1.

0 Induction System
1

N
2

N
3

N
N
2.0 Exhaust System
1

3
N
4
3.0 Cylinder Head
1

N
5

4.0 Cylinder-Bore-Stroke-Piston
1

5.0 Ignition
1

N
3


N
5

6.0 Crankcase
1

N
3

7.0 Clutch and Gearbox

4
 2006 Standards - DRAFT Changes in Blue
1.0 Induction System
Air Filters and Air Boxes
Motor must be equipped with either Air Filter or Airbox. Air Box Requirements may be imposed by
Local Track requirements. In cases where an Airbox is required they must have some form of filtration
and be commercially available for under $60 USD from the Track Operator or a supplier designated by
the Track Operator.

Fuel Pump
Fuel Pump(s) must be driven by pulse pressure in the motor, no Electronic Fuel Pumps. Dual Fuel
Pumps for Pumparound Carburetors allowed. Fuel Pump must be a seperate component from the
Carburetor.

Carburetor
Pumper Carburetors not allowed.
Pumparound Carburetors are allowed.
Any make/model of Float Bowl style carburetor allowed
Venturi Diameter not allowed to exceed 38.6 mm in diameter.
Using Inside calipers measure widest point downstream from slide.

Carburetor Boot
The stock 1999 CR125 30 Boot is recommended. As this part is is optimal from the factory and
measurements very subjective, there are no other restrictions on it.

For Seat Clearance Purposes, the RS125 Straight Boot is allowed. As a handicap the Stuffer Lobes of
the Straight Boot must be cut off flush with mounting surface and may not extend into Reedcage. This
will produce slightly less power then the 1999 CR125 Boot.

Reedcage and Reeds

Reeds are open. Carbontech Medium Reeds suggested for optimum performance.
Reedcage must be 1999 CR125 6-Petal Design. No material may be added.
Reed Stops must be 1999 CR125. Bending stops to fit into unaltered reed throat of crankcase allowed.
allowed. No removal of material from Reed Stops allowed.

2.0 Exhaust System

Pipe/Expansion chamber Max Circumference: 17-1/8 (440mm)
Pipe and exhaust flange is open to any manufacturer providing the maximum size of circumference of
any portion of the pipe is 17-1/8". (440 mm)
Measure largest diameter of the drum section (between convergence and divergence cones) with a
flexible tape measure. Pipes may have obstructions such as mouning flanges, metal tags, seams, or
weldments in the way. It is the racers obligation to assure there is an area where the circumference
can be measured by tech.

Silencer
Silencer should be a minimum of 10" long by 2-1/2" in diameter. Tracks that have noise emission
requirements shall provide any necessary supplemental rules for where noise abatement is required.
Exhaust Flange
Open

3.0 Cylinder Head

Cylinder Head Model
1998-1999 CR125 Cylinder Head only. This cylinder head has 5 holes for mounting studs in a
concentric circle.

Removal of motorcycle frame mounting lug is approved, not required.

Cooling spigots may be replaced with a substitute in the original location. One spigot may be plugged
for single water outlet.

Combustion Chamber Profile

Using approved Shockwave 99 CR125 Cylinder Head Gage, inspect Parabola of Chamber Dome and
Squish recess for apparent gaps greater the .005" deep. Competitor may clean off carbon build up
with abrasive pad. Spark Plug sealing surface must be above spark plug stem of gage.

Piston - Cylinder Deck Minimum is .020" (.50mm)

Rotate flywheel to bring piston close (to but no at) Top Dead Center. Set Depth Gage on Cylinder
Deck with edge facing down over piston. Rotate piston to TDC and past. Piston impact with gage
should not felt by inspector. - Alternate method (not preferrred) - measure depth at TDC with Depth
Gage.

Combustion Chamber Profile

Machining the cylinder head to meet the 11.0 cc requirement is allowed. The only stipulation is that
none of the combustion chamber (squish zone) may protrude below the sealing surface.

Cylinder Head Gasket thickness range - .008"-.012" (.20 - .30 mm)

Aftermarket Head Gaskets may be used.

Measure thickness of Head Gasket with calipers

4.0 Cylinder-Bore-Stroke-Piston
Cylinder must be unaltered 1999 CR125.

Exhaust Port - Cylinder top Minimum Distance: 1.145" (29.08 mm)

Note 1: This measurement is taken from the top of the cylinder to the exhaust port opening. It is not
intended to measure opening in relation to piston travel alone.

