My 09 Lifan LF200 GY-5 restore thread

[nyvdub89]

Hello CR, this will be my restore thread for my 09 gy5. It was my brothers originally and we used it for trail riding and for his class m road test. We lost the plate in the trails somewhere and parked the bike. He moved and it sat for a while. Well my motorcycle itch has sprung and I figured if it's there I might as well get it back into shape. It's going to need a little work but hopefully I can return it to its road legal glory within a month or so. :hmm:

http://i1128.photobucket.com/albums/m494/tbanksphotography/14D695F4-7ABF-4320-A04E-F5BD04563508-11824-000002ACBB191517_zpsf03c7694.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/D4C0B264-CCC3-4161-80F6-134711179A54-11824-000002ACC05D2980_zps05510163.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/801B0A10-1EA2-420A-A6EB-0A83D2BE5190-11824-000002ACC64ECAC3_zps0707c984.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/160C6155-2138-4529-A910-0D8FA68B7D2F-11824-000002ACCB8335E0_zpsa6699c24.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/4D2B8C09-534A-445B-B90A-029935E2B741-11824-000002ACD0524B30_zps254580f3.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/17A78E5B-E5D5-4EC5-B2B5-96DDE6E9C6DE-11824-000002ACD50FFB0F_zps65109401.jpg

That was yesterday exactly how it sat for 2 years. Quite an eyesore if you ask me. The amazing paint job was really a bad idea in hindsight. :doh:

Last night I removed the gauges and deoxydized them with some toothpaste and a rag. It came out pretty good in my opinion.
http://i1128.photobucket.com/albums/m494/tbanksphotography/086fa882196af9d594d43af7f677d32c_zpsf2c85280.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/f021b2d60fe71b8faff9780e12b9d077_zps9f152529.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/1d05564f0fe76f199d8ed73a05c991da_zps9a17b400.jpg

I removed the brake light assembly to see how it mounts up so I can look into integrated tail lights.
http://i1128.photobucket.com/albums/m494/tbanksphotography/07c45162f4db42952c7713268003ac70_zps5c65c10c.jpg

I also saw my brake master cylinder had corroded away from the fluid sitting for so long.
http://i1128.photobucket.com/albums/m494/tbanksphotography/90cfd5ab03b4a2fce46cad2f87742413_zps36066ac6.jpg

The throttle assembly broke on the last ride we took it on so I'm looking into a universal control with some new grips. I think the aftermarket Honda XR grips should fit. I need a new cable too, and the only ones I saw on eBay are for the pit bikes. Anyone know if these are interchangable?

I'd like to put a new air filter kit on it because I'm missing half the casing for mine. :ohno: My filter is falling apart too.
http://i1128.photobucket.com/albums/m494/tbanksphotography/51ace505ab9a7541c6ac3e97bdfd5067_zps0375336f.jpg

Pretty much my list of parts that I need so far goes as following..
New headlight with integrated blinkers. I like the sleek look..possibly these guys? (http://www.oemcycle.com/Item/product/900082493) :tup:
New brake master cylinder. Hopefully Wild_Alaskan has that
New integrated tail light. I'm thinking these (http://http://www.madhornets.com/license-plate-mount-oval-led-tail-light-integrated-turn-signals-universal-fit-black-red-lens/?gclid=CJ7l4u7Bz7cCFcad4AodV3IA1w)
Side body plastics, unless I have mine put away somewhere?:shrug:
I'd like to change my gear ratio for highway use because I want to take a 600+ mile trip up to Maine this summer. I'm kind of clueless on gear ratios. I was reading the FAQ earlier.
I need a new front mud guard. Are aftermarket XR200 guards comparable?
I need new mirrors.
I'd like to find a new seat too.
I also need a new battery but Wal-Mart should solve that.

Welp that pretty much sums it up. I'm guessing I'll dump around $300 into this thing give or take. Ive been looking at Hooper Imports but it seems like 80% of their stuff is sold out. :tdown: If anyone knows any other sites I would be very grateful. All knowledge shared is appreciated.

And just for fun, here's my other toy.
http://i1128.photobucket.com/albums/m494/tbanksphotography/7e91695c491eceaa368ceda3d9e95c49_zps13dcf36d.jpg

That should explain my username. ;)

[Wild_Alaskan]

I would take the seat to an upholstery shop and have them re cover it for you

[nyvdub89]

Wild, I think I'm going to look into that. Maybe have some new foam installed too. :)

[FastDoc]

I like the Golf. GTI?

It's not very cheap but the Edge II taillight, with or without the 12 O'Clock Labs integrated digital blinkers is excellent and highly recommended. I have one on my KLX, My Zong had one, as does Spud's Zong.

[nyvdub89]

Doc, I'll look into that. And as for my vw, it's an 02 gti 1.8t awp. It's a fun little car with all the bells and whistles except the digital ac. My old jetta had that. I was an Audi/vw tech before the school bus gig. Thanks for the love

As for an update, Wild_Alaskan has a few parts for me. Should be here within a week or two :)

[SpudRider]

The UFO Oregon head light gets pretty good reviews. :tup: I agree with Wild Alaskan regarding your saddle. ;)

I don't see where the Mad Hornets Tail Light has integrated turn signals. :hmm: As with FastDoc, I really like my DRC Edge 2 Tail Light. Unless you prefer, you don't need to integrate the turn signals with the tail light. You can always attach small, LED turn signals, or you can install flush mount, turn signals. :)

[nyvdub89]

Spud, I think I might try flush mounted led blinkers. :) The mad hornet tail light is wired up so a portion on the side of the tail will blink. My state requires blinkers but I personally don't like how stock blinkers look.:tdown:

[Weldangrind]

Sweet GTI! I haven't owned a VW for 10 years now; my last one was an '83 Jetta that I dropped an '88 Fox 1.8l into. Fun little car.

