Storm 150 engine swap

Mumen Rider · 08-29-2024, 01:21 AM

The ZS190 is a bolt on affair, you will need a new clutch cable, fuel lines, oil cooler and lines, some electrical connectors and that's about it. You will want to remove the cat inside of the muffler for better exhaust flow which involves drilling out the rivets, drilling out some spot welds and then removing the catalytic cartridge. I just need to fit the rear brake lever back on before I get the jetting dialed in if it's not already on point from several people I have talked to. After that I will throw on the body work.

Mumen Rider · 08-29-2024, 09:29 PM

The swap is complete now. The carb is a NIBBI PE26, MJ 120, PJ 40, needle position #1, Float height 19mm, air screw 1 1/2 turns out. The air filter is a Nibbi I believe, I had it laying around. It's jetted for sea level, hot and humid environment. You'll want to hot lock your exhaust nuts, they will back out if you don't.

Dusman · 08-30-2024, 01:36 PM

Nice work MumenRider! That's gonna be a ripper! I'm thinking about doing the same with my DLX sometime in the next year. Have you been able to source a skid plate yet for the ZS190? Maybe something like this would fit?
https://www.steadygarage.com/product...num-skid-plate

Mumen Rider · 08-30-2024, 09:36 PM

Yes, that skid plate would fit. The skid plate mounts to the engine at those four locations. I recommend you get the thicker starter chain from Steady Garage and the billet clutch pressure plate, I am running both. My OEM clutch plate snapped with higher pressure Honda clutch springs and the OEM starter chain is not as thick as the SG piece.

This is by far the quickest China bike I own now, it's a little rocket. I've had it up to 75mph indicated on the speedometer which is probably at least 71mph GPS, I let off because it's just crazy stupid fast on such a small bike with knobby tires.

Clutch cable to use: 38.98" 99cm Clutch Cable with Adjuster for Apollo 125 50cc Chinese 70cc 90cc 110cc KLX XR CRF SSR 125cc SDG Coolster Baja Thumpstar Chinese Dirt Pit Bike Black
https://www.amazon.com/dp/B09N7GG6BG

The oil cooler inlet and outlet are M10x1.25. You are better getting fittings and making your own line cut to size, the pre-made stuff(Amazon, eBay, etc) is going to be too long.

https://www.amazon.com/gp/product/B07WWL45V1
This oil cooler mounts to the frame at the factory locations, no modification needed. Just make sure you mount it low on the bracket or else it will rub on the gas tank.

08-29-2024, 09:29 PM	#2
Mumen Rider Join Date: May 2024 Location: Florida Posts: 108	The swap is complete now. The carb is a NIBBI PE26, MJ 120, PJ 40, needle position #1, Float height 19mm, air screw 1 1/2 turns out. The air filter is a Nibbi I believe, I had it laying around. It's jetted for sea level, hot and humid environment. You'll want to hot lock your exhaust nuts, they will back out if you don't. Last edited by Mumen Rider; 08-30-2024 at 12:47 AM.
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08-30-2024, 01:36 PM	#3
Dusman Join Date: Jan 2018 Location: NC Posts: 236	Nice work MumenRider! That's gonna be a ripper! I'm thinking about doing the same with my DLX sometime in the next year. Have you been able to source a skid plate yet for the ZS190? Maybe something like this would fit? https://www.steadygarage.com/product...num-skid-plate Last edited by Dusman; 08-30-2024 at 03:19 PM.
	0

08-29-2024, 01:21 AM	#1
Mumen Rider Join Date: May 2024 Location: Florida Posts: 108	Storm 150 engine swap The ZS190 is a bolt on affair, you will need a new clutch cable, fuel lines, oil cooler and lines, some electrical connectors and that's about it. You will want to remove the cat inside of the muffler for better exhaust flow which involves drilling out the rivets, drilling out some spot welds and then removing the catalytic cartridge. I just need to fit the rear brake lever back on before I get the jetting dialed in if it's not already on point from several people I have talked to. After that I will throw on the body work.
	2

08-30-2024, 09:36 PM	#4
Mumen Rider Join Date: May 2024 Location: Florida Posts: 108	Yes, that skid plate would fit. The skid plate mounts to the engine at those four locations. I recommend you get the thicker starter chain from Steady Garage and the billet clutch pressure plate, I am running both. My OEM clutch plate snapped with higher pressure Honda clutch springs and the OEM starter chain is not as thick as the SG piece. This is by far the quickest China bike I own now, it's a little rocket. I've had it up to 75mph indicated on the speedometer which is probably at least 71mph GPS, I let off because it's just crazy stupid fast on such a small bike with knobby tires. Clutch cable to use: 38.98" 99cm Clutch Cable with Adjuster for Apollo 125 50cc Chinese 70cc 90cc 110cc KLX XR CRF SSR 125cc SDG Coolster Baja Thumpstar Chinese Dirt Pit Bike Black https://www.amazon.com/dp/B09N7GG6BG The oil cooler inlet and outlet are M10x1.25. You are better getting fittings and making your own line cut to size, the pre-made stuff(Amazon, eBay, etc) is going to be too long. https://www.amazon.com/gp/product/B07WWL45V1 This oil cooler mounts to the frame at the factory locations, no modification needed. Just make sure you mount it low on the bracket or else it will rub on the gas tank.
	1