Start of a new zong project

[Pabesco]

Hey guys bike just arrived today and I'll collect tomorrow from shippers and customs. I I will take pics go it to post as and after I start the mods to show progress as I go along. Cleaning will be the first thing then I'll check valves and chain, then move on. I will also be installing am alarm and will update as I go,

[Weldangrind]

This will be a terrific build. Thanks for taking pics and sharing it with us.

[SpudRider]

Thanks for starting a thread on this project, Pabesco. :) Please take lots of photographs. ;)

Spud :)

[TheRealWorld]

Should be fun to watch this progress, I will be watching!

[Pabesco]

http://i1271.photobucket.com/albums/jj635/Pabesco/2DBAFCD5-5B25-44F5-ABD7-FDE931477715-3601-00000241551D30F6_zps2ce3291f.jpg
test

[Pabesco]

http://i1271.photobucket.com/albums/jj635/Pabesco/9277A474-BB75-490D-85CF-122CE3D224B4-3601-0000024117BBECE8_zps39bfb1b3.jpg
AFTER A GOOD CLEANING AND INSTALLING THE ALARM
EXHAUST AND HEADER WILL BE DELIVERED TOMORROW

[Pabesco]

http://i1271.photobucket.com/albums/jj635/Pabesco/F865CEF4-BD64-4803-B2D0-BD977B2D4FAF-3601-00000240E43C41D7_zps545f29d1.jpg

STRIPPED DOWN TO INSTALL ALARM AND CHECK AS MUCH AS POSSIBLE, JUST PICKED UP BIKE THIS DAY

[TheRealWorld]

Hey some how I did not get the info on this bike. Is this a new one? What model is it? Looks like a beautiful bile.

[SpudRider]

Your Zong looks "showroom new;" it's in excellent condition! :) Are the LEDs mounted on the fuel tank shroud part of your new alarm system?

Spud :)

[Weldangrind]

That flat black looks really good. 8)

[2LZ]

Spuds right! That thing looks brand new! :D Congrats!

I certainly wish I could get my hands on one for Mrs 2LZ and have it street legal here in The PRK! :? She likes my Q but says it's to tall in the seat. The smaller rims would shorten the seat height, I'd imagine and Spud has proven to the masses they're extremely reliable units!

[Pabesco]

thanks guys, i like it very much, its a used zong 200, lots of haze on the plastics at first, until cleaning.i was experimenting with the leds and will perminetley place them as soon as weather permits, lots of rain the last few days, headers and exhaust picked up this evening, along with feeler gauges and carb jets, will strip down to bare shell again and check everything and change what needs to be then rebuild, will take pics as i go, just wish stand would be delivered soon so i can modify crankcase cover and change sprocket,

[SpudRider]

thanks guys, i like it very much, its a used zong 200, lots of haze on the plastics at first, until cleaning.i was experimenting with the leds and will perminetley place them as soon as weather permits, lots of rain the last few days, headers and exhaust picked up this evening, along with feeler gauges and carb jets, will strip down to bare shell again and check everything and change what needs to be then rebuild, will take pics as i go, just wish stand would be delivered soon so i can modify crankcase cover and change sprocket,
What kind of stand are you ordering? You are wise to perform the left crankcase cover modification. ;) Why do you need a stand to section the left crankcase cover?

Spud :)

[Pabesco]

i want to change the oil, exhaust, rear and front sprockets, chain and carb jsts one time on saturday, ill take the day off to do as much as possible and the stand would be a great help with all that needs to be done

http://i1271.photobucket.com/albums/jj635/Pabesco/bikestand_zps49273f88.jpg

[Pabesco]

http://i1271.photobucket.com/albums/jj635/Pabesco/CA6EB000-D1DA-4331-BF25-EBD338CCD0DF-5559-0000037EE120EF5A_zpse6b13015.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/4BB6CA90-F1EF-4134-905F-005120520EDE-5559-0000037EF997D9D4_zps0107e5fc.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/01368EA6-FDD2-4542-85A8-FBBD06667867-5559-0000037F0D93B21F_zpsf79b98f8.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/EF0B840E-E292-42E4-9481-2B0BB153D09F-5559-0000037F1B871D7E_zpsf8959d32.jpg


just got the exhaust today and they fit great, also looks like header has already been shortened, hopefully not too short, ill posr updates later

[SpudRider]

I fixed your images so the thread could still be read, Pabesco. :) Please enter a "carriage return" before and after each image, so the images won't string together across the page. ;)

Spud :)

[SpudRider]

i want to change the oil, exhaust, rear and front sprockets, chain and carb jsts one time on saturday, ill take the day off to do as much as possible and the stand would be a great help with all that needs to be done

Indeed, you were wise to purchase a swingarm stand. ;) I use mine all the time. :)

Spud :)

[Weldangrind]

I finally bought one at HF; I love it!

