Zong CDI Failure at 41,800 Miles

[SpudRider]

The first CDI unit on my Zongshen 200GY-2 failed at 10,800 miles. I just replaced the second CDI unit on my Zong at 41,800 miles. Fortunately, the Zongshen CDI units are 1/4 the cost of a new, Yamaha CDI unit. I had two, spare CDI units on hand, so I still have an extra CDI unit handy. I strongly encourage all Zonshen 200GY-2 owners to acquire at least one, spare CDI unit.

Spud

[FastDoc]

Time to start trying to get another spare, Spud. The way it goes at ZS parts you'll need it in another 20-30,000 miles and they seem to need the ead time!

[SpudRider]

Originally Posted by FastDoc

Time to start trying to get another spare, Spud. The way it goes at ZS parts you'll need it in another 20-30,000 miles and they seem to need the ead time!

That's why I bought two, CDI units last time!

Spud

[wilserchinarider]

Nice going Spud...were you able to replace the CDI on a roll or did you actually have to stop the bike. :P

As of a few hours ago, I am actually a card carrying Zongite, thanks on behalf to your excellent product evaluation. Thank you! I'll post some pics of the new (to me) Zong.

http://philadelphia.craigslist.org/mcy/2676810008.html

[FastDoc]

Great deal Wiser! We look forward to your adventures on the Zong. You have been, of course, assimilated.

[Weldangrind]

Originally Posted by wilserchinarider

Nice going Spud...were you able to replace the CDI on a roll or did you actually have to stop the bike. :P

As of a few hours ago, I am actually a card carrying Zongite, thanks on behalf to your excellent product evaluation. Thank you! I'll post some pics of the new (to me) Zong.

http://philadelphia.craigslist.org/mcy/2676810008.html

139 miles on it? Score! Looking forward to a new thread with pics.

[SpudRider]

Originally Posted by wilserchinarider

Nice going Spud...were you able to replace the CDI on a roll or did you actually have to stop the bike. :P ...

I now have had 4 CDI units fail on me. I repaired 2 CDI units for my Honda XR650L motorcycle: the original unit, and a spare. :roll: Both Honda CDI units are now working great! I have also had 2 CDI units fail on my Zong. You can't repair the Zongshen CDI units; they are encased in concrete! 8O

After having 4 CDI units fail on me, I am completely familiar with the symptoms. The CDI units exhibit intermittent problems before they fail outright. Therefore, when my last Zongshen CDI unit began to cause trouble, I started the bike by popping the clutch in second gear while riding downhill. After I got home, I immediately replaced the CDI unit, and I haven't had a problem since.

Originally Posted by wilserchinarider

...As of a few hours ago, I am actually a card carrying Zongite, thanks on behalf to your excellent product evaluation. Thank you! I'll post some pics of the new (to me) Zong.

http://philadelphia.craigslist.org/mcy/2676810008.html

Thank you for the kind words, WCR! You got a great deal! Please allow me to officially welcome you to The Cult of The Zong! Resistance was futile; you have been assimilated!



We eagerly await your photos!

Spud

[FastDoc]

I'm interested in how you repaired the CDI. :P

[Weldangrind]

X2. Please share.

[SpudRider]

Ask, and ye shall receive, gentlemen.



http://www.advrider.com/forums/showthread.php?t=684756
http://www.thumpertalk.com/forum/sho...d.php?t=980822

I bet I could also fix the Zongshen CDI units, but they are encased in concrete, not potting material! 8O

Spud

[MICRider]

Spud, you are a man of many talents! Good to see that you have an ADV account as well, it's an awesome site 8)

[SpudRider]

Incidentally, I am happy to report I am also in good shape regarding the KDX220 CDI units! A British expatriot, living in South America, dissected the KDX220 CDI unit, and is selling a programmable CDI unit for $65, including shipping!



http://kdxrider.net/forums/viewtopic...hlight=kdx+cdi
http://www.dragonfly75.com/motorbike/CDIinstall2.html
http://kdxrider.net/forums/viewtopic...ght=jaguar+cdi
http://www.geocities.com/a57ngel/moto/CDI.html
http://www.geocities.com/a57ngel/moto/CDI-mod.html

Needless to say, once you buy one of his CDI units, you can easily repair it yourself. You can also copy his CDI unit and build a spare.

Spud

[SpudRider]

Originally Posted by MICRider

Spud, you are a man of many talents! Good to see that you have an ADV account as well, it's an awesome site 8)

Thank you, Stew. Incidentally, what happened to your avatar? I can't see it when you post. :(

Spud

[MICRider]

Originally Posted by SpudRider

Thank you, Stew. Incidentally, what happened to your avatar? I can't see it when you post. :(

Spud

I messed my avatar up when I was trying to upload another, I think my new one was a little too big so it was rejected

Good info on the CDI's, I never knew that they were reparable

[Weldangrind]

It never even occurred to me that we could dismantle the Honda boxes for repair. Excellent news! I wonder if the old two-smoke Yamaha CDI boxes are repairable; that was the achilles heel with those bikes; replacement CDI boxes are hen's teeth.

Thanks Spud!