Zongshen 500cc Diesel Bike Engine

[pietenpol2002]

I've watched this thing since it's roll-out back in 2010 or 2011 hoping it might go into production. It appears that's finally the case. At 10 kw it's no powerhouse, but would make a great replacement for the Yanclones. And as it was intended for a 3 wheeler it comes with reverse and an integral differential. So, for what it's worth, and apologies for the less-than-perfect translation.

http://zse.cc/productsdetail.aspx?Produ ... &CateID=51

Zongshen 500 Diesel

Engine commonly known as: DSW500 Diesel
Engine type: Single-cylinder, water-cooled, horizontal
dimensions (mm): 769 × 432 × 417
Net Weight: 85kg
Max Power: 10KW/3800 ~ 4000rpm
Package size (L × W × H ) (mm):
Displacement: 494
Maximum torque: 28N.m/2200 ~ 2500rpm
Compression Ratio:
Bore and Stroke: 86 × 85 Ignition:
Lubrication: Pressure splash
lowest fuel consumption:
Start: Electric Start
Clutch mode: Dry Clutch
Transmission mode: five-speed + reverse (with differential)

Zongshen Power DSW500 engine features:
1, the new diesel-powered vortex combustion chamber structure, better combustion, low fuel consumption (compared with the same displacement gasoline engine, fuel economy 40%); low emissions (Euro Ⅲ standard); Low noise, low speed, high torque characteristics; machine comes with balance shaft vibration, improving occupants comfort.
2, the machine comes with glow plugs, difficult to solve cold start phenomenon.
3, the machine adopts international brands fuel supply system to improve fuel economy; gear box with separate crankcase lubrication, lubrication characteristics to adapt to different needs.
4, using the integrated differential, more compact.
5, detachable wet cylinder, easy maintenance.
6, variable fuel injection timing mechanism, optimizing fuel supply time, improving external characteristics, noise, fuel consumption, vibration and a series of performance indicators.

[Eddy Wane]

Hi Ron.
That engine looks good enough for a trike conversion.
Eddy.

[gilburton]

All it needs is an output shaft either the normal left side or possibly the choice of r/h side?
Pity we don't know the price?

[coachgeo]

Judging by #4 and the gaping black hole on each side

4, using the integrated differential, more compact.

looks like this has an output on both sides intended for left and right axle for something of a 2wd ATV design. Thus for our purposes we would have to weld up the diff.

[tappy]

Axles coming straight out of the unit the diff must also include final drive reduction. To use it on a bike I'd want to take the whole lot out and so avoid having a 1:1 final drive.

[gilburton]

10kw is just under 13.5 hp. As for gearing I suspect it will be fairly low so sprockets would give the chance to experiment.
The horizontal and compact gearbox layout would allow fitting to most frames without a lot of cutting.
Be interesting to find out the price but I expect it would be only offered at a reasonable price if bought in multiple units.

[alexanderfoti]

That lookks pretty cool.

however its 85kg! thats bloody heavy!

[gilburton]

I would think that's a misprint as it would make it the same weight as an average person???

[alexanderfoti]

I would think that's a misprint as it would make it the same weight as an average person???

Must be!

[pietenpol2002]

The website (with the more current specs) lists it as <80 kg. Even so, it's still heavy. Water cooling and the differential don't help. The 2 cyl Kubota of almost identical power comes in at 53 kg. But, then you add the primary drive, clutch and gearbox and you're within striking range. I wonder how much of that <80 kg is the differential. The other curious addition is the dry clutch. With the exception of Ducati, rarely seen on unit construction.
Almost ironic that Zongshen also builds the Yanclone single used in many diesel bike conversions.

[alexanderfoti]

If it had an output shaft instead of a diff, and a vertical cylinder arrangment, then that would be a near straight swap replacement for a petrol engine!

agh, so close!

[gilburton]

It would drop straight in to an Aermacchi Harley Davidson 350SS Sprint
Bit rare in the UK but I used to have one.
At least the handlebars are rubber mounted already

[alexanderfoti]

It would drop straight in to an Aermacchi Harley Davidson 350SS Sprint
Bit rare in the UK but I used to have one.
At least the handlebars are rubber mounted already

heh, probably enough space in my frame as well! IT has variable injecting timing as well, hmmmmm

[gilburton]

And a five speed box!

