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Decided to upgrade my Orion Apollo 250 with a Honda XR250R engine
I have thought about this well, about the pro's and cons but I just can't sell my Orion... I really do like the looks of it, and despite it's Chinese made (so it can have some major upgrades here and there) it is a brand new bike...
Thing is, is that I don't like the engine (as in no power) in the dirt. So I have decided to upgrade my Apollo with a Honda 250XR engine which happens to lay around in my shed.:) This afternoon I made a small start with it: https://i.imgur.com/cYtM8MX.jpg https://i.imgur.com/L4VzZpZ.jpg https://i.imgur.com/n3zL9vU.jpg The airbox is a pain to remove... it will only leave it's place when the subframe is unbolted https://i.imgur.com/SUCDEgC.jpg Removed the wire harness and subframe https://i.imgur.com/mxR9Aib.jpg https://i.imgur.com/LGoky3G.jpg 20 minutes later and you have some extra rubbish laying around in the shed https://i.imgur.com/AwJNCZT.jpg Although I was quite happy about the build quality of the Apollo when I bought it, I have found some small issues here and there... And that is the quality of the paint of the frame, subframe and suspension... Some tiny rubbing already causing this: https://i.imgur.com/C37nrQR.jpg Hose rubbing https://i.imgur.com/N0y3F1q.jpg Some rust at the swingarm, where the mudflap sits https://i.imgur.com/JaviCr1.jpg Where the side plastic is bolted to the tank, also some rubbing marks https://i.imgur.com/WE8rxFq.jpg Also the subframe isn't painted by a high quality painter, as it seems he/she missed some spots causing some rust https://i.imgur.com/G9TZ2Ab.jpg Guess I will repaint it, I'll see that later on But besides the paint, the frame itself needs some work too to handle this lovely engine: https://i.imgur.com/8vPFSUZ.jpg On the outside the frame looks beefy right? https://i.imgur.com/aUZORcV.jpg https://i.imgur.com/zxsbWRj.jpg But see what's inside this "beefy" looking frame... https://i.imgur.com/AgEf8t3.jpg https://i.imgur.com/pUuRi2A.jpg https://i.imgur.com/hB5nl2x.jpg Jep... much air here... or hollow spaces if you would like to call it that way... :D So the Apollo needs some frame strenghtening here and there, I'll do that by welding some steel plates in and some bracing. To be continued.... :tup: |
I am looking forward to seeing how this progresses.
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What a cool project....I'll definitely be watching how it comes together.
From the looks of your shop, seems like you have the tools and know-how to make this happen. |
That bike has a nicely designed frame from what I can see. Is it a steel welded copy of a Japanese aluminum frame?
Can’t wait to see how it turns out myself! |
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I do have some nice tools but I am just a amateur mechanic :) In daily live I am just a sales manager in the food business who loves to work with his hands. But this little project will work out just fine, I have dealt with bigger and more complicated motorcycle projects in the past :tup: For example this little bike: https://i.imgur.com/sXNWN4X.jpg An old Honda Transalp 600 A couple of weeks later, a bit more modern looking and the engine got a complete engine overhaul. Same bike, just a bit different. https://i.imgur.com/RMaqPkK.jpg https://i.imgur.com/RceWJtK.jpg I just like playing around with metal :yay: Edit; the Transalp frame has been modified to accomodate the AT swingarm with the Ohlins shock. Also the frame itself has been modified and welded to place to CRF rear fender. The frontforks are from a XR. |
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It's steel for sure, but it's pressed metal. I do like the lines of the frame! :) |
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I do a lot of fabricating and goofing around that way too, but nothing as clean as that bike. Thanks for sharing! |
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One of the nicest China frames I've seen. I had an Apollo once but it was tubular taiwanese steel like the RPS..
I'm in the process of putting XR 650L controls and throttle on my Magician and am looking for a Honda CDI and coil replacement too.. |
Done a more:)
I thought that putting a XR engine into the Orion would be a piece of cake... But the truth is, is that the frame needs some serious welding and custom fabrication :hmm: First fitting https://i.imgur.com/fucXpIF.jpg None of the holes match... https://i.imgur.com/GQ4mfun.jpg https://i.imgur.com/ia5sCBN.jpg https://i.imgur.com/XL5PbjG.jpg So decided to start cutting here and there https://i.imgur.com/OU58j18.jpg https://i.imgur.com/f20vLzp.jpg Almost there :lmao: https://i.imgur.com/XZSAqxX.jpg https://i.imgur.com/e9gJ4bD.jpg https://i.imgur.com/dCx8283.jpg https://i.imgur.com/RgjFtqZ.jpg https://i.imgur.com/D5KI0OW.jpg https://i.imgur.com/oidr0Wk.jpg Chain seems straight... https://i.imgur.com/PV15wTG.jpg But no worries, as it's certainly not a straight fit... https://i.imgur.com/3YrXH2X.jpg https://i.imgur.com/wUAs0IG.jpg https://i.imgur.com/EX4aDcO.jpg I had used to lower engine mounting points as reference... But wrong guess, as it's certainly not welded straight in the Chinese factory...:doh: https://i.imgur.com/oJQoeu7.jpg So... it will be serious grinding and welding! :yay::yay::yay: |
Let me start off by saying that you are taking some amazing pictures showing the detail of your fitment issues.
I am not surprised that most of the mount points are not going to work. The XR engine is slightly different in the mount locations than the CG engine family. That said, it does at least fit within the frame for the most part. In the realms of fabrication, making some new brackets aren't all that bad. |
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What a great thread. I am smiling looking at all the pics. then I frown because i have the mechanical skills of a purple headed sea slug..........THEY DON'T HAVE HANDS!
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