Hi-Bird 200 build and help

[Killerbracing]

Ok, so I bought this pile for $200 with a clean title and a Fulmer ADV helmet. After cleaning the carb (and putting the slide in the right way) it fired right up.

It has the inverted forks and front and rear discs. But for only having only 950 miles on it, it's cosmetically trashed.

I want to do a poor man's supermoto with this thing. It has 36 hole hubs, so I just need some 17" rims.

My biggest hang up is body panels. I can't find any or any suggestions for substitutions.

Here is some pics. Stock, tore down, and tore down with a new UFO front fender.

[Killerbracing]

Here it is torn down.

[Killerbracing]

And stock.

[SpudRider]

May I suggest you consider a pair of 18-inch wheels, instead of 17-inch wheels? If you choose this option, you only need to convert the front wheel, instead of both wheels. ;)

You can use Zongshen ZS200GY-2 spokes to convert your front wheel. The ZS200GY-2 has an 18-inch front wheel which uses the same spokes as your Hibird motorcycle. You can lace the Zongshen spokes to a suitable, 18-inch rim. :) If you can't find ZS200GY-2 spokes, you can shorten your stock spokes to the appropriate length, and thread the ends with the correct die. ;)

You can purchase the body plastic for your Hibird motorcycle from the Chinese Taobao website, or Roketa.com.

http://www.roketa.com/product/parts_detail.jsp?partId=31732&partName=COVERING%20PARTS%20ASSEMBLY(3)

[bogieboy]

i am in the process of SMing my shineray with ninja 250 wheels... i got both the front and rear, discs, and cush drive hub all for $115 from ebay...they are 16" rims...not sure how much they need modded yet....lol

[Weldangrind]

I'd use the stock side panels and rear fender, ditch the tank cover and use a SM front fender (like a Polisport, rather than that UFO). You could murder it out and enjoy it.

X2 on an 18" front rim. Far less work, yet still achieves the look.

[Killerbracing]

Yeah, I hate the tank cover. Any suggestions on a replacement tank? The seat looks terrible too.

I'm not opposed to using 18s. How wide of a rim can I get away with on the back?

[Weldangrind]

Not sure, but I'd stick with the stock width for now, and perhaps lace the same width onto the front, so you could run the same size tires front and rear.

Try the stock tank without the shrouds and recover the seat. Do you plan to black everything out?

[SpudRider]

Yeah, I hate the tank cover. Any suggestions on a replacement tank? The seat looks terrible too.

I'm not opposed to using 18s. How wide of a rim can I get away with on the back?

You can install a wider rear tire just so long as it doesn't rub the drive chain. Measure the distance from your rear tire to the drive chain. Divide that distance by 1/2, then subtract another 1/2-inch for safety. You can determine the maximum size of the rear tire by doubling the remaining measurement, and adding it to the width of the current tire. Once you know the maximum tire size, you can choose a rim suitable for that tire size.

However, I think you are wise to stick with the original rim sizes. Changing both rims will almost double the cost of your conversion. Also, I would keep the front wheel narrower than the rear wheel. If the front wheel is as wide, or wider than the rear wheel, steering becomes more difficult, as if you were trying to push a plow. This situation is not conducive to good handling, especially for a supermoto bike. ;)

[Killerbracing]

I am going to trim up the back of the UFO fender and see what it looks like. I am going for all white body with carbon fiber turn signals and mirrors. Also going to paint the rims black.

[Weldangrind]

Sounds like a good look. You might also consider trimming the front of the fender, so it ends closer to the top of the tire, rather than extending beyond it.

[Killerbracing]

I'll bolt it back up and do some tape lines on it maybe this weekend.

[Killerbracing]

Gonna have to do some trim work, but it came with a tucked taillight & plate holder.

[Weldangrind]

I'd lose that lower fender; I've removed a few of them. It's easy to make a simple taillight and plate holder that bolts to the back of the subframe. There's usually a tab at the rear of the subframe that you can use for mounting.

I've installed two of these so far: http://www.ebay.com/itm/28-LED-Motorcycle-ATV-Dirt-Bike-Brake-Stop-Running-Tail-Light-Universal-12V-New-/231042328311?pt=Motorcycles_Parts_Accessories&hash=item35cb3226f7&vxp=mtr

[Killerbracing]

Yeah, I'll clamp it down and make some cut lines. Still need to figure out some side plastic and a better looking tank. I may need to relocate the starter solenoid. Oh, and color scheme has changed to all black.

