Project XL185/CG250 swap - Page 7

Pathfinders · 02-20-2021, 05:29 AM

XLsior, very nice work. Keep up the great work and postings.

Roy

XLsior · 02-20-2021, 05:23 PM

Hi franque,
yes I've seen the Bush Mechanics 1 of Australia few indigenous/aboriginal produced TV aired series back in the day. It's a good watch.

Indeed the CG engine was developed for a world without maintenance. However in Australia a new replacement engine would be $800 there are just not the volume of stock in Oz to bring prices down to point where spare parts are just around the corner. Oil is cheap engines are expensive. JBweld, wire and hose clamps are a part of any emergency break down kit here in Australia. Some people can afford to be hard on the gear I am not 1 of them.

From what research Ive done the rocker cover oil coolers tend to leak and a considered inferior to the screen relocated sump feed CG/CB coolers.

I'll probably end up spinning the flappy sander, shaving the frame and polishing the dome as Jeffery suggested at some point. but honestly tipping the engine forwards isn't that big a deal to adjust valve lash.

franque · 02-20-2021, 06:15 PM

Regardless, you could get a different valve cover that is lower profile, something like this might work: https://www.aliexpress.com/item/32672972781.html?

XLsior · 02-20-2021, 07:29 PM

Its always good to have options. Is it another $25 I want to throw at the project...not right now. the beveled sides are encouraging so thanks for finding that franque.

Good to know where the oil galley runs in the cover, so to avoid breaching it with the sander. However I think the main issue is the bike frame.

I tried buying an CG125 cover gasket to replace the old factory 1 but it appeared to be to small. So just assumed CG125/150 covers were smaller than 200/250 and not interchangable.

franque · 02-21-2021, 09:04 AM

It could just be that the rubber shrunk, which can be remedied by dipping the gasket/o-ring in gas, which will cause it to swell. I've never heard of different valve covers for different capacity engines, I think that the thing I linked earlier said CG125/150 because there aren't any CG street/dirt bikes that I know of imported into Europe, ooracing's home market, that come from the factory bigger than a 125.

I think that's because with the graduated licensing system here, you have 50s, 125s, and then 47hp limited (I think like Aus?), and then unlimited.

No one here is jumping from a 125 to a 200, or the '250' of many CGs because it isn't a meaningful step up here.

There's virtually no 200cc motorcycles of any type here, I think largely because of that. I'll do some further research and see if there are differences in the 200 vs 125. I would think that more likely than not the 125-200 are all the same, while the '250' could be different because it uses larger stud spacing for the bigger bore. No sense in having three different specifications of cylinder heads when only two are necessary.

China Rider 27 · 02-21-2021, 10:33 AM

Here is a link to the side mount oil cooler I did on my HAWK completely based on Jerry's installation. He has a video on his website too. Piece of angle iron (bike shipping metal) on the lower engine bolts. I think Jerry now has two of these one on the other side. This is the cooler by the way thought would go good between the engine and frame (couple quick release bolts outa the way for valve adjustment) 4" X 8"X1.75".

http://www.chinariders.net/showthread.php?t=23275

XLsior · 02-21-2021, 05:28 PM

Quote:

Originally Posted by China Rider 27

Here is a link to the side mount oil cooler I did on my HAWK completely based on Jerry's installation. He has a video on his website too. Piece of angle iron (bike shipping metal) on the lower engine bolts. I think Jerry now has two of these one on the other side. This is the cooler by the way thought would go good between the engine and frame (couple quick release bolts outa the way for valve adjustment) 4" X 8"X1.75".

http://www.chinariders.net/showthread.php?t=23275

Hi China Rider 27, This will likely be the oil cooler type I plan to use.
https://www.aliexpress.com/item/32946054886.html?

Will {definitely} order after the bike is running and passed inspection and made street legal...

Ahh I see now, Don't think i'll be going down the angle iron bracket mount.

I probably could just about squeeze it upfront but as I expressed I don't think it will be as effective given the parameters. for me that area is no go zone...

I'm totally fine with the side mount, sorry if it came across as problematic. I just wanted to know how others were attaching it as the kits are all set of for front mounts.

Will have to get those oil feed lines shortened that's for sure.

