Planet Minis

wearenet · 05-06-2009, 10:50 AM

This is where I will catalog my progress on my z50r with a 124cc Lifan motor build.

Video so you can hear what it sounds like.

http://www.planetminis.com/video.php...fan-125-engine

* I WILL CLEAN THIS UP WITH PICS AND A STEP BY STEP WITH ALL PARTS NEEDED SOON (see some day because I'm still working on getting it right)

* And a specials thanks to all the people who have helped with valuable info on doing it, without this effort of community members helping each other this would have cost well into a thousand dollars and times are tough for many of us who aren't sponsored.

*Done properly and with proper instuctions, this conversion should only cost you in the range of $500.00

*To make things easier on yourself, I STRONGLY suggest getting a pit bike style twist throttle KIT because the stock honda kill switch and right side controls don't do well with this setup at all. You will have length and fit issues with everything if you decide not to get a pit bike style twist THROTTLE AND CABLE. Order it over the phone and MAKE SURE it will fit the carb you are going to use with it.

*You will need a list of parts before doing it to save the headache of re-ordering and paying tons of shipping charges

*The stock pipe, I repeat the stock pipe will not fit once you do this conversion! Not even if you saw off the little plug thingee on it, it won't clear the massive clutch housing.

Have backyard mechanics on call but they are mostly car and truck guys.

Some heating and bending of things like rear brake pedal and figuring out how to mount a 200 3 wheeler carb are currently on the plate

THE ENGINE from FLEABAY

"Single cylinder, 4-stroke, 2 valves, OHC racing head, air cooled, 125cc
Bore x Stroke: 54mm x 54mm, this is a 'square' engine for best balance between power and torque

Dimension: 17"X11"X9"
Valve Sizes: 27mm intake, 23mm exhaust
Displacement: 123.7cc
Compression Ratio: 9.47:1
Ignition: CDI, 12 volt, permanent magnetic stator
Maximum Power: 8.5 Kw DIN @ 9,500 rpm
Rated Power: 6.5 Kw @ 7,500 rpm
Torque: at least 8.8 Nm @ 5,500 rpm
Gears: 4-speed, manual clutch, 1-N-2-3-4, 1 down 3 up.
Gear Ratios: 1st 2.833:1, 2nd 1.706:1, 3rd 1.238:1, 4th 0.958:1
Final Drive: 14 tooth #428 front sprocket included (we have other sprocket on sale too!!)
Lubrication: 1.1 litres, 5W/40 4-stroke motorcycle oil, pressure and splash
Fuel: Unleaded"

Marked 124cc on cylinder. Was on sale for $260 with free shipping

*IF you buy a knock off carb that does not come with a throttle cable!!!! BE PREPARED for a major hassle!!!

*So do not buy a knock off carb if it does not come with a throttle cable that fits it, they are a total pain in the a55!

*Universal "Clutch Cables" will all be the wrong length (too long)... You will have to cut them and put a little screw on end piece on them! A small motor shop should have those.

*The wiring setup on these is a HUGE PAIN IN THE A55!!! Do yourself a favor and make sure you talk to the person you are buying the engine from, and make sure you have

*You will need a WIDE FOOTPEG PITBIKE style bracket to clear the manual clutch side. The stock rear break foot pedal WILL STILL FIT. The stock footpegs also fit on pitbike style wide footpeg bracket mount thingees, I got one on fleabay for about $20 and it looks OK and welds are fine.

1. The proper CDI 12 volt box
2. The proper Coil-Super coil or whatever and the wires MATCH IN COLOR!!!
3. A wiring harness that goes from the stator witch MATCHING COLORS!!!

Wiring this engine with a mix of parts at this point is a major task if you have to figure with diagrams and trail and error. I still can't figure out how to put a kill switch on mine. I have to pull the spark plug or put it in gear... Which is dangerous and hurts like hell.

cdoublejj · 05-06-2009, 02:32 PM

well you might need a 90 degree pet cock. your pedal does seem of but i don't much about any other year except mine my lifan went in pretty easily.

wearenet · 05-06-2009, 04:17 PM

where do you get 90 deg petcocks from?

