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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: Forklift on Nov 20, 2016, 18:00:34

Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 20, 2016, 18:00:34
Hello DTT forums. I'm a new poster here. I started this thread to chronicle my installation of a Lifan 200cc 163FML motor into my 1972 SL100. I intend to use the finished bike to bushwack around the unimproved roadways and alleys (of wich there are many) here in my home of Southeast Portland, Oregon.

Below is the bike before I started the Lifan engine install.(http://uploads.tapatalk-cdn.com/20161122/364506582a0cd14a356ef3c3c24fd7ea.jpg)

A couple years previous, I purchased the bike from a couple in White Salmon, Washington for $500 running with clean title. Its not in awesome shape, but it is solid overall. Major drawbacks were a Kreem-coated tank and some dents and other bruises from a few thousand miles of trail-time. I test road the bike at purchase, but neglected to shift above third at the time. Back at home, I did some sprucing up, then took it for a ride around the neighborhood. As soon as I shifted above third gear, it would not for its life come back down without me stopping the bike and hammering the shifter. With misplaced hope, I pulled the side covers and troubleshot the problem away from the shift linkage (which I had prayed it would be) to inside the engine cases. Naively, I pulled the engine apart and found the problem to be in the shift drum and forks. Never was able to pinpoint the cause, but the project ended up back-burnered and languishing due to my idle disinterest in engine work.

A year or so back, I found online that one may swap in a 200CC Lifan 163FML engine with relative ease. Added horses, electric start, 12v system, and a fresh motor for $550 was tempting. A couple weeks ago, I decided to pull the trigger. I ordered the crate motor from PCC Motor via eBay and received it a few days ago.

The following will be my attempt to log the whole installation, break-in process, and then my review. When I've finished, I may publish an Instructable or similar on this topic as there seems to be a relatively scant quanitity of info about these motors (though I may be corrected by DTT members here).

By way of introduction to the DTT forums, I'm a 31-year-old, business jet mechanic from Portland, Oregon with an awesome, motorcycle-friendly wife, two daughters and a mutt. Thanks!
Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 20, 2016, 18:34:32
I ordered the "SET" version of this Lifan crate motor, which meant I received a carb, CDI ignition box, coil, kickstart lever, shift lever, regulator/rectifier, starter solenoid and wiring harness for the motor as well. Here's the extras unboxed.

(http://uploads.tapatalk-cdn.com/20161122/85b078d75deb7527bf0442b49f97bbfd.jpg)

On opening the box, one is greeted by the distinct aroma of Harbor Freight Tools (also known as Chinese/Thai industry). I think this is produced by a combination of the fresh rubber, and the preservative oils they lather on everything, for wich I am glad, considering these machines plow through the salt-spray of the Pacific to get here.

But! Keep in mind when unbagging the engine that it will be slicker than snot. I wiped the whole thing off before attempting to mount it in the frame. The motor after unbagging shown below.

(http://uploads.tapatalk-cdn.com/20161122/07f736ff22baa0646508c6260cd08442.jpg)

(http://uploads.tapatalk-cdn.com/20161122/b7ff8300aaa97fd786a5253c1f05642a.jpg)

Once de-oiled, my wife and I wrestled the lump into the SL's frame with ease. Well, as easy as ever, anyway. The new motor's jug is sizably larger than the 100cc original, so it was a tight squeeze.

(http://uploads.tapatalk-cdn.com/20161122/2297fd0e929be9a5e996b3f39ffb9f6b.jpg)

(http://uploads.tapatalk-cdn.com/20161122/104dcfd2e2851b38750df90e3c9ca36b.jpg)

I was able to bolt it in with the rear mounting holes and the front mounting plates, no problem. However, due to the Lifan motor being a push-rod OHV affair (unlike the OHC original Honda motor), the top mount point on the head is nowhere near the original. I've seen others simply ignore this, which is probably fine. Personally, I'll be fabbing up some new brackets for the head which will include some of the new electrics as well.

