Odd build - Page 5

crackerjac · 02-22-2017, 01:47 PM

Not sure why your thread didn't come up when I searched but it would have answered some needless posts I made, lol.

Question, just to be clear, in the end what did you convert your motor to? I believe you said it was a ZS169FMM which is 69mmx62.5mm - 232cc but you found a kit to make it 247cc?

ChondaChondaChonda · 02-22-2017, 03:23 PM

Crackerjac, My ZS169FMM is still stock internally.

It turns out that the 250cc cylinder I purchased has a larger bolt pattern than these 230 (223) cc clones. Won't work.

My bike does have a new Honda Keihin carb and a Powr-roll exhaust header. Runs really, really well.

ChondaChondaChonda · 04-03-2018, 09:37 PM

Decided that I needed to give this bike some love. It's been neglected since I picked up the Pitster LXR 250.

Member Chadzu ordered this Otom stainless header for his 230 powered XR200, but decided it would not work and gave it to me. I had hoped it might fit the LXR, but not even close.

With a little effort I was able to fit it up to this old Chonda;
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Weldangrind · 04-04-2018, 11:51 AM

Did you have to bend it?

ChondaChondaChonda · 04-04-2018, 12:35 PM

Quote:

Originally Posted by Weldangrind

Did you have to bend it?

No, but the depth of the exhaust flange was wrong, so I had to make an extension about 1/2" long and weld it to the stainless pipe.

It exits at a little more "outward" angle, so I did weld a bend from the original tailpipe in to re-align it with the Supertrapp muffler. I'll grab a few more pics. This was a late night snap.

I also mounted the original tank from my Pitster LXR250 on this bike along with the seat; it really changes the whole look and feel of the bike. Gives it a modern, sleek, low look that it was definitely missing with that old KX tank it had on it.

franque · 04-04-2018, 09:03 PM

Can you get some more pictures of the engine mounts? I'd love to do something like this!

ChondaChondaChonda · 04-04-2018, 09:43 PM

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ChondaChondaChonda · 04-04-2018, 09:47 PM

Quote:

Originally Posted by franque

Can you get some more pictures of the engine mounts? I'd love to do something like this!

Sure:

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Front mounts made of thick aluminum

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Frame drop had to be notched to clear carburetor (XR200 carb and intake):
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ChondaChondaChonda · 04-04-2018, 09:49 PM

Some from the other side:
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ChondaChondaChonda · 04-04-2018, 09:53 PM

Obviously there is still some wiring and seat mounts to finish up, but I like the direction it is headed now.

ChondaChondaChonda · 04-04-2018, 09:56 PM

I didn't originally convert this to air cooled- it was done long, long ago. The original builder used an XR200 motor, which I blew a head gasket on.

You can see in this picture that he cut the drop from the front of the frame and added the square tubing:
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ChondaChondaChonda · 04-08-2018, 06:14 PM

Decided to mimic the way a good friend setup his electric start bike.

Made a mounting tray out of aluminum- it's hard to see, but it bolts on with the sprocket cover. Two holes on the far side allow it to be aircraft safety wired to the case vent pipe.

Good centralization of weight and shorter/less wiring. I also zip tied the battery to the tray after this photo was snapped.

From kick side:

ChondaChondaChonda · 04-08-2018, 06:21 PM

The solenoid is now mounted on the other side of the starter; now wires are used. Its a "bus bar" made from aluminum and covered with heat shrink. The bus bar to the solenoid is about 1" long and holds the solenoid in place:

The positive to the battery is also an aluminum bus bar covered with 2 layers of heat shrink. If you look at the picture close you can see it curving over to the positive on the anti-gravity battery.

Nice drip of fuel there too.

I also took my old Pitster kickstand and front number plate and repurposed them to this old Chonda:

It's really starting to come together:

Rode it around the back yard for a bit. Made adjustments to the handlebars and controls. Really liking how this feels now. Planning to take it on a big desert ride tomorrow to test it all out.

david3921 · 04-08-2018, 07:11 PM

Quote:

Originally Posted by ChondaChondaChonda

Attachment 12527

Attachment 12528

Attachment 12529

What is the purpose of the upper pipe? I don't think I've seen one before.

ChondaChondaChonda · 04-08-2018, 07:25 PM

I'm guessing it's a resonance chamber. Sometimes called helmholtz chambers.

From Wikipedia :
The theory of Helmholtz resonators is used in motorcycle and car exhausts to alter the sound of the exhaust note and for differences in power delivery by adding chambers to the exhaust. Exhaust resonators are also used to reduce potentially loud and obnoxious engine noise where the dimensions are calculated so that the waves reflected by the resonator help cancel out certain frequencies of sound in the exhaust.

