No fuel flow

Fuel tap filter or in-line filter clogged. Remove the tap and clean it and the filters (Chapter 4). Fuel line clogged. Pull the fuel line loose and carefully blow through it. Float needle valve clogged. For all of the valves to be clogged, either a very bad batch of fuel with an unusual additive has been used, or some other foreign material has entered the tank. Many times after a machine has been stored for many months without running, the fuel turns to a...

Instrument cluster and speedometer cable removal and Installation

Instrument cluster Removal - J and K models 1 Remove the fairing (see Chapter 8). 2 Unscrew the knurled ring securing the speedometer cable to the back of the speedometer and detach the cable (see illustration 15.12). 3 Disconnect the two black wiring connectors in the middle of the bracket above the headlights. 4 Displace the headlight relay (see 15.9b and remove the cluster, noting how it locates (arrowed) 15.12 Unscrew the ring (arrowed) and detach the cable 15.9a then unscrew the bolts...

Using a torque wrench

Check the calibration of the torque wrench and make sure it has a suitable range for the job. Torque wrenches are available in Nm (Newton-metres), kgf m (kilograms-force metre). Ibf ft (pounds-feet), Ibf in (inch-pounds). Do not confuse Ibf ft with Ibf in. Adjust the tool to the desired torque on the scale (see illustration 4.1). If your torque wrench is not calibrated in the units specified, carefully convert the figure (see Conversion Factors). A manufacturer sometimes gives a torque setting...

Ref28 Fault Finding

This Section provides an easy reference-guide to the more common faults that are likely to afflict your machine. Obviously, the opportunities are almost limitless for faults to occur as a result of obscure failures, and to try and cover all eventualities would require a book. Indeed, a number have been written on the subject. Successful troubleshooting is not a mysterious 'black art' but the application of a bit of knowledge combined with a systematic and logical approach to the problem....

Lower

8 If the level Is below the LOWER level line, remove the seat cowling (see Chapter 8). Unscrew the reservoir cover screws and remove the cover, diaphragm plate and diaphragm. 9 Top up with new DOT 4 hydraulic fluid, until the level is just below the UPPER level line. Do not overfill the reservoir, and take care to avoid spills (see Warning above). p Ensure that the diaphragm is correctly I U seated before installing the plate and cover. Tighten the cover screws securely, then install the seat...

Lights turn signals horn and reflector

With the ignition on, check the operation of the following electrical components. Note The electrical components on certain small-capacity machines are powered by the generator, requiring that the engine is run for this check. a) Headlight and tail light. Check that both illuminate in the low and high beam switch positions. b) Position lights. Check that the front position (or sidelight) and tail light illuminate in this switch position. c) Turn signals. Check that all flash at the correct...

S

SAE (Society of Automotive Engineers) A standard for the viscosity of a fluid. Sealant A liquid or paste used to prevent leakage at a joint. Sometimes used in Service limit Term for the point where a component is no longer useable and must be Shaft drive A method of transmitting drive from the transmission to the rear wheel. Shell bearings Plain bearings consisting of two shell halves. Most often used as big-end and main bearings in a four-stroke engine. Often called bearing inserts. Shim Thin...

REF8 Tools and Workshop Tips

2.21 Comparison of surface drive ring spanner (left) with 12-point type (right) 2.23 A thread repair tool being used to correct an external thread 2.27 tap a new thread 2.28 fit insert on the installing tool 2.26 To install a thread insert, first drill out the original thread 2.29 and thread into the component A dab of valve grinding compound between the screw head and screwdriver tip will often give a good grip. 2.30 break off the tang when complete insert on the installing tool and thread it...

Dial gauge or DTI Dial Test Indicator

A dial gauge can be used to accurately measure small amounts of movement. Typical uses are measuring shaft runout or shaft endfloat (sideplay) and setting piston position for ignition timing on two-strokes. A dial gauge set usually comes with a range of different probes and adapters and mounting equipment. The gauge needle must point to zero when at rest. Rotate the ring around its periphery to zero the gauge. Check that the gauge is capable of reading the extent of movement in the work. Most...

Breaking and joining final drive chains

Drive chains for all but small bikes are continuous and do not have a clip-type connecting link. The chain must be broken using a chain breaker tool and the new chain securely riveted together using a new soft rivet-type link. Never use a clip-type connecting link instead of a rivet-type link, except in an emergency. Various chain breaking and riveting tools are available, either as separate tools or combined as illustrated in the accompanying photographs - read the instructions supplied with...

