Mod suggestions for Zong Sierra 200gy-2

[JoJo]

let us know

The last thing i touched was the kill switch, then it never started again. I hard wired it and still no spark. I think that my ignition coil went bad. It was pinched under the tank and I hope that this was the issue. I also put a screwdriver in the end of the coil and cracked the bike to see if a spark is transferring to the plug. Is this even the right thing to do? There was no spark. I've now taken the tank off to get to it and am going to look for a new one. Sunday prob won't happen, cause stores are closed.

sorry guys. this has gone from mods to repair. I hope that this isn't a start of a problematic future...

[knothead]

Originally Posted by JoJo

let us know

The last thing i touched was the kill switch, then it never started again. I hard wired it and still no spark. I think that my ignition coil went bad. It was pinched under the tank and I hope that this was the issue. I also put a screwdriver in the end of the coil and cracked the bike to see if a spark is transferring to the plug. Is this even the right thing to do? There was no spark. I've now taken the tank off to get to it and am going to look for a new one. Sunday prob won't happen, cause stores are closed.

sorry guys. this has gone from mods to repair. I hope that this isn't a start of a problematic future...

Make sure all the plug connectors behind the headlight are tight. My bike did the same thing and one of the connectors had backed out just enough to loose contact.

[JoJo]

Just check all connects behind the headlight. they all seemed to be good. went to check for a spark again and saw a couple of sparks... then nothing again. It seems like the coil is bad. Getting a new one 2mar..

[JoJo]

Just an update. I located the problem. The ignition coil and trigger coils went bad. It was probally one of the first things that I should have checked with a weak spark, but not having done this before I didn't want to take the engine apart until I checked everything else (didn't know that there was oil on the magneto and coils). the owner before me never changed the oil and the seal pieces and gunk corroded the coils. Sorry no pics. I have since changed the oil about....4 or 5 times. Starts like a champ, once again. I found the zongshen manufacturer's warehouse here and they sold me both coils for $160 installed, changed the oil and gave me a bag of everybolt I will ever need for this bike (305-500-9989). They only have stock parts and said that they could overnight anything I needed. I also saw the new 150!! Looks nice and it watercooled, aluminum and weighs only 180-190 lbs. Gonna get the new 250's soon! Can't wait to see'em!

Well, back to the mods...

Anyone know where I can get the jets for this bike? Saturday night cycles has not returned any of my emails. I haven't called CJ Cycles yet.

Also, my friend also has this bike and his bike came with 130 jets factory?? I know these bikes come with minor differences, but 130??

[SpudRider]

Congratulations on solving your starting problems! I keep hearing good reports from the people who contact Zongshen America. Also, thanks for the information on the new motorcycles from Zongshen. I can’t wait to see them advertised.

My bike runs great, so I have not bothered to examine my carburetor jets. However, China Riders member Cmike reported that his Zongshen 200GY-2 came with a size 132 main jet. The Yamaha TW200 uses the same TK MV28 carburetor as the Sierra 200. TW200 owners are reporting good results with size 130 and size 132 main jets.

If you decide to experiment, you can get TK carburetor jets from the following dealer.

http://www.motorcyclecarbs.com/Teike...Parts_C784.cfm

Spud

[SpudRider]

JoJo,
Based upon my personal experience, here is my response to your seven original questions:

Since much of the Zongshen Sierra 200GY-2 is based on the Yamaha TW200, the TW200 forum is a great place to find a lot of useful information on your motorcycle. In particular, you can learn a lot about the Zongshen airbox, carburetor, engine, and electrical system by searching this forum.

http://tw200forum.com/forums/

The Sierra 200 (200GY-2) uses virtually the same airbox, carburetor and engine as the Yamaha TW200 motorcycle. Therefore, any exhaust upgrades that work well for the Yamaha TW200 should work equally well for the Zongshen 200GY-2. However, since the exhaust headers and the muffler mounting points are different on the two motorcycles, you will need to make some modifications to get everything to fit. Listed below are links to several of the many threads concerning this subject.

http://tw200forum.com/forums/58574/ShowPost.aspx
http://tw200forum.com/forums/11391/ShowPost.aspx
http://tw200forum.com/forums/31618/ShowPost.aspx#31618

2) Once again, when it comes to the TK MV28 carburetors, you can learn a lot from the members on the TW200 forum. Also, China Riders member Cmike posted a lot of useful information on his carburetor, with photographs, a few months ago.

http://www.chinariders.net/modules.p...er=asc&start=0

Cmike reported that his Zongshen carburetor had a size 132 main jet. In the United States most Yamaha TW200 motorcycles come with a size 126 main jet. Many of the TW200 owners have upgraded their carburetors to a size 130, or larger, main jet. My motorcycle runs very well with the original, size 132 main jet; therefore, I have not changed it.

