The I-don't-know-what-I'm-doing bike project [Kymco Zing]

[Guest]

Kymco Zing '98

Place holder for my Project.

26/05/14:

I got the bike in late April for £100. Probably more then I should have paid for it, but since I know nothing at all about bikes, I wanted a bit of a project to get stuck into so I can learn.

When I got it, I had a quick look at it. Both the tyres looked like they were in good condition (still had the nobby bits poking out). The seals on the forks didn't look like they were leaking and the engine turned over when using the kick start, that was pretty much all I knew about bikes.

Having it home I had not really had time to look at it properly until this weekend.

How the bike looked when I got it:

http://i.imgur.com/87G11Hf.jpg

The bike came with a bag of 'spare parts', and some of the wires seem to be in there, along with speedo clock, some indicator lights for the front, and other bits I didn't have a clue what were.

Pictures of parts here:

http://i.imgur.com/FM0fwVx.jpg

http://i.imgur.com/EgWAwb7.jpg

http://i.imgur.com/zFGfJFp.jpg

http://i.imgur.com/icCDU9t.jpg

I noticed that pretty much all the wires had been disconnected and or cut. The next thing I noticed was I didn't have a clue what most of the wires were. http://i.imgur.com/3St7i4r.jpg

First thing I did was buy a battery. Hadn't got a clue what I needed, so I measured the hole and guessed where it should go. Got one from Halfords just to test the electrics with. The HT lead, has a coil on the end, with two terminals, I had to replace since I couldn't find the cap for the spark plug. I got a new spark plug while I was there too.

I traced where the rest of the wires coming from, and tested what I could. All the lights work on the bike, as well as the a spare parts, and the controls on the handle bars all seemed to work too (apart from the clutch cable... that's another part of the story).

Along the way of trying to identify parts I discovered a few names of stuff, so correct me if I'm wrong.

The starter motor has a big black wire going to it. It also had a 'little box' with a red wire coming from it and two smaller wires on a 2pin plug.

Today I've since learnt that the 'little box' is a relay. the two pin wire is ground and +12v applied to activate the rely and then the thick red cable can be attached directly to the battery to power the starter motor. Due to the amount of amps it draws, it needs a thicker cable on it's own circuit. (can be seen in the picture above, without battery attached). As I understand it, the two pin is later connected to the ignition circuit that allows the starter button to activate the starter motor.

The thick Red cable going from the battery to the starter motor's relay is in bad condition so I'm going to have to replace that at some point.

I've also put the inline fuse on the battery terminal, apparently this will blow instead of melting my wiring later on too.

The rectifier is under the seat and has a few wires off it. Not tested that yet.

http://i.imgur.com/rZEXRUB.jpg

The wires coming from the handle bars have also been cut, and looks like someone had done a bad job trying to re-join them up with solder and electrical tape.

http://i.imgur.com/EQpLpuu.jpg

I thought I'd at least try to get the engine started, otherwise it's pretty much scrap right (rather, more scrap then it is now).

So after reading up on it, it seems I needed to connect the two pins from the back of the HT coil to a CDI and ground.

Looks like I have a CDI in the bag of parts.

http://i.imgur.com/XwZDX0C.jpg

Unfortunately I haven't a clue how to wire it. And to make matters worse, the wires coming from the engine does not have a plug on it anymore. The wires that were connected to the CDI have been cut.

I've tested the wires from the engine and I can't seem to understand what they do.

The engine has the following wires coming from it.

Yellow

Pink

Black and Red

Green and White

Blue and White

Light Green and White.

I'm pretty sure one is going to be for the neutral light on the handle bars.

The [black and red] cable has a 3-5v charge when the engine is turned over.

That's it for now, will have another poke around tomorrow if the weather stays dry enough.

[Adam]

Hey PetrolHead on here has totally rebuilt one of these bikes so I'm sure he'll be able to help you I'll give him a shout.

Here's a link to the service manual have a look through it there might be some clues in there http://www.manualslib.com/manual/393396 ... g-125.html

[al_stu]

I'm both jealous and glad it isn't me explaining to my OH what I've bought and why...Best of luck to you. By the way, I am pretty much no use to you whatsoever. lol

[Guest]

Hi fella..

I do indeed own a Zing. That started life as this

http://i365.photobucket.com/albums/oo92/Badboyazza_2009/1001395_1408900122662107_428061919_n_zps28a6e06b.jpg

and now a custom softtail bobber.

http://i365.photobucket.com/albums/oo92/Badboyazza_2009/1959794_1469415519943900_391413692_n_zps50a5fc36.jpg

If i remember correctly, those wires that come from the engine go directly into the Reg/Rec (regulator rectified).

and should have either a block connector to join them, or multiple bullet connectors..

If your stuck about anything, be sure to let me know..

[Guest]

Hey PetrolHead on here has totally rebuilt one of these bikes so I'm sure he'll be able to help you I'll give him a shout.

