Abobobilly's CG125 Thread - Its Evolution and Stuff I Changed

[r1]

@r1! Wow. Thats a lot.

How are you checking for noise, btw? The same way i did? And are your tappets making excessive noises even when they are tight?

Loud noise like "Grrrr Grrrr" at idle speed even after adjustment of tappets at recommended zone. During ride the noise turns like "Tak Tak Tak", these are the symptoms so no need to coverup exhaust tip to check.

Not sure about other parts but i got a quote for someone a month back and it went something like this

Cylinder genuine AHL = 1500
Ring piston (complete set incl pin) = 950
Push rods = 500
Valve Stem seals = 220
Gasket set = 250
Valves = 950

Not sure about other stuff like rocker arms assembly and cam followers.
Never go for bore and sleeve, i can't recall the number of times i have met people who start complaining a month after they had head work done about oil leakage and what not, just because they have bore done.

Also better have a look at your clutch plates and pressure plates as well.

Clutch Plates Rs. 2250/-
Pressure Plates Rs. 450/-

All these rates would be comparatively less in Lahore and labour charges cannot exceed 1-1.5k max. I think 13k is more than sufficient budget to get the entire work done.

[LIST]
[*]Buy parts yourself from good genuine whole sale shop (AHL antenna shop preferred)
[*]Never compromise on genuine parts even the small stuff.
[*]Get entire work done infront of you
[/LIST]

I know you are experienced and have had a lot of work done but still my 2 cents

I planned to change the head+cylinder of CG and antenna dealer quote me:
Head - Rs. 5400/
Timing Cam Drive - Rs. 3300/
Cylinder - Rs. 2200/
Pistion - Rs. 850/
Push Rods - Rs. 800

[Chaudhary007]

Loud noise like "Grrrr Grrrr" at idle speed even after adjustment of tappets at recommended zone. During ride the noise turns like "Tak Tak Tak", these are the symptoms so no need to coverup exhaust tip to check.

I planned to change the head+cylinder of CG and antenna dealer quote me:
Head - Rs. 5400/
Timing Cam Drive - Rs. 3300/
Cylinder - Rs. 2200/
Pistion - Rs. 850/
Push Rods - Rs. 800

I am pretty sure he is minting money on cylinder and pushrods. abobobilly bought Japanese (thick) ones for Rs650 how can AHL ones be of Rs800

Why are you changing the head ? Is there any sort of deformation in it ?

[r1]

I am pretty sure he is minting money on cylinder and pushrods. abobobilly bought Japanese (thick) ones for Rs650 how can AHL ones be of Rs800

Why are you changing the head ? Is there any sort of deformation in it ?

He is minting on every item almost, changing head because of leaking issue. I will contact Makhdoom Corp today to check the prices and will share accordingly.

[abobobilly]

Engine Works Done @ 16th March 2015
TOTAL COST: Nearly Rs.12000

COST OF PARTS:

[TABLE="class: grid, width: 388, align: left"]
<tbody>[TR]
[TD="align: center"]Cylinder[/TD]
[TD="align: center"]1800[/TD]
[/TR]
[TR]
[TD="align: center"]Handle Balls[/TD]
[TD="align: center"]70[/TD]
[/TR]
[TR]
[TD="align: center"]Cylinder Gasket[/TD]
[TD="align: center"]70[/TD]
[/TR]
[TR]
[TD="align: center"]Head Gasket[/TD]
[TD="align: center"]150[/TD]
[/TR]
[TR]
[TD="align: center"]Clutch Box Gasket[/TD]
[TD="align: center"]150[/TD]
[/TR]
[TR]
[TD="align: center"]Clutch Plates (AHL Genuine)[/TD]
[TD="align: center"]780[/TD]
[/TR]
[TR]
[TD="align: center"]Clutch Lever[/TD]
[TD="align: center"]70[/TD]
[/TR]
[TR]
[TD="align: center"]Clutch Cable[/TD]
[TD="align: center"]100[/TD]
[/TR]
[TR]
[TD="align: center"]Pressure Plate[/TD]
[TD="align: center"]450[/TD]
[/TR]
[TR]
[TD="align: center"]Valve Set (Deluxe)[/TD]
[TD="align: center"]900[/TD]
[/TR]
[TR]
[TD="align: center"]Valve Guides[/TD]
[TD="align: center"]400[/TD]
[/TR]
[TR]
[TD="align: center"]Valve Seals[/TD]
[TD="align: center"]200[/TD]
[/TR]
[TR]
[TD="align: center"]Rocker (Cam Follwers)[/TD]
[TD="align: center"]400[/TD]
[/TR]
[TR]
[TD="align: center"]Rocker Pin (Cam Followers Shaft)[/TD]
[TD="align: center"]180[/TD]
[/TR]
[TR]
[TD="align: center"]Stem Steering[/TD]
[TD="align: center"]680[/TD]
[/TR]
[TR]
[TD="align: center"]Cam Gear (ISH) Set[/TD]
[TD="align: center"]680[/TD]
[/TR]
[TR]
[TD="align: center"]Challa Kitt (ISH)[/TD]
[TD="align: center"]40[/TD]
[/TR]
[TR]
[TD="align: center"]Exhaust Gasket/Washer[/TD]
[TD="align: center"]70[/TD]
[/TR]
[TR]
[TD="align: center"]Magnet Seal[/TD]
[TD="align: center"]40[/TD]
[/TR]
[TR]
[TD="align: center"]Push Rod - AHL Genuine[/TD]
[TD="align: center"]280[/TD]
[/TR]
[TR]
[TD="align: center"]Pipe Steering Handle[/TD]
[TD="align: center"]480[/TD]
[/TR]
[TR]
[TD="align: center"]Brake Leather (ISH) Front[/TD]
[TD="align: center"]220[/TD]
[/TR]
[TR]
[TD="align: center"]Brake Leather (ISH) Rear[/TD]
[TD="align: center"]150[/TD]
[/TR]
[TR]
[TD="align: center"]Front Brake Cable[/TD]
[TD="align: center"]100[/TD]
[/TR]
[TR]
[TD="align: center"]Piston Set (w/ STD Rings)[/TD]
[TD="align: center"]650[/TD]
[/TR]
[TR]
[TD="align: center"]TOTAL[/TD]
[TD="align: center"]9110 (9000 PAID)[/TD]
[/TR]
</tbody>[/TABLE]

