GPX MOTO ZS172FMM-5 User manual

GPX 250e
ZS172FMM-5 (PR250)
Engine
Operation and Maintenance
Manual
Preparation:
Proofreading:
Countersignature:
Review:
Standardization:
Approval:
Chongqing Zongshen Power Machinery Co.

Chapter 1 Main technical parameters and
specifications of the engine
1. Type: Single Cylinder, vertical, air-cooled, four-stroke,
overhead
cam )
b. Maximum torque and corresponding speed N·m/(r/min):
18.0(1±5%)/6000(1±5%)
c. Idle speed (r/min): 1400(1±10%)
d. Minimum fuel consumption rate (g / kWh): 354
3. Main structural parameters:
a. Bore×stroke: 72×61.4mm
b. Total displacement: 249.9mL
c. Compression ratio: 9.2:1
d. Ignition Advance Angle: 15°
e. Lubrication: Pressure Lubrication, Splash Lubrication
f. Valve Clearance (Cold): 0.04mm～0.06mm
g. Igniter Type: CDI
4. Clutch Type: Manual, Wet Multi-disc
5. Gear Change : Constant meshing two-stage transmission six-speed
transmission
Primary reduction ratio: 3.091
Transmission ratio of each gear:
first gear: 2.909 Second gear: 1.786 Third gear: 1.375 Fourth
gear: 1.167 Fifth gear: 0.9
6. Start mode: electric start
7. Spark plug model : Equivalent to D8TC model
8. Fuel and oil:
gasoline grade: ≥RQ90
lubricant grade: Equivalent to SJ10W/40 model (GB 11121-2006)
Lubricant capacity: 1.1L
9. Dimensions: 342×346.5×436mm
10. Net mass: 33.5kg
Chapter 2 Use and Maintenance

1. When the engine is started in a non-neutral gear, the clutch should be fully
disengaged. When starting the engine from cold, close the choke valve and
operate the throttle valve gently to start. After running for 1~3min,
accelerate again.
2. When starting with electricity, the starting time should not exceed 5 seconds
each time, and the interval between restarting should be 10 seconds. If it fails
to start 5 times in a row, check whether there is any fault. After starting the
operation, it is strictly forbidden to press the start button again.
Note: If the battery power is not enough, it can be used after driving for a few
kilometers.
3. After the cold engine is started, the 1to3engine speed should be
gradually increased after
4.of the new machine:very important, if the running-in is not good, the
failure will increase
. (1) During the running-in 0~500 kilometers, the engine should not
be subjected to excessive load, and the throttle should not be
fully opened to avoid using the same gear for a long time. ,
the speed of the vehicle should not exceed30Km/h;
(2) Within 500~1000 kilometers, the engine should not be
subjected to excessive load, the throttle should not be fully
opened, and each gear can only be80%driven at a speedAvoid
using the same gear for a long time, and the vehicle speed
should not exceed50Km/h;
(3) The new engine 500Kmshould be maintainedClearance, clutch
release stroke, etc.
5. Daily maintenance:
(1) After the running-in period, generally replace the lubricating oil after
driving for 2000 kilometers or after each race. If the oil quality changes, it can
be replaced in advance;
(2)Turn the oil dipstick to check the oil level before driving every day, if the
oil level is lower than half of the gaugeadjust
the valve clearance. Generally, the valve clearance has been adjusted when
the engine leaves the factory. When abnormal noise occurs in the cylinder
head, the valve clearance can be adjusted to the specified value: 0.04mm ~
0.06mm;
(4) The carburetor should be cleaned regularly, and necessary inspection and
adjustment should be carried out;
(5) The air filter should be cleaned regularly Inspection and cleaning: first
remove the filter element, if it is a sponge filter element, wash it with
detergent, dry it after washing, and then apply a little oil on the filter element
and install it; if it is a disposable paper filter element, replace it with a new
filter element directly. Yes;