I can trade my tank shrouds for your rear fender and tail light, if you like.

[Weldangrind]

The front fender is a three bolt on the Lifan, which makes it a bit different from generic fenders. The early '80's XR200 used a three bolt fender. I have one that is cracked, but I could trim it and send it your way for cheap.

You can recover the seat yourself for cheap, with only a staple gun. I followed the instructions of mrmaxstorey on Youtube: https://www.youtube.com/watch?v=xi6lDifsazs I bought enough UV-rated red vinyl from the local fabric store to recover the seat twice, and it was less than $10.00

[SpudRider]

Spud, I think I might try flush mounted led blinkers. :) The mad hornet tail light is wired up so a portion on the side of the tail will blink. My state requires blinkers but I personally don't like how stock blinkers look.:tdown:
I installed DRC 586 LED turn signals on the rear fender of my CRF250X.

http://www.drcproducts.com/elect/d45-58-617/index.html

http://i442.photobucket.com/albums/qq146/spudrider/Highline%20Trail/CRF250X%20Rides/crfopride097_zpsbc2afc1d.jpg

They are very bright, even in daylight, and they are practically indestructible. :) I like them a lot. :tup:

[nyvdub89]

Weld, I have the gas tank plastics. The only ones I might be missing are the plastics for the rear under the seat. PM me a price for the grunt mud guard, please! The rear tail light is busted up pretty bad. I'm not sure if you'd be interested in it still.

Spud, thank you so much for the marker idea. I was thinking about that last night and I really like that idea! We'll see what happens when I start ordering new parts.

No progress today. I was helping my lady's father with a stone wall we've been working on.

[JPG1911]

looks like you've got about as much work to do on yours as I have on mine :) I'm still not 100% sure how I'm going to mount it, but I'm strongly considering This tail light (http://www.ebay.com/itm/Motorcycle-LED-Rear-Brake-Running-License-Plate-Turn-Signal-Tail-Light-Bracket-/251286031749?pt=Motorcycles_Parts_Accessories&hash=item3a81d08d85&vxp=mtr) for my '04 UM DS200.

Good luck on the resurection

[nyvdub89]

I'm not too fond of that tail light personally. I like the one spud has on his zong better. I'm not hating on it, just personal preferences. :tup:

[JPG1911]

no doubt, the edge 2 is pretty slick. I love the scrolling/sequential/whateveryoucallit (http://www.youtube.com/watch?v=dZLJ-pSNfaU) turn signal feature. I had originally intended to buy it, but now I think I'm going for a different look on my bike. For the fronts, I was going to go with these (http://www.ebay.com/itm/Smoke-Black-10mm-Motorcycle-LED-Turn-Signals-Blinker-Lights-Universal-/271200627271?pt=Motorcycles_Parts_Accessories&hash=item3f24d12a47&vxp=mtr) b/c they're so short and stubby, but now I think I'm going to fabricate a headlight mount/wiring cover out of black diamond tread steel and flush mount these (http://www.ebay.com/itm/2x-24-Yellow-LED-Chrome-Brake-Running-Turn-Signal-Tail-Light-Motorcycle-Cruiser-/200919225971?pt=Motorcycles_Parts_Accessories&hash=item2ec7b81673&vxp=mtr) or maybe even THESE bad boys (http://www.ebay.com/itm/SMALL-SINGLE-TAPER-MOUNT-MOTORCYCLE-LED-TURN-SIGNAL-RUNNING-LIGHTS-AMBER-/170978566025?pt=Motorcycles_Parts_Accessories&hash=item27cf1ddf89&vxp=mtr) to it. I already have the diamond tread, just need to make it over to my buddy's shop and borrow the brake to bend it, and pick up some fork clamps to mount it.

[Weldangrind]

Weld, I have the gas tank plastics. The only ones I might be missing are the plastics for the rear under the seat. PM me a price for the grunt mud guard, please! The rear tail light is busted up pretty bad. I'm not sure if you'd be interested in it still.

I thought i saw that the right side tank plastic was broken. Let me know if that's correct. The front fender is yours in trade for the rear fender and light assembly, despite whatever condition it's in.

This pic seems to show it as complete:

http://i1128.photobucket.com/albums/m494/tbanksphotography/07c45162f4db42952c7713268003ac70_zps5c65c10c.jpg

[nyvdub89]

Weld, I had it off because I was looking under the tank for all the stored mud I've kept there. It's all bolted back up ATM. I need the rear fender, and I'm telling you, the tail light is all busted up. I'll take a picture in a little while and show you what I mean.

[nyvdub89]

One update I can post is that I ordered the replacement title with help from Wild_Alaskan telling me where the vin is. I really wanna look into new sprockets for highway riding. If anyone had any 411 that would help me achieve a more comfortable top end speed for something like I-95 maybe, it would be greatly appreciated. :) my front sprocket guard is broken from the trails anyhow. I need new tires too cause mine have cracks and that won't pass inspection. I also think my fork seals are shot. I remember it always being a little loose but I can press them down by hand. Grr!

