Project XL185/CG250 swap

[Moto1204]

Man this bikes been putting you through the ringer! Have you even got much miles on it?

[XLsior]

Originally Posted by Moto1204

Man this bikes been putting you through the ringer! Have you even got much miles on it?

I have only rode it for about 5min in 1st gear around my back yard before the rear brake munted up (my fault) and then the start sprag janked.

Sorted now.

Could have finished much sooner, But I had more important matters with home renovations and the whole global health situation I was not sure how much riding I would be able to do.

It was crusty barn find with an $80 unknown quality history carboot CG250 engine....

Getting it finished soon was never the intention...Just getting it finished eventually was.

Still waiting for the starter solenoid.

But this came in the mail today.....

[XLsior]

I found the 300cc air cylinder head with 16mm wrist pin on AliX.

Shipping fees hurt but i will say this was possibly the best ever packed item i have received from Alix...Double boxed double foam padding.

Behold the nominal 300cc CG250 jug....

[XLsior]

Really happy with the quality of the kit.

I have not opened the gasket and rings packets.

But when I eventually get the skirt/sleeve OD turned down the gasket kit is not much use...

Plenty of material to work with. Saw a YT vid where the standard skirt/sleeve OD was 72.6mm

Any way not installing it anytime soon until the current pool noodle honed stock cylinder with fresh piston and rings wear out.

[Moto1204]

Oh nice great find! Will the starter be able to handle that compression you think? Or will you just kick it. I’m not sure if these motors have a compression release like some other bikes. Good to see the packaging was nice. The quality looks quite swell also! I ordered a 130 big bore kit when I still had my original CT125 engine and was surprised as well by the quality and performance of it.

[XLsior]

It's only a 229cc to 250cc increase.

the compression should be about the same. Can't remember the person who has already done the big bore mod but I can't recall any issues with starting.

But yes thankfully the kick start is still an option.

[XLsior]

New pink wire starter solenoid arrived. $15 aussie buckaroos shipped...

Removed Gremlin replaced with Mogwai.

Check in Neutral...

Turn key...

Check kill switch...

Press yellow E start button...

Cranks without hesitation...

Another moment of relief.

Maybe my mind is playing tricks on me but it seems to be turning over way better now.

before it seemed like a rev ever 2/3-1sec.

Now it feels like 2 revs a second... Not sure how a bad sprag clutch could be implicated but the bike genuinely feels eager now.

The Nibbi PE28FL carb is on the way....Seems the Aussie black/red stock listing was legit.

So with that awaiting arrival, all that appears left to to do is wiring up all the other electronic gizmos...

[XLsior]

So, happy to report that the replacement gear shift sensor and AliX 102345 Gear display worked.

Basically provided the 12v supply then jacked up the rear wheel to help with selecting each gear and then matching the active wire to the correct plug display input.

I do however need to make a split connector for the neutral sender to also supply the digi dash as well.

after that I think I'll focus on indicators...

I'm still contemplating cutting back the digi dash factory cables and connectors, mainly due to the limited lamp bucket volume/space constraints.

(tried multiple times to rotate the photos rightsideup, forum upload doesn't agree)

[Megadan]

Originally Posted by Moto1204

Oh nice great find! Will the starter be able to handle that compression you think? Or will you just kick it. I’m not sure if these motors have a compression release like some other bikes. Good to see the packaging was nice. The quality looks quite swell also! I ordered a 130 big bore kit when I still had my original CT125 engine and was surprised as well by the quality and performance of it.

I'm running well past 10:1. Starter struggles a.bit but still turns over just fine.

[XLsior]

Clock works, separate 1amp fuse.

Dash turns on, 2amp fuse shared with the USB ports.

Found neutral again so synced with the gear display [0] with the dash [N] light

[XLsior]

Sorry for the upside down pictures...I've tried uploading either way and they all still prefer to post upside down regardless.

[XLsior]

horn works...

Disregard the orange wire as I rewired the the left hand switch gear so none of the colors correspond with anything factory.

however I am now more confident in the rest of my rewiring effort.

[Megadan]

Originally Posted by XLsior

Sorry for the upside down pictures...I've tried uploading either way and they all still prefer to post upside down regardless.

They are right side up for me.

[XLsior]

Ahh interesting... I'll just post them as the are then.

[franque]

Same for me, northern hemisphere!