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ZS250GY-3 (EFI)MOTOCYCLE SERVICE MANUAL THE FIRST EDITION(Aug,2013) Zongshen industrial group reserves all rights of this service manual. The specifications and pictures in this manual are only for reference.
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This trademark was registered by Zongshen Industrial Group in more than 20 countries such as Nigeria, Argent-ina and Vietnam, etc. This trademark was registered by Zongshen Industrial Group in more than 90 countries such as Japan, New Ze-aland, Germany, Canada etc.
CHAPTER 1 GENERAL INFORMATION section 1 vehicle introduction ZS250GY-3 is designed for use on road With futuramic appearance and easy operation. It adopt single cylinder,4-stroke,air 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 type wheel has good appearance and function of anti-abrasion.
Chapter 2 Structure This motorcycle mainly consists of riding system,operation system,brake system,transmission system,fuel supply system,electrical system and engine.Refer to Diagram 1-3. Diagram 1-3 structure [1]Riding system [2]Electrical system [3]Operation and brake system [4]Fuel supply system [5]Engine [6]Transmission system 1 Riding System The basic function of riding system: [1]Make motorcycle in a whole and support whole motorcycle.
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[4]Rear transmission device The function of rear transmission device is to transmit the engine power to transmission device,so that the rev is reduced and the torque is augmented.Then transmit the power to rear wheel to drive motorcycle run.The transmission of this motorcycle is chain transmission. [5]Intake and Exhaust System The function of inlet system is to guide and filtrate air,to control the volume of mixed gas flowing into cylinder according to the needs of working condition.It mainly consists of inlet pipe and air cleaner.
Chapter 2 Maintenance Knowledge Section 1 Attention Items of Maintenance When there are some problems with motorcycle,you can have it repaired at Zongshen after-service station or professional maintenance station.Meanwhile you also can refer to this maintenance manual.Parts on the motorcycle will be worn or loose during riding.
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.
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[2] Carbon Deposit Removing To remove the carbon deposit on component,we can use mechanical method or chemical method. Mechanical method is that scrape deposit with bamboo-scraper or spade and clean them with gasoline. Immerse the component,brush the carbon deposit off and clean them with hot water,which is called chemical method.
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Reaming is a fine finish by reamer,which can increase the precision degree of holes on parts and decrease the roughness degree.It improves the match precision between hole and shaft and the precision can reach grade 6 to grade 8. The basic tool for reaming is a reamer,such as fixed reamer,adjustable reamer,conical reamer and so on.Before reaming,we need to drill a bottom hole in advance,which is for the precision requirement of hole shaped and making room for reaming procedure.
(1)Ignition Time Adjustment If there is a wrong ignition advance angle,it will cause a series of problems,such as hard engine starting , power decrease,high fuel consumption,engine overheating,uncomplete fuel burning,exhaust value overrun, short service lifetime and so on.Therefore,adjust ingiton advance angle firstly. If ignition system cannot work well,check electrical ignition device,high voltage coil,ignition coil and triggering loop of magneto and so on.
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Table 2-2 Maintenance Cycle Items Mileage km Times Period Items 1000km 4000km 8000km 12000km Fuel system ● Fuel filter ● R / I R / I R / I ● Control system Choke valve cable ● Air cleaner element spark plug gap Valve clearance ●●...
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Section 1 Fuel Supply System Fuel supply system consists of fuel tank,fuel pump,injector,fuel filter and oil pipe. 1 The Structure and Working Principle of Fuel System [1] Fuel Tank Fuel tank is jointed by the armor plate which is normally 0.8mm~1.0mm.Some fuel tank is jointed apertured clapboard inside,which not only strengthens the fuel tank,but also avoids the fuel gurgitation during riding.Because of the strong erosion of oil,it must be galvanized on the surface of fuel tank.There is a fuel-adding hole on the top of fuel tank and close the fuel cap which has air hole,so that it can avoid...
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2 Disassembly and Maintenance of Fuel System [1]The capacity of the fuel tank is 16L。 When refueling, please keep air circulation and keep away from sparks and flame. Warning fuel tank cap Fuel is highly combustible.Smoking and getting close to the fire are strictly forbidden Switch off the motorcycle and operate in an airy place.