[nyvdub89]

...light assembly, despite whatever condition

http://i1128.photobucket.com/albums/m494/tbanksphotography/d0f9cbb0cb7561a1e522a301ec539425_zpsa7466bbf.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/155916e3741f0b3a23e8cfafbdcac745_zpsf564fab4.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/9609aef9be325acc72be0d9213a04689_zpsb75c625b.jpg

It's pretty beat up. If you're still interested shoot me a PM, Weld.

[nyvdub89]

Not too much today after my last post, but here's some eye candy of my gti.

http://i1128.photobucket.com/albums/m494/tbanksphotography/69bcfa27a297e0d1f93a5d6f1338ea45_zps91572f22.jpg

:)

[Weldangrind]

I have another light that will work, so I'm not worried about that. Is the fender cracked? It's hard to tell on my laptop monitor.

[Weldangrind]

Also, I trimmed the cracked portion off of the front fender for you today. It has been spray painted, so you'll need to remove the paint and paint it properly with Krylon Fusion. I laid a supermoto fender over it and traced it for shaping. If it's not what you were hoping for, no problem.

http://i158.photobucket.com/albums/t109/Weldangrind/Lifan%20200GY/IMG-20130609-00338_zps29c92dcc.jpg (http://s158.photobucket.com/user/Weldangrind/media/Lifan%20200GY/IMG-20130609-00338_zps29c92dcc.jpg.html)

[nyvdub89]

http://i1128.photobucket.com/albums/m494/tbanksphotography/af0726db7b8add97b8d421b00e825e57_zpsde4cd611.jpg

I'm not sure if I can plastic weld that. Maybe? :shrug:

I think I need a new chain, too. :hehe:

http://i1128.photobucket.com/albums/m494/tbanksphotography/d9d844d959bd592997315a401eb7997a_zps6545ca67.jpg

Should I go with the street fighter look and just mount my headlight securely? Idk I kind of like it but I also like te ufos. Opinions please?

http://i1128.photobucket.com/albums/m494/tbanksphotography/cfbd4f9db91d638b2b3f64a6ae5f1a0d_zps7af7e99b.jpg

Weld, if I can fix my fender I'd like to use it. For now this is just a side project build. Basically I'm doing an engine swap for a friend and the extra cash from that is going to cure this motorcycle itch I've had. I need my rear mud guard for this bike unfortunately. Plus it has a small hole in it anyway. Sorry buddy.

[bogieboy]

a little PB blaster and that chain is as good as new.....LOL

[JPG1911]

^ I second that, soak it overnight then clean it in a parts washer if you have one

[nyvdub89]

I have a parts washer at work. Hmmm... I still wanna increase top end though. Might be a good excuse to get a new chain/sprocket setup. ;)

[Weldangrind]

Please don't take that seriously. You don't want the chain coming apart at speed, especially when they often go on sale. I picked up an HD RK 428 for around $15 from Bike Bandit in the 130 link length. All of the other link lengths were more money, but I sure don't mind chopping links to suit.

No worries about the rear fender. I have other stuff I can work with.

Go to HF and buy the economy plastic welding kit, and buy the filler rod assortment. You'll end up with ABS, PVC and PP, one of which will likely be correct. Do a Google search on burning plastic to determine type, and you're in.

[nyvdub89]

Sweet thanks! I was joking about the chain too! I want a 520 chain with a smaller rear sprocket.

[Weldangrind]

You can swap to a 520, but it is a parasitic power loss. A good quality 428 chain will work just fine. Ask Spud, who has 56000 miles on his China bike.

[nyvdub89]

I'd like a little more top end than the 65 mph it tops out at almost pinned. I'm only 145lbs so I have a weight advantage with losing torque.

[Weldangrind]

You can certainly re-gear to gain more top speed, but a 520 will hurt the process. I presume that you have a standard XL185 cush drive rear sprocket, like this one: http://www.jtsprockets.com/catalogue/model/4971 You can select from 12 to 17 front teeth and 34 to 56 rear teeth.

No matter what top speed you get out of it, I recommend that you stay off of the freeways and primary Interstates.

[Weldangrind]

What size sprockets do you have now?

[SpudRider]

As usual, I agree with Weldangrind on all points. ;) Buy a new, size 428, drive chain. You can get great deals on the Tsubaki 428HQ and KMC 428UO drive chains. The Tsubaki is a conventional drive chain, and the KMC is an O-ring drive chain.

If you want more performance, stick with a size 428, drive chain; it has more than enough tensile strength for a 200cc engine. :) The size 520, drive chains are much stiffer, and much heavier; they will certainly sap power from small engines. ;)

Also, stay of limited access highways. These small bikes don't have enough power to keep up with the flow of traffic, let alone have any reserve power to escape from dangerous situtations. :wtf: If you need to travel the interstates, you need to get a motorcycle with a larger engine. ;)

[nyvdub89]

I think that my next bike will be a cafe racer of some sorts with a 500cc engine. :) As for the sprocket, I can go count the teeth, but according to Lifan America, it's 17 up front and 46 in the rear. I've taken my brother's zx6r out before but that's too much bike for me. There's something about that much acceleration that I think I could do without. I respect motorcycles, but I don't ever want to get too comfortable. It's always better to be alert than complacent. Just my two cents. I'll be ordering a chain this weekend. Darned bi-monthly paychecks. They make ordering parts such a pain. :tdown:

[Weldangrind]

If you genuinely have a 17/46 combo, that gives a final draive ratio of 2.71. You can't increase the front sprocket, but you can certainly decrease the rear. If it was me, I'd drop two teeth in the rear sprocket and see how the bike performs (assuming the price is right). If we can find a good source for China sprockets, the cost wouldn't be prohibitive to experiment a bit. You'll eventually find the point where the bike actually has a slower top speed.

