Project Zongshen Sierra

[Kidd91]

I just bought a 2006 Zongshen Sierra non running, tomorrow will be the first day i start on my project bike. Unfortunately I know very little on Enduro's let alone a Zongshen, I dont know whether to use synthetic or regular oil in my bike. And is it even possible to switch from regular to synthetic? if so, what are the steps into doing so? I've always admired the Zong, Since it was the first bike i learned to ride on. Also what would be the best way to clean out my Carburetor. Luckily for me i live 20minutes away from Zongshen America. parts are not the issue in my case, knowledge is. `

thanks, Kidd

[Weldangrind]

Oh, no. Do you know what you just did? You started another dreaded oil debate.

:lol:

Several of us have converted to 15W40 diesel oil, of whatever brand is on sale. Lately, I've been using Rotella, which I get for cheap at Walmart.

Yes, you can switch from synthetic to conventional. Just drain the old oil out and add whatever you wish. Make sure that you clean the filter and screen properly, and install the filter in the correct direction. http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7415

[Kidd91]

Oh, no. Do you know what you just did? You started another dreaded oil debate.

:lol:

Several of us have converted to 15W40 diesel oil, of whatever brand is on sale. Lately, I've been using Rotella, which I get for cheap at Walmart.

Yes, you can switch from synthetic to conventional. Just drain the old oil out and add whatever you wish. Make sure that you clean the filter and screen properly, and install the filter in the correct direction. http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7415

lol i appologize for that but as i stated earlier i am in experienced when it comes to this, you spoke of 15w40 diesel oil. what are the advantages to it compared to synthetic oil?

[Weldangrind]

It is a non-energy conserving oil, so it's suitable for use with motorcycle wet clutches. The only advantage over synthetic oil is the price.

BTW, Spud has more than 50,000 miles on his Zong, and he uses 15W40 diesel oil.

[SpudRider]

As usual, I agree with Weld. ;) I also like the 15W/40, diesel motor oil. It's excellent motor oil, but the price is very reasonable, because the oil refineries sell so much of this oil to commercial trucking operations. :)

However, any good motor oil will work well in your Zong, as long as it's not "energy conserving" oil, which will cause your bike's clutch to slip. The most important thing is to change you motor oil every 1,000 miles, and clean the oil filter with each oil change. ;)

Spud :)

[Kidd91]

As usual, I agree with Weld. ;) I also like the 15W/40, diesel motor oil. It's excellent motor oil, but the price is very reasonable, because the oil refineries sell so much of this oil to commercial trucking operations. :)

However, any good motor oil will work well in your Zong, as long as it's not "energy conserving" oil, which will cause your bike's clutch to slip. The most important thing is to change you motor oil every 1,000 miles, and clean the oil filter with each oil change. ;)

Spud :)

Thanks again for everything guys, i was working on the zong today with a buddy of mines that knows about motorcycles. we clean the carb out. to my surprise it wasnt as gumy and dirty as i thought itd be. i only spent $23 to get her up and running. everything worked like it was suposed too. i also changed the oil & bought a new spark plug. i will post pics later as for i do not know how to post them now. my next step is to call ZA tomorrow & order all the cosmetic parts that need to be replaced on my bike

[SpudRider]

Thanks for the good update! I'm glad your Zong is running. :)

Spud :)

[Kidd91]

Thanks for the good update! I'm glad your Zong is running. :)

Spud :)

I am too, i still have to do a couple minor things cosmetically, but for the most part it's road worthy! im gonna upload pictures of my adventure in a lil so check back in soon

[Kidd91]

http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2262_zpsd1997842.jpg




http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2256_zpsc8b9e37a.jpg




http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2259_zps717fbd52.jpg

[SpudRider]

Thanks for posting the photos. :)

If appears you need a cover for the air box. Don't ride the bike without an air filter installed, or you will suck dirt into the engine. The dirt will damage your intake valve, valve seat, and the piston rings. :(

You can buy an entire air box from Taobao; however, I would first check with Zongshen America. Another option is to put a pod filter on the intake of the carburetor. ;)

I'm glad you got the carburetor re-assembled correctly. :) You've got to be careful to get the slide diaphragm seated properly in the top of the carburetor. ;)

Spud :)

[zingshoen]

looks like the chain needs oiling :)

[Kidd91]

Thanks for posting the photos. :)

If appears you need a cover for the air box. Don't ride the bike without an air filter installed, or you will suck dirt into the engine. The dirt will damage your intake valve, valve seat, and the piston rings. :(

