Lifan 200cc OHC wiring diagram anyone?

[FastDoc]

My motor for the XR came today. No instructiuons or wiring diagram. Can anyone help?

[mizke]

damn good luck man, i hate dealing with wires.. shouldnt be to hard tho, just might take a few hours of research..

[FastDoc]

damn good luck man, i hate dealing with wires.. shouldnt be to hard tho, just might take a few hours of research..

I'm hoping one of us has done the homework already!

There is a tiny bundle of about 5 wires, very small gauge. I'm thinking that's for the gear position indicator and neutral light, I don't know. Then theres a CDI, and the coil, what I think is a regulator/rectifier, a solenoid...

The XR motor only had like 4 wires total.

[katoranger]

www.dratv.com may be of help.

http://www.hooperimports.com/showpages.asp?pid=1013

The hooper link will probably get you going.

[BillR]

I'm hoping one of us has done the homework already!
There is a tiny bundle of about 5 wires, very small gauge. I'm thinking that's for the gear position indicator and neutral light, I don't know. Then theres a CDI, and the coil, what I think is a regulator/rectifier, a solenoid...
The XR motor only had like 4 wires total.
'Course we have... :wink:
Mblas3 photo gallery (http://www.chinariders.net/gallery2/main.php?g2_itemId=5478)
I was having a fit with a headlight problem and worked with Mark's diagrams. Very helpful.
The "tiny bundle" is the for gear indicator light. You'll have a lot fewer wires than on the diagrams due to "no lights".
Good luck.
Bill R

[FastDoc]

Thank you gentlemen.

I will try to make the time to install the motor this weekend.

My nect challenge, after the wiring, will be the countershaft sprocket.

The motor has what looks like a 428, the XR is a 520. I'm hoping my old XR sprocket will fit on my new Lifan engine.

[mizke]

i would assume you would be able to swap a 520 sprocket on it. but after dealing with the wires its all down hill from there.. just dont forget to do a proper break in on the motor

[FastDoc]

The new motor is in.

Pretty much a direct fit.

The new intake boot was not angled right so I used the old one. Other than that it was straightforward.

The old sprocket does not fit on the new countershaft. The opening and the grooves are a little too small.

I may have to order an $80 special one from Hooper Imports unless someone knows what sprocket will fit an OHC Lifan but 13 teeth in size 520.

I have to go do the carb cable, then I'll look at the wiring. I also have to decide if I will go electric start or kick. I'm leaning towards electric.

[katoranger]

Doc, here is the sprocket info.

http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=1393

[FastDoc]

Thanks!

My question is then why won't my XR sprocket fit? I'm puzzled. I'll have to get my calipers out and measure. I should get a pair that are metric.

I have the wiring almost done, but I have to leave the house now and won't get a chance to finish it tonight. Maybe I'll start it tomorrow if I'm especially blessed. Then I may only be a sprocket away from riding.

Right now it is wired without a battery but I can always update it later.

[mizke]

very nice doc, hope you took some pictures.. dont need a write up on it but pictures would be awsome. it would be almost like we all where in the garage with you while you did it..

[FastDoc]

very nice doc, hope you took some pictures.. dont need a write up on it but pictures would be awsome. it would be almost like we all where in the garage with you while you did it..

I wish you all were here, I could use help!

This is one of those projects that is bigger than it seems, it's all in the details!

Tomorrow I will try to file the inside of the XR sprocket to see if I can get it to fit.

[mizke]

no matter how big the project, its always small when you break it down into steps and knock one out at a time.

thats what got me with jetting my carb. i looked at it as a whole, but when i started looking at it at one step at a time, it got easier

[katoranger]

I am thinking that the wiring may be waiting for you when you get home. If not should be tomorrow.

[FastDoc]

I am thinking that the wiring may be waiting for you when you get home. If not should be tomorrow.

It was not in the mail today. Hopefully tomorrow.

Still waiting on the sprocket, fork seals, Uni filter, and battery so there is still a ways to go. I hate not being able to finish and ride this thing, today is so nice and I have the afternoon off to work on it... :cry:

Any word on those tires? :D

[katoranger]

Hoping to peel them off tomorrow night. (I may sneak them in the kitchen tonight) I have been busy with tractor parts the past couple weeks. We are still mowing grass here.

