How To Replace Timing Belts On A Cbr 250

3 mm

MATERIAL THICKNESS: 1.0 mm 4.5 mm

Check the valve clearance for the No.1 and No.3 cylinder intake valves using a feeler gauge.

Insert the feeler gauge between the valve lifter and the cam lobe.

Valve clearance: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in)

NOTE_

• Record the clearance for each valve in case shim selection is required for adjustment.

Cbr 600f Rotor Pulse

Turn the crankshaft clockwise 1/2 turn (180°) and make sure the index line on the ignition pulse generator rotor is facing straight up as shown (not aligned with the index mark).

Check the valve clearance for the No.2 and No.4 cylinder exhaust valves using a feeler gauge.

Valve clearance: EX: 0.22 ± 0.03 mm (0.009 ± 0.001 in)

Timing Marks Cbr 600

(2) INDEX MARK

(3) TIMING MARKS

Suzuki Bandit 250 Gsf Timing Marks

(2) INDEX MARK

(3) TIMING MARKS

,(2) STOPPER TOOL

(1) SEALING BOLT/ WASHER

Hero Honda Valve Timing Setting

SHAFT

,(2) STOPPER TOOL

(1) SEALING BOLT/ WASHER

SHAFT

Turn the crankshaft clockwise 1/2 turn (180°) and make sure the T mark (notch mark) on the ignition pulse generator rotor aligns with the index mark.

Check the valve clearance for the No.2 and No.4 cylinder intake valves using a feeler gauge.

Valve clearance: IN: 0.16 ± 0.03 mm (0.006 ± 0.001 in)

Turn the crankshaft clockwise 1/2 turn (180°) and make sure the index line on the ignition pulse generator rotor is facing straight up as shown (not aligned with the index mark).

Check the valve clearance for the No. 1 and No.3 cylinder exhaust valves using a feeler gauge.

Valve clearance: EX: 0.22 ± 0.03 mm (0.009 ± 0.001 in)

ADJUSTMENT

Remove the camshafts (page 8-5). Remove the valve lifters and shims.

NOTE

Camshaft Valve Assembly Point Vmax 1200

• Shims may stick to the inside of the valve lifter. Do not allow the shims to fall into the crankcase.

• Mark all valve lifters and shims to ensure correct reassembly in their original locations.

• The valve lifter can be easily removed with a valve lapping tool or magnet.

• The shims can be easily removed with tweezers or a magnet.

Clean the valve shim contact area in the valve lifter with compressed air.

Measure the shim thickness and record it.

• Sixty-five different shim thicknesses are available: from 1.200 mm to 2.800 mm in intervals of 0.025 mm.

Calculate the new shim thickness using the equation below.

A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness

(2) INDEX MARK

1996 Katana 600 Timing Marks

(2) INDEX MARK

(1) VALVE LIFTER

Example:

Recorded valve clearance: 0.16 mm Old shim thickness: 1.725 mm Specified valve clearance: 0.20 mm

NOTE

• Verify the new shim thickness by measuring it with a micrometer.

• Reface the valve seat if a carbon deposit results in a calculated dimension of over 2.800 mm.

• If the valve seat must be refaced, re-calculate the shim thickness AFTER refacing.

Install the new shim on the valve retainer. Apply molybdenum disulfide oil to the valve lifters. Install the valve lifter in the valve lifter holes.

NOTE_

• Install unchanged shims and valve lifters in their original locations.

Install the camshaft and camshaft holders (page 8-21).

Rotate the camshafts by rotating the crankshaft clockwise several times.

Recheck the valve clearance. Remove the stopper tool.

Install the new sealing washer and cam chain tensioner sealing bolt.

Tighten the bolt securely.

Install the removed parts in the reverse order of removal.

Check that the O-ring is in good condition, replace if necessary.

Apply grease to the ignition pulse generator cover cap threads, install and tighten the cap.

Cbr 250 Pulse GeneratorValve Lifter Attachement Tweezers

(2) VALVE LIFTER

(2) Jjt^ SEALING WASHER

Cbr 600f Cam Chain Adjuster

(1) CAM CHAIN TENSIONER

(2) Jjt^ SEALING WASHER

(1) CAM CHAIN TENSIONER

Honda Cbr 1100 Cam Marks

ENGINE OIL/OIL FILTER

OIL LEVEL INSPECTION

h warning

• If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.

Start the engine and let it idle for 2 - 3 minutes. Stop the engine and wait 3 minutes.

Remove the dipstick and wipe the oil from the dipstick with a clean cloth.

With the motorcycle upright on level ground, insert the dipstick into the stick hole without screwing it in. Remove the dipstick and check the oil level.

If the level is below or near the lower level mark, remove the oil filler cap and add the recommended oil up to the upper level mark.

Recommended engine oil:

Honda GN4 4-stroke oil or equivalent motor oil certified to meet API service classification SF or SG Viscosity: SAE 10W-40

NOTE

Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.

Reinstall the dipstick.

