ZONGSHEN ZS125-86 Service Manual page 14

Bonding technology is a simple process and requires no special equipment and precious materials.
Bonded parts demand no high-precision machining. Due to these advantages, bonding technology is
widely used in the manufacture and maintenance process, such as the adhesion of the handlebar and the
steering bar, the plastic sign and painted metal parts, the brake pad and the brake shoe, etc. There are
many types of bonders, commonly used in epoxy resin and phenolic resin.
5)Assembling the Motorcycle
The last process of maintenance is assembly, which is the key to ensure that the vehicle achieves
various technical indicators.
[1.]Assembly is divided into minor assembly, sub-assembly and general assembly. In the assembly
processes, the minor assembly goes first, and then sub-assembly and lastly the general assembly. The
order of assembly is exactly opposite to the order of disassembly. That means to assemble those parts that
have been disassembled earlier, and then those parts disassembled earlier later.
[2.]The minor assembly is an early working procedure of the entire assembly process. In this
procedure, a number of related parts are connected to form a separate structural unit. Such as the brake
drum cover combination on the front wheel, brake shoe combination, and wheel rim combination, etc.
[3.]The sub-assembly is based on the minor assembly. In this procedure, all components and parts
belonging to a structural unit (an assembly) are assembled to form a separate integral structure. Such as
the front wheel assembly and rear wheel assembly, front fork assembly, and damper assembly, etc.
[4.]In a general assembly, all parts, components, units and structures are installed in proper order on
the main frame through a variety of connections so as to form a complete set.
[5.]Generally, order of operation of assembly is basically identical. The operation steps are as follows:
complete all minor assemblies firstly and then the sub-assemblies, and install the engine assembly and
gearbox assembly on the main frame; and then the following assemblies are installed in the following
order: front fork assembly, handlebar assembly, front and rear fender assembly, damper assembly, storage
rack assembly, front and rear wheel assemblies, fuel tank assembly, saddle assembly, etc; on this basis,
install the headlamp, tail lamp, sidelight, klaxon and storage battery assembly; connect all the electrical
circuits and control cables; install the transmission chains or toothed belts, various wind shields and chain
covers or belt covers, etc; finally, lubricate the entire vehicle assembled.
[6.]Because of different types and structures, the assembly sequences are also different. It may refer to
the demolition, installation and inspection procedures below.
[7.]The following points should be noted in assembly processes: choose a clean wide site; strictly
follow the assembly process requirement in the installation order; connections among parts shall meet the
requirements,
so as to prevent all kinds of washers, cotter pins and anti-loose lock plates from being mal-assembled
or missing.
3. Debugging After Maintenance
After maintenance, the interrelationship among the parts and components are affected to a certain
extent. In order to restore its performance indicators, adjustments must be made properly as provided in
this Service Manual, so that the interrelationship among the parts meets the working requirements. The
following items are to be adjusted:
1)Adjusting the duration of ignition
Improper engine ignition advance angle will cause difficulty in starting, power coastdown, fuel
consumption increase, engine overheating, incomplete combustion, excessive emission, lower service life
and so on. Therefore the ignition advance angle must be adjusted firstly.
If the ignition system is abnormal, check the electronic igniter, high voltage coil, the ignition coil on
magneto, trigger coil and other components.
2)Adjusting the Clutch
The clutch is a key component of transmission system to transmit power, must be adjusted based on
the maintenance requirements provided later. To adjust the clutch is mainly to
control grip on the clutch (usually 10 mm ~ 20 mm), and for some vehicles, also to adjust the adjusting
screws on the detatching mechanism.
3)Adjusting the Brake
Braking performance is closely related to the driving safety, and thus the correct adjustment of the
brake is essential. To adjust the brake is mainly to adjust the free stroke of front braking grip (usually
10 mm ~ 20 mm) and the free stroke of rear brake pedal (usually 20 mm ~ 30 mm). The adjustment
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methods are basically the same, and may be implemented according to the maintenance requirements
adjust the free stroke of