New Zongshen RX3 (ZS250GY-3) Dual Sport

[dpl096]

Joe's post today on the loose crankshaft nut is yet another example of the CSC midas touch. And b4 anyone asks if I really think a big name manufacturer would find out about this and not say anything .....you damn right I do. Well done to Steve and his entire CSC team.

[SpudRider]

Originally Posted by Jay In Milpitas

The nut inside the large yellow circle in the second picture?
http://www.chinariders.net/showpost....92&postcount=5

Yes, it's the nut which locks the starter sprag clutch and primary drive gear to the crankshaft.

[SpudRider]

Originally Posted by dpl096

Joe's post today on the loose crankshaft nut is yet another example of the CSC midas touch. And b4 anyone asks if I really think a big name manufacturer would find out about this and not say anything .....you damn right I do. Well done to Steve and his entire CSC team.

Well said, amigo.

[BlackBike]

Spud, I want to know if that star shaped gear on the left of the pic is the gear selector you feel when shifting gears? Next to the 2 plastic gears.

[SpudRider]

Originally Posted by BlackBike

Attachment 5990Spud, I want to know if that star shaped gear on the left of the pic is the gear selector you feel when shifting gears? Next to the 2 plastic gears.

Yes, the star gear is connected through the right half of the crankcase to the shift drum. The shift drum actuates the shift forks, which change gears in the transmission.

The star gear is actuated by the shift pawl assembly, which is actuated in turn by the shift lever on the left side of the engine.

You might enjoy reading the following thread.

http://www.chinariders.net/showthread.php?t=15589

[BlackBike]

Thanks, now I can kind of visualize what is going on with my left foot

[BlackBike]

Forks, dogs, splines and gears. Very eye opening , great post!

[Jay In Milpitas]

I think it was RJ that mentioned concern about throttle wrist fatigue on a forthcoming long distance ride. I suggest one of these. A good addition to a throttle locking device, but doesn't take the place of one.

http://www.crampbuster.com/

[rjmorel]

thanks Jay. I think a way to hold the throttle on while riding is one of the more important farkles if you ride many long days. I use to have a DR650 that I put an actual automobile cruise control on and that was one of the best things I did to the bike. On my RX3 I have a 3D printed one I made that holds up ok and consider these kind or a cramp buster to be great for transferring from bike to bike if you have multiple bikes to ride. Easy on and off if you don't need it for a short ride around town.
I am planning a Iron Butt 1000 on my RX3 June 18th. That is suppose to be the longest day this summer as far as day light. Wouldn't want to attempt it w/o a way to hold the throttle on. I plan on changing the engine oil from the Honda 10-40 dino oil I've been using to the 20-50 synthetic that CSC sells to hopefully give the engine the best possible protection for running 20+ hours straight except for fuel stops. It would make more sense to use my Honda NC700x but I want to use the RX3 and make it a challenge and for the bragging rights. First RX3 to do a Iron Butt 1000!!!! Also may put back on the original rear tire which should have several thousand miles left in it as the Shinko 244 on there now really drones at 60-65 and if I had to listen to it for 20+ hours I think I'd go gaga. rj

[3banger]

Spud,

Was there any indication the tab washer on your crankshaft nut had been improperly bent over? Or do you suspect the nut was loose and slowly worked to unbend the tab washer?

[SpudRider]

Originally Posted by 3banger

Spud,

Was there any indication the tab washer on your crankshaft nut had been improperly bent over? Or do you suspect the nut was loose and slowly worked to unbend the tab washer?

No, I think the engine was assembled properly. The tab of the locking washer which fits into the hole of the primary drive gear broke off, which allowed the entire locking washer to rotate with the crankshaft nut. I think I just got a defective locking washer, which is probably very rare.

I received my repair parts from CSC yesterday. The replacement locking washer looks good and strong, so I don't think I will have any future problems of this nature.

[rjmorel]

Spud , were you able to get all the swarf and metal tab cleaned out of the engine? Did it grind the inside of the case bad? Hope it was a "sanitary" booboo and this will be the one and only end of it. Heres to your next 15,000 miles on the bike, rj

PS,you got a picture of the case insides for us?

[dpl096]

Originally Posted by Ron B

Both sides

Ron ... you said both sides ... so there are 2 zerks ?

[SpudRider]

Originally Posted by rjmorel

Spud , were you able to get all the swarf and metal tab cleaned out of the engine? Did it grind the inside of the case bad? Hope it was a "sanitary" booboo and this will be the one and only end of it. Heres to your next 15,000 miles on the bike, rj

PS,you got a picture of the case insides for us?

Thanks for your kind words, Rob.

Yes, I found the metal tab, and I cleaned all the swarf from the engine. I also removed both crankcase covers, and inspected the engine thoroughly. I did capture a lot of photos while I was inside the engine.

I completed the engine reassembly today, and rode the bike for about five miles afterward. The bike rode well, and the engine sounded good. I will ride about 75 miles before l drain the engine oil, and inspect the oil filter and oil screens.

[Lee R]

Thanks for the pictures and description Spud. It's very encouraging seeing the response from CSC. They really are an exceptional business which Zongshen should be very very proud to have selling there bikes. If they keep this up the Japanese are going to have some heavy competition as they grow!