Odd build

ChondaChondaChonda · 10-27-2016, 11:34 PM

So I have been riding my "hybrid" dirt bike for quite a few years. It's a 1993 CR125 chassis that has sported a reliable old Xr200 motor for many, many years... the registration stickers (mostly Idaho) are 1/4" thick and go back to the early 2000's maybe more.

The old XR finally gave up the ghost a few months ago. Blew a head gasket and wiped out the piston; still ran enough to get us home, albeit slowly. I wanted a "magic" button as I'm getting too old to kick flooded bikes on peaks over 8-9000' anymore.

Initially I was going to transplant a Crf230 motor, but dang if they aren't expensive little buggers!! $$$$ After looking for a good low cost motor and not finding one I decided to try a Zongshen 169FMM instead.

My research seems to indicate that these are pretty reliable motors, but my riding buddies are really REALLY not happy with my choice. May the Zong prove them wrong!!

ChondaChondaChonda · 10-27-2016, 11:38 PM

#1 reason i want to keep my old hybrid CR125/230 is that I have spent a ton of time and money dialing in the suspension over the last few years. Custom springs for my weight, rebuilt rear shock, lightweight oil in forks, etc. It rides just the way I want it for single track and some whooped out open desert sections.

The motor is partway bolted in and I actually twisted the wiring up and fired her up for the first time about an hour ago!! Sounds really good.

ChondaChondaChonda · 10-27-2016, 11:53 PM

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She's ugly, but I love her.

ChondaChondaChonda · 10-27-2016, 11:58 PM

Here's a shot of the new motor almost bolted in. The two back mounts are on, but the top mount is a little different from the 200 so i will have to make a new one.

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ChondaChondaChonda · 10-27-2016, 11:59 PM

I pulled the cover off to try and figure out the wiring. Does anyone know the rated output of this style stator?
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For the record:
Black/red stripe goes to Honda Black/red stripe (To CDI)
Blue/white stripe goes to Honda Blue/yellow stripe (To CDI)
Green/white stripe to Honda Green (Ground)
Yellow and Peach go to regulator, which is aftermarket 4 wire. Will not work with the little Crf230 regulator.

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The 6 wire plug going into the shifter for gear indication is useless to me so I just pulled it out.

ChondaChondaChonda · 10-28-2016, 12:01 AM

I've searched for hours on "169FMM" but there just isn't much good information out there. Most of what was found came from this forum. Big thanks to those who have posted!!

Here is my motor serial for anyone curious:

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ChondaChondaChonda · 10-28-2016, 12:09 AM

One issue that I do have is the sprocket alignment. Using a laser level to sight down the hub and sprocket it was pretty plain to see that the Zong motor's offset was about 8mm too far inboard. A new retaining method will be necessary. Any ideas?

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Bruce's · 10-28-2016, 12:27 AM

Any chance you could move the engine over to line up the sprockets ?

ChondaChondaChonda · 10-28-2016, 12:31 AM

Quote:

Originally Posted by Bruce's

Any chance you could move the engine over to line up the sprockets ?

Not too easily. The clearance from the carb to the frame is already tight, so it would make that a new issue.

humanbeing · 10-28-2016, 01:59 AM

Quote:

Originally Posted by ChondaChondaChonda

...anyone know the rated output of this style stator...

2 holes CB/ 88mm https://translate.google.com/transla...F67&edit-text=

pete · 10-28-2016, 03:45 AM

start the motor... put in gear get the shaft turning...
hold a angle grinder with a cutting disc on the shaft
& put a new groove in it.....

LOL... well yer did ask...

...

culcune · 10-28-2016, 07:52 AM

Quote:

Originally Posted by ChondaChondaChonda

My research seems to indicate that these are pretty reliable motors, but my riding buddies are really REALLY not happy with my choice. May the Zong prove them wrong!!

Welcome to here! Usually, the friends are trying to keep one away from an entire bike, not the engine. I have little doubt the engine WILL prove your friends wrong.

ChondaChondaChonda · 10-28-2016, 09:02 AM

Quote:

Originally Posted by humanbeing

2 holes CB/ 88mm https://translate.google.com/transla...F67&edit-text=

Thank you!

So 90W is all. Ok. For future searchers:

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ChondaChondaChonda · 10-28-2016, 09:03 AM

Quote:

Originally Posted by pete

start the motor... put in gear get the shaft turning...
hold a angle grinder with a cutting disc on the shaft
& put a new groove in it.....

LOL... well yer did ask...

...

