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Honda CG125 TITAN ES, Service Manual

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Honda CG125 TITAN ES Service Manual Download Page 47

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Chapter 1 Engine, clutch and gearbox

41 Starting and running the rebuilt engine

1 Make a final check around the engine to ensure that

everything has been refitted correctly and tightened down
securely. Before starting the engine, unscrew the plug at the top

of the cylinder head cover, and watch this carefully during the

first few seconds of running to ensure that the oil is circulating
properly. If all is well, oil will be expelled with considerable
force, so have a rag to hand to wipe off the inevitable deluge.

Bear in mind that the engine parts should be liberally

coated with oil during assembly, so the engine will tend to
smoke heavily for a few minutes until the excess oil is burnt

away. Do not despair if the engine will not fire up at first, as it is
quite likely that the excess oil will foul the spark plug,
necessitating its removal and cleaning. When the engine does
start, listen carefully for any unusual noises, and if present,

establish, and if necessary rectify, the cause. Check around the
engine for any signs of leaking gaskets.

Before using the machine on the road, check the operation

of the clutch and brakes. Remember that if a number of new
parts have been fitted or if the engine has been rebored, it will
be necessary to follow the original running-in instructions so
that the new parts have ample opportunity to bed-down in a
satisfactory manner.

40.6 Refill crankcase to correct level with engine oil

41.1 Prime oil system before starting the engine

42 Fault diagnosis: engine

Symptom

Cause

Remedy

Engine does not start

Engine stalls whilst running

Lack of compression:

Valve stuck open
Worn valve guides
Valve timing incorrect

Worn piston rings
Worn cylinder

No spark at plug:

Fouled or wet spark plug
Fouled contact breaker points
Incorrect ignition timing

Open or short circuit in ignition

No fuel flowing to carburettor:

Blocked fuel tank cap vent hole
Blocked fuel tap
Faulty carburettor float valve

 fuel pipe

Fouled sparking plug or contact breaker points
Ignition timing incorrect
Blocked fuel

 or carburettor jets

Adjust tappet clearance.

Renew.
Check and adjust.
Renew.
Rebore.

Clean.
Clean.
Check and adjust.
Check wiring.

Clean.
Clean.
Renew.

Clean.

Clean.
Check.
Clean.

Summary of Contents for CG125 TITAN ES

Page 1: ...HONDA CG 125 Service Manual ...

Page 2: ...ot available Identified by its shrouded external spring front forks this model Was imported from June 1976 to May 1978 The CG125K1 model has the frame numbers CG125 1114636 to 1162518 Engine numbers not available It differed most noticeably from the CG125 model in having front forks with internal springs and exposed stanchions and was imported from May 1978 to March 1981 The CG125 B model has the ...

Page 3: ...ad in line with the forks The engine number is stamped on the left hand side of the crankcase immediately behind the oil strainer cap Use only parts of genuine Honda manufacture A few pattern parts are available sometimes at a cheaper price but there is no guarantee that they will give such good service as the originals they replace Retain any worn or broken parts until the replacements have been ...

Page 4: ...on any point get specialist advice IF in spite of following these precautions you are unfortunate enough to injure yourself seek medical attention as soon as possible Asbestos Certain friction insulating sealing and other products such as brake linings clutch linings gaskets etc contain asbestos Extreme care must be taken to avoid inhalation of dust from such products since it is hazardous to heal...

Page 5: ...e engine has not been dismantled since leaving the factory prevent the risk of unexpected failure of any component while riding the machine and with experience can be reduced to a simple checklist which will only take a few moments to complete For those owners who are not inclined to check all items with such frequency it is suggested that the best course is to carry out the checks in the form of ...

Page 6: ...ter 6 5 for details 2 Check the final drive chain Despite its full enclosure the final drive chain requires regular attention to ensure maximum chain life Remove the rubber plug from the chaincase inspection aperture to check the tension and carry out temporary lubrication The best lubricant is commercial chain lubricant contained in an aerosol can engine oil or gear oil are better than nothing bu...

Page 7: ...f on the other hand the clearance is too small the valves may not close completely This will not only cause loss of compression but will also cause the valves to burn out very quickly In extreme cases a valve head may strike the piston crown causing extensive damage to the engine The clearances should be checked and adjusted with a cold engine Place the machine on its centre stand and remove the r...

Page 8: ...is essential that only genuine Honda points are used Refit the rotor and set the points gap to exactly 0 35 mm 0 014 in then repeat the procedure given above The ignition timing should be correct Note The above procedure is described in full as it is the most accurate means of setting the ignition timing In practice there is no need to repeat the full procedure at every service interval Instead it...

Page 9: ...mmediately 10 Check the suspension and steering Support the machine so that it is secure with the front wheel clear of the ground then grasp the front fork legs near the wheel spindle and push and pull firmly in a fore and aft direction If play is evident between the top and bottom fork yokes and the steering head the steering head bearings are in need of adjustment Imprecise handling or a tendenc...

Page 10: ...e setting of 0 3 0 6 kgf m 2 4 Ibf ft Refill each fork leg with the specified oil Refit and tighten the fork top bolts to a torque setting of 3 0 4 0 kgf m 22 29 Ibf ft Quick glance maintenance data Oil capacity Engine gearbox unit approx 1 0 litre 1 76 Imp pint Front forks at oil change CG125 120 130 cc 4 22 4 58 Imp fl oz CG125 K1 B C E 130 140 cc 4 58 4 93 Imp fl oz Valve clearances inlet and e...

Page 11: ...ges will be saved The economy made on even a minor overhaul will go a long way towards the improvement of a toolkit In addition to the basic tool kit certain additional tools can prove invaluable when they are close to hand to help speed up a multitude of repetitive jobs For example an impact screwdriver will ease the removal of screws that have been tightened by a similar tool during assembly Wit...

