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TheGageinator's 2007 SunL 200cc build
I figured its about time for me to post a build thread on here.
About me: My name is Gage. I live south of Dallas TX. i use my atv for hunting and riding trails. and also to keep up with my son's 125cc trail rover.:) My ATV: 2007 SunL 197cc (200cc) VIN L5CAELLN77M009049 Engine Family 7KNDX250AM5 Engine model 163FML Some factory stock information for other users Stock handlebars 7inch tall 27inch wide exhaust gasket 40mm OD 33MM ID Shifter seal NJK 2095-226 28 stock carburetor PZ27 Tune-up specs 1500rpm idle 92 octane fuel 15w40 oil .7mm or .032 spark gap Sprocket 12tooth front 40tooth rear Tire size rear 20x10x10 front 21x7x10 |
First day i brought home both atv's
http://i536.photobucket.com/albums/f...psdd125c5a.jpg http://i536.photobucket.com/albums/f...ps1133df89.jpg out for the first drive http://i536.photobucket.com/albums/f...psaebbe82c.jpg Picnic to the state park http://i536.photobucket.com/albums/f...ps8a8c2367.jpg |
After a 2 hour ride, my atv would not start... so i tore it down to see what the matter was. starter sprag clutch would not re-engage
https://www.youtube.com/watch?v=LZFY...nfSLYvv0PvKlpw http://i536.photobucket.com/albums/f...psf67b042b.jpg http://i536.photobucket.com/albums/f...ps6d557fb9.jpg http://i536.photobucket.com/albums/f...ps8ceea142.jpg http://i536.photobucket.com/albums/f...psa6537d83.jpg http://i536.photobucket.com/albums/f...ps1a997e90.jpg http://i536.photobucket.com/albums/f...ps1ff72f45.jpg see the gear behind the flywheel? that is a one direction freewheel starter clutch. my clutch unfortunately would spin freely in both directions. http://i536.photobucket.com/albums/f...ps9af74c12.jpg i used an impact when to remove the flywheel bolt. 14mm. when i removed the bolt, it freed up the sprag mechanism and my clutch started working again in 1 single direction. here is a video to illustrate https://www.youtube.com/watch?v=jXg2...nfSLYvv0PvKlpw http://i536.photobucket.com/albums/f...psa4737ac4.jpg i then re-assembled it all. my starer worked great. now im having intermittent problems with part failing, i have ordered a tool to remove the flywheel to further investigate this issue. http://www.ebay.com/itm/161120336233...%3AMEBIDX%3AIT |
Next i took apart the entire front suspension to greasy and lube all points. i also greased the steering shaft
http://i536.photobucket.com/albums/f...ps894c039c.jpg i noticed that my driver side (left) rear axle side was slightly bent.i put the atv on jack stands and ran it in foreward gear to confirm the shaft IS bent. the bend cannot be seen with the naked eye. searching for a new one.. http://i536.photobucket.com/albums/f...psd87d4474.jpg http://i536.photobucket.com/albums/f...psa8f2396c.jpg |
I accidentally bent my rear rack and support o my atv doing wheelies.... i removed the plastics to unbend the frame and add supports. I HIGHLY recommend this to everyone with these quads. do it before you bend it. i could not get it straight again. i could have tried harder but i dont care.
http://i536.photobucket.com/albums/f...psggbhtbtq.jpg http://i536.photobucket.com/albums/f...pskxttbwme.jpg flat bars welded http://i536.photobucket.com/albums/f...psuwqkjdel.jpg http://i536.photobucket.com/albums/f...ps027sbmlg.jpg http://i536.photobucket.com/albums/f...ps8tzfavtj.jpg flat bars painted http://i536.photobucket.com/albums/f...ps9aihiffq.jpg |
I noticed my steering shaft was a little jerky and making a creaking sound. i took apart the top bushing, cleaned and greased.
here you see tabs that must be bent out of the way to remove the bolts http://i536.photobucket.com/albums/f...ps3jo4wgvk.jpg remove bolts and bracket http://i536.photobucket.com/albums/f...psxgkpwgho.jpg remove bushing and spacers http://i536.photobucket.com/albums/f...psp2ubueqh.jpg clean steering shaft very well and use synthetic grease to not destroy the rubber bushings http://i536.photobucket.com/albums/f...psky1s6eor.jpg http://i536.photobucket.com/albums/f...psi50mo0a5.jpg be sure to bend retaining tabs back http://i536.photobucket.com/albums/f...ps0f2dd0zs.jpg |
i installed a cheap hour meter/tach to keep track of my engine hours. the 1 wire lead simply wrapped around and zipp tied to the spark plug wire
http://i536.photobucket.com/albums/f...ps0kfiagso.jpg http://i536.photobucket.com/albums/f...psfll4ibd4.jpg |
Your quad looks really well built, and it has awesome ground clearance. I wish mine had racks like yours does.
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thank you. i heard the name SUNL and Lifan alot when learning about chinese atv's. i think they may be a slightly higher quality. who knows though.
i would really like to find some shocks to replace my "nitro" shocks with. i saw the thread about the raptor shocks.. |
The Raptor shocks have worked out well, but they were a lot of effort. I've since discovered that early '80's XR200 shocks are a near match (with a bit of tweaking) for my quad, so perhaps they'd be right for yours.
Knowing that, you could buy better quality shocks that would fit the old Hondas. |
Well bad news. The tools that I ordered to pull the flywheel on my engine did not work. Turns out that they are for 50cc and 150cc gy6 engines.
So now my atv is apart until I can get this tool. I have all new gaskets to install. I'm going to go ahead and replace all the seals and such in the area |
When I had the side engine cover off, I noticed it said zongshen inside! Just a side note. So my engine is a zongshen 163fml 197cc
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I took my atv on a 4 hour ride yesterday! Through the countryside, forest and creeks. It was a blast. I was very surprised how well the little atv did. I was riding with my nephew on his 2013 polaris sportsman 850xp. I also made go pro videos! I'll post them as soon as I get them formated
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Looking forward to your vids.
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Atv has been sitting torn apart in my garage for the past week. I REALLY need a flywheel removal tool. I'm having a very hard time finding the correct one
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