Zongshen 200GY-2: Engine Rebuild at 51,687 Miles

[Pliskin]

Spud Thank you so much for uploading the pictures and documenting your rebuild. Chinariders will enjoy this thread.
Don't know how much riding have you done since but can you feel extra cc's in Zong?

Originally Posted by SpudRider

I never considered painting either the cylinder or cylinder head, Weld. I prefer aluminum to paint; I'm waiting for the rest of my engine paint to fade away!

It makes your bike really look unique.

Spud do you know approximately what is the cost for all the parts that you needed to change plus the tools you had to use for this job?
I wish you many more happy and safe miles. Can't wait to see 100,000 km or 62,137 miles on your odometer.

[SpudRider]

Originally Posted by Weldangrind

I might have to pick up a flywheel holder like that...

I believe I bought the Pit Posse Flywheel Holder for $29.95, delivered, from an eBay vendor.

http://www.ebay.com/itm/PIT-POSSE-FL...sories&vxp=mtr

Spud

[SpudRider]

Originally Posted by Pliskin

Spud Thank you so much for uploading the pictures and documenting your rebuild. Chinariders will enjoy this thread.
Don't know how much riding have you done since but can you feel extra cc's in Zong?

It makes your bike really look unique.

Spud do you know approximately what is the cost for all the parts that you needed to change plus the tools you had to use for this job?
I wish you many more happy and safe miles. Can't wait to see 100,000 km or 62,137 miles on your odometer.

You're welcome, Pliskin. Thank you for taking the initial gamble, and ordering parts from Taobao.

I have now ridden about 220 miles since my engine rebuild. My stock engine had 196cc displacement. My first engine rebuild yielded a 199cc engine. My second, current engine rebuild yielded a 202cc engine. I can't honestly say I can notice the extra 3 cc displacement. However, my engine is running very strong, and I am very pleased with the results of my engine rebuild!







Here's the cost of the new parts I purchased for this engine rebuild from Taobao. Of course, I needed to add the agent fee and shipping charges to the cost of these items.

Zongshen camshaft: CNY 65 = USD $10.60
Zongshen rocker arms: CNY 20 = USD $3.26
Zongshen intake and exhaust valves: CNY 40 = USD $6.52
Zongshen cam timing chain: CNY 50 = USD $8.15
Zongshen piston pin: CNY 25 = USD $4.08
Zongshen complete gasket set: CNY 50 = USD $8.15
Zonshen CDI unit: CNY 100 = USD $16.30
Zongshen automatic cam chain tensioner: CNY 25 = $4.08

I also ordered the following Yamaha parts.

4th Oversize Piston for TW200: $42.87
4th Oversize Piston Rings for TW200: $22.10
TW200 cylinder O-Ring: $1.26
TW200 cylinder head O-Ring: $1.96

I also paid a machinist to bore and hone my Zongshen cylinder, and to clean my XT200 cylinder head.

Spud

[wilserchinarider]

Impressive well documented work, as usual Spud, thank you! Out of curiosity, the Zongshen parts are certainly priced right from Tabao, around $60. Roughly how much were the fees and shipping?

[FastDoc]

Nice Spud!

Great work and a great writeup! I know hoe much extra work it is to stop and take pics along the way and we all appreciate it.

I can't believe how inexpensive the parts were! How much was the machine work?

Seems like next time you'll need a cylinder too, on a 77,000 mile engine! LOL!

Any pics of the valve seal install?

[Weldangrind]

Originally Posted by Pliskin

Can't wait to see 100,000 km or 62,137 miles on your odometer.

I hadn't considered that before. Wow. That really puts it in perspective for those who are immersed in the Metric system.

[SpudRider]

Originally Posted by wilserchinarider

Impressive well documented work, as usual Spud, thank you! Out of curiosity, the Zongshen parts are certainly priced right from Tabao, around $60. Roughly how much were the fees and shipping?