Page 12: ...ovation cylinder barrel 22 Cylinder head valve removal examination and renovation 23 Examination and decarbonisation cylinder head 24 Examination and renovation rocker arms adjusters and pushrods 25 Examination and renovation cam gear and lobe and cam followers 26 Examination and renovation trochoidal oil pump 27 Examination and renovation clutch and primary drive 28 Examination and renovation gea...

Page 13: ...e bore diameter 5 47 5 48 mm 5 50 mm 0 2165 in 0 2154 0 2157 in Valve stem to guide clearance Inlet 0 01 0 03 mm 0 12 mm 0 0047 in 0 0004 0 0012 in Exhaust 0 03 0 05 mm 0 14 mm 0 0055 in 0 0012 0 0020 in Pushrods Length 1 41 1 5 141 45 mm 5 5571 5 5689 in Wearlimit 141 00mm 5 5512in Cam and followers Cam follower bore diameter 12 00 12 02 mm 0 4724 0 4732 in Wearlimit 12 05 mm 0 4744 in Cam follow...

Page 14: ...2 in 12 05 mm 0 4744 in 1 1 98 1 1 99 mm 0 4717 0 4721 in 1 1 96 mm 0 4709 in N Av 19 959 19 980 mm 0 7858 0 7866 in 19 900 mm 0 7835 in 24 900 24 920 mm 0 9803 0 9811 in 24 940 mm 0 9819 in 20 000 20 021 mm 0 7874 0 7882 in 20 050 mm 0 7894 in 4 Method of engine gearbox removal As mentioned previously the engine and gearbox are of unit construction and it is necessary to remove the unit complete ...

Page 15: ...ectrical system Separate the white multiple connector block to disconnect the generator this will be found adjacent to the battery 9 The engine is now held only by the five mounting bolts Remove the two front bolts and place them to one side It is worthwhile removing the entire engine plate to gain the maximum amount of manoeuvring room Remove the lower rear mounting bolt noting that the nut may b...

Page 16: ...river bits It will be found that most engine casing screws will need jarring free due to both the effects of assembly by power tools and an inherent tendency for screws to become pinched in alloy castings 4 A cursory glance over many machines of only a few years 5 8b then separate the generator output lead connector use will almost invariably reveal an array of well chewed screw heads Not only is ...

Page 17: ...of the position and sizes of the dowels fitted over three of the four studs One of these is fitted with an 0 ring and acts as an oil feed passage 4 The cylinder barrel is retained by two bolts passing through a flange on the left hand side Once these have been removed the barrel can be slid upwards off its mounting studs As soon as the bottom of the barrel is clear of the crankcase mouth the latte...

Page 18: ...off 12 Special bolt 13 Sleeve bolt 4 off 14 Sea ing washer 15 Sea ing washer 16 0 ring 3 off 17 Plug 18 Bolt 2 off 19 Stud 2 off 20 Stud 2 off early models later models 21 Nut 2off 22 Washer 2 off 23 Dowel 3 off 24 Bolt 3 off 25 Sparking plug 26 Inlet stub 4 27 O ring 28 Bolt 2 off 29 Stud 2 off 30 Nut 2 off 7 2a Remove the cylinder head cover to expose the valve gear 7 2b Release the three mounti...

Page 19: ...so necessary to lock the flywheel rotor while the centre nut is removed If the cylinder head and barrel have already been removed a bar can be passed through the small end eye and rested on a wooden block placed at each side of the crankcase mouth never directly on the jointing face to prevent crankshaft rotation If the rotor is to be removed whilst the engine is in the frame crankshaft rotation c...

Page 20: ...two locating dowels in the mating surface also the pushrod in the centre of the clutch Peel off the cover gasket 2 Slacken and remove the three screws which secure the oil filter cover As the cover is lifted away place some rag beneath the unit to catch the residual oil which will be caught inside the filter assembly 3 The inner half of the filter housing is retained by a slotted nut which will re...

Page 21: ... out the cam gear cam unit I 10 3 Home made peg spanner is crude but proved effective 10 4 With the nut removed slide inner housing off its splines mi W 11 1a Pass screwdriver tnrough holes in pump to release mounting screws 11 1b Pump can be lifted away as a unit ...

Page 22: ... can be withdrawn from the right hand side of the unit the quadrant centring spring disengaging from its locating lug 2 Unscrew the detent roller arm retaining bolt and carefully release the detent spring pressure before withdrawing the bolt arm and spring Note how the arm rotates against spring pressure on the shouldered portion of the bolt s shank Remove the camplate retaining bolt from the end ...

Page 23: ...away the thrust plate after releasing bolts 0 12 2a Remove the circlip to allow 12 2b outer half of clutch centre to be removed followed by clutch plates 12 2c and inner half of clutch centre 1 2 2d Clutch drum will slide off complete with slotted washer ...

Page 24: ...n position on the blocks the kickstart mechanism may be lifted out of the casing having first lifted the ratchet to release spring tension The crankshaft assembly can be lifted out of position The use of steel inserts in each crankcase half means that the main bearings are a light sliding fit and offer little resistance during removal They will remain in position on the crankshaft 2 Lift the selec...

Page 25: ...h later models Layshaft 3rd gear 29T Layshaft 4th gear 27T Layshaft Layshaft 5th gear 257 Layshaft 2nd gear 327 pinion 3 off pinion pinion pinion pinion pinion pinion pinion pinion item 16 located between items 18 and 19 fitted to CG125 set for early CGI 25 models 24 Thrust washer 25 Bearing 26 Oil seal 27 Gearbox sprocket 15T 28 Locking plate 29 Bolt 2 off 30 Kickstart shaft assembly later models...

Page 26: ...h is easily withdrawn 16 1a Disengage and remove the kickstart mechanism 16 1b Crankshaft assembly lifts easily out of case 16 2a Lift selector fork assembly slightly to allow selector drum to be withdrawn I 1 16 2b Remove the selector forks and pin as an assembly Do not dismantle ...

