BSAA s 4) MOTORCYCLE MAINTENANCE MANUAL ZONGSHEN MOTORCYCLE/S200G Y-2(EC)Maintenance Manu Foreward Since its establishment, Zongshen Industry Group, which has obtained the IS09001:2000 Certification, has developed numerous well-received motorcycles with the emission reached Euro IL standard. ZONGSHEN brand has been authorized as Chinese Famous Brand. This manual is to help our service personnel and customers know more about the service of this motorcycle. ZS200GY-2 motorcycle is a newly developed motorcycle with outstanding style and easily operation. The engine installed on this model is ZS167FML which isan air cooling, one cylinder and 4-stroke one with advantages of strong power and good acceleration performance. The spoke wheel installed, front brake is disc and rear is drum respectively,with a feature of strong reliability. This book lays stress on the disassembly/assembly, removal/installation, inspection, trouble- shooting and service methods of ZS200GY-2 motorcycle. Italso introduces the general knowledge of service tools. With both the descriptions and pictures, you may have a comprehensive understand- ing of the configuration as well as the service and repair skill. When reading this book, the users are suggested to make reference to User’s Manual and Parts Breakdown & Catalogue of ZS200GY-2 motorcycle for better understanding. This book is based ‘onthis model only. To ensure the book is always consistent with the ever updating products, Zongshen Industry Group reserves the right to make changes to the specifications of its vehicles without notification. This bookis prepared by Zuo Zongshen editor-in-chief), Wu Jian,Lei Ting, Li Heping(subeditor), Hu Zhiping, Wang Chong (executive editor), Liu Fubo, Zhongxueliang, Zhang Qiaoli (editor ).All people involved in the preparation of this book are employees of Zongshen group who have long been devoted to the development and management of the generator. Due to our limited knowledge and urgent time, itis very possible to have errors in this book.And we welcome your comments. Editor Aug. 2006ZS200GY-2(EC)Maintenance Manual CONTENT Chapter 1 General 1.1Vehicleintroduction .. 1.2Specification Chapter 2 Maintenance Knowledge 2.1 Maintenance and adjustment data 2.2 Maintenance Tool .. Chapter 3 Maintenance of Engine 3.1 Maintenance of Body 3.2 Maintenance of Crankshaft Connecting Rod 3.3 Maintenance of Valve Mechanism 3.4 Maintenance of Fuel System... 3.5 Maintenance of Intake and Exhaust System 3.5.1 Dismantle, Mount and Maintain Intake System 3.5.2 Dismantle, Mount and Maintain Exhaust system 3.5.3 Dismantle, Mount and Maintain Environmental Protection Device 3.6 Maintenance of Lubricant System 3.7 Maintenance of Cooling System Chapter 4 Maintenance of Transmission .. 4.1 Maintenance of Starter... 4.2 Maintenance of Clutch 4.3 Maintenance of Transmission 44 Maintenance of Rear Drive system Chapter 5 Maintenance of Riding System 5.1 Maintenance of Frame and Accessories 5.2 Maintenance of Suspention system 5.3 Maintenance of Wheel.... Chapter 6 Maintenance of Controls and Brakes System 6.1 Maintenance of Controls System .. 6.2 Maintenance of Brakes System Chapter 7 Maintenance of Electrical Parts and Meter System .. 7.1 Maintenance of Charging System .. 7.2 Maintenance of Ignition System 7.3 Maintenance of Signal System 7.4 Maintenance of Mluminating System .. 7.5 Maintenance of Electrical Starter control system 7.6 Maintenance of Meter Chapter 8 Analyze of Motorcycle Troubles 8.1 Analyze of Engine Trouble...ZS200GY-2(EC)Maintenance Manual Chapter1 General Vehicle introduction ZS200GY-2 motorcycle is a newly developed product with outstanding style and easily operation. The engine installed on this model is ZS67FML, which is 4-stroke, air-cooling engine with advantages of strong power and good acceleration performance. Fig-1-1 left view of ZS200GY-2 @ front fender @ headlamp @) fuel tank lock @ fuel supply valve © rearcartier © front brake gear shifting pedal @arburetor ©) side stand @ taillight ® Fig.1-2 right view of ZS200GY-2 © right rear turning lamp @ muffler @ seat @ kick starter © right front turning lamp @) front wheel (@) rear wheel @ brake @) rear brake pedal (® front shock absorberZS200GY-2(EC)Maintenance Manual 1 Specification Description Specification Length X width X height 2180mm X 810mm X 1200mm Wheetiase 375mm Size and net weight |"\fin ground clearance: 250mm [Nerwergar TRE ax Toad TORE Engine model ZSI6TFML Engine ype single, 4-sok air cooling Tore sake 70mm XT Total capacity 1960mL + compression ratio 35a Engine ‘raburetor type ‘vacuum film aircleaner foam combined with plastic lubrication way pressure and splash Starting type electric starter /Kick starter ‘max powerlcorresponding rev TO.SKW/ (7500 = 300) rmin ‘max powerleorresponding Fev TLOKW/ (7500 = 500) simin ‘max torque/corresponding rev 14.5N + m/ (6500 £ 500) r/min idle speed (1400 = 140) #/min front shock absorber hydraulic spring Riding system | rear shock absorber hydraulic spring angle of steering handlebar <48° tyre standard/ | front wheel __| 100/90-18 > 225kPa Pressure rear wheel 130/90-15/ > 250kPa Riding system — | geve was hain rmin.turning diameter 420mm, Clutch ‘multiple, wet and manual “Transmission imesh with Speed “Transmission way return spring with left control Primary decelerate ratio 3.318 Final decelerate ratio 3.286 ‘Transmission Jspeed _| 2.855 2-speed | 1.789 Gear speed ratio Sspeed | 1.318 4-speed_| 1.040 S-speed | 0.821 ‘model 428 driven chain miner | 109 contol and brake | Ont brake disc brakes rear brake ‘drum brakesZS200GY-2(EC)Maintenance Manual Description Specification ignition way en ‘gnivon timing 20° ‘before top dead cener(1200%/min) Spark plug DSEA Clearance of spark plug (0.6mm-0-Fm Capacity of battery 12V7An ” | etectrical system | Fuse 104, headlamp VSSWASW “Tall Tighi/Brake Tight 1BVSwAIW Tum signal light iavi0w x4 “Turn signal indicator 1aVLTW x2 Meter light 1BVLTWx2 Neutral indicating Tight RviTW positon light [avaw fuel brand 290 (GB_17930-1999) Capacity(neluding spare) | _> 8.0L Fuel fuel tank spare L fuel brand [ SF_15W/40__(GB 11121-1995) engine oil Capacity LL. brand HQ-10 damping oil ‘capacity (200 + S)mL Chapter 2 Maintenance Knowledge Maintenance and adjustment data Engine System a1 Cylinder, piston crankshaft and connecting rod Description Standard (mm) Limitation (am) clearance of piston and cylinder 002 0.06 eylinder intemal ameter o 67.085 piston diameter 66.955 66.425 linder head end surface i deformed _—_—— 005 Jylinderend surface is bend —— 005 end clearance of piston ring 035 0.10 side clearance of piston ing 005 010 ctearanceof piston pin and pinhole 002 08. intemal diameter of piston pin 16+ 0015, 1605 extemal diameter of piston pin 16.00 — 0009 15.855 ote diameter of connecting rod small end 1600+ 0015 16045 radial clearance of connecting rod smal end 002 005 facial clearance of connecting rd big end 001 005 xia clearance of connecting rodbig end 040 0.60 5 axial jumpimg of crankshaft 002 005:® 200G Y-2(EC)Maintenance Manual ZONESHEN 22 valve mechanism Description Standard (mm) Limitation (im) intake 36.588 + 0.05 36.550 cam height exhaust 36.63 + 0.051 36.50 valve spring length ee eat a outer 6.63 3650 valve gap 0.06.0.08 0.09-0.10 ‘width of valve seat 16-20 2.20 couternal diameter of valve intake 6.00-5.985 3.955 guide exhaust 6.00-5.955 5955 wae intake 600-6012 6.085 guide| 7 | internal diameter of valve gui Eanaaat a aaas valve [Bap between i Siem and intake 0.015-0.04 0.05 guide exhaust 0.03-0.057 0.06 ‘Transmission 23 clutch, stating gear, gearbox Description Standard _(am) Limitation (am) friction disc height 3.00-3.10 2.60 clutch [deformation of friction dise 2.800~2.825 0.20 free length of clutch spring 3730 36.50 internal diameter of gear hole 126 x 136 axial diameter of shifting fork 125 x 136 parting 8631 sternal diameter of shifting fork » 18.985 height of shifting fork claw 75 7.485 outer diameter of drum louter diameter of pricipal shaft 15.02 1494 ter diameter of countershaft 25.021 2496 gearbox cr 19.50 