Zongshen, Sierra 200--Stator Problems.

[bones33]

From someone who has been down this route before...

Step 1 remove the battery, check and top off with distilled water as needed.

Step 2 charge battery for 2 or 3 hours at no more than a 2 amps (a higher amp charger will eventually destroy the battery.)

Step 3 install the battery ensuring good contact at the terminals.

Step 4 start and run the engine with the seat off and check the voltage across the battery terminals. Voltage should increase with engine speed.

Step 5 if 13 volts or higher the battery is probably shot. If less than 13 volts it's not charging. Turn engine off. Proceed to step 6.

Step 6 unplug stator connector coming from left side engine cover. This is the one with three terminals inside up near the voltage regulator. Check resistance between each terminal, they should be exactly the same between each. Move the wires around as you do this in case there is a break in a wire, this will cause an intermittent condition indicating a problem. If resistance is unequal across terminals the stator is bad, if it's OK the voltage regulator is probably shot. To further verify the stator condition, check AC voltage across the stator terminals (two at a time) while the engine is running, voltage should be equal between each terminal. Also move the wires as you do this to check for an intermittent condition.

In my case the stator was bad. Well not actually the stator but the wire insulation inside the case leading to the stator were melted together causing a short between the stator wires. It appeared that the wire insulation was heated and crimped together at the factory possibly to ease installation, they just heated them too much. I purchased a replacement stator and the new one didn't have the melted insulation. Now all is well.

Check with Spud to see if he is still able to help with parts aquisition. If not contact Zongshen directly and be persistent and patient. Parts are still available.