Here's a link to the service manual have a look through it there might be some clues in there http://www.manualslib.com/manual/393396 ... g-125.html

 

I thought I had replied to this lastnight. Weird,

Thanks again

I had already found the service manual, but the wiring diagram is of such low quality, I couldn't make out the legend or the names of some of the locations they were going to. Not knowing a lot about bikes anyway, I can't assume the correct names from know how lol.

 

I'm both jealous and glad it isn't me explaining to my OH what I've bought and why...Best of luck to you. By the way, I am pretty much no use to you whatsoever. lol

 

Ohh you just had to go and jinx it didn't you! LOL. She found the bike this morning while taking the dog out. The only question she's asked is 'how long have you had that then?' I'm not sure if that's a good or bad...

[Guest]

Hi fella..

I do indeed own a Zing. That started life as this

http://i365.photobucket.com/albums/oo92/Badboyazza_2009/1001395_1408900122662107_428061919_n_zps28a6e06b.jpg

and now a custom softtail bobber.

http://i365.photobucket.com/albums/oo92/Badboyazza_2009/1959794_1469415519943900_391413692_n_zps50a5fc36.jpg

If i remember correctly, those wires that come from the engine go directly into the Reg/Rec (regulator rectified).

and should have either a block connector to join them, or multiple bullet connectors..

If your stuck about anything, be sure to let me know..

 

Nice bike!

Just checking your build log out, it's very inspiring. I was planning on replacing the indicators and the handle bars anyway, and recovering my seat, but I might just go for a chop now too

As for the engine wires, they are indeed bullet connectors. I don't seem to have any wires or connectors that go between. They've probably been cut out like most of it or lost from the bag of parts.

I'll have another poke about with the wires later today.

Do you know what size gear selector rod is needed? Mine seems to have snapped where it links on the engine mount.

Thanks.

[eastanglianbiker]

looks a fun little project help with new parts can be found at http://www.davidsilverspares.co.uk they are main again for kymco and fairly helpfull as well

[Guest]

David Silver Spares are a brilliant source for Kymco parts..

Good thing about the Zing, is that the engine in a CG copy engine.

Nice and easy to work on, and piss easy to get spares for.

The bullet connector wires from the engine stator, should go directly upto the reg/rec..

The reg rec is a black box with metal cooling fins, thats located under the seat of the bike mate..

And thankyou for taking a look at my build log..

I really enjoyed the project.

Would have another kymco zing anyday..

Apart from my engine going bang from lack of oil, (which is due to my ar*ehole neighbour thinking its funny to remove my sump bolt), ive had no real issues with my Zing..

Just wear and tear things really.. New clutch, tires, chain etc.

And trust me, i thrash the nuts out of it..

and for future reference.. these bikes do about 60mph top speed..

But if you want a little extra, do what i did..

Replace the CDI box with a honda CG derestricted CDI, drop a tooth on the rear sprocket, and remove the auto choke from the carb..

(i found with this choke, no matter how you adjust it.. it always remains slightly on, therefor restricting a little performance..

my bike sits happily at 70mph on a clear day.. But due to dropping a tooth, if your against any wind.. it struggles... quite alot...

But against wind, it still hits 60mph.

I will take a measurement of my gear selector rod tomorrow, once i get the bike out, and let you know

Good luck with getting the bike up and running.. I tell you... My bike really does get alot of interest and positive comments.. even before the chop, bobber modifications

[Guest]

Bit of an update.

I took a bit of time to try and work out what the wiring diagram was. This was as close as I could get it. I isolated the ignition circuit as best I could and coloured the wires to make it a little easier on the eyes and more importantly, try and provide me with some sense of direction to where I was re-creating the connections.

http://i.imgur.com/89JiarT.png

petrolhead has been a great help. He provided me with the proper pin out for the CDI and with colour wires are used.

http://i.imgur.com/s1zRC0S.jpg

But that's I got as far as I could get with the wiring, it still didn't work.

I had already managed to get a replacement loom on order for the Zing. The one that came with the bike had been cut up to the point, it was more missing then there. So hopefully this would have helped.

http://i.imgur.com/JQaVHQi.jpg

Still, I couldn't connect the rectifier/regulator to the new loom because the connect had eroded on the regulator's plug. So much so, that the pin had snapped inside, and the previous owners had already cut and put a bullet point on the end of one of the wires in an attempt to fix it.

http://i.imgur.com/tyYpK0S.jpg

So I cut the wires and put bullets on the rest of them. (was going to replace the plug on the regulator).

I removed the new loom's connector leaving just the pins in place and connected them to the bullets.

Gave everything a check and put the fuse in. Unfortunately as soon as I turned the ignition on, the magic blue smoke came out.. of something.

I checked all over and couldn't see where it was coming from, so turned on the ignition again and saw it coming from under the regulator.

unbolted it and turned it over to find it had little crack, pulled the chunk out and it seems to be the problem.

http://i.imgur.com/AX5lZeJ.jpg

I hadn't checked the physical condition of it before so it may have already been damaged. Pretty surprised that with it being such a large heat sink it popped so fast just from the ignition being on.

New one is on order. Should be here tomorrow.

Hopefully the rain stays off over the weekend enough to get a bit of work done on it.