Dong Fang DF 250 RTB Bobber Information

[Babyswiss]

GonzoX:

My shift linkage broke in the exact same spot. I was able to cut off the threaded end and carefully drill into the beefy part of the rod, tap that and bought some threaded rod to thread into the tapped section. My drilling was slightly off and you could see the shape of the threads on the outside of the rod so I JBWelded three nuts on the outside to "beef up" the rod. 700 miles later and I've had no issues. I actually think it is stronger now than the original.CIMG4519.jpg

[mrepooh]

One thing I've noticed about our tanks is that you get a false sense of torque, this is due to all the wire harnesses that are running under the tank. I recently had an issue with my ignition switch, when ever I hit a bump my engine would completely shut off. I took my tank off to chase wires to find that the female/make connector was shattered, after I repaired the connectors, I mounted the tank. After a few turns my gut was telling me that I might screw something up (6th sense from years of messing up H-60 helicopters), I back off the nuts, nabbed me some loctite, some lock nuts (the type with plastic threads), and torque to show a minimum of 3 threads... I really want to avoid getting doused with fuel, I've done that enough times with JP-5 :]

[DanDaMan]

I made a new replacement shifter rod , went to lowes hardware in the isle behind where they make the keys is welding equiptment , including stainless steel solid rod 4ft for 8 bucks

cut to length , took original rod and cut threads off , then welded those threaded ends back onto the new rod

anyone that has any exp at all with welding could knock it out for ya in about 10 minutes

[GonzoX]

Thanks Dan. Only problem is that the threaded end on mine is what actually broke. Still waiting for a return call from Killermotorsports and it's almost noone the day after. Starting to wonder if anybody out there that sells these bikes actually wants to support them.

[rollenrock]

Gonzo, you should be able to find a bolt that is similar in size and threads. Cut the head off and weld it to the rod. Either that or just thread the new rod. Simple metal work with a die set.

[DanDaMan]

my 1st try I burned thru my threading and lost about 1/2 of it , most of the threading is still showing in your picture , if can get to austin we can get u fixed up in a jiffy , or maybe mail it to me ? ill fix n mail back

but best bet get about 20 bucks together call a few shops in your area to find a welder and take what u have in to them simple cut/cut/weld , you be back on the road



shoot worst comes to worst , could just take mine off for thread sizing , go buy bolts and rod and make "new ones" and just mail em to members needing/wanting them


ps - a temp fix could be a long nut (lowes) screwed onto whats left of the rod threads , cut the bent bit off the threads and screw it into the other end of the long nut (it would look nearly identical to babyswiss picture top of page , but only 1 long nut instead of using 3 nuts)

[GonzoX]

Thanks Dan,

I only have about 1/8 inch threading left and it is visibly damaged (bent) as well on the forward side of the rod. Took it to a machine shop today and they will asses if they can or even want to make a replacement. I feel better about them doing it and having one made of better metal. In the mean time, I am supposed to have one sent to me from Killermotorsports since my bike is still under warranty.

I work nights and am getting ready for my second marriage in a week and a half so I wont have time to mess with it. Would rather pay to have one built as I want to always carry a spare if this happens again with the replacement part from China.

[ghost1133]

I work nights and am getting ready for my second marriage in a week and a half so I wont have time to mess with it. .

"YIKES" Did not learn the first time. Just kidding...

Congrats . Best.

[GonzoX]

GonzoX:

My shift linkage broke in the exact same spot. I was able to cut off the threaded end and carefully drill into the beefy part of the rod, tap that and bought some threaded rod to thread into the tapped section. My drilling was slightly off and you could see the shape of the threads on the outside of the rod so I JBWelded three nuts on the outside to "beef up" the rod. 700 miles later and I've had no issues. I actually think it is stronger now than the original.CIMG4519.jpg

Found a local machine shop and they did exactly what you did. Only cost me $10. He could only drill up to about 5/16" deep into the rod though and like yours it is slightly off a bit. Hope that will be enough. Hope to pick my bike up from my brothers place by Friday. If it lasts me 700 miles then that would be great. I will have a spare way before then. Thanks for the help guys.

[A_Pilot]

Hello all;
i have had my DF Bobber about 3 months, like the slow ride easy & light turning or the bike. I cannot for the life of me figure out why after throttle around 60MPH and fully warmed up the bike sputters then stalls i have to pull off the road. i am guessing either vapor lock, or because of gravity fed gasoline and too much shaking?? i am lost on that subject. ANY ADVISE? also very steep hills in 3rd gear (40mph) she will stall as well..
attempted: higher idle to keep gasoline "chugging", less restricting air filter,slower deceleration. i am out of ideas.
2nd my shift rod Broke in the SAME location! must be a weakness in manufacturing. called in 2+ months ago for my replacment shifter rod(still not here) luckily i have metal working connections, just be carefull the threads are REVERSED towards the acutal trans, (for safety)
the running light is a little dull but riding with one light on BRight is good enough...
i do love the bike just wish i could ride it on local 55 MHP highways with out stalling.