As far as the tail section goes, the factory katoom one is awesome. I'm going to try to use the bird's socket to retain the factory plug. The bracket has enough side meat to run my carbon fiber turn signals.

[Weldangrind]

If you're going all black with it, just use the stock tank for now, until you get the rest of the bike figured out. It'll disappear.

[Killerbracing]

Here are some updates. Took stock taillight socket, hit the sides with a grinder. It fits the new housing. I'll silicone it for extra vibration dampening.

[Killerbracing]

Went to pull the bars to start the swap to better bars and I found this! :doh:

[Killerbracing]

Got a left fork tube leaking. Gonna pull those down when my anodized paint gets here (forks are faded). Gonna do the synthetic tranny fluid in them, per spud.

For only having 950 miles, this thing needs one of everything!

[katoranger]

That bar clamp you can probably match up with a used japanese part.

[Killerbracing]

That bar clamp you can probably match up with a used japanese part.

Yeah I plucked a pair off a Kdx parts bike I have. Gonna have them and the bars blasted at the monument company tomorrow.

[bucannon]

what are you doing for side plastics? i need to find some for mine also, looks like you can only buy the full kits from that website and i dont want to order from overseas

[Killerbracing]

what are you doing for side plastics? i need to find some for mine also, looks like you can only buy the full kits from that website and i dont want to order from overseas

I understand that! I have an idea I need to try out. It's going to be a total experiment, but if it works, it's gonna be golden for guys like us.

[SpudRider]

If you have the proper tools and skills, you can make side panels from sheet metal. ;)

[Killerbracing]

If you have the proper tools and skills, you can make side panels from sheet metal. ;)

I can do that, but advise against that. Anything can cut you, but sheet metal will rip you up in a spill. Leave that stuff for show bikes.

[SpudRider]

I can do that, but advise against that. Anything can cut you, but sheet metal will rip you up in a spill. Leave that stuff for show bikes.

I have worked a little with sheet metal, but I have never made motorcycle side panels from it. We were always taught to bend over the edges of the sheet metal. Perhaps the side covers on your bike would represent a hazard, but I don't think I would have any problems with my Zong, even if I dropped the bike on pavement. I believe racers make side covers from sheet metal, and they frequently crash pretty hard on pavement. :shrug: I do know sheet metal was used a lot on classic motorcycles.

http://classicmotorcycles.about.com/b/2011/09/09/drilling-sheet-metal.htm

Nevertheless, fiberglass or carbon fiber will certainly be lighter, and probably even safer. ;)

[Weldangrind]

Here are some updates. Took stock taillight socket, hit the sides with a grinder. It fits the new housing. I'll silicone it for extra vibration dampening.

I have a new SM lower fender with LED brake and tail light (and incandescent plate light) available. It has never been installed. Interested?

771

[Killerbracing]

I have a new SM lower fender with LED brake and tail light (and incandescent plate light) available. It has never been installed. Interested?

771

Not at this moment. My unit cleaned up pretty good.

[Killerbracing]

Ok. Had a decent day, dropped my bars off this morning and had them sandblasted. Found some side plates at the cycle salvage I can make work. Just got to order them in black after I get these fitted.

[Killerbracing]

Painted the bars. Used Duplicolor metal cast.

[zingshoen]

good looking bars. a spot of red with the white n black? as for tanks, does a clarke fit? i have clarke tanks on the zong and the suzi. i would put one on the xl, but the old metal tank has more character.
otherwise, if there s a bike wrecker nearby, take the bike and try to find a matching looker. a metal tank and no side panels, everything neatly tucked away, may be a style option?

[Killerbracing]

good looking bars. a spot of red with the white n black? as for tanks, does a clarke fit? i have clarke tanks on the zong and the suzi. i would put one on the xl, but the old metal tank has more character.
otherwise, if there s a bike wrecker nearby, take the bike and try to find a matching looker. a metal tank and no side panels, everything neatly tucked away, may be a style option?

What model of Clarke tank are you running?

[Killerbracing]

Bars are ready!

[Killerbracing]

Ok, made side panel templates. I think I'm going to do those in psuedo carbon fiber. Cut down the ktm fender and said so long to the gay scooter type handlebars. Here it is thrown together. Just imagine it all black.

[Weldangrind]

What model of Clarke tank are you running?

Since he rides a Zong (a TW clone), I presume his Clarke is for a TW200. It would not likely be a match for your bike.

