hello, im rebuilding '01 zong 200gy lets talk china bikes - Page 4

SpudRider · 04-22-2013, 10:37 PM

Quote:

Originally Posted by patrickzong

I havn't moved onto any of that yet sadly, im still trying to find a manual to be able to replace my shifter pawl because I can only get into 2nd until it will not shift anymore. also having trouble finding the correct fuse used and get to fire it up but then the fuze goes.

If the fuse keeps blowing, you have an electrical short somewhere in your wiring harness. :( You need to find the short, and repair it, before you go any farther.

My Zong uses a 15 Amp, cylindrical fuse.

You don't need to replace the shifter pawl. You can learn how to repair your shifter by reading the following thread.

http://chinariders.net/modules.php?n...wtopic&t=14248

Spud

patrickzong · 04-23-2013, 12:49 AM

im stuck at the clutch assembly there is a large nut that seems to be the only thing holding it on but it wont budge

SpudRider · 04-23-2013, 12:53 AM

Quote:

Originally Posted by patrickzong

im stuck at the clutch assembly there is a large nut that seems to be the only thing holding it on but it wont budge

You are correct. The clutch perch assembly is held by a single bolt which is located just to the right of the turn signal switch. This bolt is not very large. I believe it is an 8mm bolt. You should be able to remove this bolt easily with a socket wrench.

Spud

patrickzong · 04-23-2013, 01:10 AM

this one

SpudRider · 04-23-2013, 01:34 AM

I read a lot of posts. :? Now I remember; you are trying to fix your gear shifter.

First of all, you need to straighten the tab which is locking the nut in place. You can straighten the tab by gently tapping it with a punch and hammer. After the tab is straight, you will need a clutch holding tool. After you remove all the clutch plates, this tool holds the outer clutch basket while you loosen the nut.

http://www.rockymountainatvmc.com/p/...ch+holder+tool

If you have an impact wrench, you can also loosen the nut. However, you can't set the proper torque when you re-install the clutch basket, unless you have a clutch holding tool.

Spud

SpudRider · 04-23-2013, 01:43 AM

Incidentally, that nut is torqued to a very high setting. Therefore, you might need a breaker bar to loosen the nut, in addition to the clutch holding tool.

http://www.harborfreight.com/38-driv...bar-67931.html

Make sure you get the proper size socket to fit the nut, and any adapters you might need to fit the socket to the breaker bar.

If you don't have one, you also need a torque wrench to secure the clutch nut with the appropriate tightness.

http://www.harborfreight.com/3-8-eig...rench-807.html

You can find the appropriate torque value in the Yamaha, TW200 Service Manual. The service manual can be downloaded from a link in the Zong Sticky, located at the top of the Dual Sport Forum.

Spud

SpudRider · 04-23-2013, 01:52 AM

You should read the following thread entirely before you continue this project.

http://chinariders.net/modules.php?n...r=asc&start=30

In particular you should note the following information. I encountered only one problem while repairing my Zong's gear shifter. Both Yamaha and Zongshen engines employ phillips head bolts to hold the oil pump in place. I removed these bolts easily with my impact screwdriver. If you don't have one, you should get an impact screwdriver.

http://www.harborfreight.com/impact-...ase-37530.html

Yamaha uses a Torx bolt to hold the shift drum cam in place. However, Zongshen uses another phillips head bolt. :roll: Using the same tools and techniques I used to remove the oil pump, I stripped the phillips head bolt on the shift drum cam. :evil: However, I successfully removed the stripped bolt with an EZ Out, drill bit.

http://www.harborfreight.com/12-piec...set-40349.html

When I reassembled the motor, I replaced the bolt in the shift drum cam with a Yamaha Torx bolt from an XT200 engine.

Spud

patrickzong · 04-25-2013, 12:53 AM

thank spud, im ordering that clutch holder next pay day. I recently got a new toy and as soon as i get it in my garage tomorrow a few pics will be posted but forewarned its a japanese bike with a big ol' engine.1980 kawasaki kz750

SpudRider · 04-25-2013, 02:56 AM

Congratulations! If you have time, please start a new thread on your KZ750 in our Other Stuff Forum.

Spud

patrickzong · 04-28-2013, 08:43 PM

did and done

still cant wait to get the zong up and runnin, it really has taught me a lot about working on motorcycles so much so I can revive a 33 year old bike. i want to get to where I can pick and choose what motorcycle i want to drive to work

:roll:

zingshoen · 04-28-2013, 09:17 PM

i know the feeling!

and congratulations, the kz 750 is a great bike.

patrickzong · 04-28-2013, 09:24 PM

i have another forum just for the kz750

http://chinariders.net/modules.php?n...wtopic&t=15722

its an extremely sound bike and if there are any transmission problems i WILL NOT do the repair myself since it's a lot more complex.

with my zong i only have to worry about one carb working on my kz i have to deal with 4!!
the zong is defiantly a more adventure bike for me and the kawasaki is a downtown cruiser to run downtown and the windy roads after work.[/url]

patrickzong · 05-16-2013, 03:39 AM

so I have no idea how this happened or how to get a replacement part, just thinking of putting the bike together and sell as is on craigslist

SpudRider · 05-16-2013, 03:51 AM

Quote:

Originally Posted by patrickzong

so I have no idea how this happened or how to get a replacement part, just thinking of putting the bike together and sell as is on craigslist

That's not a major problem, Patrick.

