05-27-2016, 09:03 PM | #106 |
Join Date: Feb 2016
Location: Portsmouth, Virginia, USA
Posts: 632
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Ask Luke to take a look at the water pump housing. It seems to me that if the OEM snout is too thin there must be a way to cast a snout with a built in bypass. He's an engineer so he can come up with a solution for us.
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05-27-2016, 10:41 PM | #107 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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I hope you soon feel well, mate.
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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; 05-28-2016 at 12:30 AM. |
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05-28-2016, 12:16 AM | #108 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
Here is a flash photograph which shows the flat, thick, reinforced area of the housing. We would tap into this area on the opposite side of the housing. The following photographs show the intersection of the coolant inlet with the hub of the water pump housing. We would tap into the coolant inlet about one inch upstream of the hub. Besides the spare, water pump housing, I also have an M10-1.0 tap. We can screw one of these M10-1.0 fittings with a 3/8" hose barb into the water pump housing. http://www.ebay.com/itm/Black-3-8-ba...mtr&rmvSB=true We can remove the temperature probe for the digitial display from the top of the thermostat housing, and install one of the M10-1.10 fittings with a 3/8" hose barb. The bypass will run from the top of the thermostat housing to the water pump housing. We can move the temperature probe for the digital display into one of the Koso BG018B01, Water Temperature Sensor Adapters (18mm), which we would insert into the hose running from the cylinder head to the thermostat housing. http://www.ebay.com/itm/Koso-North-A...037?rmvSB=true Here is a diagram of the proposed system.
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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 |
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05-28-2016, 12:30 AM | #109 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Finally, we would remove the stock thermostat, and install one of the spare, Thermo-Bob 3 (TB3) thermostats, which has a higher opening temperature.
The temperature probe for the digital display might not be completely accurate while the thermostat is closed, and the engine is warming up. However, it would be accurate once the thermostat has opened, and the engine has reached operating temperature. This is the only time I am interested in the temperature display, so it is completely acceptable to me. Here are the approximate costs for the required parts. Thermo-Bob 3 (TB3) spare thermometer: $19.00 plus shipping cost 2 M10-1.0 hose barbs: $10.58 2 feet of 3/8" heater hose: $2.00 2 3/8" hose clamps: $0.75 Koso BG018B01, Water Temperature Sensor Adapter (18mm): $25.90 The total cost for the system would be approximately $65 USD.
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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; 05-28-2016 at 01:49 AM. |
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05-28-2016, 12:45 AM | #110 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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The following, radiator fan switch is equivalent to the switch employed by the Zongshen RX3. This switch is designed for the following Suzuki and Kawasaki motorcycles.
Suzuki GSX-R600 97-05 GSX-R750 96-08 VL/VZ800 01-11 DL1000 V-Strom 03-09 GSX-R1000 01-04 SV1000 03-07 TL1000R/S 98-03 GSX-R1300 “Hayabusa” 99-07 Kawasaki Ninja ZX-6R 2003-2004 ZX636 2003-2004 ZX600 2003-2004 http://www.ebay.com/sch/i.html?_from...witch&_sacat=0 I have one of these spare switches, which closes at 85 degrees Celsius. Juano has reported some of the RX3 bikes in Argentina have fan switches which close at 93 degrees Celsius. Therefore, we should be able to experiment with fan switches which operate at different temperatures.
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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; 05-28-2016 at 02:53 AM. |
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05-28-2016, 02:02 AM | #111 |
Join Date: Sep 2014
Location: Arvada, CO
Posts: 1,004
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As I understand it, the bypass need to be smaller than the regular hose so that coolant will continue to pass through the radiators. The bypass will be a 3/8" hose, right? What is the size of the radiator hoses?
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Red 5 standing by! 2015 CSC red RX3 with 19" front wheel, Shinko 804/805, skid plate, tall seat, 13T/45T sprockets, progressive shock, Winyoochanok windshield, GENSSI LED headlight, SW-Motech tankbag, Shorai Lithium battery 2014 Ural Patrol |
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05-28-2016, 02:07 AM | #112 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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The regular hoses are 3/4-inch in diameter. Watt-Man recommended a 3/8-inch hose for the bypass; see post #92 of this thread.
