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04-07-2009, 03:30 AM | #1 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Zongshen Sierra 200GY-2 Countershaft Sprocket Replacement
Today I replaced the countershaft sprocket on my Zongshen Sierra 200GY-2 motorcycle. The Zongshen 200GY-2 employs a countershaft very similar to the one used by the Yamaha TW200 motorcycle. Therefore, I decided to use a Yamaha TW200 countershaft sprocket as a replacement. Because of good reports I had read on the Yamaha TW200 forum, I chose to use a PBI 50-733-15 sprocket. In the following photographs the new PBI sprocket is on the left, and my original Zongshen sprocket is on the right. The first photograph shows the “front†of the two sprockets.
The second photograph shows the “rear†of the two sprockets. You can immediately notice the wear produced on my original sprocket after riding 9,500 miles. However, if you examine the photographs more closely, you will also notice another difference. The two sprockets are almost identical, with one exception. The bolt holes for the sprocket retaining clip are smaller on the PBI sprocket designed for the Yamaha TW200 motorcycle! A quick trip to the hardware store revealed that the Yamaha TW200 sprocket employs two 5x10mm bolts, while the Zongshen 200GY-2 sprocket employs two 6x10mm bolts. The 5x10mm bolts currently cost $0.13 apiece at Ace Hardware. After buying several bolts, I returned home and installed my new PBI sprocket. Although the bolts are slightly smaller, I had no trouble using the Zongshen sprocket retaining clip. Besides the 15-tooth sprocket, I also purchased PBI sprockets with fourteen and thirteen teeth. Since I completed my left crankcase cover modification, I can now easily experiment with different sprocket ratios on my Zongshen Sierra 200GY-2. If you wish to learn more about the crankcase cover modification, you might enjoy reading the following thread. http://chinariders.net/modules.php?n...ewtopic&t=7559 Spud
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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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04-07-2009, 04:20 AM | #2 |
Join Date: Jul 2008
Location: Gijon, Asturias,Northern Spain
Posts: 396
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Take no notice of Spud. He's just showing off his Crankcase Cover Mod...
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Jincheng Monkey JC50Q-7 (two of them) Skyteam Dax replica ST110-6 (two of them) Zongshen ZS125-43 Qingqi QM200GY-BA Super Motard Yamaha Virago XV1100 Triumph Bonneville SE Qingqi QM110GY PGO Bug rider 250 Buggy |
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04-07-2009, 05:08 AM | #3 |
Join Date: Sep 2006
Location: North East England
Posts: 313
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I hope "we" are changing the chain and rear sprocker as well, it's not a good practice to change things one at at time. That front sprocket is well worn.
Jonathan. |
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04-07-2009, 06:13 AM | #4 |
Join Date: Jun 2006
Location: directly under the earths sun............NOW
Posts: 2,302
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Yep that stock counter sprocket is shot but I'd be trying to figure out why the excessive wear on just the backside of it.
Something must be misaligned. |
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04-07-2009, 07:03 AM | #5 | |
Join Date: Jul 2008
Location: Gijon, Asturias,Northern Spain
Posts: 396
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Quote:
That kind of sprocket fixing (On Hondas at least) is to a certain extent self-aligning, meaning the sprocket is free to move a little bit on the splines even with the bolts done up, so whatever is causing this wear has to be way out of line.
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Jincheng Monkey JC50Q-7 (two of them) Skyteam Dax replica ST110-6 (two of them) Zongshen ZS125-43 Qingqi QM200GY-BA Super Motard Yamaha Virago XV1100 Triumph Bonneville SE Qingqi QM110GY PGO Bug rider 250 Buggy |
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04-07-2009, 09:28 AM | #6 |
Join Date: Jun 2006
Location: directly under the earths sun............NOW
Posts: 2,302
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Yeah it is true that the counter shaft sprockets do float a little bit on most everything I have seen.
The wear on the sprocket would indicate the rear sprocket is offset to the left a bit and I'd bet there was some wear on the outer side of the rear sprocket as well but maybe not as noticeable since it is bigger. Is the engine aligned properly and how is the rear swingarm bushings/bearings, maybe the rear tire is just crooked on the swingarm. I'm just guessing because something like that should be visually inspected to see what is out of alignment. Even so if thats all after 9500 miles then thats not to bad I guess. |
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04-07-2009, 11:23 AM | #7 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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As always, Spud, thanks for taking the extra time to share so others may benefit.
