Project XL185/CG250 swap

[Megadan]

The last 5% of a bike build is always the most tedious and boring stuff. Looks amazing!

[China Rider 27]

Looks Good! Maybe a HONDA CG sticker for the tank!

[XLsior]

Originally Posted by China Rider 27

Looks Good! Maybe a HONDA CG sticker for the tank!

Had the custom Honda Decals already prepared.

However the paint on the tank mainly the clear coat isn't that great. Still has pea dings which I might sort out. Had an incident where my dog was chasing a rat and clambered over the tank chipping and scratching the paint...my fault for leaving tank on the floor. And finally I think I will seal coat the inside of the tank to prevent any more rust...

I'm also considering finding and seeing if a XL350 tank will fit for more fuel capacity...

So I'm just going to run the tank as is for a while before I finalize the decal placement.

[XLsior]

Making the bash plate fit.

Had to index some clearance around the CG250 sump plug.

The original rear mount had sheared off the rubber plate...

Decided to just hard mount the plate direct to frame. Honda probably had a reason not to and use the rubber extension thing. But Replacing it not really an option.

So did some metal persuasion and flux core zappery with the usual grind back to make it less eyesore..

I'm out of paint and low funds but will coat it in spray 'Aluminum' finish at some point.

Also might have found the XL 350 fuel tank and I think it will work...If so it might add another gallon of capacity.

[XLsior]

Additional bash plate/sump guard

[XLsior]

Originally Posted by Megadan

The last 5% of a bike build is always the most tedious and boring stuff. Looks amazing!

Think I only made it to the 80% mark

[XLsior]

Hi all,

The project had to take a back seat while more imperative issues needed to be focused on.

Getting my home weather tight with functioning amenities was more important.

So just to update managed to get things in order and can now find spare time for other interests...

I went from this...to this...

So yeah making progress...

Now back to your regular scheduled program..

[XLsior]

Gave the bash plate a coat of zinc protect aluminum color, seems to match the other aluminum components.

Preemptively drained the original oil and filled with fresh before first start more of flush break-in for the new piston and rings and such might prefer it to the mank that was in there.

Now back to fixing the wiring loom and rejiggery of the exhaust to thread the needle between the back tire and suspension.

Then all appendages crossed a first start attempt.

[XLsior]

off on a tangent,

finding a fuel cap for the xl350r tank has been a trifle... from what i can tell it uses the same as a 250xr and xr600 but I cant be certain and the aftermarket options don't seem to want to measure the fill diameter.

I purchased a lockable cg125 with matching keyignition hoping to knock a 2 birds but that cap was 10mm to small.

My original XL185 cap is 10mm to big...

So the search continues...not sure if i should keep hunting for a lockable cap as it would likely end up as a 3 key situation if i want to replace the steering stem lock.

A faff about not much...

[XLsior]

I think shaving and relocating the side mounts will be the first step, as doing so will establish the tank level/angle which might alleviate all the other issues to a degree.
at the moment it sits to high at the shoulders using the factory located mounting points.

[XLsior]

So shaved off the factory tank shoulder mounts.

Offered up the tank to frame lower on the shoulder.

Steering full lock now cleared.

With the tank leveled off cylinder head and petcock clearances much improved.

The tank inner wall at some point cannot go lower due to cylinder head.

This makes the rear tank/seat mount much higher, but when compared to the XL185 tank its clear the mount is not a flush seam fit and there is a Dog leg drop down mount.

So if i replicate this drop down 'L' bracket to meet the frame point correctly this should imply that the seat will 'Line Up' with XL350 tank closer to factory design...

What I am trying to say is I think this will be a legitimate tank capacity upgrade project...
And should not look to bad doing it either...

looking for a place to install the CDI to use both tanks interchangeably...Coil seems to fit.

Horn has to move...

[XLsior]

Cut and bent the seat mount trying to keep as much original material.

Stayed clear of the seam. Still needs an L bracket welded on but wanted to see how well it'll line up installed with the seat.

All appears ok, have to roll some of the edges where the tank corner and seat corners meet. But it's all with tolerances.

going to relocate the CDI to the batterybox location, the way the plug sticks out is so annoying. Thought I could tuck under the tank arch but not sure if both tanks will allow it.

Anyway going to chalk up the XL350 tank upgrade gamble as a win!

[XLsior]

Resolved the CDI and tank conflict.

Hacked the original frame mounts to make it all fit* paint was a minor casualty.

Could be done a little more professionally but was not keen on removing more paint and frame welding...

It's functional.

So Both tanks can be swapped over without much conflict. Seems to still have a bit of wiggle room. Though it has not been all plugged in yet.

The coil is tucked into the frame more... The wiring does not require major extensions.

Another issue I have discovered is the exhaust pipe and rear tire clearance margin...So that could be another bender in the pipeline conundrum.

[XLsior]

Is a 10amp fuse too much?

[XLsior]

Ok wasn't as bad as I thought. bit of green a red wire basically.

So managed to cut out the bad and splice in some good.

Up-rated and heatshrinked/insulated where applicable.

Smallest mini blade fuse i have is 7.5amp so will try that in a hope to prevent short circuits.