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Old 03-03-2016, 08:47 PM   #1
SpudRider   SpudRider is offline
 
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Project Phoenix: The YamaZong Rises from the Ashes

Last May I dropped my Zongshen ZS200GY-2 (Sierra) in a mud pool, and flooded the engine with dirty water. After pumping the water from the engine, I was unable to start the bike, so a friendly ATV rider delivered me home.

The next day I returned, and got the faithful Zong to start. After riding the bike down to the parking lot, I trailered the bike home.

After several oil changes, the oil filter finally stopped catching silt from the oil. I installed new piston rings, but after several hundred miles, the Zong was burning oil, and the bike didn't shift as well as before. Therefore, after riding my faithful Zong over 70,000 miles, I declared the original engine dead.

Here is the final odometer reading. I had ridden the bike for several hundred miles with a broken odometer cable, so I know I the final mileage was over 70,000 miles.

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"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 03-03-2016, 08:56 PM   #2
SpudRider   SpudRider is offline
 
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I considered splitting the crankcases, and rebuilding the original engine. However, before I tore the engine apart, I noticed more water and silt in the used motor oil. I also noted considerable slop in the connecting rod. With over 70,000 miles on the original engine, I decided not to spend more money on a tired power plant. I strongly considered parting out my faithful Zong.

However, while searching eBay, I discovered a used, 1992, Yamaha XT225 engine for sale. I decided to buy the engine, and convert my 5-speed, 196 cc Zong into a 6-speed, 223 cc YamaZong.

The engine swap is now complete. The bike is running great, and my faithful Zong has arisen from its own ashes, like the proverbial Phoenix!

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"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 03-03-2016, 08:58 PM   #3
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The engine bolted directly into the frame, and all parts aligned perfectly, including the carburetor and the sprockets.



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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 03-03-2016, 09:03 PM   #4
SpudRider   SpudRider is offline
 
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I needed to transfer the flywheel, stator, pickup coil, and stator cover from my old Zongshen engine to the fresher Yamaha engine. I also transferred the hex head bolts from the Zong engine to replace the Phillips head bolts on the Yamaha engine. Here are some photographs of the remains of the old and tired, but faithful, Zongshen ZS200GY-2 engine.



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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894



Last edited by SpudRider; 03-04-2016 at 03:08 AM.
 
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Old 03-03-2016, 09:04 PM   #5
SpudRider   SpudRider is offline
 
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I also transferred the kick starter from the Zong engine to the Yamaha engine. All the transferred parts fit the Yamaha engine perfectly.

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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 03-03-2016, 09:06 PM   #6
SpudRider   SpudRider is offline
 
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I gained 27 cubic centimeters of engine displacement, and a 6-speed transmission with the engine swap.

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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 03-03-2016, 09:13 PM   #7
SpudRider   SpudRider is offline
 
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Because of previous modifications, my ZS200GY-2 (Sierra) motorcycle now actually has more Yamaha parts than Zongshen parts. Hence, the bike shall now be officially called my YamaZong Phoenix.

After taking the bike for two rides, and approximately 70 miles, I have verified the engine is running well. Here are a few photographs from today's ride.













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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894



Last edited by SpudRider; 03-07-2016 at 01:08 AM.
 
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Old 03-03-2016, 09:29 PM   #8
AZRider   AZRider is offline
 
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Congratulations and a very nice job Spud. A rebirth and I bet you didn't gain a pound.
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Old 03-03-2016, 09:33 PM   #9
culcune   culcune is offline
 
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It does not look like 'Big Orange' has missed a beat!!
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Old 03-03-2016, 09:40 PM   #10
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Good for another 70,000 miles...

jb
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Old 03-03-2016, 09:55 PM   #11
Louis Angel   Louis Angel is offline
 
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AWESOME!!!!
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Old 03-03-2016, 10:13 PM   #12
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Very cool!


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Old 03-03-2016, 10:25 PM   #13
Azhule   Azhule is offline
 
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Quote:
Originally Posted by jbfla View Post
Good for another 70,000 miles...

jb
Or mud puddle

Looking great Spud
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Old 03-03-2016, 10:46 PM   #14
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Congrats Spud! Proves how "clone" these really are with all the bolt on parts! Very happy to see the YamaZong alive and well!
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Old 03-04-2016, 12:18 AM   #15
SpudRider   SpudRider is offline
 
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Thank you for your kind words, gentlemen. I am enjoying the extra power from the fresher, larger engine. I am also enjoying the wide ratio, 6-speed transmission. First gear is lower than the Zong's original first gear, and sixth gear is higher than the Zong's original fifth gear, providing a very nice overdrive gear.

The Yamaha engine was clean as a whistle, and obviously had low mileage based upon the tightness of the connecting rod, and very little wear on the clutch basket. I also found very little carbon deposited on the piston and cylinder head. I do believe this Yamaha engine is good for another 70,000 miles.
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Spud

"Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain

2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894



Last edited by SpudRider; 03-04-2016 at 03:19 AM.
 
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