12-02-2015, 09:02 PM | #1 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Zongshen RX3: Engine Cooling System
Overview
The engine cooling system employs antifreeze and mechanical components which work together to prevent engine overheating, and which optimize engine performance. The engine cooling system is comprised of the following components. Radiator Cap Radiators Coolant Overflow Bottle Water Pump Hoses Radiator Fans Thermal Switch Thermostat Engine/Coolant Temperature Sensor Coolant
__________________
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; 12-08-2015 at 02:33 PM. |
|
12-02-2015, 10:45 PM | #2 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Radiator Cap
The radiator cap is a pressure relief valve. The engine cooling system is a closed system. As the engine transfers heat to the antifreeze the coolant expands, creating water pressure in the system. When the water pressure reaches 16 psi (1.1 Bar), the radiator cap protects the system by venting coolant into an overflow bottle to reduce excess pressure. At the same time the radiator cap maintains moderate pressure in the closed system to increase the boiling point of the coolant, and to prevent air voids from being introduced to the coolant. When the temperature of the coolant decreases, the pressure in the system also decreases. At this point the radiator cap allows coolant to be drawn from the overflow bottle back into the system. The following video describes how a radiator cap operates.
__________________
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 |
|
12-02-2015, 10:46 PM | #3 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Radiators
The Zongshen RX3 is equipped with two radiators. Each radiator also has a protective grille which directs airflow over the radiator. Never block airflow to the radiators, or you will risk engine overheating, and engine damage.
__________________
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; 12-03-2015 at 12:46 AM. |
|
12-02-2015, 10:47 PM | #4 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Coolant Overflow Bottle
When the radiator cap vents coolant to reduce system pressure in the engine cooling system, the coolant is collected in the overflow bottle. When engine heat is reduced and system pressure decreases, the coolant in the overflow bottle is returned to the radiators. The coolant overflow bottle has markings for minimum and maximum levels of coolant. When the engine is cold, the coolant level in the overflow bottle should reach the minimum mark. When the engine is hot, the coolant level in the overflow bottle should reach the maximum mark. If the coolant level falls below the minimum mark when the engine is cold, you should add more coolant until the level reaches the minimum mark. Maintaining the minimum level of coolant will prevent air voids from forming in the cooling system.
__________________
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 |
|
12-02-2015, 10:54 PM | #5 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Water Pump
The water pump circulates antifreeze throughout the engine cooling system. The RX3 water pump is powered by the engine's counter balancer. In the following image the connection for the water pump shaft on the engine counter balancer is shown inside the red oval. The right end of the counter balancer protrudes through the right crankcase half, where it attaches to the water pump shaft. In the next image the counter balancer connection for the water pump shaft is shown inside the orange oval. The end of the counter balancer is supported in the right crankcase half by a sealed bearing. The water pump shaft is supported inside the right crankcase cover by a bearing, an oil seal, and a water seal. Below is an image of the water pump shaft with its bearing and two seals. Inside the right crankcase cover, the water pump impeller screws onto the end of the water pump shaft.
__________________
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; 12-03-2015 at 04:30 AM. |
|
12-02-2015, 11:00 PM | #6 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Hoses
The radiator hoses are designed to meet specific standards for size, temperature rating, and pressure tolerance. Inspect the hoses regularly for loose connections, cracks, or other defects. Replacement hoses must meet or exceed the original hose specifications.
__________________
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 |
|
12-02-2015, 11:03 PM | #7 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Radiator Fans
The radiator fans dissipate heat by drawing air through the cooling fins of the radiators. The fans are activated by a thermal switch located at the bottom of the left radiator. The switch closes when coolant temperature reaches 82 degrees Celsius.
__________________
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 |
|
12-03-2015, 12:41 AM | #8 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Thermal Switch
The thermal switch is open at room temperature. The switch closes, and activates the fans when the temperature exceeds 82 degrees Celsius. The operating temperature of the fan is inscribed on one face of its hexagonal locking nut.
__________________
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 |
|
12-03-2015, 12:44 AM | #9 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Thermostat
The thermostat is installed inside the thermostat housing, which is located in the radiator hose above the engine. This hose descends and connects with the right side of the engine cylinder. When the engine is cold and coolant temperatures are low, the thermostat remains closed, allowing antifreeze to remain inside the engine. This allows the engine to warm to operating temperatures.
__________________
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 |
|
12-03-2015, 12:44 AM | #10 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Temperature Sensor
This sensor contains a temperature-dependent resistor with a negative temperature coefficient. The temperature sensor is inserted into the thermostat housing.
__________________
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 |
|
12-03-2015, 12:44 AM | #11 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
|
Coolant
The recommended coolant is low-silicon antifreeze which is specifically recommended for aluminum engines. Coolant is drained from the system by removing the bolt with a copper washer, which is located at the bottom of the water pump housing.
__________________
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 |
|
03-10-2017, 02:12 AM | #12 |
Join Date: Jul 2016
Posts: 48
|
Excellent write up.
I have Chinese Cg200 water cooled 163ML. Its mixing oil with water. I resurfaced the head and cylinder using 220,300,400,800 grit papers. Now I need to check water pump if it's leaking. Is there any test one can do on it to see if its leaking water to oil from there? Regards |
|
03-11-2017, 12:29 AM | #13 | |
Join Date: Jul 2015
Location: Milpitas, CA. USA
Posts: 775
|
Quote:
http://i442.photobucket.com/albums/q...psgdtiogez.jpg Good luck. |
|
|
03-18-2017, 01:02 AM | #14 |
Join Date: Feb 2017
Location: Dannevirke, New Zealand
Posts: 47
|
Temperature gauge
Hi there, dumb question time.
Is it normal for the gauge to fluctuate. I suppose I'm used to car gauges which hit the middle of the scale and stay there. On my ride home I had to cross a pretty high pass and one hill in particular was about 5 km long. To climb it I was pegged flat out in fifth the whole way and as I neared the top I could feel the hot air flowing past my legs, then I noticed the gauge was showing four bars not the usual three. At the top of the climb I hooked sixth and in about 30 seconds the gauge dropped back. Today sitting idling while a friend did a slow turn on loose gravel I noticed it head back to four bars, but as soon as we got moving dropped down again. I checked today, the fan wasn't going. I'm guessing that all of this is quite normal and I'm overthinking again but "checking saved many a man money!" |
|
03-18-2017, 02:25 AM | #15 |
Join Date: May 2007
Location: Warshington
Posts: 928
|
Mine does that also on hot rides . I can watch the temp gage go from 3-4 bars going up hills and come back down when going down other side of hill. For piece of mind though remove radiator cap when it's cooled off and see if the coolant level is up to top. It took several refills to get mine topped off when new because of air trapped in the system. rj
__________________
Live Zong, and Prosper |
|
|
|
|
|