Project XL185/CG250 swap

[XLsior]

I appear to be unwittingly collecting throttle cables.

The 2 silver jobbies came with the throttles. both too long.

The factory original in black connected to the PZ27 has the wrong length cable throw.

The Red cable was ordered to fix the issue but i failed to read the product info and received the 960mm total length including the 120mm throw.

I thought it was 960mm+120mm...

Ugh well I'll get it right eventually. Think I'll stick to factory black this time.

[Megadan]

Originally Posted by XLsior

I appear to be unwittingly collecting throttle cables.

The 2 silver jobbies came with the throttles. both too long.

The factory original in black connected to the PZ27 has the wrong length cable throw.

The Red cable was ordered to fix the issue but i failed to read the product info and received the 960mm total length including the 120mm throw.

I thought it was 960mm+120mm...

Ugh well I'll get it right eventually. Think I'll stick to factory black this time.

Maybe we can swap some cables and see how it turns out as I have quite the collection too lol.

If you have a cable with too much free length you could always cut the barrel off, shorten it as needed, and solder a new one in place.

[XLsior]

So since switching to 12v and not really attached to the baboons backside Honda factory tail/brake lights and reg plate holder. I opted to go custom.

This is prototype (1) proof of concept though I think the 2mm thick aluminum sheet sill be adequate.

So take this as a functioning first iteration.

I found this LED reflector that suited dimensions...I also got a round circle type but decided not to use it.

This is just the top half reflector bracket. the bottom license plate holder will be separate and sandwich the rear fender.

Photos shows the basic steps. with the addition of some cut foam.. I think it might be from a yoga mat.

The bare wires will be sleeved final install.

[XLsior]

Sorry about the blurry photo but it was taken up against a wall blind and i couldn't be bothered taking a better snap.

[XLsior]

OK, so it didn't take long before I felt I could do better on the bracket.

Made some adjustments and tweaks to a better fit and finish.

I don't have a profession metal folder so the creases weren't as sharp as they could be but for hand made charm, think it's a pass.

Definitely less of a scrap metal aesthetic.

[Megadan]

That is some good quality hand fabrication in my eyes. Be proud of it.

[China Rider 27]

That is a fine piece of work! I would try to round those corners at the top right and left to look more like the fender corners.

[XLsior]

Those corners shouldn't be there its just the result of a poor bend, I tried to take the edge off but just seems to make it worse, though I understand your thinking. And might try a touch of the file.

[XLsior]

The second piece of the tail tidy and function mk1 has been fabricated.

Took the same cues from the top piece and kept the curves.

Just had to go off plate dimensions, the bike has not passed an inspection or roadworthy yet to have actual plates.

Chicken/egg.

So there is an LED brake and indicator strip.
2 LED plate illumination fixing bolts.
Red LED tail light for added road safety and any issue if the LED strip does not pass road legal specifications.

Still got to make the rear guard/battery holder then its onto wiring up literal loose ends.

[XLsior]

Took the edge of the corners.

Also here the round LED reflector version for comparison if anyone is interested.

Same single center threaded bolt fixing with 3 wire running/brake internal LED.

[XLsior]

So the 'universal' type clamps on 22mm 7/8 bars are absolute trash.

Even after some time and modification effort they were still unsatisfactory.

Purchased 22mm 7/8 specific clamps that also came with a spare set of bar end mounts too.

What can I say but its an absolute night and day difference.
These clamps have a far better design and clamp force with enough bite for the threads and clearance so I didn't have to cut bolts. They don't budge and i feel are less snaggy and safer to use.

the offset mount also make installing far easier and might provide better positioning.


So If you are planning to get Chinese Bark buster hand guards I recommend avoiding the universal crab claw type.

[XLsior]

The new CG250 wiring loom kit came with some interesting yet conflicting arrangements.

Most of the ignition wires made sense and connected accordingly.

But the lighting/indicators/horn switch gear and the loom connections don't appear to correspond with their out of the kit counterparts. The kit did not come with a diagram and I am wondering if there is meant to be a missing link.

Somewhere in between there should be indicator relays.

But I am just wondering if the users of China bikes have the same sort of mish-mash wiring mismatching conundrums. The plugs fit but the colouring appears to be all wrong.

[XLsior]

I am coming to the conclusion that the dash/cluster is the missing element to my wiring plug miss match.

[banfield]

hi has any one got a zongshen lzx200gy-2 fuel tank need to find one

[XLsior]

Um banfield...i think you might want to post this inquiry in a separate dedicated thread. I don't have a spare tank. I don't think there that many Aussies on this forum either.