250cc Quad Rebuild

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KieranM

KieranM

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I decided i would put up a thread about my quad that i bought recently. Everything was on it except axle sprocket and one rear hub/wheel.

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Its running a Zongshen 250cc shifter engine, which i beleive is a clone of a loncin/lifan 250cc.

http://image.made-in-china.com/2f0j00GMotjNDrAPkA/250CC-LONCIN-with-Reverse-Gear-Engine-WV-EP008-.jpg

If anyones could clarify a that for me it would be great.

The axle has sheared at one end (spline) and i am having a hard time trying to find a replacement, if anyone knows a good supplier it would be great. the hub is also missing. I said in an earlier thread that im having trouble breaking a bead and its for this quad, just to clarify.

The electronics are a mess and im not framilular with these engines so thats going to be interesting.

I plan to rebuild it and everything i do will be put up here. Any advise anyone has i would greatly appreciate.




Kieran
 
KieranM

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cleaned and rebuilt the carb today. Its a copy of a mikuini 27mm carb, made by dekini. It was all kinds of dirty, and the needle was not pulling up, all fixed now.

Took off the front hubs, took out bearings and trying to find replacements now. Hubs in good condition, no cracks or such. Cant say the same for the bearings though lol.

Half way through making a shifter leaver as there was none there, i have found out the it a 5 speed (reverse, neutral, 1st,2nd,3rd,4th)
so that was all kinds of fun too.

http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=PICT0011.jpg&newest=1


http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=PICT0012-1.jpg&newest=1
 
sideways

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KieranM said:
Half way through making a shifter leaver as there was none there, i have found out the it a 5 speed (reverse, neutral, 1st,2nd,3rd,4th)
so that was all kinds of fun too.
Click to expand...

Are you sure it has a reverse? The shift pattern on my dirtbike that has that engine is 1st, neutral, 2nd, 3rd, 4th, 5th. The quads I've seen with that engine had a separate reverse gearbox?

1st on mine is incredibly low, 5th takes me well over 100 km/h.

Thanks

Hayden
 
sideways

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KieranM said:
yea it has a reverse, and 4 foward. What are parts like to find for your engine, im having a hard time finding them.
Click to expand...

I've never needed any parts for mine but mine is an Atomik who are apparently quite good with parts.

I would suggest getting the genuine Honda stuff but if they've changed the gear box then god know what else they've changed. What parts do you need?

Thanks

Hayden
 
KieranM

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hopefully none lol, still have to work out the wiring to get it to fire, and recentaly i have like been spending a quarter of an hour a day on it, due to commitments, oh joy
 
KieranM

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Fitted the bearings in the hubs, and gave the hubs a coat of rust resistant paint.

Then i stripped down the quad to the bare frame, having issues with a few perished bushings, so trying to find replacements. And gave the frame a pressure wash to get all the grease off. Flat

http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=PICT0122.jpg&newest=1

http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=PICT0123.jpg&newest=1

http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=hyh.jpg&newest=1

http://s742.photobucket.com/albums/xx61/kieranm09/?action=view&current=hyh4.jpg&newest=1
 
KieranM

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so i haven't updated this in an age:

I repaired the tyre with pieces of two ply rubber, then reseated it and its perfect now, all four wheels are great.

I removed the a arms and the seals had not held up so water got in and had seized the joints, not good, so i replaced the seals and took off the rust and greased them all up. then i regreased the ball joints, the boots were very hard to find, but got them on ebay from Australia, i can post the link if anyone is stuck. Resprayed the a arms and there good as new now.











Repaired the fairings, fillered any holes or deep scratches, primed them and sprayed them royal blue.







Removed the swing arm next, chinas rust proofing didnt hold up so i had to grind down the rust with the sanding pad. lots of bubbles of rust, repaired with a few welds and sprayed in galve sprayed to be sprayed blue.












Next up is the reweld the frame.

Kieran
 
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Not sure if it helps but that bike looks suspisciously like my 125 bikes engine, so i also have a spare loom, completely basic, (like minimum to run the engine on the kick start), i could help you out if you want.

You'll need a CDI unit, ignition coil and regulator minimum to get the bike to fire. If you want the full wiring diagram of my bike i can email you it, it could well help! :)
 
KieranM

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Updates for everyone ( I can bump this because I own it and its an ongoing project, that may finish sometime next year, but untill then i will occasionaly bump it, ,mainly to annoy the users of a kart forum, about my quad :D)

I will just post pics, if anyone has questions like, why the hell is he doing that...just ask ;)















 
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