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Leaking Generator Cover Cap

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Falco
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Joined: 27 Nov 2015
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PostPosted: 18:22 - 04 Mar 2016    Post subject: Leaking Generator Cover Cap Reply with quote
Well, got a real problem with my cg 125 (2005). The Generator cap has given me trouble before, being a nightmare to get off. Having done it once before I had the exact same problem again yesterday. With the help of a punch pin and a 3lb sledge I got it off and a new one in.

However as soon as I started the bike oil started pouring out around the nut. I tightened it and set off (work is about 100 yards up the road and I wanted to test it on the road). Got there and more oil pouring out.

Came back after work and changed the new O ring I had used for the original (which was much thinner) and still oil came out when the engine was on. Trying to get it off and the head has gone...again.

But I can't see why oil is still getting out? the O ring is the right size, the cap is the right size, any suggestions about how I can stop it? The bike is my only transport and getting it working by Monday is fairly important.

Thank you.
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Falco
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PostPosted: 18:57 - 04 Mar 2016    Post subject: Reply with quote
Vincent wrote:
Have you examined it closely for cracks? Could you have you used a bolt that was too long? Remove cap and see if there's any oil down in the thread where the bolt goes.


Thanks for the reply. I can't see any cracks or anything out of the ordinary. It is exactly the same as the last one (from the same seller) but I popped the old one back in and tapped it in with the punch pin (no head left) and it seems to have stopped. Going to take it for a quick spin and see if it holds. Would a crack that lets oil out be easily visible? Is there a way to verify that the problem is with the cap? Bit miffed to have spent £15 on a cap that leaks the moment it goes in.
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Falco
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PostPosted: 19:55 - 04 Mar 2016    Post subject: Reply with quote
no luck. It is fine on the stand, but on the road leak starts again, though not as bad.
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Falco
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PostPosted: 20:46 - 04 Mar 2016    Post subject: Reply with quote
Vincent wrote:
Any chance you could post a pic so we know exactly where you're talking about?


Do you mean a picture of the crank case?

This is will hopefully be clearer than a picture taken in the dark:
https://i63.tinypic.com/1zou3xc.png however my generator cap has a hex hole rather than a slot.

I might have found the culprit though:

https://i65.tinypic.com/5x3j9g.jpg

but the crack doesn't extend into the thread itself. Is the crank case beyond help? Is there some way I can bodge it until a new one arrives (I doubt I will be able to source one by Monday).
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Falco
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PostPosted: 22:43 - 04 Mar 2016    Post subject: Reply with quote
Vincent wrote:
Aye..........that's kernackered I'm afraid. You should be able to get a used one for a tenner or so, I wouldn't bother trying to repair that one.


Well that's a bit crap Sad

Thanks for the help, much appreciated.
Guess I will clean the bike and sulk about having to use my holiday.

This is the cheapest one I can find, but no getting it before mid-next week:
https://www.ebay.co.uk/itm/Honda-CG125-CG-125-M1-2001-2003-Left-hand-side-Engine-Casing-Magneto-timing-/281780665607?hash=item419b6fbd07:g:T20AAOSwPcVV2dti#shpCntId

I maintain that at some point I will have replaced/repaired enough parts on this bike that I will get >1 month of trouble free running.
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Ed Case
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PostPosted: 23:08 - 04 Mar 2016    Post subject: Reply with quote
Yep, s'fucked. I bought an old 250 RSA 'Onda where some bloke had 'cured ' an oil leak on the head with Isopon...worked too !..
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Falco
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PostPosted: 23:57 - 04 Mar 2016    Post subject: Reply with quote
Vincent wrote:
If you havn't already, try searching "Breaking CG125" on eBay and google. trouble is, most sell the engines complete but you may get lucky.


That is a good tip, thanks. No luck for a cover, but an exhaust for half the usual price has caught my eye (and rear fairing and wheel and swing arm and....). Maybe next month Razz


Ed Case wrote:
Yep, s'fucked. I bought an old 250 RSA 'Onda where some bloke had 'cured ' an oil leak on the head with Isopon...worked too !..


Doesn't surprise me in the least. Apparently the last 1500 miles I've done was with the O-ring holding the oil in. I'd almost be tempted to put some steel putty over the crack and sand it down if I weren't such a responsible bike-owner.......
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Ariel Badger
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PostPosted: 00:06 - 05 Mar 2016    Post subject: Reply with quote
The Haynes books are not always 100% but I doubt it recommended thumping with a sledge hammer.
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Falco
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PostPosted: 00:52 - 05 Mar 2016    Post subject: Reply with quote
Ariel Badger wrote:
The Haynes books are not always 100% but I doubt it recommended thumping with a sledge hammer.


Haynes has nothing to say about the generator cover at all, based on a reading on the Haynes Manual only, one might assume that there wasn't one. I find my Haynes invaluable, but not for practical advice, often limited to unhelpful phrases such as "remove nuts and withdraw X".
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bladerunner
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PostPosted: 09:41 - 05 Mar 2016    Post subject: Reply with quote
I'd say araldite would do a good enough fix if you remove all traces of oil for now. Dare say it would make a half decent permanent repair if you do it properly. Don't bother with non genuine budget versions tho. How did you not spot the damage when you fitted the new plug?
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Falco
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PostPosted: 23:29 - 05 Mar 2016    Post subject: Reply with quote
Vincent wrote:
'Looks like it's been thumped by a bit of tarmac.


It most certainly has, but it was like that when I got it. The scrape I mean, the crack is a new development.

bladerunner wrote:
I'd say araldite would do a good enough fix if you remove all traces of oil for now. Dare say it would make a half decent permanent repair if you do it properly. Don't bother with non genuine budget versions tho. How did you not spot the damage when you fitted the new plug?


I don't have any araldite though it seems like useful stuff to have around, out of interest do you mean the epoxy resin or the repair putty or some other product they make that I am not aware of? I did use some Unibond Putty which has mostly worked (I am not a natural mechanic in case you hadn't guessed).

Took it for 3 mile ride today and only a slight slicking of oil on the case when I got back. I'd rather leave it and repair it properly when I have the replacement on (always nice to have spares), but my work may have different ideas Razz

As for spotting the damage, I assumed the problem was the cap not being done up tight enough after being undone (the oil was pouring out at an alarming rate). Once I had tried the new cap and a new O ring and screwed around panicking for a while I did spot it in the end. That was quite fast for me....
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