XLsior · 03-04-2021, 06:14 AM

Quote:

Originally Posted by franque

It could just be that the rubber shrunk, which can be remedied by dipping the gasket/o-ring in gas, which will cause it to swell. I've never heard of different valve covers for different capacity engines, I think that the thing I linked earlier said CG125/150 because there aren't any CG street/dirt bikes that I know of imported into Europe, ooracing's home market, that come from the factory bigger than a 125.

I think that's because with the graduated licensing system here, you have 50s, 125s, and then 47hp limited (I think like Aus?), and then unlimited.

No one here is jumping from a 125 to a 200, or the '250' of many CGs because it isn't a meaningful step up here.

There's virtually no 200cc motorcycles of any type here, I think largely because of that. I'll do some further research and see if there are differences in the 200 vs 125. I would think that more likely than not the 125-200 are all the same, while the '250' could be different because it uses larger stud spacing for the bigger bore. No sense in having three different specifications of cylinder heads when only two are necessary.

It's a bit Different down here franque,
basically all 4 strokes 250cc and under are learner approved (which is why I chose the xl185/cg250 as a viable learner project bike) however there are also higher displacement up to 650cc power/weight approved bikes that can also be rode on a learner/RE license...DR650 for example. Above 650cc basically needs a higher tier level of license training. The list of LAMS (Learner Approved Motorcycle Scheme) bikes are available to see via the aus.gov website

https://www.qld.gov.au/transport/lic...arner-approved

if anyone is interested in how things are done in Australia.Some States allow 50cc scooters/mopeds to be operated on a drivers license but not a motorcycle specific license.

vickytulla · 03-05-2021, 06:05 AM

went through every single page totally like it..

XLsior · 03-05-2021, 03:50 PM

Thanks vickytulla, glad you've enjoyed it all the way up till now. It's been a year so far but it was never a rush project. My home renovations have taken priority and the bikes is just a time filler and healthy distraction.

Good luck with the C70/180cc swap.

XLsior · 03-06-2021, 10:29 PM

Just sorting out the Muffler and jumbo tool tube attachments.

Used some standard 5mm thick aluminum flat bar and utilized the most appropriate factory frame mount locations.

Switching out hardware to SS allen button heads where applicable.

The jumbo burrito tube (from AliX) was larger than anticipated but does not throw out aesthetic symmetry when balanced with the muffler side. Should be able to hold a fair few tools, spare and emergency fuel.

Thankfully both clear view the rear indicators.

XLsior · 02-21-2021, 05:47 PM

It makes sense franque, obliviously for production costs in manufacturing using as many of the same parts interchangeably maximizes profitability. Searching for certain parts in the 200/250 often shows no results as its clear now that the 125/150 moniker probably suits all applications that are not effected by stroke/bore.

As an update the rocker cover you linked scratched an itch so to speak, and I inevitably ended up ordering 1 out of curiosity in the hope of making maintenance a little easier...So we'll know for sure is the covers are indeed universal fitment.

XLsior · 02-21-2021, 07:36 PM

Today's mail delivery.

My choice was based around safety, cost, colour, weight and comfort of use.

I went and tried on other helmets at my local moto gear emporium.

but ended up purchasing online due to color availability.

I wanted white as its shown to be the safest colour in non snow climates. and cooler in sunny weather (refer to summer temps)

Adventure/Dualsport type ece/dot approved.

Can't afford Japanese makes like Shoei $1k. But didn't want to scrape the bottom of the barrel in terms of safety under $200.

Bell ticked all the boxes with MIPS and less weight. Seems to have a pretty decent reputation and aftermarket support, accessories and replacement parts. $350aud shipped

Snug fit very happy.

XLsior · 03-04-2021, 12:43 AM

So the CG125 rocker cover with beveled sides arrived today.

Compared to the Zongshen factory original its definitely slimmed down. and noticeably lighter...so some minor weight reduction benefits.

But the question is can I install it while the engine is mounted in position.

Well...to do so I did indeed have to trim/sand down 1 of the fins on the cover and also grind back about 5mm off the frame as was suggested.

But yes we have "Great Success"

Kinda happy that paid off.

Seeing as I've been hitting a few snags too.

The CnC red throttle also arrived however the specific cable length the seller had shown was not what I received so made a dispute and got a partial refund to cover a new replacement throttle cable the correct length...what a faff. I'll follow up with that when the new cable arrives.

XLsior · 03-04-2021, 12:51 AM

So comparing the covers,

The CG125 does use the same 3 bolt locations but the actual footprint is slightly smaller than the ZS original.

