ZONGSHEN ZS250GY-3(EFI) User manual

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ZS250GY-3 (EFI)MOTOCYCLE
SERVICE MANUAL
THEFIRSTEDITION(Aug,2013)
Zongshen industrial group reserves allrights of
this service manual.
The specifications and pictures in this manual
areonlyforreference.

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Editor Aug,2013
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INTRODUCTIONS
The manualintruducesthestructure,wokingprinciple,disassemblyandinspection, fault diagnosisandelimination.
Also,this includes technical specifications,performance parameter and maintenance data. Withboththedescriptionsand
pictures, youmay have acomprehensive understandingof theconfiguration as well as theserviceandrepairskill.We hope
it can bring technical support and guide to all the users and after service staffs.
Technical specifications, performance parameter and maintenance data mentioned in manualare base uponthe
latest design features ofyourmotorcycle. Chongqing Zongshen AutomobileIndustryCo.Ltd.reserves therightto make
changes to the specifications of its vehicles withoutnotification. We sincerely hope you can give usyour suggestions
aboutthedesign,manufacture and qualityofthistype ofmotorcycle,so thatwecando theimprovement intime.Thank
you foryour supportand co-operation.
Allthespecifications,diagram, data and performance index in thismanual end intheprint ofthisbook. Our
companyreservestherightto change thebookwithoutany notification.All rights arereserved by Zongshen.Anypeople
orcompanieswon tcopy itif there is no permission.Otherwise,wewillgobehind the criminaland legal responsiblity.
In thisbook we take ZS250GY-3 for example to explain the detail of the disassembly,installation,inspection and
troubleshooting of thisseriesmodels.Due toourlimitedknowledge,it isverypossibletohave mistakesoromissions in
this book.And we welcomeyourcomments.
ChongqingZongshen Automobile Industry Co., Ltd.
Address: CHAOYOUCHANG,BANAN DISTRICT,CHONGQING,CHINA.
Servicehotline:4007003088
For more information, visitour website www:zongshenmotor.com
Zongshen IndustrialGroupareapplying this trademark.

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catalogue
INTRODUCTION
CATALOGUE
CHAPTER 1 GENERAL INFORMATION....................................................................................1
section 1 vehicle introduction.................................................................................................... 1
section 2structure.................................................................................................................... 2
CHAPTER 2MAINTENANCE KNOWLEDGE.............................................................................4
section 1 AttentionItems of Maintenance................................................................................... 4
section 2General knowledge of Maintenance ............................................................................................5
section3 AdjustingData of Maintenance.................................................................................... 8
CHAPTER 3VEHICLE...........................................................................................................10
section 1 Fuel Supply System................................................................................................. 10
section 2 EFI System.............................................................................................................. 13
section 3 Intake and Exhaust system....................................................................................... 20
section 4 Rear Transmission Device........................................................................................ 24
section 5 Frame and Accessories............................................................................................ 28
section 6 SteeringSystem...................................................................................................... 31
section 7 Control Steel Cable................................................................................................... 32
section 8 Shock Absorber....................................................................................................... 33
section 9 RearFork ....................................................................................................................................37
section 10 Wheel.................................................................................................................. 38
section 11 Brake................................................................................................................... 42
section 12 Meter................................................................................................................... 48
CHAPTER4 ELECTRICAL.....................................................................................................50
section 1 Basic Knowledge..................................................................................................... 50
section 2 Power Supply.......................................................................................................... 51
section 3 Control................................................................................................................... 54
section 4 Power Consumption ...................................................................................................................57
CHAPTER 5 TROUBLESHOOTING.........................................................................................60
APPENDIX CIRCUITDIAGRAM..........................................................................................74

