Instruments and Wiring Systems
 

The Zongshen Sierra 200 also closely imitates both the instrument cluster and the wiring system of the Yamaha TW200.

The Sierra 200 speedometer is the same size and shape as the Yamaha speedometer, as is the instrument light cluster. Unlike some other Chinabikes, the United States odometer of the Sierra 200 records miles traveled, not kilometers. The United States speedometer of the Zongshen indicates speeds in both miles-per-hour and kilometers-per-hour. However, the mph numbers are much smaller, and more difficult to read, than the kph numbers.

Also, the electrical wiring diagrams of both motorcycles appear very similar. However, there are some minor differences. For example, the Yamaha TW200 also employs its front turn signals as running lights; the Zongshen does not. Therefore, the TW200 has three wires going into the front turn signals, instead of two. Like most other Chinabikes, the Sierra 200 employs a BA20D headlamp bulb; the TW200 uses an H4 headlamp bulb. In another, minor variation, the two motorcycles use a different color code for their wiring systems. However, given the many similarities between the two electrical systems, it seems reasonable that many electrical components should be interchangeable.

In summary, I must state that the Yamaha TW200 is a well-built motorcycle with both proven durability and an extensive, international dealer network; the Zongshen Sierra 200 has yet to prove itself in both these regards. A prudent buyer should never underestimate these important facts. As stated many times on this forum, anyone purchasing a Chinese motorcycle should be prepared to maintain the motorcycle himself. He should also be prepared to experience greater difficulty obtaining replacement parts for his motorcycle.

Other than these very important, primary facts, my personal experience indicates that the other main differences between these two motorcycles are price, appearance, tire size and weight. The last two factors are not insignificant. As stated earlier, I know of only one DOT, off-road, rear tire available for the Sierra 200. Of course, you can change the tire sizes on this motorcycle, but it costs additional time and money to do so. Lastly, in stock form, the Sierra 200 weighs almost forty pounds more than the stock TW200. The Zongshen Sierra 200 is a heavy motorcycle for its size.

All factors considered, I am very happy with my 2006 Zongshen Sierra 200. For the price I paid, I consider it an exceptional value. After riding it over 8,500 miles this year, I am now putting it into storage for the winter. God willing, I hope to enjoy riding it for many years to come.

Spud :)

On-line Technical Resources
 

Here is a list of PDF files and on-line resources I have discovered for the Zongshen Sierra 200 (a.k.a. ZS200GY-2). I wish to offer special thanks to ChinaRiders member Forchetto for providing the first two links:

Zongshen Sierra 200 Service Manual for Europe (PDF)
http://www.mychinamoto.com/downloads...2EC-Manual.pdf

Zongshen Sierra 200 Parts Manual
http://www.zongshen.com.au/downloads/LZX200GY-2.pdf

Here is an online parts catalog for the Sierra 200 at the Zongshen International web site:
http://parts.zongsheninternational.c...ctNo=120000083

I discovered the Hyosung GF125 Service Manual. This manual contains information on the Sierra 200 front brake caliper following page 6-22.
http://www.simamoto.fr/Home/SMATLC.Nsf/0/A4B7B9BED814B694C125711E00559C0D/$FILE/SERVICE%20MANUAL-GF125.pdf?OpenElement

The Zongshen Sierra 200 copies many components used in the Yamaha TW200 motorcycle. Therefore, several Yamaha manuals contain much useful information for the Zongshen owner. Following are some links to on-line resources for the Yamaha TW200:

Yamaha TW200 Service Manual (PDF)
http://www.mediafire.com/?34muedntyxz

2001 and newer model supplement to the Yamaha TW200 Service Manual (PDF)
http://www.mediafire.com/?0mzulnyzogg

Yamaha TW200 Owner’s Manual (PDF)
http://www.mediafire.com/?8zubjzjyioj

Yamaha Mexico’s web site with PDF parts catalogs for the TW200, model years 1994-2001, 2003 and 2008.
http://www.yamaha-motor.com.mx/Manua...Off&mode=TW200

I hope everyone has a very Merry Christmas and a Happy New Year!
Spud :)

Thanks Spud, your zeal for the Zong is quite impressive, appreciate all your links, they should come in handy!

All the best to you and yours this holiday season.

Regards

Thats quite a nice looking bike.
I wish we had those here.

Hey Spud,

I just got a Zong Sierra 200, and I was wondering if you had any problem getting it registered? I have a Manuf. Certifacate of Origin, which the person I bought it from says is the same as the title. I am stil putting the bike etogether so i have not started the registration process. Wouldl like a heads up. Thanks.

P.S.
I ask because i think i purchased the bike from a guy in Seattle. Maybe the same person you bouight yours from.

Welcome to the forums, and congratulations on your new Zongshen Sierra 200! :) I did not have any problems registering my Zongshen in the state of Idaho. :)

However, the registration process is different for every state. I encourage you to contact your local Department of Motor Vehicles; they will tell you exactly what you need to do to register your new motorcycle. :)

Spud :)

In Washington I needed a bill of sale, an odometer certificate, and the certificate or origin for the Lifan (HSUN, actually, but I think it's the same bike).

The Q came all registered from the dealer.

In Idaho I needed the MCO and a bill of sale which included the odometer reading. I also needed to make an appointment with the police to conduct a VIN inspection on the motorcycle.

