Project XL185/CG250 swap

XLsior · 08-25-2020, 08:42 PM

Hello China Riders, My First post.

I found the site through Oddballsperformance channel on YT.

I'm an Aussie approaching 40. I don't know how to ride a motorbike, I am not a mechanic.

But I wanted to learn. However if I was going to own a bike, I wanted to do it the gentleman's way and save a bike from the scrap heap, while tackling some personal mental health and life issues at the same time.

I have some inspirations from youtube JenniesGarage really struck a chord with my approach to life...many other channels also providing a wealth of information and motivation..

Well I procured a legit 'Barnfind' 1992 XL185 that had seen some on the farm treatment after it was taken off the road.

It was mostly complete with free rust. But it had the compliance plate and I got paperwork for Australian registration requirements.

I bit the bullet after the bike was kicked and popped. Took it home, and then began the journey down the rabbit hole.

Project XLsior was born.

I dropped the oil from the honda 163fml to find glitter and scrags. the Jug had been puttyied on the timing chain side, suspect fail point. and the case around drive sprocket was damaged. Now I am not a rich man and the engine diagnosis to me seemed nonviable. Could it saved? probably...but for me was not cost effective.

My project seemed done and I was tempted to just call it quits and part the bike out.

But then I stumbled upon the world of Chonda swaps. And discovered the CG200 and Cg250 are based some what on my Honda 163FML engine.

So I randomly searched Gumtree aka ozzy craigslist, low and behold a CG250 OHV was available to my 15min away for $80...

Thus the fate of my bike and the journey was saved...I think.

I have done quite a lot and made some mistakes once.

But I would not of started without the inspiration of other before me so I'm paying it forward so to speak here and share what little I have learned that might help someone else.

I'm still down the novice rabbit hole, so don't expect a professional.

Cheers...

XLsior · 08-25-2020, 08:46 PM

I am guessing due to being a new member and first post that i will not be able to upload images of the project till i get some forum cred under my belt.

Bruces · 08-25-2020, 08:58 PM

Not sure if it’s the fact your new ,or that we have been having picture issues the past week or so .
Welcome !

XLsior · 08-26-2020, 01:49 AM

Quite likely both issues then.

thanks for the welcome Bruces.

Wasn't sure where to put this thread, as there was no DIY Project engines swap sort of page.

But from what I can tell the majority of Chinese offerings in the dual sport range seem to owe and inherit a lot of Honda XL/XR tropes.

I can say that the CG250 was for the most part a direct bolt in swap with a little fudging on the top motor mount and bracket. So it might not be a complete out of the box Chinese bike, But I am finding most of the stuff that comes from China just fits* on the old XL frame.

Also I don't think the common models available in the USA are obtainable in Australia. Hawks, Brozz' tao tao etc.

I am quite deep into the project now, found it had weak compression so just ordered a new 65.5mm piston/rings recently.

But as Projects go, keeping receipts is not always suggested. Self tuition fees basically.

franque · 08-26-2020, 05:24 AM

Keep it coming, and also welcome! In the meantime, you could always host the photos off-site and put up links. Just out of curiosity, it's a '92, not an '82? I was also curious, if it was in fact a '92, is it monoshock, or twin? AG bike, or regular Enduro? I'm glad you chose to post here.

XLsior · 08-26-2020, 05:39 AM

Hi Franque,
It is indeed a 91/92. In Australia the XL185 was available till the early 90's. For all intesive purposes it is exactly the same as the 80's. Was painted in the Honda white frame/red tank generation. I was looking for an 80s project bike same age as me. But this 92 eventuated. It is a twin shock rear OG Dualsport, Road legal with a compliance plate for Australian regulations.

XLsior · 08-26-2020, 05:46 AM

Attempted resize image file upload of 92 Xl185

XLsior · 08-26-2020, 05:51 AM

The new heart

XLsior · 08-26-2020, 05:53 AM

Both engines.

XLsior · 08-26-2020, 05:54 AM

The tear down

XLsior · 08-26-2020, 05:57 AM

Bareboned

XLsior · 08-26-2020, 06:11 AM

I actually started with fixing the seat...
Didn't want to bite off to much at first before taking the dive, But after i purchased the new seat cover there was no turning back and the project was now full commitment.

I would also like to point out I don't have a fully tooled up workshop.

grinder, rotarytool, hand a press drill. basic set of spanners etc, I had just invested in a 160amp fluxcore and stick welding unit.

I would consider these items fairly commonplace.

Like I stated in OP, this is my first project bike I have no experience really prior to this so I am only having a go with what I learned online.

XLsior · 08-26-2020, 06:21 AM

The seat was a full tear down, sand and treat the rust on the metal base and weld a couple of tears and hammer out some kinks.

The original foam wan in poor but mostly complete condition, I had some left over memory foam from an old mattress topper so decided to add a layer, This served to fix some flaws in the factory foam and improved the comfort factor.

I just cut the memory foam to size and fit and used spray adhesive to meld it to the existing foam.

XLsior · 08-26-2020, 06:23 AM

Seat base restore and old foam after wash and sun dry.

XLsior · 08-26-2020, 06:32 AM

Finished seat,

My only insight into the process is start from the back of the seat and work forwards to the tank.

I didn't so ended up with a torn seam at the back and the Honda graphic a bit wonky, trying to redo it just tore up the fabric more as it's held on by jagged tooth cuts in the metal base.

The added foam made it a tighter fit which probably didn;t help with the back seam issue.

Leaving the reskin to warm in the sun or a hot air gun probably would help for those need to repair their own seat covers.

08-26-2020, 01:49 AM	#4
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,449	Quite likely both issues then. thanks for the welcome Bruces. Wasn't sure where to put this thread, as there was no DIY Project engines swap sort of page. But from what I can tell the majority of Chinese offerings in the dual sport range seem to owe and inherit a lot of Honda XL/XR tropes. I can say that the CG250 was for the most part a direct bolt in swap with a little fudging on the top motor mount and bracket. So it might not be a complete out of the box Chinese bike, But I am finding most of the stuff that comes from China just fits* on the old XL frame. Also I don't think the common models available in the USA are obtainable in Australia. Hawks, Brozz' tao tao etc. I am quite deep into the project now, found it had weak compression so just ordered a new 65.5mm piston/rings recently. But as Projects go, keeping receipts is not always suggested. Self tuition fees basically. Last edited by XLsior; 11-05-2020 at 07:58 PM.
	0

08-25-2020, 08:46 PM	#2
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,449	I am guessing due to being a new member and first post that i will not be able to upload images of the project till i get some forum cred under my belt.
	1

08-25-2020, 08:58 PM	#3
Bruces Join Date: May 2018 Posts: 1,652	Not sure if it’s the fact your new ,or that we have been having picture issues the past week or so . Welcome !
	0

08-26-2020, 05:24 AM	#5
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Keep it coming, and also welcome! In the meantime, you could always host the photos off-site and put up links. Just out of curiosity, it's a '92, not an '82? I was also curious, if it was in fact a '92, is it monoshock, or twin? AG bike, or regular Enduro? I'm glad you chose to post here.
	0

08-26-2020, 05:39 AM	#6
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,449	Hi Franque, It is indeed a 91/92. In Australia the XL185 was available till the early 90's. For all intesive purposes it is exactly the same as the 80's. Was painted in the Honda white frame/red tank generation. I was looking for an 80s project bike same age as me. But this 92 eventuated. It is a twin shock rear OG Dualsport, Road legal with a compliance plate for Australian regulations.
	0