Getting back on the road

Change the oil and replace the oil filter. If this was done prior to storage, check that the oil hasn't emulsified - a thick whitish substance which occurs through condensation. Remove the spark plugs. Using a spout-type oil can, squirt a few drops of oil into the cylinder(s). This will provide initial lubrication as the piston rings and bores comes back into contact. Service the spark plugs, or fit new ones, and install them in the engine. Check that the clutch isn't stuck on. The plates can...

What is torque

9 Torque describes the twisting force about a shaft. The amount of torque applied is determined by the distance from the centre of the shaft to the end of the lever and the amount of force being applied to the end of the lever distance multiplied by force equals torque. The manufacturer applies a measured torque to a bolt or nut to ensure that it will not slacken in use and to hold two components securely together without movement in the joint. The actual torque setting depends on the thread...

Instrument and warning light bulbs renewal

1 Remove the fairing (see Chapter 8). 2 Some of the bulbs are accessible with the instrument cluster in place, but access to others is quite restricted. If it is too restricted for the bulb you are changing, displace the instrument cluster (see Section 15) to improve access - there is no need to disconnect any of the wiring connectors, though it may be necessary to disconnect the speedometer cable, depending on which bulb Is being renewed. 3 Gently pull the bulbholder out of the back of the...

Check

1 In order to determine conclusively that the ignition coils are defective, they should be tested by a dealer equipped with the special diagnostic tester. 2 However, the coils can be checked visually (for cracks and other damage) and the primary and secondary coil resistance can be measured with a multimeter. If the coils are undamaged, and if the resistance readings are as specified at the beginning of the Chapter, they are probably capable of proper operation. 3 On J and K models, remove the...

Throttle Cable Routing Cbr 400

10.8b and install the float assembly -L, N and R models shown Fit a new gasket into the groove and install the float chamber install the chamber onto the carburettor (see illustrations). 11 On J and K models, if removed, fit the washer onto the jet needle and insert the needle into the piston (see illustration 8.5c). Fit the retainer and spring into the piston, then push down on it using a Phillips screwdriver and rotate it until its tab locks under the protrusion in the piston (see...

Checking engine compression

Screw the compression gauge adapter into the spark plug hole, then screw the gauge into the adapter Low compression will result in exhaust smoke, heavy oil consumption, poor starting and poor performance. A compression test will provide useful information about an engine's condition and if performed regularly, can give warning of trouble before any other symptoms become apparent. A compression gauge will be required, along with an adapter to suit the spark plug hole thread size. Note that the...

Handlebar hard to turn

Steering head bearing adjuster nut too tight. Check adjustment as described in Chapter 1. Bearings damaged. Roughness can be felt as the bars are turned from side-to-side. Renew bearings (Chapter 6). Races dented or worn. Denting results from wear in only one position (eg, straight ahead), from a collision or hitting a pothole or from dropping the machine. Renew bearings (Chapter 6). i Steering stem lubrication inadequate. Causes are grease getting hard from age or being washed out by high...

H31136

7.4 Rear brake caliper components - J and K type shown 18 Install the caliper mounting bolt, and tighten It to the torque setting specified at the beginning of the Chapter (see illustrations). 19 If removed, connect the brake hose to the caliper, using new sealing washers on each side of the fitting. Align the hose as noted on removal (see illustration 7.2). Tighten the banjo bolt to the torque setting specified at the beginning of the Chapter. Top up the master cylinder reservoir with DOT 4...

Removal and installation

1 Remove the rider's seat (see Chapter 8). 2 Release the battery strap, and on J and K models remove the battery cover (see illustrations). 3 Unscrew the negative (-ve) terminal bolt first and disconnect the lead from the battery (see illustration). Lift up the red insulating cover to access the positive (+ve) terminal, then unscrew the bolt and disconnect the lead. Lift the battery from the bike (see illustration). 4 On installation, clean the battery terminals and lead ends with a wire brush...