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[5]First of all, dismantle the left and right side cover and seat.Then remove fixed bolt and take out the fuel tank. dismantle the WARNING fuel tank Keep the oil away from fire when dumping the oil. [6]Remove the six fixed bolt(M5×16) of fuel pump by hexagon wrench.
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[9]Check the motor of fuel pump for running.And clean or replace the fuel strainer. check the fuel pump ADVICE Replace the fuel filter when the motorcycle drives about 8000~10000Km. 3 The cause,trouble description and repair method of fuel supply system Table 4-1 Maintenance of Fuel Supply System trouble description...
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Section 2 EFI system The main effect of EFI system is to convert the fuel which is supplied from fuel tank into a mist, then mixture of the mist and air import into the combustion chamber. 1 The Structure and Working Principle of EFI system EFI system consists of ECU,nozzle,throttle valve,intake air temperature,integrated pressure sensor, engine temperature sensor,ignition coil,CKP,fuel pump,oxygen sensor.
2 Disassembly and Maintenance of EFI system The EFI of motorcycle has been calibrated before leaving the factory. When EFI system has failure, adjust idle screw of throttle voluntarily and replace or adjust parts of EFI are strictly prohibited.Please go to our service station to maintain for any queries.
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Section 3 Inlet and Exhaust System The inlet system of engine mainly consists of air cleaner and inlet pipe.The main function of which is to guide and filtrate air,reduce inlet noise and control the volume of mixed gas which is going to engine. The exhaust system mainly consists of exhaust pipe and muffler.The main function of which is to transfer the exhaust gas to atmosphere,reduce the noise when exhausting and the temperature of exhaust gas and eliminate the spark in exhaust gas.A good exhaust system can advance the inlet and exhaust...
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3 Disassembly and Maintenance of Intake System [1]Dismantle suspension bolt of air cleaner and clamp screw of inlet pipe.Remove air cleaner assembly. a i r c l e a n e r [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.
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4 Disassembly and Maintenance of Exhaust System [1]Dismantle the locknut of exhaust pipe of muffler and suspension bolt of muffler.Check whether the suspension bracket is broken.Re-joint it if broken. Locknut CAUTION When the suspension bracket of muffler is broken,replace or re-joint it. [2]Remove muffler and check whether the muffler is m u f f l e r broken or damaged.Re-joint or replace it when bro-...
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[5]Check whether there is carbon deposit at the muffler tail.Clean it. muffler tail 5 The cause,trouble description and repair method of inlet and exhaust system Maintenance of Inlet and Exhaust System Table4-3 component trouble description of description of repair method cause component description...
Section 4 Rear Transmission Device Because the export torque of engine is small and its rev is fast,it only can enhance the torque of engine to ensure the good working condition of motorcycle by 3-time deceleration.The first time is through the drive and driven gear of cluth.The second time is through the drive and driven bearing of derailleur.The third time is through the drive and driven gear of rear transmission device,so that the export power and rev of engine can economically and properly be used.
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[3]Check the abrasion of small drive chain and replace the chain assembly if necessary. Small drive sprocket wheel [4]Dismantle fixed bolt of chain box,and remove the chain box. chain box [5]Dismantle the spring clamp of drive chain. Remove tie-in of drive chain and drive chain.Check the abrasion of the tie-in of drive chain and replace it if necessary.
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[7]Remove left gasket of rear wheel and check its abrasion.Dismantle the locknut of rear axle, then take rear wheel off. L e f t gasket [8]Remove the oil seal of cushion body of rear drive sprocket wheel and check its abrasion. Oil seal [9] Remove the rear drive sprocket and check it for wear.
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3 The cause,trouble description and repair method of rear transmission device Table 4-4 Maintenance of Rear Transmission Device component trouble description of trouble description of repair method cause component description motorcycle Wholly replace drive D r i v e c h a i n h a s Drive chain disen- Gear teeth are worn.
Section 5 Frame and Accessaries Frame is the supporting framework of motorcycle.It is the main supporting part of motorcycle.Because motorcycle should bear mighty shake during running,its component and structure must have high intensity and the frame is required to be light.In this way,it is good for motorcycle to have a high-speed running.
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[3]Check all the covers of motorcycle.Re- place them if damaged. Cover ADVICE Replace the covers if damaged. [4]Check whether the seat is damaged.Re- place it if damaged. Seat ADVICE Replace seat if damaged. [5]Check whether the rubber cover of front pedal is damaged.Replace it if damaged.
