Project XL185/CG250 swap

[XLsior]

Ok the Xl comes with a raised choke cable bracket. But I also figured out that there was a likely a clutch cable retainer as a complete fitting.

So I made the effort to Unfudgeulate and repair the original design function.

My welding ability was tested. However I believe I succeeded

[XLsior]

The Triple tree is assembled and customized.

[paulsstag]

Neat project, keep up the info and photos.

[XLsior]

I saw Jake from JenniesGarage on YT make these little heatshrink funnels for holding lube oil so gravity and a little work might unstick a stuck cable and definitely lube the cables on his Trail 90 project series.

So I am not taking credit for this nifty idea.
I am keeping my original choke and clutch cables and this definitely helped.

Just going to keep topping up the fluid till comes out the bottom. Or work the cable while topping up to flush out the grit and grunge.

[XLsior]

Cleaning up the levers.

Fixing the brake light contacts was a bit finicky.

missing a bolt as you do and no idea why the adjusters are mismatched but just going to wear the imperfections and battle scars with confidence and respect to the bike's past.

[XLsior]

Found time to make another welding repair on a busted headlamp bracket.
I had to break the previous owners attempt weld the bracket on as it was not the same length and bent.

So yeah, I did ok I reckon... then went to town and solidified the inseam weld on both brackets and left the welds as is as homage to my lack of skill.

[XLsior]

So I cut the base off the OE headlight holder and found that it was the same'ish inside diameter than the LED 5500k LED HI/low H4 headlight left overs from my Van.

So I managed to use the original retention bulb holder for the H4 LED.

The indicators are just (flexible LED indicators) from Aliexpress. used a step drill bit and checked for clearances...all good. Much tidier than the original Honda indicators that hang off the levers.

That's it for now, still waiting for some parts.

I could make a attempt on front shocks but its 1 of those apprehensive things I have to get over.

[franque]

Looking great! Did you say that you don't have your license yet?

[XLsior]

That's correct Franque, I have an Australian open class C drivers license. but not a motorcycle license.

The first last time I tried to ride a motorbike I uncoordinated myself and ended up in a stinging nettle thicket. After that I sort of put the idea on the shelf.

Getting a motorcycle class license in Australia is a bit of a faff. no lack of regulations here.

I will likely enroll in a approved riding course in the foreseeable future. almost costs the same as the bike...

[China Rider 27]

Originally Posted by XLsior

I will likely enroll in a approved riding course in the foreseeable future. almost costs the same as the bike...

Hopefully they have some beaters to ride instead of that beauty.

[XLsior]

Yeah I'll be taking advantage of the supplied benders for an additional fee.

[China Rider 27]

It cost $200 where I live, good thing is if you pass the written and the driving test they give you an endorsement and you go to Dept Motor Vehicles and get it added to your license. There were 12 in my course and 11 of 12 dropped the bike at least once!

[Ktmarty]

Well done mate. Keep up the good work.

I’ve got a shed full of CG , CRF And horizontal Honda copies waiting for new homes. Love what you are doing with yours

Ps. I love JenniesGarage. Those two make me laugh. Great inspiration

[XLsior]

Received the Keihin PZ30 with throttle and filter kit in the mail the other day. Pretty happy with it.

But thought it would interesting to make some comparisons to the Mikuni missing the slide that came with the CG250 and the Keihin 27 that came with the Honda 163.

The most notable issue to me was how much of a restrictive dog leg with the inlet adapter the Mikuni came with.

Also with a touch rotary porting managed to open up the inlet adapter that came with the Honda 163.

no real issues with interchangeability the Honda inlet adapter mates up to the CG250 head perfectly and the O'ring seal to the PZ30 is adequate.

Appears that the Honda inlet adapter also has in built heat insulator too. compared to the other adapter's separate plastic spacer.

I have not opened the PZ30 to see what jets it came with.

Still waiting for more parts, can't do much with the build until my new piston and rings turn up.

[China Rider 27]

That looks to be a PZ30b or pumper carb in contrast to the the PZ30. A good carburetor with performance in mind. Wonder if you can get that PZ27 up and running? Would be nice to compare them, alas the Mikuni is not salvageable it appears. Something about getting an old carburetor running again.