Zongshen RX3: New Bike Assembly Information

[SpudRider]

This thread contains all of the information you need to know regarding the assembly of your Zongshen RX3 motorcycle from the shipping crate. Firstly, here is link to the RX3 Setup Tutorial posted at the CSC website.

http://californiascooterco.com/blog/?p=15621

[SpudRider]

Here is a link to the Zongshen RX3 Uncrating Documents.

Zongshen RX3 Uncrating Documents

[SpudRider]

Joe Berk posted a nice video at the CSC blog demonstrating four tips which will help with the assembly of your RX3 motorcycle.

[SpudRider]

Here is another excellent video describing the proper procedure for preparing an AGM battery which is shipped with an external acid bottle.

[detours]

Here are some assembly tips, info and links I pulled together from the CSC site and various RX3 forums. I don't have my bike yet, but I thought I'd share with others.

The 'Extra Items' section contains some common sense checks on a new bike and a few issues as reported by some early adopters of the RX3.

Crate Weight (unassembled)

• 478 lbs (217 kg)

Crate Size

• 7.0 x 1.9 x 3.6 ft
• 83.5 x 22.2 x 43.3 in
• 2120 x 565 x 1100 mm

Initial Assembly Instructions

• CSC RX3 Assembly Instructions
• CSC RX3 Leftover Parts List

Extra Items to Check

• Check crankcase vent plug has been removed (not applicable to US spec RX3)
• Check torque on all bolts:

• brake rotors

• brake calipers

• engine sprocket nut

• shifter pedal bolt play

• replace air filter panel screw with bolt to aid removal when luggage is installed (looking for a better pic)

• Check drive chain slack
• Check wheel alignment
• Exhaust checks:

• tighten header to engine bolts

• header to rear brake line clearance

• header to evaporation system tube clearance (below battery behind main frame)

• muffler mounting bolts

• check for weak spot weld on heat shield (if it rattles)

• Adjust throttle cable
• Check oil level before starting (US-spec bikes are about 100cc low from factory):

• replace oil with 1.5 qt new oil

• oil change tutorial

• Adjust clutch to fix hard neutral (ensure correct oil level first)
• Check electrical insulator on headlamp power
• Check and adjust headlight angle

CSC Maintenance Tutorials

• http://californiascooterco.com/rx3_m..._tutorials.htm

Edit: corrections based on info from Spudrider. New links to source issues.

[SpudRider]

Thanks for posting the detailed list.

Having assembled my bike and ridden it for over 900 miles, I can add a few comments. The RX3 is continually being improved by Zongshen, so some of the items on the detailed list above are no longer problems for the bikes being sold in the United States.

There is no need to check the crankcase vent. The crankcase vents at the front, left side of the engine. The vent goes to an oil separator, which separates into two tubes. The lower tube collects any excess oil which has been vented from the engine, and the tube descends to an area near the front of the skid plate. This tube has a plug to prevent any excess oil from venting to the ground. Do not remove this plug until you wish to empty any of the excess oil which might have been collected. After you do remove any excess oil, replace the plug. The plug not only protects the environment from oil pollution, but it also prevents dirt from entering the system, and fouling the oil separator.

The upper tube exiting the oil separator goes back and enters the air box, where it can either vent to the engine, or the outside air, via the air filter.

I have examined the entire exhaust system, and I cannot find any wires or tubes which are in danger of being damaged from excess heat. The rear brake line is well below the exhaust header and muffler. It is securely routed along the swingarm, and is well protected. I did not find any evaporative system tubes anywhere on my motorcycle. If such tubes exist, they are not located anywhere near the exhaust system.

[SpudRider]

Also, having removed my headlight, I did not discover any wires rubbing the frame. Indeed, I have not yet discovered any faults in the wiring harness. If anyone discovers a wiring defect, please do post photographs of the defective wiring so everyone can locate the problem, and correct it.

[SpudRider]

My exhaust header was securely attached to the cylinder head. However, I did tighten the bolts a little more to prevent any possible problems.

My drive chain was slightly, but not excessively tight. I rode a few hundred miles before I loosened both adjuster bolts 1/6 turn. I did check the sprocket alignment. The center of the rear axle was aligned the exact same distance from the swingarm bolt on both sides of the motorcycle.

The rear axle adjustment nuts were tight on my motorcycle. However, I do strongly encourage everyone to verify these nuts are tight on a regular basis. If one, or both of these nuts ever loosen, you can damage one, or all of the wheel bearings.

