cg125 k1 (1980) Engine, Gerabox, Neutral Indicator problem

[Rusky]

Hi, Ive been doing lots of work on my bike and have now run into problems that didnt exist before I started 'fixing' things. Please help!

Ive a cg125 K1, with a type C engine.

Ive just replaced the oil, and took off the right hand cover, replaced gasket and seal and refilled.

Ive also replaced the wiring harness, all lights except head and tail light and speedo lights work (i assume these dont work because the engine is no longer starting).

Ive also just lubed up the chain.

Before doing this, the engine ran fine, in fact ran excellently, the gears seemed fine too, without the engine running they would at first change, but then stop selecting when the engine was not turned on, but would change as usual once the engine was started.

Now it wont start, the gear pedal wont move and the gear neutral light wont light, yet the bike is stuck in neutral.

Ive checked all connections, cleaned them up and they seem fine, the engine problem did occur before the wiring harness was replaced.

Clutch lever pulls with lots of tension, but smooth action with full movement just as it did before I took off and replaced the right hand engine cover.

Thanks for any help as with all this im unsure where to start.

[mudcow007]

ive got a BR-E CG from 1984

an had issues selecting gears

the fault with mine is the selector shaft had moved when the engine had been put on its side - if that makes sense

drain oil, remove RH case cover move the selector with your hand, an you will see the selector fork thingy

https://www.ebay.co.uk/itm/Honda-CG-125-Gear-Shaft-Selector-/330834527178

this

on mine, this had slipped out of position, jiggling it around got it back an now all is well

[unitynotsocri...]

from the sound of it you may have assembled the rh clutch/or clutch thrust springarm pushrod wrong,

are you sure the new loom is a 6 volt one to match the 6 volt system?

it may not be firing because lighting circuit wire is shorting out the power coils or the missing components are essential to the loom and wont work without them.

such an old cg is lovely,,just grab some cheap pattern coils n spares....so good you get used to the 6v electrics......nearly

check you have an origional engine,there s a few differences with later cg's and chinese clones

sometimes neutral light gets lost because of loose wire to g box connector.if you ve split the crankcases and g box then you may have a jammed selector fork,or selector drum.on the end of the drum is a metal spring contact for the neutral switch,this can sometimes get lost.
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[Rusky]

Thanks to you both, you were absolutely right.

As soon as I disassembled the right hand cover I found the gear rod moveable again, when I gotit back into position the connector plate was now touching the switch again, so the gears select again and the neutral indicator is working.


Now my only problem is my spark plug is being wetted insied the engine, either by oil or petrol, this will be for another tpoic though I think.

And yes i was lucky enough to come accross someone who had an old cg125 that didnt work and was given to him, by the manual, all connections and wiring were the same for the K1 model (right for instruments) and the C type generator had the same connections for the K1 diagram, so all connected and all lights work for a minute or so when I clean up my spark plug

So 1 job done, now for the next.