel inclines Drive chain is easy to break off Adjuster is damaged Adjuster cannot be adjusted ...

Page 31: ... mainly consists of head pipe main frame tail pipe rear supporting pipe and low bending pipe It 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 accessories It makes motorcycle as an integrated part 2 Disassembly and Mainten...

Page 32: ...k whether the rubber cover of front pedal is damaged Replace it if damaged Replace the covers if damaged Replace seat if damaged Replace rubber cover of front pedal if damaged ADVICE ADVICE ADVICE Cover Seat Front pedal 6 Check whether rear armrest is broken Repalce or repair them if is Replace rear armrest if it parts ADVICE Rear armrest ...

Page 33: ...front pedal Riding safety is influenced starting lever Starting lever is dis torted or damaged Starting performance is influenced rear view mirrior Rear view mirrior is distorted or damaged Rear view mirrior gets strike or shake Riding safety is influenced Rear pedal is dis torted or damaged Comfortforriderdeclines rearcarrier Rear carrier gets strike or shake Rearcarrierisdistorted or jointing br...

Page 34: ...ance 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 adjusting nut is too tight the turning resistance of steer ing handlebar will ...

Page 35: ...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...

Page 36: ...ween 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 close of one way...

Page 37: ... 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 their abrasion Replace them if worn 6 Removethereturningspringofshockabsorberpoleand check its abrasion and distortion Replace it if distorted Drain shock absorber oil Spring clamp Oil seal Shock absorber pole Lower pipe Returning spring ...

Page 38: ...erand check its abrasion Replace it if worn 9 When installing front shock absorber add front shock absorber oil according to the stated The standard volume of front shock absorber is 330 5 mL Add shock absorber oil 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 Measure the lower pipe Spring of...

Page 39: ...ockab sorber or its lower pipe Motorcycle runs to wards one side and comfort stability and safety are influenced Motorcycle runs to wards one side and comfort stability and safety are influenced Piston lever is worn or damaged Replacefrontshockab sorber or piston lever Front shock absorber is too soft Replacefrontshockab sorber or piston ring Piston ring is worn or damaged The comfort stability an...

Page 40: ...rear fork becomes big and whether the rotating times of rear fork is too much Replace or maintain rear fork in time if it has the problems above to ensure the comfort and safety of riding Maintenance of Rear Fork 3 The cause trouble description and repair method of rear fork Table4 9 component description cause trouble description of component trouble description of motorcycle repair method rearfo...

Page 41: ...ing 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 convenient installation but poor elasticity and cannot be adjusted If the rim is distorted or damaged you should replace the whole rim The spok...

Page 42: ... off tighting nut of front wheel shaft M14 and take out front wheel shaft and front wheel assembly 4 Take out front wheel shaft bush to check whether it was abraded If it was worse replace it 5 Take out the oil seal to check whether the blade is abraded Replace it when needed Replace the wheel when it trembling over the maintainence limit value CAUTION Add grease when assembling the bush CAUTION C...

Page 43: ...tyre has leakage CAUTION If inner tyre valve core has leakage repair or replace the core If inner tyre has leakage fix or replace inner tyre 7 If front wheel shaft abrade badly knock it out by using shaft disassembling tools and replace it with the new one CAUTION 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 r...

Page 44: ...if damaged 12 Check whether rear axle is worn Replace it if worn Smear lubricant when installing CAUTION Check rear axle Check rear wheel hub Check rear axl e 13 Check whether the front and rear rim are 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 Check rear rim ...

Page 45: ...nce of inner and outer bearing is too big or its rotation is not flexible Motorcyclerunstowards one side and turning handlebar shakes dur ing running Motorcycle runs to wards one side and turning handlebar shakes during running Rear wheel is distorted Rear wheel is damaged The match of bearing hole of wheel hub and bearing is too loose Rear aluminium wheel is distorted front wheel gear box of spee...

Page 46: ...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 brakehandle compressesthe 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 ...

Page 47: ...e age line then remove the front wheel Remove front brake friction plate Remove wheel 5 Removethespeedcounterandcheckthewearbreaking of the seal blade Replace it if necessary Remove speed counter Disassemble the locking bolt Please smear glue on the bolt before installing the front brake disc to avoid bolt looseness WARNING 6 Remove the front wheel remove the front brake disc fixed bolt remove the...