[SpudRider]

Thanks for posting the tip regarding the split side panel covering the air filter.



I have not yet installed my panniers. However, after examining the motorcycles, I am confident there will be no problems accessing the top rear screw shown in the photograph. The only problem with access is likely to be the bottom rear screw on this panel, which is not visible in the photograph.

Since I currently don't have the proper bolt, I merely removed the bottom rear screw for the interim. The front portion of the split side cover is retained by a tab and two other screws at the top of the panel. Therefore, I believe the panel will be very secure without the bottom rear screw, at least until I can get the proper bolt.

[detours]

Originally Posted by SpudRider

Thanks for posting the detailed list.

Having assembled my bike and ridden it for over 900 miles, I can add a few comments. The RX3 is continually being improved by Zongshen, so some of the items on the detailed list above are no longer problems for the bikes being sold in the United States.

There is no need to check the crankcase vent. The crankcase vents at the front, left side of the engine. The vent goes to an oil separator, which separates into two tubes. The lower tube collects any excess oil which has been vented from the engine, and the tube descends to an area near the front of the skid plate. This tube has a plug to prevent any excess oil from venting to the ground. Do not remove this plug until you wish to empty any of the excess oil which might have been collected. After you do remove any excess oil, replace the plug. The plug not only protects the environment from oil pollution, but it also prevents dirt from entering the system, and fouling the oil separator.

The upper tube exiting the oil separator goes back and enters the air box, where it can either vent to the engine, or the outside air, via the air filter.

I have examined the entire exhaust system, and I cannot find any wires or tubes which are in danger of being damaged from excess heat. The rear brake line is well below the exhaust header and muffler. It is securely routed along the swingarm, and is well protected. I did not find any evaporative system tubes anywhere on my motorcycle. If such tubes exist, they are not located anywhere near the exhaust system.

Thanks for the corrections! I don't have my RX3 yet, but I compiled my list based on other reports, so I can be ready when it arrives. (Maybe it was premature to share it)

[SpudRider]

Thank you for you input; it was not the least bit premature. We appreciate the time and effort you spent making this detailed list, and we are glad you shared it with us.

[woodlandsprite]

CSC has highlighted a few additional fasteners to focus on:
http://californiascooterco.com/blog/?p=16607

Detours has already captured the Muffler Mounting and Front Caliper Bolts above.
Also called out are the Exhaust Pipe Fasteners and heat shield screws.

[SpudRider]

I think one of the hardest parts of assembling a new motorcycle is raising the bike to install the front wheel. Once the front wheel is on the motorcycle, the rest of the job becomes much easier. The RX3 is pretty heavy, so if you don't have a strong back, you will want to lift the front of the bike with a jack of some sort.

Fortunately for me, I own a Husky 3-Ton jack I purchased from Home Depot. A nice feature of this jack is the ability to remove the lifting pad, which reveals a hollow tube beneath. This feature was added so you can easily install an extension beneath the lifting surface. However, you can also use the hollow tube on this jack to securely lift the RX3 from either the front, or back of the motorcycle.

Whenever I wish to lift the rear wheel of the bike, I can remove the lifting pad, and place the hollow tube of the jack around the centerstand support on the right side of the bike, as shown below. I used this method while adjusting the shock spring preload on my RX3.

http://www.chinariders.net/showthread.php?t=14677



You can also use this method to change the rear tire, remove and lubricate the suspension linkage, et cetera.

If you remove the skid plate from the RX3, you will discover a strong mount attached to the frame which secures the front bolt of the skid plate. When assembling the bike, I removed the skid plate, and placed the hollow tube of my Husky jack around that mounting tab. The mounting tab provides a strong, secure projection which will prevent the motorcycle from slipping off the jack.

While my friend steadied the bike, I raised the front of the motorcycle using this procedure, and quickly attached the front wheel. Once the front wheel was in place, I lowered the jack, and rolled the bike to a convenient location. From that point I easily completed the rest of the bike's assembly by myself.

[Adjuster]

I am sure it has already been answered somewhere in here but is CSC offering a pre assembled deal?


/

[SpudRider]

Originally Posted by Adjuster

I am sure it has already been answered somewhere in here but is CSC offering a pre assembled deal?


/

Yes, CSC will assemble the motorcycle for you. They will also ship an assembled RX3 motorcycle to you in a custom wooden crate.