Page 27: ...ht fit on the shafts 2 The gearbox bearings are a light press fit in the crankcase castings They can be drifted out of position using a mandrel of the correct size and a hammer 3 If necessary warm the crankcases slightly to aid the release of the bearings 19 Examination and renovation Big end and main bearings 1 Failure of the big end bearing is invariably accompanied by a knock from within the cr...

Page 28: ...rtainly be the small end eye which has worn rather than the gudgeon pin although in extreme cases the latter may also have become worn The connecting rod is not fitted with a bush type of small end bearing and conse quently a new connecting rod will have to be fitted if worn This is not a simple job as the flywheels must be parted to fit the new component and is a job for a Honda Service Agent It ...

Page 29: ...valve springs exert considerable force and care should be taken to avoid the compressed assembly flying apart To this end a small magnet is invaluable for retrieving the collet halves being more delicate than fingers 2 After cleaning the valves to remove all traces of carbon examine the heads for signs of pitting and burning Examine also the valve seats in the cylinder head The exhaust valve and i...

Page 30: ...collet halves to release 23 1b the top spring seat 23 1 c and valve springs 23 1d Note lower outer spring seat around valve guide 23 1 e Valve can be withdrawn for cleaning and examination 23 1f Seal on exhaust valve only should be renewed ...

Page 31: ...ious occasion It is better to fit replacements than attempt to straighten the originals 26 Examination and renovation cam gear and lobe and cam followers 1 Examine the condition of the cam gear teeth looking for signs of chipping and wear At the same time examine the corresponding teeth of the driving gear on the crankshaft The camshaft gear can be separated from the cam lobe if desired by removin...

Page 32: ...oil type which is easily fitted after drilling and re tapping the affected thread The process is quick and inexpensive and does not require as much preparation and work as the older method of fitting brass or similar inserts Most motorcycle dealers and small engineering firms offer a service of this kind 4 Sheared studs or screws can usually be removed with screw extractors which consist of tapere...

Page 33: ...ion in the crankcase The main bearing bosses will not require heating in order that the bearings may be fitted as they are fitted with steel inserts which mean that a simple sliding fit is possible 4 The assembled kickstart mechanism should now be installed in the right hand crankcase half slide the assembly into position ensuring that the return spring engages in its hole in the casing The upper ...

Page 34: ...sition 32 2g Slide shim and sleeve gear onto other end of shaft 32 2h Place 4th gear pinion 27T in position on layshaft and fit washer and clip 32 2i Fit 3rd gear pinion 29T 32 2j Bottom gear pinion 36T has renewable bush 32 2k and fits as shown ...

Page 35: ...circlip groove it must be ignored Do not fit circlip 32 2n Slide 5th gear pinion 25T into position no circlip 32 2o Fit 2nd gear pinion 32T and thrustwasher 32 2p The assembled clusters should look like this 32 2q View of gearbox components with selector forks in posi tion ...

Page 36: ...ded ball 33 2b Place gearbox components into left hand casing 33 2a Do not omit the neutral switch contact during reassembly 33 3 The crankshaft will drop into position 33 4a Fit the kickstart mechanism 33 4b ensuring that it engages correctly ...

Page 37: ...ght spots or resistance must be investigated and rectified before further reassembly takes place 35 Replacing the crankshaft pinion oil pump and gearchange mechanism 1 Slide the crankshaft pinion into position on the splined mainshaft end Fit two new 0 rings in their recesses in the oil pump seating face then place the pump unit in position align ing the holes in the top cover and pinion so that t...

Page 38: ...houldered bolt 35 2b Note locating pin which engages in camplate 35 2c Fit camplate and tighten bolt 35 2d If the gearchange pedal shaft has been dismantled reassemble 35 2e ensuring that springs are aligned properly 35 2f Fit assembly as shown ...

Page 39: ...ial washer noting the markings denoting the outside face Fit and tighten the slotted securing nut to a torque setting of 4 0 5 0 kgf m 29 36 Ibf ft using the Honda service tool or improvised peg spanner Install a new gasket followed by the outer half of the filter unit tightening the three retaining screws evenly to avoid any risk of warpage 4 Fit the two locating dowels into the crankcase mating ...

Page 40: ...readed pillars P 36 3a Slide on the inner half of centrifugal filter 36 2c Fit pressure plate and pushrod and cup 36 3b Note markings on special washer I 36 3c which should be fitted thus 36 3d Use home made tool to tighten lockring ...

Page 41: ...hat the small projecting segment is uppermost do not forget the small spring Fit the endfloat plunger in its bore and depress it against spring pressure while the retaining bolt is tightened 4 Place the generator stator in position noting the flat at the top which engages with the head of the cam gear shaft Ensure that the rubber fillet through which the generator cables pass is located correctly ...

Page 42: ...her or small spring when refitting cam gear shaft 37 3b Depress end float plunger while single bolt is tightened 37 4a Reconnect lead to neutral switch 37 4b Ensure that generator leads pass behind guide plate 38 1 Fit sprocket and retain with the locking plate and bolts ...

Page 43: ...ll three piston rings are in the bore the padding in the crankcase can be removed and the cylinder barrel located on the two dowels and secured with two bolts at the left hand side Check that the cam followers are correctly located either side of the cam lobe as the cylinder barrel is lowered into posi tion and be careful not to scratch their feet on the cam gear teeth 7 Note the position of the t...

Page 44: ...uence The unit should be lifted into its approximate position in the frame where it can be lodged between the frame members Loosely assemble the front engine plate fitting but not tightening the mounting bolts Place the rear bolts in posi tion noting that all bolts should be fitted from the left hand side Assemble the head steady plates if these have been removed When all the bolts are in position...

