hello, im rebuilding '01 zong 200gy lets talk china bikes

[patrickzong]

http://www.mychinamoto.com/forums/attachment.php?attachmentid=10749&d=1364284752
^Before the light wreck and alabama trails in 2008

http://www.mychinamoto.com/forums/attachment.php?attachmentid=10753&d=1364284814

^current 2013
-new plastic(lifan gy150)
- minimal modifications to make it fit( Will post tutorial if needed)
of course the 150 is coming off
:lol:

I have a new front headlight on the way from china :x very long shipping time :evil: :roll:

http://www.mychinamoto.com/forums/attachment.php?attachmentid=10752&d=1364284814

also new brake light because the red plastic box broke a while ago for the stock. coming from china as well so its going to take so long to get it :cry:

http://www.mychinamoto.com/forums/attachment.php?attachmentid=10751&d=1364284814[/img]

[quadz]

Welcome to CR Patrick!

[patrickzong]

thanks man, I have always used the tutorials on here for working on this bike since no shop will touch it... other than they REALLY want to put a new exhaust on it which I agree the stock is terrible.

[edtardo]

Welcome! Can't wait to see the finished product.

[katoranger]

Welcome Patrick. I vote camo since I take it your in Alabama.

[Weldangrind]

Welcome Patrick!

Yes please, I'd be grateful for a tutorial on installing the GY150 plastics. Where did you find them? I've got a Roketa with terrible plastic, but I refuse to pay Roketa

Do you have a link for the headlight? Is it DOT?

I just bought a used TTR / XT header for my TW (which is the same as a Zong). I also bought a DG R-series muffler, because it's a bolt-on, and the price is right. I don't know how well the DG would work for you, but I bet it would be cake. There's always Spud's universal FMF two-stroke muffler option as well.

[patrickzong]

gy150 plastic- www.highrpmracer.com/body-plastic-150cc-200cc-dirt-bike-side-cover-black-p-10667.html

I will post some pictures soon to make the plastic fitting easier, its pretty much just using the existing mount right behind the seat end and making a hole next to a airbox mounting screw

the headlight is on ebay, it's says in the description that its for long range only but with my electric wiring and soldering skills i can fix any problem along the way. http://r.ebay.com/QcCzGl

I'll look into that header and exhaust, im just really tired of that fake fatty shielded pipe that comes stock on this bike, it looks even worse with the shield off.
thanks for the advice buddy!!

[SpudRider]

Welcome, fellow Zongite! :D

I moved your thread to the Dual Sport Forum so it will get more exposure. ;) Please do post a new thread showing us how you modified the Lifan plastic to fit your Zong. :)

Spud :)

[SpudRider]

I think both color schemes will look good on your Zong. However, I voted for Mossy Oak Camo, since I would love to see the final result. :) Also, I think you should give experiment with the camouflage paint job, since it is very easy to switch to matte black if you don't like the results. ;)

Spud :)

[patrickzong]

http://store.mossyoak.com/detail.aspx?ID=7762
^ I was thinking of buying these or maybe even an off brand to get a longer sheet, the black frame would go nice with the "obsession" pack though.

my next day off I will put together that tutorial

if I mess with my carb again soon I will show the airbox tube extension I did with only the original parts(not very fond of taking apart half the bike to clean a carb :x )

im thinking of buying another bike as well, a guy in alabama is selling a 1980 Kawasaki KZ750 LTD for 800 and its a STEAL all it needs is a battery a seat and tank :?: :?: :roll:

Thanks spud! I have always been on the forums using the tutorials and decided my project is enough in motion I actually have stuff to talk about!