Tool

A clutch centre holding tool can easily be made using two strips of steel bent over at the ends and bolted together in the middle 16.11 Draw the housing off the shaft 16.9 Grasp the pressure plate and clutch centre and draw the assembly off 16.13 Measuring clutch friction plate thickness 8 Unscrew the clutch nut and remove the Belleville washer from the shaft, noting which way round it fits. On R models, also remove the thrust washer, again noting which way round it fits. Discard the nut as a...

Repair and overhaul tools

1 Torque wrench (small and mid-ranges) 2 Conventional, plastic or soft-faced hammers 1 Torque wrench (small and mid-ranges) 2 Conventional, plastic or soft-faced hammers 5 Circlip pliers (internal and external, or combination) 6 Set of punches and cold chisels 9 Chain breaking riveting tool 11 Multimeter (measures amps, volts and ohms) 12 Stroboscope (for dynamic timing checks) 13 Hose clamp (wingnut type shown) 14 Magnetic arm (telescopic type shown) 15 One-man brake clutch bleeder kit

Clutch not disengaging completely

Check and adjust (Chapter 1). Clutch plates warped or damaged. This will cause clutch drag, which In turn will cause the machine to creep. Overhaul the clutch assembly (Chapter 2). Clutch spring tension uneven. Usually caused by a sagged or broken spring. Check and renew the springs as a set (Chapter 2). Engine oil deteriorated. Old, thin, worn out oil will not provide proper lubrication for the plates, causing the clutch to drag. Renew the oil and filter...

Side Rails

4 The main bearing shells can be removed from the crankcase halves by pushing their centres to the side, then lifting them out (see illustration). Keep the shells In order. 5 Clean the crankshaft with solvent, using a rifle-cleaning brush to scrub out the oil passages. If available, blow the crank dry with compressed air, and also blow through the oil passages. Check the primary drive gear and the camshaft drive gear for wear or damage. If any of the gear teeth are excessively worn, chipped or...

General information and precautions

1 If the performance of the charging system is suspect, the system as a whole should be checked first, followed by testing of the individual components. Note Before beginning the checks, make sure the battery is fully charged and that all system connections are clean and tight. 2 Checking the output of the charging system and the performance of the various components within the charging system requires the use of a multimeter (with voltage, current and resistance checking facilities). 3 When...

Sae10w40

A Unscrew the oil filler cap (arrowed) from the right-hand crankcase I cover. The dipstick is integral with the oil filler cap, and is used to check the engine oil level. 2 Using a clean rag or paper towel, wipe off all the oil from the dipstick. Insert the clean dipstick back into the engine, but do not screw it in. A Unscrew the oil filler cap (arrowed) from the right-hand crankcase I cover. The dipstick is integral with the oil filler cap, and is used to check the engine oil level. 3 Remove...

Info

5.1 Front brake master cylinder components 5.3 Slacken the two reservoir cover screws 5.3 Slacken the two reservoir cover screws 2 Before disassembling the master cylinder, read through the entire procedure and make sure that you have obtain all new parts required. Also, you will need some new DOT 4 brake fluid, some clean rags and internal circlip pliers. Note If the master cylinder is just being displaced and not completely removed or overhauled, do not disconnect the brake hose or drain the...

Removal

1 Remove the engine (see Section 5) and separate the crankcase halves (see Section 21). The selector drum and forks are located in the lower crankcase half. 2 If not already done, remove the gearchange mechanism (see Section 20). 3 Before removing the selector forks, note that each fork is lettered for identification. The right-hand fork has an R. the centre fork a C, and the left-hand fork an L (see illustration). These letters face the right-hand side of the engine. If no letters are visible,...

Xdo

Note The original equipment drive chain fitted to these models has a staked-type master (joining) link which can be disassembled using either Honda service tool, Pt. No. 07HMH-MR10100 for J and K models. 07HMH-MR10101 for L and N models or 07HMH-MR10102 for R models, or one of several commercially-available drive chain cutting staking tools. Such chains can be recognised by the master link side plate's identification marks (and usually its different colour), as well as by the staked ends of the...

Charger

4.2 If the charger doesn't have ammeter built in, connect one in series as shown. DO NOT connect the ammeter between the battery terminals or it will be ruined Reconnect the leads, connecting the negative (-ve) terminal last, and apply a thin coat of petroleum jelly to the connections to slow further corrosion. 8 The battery case should be kept clean to prevent current leakage, which can discharge the battery over a period of time (especially when it sits unused). Wash the outside of the case...