COST OF OTHER STUFF:

Plug Thin Tip (Makhdoom) Rs.380
Havoline 1L Rs.420
Rocker Base Plate Weld Rs.50

WAGES:
[TABLE="class: grid, width: 336, align: left"]
<tbody>[TR]
[TD]Clutch Box Size[/TD]
[TD]Rs.200[/TD]
[/TR]
[TR]
[TD]Valve & Head Grinding, and Guides Fitting[/TD]
[TD]Rs.400[/TD]
[/TR]
[TR]
[TD]Wages[/TD]
[TD]Rs.1000[/TD]
[/TR]
[TR]
[TD]1L Petrol (for Cleaning)[/TD]
[TD]Rs.80[/TD]
[/TR]
[TR]
[TD]TOTAL[/TD]
[TD]Rs.1680 (Rs.1600 Paid)[/TD]
[/TR]
</tbody>[/TABLE]

GRAND TOTAL NEARLY Rs.12000

Meter Reading @ Engine Work Done = 39920
Current Meter Reading = 39956

Here is the full Invoice, if anyone wants it.
-

--------------------------

Thanks to all for your support and quick answers. I wanted to share my detailed experience before, but life as you know, is becoming more hectic than usual. It took me A FULL DAY to get this done. 2 Hours just to collect parts, and then 7 Hours to get the work done. The Work began at 5:00PM, and was effectively finished at 10:30PM. Phew :S

Quiet a few things are last minute decision, by the machinist i went to. I wanted reliability for next 3-5 years, so he recommended Deluxe Valves. This time, i didn't say anything, and let him do his work. He is my neighbor, so i know that if something goes wrong, i will get his ***.

My First Ride after the work done ... i don't want to say that it felt really really good (which it did). The stroke of the bike was even more powerful than Deluxe, and was evident from its sound. But i didn't let emotions take over, because ... well, past experiences. Pehle Happiness, then later Crying :-!:-!

Anyway, today have driven the bike like 30kms, and there is an obvious different in engine behavior because of Deluxe Valves, Clutch Renewal (Size Adjustment at the Machine), and Cam Followers Change. Bike feels to be running more freely, and De-Accelerates Slower than before. I am liking the ride, however. But it also feels, well, dangerous at the same time :-#

Absolutely no alteration has been done (apart from the Deluxe Valves, and newer model Cam Followers).

POINTS TO NOTE:

-- Used Euro2/Deluxe Cam Follower (Newer Design).

• Used Deluxe Valves (Grinding was done accordingly).

• One Valve Guide was used only. Intake's Valve Guide was fine, so didn't change it. Besides, the new parts are so sh*t in quality that its not even funny. But they are cheap. Not sure if I should consider it a plug point. Anyway, still have one Brand new Valve Guide, and the shop keeper won't take it back, because it comes in pairs (intake and exhaust). (Rs.200 awein paray huay hain)

• New Cylinder was noticeably lower in quality. Less Weight than my current one was noticeably less. (WTF is this sh*t quality?)

