Cbr600 2002 Engine wont idle/run when warm

[kramdra]

Not sure what your on about, the oil was changed recently, and before that was at 122k, 108k, 100k, 91k, 83k. About every 9 months. I was doing a lot more miles last year and did not notice it was due. The oil never needs topping up.

Yes I expect the extended 14k has caused some sludge/wear or damage.

[sickpup]

[kramdra]

After much cleaning, got the rocker cover off, and there is plenty of space to work so this should be much easier than I imagined.

There is immediately some fukkery obvious. The rocker cover has not been touched since dealer head the head off at 35k miles. When I got it back it was noisey, but has not increased since.

https://i.postimg.cc/B6pPW8qr/IMG-20200522-190333.jpg

Looks like the cam bearing cover is cracked. Does not look like casting lines. Bad assembly?
https://i.postimg.cc/XqDZJTBx/IMG-20200522-190818.jpg

I will check clearances tomorrow then get the cam bearing cover off.

I could use a rough idea what temper the new shims should be, will probably make them from silversteel or en24.

[Nobby the Bastard]

Ffs just buy some from wemoto.

Why do you need to know what the temper they are. It's not like you have to make the fucking things.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[kramdra]

I could buy them but wont take long to make. That will beat waiting a week for delivery and a fiver each.

60 quid for a new chain guide. Another part I'll probably make. https://www.davidsilverspares.co.uk/parts/by-part-number/hpart_14546MBW000/

[kramdra]

To make this more interesting, my clutch casing no longer has the index mark due to crash damage repair and corrosion and quite possible the intake cam has jumped a tooth, they do not appear to line up perfectly like the manual states.

[Nobby the Bastard]

They never match perfectly because the chain stretches. That's why theres a chain tensioner. Just find the best fit.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[Hong Kong Phooey]

[sickpup]

Are you sure you've done shims before? Theres no shame in not having done them but the advice will be more in depth.

[kramdra]

[sickpup]

[kramdra]

96 fiesta 1.6 and 92 saab 9000. My first two cars

So far going slow but good, they seem within spec. Found its worth cleaning and measuring each pairing of feeler blades and trusting the mic rather than the stamped values. A decent quality set of indiviual blades 0.10-0.40 would be ideal for next time. Im starting with the smallest spec blade, recording in roman numerals with each pairing for each set of valves until the last no longer fits.

I think the intake cam is two teeth out. That would explain why it was running perfectly, one tooth jumped running badly, another tooth jumped and not running at all since. Here is a pic with engine on the T mark and 360 degrees (measuring 2 & 4 intake)

https://i.postimg.cc/90CrBf2z/IMG-20200524-182726.jpg

I will repeat the measure after with the line flush as the guide suggests to see the difference.

[sickpup]

Which one of those cams is the inlet?

[sickpup]

https://i.postimg.cc/B6pPW8qr/IMG-20200522-190333.jpg

Did you rip this off or did you find it this way?

[kramdra]

Inlets on the left. Exhause always lines up perfectly flush with the crank mark.

[Nobby the Bastard]

That inlet is at least a tooth out of alignment.

I really cant see that happening on a running engine unless you e removed some tensioning gear that altered the alignment above the sprocket.

I'm inclined to think that bent bit of toot was put in by the last person who decided that 50 quid was too much and as a result your chain has jumped a tooth. I suggest that you learn from that.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[kramdra]

The last person was the main dealer for which I paid £1000 for their services -and recived the bike back with loose brake calliper bolts and exhaust nuts. They had head off to fix exhaust threads and it took them 3 or 4 months.

The tensioner on these is known to be shit. When I removed the tension unwinder, it did not spring back out as it should. Many people fit manual CCT's for that reason. I think I will too.

As I was rechecking the inlet, the inlet accidently jumped a tooth. I decided to advance it a second tooth, to where I think it should be, but have not rotated engine since. I then removed the tension unwinder and pushed the guide back into the tensioned position. The cam moved backwards about half a tooth, which I guess is the amount of stretch in the chain. So now it is half a cam tooth from being flush.

These are my results, which means 3 shims have tightened up slightly under the limit and 5 more are right on the limit.

https://i.postimg.cc/g01x69xF/IMG-20200524-213918.jpg

[sickpup]

So a failed guide and an inlet a couple of teeth out suggests to me a failed tensioner which you should have heard. That isnt meant bitchily, just a simple it should have been caught before it became that bad.

[kramdra]

[sickpup]

Possibly some bent inlets, maybe maybe not.

Did you take the rocker cover off when you replaced the tensioner?

[Hong Kong Phooey]

I'd buy the chain guide, it's machined to the correct thickness.
Tensioners are as well known as regrecs on these.

Confirm TDC with a pencil or something in cylinder 1 then take it from there.
At that point the timing marks can be rotated as needed with the tensioner removed. Don't be surprised if it goes 1 tooth out when the tensioner goes back in, at that point mark it off in the chain with permanent marker.

Then remove the tensioner and adjust the timing chain position if needed.

Only when this is all correct you can then check the clearances.

When you get it all back together, keep a note of what shims go where, so future you knows what shims to order next time without having to take it all apart again.
____________________
'81 CG125, '97 FZS600 : '99 CBR600F4, '09 KTM RC8

[kramdra]

[sickpup]

[Nobby the Bastard]

Is the cbr engine 'interference ' or 'safe'?

My experience of highly stressed sports bike engines are that they are interference.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[kramdra]