Honda Cbr 400 Rr What Engine Can Be Fitted

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

Engine oil drain plug

Gearchange pedal bolt

Footrest and stand bolts

Engine mounting bolts

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 yoke) Rear axle nut

Brake caliper mounting bolts

Brake hose banjo bolts and caliper bleed valves Brake disc bolts Exhaust system bolts/nuts

3 If a torque wrench is available, use it along with the torque specifications at the beginning of this and other Chapters.

1 The engine must be completely cool for this maintenance procedure, so let the machine sit overnight before beginning.

2 Remove the spark plugs (see Section 5).

3 Remove the valve cover (see Chapter 2). The cylinders are identified by a number, and are numbered 1 to 4 from left to right.

4 Make a chart or sketch of all valve positions so that a note of each clearance can be made against the relevant valve.

5 Unscrew the timing inspection plug and the centre plug from the alternator cover on the right-hand side of the engine (see illustration). Discard the plug O-rings as new ones should be used. The engine can be turned using a 14 mm socket on the alternator rotor bolt and turning it in a clockwise direction only (see illustration). Alternatively, place the motorcycle on an auxiliary stand so that the rear wheel is off the ground, select a high gear and rotate the rear wheel by hand in its normal direction of rotation.

Check

6 Turn the engine until the line next to the T mark on the alternator rotor aligns with the notches in the timing inspection hole (see illustration). Note: Turn the engine in the normal direction of rotation (clockwise), viewed from the right-hand end of the engine. Now, check the position of the camshaft gears. If the 'IN' mark on the inlet camshaft gear and the 'EX' mark on the exhaust camshaft gear are aligned with the cylinder head surface with each mark the correct way up and on the outside of its respective gear, then no. 4 cylinder Is at TDC on the compression stroke (see illustration). If the 'IN' mark on the inlet camshaft gear and the 'EX' mark on the exhaust camshaft gear are aligned with the cylinder head surface with

Camshaft Cbr400

25.6a Turn the engine until the Tl mark (A) aligns with the static marks (B)

25.6b No. 4 cylinder positioned at TDC on the compression stroke

25.6a Turn the engine until the Tl mark (A) aligns with the static marks (B)

25.6b No. 4 cylinder positioned at TDC on the compression stroke

'StHX'jiU

Every 8000 miles (12,000 km) or 12 months 1.21

Camshaft Timing Honda Cbr Engine 400

25.6c No. 1 cylinder positioned at TDC on the compression stroke each mark upside down and on the inside of its respective gear, then no. 1 cylinder is at TDC on the compression stroke (see illustration). If the marks are not positioned as required for the cylinders being checked, turn the crankshaft through 360° (one complete turn).

7 With no. 4 cylinder at TDC on the compression stroke, the following valves can be checked:

a) No. 2, inlet b) No. 3, exhaust c) No. 4, inlet and exhaust

8 With no. 1 cylinder at TDC on the compression stroke, the following valves can be checked:

a) No. 1, inlet and exhaust b) No. 2, exhaust c) No. 3, inlet

9 Insert a feeler gauge of the same thickness as the correct valve clearance (see Specifications) between the cam base and follower of each valve and check that it is a firm sliding fit - you should feel a slight drag when the you pull the gauge out (see illustration). If not, use the feeler gauges to obtain the exact clearance. Note: The inlet and exhaust valve clearances are different. Record the measured clearance on the chart.

10 Rotate the crankshaft through 360° and measure the valve clearance of the remaining valves using the method described in Step 9. R models

11 Turn the engine until the line next to the

the exhaust valves for cylinders 1 and 3

25.9 Measure the valve clearance using a feeler gauge as shown

T mark on the alternator rotor aligns with the static timing mark, which is a notch in the inspection plug hole in the cover (see illustration 25.6a). Note: Turn the engine in the normal direction of rotation (clockwise), viewed from the right-hand end of the engine. Now, check the position of the camshaft gears - the 'IN' mark on the inlet camshaft gear and the 'EX' mark on the exhaust camshaft gear should be aligned with the cylinder head surface with each mark the correct way up and on the outside of its respective gear (see illustration). If the marks are not correctly positioned, turn the crankshaft through 360° (one complete turn).

12 With the engine in this position, the inlet valves for Nos. 2 and 4 cylinders can be checked.

13 Insert a feeler gauge of the same thickness as the correct valve clearance (see Specifications) between the cam base and follower of each valve and check that it is a firm sliding fit - you should feel a slight drag when the you pull the gauge out (see illustration 25.9). If not, use the feeler gauges to obtain the exact clearance. Note: The inlet and exhaust valve clearances are different. Record the measured clearance on the chart.

14 With the specified valves measured, rotate the crankshaft clockwise through 180° (half a turn) until the line next to the 'O' mark on the alternator rotor aligns with the static timing mark, and so that the 'E' mark on the exhaust camshaft gear aligns with the cylinder

the inlet valves for cylinders 1 and 3

25.11 Align the marks as shown and check the inlet valves for cylinders 2 and 4

head surface, with the mark the correct way up and on the outside of its gear (see illustration). The exhaust valves for Nos. 1 and 3 cylinders can be checked.

15 Rotate the crankshaft clockwise through another 180° (half a turn) until the line next to the 'T' mark on the rotor aligns with the static timing mark, and so that the 'IN' mark on the inlet camshaft gear and the 'EX' mark on the exhaust camshaft gear align with the cylinder head surface with each mark the wrong way up and on the inside of its respective gear (see illustration). The inlet valves for Nos. 1 and 3 cylinders can be checked.