Page 45: ...ce the flange over then so that they are located inside the flange recess and tighten the two retaining nuts securely followed by the rear mounting fasteners 5 Refit the rear chain together with the gearbox sprocket if it was removed in this manner Replace the left hand cover having first checked the contact breaker gap and ignition timing as described in Chapter 3 Refit the gearchange and kicksta...

Page 46: ...Reconnect clutch cable and check adjustment 40 3c Refit the carburettor noting guide for HT cable 40 4a Footrest assembly bolts onto underside of crankcase 40 4b Fit new sealing ring in the exhaust port 40 4c then fit exhaust system Note packing pieces ...

Page 47: ...d the engine for any signs of leaking gaskets Before using the machine on the road check the operation of the clutch and brakes Remember that if a number of new parts have been fitted or if the engine has been rebored it will be necessary to follow the original running in instructions so that the new parts have ample opportunity to bed down in a satisfactory manner 40 6 Refill crankcase to correct...

Page 48: ...ywheel assembly Renew Renew gear pinions Check oil level and adjust as necessary Rebore and fit oversize piston and rings Renew Renew cylinder barrel and piston Re adjust Renew Check and reset Rebore and fit oversize piston and rings Grind in valves Check and adjust Fit replacement Clean or renew Decoke engine Refill to specified level Strip and clean Check 43 Fault diagnosis clutch Symptom Cause ...

Page 49: ... positions Off On Reserve the latter providing a reserve supply of petrol when the main supply has run out For cold starting the carburettor has a manually operated choke The machine should run on Choke for the least amount of time The lubrication system is of the pressure fed type supplying oil to almost every part of the engine There is a centrifugal filter mounted directly on the end of the cra...

Page 50: ...compressing the return spring against the underside of the top and disengaging the cable end from its recess in the valve The needle is held by a spring clip which is itself positioned by a second clip inside the valve It is normally advisable to leave this assembly undisturbed unless obviously worn 3 Slacken and remove the two flange mounting nuts and pull the carburettor body clear of the mounti...

Page 51: ...ailable a blast of air from a tyre pump will usually suffice As a last resort a fine nylon bristle may be used 8 Do not use excessive force when reassembling a car burettor because it is easy to shear a jet or some of the smaller screws Furthermore the carburettor is cast in a zinc based alloy which itself does not have a high tensile strength If any of the castings are damaged during reassembly t...

Page 52: ...he engine to overheat Reference to Chapter 3 will show how the condition of the spark plug can be interpreted with some experience as a reliable guide to car burettor mixture strength 9 Carburettor T PFC type 1 CG125 C and E models are fitted with Honda s Transient Power Fuel Control carburettor This is an economy carburettor designed to run on a weaker mixture so reducing fuel consump tion The T ...

Page 53: ...ble adjuster 3 Mixing chamber top Gasket 5 Return spring 6 Jet needle assembly 7 Throttle valve 8 Throttle stop screw 9 O ring 10 Needle jet 11 Needle jet holder 12 Main jet 13 Pilot screw 14 Spring 15 O ring 16 Pilot jet 1 7 Float and pivot pin 18 Float needle valve 19 Gasket 20 Float bowl 21 Screw and washer 3 off 22 Drain pipe 23 Clip 24 Drain screw 25 O ring ...

Page 54: ... housing can be separated if desired and the gear and spindle removed 3 Examine each component for signs of scuffing and wear Note especially the condition of the rotors and pump body If these are at all worn the pump must be renewed Temporarily fit the rotors to the pump body and use feeler gauges to measure the clearance between the rotors and a straightedge placed acoss the pump body mating sur...

Page 55: ...on oil pump components 12 2b Casing is secured by two bolts and can be removed 12 2c to allow pinion 12 2d and spindle to be withdrawn 12 3 Check pump components as described 13 1 Centrifugal filter can be dismantled for cleaning ...

Page 56: ...n or renew Check all unions and gaskets Float needle seat needs cleaning Replace Adjust to figure given in Specifications Fit correct jet or tighten if necessary Check float valve and replace if worn Adjust screw Tighten top Refer to relevant paragraph in this Chapter Disconnect and lubricate or replace Clean Remove and clean out General lack of performance Engine does not respond to throttle Engi...

Page 57: ...l original current recommendation D8ES L7D8EA X24ES X24ES U CG125 K1 B C E DR8ES L X24ESR U Electrode gap 0 6 0 7 mm 0 024 0 028 in 1 General description The spark which is necessary to ignite the petrol air mixture in the combustion chamber is derived from an ignition coil mounted on the frame and a flywheel generator attached to the left hand crankshaft of the engine A contact breaker assembly w...

Page 58: ... check has shown them to have worn outside the limits given it will be necessary to renew the assembly Do not attempt to reface the contact breaker points as this will make it impossible to obtain the required gap and timing sett ings Use only genuine Honda replacement parts when obtaining new points 2 It is necessary to remove the flywheel rotor from the crank shaft in order to gain access to the...

Page 59: ...y to connect the probe to the contact breaker assembly is to disconnect the generator output lead connector and locate the black or black white lead to the points 2 Set the rotor so that the F mark registers with its datum mark then adjust the fixed contact so that the points just start to separate This will be indicated by the test lamp flickering or the meter needle deflecting Check that the con...

Page 60: ...in engine damage due to excess heat being generated If the correct grade of plug is fitted however it will be possible to use the condition of the spark plug electrodes to diagnose a fault in the engine or to decide whether the engine is operating efficiently or not 3 Also always ensure that the plug is of the resistor type indicated by the letter R where applicable so that its resistance value is...

Page 61: ...ould not light B Fig 3 4 Condenser test sequence A Using a battery bulb arrangement B Using a multimeter 6V10 20W Bulb should not light Bulb should not light Bulb should light Fig 3 5 Ignition coil test procedure ...