No spark or weak spark

Engine kill switch turned to the OFF position. Battery voltage low. Check and recharge the battery as necessary (Chapter 9). Spark plugs dirty, defective or worn out. Locate reason for fouled plugs using spark plug condition chart at the end of this manual and follow the plug maintenance procedures (Chapter 1). Spark plug caps or secondary (HT) wiring faulty. Check condition. Renew if cracks or deterioration are evident (Chapter 5). Spark plug caps not making good contact. Make sure that the...

Cbb

1 The battery provides power for operation of the headlight, tail light, brake light and instrument cluster lights. If none of the lights operate, always check battery voltage before proceeding. Low battery voltage indicates either a faulty battery or a defective charging system. Refer to Section 3 for battery checks and Sections 30 and 31 for charging system tests. Also, check the condition of the fuses. 2 If the headlight (HI or LO beam) fails to work, first check the fuse with the key ON...

Hed

Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. 1 Unscrew the pad retaining pin plug and the pad retaining pin, then unscrew the caliper mounting bolt (see illustrations). 2 Swing the caliper up at the back and slide out the pads (see illustration). Where fitted, remove the shims from the back of the pads, noting how they fit. 3 Inspect the surface of each pad for contamination and check that...

Inspection

5 Remove the dowels, then remove the screws securing the pump cover to the body and separate them (see illustration). 6 Withdraw the pump driveshaft along with the inner rotor, then remove the outer rotor from the pump body (see illustration). Retrieve the thrust washer if it isn't with the shaft. Note how the pin locates through the shaft and in the notches in the inner rotor, and how the punch mark on the outer rotor faces the pump cover. Clean all the components In solvent. 7 Inspect the...

Front end noise

Low fluid level or improper viscosity oil in forks. This can sound like spurting and is usually accompanied by irregular fork action (Chapter 6). Spring weak or broken. Makes a clicking or scraping sound. Fork oil, when drained, will have a lot of metal particles in it (Chapter 6). Steering head bearings loose or damaged. Clicks when braking. Check and adjust or renew as necessary (Chapters 1 and 6). Fork yokes loose. Make sure all clamp pinch bolts are tightened to the specified torque...

Fault Finding Equipment ref37

The ignition switch ON open the throttle fully and crank the engine over on the starter motor for a couple of revolutions until the gauge reading stabilises. If the starter will not operate with the kill switch OFF, turn the ignition switch OFF and refer to the next paragraph. 5 Install the spark plugs back into their suppressor caps and arrange the plug electrodes so that their metal bodies are earthed (grounded) against the cylinder head this is essential to prevent damage to the ignition...

Righthand handlebar

1 Disconnect the brake light switch wires from the switch on the underside of the master cylinder assembly. Unscrew the two handlebar switch screws and free the switch from the handlebar (see illustration). Unscrew the two throttle cable housing screws and release the throttle cables from the throttle pulley (see illustration). Position 3.10 Slacken the locknuts (A), then unscrew the linkage rod (B) it from the lever and the arm (the rod is reverse-threaded on one end and so will simultaneously...

Haynes

Rotate the crankshaft until the inner pistons are uppermost and feed them into the block first. This makes access to the lower pistons easier when compressing the rings and feeding them into the bores. 14.5 and remove the block 14.11 Lower the block and feed the pistons and rings into the little at a time, making sure the assembly is being drawn squarely down onto the dowels as the gears mesh fully. Install and tighten the cylinder block bolt, using a new sealing washer if required (see...

Torque Setting For Brake Discs Cbr 400

3.6 Remove the dust seal with a plastic or wooden tool (a pencil works well) to avoid damage to the bore and seal groove A Warning Never place your fingers in front of the pistons in an attempt to catch or protect them when applying compressed air, as serious injury could result. 6 Using a wooden or plastic tool, remove the dust seals from the caliper bores (see illustration). Discard them as new ones must be used on installation. If a metal tool is being used, take great care not to damage the...

Technical Terms Explained refmi

Decarbonisation The process of removing carbon deposits - typically from the combustion chamber, valves and exhaust port system. Detonation Destructive and damaging explosion of fuel air mixture in combustion chamber instead of controlled burning. Diode An electrical valve which only allows current to flow in one direction. Commonly used in rectifiers and starter interlock systems. Disc valve (or rotary valve) A induction system used on some two-stroke engines. Double-overhead camshaft (DOHC)...

