Zongshen Sierra 200GY-2 Crankcase Cover Mod

[Weldangrind]

Well done. It makes me wonder why it isn't two piece from the factory (aside from the obvious answers ).

[SpudRider]

Originally Posted by FastDoc

I think it looks great.

I think it looks great, also!

Spud

[FastDoc]

Originally Posted by Weldangrind

Well done. It makes me wonder why it isn't two piece from the factory (aside from the obvious answers ).

My theroy is because its a TW200 copy and the TW used an extra countershaft bearing in the cover because it was extra long to accomidate the wide rear tire.

[fishman10]

Thanks Doc, I can't take credit though.i think my friend did a great job to for using a sawsall.

[FastDoc]

Originally Posted by fishman10

Thanks Doc, I can't take credit though.i think my friend did a great job to for using a sawsall.

When I was a medical student on a Ob/Gyn rotation they had us use Sawsalls to do circumcisions. It saved a lot of time. The outcomes, however, were variable. 8O

[SpudRider]

Originally Posted by FastDoc

When I was a medical student on a Ob/Gyn rotation they had us use Sawsalls to do circumcisions. It saved a lot of time. The outcomes, however, were variable. 8O

Please tell us the name of that hospital, so we can avoid it!

Spud

[FastDoc]

Muhlenberg Hospital. IIRC Plainsboro, NJ. The hospital where House is based. There is no 'Priceton Plainsboro'

Just kidding. We used angle grinders.

[phil]

now i know what happened to my,,,,, :oops:

[TurboT]

Ouch. I didn't think I needed to read that.
:?

[Weldangrind]

It certainly explains the scars. 8O

[gainesvillerider]

Originally Posted by SpudRider

In order to support this extra long countershaft and bearing, the left crankcase cover is a solid unit. Therefore, if you wish to inspect, clean or replace the countershaft sprocket, you must first remove the entire left crankcase cover. Also, if you wish to inspect or replace the countershaft oil seal or gearshift lever oil seal, you must first remove the entire left crankcase cover.

Since the front half of the crankcase cover contains engine oil, the crankcase cover employs a gasket. Therefore, removing the left crankcase cover always involves the loss of some engine oil, and it could damage the gasket.

The Zongshen Sierra 200GY-2 copies the Yamaha crankcase cover very closely. The outside of the left crankcase cover for the Zongshen 200GY-2 is shown in the photograph below.



I can now remove the rear of the crankcase cover without disturbing the engine’s electrical system mounted in the front of the crankcase cover. I can also remove the rear section of the crankcase cover without the risk of damaging the engine gasket, or losing engine oil.

I will replace my original left crankcase cover with the modified cover when I make my next oil change.



Spud

I have taken off my stator cover taking it to work today to cut it but where can you find the seal to replace the factory one? i destroyed mine do you think a local moto shop would have one that would work? zongshen America from what i can see dosent even sell parts or do i have to become a dealer to see them? :?

[katoranger]

Yamaha TW200. Any year shold be good.

Local yamaha shop should be able to get you one. Otherwise you can get parts from Zongshen.

[SpudRider]

Originally Posted by katoranger

Yamaha TW200. Any year shold be good.

Local yamaha shop should be able to get you one. Otherwise you can get parts from Zongshen.

Allen is correct on all counts. The Yamaha gasket will cost about the same as the Zongshen gasket, and you can probably get it much faster.

This modification is one of the best mods you can make to a Zongshen 200GY-2 motorcycle! However, you should expect to ruin the gasket removing the left crankcase cover, so it is best to have an extra gasket before you tackle this modification.

Spud

[gainesvillerider]

so i took the cover off and took it to work i cut it perfect with a oil band saw it looks great and i went by the moto shop on the way home and asked the guy if i could see the gasket for a tw200 and it matched perfectly so i put it all back together and runs great did you put lock-tight back on the bolts from the cover? i noticed there was a stock sealer on them

[SpudRider]

Originally Posted by gainesvillerider

so i took the cover off and took it to work i cut it perfect with a oil band saw it looks great and i went by the moto shop on the way home and asked the guy if i could see the gasket for a tw200 and it matched perfectly so i put it all back together and runs great did you put lock-tight back on the bolts from the cover? i noticed there was a stock sealer on them

That's wonderful; if you have time, please post photos of your modified crankcase cover! I didn't use locktite when I reinstalled my left crankcase cover, and it has remained tigthtly attached. However, I certainly don't see any harm in using some blue locktite on the crankcase cover bolts.

Spud