150CC Enduro: fifty dollars to make you holler
 

I'm back after an absence of about a year (or more). I sold my 200GY last year (shown below).
http://i271.photobucket.com/albums/j...ps9r7fhcxu.jpg
Since I got back into street bikes I wasn't using it much and needed some cash so I let it go. I've missed it though and have been keeping my eyes out for another.

So... I ended up with this wreck. I don't know what it is, there are no markings on the engine:
http://i271.photobucket.com/albums/j...pslz8hyhfn.jpg

http://i271.photobucket.com/albums/j...ps2ba6jahr.jpg

The good: It was only $50
The bad: Several broken spokes on the front wheel, left front engine (stator) cover cracked, clutch handle broken, kick-starter lever broken, and, more to follow I'm sure.

I'll check it out more after work today. But it's in pretty rough shape. I have some side covers that may fit it and a front fender. I'm not concerned about the lights, as I'll probably just remove all the street stuff anyway.

I may be able to fix the engine cover with JB Weld, if I can't find a new one (I'll post a picture of the damage later to see what you guys think). But the front wheel may be a problem. I haven't seen any others with the rotor mounted on the right side before. I don't know, could be as simple as flipping a GY2/5 wheel around or just install the forks off one. You'll notice the front wheel mounts to the bottom of the forks, not to the front as in the 200 series of bikes I'm used to seeing.

Anyway, I'm glad to be back here with another Chinabike. It was the clones that got me back into riding again when I got my 200 in 2007. Since then I've accumulated a hoard of Honda CBs. Here's my favorite - a 78 750:
http://i271.photobucket.com/albums/j...ps7mytof1s.jpg

I'm in love with your CB!

Did you get a title for your new bike, or will it be dirt-only?

Thanks! I tried to set the 750 up like one that stuck in my mind when they were new and I was 18 LOL.

No title, it'll be off-road only.

Perhaps you'd just care to ask WA to box up everything he has and ship it to you. I'm sure you'll find a use for a lot of it, and you could give away what you can't use.

Hooked up a battery to it last night. Nothing, nada, zero. Thought maybe the main fuse blew since there are bare wires from the lights and signals being ripped off. The fuse was good. Checked the ignition switch and found that it was bad. I jumpered the wires from the switch (red to black and green to black with white stripe) and got power on but the starter switch didn't do anything, I may have not jumped the wires correctly, not sure. I shorted the solenoid and got it turning over but no spark.

So today I started ordering parts. Got a kit with all new ignition electrics for $24 (coil, CDI, solenoid, plug), new ignition switch, new kill/starter switch and some spokes for the front wheel. The wheel actually still looks to be okay but has a lot of broken spokes so I'm hoping I can save it. I was also lucky enough to find the engine cover for only $18. Picture of the crack below. Got a gasket set too.

http://i271.photobucket.com/albums/j...psocd4cq2c.jpg

So the project is dead in the water for now. It'll probably be two or three weeks for the parts to arrive from China. Worth the wait I think because some of the parts from U.S. sellers on ebay were a lot more expensive.

Welcome back, and thanks for sharing your project with us. :)

I'm betting that the starter solenoid trigger circuit is routed through both brake switches in parallel. Activate either switch, and the solenoid should engage when you hit the button. If not, check both switches and the starter switch for continuity.

Found out a little more about the bike by checking the VIN and engine number:

It was made by:
Manufacturer Name-Chongqing Xgjao Motorcycle Co Ltd
WMI-LX8/
Address-Shangqiao Industrial Zone
Shapingba, 400037 District Chongqing 400037, China
Product Type-Motorcycle, Moped
Source: http://www.nhtsa.gov/apps/manufacturer/lookup.htm

It's a 2004
Source: http://www.vindecoder.net/

The engine is 150CC (162FMJ) CG150 (Just Googled "162FMJ".

Just posting in case anyone else is looking for tools to help decode the numbers and for my own record.

