Honda Cityfly / CLR 125 project

[tomh]

I've been looking for a cheap 125 project for a while to restore and found a 2004 Honda City Fly with only around 6000 miles on the clock.

Mine reason I got this was to have project bike to learn on as it's a lot easier to understand how everything works when it's right in front of you. Also I had a lot of fun stripping my CG125 down and repairing my mates bikes.

Bringing the bike home:
https://i1049.photobucket.com/albums/s383/TomHanley/photo-1_zps224efd06.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/IMG_0076-1.jpg

First major problem was the engine was not running. Stripping it down revealed a missing piston and snapped exhaust valve.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_2_zps93e14e56.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_3_zps3d77f781.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_4_zps6453a183.jpg

The con rod looks slightly twisted which is the worst news as it will more than likely cost more to fix this engine than replace it. I got a new piston with the bike and when it is attached to the con rod in the barrel there was scuffs on one side of the piston as if it was sat at a slight angle.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_5_zps3039c996.jpg

Ahh that's where the piston was hiding...

The next thing I've noticed is this is a Honda XR/CG 125 engine with push rods instead of the over head cam engine from the XLR 125 that it should of come with. So my plan is source a second hand XLR engine. I've found that the Gilela Cougar 125 engine was the same XLR 125 engine down to the same wiring plugs off the magneto. If this is the case a replacement engine can be had for ~£100.

Stripping the bike down has made it obvious that this project will be more than just fixing the engine:

Problems found:
Headstock bearings pulled to center and felt notchy.
Loose spokes in rear tire and the cush drive has epically failed.
Rear shock linkage bearings seized
Air filter needs changing
The airbox to carb rubber has split

https://i1049.photobucket.com/albums/s383/TomHanley/photo_6_zps3ffea44c.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_7_zpsf4b80db3.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_7_zpsf4b80db3.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_9_zps34549830.jpg

This was the cush drive in the rear wheel. The sprocket was only held on by the circlip and all the sprocket studs came out of the wheel hub with the sprocket.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_10_zpsd8d20d0b.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_11_zpsafa61c17.jpg

So far I've got the bike nearly built up and have replaced/fixed most parts that needed to be done. To stop this project being in one post and it taking me long enough to do this much I will put the rest of my progress into another post later.

[P.]

I know these inside out now Nice little munchers, they do what they are designed to do, fly round the city, albeit CG speeds.

Bit odd though, they stopped making them in 03 and it has a seriously late registration, 13/07/2004...

Rear shock linkage bearings, I left mine in oil that was heated...pretty much on fire. Worked wonders.

[tomh]

Yeah it must be a late registered one, however I've just looked on howmanyleft.com and ONE was registered in 2004, so assuming that data is correct this bike was the last new one sold in the UK :O

Although I'm betting the older ones are in a much better condition than this was. I can't wait to get this bike on the road, every single thing is better than my CG. My CG forks are tiny when next to this bike forks.

Any chance you've still got the PDF of the Honda workshop manual? The one on here only goes up to the engine chapter.

[P.]

[tomh]

Weirdly I've been looking for the manual for weeks now but I've just tried looking again and found it on about page 6 on a google search but thanks anyway

https://www.motorkari.cz/upload/files/manualy/3533_honda-clr-workshop-manual.pdf

That is the link for it if anybody else is looking for it.

[P.]

See, it is out there! If you need any help or whatever, feel free to PM

[_Troy_]

I had me of these! Bloody awesome bikes. It would go all day with no troubles, and the extra height was nice in traffic. Wouldn't mind one again some day
____________________
Current bike: ZX6R J1
Previous bikes: CLR 125 | GS500 | ZX6R G2 | SV650

[Name_goes_here]

That seems alot of problems for a bike with only 6000miles on the clock?

Good luck to you though
____________________
Current: ZZR600

Previous: TDM850, ZX7R, TRX850,TDM850 (seriously underated bike!),XJ600 (owned for 6 hours), BMW K100, XTZ750, TDM850,GSXR600, FZR400 Streetfighter, XJ600 Streetfighter, ZXR750, FZR600 (Killed in the side of a car) And some little crappy things ridden round fields

[P.]

[Shinigami]

i'm actually selling one of these very soon.