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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 |
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05-28-2016, 02:26 AM | #113 |
Join Date: Sep 2014
Location: Arvada, CO
Posts: 1,004
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I have another question about what could result from this mod.
The mod should result in faster warm-up and reduce hot/cold spots around the cylinder. And raising the crankcase oil temp will also more quickly evaporate fuel, water and contaminants, reducing the amount of fuel in the oil. My question is this. We already collect a lot of fluid in the OCS. How do we keep the extra gases from condensing in the OCS catch tube and ensure that they are drawn up into the airbox instead?
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Red 5 standing by! 2015 CSC red RX3 with 19" front wheel, Shinko 804/805, skid plate, tall seat, 13T/45T sprockets, progressive shock, Winyoochanok windshield, GENSSI LED headlight, SW-Motech tankbag, Shorai Lithium battery 2014 Ural Patrol |
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05-28-2016, 02:37 AM | #114 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
As a secondary solution, I am going to replace the plug in the collection tube of the OCS with a bolt which is slightly loose. Before the collection tube of my OCS shrunk in size, it would slowly leak the collected fluid. I wish to reproduce that slow leak, so I don't have to check the tube all the time. Ron_B in Alabama has added a fuel petcock to the bottom of his collection tube. http://www.chinariders.net/showthrea...t=16492&page=4
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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 |
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05-28-2016, 06:57 AM | #115 |
Join Date: Feb 2016
Location: Maryland
Posts: 213
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Peter, Spud...
Luke said you guys nailed it with most of your recommendations. Luke thinks changing the thermo switch out is the easiest fix. He thinks because the aluminum engine is not getting hot enough, that is the cause to a lot of the issues. Especially the fuel in the oil. He says on Monday we should be doing the first 500 mile valve check and service, so he will have a better look at everything discussed here and follow up with a post. and yes Spud, I convinced him to start his own profile! |
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05-28-2016, 09:08 AM | #116 | |
Join Date: Sep 2015
Location: East Central Hellinois
Posts: 1,344
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Quote:
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************************************************** *** " Time you enjoy wasting, is not wasted." - John Lennon “I predict future happiness for Americans, if they can prevent the government from wasting the labors of the people under the pretense of taking care of them.” ― Thomas Jefferson "If you don't know where you're going any road will take you there" ....George Harrison song |
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05-28-2016, 10:38 AM | #117 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Alternatively, we could also tap the bottom of the right radiator, above the outlet pipe. We also still have the option to install one of the Revloc (SST8K), self-sealing fittings into the radiator hose.
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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 |
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05-28-2016, 11:06 AM | #118 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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I'm pretty sure he will be testing things, but I will let him speak for himself. I don't know his plans regarding a Thermo-Bob 3 (TB3) thermostat, et cetera.
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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 |
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05-28-2016, 03:59 PM | #119 |
Join Date: Sep 2015
Location: East Central Hellinois
Posts: 1,344
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Cool - again . . . . great work to all those who have been kicking in with ideas and expertise
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************************************************** *** " Time you enjoy wasting, is not wasted." - John Lennon “I predict future happiness for Americans, if they can prevent the government from wasting the labors of the people under the pretense of taking care of them.” ― Thomas Jefferson "If you don't know where you're going any road will take you there" ....George Harrison song |
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05-28-2016, 07:21 PM | #120 |
Join Date: Oct 2015
Location: vermont
Posts: 238
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I am not an engine designer nor do i play one on tv but i wonder about making a small engine run hotter I worked on diesels for more years than i would like to remember it was not uncommon for a cat 3406 to go 500 thou. miles unless the owner started messing with injector pump granted it will have more power but the trade off was engine rebuild before it's time i bet Zongshend spent time and money finding were this little 250 likes to run just putting my 2cents in i do believe the fuel in the catch tube is because of engine running "cold" but for now i think i will just drain it
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Peace and Zong Life
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