[katoranger]

The gearing is close to optimal. I suggest a 42-44 rear. Lower that 42 and you will have negative results.

[nyvdub89]

Thanks Kato. Thanks Weld. I'm gunna order a 44 tooth this weekend along with a new chain. New parts should be here tomorrow from Wild_Alaskan. Sweet!

[nyvdub89]

I'm looking into ordering parts ATM. Does anyone know the number of links on the gy5's chain? Changed the bikes oil today. Other than that, I'll hopefully be ordering stuff soon. Just waiting on that info. Thanks guys. :)

[nyvdub89]

So today I tore the bike down a little bit. I unbolted the gas tank because I'm going to drain it tomorrow. I also removed the battery. I'll be getting a new one this weekend. I removed the air filter. I have to order a new one, maybe just a little 30mm cone filter from ebay. Nothing special. I then removed the carburetor. I pulled it apart to find 4 year old fuel in the bowl. Man that thing was filthy. http://i1128.photobucket.com/albums/m494/tbanksphotography/7AE9D4F9-80A4-4FD8-AB80-27813409B7B1-2838-0000007CF678B7FA_zpsadab93f4.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/60148F3F-BEA8-4C45-8A5C-683031987825-2838-0000007CFD3B6A2B_zps2bef14fe.jpg
http://i1128.photobucket.com/albums/m494/tbanksphotography/DB9A7F3D-D965-43C1-967B-D6D23492D43B-2838-0000007D0217EF5F_zps8f6e0ab1.jpg

I cleaned the carb out but my phone died so no pics of the finished product. :( I hope my package from Wild_Alaskan comes in tomorrow so I can install the new throttle and get the bike running. Then from there it'll be a matter of headlights, tail lights, blinkers, tires and a new chain for it to be road legal. I'm gunna strip the paint off of it and re-spray the plastics. Nothing fancy, just some rattle can after primer. From there it'll be cruise time. 8D

[SpudRider]

:wtf:

Old fuel in the carburetor! :grr:

:ohno:

[nyvdub89]

I know. I told you, we let it sit for like 4 years. :( At least a little elbow grease and some carburetor cleaner made it all nice again. :tup:

[SpudRider]

Good for you! :tup:

[Weldangrind]

I'm looking into ordering parts ATM. Does anyone know the number of links on the gy5's chain? Changed the bikes oil today. Other than that, I'll hopefully be ordering stuff soon. Just waiting on that info. Thanks guys. :)

IIRC, it's around 126. If you buy a 130, you'll be able to cut it down to the perfect length.

[nyvdub89]

Thank you Weld! Just the info I was looking for. I almost bought a 120 link, but that would have been a pita!

[SpudRider]

It's always better to buy drive chains a little too long, rather than too short. ;) When it comes time to break the chain, measure twice, and cut once. I'm still mad at myself for ruining a perfectly good drive chain several years ago. :ohno:

[nyvdub89]

Oh I bet, Spud. That's terrible. They're not expensive, it's just the hindrance of having to order another one and wait for it again.

[bogieboy]

It's always better to buy drive chains a little too long, rather than too short. ;) When it comes time to break the chain, measure twice, and cut once. I'm still mad at myself for ruining a perfectly good drive chain several years ago. :ohno:

You could always double masterlink it....but thats my cheapskate side talking (i have done it too....LOL never had issues with it either...):D

[nyvdub89]

Carb was still gunked up so I hit it with the parts washer at a work. The parts from Wild_Alaskan came in. The throttle assembly is wonderful! Front brakes are bled, also. Unfortunately the throttle cable was wrong. I ordered one off of eBay. She lives through. I need to tune the carb and order more parts. I'm doing a buddy's engine swap in the next week or so so I'll have the cash for one bulk order for the lights, tires, chain and battery. Wooo!! Very soon, gentlemen. Then I'll be posting my rides instead of repairs. LOL

[nyvdub89]

I want a choke assembly like Spud's. Instead of pulling the choke out its on the bars.. hmmmm. ;)

[Weldangrind]

Carb was still gunked up so I hit it with the parts washer at a work. The parts from Wild_Alaskan came in. The throttle assembly is wonderful! Front brakes are bled, also. Unfortunately the throttle cable was wrong. I ordered one off of eBay. She lives through. I need to tune the carb and order more parts. I'm doing a buddy's engine swap in the next week or so so I'll have the cash for one bulk order for the lights, tires, chain and battery. Wooo!! Very soon, gentlemen. Then I'll be posting my rides instead of repairs. LOL

Good progress! What kind of engine swap are you doing?

[culcune]

I just thought of something. If you want a true rotiserie restoration, review the old, old threads regarding the Lifan GY-5s. There was a sticker on the side that EVERYBODY who bought the '5' took off, as well as a handlebar pad which had an obscure word on it. We made alot of fun with them in the mid-2000s! However, the later ones didn't have either.

