Zongshen RX3: Electrical System Maintenance

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Electrical System Maintenance

When working with your motorcycle's electrical system, it is important to observe certain safety precautions to protect both yourself, and the motorcycle.

Battery Maintenance

Do not connect or disconnect any device when current is flowing, otherwise electrical components might be damaged. The RX3 battery is maintenance free (MF). To prolong the life of the battery, never exceed the recommended charging rate.

The RX3 comes equipped with an AGM (Absorbed Glass Mat) battery. The lead plates of this battery are separated by thin sheets of glass fiber impregnated with a solution of water and sulfuric acid. AGM batteries are very safe because they will not leak acid, even if placed upside down, or if the container is broken.

AGM batteries are permanently sealed. The user never needs to add water to the battery. Oxygen and hydrogen produced during battery charging are recombined to produce water, ensuring a very small water loss during the lifetime of the battery.

Your RX3 motorcycle comes equipped with a YTZ12S battery.

Battery Capacity: 11 Ah
210 C.C.A.
Charging Rate: 1.1 amps for 10 hours

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Voltage%20Table_zpsmgacjwu6.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Voltage%20Table_zpsmgacjwu6.jpg.html)

REMOVING/INSTALLING THE BATTERY:

Always verify the ignition switch is in the OFF position before removing or installing the battery cables. Always remove the negative cable (-) first. Do not use tools which might come into contact with the positive (+) terminal and generate short circuits.

When installing the battery, always connect the positive (+) cable first. Make sure both cables are securely attached to the battery.

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Electrical Connections

The electrical system should be inspected periodically to verify proper connections and to watch for corrosion. Owners can check electrical continuity and resistance of electrical components with a digital multimeter.

Wiring Color Code

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Wiring%20Color%20Code_zpsilzrrnoi.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Wiring%20Color%20Code_zpsilzrrnoi.jpg.html)

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Symbol Codes

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/symbol%20codes_zpsvj1thsxe.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/symbol%20codes_zpsvj1thsxe.jpg.html)

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Electrical Charging System

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/charging%20circuit_zps1knc4mcr.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/charging%20circuit_zps1knc4mcr.jpg.html)

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Charging Coil Resistance

The accuracy of a digital multimeter varies by model. Low-end meters are usually accurate within 1 percent of the correct value. The resistance of the charging coil should be from 0.07 to 1.5 ohms.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/charging%20coil%20resistance_zpsxwaknf6y.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/charging%20coil%20resistance_zpsxwaknf6y.jpg.html)

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Charging Voltage

Check the battery before troubleshooting any electrical problem.

Check the charging voltage. Place the multimeter on the 20 DCV scale and connect it to the battery terminals. Start the engine, keeping the idle speed at 1,600 rpm. The charging voltage should be between 13.90 to 14.40 volts.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/battery%20charging%20voltage_zps1pdkmjpc.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/battery%20charging%20voltage_zps1pdkmjpc.jpg.html)

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Charging Current

Verify all electrical accessories are turned off. Start the motorcycle. Verify the idle speed is 1,600 rpms. Set the digital multimeter to measure at least 10 amps of current (10 DCA).

Pull the main fuse and connect the multimeter between the two terminals of the fuse holder. Check the load current at an idle speed of 1,600 rpm. The charging current at 1,600 rpm should be 1.5 to 2.0 amps.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/charging%20current_zpsr5zagqce.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/charging%20current_zpsr5zagqce.jpg.html)

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CSC Cyclone RX3 Light Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/CSC%20Cyclone%20RX3%20Light%20Circuit_zpsotgfts7b. jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/CSC%20Cyclone%20RX3%20Light%20Circuit_zpsotgfts7b. jpg.html)

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Testing Relays and Diodes

Relay: An electrical device which controls a large current by switching an electromagnet.

Electromagnet: An electrical device which magnetizes a iron core by passing a low current through a coil wrapped around the core. The electromagnet can attract a platen to close a switch which completes a circuit passing a higher current.

