O M G < NEED HELP HERE

[den]

ok , its an off topic question because its not about an mz ,, i got a problem with my sons HONDA
my son has an 04 plate honda xr125 brazil engine,(jc30e) engine,
This is soo different from all other hondas pre 2002 but apparently has the same engine as a honda cg125es 04/09 plate.
so the story.
My lad trashed third gear , literally ground all the teeth of,.So i split the crankcase and replace both gears and alls well,upon putting the crankcase back together i realise the the crankcase cover gaskets didn't fit ,, Although i bought a full set for the xr125 l4 i couldn't understand what was wrong,, upon investigating i realise this set is not the right set and i needed a set for the brazil jc30e engine,undeterred i just made a cover set from a cereal box and a die,
now the problems start
bike all back together and a week later the engine seized,took the bike to bits a found that the cylinder (not head) gasket was also soo slightly wrong and the cams oil gallery was blocked with new gasket in the way,,so after a strip down i freed up the engine and noticed all the oil had disappeared??wtf?,, there was no smoke?,,oh well , maybe it leaked out my cereal box gasket,Oh no it didn't.
with the engine in bits i honed the barrel ,installed new piston and rings,put it all back together and filled with fresh oil,
wow the engine sounds so quiet,,runs like new,, then it stalled ,, after pulling the plug i notice its covered in fresh oil,,i'm crying now,so more investigation has revealed the the engine breather pipe is dumping ALL the engine oil into the air filter box and the subsequently upon breaking it sloshes it through the carb to the engine and fills the piston chamber and exhaust,, I so don't want it to be the crankcase gasket blocking the return flow from the pump, Any ideas,,What could cause back pressure,,i got fantastic seal in the cylinder and piston,great compression,valves and timing set correct,,pushrod engine anyways,,simples,
ps
if i keep saying its not the crankcase gasket will it come true and be somthing else,

[DAVID THOMPSON]

they made 2.6 million hondas one year
thats nice
they were all honda cubs
in 160 countries
my god thats a lot of parts

try david silver spares .co.uk

http://www.davidsilverspares.co.uk/

even here in the usa he is the guy for odd stuff
see if they can get you a proper gasket set
dave
on the MZ rt125 motor the side cover gasket thickness can mess up the oil pressure

[Wallace]

ps
if i keep saying its not the crankcase gasket will it come true and be something else,

Denial, I tried that with my Speed Triple starter clutch hoping it was the battery! I'm not familiar with the internals of that engine, looking at the exploded view in the link below there is a labyrinth cast into the upper part of the crankcase to separate the oil from the crankcase compression before it enters the breather tube to the air filter. I'm doing some logical guessing here; If oil is being pumped out of the breather then it is not being allowed to return from the labyrinth into the sump and once the labyrinth area is full oil will be pumped out the breather tube by the crankcase pressure. Perhaps the crankcase gasket is incorrect for your engine blocking oil return to the sump, not what you want to hear though!

EDIT: Does the rocker cover have a breather tube connected to a fancy valve arrangement and a small tube on the inlet manifold?

Mike

http://www.oemmotorparts.com/oem5.asp?M=Honda&T=XR125L&Y=2004&L=HO-XR125L4&O=CRANKCASE&F=HO-XR125L6-PQ&L2=HO-XR125L6-PQ

[den]

thanks for the reply wallace ,, was in need of a second opinion, just wanted someone to glance over the crankcase internals,,it seems as though all my hard work was in vain.stupid trusting in ebay selling me the right gasket set anyways , i told them it was wrong and they quoted me as ordering the wrong part,,lucky i don't need a mechanic,,$$$$$$$££££££..Im going to take the engine out and split it again , who knows if the gasket is blocking another gallery somewhere(somwear) else

[Wallace]

Check for that extra breather on the cylinder head and the valve, might have something to do with that. Could be the engine is supposed to breathe in from the air filter to the crankcase and out the head for emission reasons.

Head breather shown here: http://www.oemmotorparts.com/oem5.asp?M=Honda&T=XR125L&Y=2004&L=HO-XR125L4&O=CYLINDER%20HEAD%20COVER%20(XR125L4,5,6)&F=HO-XR125L6-ON&L2=HO-XR125L3-ON

Air Suction Valve shown here: http://www.oemmotorparts.com/oem5.asp?M=Honda&T=XR125L&Y=2004&L=HO-XR125L4&O=AIR%20SUCTION%20VALVE&F=HO-XR125L6-TK&L2=HO-XR125L5-TK

Mike

[superstock]

Hello

did you find a solution to your problem as I have the same problem

my number is 07903 463362

thanks

graham

[den]

yes i did find the solution , my engine was the brazil type,,NOT THE USUAL HONDA 125 ENGINE,
its basically a cg125 engine,so you need to get the cg125 gasket set for your year ,, the cutouts are different and block oil pathways properly so it doesn't pump out the ould breather ,also on the barrel lower gasket there should be on oil hole that activates a gallery to oil the rocker shaft,
check here-http://www.ebay.co.uk/itm/FULL-COMPLETE-GASKET-SET-FITS-HONDA-CG-125-E-T-BRAZIL-/390609103910?pt=UK_Motorcycle_Parts_13&hash=item5af21dec26..

also bought a cg125 gearbox and although third gear was one tooth larger it fit and worked perfectly.have some spares left over if needed.
ill txt you my number if you need help