Haynes Honda Cg125 Owners Workshop Manual(1).pdf

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Honda
CG125
Owners
Workshop
Manual
by Pete Shoemark
with an additional Chapter on the 1985 on models
by Jeremy Churchill
Models covered
CG125. 124cc. June 1976 to May 1978
CG125K1. 124cc. May 1978 to March 1981
CG125-B. 124cc. March 1981 to March 1982
CG125-C. 124cc. March 1982 to November 1984
CG125-E. 124cc. November 1984 to April 1985
CG125(BR)-E/F. 124cc. April 1985 to April 1988
CG125(BR)-J. 124cc. April 1988 to September 1991
CG125(BR)-K. 124cc. September 1991 on
ISBN 1 85010 918 4
© Haynes Publishing 1994
All rights reserved. No part of this book may be reproduced or transmitted in
any form or by any means, electronic or mechanical, including photocopying,
recording or by any information storage or retrieval system, without permission
in writing from the copyright holder.
Printed in the USA (433-4T9)
Haynes Publishing
Sparkford Nr Yeovil
Somerset BA22 7JJ England
British Library CataloGuing in Publication Data
Haynes Publications, Inc
861 Lawrence Drive
Newbury Park
California 91320 USA
A catalogue record for this book is available
from the British Library
~
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Acknowledgements
Our thanks are due to APS Motorcycles of Wells (formerly
Fran Ridewood & Co), Paul Branson Motorcycles of Yeovil, and
CSM of Taunton, who supplied the machines featured in this
manual.
We would also like to thank the Avon Rubber Company, who
kindly supplied information and technical assistance on tyre
fitting; NGK Spark Plugs (UK) Ltd for information on spark plug
maintenance and electrode conditions and Renold Limited for
advice on chain care and renewal.
About this manual
The author of this manual has the conviction that the only
way in which a meaningful and easy to follow text can be
written is first to do the work himself, under conditions similar
to those found in the average household. As a result, the hands
seen in the photographs are those of the author. Even the
machines are not new: examples that have covered a consider-
able mileage were selected so that the conditions encountered
would be typical of those found by the average owner.
Unless specially mentioned, and therefore considered
essential, Honda service tools have not been used. There is
invariably some alternative means of slackening or removing
some vital component when service tools are not available and
risk of damage has to be avoided at all costs.
Each of the six Chapters is divided into numbered Sections.
Within the Sections are numbered paragraphs. In consequence,
cross reference throughout this manual is both straightforward
and logical. When a reference is made 'See Section 5.12' it
means Section 5, paragraph 12 in the same Chapter. If another
Chapter were meant, the text would read 'See Chapter 2,
Section 5.12'. All photographs are captioned with a
Section/paragraph number to which they refer and are always
relevant to the Chapter text adjacent.
Figure numbers (usually line illustrations) appear in
numerical order, within a given Chapter. Fig. 1.1 therefore refers
to the first figure in Chapter 1. Left-hand and right-hand
descriptions of the machines and their component parts refer to
the right and left of a given machine when the rider is seated
normally.
Motorcycle manufacturers continually make changes to
specifications and recommendations, and these, when notified,
are incorporated into our manuals at the earliest opportunity.
We take great pride in the accuracy of information given in
this manual, but motorcycle manufacturers make alterations and
design changes during the production run of a particular
motorcycle of which they do not inform us. No liability can be
accepted by the authors or publishers for loss, damage or injury
caused by any errors in, or omissions from, the information given.
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Contents
Page
Acknowledgements
2
About this manual
2
Introduction to the Honda CG125
5
Model dimensions and weight
5
Ordering spare parts
6
Safety first!
7
Routine maintenance
8
Quick glance maintenance adjustments and capacities
13
Recommended lubricants
13
Working conditions and tools
/
Chapter 1 Engine, clutch and gearbox
15
Chapter 2 Fuel system and lubrication
52
Chapter 3 Ignition system
60
Chapter 4 Frame and forks
67
Chapter 5 Wheels, brakes and tyres
80
Chapter 6 Electrical system
93
Chapter 7 The 1985 on models
107
Wiring diagrams
103, 124
Conversion factors
125
Index
126
I
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The Honda CG125 model
The Honda CG125-C model
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Introduction to the Honda CG125
The CG125 model first appeared in the UK in June 1976. It
can be regarded in many ways as a utility version of the popular
CB1 25 with which it shares many features. The basic difference
between the two models is the CG125's use of pushrod
operated overhead valves in place of the more popular overhead
camshaft arrangement. The unit provides surprisingly brisk
performance coupled with good fuel economy. The machine in
general is functional and sensibly equipped, and does not suffer
the surfeit of gadgetry so often found on its contemporaries. Its
inherent simplicity makes it an ideal learner's or commuter's
mount, both in terms of ease of riding and in its ease of
maintenance. A noteworthy feature is the adoption of a full rear
chain enclosure. Although this is by no means a new idea,
having appeared and disappeared many times over the years
with the changing dictates of fashion, it is, nevertheless, an
eminently sensible feature, greatly extending chain life.
Despite remaining basically unchanged, the CG125 has
received several modifications and has been altered slightly in
appearance to keep up with its rivals. Five distinct versions have
appeared, with differences of varying significance, which are
identified (where applicable) in this Manual by their Honda
model code suffixes. Identification details, as available, are
given below with the approximate dates of import; note that the
latter need not necessarily coincide with the machine's date of
registration.
The CG125 model (no identifying suffix) has the frame
numbers CG125-1023061 to 1111090. Engine numbers are
not available. Identified by its shrouded, external spring, front
forks, this model Was imported from June 1976 to May 1978.
The CG125K1 model has the frame numbers
CG125-1114636 to 1162518. Engine numbers not available.
It differed most noticeably from the CG125 model in having
front forks with internal springs and exposed stanchions, and
was imported from May 1978 to March 1981.
The CG125-B model has the frame numbers
CG125-1202755 to 1223689; its engine numbers start at
CG125E-1374586. It can be distinguished from the K1 model
only by its different paintwork and graphics and was imported
from March 1981 to March 1982.
The CG125-C model has the frame numbers
CG125-1272831 to 1286692; its engine numbers start at
CG125E-1513928 on. Fitted with revised tail lamp, flashing
indicator lamps, handlebar switches and the usual detail
changes to paintwork and graphics. This model is also fitted
with a higher compression engine and the (T)PFC carburettor
for greater fuel economy. Note also that the ignition switch is
combined in a new warning lamp cluster, mounted next to the
speedometer. Imported from March 1982 to November 1984.
The CG125-E model has the frame number
CG 125-1288790 to 1293380 and the engine numbers
CG125E-1689761 to 1694851. Identical to the C model
except for detail changes to the graphics, this model was
imported from November 1984 to April 1985.
All the aforementioned models are of Japanese
manufacture and are covered in Chapters 1 to 6. Later models
were manufactured in Brazil and known as the CG125(BR)
models; refer to Chapter 7 for further information.
Model dimensions and weight
Overall length
1840 mm (72.4 in)
Overall width
735 mm (28.9 in)
Overall height
1025 mm (40.4 in)
Wheelbase
1200 mm (47.2 in)
Seat height
755 mm (29.7 in)
Ground clearance
135 mm (5.3 in)
Dry weight
95 kg (209 Ib)
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