The Unofficial Zongshen Sierra 200GY-2 Bike Prep Thread

[SpudRider]

Many new Zongshen Sierra 200GY-2 owners are appearing on this forum. Therefore, I think it is time to list the common changes, modifications, and maintenance procedures that owners should consider making for their new Zongshen motorcycles.

1. Usually, the first modification necessary is to fabricate or purchase a longer positive battery cable. Zongshen supplies the United States version of the 200GY-2 bike with a very nice Yuasa YB7-A battery. However, this battery is slightly longer and taller than the Yuasa YB7C-A battery used by the Yamaha TW200. Also, the Zong battery has the overflow vent on the left side when the battery terminals are placed aft.



The YB7C-A battery used in the TW200 has the overflow vent on the left side with the battery terminals forward.



The overflow vent must be on the left side, or the seat will not fit on either motorcycle. Therefore, 200GY-2 owners need to place the Yuasa YB7-A with the battery terminals aft, and this requires a longer positive battery cable.

The YB7-A that came with my Zong is an excellent battery, and I am sure it will last a long time with proper care. However, the YB7C-A battery is 17mm shorter in height, which makes it much easier to replace the removed seat on the motorcycle. Therefore, when I need to replace my Zong battery, I will probably choose the YB7C-A model used by the Yamaha TW200.

2. The next change I would make to a new Zong is to replace the 5mm Allen bolts that secure the front brake caliper with hardened, hex head bolts. It seems that the original bolts bend a little under the force of braking, and the small Allen heads make them almost impossible to remove.



I would encourage the owners of new Sierra 200GY-2 motorcycles to replace the stock bolts with hardened, hex head bolts before the original bolts bend. My experience with these Allen bolts is detailed in the thread linked below.

http://chinariders.net/modules.php?n...liper+zongshen

3. Next I would buy some dual sport tires. To the best of my knowledge, the Kingstone 130/90-15 DOT knobby tire is the only dual sport tire that will fit the Sierra 200GY-2 rear wheel. This tire is only available from Zongshen America or its dealers. Fortunately, several choices are available in dual sport tires for the 100/90-18 front wheel, including a Kingstone tire. If you plan to do any riding in the dirt, order your Kingstone DOT knobby tires early.

4. If you live at lower elevations, you might consider moving the C-clip down one notch on the carburetor jet needle. I live and ride at elevations 4,400 feet above sea level, and higher. My carburetor runs fine with the C-clip in the middle slot of the jet needle. If your new motorcycle is revving high when hot, you should also turn in the pilot mixture screw about ¼ to ½ turn.

5. Change your engine oil after about 300 miles, and be sure to clean the oil filter. The proper procedure for changing the oil is contained in the following thread.

http://chinariders.net/modules.php?n...hen+oil+change

6. Maintaining the foam air filter element is much easier if you make the Zongshen 200GY-2 frame modification.



This frame mod is detailed in the thread listed below.

http://chinariders.net/modules.php?n...shen+frame+mod

7. I believe switching to a smaller countershaft sprocket is the single best change you can make to enhance the Zong’s performance. You can learn more about 200GY-2 countershaft sprockets at the following thread.

http://chinariders.net/modules.php?n...ewtopic&t=7565

8. Maintaining the entire drive train, as well as changing countershaft sprockets, is much easier if you perform the Zongshen 200GY-2 Crankcase Cover Modification.



If you plan ahead carefully, you can make this modification for free. To learn more about this modification, read the following thread.

http://chinariders.net/modules.php?n...ewtopic&t=7559

9. Finally, after 3,000 miles or so, new Zong owners should perform a valve lash check/adjustment on the motorcycle.



This procedure is detailed in the following thread.

http://chinariders.net/modules.php?n...ewtopic&t=6458

These are the main procedures I would perform on a new Sierra 200GY-2 motorcycle. Of course, you can make many other changes to your new motorcycle, but these are the maintenance tasks, modifications and changes I would perform first.

Spud

[forchetto]

Another great post...

You do have the workshop service manual that I've uploaded a few months ago, haven't you?. Let me know if you (or anyone else) hasn't, and I'll give you the link. It's in that "other" forum...

[SpudRider]

Originally Posted by forchetto

Another great post...

You do have the workshop service manual that I've uploaded a few months ago, haven't you?. Let me know if you (or anyone else) hasn't, and I'll give you the link. It's in that "other" forum...

Thank you for the kind words, my friend. Also, thank you very much for providing me, and other Zongshen 200GY-2 owners, with links to both the European Service Manual and the Australian Parts Manual.