19.45 internat diameter of — | M2 aooat 1998 cc 20021, 19.96 o4e gear Ma 2002 19.95 cs 25.021 2498ZS200GY-2(EC. ELT LEVEL a4 it pump Description ‘Standard (om) Limitation (mm) ‘gap of pump top 020 radial gap between outer rotor and pump 025 [gap between outer rotor and inner rotor 025 Ride system 26 wheel and shock absorber Description ‘Standard. (om) Limitation (om) depth of tre surface 40 20 stroke of front absorber shock 108 = free length of front absorber shock spring 185.9 180,00 stroke of rear absorber shock 70 free length of rear absorber shock spring 125.00 120.00 axial 2.00 jumping of im = sm vax front 2.00 jumping of axle ae am Controls Systsem 26 Controls system Description Standard (nm) Limitation (om free stroke of front brake lever 10-20 20-30 free stroke of rear brake pedal 20-30 30-40 thickness of rear brake shoe 3.9-4.0 20ZS200GY-2(EC)Maintenance Manual Assembly requirement and tools 27 Tighten torque Deserption Standard value “Torque value(Nam) [Cylinder head bolt M6 #12 Cinnecting bolt of cylinder head Me 10-12 Cylinder head nut Ms. 2030) Bolt of left crankcase cover M6 8:12 Bolt of generator rotor M10 50-60 Bott of starting motor M6 #12 Bott of timing gear M6 #12 Engine right crankcase cover bolt M6 #12 llock nut of clutch and drive gear M18 40-50 cil pump gear bolt MS 69 clutch cover boad bolt M6 12 fixing bolt of gear change drum cam M6 8.12 crankcase bolt M6 812 [Locking nut of vertical tube M6 #12, fixing bolt of handlebar M24 50-60 |fixing bolt of upper connecting block M6 25-30 |fixing bolt of lower connecting block M8 30-35 Nut of front axle MB "3035 Vehicle Inut of rear axle Mi4 60-70 [Engine suspension bolt Mi6 70.90 fixing nut of rear shock absorber Mi0 30-40 Sprocket retainer nut Mi2 60-70 steering stem bolt MB 2025 |Nut of rear rocker arm MI2 25-30 Mis O70 Assemble location a.The top mark “ |” should be toward intake position when fitting piston. b.The mark “A” on the first and second ring should be upside,and be 120 degree each other. c.The dense end of the valve spring should be downside. d.The T line of magneto,timing gear mark O and crankshaft gear mark O should be aimed. € O mark of balance shaft drive gear should aim to O mark of balance shaft pinion.200G Y-2(EC)Maintenance Manual Maintenance Tool “Motorized gun: special power tool for mantling/dismantling and clutch nut \wrench: special tool used with socket @ a | ‘A,B bolt socket: for mantling/dismantling A, B bolt and exhaust ‘muffler bolt; ‘Adaptor: electric special tool for cross, hexagon gun tip: Valve adjusting socket: for valve clearance adjustment Socket: for mantling/dismanting nuts, bolts i AoW TUT Cutting plier, nipper plier, expansion plier for manting/ dismantling flexible retainer T- socket wrench IA rotor puller: for dismantling magneto rotor Rubber hammer, iron hammer, copper hammerZS200G Y-2(EC)Maintenance Manual Feeler gauge: to measure the clearance of piston, cylinder, valve, ete. Micrometer: to measure the dimensions of piston, piston pin, ete Dial gauge: to measure the wheel bouncing, cylinder inner diameter, et. Cylinder barometer: to measure the cylinder pressure Tire barometer: to measure the tre pressureZS200GY-2(EC)Maintenance Manual '® Chapter 3 Maintenance of Engine 3.1 Maintenance of engine body Dismantle,mount and maintain cylinder head Cnfiguration of engine is shown in fig. Check engine surface and rinse sand or dirt on engine sur- face if necessary. Chfiguration of engine is shown in fig. Check leakage from engine and repair engine if necessary. remove cylinder head cover. remove C.D.I cap. check seal ring of C.D.1. cap and replace seal ring if necessary.ZS200G Y-2(EC)Maintenance Manual unscrew cylinder head nut. remove cylinder head nut washer. unscrwe bolt of intake and exhaust valve cover. check intake and exhaust valve, change seal ring of valve if necessary. valve coverZS200GY-2(EC)Maintenance Manual unscrew bolt of chain tensioner. remove tensioner and check wear of tensioner, change if necessary. unscrew connecting bolt of cylinder head crankcase. unscrewlock bolt of sprocket.ZS200GY-2(EC)Maintenance Manual remove driven sprocket and check wear of sprocket, change sprocket if necessary. remove cylinder head. check end surface and change cylinder head if necessary. the limitation of deformation shuold be 0. 5mm. check carbon deposit in combustion chamber and remove carbon deposit. 212+ZS200GY-2(EC)Maintenance Manual ZONESHEN remove camshaft, rocker shaft and rocker to check wear. change camshaft, rocker shaft and rocker if necessary. fill petrol into intake and exhaust pipe of cylinder head and check. grind valve if necessary.Check valve seat and grind valve seat if necessary. width of valve seat should be 1.6mm-2.0mm measure guide pipe inside diameter of valve and change guide pipe if necessary. the limitation of guide pipe should be 6.045mm. guide pipe micrometer check carbon deposit and remove carbon deposit and clean spark plug if necessary.adjust spark plug clearance, it should be 0.6mm-0.8mm. spark plug toola ® ZS200GY-2(EC)Maintenance M. ZONESHEN 3-1 Maintenance of Cylinder Head [Component Trouble symptom Trouble symptom description | _ Pate form of component of motoreyele Rapele metbod [Too much ol dit or sand oor heat radiation ofthe fins. | at Remove the oil dirt or sand lon the radiating fins. on cylinder head a atta on the radiating fis. aroun de posit in the "The engine overheat Remove the carbon deposit combustion chamber. Fire of pking pug Asta: bec te pring Te caine Bl oir Pepa eae ne log and cylinder head. sible to start replace the cylinder he 5 rind the cylinder hea end Serious deformation ofcy- The engine i fcuk or impor ee. renlae the ey Inder ed end sce 62s etag tonne yd HE Sa Insucient engine ag the deformation is beyond) head and ylinder. loutput; Engine speed changes| |in limit of 005mm), uring ile run Cylinder | Thee are pis, bation or pck| gir eakage between the valve and ™ e6e i lifict ripossible head [ars damageson the wert| vaiye sent due to inoproner| Me tlie engine ouput Ex-| Repair he valve seat ing mafce of valve seat. | ightness ine sped changes rng ler, The inner hole of valve guide ie tm is over wor (ie the inner The fiting clearance between | Thick blue and white fume from diameter of tie valve suid i) the valve and the valve guide [the exhaust muffler pipe. Replace the valve guide beyond the limit of 6.) ¥ o4Smm. ‘stools ‘The engine is dificult or impos-| Replace the cylinder hea Tie eyinder gaskets aeaage teers ene yee eg gett broken. Cs output; Engine speed changes dar. ing ile rn, The retainer nut is not The engine is difficult or impos-| sible to stat Insufficient engine ‘properly tightened, _| Air leakage between the cylinder a fener: output; Engine changes speed! the rea cing ite run Joi eakge between the eylinde [Improper clearance be-| Weak or no sparking from the| ou jen . ‘Adjust by slighty polling tween electrodes spark plug electrodes. the side electrode till the clearance is 0.6-0.7mm. The spark plug clestrodes| sparking from the spark plug| Teves impossible sare |e he carbon deposit fare jointed by carbon] cectrodes, estos Se deposit between the electrodes. space ig |Exeessive carbon deposit) | Te engine i fiat orimpossibe to] Remove the carbon deposit oroildtin he spark plug.| Wetk o* #0 sparking from the| sar. nsutint engine opt Engin |r oil dirt spark plug electrodes. changes spend during ie rum he engine is diicat orimposbe 0] Replace with new 5 The spark plug insulat is] Weak or no sparking from the| jn neem: ee agea| Motte wim a new speak ficient eine ouput Ens ot ofthe same ype damaged. sparkplug electrodes, changes seat digi a he engine ec vo aan Engine Air leakage between the spark The spark plug i8 not nae changes sec ding ile en ‘Tighten the spark plug properly tishtened.ZS200GY-2(EC)Maintenance Manual ZONGSHEN Dismantle,mount and maintain cylinder configuration of cylinder is shown in fig and remove dowel pin to check deformation and change dowel pin, remove cylinder gasket to check gasket, change gasket if necessary. remove tension strip to check wear and change if necessary. unscrew connecting bolt and remove cylinder to check wear, change cylinder if necessary. cylinderZS200GY-2(E ZONESHEN remove baffle ring of piston pin to check baffle ring. Never fall baffle ring into crankcase. remove piston pin to check wear, the use limi- tation of piston pin external diameter should be 15. 