Took a plunge... trying a PP LXR250 EFI

[GlennR]

That's great how well the hot water trick worked. If it hadn't I'd have tried to talk you into trying hot deep fryer oil!

[BlackBike]

]

Love, love love when a seller puts the dimensions and good wiring diagrams in their ads!! I wish more would catch onto this!
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[/QUOTE]

Come on CHONDA, the lotto is fun !

[BlackBike]

Originally Posted by ChondaChondaChonda

Cutting and grinding on the frame...oh my!



Because I had messed up my original steel subframe (when I tried to get a rivnut out by pounding it through with a chisel like a gorilla), I decided to go aluminum to shave a few pounds and add some stiffness. This was definitely more $$ than a sane person would spend on a Chinabike, but

New aluminium subframe next to stock steel.

BTW- these are much cheaper brand new from online OEM suppliers than what the bike parter guys on Ebay want. Alot of things are I'm finding out.

I recognised the side stand

You better do something about that

[BlackBike]

Omg, I posted too soon, you went after the side stand too


Too...much...to....handle....

[ChondaChondaChonda]

[ChondaChondaChonda]

Today I was tweaking the mounting position of the header pipe to give me a few mm more clearance on my Rekluse LHRB line at the rear caliper. I ended up pulling the pipe off and this is what I saw in the end:





Definitely not Megadan approved!!

So I fired up the dremel tool:



And Voila!! A new streamlined exhaust exit with no weld or ledge to interfere with efficient exit of hot gases:




Working on a few other things that I will post up when the time comes.

[JerryHawk250]

Mine was no where near that bad but still took the grinder to it. excellent job.

[ChondaChondaChonda]

No loss of rigidity, just a little weight.

[Megadan]

Megadan approves of the exhuast pipe now.

That seems to be a common thing with factory china bike headers. The Hawks and Bashans suffer from huge inner welds too. Next bike I get that is one of the first things I check.

[ChondaChondaChonda]

Originally Posted by Megadan

Megadan approves of the exhuast pipe now.

That seems to be a common thing with factory china bike headers. The Hawks and Bashans suffer from huge inner welds too. Next bike I get that is one of the first things I check.

It's not just china bikes; I've seen the same or worse in crf's and TTr's. Never checked a KTM cause most of mine were 2-strokes except the 690.

[Megadan]

Originally Posted by ChondaChondaChonda

It's not just china bikes; I've seen the same or worse in crf's and TTr's. Never checked a KTM cause most of mine were 2-strokes except the 690.

I have never seen it on any of the road bikes I have owned. Must be a dirt bike thing.

[Weldangrind]

I figured it would have to be polished to receive Megadan approval. Perhaps you received conditional approval.

[ChondaChondaChonda]

Decided to plunge on and remove the kick-start gears as I long ago jettisoned the kick lever.

Pulled the side cover:





Going after that stuff in the upper left corner!

[ChondaChondaChonda]

Spring comes off ok, but the gears won't clear without pulling the clutch basket:



Luckily, the clutch basket is very easy to pull on these motors. The big nut is 27mm and after it was off the whole assembly slides right up. No puller needed.




Pull the gear and shaft out:


Then remove the circlip on the intermediate gear and it slides right off.





The hole left where the kicker shaft used to be needed to be plugged so I found a piece of 6061 just bigger than the 18mm hole and spun out a little plug.


A bit of a press fit in, still I put red thread locker on it for insurance.




The parts removed weighed about 1.5 lbs, not including the kicker. So it's probably a 2lbs lighter.

[Megadan]

I will give you props for the level of work being done here. Good stuff.
On the flip side, and this is just personal preference, but I always preferred to keep my kick starters right here they were. It's nice to have a backup.

I guess you can always bump start it though. Easy to do with light bikes.