Project XL185/CG250 swap

[XLsior]

Finished refurbishing the rear brake assembly, feeling pretty good about it.

Decided to fire up and let it idle for awhile...

Was getting some paps and idle drops...Was assuming just stale fuel.

engine konks out...electric start cycling, no beuno.

Pull plug for inspection. Plug is showing richness....Still suspecting stale fuel.

Check spark and it's erratic.

New plug...healthy spark. Replace and try to start.

cycling...hicups. then a unpleasant "Krionk" sound and apparent lockup.

Put battery on charger.

Removed the starter transfer gear cover and gear. bump the starter motor with no load...spins fine.

try to move the transfer gear to the 1 way starter sprag gear...not moving.

Install the kick starter and try to turn the engine...engine turns with compression. but its fighting back with a resistant strain and wrrrrr noise.

I am suspecting the sprag gear has failed/locked up.

As it happens I already ordered a new 1 way back in the beginning of the project by mistake....or so I thought, it seems the electric starter issues I've had with this engine keep daisy chaining along.

Seems my time to invest in a 18v impact wrench and flywheel puller bolt has manifested.

And if i'm going to be pulling flywheels I might as well be installing the 4* timing key too.

As for the fouled plug....the carb might need some jetting tweaks....but i still think its stale fuel issue too.

Look like a few more setbacks to go...But I didn't sign up for easy mode.

[XLsior]

As suspected after removing this side case cover and trying to turn the sprag gear independent of the flywheel it won't budge.

I believe the suspect sprag gear was the original culprit to the reason why this engine was a 'bargain'

as far as bad parts on mystery bargain used motorcycle engines go this isn't the worst.

From what I can tell these might be the CG250's weakness.

My current conundrum now is how to undo the 3 hex/allen bolts that fix the sprag to the flywheel shown in the photo.

I tried to lock the sprag gear against the case with a flathead screw driver while guessing they're conventional lefty loosey threads...but they are on there f'n tight...

I don't think taking off the flywheel will make the job easier...

So I'm asking for any possible advice/help on how to undo these 3 bolts?

Going to get my 18v impact this week. have to order a new cover gasket too :P

[XLsior]

Was doing a search on the forums for any help...and It seems my sprag 'gear stopper' is non existent/awol.

Is this part really necessary though? i'm guessing at some part in time of this engines past this component never got reinstalled....

[XLsior]

https://www.chinariders.net/showthre...t=sprag&page=2

scroll down a bit and you'll see the stopper thingy I'm referring to.

It just looks like a rudimentary friction surface...

what concerns me more is the bolt hole that holds the stopper on and if it allowing oil to bypass through the hole when it shouldn't....

[JerryHawk250]

Originally Posted by XLsior

So I'm asking for any possible advice/help on how to undo these 3 bolts?

Going to get my 18v impact this week. have to order a new cover gasket too :P

I used my 20V HF impact and they came right out.

[XLsior]

Was going to get a branded 18 1/2" impact skin to integrate the rest of my 18v equipment, but it appears stock/supply is out till late April.

So just got ordered a relatively cheap set from ebay which should arrive sooner.

I have since inspected the threaded boss area used for the sprag gear friction tab and it is not linked to any oil galley.

if all that thingy did was provide a friction tab then to be honest, I think I'm happier to be rid of it.

perhaps not as bad as a Cummins killer dowel pin (KDP) or the Kawaski doohickey...

but removing any chance of a loose bolt or metal tabs flying around internally is fine by me.

[XLsior]

I'm having suspicions about my replacement sprag gear...

I think it may have been installed backwards...

so if the engine turns anticlockwise the sprag should freeplay. so when the starter motor spins the reduction gears to the sprag it turns the engine but when the engine fires the sprag allows free revs.

maybe I'm missing something and overthinking..

but i'd rather sort it out now then install are bad component.

So any confirmations would be appreciated.

Cheers.

[XLsior]

Suspicions were justified...

seems for some reason these things get sold for cg250s running clockwise and even showing the config in product images...

[XLsior]

I'm not sure why AliX/ebay/amazon appears to sell these in apparently the wrong rotation configuration for Cg200/250 engines.

However I can't see any major concerns with being able to flip the sprag.

Also it seems there are some alternative types of sprag options too...

Not sure if some are better than others.

This is the type I have at hand so I'm running with it when it come time to install.

[XLsior]

the ebay impact arrived sooner than expected along with the impact allen/hex bits.

I tried to ugga dugga the 3 bolts holding the sprag gear to the flywheel.

No good, and I was beginning to have stripped out concerns.

I also got the 16mm flywheel puller bolt so opted to confirm that flywheel would come off....

thankfully it cooperated.

I opted for old school leverage with a breaker bar using part that came from the impact set and 6mm hex bit.

So managed to get the 3 bolts out....

Then I expected to be able to separate the 2 sections....uhhh...ahhhh...hmmm.

tried hammering and leverage in the vice but I don't think even Moses could part ways.

I suspect the sprag has failed so badly it has bound up making a paper weight. Perhaps the reason why the 3 bolts would not yield as easily.

Even if i could separate the sections I am not sure if I would use the flywheel.

Looked on ebay...new flywheel and sprag assembly $40 shipped AUD.
other than chonda horizontal engine I don't think you get the same part for any other engine cheaper....

I opted to just get the new flywheel and sprag with 3 new bolts...

thankfully the sprag gear I was intending to install has the gear section I need to make the complete assembly.

Chalking up to the learning something new tally

[XLsior]

Tried more leverage

popped off....

Back to plan A.

the sprag is full of grime , but on the surface look in order.

Won't budge though.

However I will go with the new part rather than attempting to clean out etc.

On closer inspection you can see there's a ring that is supposed to be round on the sprag...it is definitely lacking a circumference.

[XLsior]

If the flywheel rotates counter/anti clockwise.

The to install a 4* key in advance would be at 4min to 12pm.
not retarded at 4min past 12pm....

Correct...?

not sure if that's a good way to explain it...this feels right (photo)

Don't want send this key home the wrong way round.

[JerryHawk250]

Originally Posted by XLsior

If the flywheel rotates counter/anti clockwise.

The to install a 4* key in advance would be at 4min to 12pm.
not retarded at 4min past 12pm....

Correct...?

not sure if that's a good way to explain it...this feels right (photo)

Don't want send this key home the wrong way round.

That is correct.

[XLsior]

Thanks Jerry.

Just got to wait for the new gasket kit to button it back up again.

[XLsior]

The gasket kit came in the mail.

trying to peel out the contents of the vacuum sealed packet was a faff, but managed to get them all out without damage and separate the 1 case cover gasket needed.

4* adv key installed flywheel and new sprag clutch and starter gear installed.

Buttoned up.

Because I was getting a rich idle decided Then to remove the PZ30 -B carb and replaced the 42 pilot jet with a 40 (38 was original) then re seated enrichment and backed out 2 turns.

recharged battery installed...

fuel tank drained and a splash of fresh go juice.

turn key...

check kill switch...

press electrical start...

nothing...

check over fuses, connections, etc... repeat...nothing.

hotwire and bump the starter...kicks over.

check the kill/starter switch...nothing out of the ordinary.

unplug starter relay and check start switch continuity...ahh ha.
(cant press yellow E start button near the handle bars while taking photo but trust me the was a continuity voltage change when pressed)

Dead stater relay....great.

This bike project sure like to throw me curve balls.