Diode: Passes a current applied to the anode, but will not pass a current applied to the cathode.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Relay%20and%20LED_zpsbfugq7le.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Relay%20and%20LED_zpsbfugq7le.jpg.html)

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Engine Starting Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Engine%20starting%20circuit_zps5qij22so.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Engine%20starting%20circuit_zps5qij22so.jpg.html)

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Testing the Starter Motor Relay

Verify the relay is wired properly. The cable from the battery must be connected to the relay terminal identified with the letter B (battery). The other terminal identified with the letter M (Motor) should be connected to the cable going to the starter.

The internal resistance of the starter relay should be 4 ohms.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/test%20starter%20motor%20relay_zpscka2m99q.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/test%20starter%20motor%20relay_zpscka2m99q.jpg.htm l)

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Spark Plug

Check the spark plug condition. Check the specification of the spark plug. Verify the spark plug is not damaged.

Measurements

Diameter: 10 mm
Hex Nut Width: 16 mm
Thread Length: 19 mm
Temperature: Mid-range
Flat Electrode
Resistor Plug

Electrode Gap: 0.7 to 0.9 mm

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Turn Signal Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/turn%20signal%20circuit_zpsllsmvx4w.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/turn%20signal%20circuit_zpsllsmvx4w.jpg.html)

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Checking the Signal Flasher

1. Check the flasher cable for input voltage.
2. Check the voltage coming from the flasher to the switches on the gray cable.
3. Check the continuity of the turn signal switches.

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Brake Light Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Brake%20Light%20Circuit_zpsyjbsakdw.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Brake%20Light%20Circuit_zpsyjbsakdw.jpg.html)

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Testing the Rear, Brake Light Switch

Disconnect the cable from the rear, brake light switch. Set the digital multimeter for a continuity test. Connect one probe of the multimeter to the black wire of the plug. Connect the other probe of the multimeter to the green/yellow wire of the plug. Check for continuity by operating the brake pedal.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/test%20rear%20brake%20light%20switch_zpsoivjwhni.j pg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/test%20rear%20brake%20light%20switch_zpsoivjwhni.j pg.html)

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Horn Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/Horn%20circuit_zpsuoxtmyhf.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/Horn%20circuit_zpsuoxtmyhf.jpg.html)

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Fuel Gauge Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/fuel%20gauge%20circuit_zpsan0idaux.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/fuel%20gauge%20circuit_zpsan0idaux.jpg.html)

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Testing the Fuel Gauge Sensor

Disconnect the plug for the fuel tank float. Set the digital multimeter for the 200 ohm range. Connect the multimeter to the sensor terminals. Connect one of the multimeter probes to the yellow/white wire. Connect the other probe to the green wire. The resistance reading for a full tank of fuel is 8 ohms. The resistance reading for an empty tank is 98 ohms.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/testing%20fuel%20gauge%20sensor_zpsojv6mxdz.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/testing%20fuel%20gauge%20sensor_zpsojv6mxdz.jpg.ht ml)

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Gear Indicator Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/gear%20indicator%20circuit_zps0q3yqybf.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/gear%20indicator%20circuit_zps0q3yqybf.jpg.html)

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/gear%20connection%20table_zpshwlmezme.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/gear%20connection%20table_zpshwlmezme.jpg.html)

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Speed Sensor Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/speed%20sensor%20circuit_zps5efcvtim.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/speed%20sensor%20circuit_zps5efcvtim.jpg.html)

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Speed Sensor Check

Disconnect the speedometer sensor. Check the voltage supply of the sensor between the green and black/red cables. The supply voltage is 12 volts.

Reconnect the speedometer sensor. Connect the multimeter into the back of the plug between the brown/white and green wires. Slowly turn the wheel and check the voltage, which should be 9.2 volts. This is the signal voltage to the sensor; it will stop six times for each rotation of the wheel.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/speed%20sensor%20check_zpstezp1fda.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/speed%20sensor%20check_zpstezp1fda.jpg.html)

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Radiator Fan Circuit

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/radiator%20fan%20circuit_zps1ejui5j1.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/radiator%20fan%20circuit_zps1ejui5j1.jpg.html)

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Cooling System Check

When the coolant system reaches its highest temperature, the display will flash. This signals the engine is overheating. Stop as soon as possible, and fix the problem to avoid engine damage.