Routine maintenance and servicing

Air filter - renewal Battery - charging see Chapter 9 Battery - Battery - removal, installation and inspection see Chapter 9 Brake caliper seals and master cylinder seal renewal 28 Brakes - fluid change Brake hoses - renewal Brake pads - wear check 3 Brake system - Carburettors - Clutch - check and adjustment 4 Cooling system - check Cooling system - draining, flushing and refilling 27 Cylinder compression - check 31 Drive chain and sprockets - check, adjustment and Engine oil pressure - check...

Cbr 400rr Temp Gauge Reading

5 Installation is the reverse of removal. Make sure the hoses are correctly installed and secured with their clamps. On completion refill the reservoir as described in Chapter 1. 3.4 noting how the lug (arrowed) locates 3.2 Detach the breather hose (A) and the overflow hose (B), then unscrew the bolt (C) and remove the reservoir 3.4 noting how the lug (arrowed) locates 4.3a Release the hose from its clip 4.3b then unscrew the lower mounting bolt(s) and swing the radiator forward 4.3c and...

How To Disable The Rev Limiter On A Kawasaki Zzr1100

Once you have found all the identification numbers, record them for reference when buying parts. Since the manufacturers change specifications, parts and vendors (companies that manufacture various components on the machine), providing the ID numbers is the only way to be reasonably sure that you are buying the correct parts. Whenever possible, take the worn part to the dealer so direct comparison with the new component can be made. Along the trail from the manufacturer to the parts shelf,...

Cbr400rr Fuel On Res Position

Models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details. 1 General information and precautions The fuel system consists of the fuel tank, fuel tap, filters, fuel pump and relay, carburettors, fuel hoses and control cables. There are two fuel filters, one is fitted inside the fuel tank and is part of the tap, and the other is in the fuel line to the pump. The carburettors used on all models are CV types. On all models...

Cbr Bike In Japan 650cc

There is no better example of the Japanese post-War industrial miracle than Honda. Like other companies which have become household names, it started with one man's vision. In this case the man was the 40-year old Soichiro Honda who had sold his piston-ring manufacturing business to Toyota in 1945 and was happily spending the proceeds on prolonged parties for his friends. However, the difficulties of getting around in the chaos of post-War Japan irked Honda, so when he came across a job lot of...

Motorcycle Headlight And Sidelight Wiring

Always use a paper towel or dry cloth when handling new bulbs to prevent injury if the bulb should break and to increase bulb life. 7.1a Disconnect the wiring connector 7 Headlight bulbs and sidelight bulbs - renewal Note The headlight bulbs are of the quartz-halogen type. Do not touch the bulb glass as skin acids will shorten the bulb's service life. If the bulb is accidentally touched, it should be wiped carefully when cold with a rag soaked in methylated spirit and dried before fitting. A...

Steering

10.4a Remove the upper mounting bolt arrowed 10.4b and lift the shock out of the frame 10.3b Shock absorber lower mounting bolt arrowed - L, N and R models 10.4a Remove the upper mounting bolt arrowed 7 Inspect the pivot hardware at the top and bottom of the shock for wear or damage. 8 On L, N and R models, withdraw the inner sleeve from the shock absorber lower mounting see illustration . Inspect the sleeve, bearing and dust seals for signs of wear and renew worn components as necessary. The...

Breaking a sealed joint

Age, heat, pressure and the use of hard setting sealant can cause two components to stick together so tightly that they are difficult to separate using finger pressure alone. Do not resort to using levers unless there is a pry point provided for this purpose see illustration 7.1 or else the gasket surfaces will be damaged. Use a soft-faced hammer see illustration 7.2 or a wood block and conventional hammer to strike the component near the mating surface. Avoid hammering against cast...

Checking the earth ground

Earth connections are made either directly to the engine or frame such as sensors, neutral switch etc. which only have a positive feed or by a separate wire into the earth circuit of the wiring harness. Alternatively a short earth wire is sometimes run directly from the component to the motorcycle's frame. Corrosion is often the cause of a poor earth connection. If total failure is experienced, check the security of the main earth lead from the negative -ve terminal of the battery and also the...

