My GIO X31 Rebuild

Alligator · 08-22-2013, 03:55 PM

Model X31 250cc
ZS169FMM(ZongShen Motor)

Purchased it off kijiji for $300 It would push start only.
I could hear that it needed new pistons. I have a mechanics ear...
My dad has his own shop, and I'm a HD Mechanic/ MECP certified/ Elctronic injection Technician.

Back to the tear down, I noticed minor stuff wrong with it valves were way out. The bike would stall when shifting (because the valves were way out)
Chain was loose (simple fix). Wiring looked like a spider's web.

Picking up piston rings and gasket kit today after work Before or after I get a bottle of vodka... Piston Rings $40 Gasket kit $38
I dropped a Washer down in to the pan... I'll try going fishing to get it out

With the Electrical I got it all figured out. Except there is a 6pin flat and flush connector beside the sprocket it was cut and taped up. The color wires are as following g/r, g/b, b/r, r, y/r, and y. g=green and so forth.

I may put a 4 led flood light on it... I dunno
performance ignition coil & performance cdi ordered off ebay
a 42mm Air filter. No need to change fuel lines, I will put a filter on it though. Carberator may get changed and I'll extrude it so I dont need to pay for jets.

Payed $300
budget for parts $250

Sell for a $1000 when its all tuned up.

I took the frame under the seat and sandblasted & spray painted a chrome/grey (Extra paint around the shop saved some money)

Any how I could keep rambling But I need some help with that electrical connector by the sprocket it doesn't lead to anything.

Weldangrind · 08-22-2013, 04:04 PM

Welcome!

I haven't checked the colours to be sure, but if the bike runs with those wires taped off, it might be a digital shift indicator harness. The stator that is often used is not unique to the bike; it is typically used in all of the dirt and street versions, and they simply connect what is needed for the application. AFAIK, the Gio never came with a digital shift indicator, so the wires would be cut and taped.

Do you need me to confirm the digital shift indicator colours?

The carb is most likely a 30mm Mikuni already, so it's ideal for the application. If you have access to a numbered drill bit set, you can drill the jets out as necessary. I you need to buy new jets, you'll find them to be very cheap.

Did you get the pushrod or OHC engine? Please post pics when you have time.

Alligator · 08-23-2013, 10:14 AM

http://s851.photobucket.com/user/lei...uette/library/

hopefully this works...

Alligator · 08-23-2013, 10:21 AM

I take it I need a puller to get the crank out. So, gotta bring the bottom end to the shop to dismantle the rest (Next Week)
What do you think about upgrading the piston to a 69mm. It's for an X35.
The carb is a 42mm intake side.
Digital shift indicator ebay if its cheap. I suppose.

oviking99 · 08-23-2013, 12:13 PM

I would be grateful if you could post a source for the pistons, etc. I'm looking for parts for a 169FML, mine being a shorter stroke, 200cc, but the same bore. I'm guessing the cylinder head is the same as mine as well, looking at the photos you posted, OHC.
Thanks.

Weldangrind · 08-23-2013, 12:14 PM

It looks like you have an OHC engine, so the only puller I'm aware of would be for the flywheel. The puller is just a bolt that threads into the female threads of the flywheel and presses on the crank.

According to the number on the motor, you have a 69mm bore. What does it measure out to be?

Does the carb say Mikuni?

You're not likely to find a digital shift indicator, unless you pirate it from a street version of the same motor. I sure wouldn't bother.

Alligator · 08-23-2013, 04:33 PM

Quote:

Originally Posted by oviking99

I would be grateful if you could post a source for the pistons, etc. I'm looking for parts for a 169FML, mine being a shorter stroke, 200cc, but the same bore. I'm guessing the cylinder head is the same as mine as well, looking at the photos you posted, OHC.
Thanks.

There's 2 things you could do find your local gio/pocket bike dealer.
See what they have that will match up to it.
Or go to honda dirt bike dealer like me. I lied I said I'm rebuilding a Honda XR200 (didn't want them to know what really riding) and I need a Piston and rings they didn't have anything instock. I decided to get a bigger piston 69mm. Let the bore begin.
my stock piston measure 65.5mm

If you wanna be cheap eBay that $&!T.

here's a link: http://www.ebay.ca/itm/Piston-65-5mm-Rings-Wrist-Pin-Kit-Honda-XR-200-13011-446-000-80-83-86-03-/181173927101?pt=Motorcycles_Parts_Accessories&
hash=item2a2ecebcbd&vxp=mtr

bogieboy · 08-23-2013, 04:50 PM

I did a ebay piston set in my shineray, upon assembly i was cranki g out 155psi compression before even seati g the rings... All parts that went in seemed same quality as anything that has come out of my 1979 honda xl75.... Cheap doesnt always mean low quality...LOL

Alligator · 08-23-2013, 04:51 PM

Quote:

Originally Posted by Weldangrind

It looks like you have an OHC engine, so the only puller I'm aware of would be for the flywheel. The puller is just a bolt that threads into the female threads of the flywheel and presses on the crank.

