Lifan 200cc 163FML Engine in Honda XR200r

I bought this bike in December of 2017. It was in pretty bad shape when I first got it but I have taken some time to restore it. Since then, I have replaced the factory engine with a Lifan 200cc 163FML that I bought off ebay for a little over $500. I have replaced the brakes, clutch cable, rear sprocket, and air filter. I have also cleaned out the gas tank and rebuilt the carb. The bike runs really well now and kick starts on the first kick with the choke on.

[@donaldolin7219]

Just did the same thing. Installation went surprisingly well. Used all stock motor mounts and a little grinding of the bottom left side of the engine case where it hit the frame.

[@TysonKlose]

@@donaldolin7219 awesome how does it run? Unfortunately my bike started smoking and I wasn’t sure what was going on. I replaced the piston and rings and it fixed the issue for a while and then it started smoking again. I’m not sure why it was doing that, but I ended up selling the bike. I wish I never got rid of the OEM Honda engine.

[@kiheirc3195]

Fantastic job your bike looks great looks like a terrific trail machine take care thanks for the video

[@TysonKlose]

Yeah. It is amazing for trail riding. I can't wait to ride it this Spring/Summer.

[@BOTAJELL]

It ain’t a 2 stroke 💥💨 but there’s nothing wrong with 4 stroke ⛽️🔥💨either so Brappp on my NITRO & BRAPPP BROTHER !! That’s a beautiful Dirt Bike! Have fun and be safe !!

[@TysonKlose]

Yeah I really want a 2 stroke bike, but most of them are expensive because they are race bikes. This one only cost me $1000. I will eventually get a 2 stroke though.

[@antbritt34]

Are your sprockets a 428 or 520 sizes I'm having trouble finding some

[@TysonKlose]

I think I used a 428 size sprocket. The stock on the xr200r is 520 size but I downsized to match the lifan engine. The drive sprocket on the lifan engine is 428 I believe.

[@antbritt34]

So u used 428 on the engine and 520 on the rear

[@TysonKlose]

@@antbritt34 428 on the engine and got a custom 428 made for the rear.

[@antbritt34]

Who custom made the sprocket

[@antbritt34]

On the rear

[@rickyparker7893]

Hi. I just bought this engine for my xr200r. Had all the wiring harness etc... but I cannot figure out how that all hooks up... not of the wires are matching. Any suggestions? Thanks

[@TysonKlose]

This forum thread helped me out. I used the stock wiring harness that came with the engine and cut off all the unnecessary wires. thumpertalk.com/forums/topic/751721-sneeze-163fml/

[@mattredd9663]

You need to check your valve settings and get that carb tuned. It's running a lil off.

[@TysonKlose]

How so? I am open to suggestions. What should I adjust on the carb to make it run better? Thank you for your input. Tyson

[@jaredshelton4718]

@@TysonKlose Same here, Not sure exactly what it is, but seems like it's idling weird.

[@janeblogs324]

My valve tappets were at zero clearance just as the forums predicted. It literally leaked compression permanently haha I felelered them to 0.13 ex and 0.08 intake. Specs are meant to be 0.125 and 0.08 I think but my gauges only had 0.13

[@janeblogs324]

Listening to yours again I suspect your starter clutch is shagged too. Does your kick starter ever kick back? Does the starter ever engage while kicking? If you take the 3 bolt starter cover off you'll see a gear that's meant to turn only 1 way. Mine will occasionally lock up preventing the 1 way, you can hear the gears chatter. Its annoying and is slowly killing my starter...also there are no bearings in there,its not designed to spin often or above 1krpm

[@janeblogs324]

I have a Chinese copy xr100r that came with that 163 lifan stock. 2008 build plate. Wish I could find an importer for a 2020 build I found this video trying to confirm its an xr200 motor lol

[@TysonKlose]

Yep. The Lifan 163fml 200cc engine fits well into the XR200r frame

[@janeblogs324]

@@TysonKlose fits in the xr100r well, but 1 top engine mount is just touching my carb. I'm still trying to confirm if they copied the motor, because this ones push rod (I will make some new rocker arms for more valve lift one day, don't need a new cam,1 advantage lol) The pz30 carb is bigger than the intake gasket and snout too. It is causing a restriction but I'll make a new snout soon and port match it

[@chancewetterman2574]

hi Tyson, how did you keep your exhaust from leaking I have a 163fml but cant seem to keep my exhaust from leaking where it bolts up it seems very loose any help would be appreciated

[@TysonKlose]

That's weird. My exhaust just bolted right on to this engine. What do you mean by saying that your exhaust is "leaking"?