Busy weekend! Picked up two more CBs. A 2007 Hi-Bird and a Baja Dirt Runner 125. The Hi-Bird has a title. I got it to run today (another bad ignition switch). Didn't ride it because the battery box is missing. Going to fab something up for that. I believe the Hi-Bird is the 250 (223) CC, it has the 169FMM OHC engine.

The Baja was missing the CDI module. The one from the Hi-Bird wouldn't fit (square vs. round plugs). The one on the 150 fit but I discovered it had a broken pin, which is probably why I can't get it fire. Still waiting on a new one I ordered. I have two other CDIs but I think they are AC fired. One is really large (compared to the one in the Hi-Bird and the 150), the other is a blue aluminum "high performance" job. Nether produced any spark on the Baja.

I had already started to dissemble the bikes and didn't get any complete pictures. The Baja looks pretty good, it's all there. The Hi-Bird has the plastics but someone spray painted them without removing the decals so it looks pretty sad.

Good scores, especially on the Hi-Bird. Good luck that it came with a decent rack.

One of the poor points of the Hi-Bird (and others) design is the long petcock that extends from the tank. If the tank is plastic, the long valve places too much stress at the mounting point, and creates a leak. Eventually, the nuts that are embedded in the plastic loosen, making it nearly impossible to solve. I managed to cobble one together with some Permatex Cold Weld and a shorter petcock.

The extended petcock is the reason for the windowed trim below the rear of the tank. I removed the red tank shroud and the trim when I installed a shorter petcock. It's not pretty, but it's not bad.

I've had it with those stock air boxes, so I use these with a 30mm Mikuni: http://www.ebay.com/itm/BLACK-42mm-B...4338a6&vxp=mtr

I was thinking of going to a pod filter. Maybe I'll have enough room to put the battery in place of the air box.

You need to update your sig to reflect your two new scores. :D

Some of the parts I ordered from the AliExpress site came in yesterday. 10 days from order to delivery is pretty good from China given the fact I'm out in the sticks and all my mail seems to take an extra day to get here (thanks to the closing of the postal sorting facility in Topeka, KS).

Regrettably, the CDI I ordered was a square plug type and I need a AC round plug for the Baja 125 and the Xgjao 150. Oh well, another spare for the collection.

I'm expecting two more packages to arrive today.

So far, I'm pretty pleased with ALiexpress.

We have another runner
 

I got the 150 running today. Needed a CDI. Noticed the slide was stuck in the carb, guess it's been sitting for a long time LOL. I didn't even clean out the carb yet, just sprayed some penetrating oil in it and removed the slide and stuck it back in. These engines are just something else. This poor thing is pumping oil out of the crack in the side cover and still starts right up. It shocked me when it started.

[youtube]gUxmX_ZG024[/youtube]

I didn't expect this much oil from the stator cover. Is it supposed to have oil in there?
http://i271.photobucket.com/albums/j...psolrotguo.jpg

The Baja Dirt Runner 125 needs a new stator. The mount for pickup is broke.
I was getting a signal from it, maybe 1 or 2 volts. The lead to the CDI was putting out 8 or 9 volts (kicking it over, no electric start on it). I'm assuming the stator is the cause of the no spark issue. I've tried a new CDI and coil and plug.
http://i271.photobucket.com/albums/j...psnvd8rx55.jpg

Just waiting on more parts now. :zzz:

The Hi-Bird doesn't need much, it's running. Just have to patch the back tube, install the ignition switch (when it comes), mount the battery somewhere, and cleanup the wiring. I'm going to put a VM26 on it with a foam filter, so the battery will go in place of the airbox.

