Project XL185/CG250 swap

[Megadan]

Originally Posted by XLsior

But I am also looking into finding the CT110/postie candidate for a possible ZS190cc swap...

That is one of my desired projects if I can ever find a good candidate for the right price.

[franque]

I'm glad about how it turned out, and for what it's worth, I'm proud of your accomplishment!

As for the 190 to Postie swap, you'll have to drill the frame to mount it, and the 190 is a bit more race-oriented, that is to say, not normally long-term reliable and a bit peaky for the street. I'd save some money and get a YX140 if it were me, they're cheaper, more reliable than the 190, and still a significant bump up from the 110. You'd still have to drill the frame or make a mount, but it would be more streetable.

[XLsior]

Ebay Australia does have the YX140 as an option also the the Lifan W150. Similarly priced. Ebay 125cc are even cheaper.

the 190cc is available and yes it more expensive and has some known issues like the dry e'start chain...
But it also has 5 gears.

[XLsior]

Checked the plug after my license course and Saturday morning jaunt.

Looked a little lean and the engine was pumping out some heat when coming to a stop if I recall. I could never get it pinned enough in the back yard to test WOT.

anyway checked the main in the nibbi PE28 and I had installed a 120.

Next size up option i had was a 125main, so installed that and went for a Sunday morning loop where there is a 100kmph marked flat strait for a good 200m or more (Metric only no freedom units)

I could not get up to 100kph even fully tucked but close, might of touched it just... but not sustained. 16t/45 sprockets.

Got home and let the bike cool down a bit before checking the plug again...a bit more nutmeg definitely not rich.

Looks pretty good to me not sure if bumping up to a 130 would improve much.

no issue with throttle response. engine felt a little cooler... for what its worth.

Needle still set on middle clip.

[XLsior]

The AN6 banjo fitting arrived today so decided to attack the oil cooler again.

If I was going to be making oil spills I also reinstalled the 4* timing advance key...Which went fine.

As for the AN6 banjo I can report the it does work with the braided hose that came with my 85ml oil cooler kit...so would probably work on the 65ml and 125ml kits too...

The banjo fitting will only replace the fittings that go into the radiator/cooler...not smaller diameter banjo fittings that go into the sump adapter.

I opted to shorten the super long length and leave the screen housing section alone.

but you could technically shorten both radiator input/output.

I don't have braided hose/toe cutters, but a wrap of masking tape and a cutoff wheel will work for a clean cut...

I exposed about 1/2" of hose at the end.
then you will need to seat the hose inside the coupling before threading in the banjo section...and bish, bash, bosh you got a oil cooler line to length.

you can push any loose braid wires into the fitting with a flat screwdriver if they poke out before locking down the fitting...

Pushed oil through the assembly with provided syringe till air bubbles stopped coming out and installed hopefully fully primed oil cooler...

Ran the bike up to temp and confirmed no leaks with signs of heat circulation to touch...

Also that sump adapter was a pain..it felt like it was cross threaded the whole time (it wasn't) and fought me most of the way. It's in fully seated and I have no intention of trying to remove it ever....

Jobs done.

[Megadan]

Nutmeg brown is exactly what you want. Your top speed is likely being limited by gearing. You likely need a smaller rear or larger front sprocket, or both, if you are looking to get more speed put of it.

[XLsior]

100kph/62mph is the max non highway marked speeds for Australian back roads...so getting there with some level of ease is the threshold.

I have a 17t front on the way...but will consider a smaller rear sprocket next new chain.

[XLsior]

In hindsight, it might be possible to wrap the masking tape tight enough that when cut the end will manage to fit in the coupling without cutting back the braided section, then when done up remove excess masking tape...

This will leave a cleaner look but might be more difficult to achieve.

[XLsior]

Xl350 tank has been internally sealed so the external appearance is next.

Chapter 3: Bonding with Bondo.

Funds are a little tight for rust converter and etch primer, then finishing coats...

But I have sand paper and bondo...So that's whats happening for now. Finding dents and filling them where applicable.

[XLsior]

Went for Sunday morning figure8 around my area.

Oil cooler was doing its job with no leaks...

Topped up with 98ron fuel (normally run 95ron) but the bike seemed to like it.

Got home and decided to do a quick mod to the tool tube to prevent the cap falling off and any curious hands an impediment long enough to prevent theft.

I just used a small drill and spit pin. If you get the angle right the hole should go through the screw cap and the case lip without going into the storage space.

[XLsior]

I purchased a phone mount from aliexpress...

Looked at most of the holders under $15 shipped to Australia.

Avoided any spring, rubber or adhesive phone holders...

So hard clamps...

I found this type which come in both bar clamp and mirror mount options..

If they went to the trouble of putting measurements and a picture of a motorcycle on the product I perceived that as a sign of slightly better quality then most generics...

The knurled thumb screw also showed bit more quality aspects...

Anyway its ok... It holds my old samsung mini which is a small but thick phone which I just use for GPS speed

And my MiA1 which I would consider to be a more standard sized smart phone.

at the back there is 2 axis fixtures 1 is tilt and is screw done up tight after adjusting.
the other is twist which is spring loaded and allows portrait and landscape phone orientation on the fly adjustment, I am not sure how long this will last as I think its the weakest point in the product and will probably be the first area of fatigue...

I used the mirror mount that is part of the honda XL brake lever Which is just a 10mm metric thread...

How well it would work on the actual mirror stem I don't know...

For how much it cost I'm ok with it...

But I purchases some silicone rubber phone holders separately as additional security fix downs.

[XLsior]

Got most of the dents rough sanded out now.

But before I start prepping for top coats, I wanted to get the underside sorted out.

I decided to go for bed liner in a can...I used this Duplicolor brand on my van wheel rims and was pretty happy with the result.

I did find some rust on the previous undercoat the last user applied so had to sand it back enough for a coat of rust converter...

then masked off the edges and threaded boss. a coat of some etch primer...

then the bed liner....

Not only should it be more than durable enough, my hope is the bed liner will dull out some of the vibration resonance at certain rev ranges where the tank sometimes 'buzzes'

Any way that's all curing now for a good couple of days..

[XLsior]

While the tank is curing...

attacking the rear rack that came with the bike...rusty and crusty but solid.

While that's all happening I also found a 3d print file for a go pro mount on my mx9 adventure helmet/

https://www.thingiverse.com/thing:4783627

So printed it out with tough resin and am really happy with the result. no Glue just clips on and holds tight...actually hard to unclip it.

dusted off my barely used GoPro Hero 3+

[XLsior]

Ebay; goat skin leather riding gloves. My cheaper gloves are already falling apart.

Aliexpress; Tire pump with inbuilt pressure gauge. 1 tire lever and 3 smaller tire 'levers' holder spoons.

Also a set of CG cam rollers...which included a new cam and center shaft.

I won't be installing the the cam but the rollers and shaft will be going into the CG300 cylinder at some point.

[XLsior]

Checking tank clearances again to make for sure nothing makes contact when installed or at full steering lock to lock before final top coat prep and paint.

Everything seems to be be fine with enough tolerance/wiggle room.

Also found 1 of my first attempts at welding had failed...no surprise. 1 of the small cross brace bars the hold the side panels failed under vibration.

I am waiting for generic side racks to modify with my rear rack into a budget adventure style rack...which will likely require some mounting points welded to the frame.

So I'll repair the cross brace then.