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3 The cause,trouble description and repair method of frame and accessories Maintenance of Frame and Accessories Table4-5 component repair method trouble description of trouble description of cause description component motorcycle Frame is struck or has Correct or replace Motorcycle cannot run Frame is distorted.
Section 6 Steering System The direction of motorcycle is operated by steering handlebar.The steering handlebar connects with direction pole.It sees the frame as the center and run the front shock absorber and operate the front wheel through the rotation of direction pole. 1 The Structure and Working Principle of Steering System [1]Steering handlebar The right steering handlebar of motorcycle is the throttle control grip, Control oil flow rate.The right holding lever...
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Section 7 Operating Steel Wire 1 Structure and Working Principle of Operating Steel Wire Operating steel wire mainly consists of steel wire,wire head and metal spring plastic hose.The steel wire should be soft so that it doesn’t break off easily and it can bear big pressure.It is normally made of several thin wires,which ensure the intensity of steel wire and make it soft.The wire hsead is 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...
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Section 8 Shock Absorber 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.
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[3]Dismantle bolt of front shock absorber and drain front shock absorber oil.Check whether the oil is bad.Replace it if bad. Drain shock a bs o r be r oi l [4]Remove the oil seal and spring clamp of front shock absorber and check whether the edge of oil seal is worn.Replace it if necessary.
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[7]Measure the inner diameter of lower pipe of front shock absorber with callipers.Check whether it exceeds the limit value of maintenance.Replace it if exceeds. Measure the lower pipe. [8]Remove the returning spring of front shock absorber and check its abrasion.Replace it if worn. Spring of shock absorber...
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[2]Check whether the left one has the same length as the right one and check whether the spring surface of shock absorber is damaged.Replace it if damaged. Rear shock absorber CAUTION When rubber components have abrasion or aging,replace them. 4 The cause,trouble description and repair method of front/rear shock absorber Table 4-8 M ai nt en an ce o f Fr on t/ Re ar S ho ck A bs or be r component...
Section 9 Rear Fork The rear fork connects rear wheel with frame.It makes rear wheel rotate around a fixed point through rear shock absorber to reduce the strike and shake of rear wheel. 1 The Structure and Working Principle of Rear Fork Because rear fork gets big strike and shake,the requirement on material and jointing is very high.It is made through the method of jointing and so on.
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Section 10 Wheel Front/rear wheel is the running component of motorcycle.It supports the weight of whole motorcycle and ensures a friction made by wheel and road to make wheel avoid sliding.Wheel can reduce and absorb the strike and shake caused by the road.The front wheel cooperates with operating part,which fixes on the direction of running.The rear wheel is transferred power by engine,which drives motorcycle to run.Wheel mainly consists of outer tire,inner tire,aluminium tire,tire hub,bearing,bush,oil seal and axle.
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[2]If front wheel is deformed by stricking or vibration, so that the bike run out of way or steering control trembling or vibrating. The wheel need to be re- placed or adjusted. Check front wheel CAUTION Replace the wheel when it trembling over the maintainence limit value。...
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[6]Put front wheel on rectification desk and rotate it in high speed to check the abrasion condition and free strock. if it is abraded, dismantle it and replace. CAUTION check front wheel shaft When there is noise or free strock turn wide, replace it with new beering.
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[10]Dismantle the locknut of rear axle .Remove rear axle and rear wheel assembly. Check rear axle. [11]Dismantle rear wheel and check whether rear wheel Check rear hub is damaged.Replace it if damaged wheel hub. [12]Check whether rear axle is worn.Replace it if worn.
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3 The cause,trouble description and repair method of wheel Maintenance of Wheel Table4-10 component trouble description of trouble description cause Repair method description component of motorcycle Motorcycle runs towards one F r o n t w h e e l i s Front wheel is distorted.
Section 11 Brake Motorcycle usually needs to decelerate and stop during riding,so brake is used to make resistance to wheel to achieve that purpose.For normal motorcycles,front brake is operated by right hand and rear brake is operated by right foot.However,among some motorcycles with automatic clutch,such as moped or scooter, the rear brake can be operated by left hand.The brake of motorcycle consists of drum brake and disc brake.