• Older Push Rods (the Japenese think ones), well ... they were absolutely fine. But the machinist insisted to use the newer ones :S Ah well, i have them as backup pair. Btw, he was continuously saying how "Flexible" push rods are better than Rigid ones. Said, AHL's push rods are thinner but have slight flex in them, to allow for any mishap :S What sorcery is this?

• ISH Brake Leathers are pretty damn good, not only for their price, but their braking power impressed me the most. I don't care if they last me barely Rs.1000 kms. They are like HALF the price of AHL Genuine, which are absolutely sh*t.

• Can anyone tell me whats so good about this NGK G-Power Titanium Tip Spark Plug? Is this expensive for a reason? @vickytulla!? Looks sexy though

• Apparently, vickytulla was right. Even after changing Cam Gear set, i can still feel the slight sound of "Ghoon Ghoon". However, i asked the Machinist (who did the engine work) and he said that it'll go away after initial running. I'll see about that.

• As per my past experience, these people adjust tappets too tight. Had a recent bad experience with the same machinist i got the work done from :p, (where engine started to make too much noise, even after a very good tappet adjustment -- it was due to excessive wear of Rocker Base Plate). Which is why i started to adjust tappets at home, by myself. So yeah, i came home opened up the bike again (before going to work), and adjusted them by myself :-# As expected, they were slightly tighter, with Intake being excessively tight :S Adjusted them in like 15 minutes this time Yeah tappet adjustment is becoming 'left hand ka khel' for me

• A couple of months ago, a stupid car wala with blacked out rear window reversed into me at a signal, without looking back. That messed up my bike's front portion again. I have been driving it like that ever since, but wanted to change the Stem Steering (Ainak) again. Which is why i had bought one this time too.

** PICTURES IN NEXT POST **

[vickytulla]

• Can anyone tell me whats so good about this NGK G-Power Titanium Tip Spark Plug? Is this expensive for a reason? @vickytulla!? Looks sexy though

Reduce over heating and cool Quickly Have a really long life have a very good combustion and burn feul properly(more power and good economy) things like that...

• Apparently, vickytulla was right. Even after changing Cam Gear set, i can still feel the slight sound of "Ghoon Ghoon". However, i asked the Machinist (who did the engine work) and he said that it'll go away after initial running. I'll see about that.

If the Goon Goooon is very dim in sound and is totally different the what it previusly was then it might really go away and is only becuase of new parts but if it has not reduced at all then that can be a concern...

[abobobilly]

[img]http://i.imgur.com/LEuq2ztl.jpg[/img] -
.:: Head & Valves Grinding ::.

-
.:: Rocker Plate Weld ::. (It was loose. Brand new was so cheap in quality that i didn't want to get it :S)

.:: Top Deluxe Valve; Bottom Older CG125 Genuine Valve ::. (Deluxe Valves are very slightly wider)

-
.:: Deluxe Valves Genuine ::.

- -
.:: Old Cylinder ::. The Cylinder from inside was too much slippery, which cased the oil to seep into combustion chamber.

.:: Older Piston ::. Due to smoke, carbon deposits can be seen ontop of it.

-
.:: Mechanic Insisted on Havoline ::. I'll change it at 800kms anyway.

.:: NGK G-Power (Left) vs. NGK Stock (Right) ::.

-
.:: Clutch & Brake Cable ::.

-
.:: Gaskets ::.

.:: New Steering Handle ::.

- - - - - - - - - -
.:: New Cam Gear Set (ISH) ::.

-
.:: New Stem Steering (Ainak) ::. (for the reasons described above i.e. that punk car wala w/ blacked out mirrors)

- - - - -
.:: New Brake Leathers (front & back) (ISH) ::.

[abobobilly]

[img]http://i.imgur.com/dG2il5Ml.jpg[/img] -
.:: Handle Balls for Stem Steering ::.

-
.:: New Cam Followers (Deluxe) ::. Why the hell do they keep calling it "Rockers"?

- - - - - - -
.:: (STD) Rings & Piston Set - AHL Genuine ::.

- -
.:: Deluxe Valves (Packed) ::.

-
.:: Cam Followers Shaft ::.

- -
.:: Valve Seals - AHL Genuine ::.

-
.:: Valve Guides ::.

-
.:: Gasket - Cylinder Head ::.

.:: New Clutch Lever ::. (Wanted to change it, to give a new feel to the clutch, but didn't - again; sh*t quality is the reason)

-
.:: Gasket - Exhaust ::.

- -
.:: ISH Challa Kitt and Magnet Seal ::.

.:: AHL Genuine Clutch & Pressure Plates ::.

-
.:: AHL Genuine Push Rods ::.