[Weldangrind]

I just thought of something. If you want a true rotiserie restoration, review the old, old threads regarding the Lifan GY-5s. There was a sticker on the side that EVERYBODY who bought the '5' took off, as well as a handlebar pad which had an obscure word on it. We made alot of fun with them in the mid-2000s! However, the later ones didn't have either.

Do you mean the Cool Boy decals? :lol:

[SpudRider]

I want a choke assembly like Spud's. Instead of pulling the choke out its on the bars.. hmmmm. ;)
You can purchase my Zong's left switchgear from Taobao. ;)

http://item.taobao.com/item.htm?spm=a230r.1.14.127.HL1VZo&id=17314578903

However, I don't know if your choke cable will fit the Zongshen assembly. :hmm:

[Wild_Alaskan]

I just thought of something. If you want a true rotiserie restoration, review the old, old threads regarding the Lifan GY-5s. There was a sticker on the side that EVERYBODY who bought the '5' took off, as well as a handlebar pad which had an obscure word on it. We made alot of fun with them in the mid-2000s! However, the later ones didn't have either.

Bar pad: Lifan Auspicious

hahah best ever, still have it ;)

[nyvdub89]

LOL those decals were terrible. Spud, I need a new choke cable anyhow :)

[nyvdub89]

Good progress! What kind of engine swap are you doing?

Weld, I'm putting two different twin cam Honda engines in. One in a 92 civic and another in a 97. Easy work. Neither should take more than 4 hours. I'm going to try and do both the same day so I can just deposit the money right after. :tup:

[Weldangrind]

Weld, I'm putting two different twin cam Honda engines in. One in a 92 civic and another in a 97. Easy work. Neither should take more than 4 hours. I'm going to try and do both the same day so I can just deposit the money right after. :tup:

Wow! You're much faster than me. I'm lucky if I can complete an engine swap in a weekend.

[nyvdub89]

Those Hondas are like Legos. There's a total of like 13 or 14 bolts to get them in. Plus the 7 for the transmission and 2 for the starter. Cake. :)

[nyvdub89]

Big update today. I'll let the video talk for me.

http://i1128.photobucket.com/albums/m494/tbanksphotography/829A030E-62BA-4D2D-B2AC-07E739A6A620-8404-000002107FA5A525_zps5c2831c7.mp4

[nyvdub89]

video (http://i1128.photobucket.com/albums/m494/tbanksphotography/829A030E-62BA-4D2D-B2AC-07E739A6A620-8404-000002107FA5A525_zpsa3e15987.mp4)

[bogieboy]

man today must be the day for getting these suckers running...hehehe check out my thread....

[nyvdub89]

It was in the air, I guess. lol I'm ecstatic. These little Chinese engines are bulletproof.

[culcune]

do you mean the cool boy decals? :lol:

yesssssssssss!

[culcune]

Bar pad: Lifan Auspicious

hahah best ever, still have it ;)

Don't ever sell it, unless somone gives you at least $2

[nyvdub89]

Don't ever sell it, unless somone gives you at least $2

A whole $2.00?!?! :wtf::lol:

[nyvdub89]

Well I got the bike running today. I ordered LED blinkers for the rear and a new battery. No more ordering until I do those engine swaps. My buddy's parts need to come in already. -__- Hopefully my throttle will arrive tomorrow so I can set my idle and enjoy it. LOL.


Current list is as follows..
1) Brake light
2) New tires
3) Headlight assembly or new plastic
4) Roll of vinyl for seat
5) Strip paint
6) New chain
7) Register and insure.

I'm going to safety training school to get my license on July 13th & 14th. It's a deduction on insurance and a waiver for the road test. I'd like to go to motor vehicles the following day and receive my license an register my bike all in one shot. I will do more things after the bike is on the road and legal, but for now I'm focusing on making it pass NYS Motorcycle Inspection. :tup:

We're almost there guys. :)

[SpudRider]

:clap:

Congratulations, and good work! :tup:

[Weldangrind]

Excellent news!

Do you know anybody with a welder? You could mod that muffler for a more free breathing system.

[nyvdub89]

My brother is a nationally certified welder in a union. ;)

[Weldangrind]

Awesome! I built a muffler for a hillbilly resto I did, and you can see it here: http://www.chinariders.net/showthread.php?t=10096 It's really easy, and a little math helps you to make sure that you're not causing a restriction.

[bogieboy]

Awesome! I built a muffler for a hillbilly resto I did, and you can see it here: http://www.chinariders.net/showthread.php?t=10096 It's really easy, and a little math helps you to make sure that you're not causing a restriction.

not a bad looking setup... do you have any sound clips of the sound of the muffler? i am wanting to get something better for my shineray and that looks like a good option seeing as i can weld no problems...LOL

[nyvdub89]

Nothing done to the Lifan today. I spent my afternoon changing my gti's axle instead. Wooo. Not. Tomorrow will consist of taking apart the opposing side hub and bringing it to a good friend's shop so we can press the old bearing out and install a new one. Hopefully some bass fishing after. :tup:

[Weldangrind]

not a bad looking setup... do you have any sound clips of the sound of the muffler? i am wanting to get something better for my shineray and that looks like a good option seeing as i can weld no problems...LOL

There's a sound clip in the build thread, near the end.

