ZONGSHEN ZS250GY-3 Service Manual Download

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LIS

Front shock absorber is the spring connecting part between front wheel and vehicle 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.

Section 8 Shock Absorber

1 The Structure and Working principle of Front/Rear Shock Absorber

2 Disassembly and Maintenance of Front 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 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.

[1]Check the effective stroke and performance of
front shock absorber,and check whether there is
leakage from front shock absorber.

[2]Dismantle four fixed bolt of front shock
absorber

，

and remove the front shock absorber.

Maintain front shock absorber in time if it

has some problems in order to ensure the riding
safety.

CAUTION

Check

front shock

absorber.

Dismantle the

bolt of front shock

absorber.

Summary of Contents for ZS250GY-3

Page 1: ...SH ZS250GY 3 EFI MOTOCYCLE SERVICE MANUAL The first edition Dec 2017 Zongshen industrial group reserves all rights of this service manual The specifications and pictures in this manual are only for reference ...

Page 2: ... 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...

Page 3: ...el Supply System 10 Section 2 Efi System 14 Section 3 Intake And Exhaust System 16 Section 4 Rear TransMission Device 20 Section 5 Frame And Accessories 24 Section 6 Steering System 27 Section 7 Control Steel Cable 28 Section 8 Shock Absorber 29 Section 9 Rear Fork 33 Section 10 Wheel 34 Section 11 Brake 39 Section 12 Meter 45 Chapter 4 Electrical 47 Section 1 Basic Knowledge 47 Section 2 Power Su...

Page 4: ...ENGLISH ...

Page 5: ...designed for use on road With futuramic appearance and easy operation It adopt single cylinder 4 stroke water 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 6: ...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...

Page 7: ...d fuel pipe 5 Electrical System The 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 ...

Page 8: ...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 stabi...

Page 9: ...ts 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 co...

Page 10: ...e of parts Then 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 ...

Page 11: ...e 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 is opposite to disass...

Page 12: ...on 2 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 adjusting bolts of disengagement parts 3 Brake Adjustment The performance of brake directly affects the riding safety so it is important to adjust brake in order Adjust the fr...

Page 13: ...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 pipe Fixed bo...

Page 14: ...s 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 fuel tank...

Page 15: ...e 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 th...

Page 16: ...leakage Replace it if necessary 7 Take out the pump and then clean the oil sludge and water in the tank with oil sludge 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 WARNING dismantle the fuel pump dismantle the fuel tank remove t...

Page 17: ...ormed Fuel tank is accidented The appearance of motorcycle is bad Repair or replace fuel tank fuel pump oil filter screen is dirty or small holes are blocked Fuel supply is not good 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 The fuel pump body is blocked Fuel supply is not good Motorcycle cannot be s...

Page 18: ...al 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 parameter...

Page 19: ...tain 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 engine starts the indicator puts out When the indicator keeps the light on or flashing that means there is failure Structural drawing of EFI system crankshaftpositionsensor LSH engine temperature sensor Inle...

Page 20: ...otorcycle 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 requirements 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 Whe...

Page 21: ...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 22: ...oint or replace it when broken 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 23: ... or replace element The body of air cleaner is broken Engine is hard to be started or cannot be started poor engine power unstable i d l e s p e e d h i g h f u e l consumption and black smoke from exhaust muffler inlet system The noise of engine inlet is big exhaust system Replace air cleaner body T h e n o i s e o f e n g i n e exhaust becomes louder leakage at vent of exhaust pipe T h e b o d y...

Page 24: ...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 of engine derailleur power exporting bearing then transfers the power to driven chain through drive chain and makes 3 time deceleration The driven chain is fastened on the cushion body by bo...

Page 25: ...of drive 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 ...

Page 26: ...ocket wheel are worn wholly replace them including big and small drive sprocket and drive chain CAUTION Left 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 influence the working of transmission system When rear drive sprocket wheel axle is worn replace it ...

Page 27: ...strange sound Clean and lubricate chain Drive chain is too tight improper tightening adjustment of chain Drive chain has strange sound Adjust the tightness of drive chain to 15mm 25mm Drive chain is too loose improper tightening adjustment of chain Drive chain has strange sound or is easy to break off Adjust the tightness of drive chain to 15mm 25mm Chain is worn Drive chain disengages from gear D...

Page 28: ...ty It mainly consists of head pipe main frame tail pipe rear supporting pipe and low bending pipe It is made through the methods of jointing riveting and so on Frame is used to support engine transmission system operation system seat fuel tank brake system and so on Meanwhile it also offers the installing point for other accessories It makes motorcycle as an integrated part 2 Disassembly and Maint...

