Posts
87
Joined
1/19/2020
Location
AU
Edited Date/Time
10/12/2022 3:21am
Hi guys, been reading along for a while so I thought I'd share my build. I just started a 96 CR125 rebuild. I brought the bike a year or two ago for $800AUD and it is rough but turns over and has spark. The guy I brought it off hadn't had it long but before him it was seemingly stored outside and probably wasn't washed in the last 10 years.
Here's a couple photos of my starting point
Here's a couple photos of my starting point
Definitely had something bouncing around in the head. Will take the rest of the top end off today and post some photos
The Shop
Water pump looked terrible and was missing the metal separator that goes between the gaskets
Luckily I've got two other 90s cr 125 motors still to build so I'll take one of the good covers from them
Threw most of the parts in the parts washer to get the bulk of the sort and oil off, now to decide what finish to do. I'm thinking I might just sand blast them then go over it with a scotch brite pad but open to suggestions
Muffler has an extremely worn pro circuit label.
Expansion chamber is a FMF fatty
I started the other bike around three years ago as a project to do while I was at uni but the lack of funds meant I cut a few corners and I'm paying for it now. Should still be good when it's done and I learnt heaps of things to improve on for this build.
The bolts in the first photo and powervalve linkage in the second were cleaned up in a small ultrasonic cleaner. They came out really good but I still might just buy a bolt kit and replace all the hardware
While I'm waiting on those I had a couple hours today cleaning parts. Decided to go over the power valve covers with a dremel and scotch brite disk. Did some work cleaning up the kick start too.
Had a look at the frame so I can try get a parts list going and definitely going to need a new linkage. If anyone has one in Australia please let me know.
Where are you located?
Pit Row
Before:
After:
Hoping to get time after work this week to put the bottom end back together
I've double checked that all parts on both shafts are there but the tabs on the gears (9 and 11 on the diagram) are contacting eachother. There is a little bit of rounding on the tabs on the middle gear so this may have been happening for a while when it was running.
Anyone have any ideas on how to fix this?
Was able to make a good transmission from two bottom ends I had but when finishing off the bottom end I snapped the Bolt that holds the shift drum pivot arm. Definitely won't be using a cheap torque wrench again. Now I'm deciding whether to repair the case or replace it. A local shop still has NOS cases available which would be awesome for the build but there about $550-600 each side
I picked up an 05 Cr bottom end very cheap so I've taken the alloy stator cover to replace the plastic ones that are stock on the 96.
Also managed to get time to replate a few case bolts as they were all rusting. Still not as good as new but definitely polished up nice. In this photo you can see the difference between the bolts that were replated. Before anyone asks, I did swap the bolt out after the photo
Tried to install my stock piston today and noticed it's 1mm oversized. Since I won't be riding for a while now I'm deciding whether to just order a new piston or save this cylinder for another project and get one of my stock bore cylinderS replated. Any thoughts?
Forgot to take photos of all the parts Al here's the Powervalve on the cylinder that came off and the cleaned one on the newer cylinder. The only thing I had to do one the sleeved cylinder was replace the bearing as it was crunchy, presumably from being blasted with media when the cylinder was cleaned.
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