Project bike: 1986 Honda CR125R

JMX82
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Hyllykallio FI
2/12/2017 8:59am
I finally got exhaust pipe fitted to the bike. I had to make some dents to expansion chamber to clear coolant hose.


Stock pipe hanger was too short so I had to make new one from 3mm aluminum sheet and rubber bumber.


New pipe looks really good on the bike


JMX82
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2/20/2017 12:32pm Edited Date/Time 2/20/2017 12:33pm
I got new Motion Pro throttle assembly mounted to the bike yesterday and after that was time get engine fired up for the first time.



Here is a short video of engine running:


Carburetor jetting was way off and left side radiator started to leak after it got warmer but at least the engine is running!

Lightning78
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Huntington Beach, CA US
2/22/2017 7:51pm
JMX82 wrote:
Frame and engine united again [img]https://p.vitalmx.com/photos/forums/2016/12/26/165730/s1200_DSC_0499.jpg[/img] Atac chamber mounted [img]https://p.vitalmx.com/photos/forums/2016/12/26/165731/s1200_DSC_0493.jpg[/img] IMS shift lever [img]https://p.vitalmx.com/photos/forums/2016/12/26/165732/s1200_DSC_0496.jpg[/img] New clutch lever with quick adjust [img]https://p.vitalmx.com/photos/forums/2016/12/26/165733/s1200_DSC_0492.jpg[/img] Front brake caliber looks pretty...
Frame and engine united again



Atac chamber mounted



IMS shift lever



New clutch lever with quick adjust



Front brake caliber looks pretty bad. I migh need a new one. Does anyone if brake calibers from another Honda models fit to this bike?





This would be my scientific wild ass guess but since you said the EXR 650 L forks are pretty much identical to the forks you have on that bike I would assume that you could probably obtain the caliper from the 650 L as well and it should be the same model as working on that bike plus I'm 90% sure it will bolt right up as well.... check into it if you agree and let me know please because I think it should work
JMX82
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2/23/2017 9:17am
This would be my scientific wild ass guess but since you said the EXR 650 L forks are pretty much identical to the forks you have...
This would be my scientific wild ass guess but since you said the EXR 650 L forks are pretty much identical to the forks you have on that bike I would assume that you could probably obtain the caliper from the 650 L as well and it should be the same model as working on that bike plus I'm 90% sure it will bolt right up as well.... check into it if you agree and let me know please because I think it should work
I've already solved the front brake problem by using brand new brake system for last generation CR125/250 from Ebay. The Ebay kit includes complete brake system with steel braided line brake pads etc..The only modification I had to do was take 1 mm off from caliber bracket mounting points and after that it was perfect fit.







1

The Shop

JMX82
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Hyllykallio FI
3/2/2017 12:52pm
I promised that my bike will shown in a local motorcycle exhipition in a week from now. It means that I have to work long nights in the garage to make it presentable. I also have to cut some corners to meet the deadline. I already cleaned my rear shock and linkage and put them on the bike without servicing them. I have to pull them out later again.







I also put new chain rollers on the bike





and got decals mounted to radiator scoops



Bman_145
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Nor Cal, CA US
3/2/2017 3:06pm
Hey, with your pipe, if thats a PC pipe they dont use the ATAC part. I think thats why its not fitting. You're running the pipe way too low. Here are some pictures of the 86 I had with an 86 PC pipe on it.





Bman_145
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3/2/2017 3:11pm





sandman768
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Saratoga Springs, NY US
3/2/2017 3:28pm
Ouch on the pipe ......slow down and test fit parts before the hammer comes out! Whenever I hammer something I"m sorry afterwards....
JMX82
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3/2/2017 9:34pm
Of course I test fitted the pipe without Atac valve and fitment was even worse then. The pipe is hand welded without any markings on it. I have come to think it might be originally made for -87 bike. I spent many hours in my garage thinking what I should do with the pipe issue. I even considered using stock pipe but it was bent too much out shape and hitting fuel tank. That's why original fuel tank on the bike was destroyed. The dents I had to made to make the exhaust fit are quite small. I got the pipe quite cheap price and getting new one would have been lot more expensive. Trust me it felt really bad to make those dents in the brand new pipe but I'm quite happy how it turned out. The dents look a lot worse in the pictures than they actually are. I work as an mechanical engineer so fitting parts and building prototypes is nothing new to me
1
Bman_145
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3/2/2017 9:46pm
Good luck with it. It should be closer to the tank but oh well. Have you fit the muffler with that pipe position yet?