Page 48: ...rear brake pedal for several times and re lease it Rotate the rear wheel assembly and check the rear wheel for free rotation Check rear brake arm 7 Measurethethicknessoffrontbrakediscwithmicrometer The limit value of repair is 2 0mm 8 Measure brake disc run outwith dialindicator and the limit value of repair is 0 3mm Check the run out Check the thickness If the thickness of brake disc exceeds the ...

Page 49: ...ceed the limit value replace it WARNING 13 Disassemble the fixed bolt of brake disc and remove it measure the thickness 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 Check friction lining Disas semble the fixed bolt Please smear glue on the bolt before ins...

Page 50: ...e area of brake shoe touching with brake drum is too small The elasticity of brake shoe spring is not enough or broken Brake pads Brake is out of control The circle surface of brake cam is worn Moving parts are rusty or have foreign things Brake is out of control or cannot return The rotation of brake cam is not flexible Brake cam Replace brake pads as a set R e p l a c e r e t u r n spring Repair...

Page 51: ...s 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 reach 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...

Page 52: ...r doesn t work Speedometer is damaged Replace speedometer The filament of indicator is burned out Speedometer is damaged Replace the bulb of meter indicator Replacebulbofindicator The filament of meter head lamp is burned out meter assembly Meter headlamp doesn t work trouble description of component component description cause trouble description of motorcycle repair method Maintenance of Meter ...

Page 53: ...nt 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 direction don t change according to the change of time is called direct current DC The other one whose inte...

Page 54: ... 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...

Page 55: ... battery is charging Because it 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 of generator Measure the resistance of generator stator with multimeter and check whether the re...

Page 56: ...nough Electroequipment cannot work normally Replacegeneratorrotor Engine cannot be started Headlightcannotilluminate Fuse tube is dam agedormelts fuse tube storage battery generator rotor charging coil component description trouble description of component trouble description of motorcycle repair method Battery has poor power no electric current export of generator Add distilled water or replace s...

Page 57: ...d 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 It is mainly divided into three types thermal resistance capacitance and transistor 4 Starting R...

Page 58: ...ck whether they are damaged or have short circuit Repair or replace them if have problems Check whether front rear brake switches are in good working condition Readjust or replace them if they are not in good working condition 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...

Page 59: ...cycle cannot be started with electric starter Motorcyclecannotbestarted with electric starter Motorcyclecannotbestarted withelectricstarter Inner connecting pointisburned out Repair or replace illu minating light chang ing switch illuminating light changing switch Inner connecting pointconnectsbad or is damaged Inner connecting point con nects bad or is damaged Illuminating light is not in good wo...

Page 60: ...ch 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 It is cylindrical There are 3 uneven bulge at the edge of holder and there is a hole which lead can get through Lampshade and...

Page 61: ...ned 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 Taillight Bulb of gear indicator Turning light 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 ...

Page 62: ...ght Thebeamoflightofheadlightis toofaror tooclose The filament of headlight is burned out Headlight doesn t illuminate Replace the bulb of headlight headlight assembly taillight brake light The filament of brake light brake lightisburned out Replace the bulb of brake light brake light The filament of brake light brake light is burned out The filament is burned out The filament of gear indicator is...

Page 63: ...ther the seal between valve and valve seat is good 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 whether engine ignition is timing Pull the valve of with hands and check whether it is com pletely closed Check the compressing pressure of cylinder Yes No Yes No No Yes Noidlespeedofengine The idle speed of en gine i...

Page 64: ...nough The compressing pres sure is normal 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 soundof flop flop Dismantlesparkplugandputyourfingeronthescrew threadholeof sparkplug then pressdownthestarting button or rapidly step the starting lever Check whether the valve element of wheel hasle...

Page 65: ...e working after starting 1 Checkwhethertheouterconnectionofenginehasleakage 2 Checkwhethervalveistiming 3 Checkwhethervalveclearanceistoosmall 4 Checkwhetherthesealofvalveandvalveholderisgood 5 Checkwhetherpiston ringbreaksofforisdead orhasinsufficient elasticity 6 Checktheabrasionofpistonringandcylinder Dip a little gas in cylinder and try to start Theelectrodeofspark plug is dry The cylinder pre...

