Inspection And Maintenance Of Abs; Parallel Mounting Of Sensor; Vertical Installation Of Sensor - ZONGSHEN ZS125-80 Service Manual

[15] Apply a dial indicator to measure the runout
of the brake disc. The maintenance limit is: 0.3mm.
Caution
If the brake disc runs out beyond the maintenance
limit of 0.3mm, it should be replaced.

4 Inspection and maintenance of ABS

Determine if ABS works properly: switch on the ignition switch and ABS trouble light (red) should be
illuminated to conduct self-testing. Upon completion of self-testing, ABS trouble light turns off (Saifu or
Bosch) or begins to flick (Continental); ABS trouble light turns off when the speed is higher than 10km/h
and if the wheel speed sensor connector and ABS module connection are plugged in or the front wheel or
rear wheel is separately rotated just before driving. Otherwise, ABS trouble light is faulty.
1. Common troubles, cause study and troubleshooting
Trouble A: after the motorcycle is energized, ABS trouble light is illuminated constantly
Cause study: ①. Disconnected ABS interfaces; ②. Improper connection of wire harness: ③. One or
more broken ABS modules or wheel speed sensors; ④. Lower or higher power source voltage. Normal
voltage stands between 9V and 16V.
Methodology: ①. Check all interfaces for missing connection or improper connection while eliminating
the trouble;
②.Check if the wire harness matches the electrical schematic diagram;
③.Read the trouble code and the description using ABS fault diagnosis tester. In case A sensor
distortion is indicated, install a new appropriate 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)
④.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 be cancelled. )
Trouble B: switch on the ignition lock, ABS trouble light turns off at end of self-testing. It is illuminated
again as the motorcycle is running or the braking is applied.
Cause study: ①. Poor contact of wire harness; ②. Misled installation of wheel speed sensor;
Methodology: ①. Check front&rear wheel speed sensor interfaces for possible poor contact of pins
and eliminate the troubles; in case a fault diagnosis tester is available, read ABS trouble code using it. If
a sensor grounded or with open circuit is indicated, check the sensor connector for poor contact carefully
and eliminate the trouble;
②. Check if the wheel speed sensor wire harness code is in compliance with the design, code
"87361..." stands for parallel mounting of sensor;
Parallel mounting of sensor (wheel axle in parallel with the outlet direction of the sensor)Code
"87362..."stands for vertical installation of sensor.
46

Parallel mounting of sensor

Measure the runout
of brake disc

Vertical installation of sensor