Made by Qingqi and also known as the CG200
Replacement Final Drive chain And Sprockets
They were able to match mine and these are the nearest equivelants:
The replacement Rear sprocket has 41 Teeth instead of 45 but this is not a problem as the gearing will be less than 10% higher.
JT Sprocket equivalents (Highly Recommended) are:
Front: JTF434 See diagram
Rear: JTF815 See diagram
JT sprockets, or their equivalents are the best guide to getting the correct ones, as their website contains the proper diagrams with dimensions. When you remove your old sprockets. it is a good idea to make a note of the centre hole diameter, as well as the pitch of the mounting holes, so as you can pre-order your new sprockets next time without yor nike being off the road while you wait for sprockets to arrive. You can usually find a match on Ebay, as long as you make sure the teeth match your sprockets. On your rear sprocket less teeth mean slightly higher gearing and more means lower. On the front sprocket, the opposite applies.
Alternative Suzuki sprockets (520)
These replacement sprockets require a 520 chain instead of the standard 428 chain normally used with this model. This should not be a problem, as you normally replace the chain and sprockets together
Front: Suzuki GN250 1982-1999 15 Teeth (520-15T)
Rear: Suzuki GT200 1979-1982 35 Teeth (520-35T)
These sprockets are normally available on ebay but make sure the rear sprocket has 4 mounting holes with a pitch of 78mm and the front sprocket has 13 inner teeth on the mounting hole.
The rear sprocket has less teeth but this will give you a higher top speed. The original gearing is really too low for a 200cc engine.
Chain 520 x 116 Links (Links may have to be removed due to the reduction in teeth of the rear sprocket). The advantage of this chain type is you can get a pre-stretched gold chain which will have a longer life, or if your'e feeling really extravegant, you could get an 'O' link chain.
Engine Sprocket Nut Removal
Another problem I had with this bike was removing the engine sprocket, as it is secured by a large nut. The trick is to leave the chain on and insert a piece of handrail through the rear wheel resting it on the swinging arm, then use a large torque wrench or a socket wrench with a length of steel tubing over it for extra leverage. You may also get away with pressing on the rear brake pedal but sometimes this isn't enough to stop the rear wheel turning.
It is not worth trying to jam a scewdriver between the sprocket teeth, as you may damage the casing or the alternator wiring. The required socket for this nut is around 26mm, but I found an Imperial equivelant socket which did the job.
See also this useful Youtube video
Starter Clutch Problems
My starter clutch jammed altogether, making impossible to start the engine via the starter motor.
Replacement of the starter clutch is made more difficult by the lack of special tools for the job.
In order to replace the starter clutch, you will need to remove the Left engine cover, then to remove the flywheel, you will need a flywheel extractor, available from this chines language site:
You will then need to go to this site: http://www.engtaobao.com where
you can oder it in English by pasting the above URL into their search
box. They will then order it for you (afer you make a payment)
and when it is in stock, you can order it for delivery (another
payment.) However it will do the job.
It is strongly advised to put a cloth under the flywheel, covering the
oil hole at the bottom. The chances are, when you get the flywheel
off, loose parts will fall out and you don't want them in your gearbox.
It is a good idea to check for metal particles in the gearbox and to
flush it all out to be on the safe side.
NOTE Always scew a nut on the end of the flywheel thread, or otherwise it will look like an ice cream cone when you have finished ! It requires some serious torque to remove a flywheel as they seem to be forced on with a machine in the factory.
The starter clutch it'self can be ordered from: http://www.chinesemotorcyclepartsonline.co.uk/viewsubcat_30415_RMR200.php
Flywheel Woodruff Key
I have also had problems with a snapped Woodruff key caused by the starter clutch jamming . The engine will not start when this happens. The correct Woodruff key for this model (which does NOT require grinding or filing), is this one from Suzuki UK:
Genuine Suzuki GT25EX (X7 1978-1981 Crankshaft Key 09420-04008-000
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