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[3] Disassemble disc brake friction plate and check the piston of brake caliper for working condition.If it cannot work well ,repair or replace hydraulic brake. Remove front brake f r i c t i o n p l a t e [4]Disassemble locking nut of front axle and Mile- age line, then remove the front wheel.
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[7]Measure the thickness of front brake disc with micrometer. The limit value of repair is 2.0mm. Check the th ic kn es s CAUTION If the thickness of brake disc exceeds the limit value of repair 2.0mm,replace the brake disc. [8]Measure brake disc run-out with dial indicator, and the limit value of repair is 0.3mm.
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[11]Disassemble the nut of rear wheel axle and remove the wheel axle and rear wheel assembly. locking nut [12]Remove friction lining and Measure the thick- ness 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.
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[15]Measure the run-out of brake disc by dial indicator and the limit value is 0.3mm. Measure the run- CAUTION If the value of run-out exceed the limit value,replace it. 3 The cause,trouble description and repair method of front/rear brake see Table 3-13: Table 3-11 Maintenance of Front/Rear Brake Trouble description...
Section 12 Meter The meter of motorcycle is to indicate the working condition of motorcycle. 1 The Structure and Working Principle of Meter [1]Speedometer Speedometer is to indicate the running speed of motorcycle and the total mileage.It is driven by front wheel.The rev of front wheel is sent to speedometer through gearshift system and soft axle,which makes magnetic cylinder rotate.Coil cuts magnetic wire,which makes whirlpool and magnetic field to cooperate with the magnetic field of magnetic cylinder,makes whirlpool disc get a torque,overcomes a resistance and drives the finger to rotate.The...
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3 The cause,trouble description and repair method of meter Main tenanc e of M eter Table4-12 component trouble description of trouble description of cause repair method component description motorcycle The filament of indi- Indicator doesn’t work. Replace bulb of indicator. The filament of indicator cator is burned-out.
CHAPTER 4 ELECTRICAL SYSTEM Part 1 Basic Knowledge In order to get a further understanding of structure and working principle of motorcycle electrical system,you should have a general conception about basic knowledge of electrics firstly. 1 Electricity、electric current、voltage and resistance The basic component of any substance is atom.There exists electropositive atomic nucleus and electronegative electron inside the atom.The quantity of nucleus is the same as electron,so which makes the positive electricity counteract the negative electricity and causes atom to be neutral.If the substance is influenced for friction or...
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Section 2 Power Supply 1 The structure and working principle of power supply Power supply part mainly consists of generator and battery.Its function is in the closed circuit of motorcycle,generator and battery has parallel connection and offers electric current to the electro-equipment in electrical system,then stores the rest power in battery.
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[1]Remove fuse tube and check whether it melts down.Replace it with the same type. Fuse tube type:12V/20A Check fuse tube. CAUTION When fuse tube is damaged,replace it with the same type. [2]Remove storage battery and measure whether its voltage is above 12V.When it’s lower than 12V, remove and charge it.
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[5]Check whether the magnetic cylinder of gen- erator rotor fades magnet.Replace magnetic cyl- inder if fades. Check magnetic cylinder. 3 The cause,trouble description and repair method of power supply part Table5-1 Maintenance of Power Supply Part component trouble description of trouble description of cause repair method...
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Section 3 Control Part 1 Composing and Function of Control Part In electrical system of motorcycle,control part is to ensure the good working condition of power supply part and power consumption part,and ensure their harmony.It can make rider control the electrical system momentarily.
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[2]Remove the flasher socket of signal system and measure the flasher with multimeter.Check whether it has short circuit.Replace it if short circuit. Flasher [3]Check whether starting relay is in good working condition.Replace it with the same type if it is not in good working condition.
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[6]Check whether the main cable is damaged. Bundle the leads in time if the insulative rubber- ized fabric is damaged. 3 The cause,trouble description and method repair of control part Table 5-2 Maintenance of Control Part component trouble description of trouble description of repair method cause...
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Section 4 Power Consumption Part The power consumption part of electrical system of motorcycle consists of following:: (1)Light-signalling Device Illuminating signal device consists of headlight,position light,taillight and meter indicator.Its main function is when motorcycle runs at night,they illuminate and have motorcycle noticed by other vehicles in order to ensure the riding safety.
