ChinaRiders Forums - View Single Post - RX3: Engine Top End Rebuild at 22,450 Miles

SpudRider · 04-27-2017, 04:49 AM

Installation of RX3 Engine in Motorcycle

Install Engine in Motorcycle

Place Hydraulic jack under Engine
Raise engine into frame
Install swingarm bolt
Install both bolts at rear of engine
Install upper bolts connecting rocker cover to engine frame
Install the two bolts connecting the intake manifold to the cylinder head

Install Clutch Cable, Shift Lever and Hoses from Engine

Install Clutch Cable to Left Crankcase Cover
Install the Oil Contaminant Separator (OCS) on Engine
Install Shift Lever

Install Electrical Connections to Engine

Connect power wire to starter motor
Connect Ground Wire
Connect stator and pickup coil wires
Connect gear indicator wire
Install MAP/MAT Sensor to Intake Manifold
Install Ignition Coil to Frame
Install Spark Plug Boot onto Spark Plug

Install Left Radiator

Install upper hose from Thermostat Housing
Connect fan electrical wire to wiring harness

Install Right Radiator

Install lower hose from water pump on right radiator
Install upper hose to right radiator
Connect fan electrical wire to wiring harness
Install hose from Thermostat Housing to Cylinder Head
Fill radiators with coolant

Install Exhaust Header and Perimeter Engine Bracket

Install lower engine bolt of perimeter engine bracket
Install Radiator Mounting Wings and both top bolts of perimeter engine bracket
Install two bolts on rear of perimeter engine bracket
Install upper engine bolt of perimeter engine bracket

Install Exhaust Header

Install both bolts for both radiators
Install rear brake pedal
Connect wires for auxiliary lights on perimeter engine bracket

Install Fuel Tank

Install fuel tank
Install upper engine guard and connect wires to auxiliary lights
Install fuel tank fairings
Install plastic side covers
Install main saddle
Install pillion saddle

Install Progressive Shock Linkage and Rear Tire

Remove Swingarm Bolt

Install shock link on engine frame
Install Drive Chain on Counter Shaft, and install Swingarm

Install the shock absorber into the frame with the upper bolt

Install the rocker arm onto the swingarm, and torque bolt to 38 foot-pounds

Install Lower Shock Bolt into rocker arm, and torque to 33 foot-pounds

Install rear bolt to link/dogbone, and torque to 38 foot-pounds
Install rear brake caliper onto swingarm
Install Rear Wheel

Replace Motor Oil and Engine Coolant

Install Engine Coolant
Fill Engine with 1.7 Quarts of Motor Oil

04-27-2017, 04:49 AM	#13
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Installation of RX3 Engine in Motorcycle Install Engine in Motorcycle Place Hydraulic jack under Engine Raise engine into frame Install swingarm bolt Install both bolts at rear of engine Install upper bolts connecting rocker cover to engine frame Install the two bolts connecting the intake manifold to the cylinder head Install Clutch Cable, Shift Lever and Hoses from Engine Install Clutch Cable to Left Crankcase Cover Install the Oil Contaminant Separator (OCS) on Engine Install Shift Lever Install Electrical Connections to Engine Connect power wire to starter motor Connect Ground Wire Connect stator and pickup coil wires Connect gear indicator wire Install MAP/MAT Sensor to Intake Manifold Install Ignition Coil to Frame Install Spark Plug Boot onto Spark Plug Install Left Radiator Install upper hose from Thermostat Housing Connect fan electrical wire to wiring harness Install Right Radiator Install lower hose from water pump on right radiator Install upper hose to right radiator Connect fan electrical wire to wiring harness Install hose from Thermostat Housing to Cylinder Head Fill radiators with coolant Install Exhaust Header and Perimeter Engine Bracket Install lower engine bolt of perimeter engine bracket Install Radiator Mounting Wings and both top bolts of perimeter engine bracket Install two bolts on rear of perimeter engine bracket Install upper engine bolt of perimeter engine bracket Install Exhaust Header Install both bolts for both radiators Install rear brake pedal Connect wires for auxiliary lights on perimeter engine bracket Install Fuel Tank Install fuel tank Install upper engine guard and connect wires to auxiliary lights Install fuel tank fairings Install plastic side covers Install main saddle Install pillion saddle Install Progressive Shock Linkage and Rear Tire Remove Swingarm Bolt Install shock link on engine frame Install Drive Chain on Counter Shaft, and install Swingarm Install the shock absorber into the frame with the upper bolt Install the rocker arm onto the swingarm, and torque bolt to 38 foot-pounds Install Lower Shock Bolt into rocker arm, and torque to 33 foot-pounds Install rear bolt to link/dogbone, and torque to 38 foot-pounds Install rear brake caliper onto swingarm Install Rear Wheel Replace Motor Oil and Engine Coolant Install Engine Coolant Fill Engine with 1.7 Quarts of Motor Oil __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894 Last edited by SpudRider; 04-29-2017 at 12:53 PM.
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