CG125 Cleanup

[tomh]

Hi, since my MOT has just expired I thought it would be a good time to take my CG apart and clean up the rust and dirt etc. The bike is a 2001 Honda CG125. I've been servicing the bike since I've got it so nearly everything is working and I shouldn't have to replace any parts. I'm just going to clean and paint parts as I go. Since it's just a 125 I'm not planning to spend much money on this however I am planning on keeping this bike once I've done my test so I would like to keep it looking as good as a CG can look

It looked like this when I bought it.

https://i1049.photobucket.com/albums/s383/TomHanley/My%20CG125/IMG_0110.jpg

However riding through the winter and not washing the bike has led it to its rust problem getting worse.

https://i1049.photobucket.com/albums/s383/TomHanley/My%20CG125/IMG_01162.jpg

I've lost the first lot of pictures but so far I've removed the tank, seat and panels.

First thing I've got to do is to remove the tail light.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0278.jpg?t=1333999772

Numberplate holder and rear indicators removed without much problem.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0281.jpg?t=1333999879

Next to remove is this rusted metal plate that holds the numberplate holder and mudguard to the frame. This is the only part I wanted to remove as it looked the worse but I've somehow ended up taking apart the whole of my bike

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0282.jpg?t=1333999982

As you can probally guess, the bolts are completely siezed in place. This is what happens when you apply force to cheap socket sets.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0285.jpg?t=1334000322

20 mins later and lots of WD40 the bolt finally unscrews

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0284.jpg?t=1334000426

Air box and battery removed. I've also removed the rear mudguard.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0293.jpg?t=1334000464

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0292.jpg?t=1334000531

The rear mudguard is the first part to be cleaned.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0302.jpg?t=1334001055

My main problem with the bike is the center stand as it has seized to the pivot pin and worn a hole into the frame.

To get access to the stand I've removed the exhaust.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0271.jpg?t=1334001401

To remove the stand first I will need to remove the brake pedal which is held on by a washer and split pin. Like most split pins on this bike they are rusted and snap straight away leaving me having to drill them out. Anyone got any advice on how to remove them intact when there in this condition.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0274.jpg?t=1334001599

You can see how much the pivot pin has worn into the frame.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0275.jpg?t=1334001701

After reading other people's experiences removing thier stand in this condition I was supprised to find that some WD40 and one big hit with a hammer removed the pin from the stand leaving both parts intact.

My plan to fix this to pass the MOT is to fill the hole with epoxy putty and then re-drill out the hole. I'm then just going to ditch the center stand and just refit the pivot pin and brake pedal.

I have found more rust on the frame than I expected although most of it is just surface rust and wipes off, other parts look quite bad.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0297.jpg?t=1334002193

Im undecieded on if I'm just going to patch these spots of rust with hammerite or repaint the whole frame.

I've got the next few days off work so I'm going to finish this over the next couple of days.

Thanks for reading,
Tom.

[Hobgoblin]

good work tom!
____________________
Plodding along on my CG

[_Iain_]

https://cdn2.holytaco.com/wp-content/uploads/2011/05/horror-like.jpg

Good luck with it mate - I'd be going bare frame, hammeriting the whole thing and building it back up.
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[tomh]

More progress done on the bike today. I've stripped the bike down to the frame leaving just the rear wheel/swingarm and front end attached. I've only just recently refurbished the forks (I'll find the pictures of this later) and I've tided up the wiring in the headlight so I didnt see the need in stripping it.

First job of the day is to fill the centerstand hole with metal epoxy putty. Just need to file it down, redrill the hole and paint it.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0306.jpg?t=1334072923

No pictures for this part but I've had the engine out and washed the frame with soapy water and a scrubber. Thankfully nearly all the rust on the frame was just surface rust and came straight off. There were a few small patches including the picture in my last post, so I've sanded them down and painted them in hammerite.

Engine and rear mudguard refitted:

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0311.jpg?t=1334073122

I've used a wire brush on the rusted metal plate, painted it with some hammerite and put it back on the bike.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0312.jpg?t=1334073240

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0313.jpg?t=1334073320

Wiring loom put back in place:

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0314.jpg?t=1334073439

Airbox back in along with the battery:

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0315.jpg?t=1334073586

New indicator relay fitted, it should be a lot nicer riding having my indicators working again.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0316.jpg?t=1334073534

How it stands now:

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0320.jpg?t=1334074146

Not much left to do now,

- Sort the rear brake pivot out and paint the brake pedal,
- Clean and refit air filter,
- Clean up body panels,
- Clean the rear shocks,
- Refit the chain.

One problem I still need to sort out is my new forks I've fitted, there off a older CG and a slightly diffrent design so when you fully tighten the front wheel spindle it pulls the fork legs in and binds the wheel. If I don't fully tighten the wheel I loose braking power as the drums shoes are not tight in the drum.

My solution to this is to make longer wheel spacers, I've got a spare wheel spacer which I'm going to cut down once I work out what size the spacer needs to be.[/img]

[tomh]

Some more jobs on the bike completed already today.

