Reiss
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Hey,
Apologies for the delayed response. Life has been hectic and I haven’t been able to focus my attention on the bike, but I’m back now.
Here are the details:
Frame is from a 2016 Hyosung GTR125R (Carb) & the rest is from a donor 2007 Hyosung GT250R (EFI). We decided to do a little project and did a full transplant of the 250 into the 125 frame. This includes the tank, loom, CDI, forks, dual rotors, breaks, engine and speedometer. We had to make some slight alterations to the frame to make the 250 airbox fit in the frame, along with the engine. It’s not perfect, but very hard to notice unless you’re looking.
So, all was good. We did the conversion, wired everything up and started her up, she burst into life and sounded delicious. However, what we didn’t realise is that the fuel pump and lines had never once been changed. They were old, solidified and showing their age and this proved to be true when whilst out on a test ride, the fuel line split open and started leaking fuel everywhere. We managed to run the tank waste pipe as a temporary fuel line to get it back to the garage.
The next thing that went wrong was the fuel cap. Unfortunately, the donor didn’t come with a set of keys, as it was already disassembled. So we had a fuel tank that we couldn’t open and we were given the bright idea to try to drill/smash the lockset open. It worked, but at the cost of the seal/inner tank being separated from the shell. We improvised, and used a mixture of petro-putty and improvised metal brackets to hold the seal, a temporary fix. When the fuel tank is full of petrol, it seeps through and spills over the tank, causing the paint to strip.
Next problem, the fuel pump plastic feeder tube running directly to the injectors snapped off. So, we had to dremmel through the top and create a new feeder tube and block the old one. Which has left the bike in a sad state really. It runs and rides, but it has a fueling issue. There isn’t enough pressure being created from the pump, so the bike struggles to accelerate under load.
It needs a new fuel pump, a fuel injection model tank without rust and realistically, it wants all of the fuel lines replacing again with the correct gauge/size fuel line. I’m contemplating doing this at the end of the month and stripping all of the fairings and having it resprayed, but life has been hectic and I’ve had to put my tinkering with bikes on the sidelines. A part of me wants to move away from Hyosung, it has served a brilliant project to tinker with and teach me the fundamentals of messing, but to say I’m sick of the sight of it is an understatement.
I know the 250 engines are difficult to come by, so if someone here is interested in taking over the project then I’m open to the idea. The bike deserves to be in capable hands, as it’s a little beaut.
Open to swaps, or offers. No price in mind really, just not looking to lose too much money here.
Solved: used chemical metal/epoxy to secure the inner plate to the tank! Apply your product, let it cure for 24 hours.
Seems to have done the trick until I can source/afford a new tank
Just in case anyone else runs into this issue.
This is my baby, a lot more to be done, but it’s a start. End of the month, going to be totally changing the colour. Stuck between a glittery emerald green or Ducati Red.
Attached a picture of the carbs for reference. We didn’t tinker with these screws, so if this is where those bungs are supposed to sit, they were already missing.Update: (apologies for formatting, written on mobile)
Just got back from my friends and it’s running much better than before. Acceleration is smoother, it doesn’t sound nearly half as unhappy and she can now idle rather than stalling out.
We opened her up and took out the carbs, gave them a solid clean using plenty of break cleaner, unclogged the jets and that seems to have done the trick.
She had an issue with the air to fuel ratio, and we’ve temporarily remedied it by drilling a small hole in the bottom of the air box to help her breath a little better.
Replaced the plugs with Iridium NGKs, the front block was a fun one to figure out.. 🙃
There doesn’t appear to be any rubber bungs in the carb adjustment screws which leads us to believe that it has been tampered with before, so to have the bike running 100% I’m going to have to get them aadjusted by a professional.
The new battery I fitted a few days ago hasn’t died since charging it, so I believe I misdiagnosed the reg/stator. We ran the battery dry today constantly starting her up during the testing process.
Jumped the bike off another battery and it maintained power after the ride home, so happy days.
So I’m happy, the bike is in a much more rideable state and touch wood, everything seems fine.
The last demon to work out is the fuel level sensor, its currently flashing on empty. I traced a yellow wire from the loom that plugs into the tank and blasted it with break cleaner but that didn’t seem to do the trick unfortunately..
Thank you for all of the advice, it is much appreciated.
Thank you for the swift replies gents.
I’ve got a friend taking a look at the bike on Friday, should be hopefully giving the carburettors a good clean & checking over for any other issues it may have underneath the fairings/airbox. I’ll report back on any findings & if messing with the carbs makes any difference come the evening. I’ll be going through the suggestions above with him.
Honestly Marcel, if coming to Yorkshire means my bike gets looked over by someone who’s familiar with these machines, I’d be more than willing to make the journey as your knowledge is invaluable.
Rj
Post above isn’t great, writing on mobile so apologies in advance.
So the issues I’ve identified so far:
– Can’t start without full choke.
– Can’t idle without throttle held at around 1-2k RPMs when choke is off.
– Battery isn’t charging whilst riding.
– Fuel indicator constantly flashing empty, even when tank is filled.
– Bogging/Sluggish acceleration, doesn’t sound healthy.
– Rubber inlets are worn, small cracks visible but only seems to be surface level. They’re 7 years old, so not surprised.
What I’m considering:
1. Remove carbs & give them a proper clean out & make sure everything is in order.
2. Upgrade the regulator with the one from the shop.
3. Replace rubber inlets with custom-made metal ones.
4. Upgrade stator with shop one. (Will have to purchase this following payday, as money is tight.)
5. Swap out plugs & caps with NGKs as recommended, along with iridium spark plugs.
This forum has a wealth of knowledge and I do appreciate the wizards behind it, but would love some additional support.
Have I missed anything? And how would I remedy a dodgy fuel level read on the dash?
If anyone is based in the Midlands and could give me hand, I’ll be happy to sort you out.
Cheers,
RJ
