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Author Topic: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade  (Read 4162 times)

Offline cxman

  • DTT SUPPORTER
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  • Posts: 2337
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #20 on: Dec 10, 2016, 20:59:26 »
You may be good with that i was wrong and the onevon my bike
Was a 17 toot
I now have a 15 and 14
1978 CX650 Super Deluxe
1979 XS1100 Special
1974 xl350
1983 cx650 Custom
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1974 kawasaki 350 bighorn
1983 GL1100 aspy full dress
1983 GL1100 Nekid
and a bunch of others

Offline Boat builder

  • Posts: 4
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #21 on: Dec 13, 2016, 02:57:53 »
What Jetting did you put in it? I just put on in my 1978 Honda Xl125, I still have to build an exhaust and finish making a new wiring harness for mine.

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #22 on: Dec 13, 2016, 15:52:24 »
I'm just using the jetting that came in the included carb for now. Don't know what that is. Once it's rideable, I'll report on the jetting. Seems okay at the moment. As you can see in the video, it starts easily ands revs freely, but that can change with a load on it.

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #23 on: Dec 23, 2016, 16:27:32 »
Battery/electrics box fabrication has begun.







The box will be positioned to clear the new air filter, which is a 42mm foam eBay item.

I also ordered a new Chinese clutch cable to fit the engine. It's the same overall length of the original cable, but has a longer unsheathed length.

Original cable:


New cable:


Seems to work well.



While replacing the tail light with a 12v 1157 bulb, I noticed the last time the bike was tagged was a month before my wife was born, ha ha.

Next, I'll fab brackets to hang the battery box and weld the assembly together. After that, I'll replace the rear sprocket, rear tire and rear brake shoes.

At that point, a little jerry-rigging should make a test-ride possible.
« Last Edit: Dec 23, 2016, 17:09:13 by Forklift »

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #24 on: Dec 29, 2016, 23:48:56 »
Battery box fab continues.





I've used two bolts tacked to the bottom to mount the regulator/rectifier.




Brackets were made for the CDI and starter solenoid.





I marked the positions of the brackets in place, then tacked them on.




I just need to mark and drill the rear mounting points for the box. Unfortunately, my hobo freight step drill broke. So until I get a new one or maybe splurge on a real Unibit, I started on the rear wheel tasks.






A quick test fit of the new sprocket confirms it is correct. The bore of the new sprocket is a bit tight, however. I suspect it's due to the thick, black powder coat. I'll sand that down for a smoother fit to allow for side play from the chain.




With the old tire off, I find the usual surface rust on the rim. These old chromed-steel rims are so beefy, though, I'm never very concerned.



That's all for now. After cleanup, the rear will get a new sprocket, new shoes, and a fresh tire.


Offline Alex jb

  • Posts: 264
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #25 on: Dec 30, 2016, 06:32:34 »
Nice fab work.



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Offline cxman

  • DTT SUPPORTER
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  • Posts: 2337
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #26 on: Dec 30, 2016, 08:34:44 »
good helper!
1978 CX650 Super Deluxe
1979 XS1100 Special
1974 xl350
1983 cx650 Custom
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1974 kawasaki 350 bighorn
1983 GL1100 aspy full dress
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 #27 on: Dec 30, 2016, 23:25:04 »
Thanks Alex jb, I appreciate that. I do a fair amount of aluminum sheet metal fab for my job as an aircraft mechanic. I was also really fortunate to be taught welding by an excellent welder at my previous job. I'm still nowhere near as good as he, but I do okay.

Cxman, that's my faithful mutt Hank, who is far more photogenic than myself. :)


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Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #28 on: Jan 06, 2017, 00:16:04 »
So, it's been a balmy 25 degrees or so here this past week. Cleaning rear wheel parts in water and Simple Green in my unheated shop space was as appealing as eating dust bunnies.

As such, I decided to work other angles. First, I decided to finish battery box fab work.





What can I say. Harbor Freight was having a New Years sale. Though, when are they not having a sale?

I used hardware store rubber grommets and some aluminum spacers to make rubber mounts for the battery box. Results are only ok. Would order beefier grommets in the future.

See the mount below.



With that done, I decided to indulge in some lathe work, and make some knurled nuts to hold down the seat. The seat simply has two studs protruding on the bottom rear. These go through tabs on the frame. The knurled nuts go on the studs to fasten it down.

I loaded up some 1/2" 6061 aluminum and faced the end.



Laid out some lines.



Turned it down to leave a raised area for knurling.



Knurled the raised end.




Drilled to #8 for M6x1.0 tap.



Chamfered the hole and tapped it.




Parted it off, then cleaned up the other end and drilled it up a bit larger half way for lightening and visual interest.




Rinse, repeat, and presto!



In place on the bike.




Weather is supposed to climb into the scorching 40's next week. So, with any luck, I'll get the rear end buttoned up soon.

Until next time!

Offline Alex jb

  • Posts: 264
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #29 on: Jan 08, 2017, 18:09:42 »
Sweet knurling!


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