HONDA CR125 ’03 OVERHAUL
(FEB 2007....)
..I AM RIDING NOW...
This is what is necessary to transform a 3 yrs old bike into a magic brand new machine.
every story begin with a single moment.... my story starts with this photo .....bike is getting a new dad (me)
there is a red phantom that is following me, today!!
right, the real job starts separating all parts from frame...
swingarm...
engine
engine
and more....
plastics and fuel tank... and exhaust..
now I can start to work on single parts and assemble them together.
FRAME and accessories:
...ready to be polished... the sand paper 800 - 1200- 2000 and some polish are the main tools..
with lot of work, this is the result... WICKED !
swingarm, link, shox, gets new bearings SKF and pivot works... and few original HONDa spares too..
assembled...
swingarm finished, now it is turn of installing the steering and the radiator
nice frame!! alu rules
the rear subframe is re-welded in the correct position because the previous owner has crashed (I think) , and the subframe was not really straight....
after the surgery,it is perfect now!!!!
The air filter box is disassembled completely to check for air leaks which can cost a cylinder and a piston!!
new sealant is applied between filter box and filter intake box
rollers are cleaned and gets new 2rs bearings...
starting kick lever is polished, and regreased.
WHEELS:
the wheels are not really good looking, they need to be polished and the sealing tape must be replaced. In the mean time, I am hammering the rear rim to make it more straight !!
The bearings are fully replaced. 3x rear wheel, 2 front. SKF all 5.
this is after!! (with new tires)
all the spacers are so worn that I had to make them new on the lathe, starting from a 40 mm rod....alu
(photo shows worn and new spacers all together...)
the gear lever is re-build with stainless steel and aluminum...
check this out!! (do you have the same model? impossible, I made it!!!)
ENGINE:
the engine, gets a complete overhaul: new bearings, new piston, new seals, polished head, and new Vforce3 reeds system.
the engine is also polished a bit on the outside.
this is the cylinder head which is polished with 3000 grit polishcream, turning the head on the lathe..
the cylinder is sanded at 0.01 mm precision...with a precise machine. a complete re-porting task is completed on the 5 ports, plus the exhaust output port..
the cylinder base is lowered 0.8 mm on the lathe... the final squish will be 0.65 mm.... ( really small!)
the new reeds valves are installed , making few slots on the carburetor collector, because the reeds that I have fount (ebay... :) ) were for a different moto, and the reeds flange was completely different!
what a best way to mount the reeds, then!
machining....
this is the result.... a tricky job...
the clutch is inspected and cleaned, ready to be mounted.. (clutch cover is polished too....)
the basement is ready to get new bearings....
and here is ready to be closed with left side basement!!
the engine is installed on the main frame. I am waiting the piston from the shop!!! :(
new piston (prox) , with polished top....
voilà.. the engine is almost done!
few small axles are re-build (from scratch) with stainless steel bars using emco lathe
EXAUST:
This is the best modification made...
The exhaust was scuffed in many points, but I am honored to be friend of the master of exhausts (and enduro!), which with his special secret techniques is able to restore and modify any exhaust on the planet!
I can show here the result , which is a bigger and more powerful exhaust, with no more scuffs!!
(no photo)
SORRY BUT i CAN'T SHOW THE SECRETS OF THIS !!
I have then sanded the exhaust to make it semi-polished looking!
and upgraded with a CIARLO PRODUCTIONS cover...
the silencer is shorted , 100 mm... polished and gets new absorbing material inside...
the internal pipe of the silencer is cleaned completely..
I can't work on them but I know Franco M. owner of SM suspension (italy) which is the king of suspension revalving !!!!
My forks and the shox are serviced and tuned by him...
These are few photos of his workshop.
SUSPENSIONS:
BRAKES:
calipers must be squared with the mill......first., and then inspected
and cleaned...
the pump gets new true surfaces, to install needle bearing on the lever.. !! cool
the rear lever is improved with a stainless steel bolt..
done.. (bearing installed
new front disc to make the braking perfect..
and new front and rear pads...
of course , last but not least, new oil DOT 5.1 ..
There is no need of getting a new ONE industries graphic set, because I wanna be different.
I think I am gonna make the honda particular at yours eyes, out there.
Here we have few ideas, that maybe can be reality one day.
At the moment, I am not interested in doing graphics, I want real things, not graphs!!!
check out few ideas, made with photo ship...
GRAPHICS:
BIKE FINISHED:
complete list of tasks done:
engine rebuilt , with new piston, reporting, trued cylinder, polished head, modified vforce3 reeds, -1.1 mm cylinder mounting (lathe..) squish 0.64
suspensions tuned, frame polished, complete bearings overhaul,
new roller bearings levers (brake, clutch, brake pedal).
new axles on clutch lever and other engine parts with stainless steel rod...
new simplified electrical enduro wiring.. with led stop/brake taillight
of course, new tires, new transmission.
new clutch cable, gas cable,
and more... that I don't remember!!
in few words, the bike is like new, probably better than!!! all tuned! perfect: rulezman STYLE
bike finished!!!
one month work. job done, moto completed, improved and lot of money saved!!!
brand new can't be perfect as this!!!
dave
UPDATE JUL 2007:
The exhaust wasn't painted, and after few scratches and scuffs I finally decided to re-sand it down to the bare steel and then spray it with a automotive clear coat. The next photo is result of the clear coat... shiny exhaust!!
the look of it is so cool. it seems all wet!
As expected after lathe first ride the exhaust changed the color, from a silver steel one to a nice burnt gold stuff!!! cool cool cool
