Project XL185/CG250 swap

[XLsior]

All coming together now...

Still plenty of nipping and tucking to go. Wiring up and circuitry etc.

Needs a set of new front drum shoes, thought I could get away with reuse the oldies but not clamping down completely at full adjustment.

Wish I could say it started and run...but no. The spark plug terminal end did not clamp on the plug so I suspect intermittent spark. I did see spark. thumb over the hole gave strong compression check and the fuel was confirmed entering the carby. new NGK Plug. could smell gas...Chinese spark plug terminal didn't like me trying to fix it either. going to replace

Anyway I tried to sort it out but the battery eventually went flat so its on the charger for now.

I have ordered a better quality spark plug boot and terminals.

Nice to have the living room floor back.

[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]

Thought i'd try to start the bike with a new coil and plug end.

Ignition wire appears to have had a short and bypassed the key switch.

puff of smoke cooked wires, not sure how localized the short traveled but seems the china wiring harness has some quality issues...

Probably just going to replace it it again...sigh.

[XLsior]

I took a punt and found an XL350 tank.

its from an 84/85 enduro model XL350R if wiki has any merit.

Why bother you might ask well, the original tank was in somewhat rough shape even with all the effort to spit shine it. Also there's fuel capacity and mpg/kmpl

xl185 1.85 Gallon (7.00 Liters) xl350 2.91 Gallon (11.00 Liters)

A potential 1 gal upgrade if the tank fits...

So I decided to tank a chance...

Does it fit...mostly yes but in some areas no.

[XLsior]

So there are some issues.

1. petcock clearance...solution shave some fins.
2. rocker cover bolt contact...tap tap with the hammer.
3 angle of seat mount...cut and bend tab to correct angle. (this is the biggest issue, adjusting this throws out all the other tolerances)
4 frame clearance tank arch ...relocate tank mounts slightly higher so tank drop closer to frame, not a requirement but a possible option. Possible location for coil and CDI.
5 Steering full lock possible contact, This is a hair of space between the tank and the shock clamp bolt head...Solution change to an allen head bolt.

Is this all worth 1gal? hard to say. but form a 50-60 expected mpg from a cg250 that equates to an extended 100km range in metric land.

The tank itself was in decent shape for its age. Price was ok shipping hurt.
unfortunately the fill cap is not the same.

[XLsior]

And finally will it still look ok after all that work is done?

An xl250 tank might of fit better but the capacity wasn't a massive increase.

I think it could be an interesting side project for a distance tank option.

Can't imagine the tank getting a better candidate.

[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]

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