I am wondering if Zongshen might use a proprietary sized gasket.

As I also compared the CG125 "High Quality" gasket with the black ZS gasket.

Well it's confirmed that the CG125 cover does fit a CG250 head.

The new Cover came with a pre installed gasket but not bolts...Something to keep in mind.

03-05-2021, 06:05 AM	#9
vickytulla Join Date: Jan 2017 Location: Lahore Posts: 186	Excellent project went through every single page totally like it.. __________________ Prime RX3 from Pakistan - Adventure Touring# RX3 - 2017 - Dirt Machine# FSE-450 - 2022 - Classic# Honda CD175 - 1977 - Daily Runner# 1992 - CG125 (engine swap CB250 Sleeper) - Project#1 : 1995 - Honda C70 w/ 180cc engine swap
	1

02-20-2021, 05:29 AM	#1
Pathfinders Join Date: Nov 2017 Location: Upstate SC Posts: 129	XLsior, very nice work. Keep up the great work and postings. Roy
	0

02-20-2021, 05:23 PM	#2
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,285	Hi franque, yes I've seen the Bush Mechanics 1 of Australia few indigenous/aboriginal produced TV aired series back in the day. It's a good watch. Indeed the CG engine was developed for a world without maintenance. However in Australia a new replacement engine would be $800 there are just not the volume of stock in Oz to bring prices down to point where spare parts are just around the corner. Oil is cheap engines are expensive. JBweld, wire and hose clamps are a part of any emergency break down kit here in Australia. Some people can afford to be hard on the gear I am not 1 of them. From what research Ive done the rocker cover oil coolers tend to leak and a considered inferior to the screen relocated sump feed CG/CB coolers. I'll probably end up spinning the flappy sander, shaving the frame and polishing the dome as Jeffery suggested at some point. but honestly tipping the engine forwards isn't that big a deal to adjust valve lash.
	0

02-20-2021, 06:15 PM	#3
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Regardless, you could get a different valve cover that is lower profile, something like this might work: https://www.aliexpress.com/item/32672972781.html?
	1

02-21-2021, 09:04 AM	#5
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	It could just be that the rubber shrunk, which can be remedied by dipping the gasket/o-ring in gas, which will cause it to swell. I've never heard of different valve covers for different capacity engines, I think that the thing I linked earlier said CG125/150 because there aren't any CG street/dirt bikes that I know of imported into Europe, ooracing's home market, that come from the factory bigger than a 125. I think that's because with the graduated licensing system here, you have 50s, 125s, and then 47hp limited (I think like Aus?), and then unlimited. No one here is jumping from a 125 to a 200, or the '250' of many CGs because it isn't a meaningful step up here. There's virtually no 200cc motorcycles of any type here, I think largely because of that. I'll do some further research and see if there are differences in the 200 vs 125. I would think that more likely than not the 125-200 are all the same, while the '250' could be different because it uses larger stud spacing for the bigger bore. No sense in having three different specifications of cylinder heads when only two are necessary.
	0

02-21-2021, 10:33 AM	#6
China Rider 27 Join Date: Dec 2018 Location: PNW Posts: 982	Here is a link to the side mount oil cooler I did on my HAWK completely based on Jerry's installation. He has a video on his website too. Piece of angle iron (bike shipping metal) on the lower engine bolts. I think Jerry now has two of these one on the other side. This is the cooler by the way thought would go good between the engine and frame (couple quick release bolts outa the way for valve adjustment) 4" X 8"X1.75". http://www.chinariders.net/showthread.php?t=23275
	1

03-05-2021, 03:50 PM	#10
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,285	Thanks vickytulla, glad you've enjoyed it all the way up till now. It's been a year so far but it was never a rush project. My home renovations have taken priority and the bikes is just a time filler and healthy distraction. Good luck with the C70/180cc swap.
	0

02-21-2021, 05:47 PM	#12
XLsior Join Date: Aug 2020 Location: Australia Posts: 1,285	It makes sense franque, obliviously for production costs in manufacturing using as many of the same parts interchangeably maximizes profitability. Searching for certain parts in the 200/250 often shows no results as its clear now that the 125/150 moniker probably suits all applications that are not effected by stroke/bore. As an update the rocker cover you linked scratched an itch so to speak, and I inevitably ended up ordering 1 out of curiosity in the hope of making maintenance a little easier...So we'll know for sure is the covers are indeed universal fitment.
	0