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Author Topic: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade  (Read 3504 times)

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #30 on: Jan 21, 2017, 15:20:11 »
So. Time for an update!



The last few weeks here brought many things, including 12" of snow. In Portland, Oregon, that means utter chaos. As a result, shipments of crucial motorcycle parts and materials clearly of great importance to the American people (like me) were delayed. But, the snow has gone and we're back up and running.

I began cleaning the rear wheel. Rust was brushed from the rim.



While cleaning the hub and spokes, I noticed more than one loose spoke. Hmm...



I soaked all the nipples in WD40 for a couple hours and checked them for freedom. About seven nipples were seized. Several others were stiff. And one broke upon turning the nipple. Sweet.



I ordered spokes and set the wheel aside. Wiring then began.



I split open the harness provided with the engine and began to rearrange it to fit the SL100 both dimensionally and functionally. I plan to add turn signals, so that was also a consideration.




At this point, I realized I needed additional wire. The Lifan engine, being a Honda clone, conveniently uses the same wire color code as Honda. I want to do this properly, so I ordered wire in the correct color combinations.

Eventually, the snow began to clear and the goodies came rolling in.




This is an NOS aftermarket muffler I bought off eBay. I will be replacing the included hardware to spruce it up a pinch. Seemed a little more fun than the ubiquitous Chinese pit bike muffler.



Mandrel bends to start exhaust fabrication.



A sheet of 1/8" neoprene to line the battery box.



Wire!

The new spokes also came in. In my next post, I'll finish the rear wheel, install the drive chain and make the battery box liner.

Offline Boat builder

  • Posts: 4
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #31 on: Jan 29, 2017, 03:11:51 »
That thing is looking great! What diameter tubing are you building your exhaust out of? I just finished building mine out of 1-1/2", which was oversize. I had to machine a custom flange to weld the exhaust to. Finished that a few days ago and I took my xl125 with the 163 engine in it for its first real ride today. Road it 40 miles around town and took it up into the mountains. It runs pretty good, but I'm getting a lot of popping from decelerating.  Its a really fun engine, and had quite a bit of power.

I have the same carb, but under the name K&F PZ30. I ordered a a keihin jet kit that should work with this carb and will try and figure out the best combo, I'll let you know when I get it tuned better.


Keep up the good work!




Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #32 on: Jan 29, 2017, 03:30:16 »
Thanks Boat builder! That xl125 looks fun. I actually just test rode my setup two days ago. I used the original exhaust in a temporary configuration. Engine ran well, but I only did a couple laps around the block.

I'm going to use 1 1/4" tubing for the exhaust. I was thinking 1 1/2" also, but I measured the port at about 1 1/8". As such, I am using 1 1/4" by 16 gauge tubing, which puts the inner diameter at around 1 1/8". I also will be turning out a flange on my lathe for it.

Hashing out the wiring harness now. Looking forward to some real riding!

Offline Boat builder

  • Posts: 4
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #33 on: Jun 26, 2017, 01:29:22 »
Any Updates Forklift. I have close to 700 miles on my bike right now. So far so good, It took me awhile to figure out my sprocket combo and I am about to upgrade to the VM28 carb per cxman's advice (Now that the shock of spending all the money fixing the bike has worn off). Hopefully you figured out the wiring diagram, it took me way longer than it should to get me wired after I made a new harness. Still forgot to wire up the horn but I should do it soon.

« Last Edit: Jun 26, 2017, 01:32:31 by Boat builder »

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #34 on: Jun 26, 2017, 03:04:49 »
Yes, I really need to update.  I got pretty busy with non-motorcycle life activities, but I've been working steadily on the SL100 all the while. I'll try to post something longer tomorrow. The bikes current state is pictured below.


Offline cxman

  • DTT SUPPORTER
  • *
  • Posts: 2291
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #35 on: Jun 26, 2017, 07:24:10 »
love your exhaust forklift

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 Boat builder

  • Posts: 4
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #36 on: Jul 02, 2017, 15:10:48 »
The new exhaust looks killer!

Offline der_nanno

  • Posts: 224
  • Faster!
    • Greasy Greg
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #37 on: Jul 03, 2017, 11:32:26 »
Now that XL125 is a sweet lil' thing... completely forgot about those!
Real freedom starts with the freedom of thought.

My Blog:
http://greasygreg.blogspot.co.at

My Turbo TR1.1 (XV1000) build here on DTT:
http://www.dotheton.com/forum/index.php?topic=72571

My XS Triple Sidecar build here on DTT:
http://www.dotheton.com/forum/index.php?topic=74211

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #38 on: Jul 07, 2017, 00:55:58 »
So, first, let me agree with der_nanno. That XL is a sweet little bike, Boat Builder. Second, I apologize for my lack of posts. I've been busy...



It may seem as though the above pictures are unrelated, but not so! All of the pictured items contributed to delayed progress on my little green alley-bike.

That said, progress has indeed been made. I shall now elaborate.

Offline Forklift

  • Posts: 23
  • Bikes: 2014 Honda CB500F, 1972 Honda SL100
1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
« Reply #39 on: Jul 07, 2017, 01:22:26 »
I did, in fact, finish the rear wheel.



I have no photos of the spoke replacements, but it was pretty straightforward. If you've never trued a spoked wheel, it's an interesting experience. Because I have a dial indicator, I was able to get total runout all around to less than .5mm radially and .2mm axially. Not going to get any better from an old welded steel rim.



One thing to note, I was unable to use the EBC grooved brake shoes I bought on the rear drum brake due to a difference in the way the springs were mounted on the shoes. The shoes on the bike were in good enough shape to re-use, luckily.



Next up, I'll post about the wiring harness rebuild that ended up happening. I decided to use Deutsch connectors, so stay tuned!
« Last Edit: Jul 07, 2017, 01:42:05 by Forklift »