You can buy an entire air box from Taobao; however, I would first check with Zongshen America. Another option is to put a pod filter on the intake of the carburetor. ;)

I'm glad you got the carburetor re-assembled correctly. :) You've got to be careful to get the slide diaphragm seated properly in the top of the carburetor. ;)

Spud :)



i bought the filter from a local motorcycle shop, the reason why the picture has it off is because the old filter was nasty & falling apart. but ive got everything now

[Kidd91]

http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2266_zps4ea1ffc8.jpg


http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2267_zps939e2d8d.jpg


http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2268_zps180b651e.jpg


http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2269_zps820846c9.jpg


http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2270_zpsee27e7c4.jpg


http://i1278.photobucket.com/albums/y517/ZongshenKidd91/IMG_2271_zps107d6b99.jpg

[Weldangrind]

Gotta love tailgate work benches. :D

I'd get rid of that chain and just replace it. Spud has researched this topic to an amazing extent, so the Zong sticky can provide you with all of the info you need.

That tank is very familiar to me; I'm using Spud's old Zong tank on my TW. :D

[Kidd91]

Gotta love tailgate work benches. :D

I'd get rid of that chain and just replace it. Spud has researched this topic to an amazing extent, so the Zong sticky can provide you with all of the info you need.

That tank is very familiar to me; I'm using Spud's old Zong tank on my TW. :D

Tailgate work benches are all we use in FL :D , ive already looked into replacing the chain. a friend of mines/ ex stunt rider works at a motorcycle shop. he's offered to help me acquire parts and help me through my restoration. these tank can take a beating :) mines had minimal rust inside after sitting for close to 3 years, since i have to wait for some parts to come in. im gonna take this time to paint those faded plastics, im missing a couple & cant seem to find anywhere they sell them around here. I called ZA numerous time & never got an answer.

[SpudRider]

Thanks for posting the photos, Kidd. :) A little Krylon Fusion spray paint, and some plastic/ABS side covers, and your Zong will look better than new. ;)

I'm sorry to hear Zongshen America is not returning your phone calls. :roll: Try sending them an email as well. ;) I have bought replacement plastic from Zongshen America in the past. However, you can also order the plastic parts from Taobao, in China. Fortunately, you can ride the bike without the side covers until the replacement plastic arrives. ;) You can also experiment with making side covers from sheet metal. ;)

Make sure you remember to replace the adjuster bolt on the bottom of the headlight before you go riding. ;)

I guess you removed the entire cover of the air box to clean out the crumbled air filter? For ordinary maintenance you only need to remove the four screws holding the small cover in the center of the air box. ;) However, this job is much easier if you modify the frame by cutting off one of the metal tabs, as shown in the following thread. :)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6690

http://i442.photobucket.com/albums/qq146/spudrider/Air%20Box%20Frame%20Mod/ZongMaintenance054.jpg

Spud :)

[SpudRider]

Rather than paint the front fender, I would just replace it with a Polisport Supermoto Fender. ;)

http://www.polisport-usa.com/motorbikes/produtos.php?ID=555

http://www.polisport-usa.com/motorbikes/img_upload/produtos_imagens/264_1_ficha.jpg

Spud :)

[Kidd91]

Thanks for posting the photos, Kidd. :) A little Krylon Fusion spray paint, and some plastic/ABS side covers, and your Zong will look better than new. ;)

I'm sorry to hear Zongshen America is not returning your phone calls. :roll: Try sending them an email as well. ;) I have bought replacement plastic from Zongshen America in the past. However, you can also order the plastic parts from Taobao, in China. Fortunately, you can ride the bike without the side covers until the replacement plastic arrives. ;) You can also experiment with making side covers from sheet metal. ;)

Make sure you remember to replace the adjuster bolt on the bottom of the headlight before you go riding. ;)

I guess you removed the entire cover of the air box to clean out the crumbled air filter? For ordinary maintenance you only need to remove the four screws holding the small cover in the center of the air box. ;) However, this job is much easier if you modify the frame by cutting off one of the metal tabs, as shown in the following thread. :)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6690

http://i442.photobucket.com/albums/qq146/spudrider/Air%20Box%20Frame%20Mod/ZongMaintenance054.jpg

Spud :)

after reading your comment i noticed that the adjuster bolt was missing to my headlight, while at work yesterday i talked to the previous owner/co-worker. i asked him if he had any of the plastics at his house still just to make sure before i bought the replacements

that metal tab does make it a pain to get to the air box filter, while we were cleaning the carb. we took that off to have a look at the bike & it took about 15 mins just to get it off without braking it.

i dont think i have their email address (ZA), would you still happen to have it ?

