Zongshen 200GY-2: CDI Diagrams and Compatibility

[SpudRider]

I decided it would be a good idea to combine the information regarding the Zongshen, 200GY-2 CDI unit into a single thread. The Zongshen Sierra (200GY-2) employs an AC-CDI unit, which has part number Z067-001. Here is a diagram showing the pin cofiguration for the CDI unit.

http://attachments.motorfans.com.cn/2011/02/18/QKQiITnXs5675.jpg

Pin #1: Connects to the positive lead from the pickup coil/pulse generator
Pin #2: Connects to the negative lead from the pickup coil/pulse generator
Pin #3: Connects to ground
Pin #4: Connects to the primary lead of the ignition coil
Pin #5: Connects to the kill switch
Pin #6: Connects to the negative lead of the exciter/charge coil of the stator
Pin #7: Connects to ground
Pin #8: Connects to the positive lead of the exciter/charge coil of the stator

Here is a wiring diagram which shows how the Zongshen CDI unit connects to the rest of the electrical system.

http://i1237.photobucket.com/albums/ff466/cromiro/zong200cc.jpg

The CDI unit for the Zongshen 200GY-2 can be purchased from Taobao.com. Make sure you order an AC-CDI unit, with part #Z067-001. ;)

[SpudRider]

Here is the wiring diagram for the Zongshen 200GY-2, as provided in the European Service Manual for the bike.

http://i442.photobucket.com/albums/qq146/spudrider/Zongshen%20CDI%20Unit/ZS200GY-2WiringDiagram_zpsa47eef5a.jpg (http://s442.photobucket.com/user/spudrider/media/Zongshen%20CDI%20Unit/ZS200GY-2WiringDiagram_zpsa47eef5a.jpg.html)

[SpudRider]

The Chinese CDI units have been known to fail, so it is always a good idea to have a spare CDI unit on hand. The spare CDI unit greatly facilitates troubleshooting the bike's electrical system. Also, should your CDI unit begin to falter, you can install the spare CDI unit, and go riding, instead of waiting for a replacement to arrive from China. ;)

It is also important to know the stator and pickup coil will eventually fail for any motorcycle where these units are bathed in engine oil. After many miles of operation the hot engine oil will eventually remove the varnish from the wire coils, resulting in short circuits for either the stator, and/or the pickup coil. :ohno:

If the spare CDI unit doesn't solve your electrical problems, you should measure the resistance values for the stator and pickup coil, as explained in the following thread. ;)

http://www.chinariders.net/showthread.php?p=152756#post152756

I recently replaced the stator and pickup coil on my Zongshen 200GY-2. My Zong's fuel mileage has increased, and the engine once again purrs from idle, to wide-open-throttle. :tup: You can purchase the Zongshen stator and pickup coil from Taobao.com. ;)

Incidentally, the Yamaha stators and pickup coils will also fail. ;) I recently helped my good friend Andy replace the stator and pickup coil in his 2004 Yamaha TT-R225 with Zongshen parts. At that time we also, necessarily, switched his bike over to the Zongshen CDI unit. ;) The Yamaha replacement parts would have cost over $500. :wtf:

The Zongshen stator and pickup coil fit perfectly inside his Yamaha stator cover. :) We connected the appropriate wires from his wiring harness to the Zongshen parts, and his bike runs great. :tup: Here is the TT-R225 wiring diagram from the Yamaha Service Manual.

http://i442.photobucket.com/albums/qq146/spudrider/Yamaha%20TT-R225%20CDI%20Conversion/TT-R225WiringDiagram_zpsbecda509.jpg (http://s442.photobucket.com/user/spudrider/media/Yamaha%20TT-R225%20CDI%20Conversion/TT-R225WiringDiagram_zpsbecda509.jpg.html)

If wired properly, the Zongshen stator, pickup coil, and CDI unit will work perfectly in the following Yamaha motorcycles. :)

