Honda BenlyTC CD125 twin - re-build time

[doubledave]

This is my little work horse bike which has kept me going through thick or thin, rain or shine whilst every other machine surcomes to unreliability - but alas, after a year of trawling around my fatarse it's in serious need of new rings.

Sorry, no full bike pics as yet, but I took it to bits the other day and it's a wonder it even ran - let alone reliably - starts first touch of the button every morning. I don't know if you can see this (bit of a dodgy photo - no zoom), but this tiny little plug was absolutly caked in tar and crud - you couldn't even see the filament!





Anyway, I'm waiting for my next stint of days off, then I'm going to try out my new honing tool, and give it some new rings (already got them here), and an all round polish and pimp to go with the new tryres I just gave it. I'll keep you posted.

[twoblackcats]

Mate had one of these that lasted through years of neglect and was sold on for a good price too.
I had a 200 which was sadly nicked one night from outside my flat, chased some kids 3 up on it a few weeks later but lost them as I was pedal powered at the time.
Still got a rickman fairing for it somewhere, lovely bikes these small twins.

[doubledave]

Absolutely - I take care of all my vehicles, apart from this one. Since getting it two years ago, I've done nothing but ride it to and from work everyday (I've only managed about 60 miles on the Z so far - between braking down and blowing up!). This shot here is the first time I've ever removed the plugs as there has been no need! I only started putting oil in it about 2 months ago when it started smoking - it is unequivocally the most reliable thing I've EVER owned - car or bike - so it deserves a bit of love. This rebuild is going to see it all polished, honed, new rings, new silencers, new casings (got some nice spares), new tyres (did them last week - pain in the harse!) and a little respray tickle on the frame. Should have an updates pretty soon - wife time pending!

[doubledave]

Mmmm. It's not going very well.

I've got a load of pics, but not here at work. I've been trying out my new polishing wheels on the rocker cover, and the wire brush wheels on the pots/head, and they've come up a treat. What isn't going well however is I dropped a chuffing circlip down inside the crank case - not good. After a good bit of swearing and stuff, I drained the oil out the sump - nothing came out. Had a good old fish around with a bit of hooked wire, but couldn't find anything. Took off the side casing (oil pump side) and tried removing the pump to gain access to the main casing - not good. It's held on by three big philips screws which were tightened up by Mr T or something. Had the engine on it's side, leaning in to the screw but the bugger wouldn't budge (starting to mash up the heads). Instead I removed the collector rubber with the oil filter in it to gain more access, but it was fruitless. I spent the next three hours flushing the engine this way and that, with a mix of filtered oil engine oil and fuel but nothing came out. I dropped the engine at one point (only about 30cm's) and all the chuffing oil spilt out all over the floor - and me. I was not amused.

After a cup of tea and a smoke, I decided "balls, I'm just gonna leave it in there and hope for the best", so I started putting back together again. This is when I found out one of my sets of new rings was missing a ring, so I had to recyle one from the old set - not ideal. Anyway, after spending an extraordinary amount of time scraping off the old stubborn gaskets (original from new) I set about putting the pistons in the pots and then the pots on the bike. This, ladies and gentlemen, was when I dropped another chuffing circlip inside the crankcase.

Really not impressed.

Suffice to say, it has now turned into a huge job involving a full engine strip down and nut and nut and bolt rebuild. What a load of cack!

[CGK1]

Crap luck I'd take the time to get them out, just to make sure its all gonna work well. As for the screws, mine were really tight, but i used a phillips head socket for a 1/4 inch rachet. Theres alot more leverege, but if you do try it make sure to push down so the screw doesnt round off

[chopnpop]

balls :/
it is a bit of a fine art getting those circlips in. i had a couple close calls my self..
just an excuse to ensure the bottom end and stuff is all in good condition..
screws.. you need an impact screwdriver. and even with that you'll struggle to get them undone.. (i spent a couple hours messing around with them on the generator)

good luck though, and keep us posted. and if you get fed up.. you could always give the engine to me haha..