TheGageinator's 2007 SunL 200cc build - Page 2

Weldangrind · 12-25-2014, 11:15 PM

Remove the flywheel bolt, and check the female thread. Is it left hand or right hand? I'm not talking about the bolt that secures the flywheel, but rather the large internal female thread that will be revealed after the bolt is removed.

TheGageinator · 12-26-2014, 08:34 AM

i didnt think about it maybe being left hand threads... il check that tonight. i have 2 large tap and die sets, and neither of them had the tools that would match up so i could identify the threads... i think it may be 18 threads per inch. i keep seeing a ton of tools for a gy6. i dont know why its so hard to find one for this zong 197cc engine

Weldangrind · 12-26-2014, 12:39 PM

It's because there were a few different styles. BTW, it will be metric, not SAE thread.

If it is right hand thread, you'll be able to buy a bolt that will screw in, which you can use to pop the flywheel off. Easy, fast and cheap. Rarely are those three words used to describe the same thing.

TheGageinator · 12-27-2014, 08:19 AM

haha it would be nice if i get to use those words on this job. i checked, and I have right hand threads. i need to find a bolt now. will update

Weldangrind · 12-27-2014, 02:27 PM

Fastenal is a good source.

TheGageinator · 12-28-2014, 12:19 AM

I got it! You were right! I just used a metric bolt and impacted in! The flywheel popped right off. I'll post the thread pattern when I find out what it is. I got lucky and just found a bolt that worked.

I did notice that my starter clutch was broken. That's where my starting problem was coming from. The Sprag Clutch came loose from the gear. I have ordered a new one for $38 on eBay. I also ordered all new seals and o-rings

Starter clutch
http://pages.ebay.com/link/?nav=item...633894&alt=web

Shifter seal
http://pages.ebay.com/link/?nav=item...018066&alt=web

Crankshaft seal behind starter clutch
http://pages.ebay.com/link/?nav=item...390929&alt=web

Complete engine gasket set
http://pages.ebay.com/link/?nav=item...113143&alt=web

The clutch and gear are supposed to be one piece.....

Flywheel scared from clutch going bad

Weldangrind · 12-31-2014, 11:48 AM

Glad to hear you were able to remove the flywheel for cheap. The price on the replacement parts isn't too bad.

Please post a follow-up as you begin repairs.

TheGageinator · 01-05-2015, 09:38 PM

Got the starter clutch changed out! I also changed all the seals and O-rings in the process.

Starts up like a champ

everything went back together well, but the shifter seal is still dripping oil when not driving. slow drip.

TheGageinator · 01-05-2015, 09:41 PM

Got some goods installed today! ProTaper pillow-top grips and some cheap hand gaurds.

TheGageinator · 01-05-2015, 09:51 PM

when working on my atv, i lifted it up to place it on jack stands. I noticed that driver (left) side front wheel was closer to the ground..... the passenger(right) side was higher. after some investigating, i found that the driver(left) side upper a-arm mounts were welded too low on the frame... great.

i adjusted the passenger side lower shock mount to match the offset. now its level.... ill have to get the plasma cutter out and re-weld the mounts later.

right side ok

left side bracket welded too low on the frame tubing

TheGageinator · 01-05-2015, 09:53 PM

I found some Yamaha banshee front shocks that are the exact same length as the stock ones! i held them in place, and noticed that the mounts will need to be widened. I tried putting one on the back, but it was WAY too soft. im thinking they will be perfect up front.

they are 15inches from eye to eye

TheGageinator · 01-05-2015, 10:41 PM

Put some tusk headlight bulbs in today! I'll take a picture at night when I get a chance. They are 35watts. Stock ones were 18watts

http://pages.ebay.com/link/?nav=item...281697&alt=web

Weldangrind · 01-06-2015, 12:45 AM

Not at all surprised to see the control arms at different heights.

Good call on the Banshee shocks! I wondered if those would work, since my quad is so closely patterned after a Banshee.

That headlight might be a bit much for your stator. Beware dead batteries.

TheGageinator · 01-10-2015, 11:33 AM

i stretched my shifter lever 2 inches today. i could shift ok with shoes on, but not with boots. woohoo

.

Weldangrind · 01-12-2015, 12:08 PM

Nice work.