(http://uploads.tapatalk-cdn.com/20161122/842b8ad9585663f7473ff5ff6b35b36f.jpg)

This is the very old school shift lever included in the set.  :)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Nov 20, 2016, 19:44:21
i am just doing the final tweaks and dial in on a 1971 cb100 with the same lifan200
i got the set motor but the supplied carb sucked
so i have now replaced it with a vm28 mikuni
i have a custom exhaust while the jetting dial in is not perfect yet
the thing goes like hell we clocked it on gps friday at 68mph in fourth gear and not anywhere near redline
it even wheelies
it will bring a big grin to your face when you ride it

you need to make a upper motor mount set up or the motor will turn the frame into a vibrating tuning fork
also drill the back two bolt holes out to 10mm and use 10 mm bolts the size the lifan holes are made for
Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 20, 2016, 20:15:40
cxman,

Good to hear you've had success with this motor. I am, indeed, looking forward to riding it.

I've got some 1/8" mild steel plate I'll be making new upper mount brackets from. Interesting about the rear mount bolt size. I'll be looking into that. Frankly, the front bolts seemed similar, but the stock bracket's holes are oversized quite a bit. Wide manufacturing tolerances, I'm guessing. Didn't know the holes in the Lifan engine case were actually larger than original. Been a while since I had the original engine out of storage.

As for the carb, I'll run with the cheapy for now and see what happens. I intend to use the stock exhaust header, if possible, and put a more size appropriate slip-on muffler in place. Can't use the original airbox boot (different size), so I'll run a pod filter.

For all interested, it should be noted I received absolutely no information with this motor. No parts breakdown, break-in guide (aside from a sticker on the side cover), no mount point dimensional drawing, nada. Just the packing slip from PCC Motor.

Below are some pics of the supplied carb.

(http://uploads.tapatalk-cdn.com/20161122/b0fea1b3deb05dec5af2da1ef08a862c.jpg)(http://uploads.tapatalk-cdn.com/20161122/c339eb0d92c3aca59832bc2af9796139.jpg)(http://uploads.tapatalk-cdn.com/20161122/df997ef6bc186806b21d21c2496608a3.jpg)


"HONGDA" huh? A mark of high quality somewhere, I suppose... You can find these carbs online for $15-$20 new, so I'm not expecting much.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Nov 21, 2016, 08:26:53
you should post or forward me some pics of your wiring harness when you get that far

mine i had to change the ground pin position at the cdi to get it to fire and apparently this is common

i dont know about the front mount bolts as mine were missing so i just used what fit i believe i also used 10mm  there

i did nit have the stock pipe so i fabbed one up using 1 3/8 then 1 1/2 to the muffler and used a aluminum flange

Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Alex jb on Nov 21, 2016, 17:21:46
Sounds like an interesting swap, pics are broken though.


Sent from my iPhone using Tapatalk
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 21, 2016, 20:58:54
Alex,

Pics should work now, I think.


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Nov 21, 2016, 22:10:42
yours is a lot nicer looking lol but mine will get there

(http://i1197.photobucket.com/albums/aa422/murrayfeldman/20161121_190928_zpsbax9ji7j.jpg) (http://s1197.photobucket.com/user/murrayfeldman/media/20161121_190928_zpsbax9ji7j.jpg.html)

(http://i1197.photobucket.com/albums/aa422/murrayfeldman/20161121_190959_zpsoghc8xjd.jpg) (http://s1197.photobucket.com/user/murrayfeldman/media/20161121_190959_zpsoghc8xjd.jpg.html)

(http://i1197.photobucket.com/albums/aa422/murrayfeldman/20161121_191006_zpsyy0yxrxz.jpg) (http://s1197.photobucket.com/user/murrayfeldman/media/20161121_191006_zpsyy0yxrxz.jpg.html)


i will take a few when we do some testing tomorrow
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 23, 2016, 14:27:23
The included carb won't install in place unless you loosen the screws securing the boot to the head.

(http://uploads.tapatalk-cdn.com/20161123/da2b26f478ce857b3609f78975af1352.jpg)

(http://uploads.tapatalk-cdn.com/20161123/7d1f03936665422ed91e4a5923450dfc.jpg)

(http://uploads.tapatalk-cdn.com/20161123/e5a286db9574e204608f0580e8b46808.jpg)

Not much room between the choke mechanism and the frame.

