Honda 1976 CG125 - First build from Garage find

[UKKWF]

Hi All, My first post here. Just a blog or entries of my progress.
Picked up a Honda CG125 off eBay for £240.00. Came with no paperwork, Garaged for 4 Years, but "was running fine prior to this". Wheels, brakes, throttle and clutch all feel fine. Wheels turn freely.
It apparently had a new chain, flasher unit and back tyre prior to storage along with the exhaust.

So picked it up and stripped it down. Ordered a few new things, Battery, Ignition, Oil , Spark Plug & Air Filter. I also bought a new ignition coil for good measure as the old one was a rusty disaster.

Fired it up a few days ago after resetting the valve clearance, changing oil, fitting new ignition coil & spark plug and charging battery. Seemed to be running on idle, but would only do so with full choke. Anytime choke was taken off bike would rev and then stall. Neutral light would be on, indicators had a very faint glow, non in the front or front headlight for that matter and no ticking was heard from flasher unit. So i have ordered a new flasher unit for the bike, Also the front break light worked but the back break didn't, I found this to be the missing spring which holds the wire to the break.

I cleaned the carb and jets with STP Carb cleaning and sprayed air through all holes but noticed that the Heat guard between the engine and carb had cracks in it along with the rubber seals between the carb and heat shield & heat shield and engine looking pretty worn - Which is where i suspect the air leak is getting in therefore making the bike not idle correctly. Although the air filter i have on the bike now is a "performance" one, So its possible that i need to change the idle speed and fuel mixture? Although i think they may have been tampered with anyway (Does anybody have the factory settings?)

Today i also managed to blow the fuse (of which i ordered 2 new ones, 10A) and also took the main headlight apart to find the blue wire attaching to the headlight completely corroded.


My first aim is to get the bike passing an MOT. I'm going to order a new headlight as my old one is completely cracked all along the shell from a previous screwdriver job. I believe the indicators should work when my fuses and indicator relay get here, As the bulbs look fine and not like they have blown.

I also am in the process of sanding and repainting the petrol tank, Old metal air filter box and frame.

Oh and i applied for the V5 after i checked that the bike had no criminal history of which it hadn't and i am the third owner, 26k Miles! I got a letter from the DVLA last week also stating that the V5 will be in the post to me sometime this week.

Will continue to update my progress with photos and will add some previous one's later.

Cheers


The bike when i first got it:


https://i.ebayimg.com/t/HONDA-CG-125-GARAGE-FIND-CLASSIC-/00/s/NzY4WDEwMjQ=/z/sksAAOxydkZRjmKG/$T2eC16RHJF0FFZ+LYBmNBRjmKGLI3w~~60_58.JPG

[UKKWF]

Photo from when first got her:
https://distilleryimage8.s3.amazonaws.com/363ddc0cc19911e287d022000a1fc4f9_7.jpg


https://sphotos-c.ak.fbcdn.net/hphotos-ak-frc1/481582_10151498660187615_1481440092_n.jpg

Carb before cleaning
https://sphotos-e.ak.fbcdn.net/hphotos-ak-prn2/972333_10151505673997615_1107843055_n.jpg

More to come tomorrow...

[UKKWF]

Ok so iPhone has broke so no photos can be uploaded at the minute.
Ended up sanding down the entire air-box, tank and camhead(?)/top of engine as the paint on before had all flaked off.

Went into town and bought some primer and black gloss spray. The primer isn't an anti-rust one, will this matter too much? Need to get some Heatproof paint for top also.

Will put some photos of my tyres when i can as i don't know whether they should be replaced or not. They look like they have tread still left in them but also look shiny and quite stiff so wanted another opinion.

Once this has passed its MOT i'm thinking of turning it into a cafe racer, but who knows we will see. My V5c also came through the door! Happy days

I've heard that as my bike is a '76 model it can pass a MOT without indicators? Would i have to completely take them, the wiring for them and the handlebar controls off? Any advise much appreciated, lets see what tomorrow brings...

[UKKWF]

Nothing today then pissed it down. Will prime air box and tank tomorrow. Decided I wana do 2-3 coats of primer and around 5 coats of finish sanding after each one. Photos to follow...