[FastDoc]

No rush at all. I think I have one more mowing here for the season and that's it. I HATE yardwork!

[katoranger]

Tires are off and ready. They didn't put up a fuss.

[mizke]

No rush at all. I think I have one more mowing here for the season and that's it. I HATE yardwork!

i ya i hate yard work to man, this summer it didnt rain for like a month and a half after i mowed the yard.. it was awsome, then a month and a half later it rained for 19hrs non stop.. 3 days later the yard was shin high and it took another 2 days for the grass to dry out enough to mow..

my back yard is big enough if i really wanted to and could afford it, i could get a mower attachment for my quad and use that.. but ya id be tempted to do some tractor pull type stuff with the mower on it.

[FastDoc]

I hate yardwork. As long as everything continues to grow back it seems like a waste of time to me. It does not help I live on three manicured acres.

The house and property are for sale. I bought this giant place to make the (ex)wife happy. :twisted:

Didn't work. :roll:

[mizke]

not trying to go off topic here, but i wouldnt sell it. you can do whatever you want, you room for the toys and room to ride the toys.

if i was rich enough id have my yard tore up, all the grass killed so it does not grow back and have astro turf installed.. year round green perfect yard with out ever have to mow, water, weed, feed or anything..

[FastDoc]

With the amount it costs me to live here I could buy a very nice, new Japanese motorcycle every month.

It's just me and my stray adopted cats in 5,000 square feet.

I can 'afford' it, but it's hard to save and pay spousal support and give to the church and everything else at the same time. I've not been able to put much into my retirement since I started paying the divorce lawyers, etc.

Not complaining mind you, it's an amazing home, but I'd do fine with a small house in the country with a nice heated shop or barn.

[katoranger]

Just need a room in the heated shop with a shower. No house needed.

[FastDoc]

Just need a room in the heated shop with a shower. No house needed.

That's OK for us, but I have a nice young lady friend who would likely enjoy more amenities.

[Cal25]

my house is built inside my shop. I like it but it aint for everyone.

[katoranger]

http://i39.photobucket.com/albums/e166/katoranger/motolivingroom.jpg


Back on topic. The wiring should arrive today.

[katoranger]

my house is built inside my shop. I like it but it aint for everyone.

Growing up in in IA my neighbors had a house attached to the dairy barn.


I always wanted a 4 car garage with attached house.

[FastDoc]

We may have set a CR record for thread drift!

Looking forward to the wiring. If it's here tonight I may have it running! I ordered a gel sealed battery, and a Uni sock type airfilter, and constructed battery cables for it.

Still waiting on fork seals I ordered 11 days ago.

Note to all of us.

MOTORCYCLE SUPERSTORE.

Just buy from them. NO PLACE else shipps as fast. Wish I did not order seals from some lesser know dude on eBay.

[katoranger]

I have good service from them also.

[FastDoc]

Got the wiring half done. Trying to figure out the starter button. I think it may not work from water damage. Been soldering and shrink tubing for a long time tonight!

Tomorrow I'll work more on it and find out if Hooper's wiring diagrams are right. HOPEFULLY I'll have the sprocket soon and have this baby on the trails by next weekend.

[katoranger]

The start button is really simple to take apart and clean, but they are also very cheaply made too. Hint(Radio Shack is your friend)

Replacement push moment switch and you can fit it in the mount.

[FastDoc]

I'll take it apart and try cleaning it. The on/off switch works, I may keep iyt and use it for that. I already have a momentary switchc left over from another project I can use.

[mizke]

i know rmatvmc sells the pro armor kill switches for pretty cheap.. if needed i bet you could use one of those as a start button..

[FastDoc]

Update.

I got the sprocket on, and some of the wiring soldered, but have not had enough time to do much more.

I really hope this works!

The Lifan countershaft sprocket cover will require some modification (ie angle grinder) to fit between the engine and the frame.

[FastDoc]

I also have to figure out a battery rack, and have Ron weld something up. I also need to fabricate a negative battery cable, then IF all my wiring is correct (A big if, I had to integrate 2 different wiring diagrams. One had the right CDI, the other had the right RR, but no one diagram had both...), I have to waterproof and hide everything.