Hmmm...

ChondaChondaChonda · 10-28-2016, 09:09 AM

Quote:

Originally Posted by culcune

Welcome to here! Usually, the friends are trying to keep one away from an entire bike, not the engine. I have little doubt the engine WILL prove your friends wrong.

The backlash against this motor has been epic. My intent with this forum post is to document the issues that may or may not come up such as the sprocket alignment. If this motor ever leaves me stranded it will be a chorus of "We told ya' so!!".

10-27-2016, 11:59 PM	#5
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	I pulled the cover off to try and figure out the wiring. Does anyone know the rated output of this style stator? For the record: Black/red stripe goes to Honda Black/red stripe (To CDI) Blue/white stripe goes to Honda Blue/yellow stripe (To CDI) Green/white stripe to Honda Green (Ground) Yellow and Peach go to regulator, which is aftermarket 4 wire. Will not work with the little Crf230 regulator. The 6 wire plug going into the shifter for gear indication is useless to me so I just pulled it out. Last edited by ChondaChondaChonda; 10-28-2016 at 09:04 PM. Reason: Add wiring details.
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10-28-2016, 12:01 AM	#6
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	169fmm I've searched for hours on "169FMM" but there just isn't much good information out there. Most of what was found came from this forum. Big thanks to those who have posted!! Here is my motor serial for anyone curious: Last edited by ChondaChondaChonda; 10-28-2016 at 12:32 AM. Reason: spelling
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10-28-2016, 12:09 AM	#7
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Odd build, odd guy, odd Introduction; I know...I know! One issue that I do have is the sprocket alignment. Using a laser level to sight down the hub and sprocket it was pretty plain to see that the Zong motor's offset was about 8mm too far inboard. A new retaining method will be necessary. Any ideas?
	0

10-28-2016, 03:45 AM	#11
pete Join Date: Jan 2012 Location: ChCh , NZ Posts: 2,261	start the motor... put in gear get the shaft turning... hold a angle grinder with a cutting disc on the shaft & put a new groove in it..... LOL... well yer did ask... ... __________________ 09 XT660R ... 06 TTR250 ... 80 Montesa H6 125 Enduro... 77 Montesa Cota 348 MRR "Malcom Rathnell Replica"... Current resto projects.. 81 Honda CT110... 80 Kawasaki KL250A1... 11 Husaburg TE125 enduro... "sold" along with another 31... Lifan 125 Pitbike.. "stolen" ... KIWI BIKER FORUM...... http://www.kiwibiker.co.nz/forums/content.php All the best offroad rides in NZ... http://www.remotemoto.com/ E-mail... xtpete1@gmail.com
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10-27-2016, 11:34 PM	#1
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Odd build So I have been riding my "hybrid" dirt bike for quite a few years. It's a 1993 CR125 chassis that has sported a reliable old Xr200 motor for many, many years... the registration stickers (mostly Idaho) are 1/4" thick and go back to the early 2000's maybe more. The old XR finally gave up the ghost a few months ago. Blew a head gasket and wiped out the piston; still ran enough to get us home, albeit slowly. I wanted a "magic" button as I'm getting too old to kick flooded bikes on peaks over 8-9000' anymore. Initially I was going to transplant a Crf230 motor, but dang if they aren't expensive little buggers!! $$$$ After looking for a good low cost motor and not finding one I decided to try a Zongshen 169FMM instead. My research seems to indicate that these are pretty reliable motors, but my riding buddies are really REALLY not happy with my choice. May the Zong prove them wrong!!
	2

10-27-2016, 11:38 PM	#2
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	#1 reason i want to keep my old hybrid CR125/230 is that I have spent a ton of time and money dialing in the suspension over the last few years. Custom springs for my weight, rebuilt rear shock, lightweight oil in forks, etc. It rides just the way I want it for single track and some whooped out open desert sections. The motor is partway bolted in and I actually twisted the wiring up and fired her up for the first time about an hour ago!! Sounds really good.
	1

10-27-2016, 11:53 PM	#3
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	She's ugly, but I love her.
	1

10-27-2016, 11:58 PM	#4
ChondaChondaChonda Join Date: Oct 2016 Posts: 547	Here's a shot of the new motor almost bolted in. The two back mounts are on, but the top mount is a little different from the 200 so i will have to make a new one.
	0

10-28-2016, 12:27 AM	#8
Bruce's Join Date: Apr 2015 Location: Sudbury ,Ontario Posts: 855	Any chance you could move the engine over to line up the sprockets ?
	0