In some two-stroke engines, a Helmholtz resonator is used to remove the need for a reed valve. A similar effect is also used in the exhaust system of most two-stroke engines, using a reflected pressure pulse to supercharge the cylinder (see Kadenacy effect.)

Probably just for looks on this pipe.

02-22-2017, 03:23 PM	#62
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Crackerjac, My ZS169FMM is still stock internally. It turns out that the 250cc cylinder I purchased has a larger bolt pattern than these 230 (223) cc clones. Won't work. My bike does have a new Honda Keihin carb and a Powr-roll exhaust header. Runs really, really well. __________________ 1993 CR125 powered by Zongshen 223cc OHC 2̶0̶1̶6̶ ̶L̶X̶R̶ ̶2̶5̶0̶ ̶E̶F̶I̶ ̶ Sold 2018 GPX Moto FSE250R 1993 Fantic Key-Roo 250
	1

04-03-2018, 09:37 PM	#63
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	New update Decided that I needed to give this bike some love. It's been neglected since I picked up the Pitster LXR 250. Member Chadzu ordered this Otom stainless header for his 230 powered XR200, but decided it would not work and gave it to me. I had hoped it might fit the LXR, but not even close. With a little effort I was able to fit it up to this old Chonda;
	1

04-04-2018, 11:51 AM	#64
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Did you have to bend it? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

04-04-2018, 09:43 PM	#67
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Pics of Otom exhaust
	1

04-04-2018, 09:49 PM	#69
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Frame mounts Some from the other side:
	1

02-22-2017, 01:47 PM	#61
crackerjac Join Date: Sep 2016 Posts: 103	Not sure why your thread didn't come up when I searched but it would have answered some needless posts I made, lol. Question, just to be clear, in the end what did you convert your motor to? I believe you said it was a ZS169FMM which is 69mmx62.5mm - 232cc but you found a kit to make it 247cc?
	0

04-04-2018, 09:03 PM	#66
franque Join Date: Nov 2017 Location: Marseille, France -> Conakry, Guinea Posts: 1,481	Can you get some more pictures of the engine mounts? I'd love to do something like this!
	0

04-04-2018, 09:53 PM	#70
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Obviously there is still some wiring and seat mounts to finish up, but I like the direction it is headed now.
	0

04-04-2018, 09:56 PM	#71
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Front frame I didn't originally convert this to air cooled- it was done long, long ago. The original builder used an XR200 motor, which I blew a head gasket on. You can see in this picture that he cut the drop from the front of the frame and added the square tubing:
	1

04-08-2018, 06:14 PM	#72
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Zong powered CR125 battery relocation Decided to mimic the way a good friend setup his electric start bike. Made a mounting tray out of aluminum- it's hard to see, but it bolts on with the sprocket cover. Two holes on the far side allow it to be aircraft safety wired to the case vent pipe. Good centralization of weight and shorter/less wiring. I also zip tied the battery to the tray after this photo was snapped. From kick side: Last edited by ChondaChondaChonda; 04-08-2018 at 06:51 PM. Reason: clarity
	2

04-08-2018, 06:21 PM	#73
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	The solenoid is now mounted on the other side of the starter; now wires are used. Its a "bus bar" made from aluminum and covered with heat shrink. The bus bar to the solenoid is about 1" long and holds the solenoid in place: The positive to the battery is also an aluminum bus bar covered with 2 layers of heat shrink. If you look at the picture close you can see it curving over to the positive on the anti-gravity battery. Nice drip of fuel there too. I also took my old Pitster kickstand and front number plate and repurposed them to this old Chonda: It's really starting to come together: Rode it around the back yard for a bit. Made adjustments to the handlebars and controls. Really liking how this feels now. Planning to take it on a big desert ride tomorrow to test it all out.
	0

04-08-2018, 07:25 PM	#75
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	I'm guessing it's a resonance chamber. Sometimes called helmholtz chambers. From Wikipedia : The theory of Helmholtz resonators is used in motorcycle and car exhausts to alter the sound of the exhaust note and for differences in power delivery by adding chambers to the exhaust. Exhaust resonators are also used to reduce potentially loud and obnoxious engine noise where the dimensions are calculated so that the waves reflected by the resonator help cancel out certain frequencies of sound in the exhaust. In some two-stroke engines, a Helmholtz resonator is used to remove the need for a reed valve. A similar effect is also used in the exhaust system of most two-stroke engines, using a reflected pressure pulse to supercharge the cylinder (see Kadenacy effect.) Probably just for looks on this pipe.
	0