[SpudRider]

after reading your comment i noticed that the adjuster bolt was missing to my headlight, while at work yesterday i talked to the previous owner/co-worker. i asked him if he had any of the plastics at his house still just to make sure before i bought the replacements

that metal tab does make it a pain to get to the air box filter, while we were cleaning the carb. we took that off to have a look at the bike & it took about 15 mins just to get it off without braking it.

i dont think i have their email address (ZA), would you still happen to have it ?
I think the headlight adjuster bolt is the same size and thread pitch as the two mounting bolts on the sides of the headlight shroud. Try one of the other headlight bolts, and see if it fits in the bottom tab of the headlight bracket. However, don't try to force the bolt into the bracket, or you might strip the threads. 8O Either the bolt fits easily, or it doesn't. ;) If the bolt fits, you can easily find a replacement bolt at the local hardware store. :)

Here's the link to Zongshen America's website.

http://www.zongshenamerica.com/

If you click the "contact us" tab at the top of the webpage, it will take you to a web page where you can send an email. However, since you are only 20 minutes away, I encourage you to take a trip and visit Zongshen America. ;)

Spud :)

[Kidd91]

I think the headlight adjuster bolt is the same size and thread pitch as the two mounting bolts on the sides of the headlight shroud. Try one of the other headlight bolts, and see if it fits in the bottom tab of the headlight bracket. However, don't try to force the bolt into the bracket, or you might strip the threads. 8O Either the bolt fits easily, or it doesn't. ;) If the bolt fits, you can easily find a replacement bolt at the local hardware store. :)

Here's the link to Zongshen America's website.

http://www.zongshenamerica.com/

If you click the "contact us" tab at the top of the webpage, it will take you to a web page where you can send an email. However, since you are only 20 minutes away, I encourage you to take a trip and visit Zongshen America. ;)

Spud :)


Thanks Spud, i got ahold of ZA today & they told me that they'll be getting a shipment next week, While i wait im going to compose a list of the things i need & order all the parts at the same time. then go there myself &pick everything up in one shot.

im also getting set of new tires, as the ones on my zong now are a little sun dried. i dont want to take the chance with them. id rather have extra/spare parts, just in case anything were to happen id be prepared. taking advantage that ZA is close by

[SpudRider]

You are very fortunate to be so close to Zongshen America headquarters. ;) I suggest you get the following items.

At least one, spare CDI unit. If you can afford it, get two. ;)
Brake pads for the front wheel.
Spare, ABS side covers.
Several spare clutch levers.

You might also want to get spare odometer, and clutch cables.

Spud :)

[Kidd91]

You are very fortunate to be so close to Zongshen America headquarters. ;) I suggest you get the following items.

At least one, spare CDI unit. If you can afford it, get two. ;)
Brake pads for the front wheel.
Spare, ABS side covers.
Several spare clutch levers.

You might also want to get spare odometer, and clutch cables.

Spud :)

do those parts usually end up giving out? im not as knowledgeable as you are on motorcycles as you are, what does a cdi unit control?

i know ill be needing brake pads, i also need a new clutch lever. the one i have now is broken

[SpudRider]

...do those parts usually end up giving out? im not as knowledgeable as you are on motorcycles as you are, what does a cdi unit control?

i know ill be needing brake pads, i also need a new clutch lever. the one i have now is broken
CDI is an acronym for "capacitive discharge iginition." The CDI unit is the black box which controls the firing of the spark plug. The Chinese CDI units are notorious for failing. :roll: Fortunately, the Chinese CDI units are not very expensive, especially when compared to Japanese CDI units. :)

It's good to have at least one spare CDI unit, since it will greatly facilitate troubleshooting the electrical system. Also, when (not if) the CDI unit fails, you can substitute your spare CDI unit and keep on riding. Otherwise, you might need to wait a long time for the next boat to arrive from China. ;)

The front brake pads seem to last forever. I'm still using my original brake pads after 53,000 miles. :) However, the brake pads are inexpensive, and it's always good to have a spare pair handy, in case you need them. ;)

I don't know of any replacement for the Zong's clutch lever, so it's good to have several spares, especially since it is so inexpensive. Fortunately, a brake lever from the Kawaskaki KLR650 will fit your Zong.

