2009 gio. X31? Zongshen motor?

PoppaHaze · 05-21-2020, 02:56 AM

Okay, so here's the down low.

Picked this bike up from a friend's in law for a bottle of rye. He said it's a 250. Supposedly he's done the top end of the motor, gotten to the timing, and given up. Its obviously been dismantled, including the head. After a few quick looks, I already had more questions than answers.

I'm totally new to the gio's. But I have done timing chains on a few other ohc engines. Looking at the flywheel through my site hole, I cant find any markings as to where tdc or bdc is. Same with the cam, no markings there either.

I would love to be able to identify what kind of bike I have, hopefully get my hands on a service manual. Or what engine it was modeled after.

Essentially all you do is find tdc on compression stroke and set valve clearance to 4 thou exhaust, 3 thou intake?

I can tell already this community is an extremely knowledgable one, and I look forward to joining in on it. Thanks for the time.

franque · 05-21-2020, 03:20 AM

Welcome! Do you have the top cover that goes with the engine? It seems like a nice buy, but you'll need that. The XR200 manual should help with engine assembly, but like you were saying, it might be hard to properly assemble without markings.

Are you sure that there's no markings on the cam gear (could be on the other side of the gear, if it was put on backwards) or flywheel? You might need a flashlight to see them, you're looking for a |T or |F mark. You might also need to remove the timing cover, because sometimes they're marked on top of the flywheel.

PoppaHaze · 05-21-2020, 03:24 AM

Yup, I've got the valve cover. I just took it off to get a look at the cam/valves.

To be honest I didnt check the back side of the cam, that's a great idea. I had my flash light in the flywheel site hole looking for the T or F but to no avail.

I'll check behind the timing cover next and the back side of the cam.

PoppaHaze · 05-21-2020, 04:47 PM

So I found the engine code.

I guess next ill pull the flywheel cover off and look for alignment marks.

Does anyone know where the cam lobes should be orientated prior to me putting the valve cover back on? With no markings on the cam, I'm kinda shooting in the dark.

**JerryHawk250** · 05-21-2020, 05:15 PM

Sprocket bolts should be vertical and lobs facing down @ TDC

franque · 05-21-2020, 05:38 PM

It's not really a valve cover per se, and in some ways, it's best not to think of it that way, because removing it is almost always unnecessary, and you need to reseal it with a thin coating of Honda/Yamabond so it won't leak, as it doesn't have a gasket. Make sure that you get not surfaces clean with a razor blade, too. Best of luck, we're happy to help!

PoppaHaze · 05-21-2020, 05:58 PM

You guys are awesome!

Thanks so much for the quick replies. I cant wait to get home from work and give it a go.

PoppaHaze · 05-21-2020, 08:51 PM

I saw on an Ebay add for the same motor this statement. Is anyone able to confirm?

Suitability: Direct replacement for Orion Apollo AGB30, 31 and Hummer range All Atomik 250cc air cooled Bikes and all Crossfire 250cc air cooled bikes.

If this is true, does anyone have service manual for any of those engines? I couldnt find them on the google.

I'm looking specifically for valve clearances now.

humanbeing · 05-22-2020, 03:21 AM

https://www.motorfans.com.cn/forum.p...=343764&page=1 (needs change to desktop mode if view from mobile device) had some pics rebuild vertical Chonda ohc engine.
===
Most "69" are lies. 65.5mm is the answer... Just find a Honda shop manual (63.5*62.2 XLR200R https://www.4shared.com/office/xZy8oNOV/ ... | 65.5*62.2: CRF230) in 'net & call it a win since u had experince working on ohc machine.

franque · 05-22-2020, 07:09 AM

Looking at it again, I would consider disassembling the motor to remove all of the red silicone, it's not good for the life of a motor, it has a tendency to clog up oil pumps/ruin bearings. I would check the bore, as alluded to above by humanbeing, and order a corresponding gasket set. If you need part numbers, I can get you Honda ones.

Yeg.chrisc · 06-18-2020, 11:02 PM

Take the stator cover off. And the flywheel will have marks, you just can't see them through the sight hole that's in the cover itself. Then you'll be able to find TDC. And then line the cam up so the bolt holes are vertical with the cylinder. One line of the cam sprocket should line up with the top of the cylinder.

05-21-2020, 05:15 PM	#5
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,713	Sprocket bolts should be vertical and lobs facing down @ TDC __________________ 2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
	1

05-22-2020, 03:21 AM	#9
humanbeing Join Date: Mar 2008 Posts: 2,436	https://www.motorfans.com.cn/forum.p...=343764&page=1 (needs change to desktop mode if view from mobile device) had some pics rebuild vertical Chonda ohc engine. === Most "69" are lies. 65.5mm is the answer... Just find a Honda shop manual (63.562.2 XLR200R https://www.4shared.com/office/xZy8oNOV/ ... \| 65.562.2: CRF230) in 'net & call it a win since u had experince working on ohc machine. __________________
	4

05-21-2020, 03:20 AM	#2
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Welcome! Do you have the top cover that goes with the engine? It seems like a nice buy, but you'll need that. The XR200 manual should help with engine assembly, but like you were saying, it might be hard to properly assemble without markings. Are you sure that there's no markings on the cam gear (could be on the other side of the gear, if it was put on backwards) or flywheel? You might need a flashlight to see them, you're looking for a \|T or \|F mark. You might also need to remove the timing cover, because sometimes they're marked on top of the flywheel.
	1

05-21-2020, 03:24 AM	#3
PoppaHaze Join Date: May 2020 Posts: 5	Yup, I've got the valve cover. I just took it off to get a look at the cam/valves. To be honest I didnt check the back side of the cam, that's a great idea. I had my flash light in the flywheel site hole looking for the T or F but to no avail. I'll check behind the timing cover next and the back side of the cam.
	0

05-21-2020, 05:38 PM	#6
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	It's not really a valve cover per se, and in some ways, it's best not to think of it that way, because removing it is almost always unnecessary, and you need to reseal it with a thin coating of Honda/Yamabond so it won't leak, as it doesn't have a gasket. Make sure that you get not surfaces clean with a razor blade, too. Best of luck, we're happy to help!
	1

05-21-2020, 05:58 PM	#7
PoppaHaze Join Date: May 2020 Posts: 5	You guys are awesome! Thanks so much for the quick replies. I cant wait to get home from work and give it a go.
	1

05-21-2020, 08:51 PM	#8
PoppaHaze Join Date: May 2020 Posts: 5	I saw on an Ebay add for the same motor this statement. Is anyone able to confirm? Suitability: Direct replacement for Orion Apollo AGB30, 31 and Hummer range All Atomik 250cc air cooled Bikes and all Crossfire 250cc air cooled bikes. If this is true, does anyone have service manual for any of those engines? I couldnt find them on the google. I'm looking specifically for valve clearances now.
	0

05-22-2020, 07:09 AM	#10
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Looking at it again, I would consider disassembling the motor to remove all of the red silicone, it's not good for the life of a motor, it has a tendency to clog up oil pumps/ruin bearings. I would check the bore, as alluded to above by humanbeing, and order a corresponding gasket set. If you need part numbers, I can get you Honda ones.
	1

06-18-2020, 11:02 PM	#11
Yeg.chrisc Join Date: May 2020 Location: Calgary Posts: 16	Take the stator cover off. And the flywheel will have marks, you just can't see them through the sight hole that's in the cover itself. Then you'll be able to find TDC. And then line the cam up so the bolt holes are vertical with the cylinder. One line of the cam sprocket should line up with the top of the cylinder.
	0