newbie and new to me - Page 3

Weldangrind · 03-16-2014, 04:09 PM

That explains it. You'll need to get a special tool to remove the centrifugal pickup (which is just above the clutch in your pic, secured with three Phillips screws) and the clutch. This tool will remove both parts for you: http://www.ebay.com/itm/Honda-Motorc...909af6&vxp=mtr

When you remove the cover from the centrifugal pickup, you'll likely find some silver sludge inside. Make sure you clean it all out. It's a good idea to replace the gasket that is under the cover as well. If you have access to an impact wrench, it will make removal of the three Phillips screws much easier. They strip easily.

When installing the bolts that worked loose, clean them well and secure them with blue Loctite 242 or red Loctite 262. Use 242 on the Phillips screws.

stretch8668 · 03-16-2014, 04:17 PM

I already had phillips screws out how I found out needed special tool and clutch is held in place with snap ring thanx for link now I know what gotta get

stretch8668 · 03-17-2014, 06:22 PM

The bolt on bottom is screwed into case my question is what goes into hole on right

Weldangrind · 03-18-2014, 10:50 AM

Not sure. It looks like there are two available points for the shifter detent, which is the item at the bottom of your case. It has a spring-loaded roller that applies pressure to the shifter star, and that's what you feel when you shift gears. When you remove the clutch, shifter detent and shifter star, it should all be clear. If not, let us know, and I'll remove a cover on a spare engine I have.

stretch8668 · 03-18-2014, 11:50 AM

Ok thanx I just ordered tool some I can take that piece off so can then take clutch off then I can tighten and loc tite everything. I also got some blue gasket maker and bought blue and red loc tite

stretch8668 · 03-18-2014, 07:01 PM

What is shifter star suppose to look ln first just in case its outta wack

stretch8668 · 03-19-2014, 12:14 AM

Any idea where I can get an engine manual for this and I also found out they had two versions of the 163fml

Weldangrind · 03-19-2014, 01:01 AM

Don't worry about the placement of the shifter star, since it has a small hole on the back that engages with a pin. It only goes on one way.

Your engine is identical to the CG125, which was very popular in Brazil and the UK; there is a ton of info for it online.

stretch8668 · 03-19-2014, 08:50 AM

Awesome thanks found an engine repair manual for the cg125 and its extremely similar to the 200 I'm hopfully gonna tackle this this weekend if I get tool and if the weathers "warm" enough

stretch8668 · 03-22-2014, 03:38 PM

Got tool today and tightened bolt I'm hoping that's what problem was leaving it empty overnight to let silicone cure. The shifting star wasn't even on the pin on shifting shaft ill see how it goes tomorrow after fill it back up with oil.

SpudRider · 03-22-2014, 04:42 PM

It sounds like you fixed the problem.

You can safely test your repair by rolling the bike and trying to shift the transmission before you replace the crankcase cover and refill the engine oil.

stretch8668 · 03-22-2014, 05:11 PM

Just did it already had cover on don't know why didn't try it before did cover. I noticed when was tightening lock nut on crank that the bike was moving while I did it so I assumed it was working. Ill find out tomorrow though fingers crossed

stretch8668 · 03-23-2014, 11:43 AM

Got her drivin again and for a 200cc it moves me pretty good (I'm 6'4" and 240lb). Found some things I wanna improve upon like a bigger stiffer rear shock and drain and fill forks as there lil too soft for me. All in all no complaints. .......yet

Weldangrind · 03-23-2014, 01:33 PM

Excellent!

Can you move the lock nuts on the shock, to apply more pressure to the spring?