[Weldangrind]

Nothing done to the Lifan today. I spent my afternoon changing my gti's axle instead. Wooo. Not. Tomorrow will consist of taking apart the opposing side hub and bringing it to a good friend's shop so we can press the old bearing out and install a new one. Hopefully some bass fishing after. :tup:

Pressing the bearing out of the GTI hub?

[nyvdub89]

The axle was a piece of cake. The wheel bearing took a little more finessing. I also replaced my passenger side tie rod end because it was seized so I cut it off to remove the hub. It's all buttoned up and ready to go. My throttle cable came in but it's about 3" too short. Any left handed turn makes the engine rev. The seller doesn't have any larger either. Just my luck. ):

[Weldangrind]

At the very least, you have a length reference that you can use for the next cable you order.

I feel your pain on the front end work. I pulled the tie rods out of Mrs. Weldangrind's Intrepid today, because the inner tie rod bushings were totally wasted, with only 75000 miles on it. The good news is that the replacements are poly two-piece units, and I slathered 'em with moly grease to prevent squeaking. I'm not sure how I would have pressed those bushings in without a 12 ton press.

[nyvdub89]

Oyee. I'd have done the same thing. I happen to have a 20 ton press at my disposal. I'd still replace the whole unit because of warranty issues. I'd rather not have to press something in and out multiple times and possibly compromise the strength if said unit be it a control arm, tie rod, ball joint, etc. My exception is wheel bearings because of how large the hub is.

[Xrrl]

Hi! I'm posting in regards to your gearing situation. I once experimented with a 17 front 36 rear sprocket combination and the bike will only run (and I mean it, WOT) at 65ish MPH, 70 down a light hill and I'm 6' tall and weigh 131 lbs! You'll probably be better to stay away from any smaller of a rear sprocket than around 43 teeth, as suggested by others. Current (stock) gearing runs 4.9k RPM to go 45 MPH. With a 43 tooth rear sprocket, your speeds will be matching to your RPMs. 45 MPH = 4500 RPM, 55 MPH = 5500 RPM, so on and so forth. (By the way, you were correct on the stock sprockets being a 17 tooth front and 46 tooth rear)
I decided on changing my rear sprocket back to stock simply due to the fact that it seems to put a significant strain on the clutch when taking off (just on level ground). Then again though, when I got the bike I had suspected the frictions had some glazing...when taking off there is a lot of slippage, when the slipping finally gets close enough to the engine RPMs it jerks hard and locks the clutch. I'm no expert on it but that's what I suspect. I have absolutely no idea where to get new frictions for the bike so I need to take it as easy as possible on what I have.
A great website you can use for finding what sprockets you'd want to run is www.gearingcommander.com
The exact model stock information is not available but I have the info on hand if you wish to use the website and have accurate data.
Sorry for this lengthy and probably unorganized post, but I just had a lot to say and I'm sort of new to posting on forums.

[Weldangrind]

I have absolutely no idea where to get new frictions for the bike so I need to take it as easy as possible on what I have.

Thanks for all of that good info. Finding replacement clutch parts is the easy part, since they're made by the millions. If you have a Honda clone motor, then the XR200 clutch plates are a perfect fit, should you want something other than stock. As well, you could use aftermarket clutch springs to increase the clamping pressure.

EBC XR200 style clutch plates: http://www.ebay.ca/itm/80-84-HONDA-XR200-EBC-Dirt-Bike-Stock-Style-Clutch-Plate-Set-CK1119-/310615037981?pt=Motorcycles_Parts_Accessories&hash=item485219581d&vxp=mtr

Original China clutch plates, Honda style: http://www.ebay.ca/itm/Clutch-Plates-Set-for-Honda-CG125-Pit-Bike-Moped-ATV-Go-Kart-/281027904160?pt=LH_DefaultDomain_100&hash=item416e9182a0&vxp=mtr

[nyvdub89]

XRRL thanks for the great info. Weld, once again you are always knowledgable!

My blinkers came in today. I mounted those babies up. I'm not showing them until I get a new tail light. I adjusted my pilot screw yesterday but couldn't get the bike to run at all. I forgot to adjust the idle screw. :doh:Well I did that just before and needless to say she stayed running without a throttle installed nor choke for that matter. But it is like 90°f and 94% humidity right now. :tup: Battery and throttle should be here by Saturday the latest. I should be doing the swap this Friday so I might run to my local motorcycle dealer and see what goodies they have that I might coincidentally also need. ;)

Hope everyone is riding well and staying safe! I've only got 20 days to get this baby legal to be on target. :) It's spending time. ;)

[Xrrl]

What a breakthrough, thank you so much Weldandgrind! I was always worried about the clutches completely giving way and having to park the bike! :(
As an addition to my previous post, I ordered a 42 tooth rear sprocket for my bike last night and it should be here tomorrow. I'm planning on using my bike for travelling a 60 mile round trip through a lengthy 55 MPH speed zone so I want to be able to keep up and rid myself of the fear of engine troubles...:tdown:
I'm not meaning to hijack a thread, I'm only posting because my experience with new gearing may be useful to nyvdub89.
Oh! and all this time and I haven't even mentioned what I ride...LOL. It's a 2008 Lifan LF200GY-5.

[nyvdub89]

Nice bike XRRL. ;) I like your taste in bikes. LOL!