855mm. Never fall baffle ring into crankcase. remove piston to check wear. the maximum, limitation of external diameter should be 66.825mm and the minimum limitation of piston pin hole inter- nal diameter shoule be 16.05mm, check wear of connecting rod small end and the maximum limitation should be 16.045mm. -16-ZS200GY-2(EC)Mainten: remove residual gasket on cylinder surface and check deformation of cylinder, change if necessary. remove cylinder and check wear of cylinder, change if necessary. check deformation of cylinder end face and the deformation limitation is 0.05mm. measure intemal diameter of cylinder from upper, mid and lower, the max. limitation is 67. 045mm.® ZS200GY-2(EC)Maintenance Manual ZONGSHEN 32 Maintenance of Cylinder body Component “Trouble symptom of Damage form rouble symptom of motorcycle | Repair met description . component ea | te Son ano tad poo at mtaton of [Remove the oll dito ltoo much oil dirt or sand) Poor heat radiation of the fins sand on the radiatin on the radiating fins. |on cylinder head The engine overheats i . Serious deformation of cy ‘The engine i difficult or impossible Grind the cylinder head Hinder end surface (larger Ait leakage between the cyl. start Insufficient engine outpulend surface or replace| than limitation of 0.0Smm) inder head and cylinder. | Egne changes speed during idle rn. |the cylinder head, Cylinder . IThe eylinder is worn (large than 67.045mm) The fitting clearance between the cylinder and piston, pis- ton ring is too wide [The engine is difficult or impossible to start, Insufficient engine outputs [Engine changes speed during idl run-Thick blue and white fume from| the exhaust muffler pipe. [Repair with boring] machine or replace the eylinder [The cylinder gasket is] lbroken. Jit leakge between the cylinder and| crankcase. Replace the cylinder gasket Dismantle, mount and maintain crankcase Unscrew engine oil plug and check oil to check oil and oil level. remove clutch rod and stell ball, check wear of rod. change clutch rod and stell ball if necessary.ZS200GY-2(EC)Maintenance Manual view of right crankcase is shown in fig, and check wear of balance shaft bearing, crankshaft bearing, prin- cipal and countershaft. view of right crankcase is shown in fig, and check wear of balance shaft bearing, crankshaft bearing, principal and countershaft, change if necessary. view of left crankcase is shown in fig and check wear of countershaft oil seal, gear change lever oil seal. change if necessary. view of left crankcase is shown in fig and check ‘wear of balance shaft bearing, principal shaft bearing and countershaft bearing. change if necessary. principal shaft bearing balahceshaft bearingz ® ZS200GY-2(EC)Maintenance Manual ZONGSHEN engine number is stamped on right crankcase and remove oil plug and check oil quality check lubricant level and add if below lower line. unscrew filter net cap bolt of right crankcase cover and remove filter cap. remove filter net cap to check rubber ring and re- ‘move filter net to clean. =20-ZS200GY-2(EC)Maintenance Manual remove right crankcase cover and check oil line, clean right crankcase cover oil line remove fuel inspection cap and check seal ring of fuel inspection cap. change seal ring if necessary. unscrew bolt of left crankcase cover and re- ‘move crankcase cover to check. change gasket. check bolt of stator and trigger coil, check wear of roller needle bearing of electrical starter. change stator if necessary. 294 trigger coil bearingZS200GY-2(E Take off the residual bolt in crankcase as shown in fig, and remove broken bolt. Triangle taper of wedge ‘2Residual bolt 3.Crankcase 33 Maintenance of crankcase ComPaRER | panage a ‘Trouble spon oF “Trouble Spo ar description component of motoreyele ‘Crack in the crankcase | it leakage from the crankcase, | Repair of replace tre i Oieakge om We ST] wanes plug screw is ineffective. |_| leftand right crankcase. cylinder head fasten nut is im threaded holes of eylider | Possible to screw firmly so sir leakage between head an engine is difficult or imposible] Repair the threaded hole to start Insufficient power;un-|or replace the tolt ae ineffive stable ile crankeate aa sable idle speed " Crankoase - eylinder bead fasten nuts ; engin is dificult or impossible Re ylinder bolt ofthe extnder is Iposibet sere fly so tha SHEN fcuk o a 7 pace the cylin a pore nsuficient power un poe eit Teakage ber head andl sable idle ‘speed eytinder oil seal is damaged or oill caledgeis damaged | | illeakage from the oi seat_| Replace he i sel ankaae cave aparece eas overs worn Oientage rom te can cover| FSET Right crankcase racked. ——— cover. cover | gasket is broken, Oilleakage between case Cover] Replace the gasket and the case RECOV WOT Replace crrpairthe ca Left crankese | cracked | ortteakage trom te cas cover] 9. cover | gasket of lef crankease I [Oil leakage between the case| | Replace the gasket broken. ~~ __ooover ana the case”)Maintenance Manual Maintenace of crankshaft connecting rod Dismantle, mount and maintain crankshaft connecting rod Unscrew fixing bolt of crankcase. remove left crankcase.never fall principal shaft, coutnershaft and starting shaft washer into crankcase, remove crankshaft connecting rod and check wear of bearing, change if necessary. ‘connecting rod® | ZS200G Y-2(EC)Maintenance Manual ZONGSHEN remove balance shaft and check wear of bal- ance shaft neck. change balance shaft if necessary, check clearance of connecting rod big end and change connecting rod if necessary. | ‘measure external diameter of piston and check wear of piston, the minimum limitation should be 15.95mm. piston pin micrometer measure side gap between piston ring and pis- ton groove. the maximum limitation is 0.08mm. ‘groove feeler gaugeZS200GY-2( ntenance Manual check baffle ring of piston pin and change baffle ring if necessary. measure piston skirt diameter to check and the use limitation should be 66.825mm.change piston if necessary. ‘measure diameter by moved 15mm upwards from. piston bottom. ‘change piston ring if necessary and the fixing pro- cess is shown in fig, {Ast ing 2.2nd ring 3.il ring 4.scraper Soil ring 6 mark® ZS200G Y-2(EC)Maintenance Manual ZONESHEN Measure radial jumping of crankshaft and check both ends of crankshaft, the limitation is 0.05mm. ‘Measure axial jumping of connecting rod and check needle bearing, the limitation is 0.05mm. ‘Measure connecting rod big end gap and check gap. the limitation is 0.60mm. change connecting rod if necessary. check axial jumping of crankshaft and the limi- tation is 0.05mm.ZS200GY-2(EC)Maintenance Manual x Maintenance of Crankshaft Connecting Rod description] Damage form el ‘Trouble symptom of vehicle ‘maintenance method | Carbon deposit on piston! ‘The engine overheats. remove carbon deposit. top lhe engine is ifcult or imposible t carbon deposit inthe ring | The piston rng is seized in 0 tasutiient engine oupet hil groove ‘ring groove. lbiue and white fume from the exhaus Temoe carbon deposit. mutt pipe The engine is dificult or impossible Sculfing or soratches on seufing or seraches on the tart Insuicient engine ona thi the surface of piston skit. surface of piston skirt. [blue and white fume from the exhausy RePlaee the piston. Piston mutt pipe excessive wear of piston] | etwoen [eMt® i dificult or impossible to star ater ess than imi | ine clearance between seen engine ou thick bean tbepiston and the linger is Replace the piston. ston of 66.825mm) | eatin ante ine ae rom te exat mut pipe "=P SE AEP fing clearance bet™2e0 ue and whi fume om th cxceive weapons goorisone| Sekt and whe ome om Be | sy pow org lexessve wear of piston pin hleinter diameter is fivig