Do you have a welder friend? You could cut it so it fits better or just cut the tabs off and weld them in a better position.

JMX82
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3/2/2017 9:59pm
The silencer fits really well on its place. Too bad I didn't took any pictures when I was test fitting it. The pipe is quite different shape compared to stock in the portion where its comes near the fuel tank and wouldn't look the same unless it was really heavily modified. I was considering moving mounting tabs on the pipe but that would not make any difference on the clearance issues.
Bman_145
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3/2/2017 10:09pm
Got it. Good luck with the rest of the build. Looking forward to seeing it all together!
Mixon848
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Oakley, CA US
3/3/2017 7:27am
Positive vibes and great energy sent to your thread and build. You are doing a great job. Sometimes we must do what we must do to get our bikes put together and as long as they meet our goals and our standards then we can move on with joy in our spirit and a smile on our face (while twisting the throttle).

I am truly enjoying your build, and think it is great how you had no problem grabbing the Chinese Front Master Cylinder and Rotor/Brake Pad Kit. A buddy of mine who is doing a 1991 Suzuki RM125 build did the same thing with great results.

Once again. Excellent job. And I can't wait to hear/read a full on report once you get a good ride in on her.
JMX82
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Hyllykallio FI
3/3/2017 10:35pm
Thank you for your positive words. After this conversation I got inspiration to rebuild the silencer and mount it to the bike.

This it how the silencer looked before:



Inside of it was few feet long piece of steel wire and few pieces of wool...



Parts cleaned and ready to be assembled



It turned out ok. Maybe I will change the silencer for better one later



Silencer back in the bike





Test fitting side panel





billyslad
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12/31/2014
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GB
3/4/2017 12:35am
You are right the exhaust does not fit well
PC one is without the power valve it looks like it is off a later year
ATAC was used for 84-6 in that design

The design will be quite important and the silencer will need to match the design of the expansion pipe to gain the most

This is due to the sound waves as well as length of silencer and size of the expansion chamber
It would be usual for the pipe to be set up for port timings and heights and cylinder volume etc and with your hrc cylinder could be quite different to stock and quite individual
I have a spare 86 pipe that has been modified to fit without the atac if you want it let me know it is only gathering dust

Nothing like a bit of pressure going to a show haha

Mixon848
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Oakley, CA US
3/4/2017 4:46am
JMX82,

Keep up the great work. Finland will soon have another great post vintage piece of Motocross history back on the track. I know many who have an average man's budget will obtain so much positive motivation from your thread and build. I am most certainly keeping an eye on it. Keep of the great work and posts. Nothing like Honda CR's from that era.
JMX82
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Hyllykallio FI
3/5/2017 10:49am
She is a roller now Smile


Nice new Pirelli rear tire



New shock mudguard



Shock reservoir mounted proberly



JMX82
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3/7/2017 10:26pm Edited Date/Time 3/7/2017 10:29pm
It's starting to resemble a race bike again





JMX82
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3/9/2017 12:13am Edited Date/Time 3/9/2017 12:15am
Yesterdays work:




Left side number plate is in quite poor condition but I haven't been able to find any reasonable priced replacement part. My only option is try to repair it for the weekends motorcycle exhibition and try to find good one later




JMX82
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3/9/2017 9:40pm Edited Date/Time 3/9/2017 9:48pm
I spent long night in the garage and the bike is ready for the exhibition.


There are still lots of things to do:

-Shock rebuild
-New linkage bearings
-New rear sprocket
-Repair left side radiator leak
-New brake shoes for the rear brake
-Sort out jetting issues
-Finding number plates that are in better condition




JMX82
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3/10/2017 12:17pm
The bike is now on our club stand at the motorcycle exhibition.





wsc96
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AU
3/10/2017 12:38pm
Very cool. Looks great. Job well done.
Mixon848
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Oakley, CA US
3/13/2017 9:30am
JMX82 wrote:
The bike is now on our club stand at the motorcycle exhibition. [img]https://p.vitalmx.com/photos/forums/2017/03/10/180722/s1200_DSC_0616.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/03/10/180723/s1200_DSC_0614.jpg[/img]
The bike is now on our club stand at the motorcycle exhibition.





