400cc Lifan V2

[Wild_Alaskan]

After a hard summer of rallying and sitting idle for the following 9 months the lifan is ready to be freshened up. there were a few problems with the original design. the oil tank (for the dry sump motor) that was made as a copy of the exhaust would leak oil out of its breather very easily, and could cause oil starvation when wheeling at low oil levels.

the suspension was very harsh at the low end of the stroke and was not very progressive. there were some issues with bottoming on drops of over 6ft.

so to remedy these issues I will be converting the upper frame and down tube in to an oil tank. I will be adding a tubular lower frame, replacing the dropout style angle iron style system i had going. this will reinforce the beam the linkage will mount to and add mounting options for replaceable skid plates.
the original high suspension mount was interfering with the air filter and the linkage will also solve this problem.

these are a work in progress, have pics sometime tomorrow probably.

for new people this is the original project thread: http://chinariders.net/modules.php?name=Forums&file=viewtopic&t=9275&highlight=400cc

and the final product:
http://www.youtube.com/watch?v=20HoU8OK_Y0

[2LZ]

Hey WA! Thanks for the refresher course! :D

I can honestly say, I'm pretty sure the Chinese had NO IDEA what some young energetic guy with a torch and great imagination (and plenty of ingenuity and talent, I might add), had up his sleeve, when they first assembled that bike! :lol: 8)

[Weldangrind]

Man, I hope you're taking mechanical engineering in school. You have a natural ability that you should fully develop.

[FastDoc]

Amen to what these two gentlemen said. :D

[Wild_Alaskan]

Ok heres what I've got so far. here are the nearly complete bars for the cradle

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-128-20-44-40-1-Snapshot_20110508.jpg

the oil fill hole and the breather hole

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-128-20-44-40-2-Snapshot_20110508_1.jpg

over view

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-128-20-44-41-3-Snapshot_20110508_2.jpg


I am going to college for mechanical engineering btw
:D

[Wild_Alaskan]

sorry the pictures came out horrible, ill try using my cell phone instead of my webcam next time. soon i will have a replacement charger for my camera that my sister stole.

[Weldangrind]

This bike should be your final exam project.

[2LZ]

This bike should be your final exam project.
WA...try not to teach your Prof to much.... They really hate that. 8)

[SpudRider]

Welcome back for the summer, WA! I am popping the corn, and subscribing to another of your great project threads! :D

Spud :)

[katoranger]

Welcome back for the summer, WA! I am popping the corn, and subscribing to another of your great project threads! :D

Spud :)

Me too. If something goes wrong I have another frame here.

[Wild_Alaskan]

thanks guys :)

got some more work done and pictures im working during the days so progress wont be super fast.

here is the oil tank fill tube and vent. the tube extends to about where the gas tank starts to slope back making for easy access with a funnel.

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-130-2-12-44-3-0copy509112142a.jpg

one of the side plates ready to go on to maximize oil compacity

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-130-2-12-44-2-0copy509112141a.jpg

one of the bars for the cradle just about to go on

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-130-2-12-43-1-0copy509112140a.jpg


still pretty bad pictures with the cell phone in a couple weeks they will improve :D

[Wild_Alaskan]

woops double posted somehow

[SpudRider]

Thanks for the update, WA! :)

Spud :)

[katoranger]

Need to swing past costco for more popcorn.

[Weldangrind]

No disrespect intended towards your welding skills; I recommend that you test the final container with water to check for leaks. It will more easily run out, and it won't ignite if you need to weld further.

[Wild_Alaskan]

things are not going well for the frame oil tank, the stick welder leaves slag deposits that will leak and are extremely hard to get out and are nearly impossible to weld over, there are also leaks along many of the seams and the holes for the gastank and where the rest of the frame connects to it.

I also made the discovery that my swing arm is bent :x . one side is bowed around where the shock mounts. not sure what im going to do with this thing. I can use the old oil system and do the frame modifications but the bent swing arm is a problem. i have a feeling i would bend a new one just as easy and converting to an xr one will mean more huge frame mods as the swing arm is about an inch wider.

:cry:

[SpudRider]

I'm sorry to hear of the difficulties, WA. :( I can't offer a solution, but I hope someone else can. :?

Spud :)

[katoranger]

I have another swingarm. Two actually. Maybe you can reinforce one.

[Weldangrind]

I still have some old CR125 stuff that would be an awesome addition. I have the entire frame, swingarm and giant reservoir shock.