[mudcow007]

oow thats a really early one

i bought a scabby one, an "kinda" restored it

from https://i25.photobucket.com/albums/c81/mudcow007/cg125-1_zpse4254da8.jpg

too

https://i25.photobucket.com/albums/c81/mudcow007/Done_zps13ca7fb2.jpg

notice you're s has the different shocks..

is you'res also a 6v?

for my engine i used "engine blue" an polished the case covers. mine came up a treat

my frame was painted with smooth hammerite

[UKKWF]

Yeh mines a 6v too. I was going to mention the shocks, Where did you get your ones from because they don't look like the stock ones, your back seems to sit a lot lower - not a bad thing i think it looks great! Also interested as to where you got 6v bullet indicators or did you mod some 12v ones? cheers

[mudcow007]

i snipped off all of my bullets as they were all corroded an fluffy

i just replaced them with these

just buy a proper crimping tool!!

the shocks are off a SUKIDA SK 125-2 (what ever one of them is) that was being broken on ebay for £10

[UKKWF]

[mudcow007]

they look spade connectors to me on the indicators, you might have to nip them off an replace with bullets.

its worth noting the bullets that come on the bike from standard are tiny compared to the crimp ons

this has been my first bike, its the most simple bike in the world to strip/ rebuild. I think the whole loom on mine is about 6 wires!!

[UKKWF]

So yesterday i finished sanding the tank down and priming both it and the air filter box. Gave em a quick wipe with white spirit before applying the primer and there gonna sit for 24 hours before they get sanded down and another coat applied. Here is how they look:
https://distilleryimage7.ak.instagram.com/8c4d1d7adb1a11e2b66c22000ae80d1c_7.jpg
https://distilleryimage4.ak.instagram.com/8cf223badb1a11e2a82b22000a9f1408_7.jpg

This stuff is going on after. Ill do about 3-5 Coats of finish, Again sanding as we go.
https://distilleryimage4.s3.amazonaws.com/37ad69cedb2811e2b01422000aaa05b1_7.jpg

This is what the tyre situation currently looks like. As i say i don't know when they were last changed, The back was supposedly 4 years ago. Can anybody share some advise as to if they would pass a MOT or new ones will be required? I'll buy some new ones after MOT anyway but rather save the money at this stage.
FRONT:
https://distilleryimage3.s3.amazonaws.com/76ed696adb2611e2977522000a9f308b_7.jpg
BACK:
https://distilleryimage1.s3.amazonaws.com/90db46bcdb2611e2896922000a1fbe1a_7.jpg

Also i checked the rectifier again and saw that it looks corroded? (the white/greeny stuff) Does this look quite bad and like it could do with replacing?
https://distilleryimage5.s3.amazonaws.com/bf579374db2611e29e3522000a1fbc06_7.jpg

Go to a interview next week also about a college course im applying for @South Thames College - Motorcycle Repair and Maintenance IMI (Institute of the Motor Industry) Diploma. Just wanted to know if anyone who has done & completed this course, Your views of it

Anyway here is how she stands currently (put the tank on there just before priming)
https://distilleryimage4.s3.amazonaws.com/360bc062db2711e2bdb622000a1f9860_7.jpg

[UKKWF]

ended up sanding 'em both down and applying second coats of primer to both, not very interesting at all. Will write up again once first coat of finish is on. Thinking about changing the air filter to a velocity stack if it doesn't run well with the carb and its current jetting.

Tank second coat:
https://distilleryimage7.ak.instagram.com/37e1a8aedb8411e2b83422000a1f9e4c_7.jpg

Airbox second coat:
https://distilleryimage6.ak.instagram.com/52ec1cb0db8411e2996b22000aaa21dc_7.jpg

[UKKWF]

made an awful mock up of what im thinking about doing once bike is running, the t bars would have an 8 inch rise to give my back some support and would also be alot my comfortable riding position. not the best paint skills..

https://sphotos-d.ak.fbcdn.net/hphotos-ak-prn2/5604_10151555616472615_1488191602_n.jpg

[UKKWF]

Update so far.....Ok so tank has its first coat of primer on, Airbox is on its second. Should get those finished tomorrow.

Tank after first coat:
https://i6.photobucket.com/albums/y211/kyranxxx/IMG_1146.jpg

Airbox after second:
https://i6.photobucket.com/albums/y211/kyranxxx/IMG_1135.jpg

Cleaned up the front end a little aswell..
https://i6.photobucket.com/albums/y211/kyranxxx/IMG_1136.jpg

And here is the new heat-shield compared to old one on the right..
https://i6.photobucket.com/albums/y211/kyranxxx/IMG_1128.jpg

Ok so i now have a few questions. If anyone could help or share some advise that would be great.
The bike is starting on first kick.. however only with full choke applied. I thought at first this could be a problem due to the cracks/seals connecting the carb to engine as i mentioned, however when the bike was ticking over i sprayed wd40 over these points and with the new heat shield on and the bike didnt rev at all.
Which then lead me to the air filter. Now ive gone for a "pod" type one and i know the CG125s have a few problems with these. The bike idles OK however whenever the slightest bit of choke is taken off the bike stalls and turns off.
I checked the spark plug which showed a black soot - meaning running too rich... Which is also meant to be the problem with the Pod style filters, they actually restrict the flow of air...