[nyvdub89]

Today my new battery came in, I worked on some school buses, and i'ts raining. That about sums up any new activity for now. lol

[Xrrl]

Wanted to give a little more info on the sprocket situation...my rear sprocket came in on Tuesday and I am more than happy with it. I expected a little more speed, but for now it's good enough. I ordered a 42t rear sprocket and I can now travel confidently in 45 MPH zones, lol. With a 17t front and 42t rear, the RPMs scale exactly with the speed traveling in 5th gear. For example, 40 MPH = 4,000 RPM, 45 = 4,500 RPM. I try to keep the engine below 5.5k RPMs so seeing how everyone likes to run 50 in 45s, it's perfect.
The takeoff has a speed of +.4 MPH, and from personal experience, it's not very noticeable at all when compared to stock when taking off. Acceleration is also still quite great. There's no excessive lugging and 5th gear doesn't feel like an overdrive at all. I never exceed half-thottle when riding. :tup:

[nyvdub89]

Thanks for the information X! I appreciate it. :D

[Weldangrind]

Wanted to give a little more info on the sprocket situation...my rear sprocket came in on Tuesday and I am more than happy with it. I expected a little more speed, but for now it's good enough. I ordered a 42t rear sprocket and I can now travel confidently in 45 MPH zones, lol. With a 17t front and 42t rear, the RPMs scale exactly with the speed traveling in 5th gear. For example, 40 MPH = 4,000 RPM, 45 = 4,500 RPM. I try to keep the engine below 5.5k RPMs so seeing how everyone likes to run 50 in 45s, it's perfect.
The takeoff has a speed of +.4 MPH, and from personal experience, it's not very noticeable at all when compared to stock when taking off. Acceleration is also still quite great. There's no excessive lugging and 5th gear doesn't feel like an overdrive at all. I never exceed half-thottle when riding. :tup:

I suspect that your tach isn't being honest with you.

[Xrrl]

I suspect that your tach isn't being honest with you.

Hmm..you could be right. Why do you say that? I've yet to compare it to a GPS but it feels in the +-5mph area for what the actual speed would be.

[Wild_Alaskan]

lifan speedos typically run 10-15% higher than your actual speed also ;)

[Wild_Alaskan]

The axle was a piece of cake. The wheel bearing took a little more finessing. I also replaced my passenger side tie rod end because it was seized so I cut it off to remove the hub. It's all buttoned up and ready to go. My throttle cable came in but it's about 3" too short. Any left handed turn makes the engine rev. The seller doesn't have any larger either. Just my luck. ):

Look for a throttle for a two stroke motocross bike (125cc or 85cc would be pretty close) that has the dimensions you are looking for, you may need to upgrade the throttle tube to one with a roller on top though to take up the extra cable.

i believe denis kirk lists the dimensions with all after market throttle cables

[bogieboy]

Wanted to give a little more info on the sprocket situation...my rear sprocket came in on Tuesday and I am more than happy with it. I expected a little more speed, but for now it's good enough. I ordered a 42t rear sprocket and I can now travel confidently in 45 MPH zones, lol. With a 17t front and 42t rear, the RPMs scale exactly with the speed traveling in 5th gear. For example, 40 MPH = 4,000 RPM, 45 = 4,500 RPM. I try to keep the engine below 5.5k RPMs so seeing how everyone likes to run 50 in 45s, it's perfect.
The takeoff has a speed of +.4 MPH, and from personal experience, it's not very noticeable at all when compared to stock when taking off. Acceleration is also still quite great. There's no excessive lugging and 5th gear doesn't feel like an overdrive at all. I never exceed half-thottle when riding. :tup:

man you could have a good bit more speed with just revving it out....i have an uncapped rev limiter and can pace traffic on the local highway from the frontage road... thats spinning about 9k though on the stock 17/56 combo...LOL and pegged...

[nyvdub89]

I got in touch with the supplier from the first cable I bought and they said they would exchange it for the correct length I need. They just got in cables that are 39" in length with straight cable adjusters. The second cable I bought was the correct length but it has a 90° cable adjuster and the housing is about half an inch too long causing the bike to rev because the slide couldn't close fully. Oh well you live and you learn with these Chinese bikes.

[SpudRider]

...Oh well you live and you learn with these Chinese bikes.
You are a kindred spirit, and a true China Rider. ;)

[Weldangrind]

Hmm..you could be right. Why do you say that? I've yet to compare it to a GPS but it feels in the +-5mph area for what the actual speed would be.

My Lifan tach was ridiculous, and I don't trust them. Can you borrow a tune-up tach from an old-school mechanic? Prehaps you could compare your tach with a decent instrument.

I also don't trust China speedometers. A GPS comparo is a good idea.

[nyvdub89]

You are a kindred spirit, and a true China Rider. ;)

Thanks Spud! :tup:

[nyvdub89]

I will never ever EVER wrap a seat again. At least not one with this bad of a curve. I must be missing 5 of the 7 layers of skin on my fingers and they've been callused for years from guitar playing. :( Not really but in all seriousness the curve on my seat made it hard. And it's not perfect. Darn! And yes, those were staples I had to pull out to stretch the vinyl even more. -__-

http://i1128.photobucket.com/albums/m494/tbanksphotography/2E7971DE-10D2-4732-81F3-B39207A5399C-1098-000000292F6D5E31_zpse9890db9.jpg

[Weldangrind]

I think you did a nice job. If you want to tackle it again in a few days, you could likely get rid of the wrinkles altogether.

