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

[SpudRider]

My Zong was burning a lot of oil, and I noticed an ominous sound coming from the cylinder head. 8O Therefore, I disassembled the top end of my Zong's engine to determine the cause of the noise.

I discovered the exhaust valve rocker of my Yamaha, XT200 cylinder head was worn. To verify the cause of my Zong burning oil, I took the cylinder to my machinist to have him measure it with his bore gauge; it was well worn. Therefore, I decided to have the machinist rebore the cylinder to 1.00 mm oversize.

I had the machinist blast the carbon deposits from my cylinder head. My old valves and valve seats were in good shape. However, I already had some new, Zongshen valves, so I decided to install them. To repair the damage to the exhaust valve rocker, I ordered two new rocker arms and a new camshaft from Taobao. I also ordered new, TW200, valve stem seals. In addition, I ordered a new, automatic cam chain tensioner from Taobao.

I ordered a 4th oversize, Yamaha, TW200 piston and piston rings. I ordered a new piston pin from Taobao. I already had a new pair of Zongshen circlips for the piston pin. I also ordered a complete gasket set and a new, cam timing chain from Taobao.

Spud