Page 62: ...he combustion chamber or poor quality fuel oil Carbon fouling Dry black sooty deposits leading to misfire and weak spark Caused by an over rich fuel air mixture faulty choke operation or blocked air filter Oil fouling Wet oily deposits leading to misfire and weak spark Caused by oil leakage past piston rings or valve guides 4 stroke engine or excess lubricant 2 stroke engine Overheating A blistere...

Page 63: ...lug gap incorrect or has whiskered Incorrect ignition timing Weak points arm return spring Defective ignition coil Low output from flywheel generator Plug lead insulation breaking down Check plug and adjust gap or renew Renew Clean or renew and check gap Check for arcing Renew condenser Adjust and clean or renew Gheck timing and points gap Renew Renew after expert testing Have tested and renew Che...

Page 64: ...r limit Lower leg bore diameter 31 000 31 039 mm 31 100 mm 1 2244 in 1 2205 1 2220 in Bottom bush damper piston diameter 30 936 30 975 mm 30 900 mm 1 21 65 in 1 2180 1 2195 in Fork spring free length CG125 185 90 mm 7 3189 in 170 00 mm 6 6929 in CG125 K1 B C E 41 1 60 mm 1 6 2047 in 391 00 mm 1 5 3937 in Fork oil capacity per leg CG125 at oil change 120 130 cc 4 22 4 58 Imp fl oz CG125 at rebuild ...

Page 65: ...n now be lifted off and the handlebar assembly rested across the top of the petrol tank 2 Disconnect the speedometer drive cable and then release its retaining bolts and lift the instrument head away detaching the bulbholders from the base as this is done 3 Remove the headlamp unit from its shell by releasing the single screw which secures the rim The headlamp can be removed completely by disconne...

Page 66: ...nal vari able rate spring After the leg concerned has been removed from the yokes the spring and headed spring guide may be slid off the stanchion The guide serves to hold the top of the spring concentric to the stanchion and thereby removes any tendency for the spring to chatter It is unlikely to suffer any noticeable degree of wear It will be noted that the forks are fitted with variable rate sp...

Page 67: ...ff 21 Washer 2 off 22 Washer 2 of 23 Fibre washer 2 off 24 Oil seal 2 off 25 Drain plug 2 off 26 Circlip 2off 27 Spring ring 4 off 28 Spring ring 2 off 29 Top bush 2 off 30 Bottom bush piston 2 off 31 Top bolt 32 Screw 2 off 21 21 Fig 4 2 Fork yokes and bearings 7 2 3 4 5 6 7 8 Cableclip Bearing cup 2 off Right hand clamp helmet lock Handlebars Guide Lower yoke and stem Uppercone Dust seal 9 Washe...

Page 68: ... rolling the stanchion on a surface plate or sheet of plate glass It is possible to straighten a slightly bent stanchion in a hydraulic press or flypress This is however a task for an expert and his advice on the practicability of straightening a stanchion should be heeded 6 When reassembling the forks make sure the spring rings on the stanchion are seated correctly When fitting the new seal lubri...

Page 69: ...r plain bush for wear 7 6a Note the position of spring rings 7 6b which locate the bushes on the stanchion 7 6c Do not omit restrictor if removed 7 6d Fit lower leg over bushes 7 6e Renew seal and replace the circlip ...

Page 70: ...d stem is passed through the head set It has been known for a ball to be displaced drop down and wear a groove or even jam the steer ing so be extremely careful in this respect 2 Take particular care when adjusting the steering head bear ings the lockring should be locked in place with the steering stem nut sufficiently to remove all the slack but not tight otherwise damage to the cups or ball bea...

Page 71: ...er 11 off Spring washer 6 off Bolt 2 off Bolt 2 off Bolt 2 off 11 Swinging arm examination and renovation 1 To check for wear in the swinging arm bushes hold the frame firmly in one hand and with the other shake the rear wheel There should not be any side play at all if there is replacement of the swinging arm pivot bearings may be necessary 2 Remove the rear wheel assembly as described in Chapter...

Page 72: ... Washer 4 Dust seal 5 Stanchion 6 Circlip 7 Backing ring 8 Oil seal 9 Upper bush 10 Circlip 2 off 11 Lower bush 12 Circlip 13 Spring 14 Lower leg 15 Sealing washer 16 Oil drain bolt 1 1 4b and withdraw the pivot shaft 11 4c Remove swinging arm from frame 1 1 4d noting washers each side of exhaust mounting bracket ...

Page 73: ... hydraulically damped spring type Each unit consists of a hydraulic damper effective primarily on rebound and a concentric chromed spring It is mounted by way of rubber bushed lugs at top and bottom 2 The suspension units are provided with an adjustment of the spring tension giving five settings The settings can be easily altered without removing the units from the machine by using a C spanner bot...

Page 74: ...n A strong return spring attached to a small lug on the right hand side of the stand retracts and holds the stand in position when not in use 2 Periodically the pivot pin should be lubricated with grease This is fairly important as its exposed position renders it susceptible to corrosion if left unattended 3 Be especially careful to check the condition and correct location of the return spring If ...

Page 75: ...ith the instruc tions given in the preceding paragraph Try to avoid tight bends in the run of the cable because this will accelerate wear and make the instrument movement sluggish 18 Dualseat removal 1 The dualseat is fixed to the rear of the machine by two brackets bolted to the rear part of the frame assembly At the front there is a bracket under the seat which engages with a location bracket on...

Page 76: ...ings Slack steering head bearings Worn fork bushes Ineffective fork dampers Ineffective rear suspension units Suspension too soft Fork legs out of alignment twisted in yokes Worn swinging arm pivot Check and renew Check and renew Check and realign Slacken until adjustment is correct Tighten until adjustment is correct Dismantle forks and renew bushes Check oil content of front forks Check whether ...