Page 29: ... 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 30: ...or being struke Right cover is damaged Appearance is influenced Replace or repair right cover front fender Front fender gets strike or shake Front fender is distorted or damaged Motorcycle makes sound during running Replace front fender rear fender Rear fender gets strike or shake Rear fender is distorted or damaged Motorcycle makes sound during running Replace rear fender seat Seat cover is damag...

Page 31: ... 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 handlebar 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 steering handl...

Page 32: ...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 ...

Page 33: ...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 34: ...ck 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 Remove the returning spring of shock absorber pole and 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 35: ...absorber and 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 Sp...

Page 36: ...ront shock absorber or piston lever Front shock absorber is too soft Replace front shock absorber or piston ring Piston ring is worn or damaged The comfort stability and safety of riding decline The comfort stability and safety of riding decline The edge of oil seal is worn or damaged Oil seal has leakage Front shock absorber is too soft Replace oil seal of front shock absorber Front shock absorbe...

Page 37: ...mponent of 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 Check rear fork CAUTION Maintenance of Rear Fork 3 The cause trouble description and repair method of rear fork rear fork Motorcycle runs towards one side and comfort stability and safety are influence...

Page 38: ...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 39: ...e 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 ...

Page 40: ...er 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 an...

Page 41: ... 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 axle 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 42: ...rning handlebar shakes during running Replace bearing front tire Tire is worn It is easy to slide during running and it is hard to avoid side sliding Replace outer tire gear box of speedometer Gear is damaged Speedometer finger cannot swing Replace the gear box of speedometer The transmission ring of gear wheel is damaged Speedometer finger cannot swing Replace the gear box of speedometer rear whe...

Page 43: ...f 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...

Page 44: ... line then remove the front wheel Remove front brake friction plate Remove wheel 5 Remove the speed counter and check the wear breaking 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 ...

Page 45: ...brake pedal for several times and release it Rotate the rear wheel assembly and check the rear wheel for free rotation Check rear brake arm 7 Measure the thickness of front brake disc with micrometer The limit value of repair is 2 0mm 8 Measure brake disc run out with dial indicator and the limit value of repair is 0 3mm Check the run out Check the thickness If the thickness of brake disc exceeds ...

Page 46: ...xceed 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 thickness 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 Please smear glue on the bolt before installing the rear brake disc to avoid bolt loosenes...

Page 47: ...ate sensor a elimination process is employed if ABS fault diagnosis tester is not available To eliminate the trouble by replacing the existing sensor one after another after installing a new sensor the trouble light would turn off when speed is higher than 20km h Check power source voltage using a multimeter in case the motorcycle is able to start as usual the voltage is normal Such check item can...

Page 48: ...soft or gone Cause study 1 Poor sealing of brake fluid which leads to leakage of brake fluid 2 Brake system vacuum filling fails It fails to fill brake fluid with the 2nd circuit of ABS control module 3 Brake caliper falls off Methodology 1 Check the brake lines for leakage of brake fluid and fasten the leaking points and bleed air again 2 After bleeding attempts are made to drive Ensure bleeds oc...

Page 49: ...he 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 speedometer once a year Add luboil to where it needs Check connection Section 12 Meter 2 Disasse...

Page 50: ...ir method meter assembly The filament of indicator is burned out The filament of indicator is burned out Indicator doesn t work Replace bulb of indicator The filament of meter lamp is burned out The filament of meter head lamp is burned out Meter lamp doesn t work Replace the bulb of meter indicator Speedometer is damaged Speedometer is damaged Speedometer doesn t work Replace speedometer ...

Page 51: ...z Electric current I and voltage U have direct proportion and electric current I and resistance R have inverse proportion Its formula is I U R Also U IR 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 whic...

Page 52: ...e 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 ha...

Page 53: ...tery 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 resist...

Page 54: ...ctric current export or poor export of generator Engine is hard to be started or cannot be started The electric power of motorcycle is not enough Electro equipment cannot work normally Replace generator rotor fades magnet no electric current export of generator Engine cannot be started Headlight cannot illuminate storage battery damaged no power Starting motor doesn t run Replace storage battery S...

Page 55: ...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 56: ...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 57: ...ly Motorcycle cannot be started with electric starter Check storage battery fuse tube Fuse tube is damaged or melts down no electric power Starting motor cannot run R e p l a c e f u s e tube illuminating light changing switch Inner connecting point connects bad or is damaged Inner connecting point connects bad or is damaged Illuminating light is not in good working condition or cannot work Repair...

Page 58: ...ich 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 an...

Page 59: ...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 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 Turning light ...