Note 2: Exhaust Valves may be plugged. Plug is a non-tech item. Plugs may have blades removed or
angled to blend flow into passage. In some cases the blades may appear to provide a false reading of
depth - this is OK as long as inspection does not indicate any grinding. CR125 Exhaust ports have a
height that is controlled by the machining operation of the Exhaust valve and is very accurate in
controlling port location.
Insert Approved Port Height Check Gage (1.140" Step) tool into Cylinder in line with Exhaust Port
Center. Inspect through Port - Gage end should not extend past Port Opening at edge. Check both
ports at highest points.

Stroke:2.149" (54.59 mm) maximum

Piston may rock on pin. Measure depths directly above pin. Measure Piston depth at TDC. Measure
Piston depth at BDC. Subtract TDC from BDC to get the stroke.

Bore: 2.129" (54.10 mm) Maximum

Measure with Inside Micrometer.

Cylinder Height Minimum: 3.305" (83.95mm)

Remove Cylinder and measure Base Surface to Head Surface with calipers.

Base Gasket Thickness: .010 - .030

Measure Base Gaskets

Port Inspection

Print the Port Template and use as a reference. If Ports appear substantially different the Tech
Inspector should follow up with a close inspection for any evidence of grinding to modify the port sizes.
Small differnces in sizes make very little difference in performance gains. Any DQ actions should be
based on obvious modification evidence.

Link to Port Map Template http://www.kartweb.com/Standards/125Stock/stock.jpg

Ancillaries
Studs Bolts and washers are non-tech.
Exhaust Flange is open.

Piston
Flat Top design only.
Distance from Piston Pin edge to top of Piston - .800 - .810" (20.32 mm - 20.57 mm)
Slide piston pin out of piston with 1/4" protruding. Measure depth from top of piston to pin top edge
with caliper slide.
Piston Ring Minimum Thickness: .038" (.96 mm)
Measure with calipers.

5.0 Ignition
Stock 1999 Honda CR125 Coil

Stock 1999 Honda CR125 Capacitive Discharge Ignition (CDI) System.

Denso Part Number 071000-1410 should be legible on Tag. CDI cannot be DQ'd over TAG legibility.
This only serves to validate component.

CDI Grid Swap

 The Tech Steward shall have the option to collect CDI Units between heats and redistribute them at
impound. This is at the Tech Stewrad/Promotors discretion. It is only recommended when some
motors sound to be revving a little higher then others, or needing less gearshifts on a given lap.

Stock 1999 Honda CR125 Flywheel and stator.

No material may be removed from Flywheel. Flywheel Key may not be machined to offset timing.
Stator may be mechanically advanced or retarded within the range of the factory Stator Plate. Stator
Plate cannot be altered to increase adjustment range.

Spark Plug and Ignition Wires are non-tech.

No additional components may be electrically connected to the CDI or Coil. Only an inductive RPM
sensor may be used

6.0 Crankcase
Kick Start Boss may be removed and plugged. The 5 horizontal RS Boot does not require the boss to
be removed to fit most carburetors.

Internal Crankcase modifications are not allowed. No excessive material removal or addition. Some
grinding of flash is be allowed not to exceed .04" in depth. (Some cases come with flash removed)

Inspect for obvious removal of material particulary beneath cylinder transfer ports.

Crankshaft must be OEM Honda CR125 any year. May be polished for slip fit of bearings. This does
not enhance performance but allows for easier assembly/disassembly. Precision alignment of crank is
allowed. No material may be added or removed from Crank Wheels or Rod.

Main Bearing Balls to be steel material.

Seals and gaskets are non-tech.

7.0 Clutch and Gearbox

Stock OEM Honda CR125 Clutch components only. All 7 Clutch Disks and 6 Clutch Plates must be
installed. Stock OEM 1999 CR125 Clutch Basket and Pressure Plate. Any Clutch Springs allowed.

Transmission Bearing Balls and Rollers to be steel material.

Micro-polishing of Gears allowed. There are no power gains with this treatment, and seldom any
performance gains. Occasionally Micro-polishing may help a solve a sticking gear problem that
normally corrects itself after a few hours of use.

Five or six gears are allowed. Gears are per the 1994-96 ratios as follows;
First - 14/33
Second - 15/28
Third - 19/29
Fourth - 21/27
Fifth - 23/26
Sixth - 24/24
 2005 Standards Superceded by 2006 Standards
1.0 Induction System
1 Air Filters and Air Boxes
Motor must be equipped with either Air Filter or Airbox. Air Box Requirements may be imposed by
Local Track requirements. In cases where an Airbox is required they must have some form of filtration
N and be commercially available for under $60 USD from the Track Operator or a supplier designated by
the Track Operator.