The original battery holder and air box assembly is removed. I'm doing a full 6v to 12v conversion, so I'll be fabbing a custom battery and electrics holder.

(http://uploads.tapatalk-cdn.com/20161123/ef929dad715da4d87f526887662190d7.jpg)

(http://uploads.tapatalk-cdn.com/20161123/b157e3fecd11f2b83dc96c77e9cf8295.jpg)

Next, I'm going to carefully correct the bolt size problem cxman pointed out, then start working toward a first start on the engine.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Nov 23, 2016, 21:30:25
I looked into the bolt size issue and here's what I found. The mounting holes in my Lifan measure not quite 9mm inner diameter. This is consistent with a loose fit for an 8mm bolt, which is the Honda original size. Curious, I grabbed the box with the cases from the Honda motor and found them to be basically the same, if not slightly larger. As such, I'm sticking with the original hardware.

I couldn't even get a 10mm bolt through the Lifan's mounting holes.

Here's a pic of the original top bolt going through the Lifan top mount hole, just to see the fit.
 (http://uploads.tapatalk-cdn.com/20161124/5850a622b999d9d0e360347225effd0f.jpg)

This, from my experience is a pretty typical fit for bikes of this age.

I wonder, cxman, if our Lifans are just a bit different here. I've already been surprised at the number of little differences there seem to be among these engines.

Case in point, mine has no "LIFAN" on the right hand side cover.

(http://uploads.tapatalk-cdn.com/20161124/ffe43c2f7ffcf9ee314a8a4d4e263809.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman 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
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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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Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman 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
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 01, 2016, 12:34:11
Here's that "break-in" sticker. Pretty amusing.
(http://uploads.tapatalk-cdn.com/20161201/a7bfdf27a7144e631bfa87bf4f0be32b.jpg)

The original exhaust, unfortunately, no longer fits. The Lifan engine's side cover includes a sight glass where the original does not.
(http://uploads.tapatalk-cdn.com/20161201/e7e0b5cd2abe46761d7fd3085da4401c.jpg)
(http://uploads.tapatalk-cdn.com/20161201/40bfe44c44163241d357e263c534a356.jpg)

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.
(http://uploads.tapatalk-cdn.com/20161201/4f1db4cc9d54f40e8a39f5acadf5aaf7.jpg)

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.
(http://uploads.tapatalk-cdn.com/20161201/f7c1644d72beaacb4080ee87b05db70f.jpg)

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. :)
(http://uploads.tapatalk-cdn.com/20161201/35948550f8f3f2d0de6d760384c3f295.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 01, 2016, 21:02:20
1. Pull off wheel.
(http://uploads.tapatalk-cdn.com/20161202/00d5b2039661b6f6e7ab273d6a5c7338.jpg)

2. Remove tire, tube, rim strip.
(http://uploads.tapatalk-cdn.com/20161202/668a31842f9de7c341da897265ef9db9.jpg)

3.Examine rust.
(http://uploads.tapatalk-cdn.com/20161202/05bca530382d053000171542efc0bea3.jpg)

4. Remove rust.
(http://uploads.tapatalk-cdn.com/20161202/869bf66bc6d660b0ce001a69a5aa9b98.jpg)

5. Do a lot of cleaning, polishing, and other stuff I forgot to photograph.
(http://uploads.tapatalk-cdn.com/20161202/76f0e6d054e8acebfbb20eb54d81d285.jpg)


6. Install fresh brake shoes and reassemble. I used EBC 303G grooved shoes.
(http://uploads.tapatalk-cdn.com/20161202/ec37b9fd654c9dc7392d0f0fc7e0658b.jpg)

Next, first start of new engine.
Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 02, 2016, 00:07:02
On to the first start!

