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

[hect75]

So, tightening the bolts will remove the studs? Once the studs are removed, do I need to replace them for a new ones or can I use the same ones? If stock studs can be used, what do I need to do to putting back, pounding the studs with hammer or rubber mallet? Getting the TW200 spare parts are difficult down here because this model is not sold here in Mx.

Thanks Spud for the info

[SpudRider]

Originally Posted by hect75

So, tightening the bolts will remove the studs? Once the studs are removed, do I need to replace them for a new ones or can I use the same ones? If stock studs can be used, what do I need to do to putting back, pounding the studs with hammer or rubber mallet? Getting the TW200 spare parts are difficult down here because this model is not sold here in Mx.

Thanks Spud for the info

No, you must loosen each stud by turning it counterclockwise. You can grip each stud with vise grips to loosen it. Otherwise, you can tighten two nuts on top of each stud, and loosen the stud by turning the bottom nut counterclockwise.

Yes, if you wish, you can re-use the original studs. Tighten the studs clockwise after you re-assemble the cylinder onto the engine block.

Your bike was sold in Mexico as the QLink XRanger 200. Perhaps you can order parts from QLink Mexico. Otherwise, you can order Yamaha parts from the United States, or you can order Zongshen parts from Taobao.com. If you remove either the cylinder head, or cylinder, you definitely need to order new gaskets. Here is a complete gasket set for you motorcycle sold at Taobao.com.

http://item.taobao.com/item.htm?spm=...id=18298326572

[tpar1220]

spud,

i didn't realize you had rebuilt your zongs engine a couple times. good to see it can be done so inexpensively!

was your zong street legal from factory? or did you go thru the trouble of getting it plated? i still have my um dtf200 sitting in barn. it is nearly new condition but i am not sure what i am gonna do with it. i have my klr and a plated ktm 300. so the dtf200 is sitting.

and am currently working on dads old honda 400a.



so.... not sure what i am gonna do with the dtf200. don't want to plate/insure another bike to find i don't like it.

[FastDoc]

I love the Honda!

[tpar1220]

Originally Posted by FastDoc

I love the Honda!

thanks... yeah, i am diggin it too. was totally stock. i have been changiing it up some and finally got it plated, which was a bit of a headache due to previous owner and paper work... but is done! i just need to make up a rear light mount. i found a utility trailer light works well and weighs nearly nothing. i have the mount done just need to put together and wire it. then call ins co and insure it.

and finally be able to put some miles on it. when i do i may start another thread on that thing.

[SpudRider]

I also love that Honda; it looks a lot like my first motorcycle, a 1979 Honda Hawk II. Please do start a new thread on your rebuild of that bike in our Other Brands Forum.

My Zong was street legal right out of the shipping crate. My Christian brother Andy helped me assemble the Zong. After adding electrolyte to the battery, I went for a 25-mile ride that evening, as soon as the bike was assembled. My Zong is still running strong over 61,000 miles later.

[hect75]

Spud, one more question. What if I use the RTV silicone instead of gasket? wiil it work? Vento sells the Mountrack's spare parts, however, some are out of stock (e.g., one of the cylinder gaskets, not remember which one). There are some shops that sell cardboard (1 by 1ft) for gasket (or cardboard gasket) that probably would work if I don't get the gaskets at the Yamas dealer.

Thanks for your comments and time.

God bless

[SpudRider]

I strongly suggest you purchase either Vento, Zongshen, or Yamaha gaskets. The cylinder head gasket is tri-metal; you can't use a paper gasket, or you will get a cylinder compression leak.

If the cylinder base gasket is paper ( I don't remember), you can probably trace and cut one, but I would certainly prefer to buy the proper, Yamaha gasket.

[alex_in_az]

Originally Posted by hect75

Spud, one more question. What if I use the RTV silicone instead of gasket? wiil it work? Vento sells the Mountrack's spare parts, however, some are out of stock (e.g., one of the cylinder gaskets, not remember which one). There are some shops that sell cardboard (1 by 1ft) for gasket (or cardboard gasket) that probably would work if I don't get the gaskets at the Yamas dealer.

Thanks for your comments and time.

God bless

OK I'm a little embarrassed to admit this, but as a 16 year old boy, 35 years ago I used a Christmas card as a barrel to case gasket on my CB125. It worked out just fine

[SpudRider]

Originally Posted by alex_in_az

OK I'm a little embarrassed to admit this, but as a 16 year old boy, 35 years ago I used a Christmas card as a barrel to case gasket on my CB125. It worked out just fine

The Vento Mountrack/Zongshen 200GY-2 engine is a close copy of the Yamaha TW200 engine. I know a lot of the TW200 bikes have developed oil leaks at the cylinder base gasket. If my memory serves me correctly, the oil leak usually occurs at the left front side of the cylinder. Rather than taking a chance of rebuilding the engine, only to get an oil leak, I would strongly recommend getting an OEM gasket. They really don't cost that much. You can get a gasket set for the entire engine from Taobao for only $8.06 USD.

http://item.taobao.com/item.htm?spm=...id=18298326572

[hect75]

It's not a good idea using the cardboard gasket according to your experience Spud. You're right, the leak is in the front left side of the cylinder. I will call or stop by Yama's shop and ask about both gaskets. Thanks Alex for your comment, I got it.

Cheers

[SpudRider]

Before you tear the engine apart, please answer a few questions for me. Is your engine running well? Is the oil leak only coming from the left front of the base of the cylinder? Is the oil leak minor? If the answer to all these questions is yes, you probably don't need to tear the engine apart. You can certainly try to seal a small leak with either silicon or black, RTV sealant, before you go to the trouble, and the expense, of disassembling the engine.

[humanbeing]

Entire gasket or just the F***ed up : http://item.taobao.com/item.htm?id=1561733424

[hect75]

Spud, the engine is running good, leaking is mainly on the left side as well as in front and rear sides. Also learned the fork is loosing oil at the upper part (see the pic). I used the rtv silicone but I think I need to reseal again and see what happens. Obviously, I don't want to dissemble the engine and screw up for nothing but your feedback will help a lot. http://s123.photobucket.com/user/hrm...brary/Cylinder

Thanks for your help.

[SpudRider]

As long as you keep the engine oil at the proper level, you won't have any mechanical problems. If you wish, you can safely delay the repair until it becomes too much of a chore to keep adding oil.

I can't see any oil leaking from the fork. If oil is leaking from the top of the fork, you need to tighten the fork cap.