LoudFastUgly · 05-06-2009, 05:20 PM

Well, it looks like a 120; not a 125. Lifan? Wiring diagram is here:
http://www.planetminis.com/f21/crf-i...ide-27604.html

See post by rbracing for your bike. The CDI tucks away nicely under the spine. I mounted the coil off of the intake/carb bolt (thanks Razzo!).

The 90 degree petcock is not off the shelf, you make it. Can't find it anywhere in Canada (Acklands Grainger, Hydraulic shops, Home Desperate and many more). I tapped the inside of the fuel petcock standoff 10x1.00, used a banjo off of an Integra rear caliper and sealed it up with Loctite pipe joint compound. You're ATC carb has a fuel petcock on it yes?

Check at a local bicycle shop for a clutch perch and lever if you want to run the exhisting bars. I cut a spacer for mine out of aluminum to run a 7/8" perch.

Let us know if you've got any questions!

dirtbkr188 · 05-06-2009, 05:34 PM

The stock '86 petcock is already a 90 degree one, the outlet is to the front of the bike

LoudFastUgly · 05-06-2009, 07:38 PM

Quote:

Originally Posted by dirtbkr188

The stock '86 petcock is already a 90 degree one, the outlet is to the front of the bike

Yawn.

He's going to have to make something, unless he wants two petcocks...

dirtbkr188 · 05-06-2009, 08:00 PM

Quote:

Originally Posted by LoudFastUgly

Yawn.

He's going to have to make something, unless he wants two petcocks...

???

None of the ATC200 carbs have a petcock mounted to the carb bowl, they are mounted to the fuel tank.

The '79-'99 Z50R handlebars are 7/8", by the way...

LoudFastUgly · 05-06-2009, 08:28 PM

Are you sure or do you want to edit your post some more?

dirtbkr188 · 05-06-2009, 08:37 PM

I'm 100% positive on both counts...

wearenet · 05-06-2009, 09:49 PM

ok I see, yeah it is already 90 deg, goes toward the forks. No way I'm going to drill this tank unless I'm desperate. I will make the carb fit somehow. Still waiting on the package, hopefully tomorrow.

Do I need to get something to wire this engine besides what is on the stock z50r? that is a confusion point for me. I don't know what a cdi box is, I know I need to connect 2 wires and there are 2 wires that come from under the seat when I removed the 50 engine. This motor has many wires so I will try to use some diagrams. I've tried to find a thread where someone put this on a z50 and can't, it would be the same process as a crf50 though I'd imagine except that a z50r is not setup for 12v cdi? I dunno and the guy who was going to help me with this is busy this weekend.

z50_stunter · 05-06-2009, 10:44 PM

When I did my lifan swap in my z50, I referred to the wiring diagrams on dratv.com, and it helped immensely. They show how to wire the cdi box, as well as the rest of the bike.

wearenet · 05-07-2009, 05:09 PM

The gas line is squished up by the 200 atc carb but I think it will still work ok.

The gear that came with the Lifan needs to be ground around the edges. It fits on the 420 Honda chain, but it is way to tight so I need to grind around the edges so it is beveled.

Still totally confused by the wiring, the wires coming off the Honda cdi are black and black so I am not sure which is which.

dirtbkr188 · 05-07-2009, 05:30 PM

Are you trying to use a Honda 12V CDI wiring harness to connect your Lifan engine to? Or are you trying to use the 6V wiring that the Z50R came with?

wearenet · 05-07-2009, 05:36 PM

6v of this year bike

dirtbkr188 · 05-07-2009, 05:41 PM

You have to have a 12V wiring harness with a CDI and a 12V ignition coil in order to run your Lifan engine.

wearenet · 05-07-2009, 05:48 PM

This is why I named it "n00b wrencher thread"

I never worked on bikes just rode them, now I can't afford to have a shop do it for me though.