I've had excellent luck with Krylon Fusion for painting plastic.

[Killerbracing]

Since he rides a Zong (a TW clone), I presume his Clarke is for a TW200. It would not likely be a match for your bike.

I've had excellent luck with Krylon Fusion for painting plastic.

Cool. I'll paint the tank and the rear fender with it.

[SpudRider]

Indeed, the Krylon Fusion is excellent spray paint for plastic. :tup: You can puchase the Krylon Fusion at Walmart, among other stores. :)

[zingshoen]

What model of Clarke tank are you running? the largest which fit, i think they are these:

http://clarkemfg.com/xt225-yamaha-19922009-41-gallons-p-306.html

the XT225 tank fits the zong, not the TW200

http://clarkemfg.com/drz-400s-20002013-dual-sport-39-gal-p-288.html

which frame is the hibird modelled upon? xr? just wondering if one could fit larger clarke tank.

[Killerbracing]

Didn't do too much tonight. Got brackets and zip ties off the fork tubes. Guess ill put it on the lift and yank those leaky bastards off this weekend. The scrapers are good. Worst case scenario is I'll have to order new seals at work next week.

Uncovered the seat pan. It's not only ugly and wide, it's busted like crazy. 2 mounts and 2 rubber bumpers obliviated.

The engine runs great, sounds kinda mean without the muffler. Too bad the best things about the bike is the motor, brakes and fork.

The ignition switch has a short in it. Have to hold the key to keep connection.

I know it'll be worth it when I'm done. But this thing is a pile of poop.

[Weldangrind]

Cool. I'll paint the tank and the rear fender with it.

I wouldn't paint the tank. Gas fumes will permeate the tank and blister the paint right away.

[SpudRider]

X2; nobody has ever had any success painting a plastic fuel tank. ;) The gasoline fumes passing through the tank will definitely cause the paint to blister. :ohno:

[Killerbracing]

Broke down the fork tubes tonight. I'll remove the seals tomorrow night and hopefully re anodize the tubes this week. Depends on the weather. Then I can go back to body mods.

I can't wait until I buy tires. That will mean the nightmare is over. Lol

[culcune]

I can't wait until I buy tires. That will mean the nightmare is over. Lol

Since your Hibird is pretty much the same bike as the Lifan GY-2, the wheels for the majority of these are 1979 Honda Xl185 based, at least as far as aftermarket rear sprockets are concerned. I don't know if you have taken the angle to look into if anyone has successfully found motard wheels for an old XL, in addition to seeing if you can find wheels via the Chinese bike route. Just thought of that...

[Killerbracing]

Since your Hibird is pretty much the same bike as the Lifan GY-2, the wheels for the majority of these are 1979 Honda Xl185 based, at least as far as aftermarket rear sprockets are concerned. I don't know if you have taken the angle to look into if anyone has successfully found motard wheels for an old XL, in addition to seeing if you can find wheels via the Chinese bike route. Just thought of that...

I was going to relace my hubs, but if I'm not opposed to replacing them altogether with something else.

[Weldangrind]

Broke down the fork tubes tonight. I'll remove the seals tomorrow night and hopefully re anodize the tubes this week.

My son and I broke down the fork tubes on his Lifan last year, and we used oven cleaner to remove the anodized coating. Simply spray it on the aluminum, watch the gold anodizing turn purple and fall off and then rinse really well.

We painted the outer fork tubes red with high-heat engine enamel, and they held up well. Next time I take them apart, I hope to have a powdercoating setup.

[Killerbracing]

Before

[Killerbracing]

After

[Weldangrind]

Those look great! How did you do it?

[katoranger]

Looks better than new. They didn't look that good from the factory.

[Killerbracing]

Thanks guys! Believe it or not, that is the dupli color metal cast system. It also took some brake clean to degrease, sanding and prep solvent as prep.

[Killerbracing]

Fixed the ignition switch short. One of the screws was gone and the other was walking out. They are 4mm if you need some.

[Killerbracing]

Got one number plate made. Just got to trim it up.

[Weldangrind]

It's really starting to take shape.

[Killerbracing]

Got the other side roughed in. Now I get to try to figure out what seat or seat/tank combo to use.

[Killerbracing]

Washed up the tank and a little bit of frame. It's going to clean up well. Just have to find a seat. Any suggestions? There's a bike show in Springfield in a month. Gonna try to shotgun this thing together and take it.