clearance between the suing sound ofthe piston pin and of Imore than limitation ofpison ring andthe hole is} in eying, than limitation of Pee ages a cre Replace the piston. ca overage. Replace crankshaft Icrank pin | excessive worn Radial and axes gp is t00| surking sound ofthe big-end bearing | ®*? i connecting rod needle bearing is over| zagial and axes gap is to Striking sound of the big-end bearing | Replace crankshaft worn large. connecting rod. Bearing Me cana bexing ‘Abnomal sound during the crankshaft] Replace crankshaft over wor or damag ae . fhe engine i ficult or imposible lsat nsuficient engine ouput hic piston ring is fractured, | Piston ting is fractured. J a white fume from the exhaus| Replace piston set Piston mutt pipe ving set piston sing is over worn lend or side gap is over larg IThe engine is difficult or impossible t start. Insufficient engine output; tic lblue and white fume from the exhaus mute pipe. Replace piston set.3S, ZS200GY-2(EC >)Me TCHR ETE ZONESHEN Maintenance of Crankshaft Connecting Rod lescription Damage form eee ‘Trouble symptom of vehicle ‘maintenance method He engine is dificult or impossible nsutisiet elasticity of] font of piston rng nd sur. Insufficient engine OUpU Replace piston set Piston [piston ring. ti hick blue and white fume from t ee exhaust muffle pipe piston ring gap isnot sag iin Improper fixing bie and white fume rom muffle pipe Refiting excessive wear exter | ay ‘ing clearance between pis ison ia | diameters essai | MES MET] Sy sand pison pin | Relic pion pla tation of 15.095mm) [excessive wear of small-end| ~ |hote ner diamter is morefiting clearance between| Replace crankshaft ithan limitation of 16.|small-end and piston pin is| Striking sound of piston pin ‘connecting rod. |o4Smm) lover large. Connect Repl kshaft ing 0d | connecting rod is bend | connecting rod is bend ‘Striking sound of cylinder ie eae connecting ial and axes gap is too | Stiking sound of the big-end bear | Replace crankshaft ‘big-end hole is over worn. Radial and Ct vd - Repl shaft are ing connecting rod iin Replace timin Timing |The gear is over worn or ‘Abormal sound from drive chain Z c sprocket [jure sprocketS200G Y-2(EC)Maintenance Manual Maintenace of valve mechanism Dismantle, mount and maintain crankshaft connecting rod remove cylinder head assembly and remove valve clip and spring, valve by tool to check wear, change if necessary. unscrew bolt of cylinder head cam shaft. remove cam shaft baffle to check and change if necessary. remove valve rocker shaft, rocker and camshaft to check wear, change if necessary. rocker shaft® ZS200GY-2(EC)Mainten: ZONGSHEN remove rocker, rocker shaft and timing cam to check wear, change if necessary. ‘measure valve spring length and check wear of valve spring, the minimum limitation of inner spring is 36.00mm, the minimum limitation of outer spring is 36.50mm. Caution: the end with dense spring should be downwards when fitting, ‘measure minimum limitation of outer diameter is 5.95Smm and check carbon deposit on valve stem, ‘measure valve interface width and the limita- tion is 2.20mm. change valve if necessary. “.30-ZS200G Y-2(EC)Maintenance Manual Check deformation of valve stem and measure the limitation of roundness is 0.05mm. change valve a stem if necessary. | fF} i | a 1 dial dange valve stem check cam lift and the minimum limitation of cam | lift is 36.50mm. change camshaft if necessary. ws cede lift fuel hole check wear of camshaft neck and gap between camshaft and bush.change camshaft or bush if necessary. | check wear of rocker interface and gap between rocker shaft and rocker. change rocker shaft or | rocker if necessary. | fie rocker rocker shaftZS200GY-2(EC)Maintenance Manual Measure external diameter of rocker by mi- crometer and the minimum limitation is 11.93mm. ‘check wear of drive sprocket and change drive sprocket if necessary. sprocket check wear of timing chain, tension strip and chain guide and change if necessary check wear of tension strip and change tensioner if necessary. 2. hain tensionerZS200G Y-2(EC)Maintenance Manual remove valve cover firstly when adjusting engine timing position. remove fuel inspection cap and rotate magneto to make piston locate at top dead center and make T aim to mark of left crankcase cover. Lineal mark of timing sprocket should be aimed to lineal mark of cylinder head plane when T mark aimed to mark on left crankcase fuel inspection cap. adjust sprocket location if necessary. adjust valve gap. intake gap should be 0.06-0.08mm exhaust gap should be 0.08-0.10mm. adjustment nut 33‘® ZS200G Y-2(EC)Maintenance Manual 35 Maintenance of Valve Mechanism [Description Damage form Teouble smpiom of Trouble symptom of vehicle | Maintenance method ‘valve oil edge of vale ol seal is worn, aged ick ae and white Fame fom Pear | eet Replace valve il seal excessive wear(ltng is less than Insufficient engine output. | Replace the camshat af /min. limitation- 36.50mm) ~ er " a " camshaft axial or radial clearance ofthe exesivewenoinrttcam arin oo wide Incive| “Moma und ead ding | nd bering or damaged bearing swiveling or anormal camshaft wansmission place cams sound uring swiveling Sa gap scan ore Valve siting sound [Replace roker arm excestive wear of rocker arm shall big gap between rocker arm Rocker |hole (inner diameter is more that ‘Valve striking sound. [Replace rocker arm. oe | ee Gree ces and rocker arm shaft . excessive weat of rocker Tallis san bowen wokeranm and (external diameter i less than limi-| B18? ee place rocker shaft tation~11.93mm ) ‘rocker arm shaft. Me iking sound. Repl a engine i diffu or impos Carbon deposit on surface. tis impossible to ft valve and Jesse vo start. Insufficient en- [Remove carbon deposit. valve seat tightly. jgine output; unsteady idle working surface is over worn oF [is ipoqstte wo te vatve ana | €A2i0€ fs ical or impor- has pits, pock marks, ablation or | Y impossi fo Btvalveand ig sat, Insufficient en- | Replace valve damage. coud gine output; unsteady idle excessive wear of vave stem Valve |(estemsl dimer of intake stem i 88P between valve stem and] sun fom vale, hick ue jas than limitation- 6 5.95Smm,|guide tube is over large and white fume from mule | Replace valve exhaust diameter is less than limi Fi tation-5.95Smm) Pie. valve stem is deformed. valve an no close completely.| engine ean not start. Replace valve gap between valve stem and] thick blue and white fume excessive wear of valve stem ide ube i over lar Replace valve en ree {from muffle pipe. valve stem is deformed. valve an notclosecompletely.| engine can nt start. Replace valve vate] insuicient lst or sping | is impossibleo ithe ve The steering stem is Steering tem | 1 Replace steering stem7ZS200GY-2(EC)Maintenance Manual unscrew lock bolt of upper connecting plate and. check upper connecting plate. unscrew lock bolt of lower connecting plate and check lower connecting plate. uscrew fixing bolt of front fender. unscrew fixing nut of front axle and remove front wheel. unscrew front brake plier bolt and remove Drake plier. brake plier® 200G Y-2(EC)M. ance Manual ZONGSHEN remove front shock absorber assembly. unscrew oil filling bolt of front shock absorber. oil filling bolt drain damping oil to check lubricant and change Tubricant if necessary. gage shock absorber | remove dustproof cover, circlip and oil seal to check wear of oil seal blade and deformation of circlip.ZS200GY-2(EC)Maintenance Manual Measure length of shock absorber spring and check bend or deformation of spring. change spring if necessary. remove return spring to check wear and change return spring if necessary. Measure length of return spring and check bend or deformation of spring. Add oil (200 + 10)ml based on standard. ZONGSHEN circlip return spring LH return spring ve] t 81s-82- ® ZS200GY-2(EC)Maintenance Manual Z0NERHEN 53 Maintenance of Front Shock Absorber Tops Tea RmpORTT Tatler 7 description form ‘component of motorcycle ‘hod Front sack | The elati force i nsf | Tee nwo hock ater [ON SPOT eam hock absorber absorber spring | cient or broken is Insufficient or broken spring ot rot aaber working Front shock Bending and deformation ‘Front shock sirut fs bent and deformed loft-track in running Iconect replace front shock sat Working stroke surface is damaged or scratched Leakage from cil [Leakage at front shock ey inder [Replace front shock strut litle litle sorber Seat [Working stroke surface Cr coating patil is worn out | Leakage from oil seal _| Leakage at font shock c-| Repgce front shock eylinder expose the substrate inder Front shock | Broken deformed and dam | Leakage at front shock eyl- [Leakage at font shock eyF| cylinder | aged inder nder Replace piston rod Over soft at Tonk shack Over worn or damaged | eae Replace piston ring Piston cod [Piston ring is over worn or i ver sofa font shock etn Replace piston ring ‘Cat edge over worn or dam Teakage a font shook wb Leakage from oi sea ee ee ee Replace oi seal Shock a | suflicent of amount or too] Tsuficent shock oll orto | Over sof of front shock ab [FH shock ol as per he apes fied stipulat(120 + Smal) Disassemble, disassemble and maintain rear shock absorber unscrew rear rocker lever nut and check wear of rear rocker lever bush. change bush if necessary. unscrew rear shock absorber bolt and check wear of rear shock absorber bush.change bush if necessary.ZS200G Y-2( C)Maintenance Manual remove dowel pin and remove bush. remove rear shock absorber assembly and change rear shocker absorber if necessary. check rear shock absorber and change rear shock absorber if necessary. s4 Maintenance of Rear Shock Absorber Component Trobe apm Table wom Pag fe irmetod description 7 ‘of component. cof motoreycle Rep Reg ses rn car shck borer sping iron | Rear shock aboter is over sot | Reps ear hack bose ear shock [sate foce thane lease econ foe absorber Leakage at rear damper xe at rear damper Staves Sock sbsorbe' | Replace rear damper attr Leta ter emer [Laan at dan woand aust nome ne |e Piston rod on rear damper In beat, deformed or broken Piston rod on rear damper is bent, deformed or broken Rear shock absorber is over| hard Replace rear damper Rear rocker arm Deformation ‘The rear rocker arm is deformed Off-tracking in running Coretorrplacerarockr sm Breakage ‘The rear rocker is broken Its impossible to run Wel oc eplce ear ocker am® 7S200G Y-2(EC)Maintenance Manual ZONGSHEN Maintenance of Wheel Disassemble, assemble and maintain wheel Unscrew lock nut of front axle and remove front axle, remove front wheel assembly to check front spoke broken and change spoke then correct rim. remove front axle bush. remove oil seal and check wear of oil seal change oil seal if necessary.7ZS200GY-2(EC)Maintenance Manual check wear of bearing and change front axle bearing if necessary. check wear of speedometer gear and lubricate gear if necessary. unscrew lock nut of rear axle to check rear axle and nut. remove rear axle and check bend of rear axle, remove rear wheel assembly.5200G Y-2(EC)Maintenance Manual remove rear axle bush and check wear of bush, change bush if necessary. remove oil seal to check wear and change oil seal if necessary. check wear of rear axle bearing and change rear axle bearing if necessary. ‘unscrew rear chain dise bolt and remove sprocket. remove rear chain disc bush to check wear and change bush if necessary.ZS200G Y-2(EC)Maintenane check wear of tire and change rear outer tie if limitation of 2mm is exceeded. check rear brake hub and remove dirt and sand. Manual in rear hub. 55 Maintenance of Front and Rear Wheels Component Trouble symptom Trouble mpiom mage form Repair method description ome cof component ‘of motorcycle Front wheel rim is deformed | Front wheel rim is deformed. | OM tacking in runing, steering tance vibes oF sakes in running | RePlace front bub te hub bearing hole is over| The bearing block hole has a] OM tacking in runing, seeing) Front wheet_| worn Toose match with the bearing. | handle virats or shakes in ruming| REP fs [Bearing is over worn or|T™2a!snd aia gaps of bearing | Off tracking in runing, ster ef inner and outer rings are oo be r| ing handle vibrates or shakes in| Replace bearing damaged. is insuicient aon running [The inner dre is prcked or | ron tire has very low pres-| Inflenible of direction handle,| Repair or replace inner broken sure insutficiemt engine output | ce Front tre Its possible to slip and has a The tire is over worn poor slip proof function | Replace outer tre “The indicator of the speedom- | Replace speedometer gear Gear is damaged. a Pcrecaraiakan Speedometer eter fails to move box gearbox [The gear drive ting is “The indicator ofthe speedom-| Replace speedometer gear damaged. ter fails to move box Rear rim ie twisted and) Rear rim is twisted and] Off tracking in running, 4 | postce rear sim deformed, deformed whee! wobbles in running Misfunction of rear brake Rear brake drum is over wor Replace rear tim Rear wheel “The hub bearing hole is ove} The bearing block hole has a Off tracking in running, rear worn toose match with the bearing. | wheel wobbles in running | Replace rear rim “The bearing is over worn and = Sl anédil gas oF =F | Or cracking in running, rea inner and owe sngs are 10 big or Replace beating damaged ee eee wheel wobbles in running ‘The inner re Ts pricked 0 Thflexible of direction handle, [Repair or replace inner broken Rear tre has very low presse insufficient engine output | tre Boas Tris possible to slip and has a ‘The te is over wom oot stip proof function __| Replace outer tire= 88 - Los ZONESHEN, ZS200GY-2(EC)Maintenance Manual Chapter 6 Maintenance of Control and Brake Sytstem Disassemble, assemble and maintain control system dismantle right controls and check throttle lever. clean or change if necessary. remove throttle cable to check wear and lubri- cate it, remove throttle cable to check wear of core and clean or lubricate it. remove clutch cable, throttle cable and odom- eter cable to clean and lubricate cable. clutch cable throttlé cable odometer cableZS200GY-2(EC)Maintenance Manual check free stroke of front brake lever and adjust free stroke by professional if stroke is out of range. the stroke should be 10mm-20mm. check front brake oil cup and add brake oil if, below lower line. check oil leakage from oil tube and change brakes system if necessary. adjust clutch cable and check clutch disengagement. adjust clutch free stroke at clutch cable bracket if can not be adjusted at clutch lever. adjistment nut -89-Los ZONGSHEN check disengagement and engagement of clutch, ZS200GY-2( C)Maintenance Manual adjust free stroke to 10mm-20mm. check free stroke of rear brake pedal and adjust rear free stroke if necessary. free stroke of rear brakes pedal should be 20mm- 30mm. free stroke of rear brake pedal can be adjusted by adjustment nut rear brake light switch also be adjusted while adjusting free stroke of rear brake pedal. adjustment nut 61 Maintenance of Control system Compan Tea pa "7 a rouble sympa —_ deseiion | Damage ST ‘of component fmaercrele Repair method Stering handle |derormed, 5 [ihe stering handle is bent and | Off-rackinginrumning, | OTCLOrTeplace steering [Over small ofthe fice ake Readjut he fe wake Over big of the free sok far of rear Readjuat the fre stake fomcatecos frie el bis inte] caeisingeste rar [Cuchaipngorena [Co NNEC choke and tote are imposible choke and toate |! 2601s ieee een ae Te luchis spying or ot | len abt or epace conrl cable is broken ‘The clutch snot fly discon [Reads the re stoke [Re free svoke is over smal Mistnctionofreartrake | replace contol cable 90. Rear brake pedal ‘The free stoke is over large | Misfunction of rear brake Readjust the free stokeZS200GY-2(EC)Maintenance Manual x ® ZONGSHEN Maintenance of Brake System Disassemble, assemble and maintain brake system Check brake oil if front brake oil cup and add brake oil if below lower lilne. unscrew front brake piler bolt and remove front brake piler assembly. check wear of front brake shoe and change brake shoe if necessary. the limitation of brake shoe should be 2mm. front brake ise check oil leakage from front brake oil pipe and | change oil pipe if necessary. ; Caution: maintenance of front brake oil pipe should | be done by professional.