Page 77: ...pped with two identical single leading shoe sis brake units the drums being integral with the wheel hub On all models chromium plated steel wheel rims are laced to the hub by spokes the front and rear rims being of 18 in and 17 in diameter respectively The front rim carries a 2 50 in section tyre while the rear fitment is of 3 0 0 in section 2 Front wheel examination and renovation 1 Place the mac...

Page 78: ...he specialist engineering firms who undertake this work should be sought 4 If fork oil or grease from the wheel bearings has badly con taminated the linings they should be renewed There is no satisfactory way of degreasing the lining material which in any case is relatively cheap to replace Measure the thickness of the friction material if it is worn at any point to or beyond the specified wear li...

Page 79: ...draw the wheel spindle and lower the wheel clear 4 1 a Brake plate assembly can be lifted out of drum 4 1b for examination and renovation 4 2 Examine the brake drum surface for signs of scoring 4 5 Method of removing brake shoes for inspection or renewal ...

Page 80: ...indicates that the brake shoes are lightly in contact with the drum surface Turn the adjuster nut back by y 1 turn until the noise stops Spin the wheel and apply the brake hard once or twice to settle the brake Check that the wheel is still free to rotate and that the adjustment has remained the same This setting should give you 20 30 mm J 1 J inch free play measured at the extreme tip of the hand...

Page 81: ...se to one side There is no need to remove the left hand engine casing Slacken the rear brake adjuster nut and remove it to release the brake rod Reassemble the rear brake rod components to avoid loss 2 Turn the rear wheel until the joining link in the drive chain is accessible then using pointed nosed pliers prise off the spring link and separate the chain Reassemble the joining link parts on one ...

Page 82: ...ly remove the lower suspension mounting bolts to allow the swinging arm to be moved to clear the end of the silencer The spindle can now be withdrawn and the wheel lowered clear of the frame 10 Rear brake examination and renovation 1 With the rear wheel removed from the frame the brake plate assembly can be pulled clear of the drum for examination The rear brake is identical to the front drum brak...

Page 83: ...uipment necessary to extract the old bushes and fit the new ones It is extremely unlikely that this operation can be performed at home due to the tight fit of the bushes In all probability any attempt to dislodge them will result in the inner metal sleeve tearing out of the rubber making subsequent removal difficult 3 Check the condition of the sprocket teeth if they are hooked chipped or badly wo...

Page 84: ...ors Remove inner tube from tyre When first bead is clear remove tyre as shown When fitting partially inflate I inner tube and insert in tyre Work first bead over rim and feed valve through hole in rim i Partially screw on retaining nut to hold valve in place Check that inner tube is positioned correctly and work second bead over rim using tyre levers Start at a point opposite valve Work final area...

Page 85: ...A large socket makes a useful drift 11 2d New seals should be fitted together with bearings 12 1a Sprocket is retained by large diameter circlip 12 1b The pins engage in bonded rubber bushes 12 3 Number of teeth is stamped on the rear wheel sprocket ...

Page 86: ...re clearly marked with a series of horizontal lines above the adjusters to provide a simple visual check If desired wheel alignment can be checked by running a plank of wood parallel to the machine so that it touches the side of the rear tyre If wheel alignment is correct the plank will be equidistant from each side of the front wheel tyre when tested on both sides of the rear wheel It will not to...

Page 87: ...b Ensure that drain holes remain clear unblock if necessary 14 4 Marks ensure correct wheel alignment 14 8 Closed end of link should face direction of travel l 14 9 An equivalent British made chain is available Fig 5 4 Checking wheel alignment A and C Incorrect B Correct ...

Page 88: ... before removing the backing from the patch and applying the patch to the surface 7 It is best to use a patch of self vulcanising type which will form a very permanent repair Note that it may be necessary to remove a protective covering from the top surface of the patch after it has sealed in position Inner tubes made from synthetic rubber may require a special type of patch and adhesive if a sati...

Page 89: ...wheel rim most likely front wheel Tyre not straight on rim Brakes binding Ends of brake shoes not chamfered Elliptical brake drum Badly worn pads Brake cam binding in housing Weak brake shoe springs Worn or badly adjusted final drive chain Hooked or badly worn sprockets Loose rear sprocket Worn damper rubbers Check rim alignment by spinning wheel Correct by retensioning spokes or building on new r...

Page 90: ...Stop tail lamp 6V 21 5W Note Some CGI25 C and E models may use 6V 17 5 3W stop tail lamp bulbs check bulbholder marking for correct bulb rating 1 General description The electrical system is powered by a generator mounted on the left hand end of the crankshaft It is normally of ND Nippon Denso manufacture though occasionally a Hitachi unit is used The latter can be identified by its having three g...

Page 91: ...generator coils as shown in Fig 6 2 and check also that the rectifier is in good condition as described in Section 4 Always have your findings checked by an expert using the correct test equipment before attempting repairs or renewing components 4 Rectifier checking for malfunction 1 The rectifier as mentioned previously changes the alter nator output from ac to dc It takes the form of a small sea...

Page 92: ...generator may fail to keep pace with the heavy electrical demand Under these circum stances it will be necessary to remove the battery from time to time to have it charged independently 2 The battery is located behind the left hand side panel It is secured by a strap which when released will permit the battery to be withdrawn after disconnection of the leads Remember that the machine has a negativ...

Page 93: ...1 220 at 20 C 68 F will be fully charged approximately 1 2 hours 6 Headlamp replacing bulbs and adjusting beam height 1 To remove the headlamp lens reflector unit unscrew the single screw at the bottom of the unit early models or the two screws which pass through the shell one on each side just When the charging is urgent quick charging method may be used however the recommended charging current r...

Page 94: ...ing and the headlamp switched to main beam the centre of the concentrated area of light should be at the same height on the wall as the headlamp is from the ground loWER LEVEL UASA 6N6 3B VUASA BATTERY CO LTD MADE IN JAPAN 5 4 Maintain electrolyte between two level marks 7 If the headlamp rim and reflector are to be dismantled at any time note the location of the reflector before disturbing it so ...