[SpudRider]

The plastic "hose" from the air box to the carburetor is really nasty. :roll: I am very glad I pulled out the plastic "hose," and replaced it with the real rubber hose from the Yamaha TW200. ;) I ordered, and installed part #6 in the following diagram.

http://images.powersportsnetwork.com/fiche/images/YAMAHA/2006/motorcycles/18065_intake.gif

The Yamaha hose fits perfectly! Removing and installing the carburetor is now a simple task, and the air seal is perfect! :D

Spud :)

[patrickzong]

I was looking at that post you did and I decided if my idea didn't work out I would go that route.

basically I just pulled the existing hose out to the that second lip and put some sealant around the edges

by the way do you know what socket size the spark plug is? my spark plug socket set lost in a move and I dont feel like buying an entire set. :lol:

[SpudRider]

The D8EA spark plug fits an 11/16-inch, or 18mm socket. ;)

Spud :)

[zingshoen]

i think my next bike project is going to be camouflage, coz i ve exhausted my other fave colours :-)

[Weldangrind]

gy150 plastic- www.highrpmracer.com/body-plastic-150cc-200cc-dirt-bike-side-cover-black-p-10667.html

I will post some pictures soon to make the plastic fitting easier, its pretty much just using the existing mount right behind the seat end and making a hole next to a airbox mounting screw

the headlight is on ebay, it's says in the description that its for long range only but with my electric wiring and soldering skills i can fix any problem along the way. http://r.ebay.com/QcCzGl

I'll look into that header and exhaust, im just really tired of that fake fatty shielded pipe that comes stock on this bike, it looks even worse with the shield off.
thanks for the advice buddy!!

It looks like those panels will bolt on to my Roketa without any mods. Did the decals come off easily?

I doubt that headlight is DOT, but as long as it's bright enough (and adjustable), I don't see the problem. If you like it, I might buy one for my bike.

[patrickzong]

I mean I live in alabama and the cops probably dont even know what dot is hahaha

it may fit your roketa im not to sure, if it does not fit ,finding some mount points to drill holes isn't that difficult (dont be afraid of that airbox, its your friend when it comes to this just make sure you put some good sealant on the inside of the airbox where the screw came through)

my zongs original tail piece does not line up with the new side panels
I dont mind personally because I think that the back end looks pretty cool without it
when the new tail light comes in Im going to mess around with the idea of mounting it on top of the tail instead of on the bottom if that isn't to complicated for me to explain haha

[Weldangrind]

That makes perfect sense. I'm sorting out how to deal with the existing Roketa tail, since the fender is in pieces. I have a generic black rear fender, and I'm hoping to make that work.

[patrickzong]

http://25.media.tumblr.com/6c089b6abb7b7c147d9b4a4fe6345be5/tumblr_mkgn8kpwVt1qfxf5ao1_500.jpg

I had a little time so I thought i would post a better picture of what i ment about that back end and not having the tail piece. It will improve with that tail light im waiting on.

[SpudRider]

http://25.media.tumblr.com/6c089b6abb7b7c147d9b4a4fe6345be5/tumblr_mkgn8kpwVt1qfxf5ao1_500.jpg

I had a little time so I thought i would post a better picture of what i ment about that back end and not having the tail piece. It will improve with that tail light im waiting on.
You can also get plastic side covers from Zongshen America, or Taobao. ;)

http://25.media.tumblr.com/6c089b6abb7b7c147d9b4a4fe6345be5/tumblr_mkgn8kpwVt1qfxf5ao1_500.jpg

http://item.taobao.com/item.htm?spm=a230r.1.14.24.0Un0L5&id=23511856002

http://img01.taobaocdn.com/bao/uploaded/i1/19902020829484673/T1x9tRXs0aXXXXXXXX_!!0-item_pic.jpg_310x310.jpg

Spud :)

[patrickzong]

I would go back to the original pieces but i dont have the lower plastic part that covers up the electronics on the right side. I would love to move those electronics but I can find a safe place to do so.

[SpudRider]

I would go back to the original pieces but i dont have the lower plastic part that covers up the electronics on the right side. I would love to move those electronics but I can find a safe place to do so.
Are you talking about the black side covers with the round "dimples?"

http://item.taobao.com/item.htm?spm=a230r.1.14.156.qN8mGo&id=16215582470

http://img02.taobaocdn.com/bao/uploaded/i2/12040018779746238/T1IAguXcXaXXXXXXXX_!!0-item_pic.jpg_310x310.jpg

If so, you can also buy these side covers from either Zongshen America, or Taobao. :)

Spud :)

[patrickzong]

