SpudRider
04-15-2009, 04:05 AM
Many new Zongshen Sierra 200GY-2 owners are appearing on this forum. Therefore, I think it is time to list the common changes, modifications, and maintenance procedures that owners should consider making for their new Zongshen motorcycles. :)
1. Usually, the first modification necessary is to fabricate or purchase a longer positive battery cable. Zongshen supplies the United States version of the 200GY-2 bike with a very nice Yuasa YB7-A battery. However, this battery is slightly longer and taller than the Yuasa YB7C-A battery used by the Yamaha TW200. Also, the Zong battery has the overflow vent on the left side when the battery terminals are placed aft.
http://i442.photobucket.com/albums/qq146/spudrider/200GY-2%20Battery/ZongMaintenance014.jpg
The YB7C-A battery used in the TW200 has the overflow vent on the left side with the battery terminals forward.
http://i442.photobucket.com/albums/qq146/spudrider/200GY-2%20Battery/YB7C-A.jpg
The overflow vent must be on the left side, or the seat will not fit on either motorcycle. Therefore, 200GY-2 owners need to place the Yuasa YB7-A with the battery terminals aft, and this requires a longer positive battery cable. ;)
The YB7-A that came with my Zong is an excellent battery, and I am sure it will last a long time with proper care. However, the YB7C-A battery is 17mm shorter in height, which makes it much easier to replace the removed seat on the motorcycle. Therefore, when I need to replace my Zong battery, I will probably choose the YB7C-A model used by the Yamaha TW200. ;)
2. The next change I would make to a new Zong is to replace the 5mm Allen bolts that secure the front brake caliper with hardened, hex head bolts. It seems that the original bolts bend a little under the force of braking, and the small Allen heads make them almost impossible to remove.
http://i442.photobucket.com/albums/qq146/spudrider/Brake%20Caliper/OldBolts.jpg
I would encourage the owners of new Sierra 200GY-2 motorcycles to replace the stock bolts with hardened, hex head bolts before the original bolts bend. My experience with these Allen bolts is detailed in the thread linked below.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6514&highlight=front+brake+caliper+zongshen
3. Next I would buy some dual sport tires. To the best of my knowledge, the Kingstone 130/90-15 DOT knobby tire is the only dual sport tire that will fit the Sierra 200GY-2 rear wheel. This tire is only available from Zongshen America or its dealers. Fortunately, several choices are available in dual sport tires for the 100/90-18 front wheel, including a Kingstone tire. If you plan to do any riding in the dirt, order your Kingstone DOT knobby tires early. ;)
4. If you live at lower elevations, you might consider moving the C-clip down one notch on the carburetor jet needle. I live and ride at elevations 4,400 feet above sea level, and higher. My carburetor runs fine with the C-clip in the middle slot of the jet needle. If your new motorcycle is revving high when hot, you should also turn in the pilot mixture screw about ¼ to ½ turn.
5. Change your engine oil after about 300 miles, and be sure to clean the oil filter. The proper procedure for changing the oil is contained in the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7415&highlight=zongshen+oil+change
6. Maintaining the foam air filter element is much easier if you make the Zongshen 200GY-2 frame modification.
http://i442.photobucket.com/albums/qq146/spudrider/Air%20Box%20Frame%20Mod/ZongMaintenance054.jpg
This frame mod is detailed in the thread listed below.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6690&highlight=zongshen+frame+mod
7. I believe switching to a smaller countershaft sprocket is the single best change you can make to enhance the Zong’s performance. You can learn more about 200GY-2 countershaft sprockets at the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7565
8. Maintaining the entire drive train, as well as changing countershaft sprockets, is much easier if you perform the Zongshen 200GY-2 Crankcase Cover Modification.
http://i442.photobucket.com/albums/qq146/spudrider/Crankcase%20Cover/Finishedcovercloseup.jpg
If you plan ahead carefully, you can make this modification for free. To learn more about this modification, read the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7559
9. Finally, after 3,000 miles or so, new Zong owners should perform a valve lash check/adjustment on the motorcycle.
http://i442.photobucket.com/albums/qq146/spudrider/Valve%20Adjustment/ZongMaintenance072.jpg
This procedure is detailed in the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6458
These are the main procedures I would perform on a new Sierra 200GY-2 motorcycle. Of course, you can make many other changes to your new motorcycle, but these are the maintenance tasks, modifications and changes I would perform first.