® ZS200G Y-2(E aintenance Manual ZONESHEN unscrew front axle nut and remove front wheel assembly. unscrew front brake disc bolt and remove front brake disc. check deformation of front brake disc and measure thickness of front brake disc, the limi- tation is -0.3mm. remove drive chain and dismantle rear axlenut, -92-200G Y-2(EC)Maintenance Manual unscrew rear brake disc fixing nut and ad- justment nut, remove rear axle assembly. remove rear wheel assembly and remove rear brake disc. remove rear brake shoe. check rear brake shoe and the limitation is 2.0mm. change rear brake shoe if necessary.z ® ZS200GY-2(EC)Maintenance Manual ZONGSHEN check wear of rear brake cam and change rear brake cam if necessary. check operation of rear swing lever and remove swing lever and rear brake cam, then lubricate cam. 62 Maintenance of front and rear brake Component Damage fom Troublsymetom of] Trouble symptom of Maintenace method component mowrya met {DOTS oc DOTA o wpperimi mark brake igi sins rake tigi is insuticien |] lose effet diy brake ligui —_ ] | owettex replace brake liquid | surface of walls damaged —_ ]_ aweetect repo main pump | front | brake | main | wilasover wom los effect rcpalce main pump | pump | assembly] oilcase is cracked cilleakage lose eect rep main pump ston surface i cracked lot effect repaee main pump piston 294. pistons damaged lose eect repalce main pump pistonZS200GY-2(EC)Ma intenance Manual ZONGSHEN Maintenance of front and rear brake nile symptom of | Trouble sympiom of ‘omponent Damage form ereraceacctaa acinar Maintenace method tr entry into ol pipe rakes lose effect exhaust front brakes pipe cit pipe is broken cil leakage brakes pipe | brakes lose effect eee front brake ol pipe is clogged | ol leakage brakes pipe rakes lose effect lean or replace brake ol abel wall is broken or cacked brakes lose effect replace front brake calliper front brake | wale over worn brakes lose effet replace front brake ea calliper assembly from bake cape is roken | it Teakaze from |rakes tse fst replace front brake caliper seal ring is broken or worn oil leakage brakes lose effect replace front brake calliper friction plate is over worn brakes lose effect replace brake fttion dsc surface of piston i dmaged or brakes lose effect, worn ® “ replace brake caliiper piston ee brakes lose effect or fic- | clean and Ibricate guide tion ise cannot return | ig trom | over"orn brakes lose eect replace font brake die brake ise deformed [brakes lose effect replace front brake disc friction disc is over worn lose effet replace brake shoe brake shoe surface is worm lose effect replace brake shoe brake interface of brake shoe and brake shoe | dum is smal ose effect replace brake shoe friction dum is sat wt brakes show can notre: | ‘shoe spring is broken turn replace return spring operate inflexibley | brakes lose effect or brakes | Jocal rusted show ean not return clean and lbrieate brake cam brake cam ‘over worn | brake cam brakes lose effet replace brake cam 2952® ZS200GY-2(EC)Maintenance Manual ‘ZONESHEN Chapter 7 Maintenance of Electrical Part and Meter Maintenance of Charging System Disassemble, disassemble and maintain charging system tum on ignition switch and check signal indi- cators operation,check charge system if necessary. remove fuse to check and change same type fuse. dismantle battery and measure voltage, remove battery to charge if below 12V. dismantle magneto charging loop socket and ‘measure short circuit of charge loop, change charge loop if necessary. 296 - charge loop connectorZS200GY-2(EC)Maintenance Manual measure output voltage of rectifier and change rectifier if below 13.0V. the output voltage should be 13.0V-14.5V. check loose or rust of charge circuit cathode and tighten or maintain circuit if necessary. unscrew left crankcase cover bolt and remove left crankcase cover. remove left crankcase cover and check wear of magneto stator, change stator if necessary.ZS200GY-2(EC)Maintenance Manual Check if magnetic rotor demagnetizate and dis- ‘mantle starting clutch, replace magnetic rotor. a Maintenance of Charging System Component Trosienymptom = — Danage fom ee Teas sre Repirmethod scion of component peer Tihtng calls hort cir Te iting oi has ai aki a ee Replace lighting ci Magnetic. |Lighing coi cut isbo ry gh coil has no out-| Insufficient battery charging. generator | ken, ne resistance value | out voltage ‘misfunction of signal system Replace lighting coil Nat wnuticon bay Oa Rectifying Rectifying regulator is broken | Resin | uel bing regloris bots je itunnaing pin cro" enlace cetpng regulate [circuit or short circuit illuminating light is easy to burn out The baery i damaged. | No power output The surer motor i not running | Replace batery [Fie water motor wot amano the storage ime is too| Teri ineuficient power or Complement ctagiag or telew |the voltage is too low. | 7™INB insuficienty, the signal sys-| COP! ing Bamary [fos an nmin volae Is ts Seas place battery, tolyte sn. |ZS200GY-2(EC)Maintenance Manual Maintenance of Igni Disassemble, assemble and maintain ignition system Turn on ignition switch to check operation of vehicle and check charge system if vehicle can not be started, Start motorcycle by kick lever or press electric starter and run engine. check sparking of high tension ignition coil and check ignition system if abnormal. the output voltage should be above 10,000 volt, spark should be in blue, Remove spark plug and check cylinder pressure dismantle engine to check if insufficient pressure. spark plug ZONGSHEN =99-® ZS200GY-2(EC)Maintena ZONGSHEN check short circuit of spark plug cap electrode if normal and change spark plug cap if necessary. check if there are carbon deposit on spark plug or spark plug clearance is over large, adjust clearance to 0.6mm-0.7mm. remove connector of ignition coil and trigger coil, check ignition loop and trigger coil by multimeter. remove C.D.I. connector and check resistance between Black and Red wire of ignition switch. change if abnormal. = 100-ZS200GY-2(EC)Maintenance Manual ZONGSHEN dismantle C-D.Loutlet and check high tension loop. change high tension loop if necessary. dismantle left crankcase cover to change igni- tion loop and trigger loop if abnormal. ignition oop 72 Maintenance of ignition system lescription Damage form ‘Trouble symptom of component ed ‘Maintenance method ican wor cn satin innitio n} shot circuit ‘Weak oo pater fhe pk eee cower paraeeeae Safcien engine power and u-|cMANECieiton power lop ? sue ile ped ‘oP Yo sparkover of the sf iugel broken circuit (2) | Nosparkover oft park plug electrode. he engine does not start. |change ignition power loop eatorospetoverstiespt pag | tients rca st ist ; ict engine ower snd wna Replace igri ieee | Soca tote at | cal | Bete cet Gesste] oprah pa igelede, | Thee dos tsa Replace geri soot Nospetoverothesput pug ceoode,| Theengine dnsntsurt | Relaeignion swith Igiton switch |proke eae Gein ss Replace gon sich | rte) cr ign | \Norunt | Nosuiorerofbekpvgelsm | Thecngnedosntsar. | Replace CDtigiionunit | ites os oa, a Weak orm spkover of he sk pl svat fetetengin power an aah — Repl ition ol | fenton a fet eng Rel gitoncoi Bric cro Gear | fae Noskvrofienmpogcetde. | Te cp dott place inion® '200G Y-2(EC)Maintenance Manual ZONESHEN Maintenance of signal system tum on ignition switch to check indicator and check signale system as follows. dismantle battery and measure voltage, remove battery to charge if below 12V. dismantle charging loop socket and check short circuit of charging loop. change magneto charge loop. check rectifier by multimeter. - 102 -$200G Y-2(EC)Maintenance Manual ZONGSHEN dismantle fuse to check and change same type fuse if necessary, dismantle signale system falsher socket and check short circuit of falsher, change falsher if necessary. dismantle left controls switch and check rust ot contact of turn indicator switchm repair or change left