YOU ROCK SPUD! :D

[patrickzong]

ok i ran into a problem, i think my shifter shaft is in half. I can get it into first but thats it, it will not go to second, the shifter moves freely up like its going to shift but there is no click or gear change. any help would be awesome

[SpudRider]

ok i ran into a problem, i think my shifter shaft is in half. I can get it into first but thats it, it will not go to second, the shifter moves freely up like its going to shift but there is no click or gear change. any help would be awesome
First of all, check to make sure the bolt on the shift lever is tight. If the bolt won't tighten fully, remove the shift lever and widen the gap between the bolt with a hacksaw/dremel tool. After you re-install the shift lever, you will be able to tighten the bolt more securely. ;) Also, rotate the shift lever down a notch, so you don't have to lift the lever so high in order to upshift. ;)

If the bolt on the shift lever is tight and rotating the lever downward doesn't help, you probably need to swap the dowels on the shift drum which is engaged by the shift shaft pawl. To perform this procedure you need to drain the engine oil and remove the right crankcase cover. You can read about this procedure at the following thread. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=14248

Spud :)

[patrickzong]

looks like i have an off day project.

[SpudRider]

looks like i have an off day project.
Hopefully you can fix the problem by rotating the shift lever and/or tightening the bolt. If those fixes don't work, I suggest you start a new thread on your shift lever repair, and take lots of photographs. :) We can talk you through the repair, step-by-step, and the resulting thread will be a helpful resource for future Zong owners who encounter this problem. ;)

Spud :)

[Weldangrind]

If the bolt on the shift lever is tight and rotating the lever downward doesn't help, you probably need to swap the dowels on the shift drum which is engaged by the shift shaft pawl. To perform this procedure you need to drain the engine oil and remove the right crankcase cover. You can read about this procedure at the following thread. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=14248

Spud :)

I had forgotten about that thread. Thanks for the reminder, Spud.

[patrickzong]

http://25.media.tumblr.com/4cdaf5b4834f4cead4c03b2f9812a507/tumblr_ml11hjCnuC1qfxf5ao1_1280.jpg


http://25.media.tumblr.com/78d0011a4563a7b644b5bb56a207578a/tumblr_ml11hjCnuC1qfxf5ao2_1280.jpg


FINALLY got goodies from china
still working on it, will post more pictures

[Weldangrind]

I like that rear fender. Does it have a provision for a plate?

[SpudRider]

It's always nice to see goodies arrive! Both headlight and fender look great. :D

Spud :)

[patrickzong]

it does not have a place for the plate right now but i'll figure something out,
i REALLY like the headlight, im in the process of the lighting but have to wait for a day off to finish. I will continue posting to this thread and any mod's or repairs will be on the appropriate blog but also linked to this main blog.

[patrickzong]

tag light is on when brakes are off
http://24.media.tumblr.com/71910294b01a50d634bd339dbd059bd9/tumblr_ml2qk3H8VK1qfxf5ao1_1280.jpg
brake light
http://24.media.tumblr.com/be2daa4e784af0c6d408d569ada2d471/tumblr_ml2qk3H8VK1qfxf5ao2_1280.jpg

I used the original tail light connector clip and found out what wire are what by trial and error
once i had the figured out I went to solder and wrap
http://24.media.tumblr.com/3e9777e73fab9ff06df8bd6402b299a5/tumblr_ml2qk3H8VK1qfxf5ao3_1280.jpg

http://24.media.tumblr.com/16a6ad078fe120503afb86858fedd5a4/tumblr_ml2qk3H8VK1qfxf5ao4_1280.jpg

this is getting real fun guys, thanks for all the help and support. nice to know there are great china riders out there.

[SpudRider]

That is a very nice tail light. :D Thanks for sharing your project with us, fellow Zongite!

Spud :)

[Weldangrind]

That's really cool. 8)

So I understand, does the tail light have a separate lens underneath for lighting the tag? Do you have an eBay link for that fender?

