Help me understand horizontal E-start 125 ignition system

Tranberg · 03-08-2016, 01:22 PM

Edit: Question about air filter in ths post: http://chinariders.net/showpost.php?...72&postcount=8

Hello all

Please point me in the right direction to understand the ignition system on Zongshen 125 horizontal engine with E-start.

I've bought a non-running Zongshen ZS125-47 underbone with 200km on the odometer.

The seller already replaced the CDI unit, which plugs into a 5-core cable, that ends in a gear indicator switch on the motor. ???
I bought a new ignition coil, but that didn't change anything.

All the wiring connectors are sloppy, and I plan to solder the wires instead.

When wiggling the connectors, the indicated gear lamps change between neutral, 4 and dimly 3.

Tranberg · 03-08-2016, 02:46 PM

I suspect that the electrical terminals were torn out of the housings and put incorrectly together by the dreaded previous owner.

humanbeing · 03-08-2016, 04:26 PM

Quote:

Originally Posted by Tranberg

The seller already replaced the CDI unit, which plugs into a 5-core cable, that ends in a gear indicator switch on the motor. ???....

Holy CRAP!!!
AC-CDI

DC-CDI

===
http://www.dansmc.com/electricaltesting.htm | http://fanyi.baidu.com/transpage?que...to=en&render=1 | http://fanyi.baidu.com/transpage?que...to=en&render=1
===
Wiring diagram http://pan.baidu.com/s/1gdS4vWB (stolen from ISBN: 9787115143907)

Tranberg · 03-08-2016, 05:21 PM

Thanks a bunch.
Meanwhile I found a picture on T-BoltUSA, where they specifically warn you that the gear indicator plug fits into the CDI socket.

It COULD be a cover-up to mask that the engine is blown after only 200 km.

Worst case, an engine is only $360, I paid $370 for the bike.

I think I will have it running by tomorrow!

EDIT: I see that the ZS125-47 wiring diagram shows a 4-wire "DC-CDI", but mine has the black/red wire from the stator like shown in diagrams for 5-wire A/C-CDI from T-BoltUSA

humanbeing · 03-08-2016, 07:33 PM

Horizontal chonda AC-CDi had 2 types.
smaller: 嘉陵70 (CD70 clone) | bigger: 大阳100 (C100 clone)

Weldangrind · 03-09-2016, 10:35 AM

I doubt that the motor is blown. It's more likely that the valves aren't set properly, and the PO didn't understand how to adjust them (or even think of it).

Tranberg · 03-09-2016, 12:10 PM

It's alive!
All I had to to was to switch the connectors.
The green plug from the gear indicator goes to the beige socket of the wiring harness, and the beige plug from the motor goes to the green socket of the CDI.
It fired up, but I had to give full choke.

I plugged off the large intake spigot on the exhaust air injection thingy, which had no hose on it, and then I could adjust a decent idle.

The clutch didn't release by pressing the gear lever, so I turned out the adjustment screw until it did. What's the correct procedure? Neutral is hard to find when the clutch works, otherwise not.

I got a late start, because the guy who owns the place where I unloaded it and locked it away for the night was in a bad mood, and didn't get up before 1 PM.

Tomorrow I will get it licensed, I only have to go ½ mile and pay $125.

Tranberg · 03-10-2016, 03:35 PM

Today I got it licensed so I could ride it legally. Highest recorded speed by Endomondo on my Iphone was 88 kph/55MPH

I think it's running lean at WOT, but cleaning the carb and raising the needle all the way helped a lot at intermediate throttle openings.

I closed the four ½" holes some precious owner made in the air filter box, which only contained a flat metal plate with a metal screen.

QUESTION: Where can I find a service manual for this Zongshen ZS125-47, to determine how the filter is supposed to look?

I've found the airbox on TaoBao, but what's supposed to be inside? http://sea.taobao.com/item/en/40788633962.htm
This sponge? http://sea.taobao.com/item/40818127787.htm

humanbeing · 03-10-2016, 05:22 PM

Quote:

Originally Posted by Tranberg

... Where can I find a service manual for this Zongshen ZS125-47, to determine how the filter is supposed to look?

I've found the airbox on TaoBao, but what's supposed to be inside? http://sea.taobao.com/item/en/40788633962.htm...