Below you will find the wiring diagram I found most useful.
(http://uploads.tapatalk-cdn.com/20161202/8d99fdcd65b18636fa4197cf623abfda.jpg)

This is the pin-out of the CDI unit provided.
(http://uploads.tapatalk-cdn.com/20161202/3b55cbac2c9c42cb4dc29a09f53d9e0e.jpg)

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.
(http://uploads.tapatalk-cdn.com/20161202/db4d210c6140f00852cfdde960693dcc.jpg)

The second defect was at the stator connector. See if you can spot it.
(http://uploads.tapatalk-cdn.com/20161202/0e676aa801ba10f03e58e5a568a5110b.jpg)
(http://uploads.tapatalk-cdn.com/20161202/da0b0ea0410cd448febd4c4ef1cbcb58.jpg)
A quick re-pin corrected the misplaced exciter coil wire. After that, I started getting spark.

Ready to run.
(http://uploads.tapatalk-cdn.com/20161202/ef3defa54d14a30809acd44dc7d44793.jpg)

Jerry-rigged electrics.
(http://uploads.tapatalk-cdn.com/20161202/b686b1de17acdc6c4ba0e8f69e78f64a.jpg)

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

https://youtu.be/AxQOxGfyuXg

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!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman 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
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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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Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman 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
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 10, 2016, 19:02:54
Apparently, it's a 15 tooth.
(http://uploads.tapatalk-cdn.com/20161210/119daf0405e3e81e530d57fea6889186.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman 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
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Boat builder 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.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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.
Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 23, 2016, 16:27:32
Battery/electrics box fabrication has begun.

(http://uploads.tapatalk-cdn.com/20161223/33a59851877f97461910bd23913a52b8.jpg)
(http://uploads.tapatalk-cdn.com/20161223/fe70b544504b5729caf5913905630a3d.jpg)
(http://uploads.tapatalk-cdn.com/20161223/941859cbdd24a235e9fa45554ea41d60.jpg)
(http://uploads.tapatalk-cdn.com/20161223/3dd11b4b087e4adf5ad4555056fc10c8.jpg)
(http://uploads.tapatalk-cdn.com/20161223/5297fbe7d9b3ca57feeee1ea5fc62320.jpg)

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:
(http://uploads.tapatalk-cdn.com/20161223/19e61d63b732551f82f6f13e7c61a50b.jpg)

New cable:
(http://uploads.tapatalk-cdn.com/20161223/dfc92658831c8a23e84a28ca91ced5fc.jpg)

Seems to work well.

(http://uploads.tapatalk-cdn.com/20161223/b4346278092fcfe6abd7918eff19ac70.jpg)

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.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Dec 29, 2016, 23:48:56
Battery box fab continues.

(http://uploads.tapatalk-cdn.com/20161230/3145bac13d3a262d2e52a18722fe5264.jpg)
(http://uploads.tapatalk-cdn.com/20161230/9bbb1351b3e3d4a84d7e251b8d79aadd.jpg)
(http://uploads.tapatalk-cdn.com/20161230/79d338c903c89e89f1490aa0d691319a.jpg)

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

(http://uploads.tapatalk-cdn.com/20161230/0e41960e240c8a032ec1f1ca5f4c5734.jpg)
(http://uploads.tapatalk-cdn.com/20161230/2e236d66f19c0e62dbe52351c8dfb6f7.jpg)

Brackets were made for the CDI and starter solenoid.

(http://uploads.tapatalk-cdn.com/20161230/4ec7fa9085724a6cf8d3c5ad30489e19.jpg)
(http://uploads.tapatalk-cdn.com/20161230/64a61ff6a8478ac934bf80c752f92618.jpg)
(http://uploads.tapatalk-cdn.com/20161230/79e468b10c12eba09f845b5c2b45917e.jpg)

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

(http://uploads.tapatalk-cdn.com/20161230/64cb366a7b4520e882cfafe7db601dd3.jpg)
(http://uploads.tapatalk-cdn.com/20161230/413522e1f151ab616cd544ffb36dbed4.jpg)

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.

(http://uploads.tapatalk-cdn.com/20161230/25565d1d9be6ec4fdfd16a4cd2f6d462.jpg)
(http://uploads.tapatalk-cdn.com/20161230/ae1e8f81027867aac665bdc8b566063c.jpg)
(http://uploads.tapatalk-cdn.com/20161230/6592139454f20cc609b00010e6bf442d.jpg)
(http://uploads.tapatalk-cdn.com/20161230/8949ae7d302fb2517587109193dbf9a6.jpg)

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.

