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RE: Lifan 125 into the Ex Bogger C90
Posted by : LVCampbell (80.76.123.241) 
Inappropriate or SPAM?
On Monday 02/07/12 at 16:50:23
I have done just what you plan to do. Hopefully my comments might assist.
I had read several forums that say something like "It's a straight swap" - this is incorrect - or at least was in my experience.
The bolt hole centres for the engine mounting are the same.
The exhaust exits the Lifan head at a very slightly different angle, which require me to adjust the downpipe and mill elongated slots in the exhaust support bracket.
The inlet manifold causes the carburretor to sit slightly higher, which means the stock air filter will not fit.
The foot peg bracket on the RHS requires to be adjusted, which can be done by heating (removed the new engine)and several trial fits - and the brake pedal therefore required to be adjusted (I did so by adding a small pool of weld to the pedal stop).
The standard gear change has to be adjusted if you wish to use the heal-toe lever.
If you wish to use the Honda generator cover you have to remove material from within - where the neutral switch sits.
The front sprocket that arrived with the Lifan was too thick for the chain - it is very hard material (induction hardened). Luckily I have a several machine tools and was able to machine this back (the splines are larger than the Honda original so you cannot use the old one).
Otherwise it goes straight in !!
I'm a professional engineer, with a comprehensive workshop - and it took more effort than I had understood to be the case.
Oh yes- forgot -fit a clutch lever.
Best Regards
LVCampbell
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