DB-07A/RSX 200E Assembly Help

Matnique · 09-07-2007, 05:55 PM

Just unpacked my new bike from its crate. I am desperately trying to make sense of the installation manual. I have problems with the rear shock/swing arm assembly. How did you manage this seemingly unsurmountable task? There is no apparent play in the shocks so I am not able to match it to the swing arm to place the bolt and join them together. As this is the first step, my installation is now stalled. I would greatly, greatly appreciate any help with installation tips and procedures. My manual does not really do it for me. How did you keep the bike up during installation? Help!

bronevaya · 09-07-2007, 06:01 PM

drop the rear tire, as in, set the bike up on something, supporting it in the middle, like a milk crate or some sort of small chair. with the rear wheel hanging, move the swing arm and secure the bolt.

culcune · 09-07-2007, 06:02 PM

A member, (alchemy541)who has not been active in a long while, used straps from his ceiling.

http://www.chinariders.net/gallery2/...g2_itemId=1796

Matnique · 09-07-2007, 09:05 PM

Yeah, the milk crate in the middle handled it, thanks. I was able to secure the swing arm to the shocks. Next step was the front tire install. Okay, seems like a straightforward thing; however, the disc pads didn't want to remain open. I had already put in the handlebars, the odometer, ignition, choke and the front signal lights (haven't found where you plug the wires for these). Now I have to raise the front about 10" to slide in the front tire and bolt them in with the speedometer disc. How would you release the disc pads so that there is room for the metal disc to slide in? And how do you raise the front end to the necessary height to bolt the tire in? I'm totally new to this and so I am needing any tips and know-how from you guys who have successfully completed your assembly.

ob1 · 09-07-2007, 09:13 PM

Stick a flat screwdriver in between the pads and twist, do it at both ends.

Not knowing your exact front end assy...

Start the axle through the fork, and push enough through to hold the spacer. put the wheel into position with the brake disc in the caliper, then push the axle through the wheel. Put the other spacer in, then push through. look at the wheel alignment to the other fork, align, push, and bolt it in.

Matnique · 09-07-2007, 11:10 PM

You've got to love this forum. Problem handled. Thanks a bunch.

madmaximum · 09-08-2007, 12:48 AM

I have that same bike, so a few tips.
Check the fuel line to make sure it isn't too long & pinched shut. Check EVERY nut & bolt you can see to make sure they are tight. Then dig for the ones you can't see. I know most folks on here are fans of loctite, but I will admit that I have not used any. After 3500 miles I had one screw fall out on me, & that was on the chrome shield covering the exhaust above the clutch arm.
Get yourself a cable luber and shoot those cables up.
Change out the stock tubes with HD ones, my rear one let go on the first ride.
Watch the kickstand, mine had to be rewelded .
Use some material from the packing crate to reinforce the battery box, it's going to break.
There is a sticky thread that covers all this & much more on the setup of these bikes. Go thru that and you should be ok. If you have more questions there are a lot of good people on here to help out.
Good luck & enjoy your new bike!

Matnique · 09-08-2007, 06:50 PM

I'm not quite there yet. What is that small rubber tube that says ventilation tube, do not touch? I tried to fire the bike up. No go. It wouldn't turn over. It would when I give it some throttle; however, it idles very low and stalls after a while. Idle speed is an issue. Or perhaps I would need to ride the bike some to get it real warmed up, I don't know. It is just stalling and is hard to start for now. A dissapointment but I'm sure there is a remedy, I just don't know yet.

ridgerunner · 09-08-2007, 07:23 PM

Have you done the carb adjustment like in the ds prep thread? Move the clip on the needle and all that jazz.
http://www.chinariders.net/modules.p...showpage&pid=3
Here's the link to explain it better than I did.

stixx3969 · 09-10-2007, 09:37 PM

Check your plug wire and make sure it is secure in the clip on the cylinder head. If not it may lay on the exhaust and melt through.

Matnique · 09-10-2007, 10:56 PM

Plug? Which plug? I see a thin tube marked ventilation which appears to belong somewhere but it seems to be just hanging with no place to go. Is that what you're referring to?

madmanjustice · 09-10-2007, 11:55 PM

Quote:

Originally Posted by Matnique

Plug? Which plug? I see a thin tube marked ventilation which appears to belong somewhere but it seems to be just hanging with no place to go. Is that what you're referring to?

Spark plug.

IronFist · 09-11-2007, 04:27 AM

Matnique, I am very new too. I found that posting pics of what I need help with has worked. When people see the tube you're talking about they know exactly what you're talking about. Can you embed pics, or have you started an album? Do you have a camara?

madmaximum · 09-11-2007, 07:07 AM

That tube is most likely the crankcase vent tube. It doesn't connect to anything, it is supposed to just hang down.