Carburetor Float Needle Cbr 400 Rr

To record the pilot screw's current setting, turn the screw in until it seats lightly, counting the number of turns necessary to achieve this, then fully unscrew it. On installation, the screw is simply backed out the number of turns you've recorded. 8.6b and use it to pull the retainer out fits inside the holder. Push the needle up from the bottom of the piston and withdraw it from the top see illustration 10.12a . Note the washer that fits between the head of the needle and the piston....

Coolant temperature gauge

Replacement - J and K models 30 Remove the instrument cluster see Section 15 . 31 Remove the screw securing each wiring connector, making a note of which fits where see illustration . 32 Carefully pull the light bulbholder out of the back of the temperature gauge see illustration 16.31 . 33 Remove the two nuts and their washers securing the temperature gauge to the bracket and carefully withdraw the gauge from the front see illustration 16.31 . 34 Installation is the reverse...

Honda 07501-4220100

1 The hoses will in time deteriorate with age and should be renewed regardless of their apparent condition. 2 Refer to Chapter 7 and disconnect the brake hoses from the master cylinders and calipers. Always renew the banjo union sealing washers. A Warning Petrol gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. Don't smoke or allow open flames or bare light bulbs near the work area, and don't work in a garage where a natural gas-type...

Cb400rr Coolant Flush

Place a suitable container below the water pump to catch any residual oil as the water pump is removed. 5 To remove the pump cover, unscrew the 8.2 Check the drain hole arrowed for evidence of leakage 8.2 Check the drain hole arrowed for evidence of leakage 8.5a Water pump cover bolts arrowed 8.5b Water pump cover bolts arrowed and hoses - J and K models and hoses - L, N and R models 8.5a Water pump cover bolts arrowed 8.5b Water pump cover bolts arrowed and...

Speedometer cable

11 Remove the fairing see Chapter 8 . 12 Unscrew the knurled ring securing the speedometer cable to the back of the speedometer and detach the cable see illustration . 13 Remove the screw securing the lower end of the cable to the drive housing on the front sprocket cover and detach the cable see illustration . 15.13 Remove the screw arrowed and detach the cable 15.5a then unscrew the bolts arrowed 15.8 Disconnect the wiring connectors illustration 6.3a . Unscrew the bolt securing the wiring...

Cbr 400 Pulse Crank

Note Models are identified by their production code letter - refer to 'Identification numbers' at the front of this manual for details. General information Cylinder numbering from left-hand to right-hand side of the bike 1-2-3-4 Full advance J and K models L, N and R models Resistance 340 to 420 ohms 20C Secondary winding resistance with plug caps and leads Note Where a specified setting is not given for a particular bolt, the general settings listed at the beginning apply. The dimension given...

Installing Camshafts On Honda Cbr 400rr

Cbr 400 Timing Cames

Before renewing camshafts or holders because of damage, check with local machine shops specialising in motorcycle engine work. In the case of the camshafts, it may be possible for cam lobes to be welded, reground and hardened, at a cost far lower than that of a new camshaft. If the bearing surfaces in the holders are damaged, it may be possible for them to be bored out to accept bearing inserts. Due to the cost of new components it is recommended that all options be explored. 9.10 Measure the...

Installation

8 Check that the mating surfaces of the cylinder block and crankcase are free from oil or pieces of old gasket. If removed, fit the dowels into the crankcase. 9 Remove the rags from around the pistons, and lay the new base gasket in place on the crankcase making sure all the holes are correctly aligned. Never re-use the old gasket. 10 If required, install piston ring clamps onto the pistons to ease their entry into the bores as the block is lowered. This is not essential as each cylinder has a...

Fuelair mixture incorrect

Dirt, water and other contaminants can clog the main jets. Clean the fuel tap filter, the fuel pump in-line filter, the float chamber area and the jets and carburettor orifices Chapter 4 . Main jet wrong size. The standard jetting is for sea level atmospheric pressure and oxygen content. Air filter clogged, poorly sealed or missing Chapter 1 . Air filter housing poorly sealed. Look for cracks, holes or loose clamps and renew or repair. Fuel level too low. Check float height...

