Operating Steel Wire; Maintenance Of Operation System - ZONGSHEN ZS250GY-3(EFI) Maintenance Manual

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
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 wire and
spring hose.
2 Maintenance of Operating Steel Wire
In order to keep operating steel wire working well and
prolong its sevice lifetme,termly cleaning and lubricat-
ing is necessary.For the first time,you can do it after
1500km,and then every 3000km.Here are two meth-
ods for lubrication:one is dip in,the other is injection.
Dip In Lubrication
Operate as follows:
[1]Dip the whole steel wire in coal oil for 5-10min.
Pull the steel wire to clean out the deposit in hose.
[2]Dip the whole steel wire in the mixed oil which
has persentage of 1:1 of coal oil and luboil.Pull the
steel wire to make mixed oil flow into the hose.
[3]Remove operating steel wire and clean the
mixed oil outside.
Injection Lubrication
Operate as follows:
[1]Enlace the end of metal spring plastic hose of operat-
ing steel wire with transparent adhesive tape.Make it as
a pipe.as the picture:
[2]Raise the end with adhesive tape and pull out of steel
head.
[3]Dip luboil in the hose with oil kettle until there is oil
dripping from the lower steel wire.
The cause,trouble description and repair method of operation system
Table4-7
component
description
H a n d l e b a r i s
handlebar
distorted.
Steel wire cannot
Operating
f l e x i b l y p u l l e d
steel cable
outside the cable.
of clutch
Steel wire breaks off.
The free stroke is
rear brake
too small.
pedal
The free stroke is
28
too big.
Section 7 Operating Steel Wire
Main tenance of Oper ation Sy stem
trouble description of
cause
component
Handlebar is distorted.
Clutch handlebar is hard
to be operated or cannot
be returned well.
wire head
steel wire
adhesive tape
metal hose
trouble description of
motorcycle
Motorcycle runs towards one side.
Clutch slides or cannot
disengage completely.
Clutch cannot disen-
gage completely.
Rear brake pedal cannot
be returned to the origi-
nal place.
Rear brake loses control.
o i l k e tt l e
repair method
Correct or replace
handlebar.
Clean,lubricate or re-
place operating steel
cable.
Replace operating
steel cable.
Readjust the free stroke.
Readjust the free stroke.