According to the number on the motor, you have a 69mm bore. What does it measure out to be?

Does the carb say Mikuni?

You're not likely to find a digital shift indicator, unless you pirate it from a street version of the same motor. I sure wouldn't bother.

I'm pretty sure this engine is built of multiple engines just throwin together... The piston mos-def measured 65.5mm on the caliper.

Yeah the plug is for a digital shift indicator.

The puller is to pull the gears off. I can get off the gear where the stator goes off.

Any how It looks like they used alot of gasket sealer on the crankcase so I'll be most likely be buying a new motor. I found one for $500 + $50 for shipping, out of BC..

bogieboy · 08-23-2013, 05:39 PM

Quote:

Originally Posted by Alligator

I'm pretty sure this engine is built of multiple engines just throwin together... The piston mos-def measured 65.5mm on the caliper.

my engine was the same way... i assumed it was a 163fml, and it is, but the case wass tamped 169fml...LOL so i think they just slapped whatever parts into the cases they had... mine is a 63mm bore fyi...

oviking99 · 08-23-2013, 07:09 PM

I appreciate the info. Interesting, the bore in my ZS169FML OHC cylinder is 68.95mm averaged. My piston is 68.55 +-. The wrist pin is 17mm.

humanbeing · 08-24-2013, 05:33 AM

The difference btw Zongshen 69mm & std Honda clone: http://item.taobao.com/item.htm?id=13332079586

Gasket http://item.taobao.com/item.htm?id=14248656344
Piston related: http://item.taobao.com/item.htm?id=14513296177
The stock 200 piston http://item.taobao.com/item.htm?id=18850702171 uses thinner ring which f****ed up faster than the above 250 (100% compatible) parts.
---
If it's serious f***ed, u need this kit: http://item.taobao.com/item.htm?id=15186315205 Rings made by http://www.dongya.cn/ Piston made by http://www.ztjg.com/

oviking99 · 08-24-2013, 07:03 PM

Quote:

Originally Posted by humanbeing

The difference btw Zongshen 69mm & std Honda clone: http://item.taobao.com/item.htm?id=13332079586

Gasket http://item.taobao.com/item.htm?id=14248656344
Piston releated: http://item.taobao.com/item.htm?id=14513296177
The stock 200 piston http://item.taobao.com/item.htm?id=18850702171 uses thinner ring which f****ed up faster than the above 250 (100% compatible) parts.
---
If it's serouis f***ed, u need this kit: http://item.taobao.com/item.htm?id=15186315205 Rings made by http://www.dongya.cn/ Piston made by http://www.ztjg.com/

Many thanks, humanbeing

Alligator · 08-26-2013, 11:23 AM

Okay so I got it all apart and yeah everything is slapped together of random parts. It was very frustrating... Any how what engine should I put into my bike now? ( I don't wanna put back in a lemon ) Will the x35 motor fit.
I'm assuming so since some of my engine parts are from an x35.... gasket kit, half of the crancase.... ugh.

08-22-2013, 03:55 PM	#1
Alligator Join Date: Aug 2013 Posts: 7	My GIO X31 Rebuild Model X31 250cc ZS169FMM(ZongShen Motor) Purchased it off kijiji for $300 It would push start only. I could hear that it needed new pistons. I have a mechanics ear... My dad has his own shop, and I'm a HD Mechanic/ MECP certified/ Elctronic injection Technician. Back to the tear down, I noticed minor stuff wrong with it valves were way out. The bike would stall when shifting (because the valves were way out) Chain was loose (simple fix). Wiring looked like a spider's web. Picking up piston rings and gasket kit today after work Before or after I get a bottle of vodka... Piston Rings $40 Gasket kit $38 I dropped a Washer down in to the pan... I'll try going fishing to get it out With the Electrical I got it all figured out. Except there is a 6pin flat and flush connector beside the sprocket it was cut and taped up. The color wires are as following g/r, g/b, b/r, r, y/r, and y. g=green and so forth. I may put a 4 led flood light on it... I dunno performance ignition coil & performance cdi ordered off ebay a 42mm Air filter. No need to change fuel lines, I will put a filter on it though. Carberator may get changed and I'll extrude it so I dont need to pay for jets. Payed $300 budget for parts $250 Sell for a $1000 when its all tuned up. I took the frame under the seat and sandblasted & spray painted a chrome/grey (Extra paint around the shop saved some money) Any how I could keep rambling But I need some help with that electrical connector by the sprocket it doesn't lead to anything.
	0