16 Rotate the crankshaft clockwise through 180° (half a turn) until the line next to the 'O' mark on the alternator rotor aligns with the static timing mark, and so that the 'E' mark on the exhaust camshaft gear aligns with the cylinder head surface, with the mark the wrong way up and on the inside of its gear (see illustration). The exhaust valves for Nos. 2 and 4 cylinders can be checked.

Adjustment

17 When all clearances have been measured and charted, identify whether the clearance on any valve falls outside that specified. If it does, the shim between the follower and the valve must be replaced with one of a thickness which will restore the correct clearance.

18 Shim replacement requires removal of the camshafts (see Chapter 2). There is no need

the exhaust valves for cylinders 2 and 4

1.22 Every 8000 miles (12,000 km) or 12 months

25.19a Remove the follower ... 25.19b ... and either retrieve the shim from inside the follower...

25.19a Remove the follower ... 25.19b ... and either retrieve the shim from inside the follower...

25.20a The shim size should be marked on its face ...

25.20b ... but measure it anyway

25.19c ... or from the top of the valve, using either a magnet...

25.19d ... or a screwdriver with grease on it specified, subtract the measured clearance from the specified clearance then deduct the result from the original shim thickness. For example:

Sample calculation - inlet valve clearance too small

Clearance measured (A) - 0.08 mm Specified clearance (B) - 0.16 mm (0.13 to

0.19 mm) Difference (B - A) - 0.08 mm Shim thickness fitted - 2.475 mm Correct shim thickness required Is 2.475 -0.08 = 2.395 mm Note: If the required replacement shim is greater than 2.800 mm (the largest available), the valve is probably not seating correctly due to a build-up of carbon deposits and should be checked and cleaned or resurfaced as required (see Chapter 2).

22 If the valve clearance was greater then specified, subtract the specified clearance from the measured clearance, and add the result to the thickness of the original shim. For example:

Sample calculation - exhaust valve clearance too large

Clearance measured (A) - 0.35 mm Specified clearance (B) - 0.22 mm (0.19 to

0.25 mm) Difference (A - B) - 0.13 mm Shim thickness fitted - 1.975 mm Correct shim thickness required is 1.975 + 0.13 = 2.105 mm

23 Obtain the correct thickness shims from your dealer. Where the required thickness Is not equal to the available shim thickness, round off the measurement to the nearest available size. Shims are available in 0.025 mm Increments from 1.200 mm to 2.800 mm.

24 Obtain the replacement shim, then lubricate it with molybdenum disulphide oil (a 50/50 mixture of molybdenum disulphide grease and engine oil) and fit it into its recess in the top of the valve, with the size marking

25.19c ... or from the top of the valve, using either a magnet...

to remove both camshafts if shims from only one side of the engine need replacing.

19 With the camshaft removed, remove the cam follower of the valve in question using either a magnet or a pair of pliers (see illustration). Retrieve the shim from either the inside of the follower or pick it out of the top of the valve, using either a magnet, a small screwdriver with a dab of grease on it (the shim will stick to the grease), or a screwdriver and a pair of pliers (see illustrations). Do not allow the shim to fall into the engine.

20 The shim size should be stamped on its face, however, it is recommended that the

25.20a The shim size should be marked on its face ...

25.19d ... or a screwdriver with grease on it shim is measured to check that it has not worn. The size marking is in the form of a three figure number, eg 180 indicating that the shim is 1.800 mm thick (see illustrations). Where the number does not equal a shim thickness, it should be rounded up or down, eg 182 or 183 both indicate that the shim is 1.825 mm thick. Shims are available in 0.025 mm increments from 1.200 to 2.800 mm. The new shim thickness required can then be calculated as follows. Note: Always aim to get the clearance at the mid-point of the specified range.

21 If the valve clearance was less than

25.20b ... but measure it anyway

Every 8000 miles (12,000 km) or 12 months 1.23

25.24a Fit the shim with its size marking facing up ...

on each shim facing up (see illustration). Check that the shim is correctly seated, then lubricate the follower with molybdenum disulphide oil and install it onto the valve (see illustration). Repeat the process for any other valves until the

25.24b ... then install the follower

clearances are correct, then install the camshafts (see Chapter 2).

25 Rotate the crankshaft several turns to seat the new shim(s), then check the clearances again.

26 Install all disturbed components in a

Honda Cbr400rr Rings
25.26 Fit new O-rings onto the plugs

reverse of the removal sequence. Use new O-rings on the centre plug and the timing inspection plug and smear them and the plug threads with molybdenum disulphide oil (a 50/50 mixture of molybdenum disulphide grease and engine oil) (see illustration).

Every 12,000 miles (18,000 km) or 18 months

Carry out all the items under the 4000 mite (6000 km) check:

Caution: If the machine is continually 1 Remove the old air filter as described in ridden in continuously wet or dusty Section 8 and install a new one.

conditions, the filter should be renewed more frequently.

+3 0

Responses

  • Wilfredo
    Can i tdc with axle in honda?
    4 years ago
  • JOAN JANSSEN
    How do I align my crank valve on my CBR 400?
    10 months ago
  • fatima
    How do I set the timing on a CBR 400 and valve clearance gauge?
    10 months ago
  • TAPIO
    Is cbr 400 engine same as cbr600?
    9 months ago
  • ugo
    How does the clamps for the valve timing go and what way do the initials sit on a 400 CBR RR?
    8 months ago

Post a comment