For engine oil change, see below.

ENGINE OIL AND FILTER CHANGE

NOTE

• Change engine oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining.

A WARNING

Engine and exhaust system parts become very hot and remain hot for some time after the engine js run. Wear insulated groves or wait until the engine and exhaust system have cooled before handling these parts.

Remove the dipstick.

Place an oil drain pan under the engine to catch the oil, then remove the drain bolt.

1996 Softail Transmission Drain Plug

(1) DRAIN BOLT

Remove the side fairings (page 2-3). Remove the oil filter using the oil filter wrench.

Tool:

Oil filter wrench 07HAA - PJ70100

Check that the sealing washer on the drain bolt is in good condition, replace it if necessary.

Install and tighten the drain bolt to the specified torque. Torque: 30 N-m (3.0 kg-m, 22 Ib-ft) Apply oil to the new oil filter O-ring.

Install the new oil filter and tighten to the specified torque. Torque: 10 N-m (1.0 kg-m, 7 Ib-ft)

Fill the crankcase with the recommended oil (page 3-11). Capacity:

3.4 i (3.6 US qt, 3.0 Imp qt) at draining 3.7 I (3.9 US qt, 3.3 Imp qt) at oil filter change

Install the dipstick.

Start the engine and recheck the oil level (page 3-11). Make sure that there are no oil leaks.

CARBURETOR SYNCHRONIZATION

À WARMING

• If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.

NOTE

• Perform this maintenance with the engine at normal operating temperature and transmission in neutral. Place the motorcycle on a level surface.

Remove the fuel tank (page 2-4).

Remove the left and right engine hanger plates.

No.1 CYLINDER:

Remove the plug and washer from the cylinder head intake port.

a warming

• Remove the rubber cap by pinching the end of the cap. Do not pinch the cap body or it will be damaged.

No.2, 4 CYLINDER:

Remove the rubber caps from the vacuum joint on cylinder head intake port. No.3 CYLINDER: - 49 STATE, CANADA TYPE:

Remove the rubber cap from the vacuum joint on cylinder head intake port.

Cbr Vacuum Tube Intake Port

(3) CALIFORNIA TYPE

(3) CALIFORNIA TYPE

Fzs 600 Fazer Oil Filter

(2) i^n OIL FILTER WRENCH

(1) OIL FILTER

(1) RUBBER CAP

Oil Filler Cap 1995 Honda Cbr 600

(1) RUBBER CAP

• CALIFORNIA TYPE:

Disconnect the No.3 cylinder vacuum tube from the pulse secondary air injection (PAIR) control valve.

Screw the adaptor in the No.1 intake port vacuum hole and connect the vacuum gauge tube to the adaptor.

Connect the vacuum gauge tubes to the No.2, 3, 4 vacuum joints.

CALIFORNIA TYPE ONLY:

Connect the vacuum gauge tube to the No.3 vacuum tube.

Install the fuel tank and connect the fuel tube but do not install the fuel tank mounting bolts.

1.Turn the fuel valve ON. Start the engine and adjust the idle speed to the specification.

Idle speed : 49 State, Canada type: 1,200 ± 100 rpm California type: 1,400 ± 100 rpm

2.Check the difference in vacuum between each carburetor. Carburetor vacuum difference: Within 30 mm Hg (1.2 in Hg) NOTE

• No.3 carburetor is the base carburetor.

3.Synchronize to specification by turning the adjusting screws with the phillips screwdriver as shown.

4.Be sure that the synchronization is stable by snapping the throttle grip several times.

5.Snap the throttle grip several times and recheck the idle speed and difference in vacuum between each carburetor.

Disconnect the vacuum gauge and install the removed parts.

Torque:

Engine hanger plate 10 mm bolt: 45 N»m (4.5 kg-m, 33 Ib-ft)

(1) VACUUM TUBE

(1) ADAPTOR

(1) ADAPTOR

(1) ADJUSTING SCREWS

Gsf 600 Idle Adjustment Screw

(1) ADJUSTING SCREWS

(1) SCREW DRIVER

ENGINE IDLE SPEED

NOTE

• Inspect and adjust idle speed after all other engine adjustments are within specifications.

• Engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient.

Warm up the engine.

Support the motorcycle on a level surface and shift the transmission into neutral.

Check the idle speed and adjust by turning the throttle stop screw if necessary.

Idle speed : 49 State, Canada type: 1,200 ± 100 rpm California type: 1,400 ± 100 rpm

RADIATOR COOLANT

LEVEL CHECK

Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER" and "LOWER" level lines with the motorcycle in a vertical position on a flat, level surface.

If necessary, remove the reserve tank cap and fill to the "UPPER" level line with a 50-50 mixture of distilled water and antifreeze {coolant mixture preparation: page 6-4).

CAUTION

• Be sure to use the proper mixture of antifreeze and distilled water to protect the engine.

• Use distilled water. Tap water may cause the engine to rust or corrode.

Check to see if there are any coolant leaks if the coolant level decreases very rapidly.