09-07-2007, 05:55 PM	#1
Matnique Join Date: Aug 2007 Location: Union, NJ Posts: 27	DB-07A/RSX 200E Assembly Help Just unpacked my new bike from its crate. I am desperately trying to make sense of the installation manual. I have problems with the rear shock/swing arm assembly. How did you manage this seemingly unsurmountable task? There is no apparent play in the shocks so I am not able to match it to the swing arm to place the bolt and join them together. As this is the first step, my installation is now stalled. I would greatly, greatly appreciate any help with installation tips and procedures. My manual does not really do it for me. How did you keep the bike up during installation? Help!
	0

09-07-2007, 06:02 PM	#3
culcune Join Date: May 2006 Location: Yuma, Arizona Posts: 9,035	A member, (alchemy541)who has not been active in a long while, used straps from his ceiling. http://www.chinariders.net/gallery2/...g2_itemId=1796 __________________ "They say that life's a carousel, spinning fast you got to ride it well..." TGB Delivery Scooter 150 TMEC 200 Enduro--carcass is sadly rotting in the backyard
	0

09-08-2007, 12:48 AM	#7
madmaximum Join Date: Jan 2007 Location: Central PA Posts: 284	I have that same bike, so a few tips. Check the fuel line to make sure it isn't too long & pinched shut. Check EVERY nut & bolt you can see to make sure they are tight. Then dig for the ones you can't see. I know most folks on here are fans of loctite, but I will admit that I have not used any. After 3500 miles I had one screw fall out on me, & that was on the chrome shield covering the exhaust above the clutch arm. Get yourself a cable luber and shoot those cables up. Change out the stock tubes with HD ones, my rear one let go on the first ride. Watch the kickstand, mine had to be rewelded . Use some material from the packing crate to reinforce the battery box, it's going to break. There is a sticky thread that covers all this & much more on the setup of these bikes. Go thru that and you should be ok. If you have more questions there are a lot of good people on here to help out. Good luck & enjoy your new bike! __________________ 2005 RSX-200E 2004 Suzuki Eiger 1999 Arctic Cat 250 1977 Kawasaki KH400, aka Green Ripper
	0

09-08-2007, 07:23 PM	#9
ridgerunner Join Date: Jun 2007 Location: Fairbury, IL Posts: 63	carb adjustment Have you done the carb adjustment like in the ds prep thread? Move the clip on the needle and all that jazz. http://www.chinariders.net/modules.p...showpage&pid=3 Here's the link to explain it better than I did.
	0

09-10-2007, 09:37 PM	#10
stixx3969 Join Date: Jul 2006 Posts: 146	One more thing Check your plug wire and make sure it is secure in the clip on the cylinder head. If not it may lay on the exhaust and melt through.
	0

09-07-2007, 06:01 PM	#2
bronevaya Join Date: Jun 2007 Posts: 162	drop the rear tire, as in, set the bike up on something, supporting it in the middle, like a milk crate or some sort of small chair. with the rear wheel hanging, move the swing arm and secure the bolt.
	0

09-07-2007, 09:05 PM	#4
Matnique Join Date: Aug 2007 Location: Union, NJ Posts: 27	Yeah, the milk crate in the middle handled it, thanks. I was able to secure the swing arm to the shocks. Next step was the front tire install. Okay, seems like a straightforward thing; however, the disc pads didn't want to remain open. I had already put in the handlebars, the odometer, ignition, choke and the front signal lights (haven't found where you plug the wires for these). Now I have to raise the front about 10" to slide in the front tire and bolt them in with the speedometer disc. How would you release the disc pads so that there is room for the metal disc to slide in? And how do you raise the front end to the necessary height to bolt the tire in? I'm totally new to this and so I am needing any tips and know-how from you guys who have successfully completed your assembly.
	0

09-07-2007, 09:13 PM	#5
ob1 Join Date: Jul 2006 Posts: 499	Stick a flat screwdriver in between the pads and twist, do it at both ends. Not knowing your exact front end assy... Start the axle through the fork, and push enough through to hold the spacer. put the wheel into position with the brake disc in the caliper, then push the axle through the wheel. Put the other spacer in, then push through. look at the wheel alignment to the other fork, align, push, and bolt it in.
	0

09-07-2007, 11:10 PM	#6
Matnique Join Date: Aug 2007 Location: Union, NJ Posts: 27	You've got to love this forum. Problem handled. Thanks a bunch.
	0

09-08-2007, 06:50 PM	#8
Matnique Join Date: Aug 2007 Location: Union, NJ Posts: 27	I'm not quite there yet. What is that small rubber tube that says ventilation tube, do not touch? I tried to fire the bike up. No go. It wouldn't turn over. It would when I give it some throttle; however, it idles very low and stalls after a while. Idle speed is an issue. Or perhaps I would need to ride the bike some to get it real warmed up, I don't know. It is just stalling and is hard to start for now. A dissapointment but I'm sure there is a remedy, I just don't know yet.
	0

09-10-2007, 10:56 PM	#11
Matnique Join Date: Aug 2007 Location: Union, NJ Posts: 27	Plug? Which plug? I see a thin tube marked ventilation which appears to belong somewhere but it seems to be just hanging with no place to go. Is that what you're referring to?
	0

09-11-2007, 04:27 AM	#13
IronFist Join Date: Apr 2007 Location: Toronto Ontario Canada Posts: 2,585	Matnique, I am very new too. I found that posting pics of what I need help with has worked. When people see the tube you're talking about they know exactly what you're talking about. Can you embed pics, or have you started an album? Do you have a camara?
	0

09-11-2007, 07:07 AM	#14
madmaximum Join Date: Jan 2007 Location: Central PA Posts: 284	That tube is most likely the crankcase vent tube. It doesn't connect to anything, it is supposed to just hang down. __________________ 2005 RSX-200E 2004 Suzuki Eiger 1999 Arctic Cat 250 1977 Kawasaki KH400, aka Green Ripper
	0