I need this right?

THIS WIRE HARNESS IS A GO BETWEEN FROM YOUR NEW

LIFAN/ZONGSHEN ENGINE TO YOUR OLD HONDA ORIDGINAL WIRE

HARNESS. THIS IS ALL YOU NEED (WITH A CDI UNIT AND CDI COIL)TO GET SPARK...

HOWEVER,, YOU WILL STILL NEED TO ADDRESS THE NEW ENGINES

ELECTRICAL OUTPUT ISSUES IF YOU HAVE LIGHTS AND OR A

BATTERY

dirtbkr188 · 05-07-2009, 05:50 PM

I understand completely, I'm just letting you know what you need to get to run your Lifan engine in your Z50R...

doopsx3 · 05-07-2009, 05:52 PM

I have a new China 12v wiring harness w/CDI but it may be overkill for ya cuz it is also for E-Start and has the solenoid and voltage regulator with it...

wearenet · 05-07-2009, 06:05 PM

Quote:

Originally Posted by doopsx3

I have a new China 12v wiring harness w/CDI but it may be overkill for ya cuz it is also for E-Start and has the solenoid and voltage regulator with it...

Your selling it? If so all I need is the bike to start, anything left over I can just cut off right? PM me if you think it will work for me with a pic or something if you want.

doopsx3 · 05-07-2009, 06:11 PM

Quote:

Originally Posted by wearenet

Your selling it? If so all I need is the bike to start, anything left over I can just cut off right? PM me if you think it will work for me with a pic or something if you want.

I would not cut it off...tape it up n save it for later..never know ya may want to run baja lighting on that bad azz 50 some day...here is a pic..it is with a buch of other stuff...I can get ya better pic when I get home if ya want...it comes with a CDI, starter solenoid, and rectifier and all is brand new $40 shipped

05-06-2009, 10:50 AM	#1 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	125 Lifan into 1986 z50r n00b wrencher thread This is where I will catalog my progress on my z50r with a 124cc Lifan motor build. Video so you can hear what it sounds like. http://www.planetminis.com/video.php...fan-125-engine * I WILL CLEAN THIS UP WITH PICS AND A STEP BY STEP WITH ALL PARTS NEEDED SOON (see some day because I'm still working on getting it right) * And a specials thanks to all the people who have helped with valuable info on doing it, without this effort of community members helping each other this would have cost well into a thousand dollars and times are tough for many of us who aren't sponsored. Done properly and with proper instuctions, this conversion should only cost you in the range of $500.00 To make things easier on yourself, I STRONGLY suggest getting a pit bike style twist throttle KIT because the stock honda kill switch and right side controls don't do well with this setup at all. You will have length and fit issues with everything if you decide not to get a pit bike style twist THROTTLE AND CABLE. Order it over the phone and MAKE SURE it will fit the carb you are going to use with it. You will need a list of parts before doing it to save the headache of re-ordering and paying tons of shipping charges The stock pipe, I repeat the stock pipe will not fit once you do this conversion! Not even if you saw off the little plug thingee on it, it won't clear the massive clutch housing. Have backyard mechanics on call but they are mostly car and truck guys. Some heating and bending of things like rear brake pedal and figuring out how to mount a 200 3 wheeler carb are currently on the plate THE ENGINE from FLEABAY "Single cylinder, 4-stroke, 2 valves, OHC racing head, air cooled, 125cc Bore x Stroke: 54mm x 54mm, this is a 'square' engine for best balance between power and torque Dimension: 17"X11"X9" Valve Sizes: 27mm intake, 23mm exhaust Displacement: 123.7cc Compression Ratio: 9.47:1 Ignition: CDI, 12 volt, permanent magnetic stator Maximum Power: 8.5 Kw DIN @ 9,500 rpm Rated Power: 6.5 Kw @ 7,500 rpm Torque: at least 8.8 Nm @ 5,500 rpm Gears: 4-speed, manual clutch, 1-N-2-3-4, 1 down 3 up. Gear Ratios: 1st 2.833:1, 2nd 1.706:1, 3rd 1.238:1, 4th 0.958:1 Final Drive: 14 tooth #428 front sprocket included (we have other sprocket on sale too!!) Lubrication: 1.1 litres, 5W/40 4-stroke motorcycle oil, pressure and splash Fuel: Unleaded" Marked 124cc on cylinder. Was on sale for $260 with free shipping IF you buy a knock off carb that does not come with a throttle cable!!!! BE PREPARED for a major hassle!!! So do not buy a knock off carb if it does not come with a throttle cable that fits it, they are a total pain in the a55! Universal "Clutch Cables" will all be the wrong length (too long)... You will have to cut them and put a little screw on end piece on them! A small motor shop should have those. The wiring setup on these is a HUGE PAIN IN THE A55!!! Do yourself a favor and make sure you talk to the person you are buying the engine from, and make sure you have You will need a WIDE FOOTPEG PITBIKE style bracket to clear the manual clutch side. The stock rear break foot pedal WILL STILL FIT. The stock footpegs also fit on pitbike style wide footpeg bracket mount thingees, I got one on fleabay for about $20 and it looks OK and welds are fine. 1. The proper CDI 12 volt box 2. The proper Coil-Super coil or whatever and the wires MATCH IN COLOR!!! 3. A wiring harness that goes from the stator witch MATCHING COLORS!!! Wiring this engine with a mix of parts at this point is a major task if you have to figure with diagrams and trail and error. I still can't figure out how to put a kill switch on mine. I have to pull the spark plug or put it in gear... Which is dangerous and hurts like hell. Attached Thumbnails Last edited by wearenet; 05-26-2009 at 11:33 PM.*

