Ravi Piaggio 250cc (Touring Machine)

[Silver_Knife]

Bought this bike on 3-6-2011, after touring and enjoying beauty of Pakistan on this machine for almost 4 years i finally decided to swap engine to bigger displacement as a i tumbled upon a good deal.

My bikes engine was already in a bad condition, as it was consuming oil and didn't go beyond 100km/h most of the times. Nonetheless the engine was still performing well and would have served me good for another 1 years without any major problems.

I seized this opportunity to get a 250cc engine from Lahore via link of @vickytulla. Another reason to opt for engine swap is a bolt on fit. i didnt wanted any changes in frame so it was a good opportunity.

I will start this thread in sequence so that everything is clear and give proper instructions, do and dont's in case someone is willing for a swap.

Final Product after engine swap.

[Silver_Knife]

Received engine with radiator.

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After cleaning gunk and oil

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I started assembly at home, getting instructions from Waqar Ahmed, firstly i needed to change ignition coil so that all the electrical systems, CDI etc will work properly without spending any money on changing CDI etc. so i took out the magnet cover

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Taking self unit out.

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Left one is from 250cc engine and right is from old 125cc engine

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[Silver_Knife]

After changing the ignition coil, its time to take out old engine from chassis. I did it at home alone. its was easy to take engine out. Here is comparison of old engine and new one.

Size is almost same, the only difference is size of fins

[Silver_Knife]

I must say taking engine out was fun. But the real struggle started when i had to put engine back in frame. It was ramadan, so i had to take help from my bro. to put the engine back in frame

[Silver_Knife]

I didnt took any pictures while putting engine back to frame. but it was a bolt on fit. except for a top bolt for which i had to take one "Patri" out so that it fits easily

[Silver_Knife]

The top mount holds engine with the help of two metal sheets. i took 1 out for a proper fit

[Silver_Knife]

Bolt on fit

[Silver_Knife]

Bigger displacement engine requires a bigger carburetor, Ravi piaggio 125 comes with pz-27 carburetor. so i changed it to PZ-30 which is easily available and is normally available at rickshaw spare parts shop

[Silver_Knife]

Cranked the engine and the self was not working so i gave direct current to self but still it was unable to start for unknown reason. So i ad to tow the bike to electrician. He spent 2 hours and finally self was working. but the self unit was all worn out. so i had to purchase new self unit for 800rs, easily available with rickshaw part dealers

[Silver_Knife]

Temperature regulator (Thermostat) was also broken, so had to purchase new one. Again easily available with rickshaw spare parts dealers. It costed 320rs

[Silver_Knife]

Now the engine completely mounted and starting. Had to go to welder. To fit the radiator, and silencer as the silencer bend needs to be trimmed for proper fitting of radiator at front.

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[Silver_Knife]

Here;s a pic of how bend was cut and fixed.

[asad01]

Images not showing after post #4.

[junaidakhtar01]

sikander bro great to see the bike with this 250 machine yar mere pas tamam pics display ni horahin!!!!!!!!