3) Cmike and Wool-Z both reported that they moved their jet needle C-clips one slot lower from the factory setting into the second-to-last slot on the carburetor jet needle.

http://s527.photobucket.com/albums/c...current=17.jpg

In the United States, a tamper-resistant, EPA-mandated jet needle with no adjustment slots for the C-clip hampers the Yamaha TW200 owners. Therefore, they must use shims to raise their jet needles.

http://tw200forum.com/forums/28956/ShowPost.aspx

However, it appears that they shim up the needles to just about the factory setting on a Zongshen Sierra 200GY-2.

I ride at elevations of 4,400 feet above sea level and higher. My motorcycle starts and runs very well with the C-clip at the factory setting in the middle, or third, slot from the top of the jet needle. Therefore, I haven’t tampered with my carburetor’s C-clip. Since you are riding at sea level you might want to experiment by lowering the C-clip one slot, and noting the results.

4) The Yamaha TW200 and Zongshen Sierra 200 both use the same constant velocity carburetor. Once again, you can find a lot of information regarding airbox modifications by searching the TW200 forum. However, modifying the airbox for a constant velocity carburetor can be tricky. If you are going to do much off-road riding I would stick with the standard airbox. The standard airbox keeps the foam air filter element much cleaner and drier than an exposed, unipod air filter element. In my experience the Sierra 200 produces good power and gets great gas mileage using the standard airbox. After all, Yamaha has been successfully using this design for over twenty years. I ride a lot in the dirt, so I have not altered the airbox on my Sierra 200. However, I did make a minor modification to my motorcycle’s frame to allow easier access to the airbox cover. I will soon post a new thread that details this modification.

5) American Motorcycle Tires is a great place to find a wide variety of street tires for your Sierra 200.

http://www.americanmototire.com/cata...x.php?cPath=33

However, finding dual-sport tires is more difficult. To the best of my knowledge, only Zongshen manufactures a DOT knobby tire for the rear wheel. You have a little more choice if you want to buy a dual sport, DOT knobby tire for the front wheel.

6) Several owners on this forum who have tried performance CDI units have scrapped them for the original CDI units. Based on the experience of others, I have decided not to switch my CDI unit.

7) The Sierra 200GY-2 has a 46-tooth rear sprocket. The Lifan motorcycles use a Honda CB125 rear sprocket, size JTR 269; these sprockets are available in many sizes. The Sierra 200GY-2 rear sprocket has different dimensions from the JTR 269, and the Zongshen sprocket employs six bolt holes. I would not recommend using the JTR 269 sprocket on your Zong. However, the 46-tooth Zongshen Sierra 200GY-2 rear sprockets are available from Zongshen for $15.

The front sprocket for the 200GY-2 has 14-teeth, and it is an exact copy of the Yamaha TW200 sprocket. This sprocket is also available as JT sprocket model #JTF 1559.14, Parts Unlimited sprockets #K22-2675 and #K22-2601C, and Zongshen sprocket #23401-L067.

When you need to replace your sprockets I would recommend that you order the factory rear sprockets from Zongshen. If you get the Zongshen rear sprocket you will not have a choice for different sizes. However, a 15-tooth countershaft sprocket is available from Parts Unlimited; it is sprocket model #K22-2601C.

Good luck with your motorcycle! I hope you enjoy many happy, safe miles on your Zongshen Sierra 200; it is a great little bike.

Spud

[JoJo]

Hey Spud, thanks for all the good info. I appreciate you taking the time. I have one question (for now). When looking for an exhaist muffler I've been seeing the same mufflers but they say different thing for different bikes like: for 01-06 yammaha and 06-08 KTM's? Does this mean that these won't fit my bike. I'm pretty sure that as long as they are not welded to the headed pipe they should fit right? Also, what role does say getting a exhaust for a 250cc or 150cc play in selecting a muffler. I c some guys on the forum here have smaller exhaust mufflers with larger cc engines.

thanks in advance!

[katoranger]

I have one from a crf150r which is pretty much a straight through design. They use the same muffler on the crf230r too. It flows alot better than the stock unit, but it is also loud.

Allen

[SpudRider]

Originally Posted by JoJo

...When looking for an exhaist muffler I've been seeing the same mufflers but they say different thing for different bikes like: for 01-06 yammaha and 06-08 KTM's? Does this mean that these won't fit my bike. I'm pretty sure that as long as they are not welded to the headed pipe they should fit right? Also, what role does say getting a exhaust for a 250cc or 150cc play in selecting a muffler. I c some guys on the forum here have smaller exhaust mufflers with larger cc engines.

thanks in advance!

I am sorry to say that I am not an expert on exhaust systems. Therefore, I hope that other, more knowledgeable members will also respond to your question.

However, I believe that the different models of muffler are designed to be tuned for optimum performance based upon the carburetor, engine displacement, length of header exhaust pipe, et cetera, for each particular motorcycle. Also, each model of motorcycle can have different mounting points and different mounting hardware for its muffler.