controls switch if necessary. check turn light bulb and change bulb if | necessary. - 103® S200G Y-2(EC)Maintenance Manual ZONESHEN check contact of brake light socket and tail light socket, tighten socket if necessary. check operation of brake light and adjust or change brake light switch if necessary. ccheck tail light bulb and brake light bulb, change bulb if necessary. check rust or contact of horn switch and repair or change left controls holder if necessary.ZS200GY-2(EC)Maintenance Manual adjust hom sound or change same type hom if necessary. check contact of neutral indicator socket. neutral indicator socket 13 Maintenance of Signal System Tonpene — Teaco Geanpion | __Pansefom ‘en meee a Tenia Winker — | Filament is burnt out Winker bulb filament is burt out | Winker is out of work Replace winker ball Winker switeh| Poor connection of inner con- Poor connection of winkerswited Winker is out of work Repair or replace winkr switch Winker sou of work orn fashing ordamaged Flasher imerbun ot asherianer par is but oot es ‘Brake light |Ianer cont nto eno | Tne cots ot return oh Braking ght onal he neo Switch | [ime potionor damaged | poton or damaged euro work epace taking ight switch Rear tighy | et samen of aright | The it amen of ae and PH HODM Hicut ofwork brake light | aod aking ight are but ot | baking ight hart ot epace rarligh/raking ht ec or oat of work ors Poor connect o ge con | Poo connection of hr baton in sbeomal sound Horn buon |Per comesi oes const fon Repo relce or ton Tductiehom | nor ainsoncrtmagea | BECO borin pasta of cic om iw of Wor os Teng catch abnormal sound Neutral switch Poor connection af switch “The neutral inleator switch has poor connection The neural indicator i ot of work Replace neural switch Neutral indicator The ftament i burnt ou The net inditoe Sarent is bar cut damaged [The neal indicator is out of werk Replace neural ndistor® '200G Y-2(EC)Maintenance Manual ZONESHEN Maintenance of Illuminating System Disassemble,assemble and maintain illuminating system ‘tur on ignition switch to check headlight. Check battery electrolyte and add electrolyte then charge if below lower line. measure output voltage of rectifier and change rectifier if below 13.0V. the output voltage should be 13.0V-14.5V. remove charge loop socket and measure short cir- cuit of charge loop, change charge loop. - 106-ZS200GY-2(EC)Maintenance Manual dismantle battery and measure voltage, remove battery to charge if below 12V. remove fuse to check and change same type fuse. dismantle left controls switch and check rust or contact of headlamp, change left controls switch if necessary. unscrew fixing bolt of headlamp mask and re- move headlamp. headlamp mask -107-® ZS200GY-2(EC) Maintenance Manual ZONGSHEN remove headlamp switch socket to check socket. remove headlamp socket to check contact of socket. remove high beam socket, low beam socket and passign light socket to check. remove headlamp socket to check contact be- ‘tween headlamp socket and headlamp bulb. - 108 -ZS200GY-2(EC)Maintenance remove headlamp bulb to check burn and change same type bulb of 12V35W/35W. fit headlamp bulb and socket then check opera- METI tion of headlamp. 14 Maintenance of Muminating System Component Tratle mpm Table ampom Dam m epsir method description ge form of component of motorcycle Reps Insufficient ouput volage of magneto | Coil iets short Femintinggad | Hea ig isin detective level | Replace ci ihainating oil [Coil circuit is broken. | Noouiptofillminsng cit | Headlights in defective level. | Replace eo ight bundle is not properly] The bes es oo nea Tighe * Property| The headlight bund ‘Adjust the head tight bundle Head ign | sins oor assembly | The filament of head light is | The filament of head light is bumt © | pura out oe " Head ight is in defective level | Replace headlight bulb Far lighrake| The filament of ear ight andl The lamentoficr light andra | The lament of rear light and epi er lighvbrake bulb light [brake light is burnt out. | tights burnt out, brake light is burnt out, | RePair rear i ominnig ug POE eemEton of nner con-] Por conection of ner cont | Mamianting Tights sbvomal | Repair or replace anna lod diner wie 26t OF it is damaged. oritis damaged. fo out of work ing/high-low light switch® ZS200G Y-2(EC)Maintenance Manual ZONGSHEN Maintenance of electric start control system Diasssemble, assemble and maintain electric start control system turn on ignition switch and check electric start, remove fuse to check and change same type fuse. dismantle battery and measure voltage, remove bat- tery to charge if below 12V. check electrode plate and change battery or add electrolyte. unscrew fixing bolt of electrical start button to check short circuit of electrical start switch, change electrical start if necessary. -110- electrical start bution |ZS200GY-2(EC)Maintenance Manual check connector of battery anode and cathode, tighten connector immediately if necessary. measure output voltage of rectifier and change rectifier if below 13.0V. the output voltage should be 13.0V-14.5V. remove charge loop socket and measure short circuit of charge loop, change loop if necessary. | remove relay and measure short circuit of relay, change same type relay if necessary. =u® ZS200GY-2(EC)Maintenance Manual ZONGSHEN check connector of relay wire and tighten connector. check operation of motor and dismantle motor to repair or change if necessary. tum on flameout switch and press electrical start button change flameout switch if vehicle can not be started by electrical start button. check short citcuit of clutch electrical statr con- trol switch and change if necessary. a electrical start control switchZS200GY-2(EC)Maintenance Manual ® remove side stand switch and measure short circuit, change if necessary. ‘start switch 1s Maintenance of Electric Starting Control System a Damage form Trouble symptom “Trouble symptom of motorcycle Repair method Inner cil circuits shor or ro- |suaer motors out of work | Motreycle impossible wo stat up| Replace starting relay starter relay |: Stator motor rotation is Tet |Motorycle imposible wo sar up sae Replace stating relay Inner contact is ablation ‘Staring [Poor connection of inner con- Passion esas Suaner morris out of work _|Motorycle i impossible stat up | “Replace button No output or insufficient out-|suarcr motor is out of work oF [Motorcycle is impossible to stat up | Inspect bater put roxio sieeve ee impo Py eee y BatteryZS200GY-2(EC)Maintenance Manual Maintenance of meter Dismantle, fit and maintain meter tur on ignition switch to check neutral indica- tor and operation. remove fuse to check and change same type fuse. dismantle battery and measure voltage, remove battery to charge if below 12V. check electrode plate and change battery or add electrolyte. dismantle odometer cable firstly then unscrew fixing bolt of meter and remove meter. =4- ‘odometer cable {ZS200GY-2(EC)Mainten dismantle meter cover to check and change bulb if necessary. indicator bulb check operation of odometer,tachmeter and fuel gauge, and check if indicator bulb is bumed, change bulb if necessary. remove meter core to check odometer core, tachmeter core broken, change meter assembly if, necessary. 