ZONGSHEN ZS250GY-3(EFI), Maintenance Manual

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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 and 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 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.
[4]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 tools,please operate as regulation.Please
energize equally and pay attention to the direction.
[7]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 79
℃～
90
℃
and immerse for 10min
～
15min,then take out the metal parts and clean,which is called heat cleaning.