Bottle Brush Hone For Motorcycle

Refer to Tools and Workshop Tips for details of installing a thread insert and using screw extractors. 7 Install all components and assemblies, referring to the relevant Sections of this Chapter and to Chapters 9 and 3, before reassembling the crankcase halves. 8 Do not attempt to separate the cylinder liners from the cylinder block. 9 Check the cylinder walls carefully for scratches and score marks. 10 Using a precision straight-edge and a feeler gauge set to the warpage limit listed in the...

Honda Cbr 400 Bearing Shells

Connecting Rod Side Clearance

On L, N and R models, to ease removal of the pistons, remove any ridge of carbon built up on the top of each cylinder bore. If there is a pronounced wear ridge, remove it using a ridge reamer. Caution Do not try to remove the piston connecting rod from the bottom of the cylinder bore. The piston will not pass the crankcase main bearing webs. If the piston is pulled right to the bottom of the bore the oil control ring will expand and lock the piston in position. If this happens it is likely the...

Refer to Chapter 1 for spark plug maintenance

Normal condition - A brown, tan or grey firing end indicates that the engine is in good condition and that the plug type is correct Ash deposits - Light brown deposits encrusted on the electrodes and insulator, leading to misfire and hesitation. Caused by excessive amounts of oil in the combustion chamber or poor quality fuel oil Normal condition - A brown, tan or grey firing end indicates that the engine is in good condition and that the plug type is correct Ash deposits - Light brown deposits...

Cbr 400 Rr Water Joint

Note It is antisocial and illegal to dump oil down the drain. To find the location of your local oil recycling bank, call this number free. 8.7 On L, N and R models, locate the inlet tabs on the air duct lugs arrowed 8.3d Removing the element-L, N and R models 8.4 Direct the air from the inside out 8.7 On L, N and R models, locate the inlet tabs on the air duct lugs arrowed 8.3d Removing the element-L, N and R models 1.12 Every 4000 miles 6000 km or 6 months 10.6a Pressure cap arrowed -J and K...

J and K models

1 Make sure the transmission is in neutral. Remove the clutch and the oil pump drive sprocket and chain see Section 16 . 2 Unscrew the gearchange lever linkage arm pinch bolt and remove the arm from the shaft, noting the alignment punch marks see illustration 20.22 . If no marks are visible, make your own before removing the arm so that it can be correctly aligned with the shaft on Installation. 19.18b then apply a thread-lock to the bolt 3 Wrap some insulating tape around the gearchange shaft...

Gear Assembly Honda Cbr400

Cbr 400 Cylinder Block

Check for proper sealing of the valves by pouring a small amount of solvent into each of the valve ports. If the solvent leaks past any valve into the combustion chamber area the valve grinding operation on that valve should be repeated. illustration . Compress the spring with the valve spring compressor and install the collets see illustration . When compressing the spring, depress it only as far as is absolutely necessary to slip the collets into place. Make certain that the collets are...

How To Set A Cbr 400 Damper Pre Load

Use a ratchet-type tool when installing the fork top bolt. This makes it unnecessary to remove the tool from the bolt whilst threading it in making it easier to maintain a downward pressure on the spring. bolt to engage the threads of the top bolt with the fork tube. This is a potentially dangerous operation and should be performed with care, using an assistant if necessary. Wipe off any excess oil before starting to prevent the possibility of slipping. Keep the fork tube fully extended whilst...

How To Assemble Honda Cbr 400 Fork

Freeplay in the fork due to worn fork bushes can be misinterpreted for steering head bearing play - do not confuse the two. 21.5 Unscrew the fork clamp bolts arrowed 3 Point the front wheel straight-ahead and slowly move the handlebars from side-to-side. Any dents or roughness in the bearing races will be felt, and if the bearings are too tight the bars will not move smoothly and freely. If the bearings are damaged or the action is rough, they should be renewed see Chapter 6 . If the bearings...

Honda Cbr 400 Rr What Engine Can Be Fitted

Honda Cbr400rr Rings

1 Since vibration of the machine tends to loosen fasteners, all nuts, bolts, screws, etc. should be periodically checked for proper tightness. 2 Pay particular attention to the following Spark plugs Shock absorber and suspension linkage bolts and swingarm pivot bolts Handlebar clamp bolts Front axle bolt and axle clamp bolts Front fork clamp bolts top and bottom Brake hose banjo bolts and caliper bleed valves Brake disc bolts Exhaust system bolts nuts 3 If a torque wrench is available, use it...