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04-27-2017, 04:49 AM | #1 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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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
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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; 04-29-2017 at 12:53 PM. |
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04-27-2017, 05:06 AM | #2 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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You must remove the two bolts from the intake manifold before you can remove the engine from the motorcycle. I suggest removing the MAP/T sensor from the intake maifold before you remove these two bolts.
Removing the MAP/T sensor makes it easier to access the two bolts. Also, while the MAP/T sensor is removed, you should clean it with Mass Airflow Sensor Cleaner. Cleaning this sensor periodically will improve engine performance. http://www.autozone.com/miscellaneou...ner/36011_0_0/
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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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04-27-2017, 08:27 AM | #3 |
Join Date: Sep 2015
Location: Neuquén, Argentina
Posts: 128
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Thank you!
Thank you Spud : another great RX3 maintenance tutorial!
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______________ - ex Honda MB100 (1981) - ex Honda Nighthawk 250 (1991) - ex Honda Storm 125 (2009) - ex Corven Triax 250 Touring (2016) (Zongshen RX3 carb) Benelli TRK 502 (2018) |
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04-27-2017, 08:47 AM | #4 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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De nada, amigo. Thank you for your kind words.
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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; 04-27-2017 at 01:39 PM. |
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04-27-2017, 09:01 AM | #5 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Here is another tip.
The cam sprocket also has a dot in addition to the "L" and "R" markings on the camshaft sprocket. You can see this dot at the 11 o'clock position in the photograph below. When you install the timing chain on the cam shaft, try to place this dot even with the top of the cylinder head on the right/intake side of the cylinder head. When placed in this manner, the "L" and "R" markings will be placed in the correct vertical locations. If you are satisfied with this alignment, you can apply some black RTV silicon to the cylinder head, and begin the final installation of the rocker cover.
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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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04-27-2017, 01:02 PM | #6 |
Join Date: Mar 2009
Location: Sardis, BC, Canada
Posts: 25,977
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Wonderfully comprehensive tutorial! Of course, I focused on how you welded extensions onto the center stand; have you started a thread about your welder?
I also liked the idea of making a board adapter for your floor jack. I'm going to borrow that mod. Have you considered non-stock valves? Perhaps there are stainless valves that would fit this engine.
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Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer |
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04-27-2017, 02:06 PM | #7 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Thank you, Weld.
Regarding the welding, I must confess I got lazy. I should have posted, "I coaxed my good friend Andy to weld some extensions onto the center stand." I will go back and correct my post. I did a little stick welding back in the 90's, but I need to get that Eastwood welder you recommend. The board adapter works very well. It provides a nice, wide and stable platform for lowering, and raising the engine into place. I used it to remove the stock engine, and install a Yamaha XT225 engine in my Zongshen Sierra. The adapter worked equally well with the NC250 engine in my RX3. I have not confirmed any other valves which fit the NC250 engine. Of course, the problem might also reside with the valve seats. So far, the valve clearances are holding. I hope the new valves and cylinder head have solved the problem. Incidentally, I also installed four, new valve springs during this engine work. The cam chain was in very good condition, and did not exhibit any elongation, as the timing marks aligned perfectly.
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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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04-27-2017, 02:29 PM | #8 |
Join Date: Oct 2015
Location: FL, GA, NC
Posts: 771
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Thanks for the detailed procedure.
I suspect the intake valves on my RX3 have done the same as yours.....(12.5k miles). .....the clearances went to zero within 1,000 miles. Yet, the most recent check revealed the intakes increased by .002". Is there a way to determine if the valves have receded into the head without disassembling the engine? Most importantly, what are the options for those of us that don't have the time, skill, tools, work space, or inclination to perform the task? Has anyone had CSC successfully find them a local mechanic to perform major repairs? jb
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2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........ |
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04-27-2017, 03:17 PM | #9 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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You're welcome, JB.