[Pabesco]

its that simple to get some things done i see lol, i tryed everything i could to get the pics to line up one under the other but didnt think to use a space, i know now for the next set of pics, i installed the exhaust system earlier today and it sounds great, i will be riding tonight and will post pics asap
thanks guys

[SpudRider]

its that simple to get some things done i see lol, i tryed everything i could to get the pics to line up one under the other but didnt think to use a space, i know now for the next set of pics, i installed the exhaust system earlier today and it sounds great, i will be riding tonight and will post pics asap
thanks guys
Place each image on a separate line, and insert a blank line between each image. ;)

I'm glad you got the exhaust system installed! We eagerly await your photos. :)

Spud :)

[Pabesco]

just installed nex fmf exhaust and stainless steel header today. now it sounds like im riding a mans bike, lol

http://i1271.photobucket.com/albums/jj635/Pabesco/D7E8BE13-598C-4581-A260-3D705BA9E677-5917-000003A7030400C2_zps48891e53.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/575966A3-BD92-47F8-9292-4B8E793EDE65-5952-000003B04DDA750F_zps622e9e2e.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/F15E3985-5A55-440B-A3FF-70FD2F9A6722-5952-000003B06FB6EAF4_zps02ebc734.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/0AD792EC-76B0-4278-B873-D95539E820AF-5952-000003B09C373E51_zpsb733b10f.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/E7D0287A-8AF2-4A83-9C9B-13D807C96C1C-5952-000003B0B28ED709_zps3b983dcb.jpg

[Pabesco]

finished the led lights setup and tried to capture, might need to use camera in a bit more lighting,

http://i1271.photobucket.com/albums/jj635/Pabesco/th_152F5274-2234-4E0A-A2E1-12B426AD5AE2-5952-000003B10C3EC167_zps74dfd426.jpg (http://s1271.photobucket.com/albums/jj635/Pabesco/?action=view&current=152F5274-2234-4E0A-A2E1-12B426AD5AE2-5952-000003B10C3EC167_zps74dfd426.mp4)

[SpudRider]

Your new exhaust system looks great, Pabesco. :)

Spud :)

[Pabesco]

just click on image above , video will play

[Pabesco]

thank you very much spud, also i can actually smell the difference in the exhause fumesm so im going to install the 132.5 carb main jet nextm ill post pics slao

[Weldangrind]

That exhuast looks really good! Money well spent.

[Pabesco]

just changed oil today , used valvoline full synthetic 5w40, is this ok and is one quart enough, i read a bit and some say 1 litre, others 1 quart 5 oz, which is best? seems to run well.
thanks guys

[SpudRider]

just changed oil today , used valvoline full synthetic 5w40, is this ok and is one quart enough, i read a bit and some say 1 litre, others 1 quart 5 oz, which is best? seems to run well.
thanks guys
Yes, that motor oil is fine. I only use 1 quart of motor oil in my Zong. :) Check for the proper oil level at the oil sight glass on the right crankcase cover. ;)

Spud :)

[Pabesco]

I totally agree weldangrind money well spent. I love the sound and the feel of the extra power.

[Pabesco]

Finally found someone to cut the crank case cover for me so I will be changing the sprockets and chain over the weekend. I will be sure to post as many pics as possible.

[Pabesco]

Spud I forgot to say thank you for the advice on the oil. I only used one quart and when I level the bike the oil level is Exactly where it should be. I will also be checking and setting the valves over the weekend
Thanks again guys for all the help

[Pliskin]

Pabesco you Zong looks good. :) Did you get the exhaust from ebay? Any chance or recording the sound with new exhaust?

[TheRealWorld]

Are you going to change both sprockets?