Thank you, WCR. Incidentally, TaobaoTrends has changed its name to TBTrends. The shipping fees are explained at the TBTrends.com website.

http://www.tbtrends.com/shipping.html

You take a big hit on the first 500 grams (half kilogram); however, each additional 500 grams is much less expensive. I have found it's a good estimation to add 50 percent of the item's price as the expected shipping charge for that item. Therefore, I expect a $10 item will result in a total price of $15, delivered.

TBTrends charges 10 percent of the item's cost as an agent's fee, which is very reasonable. They take care of all language difficulties by ordering the parts from the different vendors. They receive the items, pack them well in a single package, and ship it to your doorstep. The TBTrends agent communicated promptly in acceptable Chinglish, and provided good customer service. I will purchase from TBTrends again.

TBTrends packed my items very well; everything arrived in excellent condition. My parcel arrived in Idaho 4 days after being shipped from Hong Kong by DHL Express.

Spud

[SpudRider]

Originally Posted by FastDoc

Nice Spud!

Great work and a great writeup! I know hoe much extra work it is to stop and take pics along the way and we all appreciate it.

I can't believe how inexpensive the parts were! How much was the machine work?

Seems like next time you'll need a cylinder too, on a 77,000 mile engine! LOL!

Any pics of the valve seal install?

Thank you, Doc. I paid my machinist $75 to bore and hone the cylinder. I delivered the cylinder, piston, and rings to him for machining. He tests the ring gap after the job is completed. He charged $25 to clean my cylinder head, which was well worth the money. Lapping both valves was a 15-minute job using a clean cylinder head and new valves.



Yes, I realize I will need a new cylinder if I can't find a 6th oversize piston and rings. However, I can buy a new Zongshen cylinder from Taobao for $22 (CNY 135), plus shipping. 8O

http://item.taobao.com/item.htm?spm=...&id=9349755579

I would also buy the Chinese piston and piston rings, since I am convinced the Yamaha TW200 parts come from the same Zongshen factory.

Spud

[SpudRider]

Originally Posted by Weldangrind

I hadn't considered that before. Wow. That really puts it in perspective for those who are immersed in the Metric system.

I will probably reach 52,000 miles on the Zong's odometer today, Weld. Therefore, I am rapidly closing in on 85,000 kilometers.

The Zong is a great little bike; I still haven't learned to use its full potential. My Zong is the best $950 dollars I ever spent.



Spud

[Weldangrind]

Originally Posted by SpudRider

However, I can buy a new Zongshen cylinder from Taobao for $22 (CNY 135), plus shipping. 8O

That has to be less than the cost of boring out your existing cylinder! That said, I'll bet you could easily find a Wiseco piston in any overbore you wish.

[humanbeing]

Originally Posted by SpudRider

...buy a new Zongshen cylinder from Taobao for $22 (CNY 135), plus shipping. 8O
http://item.taobao.com/item.htm?spm=...&id=9349755579
I would also buy the Chinese piston and piston rings...
Spud

Those goodies: http://item.taobao.com/item.htm?id=6765557290 | http://item.taobao.com/item.htm?id=5735956344

[SpudRider]

Originally Posted by humanbeing

Those goodies: http://item.taobao.com/item.htm?id=6765557290 | http://item.taobao.com/item.htm?id=5735956344

Thanks for sharing the links, Humanbeing!

Spud

[humanbeing]

Pin spec from one of the maker:
http://www.lcdrkj.com/usr_web/Produc...ore.asp?id=310 LY200

[MICRider]

Dunno Spud, I'd say that's pretty much using it to it's full potential right there!

[SpudRider]

Originally Posted by Weldangrind

That has to be less than the cost of boring out your existing cylinder! That said, I'll bet you could easily find a Wiseco piston in any overbore you wish.

I might be wrong, but I believe the TW200 owners are using Wiseco pistons designed for the Yamaha, YTM200 three-wheelers built in 1984-85.

http://www.wiseco.com/ProductDetail....85&AppID=19139

However, these Wiseco pistons have a largest bore of 68.0 mm, which is the size piston I am now employing. :? In any event, as you stated, the Wiseco piston and rings would cost much more than getting a new, Zongshen cylinder.

Spud