Clearance issues???

[Jmoozy27]

While assembling my latest build I have hit a fork in the road. A part of the frame that was initially a motor mount and support is in the way of my proposed carb intake.


My first thought was cut it out. No big deal. But now I'm second guessing.


So my question is to cut or not to cut???

[muthey]

you could cut and reshape, or you could try a different style intake for it that will allow your carb to clear or come straight out the side.

[3WW Star-John_Neary]

did you plan on running a airboot to a airbox or just a K&N or foam filter directly attached to the carb?

[onformula1]

Cut it out, move it up or down is you can.

I would cut it out and fab a new round bar out of thick walled tubing or round bar and gusset that area.

I think the diagram picture I send you said to remove that? (That picture is on my other computer so I can't check right now)

[El Camexican]

If you do cut it out I would weld in the new tube before cutting out the old one if possible. Less chance of the frame distorting.

[Jmoozy27]

I would like to keep it but it is very strategically placed from the factory. I planned on running the stock 86 200x air box because I have everything. The support was already causing clearance issues with the exhaust so I had considered removing it along time ago. By moving the support lower it would free up the exhaust but would hinder the carb placement ever more. Moving it higher frees up the carb but makes the exhaust basically impossible.

[onformula1]

How about something like this?

********__________
_______/

Well, my drawing works, until I hit the enter button??? (Ignore the "*")

How about a bar across bent 45 degrees then across?

[3WW Star-John_Neary]

could you lower the front of the engine to get the carb aimed upward so the intake boot clears the frame brace?

[DohcBikes]

Engine swap? Maybe a 200x engine would fit.

[86125m]

What about a pod filter with a 90 degree angle. I think their is just enough clearance for it. However here in south Louisiana you really do need an air box. But it is a thought

[DohcBikes]

Your pipe needs at least 1/4" of clearance everywhere or it and your frame are going to be a noisy corroded nightmare.

Isn't this essentially an excersize in seeing how fast you can make this engine move with this configuration? If that is the case then stop worrying about the airbox.

You need to cut the whole brace out, do what you need to do with the pipe and intake, then find a way to reintroduce the majority of the strength you removed. Simply notching or zigzagging the brace is going to look ghetto, not factory like you want it to.

Frame distortion is not a concern in that area while the frame is idle. Furthermore, if the frame pops apart or squeezes together when cut from being loaded up by that brace, then relieving the stress and contained energy was a good thing.

Ready to blast and paint that frame again? Suggest you mock up the entire bike before this round

[Jmoozy27]

Problem solved. I feel that removing that brace won't effect the integrity of the frame very much. The 200x motor did not mount through the swinger like this one will. I feel like that will make the difference. Thanks for everyone's participation.

[DohcBikes]

You need to replace the brace at some point when everything is in place the way you want it.

The square 200x frames are prone to breakage, regardless of what the biased 2nd gen owners say. Even you DC

With all that monster power you'll be throwing down you can't just cut it out and leave it out. Dat's whack, man.

J- Rarely (never) does a true custom that is built correctly only need the engine mocked up once. If you want a good finished product you will need to go through the entire process as it requires, regardless of the want to save labor or time.

It looks like the carb top and throttle linkage may be a clearance issue as well?

[Jmoozy27]

I've been looking at frames all night. 1st and 3rd gen 250r don't have that brace. Neither do the cr125 frame that the motor came out of. I think it's fine.

[Ol Deuce]

The hose trick always works