12-25-2014, 11:15 PM	#16
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Remove the flywheel bolt, and check the female thread. Is it left hand or right hand? I'm not talking about the bolt that secures the flywheel, but rather the large internal female thread that will be revealed after the bolt is removed. __________________ 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

12-26-2014, 12:39 PM	#18
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	It's because there were a few different styles. BTW, it will be metric, not SAE thread. If it is right hand thread, you'll be able to buy a bolt that will screw in, which you can use to pop the flywheel off. Easy, fast and cheap. Rarely are those three words used to describe the same thing. __________________ 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

12-27-2014, 02:27 PM	#20
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Fastenal is a good source. __________________ 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

12-28-2014, 12:19 AM	#21
TheGageinator Join Date: Jun 2014 Posts: 142	I got it! You were right! I just used a metric bolt and impacted in! The flywheel popped right off. I'll post the thread pattern when I find out what it is. I got lucky and just found a bolt that worked. I did notice that my starter clutch was broken. That's where my starting problem was coming from. The Sprag Clutch came loose from the gear. I have ordered a new one for $38 on eBay. I also ordered all new seals and o-rings Starter clutch http://pages.ebay.com/link/?nav=item...633894&alt=web Shifter seal http://pages.ebay.com/link/?nav=item...018066&alt=web Crankshaft seal behind starter clutch http://pages.ebay.com/link/?nav=item...390929&alt=web Complete engine gasket set http://pages.ebay.com/link/?nav=item...113143&alt=web The clutch and gear are supposed to be one piece..... Flywheel scared from clutch going bad Last edited by TheGageinator; 12-28-2014 at 10:22 PM.
	0

12-31-2014, 11:48 AM	#22
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Glad to hear you were able to remove the flywheel for cheap. The price on the replacement parts isn't too bad. Please post a follow-up as you begin repairs. __________________ 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

12-26-2014, 08:34 AM	#17
TheGageinator Join Date: Jun 2014 Posts: 142	i didnt think about it maybe being left hand threads... il check that tonight. i have 2 large tap and die sets, and neither of them had the tools that would match up so i could identify the threads... i think it may be 18 threads per inch. i keep seeing a ton of tools for a gy6. i dont know why its so hard to find one for this zong 197cc engine
	0

12-27-2014, 08:19 AM	#19
TheGageinator Join Date: Jun 2014 Posts: 142	haha it would be nice if i get to use those words on this job. i checked, and I have right hand threads. i need to find a bolt now. will update
	0

01-05-2015, 09:38 PM	#23
TheGageinator Join Date: Jun 2014 Posts: 142	Got the starter clutch changed out! I also changed all the seals and O-rings in the process. Starts up like a champ everything went back together well, but the shifter seal is still dripping oil when not driving. slow drip.
	0

01-05-2015, 09:41 PM	#24
TheGageinator Join Date: Jun 2014 Posts: 142	Got some goods installed today! ProTaper pillow-top grips and some cheap hand gaurds.
	0

01-05-2015, 09:51 PM	#25
TheGageinator Join Date: Jun 2014 Posts: 142	when working on my atv, i lifted it up to place it on jack stands. I noticed that driver (left) side front wheel was closer to the ground..... the passenger(right) side was higher. after some investigating, i found that the driver(left) side upper a-arm mounts were welded too low on the frame... great. i adjusted the passenger side lower shock mount to match the offset. now its level.... ill have to get the plasma cutter out and re-weld the mounts later. right side ok left side bracket welded too low on the frame tubing
	0

01-05-2015, 09:53 PM	#26
TheGageinator Join Date: Jun 2014 Posts: 142	Banshee shocks! I found some Yamaha banshee front shocks that are the exact same length as the stock ones! i held them in place, and noticed that the mounts will need to be widened. I tried putting one on the back, but it was WAY too soft. im thinking they will be perfect up front. they are 15inches from eye to eye Last edited by TheGageinator; 01-05-2015 at 10:31 PM.
	0

01-05-2015, 10:41 PM	#27
TheGageinator Join Date: Jun 2014 Posts: 142	Put some tusk headlight bulbs in today! I'll take a picture at night when I get a chance. They are 35watts. Stock ones were 18watts http://pages.ebay.com/link/?nav=item...281697&alt=web
	0

01-06-2015, 12:45 AM	#28
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Not at all surprised to see the control arms at different heights. Good call on the Banshee shocks! I wondered if those would work, since my quad is so closely patterned after a Banshee. That headlight might be a bit much for your stator. Beware dead batteries. __________________ 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

01-10-2015, 11:33 AM	#29
TheGageinator Join Date: Jun 2014 Posts: 142	i stretched my shifter lever 2 inches today. i could shift ok with shoes on, but not with boots. woohoo . Last edited by TheGageinator; 01-11-2015 at 12:00 AM.
	0

01-12-2015, 12:08 PM	#30
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Nice work. __________________ 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