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Author Topic: Lifan 150cc big-bore kit: Installation  (Read 38603 times)

Offline stroker crazy

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Lifan 150cc big-bore kit: Installation
« on: Jan 02, 2014, 06:24:59 »
Remove seat and petrol tank to allow clear access:



Remove carburettor and intake, spark plug, exhaust, horn and bracket:



Remove head steady bracket, the two bolts holding the front engine mounting bracket to downtube, top rear mounting bolt, and loosen bottom rear mounting bolt:



Remove tappet cover:



Remove rocker assembly; when lifting pushrods, make a note of which is intake and which exhaust:



Remove the four head bolts, not forgetting the cam locating bolt on LHS of motor:



Lift head clear, keeping a look out for the dowels between head and cylinder:



Undo cylinder location screws on LHS of motor:



Lift cylinder, taking care to stuff crankcase openings as soon as possible



Pry out circlip from one end of gudgeon pin and push pin through the piston from the opposite side. (do not re-use circlips!)



Install new piston noting marked inlet side (lightly oil gudgeon pin to install),
make sure circlip gaps are to top or bottom rotate rings so that the gaps are 60 degrees apart:



Swap cam followers from original cylinder (be careful not to lose the wave washer) to the new cylinder:



Dowels in place in head:



Install 8mm/6mm exhaust studs:



Smear a very light coat of silcon sealant on cylinder mating surface, if you are not using a base gasket:



After cleaning any gasket remains from crankcase and replacing dowels, lightly oil the cylinder and carefully slide into place over the piston (remove the stuffing when the rings are inside the cylinder):



Position head gasket and top dowels:



Bolt head in place (20–22lbf. or 28–30n/m) and replace cam locating bolt (13–16.5 lbf.). Be very careful when replacing the pushrods – angle them toward the outside corner and rock the cam using the kick-start lever to ensure contact. If not positioned correctly they will drop into the motor, necessitating the removal of the head and cylinder in order to retrieve them:



Replace rocker assembly:



Replace engine mounting bolts (8mm 22.5–27.5 n/m)

Adjust valve clearances – intake 0.1mm (0.004˝), exhaust 0.15mm (0.006˝). For correct TDC inlet valve should be closing as piston rises.

Replace tappet cover, refit head steady, carby, spark plug, horn, tank, etc.

Before starting, remove oil bleed screw from rocker cover. Start motor; when oil bleeds from from vent, replace screw.
« Last Edit: Sep 26, 2017, 06:06:05 by stroker crazy »
“Ride like the Wind” W.H.

Offline mikeyw64

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Re: Lifan 150cc big-bore kit: Installation
« Reply #1 on: Jan 02, 2014, 06:38:31 »
a nice concise write up Sir  8)

One question

Quote
Adjust valve clearances – intake 0.1mm (0.004˝), exhaust 0.15mm (0.006˝).

Were they the settings recommended with the kit as aren't the standard settings 0.005 inlet & exhaust?

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Jessica's story, a Work in Progress     My Original "It all started here " thread                   My "Rebirth" thread

Offline stroker crazy

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Re: Lifan 150cc big-bore kit: Installation
« Reply #2 on: Jan 02, 2014, 06:42:31 »
They're the Lifan recommendation Mikey.

Crazy
“Ride like the Wind” W.H.

Offline WJPez

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Re: Lifan 150cc big-bore kit: Installation
« Reply #3 on: Jan 02, 2014, 07:18:24 »
Did you need to use a piston ring compressor or does the bore slot over the piston easily? Dis you get the kit from OORacing?

Wayne

Offline stroker crazy

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Re: Lifan 150cc big-bore kit: Installation
« Reply #4 on: Jan 02, 2014, 07:34:45 »
No, you don't need a ring compressor and yes, it's the OORacing kit.

Crazy
“Ride like the Wind” W.H.

Offline orrible-64

  • Posts: 713
Re: Lifan 150cc big-bore kit: Installation
« Reply #5 on: Jan 02, 2014, 09:04:57 »
nice walk through..thanks for going to the effort..was going to photograph when i did mine  but got carried away doing job and didn't take any.

it is not too hard a job ..even for the unexperienced. take your time and follow this excellent guide.
only advice that was given on an earlier entry in main page was to put a long screwdriver through gudgeon pin so you do not loose circlips(used to call them "jesus clips" cause that is what you yell out when it flies off to unknown part of shed).

Offline orrible-64

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Re: Lifan 150cc big-bore kit: Installation
« Reply #6 on: Jan 02, 2014, 09:14:22 »
don't forget to crack the oil bleed bolt on rocker cover and do up when oil bleeds out from hole...this will insure you get proper lube to rockers

Offline HerbertD

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Re: Lifan 150cc big-bore kit: Installation
« Reply #7 on: Jan 02, 2014, 10:09:39 »
Thanks Crazy,

Excellent write up and looking to do the 150cc upgrade very shortly myself. At this rate, we will be running out of  mods to improve things further!

Offline mikeyw64

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Re: Lifan 150cc big-bore kit: Installation
« Reply #8 on: Jan 02, 2014, 11:31:22 »
nice walk through..thanks for going to the effort..was going to photograph when i did mine  but got carried away doing job and didn't take any.

it is not too hard a job ..even for the unexperienced. take your time and follow this excellent guide.
only advice that was given on an earlier entry in main page was to put a long screwdriver through gudgeon pin so you do not loose circlips(used to call them "jesus clips" cause that is what you yell out when it flies off to unknown part of shed).

Crazy mentioned not to reuse the circlips from the gudgeon pin. Are new ones included in the kit?

__
Jessica's story, a Work in Progress     My Original "It all started here " thread                   My "Rebirth" thread

Offline stroker crazy

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Re: Lifan 150cc big-bore kit: Installation
« Reply #9 on: Jan 02, 2014, 14:59:14 »
Are new ones included in the kit?

Yes!

Crazy
“Ride like the Wind” W.H.