(http://uploads.tapatalk-cdn.com/20161230/45bc51706f9071d3817c1eca48793dc8.jpg)
(http://uploads.tapatalk-cdn.com/20161230/95278c4a66923882affd4d7b18303f3c.jpg)

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.

(http://uploads.tapatalk-cdn.com/20161230/1a40ea8959ee84819c84908d5a2656f5.jpg)

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

(http://uploads.tapatalk-cdn.com/20161230/de29f317d7cd90cda1484661d8d15030.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Alex jb on Dec 30, 2016, 06:32:34
Nice fab work.



Sent from my iPhone using Tapatalk
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Dec 30, 2016, 08:34:44
good helper!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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. :)


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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.

(http://uploads.tapatalk-cdn.com/20170106/2eaefebe8fa8551f1328d5c9651f7014.jpg)

(http://uploads.tapatalk-cdn.com/20170106/55b58b996f1f2aa3a6cce67aa74691ad.jpg)

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.

(http://uploads.tapatalk-cdn.com/20170106/12a9795e13b97c725a141ef19dfa9e3e.jpg)

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.

(http://uploads.tapatalk-cdn.com/20170106/7cbbbd35c4e9fd20e0d38127decc76e6.jpg)

Laid out some lines.

(http://uploads.tapatalk-cdn.com/20170106/a5edbc47a7948985b29c1900f103ba98.jpg)

Turned it down to leave a raised area for knurling.

(http://uploads.tapatalk-cdn.com/20170106/5f4a3dbcddb0b1228966f40fbca14e20.jpg)

Knurled the raised end.

(http://uploads.tapatalk-cdn.com/20170106/452a5d50768e06414291e538650fd383.jpg)
(http://uploads.tapatalk-cdn.com/20170106/2f3129bffd531eba31d022645bb2efda.jpg)

Drilled to #8 for M6x1.0 tap.

(http://uploads.tapatalk-cdn.com/20170106/49ed0747620b4f1a21d3f2b27696a87d.jpg)

Chamfered the hole and tapped it.

(http://uploads.tapatalk-cdn.com/20170106/6dff0fed450748108a07c00bb38997b6.jpg)
(http://uploads.tapatalk-cdn.com/20170106/69054d46579e1b5ce9c888e0953e9b20.jpg)

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

(http://uploads.tapatalk-cdn.com/20170106/4f65d66eb8da907dc42ade918daf531d.jpg)
(http://uploads.tapatalk-cdn.com/20170106/9e0c17cda7bbf42876bcef720953b765.jpg)

Rinse, repeat, and presto!

(http://uploads.tapatalk-cdn.com/20170106/58737485fcbc207d0e005c9a64d73baa.jpg)

In place on the bike.

(http://uploads.tapatalk-cdn.com/20170106/f3c5c96d794b312ac9340e28a9c4f844.jpg)
(http://uploads.tapatalk-cdn.com/20170106/be90012b9dbdecf44661e076847d2563.jpg)

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!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Alex jb on Jan 08, 2017, 18:09:42
Sweet knurling!


Sent from my iPhone using Tapatalk
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Jan 21, 2017, 15:20:11
So. Time for an update!

(https://uploads.tapatalk-cdn.com/20170121/bf104f446891219ae485880535242955.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170121/61e1bbce71355ea6095895e95618ae9e.jpg)

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

(https://uploads.tapatalk-cdn.com/20170121/65acaab1aeaa236c90dac716db26f207.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170121/c5fb098e83578f24ceae018f4950864f.jpg)

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

(https://uploads.tapatalk-cdn.com/20170121/122e1e53059cef6afa391b23d999f92d.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170121/3802d8db02a3ce7a25c0a9e350de6461.jpg)
(https://uploads.tapatalk-cdn.com/20170121/b81995ae9b95522044c645c24b61a2b0.jpg)(https://uploads.tapatalk-cdn.com/20170121/d65742b4816e29b511ebad4f60038a50.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170121/48f6b74b6ebfc14abdbe70dca1bb27fd.jpg)
(https://uploads.tapatalk-cdn.com/20170121/f35e1c7d6b87f3f072f0c3c12fdac6ee.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170121/c26279c640f241a878657c7c1e07e7ef.jpg)

Mandrel bends to start exhaust fabrication.

