This repair and service manual covers 1976-2000 Honda CG125 motorcycle models, including:
Book Excerpt: 1976-2000 Honda CG125 Repair Manual
- Honda CG125, 1976-1978
- Honda CG125K1, 1978-1981
- Honda CG125B, 1981-1982
- Honda CG125C, 1982-1984
- Honda CG125C, 1982-1984
- Honda CG125E, 1984-1985
- Honda CG125BR-E/F, 1985-1988
- Honda CG125BR-J, 1988-1991
- Honda CG125BR-K, 1991-1995
- Honda CG125BR-S/T, 1995-1997
- Honda CG125W, 1997-2000
ENGINE CLUTCH AND GEARBOX
REPLACING THE CAMSHAFT, GENERATOR AND LEFT-HAND CASING FITTINGS
WHEELS, BRAKES AND TIRES
- Turn the unit over and support it on wooden blocks with the left-side uppermost. Fit the gauze crankcase strainer, its spring and the large hexagon-headed cover. Push the neutral indicator switch into position in the crankcase bore.
It is worthwhile ensuring that the rubber plug, which retains the switch, is fitted to the outer casing, as this is easily overlooked.
- The crankshaft pinion which drives the cam gear is marked with a center-punched timing dot. The crankshaft should be rotated so that this mark is at the top, nearest to the cam gear.
The cam gear has a corresponding mark, and should be placed in position so that these two marks corresponded exactly.
As long as this precaution is observed, the valve timing will be set correctly, but on no account overlook this setting as it is critical to the operation of the engine.
- Place the shim under the head of the cam gear shaft, then fit the gear shaft in the crankcase bore, taking care that the O ring is not nipped as the head of the shaft enters its recess.
The head of the shaft should be positioned so that the small projecting segment is uppermost; do not forget the small spring.
Fit the end float plunger in its bore, and depress it against spring pressure while the retaining bolt is tightened.
- Place the generator stator in position, noting the flat at the top which engages with the head of the gear shaft. Ensure that the rubber fillet through which the generator cables pass is located correctly.
The generator rotator can now be placed over the mainshaft, and its securing nut tightened to a torque setting of 4.0 ? 5.0 kgf m (29-36 lbf ft), having locked the crankshaft in the same way as described during the removal sequence.
Route the neutral switch lead between the casing webs, noting the rubber packing piece, and reconnect the end at the switch. Make sure the main output leads pass beneath the small guide plate at the top of the casing.
ADJUSTING THE FRONT BRAKE
FRONT WHEEL BEARINGS: REMOVAL AND REPLACEMENT
- Adjusting the front brake is best accomplished with the front wheel free to rotate. Spin the wheel and carefully screw the adjusting nut down until you hear a rubbing sound which indicates that the brake shoes are lightly in contact with the drum surface. Turn the adjuster nut back by 1/2 - 1 turn until the noise stops.
Spin the wheel and apply the brake hard once or twice to settle the brake. Check that the wheel is still free to rotate and that the adjustment has remained the same. This setting should give you 20-30 mm (3/4 ? 1-1/4 inch) free play measured at the extreme tip of the handlebar brake lever.
- Check the condition of the brake cable ensuring that all components are in good condition, properly lubricated and securely fastened.
Note that the operating mechanism is at its most efficient when, with the brake correctly adjusted and applied fully, the angle between the cable and the operating arm on the brake backplate does not exceed 90°.
This can be adjusted by removing the operating arm from the brake camshaft and rotating it by one or two splines until the angle is correct. Ensure that all components are correctly secured on reassembly.
- There are two bearings in the front wheel. If the wheel has any side play when fitted to the machine or any roughness, the wheel bearings need to be renewed.
- Using a small flat ended drift, place it inside the hub against one of the wheel bearings and tap the bearing out of position. Remove central spacer and then tap out the other bearing from the other side. Drive the bearings outwards in each case.
- Use a good quality grease and grease the new bearings. Tap in one bearing, turn the wheel over, insert the central spacer and then tap in the other bearing. Fit each bearing with the dust seal facing outwards and do not cut or damage it when tapping it home.
- Replace the outer left-hand oil seal which will have become dislodged. Renew it if necessary.
Subject: 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000 Honda CG125 service, maintenance, repair. ISBN-10: 1859605893 | ISBN-13: 9781859605899 | Haynes 0433