08-22-2013, 04:04 PM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Welcome! I haven't checked the colours to be sure, but if the bike runs with those wires taped off, it might be a digital shift indicator harness. The stator that is often used is not unique to the bike; it is typically used in all of the dirt and street versions, and they simply connect what is needed for the application. AFAIK, the Gio never came with a digital shift indicator, so the wires would be cut and taped. Do you need me to confirm the digital shift indicator colours? The carb is most likely a 30mm Mikuni already, so it's ideal for the application. If you have access to a numbered drill bit set, you can drill the jets out as necessary. I you need to buy new jets, you'll find them to be very cheap. Did you get the pushrod or OHC engine? Please post pics when you have time. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer Last edited by Weldangrind; 08-22-2013 at 09:47 PM.
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08-23-2013, 12:14 PM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	It looks like you have an OHC engine, so the only puller I'm aware of would be for the flywheel. The puller is just a bolt that threads into the female threads of the flywheel and presses on the crank. According to the number on the motor, you have a 69mm bore. What does it measure out to be? Does the carb say Mikuni? You're not likely to find a digital shift indicator, unless you pirate it from a street version of the same motor. I sure wouldn't bother. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

08-24-2013, 05:33 AM	#12
humanbeing Join Date: Mar 2008 Posts: 2,436	The difference btw Zongshen 69mm & std Honda clone: http://item.taobao.com/item.htm?id=13332079586 Gasket http://item.taobao.com/item.htm?id=14248656344 Piston related: http://item.taobao.com/item.htm?id=14513296177 The stock 200 piston http://item.taobao.com/item.htm?id=18850702171 uses thinner ring which f**ed up faster than the above 250 (100% compatible) parts. --- If it's serious fed, u need this kit: http://item.taobao.com/item.htm?id=15186315205 Rings made by http://www.dongya.cn/ Piston made by http://www.ztjg.com/ Last edited by humanbeing; 08-24-2013 at 07:32 PM.*
	0

08-23-2013, 10:14 AM	#3
Alligator Join Date: Aug 2013 Posts: 7	http://s851.photobucket.com/user/lei...uette/library/ hopefully this works...
	0

08-23-2013, 10:21 AM	#4
Alligator Join Date: Aug 2013 Posts: 7	I take it I need a puller to get the crank out. So, gotta bring the bottom end to the shop to dismantle the rest (Next Week) What do you think about upgrading the piston to a 69mm. It's for an X35. The carb is a 42mm intake side. Digital shift indicator ebay if its cheap. I suppose.
	0

08-23-2013, 12:13 PM	#5
oviking99 Join Date: Jun 2013 Location: Cumming, GA Posts: 303	I would be grateful if you could post a source for the pistons, etc. I'm looking for parts for a 169FML, mine being a shorter stroke, 200cc, but the same bore. I'm guessing the cylinder head is the same as mine as well, looking at the photos you posted, OHC. Thanks.
	0

08-23-2013, 04:50 PM	#8
bogieboy Join Date: May 2013 Location: finger lakes NY Posts: 2,045	I did a ebay piston set in my shineray, upon assembly i was cranki g out 155psi compression before even seati g the rings... All parts that went in seemed same quality as anything that has come out of my 1979 honda xl75.... Cheap doesnt always mean low quality...LOL
	0

08-23-2013, 07:09 PM	#11
oviking99 Join Date: Jun 2013 Location: Cumming, GA Posts: 303	I appreciate the info. Interesting, the bore in my ZS169FML OHC cylinder is 68.95mm averaged. My piston is 68.55 +-. The wrist pin is 17mm.
	0

08-26-2013, 11:23 AM	#14
Alligator Join Date: Aug 2013 Posts: 7	Okay so I got it all apart and yeah everything is slapped together of random parts. It was very frustrating... Any how what engine should I put into my bike now? ( I don't wanna put back in a lemon ) Will the x35 motor fit. I'm assuming so since some of my engine parts are from an x35.... gasket kit, half of the crancase.... ugh.
	0