How to repair Honda CG125 Bike engine | How To repair Bike complete engine | Bike Technology

How to rebuild bike engine. How to rebuild bike engine completely.
1. Preparation & Disassembly

· Work Area: Clean, well-lit, and organized space is essential.
· Tools: Basic metric sockets, wrenches, impact driver (for Phillips screws), torque wrench, engine stand (helpful), and labeled containers for parts.
· Parts Reference: Use detailed parts diagrams to identify components and part numbers before ordering replacements.
· Process: Document every step with photos or notes, especially for wiring and cable routing. Keep bolts and parts for each sub-assembly (like the clutch or gearshift mechanism) separate.

2. Inspection, Cleaning & Parts Replacement

· Cleaning: Thoroughly clean all parts. The rebuild in the forum was done by washing casings and parts with petrol and cotton rags.
· Critical Checks:
· Cylinder & Piston: Measure cylinder bore for wear/taper; inspect piston and rings for scoring.
· Crankshaft & Bearings: Check crankshaft journals and all bearings (main, connecting rod) for smooth operation and no play.
· Valvetrain: Inspect camshaft, rocker arms, and valve stems for wear. Lap valves and replace seals.
· Transmission: Check gear teeth for chipping or pitting and shift forks for bending.
· Clutch: Measure friction plate thickness and check steel plates for warping.
· Gaskets & Seals: Replace all gaskets, oil seals, and O-rings with a quality set.

3. Reassembly & First Start

· Lubrication: Coat all moving parts liberally with assembly oil or fresh engine oil during reassembly.
· Torque Specifications: Crucially, use a service manual for all bolt torque specs. Do not guess.
· Final Steps: After reassembly, refill with the correct amount of oil (e.g., 1.0 liter for some models). Check for leaks. For the first start, be prepared to stop immediately if you hear unusual noises.
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