Lifan 200 Swap Troubleshooting

jackson · 12-21-2016, 05:55 PM

Hey there everyone, long time lurker here, but recently registered with the hopes of getting a bit of mechanical advice. (I apologize in advance for the long post) In the beginning of the year I bought my first motorcycle, a 77 Xl100. I had a blast riding it for a few months, but I've got this terrible habit of "fixing" things that aren't broken and bought a new Lifan 200 to swap in.

This is the engine FWIW: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

I started the swap back in July, and mounted the new engine in an afternoon. Figuring it would be better to leave the wiring to a pro, I bring it to a shop to finish the wiring harness. The shop can't get the bike to run, saying there is a weak spark while kickstarting and no spark with the starter motor. After a month or so, the shop later says they figured out the problem and I just need to buy a different harness. (This is the new harness https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1)
The shop puts the new harness in along with the new electronics and still has the same problem. Eventually the shop tells me they are stumped, and to just come pick it up.

I bring it to another local shop, these guys have had it for a few months and have the same problem and can't figure it out. I've called PCC Motors (The Amazon seller) and they couldn't help, and at this point it's been too long to get my money back through Amazon.

Both shops say they have checked the obvious, (fuel, compression, battery, wiring and grounds etc) and we had the same problem with either wiring harness, and with both coils and CDIs.

At this point I don't even know where to start troubleshooting. My best guess would be the pickup coil, simply because I think that's the last electrical/ignition part that hasn't been replaced. Maybe a neutral safety switch or something similar that both shops somehow missed? Any help or guidance would be greatly appreciated!

TL;DR Brand new Lifan 200 won't start. Weak spark with kickstart, none with electric start. All obvious parts and causes checked.

12-21-2016, 05:55 PM	#1
jackson Join Date: Dec 2016 Posts: 9	Lifan 200 Swap Troubleshooting Hey there everyone, long time lurker here, but recently registered with the hopes of getting a bit of mechanical advice. (I apologize in advance for the long post) In the beginning of the year I bought my first motorcycle, a 77 Xl100. I had a blast riding it for a few months, but I've got this terrible habit of "fixing" things that aren't broken and bought a new Lifan 200 to swap in. This is the engine FWIW: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1 I started the swap back in July, and mounted the new engine in an afternoon. Figuring it would be better to leave the wiring to a pro, I bring it to a shop to finish the wiring harness. The shop can't get the bike to run, saying there is a weak spark while kickstarting and no spark with the starter motor. After a month or so, the shop later says they figured out the problem and I just need to buy a different harness. (This is the new harness https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1) The shop puts the new harness in along with the new electronics and still has the same problem. Eventually the shop tells me they are stumped, and to just come pick it up. I bring it to another local shop, these guys have had it for a few months and have the same problem and can't figure it out. I've called PCC Motors (The Amazon seller) and they couldn't help, and at this point it's been too long to get my money back through Amazon. Both shops say they have checked the obvious, (fuel, compression, battery, wiring and grounds etc) and we had the same problem with either wiring harness, and with both coils and CDIs. At this point I don't even know where to start troubleshooting. My best guess would be the pickup coil, simply because I think that's the last electrical/ignition part that hasn't been replaced. Maybe a neutral safety switch or something similar that both shops somehow missed? Any help or guidance would be greatly appreciated! TL;DR Brand new Lifan 200 won't start. Weak spark with kickstart, none with electric start. All obvious parts and causes checked.
	0