Closet Honda of that style (泰本田 thai Honda) sold in EU is ANF125 (carb version) https://en.wikipedia.org/wiki/Honda_Wave_series
http://www.bike-parts-honda.com/iden...t_n_chassis_2=
The Honda are supposed like http://item.taobao.com/item.htm?id=43230548371
Chinese version often use washable "foam" instead

03-08-2016, 01:22 PM	#1
Tranberg Join Date: Feb 2016 Location: Denmark, Europe Posts: 53	Air filter for Chinese underbone Edit: Question about air filter in ths post: http://chinariders.net/showpost.php?...72&postcount=8 Hello all Please point me in the right direction to understand the ignition system on Zongshen 125 horizontal engine with E-start. I've bought a non-running Zongshen ZS125-47 underbone with 200km on the odometer. The seller already replaced the CDI unit, which plugs into a 5-core cable, that ends in a gear indicator switch on the motor. ??? I bought a new ignition coil, but that didn't change anything. All the wiring connectors are sloppy, and I plan to solder the wires instead. When wiggling the connectors, the indicated gear lamps change between neutral, 4 and dimly 3. Last edited by Tranberg; 03-10-2016 at 03:35 PM.
	0

03-08-2016, 07:33 PM	#5
humanbeing Join Date: Mar 2008 Posts: 2,436	Horizontal chonda AC-CDi had 2 types. smaller: 嘉陵70 (CD70 clone) \| bigger: 大阳100 (C100 clone) __________________
	0

03-09-2016, 10:35 AM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	I doubt that the motor is blown. It's more likely that the valves aren't set properly, and the PO didn't understand how to adjust them (or even think of it). __________________ 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
	0

03-10-2016, 03:35 PM	#8
Tranberg Join Date: Feb 2016 Location: Denmark, Europe Posts: 53	Today I got it licensed so I could ride it legally. Highest recorded speed by Endomondo on my Iphone was 88 kph/55MPH I think it's running lean at WOT, but cleaning the carb and raising the needle all the way helped a lot at intermediate throttle openings. I closed the four ½" holes some precious owner made in the air filter box, which only contained a flat metal plate with a metal screen. QUESTION: Where can I find a service manual for this Zongshen ZS125-47, to determine how the filter is supposed to look? I've found the airbox on TaoBao, but what's supposed to be inside? http://sea.taobao.com/item/en/40788633962.htm This sponge? http://sea.taobao.com/item/40818127787.htm Last edited by Tranberg; 03-10-2016 at 04:13 PM.
	0

03-08-2016, 02:46 PM	#2
Tranberg Join Date: Feb 2016 Location: Denmark, Europe Posts: 53	I suspect that the electrical terminals were torn out of the housings and put incorrectly together by the dreaded previous owner.
	0

03-08-2016, 05:21 PM	#4
Tranberg Join Date: Feb 2016 Location: Denmark, Europe Posts: 53	Thanks a bunch. Meanwhile I found a picture on T-BoltUSA, where they specifically warn you that the gear indicator plug fits into the CDI socket. It COULD be a cover-up to mask that the engine is blown after only 200 km. Worst case, an engine is only $360, I paid $370 for the bike. I think I will have it running by tomorrow! EDIT: I see that the ZS125-47 wiring diagram shows a 4-wire "DC-CDI", but mine has the black/red wire from the stator like shown in diagrams for 5-wire A/C-CDI from T-BoltUSA
	0

03-09-2016, 12:10 PM	#7
Tranberg Join Date: Feb 2016 Location: Denmark, Europe Posts: 53	It's alive! All I had to to was to switch the connectors. The green plug from the gear indicator goes to the beige socket of the wiring harness, and the beige plug from the motor goes to the green socket of the CDI. It fired up, but I had to give full choke. I plugged off the large intake spigot on the exhaust air injection thingy, which had no hose on it, and then I could adjust a decent idle. The clutch didn't release by pressing the gear lever, so I turned out the adjustment screw until it did. What's the correct procedure? Neutral is hard to find when the clutch works, otherwise not. I got a late start, because the guy who owns the place where I unloaded it and locked it away for the night was in a bad mood, and didn't get up before 1 PM. Tomorrow I will get it licensed, I only have to go ½ mile and pay $125.
	0