The 150 needs a few front spokes and the stator cover. Both are on order. Then I need to clean up the wiring (remove the lights, horn, etc.) and it'll be good to go. I'll probably sell it as quick as I can. It has the most potential for profit. I've spent about $125 on it (Spokes $10, CDI $8, Stator cover $20 , ignition switch $2, front tube $14, battery $23, clutch lever $8, front master cylinder $14, hand grips and throttle tube $6, kick starter lever $18). Man this stuff adds up fast :doh: So $175 total with the $50 purchase. I should be able to get $400 for it when it's all said and done.

:doh:I just made a spreadsheet of the all the parts I've ordered for these three...don't ever do that:doh:

I've learned not to; it ruins my joy.

Yes, the stator is bathed in oil.

I got the new stator for the Baja 125. Didn't want to wait so I got it off ebay. It was pricy. The plug was different so I cut the plug of the old one and spliced the wires. Of course, the wires can't be the same colors either but I matched them up to their origination points of both stators. Only real difference was the green on mine was black on the new one. Anyway, wired it all up and still no spark. Tell me it's something stupid like the cover has to be on because I didn't reinstall it. Yet. Tried two CDIs and two coils. The lead to the CDI is putting out 40 to 50 volts AC and the lead to the CDI trigger is putting out a small DC charge (~4). Do I need to set the air gap on pickup for the trigger? It was slightly bent coming out of the box so I just made it 90 degrees again. I've followed all the basic wiring diagrams for the CDI and coil. It all seems correct. I'm going test all my splices again tomorrow and pull the CDI and coil off the 150, even though I'm sure I've tested the ones I'm using on the 125 on the 150 now to be sure they worked.

This bike doesn't have lights, starter, or a battery. It's dead simple, maybe too simple for me. LOL. From the stator I'm using the two wires from the pickup and the AC power to the CDI. One of the pickup wires is also the ground (green on my bike, black on the stator). I don't use the yellow and white wires from the stator as there is no battery or lights. The kill switch is working.

Oh, no. It's the CG125M (90s Honda) stator ie. very difficult to obtain in states
https://item.taobao.com/item.htm?id=45436206603
What's the ohm reading of stator's source coil & pickup trigger? It's very difficult to obtain correct info of this model.
---
Check the trigger gap (~0.5mm) http://www.sanxin.com.cn/Exhibit/exhview.asp?pid=8 if misfire happends as CDI maker said
---
https://translate.google.com/transla...107&edit-text=

Thanks. I will check those resistance readings tonight.

I got it to fire. I did not have the second ground wire coming out of the CDI hooked up. Thought it wasn't necessary. Once I ran a ground to that pin on the CDI I got spark.:clap:

Awesome! How does it run?

Not really running yet. The carb is all gummed up so I just got it fire with a little gas in the intake. Plus, I've got the exhaust off. The muffler weld broke so I've got to get it welded back on. Now that I've got the ignition squared away I can really start fixing it up.

Cool. That's an encouraging starting point.

I got the spokes for the 150's front wheel in the mail from China. Wrong bend. The length was right but I need'ed a 90 degree "jbend". Since I only had to replace a few spokes replaced, I just went ahead and re-bent them in a vice.

Took me a few hours to replace the missing spokes. Wasn't planning on it being a big deal, but you have to remove several spokes to get new spokes in. :doh:

I just put the bike on a stand and put the wheel on to use the forks as a truing stand.
[youtube]Hahok_4rIcI[/youtube]
https://youtu.be/Hahok_4rIcI

As you can see, I've still got some work to do but it's pretty close (for a dirt bike wheel). The new spokes pulled into their sockets nicely.

I also got the spokes for the rear of the Baja 125. They are way off and I can't use them. Spent some time searching last night and ordered another set, again all the way from China.

Got my stator cover installed on the 150. I think I messed up the starter. Didn't know that the front just pops out of the stator cover. Ended up taking the starter apart.


Any tips for pulling the exhaust? I want to paint it but the muffler and head pipe are seized together. Not sure I can wrangle it out that way.

Starters are expensive. Guess I better take it apart again.