Quote:
I suggest you talk to Gerry at CSC and tell him your maintenance record of how often you did each valve lash check, and the required adjustments. As with me, he might tell you to have a leak down test performed. I bought an OTC 5609, Cylinder Leakage Tester Kit, shown in the link below. It does an excellent job, and I highly recommend it. http://www.tooltopia.com/otc-tools-5...FQsuaQodCX8J6g However, be forewarned. Even if your engine passes a leak down test, you still might have valve recession. My cylinder did not leak, but the valve recession was obvious from a visual inspection. Once again, I would call Gerry at CSC and ask for his advice. If you, or anyone else has this problem, he should try to resolve the issue before his warranty expires. That is why I talked to Gerry several times about this problem, and performed a leak down test last fall. This gave me enough time to get authorization to tear down the engine, find the problem, and fix the problem before my warranty coverage expired. Based upon my experience with this problem, I decided to post this thread as a service to the RX3 community.
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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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04-27-2017, 06:35 PM | #10 | ||
Join Date: Oct 2015
Location: FL, GA, NC
Posts: 771
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Quote:
I tried to use my borescope to no avail.....sparkplug hole too small for access. Got a better view with a LED flashlight and eyeballs. Quote:
And an asset to CSC.....you should be on the payroll.... However, I would wager that when buyers signed up for a "user maintained" motorcycle, they didn't think that included removing the engine, and rebuilding the top end. jb
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2016 Honda CB500F......2017 Triumph Street Twin 2014 XT 250........ |
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04-27-2017, 08:25 PM | #11 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
I'm hoping my experience with this valve recession is a rare occurrence. However, when you mentioned your valve clearances had not stabilized, I felt a moral obligation to warn you, and others, of the possibilities. I think you might be having other engine problems. I also believe you have some time left on your warranty. I suggest you contact CSC and ask them to help you resolve these issues. If you were nearby, I would certainly help you with the engine work myself. Unfortunately, you live about as far away from Idaho as possible.
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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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04-27-2017, 02:44 PM | #12 |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,084
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Great write-up Spud! Excellent and complete, as always.
I remember back in the 70's, when unleaded fuel first came out, it was eating up the valve seats and the manufacturers had to go to hardened valve seats. I wonder if this is what's happening here? Did the old valves look worn or just the seats?
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-27-2017, 03:23 PM | #13 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
Since the valve recession was obvious, I didn't remove any of the valves for inspection. I wanted to ship the untampered cylinder head to Gerry for his inspection. I also didn't care to do the extra work. Is unleaded fuel required in China? I don't know. If the Chinese are still using leaded fuel, you might very well be correct. I remember reading somewhere that the Italian company, Piaggio, designed the NC250 engine. I suspect the Italians designed the engine for use with unleaded fuel. I'm hoping my experience with this problem is a rare exception. However, I felt an obligation to warn others who might be experiencing the same problem.
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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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04-28-2017, 10:49 AM | #14 | |
Join Date: Mar 2010
Location: Volcano, Ca
Posts: 7,084
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Quote:
Now....I've never been one to believe in "Miracle in a Can", but I've been running that Lucas fuel treatment that CSC recommended for break in.....just because they recommended it for break-in. Do you think this stuff really does any good and also, have you been running it in your RX3? Here's a quote from the Lucas website. "Lucas Fuel Treatment should definitely be used in vehicles that require leaded fuel because it actually replaces the benefits of lead in gasoline...." Makes ya wonder.
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"Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350 |
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04-28-2017, 01:55 PM | #15 | ||
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
Quote:
https://www.walmart.com/ip/Lucas-Oil...ingMethod=p13n Thanks for raising this issue, 2LZ. I am going to do some research on this topic, and start a new thread regarding it. I also seem to remember that HumanBeing reported the fuel in China is terrible. If so, one would think that any possible valve face/seat defects would be causing a lot of problems for Chinese owners of the RX3.
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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; 04-28-2017 at 02:35 PM. |
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