Page 95: ...ulb 9 Grommet 10 Shell 11 Bolt 2 off 12 Washer 2 off 13 Nut 2 off not fitted to early CGI25 models Fig 6 7 Headlamp unit CG125 C and E models 2 3 4 5 6 Rim Glass Gasket W clip 4 Reflector Headlamp off bulb 7 8 9 10 11 Bulbholder Bulbholder Grommet Pilot lamp bulb Shell 12 Bolt 2 off 13 Screw 2 off 14 Spring washer 2 off 15 Spacer 2 off 16 Nut 2 off ...

Page 96: ...to the bracket the housing can then be raised sufficiently for the bulbholders to be unplugged These bulbs are of the capless type and are pressed into their sockets be careful not to damage the fine wire terminals on fitting the new bulb 11 Flashing indicator lamps 1 The forward facing indicator lamps are connected to stalks which are attached to the headlamp brackets The hollow stalks carry the ...

Page 97: ...l times In an extreme emergency and only when the cause of the failure has been rectified and no spare is avail able a get you home repair can be made by wrapping silver paper around the blown fuse and re inserting it in the fuse holder It must be stressed that this is only an emergency measure and the fuse should be replaced at the earliest possible opportunity as it affords no protection at all ...

Page 98: ...ction between the brown wire terminal and earth The correct resistance for the unit fitted to CG125 C and E models is 2 ohms a similar reading can be expected from the unit fitted to earlier models If the reading obtained is significantly different the resistor must be considered faulty and renewed 18 Wiring layout and examination 1 The cables of the wiring harness are colour coded and will corres...

Page 99: ... 2 off 22 Bolt 2 off 23 Screw 24 Screw 25 Nut 2 off 26 Spacer 27 Washer 4 off 28 Cable clip 3 off 29 Fuse 19 Fault diagnosis electrical system Symptom Cause Remedy Complete electrical failure Dim lights horn inoperative Constantly blowing bulbs Blown fuse Isolated battery Discharged battery Vibration poor earth connection Check wiring and electrical components for short circuit before fitting new ...

Page 100: ...G INDICATOR LAMP REAR STOP SWITCH GROUND fRAME OFF N oooo oo o o o w y BAT R W R REAR FLASHING INDICATOR LAMP Colour key B Blue LG Light green Bk Black 0 Orange Br Brown P Pink G Green R Red Gr Grey W White LB Light blue Y Yellow HEADLIGHT CONTROL SWITCH 3S o LG R CZIO LG R FLASHING INDICATOR WARNING LIGHT NEUTRAL INDICATOR LIGHT SPEEDOMETER ILLUMINATING LIGHT FLASHING INDICATOR T 8 G CONTROL HORN...

Page 101: ...ON CCIOK TCH BA o R OHTWUIT HO o 16 o 8 I fO s IGNITICM SWITCH Colour key B Blue LG Light green Bk Black 0 Orange Br Brown P Pink G Green R Red Gr Grey W White LB Light blue Y Yellow REAR RHAND FLASHING INDICATOR LAMP TAIL STOP LAMP REAR L HAND FLASHING INDICATOR LAMP HEADLIGHT OlMMEfi SWITCH CONTINUITY NEUTRAL SWITCH OFF O N L P COLOR x O B o a a TL O O o Br Cl o o o CH o p C3 o 1 m O o o o R w W...

Page 102: ... o o o ON B A O fO E O FLASHING HORN DIMMER SWITCH INDICATOR REAR R HAND FLASHING INDICATOR LAMP STOP TAIL LAMP o o H IN L o o o o u r FREE PUSH o o Colour key Bl Black Lg Light green Br Brown 0 Orange Bu Blue P Pink G Green R Red Gr Grey W White Lb Light blue Y Yellow Wiring diagram CG125 C and E models O 01 ...

Page 103: ...106 The CG125 BR E F model The CG125 BR J model ...

Page 104: ...The following specifications apply to the CG125 E F J and K Brazilian built models imported from April 1985 onwards Information is given only where different from that applicable to the CG125 E Japanese built model described in Chapters 1 to 6 of this manual Model dimensions and weight CG125 BR E F J CG125 BR K Overall length 1936 mm 76 2 in 1985 mm 78 1 in Overall width 745 mm 29 3 in 735 mm 28 9...

Page 105: ... sleeve bolt CG125 BR E F and J models 2 3 2 8 16 5 20 CG125 BR K model 3 3 23 Crankcase and crankcase cover screws 0 8 1 2 6 9 Selector drum camplate bolt 1 0 1 6 7 11 5 Selector drum stopper arm bolt 0 8 1 2 6 9 Generator stator screws 0 8 1 2 6 9 Gearbox sprocket mounting bolts 1 0 1 6 7 11 5 Endfloat plug mounting bolt 1 0 1 6 7 11 5 Engine oil drain plug where fitted 2 0 3 0 14 5 22 Oil filte...

Page 106: ... 0 09 Imp fl oz Rear suspension Travel CG125 BR E F and J models 64 mm 2 52 in CG125 BR K model 80 mm 3 15 in Suspension unit spring free length Standard 197 7 mm 7 7835 in Wear limit 194 0 mm 7 6378 in Note Springs must be fitted with closer pitched coils at the top Torque wrench settings Component kgf m Ibf ft Steering stem nut 6 0 7 0 43 50 5 Steering head bearing adjuster lockring assembly onl...

Page 107: ...rking on one of the Brazilian models first check the relevant part of this Chapter If no information is given it can be assumed that the procedure or specification is unchanged from that given in the relevant part of Chapters 1 to 6 4 As with their Japanese predecessors the Brazilian models have appeared in a number of slightly different versions Each can be identified as follows 5 The first model...

