04-08-2013, 04:57 PM | #31 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
The XT250 engine case is definitely different from the Zong/TW200 engine case. An XT250 cylinder would not fit the ZS250GS crankcase. :( Spud
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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 |
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04-08-2013, 10:19 PM | #32 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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I thought crap like that only happend to me....
Sorry to hear about your clip. At least you'll get to inspect everything. I remind myself when I make mistakes like this. This is why the pros are pros. I enjoy tinkering but I'd have surely lost my cool over that one. I like the idea of using Yamaha parts where you can. We are lucky to have experts here like Spud and Weld. I'm interested to hear what was causing the problem. Like I said I gave up on mine when I discovered you can't remove the head in situ.
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04-08-2013, 10:22 PM | #33 |
Join Date: Mar 2009
Location: Southeastern Washington desert
Posts: 14,761
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Except, the bolt that holds the top sprocket in place for the cam chain was halfway undone, and the threads halfway in were messed up.
If your motor ran, that bolt would have probably have fallen out. If that happened the motor would have been heavily damaged.
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04-10-2013, 12:23 PM | #34 |
Join Date: Feb 2013
Posts: 32
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04-10-2013, 02:09 PM | #35 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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That's a common metric bolt, you shouldn't have any problem replacing it at Ace Hardware, et cetera. Please clean up the cam sprocket, and post another photograph of it. If the keyway isn't damaged, the cam sprocket is good, and you merely need to replace the bolt. I would also gently run a thread tap through the camshaft to clean up the internal threads.
The camshaft, bolt, washer, and cam sprocket are all Yamaha parts. However, if necessary, you can get a brand new camshaft from China for about $10. Spud
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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 |
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04-10-2013, 02:41 PM | #36 |
Join Date: Feb 2013
Posts: 32
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sorry had two pictures of the same bolt. 3 days and still no reply from zongshen america.
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04-10-2013, 03:45 PM | #37 |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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I'm sorry to say it, but you need to keep contacting Zongshen America. They keep a nice inventory of parts, and the prices are great, but they don't have the best customer service. :roll:
Let's see a photograph of the end of the camshaft where you removed the cam sprocket. I want to see if end of the camshaft has been damaged. Also, please clean up the dirty side of the cam sprocket, and post another photograph of it. Spud
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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 |
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04-10-2013, 07:44 PM | #38 |
Join Date: Feb 2013
Posts: 32
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spud were you referring to pic a or b? one or two? feel like your at the doc yet? let me know. in the mean time ill soak the sprocket in some gas and see if i cant shine it up. Ill also snap some photos of where the sprocket threads onto.
Also, I have the engine torn down most of the way now but i have hit a roadblock. Anyone know of an easy way to remove the magneto, and also the clutch basket? Thanks, M0t0 |
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04-11-2013, 03:47 AM | #39 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
Also, please post a photograph of the end of the camshaft. I want to see if the key, or the fluting on the end of the camshaft is damaged. To remove the clutch basket you need a clutch holding tool. http://www.rockymountainatvmc.com/p/...rm=clutch+tool To remove the flywheel, you need a flywheel holder. You also need a flywheel puller. Are you planning to split the crankcase? You don't need to split the crankcase to fix a compression problem. I assume you are pulling the flywheel to replace the cam chain. Why do you want to remove the outer clutch basket? :?: Spud
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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 |
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04-11-2013, 08:07 AM | #40 |
Join Date: May 2007
Location: Altamont, Kansas
Posts: 15,103
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Spud, he thinks that he dropped a wristpin clip in there.
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04-11-2013, 11:27 AM | #41 | |
Join Date: Feb 2013
Posts: 32
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Quote:
I have the center bolt removed from the flywheel but wasn't sure if i could use a gear puller to get it out or something else. Ill order up the clutch basket holder. Any recommendations on a flywheel puller? Thanks, m0t0 P.S. Spud ill post new pics later today. Thanks again everyone for all the help. |
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04-11-2013, 05:12 PM | #42 |
Join Date: May 2007
Location: Altamont, Kansas
Posts: 15,103
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I recommend swinging to the nearest dirt bike shop and getting one that fits yamaha 200cc engines. They are not that expensive and usually fit many bikes. I have the one that fits most smaller hondas.
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04-11-2013, 06:58 PM | #43 |
Join Date: Feb 2013
Posts: 32
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I'm sorry i should have clarified. Any idea what size i need? If i'm going to order a clutch holder ill just order one of those at the same time. I have nothing against buying local, but most of the shops in town aren't very helpful or friendly. The one shop i normally do business with and trust has kept me waiting for 7 months for some fairing bolts... Apparently they are "on order"
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04-11-2013, 07:29 PM | #44 |
Join Date: May 2007
Location: Altamont, Kansas
Posts: 15,103
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Spud will know. Whatever fits the yamaha tw200.
Allen
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You meet the nicest people on a Honda Clone. |
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04-11-2013, 10:41 PM | #45 | |
Join Date: Jul 2008
Location: Idaho
Posts: 25,054
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Quote:
http://www.motionpro.com/motorcycle/partno/08-0027/ You can buy the same flywheel puller, with a different brand name, from a variety of vendors. Spud
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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 |
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