[SpudRider]

Finally found someone to cut the crank case cover for me so I will be changing the sprockets and chain over the weekend. I will be sure to post as many pics as possible.
Good for you! :D We eagerly await your photos. ;)

Spud :)

[Pabesco]

Thanks guys,
Yes I did get the exhaust off eBay also the header setup, I will do a video of the sound and post, I will be changing both sprockets, the rear will be 50t and the front will be 14t for now, I have 13t and 12t on order now and will experiment with those later, I will also order a 54t later but most likely, following spuds testing, I will properly stick with the 14/50 setup, I won't be doing any off road at all
. Looking fwd to the weekend now

[SpudRider]

I hope you realize you are going to need to do a little grinding on that 50T sprocket, Pabesco. ;)

Spud :)

[Pabesco]

Yes I do. I read almost all of your posts about the zong and I'm learning a great deal becaus of those. Thanks spud.

[SpudRider]

Yes I do. I read almost all of your posts about the zong and I'm learning a great deal becaus of those. Thanks spud.
You're welcome. :)

Spud :)

[Pabesco]

hey guys, i did the crankcase mod earlier today and cleaned the oil filter. this was surprisingly very dirty

http://i1271.photobucket.com/albums/jj635/Pabesco/84A51EE9-A0E3-4F4A-ABC7-8A2BF251007B-11873-00000849A0958CD9_zpsfe62ba4c.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/8573DE3D-9ED9-42E3-B37E-CCD7D5A52536-11873-00000849B416F97D_zpsf6af6fc7.jpg

looked alot better after cleaning
http://i1271.photobucket.com/albums/jj635/Pabesco/9837B7F3-74F2-473C-9D12-FDB57362A64D-11873-0000084A19E9CB30_zps8672e2c5.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/85C2832F-6883-4922-883B-EECCC0B49083-11873-0000084A09E8AF03_zps8cec61be.jpg

as suggested i took photos of the components inside the cover before removing them, this helped when it was time to replace
http://i1271.photobucket.com/albums/jj635/Pabesco/54A46921-9778-4D9C-A9BB-A648E4E4AE8E-11873-0000084AB1BD2E9F_zps362a5666.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/AD686A69-711D-411D-9D58-6182FED9BD7E-11873-0000084A9C2DDA47_zps4af58c65.jpg

went to welder buddy of mine who did the cut for me
http://i1271.photobucket.com/albums/jj635/Pabesco/D176B138-DC2D-40C6-A135-2ECB2C1629C0-11873-0000084A339512CA_zpsafe28030.jpg

here is the after pic
http://i1271.photobucket.com/albums/jj635/Pabesco/6BB417B4-5956-40B7-BF3F-AC0F8636E84F-11873-0000084A574711A7_zps0d1d9376.jpg

using a rear wheel stand made the work much easier
http://i1271.photobucket.com/albums/jj635/Pabesco/AD01D863-8A33-40C1-A79A-1F20373F4B8B-11873-0000084A847759B8_zpsdb20dc9c.jpg

i will be changing the chain tomorrow and check the valves seating, i will post those pics then,

[TheRealWorld]

Great project! I have a hunch you have thought of this, but I would put an hour on that oil and change it again. See how the filter looks at that point.

[Pabesco]

actually didnt think of that, i will do that as well tomorrow
thanks for the great advice

[Pabesco]

hey spud, or anyone else who would know, the new chain i got, the gold oring that you suggested, seems a bit longer than the original, i am going to use the chain with a 14/46 until monday when i collect the 50t for the rear, would the new chain in its present state be too long or would it adjust properly, do i need to remove a fre links?
thanks

[SpudRider]

Great project! I have a hunch you have thought of this, but I would put an hour on that oil and change it again. See how the filter looks at that point.
actually didnt think of that, i will do that as well tomorrow
thanks for the great advice
I wouldn't change the oil again. That oil filter looks exactly as I would expect it to look for the mileage on your Zong. ;)

Spud :)

[SpudRider]

hey spud, or anyone else who would know, the new chain i got, the gold oring that you suggested, seems a bit longer than the original, i am going to use the chain with a 14/46 until monday when i collect the 50t for the rear, would the new chain in its present state be too long or would it adjust properly, do i need to remove a fre links?
thanks
Yes, your new, 132-link drive chain is 6 links longer than the stock drive chain. ;) The new chain will be too long for a 14T/46T sprocket combination. Use the old drive chain until you install your larger, rear sprocket.