Page 66: ...isdarkblack Exhaustmuf fler emits black smoke when engine runs with themedium lowspeed Theacceleratingperfor manceisbadandidlespeedisunstable Butitis normal when with high speed spark plug dielectric is brown Combustible mixed gas is too thin Combustiblemixedgasisthick Checkwhethercylinderex haust port and exhaust mufflerareblockedwithcar bondeposite Check lubricating system 1 Check whether the oi...

Page 67: ...s or without economical speedor with low speed 2 Check whether the oil no is correct Wheel turns hard Support vehicle with side stand and rotate wheel with hands Checkwhethertheoperationiscorrect Engine fuel exceeds consumptivestandard Checkthemixedratioofcombus tible mixed gas Combustiblemixedgas is too thin Check whether therev ofengineis toofast Yes No Yes No Yes No Checkignitionsystem Check wh...

Page 68: ...t muffler of 4 stroke engine emits blue and whitethicksmoke No Yes Yes No No Yes Improve operation method Check whether the gearshift axle is distorted or whether gearshift arm is distorted or worn Check whether cluth disengages uncompletely Checkwhetheroperationofgearshift isharmonious Readjust it Startengineandcheckwhethertheidlespeedofengine is too fast 1 Check whether the elasticity of cluth s...

Page 69: ...idesanddisengagesuncompletely Wholly replace cluth spring Check whether drive and driven hub trough are worn to be zigzag Checkwhethertheelasticityofcluthspring iswell proportioned Repair or replace them No Yes No Yes No Yes No Checkwhethertheforkiswornordistorted Checkwhetherconvexpawlsofmeshgeararewornto cone shapedandwhetheroppositegrooveofgearend is worn to be bell mouthed Disassemble crankcas...

Page 70: ...iclecable Measuretheresistancewithohmicmeterandcheckwhethertheresistance between export leadof chargingcoil accords withthe standardvalue Resistance value is smaller than standard value Resistance value accords withstandard value Resistancevalueisinfinite Battery cannot be charged Charging coil has short circuit Install the connecting component between generator lead and vehicle cable Remove recti...

Page 71: ... Disassemble starting motor 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 3 Check whether armature comb is worn 4 Check whether armature coil has open circuit or short circuit The coil of starting relay has open circuit or short circuit 1 Check whether the connecting point of inner clutch switch has bad con...

Page 72: ...le head light assembly and check whether its bulb is burned out Replace the bulb of head light and check whether other bulbs are burned out Checkwhetherthereispowerexportfrom thepowerimportleadofilluminatingswitch withthemethodofconnecting abulb With a lead make short circuit be tween electric source lead of illumi nating switch and export lead Generatororthecircuitbetweenigni tion switch and illu...

Page 73: ...rectifier Short circuit or tanct is not good Normal Rectifier has trouble Illuminatinglamplight is weak AC supply illuminating system Replacerectifier I l l u m i n a t i n g lamplight becomes normal Illuminatinglamplightis still weak Checkwhetherthechargingcoiland chargingsystemof magnetois short circuit Rectifier is bad Check and eliminate No ...

Page 74: ...ery is poor Remove the cover of turninglightandcheck whether ofturninglight is burned out Turn on off turning light switch Make short circuit for two ends of flasher with a lead or a screwdriver Replace of turning light and check whether the com mutated adjuster works well After short circuit turning light still cannot illuminate Aftershortcircuit turninglight canilluminate Remove the connecting c...

Page 75: ...agewithmultimeter When rubbing there is spark or the voltageisnormal When rubbing there is no spark or the voltageisnotnormal The power wire between ignitionswitchandelectric horn has open circuit Connectthepowerleadofelectrichorn Connect the non power connection of electric horn connectionofbutton withthe cathodewire Afterconnection theelectric horncanmake sound After connection the electric horn...

Page 76: ... or open circuit Whenrubbing there is spark The lead between brake light switchandbrakelighthasshort circuit or open circuit No Yes No Yes Dismantle high voltage wire and check whether there is spark spurt Engine starts hard Fire No fire Sparkplugisdagmaged Cut off the connecion of charging coil of generator and triggering coil and respectively measure the voltage Reconnect it Turn off the ignitio...

Page 77: ...70 ENGLISH APPENDIX CIRCUITDIAGRAM ...

Page 78: ...71 ENGLISH Copyright reserved by Zongshen group Format160mm 230mm The 1st edition Aug 2013 The 1st print Aug 2013 ...

Page 79: ......

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