Until we get more info re price etc it's probably a no go as I wouldn't think it will be anywhere near the low price of the Yanclones

[alexanderfoti]

And a five speed box!

Until we get more info re price etc it's probably a no go as I wouldn't think it will be anywhere near the low price of the Yanclones

thats a point

[sbrumby]

This must be produced for a particular purpose ie. quad. The half shafts that need to fit the diff must be from an existing vehicle ? probably rigid back end quad as each shaft would need two UJ joints if it was to have suspension.
A lot of talk about it just fitting into bike frames. But if it has to be mounted as in the photo have you notice the length.

[Eddy Wane]

Yes it is a bit long at 750mm overall. It is a pity the manufacture hasn't taken a leap of faith and married the motor to one of their motorcycle engine gearboxes. Perhaps their product is aimed at the utility market quad, ATV and 3 wheeler etc. I am still surprised that only a handful of manufacturers have taken up the diesel bike gauntlet.

Most of the attempts at commercial production has either created a bike that is too expensive and therefore low sales or what appeared to be a potential sure fire hit never got beyond military production (HDT) and now apparently is no longer being produced, although Altius Automotive in Chennai was supposed to be producing the machine rebranded as the Scimitar and even now still have not done so.

Maybe Jochen Sommer has the right idea (who has one in the UK?) but I would like to see one of his bikes done up like a 60's tourer with twin seat, full fairing and panniers.

End of rant.

[gilburton]

The Sommer bike currently retails for around £7500.
Henry Price around £4000.
I think the problem is more to do with the enthusiast(us) who will not be willing to pay these sort of prices and enjoys creating a bike in the first place.
Unless a major manufacturer picks up the challenge then I don't see diesel bikes becoming mainstream as the average biker doesn't want 50 mph performance and a high price as these are essentially hand built bikes.
It would help lower the cost with mass production and also with legislation/insurance but the manufacturers have to conform to world legislation to make it viable but as we all know emissions will be the killer of the diesel bike.

[boutje]

I have found the same engine here on alibaba.com with a price:

http://www.alibaba.com/product-gs/66890 ... NTIAL.html

[gilburton]

H'mm $1950 or £1165 for a single item? Less for multiple purchases with a minimum of 5 units ordered.
Anyway re the length how does that compare with more conventional engine layouts and don't forget that is including transmission?
Anyone near their bikes with a tape measure have a measure from the front of the engine to the rear of your gearbox/CVT just out of interest

[alexanderfoti]

Ill measure when im near.

I assume, if its got a diff at the back, that it can be welded closed, and the one side used with a sprocket on the end?

[gilburton]

I'm sure if anyone put in a substantial order(not likely) the makers would do it and put a blank in the side not required.

[Blunt Eversmoke]

Integrated gearbox and diff make for easy installation, and have some potential for weight reduction. That's nice and dandy.

However, what I cannot understand is why Zongshen limited themselves by doing a one-cylinder configuration - where they could easily do a double (V2, straight double, boxer, you name it) and double the HP by making their engine-gearbox combo only some ten-thirteen kilos heavier.
Compare the data for 400 ccm single and 840 ccm V2 Yanclones, being based on identical technology and produced on similar equipment, and you'll see what I mean.
A 20 KW unit weighing 90-95 kilos complete with gearbox (and diff, since they are so keen on keeping that) would sure fit nicely in a Harley or Dnepr/Ural. And that's without taking into account the possibility to super/turbocharge it...

[coachgeo]

Zongshen web site seems devoid of anything but headers and footers

[gilburton]

However, what I cannot understand is why Zongshen limited themselves by doing a one-cylinder configuration

Don't think they are interested in speed/power??
It's meant for utility vehicles/rickshaws so economy/long life will be the goal??

[tappy]

Cost. It's far, far cheaper to make a single than a multi-cylinder engine. It's not so much the cost of manufacturing the components, more the cost of inspection, adjustment, servicing etc.