New air filter foam oiled and fitted.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0336.jpg?t=1334135342

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0338.jpg?t=1334135432

My brake lever mount has snapped off but I don't want to pay £15 for a second hand one so I've made a new mount which works better than the original one. The lever doesn't move up and down any more, I just need to paint it black to finish it.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0333.jpg?t=1334135103

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0334.jpg?t=1334135354

Rear reflector fitted to pass MOT and make me a bit more visible.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0340.jpg?t=1334135585

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0339.jpg?t=1334135439

New brake shoes fitted at front and back, my rear shoe was in a bad condition and had several chips in it. The drum looks OK though.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0335.jpg?t=1334135423

I've been thinking about the body panels and the state there in, with the left side looking the worse after my crash.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0343.jpg?t=1334135598

I really want to repaint the panels but with my holiday coming up soon, I would rather paint them myself to save money, the only problem being is I have no experience of doing this...

[bikertomm]

Nice one mate looking good!

What did you use to clean the engine casing / block?

Mines basically the same and I want to get it looking clean!


____________________
07' Honda Hornet now full powaah! My guide on performing an oil change!

[tomh]

Thanks, my engine is the one bit where I've not really needed to do much to get it looking clean though, the person I got it off repainted the engine cases just before I bought it so all I needed to do is scrub it down with some soapy water to get it looking good again.

You can see it from around when I first got it in the first pic.

Not got much else done today, I've drilled out the pivot hole on the frame and painted it up. The brake pedal is painted in black ready to go back on the bike but I've gone through several drill bits trying to drill out the old split pin on the pivot pin. I need to do get some new drill bits to finish that off. Until then I can't put my rear brake pedal back on.

I've also made a new wheel spacer for my front wheel which would have fit perfect if I hadn't of lost it somewhere I'm not looking forward to trying to take the front wheel off on my own without a center stand though...

Once them two jobs are finished I'm going to get all the body panels back on and get my MOT sorted.

I'm not going to bother repainting the bike as I'm planning on buying a old 250cc+ bike that I can restore as I've really enjoyed stripping this bike down, it will also motivate me to get my test done

[pendulum]

This is exactly what I want to do with my CG, clean it up a bit and deal with all the surface rust because it looks bad.

A bit scared of painting though as I've hardly done any painting before. Just read this:

Hammerite Paint is specially formulated to be applied directly onto rusty metal with minimal surface preparation.
Is it really that simple? If so I will give it a go pretty soon!

Anyway. Just wanted to say. Your thread is useful.

[blurredman]

I have a '91 CG.

I did the exact same thing, and my god the rear of the frame (where the back plastic mounts on) was very bad.


All surface rust however and it was still extremely solid. A little hammerite goes a long way!


Good progress!
____________________
CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S, 1979 MZ TS150.
Current: 1973 MZ ES250/2 - 18k, 1979 Suzuki TS185ER - 10k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 40k, 1989 MZ ETZ251 - 51k.

[deleted111]

I ditched my centre stand and fitted a sidestand, best thing I've ever done to my CG.

Good work so far!

[Tim..]

Nice progress

But

Do yourself a favour and buy a new (or 2nd hand) brake lever mount
____________________
Project builds: My VFR400 nc30 build thread + Honda Britain Rep VFR + What? Another VFR +Project 'cos I want one' + V8 coffee table
www.marshallracing.co.uk
OCD - Helping to bring the standard of my bikes up and make me slowly go mad since 1999

[Hobgoblin]

[tomh]

Thanks for the replys, not got much done today as it was going dark by the time I got home from work but all my main jobs have been done.

My rear brake pedal is back on the bike as I've finally drilled out the split pin on the pivot pin, I really need to buy a punch instead which would of been much quicker. The rear brake pedal doesn't have much travel any more but I'm guessing that is due to it having new brake shoes.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0344.jpg?t=1334271508

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0346.jpg?t=1334271948

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0349.jpg?t=1334271993

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0350.jpg?t=1334272024

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0351.jpg?t=1334272079

I've also cut down a old wheel spacer and filed it down so my new fork doesn't bend in and bind the wheel when tightening the wheel spindle.

My front brake lever mount works quite well, ill take a picture of it tomorrow but I suppose I should really buy one to pass the MOT.

It got to dark to do anything else but I will have it all back together tomorrow and I will get my MOT booked

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0358.jpg?t=1334272439

[tomh]

More progress

My bike is more or less back together. All body panels, the tank and exhaust are back on although my mudguard has been taken off to repaint the inside as it's really rusty.

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0361.jpg?t=1334347954

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0366.jpg?t=1334347973

Really happy with the results of rebuilding the bike. My brake pedal is really nice to use now and no longer wobbles all over the place. The stopping power is a lot better with the new shoes I've fitted.

Going to get my MOT booked tomorrow. I've still got little jobs to do like repaint the fork legs but I'm going to leave them as they are for now. I'm going to autosol the chrome when I'm bored enough to do it

I also got a letter from the DVLA telling me my tax is due at the end of the month, my dad also got his letter...

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0359.jpg?t=1334348267

I love how cheap my CG is to run!