2 Fuel Pump
Fuel Pump(s) must be driven by pulse pressure in the motor, no Electronic Fuel Pumps. Dual Fuel
N Pumps for Pumparound Carburetors allowed. Fuel Pump must be a seperate component from the
Carburetor.

3 Carburetor
Pumper Carburetors not allowed.

N Pumparound Carburetors are allowed.

Any make/model of Float Bowl style carburetor allowed
Venturi Diameter not allowed to exceed 38.6 mm in diameter.
Using Inside calipers measure widest point downstream from slide.

4 Carburetor Boot
The stock 1999 CR125 30 Boot is recommended. As this part is is optimal from the factory and
measurements very subjective, there are no other restrictions on it.

N For Seat Clearance Purposes, the RS125 Straight Boot is allowed. As a handicap the Stuffer Lobes of
the Straight Boot must be cut off flush with mounting surface and may not extend into Reedcage. This
will produce slightly less power then the 1999 CR125 Boot.

5 Reedcage and Reeds

Reeds are open. Carbontech Medium Reeds suggested for optimum performance.
N Reedcage must be 1999 CR125 6-Petal Design. No material may be added.
N Reed Stops must be 1999 CR125. Bending stops to fit into unaltered reed throat of crankcase allowed.
allowed. No removal of material from Reed Stops allowed.
 2.0 Exhaust System
1 Pipe/Expansion chamber Max Circumference: 17-1/8 (440mm)
Pipe and exhaust flange is open to any manufacturer providing the maximum size of circumference of
any portion of the pipe is 17-1/8". (440 mm)
Measure largest diameter of the drum section (between convergence and divergence cones) with a
flexible tape measure. Pipes may have obstructions such as mouning flanges, metal tags, seams, or
weldments in the way. It is the racers obligation to assure there is an area where the circumference
can be measured by tech.

3 Silencer

N Silencer should be a minimum of 10" long by 2-1/2" in diameter. Tracks that have noise emission
requirements shall provide any necessary supplemental rules for where noise abatement is required.

3.0 Cylinder Head

1 Cylinder Head Model
1998-1999 CR125 Cylinder Head only. This cylinder head has 5 holes for mounting studs in a
concentric circle.

N Removal of motorcycle frame mounting lug is approved, not required.

Cooling spigots may be replaced with a substitute in the original location. One spigot may be plugged
for single water outlet.

2 Combustion Chamber Volume (CCV) Minimum 11.0 cc

Tilt motor to align spark plug hole perpendicular to ground. Bring piston to Top Dead Center. Install
Lad Tool. Fill Calibrated 20cc Glass Lab Burette with Marvel Mystery oil, bleed drip tube, and top up to
20cc mark. Drain 11.0 cc of oil - overflow not allowed. Use care when dispensing oil - this should be
done in under 30 seconds, yet not to exceed 11.0cc. Turn flywheel 90 to allow oil to drain into
exhaust port after checking.

3 Squish depth Minimum is .035" (.89mm)

Rotate flywheel to bring piston about 1/4" from Top Dead Center.Using Flux Core Tin-Lead solder
insert through spark plug hole with a 90 bend at 1.5" from end to point to left side of kart. (in line
with wrist pin). Rotate flywheel to force piston to crush solder 2 times. Withdraw solder and measure
thickness. Cut off crushed tip of solder and repeat on Squish Surface on right side.

4 Combustion Chamber Profile

Machining the cylinder head to meet the 11.0 cc requirement is allowed. The only stipulation is that
N none of the combustion chamber (squish zone) may protrude below the sealing surface.

5 Cylinder Head Gasket thickness range - .008"-.012" (.20 - .30 mm)

Aftermarket Head Gaskets may be used.

Measure thickness of Head Gasket with calipers

 4.0 Cylinder-Bore-Stroke-Piston
1 Cylinder must be unaltered 1999 CR125.

2 Exhaust Port - Cylinder top Minimum Distance: 1.145" (29.08 mm)

Note 1: This measurement is taken from the top of the cylinder to the exhaust port opening. It is not
intended to measure opening in relation to piston travel alone.

Note 2: Exhaust Valves may be plugged. Plug is a non-tech item. Plugs may have blades removed or
angled to blend flow into passage. In some cases the blades may appear to provide a false reading of
depth - this is OK as long as inspection does not indicate any grinding. CR125 Exhaust ports have a
height that is controlled by the machining operation of the Exhaust valve and is very accurate in
controlling port location.