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[1]Front fender
[2]Front shockabsorber
[3]Steering
[4]Fueltank
[5]Rear armrest
[6]Frontwheel
[7]Front brake
[8]Gearshiftpedal
[9]Side stand
[10]Rear wheel
[1]Taillight assembly
[2]Muffler
[3]Seat
[4]Ignitionlock
[5]Headlight
[6]Rear brake
[7]Rear pedal
[8]Frontpedal
[9]rear brakepedal
CHAPTER1GENERAL INFORMATION
section 1 vehicleintroduction
ZS250GY-3 is designed for use on road With futuramic appearance and easy operation. It adopt single
cylinder,4-stroke,aircooling engine.Thistype of enginehasthe advantagesofgood cooling,powerfuland
goodacceleration.The frameis pipejointwhichhas hightensityandgoodrigidity.Thebrakesystem
adoptsthecombinationof frontandreardisc sothatit could ensure thestabilization andsafety.Andrim
type wheel has good appearanceandfunctionofanti-abrasion.
FIGURE1-1Left view of motorcycle
FIGURE 1-2 Right view of motorcycle
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1 Riding System
The basic function of riding system:
[1]Make motorcycle in a whole and support whole motorcycle.
[2]Receive thetorque from transmission setup.Providetractionfor motorcyclerunning through thecontact of wheel
androad.
[3]Endure and transmit road function andenduretorquemadebytheoutside force of wheel.
[4]Absorb and handle the strike and shake produced during motorcycle running.
Ridingsystem mainly contains frame assembly,front/rear shock absorber,front/rearwheel andsome other accesories.
2Operationand Brake System
Themainfunction ofoperation systemisto control running direction,running speed,brake,illumination and
signals,andtoensuremotorcycle runningsafety.
Theoperation andbrake systemmainlyconsistsofsteeringsetup,brakesetupandsomerelative controlling
handlebar,controlling switch,steel cable and accessories.
3 Transmission System
Thebasicfunctionof transmission systemis to augmenttorque orreduce transmission speed accordingto the road
conditionand runningneed,After that,to transmitthe resulttodrivewheel andtomake motorcyclerun.
Transmissionsystem mainlyconsistsofstartingdevice,clutch,gearshiftand accessories of reartransmission
device.
[1]Starting Device
Thefunction of starting device is to startengine and to make engineautomaticrunning.The starting device of
motorcycle is dividedinto two modes.One iskick starting,and the other is electric starting.
[2]Clutch
Thefunction of clutch istotransmit or cut off the power fromengine reliablyand softly,and toensuremotorcycle
stable start andgearshift.The clutchof thismotorcycle adoptsautomatic,wet and multiple.
[3]Gearshift
Thefunction of gearshift istochangetherev and drivetorque ofmotorcycle transmissionandtoensureproperpull
andspeed ofmotorcycle,sothat itcan adaptthechangablerunningcondition.The gearshiftof this motorcycle adopts
gradational gearshift.
Chapter 2Structure
Thismotorcycle mainly consists ofridingsystem,operationsystem,brakesystem,transmissionsystem,fuel
supplysystem,electrical system and engine.Refer to Diagram 1-3.
Diagram1-3 structure
[1]Riding system
[2]Electricalsystem
[3]Operationand brake system
[4]Fuel supplysystem
[5]Engine
[6]Transmissionsystem

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The functionofreartransmissiondeviceisto transmitthe enginepower to transmissiondevice,so that
therev is reducedand thetorqueisaugmented.Thentransmitthepowertorearwheeltodrivemotorcycle
run.The transmission of this motorcycle is chain transmission.
[5]Intake and Exhaust System
The function of inletsystem is to guideandfiltrate air,to controlthe volume ofmixedgasflowinginto
cylinderaccording to the needs of working condition.It mainly consists of inletpipeandair cleaner.
The functionof exhaust system is to vent the exhaust gas in cylinder andto reduce the noise during
exhausting.It mainly consistsof exhaust pipe and muffler.
[6]FuelSupplySystem
The functionof fuel-supplyingsystem isto confectclean gas andair intomixedgaswith proper
proportion accordingtotheworkingconditionofengine,andtoofferthe mixed gastimelyand
quantificationally toburning chamber tokeepburning.
The fuel supply system mainly consists of fuel tank,fuel pump,fuel injector,fuel filter and fuel pipe.
4 Electrical System
Thefunctionofelectricalsystemistoofferelectric power to the starting and runningofmotorcycle,and
to send soundor lightsignals so that the runningsafety can be ensured.The electrical system mainly
contains the part ofelectric power supply,electric power consumption andelectric powercontrol.
[1]ElectricSupply
The part ofelectric supply mainly consists of generator and battery.Whengenerator reaches acertain rev
driven by engine,generatorwill export eletric power,which not only offers thepower to electric setup,but also
to thebatteryso that it can becharged.The battery can transfer chemical power to electric power,whichcan
support starting,illumination and signal setup.
[2]ElectricConsumption
The function of electric consumption part is to offer severalkinds of sound or light signals to ensure
running safety,meanwhileitcanstartengineconveniently andfast.Itmainly consists of illuminating
signaldevice and electricstarter device.
[3]Control Part
Thefunctionofcontrolpart is toensureand adjust electric supplyand electricconsumption.It mainly
consistsof ECU,rectifier,starter relay,fuse，control switch andmain wire.
Engineisadevice,whichis tomakefuelburninthecylinderand totransfer heattomechanical power.
it isthe power producer of motocycle.(the maintenance of engineplease refer to theengine service
manual)
5Engine
[4]Rear transmissiondevice