Odometer and clutch cables will occasionally fray. Fortunately, they aren't expensive, so it's always good to have some spares on hand. ;)

If you drop your Zong, you will discover the ABS side covers are fragile. Undoubtedly, that's how the previous owner lost the original "plastic" on your Zong. If you have spare, ABS side covers, you can install them while you repair the damaged side covers. The side covers are unique to the Zong; you won't find an aftermarket replacement. ;)

Spud :)

[Kidd91]

had a day off today and got REALLY bored, and started paint today. i choe to go with neon green plastics, its a very visible color

i only got to put on the 1st coat due to windy weather. now in dimmer light i see that i messed up on it. i have to go back and even the paint, also do the back side of the plastics, i had to primer them due to sun faded areas of orange. if all else fails i might just buy new plastics from ZA.


http://s1278.beta.photobucket.com/user/ZongshenKidd91/library/Paint

for some reason my computer i saying that i am missing a plugin. this link will take you to all of the paint ing pics i have

[Weldangrind]

Looking good! 8)

http://i1278.photobucket.com/albums/y517/ZongshenKidd91/Paint/IMG_2289_zps535f4745.jpg (http://s1278.beta.photobucket.com/user/ZongshenKidd91/media/Paint/IMG_2289_zps535f4745.jpg.html)

[SpudRider]

You're off to a good start, Kidd. :D

Spud :)

[Kidd91]

Looking good! 8)


thanks guys i want to add a b;ack racing strip down the middle to hide some imperfections but other than that im happy with the outcome

[Kidd91]

today i filled my gas tank up to ride it around the neighborhood, since i havent registered it yet. i noticed that my petcock had gasoline dripping off of it. i'm no mechanic but im pretty sure that means that it needs to be changed. should i be severely concerned about this?

[Weldangrind]

If you take it apart, you'll find o-rings that can be replaced. Buy an assorted o-ring kit like the one at Harbor Freight, and you should be able to fix it.

[Kidd91]

If you take it apart, you'll find o-rings that can be replaced. Buy an assorted o-ring kit like the one at Harbor Freight, and you should be able to fix it.


yea i called my buddy who helped me get the bike running, he suggested the same thing. hopefully i can get it done tomorrow

[SpudRider]

Sometimes the problem is fixed if you just tighten things up. ;)

Spud :)

[Kidd91]

Sometimes the problem is fixed if you just tighten things up. ;)

Spud :)

tightening isnt the problem in this case. it looks like its tightened completely. before i can examine more i have to drain the tank & have a peek

i took a couple pics with the newly painted headlamp plastic attached to my bike. i have to finish the paint job still, but my main concern is getting the bike registered so that way i can get my only mode of transportation going

[Weldangrind]

Take your time. It's important that the bike is safe.

[SpudRider]

Take your time. It's important that the bike is safe.
X2; safety and reliability are paramount. ;)

Spud :)

[Kidd91]

i fixed the problem of the petcock today i found a guy parting out his zong on craigslist & i paid 45 us

[SpudRider]

That's great! :) Can you get plastic/ABS side covers from him? Is he selling the CDI unit for a fair price ($15 or so)? If you can buy the rear wheel for a good price, you can build a custom, 18-inch rear wheel using the stock hub. ;) What goodies does he have left?

Spud :)

[Kidd91]

That's great! :) Can you get plastic/ABS side covers from him? Is he selling the CDI unit for a fair price ($15 or so)? If you can buy the rear wheel for a good price, you can build a custom, 18-inch rear wheel using the stock hub. ;) What goodies does he have left?

Spud :)


all he had left was the speedometer, carb, & tank he sold everything even the frame

[SpudRider]

I'm glad you got the fuel tank, Kidd. :) What did he want for the other parts? Did you buy them?

Spud :)

[Wool-Z]

Like your choice in colors. I decided to paint my Zong this past summer . I choose the opposite though mostly all black with green front fender, green headlight plastic & green stripe down middle back fender.

[Kidd91]

Spud- i only bought that one piece.

yeah i love green & ive decided to buy an extra set of plastics & have them vinyl wrapped for when i want to show off my bike

[Kidd91]

Like your choice in colors. I decided to paint my Zong this past summer . I choose the opposite though mostly all black with green front fender, green headlight plastic & green stripe down middle back fender.



im doing the same thing with the stripe down the middle but in black