Honda Deluxe Swapped with 200cc Engine

[taha66]

AoA
I m back on PW after a long time with a project. I have kept CD70, CG125, Ravi Piaggio, YBR and YBR G, Qingqi Trail 150 and GS 150 in past. No bike gave me proper power and pleasure during my tour to Norther areas. Let me tell you that I have done Pir Chanasi, Rohtas Fort and small tours on YBR but on the uphill of Pir Chanasi , YBR disappointed me. I sold YBR and bought Qingqi 150 for Mega tour to Khunjerab via Noori Top. After crossing ISB, the bike started missing due to less oxygen and this missing continued till I came back ISB again. I did a tour of 2400 km with continuous missing.So it spoiled pleasure of the tour. Then I bought GS150, and it was unable to go uphill of Thandiyani Waterfall. So I sold it too.
Previously, the experience of engine swap was bot successful for me two years ago when I swapped 200cc water cooled engine in Ravi Piaggio. But this time I had no other option other than engine swap.

Now the question was, which bike should be selected for engine swap.
I selected Honda Deluxe 125 because of

1. 5 inches front forks travel
2. Double piston calliper disc brake
3. Large rear drum for better braking
4. Ideal chasis for engine swap as no alteration is required.
5. Wider rims
6. Strong and cheap spare parts back up.

Now engine need to be selected for swap. I approached to our Ustad @vickytulla and asked for suggestion. He offered me Tiger Boxer ST200 engine which 17HP having 17Nm torque and air cooled SOHC engine which I readily accepted.

Then search for bike was started in the local market. As I wanted lower model bike so that project wont go out of budget. So I selected 2013 model deluxe in mint condition in reasonable amount.

[taha66]

I rode this bike like 15 days but due to its extreme vibrations at higher RPMs , I wanted to swap its engine ASAP.
Its vibrations are lesser than CG in lower RPMs but they become equivalent to CG at higher RPMs. I was used to the smooth rides of GS and YBR so it was a miserable condition for me.
I contacted @vickytulla for appointment of engine swap
He asked to come over weekend to complete the job. So the very next sunday was the first Roza of Ramzan and our engine swapping day

[vickytulla]

Is this your thread for the deluxe which beat the hell out of all "famous" wannabe racers of lahore ? or kitna namak chirkana hay ? PW do not promote racing's nevertheless...

but yes the bike reallly performed out of the way in those mountains as I witnessed!! (Y)... (Y)

Will be creating tour thread soon...

[taha66]

Hahahahah no I m not here to discuss drag racing. I actually wanted to share the experience of swapping engine second time in a different machine. So that all the questions of different PWers who want to swap engine are rectified.

[hamikhan]

Waiting for more!!!!!!!

[taha66]

So The day came, I approached Waqar bhai on Sunday Morning. We randomly picked one engine from the bunch of engines.

I dont want to go to mechanic for this swap because the engine was bolt on fit in deluxe frame. As we already had swapped water cooled engine in piaggio so I wanted to swap this engine from my hands.
The problem was that Waqar bhai and I both were fasting so we needed assistance. We called Waqar bhai's friend Hafiz who was not fasting for assistance.
Finally, work started. We dismantled the original engine from the bike. And put the Tiger Boxer 200 ourselves.

[asjdsm]

Good thread I m watching it.

LOL at hafiz not fasting...

I still have that water cooled engine with me. Will do its swap so I can taste zaiaqa tul water cooled engine. Hahaha.

[vickytulla]

yar ye tu promotional water marks wali foto hay... ye tu facebook say copy ki hay apnay pw nay thread ban ker dena tera... ... post the orignal one... let me whatsapp you the rear footage :d

rk started. We dismantled the original engine from the bike. And put the Tiger Boxer 200 ourselves.

[taha66]

Okay ustad delete it and post original one here.

[taha66]

hahah my experience is quite different this time, air cooled boxer is giving me 'CHASS'

[taha66]

So after the 3 hours of mechanicki while fasting we were able to fit the engine.
So our ustad @vickytulla testing the first response of engine

Now the issue was the fitting of footrests of the bike. The new engine had a larger belly as compared to stock CG's engine. So we had to extend the foot rest bar from a welder. So the first step was over
Bike was in running condition. Fortunately, there was no extra engine noises and engine was running smoothly.

[asjdsm]

How was it a bolt fit? I heard it to be bolt on fit to piaggio but also heard that deluxe and piaggio are different frame ?