XT200
TW200
XT225
TT-R225
TT-R230

I purchased the appropriate wiring harness for the Zongshen CDI unit from eBay. The Zongshen CDI unit employs the same wiring harness as the Lifan 150cc pit bikes. ;)

http://www.ebay.com/itm/WIRE-HARNES-150CC-LIFAN-ENGINE-PIT-BIKE-/130554557680?hash=item1e65a874f0&item=130554557680&pt=Motorcycles_Parts_Accessories&vxp=mtr#ht_4216wt_985

http://i.ebayimg.com/00/$(KGrHqYOKnUE4LE9rp+BBOMU-7ROig~~0_12.JPG

[SpudRider]

Here are links to a few more threads containing information on the CDI unit for the Zongshen 200GY-2.

http://www.chinariders.net/showthread.php?t=11073
http://www.chinariders.net/showthread.php?t=8576
http://www.chinariders.net/showthread.php?t=10117
http://www.chinariders.net/showthread.php?t=9748

[Weldangrind]

Excellent info!

I've considered switching my TW to Zong wiring, since I can buy a box full of Zong CDI's for the price of one used Yamaha CDI.

[SpudRider]

Brother Andy didn't have any spark for his 2004 TT-R225. We measured the resistance for the pickup coil, and got zero ohms, which is a direct short circuit. :ohno: We then measured the resistance of the source/exciter coil, and it was below specifications. :tdown:

I had a spare Zongshen stator and pickup coil handy, so we drained the oil and installed them in the Yamaha stator cover. Needless to say, the Zongshen parts fit perfectly. ;) At that point, it was simplest, and wisest, to also covert to the Zongshen, Z067-001 CDI unit. After making all the correct connections, the bike fired right up. :tup:

Andy says his TT-R225 has never run better. :) Now that he has a strong, consistent spark, his fuel mileage has also increased about 25 mpg. ;)

[Weldangrind]

Wow! I jump of 25mpg is considerable.

I already have the Zong wiring harness, so I might as well buy the CDI, etc.

[culcune]

I never had an issue with my '09 bike's CDI, so was surprised when I pulled up to the main prison gate on my new TMEC, the bike died when I was showing my ID, and would not restart. Fuel was near full, and spark plug was still silver with no hint of carbon buildup. I got a ride home, got on Chinariders, and someone with a Skyteam had the same issue as to bike not starting, and someone mentioned CDI. I drove all the way back to work with my '09's CDI and tools, and realized that I did not bring my keys once I had swapped out the CDI. A coworker gave me a ride the next morning (I made sure I had the keys!), and since the bike was parked near the main prison gate, I hopped on the bike, turned the key, and she started right up (I had failed to bring a helmet or even my 'Ducati' Oakley sun-glasses since we don't have a helmet law but one is required to have eye protection if the bike does not have a windshield), unexpectedly, since I doubted it would be such a simple fix.

I rode the 16 miles home with the wind whipping through my hair, eyes, and mouth. Called Excalibur, and they sent me a warranty CDI as well as I paid for an extra one. I theoretically have 3 spares, just in case!

[humanbeing]

DC CDI
http://attachments.motorfans.com.cn/2010/10/20/wMDPYWeVD5152.jpg
U can try that if knows the stuff. Pin 7/8 = Nil
---
The connector http://item.taobao.com/item.htm?id=36436062840 These 8 pin are very common on late year Suzuki.
---
...measured the resistance of the source/exciter coil, and it was below specifications...
Some chinese mechanic are very lazy to open the cover. Quick Solution: This http://item.taobao.com/item.htm?id=5279928900 thingy that mocks it OR DC-cdi

[Weldangrind]

Some chinese mechanic are very lazy to open the cover. Quick Solution: This http://item.taobao.com/item.htm?id=5279928900 thingy that mocks it OR DC-cdi

Is that a voltage amplifier?

[Weldangrind]

U can try that if knows the stuff. Pin 7/8 = Nil

Are you saying that pin 7 & 8 are not used?

[SpudRider]

...The connector http://item.taobao.com/item.htm?id=36436062840 These 8 pin are very common on late year Suzuki.
---

Some chinese mechanic are very lazy to open the cover. Quick Solution: This http://item.taobao.com/item.htm?id=5279928900 thingy that mocks it OR DC-cdi

Thanks for posting the link to the 8-pin connector, HumanBeing. :) That particular connector has 8 blue wires; I hope some of the others have 8 wires of different colors. ;)

Do you substitute the following part for the standard ignition coil?

http://item.taobao.com/item.htm?id=5279928900

[SpudRider]

Are you saying that pin 7 & 8 are not used?