[patrickzong]

this is the ebay link
http://www.ebay.com/itm/290803968757?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
it's from china and will take at the least 3 weeks to get to you
the tag light is another row of l.e.d.'s in the housing next to the red brake l.e.d.'s

as for the tag im still working something out, im in the process of selling my drums and getting an older cruising bike with a bigger motor.

my idea is to work out a series of metal rods and small dual mounted clamps to make a plate holder,i'll go to home depot after pay day and see if I can work something up.

the tail light can also be mounted underneath the bar where the original was, i just did mine on the top because my stock rear plastic isn't fitting at the moment.

[SpudRider]

...my idea is to work out a series of metal rods and small dual mounted clamps to make a plate holder,i'll go to home depot after pay day and see if I can work something up.

the tail light can also be mounted underneath the bar where the original was, i just did mine on the top because my stock rear plastic isn't fitting at the moment.
Can you mount the license plate directly to the fender? If not, you can also go the local, trailer supply store, and buy a Webar 003201, license bracket for $1.99. ;)

http://images.oreillyauto.com/parts/img/medium/wsb/003201_a.jpg

Spud :)

[patrickzong]

i need some help figuring out how to find a part
im looking for the top clamps for the handlebars but im not sure how many mm the handle bar is or if others would work.

[SpudRider]

i need some help figuring out how to find a part
im looking for the top clamps for the handlebars but im not sure how many mm the handle bar is or if others would work.
The Zong has a standard, 7/8-inch handlebar. Therefore, I presume you could use any top clamps which fit a 7/8-inch handlebar. Also, you might be able to order handlebar clamps from either Zongshen America, or Taobao.

Spud :)

[Weldangrind]

Zong clamps from whatever source would be your best bet, since the center to center distance will be correct, as will the offset. The offset that is machined into the clamps is matched to the top triple tree, and it's important to install them the right way around.

[SpudRider]

I hope I didn't give you bad information, Patrick. I thought you were looking for only the very top part of the handlebar clamps. :roll:

Spud :)

[SpudRider]

Zong clamps from whatever source would be your best bet, since the center to center distance will be correct, as will the offset. The offset that is machined into the clamps is matched to the top triple tree, and it's important to install them the right way around.
Please explain what you mean by "offset," Weld. :)

Spud :)

[Weldangrind]

Pehaps I should have said gap instead of offset. For the benefit of riders who may be new to the sport, the handlebar clamps are usually designed so that there will be a gap between the top clamp and the saddle.

The idea is to have no gap at the front of the clamp (what we'll call the headlight side) and a small gap at the rear (the rider side). Place a clamp on a table or other flat surface, and you'll see what I mean. On Yamahas, there is usually a punch mark that helps you to determine which way the clamps should sit, but our beloved China bikes don't have such a mark.

Once you've identified the long side, place it facing forward on the saddle, and torque it to around 20 ft/lbs. Once it's torqued, do the same for the short side (again, that faces the rider) and torque it as well.

Make sense?

[SpudRider]

Thank you for the posting the good information, Weld. :) In your description, when you say "saddle," I assume you are describing the bottom portion of the handlebar clamp.

I have another question. ;) Shouldn't all the top clamps designed for 7/8" handlebars work for all 7/8" handlebars? :?:

Spud :)

[Weldangrind]

Ideally, but there's no standard for that. The clamps may be different heights, widths and lengths, and they may have dissimilar center-to-center bolt spacing, along with dissimilar rear gaps.

Most of the holes are bored to 7/8", but that's only part of the story.

[patrickzong]

I havn't moved onto any of that yet sadly, im still trying to find a manual to be able to replace my shifter pawl because I can only get into 2nd until it will not shift anymore. also having trouble finding the correct fuse used and get to fire it up but then the fuze goes.

[SpudRider]

I havn't moved onto any of that yet sadly, im still trying to find a manual to be able to replace my shifter pawl because I can only get into 2nd until it will not shift anymore. also having trouble finding the correct fuse used and get to fire it up but then the fuze goes.
If the fuse keeps blowing, you have an electrical short somewhere in your wiring harness. :( You need to find the short, and repair it, before you go any farther. ;) My Zong uses a 15 Amp, cylindrical fuse.