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[4]Check whether the taillight is burned-out.Re- place it with the same type if burned-out. Taillight [3]Check whether the turning light is burned-out. Replace it with the same type if burned-out. Turning light [4]Check whether the bulb of meter indicator is burned-out.Replace it if burned-out.
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3 The cause,trouble description and repair method of power consumption part Maintenance of Power Consumption Part Table5-3 component trouble description of trouble description repair method cause description of motorcycle component The adjustment of Adjust the beam of light The beam of light of headlight is beam of light is of headlight.
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Chapter 5 Analysis of Motorcycle Troubles Section 1 Analysis of Engine Trouble Analysis of Poor Idle Speed of Engine poor idle speed of engine The idle speed of en- The idle speed of en- No idle speed of engine gine is too high. gine is unstable.
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1.2 Analysis of Insufficient Engine Power E n g i n e p o w e r i s insufficient. Support motorcycle with main stand,make it off the ground and rotate wheel with hands. Wheel rotates freely. Wheel rotates hardly. Check the pressure [1]Check whether brake is dead.
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1.3 Analysis of Engine Start Engine cannot be started or is hard to be started. Check ignition system. Remove piston and check whether there is carbon deposit between the electrode of spark plug. Check whether there is spark spurt Clean out car- between the electrode of spark plug.
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Analysis of engine overheating Supply the same type of liquid. Check whether the pump is damaged. spark plug dielectric is white. When accelerating,engine has intermission.The engine power is insufficient. The ratio of Combustible mixed gas is normal. Check whether air filter is blocked. Check whether fuel filter is Check whether oxygen sensor is work- blocked.
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Analysis of over consumption of engine fuel Engine fuel exceeds consumptive standard. Check whether the operation is correct. Support vehicle with side stand and rotate [1]Check whether motorcycle runs with loads or without wheel with hands. economical speed or with low speed. [2]Check whether the oil no.
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Analysis of exhaust muffler of 4-stroke engine The exhaust muffler of 4-stroke engine emits blue and white thick smoke. Check whether the oil level of crank- case exceeds the upper mark. The oil in crankcase is too much.The redundant oil Start engine.When it runs with high speed,remove oil should be discharged and let the oil level not exceed ruler and check whether the oil adding hole emits smoke.
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1.8 Analysis of derailleur gearshift derailleur gearshift Check whether the positioning spring breaks off or its elasticity is insufficient. Disassemble crankcase and check Replace it. whether its mesh of gear is correct according to the standard. Th e d e p th o f ge a r The depth of gear mesh mesh is not enough.
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Section 2 Analysis of electrical part Analysis of battery Battery cannot be charged. Remove the connecting part between the generator lead and vehicle 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 Resistance value accords Resistance value is infinite.
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2.3 Analysis of starting motor S t a r t i n g m o t o r doesn’t run. Turn on ignition switch and press the horn button or turn on/ off turning light switch. Eletric horn cannot make sound or make poor sound. Electric horn makes rotund sound.Turning light illuminates brightly.
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Analysis of illuminating light All illuminating light don’t illuminate. AC power supply illumi- nating system Remove the connecting component between the lead bundle of generator and vehicle cable. Check whether there is power export from the export lead of illuminating coil with a bulb. The bulb doesn’...
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Analysis of illuminating light bulb The bulb of illuminating light is easy to burn out. Replace rectifier Short circuit or Normal tanct is not good. Rectifier has trouble Analysis of illuminating light Illuminating lamplight is weak AC supply illuminating system Replace rectifier I l l u m i n a t i n g Illuminating lamplight is...
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Analysis of turning light Turning light doesn’ t illuminate. All turning light don’t All turning light of one side Some turning lights of one side illuminate. don’t illuminate. don’t illuminate. Remove the cover of turning light Press horn button and check Remove the cover of turning light and check whether of turning el ec tri c h or n.
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2.9 Analysis of electric horn Electric horn can- not make sound. Turn on ignition switch,turn on/off turning light switch and check the turning light. Turning light cannot illuminate or Turning light can illuminate brightly. illuminate dimly. Power supply of storage The power of storage battery is not battery is normal.
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2.10 Analysis of brake light Brake light doesn’t illuminate. Dismantle the cover of brake light and check whether its bulb is burned-out. Replace the bulb of With a lead,make short circuit between two brake light. connection end of brake light switch or two lead end.
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