Page 108: ...angs 1 7f Pilot lamp bulbholder is a press fit engage with matching slots in holder in reflector 1 7g bulb is of bayonet type always 2 1 Modified battery retaining strap ensure correct wattage bulb is fitted note spare fuse location arrow on BR K model 4 2 Air filter cover is retained by six screws note sealing gasket 4 3 Note two flame traps one is fitted 4 4a Withdraw element assembly next to fi...

Page 109: ...ing with one of the flame traps Withdraw the assembly and remove the single retaining screw to separate the component parts 5 Check the element for splits tears or severe clogging and renew it if necessary Clean the element as described in Routine maintenance and reassemble the element components Refit them to the filter casing so that no unfiltered air can leak past then refit the filter cover wi...

Page 110: ...ripped for repair The areas of wear are the piston cylinder group the head gasket or the valves The piston cylinder group can be checked by removing the gauge pouring a small amount of oil into the cylinder bore then repeating the test If the pressure recorded is significantly increased the piston piston rings or cylinder barrel are at fault if the pressure remains unchanged the head gasket or val...

Page 111: ...o the layshaft 3rd gear pinion with its marking facing upwards ie to the left The centre fork is fitted to the mainshaft 4th gear pinion The left hand fork is fitted to the layshaft 5th gear pinion with its marking facing downwards ie towards the other forks 4 Insert the selector drum so that the neutral switch contact aligns with the switch terminal and manoeuvre the fork guide pins into their re...

Page 112: ...ubricate all bearing surfaces with molybdenum disulphide based grease When all compo nents are in place check the pump operation to ensure correct installation and smooth return under spring pressure Use the cam arm adjuster to eliminate all clearance between the cam and arm and between the arm and rod as a preliminary setting for final adjustment see Section 1 5 7 As described above all other car...

Page 113: ... gaiter is undamaged note pump delivery valve in gasket surface 13 4a Carefully clean components of pump one way valves 13 4b and be careful not to mix them up note sealing O ring fitted to delivery valve 13 5 If linkage must be dismantled note how components are fitted before removal 13 6 Use cam arm adjuster to eliminate clearance on reassembly initial setting 13 7a Carburettor jets are the same...

Page 114: ...well be obtained only by using both adjusters to achieve a compromise setting This is simplified on later models which have only the twistgrip adjuster The throttle cable must have 2 6 mm 0 08 0 24 in free play measured in terms of twistgrip rotation When the throttle cable is correctly set tighten the twistgrip adjuster locknut refit the rubber sleeve over both adjusters and check that the idle s...

Page 115: ...split clamp of each yoke slightly by removing the pinch bolt and working the flat blade of a screwdriver into the clamp Exercise extreme caution when doing this as the clamps can be overstressed and broken easily 20 Front fork legs dismantling and overhaul 1 Dismantle and rebuild the fork legs separately and store the components of each leg in separate clearly marked con tainers so that there is n...

Page 116: ...o tip out the damper rod seat The oil seal can be prised out of the lower leg using a large flat bladed screwdriver which has had any sharp edges ground off be very careful not to damage the top edge or to scratch the seal housing when using this method Do not apply excessive pressure if the seal proves difficult to remove pour boiling water over the outside of the lower leg to expand the alloy su...

Page 117: ... its specified torque setting when the stanchion is held either in a vice with padded jaws or in the machine s fork yokes 22 Front fork legs refitting 1 On refitting check that the upper length of each stanchion is clean and polished and that all traces of dirt and corrosion have been removed Apply a thin smear of grease to ease the passage of the stanchion through the yokes and to prevent corrosi...

Page 118: ...ntings Press each latch to the rear to release and where applicable unlock the helmet lock to release the wire clip 4 On refitting hook the seat front mounting under its locating bracket and press the seat down at the rear so that its two latches snap into engagement Where fitted slip the wire clip into the helmet lock to provide a measure of security Tail fairing CG125 BR K only 5 Remove the seat...

Page 119: ...er Fig 7 4 Front wheel and brake 10 Brake shoe 2 off 11 Return spring 2 off 12 Seal 13 Speedometer drive gear 14 Washer 2 off 15 Camshaft 16 Brake plate 17 Screw 18 Castellated nut 19 Split pin 20 Dust seal 21 Return spring 22 Wear indicator plate 23 Actuating arm 24 Bolt 25 Nut 26 Trunnion 27 Adjusting nut X J I r ...

Page 120: ... Regulator rectifier unit location and testing 1 The 12 volt electrical system fitted to these models uses a combined regulator rectifier unit to replace the rectifier and resistor fitted to the earlier models 2 The unit is fitted either under the seat in front of the rear mudguard or under the petrol tank immediately behind the steering head Remove the seat and petrol tank if necessary to gain ac...

Page 121: ... I TL REAR RIGHT HAND FLASHING INDICATOR LAMP REAR LEFT HAND FLASHING INDICATOR LAMP LIGHTING DIMMER TURN SIGNAL NORN SWITCH HO BAT IG E ON 9 6 OFF 9 5 TL Cl HL ON o 6 9 N o o o p 9 6 OFF HL Hi Lo Q 9 T if N 5 0 HiS 9 6 R W L L 9 4 N R 9 4 HO BAT PUSH 9 6 FREE Bl Black Br Brown Bu Blue G Green Colour key Gr Grey Lb Light blue Lg Light green 0 Orange P Pink R Red W White Y Yellow Wiring diagram CG1...

Page 122: ...per square inch psi Ibf in2 Ib in2 Millimetres of mercury mmHg Inches of water inH20 Inches of water inH20 Pounds force per square inch psi Ibf in2 Ib in2 Kilograms force centimetre kgfcm kgcm Newton metres Nm Pounds force feet Ibf ft Ib ft Kilograms force metres kgf m kg m Newton metres Nm Kilograms force metres kgf m kg m X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 0 0394 3...

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