I have had good experience with using the fork oil that Spud recommends, which is Valvoline Max Life Dex / Merc. Good stuff.

stretch8668 · 03-23-2014, 02:56 PM

I haven't tried lock nuts yet and want a taller seat height also but I've read spudes yhread bout the front shocks couple of times I'm just waiting for warmer weather as its cold in nh

03-16-2014, 04:09 PM	#31
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	That explains it. You'll need to get a special tool to remove the centrifugal pickup (which is just above the clutch in your pic, secured with three Phillips screws) and the clutch. This tool will remove both parts for you: http://www.ebay.com/itm/Honda-Motorc...909af6&vxp=mtr When you remove the cover from the centrifugal pickup, you'll likely find some silver sludge inside. Make sure you clean it all out. It's a good idea to replace the gasket that is under the cover as well. If you have access to an impact wrench, it will make removal of the three Phillips screws much easier. They strip easily. When installing the bolts that worked loose, clean them well and secure them with blue Loctite 242 or red Loctite 262. Use 242 on the Phillips screws. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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03-18-2014, 10:50 AM	#34
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Not sure. It looks like there are two available points for the shifter detent, which is the item at the bottom of your case. It has a spring-loaded roller that applies pressure to the shifter star, and that's what you feel when you shift gears. When you remove the clutch, shifter detent and shifter star, it should all be clear. If not, let us know, and I'll remove a cover on a spare engine I have. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-19-2014, 01:01 AM	#38
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Don't worry about the placement of the shifter star, since it has a small hole on the back that engages with a pin. It only goes on one way. Your engine is identical to the CG125, which was very popular in Brazil and the UK; there is a ton of info for it online. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-22-2014, 04:42 PM	#41
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	It sounds like you fixed the problem. You can safely test your repair by rolling the bike and trying to shift the transmission before you replace the crankcase cover and refill the engine oil. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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03-23-2014, 01:33 PM	#44
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Excellent! Can you move the lock nuts on the shock, to apply more pressure to the spring? I have had good experience with using the fork oil that Spud recommends, which is Valvoline Max Life Dex / Merc. Good stuff. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-16-2014, 04:17 PM	#32
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	I already had phillips screws out how I found out needed special tool and clutch is held in place with snap ring thanx for link now I know what gotta get
	0

03-17-2014, 06:22 PM	#33
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	The bolt on bottom is screwed into case my question is what goes into hole on right
	0

03-18-2014, 11:50 AM	#35
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Ok thanx I just ordered tool some I can take that piece off so can then take clutch off then I can tighten and loc tite everything. I also got some blue gasket maker and bought blue and red loc tite
	0

03-18-2014, 07:01 PM	#36
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	What is shifter star suppose to look ln first just in case its outta wack
	0

03-19-2014, 12:14 AM	#37
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Any idea where I can get an engine manual for this and I also found out they had two versions of the 163fml
	0

03-19-2014, 08:50 AM	#39
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Awesome thanks found an engine repair manual for the cg125 and its extremely similar to the 200 I'm hopfully gonna tackle this this weekend if I get tool and if the weathers "warm" enough
	0

03-22-2014, 03:38 PM	#40
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Got tool today and tightened bolt I'm hoping that's what problem was leaving it empty overnight to let silicone cure. The shifting star wasn't even on the pin on shifting shaft ill see how it goes tomorrow after fill it back up with oil.
	0

03-22-2014, 05:11 PM	#42
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Just did it already had cover on don't know why didn't try it before did cover. I noticed when was tightening lock nut on crank that the bike was moving while I did it so I assumed it was working. Ill find out tomorrow though fingers crossed
	0

03-23-2014, 11:43 AM	#43
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	Got her drivin again and for a 200cc it moves me pretty good (I'm 6'4" and 240lb). Found some things I wanna improve upon like a bigger stiffer rear shock and drain and fill forks as there lil too soft for me. All in all no complaints. .......yet
	0

03-23-2014, 02:56 PM	#45
stretch8668 Join Date: Mar 2014 Location: keene nh Posts: 206	I haven't tried lock nuts yet and want a taller seat height also but I've read spudes yhread bout the front shocks couple of times I'm just waiting for warmer weather as its cold in nh
	0