Yes, instead of connecting to an exciter/source coil on the stator, the DC-CDI unit is connected to the 12V battery at pin #6. Pin #8 is not used, and pin #7 is either connected to ground, or not used.

I have a DC-CDI unit in my Honda XR650L, and I am not a big fan of the DC-CDI units. :ohno: I prefer the AC-CDI units installed in both my Zong, and my Honda CRF250X. ;) The DC-CDI units have an internal transformer which boosts the 12V supplied by the battery to charge the capacitor. However, this internal transformer gets hot during operation, and the thermal cycling of this transformer can weaken the solder joints, or damage other components inside the DC-CDI unit. :tdown:

If the hot engine oil damages the exciter/pulse coil on the stator, it will undoubtedly also damage the pickup coil and the charging coils of the stator. Therefore, I don't think the DC-CDI unit is more reliable than the AC-CDI unit. Indeed, in my experience, the DC-CDI unit is less reliable, because of the heat generated by the internal transformer. Therefore, I personally would not convert from an AC-CDI unit to a DC-CDI unit. I would rather replace the stator periodically, or whenever it begins to fail. ;)

[SpudRider]

Wow! I jump of 25mpg is considerable.

I already have the Zong wiring harness, so I might as well buy the CDI, etc.

I haven't examined the TW200 wiring diagram, but I suspect you will need to rewire the kill switch if you convert to a Zongshen CDI unit. ;) Brother Andy rewired his kill switch so it would ground pin #5 of the Zongshen CDI-unit. The Yamaha bikes are killing the engine using a different method which I don't understand. ;)

[Weldangrind]

I have a DC-CDI unit in my Honda XR650L, and I am not a big fan of the DC-CDI units. :ohno: I prefer the AC-CDI units installed in both my Zong, and my Honda CRF250X. ;) The DC-CDI units have an internal transformer which boosts the 12V supplied by the battery to charge the capacitor. However, this internal transformer gets hot during operation, and the thermal cycling of this transformer can weaken the solder joints, or damage other components inside the DC-CDI unit. :tdown:

Does the headlight come on without the engine running in any of your bikes?

[humanbeing]

...I hope some of the others have 8 wires of different colors...
Vinyl Tape works good in marking the difference.
Qualified sparky in China always stocks these color http://item.taobao.com/item.htm?id=15260137841 | http://item.taobao.com/item.htm?id=36602654320
I "borrowed" the whole color collection from my contractor uncle when doing improvement project in the ancestral house. ***second great grandpa was in OZ during gold rush & made some fortune to built it.
---
off topic:
In theory , it's as national standard BUT many are wired as "old" British in my home county.
http://en.wikipedia.org/wiki/Three-phase_electric_power#Color_codes
---

[SpudRider]

Does the headlight come on without the engine running in any of your bikes?

Yes, the headlight illuminates when the ignition key is activated for both my Zongshen 200GY-2, and my Honda XR650L. The Zong employs an AC-CDI unit, and the XR650L employs a DC-CDI unit.

My CRF250X had a lighting coil for an AC headlight, but I converted my CRF250X to a pure DC system using a Trail Tech stator and regulator/rectifier. :tup:

http://www.rockymountainatvmc.com/p/955/20359/Trail-Tech-Complete-Stator-Kit?term=trail%20tech%20stator

http://www.rockymountainatvmc.com/images/prod/400/t/tra_08_com_sta_kit_100w_yfz.jpg

The CRF250X has an AC-CDI unit.

The DC-CDI units for the Honda XR650L are notorious for failure. These CDI units become noticeably hot during operation. The solder joints on the printed circuit board of this DC-CDI deteriorate, and fail. Most people suspect the thermal cycling of the internal transformer is responsible for the ruined solder joints. :ohno:

[Weldangrind]

Interesting.

My Lifan will run the headlight with the engine off, but my TW will not, nor will my old TS Suzukis.

[SpudRider]

Interesting.

My Lifan will run the headlight with the engine off, but my TW will not, nor will my old TS Suzukis.