Page 60: ...ulb of headlight taillight brake light The filament of taillight brake light is burned out The filament of taillight brake light is burned out The filament of taillight brake light is burned out Replace the bulb of taillight brake light turning light The filament is burned out The filament of turning light is burned out Turning light doesn t illuminate Replace the bulb of turning light gear indica...

Page 61: ...r of cable and whether valve spring is too soft Shut off ignition switch and hold for 10s of downtime then restart switch when idling stepping motor returns 1 Check whether the outer connection part of engine has leakage 2 Check whether valve timing is normal 3 Check whether the valve clearance is too narrow 4 Check whether the seal between valve and valve seat is good 5 Check whether the piston r...

Page 62: ...n ring and cylinder Start engine and gently turn throttle control grip inward Observe the rev change of engine The compressing pressureisnotenough The compressing pressure is normal Finger cannot feel strong gas rush outward and the compressing pressure of cylinder is not enough Finger can feel strong gas rush outward Meanwhile there is sound of flop flop Dismantle spark plug and put your finger o...

Page 63: ... circuit Enginecancontinue workingafterstarting 1 Check whether the outer connection of engine has leakage 2 Check whether valve is timing 3 Check whether valve clearance is too small 4 Check whether the seal of valve and valve holder is good 5 Check whether piston ring breaks off or is dead or has insufficient elasticity 6 Check the abrasion of piston ring and cylinder 1 Check whether the air hol...

Page 64: ...g dielectric is dark black Exhaust muffler emits black smoke when engine runs with the medium low speed The accelerating performance is bad and idle speed is unstable But it is normal when with high speed spark plug dielectric is brown Combustible mixed gas is too thin Combustible mixed gas is thick Check whether cylinder e x h a u s t p o r t a n d exhaust muffler are blocked with carbon deposite...

Page 65: ...e is fastened Inflate according to the stated standard Pressure is normal Pressure is too low Check the tire pressure 1 C h e c k w h e t h e r b r a k e i s blocked 2 Check whether the axle is worn 3 Check whether the clapboard of wheel hub has installed or is too short Wheel turns normally 1 Check whether motorcycle runs with loads or without economical speed or with low speed 2 Check whether th...

Page 66: ...uffler of 4 stroke engine emits blue and white thick smoke No Yes Yes No No Yes Improve operation method Check whether the gearshift axle is distorted or whether gearshift arm is distortedorworn C h e c k w h e t h e r c l u t h disengages uncompletely Check whether operation of gearshift is harmonious Readjust it Start engine and check whether the idle speed of engine is too fast 1 Check whether ...

Page 67: ...s uncompletely Wholly replace cluth spring Check whether drive and driven hub trough are worn to be zigzag Check whether the elasticity of cluth spring is well proportioned Repair or replace them No Yes No Yes No Yes No Check whether the fork is worn or distorted Check whether convex pawls of mesh gear are worn to cone shaped and whether opposite groove of gear end is worn to be bell mouthed Disas...

Page 68: ...ehicle 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 Resistance value is infinite Battery cannot be charged Charging coil has short circuit Install the connecting component between generator lead and vehic...

Page 69: ...isassemble 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 circuitorshortcircuit 1 Check whether the connecting point of inner clutch switch has bad connecti...

Page 70: ...ad light assembly and check whether its bulb is burned out Replace the bulb of head light and check whether other bulbs are burned out Check whether there is power export from the power import lead of illuminating switch with the method of connecting a bulb With a lead make short circuit between electric source lead of illuminating switch and export lead Generator or the circuit between ignition s...

Page 71: ...r Short circuit or tanct is not good Normal R e c t i f i e r h a s trouble Illuminating lamplight is weak AC supply illuminating system Replace rectifier Illuminating lamplight becomes normal Illuminating lamplight is still weak Check whether the charging coil and charging system of magneto is short circuit Rectifier is bad C h e c k a n d eliminate No ...

Page 72: ...ebatteryis low Remove the cover of turning light and check whether of turning light 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 commutated adjuster works well After short circuit turning light still cannot illuminate After short circuit turning light can illuminate Remove the c...

Page 73: ...tage with multimeter When rubbing there is spark or the voltage is normal When rubbing there is no spark or the 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 horn can make sound After con...

Page 74: ...uit or open circuit When rubbing there is spark The lead between brake light switch and brake light has short 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 Spark plug is dagmaged Cut off the connecion of charging coil of generator and triggering coil and respectively measure the voltage Reconnect it Turn off...

Page 75: ...ENGLISH 71 APPENDIX CIRCUIT DIAGRAM ...

Page 76: ...ENGLISH 72 Copyright reserved by Zongshen group Format160mm 230mm The 1st edition Dec 2017 The 1st print Dec 2017 ...

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ZONGSHEN ZS250GY-3, Service Manual

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