Project XL185/CG250 swap - Page 15

XLsior · 08-17-2021, 11:33 PM

Had to shave the head around the petcock....

I'll say no more.

XLsior · 08-20-2021, 02:09 AM

Using the Rectifier mounting location I decided to CAD/FAB a lower splash guard.

Think I covered all the clearances, hopefully it wont buzz and vibrate to much with the engine running. I'll use the ol' foam tape if it does.

XLsior · 08-20-2021, 02:12 AM

had to file out some holes for it all to line up as the battery box was made to use the other rectifier that cooked itself...

Should rectifiers be rubber pad isolated perhaps?

XLsior · 08-22-2021, 10:55 PM

To minimize the chances of losing the kick stand foot i opted to use some silicone shmoo. It's just what i had lying around.

Primarily a suction fit and hopefully should soak up the shakes and prevent it undoing itself.

also used it on the threads and did dremel some clearance where the clamp down rings meet the original foot peg end.

XLsior · 08-23-2021, 01:58 AM

Having got the bike running confidently,

Was only just mentioning to Stewbrash that the chip shortages had impacted the restocking of my intended digi dash choice.

Well next day I get the back in stock email...the ducks are lining up.

Went with the Acewell 3701...would have preferred the 3702 but not a stocked item.

Had to get a ADR (Australian Design Rules) approved gauge for road worthy. so ebay Chinese offerings were not an option.

Looked at the Trial tech Vapor..but they are expensive for not much substance.

I stumbled on the Acewells which were Australian distributed.

$200 AUD shipped...not cheap but reasonable for the quality.

What sealed the deal for me was the ability to use a XL/XR front drum speed sensor cable adapter which maintains the factory look.

Also the dimensions are about perfect for the windshield recess.

I like the fit and finish and build quality...

Good instructions too.

I know they are sold in the UK, not sure about the USA.

buzz · 08-23-2021, 12:10 PM

what goods a seat going to do, more important things 1st

XLsior · 08-23-2021, 04:18 PM

Quote:

Originally Posted by buzz

what goods a seat going to do, more important things 1st

If you are referring the the start of the project.

I began with the seat because the seat cover arrived and I had the materials to work on it first. Secondly was not confident in my welding skills yet to tackle the frame.

not sure what the purpose of your comment is other than some form of gaslighting.

or maybe you just like to enjoy riding bikes without seats...

PhildoScaggins · 08-24-2021, 08:49 AM

Quote:

Originally Posted by XLsior

or maybe you just like to enjoy riding bikes without seats...

stewbrash · 08-24-2021, 01:29 PM

XLsior, just curious, is the Honda XL 185 more or less the same size as out Bashans, Hawks, TBR7's? Sure looks it...does it also have the 21/18 setup? I also would have a seat on my motorcycle!

XLsior · 08-24-2021, 02:37 PM

Hi @Stewbrash,
The Xl185 was the last of the twinshocks, before you had the Xl175/125 and before that the SL's...after the Xl185 it went into tho pro link mono shock XR era. I would say the XR250 is probably the closer comparison to the china 200/250 dual sports.

Yes the Xl185 uses 21"-18" but in a 1.40 and 1.85 rim.

I'll take a hub to hub, seat and ground to handle bar base clamp measurements. but going from how tight the Cg250 engine fits in the frame and the distance between the front wheel and front engine mount I can tell the Xl185 is a smaller overall package to the China 250's maybe closer to the china 200's.

XLsior · 08-24-2021, 10:10 PM

Ground to seat 850mm (seat has additional gel memory foam layer)

Wheel hub to hub 1330mm.

Ground clearance 280mm.

Ground to the barclamp 1000mm +/-

Back of the tire to engine mount 200mm.

