96 CR125 Build

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1/27/2020 7:09 PM
Edited Date/Time: 1/27/2020 7:10 PM

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 PhotoPhoto

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1/27/2020 7:23 PM

I don't have high hopes for the condition of the cylinder after looking at the air box Photo

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1/28/2020 5:32 AM

Hopefully the filter did it’s job! I like to spray a penetrating oil on all the nuts, bolts, axles before I start tearing the bikes down. Lay it over & let it seep-into the swingarm & linkage bolts. Let it sit overnite. It really helps with frozen bolts during teardown. Parts are plentiful for these CR”s... good luck

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1/28/2020 2:57 PM

Thankfully the swingarm pivot had a lot of grease on it and came out easily. Last 96 Cr I started building I ended up cutting the pivot bolt out. I'm guessing the owner before me must've greased it as the grease was pretty fresh but everything else was rusted in. There was also a lot of bolts with lecture that really don't need it.

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1/28/2020 3:03 PM

Air filter was definitely a sign of things to come Photo
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Definitely had something bouncing around in the head. Will take the rest of the top end off today and post some photos Photo

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1/29/2020 1:40 AM

Got the top end off this morning and aside from a lot of dirt in the motor it was surprisingly good. Cylinder didn't have any large scratches but I'll probably still send it out to be safe Photo

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Water pump looked terrible and was missing the metal separator that goes between the gaskets
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1/29/2020 6:09 PM
Edited Date/Time: 1/29/2020 6:23 PM

Started some parts cleaning and there's a lot of material lost in the water pump cover.
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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

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1/29/2020 10:04 PM

What type of silencer is on that? End cap looks longer than a PC.

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1/30/2020 10:23 AM

Looks like a rough base to start but you can do it! Just got mine finished last year. If your looking for a good replica seat cover go to throttlejockey and ask for a seat in the 96 style. They don’t advertise that style but when I asked if they could they said no problem! Photo
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1/30/2020 4:58 PM
Edited Date/Time: 1/30/2020 5:21 PM

689 wrote:

What type of silencer is on that? End cap looks longer than a PC.

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Muffler has an extremely worn pro circuit label.
Expansion chamber is a FMF fatty
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1/30/2020 5:14 PM

Dillpickle312 wrote:

Looks like a rough base to start but you can do it! Just got mine finished last year. If your looking for a good replica seat cover go to throttlejockey and ask for a seat in the 96 style. They don’t advertise that style but when I asked if they could they said no problem! Photo
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Thanks for the tip. You're bike looks great. Still deciding whether to go back to stock or do something different with graphics and seat cover. I have another 96 I've been working on for a while that I planned to do closer to oem but had a last minute change.
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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.

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2/2/2020 11:21 PM

Spent a couple hours this afternoon sand blasting some motor parts then finished off the clutch cover with some scotch brite. Still has some pitting but it'll get ridden so this should be fine
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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

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2/3/2020 2:05 AM

oooohhhh man such a beautiful bike in any condition. I just found a new old stock Honda red disc cover !!! nothing better than that red colour . They look so good with stock graphics

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2/3/2020 1:50 PM
Edited Date/Time: 2/3/2020 11:20 PM

Garage11 wrote:

oooohhhh man such a beautiful bike in any condition. I just found a new old stock Honda red disc cover !!! nothing better than that red colour . They look so good with stock graphics

Yeah, they're a great looking bike. Not sure what way I'm going on graphics but definitely want plenty of the Nuclear red plastics on this when it's done

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2/4/2020 2:32 AM

Garage11 wrote:

oooohhhh man such a beautiful bike in any condition. I just found a new old stock Honda red disc cover !!! nothing better than that red colour . They look so good with stock graphics

Darcy16 wrote:

Yeah, they're a great looking bike. Not sure what way I'm going on graphics but definitely want plenty of the Nuclear red plastics on this when it's done

Yeah it is hard the factory Honda racing graphics look amazing too!!! Im trying to get a 2010 front end for mine so probably wont be able to keep that nuclear red disc cover or fork guards

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2/4/2020 3:11 AM

I've recently picked up an 08 crf450 front end that I'm thinking I'll use for this but luckily the Cr fork guards and fender will bolt up

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2/4/2020 3:30 AM
Edited Date/Time: 2/4/2020 3:31 AM

The other option that I was thinking was the white front with red rear like this
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2/16/2020 6:00 PM
Edited Date/Time: 2/17/2020 12:38 AM

Have always had help with bottom end rebuild but going to try this one myself. Ordered a case splitter and crank installer today so hopefully get them by Friday.
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.
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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. Photo

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2/22/2020 1:17 AM

I have a spare linkage arm if you are after one..

Where are you located?

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2/23/2020 2:13 AM

689 wrote:

I have a spare linkage arm if you are after one..

Where are you located?

Located in Geelong. Would be keen to buy it if you've got one

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3/10/2020 7:54 PM

Finally got some time to work on the bike again today. Crank had no movement but after seeing all the dirt in the top end I wanted to tear the motor all the way down. Got the cases split and started cleaning them up. There was a lot of dirt in the motor. Found some small weld repairs on both cases that I'll inspect better once they're clean but they look alright. I was planing on just doing crank and main bearings but the transmission bearing just fell out when I was cleaning so I'll probably just replace everything to be safe.
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3/15/2020 11:22 PM

Got the cases cleaned today. Not perfect but good for a rider. Also tried to zinc plate some motor mount bolts and parts from the rear shock that were rusty. Hadn't done it for a while and the plating come out dull but should look alright after a bit of a polish.
Before:
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After:
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3/17/2020 2:33 PM

689 wrote:

I have a spare linkage arm if you are after one..

Where are you located?

Darcy16 wrote:

Located in Geelong. Would be keen to buy it if you've got one

I will have a look for in the next week and let you know.

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3/23/2020 2:07 AM
Edited Date/Time: 3/23/2020 2:08 AM

Cleaned and inspected the transmission today and thankfully it was all in good condition aside from the bearings. I went to a few stores and looked online but couldn't find a transmission bearing kit or even the individual bearings so I took the removed bearings to a local bearing shop and was able to get everything I needed for under $50.
Hoping to get time after work this week to put the bottom end back together

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3/29/2020 8:06 PM

Got the crank in today and installed the transmission. Seemed to spin smooth but when I was testing out the gears (only sitting in the right side case) two mainshaft gears were hitting in neutral.
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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?

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3/29/2020 11:44 PM

Put new gears in, the look really rounded off. Maybe you can take them out and look how worn they are?

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4/5/2020 7:46 PM

NiekL wrote:

Put new gears in, the look really rounded off. Maybe you can take them out and look how worn they are?

I took them back out and the gears causing the issue are a lot worse than I first thought. Luckily I've got another Cr 125 bottom end so I'll try split that in the next week or so and see how the transmission is in that

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4/6/2020 4:23 AM

I believe most gears are still available from Honda new. Transmission is not an area you want to cut corners on. Do it right while you have it apart.

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4/16/2020 3:26 AM


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
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5/12/2020 9:33 AM

Been a bit slack posting on here. Got the button end all sorted out aside from the clutch. I've got another basket to swap with the one in there now. Photo
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.
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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

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