This is not a simple project. It's more than I'd expected. Must keep morale high.

[mizke]

if you need cable for the battery cables, find a local car stereo place that does custom audio systems in cars. the cable is cheap and super high quality.. id say prices would be around $1-$1.25 foot, wish there was a cheapish decent quick connect for the batteries in these bikes and quads. ive had to get in the habit of disconnecting my negative cable so the charge on my battery will last more then 2 days

[Weldangrind]

You're blazin' trails for the rest of us, Doc. :D I haven't encountered anyone who has repowered a Honda with a China engine yet. I believe that it's a plan of Kato's, but I don't think his is complete yet.

[katoranger]

I am no where close to completion. Haven't even started yet. Maybe after Christmas.

Anyway use a heavier cable for the ground. I believe you will get better performance from the starter. The little ones that come stock are not enough.

[FastDoc]

I have some leftover very heavy cable, I forget the gauge (4 maybe?) that I used to power the subwoofer in my pickup.

My main concern is the wiring, if it's correct. Having to integtate 2 wiring diagrams scares me. I'm afraid of hurting something when I hook up the battery.

The fork seals are still not here after 2 weeks. I think the eBay guy screwed me.

He has a tracking number but when I follow that it does not look like the parts were ever actuially picked up. I think I'm out $25 and will just order another set from the Motorcycle Superstore and forget the money lost.

The battery and pod filter should be here soon. I'll figure out the jetting based on how, and if, it runs.

Stay with me guys...

[katoranger]

4 guage should be heavy enough. You won't have to worry about grounding problems.

[mizke]

ya that ground cable would be more then the bike would ever need..

i wouldnt mind a china powered big 4 brand quad.. cheap motor and still be able to use the awsome aftermarket parts like swingarms, extended control arms, bumpers, nerf bars..

doc just when you get to the point, hook up the battery and turn the key to on. wait for smoke, if there is none after a minute. you should be fine to start it..

[FastDoc]

It runs.

I can hardly believe it but it runs.

The solenoid does not seem to work. It clicks but does not turn the starter. If I cross the terminals with a screwdrive it starts.

Getting there.

Need the battery (I'm using a spare battery next to the bike sitting on a chair now) and the air filter and she may be ready for a test ride soon.

I have no idea if its charging, will worry about that next.

[mizke]

well if you have a kick starter on it, then figuring it out wont be a big deal. if the battery goes out, just kick it. but at least it runs.. ive had good luck with the battery i got off the guy on cl for 25 bucks.. its the same one that autozone sells.

but congrats..

[SpudRider]

Congratulations, Doc! :D If you have time, will you post some photos?

Spud :)

[FastDoc]

I'll take some before I move onto the next step. Then I'll make the wiring 'pretty' and rephotograph.

The new kickstarter does not work, it does not clear the rear brake pedal. I have to see if the old one will work. If not I can modify one or the other or make it electric start only.

I wonder what's up with the solenoid. I have Bill's flood ravaged one to try but I can't imagine it would be better than the new one...

[mizke]

id try real hard to keep the kick starter, just incase the battery goes while you are away from the house..

if anything you make one that is attached to the bike some where out of sight, only to be pulled out in the event the battery happens to die while you are away from the house.. kick start it and then put the kick start lever back in its hiding spot and head on down the road

[Weldangrind]

It runs.

I can hardly believe it but it runs.

Yaaaay!!!

Congrats! Can't wait for photos. Video would be nice too.

[MICRider]

Grats on the internal combustion! Cant wait to see some pics of it :)

[katoranger]

I am curious to know about the kickstarter. The may prove to be a problem on mine then too. I was considering just using the kick start.


For the solenoid. Likely that the new is bad out of the box. Give the flooded one a try. Otherwise lawn and garden ones work well and can be found at home depot and walmart I believe for cheap.

I probably have 3-4 of them if you would like me to mail some.

Allen

[FastDoc]

The old Honda kickstarter will work, but the ball spring indent is sloppy. The new Lifan one does not clear the brake pedal, but I can make a small bend in the pedal arm and it will work. either way I'll go with one or the other.

I will try the drowned solenoid, if it does not work I have to go to Home Despot anyway to get an oil and air filter for the lawnmower before I put it up for the season anyways.