(https://uploads.tapatalk-cdn.com/20170121/be68b728501336fe53642c24d1cc548c.jpg)

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

(https://uploads.tapatalk-cdn.com/20170121/bf0b7eff8d0b22fbf66aba1a5ddea915.jpg)

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.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Boat builder 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!

(http://i.imgur.com/RQNc6BU.jpg)

(http://i.imgur.com/trK7tx9.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Boat builder 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.

(http://i.imgur.com/cizi1O7.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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.

(https://uploads.tapatalk-cdn.com/20170626/6ff909394cbbf3e938639a90799c9d1a.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Jun 26, 2017, 07:24:10
love your exhaust forklift

Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Boat builder on Jul 02, 2017, 15:10:48
The new exhaust looks killer!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: der_nanno on Jul 03, 2017, 11:32:26
Now that XL125 is a sweet lil' thing... completely forgot about those!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift 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...

(https://uploads.tapatalk-cdn.com/20170707/974a17cffd65ee3851fec9e0b43c194e.jpg)(https://uploads.tapatalk-cdn.com/20170707/6e002095ff65edd4c98c8c08548f8ee8.jpg)(https://uploads.tapatalk-cdn.com/20170707/8999ea5233a938c490315026e48bd62f.jpg)(https://uploads.tapatalk-cdn.com/20170707/da9b09a5f7ad4ae936fab0359f2bd6f4.jpg)

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.
Title: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Forklift on Jul 07, 2017, 01:22:26
I did, in fact, finish the rear wheel.

(https://uploads.tapatalk-cdn.com/20170707/03ccc1eefc11f8b47ce1f9ca822b1bd5.jpg)(https://uploads.tapatalk-cdn.com/20170707/6ef6107ff5652a0a27f2eb54cefd526b.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170707/c8b787b4e729b39140f98356e5463ced.jpg)(https://uploads.tapatalk-cdn.com/20170707/9aae75f9b9a6dd6e6d3ab40588a299e6.jpg)

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.

(https://uploads.tapatalk-cdn.com/20170707/c5e9aa491140c81ac3a596b110817066.jpg)(https://uploads.tapatalk-cdn.com/20170707/605296bb4f7ca803d66b2c303058ea4a.jpg)

Next up, I'll post about the wiring harness rebuild that ended up happening. I decided to use Deutsch connectors, so stay tuned!
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: vwrabbit on Jul 08, 2017, 17:36:44
Nice build! I'll be following. I have a '75 CB125S2 that I wouldn't mind upping the CCs on.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Nick93023 on Jun 23, 2018, 19:31:29
Hey Forklift did you ever get this going? I am doing a full restoration of a 1972 sl100 and a lifan swap at the same time.
(http://i148.photobucket.com/albums/s25/nickm_90/20180614_162544_zpsexqksuv9.jpg)
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Jun 23, 2018, 20:22:44
he has it on the road last i talked to him he asked me about the vm28 mikuni carb i run on my cb100/lifan200
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: Nick93023 on Jun 23, 2018, 20:30:43
I will be going with that same mikuni carb also. This thread has been so helpful with my project. I am struggling with the wiring though.
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: cxman on Jun 24, 2018, 13:06:00
yup that was a pita mine is all 12volt now

im going to do 2 cb125s with the lifan 200 and i think i i will get matt to make me 2 new harnesses with matching controls
Title: Re: 1972 SL100 Lifan 200CC 163FML Engine Swap and 12V Upgrade
Post by: davidstipek on Mar 23, 2019, 06:34:49
Did you ever create a top engine mount for this?? I have a Custom Hardtail frame I am putting Boxer 200cc in. Boxer is Thai version of Honda/Lifan 200cc motor.
I would also like a good picture (s) of rear and front mounts too Multiple angles would be great!!

If you are using factory mounts can you supply Model and year or part number? (s)

Attached photo of Carb will work / works great as it is original for 200cc engine... I have several!

Keep in touch, please!
David (Chiang Mai, Thailand / Originally from Bothell WA... Saw your Washington plates!)