02 CR125 Clean up

Not planning on anything too modern on the front, probably just the 07 CR front fender so it’s not as round and a Cycra stadium number plate

Managed to get the bearings and most of the seals installed last night and got the cases back together today. It’s hard to get a few hours on the same day to work on it, but we’re making progress. 
For the bearings I sourced all of them from two stores and was able to get all of the bearings inside the motor for around $120. The OEM NTN bearings are $34 each at a dealer but I was able to get the 63/22 NTN from a bearing shop for $12 each. For a small amount of work it’s a good saving and I was able to stick to Koyo, NTN and SKF bearings. 
To show how little use this has had, check out the gears. The wear actually looks worse in the photo. 
 

I brought a motor stand recently, not sure if it was worth it yet, but it did make it easier to check the cases were getting pressed together evenly. 


 

Got the motor together after work tonight. Thought I had an issue at first as the crank would spin but had more drag than it should. Checked the clearance and noticed it wasn’t centred in the case. A bit of work with the rubber mallet got it centered and spinning much easier. 

Didn’t take any photos of the process as I just wanted it to get it done tonight. Managed to get it all buttoned up aside from getting the head torqued down as I couldn’t find my box of copper washers. Later checked online and realised Honda didn’t put crush washers on these. 
Pretty happy with how it looks, now just need to get it in the frame and see how it runs. 

Slowly getting more parts on. The bike didn’t come with the CDI mount bracket so I need to decide whether to buy/make a new one or relocate the CDI and install a spare HPSD I have. 

Thanks for the tip. It’s already tight swapping filters without adding anything to the airbox so that might be a better option. I think I’ll mount the pipe and everything then see what space I have.