Measuring the Exhaust Port distance uses a.094" diameter drill rod by 2.20" long. The length is critical
as it will control the insertion depth into the exhaust port.

Push piston down below Exhaust port open position. Lay.094" Drill Rod flat on piston - insert on end
in the exhaust port with the drill rod crossing the center of the piston and contacting the wall on the
other side. Raise piston until drill rod is stopped by port roof while keeping drill rod flat across piston.
Measure depth to piston with calipers. Deduct .094" from measurement. Repeat for right side exhaust
port.

3 Stroke:2.149" (54.59 mm) maximum

Piston may rock on pin. Measure depths directly above pin. Measure Piston depth at TDC. Measure
Piston depth at BDC. Subtract TDC from BDC to get the stroke.

4 Bore: 2.129" (54.10 mm) Maximum

Measure with Inside Micrometer.

5 Cylinder Height Minimum: 3.305" (83.95mm)

Remove Cylinder and measure Base Surface to Head Surface with calipers.

6 Base Gasket Thickness: .014 - .031

Measure Base Gaskets

7 Port Inspection

Print the Port Template and use as a reference. If Ports appear substantially different the Tech
Inspector should follow up with a close inspection for any evidence of grinding to modify the port sizes.
N Small differnces in sizes make very little difference in performance gains. Any DQ actions should be
based on obvious modification evidence.

Link to Port Map Template http://www.kartweb.com/Standards/125Stock/stock.jpg

8 Ancillaries
Studs Bolts and washers are non-tech.
Exhaust Flange is open.

9 Piston
Flat Top design only.
Distance from Piston Pin edge to top of Piston - .800 - .810" (20.32 mm - 20.57 mm)
Slide piston pin out of piston with 1/4" protruding. Measure depth from top of piston to pin top edge
with caliper slide.
Piston Ring Minimum Thickness: .038" (.96 mm)
Measure with calipers.
 5.0 Ignition
1 Stock 1999 Honda CR125 Coil

2 Stock 1999 Honda CR125 Capacitive Discharge Ignition (CDI) System.

Denso Part Number 071000-1410 should be legible on Tag. CDI cannot be DQ'd over TAG legibility.
N This only serves to validate component.

3 CDI Grid Swap

The Tech Steward shall have the option to collect CDI Units between heats and redistribute them at
impound. This is at the Tech Stewrad/Promotors discretion. It is only recommended when some
motors sound to be revving a little higher then others, or needing less gearshifts on a given lap.

4 Stock 1999 Honda CR125 Flywheel and stator.

No material may be removed from Flywheel. Flywheel Key may not be machined to offset timing.
N Stator may be mechanically advanced or retarded within the range of the factory Stator Plate. Stator
Plate cannot be altered to increase adjustment range.

5 Spark Plug and Ignition Wires are non-tech.

No additional components may be electrically connected to the CDI or Coil. Only an inductive RPM
6 sensor may be used

6.0 Crankcase
Kick Start Boss may be removed and plugged. The 5 horizontal RS Boot does not require the boss to
1
be removed to fit most carburetors.

Internal Crankcase modifications are not allowed. No excessive material removal or addition. Some
2
grinding of flash is be allowed not to exceed .04" in depth. (Some cases come with flash removed)

N Inspect for obvious removal of material particulary beneath cylinder transfer ports.
Crankshaft must be OEM Honda CR125 any year. May be polished for slip fit of bearings. This does
3 not enhance performance but allows for easier assembly/disassembly. Precision alignment of crank is
allowed. No material may be added or removed from Crank Wheels or Rod.

4 Main Bearing Balls to be steel material.

5 Seals and gaskets are non-tech.

7.0 Clutch and Gearbox

Stock OEM Honda CR125 Clutch components only. All 7 Clutch Disks and 6 Clutch Plates must be
1
installed. Stock OEM 1999 CR125 Clutch Basket and Pressure Plate. Any Clutch Springs allowed.

2 Transmission Bearing Balls and Rollers to be steel material.

Micro-polishing of Gears allowed. There are no power gains with this treatment, and seldom any
3 performance gains. Occasionally Micro-polishing may help a solve a sticking gear problem that
normally corrects itself after a few hours of use.

4 Five or six gears are allowed. Gears are per the 1994-96 ratios as follows;
First - 14/33
Second - 15/28
Third - 19/29
Fourth - 21/27
Fifth - 23/26
Sixth - 24/24
 1.0 Legacy Motors
Former Modified (SKUSA S1 Spec) Bottom Ends
Legacy Motors are defined as those with material added or removed from inside
the crankcase. Legacy motors that have been converted to stock configurations
may have some small gains or losses in performance depending on the
modification that has been done.
Competitor must declare that he/she is entering a Legacy Motor
Other Specifications same as 99 CR125
Legacy Motor Handicap - 10 lbs.

