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. 

Haven’t had much time to work on the bike but I did clean up the stock exhaust in my lunch break. It’s got a couple small dings but should do the job

Decided for now to just get the CDI mounted in the stock position and I will look into putting on the steering dampener after I ride it. 
I 3D printed a basic bracket to get it in the stock position but the cables to connect the CDI were very tight. I then lowered it 20mm but I think I might lower it again to get some more slack. I also added some slots to run a cable tie through to hold the rectifier for my light setup. Once I get the setup right, I’ll modify the bracket to suit and will get some PETG filament that isn’t orange or make it from ASA. 

While I was mucking around with the bracket I decided to make a fork height gauge and a few different chain slack gauges. I was surprised checking the manual that the spec for the CR is 25-35mm. I’ve always just run the old two to three fingers so this will be an upgrade. 

Will do. I’m going to make a new mount that will drop the CDI lower to reduce the bend in the cables

Haven’t made any bike progress but had enough targeted marketing to pull the trigger on a 30L ultrasonic bath. I’ve got a 2L unit I use for carbs and convinced myself a bigger one could do motors and if I do some work for other people it won’t cost me anything. 
I tested it with some parts I am going to vapour  blast and coat for someone and it saved so much time compared to manual cleaning in the parts washer. 

Sadly it’s too late for this build but I’ll definitely use this a heap on my next builds. I only took before and afters on Snapchat but I’ll try remember to get some good photos next time I use it. 
For around $250AUD it seems like a very good deal