Brakes: Overhaul; Regulator/Rectifier Unit: Location And Testing; Ignition Switch: Removal And Refitting; Instrument Panel Bulbs: Removal And Refitting - Honda CG125 Service Manual

27 Brakes: overhaul

1 When overhauling the brakes check that the brake operat-
ing cam is working smoothly and is not binding in its pivot. The
cam can be removed by withdrawing the pinch bolt from the
actuating arm and pulling the arm off the shaft. Before
removing the arm, if the manufacturer's alignment punch marks
cannot be seen, it is advisable to mark its position in relation to
the shaft so that it can be relocated correctly with the wear
indicator pointer.
2 Remove any deposits of hardened grease or corrosion from
the bearing surface of the brake cam and shoe by rubbing it
lightly with a strip of fine emery paper or by applying solvent
with a piece of rag. Lightly grease the length of the shaft and
the face of the operating cam prior to reassembly. Clean arid
grease the pivot stub which is set in the backplate.
3 On the front brake only, check the condition of the felt seal
which prevents the escape of grease from the end of the
camshaft. If it is in any way damaged or too dirty to be of further
use, it must be renewed before the shaft is relocated in the
backplate. Dip the seal in clean engine oil before refitting it,
pack grease into the backplate passage and refit the camshaft.
Hook the return spring inner end into the backplate hole.
4 On front and rear brakes, fit the wear indicator to the
camshaft, aligning the indicator inner tab with the matching slot
in the camshaft splines. Check that the camshaft is rotated to its
correct position then refit the actuating arm, aligning its punch
mark with that of the camshaft. On front brakes only, hook the
return spring outer end over the arm. Tighten the arm pinch bolt
to the specified torque setting, then refit the brake shoes.
5 On all models, note that the brake operating mechanism is
at its most efficient when, with the brake correctly adjusted and
applied fully, the angle between the cable or rod and the
actuating arm on the brake backplate does not exceed 90°. This
can be adjusted by removing the actuating arm from the brake
camshaft and rotating it by one or two splines until the angle is
correct. Ensure that all components are correctly secured on
reassembly.

28 Regulator/rectifier unit: location and testing

1 The 12 volt electrical system fitted to these models uses a
combined regulator/rectifier unit to replace the rectifier and
resistor fitted to the earlier models.
28.2 Location of regulator/rectifier unit - later models shown
Chapter 7 The 1985 on models
2 The unit is fitted either under the seat, in front of the rear
mudguard, or under the petrol tank immediately behind the
steering head. Remove the seat (and petrol tank, if necessary) to
gain access to it. The unit is a heavily finned sealed metal unit;
on later models it is rubber-mounted to the frame top tube and
is covered by a rubber sheath.
3 The regulator side of the unit can be tested only by a
general check of the charging system output, as described in
Chapter 6, Section 3. If the results obtained differ widely from
those specified in this Chapter then one or more components of
the system is faulty. While basic tests of the generator coils can
be made as described in Chapter 6, if a charging system fault is
suspected the machine should be taken to a Honda Service
Agent for testing by an expert. The only way of curing a faulty
regulator/rectifier unit is to renew it; owners are advised to have
their findings confirmed by an expert using the correct test
equipment before condemning a component.
4 The rectifier side of the unit can be checked by measuring
the resistances each way across the red and white wire
terminals, as described in Chapter 6, Section 4. If the rectifier
diode is faulty, the complete unit must be renewed.
5 Always ensure that the unit's connections are clean and
securely fastened and that its mountings are secure.

29 Ignition switch: removal and refitting

Note that the ignition switch mounting in the instrument
panel is the same as that described in Chapter 6 for the earlier
models. It will be necessary to remove the complete panel and
dismantle it, as described in Section 25, to gain access to the
switch mounting.

30 Instrument panel bulbs: removal and refitting

Although the panel is very different in appearance the
instrument and warning lamp bulbs are fitted in the same way
as described in Chapter 6 for the later models. Note that it may
be necessary to remove the two mounting bolts and to lift the
panel upwards to gain access to an awkwardly placed
bulbholder.
30.1 Instrument panel bulbs are of capless type - remove and
refit as described for earlier models
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