Here is a list of PDF files and on-line resources I have discovered for the Zongshen Sierra 200GY-2 (a.k.a. ZS200GY-2). Once again, I wish to offer special thanks to China Riders member Forchetto for providing me with the first two links:

Zongshen Sierra 200 Service Manual for Europe (PDF)
http://www.mychinamoto.com/downloads...2EC-Manual.pdf

Zongshen Sierra 200 Parts Manual (PDF)
http://www.zongshen.com.au/downloads/LZX200GY-2.pdf

Here is an on-line parts catalog for the Sierra 200 at the Zongshen International web site:
http://parts.zongsheninternational.c...ctNo=120000083

I discovered the Hyosung GF125 Service Manual. This manual contains information on the Sierra 200 front brake caliper following page 6-22.
http://www.simamoto.fr/Home/SMATLC.Nsf/0/A4B7B9BED814B694C125711E00559C0D/$FILE/SERVICE%20MANUAL-GF125.pdf?OpenElement

The Zongshen Sierra 200 copies many components used in the Yamaha TW200 motorcycle. Therefore, several Yamaha manuals contain much useful information for the Zongshen owner. Following are some links to on-line resources for the Yamaha TW200:

Yamaha TW200 Service Manual (PDF)
http://www.mediafire.com/?34muedntyxz

2001 and newer model supplement to the Yamaha TW200 Service Manual (PDF)
http://www.mediafire.com/?0mzulnyzogg

Yamaha TW200 Owner’s Manual (PDF)
http://www.mediafire.com/?8zubjzjyioj

Yamaha Mexico’s web site with PDF parts catalogs for the TW200, model years 1994-2001, 2003 and 2008.
http://www.yamaha-motor.com.mx/Manua...Off&mode=TW200

If I have overlooked any other on-line resource, I sincerely hope other forum members will post that information.

Spud

[katoranger]

Another Top Notch Spud post.

This will need to be moved in the the new Big Tech Sticky.

[SpudRider]

Originally Posted by katoranger

Another Top Notch Spud post.

This will need to be moved in the the new Big Tech Sticky.

Thank you, Allen. I sincerely hope this information helps new Zongshen 200GY-2 owners.

Spud

[AZ200cc]

Nice work Spud! 8)

[SeerAtlas]

Spud, regarding the Mr and Mrs. OWL trip across China on two Zong's, I was appalled at the amount of metal bits shown clinging to the oil filter at his first oil change. He also posted that the second oil change revealed a similar amount yet the engines kept on chugging along.

Did you find anything similar in your Zong? Frankly I'm amazed that the bikes kept running with that much crap in the crankcase. I would've expected scored bearings and cylinder walls, loss of compression etc.

Seer

[SpudRider]

Originally Posted by SeerAtlas

Spud, regarding the Mr and Mrs. OWL trip across China on two Zong's, I was appalled at the amount of metal bits shown clinging to the oil filter at his first oil change. He also posted that the second oil change revealed a similar amount yet the engines kept on chugging along.

Did you find anything similar in your Zong? Frankly I'm amazed that the bikes kept running with that much crap in the crankcase. I would've expected scored bearings and cylinder walls, loss of compression etc.

Seer

That is a great adventure thread, isn’t it? I assume you are referring to the picture of the oil filter shown on page 2, post #19 of that thread.

http://www.advrider.com/forums/showt...=371656&page=2

Both the Yamaha TW200 oil filter, and the Zongshen 200GY-2 copy of that oil filter, pick up a lot of crud from the circulating oil. Especially as the new engine is “breaking in,” you will notice engine sludge, some small rubber chunks, and a few metal shavings clinging to the oil filter. If you search the TW200 forum you will find a lot of pictures of TW200 oil filters covered with gunk. For example, check out the following two threads.

http://tw200forum.com/forums/44430/ShowPost.aspx

http://tw200forum.com/forums/34324/ShowPost.aspx

Here are a couple of photographs from those threads showing the dirty Yamaha oil filters.





Most of the gunk you see on Mr. Owl’s filter is oil sludge. However, if you look closely you will see some rubber and a few pieces of metal. I must admit, his filter looks worse than mine ever did! I wonder how long he waited before he made his first oil change? :roll: However, this situation is fairly typical for both the Yamaha and Zongshen motorcycles. Of course, for all these small motorcycles it is very important to change the engine oil regularly. Clean the oil screen and oil filter every time you change your oil, and the engine will be just fine. If anyone is interested, located below is a link to the Zongshen 200GY-2 oil change tutorial.

http://chinariders.net/modules.php?n...hange+tutorial

Spud

[FastDoc]

One way to interperet that is to say the the filter is doing it's job well. Keep it clean and it should all be good.

[SpudRider]

Originally Posted by FastDoc

One way to interperet that is to say the the filter is doing it's job well. Keep it clean and it should all be good.

Exactly! This oil filter does a great job, and these two bikes have very tough little engines. I have now rode my Zong for almost 10,000 miles, and the engine is as good as new.

Spud

[Crni]

Excelent topic!

Love your mods,my brake caliper just fell off one day

Thank god on rear break and low traffic...
:oops:

[SpudRider]

Originally Posted by Crni

Excelent topic!

Love your mods,my brake caliper just fell off one day

Thank god on rear break and low traffic...
:oops:

Amen! Thank God you did not get injured, and thank you for your kind words!

Spud