I need to cut the steel for the battery box and have my friend weld it. I intend to use the steel from the shipping carton that my friend's Q came in. Chinasteel for a Chinapowered Honda.

Seems just.

[Weldangrind]

Seems just. Poetic even.

Home Despot. That cracked me up! :lol:

I've taken Honda kickers apart before to tune out the sloppiness. Just carefully file away any burrs around the ball socket, lightly stamp the ball into the socket and stretch the spring. Pack the whole deal with wheel bearing grease and it should be much better.

On occasion, I have had to weld a tiny bead on the shoulder that the kicker stops against, so that the kicker is perpendicular to the engine when in the starting position.

Please post a pic and show us how the kickers don't work with the XR frame. I thought that the China motor would be identical to the XR motor on the right side.

[FastDoc]

Good idea.

My friend had to weld a bead to make it perpindicular on his 1969 BSA. He knows how to do it. I may bring him my XR kickstarter to fix also.

Will take some pics, I may even have already but not downloaded them.

I wish I knew how to weld and was not so dependant on others, but heck, I can do all sorts of other things. Can't do it all! :roll:

The motor is not the same dimentionally.

It fits, but there is NO WAY to get the countershaft sprocket cover on. The motor is much wider in that area than the original. I see an angle grinder in it's future... 8O

The new carb holder is at the wrong angle to work with the rear shock so I had to reuse the old one.

The right side may be semi-identical, it's the kickstarter itsel that is a little different.

Also the Lifan is a 5 speed, the Honda is a 6 speed. Big difference there.

BUT I got the BRAND NEW Chinamotor for $357! :P

I'm a happy miser! :D

[Weldangrind]

MIG welding is certainly within your scope. Like I always say, if you can fog a mirror, you can MIG weld.

If I was in the market for a new 110 volt MIG today, I'd buy this one: http://www.eastwood.com/mig-welder-110vac-135a-output.html

[SpudRider]

...Also the Lifan is a 5 speed, the Honda is a 6 speed. Big difference there.

BUT I got the BRAND NEW Chinamotor for $357! :P

I'm a happy miser! :D
Spoken like a true China Rider! :D

Spud :lol:

[SpudRider]

It's time for a minor, temporary, dare I say righteous threadjack! ;) Today Brother Bill, a.k.a. FastDoc, achieved sixth place on the total posts list at China Riders! Doc, I think it's fair to say you have found a home here! :lol: We certainly love having you here, and would miss you dearly if you ever departed! :D

Spud :D

[FastDoc]

It's time for a minor, temporary, dare I say righteous threadjack! ;) Today Brother Bill, a.k.a. FastDoc, achieved sixth place on the total posts list at China Riders! Doc, I think it's fair to say you have found a home here! :lol: We certainly love having you here, and would miss you dearly if you ever departed! :D

Spud :D

Thank you brother Spud.

I really DO feel at home here, and I enjoy learning from, and sharing my knowledge with you all.

Indeed when I'm out on a ride or working on something, I'm thinking about you guys.

Indeed you have seen me through a lot, including my crash of almost exactly one year ago.

[TurboT]

It's time for a minor, temporary, dare I say righteous threadjack! ;) Today Brother Bill, a.k.a. FastDoc, achieved sixth place on the total posts list at China Riders! Doc, I think it's fair to say you have found a home here! :lol: We certainly love having you here, and would miss you dearly if you ever departed! :D

Spud :D

We keep post count standings?? 8O

Who knew. Mizke will pass us all by month's end. :lol:

[mizke]

nah i wont pass you guys for awhile, since my quad is running so good i dont have to post about problems.

and i dont see myself making to many new posts in the near future unless i get a wild hair to do something to my quad, then have the ever so sobering moment of saying to myself " oh crap i screwed up the quad, time to post"

i mainly lurk now and add my 2 cents here and there..plus with the new job i dont have the same kind of down time i did with my last job.