Contact the local DMV as soon as you can, and they will help you make the process as painless as possible. :)

Spud :)

Thanks for the responses, and thanks for the welcome!!

If you get a chance, please post some photographs of your new motorcycle. We love photographs! :D

Spud :)

http://www.youtube.com/watch?v=aqzWhFzBHz8

:D

Wanna mod it?

Well I'll start with an udate on my previous question...Registration here in Renton was pretty easy. I took my Certificate of Origin and Invoice to the local DOL/DMV. A lady asked a few questions i did not know the answer to, so we made stuff up, soon after I walked out with a tag and registration. Lady told me it would be a couple of weeks before i get my title.

I had called a Zongshen dealer in Eastern, WA before placing my previous post and they were the ones telling me i would have trouble getting my registration and title, I will find out in a couple of weeks. He was probably just upset i got the same bike they sell for half the price.

A few problems I ran into:

1. There is no assembly instructions. It took me a few hours to put some pieces together like the bark busters and fork guards. It is not as easy assembly as posted on craiglist.

2. Incorrect hardware; while installing the front fender the illustration called for 20 mm screws, i only found 25 mm which were a little long, but you can use extra washers to pick up slack.

3. The positive cable for the battery was too short, I had to buy a cable extension for the cable to reach the terminal. The battery also sits high and creates a small gap under seat.

http://picasaweb.google.com/oreo313/...94961969140018
http://picasaweb.google.com/oreo313/...94986912802450
http://picasaweb.google.com/oreo313/...94995296691922

4. My oil filler cap is directly under exhaust pipe, i had to cut the cap's prongs in order to remove cap and add oil.

http://picasaweb.google.com/oreo313/...94962950433106

5. I broke the aft edge of the air intake box cover trying to remove it, I saw Spud modified his frame for this reason.

6. My right rear blinker blew out.

7. Had a fuel leak over the fule shut-off valve, had to remove and replace o-ring.

8. Have to tighten up slack in chain.

9. I am still regulating the carb to find the bike's (and mine) happy place.

On the bright side:
1. The bike handled pretty good on the road.
2. Was sturdier than i thought
3. Very maneuverable.

I hope i get my money's worth once i get that carb adjusted right. I will look into mods later down the road, right now i must get those offroad tires. The Zongshen dealer in Naches, WA has the set for $140. I will install them after the break in period.

Will try to post pics when the sun comes out!

Thanks Spud for all of your posts and tutorials, big help!!

To be honest Oreo, I have had 6 of these bikes in my posession over the last 14 mths. All have had some weird qwirks in the build phase out the crate that needs some TLC to work out to get it road worthy. Having some mechanical knowledge + experience around motorcycles helps to get things adjusted.

After all is said and done though...The bike performs like a dream and the pound for pound dollar for dollar value is very hard to be beat by anything out there, when comparing a brand new bike, chinese of japanese.

I hope you enjoy your Zong! As a caveat, I just got around to installing an FMF Q2 on a customers bike, I became a dealer for the Sierra locally, and it took some welding to get it done right, but let me tell you, the difference is amazing. Very worthwhile mod, and I am looking for another exhaust mod for one of my other bikes.

Peace

I have heard that getting the Zongshen 200GY-2 registered in Washington is an easy task. I am glad things went well for you. :D Also, it is common for state governments to take several weeks to process a vehicle title.
I think you are correct. ;)
I must admit, one of my friends is an experienced diesel mechanic, and I had my Zong delivered to his shop. I watched and helped as he assembled my motorcycle. Needless to say, he didn’t have any difficulties. ;) He just looked at the drawings in the 200GY-2 Parts Catalogue to understand how things were assembled. :D
I don’t remember having any problems of that type, but thanks for the tip! Future Zong owners should take note. ;)
Yes, the positive battery cable was also too short on my motorcycle. My friend fabricated a longer cable, similar to yours. Zongshen supplies 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/q...tenance014.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/q...ery/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 the 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. ;)

If you want to learn more about battery options for your Zongshen 200GY-2, do a search over at the TW200 forum. You can learn a lot about your Zongshen 200GY-2 motorcycle by reading about and researching the Yamaha TW200. ;)
I use an ordinary pair of pliers to remove my oil cap, and I use a funnel to add the new engine oil. ;)
Yes, do the frame mod; it make air filter maintenance much easier! Don’t ask me how I know…:lol:

http://i442.photobucket.com/albums/q...tenance001.jpg

However, I strongly suggest you rent or buy an angle grinder for this job! The steel used to construct the Zongshen frame is very hard, and you don’t want to try cutting it with a dremel tool! Don’t ask me how I know…:lol:
Thanks for the tip! I haven’t had any problems, but I will keep an eye on mine! :)
I have not done anything to my carburetor; it runs great. Maybe I will play with the jetting later on; right now I enjoy riding my Zong much more than wrenching on it. ;) My only adjustment was to slightly lean out the pilot mixture screw. My bike was revving too high once the engine got hot.
Yes, the DOT knobby tires are great! They are the best change I have made to my motorcycle! :D I am sure you will enjoy your new Sierra 200GY-2, it is a great little motorcycle! :)
You are very welcome. :) Please do post lots of photos, and change you oil somewhere around 500 miles. You might want to check out this oil change tutorial thread:

http://www.chinariders.net/modules.p...hange+tutorial

Spud :)