Project NX200

[nx_guy]

Project Honda NX125 to NX200.
Little did I know when I purchased this - I'd take it to the shop and pick it up in a box. Very sad day.

Here is the very happy days - but with out much power. It had loads of over spray on the plastics - been stored in a body shop.

http://i1192.photobucket.com/albums/aa329/nx_guy/HondaNX1_102010.jpg

Tires - hard and dry cracked

Looks like it will fit - right(?)
http://i1192.photobucket.com/albums/aa329/nx_guy/HondaMotor5_052011.jpg

It's in the HOLE - if I can quote Bill Murray.
http://i1192.photobucket.com/albums/aa329/nx_guy/HondaMotor6_052011.jpg

Now I'm stuck because of the wiring diagram issues with Lifan...
http://i1192.photobucket.com/albums/aa329/nx_guy/HondaMotor15_052011.jpg

As you can see the garage floor looks nice, the motor came in the same week we planned to epoxy the floor.

nx_guy

[FastDoc]

AWESOME!!!! :D :D

Have you seen the wiring diagrams on Hooper Import's website?

[nx_guy]

Yes - it didn't match what was on the engine (163fml-2).

[FastDoc]

If you ignore the harness for the wires that deal with the gear position indicator it's pretty straight forward, if not time consuming.

I refer you to my threads on the construction of The Dirt Rat where I dealt with the same issue.

[katoranger]

You are going to have a great ride there. Looks like a perfect honda to be repowered.

[SpudRider]

Did the engine bolt right in, without any problems? The 163-FML2 engine looks great in your bike! :)

Spud :)

[Weldangrind]

That's gonna be the perfect 200cc bike. Nice and light, no frills and a very capable commuter. I do have my concerns about the front brake, but there might be a dirt bike workaround if necessary. I installed an '85 XR250 front end onto Son of Weldangrind's '83 XR200R, and it was a perfect fit.

Voila. Disc brake. :D

[nx_guy]

The motor went right in - top engine mount didn't work, but I can fix that.

After combing the inky-shadows of the internet. Looks like Lifan got a deal on some cheap wire because they changed their colors based off the diagrams I've seen.

I need a closeup look at the colors that are standard on the main harness coming out the motor.

Here is mine.
Top Row (left to right)
Green/White, Yellow, (blank)

Bottom Row(left to right)
Blue/White, Pink, Black/Red

http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1370.jpg

If anyone can have l look see on their colors and let me know - I'd appreciate it.

nx_guy

[Weldangrind]

Just to clarify, did the Lifan come with a new CDI, coil and reg / rec? If so, I'd use 'em, rather than trying to use the Honda stuff.

[Weldangrind]

This looks to be similar.

http://forum.grasscity.com/photopost/data/500/200_wiring.jpg

[katoranger]

Is that the rectifier plug?

[nx_guy]

Because of new EPA regs and CARB stuff all I got was the motor.

I'd been trying to get the package deal since May but just now got one
after the fact and they removed the bundled items which would have
saved me the headache.

That diagram is different then what is on Hooper's site.
I maybe having other issues since I'm using the existing Honda stuff.

Getting spark, headlight doesn't work with key on, the starter does if
I jump it. It should start and run as is but would like to understand
what's happening + would be nice to turn it off/kill.

Thanks.
Back to the garage!!!

[nx_guy]

That's the Lifan Stator/Mag plug - cut off so I could connect to the stock wiring.

[Weldangrind]

If that's the case, I recommend Molex style connectors. The connector bodies and terminals are cheap, and the extraction tool allows you to take them apart for repairs as necessary. I buy the bodies and connectors at my local electronics store.

[2LZ]

Because of new EPA regs and CARB stuff all I got was the motor.
UH OH! Another PRK'er! 8O
My guess on the top mount would be that you're replacing a OHC motor with a OHV motor. Maybe the one Doc put in his Dirt Rat could have possibly mated up?
Just a keyboard guess........... :?