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Happy to serve. |
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04-07-2009, 11:48 AM | #8 |
Hi
Great information Spoud ! Could you please report results of 14 and 13th sprocket driving, iam also interested to change sprockets on my zong (front sprockets), so please,report results, thanks |
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04-08-2009, 01:02 AM | #9 |
Join Date: Apr 2007
Location: Show Low Arizona
Posts: 2,889
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Nice work Spud, Looks like You uncovered another issue on the procees though.
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<br />2001 Suzuki DR200SE<br />1997 Suzuki RM250 YIKES<br />1995 Yamaha Breeze 125 daughters<br />1991 Honda XR80r Restored<br />maybe a 2003 Yamaha TTR90 |
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04-08-2009, 12:49 PM | #10 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
Spud
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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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04-08-2009, 01:51 PM | #11 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
I make it a habit to inspect my rear sprocket every time I lubricate my drive chain. Also, every time I change my engine oil I remove my drive chain, immerse, and brush it with kerosene. I then soak the drive chain in the used, warm engine oil before I reattach it to the motorcycle. Before I replace the drive chain I closely inspect the rear sprocket. Fortunately, my Zongshen Sierra 200GY-2 has an excellent “cush drive†on the rear wheel. After 9,500 miles of use, my rear sprocket appears to be almost as good as new! Below I have posted a recent photo of the inside of my rear sprocket, attached to the cush drive plate. Here is a recent photo of the outside of the rear sprocket and cush drive plate. Here is a photo of the inside of the large, robust, rubber absorption block. Finally, this photo shows the left side of the rear hub, where the “cush drive†mates to the rear wheel. The “cush drive†on my Zongshen does an excellent job smoothing out the transmission of power to the rear wheel of the motorcycle. As you can see, it also does a superb job preserving the rear sprocket from wear. However, it is much more difficult to inspect and replace the countershaft sprocket on the Zongshen 200GY-2. Because this motorcycle is patterned after the Yamaha TW200, the entire left crankcase cover must be removed before you can access the countershaft sprocket. Therefore, the almost complete lack of wear on the rear sprocket can be very deceptive. Also, motorcycle riders just beginning to learn how to maintain their bikes might be unaware of an important fact; the countershaft sprocket wears more quickly than the rear sprocket. Because of this great difference in wear patterns between the two sprockets, I highly encourage all 200GY-2 owners to perform the Zongshen 200GY-2 Crankcase Cover Modification the next time they change their engine oil. http://chinariders.net/modules.php?n...ewtopic&t=7559 Spud
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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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04-08-2009, 02:17 PM | #12 | ||
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
The countershaft sprocket on my Zong 200GY-2 moves very little when attached to the countershaft by the retaining plate. Also, the quality of metal used to manufacture the original sprocket might not be the best. These factors undoubtedly contributed to the sprocket's wear pattern. However, my new PBI sprocket is very well made. According to the manufacturer, it is: “Manufactured from Pro quality chromoly steel approaching 200,000 psi yield. Case hardened, finished with electroless nickel plating.†[sic] Now that I can easily access my countershaft sprocket, I will keep a close watch to see how the PBI sprocket wears in relation to the original, Zong sprocket. Spud
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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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04-08-2009, 03:00 PM | #13 | |||
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Here is a photograph of the drive chain alignment. Here is a photo of the wear pattern on the top of the chain slider. Quote:
All in all, I tend to agree with your final assessment; I am not too disappointed with the sprocket wear after 9,500 miles. However, I truly appreciate your thoughtful advice. I certainly intend to keep a close watch on things. I will report back as I notice the wear pattern on my new PBI countersprocket. Spud
__________________
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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04-08-2009, 04:03 PM | #14 |
Join Date: Jun 2006
Location: directly under the earths sun............NOW
Posts: 2,302
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Of course that was 9500 miles with what sounds like excellent chain maintenance other riders results will very.
Good work on maintaining that chain & sprockets. With the chain off and using a TRUE straight edge of some sort from the rear sprocket to the front sprocket should show any misalignment pretty easily I would think. I'm wondering if there is some sort of motorcycle laser alignment tool for sprockets. |
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04-08-2009, 04:04 PM | #15 | |||
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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The weather was beautiful, so I went for a nice long ride yesterday. I am very happy that Spring has finally arrived, and I am also happy to report that the new PBI countersprocket worked great! As a matter of fact, Max, I think I will install the 14-tooth sprocket today. I will let you know my impressions after a few days of riding. Spud
__________________
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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