The two-stokes bikes usually don't have a battery. They employ a kick starter, and use an AC lighting coil on the stator to illuminate the headlight. Therefore, the engine must be running, and the flywheel turning, before the lighting coil generates AC electricity for the headlight.

What model year is your TW200? It must have a lighting coil. If so, you will convert your TW200 to a pure DC system if you install the Zongshen stator. The Zongshen system will generate more power to charge your battery, and will give you a nice, steady headlight at all rpms. :)

However, you will probably need to install a larger regulator/rectifier. I suggest you get the unit employed by my Zongshen 200GY-2. You will also need to connect your headlight to a keyed power line which is connected to the battery. ;)

[Weldangrind]

All three of my old TS Suzukis are factory dual sport bikes, so they're all equipped with batteries.

My TW is a '93, and it was built before the introduction of the more powerful stator. I might upgrade eventually. If I do, I'll change to all Zong.

[SpudRider]

All three of my old TS Suzukis are factory dual sport bikes, so they're all equipped with batteries...

That's interesting. The Honda CRF250X is similar. It has a battery for an electric starter, but it still employs an AC lighting coil for the headlight. :hmm: I'm much happier after I converted my CRF250X to a pure DC system. :)

...My TW is a '93, and it was built before the introduction of the more powerful stator. I might upgrade eventually. If I do, I'll change to all Zong.

You can't go wrong if you go all Zong. ;)

:hehe:

[SpudRider]

Vinyl Tape works good in marking the difference.
Qualified sparky in China always stocks these color http://item.taobao.com/item.htm?id=15260137841 | http://item.taobao.com/item.htm?id=36602654320
I "borrowed" the whole color collection from my contractor uncle when doing improvement project in the ancestral house. ***second great grandpa was in OZ during gold rush & made some fortune to built it.
---
off topic:
In theory , it's as national standard BUT many are wired as "old" British in my home county.
http://en.wikipedia.org/wiki/Three-phase_electric_power#Color_codes
---

Thanks for reminding me about the vinyl tape, HumanBeing. :)

[humanbeing]

...I hope some of the others have 8 wires of different colors...
Below maybe the right connector:
===
Chinese: DJ7081Y-2.3-21 http://item.taobao.com/item.htm?id=39109777167
Furukawa https://www.furukawa.co.jp/tukuru/pdf/auto/auto_wpcon_01rfw.pdf
===

[SpudRider]

Indeed, that appears to be the correct connector! Thank you, HumanBeing. :tup:

[gilben91]

Anyone have any clue where i'd be able to get a proper wiring harness for the 2006 zongshen ZS200GY desert fox. i've looked everywhere but it seems like the only part i cant find.

[Weldangrind]

Anyone have any clue where i'd be able to get a proper wiring harness for the 2006 zongshen ZS200GY desert fox. i've looked everywhere but it seems like the only part i cant find.

Welcome! Thanks for joining us. I recommend Taobao, since I've purchased several parts there for the ZS200GY, although not for a few years.

[humanbeing]

Welcome! Thanks for joining us. I recommend Taobao...
:) Keywords: 电缆 沙漠飞狐

[Whitapple1]

Do you know if the CDI units are still available from Taobao? I looked at their website and entered the part number in the search box but didnt find anything. Anyone in the US selling these units? I have a 2006 200 GY tht has a failed cdi unit.

[NzBrakelathes]

Do you know if the CDI units are still available from Taobao? I looked at their website and entered the part number in the search box but didnt find anything. Anyone in the US selling these units? I have a 2006 200 GY tht has a failed cdi unit.

I might be able to help but I am a seller etc.

[humanbeing]

Do you know if the CDI units are still available from Taobao...
Use image search
https://www.youtube.com/watch?v=YTALDcM2Ero
[Hints]
Item #: 39214124554 [交流CDI] / Agent: sup**buy / shipping method: EUB (known as ePacket in proper English)

[Lakamla]

Salut ,
Sur mon boîtier CDI Zongshen, référence zs201223 sur les 8 pin le faisceau utiliser que 5 branchement,
J'aimerais installé un CDI racing de chez Ali express le Bleu a 10 ou 15 euro

[Lakamla]

Es ce que les CDI Zongshen model zs200.... C'est des Ac ou des Dc