(6) Regularly check and adjust whether the fastening bolts are loose.
6. Idle speed adjustment:
(1) Preheat the engine to the working temperature;
(2) Tighten the idle speed adjustment screw first, and then back it
1.25 turns;
(3) Adjust the throttle stop screw to make the speed reach the
specified idle speed. If the speed is too low, the engine is easy to
stall;
(4) Fine-tune the idle speed adjustment screw left and right, and
fix it at the position of the highest stable speed of the engine;
(5) Then re-adjust the throttle stop screw to make the speed reach
the specified idle speed. ;
(6) Repeat(3),(4)and(5)until the idle speed screw is tightened or
loosened, but the speed does not drop, so far the idle speed
adjustment is completed.
7. The clutch is started in neutral. When the idling is in gear and the flame is
turned off, the clutch adjusting screw needs to be properly tightened.
8. When the clutch is running at idle speed, the noise should be stable and
consistent. When refueling and returning oil, it is normal for the clutch to
make a slight "gig" sound. When the speed is stable, the sound will disappear.
9. The engine model and serial number are printed on the left crankcase (bottom)
where it is easily seen. (See attached drawing 1)
Chapter 3 Engine Trouble Checklist
1、Difficulty starting or unable to start
Troubles
hooting
Cause
Troubleshooting Method
operation
Improper
as required by the manual
supply
system
fuel
the
Operate
Trouble
Fuel accumulated in the
cylinder Exhaust the fuel
air filter in the cylinder is
blocked
Clean the air filter
system air leakage
the carburetor and air filter
connecting
bolts
Tighten
according
to
intake
regulations Carbon
deposits and clean with
gasoline
Spark plug gap
adjustment of the gap

Improper
0.6~0.7mm
Spark plug ablation
Replace
ele
ctr
ica
l
com
pon
ent
s
fau
lty
Ignition coil is
broken Replace
replace the
igniter (CDI) is
broken Replace
replacement
Magneto coil is
broken or solder
joints fall off
Replace or repair welding
lines Or check the circuit
breaker
connect
the air
circuit, the
cylin
der
com
pres
sion
force
is
low,
and
the
plug leaks
Tighten the spark plug
cylinder head or the
joint surface of the
cylinder body
and wipe the plane, install the
gasket, and tighten the
cylinder head nut.
spark
,
,Serious wear of the
cylinder block
Replace the piston ring or
the air leakage of each
joint surface of the
intake pipe of the
Tighten the connecting
bolts The
blocked
Clean the air filter
not
smo
oth
filter is
air
exhaust
The
The valve clearance
adjustment is too large or
too small
. Adjust the clearance
other
with the wrong
Replace the fuels
. 2.engine
fault
clues
Troubleshooting
methods
No idle
speed
improper adjustment
tuning screw
adjust
Re
-
of
carbureto
r
-The spring force of the
carburetor throttle valve is too
spring

small
. The idle speed orifice is too
large.
Replace the carburetor with
unstable
idle speed
ignition timing is incorrect
. Adjust the ignition time as
specified.
mixture is too rich or too lean
.
.
theSpecified value
3. Unstable engine operation
Fault
clues
Troubleshooting
method
The oil
state.
oil circuit
electrica
l
voltage line or the ignition
coil leakage
. Replace the
capacitor with open circuit or
leakage
blocked
Clear
. Engine overheating
fault
clues
Troubleshooting
method
Overload
or high-
speed
long-term
operation
Use low gear or long-term
operation on bad roads
Improve the operation
method or temporarily stop
for a long time with full
throttle operation
Properly adjust the throttle
clutch slip
Adjust the
muffler blockage and
remove carbon deposits
Fuel
system
The
fuel mixture ratio is not
correct
. Adjust the oil pump to
match the carburetor
The mixture is too rich or too
lean
Adjust the carburetor
.stop
clues
causes
methods
troublesh
ooting
Fault
fault
_
_
_
_
_
Engine
automatic
and
ofOr
the cylinder is seized
seriously, the piston is seized,
repair or replace
other mechanical seizures.
After the fault
identified, repair or replace
the
fault
Troubleshooting
methods

clues
6. Clutch fault
fault
clues
Fault cause
troubleshooting method
Clutch
slip
Clutch control system
improper adjustment or
damage
Adjust, repair or replace the
friction plate worn or
damaged
Replace the
spring loss of elasticity or
shorten the size
Replace the
clutch
separatio
n
incomplet
e
separation stroke Improper
adjustment, repair or replace
the
friction platethickness is not
suitable
to replace the
spring with uneven spring
force
Adjust the same set of
springs
7. Shifting and shifting are not working
clues
Troubleshooting
methods
Can't
hang up
The shift
fork is broken or deformed
Replace the shift fork
shift hook or shift shaft
assembly is broken or
deformed
the
difficulty
Replace
fault
shiftingInconsistent operation
Improve the operation
shift hook is worn or eccentric
Replace the
cam groove or pin is worn
the
self-
shedding
gear contact claw or hole wear
Replace the gear
limit fast
gear
cylinder
ReplaceShift Fork
Attachment
Chapter 4 Ignition Circuit Diagram of

1