[Weldangrind]

Why not repair and recover the existing seat? You could do virtually any colour you like.

[cheesy]

I've following this and wondering what might have been.:ohno:

[Killerbracing]

Why not repair and recover the existing seat? You could do virtually any colour you like.

I would be better off making a new pan with fiberglass. The stock one doesn't line up right with the tank anyways.

[Killerbracing]

I've following this and wondering what might have been.:ohno:

I think of it as a technical challenge and an art project at the same time. Lol

[Killerbracing]

Put the forks together and gave the bird a bath.

I used Mobil 1 synthetic ATF. Holy stench batman! Stuff smells like a week old dead dog that was in the middle of taking a shit when it died!

[Killerbracing]

Just had a vision. I'm thinking about thrash building this bike this week. Put off the supermoto wheel build until next week. I think my only limitation is the seat and muffler at this point. I really need to ride. This winter has been terrible and I have a birthday party to go to next Saturday evening. It's a mile away and would be a good local bolt checking adventure!

[SpudRider]

Put the forks together and gave the bird a bath.

I used Mobil 1 synthetic ATF. Holy stench batman! Stuff smells like a week old dead dog that was in the middle of taking a shit when it died!

All that ATF stinks. ;) However, even if it stinks, the Mobile 1 Synthetic ATF works very well in forks. :tup:

[SpudRider]

Just had a vision. I'm thinking about thrash building this bike this week. Put off the supermoto wheel build until next week. I think my only limitation is the seat and muffler at this point. I really need to ride. This winter has been terrible and I have a birthday party to go to next Saturday evening. It's a mile away and would be a good local bolt checking adventure!

That sounds like a good idea, KB. :)

[Weldangrind]

I agree. Might as well get to know the bike, and then make changes over time.

[Killerbracing]

Got my exhaust and battery tray loaded to go to the sand blaster in the morning.

Then after my sales route, the quest for a seat and an exhaust can begins. Thank goodness for cycle salvages.

[Weldangrind]

On the last bike I built, I welded on a muffler from a 2002 XR250R. I did that for the benefit of the USFS, so they're happy with the spark arrestor.

[Killerbracing]

On the last bike I built, I welded on a muffler from a 2002 XR250R. I did that for the benefit of the USFS, so they're happy with the spark arrestor.

I scored a new old stock cobra muffler for a 500 quad racer for $40.

[Killerbracing]

Ok, picked up a Xr 200 seat. Gonna have to mod the mounts, but it something to plant butt on that looks halfway presentable.

[Weldangrind]

I'm thinking that an XR200 tank would be a good match. It might take some minor fab work to fit it properly, but it will match the seat. I'd hold out for a red one.

[Killerbracing]

I'm thinking that an XR200 tank would be a good match. It might take some minor fab work to fit it properly, but it will match the seat. I'd hold out for a red one.

I'll see what happens. I was really tempted last night to scrap the whole thing and buy a DR350. Lol

[katoranger]

I would have to agree with Weld on the matching tank.

[Killerbracing]

I would have to agree with Weld on the matching tank.

Haven't found a black one yet. Well, one that isn't $250 bucks anyway.

[Killerbracing]

Finally got the controls sorted out. Grips and headlight is next.

[Killerbracing]

Oooh! Mulisha grips!

[Killerbracing]

Went back to salvage diving, gonna have to dye it, but here's the new seat.

[Killerbracing]

Polisport is on.

[SpudRider]

The Polisport headlight looks great. :tup: Have you considered the Polisport Universal Front Fender? I really like mine. :)

http://i442.photobucket.com/albums/qq146/spudrider/2012%20Rides/March/Zongride3-21-12003.jpg

[Killerbracing]

The Polisport headlight looks great. :tup: Have you considered the Polisport Universal Front Fender? I really like mine. :)

http://i442.photobucket.com/albums/qq146/spudrider/2012%20Rides/March/Zongride3-21-12003.jpg

Thanks Spud! I am looking at polisport's universal sm fender if I don't like how my UFO cutdown experiment goes!

Can't wait to get this thing on 18's with low profile tires. With the new seat, it's as tall as a supercross bike!

[Killerbracing]

This project is going slow. Here is the rear fender.

[Killerbracing]

Got the Drz400 tank today. No way to physically make it fit, so back to the drawing board.

[Killerbracing]

Fixed the stock seat pan with epoxy and yanked around 300 staples out of it. Hope to test ride it this weekend.