If the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system. Be sure to remove all air from the cooling system as described on page 6-4.

Coolant 1995 Honda Cbr 600

COOLING SYSTEM

Check the radiator air passages for clogging or damage. Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water.

Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.

For radiator replacement, refer to page 6-8.

Check for any coolant leakage from the water pump, water hose and hose joints.

Make sure the hoses are in good condition; they should not show any signs of deterioration.

Replace any hose that shows any sign of deterioration. Check that all hose clamps are tight.

SECONDARY AIR SUPPLY SYSTEM (California type only)

Check the air supply hoses between the reed valve and intake pipes for deterioration, damage or loose connections. Make sure the hoses are not kinked or pinched.

NOTE

• If the hoses show any signs of heat damage, remove the reed valves and inspect for damage (page 5-38).

Check the vacuum hose between the intake port and valve for deterioration, damage or loose connections. Make sure the hose is not kinked or pinched.

EVAPORATIVE EMISSION CONTROL SYSTEM (California type only)

Check the tubes between the fuel tank, EVAP canister, EVAP purge control valve, EVAP CAV solenoid valve and carburetors for deterioration, damage or loose connections. Check the EVAP canister for cracks or other damage.

Refer to the Vacuum Hose Routing Diagram label and Cable & Harness Routing (page 1-20) for tube connections.

Vacuum Hose Diagram For Honda Cbr

DRIVE CHAIN

DRIVE CHAIN SLACK INSPECTION

A warming

• Never inspect and adjust the drive chain while the engine is running.

Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral.

Check the slack in the drive chain lower run midway between the sprockets.

Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically for use O-ring chains. Wipe off the exess chain lube.

ADJUSTMENT

Loosen the axle nut.

Loosen both lock nuts and turn both adjusting nuts until the correct drive chain slack is obtained.

Make sure the index marks on the both adjusters are aligned with the rear edges of the axle slots in the swingarm.

Tighten both lock nuts.

Tighten the rear axle nut.

Recheck chain slack and free wheel rotation. Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically for use on O-ring chains. Wipe off the exess chain lube.

Check the chain wear label.

If the arrow mark of the chain adjuster reaches the red zone on the label, replace the drive chain with a new one.

Replacement chain: RK50MFO DID50V4

CLEANING, INSPECTION AND LUBRICATION

CHAIN

Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubricating.

Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or other wise appears unservicable. Installing a new chain on bodly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprockets as necessary.

Honda Goldwing Points Adjustment

(4) ADJUSTING NUT

(3) INDEX MARKS

(DWEAR LABEL

(3) NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT

Ring Chain Lube Points

(3) NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT

Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically for use on CD-ring chains. Wipe off the exess chain lube.

SPROCKETS

Inspect the drive and driven sprocket teeth for damage or wear. Replace if necessary.

Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly.

Check the attachment bolt and nuts on the drive and driven sprockets. If any are loose, torque them.

REPLACEMENT

This motorcycle uses a drive chain with a staked master link. Loosen the drive chain (page 3-16). Assemble the special tool as shown. Tool:

Drive chain cutter 07HMH - MR10102 or

NOTE

• When using the special tool, follow the manufacturer's instructions.

07hmh Mr10102
(2) PRO HONDA CHAIN LUBE OR EQUIVALENT

(1) LUBRICATE

Locate the crimped pin ends of the master link from the outside of the chain, and remove the link with the drive chain cutter.

Tool:

Drive chain cutter

Remove the drive chain.

(1) MASTER LINK

(1) MASTER LINK

Chain Link Tool Motorcycle Diagram

Remove the excess drive chain links from the new drive chain with the drive chain cutter.

NOTE

Include the master link when you count the drive chain links.

Standard link: 108 links Replacement chain: RK50MFO DID50V4

CAUTION

• Never reuse the old drive chain, master link, master link plate and O-rings.

Install the new drive chain.

Assemble the new master link, O-rings and plate. CAUTION

• Insert the master link from the inside of the drive chain, and install the plate with the identification mark facing the outside.

Assemble and set the drive chain cutter.

Tools:

Drive chain cutter

Link plate holder

07HMH - MR10102 or 07HMH - MR1010B (U.S.A. only) 07NMH - MW00110 or 07NMH - MW0011A (U.S.A. only)

Make sure that the master link pins are installed properly. Measure the master link pin length projected from the plate.

Standard length: RK : 1.2 - 1.4 mm (0.05 - 0.06 in)

Stake the master link pins.

Ring Master Link InstallChain Holder Tool And Insert

MASTER LINK

<4) [s tool I DRIVE CHAIN CUTTER

Make sure thatthe pins are staked properly by measuring the diameter of the staked area using a slide caliper.

Diameter of the staked area:

Master Link Motorbike Chain

After staking, check the staked area of the master link for cracks.

If there is any cracking, replace the master link, O-rings and plate.

CAUTION

• A drive chain with a clip-type master link must not be used.

TEST

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