Project XL185/CG250 swap

[XLsior]

Hi all,

The project had to take a back seat while more imperative issues needed to be focused on.

Getting my home weather tight with functioning amenities was more important.

So just to update managed to get things in order and can now find spare time for other interests...

I went from this...to this...

So yeah making progress...

Now back to your regular scheduled program..

[XLsior]

Gave the bash plate a coat of zinc protect aluminum color, seems to match the other aluminum components.

Preemptively drained the original oil and filled with fresh before first start more of flush break-in for the new piston and rings and such might prefer it to the mank that was in there.

Now back to fixing the wiring loom and rejiggery of the exhaust to thread the needle between the back tire and suspension.

Then all appendages crossed a first start attempt.

[XLsior]

off on a tangent,

finding a fuel cap for the xl350r tank has been a trifle... from what i can tell it uses the same as a 250xr and xr600 but I cant be certain and the aftermarket options don't seem to want to measure the fill diameter.

I purchased a lockable cg125 with matching keyignition hoping to knock a 2 birds but that cap was 10mm to small.

My original XL185 cap is 10mm to big...

So the search continues...not sure if i should keep hunting for a lockable cap as it would likely end up as a 3 key situation if i want to replace the steering stem lock.

A faff about not much...

[XLsior]

So when adjusted the header pipe bend radius to clear the clutch cable the exit point was also moved this unfortunately resulted on the exhaust making contact with the tire.

I didn't want to adjust the header again so tried to tweak the coupling angle...this resulted in having to re wrap the header...if you thought wrapping an exhaust was an itchy task i seriously don't recommend doing it twice. And dont even think you can just undo the the start point and fidget it back again...just undo it all and save yourself the fuss...

Ok. so the coupling angle was not enough and I was not prepared to re wrap a 3rd time.

Moving down the system it was up to the muffler pipe to make the required adjustments.

Ended up adding more kink in the bends that were already present...

Which thankfully worked with enough clearance between the suspension and tire and the added benefit of a more parallel fender/muffler aesthetic.

cut bend, cut bend, cut bend. get angle and tack ...check fit weld* and flappy disk finish.

this is also why your try and leave a little spare paint in the rattle can in case of touch up moments like these.

[XLsior]

I think it'll be fine....

[stewbrash]

Nice job on the bike Xlsior, really enjoy seeing you attack all the issues and problems in such a forceful manner!

[XLsior]

Skill up perks.

I don't mind tackling problems as long as there is a possible solution. Just have to expect a few steps back before moving forwards sometimes.

Due to the global integrated chip shortages my planned digital dash has been put on back order for a very long time, which sort of took the wind out of the sails on getting the bike on the road any time soon.

Maybe i just enjoy making things harder for myself. But when it's all up an running there won't be many other bikes like it...

[XLsior]

So I took the cooked loom, tore it back and cut out the frizzled sections and re-spliced better grade auto cable. Mainly using insulated twin core and replacing the main 12v feed (red) and 12v live ignition (black)

I then reconnected the key ignition with better waterproof connectors in a hope to prevent a short occuring in the same place.

Installed a mini blade fuse holder and 10amp fuse close to main battery + terminal.

Hooked it all back up and got a crank but no start...checked plug and spark. Still fuel related think.

The crank over was rather weak so I took out the battery to trickle charge and tried to hook up a slightly larger 9ah motorcycle battery....

Well if you look at the photos it appears the 10mp fuse failed to break and Fried the loom again around the regulator connector between the 12v Feed (+red) and the earth (-green).

I'll see how far the green wire cooked but it appears my luck with electrical gremlins and this project are proving to be a challenge to say the least.

[XLsior]

Is a 10amp fuse too much?

[XLsior]

Ok wasn't as bad as I thought. bit of green a red wire basically.

So managed to cut out the bad and splice in some good.

Up-rated and heatshrinked/insulated where applicable.

Smallest mini blade fuse i have is 7.5amp so will try that in a hope to prevent short circuits.

[XLsior]

Cooked the rectifier...probably bad from the start.

its smells worse than it looks.

Reused old rectifier for the original hack loom...had to change plugs.

cranking again 7ah battery doesn't seem to have enough oomph for prolonged testing.

9ah seems to have the juice.

rechecked valve lash...its there.

spark seems white and regular.

So my only current path of deduction suggests carby/fueling.

letting the starter motor cool down for awhile before I try again.

Going to cut the neg (-) ring terminal end into a fork so I can pull it off without having to unscrew the whole lock bolt from the battery terminal, in case of any further electrical emergencies.

[XLsior]

Ive only gone and gosh darn done it.

More Choke was in order...flushed carby installed 115 and 42 jets.

Youtube doesn't like me or my comments so Ive uploaded a small bit of idle burbling and a few rev squirts on Bitchute for those interested.

Changing the flush oil now that its heat cycled...cleaned the screen too...

Fitting the new chain is next up but I'm celebrating with a cold glass of homebrew ale.

It's been over a year...granted I took my time for various reasons. But not much can rub the smile off my face now.

https://www.bitchute.com/video/Q0oadeBSSI5r/

[China Rider 27]

CG strong, Ride Hard!

[XLsior]

Back to Electrics and cable management.

Replaced the stator to loom plug end with a better waterproof upgrade.

Replaced the battery to starter solenoid link with rated 24awg wire. Definitely better quality than the china loom.

lug ends, heat shrink, perforated loom tape and split seam conduit as added insulation...Considering my whole battery box is made from sheet aluminum any cuts or exposed wires will short out on contact.

If i can prevent an electrical fire then i'll make the effort.

Oh yeah I did fit the chain too...no pics yet working on the guard. However my XL185 has a sprung chain tension system so im not sure how im supposed set the tension...with or without tensioner pressure.

I adjusted it under tensioner pressure and it seems good to me

[JerryHawk250]

I use those same WP connectors. The work great. Way better than the stock connectors.