When you install the larger rear sprocket you will need to shorten the new drive chain by removing an even number of links. ;)

Spud :)

[Pabesco]

ok thanks very much, ill change the oil again on monday and find a way to shorten the new chain tomorrow, i just recieved the new rear sprocket today and will install tomorrow, not doing much today seeing its my 43rd birthday, and believe me im grateful to The Almighty God for allwoing me to see the beginning of another birth year, ill update asap, thanks again guys

[Pabesco]

finished installing counter sprocket (14t), checked the valves, changed the carb jet to 132.5, and clecned the front wheel
these are the tools i made as per spuds advice

http://i1271.photobucket.com/albums/jj635/Pabesco/F1BC51B3-D74D-4AE3-BB76-A8682C505CA3-12306-0000086A803C25A1_zps84bd37f5.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/712DE53A-2888-411D-B2E0-2D1DB11A0F90-12306-0000086A88ED6323_zps8a1aea75.jpg

look of the crankcase after the cut and reinstall
http://i1271.photobucket.com/albums/jj635/Pabesco/1EC42A51-CD34-48FC-B808-0E0BB233AEFF-12306-0000086A99940AEC_zps81e4ceb3.jpg

pics of valves exposed and checked and retightened
http://i1271.photobucket.com/albums/jj635/Pabesco/F13EDD8F-8217-45FC-BE8E-08C887B3AB6F-12306-0000086AB3D981DC_zps6877646e.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/E734C0F2-B3CB-4FF9-89A2-1BF17804B4D7-12306-0000086ABA17BFE9_zps56617375.jpg

pics of carb and jets
http://i1271.photobucket.com/albums/jj635/Pabesco/FFEEDCC3-E7F4-40FF-843B-B89D2F3EEE06-12306-0000086AAE2DDB2D_zps6995dd9b.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/ACBC7E20-B743-494E-8715-0ACBDF217A9D-12306-0000086AA8742F4F_zpsd3500838.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/CC14E707-CC1D-45F1-9B36-328FAF4DF4F0-12306-0000086AC6AAAF3E_zpsc7e1d570.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/6EA86DA0-13E1-40EB-9749-073E3C6AAC6E-12306-0000086AC02971E3_zpsf6301fa8.jpg

bike reassembled
http://i1271.photobucket.com/albums/jj635/Pabesco/970C3775-52E3-43F2-AB26-CF04FCF2F215-12306-0000086ACCEA18A8_zps2228fb67.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/D976D857-5970-452E-B332-4480B063C208-12306-0000086AD28B7626_zpsdc712a59.jpg

front wheel first clean, polish later
http://i1271.photobucket.com/albums/jj635/Pabesco/2EC3393B-9128-489F-A205-5C67EFCA6EEC-12306-0000086B167A10B8_zps7ac4508d.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/26CE6435-0D37-45E0-B1F9-205A6A21AC5C-12306-0000086B0EB68D88_zpsb944e8f0.jpg

http://i1271.photobucket.com/albums/jj635/Pabesco/3B0CE37F-5A19-4E85-965D-9BEF8549719E-12306-0000086B08C2D07B_zps57eb9c74.jpg

video of how bike sounds after exhaust installed, hope its clear enough
http://i1271.photobucket.com/albums/jj635/Pabesco/th_F9DE3F0C-B691-450B-94F2-3AE798EBD175-12306-0000086AF5606AA7_zps4d6eaf36.jpg (http://s1271.photobucket.com/albums/jj635/Pabesco/?action=view&current=F9DE3F0C-B691-450B-94F2-3AE798EBD175-12306-0000086AF5606AA7_zps4d6eaf36.mp4)

[SpudRider]

ok thanks very much, ill change the oil again on monday and find a way to shorten the new chain tomorrow, i just recieved the new rear sprocket today and will install tomorrow, not doing much today seeing its my 43rd birthday, and believe me im grateful to The Almighty God for allwoing me to see the beginning of another birth year, ill update asap, thanks again guys
I sure you don't need to change the oil again. But, if it makes you feel better, it's only a quart of oil. ;)

Search this forum for tips on how to shorten the drive chain. We discussed this matter recently. :)

P.S. Happy Birthday!

