Advertisement
114
machines and can be easily obtained from a good motorcycle
dealer.
2
Note that the piston crown marking mentioned in Chapter
(larger) inlet valve cutaway which must face to the rear on
reassembly.
3
The clutch release mechanism is very slightly modified (see
accompanying photographs).
4
The crankcases and crankcase covers are now secured by
hexagon-headed screws which will require the use of a very
slim, deep, 8 mm (spanner size) socket if they are to be removed
and refitted without risk of damage. Sockets of the appropriate
type are usually only available in the smaller drive sizes; ensure
that the necessary tools and adaptors are purchased with the
socket.
9
Dismantling and rebuilding the engine/gearbox unit:
separating the crankcase halves
1
In Chapter 1 owners are recommended to lift off the
crankcase right-hand half, leaving all internal components in the
deeper left-hand casing.
2
For later models, work will be found much easier if the
crankcase left-hand half is lifted off, leaving all components in
the right-hand half.
3
On reassembly, therefore, mesh together the gearbox
clusters and fit them to their bearings in the crankcase right-
hand half. Ensure that all thrust washers are refitted and that
both shafts rotate freely.
4
Refit the gear selector components as described in Section
Chapter 1.
5
Fit a new gasket over the two locating dowels, lubricate all
bearings and refit the crankcase left-hand half, following the
instructions given in Chapter 1.
Fig. 7.1 Modified selector mechanism components
1
Fork shaft
2
Right-hand selector
fork
See Fig. 1.5 for details of remaining components
Chapter 7 The 1985 on models
3
Centre selector fork
4
Left-hand selector
fork
10 Gear selector mechanism: general
1
Although generally unchanged the selector mechanism has
received a few detail modifications. Refer to the accompanying
illustration for details.
2
On removal, note that the selector fork shaft can be
withdrawn as soon as the crankcase halves have been
separated. Rotate the forks away from the selector drum,
withdraw the drum and then lift out each fork in turn, making
notes or marks as required to ensure correct identification of
each fork and of which way up it is fitted.
3
On reassembly the right-hand fork should be refitted to the
layshaft 3rd gear pinion, with its marking facing upwards (ie, to
the left). The centre fork is fitted to the mainshaft 4th gear
pinion. The left-hand fork is fitted to the layshaft 5th gear
pinion, with its marking facing downwards (ie, towards the
other forks).
4
Insert the selector drum so that the neutral switch contact
aligns with the switch terminal and manoeuvre the fork guide
pins into their respective grooves. Lubricate and insert the
selector fork shaft, then rotate the drum to check that all gears
can be selected, then return to the neutral position.
11 Petrol tank: removal and refitting
The petrol tank rear mounting is now secured by a single bolt
and washer (see accompanying photograph). On refitting, always
ensure that the tank rear mounting bracket is settled correctly
on the rubber spacer before tightening the bolt.
12 (T)PFC carburettor: removal - CG125-C, E and
Brazilian models
1
First remove its two retaining screws and withdraw the
carburettor cover, then switch off the petrol tap and disconnect
the feed pipe from the tap spigot. Pull the drain tube clear of the
engine and frame. Remove the right-hand side panel for extra
working space.
2
Slacken the screw clamp which secures the air filter hose to
the carburettor. Slacken the adjuster locknut and unscrew the
accelerator pump cable adjuster from its bracket, then discon-
nect the cable end nipple from the pump cam.
3
Unscrew the two bolts securing the inlet stub to the
cylinder head, then partially withdraw the carburettor assembly
until the carburettor top can be unscrewed and the throttle
valve withdrawn.
4
The throttle valve assembly can be dismantled as described
in Chapter 2, Section 5. Note that the valve can be detached
easily with the carburettor in place by removing the seat and
either removing the petrol tank or lifting it at the rear.
5
The inlet stub can be detached by removing the two nuts
which secure it to the carburettor. Examine the O-rings at each
end of the stub; these must be renewed to prevent induction
leaks if they are in any way flattened, worn, or damaged.
13 (T)PFC carburettor: overhaul - CG125-C, E and
Brazilian models
1
The float bowl can be detached complete with the ac-
celerator pump diaphragm and rod assembly in place, if
required. All other components of the carburettor are the same
as the later type of carburettor described in Chapter 2; refer,
therefore, to that Chapter for all information unless shown
below. Do not disturb the accelerator pump linkage unless
absolutely necessary; it is pre-set at the factory and will not
require adjustment in normal use unless disturbed.
Advertisement
Chapters