- -
.:: NGK G-Powe Titanium Tip Plug ::.

-
.:: New Cylinder ::.

P.S. I didn't take many pictures of the Older Parts i took out, but i might take them. Because i have each and every part with me. Didn't leave a thang at his shop

[abobobilly]

@vickytulla! So you are saying that it really is a better choice than the stock NGK? Really no drawbacks? (Like incase with those Racing plugs we saw a few years ago, still cost like 1000 rupees for one plug :S -- can't quite recall their names, though).

Also, do you guys have any concerns about me using Deluxe Valves? I mean, your thoughts. No need to sugar coat anything. Just say it whatever it is @r1

[vickytulla]

lots of people are using this plug right now including many PW memebers and had a good feedback about it.

lol ... about Deluxe valves, though i do think they are good enough then local 3rd class valves but I would have preferred the Carbon Alloy deisal engine valves... becuase they cost less and last really long given they are fitted by good machinist.

@vickytulla! So you are saying that it really is a better choice than the stock NGK? Really no drawbacks? (Like incase with those Racing plugs we saw a few years ago, still cost like 1000 rupees for one plug :S -- can't quite recall their names, though).

Also, do you guys have any concerns about me using Deluxe Valves? I mean, your thoughts. No need to sugar coat anything. Just say it whatever it is @r1

[Chaudhary007]

Nice detailed post with pics, will be beneficial to all.

Aren't deluxe valves going to have an effect on the economy ? :S

[abobobilly]

Aren't deluxe valves going to have an effect on the economy ? :S

Well if it does, i will surely mention it here.

Right now, i am fed up with this bike's front portion. BC seedha he nai hota. Everyone (Denters, other shop keepers) think i am crazy

Even after fitting the new Stem Steering yesterday, my front shocks are still feeling rigid. That indicates that the brand new Stem Steering might also be misaligned :S

The era of mindf*ck has come back for me

[r1]

Hows the performance so far and how much running period after ring+pistons? Did you change the whole cam timing gear shaft or just the primary drive?

[asjdsm]

is this head gasket of 3 metal sheets?

mostly they reduce Compression.. good work..

[saboor73]

is this head gasket of 3 metal sheets?

mostly they reduce Compression.. good work..

it obvious thicker gaskit = more space between head and piston more volume in compression are (on piston top position) resultant in less compressed air/fuel

[ab6666]

[img]http://i.imgur.com/dG2il5Ml.jpg[/img] -
.:: Handle Balls for Stem Steering ::.

-
.:: New Cam Followers (Deluxe) ::. Why the hell do they keep calling it "Rockers"?

- - - - - - -
.:: (STD) Rings & Piston Set - AHL Genuine ::.

- -
.:: Deluxe Valves (Packed) ::.

-
.:: Cam Followers Shaft ::.

- -
.:: Valve Seals - AHL Genuine ::.

-
.:: Valve Guides ::.

-
.:: Gasket - Cylinder Head ::.

.:: New Clutch Lever ::. (Wanted to change it, to give a new feel to the clutch, but didn't - again; sh*t quality is the reason)

-
.:: Gasket - Exhaust ::.

- -
.:: ISH Challa Kitt and Magnet Seal ::.

.:: AHL Genuine Clutch & Pressure Plates ::.

-
.:: AHL Genuine Push Rods ::.

- -
.:: NGK G-Powe Titanium Tip Plug ::.

-
.:: New Cylinder ::.

P.S. I didn't take many pictures of the Older Parts i took out, but i might take them. Because i have each and every part with me. Didn't leave a thang at his shop

why did u changed the cylinder and ring piston?

[Chaudhary007]

why did u changed the cylinder and ring piston?

Cylinder = Bore and Sleeve is not a permanent long lasting solution
Ring piston = Was blowing smoke occasionally

Feel free to add anything else bro @abobobilly

[asjdsm]

it obvious thicker gaskit = more space between head and piston more volume in compression are (on piston top position) resultant in less compressed air/fuel

bigger gasket increases squish band and the volume of combustion chamber .. therefore the volume of air/fuel mixture displaced by piston from bottom dead center to top dead center will find itself in increased sized chamber.thus reducing CR.

and our mechanics use it asking people its genuin made of metal. not the fiber one.

however i have excellant expeirence with fibrer gasket.. long lasting .. goo CR and sealing ability.. these metal sheets leak quickly...

[ammarzahid]

@asjdsm any idea where to find 2.15 tagasako rim in pindi?

[asjdsm]

no idea bro .. have you wandered around in waris khan ? circular road ?

@asjdsm any idea where to find 2.15 tagasako rim in pindi?

[amjad635]

Thanks For Such An Detail Post Of Engine Work Abobobilly