The only thing that i think could now be the problem is the jeting screw on the carb, if this has been turned too much. Could this be my problem leading to too rich a mixture??? It still doesnt make sense with the choke though.. i thought full choke would be restricting the air... therefor messing up the mixture to run with even less air than it already has got if its supposedly running "too rich".


Another problem i have is with the indicators. I installed my new fuse and flasher unit. Ive checked the wires and they all seem ok.. The neutral light, front & Back break light, indicator light on speedo flashes fine however none of the indicator bulbs flash or turn on. I have checked them and none of them seem blown?? I dont know when they were last replaced. Before i go ahead and buy new bulbs could the issue be as the bike is so old if only 1 of the bulbs has gone would that not make any of them work because it disconnects the circuit?

these are the main problems im having at the minute, apart from that though everything else is coming along ok.. gonna buy a new headlight and need to sand the frame down next ready to be painted.

If anyone could think of what the problems could be, please give your 5 cents... Cheers...

[mudcow007]

check the rating on the flasher (will be stamped/ printed on the flasher unit) an check the bulb wattage

if the bulb wattage is over or under the flasher rating they wont work.

i think its a grey wire from the flasher to the switch, check that wire

[UnspeedySam]

The idling problem is most likely a blocked pilot jet...at least that's what it's been the last two times I've had it with bikes that have been sat for long periods. Unblocking them has always been futile so I've gone and spent £2 on a new one. The reason it works on choke is that that is essentially another jet adding fuel to the mixture.

Do the indicators have 1 or 2 wires going into them? If it's only 1 then the frame will be used as the earth for them and so all metal between the bulb and the frame will need a clean up to make the connection work. If it's 2 wires, then same thing but with the contacts on the earth wire.

If you've got a voltmeter then put one probe on the negative of the battery and the other on the positive part (usually the blob of metal in the bottom) of the bulb holder, and see if you get any reading...if not then there's no voltage getting to the bulb and you have an actual problem with the flasher relay or wiring. If the dash is flashing I don't think it can be the relay, if the wattage of the bulbs in incorrect for the flasher then they'll still flash...but more dimly.

The rear tyre looks fine, but the front looks both perished and low on tread, so I'd splash out on a new one. Metzeler ME22s are good and cheap. I got mine from www.­001bike.­co.­uk at £25 each but their site seems to be down right now.
____________________
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

[TwoWheelsDail...]

Looks cool man! put a rs125 front end on it and i recon it would look sweet! I have been browsing ebay for a project and this seems like it would be a good one. Just need more power!
____________________
Suzuki GSR 750 - 33BHP (Restriction Ends 17/12/2014)
KTM Duke 125 - SOLD
www.facebook.com/TwoWheelsDaily | www.twitter.com/TwoWheelsDaily | www.instagram.com/TwoWheelsDaily

[UnspeedySam]

[UKKWF]

Changed the mixture screw 2 full turns out and now shes firing almost every 1st or 2nd kick and running without choke...i uploaded a video to youtube because although she is idling now, i think theres a knocking noise coming from the engine which i know could be a number of things, hopefully its just the tappets.

however i am now having problems with the throttle. Whenever i accelerate at full twist the engine doesn't seem to rev but rather go "dull" ? the noise i mean is at around 1.00 minute in the video . i don't know how to describe it properly so if anyone could watch the video on the link below and share some advise would be great

https://youtu.be/hM8UcoCXiKE

Also all the indicators are working now apart from the front right one. Front left one is fine, back two are a little dull but i will clean up all the connectors. They have 2 wires coming off them, one which earths to the frame.

[TUG]

[UKKWF]

[tomh]

Your exhaust gasket is massively leaking, you can see the exhaust smoke in the video when the engine misfires.

This will be causing the engine to run lean, you can hear this aswell as the idle speed is inconsistent and it is also a bit slower to return to idle after using the throttle. This will also be the cause of the load engine/ticking noise.

[UKKWF]

[i.p.phrealy]

[UKKWF]

Wow fair enough that seems quite the runner then. I thought because they were the copy at the rate you pay new they would be poorly made but i stand mistaken.

Gonna not order any parts till sunday when i go to a swapmeet and see what i can pickup there.

Have ordered the right gasket set however similar to the one pictured below.

https://img.auctiva.com/imgdata/4/1/0/9/2/5/webimg/540604161_tp.jpg

more to come when ive fitted them...

[tomh]

The exhaust gasket is in that kit

Make sure you remove the old gasket, its even possible that an older gasket is behind that one as it will be covered in black soot making it look like there isn't one fitted.