[nyvdub89]

I might do that. I'm not too concerned as I've said. This isn't a $8000 motorcycle. Although I've spent a whole $100 so far on it. ;)

[SpudRider]

I agree with Weld. I think you did a pretty good job. :) However, I bet you can do even better if you keep after it. ;)

[nyvdub89]

I'm kind of in a pickle with my carburator. I was getting a cut out between idle and 1/4 throttle telling me I needed to either adjust my pilot screw or increase my pilot jet. I adjusted the screw, lost my perfect position of idle and had to start from scratch. I followed the rule of thumb to start at 3 full turns backed off from all the way in. Unfortunately that wasn't the sweet spot. I've tried everywhere in terms of half turns from 1 - 4 out from snug. I'm not sure if I need a new pilot jet because I don't have my entire air filter assembly on. I was going to throw mesh over the tubing that ran behind the air filter because my filter is completely shot and the sealant around the housing that connected it to the tube rotted away. At 3 1/2 turns out I was getting a puff of white smoke from ignition but it wouldn't stay running. Any suggestions?

[Weldangrind]

First, if you need to turn the pilot mixture screw out more than two turns, your slow jet is too small (assuming it's clean).

Second, the needle comes into play by about 1/4 throttle, so perhaps you need to move the clip. I'd move it down one notch and try again.

[nyvdub89]

I'm kind of lost because everything I know about carburstors says a pilot jet too small would lean the a/f mixture out but I pulled my plug and it was running rich. As for the clip, I'm not sure what you mean by that. My fuel mixture screw has a spring above it ans that's it. :shrug:

[Wild_Alaskan]

running with no air filter will increase off idle bog. i found these gy-5 ran better down low tuned wrong. turn the mixture screw in a little more than it should be and compensate for the rpm loss by adjusting the idle up to the proper setting

also it is possible to get a cover over this curve just keep at it, took me a couple hours and I've done several seats before, this was by far the hardest.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Sales%20Ebay/100_0030.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Sales%20Ebay/100_0030.jpg.html)

[nyvdub89]

That bag of frosted flakes looks amazing, WA. ;) :lol:

[Weldangrind]

I'm kind of lost because everything I know about carburstors says a pilot jet too small would lean the a/f mixture out but I pulled my plug and it was running rich. As for the clip, I'm not sure what you mean by that. My fuel mixture screw has a spring above it ans that's it. :shrug:

Time for some theory.


The slow jet is a fixed jet that you can unscrew and replace. It is responsible for idle.
The pilot mixture screw is the transition that takes you from idle to main.
The jet needle is pulled out of the main jet as the throttle is opened, and the base height setting determines mid-range behaviour.
The main jet is a fixed jet that you can unscrew and replace. It is responsible for 3/4 to WOT.
You'll find the jet needle within the slider. If you unscrew the top cap where the throttle cable enters, you can remove the slider assembly. The jet needle pokes out the bottom of the slider, and the base height of the needle can be adjusted by moving the circlip to a different position. If you move the clip down one notch, it will run richer in the midrange.

For setup, the slow jet needs to be big enough to flow the right amount of fuel to meet the air intake and exhaust. The right slow jet will allow the engine to idle properly and warm up quickly.

With a warm engine, you should be able to open the throttle quickly without (much) bogging or hesitation. Adjust the pilot mixture screw to create a smooth throttle opening. If you need to open the pilot mixture screw more than two turns, the slow jet is too small.

The jet needle controls the midrange, which is from 1/4 to 3/4 throttle. If there is a stumble in the midrange, try moving the clip down one notch. Did that make it better or worse? Move the clip as necessary.

At 3/4 to WOT, the main jet is on it's own. If it behaves like it's running out of fuel at the top end, it's too small.

Think of your carb like a relay race: slow jet / pilot mixture screw / jet needle / main jet. Make sense?

[nyvdub89]

Yes. I understand that all. I'm just lost in that I had it perfect by a fluke and now I can't get it to run at all anymore.

[nyvdub89]

My headlight came in while I was in Wildwood! Wooooo! It has integrated headlights and blinkers. I wanted to do the UFO headlight but that can be later because at the moment I just want the bike to pass inspection. So here is my non-DOT headlight that was a whole $29. :shrug: ;)

http://i1128.photobucket.com/albums/m494/tbanksphotography/B6AEAB7A-450A-4FE4-BA84-6FCCC53D6DC7-7598-00000216E126F7FD_zps5887d580.jpg

[SpudRider]

The headlight looks good. :) I thought it was a UFO for sure. ;)

[nyvdub89]

Shhh Spud, don't tell anyone it's not. It'll be our little secret ;) :lol:

[nyvdub89]

Anyone know which jets work in my carburator? It's a 3 screw type. I want to try a 42 pilot jet like I've seen suggested here and other places online. Thanks guys! :)

[Weldangrind]

When I've tried to find jets for the Keihin (three bowl screw) clones, I met with frustration. The easy way out is to buy a 30mm Milkuni on eBay, because you can buy jets at the local Yamaha dealer or online without any trouble.

I've seen three different types of jets in the Keihin clones so far, but the Mikunis are consistent. http://www.ebay.com/itm/Carburetor-Carb-ATV-Dirt-Bike-Quad-Honda-MIKUNI-30mm-/170856879323?pt=Motorcycles_Parts_Accessories&hash=item27c7dd14db&vxp=mtr