Glad to see that you got it done in time for the exhibition. Thank you so very much for doing a Non-Purest bike build with this 1986 Honda CR125, it gives those without a silver spoon in their mouth and an unlimited budget something to look at that is a reality for them to accomplish.

Great job. Now can we get a video clip of it ripping around a track? :-)
JMX82
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Hyllykallio FI
3/13/2017 9:45am
Thank you Mixon848 Smile Exhibition was succes and my bike was definitely the star of our stand. I think I going take some break from build for a while and finish the bike before summer season starts here.



1
Mixon848
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3/13/2017 9:50am
JMX82 wrote:
Thank you Mixon848 :) Exhibition was succes and my bike was definitely the star of our stand. I think I going take some break from build...
Thank you Mixon848 Smile Exhibition was succes and my bike was definitely the star of our stand. I think I going take some break from build for a while and finish the bike before summer season starts here.



What a great photo. Nice, shiny and clean. So happy to hear that the exhibition was a great success. Those Fork Gaters and the color of the lower Fork Tubes are so stand out.
Jim in VA
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Louisville, KY US
3/14/2017 6:03pm
Nice job on the CR! I've been following it, and wanting to post, but somehow got signed out of the site and had a rough time recovering my password. I know you still have a bit more to do, but it really looks good. I know you were having a tough time with the pipe at one point, and I have an N.O.S. Honda pipe from that time period. It's marked 84-89, but would have to be no later than 88 due to the low boy pipe in 89. I think it's probably 85-86, let me know if you're interested, but I'll include a couple pics regardless.

I'm about to start restoring my 88 CR125 that I've had since 1992, and not ridden since 98-99. It's still in good shape, just needs a little love after all of that time sitting. Everyone's builds are great inspiration to get back in the saddle on my favorite old bike! Thanks





Smed
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KYABRAM, VIC AU
3/17/2017 12:31am
Jim in VA wrote:
Nice job on the CR! I've been following it, and wanting to post, but somehow got signed out of the site and had a rough time...
Nice job on the CR! I've been following it, and wanting to post, but somehow got signed out of the site and had a rough time recovering my password. I know you still have a bit more to do, but it really looks good. I know you were having a tough time with the pipe at one point, and I have an N.O.S. Honda pipe from that time period. It's marked 84-89, but would have to be no later than 88 due to the low boy pipe in 89. I think it's probably 85-86, let me know if you're interested, but I'll include a couple pics regardless.

I'm about to start restoring my 88 CR125 that I've had since 1992, and not ridden since 98-99. It's still in good shape, just needs a little love after all of that time sitting. Everyone's builds are great inspiration to get back in the saddle on my favorite old bike! Thanks





Nice condition! It's got the wrong brackets for 86, they have a bracket on the inside of the header, Dunno what the actual difference is besides the brackets though, my money is on 85 but could be 84
FRANK121
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4/11/2017
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Bourbon, MO US
4/11/2017 11:17am
What Yamaha pegs are those? And I read somewhere that the Yamaha springs will work?
JMX82
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Hyllykallio FI
4/11/2017 9:26pm Edited Date/Time 4/11/2017 10:39pm
FRANK121 wrote:
What Yamaha pegs are those? And I read somewhere that the Yamaha springs will work?
Foot pegs are from Ebay http://www.ebay.com/itm/Yamaha-YZ-85-125-250-YZ85-YZ125-YZ250-YZ400-WR-… I modified original honda springs to work with them but you can get special made springs from Phil Denton Engineering . I don't know if Yamaha springs will work
combatmx
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1/3/2017
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Wappingers Falls, NY US
4/12/2017 10:04am
I have a nice clean tank for 87 Cr 125 and allso silver rims with drum brakes good tires and I will give ya the front brake cable with it and what ever the rear brake has if u want TeX me 914-424-6477 and we can come up with price

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