Share more about the swap.
Cdi wiring rectifier carbator sprocket?

[taha66]

bolt fit?

Bro piaggio and deluxe have different frames but share the same housing and mounts for engine. This engine is bolt on fit on CG , CGDeluxe, Piaggio, Wego/Derbi, any Chinese 125.

Plus the carburettor PZ30 that I used belongs to rickshaw breed. Sprocket setup is stock 14*43 .
For rectifier, its a long story. I used Rickshaw rectifier in the start which damaged 2 batteries due to over charging. So after R&D with Waqar bhai, we opted for Ravi Piaggio Rectifier, now its going smoothly Alhamdulillah

[taha66]

Now I ll list about the cosmetic upgrades which I did on my bike.
1- Both tyres changed to Panther Trekker. Front : 3.00-18
Rear: 100/90-18
2- Rear Shocks were rock hard due to damaged pump. I replaced them with GS150 shocks which were available in cheap price.
3- Digital speedo meter was installed on bike to have accurate readings.
4- USB charger was installed with built in volt meter.
5- Special Self start button was bought from Aliexpress with engine kill switch.
6- 2 LEDs were installed on handle bar.
7- Original Front cowling was replaced with Xanadu 55w H4 beam.
8- placed 20W Motoled in the Xanadu beam.
9- Placed heavy 9Amp battery in place of small 4A battery which cannot support self start.
10- Honda's side mirrors are of very poor quality so I opted for Suzuki GS150 side mirrors.

Pictures are in the following

Digital Meter , Usb charger with volt meter and special Self start push button with engine kill switch

Fully washed and detailed by myself. Shining like new bride

[hamikhan]

Bro you got A really nice neat & clean piece of bike in reasonable amount

[asjdsm]

That's new to me that deluxe and pigayo share same engine mounts. Great.

What is fuel average and at what rpm does it stays while riding on straight road at 100km/h.

Exhaust seems stock? Should be very restrictive?

And Immense thanks for the detailed reply..

[taha66]

Yes bro the mounts of CG, Piaggio, etc are same. Suzuki and Yamaha have different mounts than CG.

For RPM, my tacho meter is not working yet thats why I cant tell the exact RPMs but bike easily cruises on 100.

Actually CG and CG deluxe have already free flow exhausts so there is no need to change the exhaust.

[asjdsm]

Was cdi and coil also changed?
What about wiring?

[taha66]

No I am using the original AHL CDI and Ignition coil. these both are working perfectly. Wiring is done by an electrician. he put a bigger battery in it, installed car's self start relay.Stock CG and CG deluxe and even CBF comes with a dynamo headlight means if u drop the accelerator then the headlight becomes dimmer. I wanted to get rid of that function of AHL bikes, the electrician made the headlight direct with battery now I am much comfortable and have clear vision even on low RPMs.

[taha66]

NOW COMING TOWARDS THE PROBLEMS THAT I FACED

The biggest problem till now I faced in the failure of battery twice. I was using 9A lead acid battery. we did some juggarh to fit the big 9A battery in place of a tiny 4A battery which comes in stock CG deluxe. After 15 days of the swap, the self starter of bike did not work. i checked the battery then it was full dry and having not a single drop of water. but tb tk buht dair ho chuki thi, battery ka cell damage hochuka tha. the battery was in warranty so I went to the dealer to claim the warranty which he readily replaced with a new one. I installed the new battery without diagnosing the root cause of the battery damage.
and after 20 days, that battery went dead too
I was like Bhainss ki dum Teeka lg gya aik aur. because the dealer said that it cant be claimed twice.

Khair, I started brain storming. the main symptom was drainage of battery electrolyte which is a clear signage of over charging of rectifier. So I went to the electrician from whom I got my wiring done. He cut one or two wires of rectifier and said ab ye theek charge krega. So I got a new battery of 9A worth 1500 PKR again. After a week on installing a new battery, i went on my annual tour to Deosai with @vickytulla @angel82 @NOM1 @RocketScience.
When I reached Rama, the battery of the bike got dead again. I can imagine my condition while hitting kicks of the bike for rest of 7 days of the tour. But I filled some water in the battery and battery got live again. So tour went well Alhamdulillah, about the tour, Waqar bhai has aleady made a thread so you can get details from there.

Khair tour se wapas aa kr, I consulted with Waqar bhai who gave me Ravi Piaggio's rectifier and I got that rectifier fit from his electrician. its been 3 weeks already and Now the battery electrolyte level is not going down and bike start with self like a charm