05-06-2009, 02:32 PM	#2 (permalink)
cdoublejj 3rd Gear Member Join Date: Oct 2008 Location: St.Joe MO Posts: 1,371 My Mood:	Re: 125 Lifan into 1986 z50r n00b wrencher thread well you might need a 90 degree pet cock. your pedal does seem of but i don't much about any other year except mine my lifan went in pretty easily.

05-06-2009, 04:17 PM	#3 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	Re: 125 Lifan into 1986 z50r n00b wrencher thread where do you get 90 deg petcocks from?

05-06-2009, 05:20 PM	#4 (permalink)
LoudFastUgly 2nd Gear Member Join Date: Aug 2008 Location: GTA, Ontario, Canada Posts: 383	Re: 125 Lifan into 1986 z50r n00b wrencher thread Well, it looks like a 120; not a 125. Lifan? Wiring diagram is here: http://www.planetminis.com/f21/crf-i...ide-27604.html See post by rbracing for your bike. The CDI tucks away nicely under the spine. I mounted the coil off of the intake/carb bolt (thanks Razzo!). The 90 degree petcock is not off the shelf, you make it. Can't find it anywhere in Canada (Acklands Grainger, Hydraulic shops, Home Desperate and many more). I tapped the inside of the fuel petcock standoff 10x1.00, used a banjo off of an Integra rear caliper and sealed it up with Loctite pipe joint compound. You're ATC carb has a fuel petcock on it yes? Check at a local bicycle shop for a clutch perch and lever if you want to run the exhisting bars. I cut a spacer for mine out of aluminum to run a 7/8" perch. Let us know if you've got any questions!

05-06-2009, 05:34 PM	#5 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: 125 Lifan into 1986 z50r n00b wrencher thread The stock '86 petcock is already a 90 degree one, the outlet is to the front of the bike

05-06-2009, 08:28 PM	#8 (permalink)
LoudFastUgly 2nd Gear Member Join Date: Aug 2008 Location: GTA, Ontario, Canada Posts: 383	Re: 125 Lifan into 1986 z50r n00b wrencher thread Are you sure or do you want to edit your post some more?

05-06-2009, 08:37 PM	#9 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: 125 Lifan into 1986 z50r n00b wrencher thread I'm 100% positive on both counts...