[FastDoc]

The Dirt Rat was an OHC motor.

[nx_guy]

Close enough to put a DONE STAMP on it.
Yesterday after looking things over and over we determined it was the
neutral safety switch. It's needed for the system on the NX.
Thanks - Weldangrind for the diagram. The Hooper Site wasn't correct.

Wiring during testing.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1372.jpg

Wiring tucked
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1373.jpg

Another shot
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1375.jpg

Tank and front plastic is on.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1376.jpg

Seat on.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1377.jpg

Digging out the Dirt Dobber - they were all over the bike as we worked on it.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1374.jpg

Sprocket Cover - ON.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1379.jpg

Left side - Done.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1383.jpg

Right side - Done.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1385.jpg

First Ride - it was hot out.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1380.jpg

I currently have 55 miles on it using the MotoMan's break-in.
Plus a little from this guy http://www.calsci.com/motorcycleinfo/NewBike.html#BreakIn
Thanks to my Wife for her help @ Soldering & Multi-Meter skills - She's
the greatest.

Also thanks for everyone on the forum for the help - greatly appreciated.
I currently have $475 in the project - not including the bike.
$459 - motor, $10 - clutch cable, $5 exhaust gasket.

This bike will live on for years.

[FastDoc]

I am SUPER impressed with your work, sharing it with us, and the result. We all look forward to hearing more about the final product!

[Weldangrind]

Congrats on a clean install. That tank looks quite a bit like the profile of an XR tank; have you considered changing the tank and removing the NX plastic?

Does there seem to be a considerable performance difference with the new engine?

The test pilot seems to have forgotten their trousers.

[SpudRider]

The bike looks great! :) Can you post a photograph showing how you attached the motor mounts at the top of the engine?

Spud :)

[nx_guy]

I like the NX plastic - Weldangrind, bit expensive to replace if I can get them anymore (One cowl is $200).
The gauges really stick out and without the plastics it would look strange - a larger tank would be bonus.

The old motor only had 135 psi and should be 180 psi... It struggled to get it up to 45 mph and keep it there, if there was a wind forget about it.. Take the car.. The NEW motor has way more power then stock - felt like riding my wife's DR200. My XT225 has more pep + I've got an FMF pipe on it.

I'll snag a couple of pics of the top motor mount this week-end (SpudRider).
Need to get the brackets drilled out along with changing the oil.

One thing that throw us off was when the key is on, the head lights on or use to be (need to fix that).

[nx_guy]

Little update - bike runs great.
Working on getting a smaller back sprocket made but need some mounting bolts from EBAY first.

Clean Plug after a little adjustment of the carb.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1412.jpg

Little filing.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1413.jpg

Top motor mount is adjusted and on.
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1416.jpg

Got about 400 miles on the clock with no problems.
Thanks again for the help.

[FastDoc]

Your bike looks great. This was an excellent project, you did a great job, and in very little time. :D

[SpudRider]

Thanks for posting the photos of the motor mounts; they didn't require much modification at all! :) Your bike looks great; thanks for sharing this project with us. :D

Spud :)

[Weldangrind]

Well done! It looks like the mounting hole just needed to be elongated a bit. What is the small rubber hose at the intake side of the head for? Is that a fuel line awaiting a carb?

I like your railroad tie anvil; I have the same model.

[FastDoc]

Weld is an expert observer of photographic detail! :P

[nx_guy]

Good catch Weldangrind - that hose by the intake is the gas line that goes in the gas tank, by the carb top you can kind of make out the fuel filter. Just fell down and looks strange. Did check those boost bottles on ebay today - Hmmm.

Here is a bonus shot of the front end without the plastic - not to pretty. The 05 XT225 is in the back
http://i1192.photobucket.com/albums/aa329/nx_guy/IMG_1417-1.jpg

Once I get the new sprocket on I'll post some picks - just waiting on the Mail Person :)

[BrianW]

Great work, I am very impressed at how well your bike turned out! Please keep us updated as you rack up the miles!