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Author Topic: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade  (Read 3477 times)

Offline cxman

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  • Posts: 2289
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #10 on: Nov 23, 2016, 22:21:55 »
well 10 mm slid thru on mine

and the carb that came with mine was not like yours

i also dont have the decal near the dipstick
1978 CX650 Super Deluxe
1979 XS1100 Special
1980 XS650
1980 cx500  The Beast
1983 GL650 i
1983 cx650 Custom
1973 CB450
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1977  gl1000
1976 gl1000 LTD
 1983 GL1100 Nekid
and a bunch of others

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #11 on: Nov 24, 2016, 00:05:18 »
As I recall, that decal has the "run in" instructions. Pretty basic and in poor English. Basically says only 35mph or less for first 160 miles, then change oil. I'll get a photo of it later.


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Offline cxman

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  • Posts: 2289
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #12 on: Nov 24, 2016, 07:19:51 »
i ran mine for 1 hr nice and easy then changed oil

since then it has run about another 3 hrs and has hit 70 mph a few times lol
1978 CX650 Super Deluxe
1979 XS1100 Special
1980 XS650
1980 cx500  The Beast
1983 GL650 i
1983 cx650 Custom
1973 CB450
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1977  gl1000
1976 gl1000 LTD
 1983 GL1100 Nekid
and a bunch of others

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #13 on: Dec 01, 2016, 12:34:11 »
Here's that "break-in" sticker. Pretty amusing.


The original exhaust, unfortunately, no longer fits. The Lifan engine's side cover includes a sight glass where the original does not.



As a result, the header contacts the engine there and prevents the header flange from sitting flatly on the exhaust port face. Oh well.

Being forced into fabbing a new header may be a good thing, anyway. Referencing a CB350 header and SR185 header in my shop, both measure 1.5" OD and at least 1.38" ID. The original SL100 header measures 1.25" OD and about 1.1" ID. If a 160cc and 185cc cylinder both use exhausts above 1 3/8" ID, a 200cc will need similar.

All this means I can justify the price of a new die set for my tube bender, ha ha.

In the mean time, I was able to "reconfigure" in order to test start the new powerplant.


Got things hooked up for the first start, then realized the battery I was going to use was almost dead. So I threw it on the charger.

In the meanwhile, I had received some goods to refresh the wheels and brakes.


Up went the front end, and I will get the wagon wheel ready for the wet, muddy, jungle-like tracts of eastern Portland that are in fact, public roads. :)

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #14 on: Dec 01, 2016, 21:02:20 »
1. Pull off wheel.


2. Remove tire, tube, rim strip.


3.Examine rust.


4. Remove rust.


5. Do a lot of cleaning, polishing, and other stuff I forgot to photograph.



6. Install fresh brake shoes and reassemble. I used EBC 303G grooved shoes.


Next, first start of new engine.

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #15 on: Dec 02, 2016, 00:07:02 »
On to the first start!

Below you will find the wiring diagram I found most useful.


This is the pin-out of the CDI unit provided.


These were useful in large part because there were two defects in the supplied wiring harness. Thanks goes to cxman for warning me of this.

One was the apparently common mis-pinned four-pin CDI connector. The ground needed to be moved to the originally empty location. The winning arrangement is shown below.


The second defect was at the stator connector. See if you can spot it.


A quick re-pin corrected the misplaced exciter coil wire. After that, I started getting spark.

Ready to run.


Jerry-rigged electrics.


I put a little go-juice in the tank and fired it up! A little video is linked below.



Seems to work well. Only start hiccup was a leaking petcock strainer bowl, which turned out to be due to a missing backup washer for the o-ring.

Next up, I will fab the new battery and electrics holder and start work on the exhaust fab. Other tasks include refreshing the rear wheel, new chain and rear sprocket, massaging the Chinese wiring harness, and converting the lighting to 12v. Stay tuned!
« Last Edit: Dec 02, 2016, 00:33:27 by Forklift »

Offline cxman

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  • Posts: 2289
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #16 on: Dec 02, 2016, 08:32:55 »
just an update

i re used the 14 tooth front sprocket from the cb100 and its to tall for the lifan gear spread and ratios /power band

i have a 13 tooth and 12 on its way

the motor lugs in 5th

and will only do 75 in 4th now that i have it jetted right
1978 CX650 Super Deluxe
1979 XS1100 Special
1980 XS650
1980 cx500  The Beast
1983 GL650 i
1983 cx650 Custom
1973 CB450
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1977  gl1000
1976 gl1000 LTD
 1983 GL1100 Nekid
and a bunch of others

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #17 on: Dec 02, 2016, 11:47:58 »
Interesting. I just planned on using the front sprocket included with the Lifan. We'll see how things go when I get there.


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Offline cxman

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  • Posts: 2289
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #18 on: Dec 02, 2016, 12:19:27 »
mine did not com ewith one or t got lost how many teeth does it have?

from the pics i see its a 14 tooth as well so may be on no help to me
1978 CX650 Super Deluxe
1979 XS1100 Special
1980 XS650
1980 cx500  The Beast
1983 GL650 i
1983 cx650 Custom
1973 CB450
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1977  gl1000
1976 gl1000 LTD
 1983 GL1100 Nekid
and a bunch of others

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #19 on: Dec 10, 2016, 19:02:54 »
Apparently, it's a 15 tooth.