Magician 250 frame breaking apart and other problems

Andrew.g13 · 04-10-2019, 02:51 PM

Good Afternoon Everyone, so far i made 1100 miles on my 250 Magician and problem arose such as loose screws and leaking air box in which it got fix thanks to you guys

But now i got new problems with the part of the frame breaking apart and i got my clutch lever leaking oil and the metal rod that hold the exhaust to the engine broke in half. i dont know how to fix these problem. Ill upload these pictures below.

2LZ · 04-10-2019, 03:11 PM

Well that sucks.
Didn't we someone else here with a frame issue on a Magician?

psychprof · 04-10-2019, 03:21 PM

Would the broken bolt and the frame be a (sort of) easy fix? Couldn't he just extract the bolt and then re-thread that hole?

As for the frame, I'd think a welder could take care of that for not a lot of money, no?

Is this a Magician thing? Do Hawks have similar issues? I don't imagine you were riding this too hard.

**JerryHawk250** · 04-10-2019, 03:24 PM

Quote:

Originally Posted by psychprof

Would the broken bolt and the frame be a (sort of) easy fix? Couldn't he just extract the bolt and then re-thread that hole?

As for the frame, I'd think a welder could take care of that for not a lot of money, no?

Is this a Magician thing? Do Hawks have similar issues? I don't imagine you were riding this too hard.

Not a Hawk issue. I've had mine for 2 1/2 years with no frame failures. I'm about 50/50 on and off road and not real gentle with the bike when off road.

**JerryHawk250** · 04-10-2019, 03:27 PM

Quote:

Originally Posted by Andrew.g13

Good Afternoon Everyone, so far i made 1100 miles on my 250 Magician and problem arose such as loose screws and leaking air box in which it got fix thanks to you guys

But now i got new problems with the part of the frame breaking apart and i got my clutch lever leaking oil and the metal rod that hold the exhaust to the engine broke in half. i dont know how to fix these problem. Ill upload these pictures below.

The exhaust bolt can be removed with a screw extractor. Looks like you have enough of the stud sticking out to weld a nut on there and remove. Had lots of luck with that method.

Andrew.g13 · 04-10-2019, 03:57 PM

I most likely gonna do that, im gonna take it to home depot to see if they have a similar size.

**JerryHawk250** · 04-10-2019, 04:01 PM

As far as the shift lever seal you can get that from CSC. It's the same as the TT250. https://store.cscmotorcycles.com/TT2...p/zt55-122.htm

Andrew.g13 · 04-10-2019, 04:26 PM

Quote:

Originally Posted by JerryHawk250

As far as the shift lever seal you can get that from CSC. It's the same as the TT250. https://store.cscmotorcycles.com/TT2...p/zt55-122.htm

Awesome thank you very much

Andrew.g13 · 04-10-2019, 04:28 PM

Since i lost that frame part with the bolt include, does anyone knows the type of bolt that is?

**JerryHawk250** · 04-10-2019, 04:42 PM

Quote:

Originally Posted by Andrew.g13

Since i lost that frame part with the bolt include, does anyone knows the type of bolt that is?

class 8.8 - 8m bolt.

Andrew.g13 · 04-10-2019, 05:02 PM

Quote:

Originally Posted by JerryHawk250

class 8.8 - 8m bolt.

Thanks again, ill work on it once i get home, hopefully in one piece.

Megadan · 04-11-2019, 12:13 AM

Exhaust stud is your fairly standard M8 x 1.25 variety. If you have an ACE Hardware nearby there is a good chance you can get one there, if not most parts stores will likely have one. I would recommend replacing both studs together.

Quote:

Originally Posted by 2LZ

Well that sucks.
Didn't we someone else here with a frame issue on a Magician?

This would be the third Magician owner on here that has posted at least one weld failure/crack, and Motocheez has a video on his as well.

zendick · 04-11-2019, 01:10 AM

200+ lb magcian rider with >6k on the odo, no frame issues. I catch air almost every day I ride when I hit the railroad tracks at 45 or so.

I think the issues may be caused by lack of routine fastener maintenance. Any play creates havoc on this bike quickly.

timcosby · 04-11-2019, 09:18 PM

thats what i was thinking. once something loosens up it wiggles like a muther till it breaks something.

_skid87 · 05-08-2019, 06:03 AM

Quote:

Originally Posted by JerryHawk250

The exhaust bolt can be removed with a screw extractor. Looks like you have enough of the stud sticking out to weld a nut on there and remove. Had lots of luck with that method.

I would attempt this OP.. and the heat from the weld will make it come out easier. I just lost both of the nuts that hold the flange down on my last ride. I got both studs out with vice grips. I found that the bolts that held the crate together were the right thread, a little short with a lock washer but I got them tightened down pretty good, dripping with red loctite also

04-10-2019, 03:11 PM	#2
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,102	Well that sucks. Didn't we someone else here with a frame issue on a Magician? __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350
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04-10-2019, 04:01 PM	#7
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,588	As far as the shift lever seal you can get that from CSC. It's the same as the TT250. https://store.cscmotorcycles.com/TT2...p/zt55-122.htm __________________ 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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04-11-2019, 09:18 PM	#14
timcosby Join Date: Nov 2016 Location: robertsdale alabama usa Posts: 1,007	thats what i was thinking. once something loosens up it wiggles like a muther till it breaks something. __________________ 1991 harley heritage softail classic 2016 hawk kaw h1 400 tripple 13' long chopper in progress 2009 johnny pag bar hog 2004 hd electra glide ultra classic shriner edition 1997 harley davidson 1200 sportster 1972 harley davidson amf sx250
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04-10-2019, 03:21 PM	#3
psychprof Join Date: Feb 2019 Posts: 38	Would the broken bolt and the frame be a (sort of) easy fix? Couldn't he just extract the bolt and then re-thread that hole? As for the frame, I'd think a welder could take care of that for not a lot of money, no? Is this a Magician thing? Do Hawks have similar issues? I don't imagine you were riding this too hard.
	0

04-10-2019, 03:57 PM	#6
Andrew.g13 Join Date: Mar 2019 Posts: 10	I most likely gonna do that, im gonna take it to home depot to see if they have a similar size.
	0

04-10-2019, 04:28 PM	#9
Andrew.g13 Join Date: Mar 2019 Posts: 10	Since i lost that frame part with the bolt include, does anyone knows the type of bolt that is?
	0

04-11-2019, 01:10 AM	#13
zendick Join Date: May 2018 Posts: 32	200+ lb magcian rider with >6k on the odo, no frame issues. I catch air almost every day I ride when I hit the railroad tracks at 45 or so. I think the issues may be caused by lack of routine fastener maintenance. Any play creates havoc on this bike quickly.
	3