auto5man
10-02-2013, 11:50 PM
Some of you may have seen my posts on 125's but this is a different one...let me explain. I have three 125's. Bought one last summer which runs, and I havn't posted pictures of. Shortly after that I bought a "parts bike" for 50.00. And then last month I bought another running 125 and that's the one I've posted several pictures of work I've been doing on that.
So back to the parts bike....a few weeks back I got to looking at it more closely and realized it's actually in better shape in a general way, than either one of the other 125's I have that run. It hasn't been rednecked to death and everything is pretty much original or close to it. The plastics are in pretty good shape and the tires are like new. So here is a pic showing the sad damage that doomed the poor thing to someones backyard. Not a great picture but you can see the damage to the left engine cover spacer and the missing sub trans.
178297
I've never worked on an ATV before, just ridden them so I was a little intimidated about tearing into this motor....but I only spent 50.00 on in it the first place and figured I can't break what's already broke...go for it. That fateful decision led me to this site...now I'm addicted, as they say. Here is another picture of the spacer after removal:
178299
Probably what happened is the chain came off at fairly good rate of speed (the chain had an obvious kink too) and bunched up on the front sprocket tearing out the housing.
Anyway, I got the spacer housing and recoil assembly from ebay, and various other small parts it needed from parts sites I learned about from 3WW and put her all back together again. The most challenging part was the right side of the engine with clutch parts and getting stuck screws and bolts out. Kb was a big help to me in strategies for dealing with that. Here is a series of pics showing a pin that the shift return spring fits onto. It was broken off below the surface...got it backed out with a left hand drill bit:
178303
178304
178305
178306
Here is everything back together except for the sub trans...got dark and had to save that for the next day.
178300
And the next day I got the sub trans on (was a little tricky) and then back on the bike.
178301
178302
I had been dreading the inevitable carb rebuild, but today I tackled that. It was pretty dirty and gummed up with almost like a varnish looking build up. Some of the metal inside was corroded to the point that I almost decided to drop back and punt, and order an new carb (decided to press on and see what happened). A couple of the parts I wasn't able to get out, like the little plastic filter close to the petcock valve housing. Since I couldn't get all the plastic and rubber parts out I couldn't soak it in my paint can of carb clean. Kinda took shortcuts and scrubbed with kerosene and brushes, and soaked what I could. Blew out all the passages with compressed air. I used a Shindy carb rebuild kit that I got from G&H Discount ATV. The first pic shows how bad it looked on the inside, second pic shows the carb re-installed after cleaning and rebuild.
178310
178311
I have to say I didn't have much faith but decided that I've been this far, might as well give a try at starting. I forgot to check how many turns the pilot screw was turned when I took the carb apart, so I had to guess. I'm a total newb at this but let me tell you these Honda motors WANT TO LIVE. Took me about 20 pulls and trial and error backing out the screw to allow more fuel but here's what happened next:
http://youtu.be/SRvMwOBmt-w
WOOOOOHOOOoooooooooooo! I was sort of shocked that it started, I must say. After starting it ran great and will start on the first pull everytime. Feels like a total luxury to have a stock keyed ignition switch (my other two 125's don't). Obviously I have alot of work left to do, but I'm getting there....its downhill from here on out. At this point, all the work I have left to do I've done on my other 125 so it will be relatively smooth sailing. This trike has much better compression than my other two, its obvious. Shifted through all the gears while it was running so my work on the right side of the motor paid off. Sub trans shifts between high and low smoothly. Next will be new air filter, new chain, new sprockets (already replaced the front), then brake jobs front and rear, new brakes cables and exhaust cables, exhaust, new seat, etc. This post has been long enough, but I'll close with a pic of the rear plastics. Thanks 3WW, what a great resource website is!
178313
So back to the parts bike....a few weeks back I got to looking at it more closely and realized it's actually in better shape in a general way, than either one of the other 125's I have that run. It hasn't been rednecked to death and everything is pretty much original or close to it. The plastics are in pretty good shape and the tires are like new. So here is a pic showing the sad damage that doomed the poor thing to someones backyard. Not a great picture but you can see the damage to the left engine cover spacer and the missing sub trans.
178297
I've never worked on an ATV before, just ridden them so I was a little intimidated about tearing into this motor....but I only spent 50.00 on in it the first place and figured I can't break what's already broke...go for it. That fateful decision led me to this site...now I'm addicted, as they say. Here is another picture of the spacer after removal:
178299
Probably what happened is the chain came off at fairly good rate of speed (the chain had an obvious kink too) and bunched up on the front sprocket tearing out the housing.
Anyway, I got the spacer housing and recoil assembly from ebay, and various other small parts it needed from parts sites I learned about from 3WW and put her all back together again. The most challenging part was the right side of the engine with clutch parts and getting stuck screws and bolts out. Kb was a big help to me in strategies for dealing with that. Here is a series of pics showing a pin that the shift return spring fits onto. It was broken off below the surface...got it backed out with a left hand drill bit:
178303
178304
178305
178306
Here is everything back together except for the sub trans...got dark and had to save that for the next day.
178300
And the next day I got the sub trans on (was a little tricky) and then back on the bike.
178301
178302
I had been dreading the inevitable carb rebuild, but today I tackled that. It was pretty dirty and gummed up with almost like a varnish looking build up. Some of the metal inside was corroded to the point that I almost decided to drop back and punt, and order an new carb (decided to press on and see what happened). A couple of the parts I wasn't able to get out, like the little plastic filter close to the petcock valve housing. Since I couldn't get all the plastic and rubber parts out I couldn't soak it in my paint can of carb clean. Kinda took shortcuts and scrubbed with kerosene and brushes, and soaked what I could. Blew out all the passages with compressed air. I used a Shindy carb rebuild kit that I got from G&H Discount ATV. The first pic shows how bad it looked on the inside, second pic shows the carb re-installed after cleaning and rebuild.
178310
178311
I have to say I didn't have much faith but decided that I've been this far, might as well give a try at starting. I forgot to check how many turns the pilot screw was turned when I took the carb apart, so I had to guess. I'm a total newb at this but let me tell you these Honda motors WANT TO LIVE. Took me about 20 pulls and trial and error backing out the screw to allow more fuel but here's what happened next:
http://youtu.be/SRvMwOBmt-w
WOOOOOHOOOoooooooooooo! I was sort of shocked that it started, I must say. After starting it ran great and will start on the first pull everytime. Feels like a total luxury to have a stock keyed ignition switch (my other two 125's don't). Obviously I have alot of work left to do, but I'm getting there....its downhill from here on out. At this point, all the work I have left to do I've done on my other 125 so it will be relatively smooth sailing. This trike has much better compression than my other two, its obvious. Shifted through all the gears while it was running so my work on the right side of the motor paid off. Sub trans shifts between high and low smoothly. Next will be new air filter, new chain, new sprockets (already replaced the front), then brake jobs front and rear, new brakes cables and exhaust cables, exhaust, new seat, etc. This post has been long enough, but I'll close with a pic of the rear plastics. Thanks 3WW, what a great resource website is!
178313