You don't need to replace the shifter pawl. You can learn how to repair your shifter by reading the following thread. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=14248

Spud :)

[patrickzong]

im stuck at the clutch assembly there is a large nut that seems to be the only thing holding it on but it wont budge

[SpudRider]

im stuck at the clutch assembly there is a large nut that seems to be the only thing holding it on but it wont budge
You are correct. The clutch perch assembly is held by a single bolt which is located just to the right of the turn signal switch. This bolt is not very large. I believe it is an 8mm bolt. You should be able to remove this bolt easily with a socket wrench. ;)

Spud :)

[patrickzong]

http://24.media.tumblr.com/9f3884ac1682f7461d8d99c1e6010567/tumblr_mlozmcCWfs1qfxf5ao1_500.jpg
this one

[SpudRider]

I read a lot of posts. :? Now I remember; you are trying to fix your gear shifter. ;)

First of all, you need to straighten the tab which is locking the nut in place. You can straighten the tab by gently tapping it with a punch and hammer. After the tab is straight, you will need a clutch holding tool. After you remove all the clutch plates, this tool holds the outer clutch basket while you loosen the nut.

http://www.rockymountainatvmc.com/p/43/-/171/989/-/18289/Tusk-Clutch-Holding-Tool?term=clutch+holder+tool

http://www.rockymountainatvmc.com/images/prod/400/t/tus_08_clu_hol_too.jpg

If you have an impact wrench, you can also loosen the nut. However, you can't set the proper torque when you re-install the clutch basket, unless you have a clutch holding tool. ;)

Spud :)

[SpudRider]

Incidentally, that nut is torqued to a very high setting. Therefore, you might need a breaker bar to loosen the nut, in addition to the clutch holding tool.

http://www.harborfreight.com/38-drive-17-breaker-bar-67931.html

Make sure you get the proper size socket to fit the nut, and any adapters you might need to fit the socket to the breaker bar.

If you don't have one, you also need a torque wrench to secure the clutch nut with the appropriate tightness.

http://www.harborfreight.com/3-8-eighth-inch-drive-click-type-torque-wrench-807.html

You can find the appropriate torque value in the Yamaha, TW200 Service Manual. The service manual can be downloaded from a link in the Zong Sticky, located at the top of the Dual Sport Forum. ;)

Spud :)

[SpudRider]

You should read the following thread entirely before you continue this project. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=14248&postdays=0&postorder=asc&start=30

In particular you should note the following information. I encountered only one problem while repairing my Zong's gear shifter. Both Yamaha and Zongshen engines employ phillips head bolts to hold the oil pump in place. I removed these bolts easily with my impact screwdriver. If you don't have one, you should get an impact screwdriver.

http://www.harborfreight.com/impact-screwdriver-set-with-case-37530.html

Yamaha uses a Torx bolt to hold the shift drum cam in place. However, Zongshen uses another phillips head bolt. :roll: Using the same tools and techniques I used to remove the oil pump, I stripped the phillips head bolt on the shift drum cam. :evil: However, I successfully removed the stripped bolt with an EZ Out, drill bit. :D

http://www.harborfreight.com/12-piece-screw-extractor-set-40349.html

When I reassembled the motor, I replaced the bolt in the shift drum cam with a Yamaha Torx bolt from an XT200 engine. ;)

Spud :)

[patrickzong]

thank spud, im ordering that clutch holder next pay day. I recently got a new toy and as soon as i get it in my garage tomorrow a few pics will be posted but forewarned its a japanese bike with a big ol' engine.1980 kawasaki kz750
http://24.media.tumblr.com/115ef7242c47ec4a32acacad373efbf5/tumblr_mlqcn02v171qfxf5ao1_1280.jpg

[SpudRider]

Congratulations! If you have time, please start a new thread on your KZ750 in our Other Stuff Forum. :D

Spud :)

[patrickzong]

did and done :D still cant wait to get the zong up and runnin, it really has taught me a lot about working on motorcycles so much so I can revive a 33 year old bike. i want to get to where I can pick and choose what motorcycle i want to drive to work :lol: :roll:

[zingshoen]

i know the feeling!

and congratulations, the kz 750 is a great bike.

