Help with Zongshen 200cc engine

HotTommy · 05-10-2023, 11:00 AM

I recently bought a new "X-PRO ZongShen 4-stroke Vertical ATVs Engine with Manual Transmission w/Reverse, Electric Start for 200cc 250cc ATVs" Model # 308-999040. I will be using it in a custom vehicle and I need to understand the engine better. If there is a source such as a parts diagram or service manual, that would be great. Failing that, I have the first of what may be several questions for those familiar with this family of engines.

In this picture, is the arrow pointing to the clutch? Also, there is a horizontal bolt at the top of the head. What is it for?

In this picture, what is the black hose for?

In this picture, is the splined shaft the shifter?

**JerryHawk250** · 05-10-2023, 11:53 AM

Welcome aboard! That is a Honda CG clone which is very similar to the Hawk 250 among a bunch of other china bikes with GC engines.

Mudflap · 05-10-2023, 12:34 PM

Talking about the small bolt in the valve cover? There are oil passages inside the valve cover that spray oil onto the rocker arms. The factory drills one of those passageways from the outside then uses that bolt to plug the hole.

Find a service manual for a Honda CG125 motorcycle.

HotTommy · 05-10-2023, 05:14 PM

Terrific information. Thanks all.

One more question today: Is there a convenient place to tap into a pressurized oil line for an accessory?

Mudflap · 05-10-2023, 05:46 PM

Quote:

Originally Posted by HotTommy

Terrific information. Thanks all.

One more question today: Is there a convenient place to tap into a pressurized oil line for an accessory?

There are aftermarket valve covers that divert pressurized oil to an oil cooler.

HotTommy · 05-11-2023, 09:06 PM

Today's question is about wiring. The engine I bought has a manual transmission with four forward speeds and reverse. My guess is there is an electric circuit to prevent going into reverse by accident. Using the Honda CG search I have yet to find a wiring diagram that addresses reverse gear. Can anyone suggest a source for such a diagram or perhaps a way to deduce which wire might control access to reverse gear? The engine comes with two 6-pin connectors. . . . And thanks again for all the good info.

**JerryHawk250** · 05-12-2023, 09:45 AM

The 6 pin connector is for a gear indicator. The shifting mechanism id mechanical and not controlled electrically.

Mudflap · 05-12-2023, 09:54 AM

To find which wire is reverse put engine in reverse gear and check which wire is grounded, that's the one. The switch in the engine grounds one wire for each gear and neutral, thus 6 wires.

Bruces · 05-12-2023, 11:23 AM

The wiring has nothing to do with reverse ,other than to turn on a light ,it is not a gear lockout or anything ,and reverse can be selected anytime including when driving foreward so you have to be careful with these engines in a dirt bike etc .

HotTommy · 05-12-2023, 04:16 PM

Great info. You guys are a wellspring of knowledge.

chinazuki · 05-15-2023, 01:03 PM

"I will be using it in a custom vehicle"

I guess I am the one not afraid to ask humbly....What is it?

HotTommy · 08-30-2023, 06:19 PM

Sorry for the slow response. I'm trying to fit the engine in a 1958 Berkeley (motorcycle engine powered) sports car.

HotTommy · 08-30-2023, 08:58 PM

I have two new questions related to accessing a pressurized oil source. First, I have searched for a while without success for cylinder head cover with ports for an external oil cooler. I would appreciate guidance on how to find one. Second, I have discovered four threaded holes on the bottom of the engine whose purpose is not obvious. I can't tell if they are blind holes or they actually go somewhere. Does anyone know their purpose?

Bruces · 08-30-2023, 09:02 PM

Those are holes to install foot pegs .

Mudflap · 09-01-2023, 08:49 AM

Quote:

Originally Posted by HotTommy

I have two new questions related to accessing a pressurized oil source. First, I have searched for a while without success for cylinder head cover with ports for an external oil cooler. I would appreciate guidance on how to find one. Second, I have discovered four threaded holes on the bottom of the engine whose purpose is not obvious. I can't tell if they are blind holes or they actually go somewhere. Does anyone know their purpose?

