Zongshen Sierra 200/Chinabike Front Brake Caliper Inspection

[david3921]

I'm with Spud. The trouble sounds to be at the master cylinder rather than below. There's a valve in the cylinder that allows the fluid to flow back after braking. There is no place for the fluid to go if it's too full. I would bleed the brakes again and allow the fluid in the cylinder to go down half way and see if the problem goes away.

[Dahamaster]

I know it's been awhile but just an update to my brake problems. The rubbing of the rotor wasn't the issue, the issue was (I believe) the master cylinder unit. I ended up replacing both the master cylinder and the caliper. However, that didn't fix the problem of the wheel seizing up. I still had to pull off the road and do emergency bleeds. Well, as of today I put on a different master cylinder unit. It's an OEM unit for the Suzuki DR models. It's a little bit larger, but it fits perfectly. Simple, easy bolt together job. Bled the brakes and took the Zong for a ride tonight and the front brake works excellent. For now that is...I won't know for sure if the brake problem is fixed for another week or two. If the wheel stays clean and doesn't seize up, then problem solved.

I bought the unit off eBay from a store called "usa-motorcycles-inc." They have tons of OEM stuff for all kinds of bikes. I took a chance on the DR master cylinder seeing the similiarities in design and of course the bolt dimensions. All are the same as the Zong. Mirror post too. Only modification it needed was to remove the factory plastic handguards as the unit is a tad bit larger and the lever is longer. But certainly can't complain yet. If I want to, I can always put another set of handguards or Bark Busters on it.

I also had a nagging transmission problem. The shifting was very bad and finally gave up. You could shift up in the gears, but not down past 4th. Had to take it down to my bike shop where it sat for 4 months. (long story) The shop said it was a clip that fits on the other side of the gear shift shaft. They had to tear down the motor to get it fixed and that required an engine gasket kit (thanks Nestor) and now it rides and shifts perfectly. As my luck runs, the shop screwed up the job and I had to take it back because it was leaking oil, the gasket on the left side wasn't installed correclty, and the electric starter wouldn't work--plus they gave me back a bike with a dead battery. (never thought to keep it charged for keeping it for 4 mos.) Anyway, the Zong is fixed, doesn't leak oil, starter works, and the front brake is working again. (for now)

[Weldangrind]

Sounds like good luck with the master. You generally need to match the master size to the caliper piston, but it sounds like it works properly.

Sorry to hear that the shop messed it up, but at least it works now. Happy trails!

[SpudRider]

I'm glad you got all your problems fixed, Daha.

Spud

[obso]

The old ebay vendor link is no longer working so here's a new one. Same $9.99 with reasonable shipping to everywhere. I am in no way affiliated with the seller other than I bought my brake pads from them and they said they keep plenty in stock.

http://www.ebay.com/itm/261009181062...84.m1423.l2649

And for rears*
http://www.ebay.com/itm/310395965606...84.m1423.l2649


* "should" fit. I'll update on fitment when my set makes it here.

[SpudRider]

Thanks for updating the link to for the front brake pads, Obso!

The link you provided for the rear brake shoes appears to be correct also! Thanks for doing the research, and reporting your findings.

Spud

[SpudRider]

For future reference, the following brake pads will fit the front brake caliper of the Zongshen 200GY-2.

SOK LD440

The following brake shoes will fit the rear drum brake of the Zongshen 200GY-2.

SOK 204

Spud

[Weldangrind]

Originally Posted by obso

The old ebay vendor link is no longer working so here's a new one. Same $9.99 with reasonable shipping to everywhere. I am in no way affiliated with the seller other than I bought my brake pads from them and they said they keep plenty in stock.

http://www.ebay.com/itm/261009181062...84.m1423.l2649

And for rears*
http://www.ebay.com/itm/310395965606...84.m1423.l2649


* "should" fit. I'll update on fitment when my set makes it here.

Thanks for the update. If you are so inclined to show us any differences, that would be great.

[obso]

The fronts are an exact match. The rears are really close.


The difference is that they are a little thinner on the end that fits around that post at the top.


And on the other end where they fit against the cam, the stock shoes had a steel insert to prevent wear. The replacements are just cast aluminum.



Differences aside they seem to fit and work just fine.

[SpudRider]

Thanks for the update, Obso.

My Vesrah VB223 brake shoes have the same dimensions as the SOK 204 brake shoes. However, the Vesrah brakes shoes have steel inserts where the brake shoes contacts the brake cam. I would not trust brake shoes without the steel insert. :( Perhaps you got a defective pair of SOK 204 brakes shoes? :?: However, whether the SOK 204 brakes shoes are poorly designed, or defective, I would not not recommend them without the steel inserts. 8O

Another important dimension to consider is the distance between the holes for the brake springs. I have installed the Vesrah VB223 brake shoes in my stock, Zongshen, rear brake assembly, and the Veshrah brakes shoes work well with the stock, Zongshen brake springs.

Spud

[Wild_Alaskan]

the pins/bushings the caliper rides on are very worn out on mine. is there a source for just these parts (same caliper as spuds) ? or will i need to get a whole new caliper assembly?

[SpudRider]

My Zong employs the standard, Chinese, front brake caliper. This is the same front brake caliper employed by the 2004 Hyosung GF125, and the 1989 Suzuki GP125. Therefore, you might be able to purchase the appropriate Hyosung or Suzuki parts. However, you are probably better off buying a new, Chinese brake caliper.

Spud