[patrickzong]

i have another forum just for the kz750

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=15722

its an extremely sound bike and if there are any transmission problems i WILL NOT do the repair myself since it's a lot more complex.

with my zong i only have to worry about one carb working on my kz i have to deal with 4!!
the zong is defiantly a more adventure bike for me and the kawasaki is a downtown cruiser to run downtown and the windy roads after work.[/url]

[patrickzong]

so I have no idea how this happened or how to get a replacement part, just thinking of putting the bike together and sell as is on craigslist

[SpudRider]

so I have no idea how this happened or how to get a replacement part, just thinking of putting the bike together and sell as is on craigslist
That's not a major problem, Patrick. ;) You can get a right crankcase cover (clutch cover) from Zongshen America, Taobao, or Yamaha. :)

http://item.taobao.com/item.htm?spm=a230r.1.14.153.M4SSfb&id=4347477630

http://img01.taobaocdn.com/bao/uploaded/i1/T1WGxtXaJyXXbT4vDX_084851.jpg_310x310.jpg

That part costs 120 Yuan, plus 20 Yuan for domestic shipping to a TBTrends agent. Therefore, the cost is only $22.77 USD, plus shipping charges from China to your doorstep. ;)

[patrickzong]

what do you think caused it? could it have been from putting it on at a slight angle? this thing has gotten me scratchin my head but heck i like a challenge as long as its a cheap one. Im about to have my kz750 in the shop so this is going to get lovin for a while. picked up a 50cc mini chopper too, short build to sell and buy atv to fix up and clear wooded area in the back yard. may just post before and after pics in here since its just 4 photos and i wont have it that long


also i dont know how to order from that site, my google chrome translator is only doing so much

[SpudRider]

what do you think caused it? could it have been from putting it on at a slight angle? this thing has gotten me scratchin my head but heck i like a challenge as long as its a cheap one...
It beats me, Patrick. :hmm: I don't know how you did it. :shrug: However, it's not an expensive thing to fix. ;)
...also i dont know how to order from that site, my google chrome translator is only doing so much
You can learn how to order from TBTrends by reading the following threads.

http://www.chinariders.net/showthread.php?t=10750
http://www.chinariders.net/showthread.php?t=11529

You can contact Zongshen America to order the part from them.

http://www.zongshenamerica.com/

You can also order the part for the Yamaha TW200; it will fit perfectly.

http://www.cyclepartswarehouse.com/fiche_section_detail.asp?section=199570&category=motorcycles&make=YAMAHA&year=2006&fveh=4539

[patrickzong]

it looks like I will have to pay 170+ for a new cover, i have not had any luck finding the parts any where else and I want to get this out of my garage asap so I can get some other projects finished off. I plan on getting another enduro after i sell the zong though, there is one for sale down the road for 250 that just needs some tlc
I want to go more street fighter and less trail blazer. minimal fairings and some bold street tires with spokes.

[SpudRider]

Did you get a chance to check out the clutch cover I mentioned in post #59? It will surely cost you much less than a Yamaha clutch cover. ;)

[patrickzong]

I have been looking around, I have found a yamaha cover that i may get or try at the chinese website. I have had no luck finding a performance exhaust header maybe like a 4 stroke fmf system or something, after i figure out that i can get a new muffler.

[SpudRider]

I have been looking around, I have found a yamaha cover that i may get or try at the chinese website. I have had no luck finding a performance exhaust header maybe like a 4 stroke fmf system or something, after i figure out that i can get a new muffler.
I installed a stainless steel, exhaust header from an XT225. I then mounted an FMF Universal Spark Arrestor. This installation is very simple to perform, and very robust. My Zong lost a lot of weight after ditching the very restrictive, very heavy, stock muffler, and my engine now performs better as well. :)

http://www.chinariders.net/showthread.php?t=5974
http://www.chinariders.net/showthread.php?t=6916

[patrickzong]

I havnt had any luck looking for a highflow header is what I should of said, http://www.chinariders.net/attachment.php?attachmentid=408&stc=1&d=1380047841
something like that, Im sure i would have to rejet or something to get a high flow.
http://www.fmfracing.com/Products/MX/264

that xt225 header does look nice though and would be a nice alternative if I cant figure out how to do this high flow. thanks for the advice though man!