05-06-2009, 09:49 PM	#10 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	Re: 125 Lifan into 1986 z50r n00b wrencher thread ok I see, yeah it is already 90 deg, goes toward the forks. No way I'm going to drill this tank unless I'm desperate. I will make the carb fit somehow. Still waiting on the package, hopefully tomorrow. Do I need to get something to wire this engine besides what is on the stock z50r? that is a confusion point for me. I don't know what a cdi box is, I know I need to connect 2 wires and there are 2 wires that come from under the seat when I removed the 50 engine. This motor has many wires so I will try to use some diagrams. I've tried to find a thread where someone put this on a z50 and can't, it would be the same process as a crf50 though I'd imagine except that a z50r is not setup for 12v cdi? I dunno and the guy who was going to help me with this is busy this weekend. Last edited by wearenet; 05-06-2009 at 10:01 PM. Reason: info

05-06-2009, 10:44 PM	#11 (permalink)
z50_stunter PM Newbie Join Date: Mar 2008 Location: Midland, TX Posts: 36	Re: 125 Lifan into 1986 z50r n00b wrencher thread When I did my lifan swap in my z50, I referred to the wiring diagrams on dratv.com, and it helped immensely. They show how to wire the cdi box, as well as the rest of the bike.

05-07-2009, 05:09 PM	#12 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	Re: 125 Lifan into 1986 z50r n00b wrencher thread The gas line is squished up by the 200 atc carb but I think it will still work ok. The gear that came with the Lifan needs to be ground around the edges. It fits on the 420 Honda chain, but it is way to tight so I need to grind around the edges so it is beveled. Still totally confused by the wiring, the wires coming off the Honda cdi are black and black so I am not sure which is which. Attached Thumbnails

05-07-2009, 05:30 PM	#13 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: 125 Lifan into 1986 z50r n00b wrencher thread Are you trying to use a Honda 12V CDI wiring harness to connect your Lifan engine to? Or are you trying to use the 6V wiring that the Z50R came with?

05-07-2009, 05:36 PM	#14 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	Re: 125 Lifan into 1986 z50r n00b wrencher thread 6v of this year bike

05-07-2009, 05:41 PM	#15 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: 125 Lifan into 1986 z50r n00b wrencher thread You have to have a 12V wiring harness with a CDI and a 12V ignition coil in order to run your Lifan engine.

05-07-2009, 05:48 PM	#16 (permalink)
wearenet 1st Gear Member Join Date: Jan 2009 Location: Michigan, All over Posts: 134	Re: 125 Lifan into 1986 z50r n00b wrencher thread This is why I named it "n00b wrencher thread" I never worked on bikes just rode them, now I can't afford to have a shop do it for me though. I need this right? THIS WIRE HARNESS IS A GO BETWEEN FROM YOUR NEW LIFAN/ZONGSHEN ENGINE TO YOUR OLD HONDA ORIDGINAL WIRE HARNESS. THIS IS ALL YOU NEED (WITH A CDI UNIT AND CDI COIL)TO GET SPARK... HOWEVER,, YOU WILL STILL NEED TO ADDRESS THE NEW ENGINES ELECTRICAL OUTPUT ISSUES IF YOU HAVE LIGHTS AND OR A BATTERY Last edited by wearenet; 05-07-2009 at 05:54 PM.

05-07-2009, 05:50 PM	#17 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,972	Re: 125 Lifan into 1986 z50r n00b wrencher thread I understand completely, I'm just letting you know what you need to get to run your Lifan engine in your Z50R...

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05-07-2009, 05:52 PM	#18 (permalink)
doopsx3 3rd Gear Member Join Date: Aug 2008 Location: San Diego Posts: 3,947 My Mood:	Re: 125 Lifan into 1986 z50r n00b wrencher thread I have a new China 12v wiring harness w/CDI but it may be overkill for ya cuz it is also for E-Start and has the solenoid and voltage regulator with it...