honda cg 125 es-4 2004... front brake lever pressure!!!

[jadonx]

Hi all, need bike back on road as I drowned my car!!

Went to get bike MOT'd and failed on imaginary front fork oil damper seal leak and insufficient travel of brake lever after brake application.

The tester said front brake was working ok but he could pull lever fully into handle.

I tried this but had to pull hard from end of lever.

I checked caliper seals and tried bleeding system. Still the same so I have replaced the master cylinder seals with piston. Still no joy I rang the honda service who couldn't understand why it failed any way as it passed on the rolling road.

I have rang the MOT mechanic and he told me to change the hose. I have just replaced this now with a Hel racing hose.
I have bled system again and left lever ty-wrapped to handle all night to expel any air from master cylinder.

I just was curious as to the pressure needed to exert lever against handle. I measured about 25 pounds near ball end of lever and after changing hose I think its improved to about 35 pounds.

I would just like a figure for when I take it back in now for a FULL retest again.

PLEASE HELP......NO HAIR SO I'M SCRATCHING INTO MY SKULL.

[kramdra]

sounds like BS. did the brakes function ok on the brake tester?

Bleed them and retest somewhere else.

[jadonx]

Yes brakes good on tester. They must be a point where a brake lever can be pulled in, like if Mike Tyson had hold of it lol.

Ive wasted money too on fork seals as when I took dust seals off they were bone dry. I had covered metal with oil for winter protection!!

Just makes me sick cos need bike for work now and this is pissin me off.

My usual tester was on hols so took it there so, might now find someone else. Only prob is some one else might fight other probs where as this one might at least remember the two failures and i could convince him now that they're ok.

[jadonx]

Or as to the bleeding. I took caliper off and held pads and piston back with G clamp and inverted bleed nipple with caliper tied up.
I don't think I can get any more air out of master cylinder.

Problem is there about 10mm of freeplay before handle moves piston, which then feels firm. I can only then move it further by pullin near end of lever hard.

I did even think about putting packing between lever/piston to take up free play but thats interfering with the design. There is no back stop or other mech. adjustments on lever.

cheers.

[jadonx]

Is there anybody with a cg 125 out there who could give me an idea of the force required to pull lever right in?
I can't do mine from normal position but can from right at the ball end.
If i could drive to a dealer right now I would but bike is sorn'd so i'm in the shit! gonna book a fresh MOT tomorrow.
I used a luggage spring balance and reads 30 pounds near end when handle meets grip.

cheers in advance

[kingsmith]

i can pull my brake lever on my cg125 all the way but goes through the mot fine, with enought force you probley pull any brake lever back to the grip, find your self another test place sounds like a dick..
____________________
honda cg 125 copy cheap and crap, perfect for work..
suzuki gsxr600 srad 2000
passed 12/11/09 happy boy

[jadonx]

[cg125erinit]

somewhat necro thread but yeah I find it *impossible* to get the kind of rock hard firmness on my cg125 I am accustomed to on twin pots or better on bigger bikes. the front disk brake on the cg125 is f*** shyte and I prefered the drum for ease of maintenance.

every time I get an mot I have to argue with the tester about it too and they often try to fail it. the fact is - its a piece of shit braking system. the master cylinder is far too small and the caliper bleed nipples corrode and leak like bitches.