Therefore, if an aftermarket muffler is improperly tuned to the motorcycle’s exhaust system, it can actually cause a loss in engine performance from the stock muffler. The members over at the TW200 forum sometimes get into very detailed discussions regarding this subject. Here is a representative thread concerning aftermarket mufflers.

http://tw200forum.com/forums/1/23283...ost.aspx#23283

I am unaware of any aftermarket muffler designed specifically for the TW200. Therefore, some of the TW200 owners are buying mufflers designed for the Yamaha XT225, TT-R225 or TT-R230 motorcycles. However, one member of the TW200 forum swears by his FMF Turbine Core II, a silencer designed for two-stroke motorcycles!

I really don’t know who is correct. :roll: I am satisfied with the performance and low noise of my factory stock muffler. However, I am disappointed with its weight. I might be tempted to experiment with a quiet muffler that weighed significantly less than the factory unit.

Spud

[JoJo]

Lots of good info in that forum. The FMF Turbine dou was the muffler I was looking at. Found one for $139 just might get it. Also, I just purchased these AIRVENT Uni 1" air filters. They are 1" round and pop into the air box. I got a 1" hole saw and cut 2 holes in the top part of my airbox cover and popped two in. I immediately noticed a nice change in performance. Air flowed much better and felt more powerful and smooth all around. Six came in the pack for $9.99. I took pictures but cant upload anything to my gallery page?? I might pop 1 more in later this week. Could put all six, but not going to push it. I think that this was a great alternative to a new air filter and cutting out the box! Kinda keepin it stock with a nice upgrade. Gave my China girl some more suckee suckee power!

I think that I'm going to move my C-clip down one also.

I also think that I need a valve adjustment. I hear tapping coming from the engine and I'm guessing that it's the valves. Going to check'em out this week and adjust'em.

[SpudRider]

JoJo,

I am glad to hear your Zong is running strong!

If you decide to get the FMF Turbine Core 2, I found it on sale for $107.94 at the following vendor.

http://www.oemcycle.com/Item/product/326/

You probably want to order item #27-0942 that fits 1-1/4 inch exhaust pipes. If you order $125 worth of items from this vendor you will get free shipping. You could add a pair of rear brake shoes or two oil filters to reach that total.

If you plan to check your valve clearance you might want to read the following two threads.

http://chinariders.net/modules.php?n...ewtopic&t=1655
http://chinariders.net/modules.php?n...ewtopic&t=6458

Good luck, and please let us know how things turn out for you.

Spud

[JoJo]

Thanks for the links. I was looking around for a muffler specific to a 4-stroke and the FMF Power core 4 came up? Is it specifically for a 4-stroke?

http://cgi.ebay.com/ebaymotors/Motoc...4284QQtcZphoto

what ya think?

[SpudRider]

JoJo,

If you do a search over on the TW200 forum you will find a lot of information regarding the FMF Power Core 4. For example, examine this thread:

http://tw200forum.com/forums/22881/ShowPost.aspx

A few of the TW200 owners are using the FMF Power Core 4 muffler designed for the Yamaha TT-R225 and TT-R230 motorcycles. Some of the T-Dub owners like this muffler, but they say it is very loud. The FMF Turbine Core 2 is supposed to be much quieter.

In my experience the stock Zongshen muffler is very quiet, and it produces good power. However, it is a lot heavier than any of the FMF silencers.

Spud

[JoJo]

I checked out the forum on the powercore 4. This muffler has the forestry seal on it. doesn't that mean it should be under the decibel rating? I was riding today thinking about it and I do like the quiet, just the sound of the engine sound. I still want the upgrade and am still decideing while I generating some funds$$.

I just adjusted my valves today (that tapping was starting to drive me nuts!!! I was itchin to get this done) will little to no issued following the tutorial in the forum.

I also added another one of those 1" air filters into the airbox cover and lower my C-clip down to 4. So far bike sounds and feels great.

While deciding which exhaust to purchase, I've thought about putting a SS header pipe in as well. Give her some bling up front! What about any ofthose expansion chamber headers?? Anybody installed any that work?don't work?

[SpudRider]

JoJo,

I can't say I know much about the U.S. Forest Service rating system for mufflers. However, I keep reading that the FMF Power Core 4 is very noisy. In fact, the author of the following post claims that after installing the Power Core 4 on his TW200, he "couldn't sneak up on a chainsaw." 8O

http://tw200forum.com/forums/59616/ShowPost.aspx

As another option you could purchase the quieter, FMF Q4 muffler. You could also buy "Quiet Core" inserts for the FMF Power Core 4. However, both these options will cost you more money. :(

I also don't know much about expansion chamber headers. However, I am a big fan of the stainless steel header pipes used on the Yamaha XT225, TT-R225 and TT-R230 motorcycles. Any of these header pipes should work well with your Zongshen 200GY-2.

Spud