Spud :)

[Pabesco]

Will do spud. Thanks. Very much again

[SpudRider]

Thanks for posting the nice photos, Pabesco. :) Your list of "Spudifications" is increasing daily! ;)

Spud :)

[Pabesco]

This is really an enjoyable learning experience thanks to guys like you. Weldandgrind and others

[Pabesco]

Forgot to mention pleskin and the real world. Thanks guys

[TheRealWorld]

Great pictures, great project and yes, these guys are also great!

[FastDoc]

Great pics and great bike. :D

That exhaust won't melt the tailights will it? That was an expensive issue with the Q4 on my KLX... :roll:

[Pabesco]

Thanks guys. Doesn't look like any damage at all on the ail light or reflector so far.

[SpudRider]

...That exhaust won't melt the tailights will it? That was an expensive issue with the Q4 on my KLX... :roll:
No, the exhaust gases won't melt the turn signal. :) However, Pabesco should remove the right rear reflector which is located just behind the exhaust outlet. Otherwise, he will just lose it, anyway. ;)

Perhaps some red loctite or a nyloc nut will will save the reflector. :idea: However, if the nut is not locked onto the bolt, the exhaust gases will vibrate the reflector and cause it to fall off the frame. :roll:

Spud :)

[FastDoc]

Good to know.

My TBR darkened but did not melt the blinker. My Q4 killed it, somewhere in Idaho... :roll:

I upgraded to an Edge II with the 12 O'Clock labs integral signal processer. Looks and works great but oh the $$$ :roll: .

BTW stuff falls off all bikes not just Chinese :lol: .

Yesterday I'm riding my YZ home from a long D/S ride. I feel a gentle push on my right boot. I look down to see my nice custom billet kickstarter had fallen off. The retention bolt vibrated out.

I put it in a backpack and rode home. I replaced the bolt with a dab of blue Locktite. Good to go! :P

[Weldangrind]

Somehow, I missed the tip of putting a Robertson screw into a Marrette clamp. Brilliant! BTW, Robertson screws are a Canadian invention. :D

Happy birthday! Your bike looks terrific. 8)

[TheRealWorld]

Hey that video is very interesting, Thanks!

[Pliskin]

Pabesco, Thank you for all the pics you've posted. Nice to see another Zong.
As how to shorten your chain read this post. I got all the help i needed.
http://www.chinariders.com/modules.php?name=Forums&file=viewtopic&t=14109&highlight=pliskin
Crankcase mod looks very similar to mine. :)
Your bike looks better than new now. Thank you for posting sound of your new exhaust. :D Was very curious to hear the difference. Yes it does sound different. Very cool.
Forgot to mention pleskin and the real world. Thanks guys
Glad I could help.

[Pabesco]

Thank all you guys for the kind words and birthday wishes. Cod t have gotten this far with out the great advice from peoria like you. Thank you for helping me build a better bike. I changed the rear sprocket to a 50t and shortened the sw chain after watching the links provided and I'm very pleased with the way it feels now. I will post pics tomorrow and I will use the locktite on that reflector as advised
Thanks again guys

[SpudRider]

Did you trim the 50T sprocket, or the rear hub, Pabesco? If you have time, please post a photograph of your 50T rear sprocket. :)

Spud :)

[Pabesco]

Sorry for such a late reply, I took the bike to a friend that works on motorcycles and has been a rider for many years and he instead of trimming the sprocket, trimmed the tabs off the hub. It's a pretty good fit and he stated that the bolts are the true alignment for the sprocket and the fitment would still be perfect without any complications, so far so good. I would really lie to know some of the opinions from you guys on this also.
Thanks guys and have a great vening

[SpudRider]

I agree with your friend. ;) I would much rather trim the aluminum hub, once, than trim the steel sprocket every time. :)

Spud :)

[Pabesco]

Glad to know I have persons leading me I. The right direction
Thanks

[miami]

hey where did you get the whole exaust and how much

[Pabesco]

i found the parts on ebay, the exhaust was $108, the header and exhaust pipe was $80 including shipping

[miami]

hey where did you get the new parts at and how much especially the header

[miami]

yeah on ebay what you look it under can you send me the links please that the only thing iam missing

[Pabesco]

I searched a bit and this was just one guy that had the parts probably from a bike he stripped for parts. I don't think he has any others. I'll find the link from eBay and post it just in case

[miami]

let me ask from what bike did the exaust came from that i can find compatible for the zong

[Pabesco]

The owner had it listed as a Yamaha xt225