Fully working, with 9 months tax and mot, i've moved onto a hornet and can't afford to keep both.
____________________
Current: Honda City Fly CLR125 2003 Honda CB600F Hornet 2008 Yamaha FZ6 S2 + 1991 Kawasaki GPZ500
"Once you realize what a joke everything is, being the Comedian is the only thing that makes sense.

[P.]

[_Troy_]

[tomh]

My plan for the bike is to get it mechanically perfect and on the road and then later on when the weather is warmer ill spray all the metal parts and the side panels etc

The bike has not done not many miles but I'm the 10th owner of the bike which is why it's in such a state. It's just been abused and sold on every year. Amazingly the bikes still got a MOT till the end of next month. It's got a brand new Michelin Sporty tire and the front has plenty of tread left.

So far I've stripped the forks and changed the seals/oil, I've also sorted the steering head bearings. The locknut was way overtightened which was causing the headstock to pull to center. The bearings were in good condition, they just needed cleaning and re greasing. The speedo mounting lug has snapped off but was luckily still there so I plastic soldered that back on.

The rear shock linkage was seized and a nightmare to remove. The bolt turned but would not remove as it was seized to the collars inside the bearing. I had to hacksaw off the bolts for the linkage to frame bolt and linkage to swingarm. I took the bearings to a local bearing shop as honda wanted around £60 not including new bolts/collars. I got them for £10

I ended getting the bolts/collars from Honda which cost about £20

https://i1049.photobucket.com/albums/s383/TomHanley/photo_14_zpsf2a70575.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_13_zps622a15e1.jpg

Home made bearing installation tool which consisted of a cylinder head bolt which was sat perfectly on the bearing but fitted inside the linkage and attached a metal bar.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_15_zpsf281e54a.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_16_zpsc536c214.jpg

The bike is now starting to come back together. I degreased the frame with GUNK which cleaned it up well and then touched it up with hammerite. As much as I hate the stuff it doesn't look too bad.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_17_zpsd36ce8f9.jpg

https://i1049.photobucket.com/albums/s383/TomHanley/photo_18_zps7997890b.jpg

My dog posing with the bike

https://i1049.photobucket.com/albums/s383/TomHanley/photo_19_zpsd6c5bb89.jpg

Looking more like a bike, although the suspension linkage is not connected in the photo so it's sitting a bit lower there.

https://i1049.photobucket.com/albums/s383/TomHanley/photo_22_zpsa49fad7f.jpg

And that's nearly where i'm currently up to, the front end is fully assembled now and the next job to do is sort out the brake caliper

[UnspeedySam]

Poor bike...no bike should look that bad after 8 years...especially not a Honda.

Glad you're giving it a new lease of life
____________________
Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

[Shinigami]

[Yoyo]

They are quite well known for popping pistons. The one I am rebuilding, has been through 3engines all suffering the same fate.

Over rev, exhaust valve pops, piston broken.
____________________
Joe: I don't wish to floccinaucinihilipilificate your choices, but the best word in the world is gaylord.

[r3apd]

Hi,
Could any of you post a picture of CDI plug showing which wire goes in which pin. I'm rebuilding this beautiful bike and have a bit of a mess in CDI department. Any help much appreciated.
Thanks

[tomh]

[Shinigami]

[P.]

Be pleased you have the full metal cover. Becoming somewhat a rarity online

[Shinigami]

didn't get time to check it this weekend as was busy with some bits on the other bike, tidying up the city fly this weekend so will look then
____________________
Current: Honda City Fly CLR125 2003 Honda CB600F Hornet 2008 Yamaha FZ6 S2 + 1991 Kawasaki GPZ500
"Once you realize what a joke everything is, being the Comedian is the only thing that makes sense.

[tomh]

[Crazy Manx Man]

Miss my cityfly.

Had it three up once (one person sat on front mudguard facing backwards) must've been pulling a 250kg load easily and it didn't complain one bit!

Should've of bought it back when I had the chance a few years back for nostalgia.
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Too Fast For Even The Plod To Keep Up With

[paddlesat16]

Nice little project, looooookin goood
____________________
I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[Shinigami]

now someone buy my city fly off me :p
____________________
Current: Honda City Fly CLR125 2003 Honda CB600F Hornet 2008 Yamaha FZ6 S2 + 1991 Kawasaki GPZ500
"Once you realize what a joke everything is, being the Comedian is the only thing that makes sense.