Some maintenance tips:
http://www.motorfans.com.cn/bbs/view...authorid=75082

if you have a torch of any sort (propane will do) heat the joint a bit and try to twist the header out of the muffler pipe...

Unless you can manage to wiggle the whole assembly out, which will then allow a little careful twisting.

After you have separated the header and mid-pipe, try the electrolytic de-rusting trick. It's amazing.

Looks like I hamfisted the starter back together and broke one of the brushes. So add another $35 to the spreadsheet for a new one.

I got the exhaust off. After letting is sit with some penetrating oil it came apart with just a little twisting. Gave it few coats of BBQ paint (also found a use my wife's plant hangers. LOL).

Expecting a lot of packages from China this week. Was hoping to have all three bikes almost ready to go by this weekend but I ran into big problems with broken spokes. I got the front wheel of the 150 all done. But found a broken spoke on the back of the hi-bird, and there are several broken on the Baja 125. So it'll be another couple of weeks before I get those parts in. I've only been able to find spokes on AliExpress.

Since I'm dead in the water waiting on parts, I did some mockups of the body work on the 150 using some spare plastics I had laying around. The tank plastics that came with it (that's the only body work it had with it) were broken, I' trimmed up both sides, cut off the forward parts that were broke. It looks okay without the tank cover but there's a huge gap between the seat and tank so I tried it with the trimmed covers. Not sure if I'm going to use them or not. But it looks more like a motorcycle now.

Both muffler and side panels look good. :tup:

I like your muffler hanger; good idea!

I might have the tank cover if you want it. It's yours for the cost of shipping plus on pint of cheap IPA.

I'd like to have that tank cover. :clap: I'll send you some Kansas wheat ale.

I got the 150 pretty much ridable. The new starter arrived Friday.

I installed a new PZ27 carb to replace the original PD and went with a foam air filter. I used a 105 main jet and a 42 slow jet to start. Seems to be running really well. Nice and smooth from idle to redline. I haven't done any plug chops yet, just to hot out to be standing on the side of the road pulling the plug. But I did stop for a "photo op" LOL.:hi:

The BBQ paint is holding up on the exhaust, but I've only ridden it a couple of times for a total of about 10 miles. Time will tell on that I suppose.

The speedometer isn't hooked up, waiting on a new cable for that. However, the bike does seem pretty quick for a 150, it has good power.

Hi-Bird Caliper
 

Got a big problem with the front brake on the Hi-Bird. I noticed there was only one bolt holding the caliper on when I bought it. Didn't worry too much about or even look that closely.

Upon further inspection, it turns out the it's the wrong caliper. The bottom bolt will not line up with the mount on the fork. The mounts have a 60MM spacing but the caliper bracket is about 65MM, and even if it did line up, the body of the caliper is in the way (can't draw it all the way to the fork). I ordered a single piston caliper off ebay (the only one I could find with a 60MM bolt spacing) but it's way to small. It's meant for a little pit bike. I've been searching Taobao with no luck (Humanbeing, are you there? Help.).

Maybe a little safety wire will work? Just kidding! But, I'm thinking of swapping the forks from the 150 onto the Hi-Bird. Since the Hi-Bird will be ridden on the street proper brakes are a must. I could bodge some kind of mount and put these forks on the 150, which will be off road only. Still, sort of a scary proposition.

Caliper?
 

The attached image, might be the caliper I'm looking for.

60mm is found in some Suzuki street bike http://item.taobao.com/item.htm?id=16979328878 | http://item.taobao.com/item.htm?id=41278290637

Thanks HB! This confirms so others that I was looking at on Aliexpress as well.

Swapping forks might be doable, but it will depend on the stem length and diameter. In all likelihood, they're identical.

That is only a mounting plate, and nothing stops you from making one. Find some steel that is the same thickness, use the existing plate as a template for the caliper side, make a cardboard template for the bolt hole side and start drilling. It might take you an afternoon, but it would be worth it.

Do you have access to a MIG welder?