Project Phoenix: The YamaZong Rises from the Ashes

[SpudRider]

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.

[SpudRider]

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!

[SpudRider]

The engine bolted directly into the frame, and all parts aligned perfectly, including the carburetor and the sprockets.

[SpudRider]

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.

[SpudRider]

I also transferred the kick starter from the Zong engine to the Yamaha engine. All the transferred parts fit the Yamaha engine perfectly.

[SpudRider]

I gained 27 cubic centimeters of engine displacement, and a 6-speed transmission with the engine swap.

[SpudRider]

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.

[AZRider]

Congratulations and a very nice job Spud. A rebirth and I bet you didn't gain a pound.

[culcune]

It does not look like 'Big Orange' has missed a beat!!

[jbfla]

Good for another 70,000 miles...

jb

[Louis Angel]

AWESOME!!!!

[Adjuster]

Very cool!


/

[Azhule]

Originally Posted by jbfla

Good for another 70,000 miles...

jb

Or mud puddle

Looking great Spud

[2LZ]

Congrats Spud! Proves how "clone" these really are with all the bolt on parts! Very happy to see the YamaZong alive and well!

[SpudRider]

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.