Spud :)
1. Usually, the first modification necessary is to fabricate or purchase a longer positive battery cable. Zongshen supplies the United States version of the 200GY-2 bike with a very nice Yuasa YB7-A battery. However, this battery is slightly longer and taller than the Yuasa YB7C-A battery used by the Yamaha TW200. Also, the Zong battery has the overflow vent on the left side when the battery terminals are placed aft.
http://i442.photobucket.com/albums/qq146/spudrider/200GY-2%20Battery/ZongMaintenance014.jpg
The YB7C-A battery used in the TW200 has the overflow vent on the left side with the battery terminals forward.
http://i442.photobucket.com/albums/qq146/spudrider/200GY-2%20Battery/YB7C-A.jpg
The overflow vent must be on the left side, or the seat will not fit on either motorcycle. Therefore, 200GY-2 owners need to place the Yuasa YB7-A with the battery terminals aft, and this requires a longer positive battery cable. ;)
The YB7-A that came with my Zong is an excellent battery, and I am sure it will last a long time with proper care. However, the YB7C-A battery is 17mm shorter in height, which makes it much easier to replace the removed seat on the motorcycle. Therefore, when I need to replace my Zong battery, I will probably choose the YB7C-A model used by the Yamaha TW200. ;)
2. The next change I would make to a new Zong is to replace the 5mm Allen bolts that secure the front brake caliper with hardened, hex head bolts. It seems that the original bolts bend a little under the force of braking, and the small Allen heads make them almost impossible to remove.
http://i442.photobucket.com/albums/qq146/spudrider/Brake%20Caliper/OldBolts.jpg
I would encourage the owners of new Sierra 200GY-2 motorcycles to replace the stock bolts with hardened, hex head bolts before the original bolts bend. My experience with these Allen bolts is detailed in the thread linked below.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6514&highlight=front+brake+caliper+zongshen
3. Next I would buy some dual sport tires. To the best of my knowledge, the Kingstone 130/90-15 DOT knobby tire is the only dual sport tire that will fit the Sierra 200GY-2 rear wheel. This tire is only available from Zongshen America or its dealers. Fortunately, several choices are available in dual sport tires for the 100/90-18 front wheel, including a Kingstone tire. If you plan to do any riding in the dirt, order your Kingstone DOT knobby tires early. ;)
4. If you live at lower elevations, you might consider moving the C-clip down one notch on the carburetor jet needle. I live and ride at elevations 4,400 feet above sea level, and higher. My carburetor runs fine with the C-clip in the middle slot of the jet needle. If your new motorcycle is revving high when hot, you should also turn in the pilot mixture screw about ¼ to ½ turn.
5. Change your engine oil after about 300 miles, and be sure to clean the oil filter. The proper procedure for changing the oil is contained in the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7415&highlight=zongshen+oil+change
6. Maintaining the foam air filter element is much easier if you make the Zongshen 200GY-2 frame modification.
http://i442.photobucket.com/albums/qq146/spudrider/Air%20Box%20Frame%20Mod/ZongMaintenance054.jpg
This frame mod is detailed in the thread listed below.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6690&highlight=zongshen+frame+mod
7. I believe switching to a smaller countershaft sprocket is the single best change you can make to enhance the Zong’s performance. You can learn more about 200GY-2 countershaft sprockets at the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7565
8. Maintaining the entire drive train, as well as changing countershaft sprockets, is much easier if you perform the Zongshen 200GY-2 Crankcase Cover Modification.
http://i442.photobucket.com/albums/qq146/spudrider/Crankcase%20Cover/Finishedcovercloseup.jpg
If you plan ahead carefully, you can make this modification for free. To learn more about this modification, read the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=7559
9. Finally, after 3,000 miles or so, new Zong owners should perform a valve lash check/adjustment on the motorcycle.
http://i442.photobucket.com/albums/qq146/spudrider/Valve%20Adjustment/ZongMaintenance072.jpg
This procedure is detailed in the following thread.
http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=6458
These are the main procedures I would perform on a new Sierra 200GY-2 motorcycle. Of course, you can make many other changes to your new motorcycle, but these are the maintenance tasks, modifications and changes I would perform first.
Spud :)