For the oil cooler you can use a kit for a Honda CG125 that will come with a new valve cover with taps for the cooler hoses. I have one on my quad that has a CG engine like your Zongshen. Works great.

05-10-2023, 11:00 AM	#1
HotTommy Join Date: May 2023 Posts: 17	Help with Zongshen 200cc engine I recently bought a new "X-PRO ZongShen 4-stroke Vertical ATVs Engine with Manual Transmission w/Reverse, Electric Start for 200cc 250cc ATVs" Model # 308-999040. I will be using it in a custom vehicle and I need to understand the engine better. If there is a source such as a parts diagram or service manual, that would be great. Failing that, I have the first of what may be several questions for those familiar with this family of engines. In this picture, is the arrow pointing to the clutch? Also, there is a horizontal bolt at the top of the head. What is it for? In this picture, what is the black hose for? In this picture, is the splined shaft the shifter?
	0

05-10-2023, 11:53 AM	#2
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,552	Welcome aboard! That is a Honda CG clone which is very similar to the Hawk 250 among a bunch of other china bikes with GC engines. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	1

05-12-2023, 09:45 AM	#7
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,552	The 6 pin connector is for a gear indicator. The shifting mechanism id mechanical and not controlled electrically. __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	1

05-15-2023, 01:03 PM	#11
chinazuki Join Date: Sep 2022 Location: arkansas Posts: 43	*"I will be using it in a custom vehicle"* I guess I am the one not afraid to ask humbly....What is it? __________________ arkansas
	0

05-10-2023, 12:34 PM	#3
Mudflap Join Date: Sep 2014 Posts: 1,870	Talking about the small bolt in the valve cover? There are oil passages inside the valve cover that spray oil onto the rocker arms. The factory drills one of those passageways from the outside then uses that bolt to plug the hole. Find a service manual for a Honda CG125 motorcycle.
	2

05-10-2023, 05:14 PM	#4
HotTommy Join Date: May 2023 Posts: 17	Terrific information. Thanks all. One more question today: Is there a convenient place to tap into a pressurized oil line for an accessory?
	0

05-11-2023, 09:06 PM	#6
HotTommy Join Date: May 2023 Posts: 17	Today's question is about wiring. The engine I bought has a manual transmission with four forward speeds and reverse. My guess is there is an electric circuit to prevent going into reverse by accident. Using the Honda CG search I have yet to find a wiring diagram that addresses reverse gear. Can anyone suggest a source for such a diagram or perhaps a way to deduce which wire might control access to reverse gear? The engine comes with two 6-pin connectors. . . . And thanks again for all the good info.
	0

05-12-2023, 09:54 AM	#8
Mudflap Join Date: Sep 2014 Posts: 1,870	To find which wire is reverse put engine in reverse gear and check which wire is grounded, that's the one. The switch in the engine grounds one wire for each gear and neutral, thus 6 wires.
	2

05-12-2023, 11:23 AM	#9
Bruces Join Date: May 2018 Posts: 1,572	The wiring has nothing to do with reverse ,other than to turn on a light ,it is not a gear lockout or anything ,and reverse can be selected anytime including when driving foreward so you have to be careful with these engines in a dirt bike etc .
	2

05-12-2023, 04:16 PM	#10
HotTommy Join Date: May 2023 Posts: 17	Great info. You guys are a wellspring of knowledge.
	0

08-30-2023, 06:19 PM	#12
HotTommy Join Date: May 2023 Posts: 17	Sorry for the slow response. I'm trying to fit the engine in a 1958 Berkeley (motorcycle engine powered) sports car.
	0

08-30-2023, 08:58 PM	#13
HotTommy Join Date: May 2023 Posts: 17	I have two new questions related to accessing a pressurized oil source. First, I have searched for a while without success for cylinder head cover with ports for an external oil cooler. I would appreciate guidance on how to find one. Second, I have discovered four threaded holes on the bottom of the engine whose purpose is not obvious. I can't tell if they are blind holes or they actually go somewhere. Does anyone know their purpose?
	0

08-30-2023, 09:02 PM	#14
Bruces Join Date: May 2018 Posts: 1,572	Those are holes to install foot pegs .
	1