Structure And Working Principles Of Steel Wire Rope For Control; Maintenance Of Steel Wire Rope For Control - ZONGSHEN ZS125-80 Service Manual

1. Structure and Working Principles of Steel Wire Rope for Control

The steel wire rope for control includes a steel rope, a wire-draw head and a plastic hose with a metal
spring, etc. Made of multiple strands of steel wires, the steel rope should be soft and durable and is
able to carry a heavy load. This will not only ensure the strength of the steel rope, but also make it very
soft. The wire-draw head and steel rope are connected using soldering, ramming, zinc alloy die casting
and other methods. The outer layer of the hose is plastic, and the inner layer is spring-like flexible pipe
by winding a steel wire. It not only adapts to multi-direction bending, but also changes the length when
subject to axial pressure. A layer of nylon sleeve is attached between the metal-spring plastic hose and
the steel rope, in order to avoid the direct friction between them.

2. Maintenance of Steel Wire Rope for Control

It is essential to clean and lubricate the steel wire rope for control regularly in order to ensure reliable
operation and to extend its service life. For the first 1500km and each 3000km afterwards a vehicle runs,
the wire rope should be cleaned and lubricated. The wire rope can be lubricated in two ways: soaking and
dripping.
A. The lubrication by soaking has steps as follows:
wire-draw
Steel rope
Adhesive tap
Metal hose
Refer to Table 4-7 in respect of damage forms, fault phenomena and common maintenance
methods of the control system:
Component
Damage Form
Name
The steering bar is bent
Steering bar
and deformed.
T h e r o p e i s p u l l e d
inflexibly in the rope
Clutch control
coat.
rope
The steel rope breaks.
Too short free stroke
R e a r b r a k e
pedal
Too long free stroke
Section 8 Steel Wire Rope for Control
Oilcan
Table 4-7: Maintenance of Control System
Component Fault
Phenomenon
The steering bar is bent
and deformed.
It takes great effor ts to
m a n i p u l a t e t h e c l u t c h
control rope or the rope
does not return to position
properly.
------------------------------ Clutch drags
------------------------------
------------------------------
[1.]Soak the entire set of wire rope in kerosene
for 5-10min, while pulling it back and forth to
wash out the debris inside the hose.
[2.]Soak the entire set of wire rope in mixed oil
prepared by 1: 1 to and lubricant for 5min, while
pulling it back and forth to push mixed oil into the
hose.
[3.]Take out the steel wire rope for control and
wipe out the mixed oil outside.
B. Drip-feed lubrication
Steps are as follows:
[1.]Wrap a transparent tape to the end of metal-
spring plastic hose in a tubular form as shown.
[2.]Hold up the end wrapped with the tape,
and pull out the wire-draw head.
[3.]Use the oil tank to slowly immerse the hose
in the oil until the bottom of the steel rope drips oil.
Motorcycle Fault
Phenomenon
The motorcycle runs off
tracking.
Clutch slips or drags
The rear brake shoe fails
to return.
The rear brake fails.
Maintenance Method
Rectify or replace the
steering bar.
C l e a n, l u b r i c a t e o r
replace the control rope.
Replace the control rope.
Readjust the free stroke.
Readjust the free stroke.
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