[Weldangrind]

I also have the front forks. You could make an amazing bike with that setup. I once came across a post (thumpertalk maybe?) wher a guy stuck an XR200R engine in an '88 CR125, and he said it was the ultimate bush bike. The suspension range on a CR125 frame is remarkable, but the 125 stuff is light enough for general use. The CR250 stuff is a little stiff for bush riding.

BTW, a MIG welder is your friend. http://www.eastwood.com/mig-welder-110vac-135a-output.html

[dmmcd]

things are not going well for the frame oil tank, the stick welder leaves slag deposits that will leak and are extremely hard to get out and are nearly impossible to weld over, there are also leaks along many of the seams and the holes for the gastank and where the rest of the frame connects to it.

I would think to get a nice sealed joint, you will definitely want to TIG weld it. Even MIG leaves a considerable amount of slag and you can get porosity. You will have to make sure the tubes are well prepped and very clean before welding.

Or go over the whole thing with JB weld... but I wouldn't trust it in the long run.

[Weldangrind]

What if you created a bolt in section of the downtube, and spent time with it on the bench to make it totally watertight? You could then weld in bungs that allow oil in / out, and then supplement it with an external cooler. The XR400 cooler fits nicely behind the headlight.

[FastDoc]

I don't have the knowledge to contribute but I must say I enjoy the thread and the knowledge of our group and the desire to help and share.

As I've said before, it's great to know you guys.

[SpudRider]

I agree with Weldangrind; an XR400 cooler should work well for you. In addition, you easily acquire a number of different automotive transmission coolers you can attach externally to the bike with hi-temperature hose. :)

Spud :)

[Weldangrind]

I thought about an automotive cooler as well Spud, but then the issue of protecting it comes up. WA could fabricate an expanded metal cover for it, but the XR400 cooler just makes more sense.

[SpudRider]

I thought about an automotive cooler as well Spud, but then the issue of protecting it comes up. WA could fabricate an expanded metal cover for it, but the XR400 cooler just makes more sense.
I agree; the XR400 cooler is a great solution! :D However, if one is on a tight budget, he can acquire an automotive cooler from a salvage yard for little cost. If you attach the automotive cooler under the headlight, on top of the fender, you can protect it pretty well; many XR650L owners are employing this method. However, the hose can get kinked when you move the cooler to the forks, instead of the bike's frame. ;)

Spud :)

[Wild_Alaskan]

totally missed kato's post for some reason. ended up getting one off ebay for $50 ill post the reinforcing mods when it gets here :lol: . i got the cradle attached and tested to make sure the motor would still come in and out. all is good in that department. get some pictures at some point

[katoranger]

$50. Mine would have been free.

[Wild_Alaskan]

the motor is basically mounted now. I'm going to put the suspension linkage back on soon :lol: here is a picture of the old swing arm with a carpenters square on top of it to show how bent it is.

http://usera.ImageCave.com/sheridanjoyce/bikemods/0522111719a.jpg

[Wild_Alaskan]

frame is done, swingarm is reinforced, and linkage is ready to go. all is coming out great :D if i have enough time i may throw it back together tomorrow.

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-150-0-40-33-1-P1010216.jpg

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-150-0-40-33-2-P1010217.jpg

[Weldangrind]

So, what's left that's China bike? The forks? :lol:

I hope you can get all of that insulation in the attic before it gets cold again.

[SpudRider]

It looks good, WA! Thanks for the update, and the photos! :D

Spud :)

[Wild_Alaskan]

So, what's left that's China bike? The forks? :lol:

pretty much :?

[Weldangrind]

It's tough to tell from the pic, but did you weld a diamond plate over the swingarm? That's a good idea. :idea:

[Wild_Alaskan]

yep diamond plates on both sides of the swingarm. the wiring harness i purchased a while back from hooper works! :D just need to get a 4 pin rectifier, since mine is 6 pin. the bike is plumbed back to the fake muffler. the turn signals and a brake light work, and it has spark. cant wait to take it for a ride and see what the stage two cam does for this thing.

ill get some pictures for you guys tomorrow

[Weldangrind]

Cool! I didn't realize that you put a cam in it. Good luck! :D

[SpudRider]

As always, we eagerly await your photos, WA! :)

Spud :)

[Wild_Alaskan]

Took it out on its first ride recently, worked great FCR needs some tuning though.

looking out at the glacier

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-185-2-30-7-1-100_0010.jpg

friend and his yz 450

http://usera.ImageCave.com/sheridanjoyce/bikemods/2011-185-2-30-7-2-reuben.PNG.jpg

[Weldangrind]

Got pics of your completed bike?

[Wild_Alaskan]

soon, still need to make a new exhaust,figure out the headlight, and put on the tail light