[SpudRider]

It's time for a minor, temporary, dare I say righteous threadjack! ;) Today Brother Bill, a.k.a. FastDoc, achieved sixth place on the total posts list at China Riders! Doc, I think it's fair to say you have found a home here! :lol: We certainly love having you here, and would miss you dearly if you ever departed! :D

Spud :D

We keep post count standings?? 8O

Who knew. Mizke will pass us all by month's end. :lol:
Indeed, we do keep count, Turbo. ;) I was just getting ready to congratulate you on passing the exclusive, 2,000 post mark! You are now one of the top ten posters at China Riders! :D Needless to say, we love having you here as well, Turbo! Thank you for all your helpful, interesting posts. :)

Spud :)

[FastDoc]

Bill's drowned solenoid works fine, the new one's defective, go figure.

Bike seems to run well. Have not been able to ride it yet due to no battery (I'm using a big battery on a chair next to the bike hooked up on cables now) or air filter. Hopefully tomorrow will get 'correct' battey duct taped in temporarily and sock fitted and take it for a ride.

The countershaft sprocket cover won't fit with any amount of cutting, and the Honda part is quite different and won't fit the new motor. So, no countershaft sproket cover. Seems like it will be OK.

[FastDoc]

I have the wiring mostly loomed up and tucked away.

Getting there.

Need starter switch repaired or figured out...

[SpudRider]

Bill's drowned solenoid works fine, the new one's defective, go figure...
:lol: Only a China Rider would understand, Brother Bill. ;)
...The countershaft sprocket cover won't fit with any amount of cutting, and the Honda part is quite different and won't fit the new motor. So, no countershaft sproket cover. Seems like it will be OK.
I'm sure it will be fine, Bill. :) You are breaking new ground! Pretty please, can we see some photos. :roll:

Spud :)

[mizke]

I have the wiring mostly loomed up and tucked away.

Getting there.

Need starter switch repaired or figured out...

you could get one from a auto parts store, or order one for a big 4 brand atv or dirt bike..

[FastDoc]

Bill's drowned solenoid works fine, the new one's defective, go figure...
:lol: Only a China Rider would understand, Brother Bill. ;)
...The countershaft sprocket cover won't fit with any amount of cutting, and the Honda part is quite different and won't fit the new motor. So, no countershaft sproket cover. Seems like it will be OK.
I'm sure it will be fine, Bill. :) You are breaking new ground! Pretty please, can we see some photos. :roll:

Spud :)

I just opened a new thread to post a bunch in this forum. I even included a pic of Martin The Cat's successful hunt... :D

[SpudRider]

Thanks, Bill; the photos, and video are great! :) Here's a link to the thread containing the photos. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&p=108406#108406

Spud :)

[TurboT]

Awesome!

[katoranger]

Even drowned china parts still work.

BillR's bike is living on in many new homes. :lol:

Now I am wanting to get my bike done.

[Cal25]

We will all help out. Just post a pic and we will tell you what needs to be done next. :lol:

[FastDoc]

Even drowned china parts still work.

BillR's bike is living on in many new homes. :lol:

Now I am wanting to get my bike done.

You're lucky I jumped in first! This is not as straightforward as some would have you think. Where are you in your project, and what are your intentions?

[FastDoc]

We will all help out. Just post a pic and we will tell you what needs to be done next. :lol:

Cool. When are you coming over with your welder? :P

[katoranger]

Tell me the dimensions and I can weld up a box.



My current status on my honfan gr200r is not started yet.

I got the bike in a rolling chassis/basket case on trade for getting some others running. The engine from my Gy2 is on the shed floor awaiting mounting.

I did plan to paint it up, but I may just go ahead and follow Doc's lead and just put it together and ride.

Fortuntately mine is an 87 and already had a CDI ignition setup. I can run it off the stock wiring.

[Weldangrind]

'83 has CDI as well.

[katoranger]

Doc, do you have the part number for the sprocket?

[FastDoc]

Don't have it now. I still have the box in the garage so I can get it for you. Its an off the shelf part I bought through Hooper Imports.

Thanks on the offer to weld a box. I may take you up on it but it may also be a good learning project for my friend to teach me when he gets back from his trucking run. We'll see...

[katoranger]

I needed to use the welder again today. Carriage bolt on a vintage john deere stripped the square hole. Solution. Weld it in place. Just alittle tack and I was able to remove the nut.

http://i39.photobucket.com/albums/e166/katoranger/utf-8BSU1HMDA1NDYuanBn.jpg