You can get a right crankcase cover (clutch cover) from Zongshen America, Taobao, or Yamaha.

http://item.taobao.com/item.htm?spm=...&id=4347477630

That part costs 120 Yuan, plus 20 Yuan for domestic shipping to a TBTrends agent. Therefore, the cost is only $22.77 USD, plus shipping charges from China to your doorstep.

patrickzong · 05-16-2013, 04:08 AM

what do you think caused it? could it have been from putting it on at a slight angle? this thing has gotten me scratchin my head but heck i like a challenge as long as its a cheap one. Im about to have my kz750 in the shop so this is going to get lovin for a while. picked up a 50cc mini chopper too, short build to sell and buy atv to fix up and clear wooded area in the back yard. may just post before and after pics in here since its just 4 photos and i wont have it that long

also i dont know how to order from that site, my google chrome translator is only doing so much

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04-23-2013, 01:34 AM	#50
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	I read a lot of posts. :? Now I remember; you are trying to fix your gear shifter. First of all, you need to straighten the tab which is locking the nut in place. You can straighten the tab by gently tapping it with a punch and hammer. After the tab is straight, you will need a clutch holding tool. After you remove all the clutch plates, this tool holds the outer clutch basket while you loosen the nut. http://www.rockymountainatvmc.com/p/...ch+holder+tool If you have an impact wrench, you can also loosen the nut. However, you can't set the proper torque when you re-install the clutch basket, unless you have a clutch holding tool. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-23-2013, 01:43 AM	#51
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Incidentally, that nut is torqued to a very high setting. Therefore, you might need a breaker bar to loosen the nut, in addition to the clutch holding tool. http://www.harborfreight.com/38-driv...bar-67931.html Make sure you get the proper size socket to fit the nut, and any adapters you might need to fit the socket to the breaker bar. If you don't have one, you also need a torque wrench to secure the clutch nut with the appropriate tightness. http://www.harborfreight.com/3-8-eig...rench-807.html You can find the appropriate torque value in the Yamaha, TW200 Service Manual. The service manual can be downloaded from a link in the Zong Sticky, located at the top of the Dual Sport Forum. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-23-2013, 01:52 AM	#52
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	You should read the following thread entirely before you continue this project. http://chinariders.net/modules.php?n...r=asc&start=30 In particular you should note the following information. I encountered only one problem while repairing my Zong's gear shifter. Both Yamaha and Zongshen engines employ phillips head bolts to hold the oil pump in place. I removed these bolts easily with my impact screwdriver. If you don't have one, you should get an impact screwdriver. http://www.harborfreight.com/impact-...ase-37530.html Yamaha uses a Torx bolt to hold the shift drum cam in place. However, Zongshen uses another phillips head bolt. :roll: Using the same tools and techniques I used to remove the oil pump, I stripped the phillips head bolt on the shift drum cam. :evil: However, I successfully removed the stripped bolt with an EZ Out, drill bit. http://www.harborfreight.com/12-piec...set-40349.html When I reassembled the motor, I replaced the bolt in the shift drum cam with a Yamaha Torx bolt from an XT200 engine. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-25-2013, 02:56 AM	#54
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Congratulations! If you have time, please start a new thread on your KZ750 in our Other Stuff Forum. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

04-23-2013, 12:49 AM	#47
patrickzong Join Date: Mar 2013 Posts: 44	im stuck at the clutch assembly there is a large nut that seems to be the only thing holding it on but it wont budge
	0

04-23-2013, 01:10 AM	#49
patrickzong Join Date: Mar 2013 Posts: 44	this one
	0

04-25-2013, 12:53 AM	#53
patrickzong Join Date: Mar 2013 Posts: 44	thank spud, im ordering that clutch holder next pay day. I recently got a new toy and as soon as i get it in my garage tomorrow a few pics will be posted but forewarned its a japanese bike with a big ol' engine.1980 kawasaki kz750
	0

04-28-2013, 08:43 PM	#55
patrickzong Join Date: Mar 2013 Posts: 44	did and done still cant wait to get the zong up and runnin, it really has taught me a lot about working on motorcycles so much so I can revive a 33 year old bike. i want to get to where I can pick and choose what motorcycle i want to drive to work :roll:
	0

04-28-2013, 09:17 PM	#56
zingshoen Join Date: Jun 2009 Location: Brisbane, Queensland, Australia Posts: 648	i know the feeling! and congratulations, the kz 750 is a great bike. __________________ 1971 Garelli Gulp 50cc with open ports and 16 mm Bing Carbie + 1980 Honda XL 223 ZS + 2007 Zongshen LZX200G + DR400SM
	0

04-28-2013, 09:24 PM	#57
patrickzong Join Date: Mar 2013 Posts: 44	i have another forum just for the kz750 http://chinariders.net/modules.php?n...wtopic&t=15722 its an extremely sound bike and if there are any transmission problems i WILL NOT do the repair myself since it's a lot more complex. with my zong i only have to worry about one carb working on my kz i have to deal with 4!! the zong is defiantly a more adventure bike for me and the kawasaki is a downtown cruiser to run downtown and the windy roads after work.[/url]
	0

05-16-2013, 03:39 AM	#58
patrickzong Join Date: Mar 2013 Posts: 44	so I have no idea how this happened or how to get a replacement part, just thinking of putting the bike together and sell as is on craigslist Attached Thumbnails
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05-16-2013, 04:08 AM	#60
patrickzong Join Date: Mar 2013 Posts: 44	what do you think caused it? could it have been from putting it on at a slight angle? this thing has gotten me scratchin my head but heck i like a challenge as long as its a cheap one. Im about to have my kz750 in the shop so this is going to get lovin for a while. picked up a 50cc mini chopper too, short build to sell and buy atv to fix up and clear wooded area in the back yard. may just post before and after pics in here since its just 4 photos and i wont have it that long also i dont know how to order from that site, my google chrome translator is only doing so much
	0