1-6 Maintenance of meter ‘Component Damage form ‘Trouble symptom of component | Trouble symptom of motrycle | Maintenance method description wink indicator filament is bart out winker indicator lament i burt ot ‘Winker indcator is out of wore Replace winkerindisto ‘meter illuminator lament Meter assembly_|is burt out meter iluminatr filament is bar ou ituminator is ox of work Replace meter iluminator tab speedomster is damage. speedometer is damaged. ‘Speedometer is ou of work Replace speedometer Tachometer is damaged Tachometer is damaged, “Tachometer is out of work Replace tachometer® 7ZS200GY-2(EC)Maintenance Manual ZONESHEN Chapter 8 Analyze of MotorcycleTroubles 8.1 Analyze of Engine Trouble 8.1.1 Analyze of engine idle speed failure Engine idle speed failure oT (Engine has no idle speed [The idle speed is too high [Engine idle speed is wast r ees ces allie cambursorvalewaheck] [Check whetberthe engind Pressure of cylinder whether it is completely closed ignition is on timing 7 * Yess No Yen) —» No pressure cylinder com- || shether the||the iron line ofthe | |whether | — |state of the CDI ; Press pressure | Jiatejetis | Jeun control cables| |the spark| ignition system Pa ‘ lover large _| is flexible in te plug gap | 2. tnspect the cn ncaa | FTE te skeveort| [sear] got ing parts have leaks; _ | |°a*buretor idle| we oe s + lwheel and trigger] 2. Check whether the | [SPe¢¢ over so |Yes_No _ [coil for tightness air inlet and exhaust is pes Se Adjust Ee the on timing; Engine now has] [Engine without Fe aanen 3. Check whether the | [idle seed te sree electrode | mixing valve clearance is| Improper adjust-] [Check whether the gap so 7 Iment of the car-| carburetor idle jet, 4. Check whether the | [Puretor air adjust-| idle oil channel and ling screw or the) |air channel is airproof of the valve and | linrottle adjusting | jammed valve seat is in good | |screw No Yes condition; £ 7 5. Check whether the Check whether the Clean and dredge piston ring is damaged carburetor float over high or the insufficient = ~ No | spring; [Adjust the float height to the 1. Check whether the insulator of | 6. Check the condition | | standard data or replace the float the carburetor is cracked; | of the piston ring and 2. Inspect the carburetor fitting | cylinder. nut for tightness7ZS200GY-2(EC)Maintenance Manual ZONGSHEN 1.2 Analyze of engine power insufficient Engine power is insufficient [Hold the main stand to make the wheel away] {from the ground,rotate the wheel by hand T [The wheel rotate freely |The wheel rotate hardly 7 r Check the pressure of the wheel 1. Check whether the brake is delay; 7 12. Check whether the wheel shaft is over — worn or damaged; Pressure is to0 low ee eo 3. Check whether the hub is short T (Check whether there is ar Teakage | [Remove the spark plug, plug up the lfrom the tire valve element or the | thread hole,then press the starting tire is broken. [button or step on the starting pole —_—SSS [The finger can feel the strong [The finger can not feel outward gas and the sound the strong outward gas r T The cylinder pressure [Insufficient of the cylinder press ability is in gear Z v 1. Check whether the engine [Start the engine,accelerate the throttle outside connecting part has leaks; gradually to check the engine rotate changes 2, Check whether the sir inlet and —— exhaust is on timing; The engine rotate speed increased | [The engine rotate speed 3. Check whether the valve [with the enlarge of the gun __|_ {not increased with the clearance is narrow; enlarge of the gun 4, Check whether the airproof of Chek whether the engine ignition ison Uning i ale aa een Ed " condition; | Yes ———_________+_______No 5. Check whether the piston ring | [I Check whether the fuse supply system is |]. Check the state of CDI } is damaged or the spring elasticity through; ignition system; is insufficient; 22. Check whether the carburetor,ait 2. Inspect the magneto || 6, Check the condition of the \cleaner,muffer exhaust is jammed; flywheel and trigger coil. piston ring and cylinder. | |B. Check whether the carburetor float for tightness. | [height is properlyb 4 ® ZS200GY-2(EC)Maintenance Manual ZONGSHEN 8.1.3 Analyze of engine starts hard or fails to start Engine starts hard or fails to start r [Check the ignition system i [Remove the spark plug,check whether the electrode is carbon connected No es Do the spark experiment of the spark plug [Remove the carbon deposit [No spark or dim spark from the electrode [Strong blue or purple spark from the electrode] Dismantle the spark plug cap to do} [Check whether the engine ignition is the high voltage spark experiment on timing by the ignition timing light t Nop ves [Strong blue spark 1)Check the state of CDI ignition | [Loosen the carburetor T system, drain oil serew,check Check whether the a teens vst lan reat \ 2yInspect the magneto flywheel | | whether there is oil out spark plug , r : park plug Spark Plug) [Dim spark or] land trigger coil for tightness. {from the carburetor cap with trouble no spark i © spa overflow pipe (Check the suppl : : (Chesk whether) : No i ‘whether ‘whether 7 = = | heck whether) (Check whether tha aoe a i (eke) [CRA weer fediton the | the ignition coil exon sen the Lytinder | fiers foe inthe fenton power |istumoft or | insides mmoff or|fgnton system | [7 | deer bupply short circuit | |short circuit lis with trouble | ye : No z £ 1L iycheek whether the Full “Magneto ignition] (Cylinder pressure Insufficient of ae 5 system without is insufficient cylinder pres ability} lowhole is jamed:2) in vectng point i T eck whether the oil the —— Dis. _||DCheck whether the engine outer connection parti tter and switch is it 1.Check whether] |mantl||has leaks:2)Check whether the air inlet and ‘ammed;3)Check whether | the ignition power| | ye |fexhaust is on timing;3)Check whether the valve tne fuel switch is in good supply is broken|| spark ||clearance is narrow;4)Check whether the seal of ondition;4)Check or short circuit; || Jug tothe valve and valve seat isin good condition;5) | vhether the carburetor oil | 2. Check whether| | check ||Check whether the piston ring is broken or inlet hole is jammed:5) the trigger coil is clamped in the groove ;6)Check the condition of check whether the float | broken or short piston and cylinder is too high | circuit GSS Wet spark plug electrode Dry spark plug electrode | ee | [Check whether the oil is overflow in the carburetor] [Drop a little oil into the cylinder and try to start | ‘Yesr x jNo —— T. Check the seal condition of the carburetor float] [Check | [Running time is shor] [Can work continuous needle valve and seat; whether 2 t 2. Check whether the surface of the needle valve] Ithe air [Trouble with the carbure- eta. is worn; — tor starting system 3. Check whether the carburetor float is damaged; tarting thickness system |4. Check whether the carburetor float is too low | fammed (staring =ZS200GY-2(EC)Maintenance Manual ZONGSHEN 8.1.4 Analyze of engine overheat [Engine is overheat T Check whether the control way is correct Yes, no 1. Check whether the oil is lower than the (Check the cooling system ‘brand or storage time is too long; T 12, Check whether the engine is in the Cool the engine by wind high speed condition or overload SoS eae . dirt on the radiating fins No. SS ‘Check whether the engine Clean ignition is on timing No ire 1. Check the condition of CDI [Check whether the clutch is skid ignition system; Yes No 2. Inspect the magneto wheel and | (> anis slid nove the spark plug and judge the trigger coil for tightness. 7 ratio of the mixing gas according to the col pee lat the bottom of the insulator and other labnormal symptom or ‘The bottom of the spark plug is black,black | [The bottom of the spark The bottom of the spark fuse or fire a gun during the engine in the plug insulator is brown plug is white,intermission during acclerate,carbure- middle or low speed.acclerate performance is|_ rar aising vaio of nsufficientspeed is instable during idle run, | |. ising bury gas tor is backfire,insuffcient normal in high speed running fi power of the engine F Thick ofthe mixing buy gas] [Check whether | [Check the lubrication sytem | (Thine of he I | T. Check the air cleaner a an 1. Check whether the oil is puny —— | |2. Check whether the carburetor] | coe ig insufficient in the crankcase:| [T, Check whether the stating system(iethe starting | |smmed 2. Check whether the oil is || uel switch is in good| thickness system) is in good lover dirt or viscosity is low; || condition; condition; 3.Check whether the oil |]2. Check whether the | 3. Check whether the carburetor] filter is jammed; carburetor float is too float is too low 4. Check whether the oil | | high; | [pump is in good condition; ||3, Check whether there| 5. Check whether the Iubri- | |is jam on the carbure-| cation channel is jammed | |tor jet and channels 1192