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2006 Honda XR125L Top End Tear Down (Push Rod CG125 Engine)

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zzpza
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PostPosted: 19:24 - 07 Apr 2016    Post subject: 2006 Honda XR125L Top End Tear Down (Push Rod CG125 Engine) Reply with quote

I've been trying in vain for about two weeks to try to get my little green lane wannabe to start. Air, fuel, spark - it has all three. Then last weekend I checked compression, and found it was 2 bar. There's the problem!

I had originally hoped to get a 144/149cc cylinder and piston, but all the ones I could find needed a bigger throat on the crank case than mine has, and I really didn't want to have it machined out, so I went with keeping it at 124cc.

I've ordered a Chinese cylinder and piston off eBay. This is my third bike and only for fun, so if it craps out / wears fast that's not so much of an issue. I know you get what you pay for, but I've barely ridden this bike since I bought it (in it's current condition), so don't know if I want to keep it or not.

Carb and inlet manifold removed, exhaust detached (can't remove it as one of the genius POs welded the down tube to the silencer).
https://i.imgur.com/Q8fyLfr.jpg

Rocker cover removed.
https://i.imgur.com/ftiv0Cb.jpg

Rockers removed.
https://i.imgur.com/DOh13AA.jpg

Head removed. A 'bit' of carbon to clean off.
https://i.imgur.com/hph9D6w.jpg

Cylinder removed.
https://i.imgur.com/3KujZmi.jpg

Piston exposed.
https://i.imgur.com/6LGR4IZ.jpg

Scoring on the barrel.
https://i.imgur.com/36O5vkX.jpg

Scoring on the piston.
https://i.imgur.com/Bhq7t1T.jpg

https://i.imgur.com/eGQBuZv.jpg

Is that soot past the rings?
https://i.imgur.com/otQJp06.jpg

Waiting for rebuild.
https://i.imgur.com/LkesEyj.jpg

So I've ordered a new Chinese piston / bore / rings / gudgeon pin / gaskets set, as well as a few tools I'm short (got bugled a few years ago and most of my tools nicked). I doubt it's all going to turn up this weekend, so will (hopefully) be putting it back together weekend after next. Assuming there's not something I've forgotten to order!
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