I am 5'9 old money and Id say with proper riding boots I'd be flat foot planted on the ground.

not sure about weight...30 year old Japanese steel not exactly feather light.

stewbrash · 08-24-2021, 11:59 PM

Yeah XLsior...all my measurements on the Bashan BSR were about 1 1/2 to 2 inches taller, longer...but admittedly, it was eyeballish measuring too...not enough to make any difference-in my book.

Hub to hub...1375mm (1 3/4" longer)

Ground clearance at front of motor...300mm (3/4")

Ground to handle bars...1060mm (2 1/4")

Ground to seat...890mm (1 1/2")

As you'll see in the photo...I got the same chinese bark-busters that you have...although mine went on smoothly...must be because the handlebars were made in China! LOL! (Not Japan)

XLsior · 08-25-2021, 02:26 AM

that's pretty close.

My rear wheel is about %50 adjusted so hub to hub could be the same...

perhaps the illusion of a smaller bike is how the fuel tank sits on the frame shoulders...

If you refer back you'll see how the petcock fouled on the cylinder head so my tank sit way down and my seat does not overlap the tank.

Also had to use a cg125 rocker cover, shave the frame and remove the tank to remove and adjust valves.

The fruit does not fall far from the tree...

XLsior · 08-25-2021, 02:37 AM

As for bark busters...if you get the specific size bar clamp (not the universal crab claw type) and don't have raised choke cable like The XL185 does.

Then fitting it to a bike should go smooth.

XLsior · 08-27-2021, 12:10 AM

Making a PCV/Chain Lubricator.

I understand engine oil is not chain lube...but it is a lubricant. However crank case oil will contain other combustion byproducts which will probably have a detrimental effect on o'ring type chains...So I would advise not doing this. I still intend to service and maintain the chain as intended.

So allow me to entertain my inner mad scientist and stick a whatsit into a thingamajig and make a doodad.

Had to use 2 ebay special non return valves 10mm and 6mm barb ends.

then swap over the barbs to make a 10mm>6mm non return valve.

Who am I to argue with Heng Tong...its oil resistant...it was supposed to be red though, not orange...and I bought it as fuel hose?...anyway.

Drill out a couple of holes and BAM...crank case vent/chain oiler.

I'll see how it goes but can add a rubber grommet if the hose cuts to easily on the splash guard.

Also working on the dash bracket too, but am waiting for a 12v to USB outlet adapter before I make any holes and metal bends...

08-24-2021, 02:37 PM	#220
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,282	Hi @Stewbrash, The Xl185 was the last of the twinshocks, before you had the Xl175/125 and before that the SL's...after the Xl185 it went into tho pro link mono shock XR era. I would say the XR250 is probably the closer comparison to the china 200/250 dual sports. Yes the Xl185 uses 21"-18" but in a 1.40 and 1.85 rim. I'll take a hub to hub, seat and ground to handle bar base clamp measurements. but going from how tight the Cg250 engine fits in the frame and the distance between the front wheel and front engine mount I can tell the Xl185 is a smaller overall package to the China 250's maybe closer to the china 200's. Last edited by XLsior; 08-28-2021 at 04:54 PM.
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08-25-2021, 02:26 AM	#223
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,282	that's pretty close. My rear wheel is about %50 adjusted so hub to hub could be the same... perhaps the illusion of a smaller bike is how the fuel tank sits on the frame shoulders... If you refer back you'll see how the petcock fouled on the cylinder head so my tank sit way down and my seat does not overlap the tank. Also had to use a cg125 rocker cover, shave the frame and remove the tank to remove and adjust valves. The fruit does not fall far from the tree... Last edited by XLsior; 08-25-2021 at 04:23 AM.
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08-23-2021, 12:10 PM	#216
buzz Join Date: Dec 2020 Location: Dayton Pa. Posts: 861	what goods a seat going to do, more important things 1st
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08-25-2021, 02:37 AM	#224
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,282	As for bark busters...if you get the specific size bar clamp (not the universal crab claw type) and don't have raised choke cable like The XL185 does. Then fitting it to a bike should go smooth.
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