2.0 Non-Spec Motors

Alternate motors

A small number of Stock Motos exist that are not a 99 CR125 spec. Local markets
may want to offer the option of competition with these motors in their respective
Stock 125 Class to maintain larger race fields. To allow integration of these
motors, the following guidelines are suggested;

Yamaha offered a Kart Specific YZ125 Motor that includes an Ignition Curve
superior to the 99 CR125. Some specifications for this motor may differ from the
99 CR125. The following specifications are suggested for the YZ125.

CCV - 11.0cc

YZ125 Squish Minimum .040"

Exhaust Pipe Maximum Circumference - 15-5/8"

Carburetor - same as 99 CR125 Spec
Reeds and Reed Cage - Stock unaltered YZ125 Reeds and Cage
Ignition - OEM, non Programmable

Applies to 2000 and later Honda CR125 only. Models prior to 1999 should not be
acceptable. May have 6 - speed gearboxes.

CCV - 11.0cc

Cylinder Head - same as 99 CR125 except bolt pattern has two offset stud holes.

Exhaust Pipe Maximum Circumference - 15-5/8"

CR125
Carburetor - same as 99 CR125 Spec, except that Power Valve control from
Ignition CDI must be disabled.
Reeds and Reed Cage - same as 99 CR125 Spec

Ignition - OEM, non Programmable

Cylinder and Piston - same as 99 CR125 Spec
 1.0 Shifter Group 1
Premiere 125cc Class

This class combines both ICC and Modified Moto powerplants in an equitable manner
while keeping weights intact. Tech is maintained at a relatively simple level yet
incorporates the full variety of 125 Rules from various organizations.

Moto1, Moto2, ICC Weight = 385 lbs

CCV Minimum = 10.0 cc

Air Filter or 3 x 29mm Airbox with filter per local noise requirements
Moto 1 54.09 mm Bore X 54.59 mm Stoke maximum
Non-Tech; Ignition System, Induction System, Pipe, Gearbox
Silencer should be minimum 12" long X 2-1/2" diameter.

54.09 mm Bore X 54.59 mm Stoke maximum

Air Filter or 3 x 29mm Airbox with filter per local noise requirements
Pipe Circumference Maximum - 15-5/8"
Moto 2
54.09 mm Bore X 54.59 mm Stoke maximum
Non-Tech; CCV, Ignition System, Induction System, Gearbox
Silencer should be minimum 12" long X 2-1/2" diameter.

Tracks under 1.5 miles in length - 2 x 22mm Airbox

ICC Tracks over 1.5 miles in length - 2 x 29mm Airbox
Motor Specifications per CIK Homologation
 2.0 Shifter Group 2
Recreational 125cc Class Weights

Group 2 combines 125 Stock, 125 Heavy, and 80 Senior Sub-Classes

together to provide a full field. Local markets generally possess a
more dicverse range of skills then at the National level. The formula
to combine these classes is equitable although some tracks may favor
one or the other a little differently. Very similar to the TAG concept,
weight is used to adjust Sub-Classes.

Group 1 Same technical specifications as Group 1 425 Lbs

125 Stock Same technical specifications as 125 Stock. 385 Lbs

Same technical specifications as Local Option 385 Lbs

Local Option
125 395 Lbs
Local Option Legacy Motors

80cc Same technical specifications as SKUSA/IKF/WKA, Rear Brakes only 350 Lbs
Add 10 lbs for front Brakes 360 Lbs
 3.0 Proposed Shifter Group 3
Junior Shifter Class (Proposed for 2006) Weights

Group 3 is currently in the proposal phase for 2003. The concept is

based on offering a restricted 125cc Stock class to Junior Drivers and
merging the existing modified 80cc. The current modified 80cc package
is on the decline due to the costs of development and operation.
Feedback is encouraged.

Same technical specifications as National Level Standards only except

Carburetor.
Spec Carburetor; 30mm Dell'Orto, no pumparound. No grinding, tool
125 Stock marks or polishing allowed. 350 lbs
Note: Dell'Orto chosen as it does not need the extra expense of
Pumparound Conversion. My require simple manifold adaptor.
Note: Front Brakes are required.

80cc Same technical specifications as SKUSA/IKF/WKA, Rear Brakes only 330 lbs
Add 10 lbs for front Brakes 340 lbs
 Release History
Issue Change Summary Date
1 First Release May 30 2005