[@chancewetterman2574]

@@TysonKlose so where the head pipe fits into the engine it has about 1/4 inch play where it's very loose and it's not making contact

[@chancewetterman2574]

@@TysonKlose I've done a lot of looking around and it seems I'm missing a metal collar of sorts that fits around the end of the exhaust, did you have something of that nature?

[@TysonKlose]

@@chancewetterman2574 Sorry for the late reply. I used the stock one that came on my xr200r?

[@TheRedneckTelevision]

I did one of these a few years ago. Just do not run ethanol gas and you'll have a good bike.

[@TysonKlose]

Thanks for the heads up. Yeah, I always run ethanol free gas on every small internal combustion engine like this.

[@TheRedneckTelevision]

@@TysonKlose I always try mention that on china bike videos to hopfully save anyone who see my comments some money.

[@TysonKlose]

@@TheRedneckTelevision I appreciate it. The engine has been superb since I bought it, but it does have some issues idling. I need to look at the carb and go from there.

[@frankh.3849]

I have a Chinese clone of this bike. What size rim is on the back?

[@TysonKlose]

I have no idea. I sold this bike 2 years ago. The bike was a 2000 XR200R.

[@frankh.3849]

@@TysonKlose I finally figured out. It was cost around $130 😂🤣

[@ruxpin76]

Were you the one in NC that I chatted with about buying this bike a couple of weeks ago? I'd be curious to chat about the conversion process, although I assume you sold it...

[@TysonKlose]

I could have been. I talked to a lot of people through facebook marketplace. Sold this bike a few weeks ago to buy a '08 crf250r. I can still chat about it if you want. It is a very simple conversion.

[@ruxpin76]

@@TysonKlose Mostly curious where your sourced the engine?

[@TysonKlose]

@@ruxpin76 Sorry for the late reply. I got mine off ebay.

[@ruxpin76]

@@TysonKlose Sorry that it's been a while, but I have a chance to work on my XR200R again.... did you have to modify any of the mounting tabs on the bike, or engine to do the conversion, or was it a literal bolt-up and go project (except wiring)? Thanks.

[@antbritt34]

What are your sprockets sizes

[@kanyemcfadden5415]

How is the reliability on this engine how is it holding up as the hours pass on the motor?

[@TysonKlose]

Engine has been fairly reliable up to this point. I replaced the piston and rings at what I would guess it 100 hours.

[@kanyemcfadden5415]

@@TysonKlose I just installed one on my xr200 and I’m needing the sprockets because the 520 stock xr200r one doesn’t fit. How did you get ahold of yours?

[@raulahernandez5128]

Acá en México por mucho tiempo se hizo lo mismo, al dañar el motor original de xr 200, se inprovisaba montando motores chinos en el mismo chasis de Honda.

[@TysonKlose]

Me alegra saber que le salió bien. Debería publicar un video de su motor en youtube.

[@raulahernandez5128]

@@TysonKlose No es nada del otro mundo, solo se desmonta el motor original y se monta el chino. Sin modificar el chásis.

[@adamsorell4851]

i got same engine but it idles good then just shut off. its ok when i drive it but it wont stay idling too long

[@TysonKlose]

I kinda have the same issue sometimes. The idling is weaker when the bike is leaned on its side on the kick stand.

[@jakeburns6148]

The carb may need cleaned

[@janeblogs324]

@@TysonKlose funny you say that, mines hard to start while leaning on stand too

[@djmelom9277]

1600 RPM on ralentí?

[@rexeter3497]

yeah, they didn't set it up right. there's a leak in the intake or they did not tune the idle speed correctly.

[@sdonnan09]

Was this a direct swap? All electrical plug and play as well?

[@TysonKlose]

The engine, carb, and exhaust swapped in directly, but the wiring was a challenge. The engine came with a wiring harness, but I had to modify and simplify it to meet the needs of my bike.

[@jadenpower189]

Hey Tyson, I was just wandering what air filter you used ?

[@TysonKlose]

I am pretty sure I just used the stock Honda air filter. I did not modify the air box at all.

[@izzyliu1988]

hi Tyson, where did you mounting the battery?

[@TysonKlose]

Hi, I actually did not mount any battery. This engine can be ran with out any battery. Thanks!

[@BOTAJELL]

First and second Like 👍ANY ?’s

[@diyside]

Nice swap. I have the same engine and a 91 xr250r frame that I am building. How is the engine holding on?

[@TysonKlose]

It started smoking after a year. I think that is because I had the piston rings aligned so oil bypassed into the cylinder.

[@murugandorairajumurugandor434]

I want engine send me price

[@TysonKlose]

Are you serious?

[@ballzmahonee5645]

Love these Chinese 200s

[@TysonKlose]

Me too! My engine still works perfectly to this day.