Check the fan diode.

Turn on the ignition switch. Set the digital multimeter to measure voltage on the 20 VDC Scale.

Check the diode input voltage. Connect the red probe of the multimeter to the black wire of the diode. Connect the black probe of the multimeter either to the green wire, or the chassis. Consult the photograph below to verify the correct placement of the probes. Input voltage to the diode should be 12 volts.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/fan%20diode%20input%20voltage%20check_zpsmxioif8z. jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/fan%20diode%20input%20voltage%20check_zpsmxioif8z. jpg.html)

Check the diode output voltage. Connect the red probe of the multimeter to the black/yellow wire of the diode. Connect the black probe of the multimeter either to the green wire, or the chassis. Consult the photograph below to verify the correct placement of the probes. Output voltage from the diode should be 12 volts.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/fan%20diode%20output%20voltage%20check_zpswewhz2pe .jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/fan%20diode%20output%20voltage%20check_zpswewhz2pe .jpg.html)

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Check the thermal switch for the radiator fans.

The temperature switch is normally open at room temperature. The temperature at which the switch closes is recorded on a side of the hexagonal nut. The closure temperature is 82 degrees Celsius.

To test the switch, remove it from the radiator. Place the switch in a pan of water, and heat the water temperature higher than 82 degrees Celsius. Configure a digital multimeter for a continuity test, and connect the probes to the terminals.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/thermal%20switch%20test_zpsh2rb2yna.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/thermal%20switch%20test_zpsh2rb2yna.jpg.html)

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Radiator Fan Check

Check the resistance of both electric fans. Configure a digital multimeter for a resistance of 200 ohms. Connect the multimeter to the terminals of the electric fan. Resistance should be 4 ohms.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/fan%20resistance%20check_zpsipit7yvp.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/fan%20resistance%20check_zpsipit7yvp.jpg.html)

Check the input voltage to the fans. Configure the multimeter to measure voltage (20 VDC Scale). Disconnect the right electric fan. Connect the red probe of the meter to the black/blue. Connect the black probe of the meter to the green wire. The multimeter should measure 12 volts.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/fan%20input%20voltage%20test_zps3hjkgrtx.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/fan%20input%20voltage%20test_zps3hjkgrtx.jpg.html)

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Engine/Coolant Temperature Sensor

The Engine Control Unit (ECU) of the fuel injection system adjusts the fuel mixture to the engine based upon input from the engine/coolant temperature sensor. This sensor is located in the thermostat housing beneath the fuel tank.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/coolant%20temperature%20sensor_zpsdi9zneeu.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/coolant%20temperature%20sensor_zpsdi9zneeu.jpg.htm l)

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Testing the temperature sensor.

Configure the multimeter to measure ohms (scale 2K). Connect one probe of the multimeter to the electrical terminal of the sensor. Connect the other probe to the sensor body. At a temperature of 20 degrees Celsius, the resistance should be 555 ohms.

Place the temperature sensor in a container of water. Raise the temperature of the water to 82 degrees Celsius. You should obtain a resistance of .056 ohms at 82 degrees Celsius.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/testing%20the%20temperature%20sensor_zpscmgs0r4g.j pg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/testing%20the%20temperature%20sensor_zpscmgs0r4g.j pg.html)

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Thermostat

The thermostat allows coolant to move from the engine through the radiators. The thermostat is installed inside a housing which is placed in the hose which enters the top of the engine.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/thermostat%20housing_zpscokj3dxz.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/thermostat%20housing_zpscokj3dxz.jpg.html)

When the coolant temperature is low, the thermostat valve is closed, keeping the coolant inside the engine. This allows the engine to quickly reach the correct operating temperature during cold weather.

When the coolant temperature rises to 70 degrees Celsius, the thermostat valve opens, allowing the coolant to circulate through the radiators, cooling the engine.

http://i442.photobucket.com/albums/qq146/spudrider/Zong%20Electrical%20System/coolant%20thermostat_zpskoluoeiw.jpg (http://s442.photobucket.com/user/spudrider/media/Zong%20Electrical%20System/coolant%20thermostat_zpskoluoeiw.jpg.html)