Hi All, so after 10 years I finally got my **** back on a Blade......kinda.

My introduction to the CBR family started in 2000 when I bought a CBR400 Fireblade (can't remember the year model). I was super happy because this was my first tase of a 'superbike'. Chatting to someone online at the time and he referred to it as the baby blade, I was not happy.

So after losing the 400 in a fire, I decided to trade in my VW Polo for a 1992 Honda Fireblade 900RR, she made my heart smile. This was also the first time I repaired a bike myself (due to low budget) using only a Haynes manual as my guide. Couple of years later I got the 2005 Honda Fireblade 1000, did some tinkering to make her faster, really had fun with that one. Until I traded her for a Harley...... long story.

Last year I got a 2002 Honda Blackbird, really loving that machine!!

And a couple of weeks ago I got the brainfart to buy a 2007 Honda Fireblade 1000 (in much need of TLC and a engine knocking noise). After watching too many rebuild videos on YouTube, I thought to myself: "Myself, I reckon you can do this" and so I did.

At this point in time, all symptoms point towards the valve clearance and that is where I'm headed next. Hopefully a couple of shims can sort out the issue. My first stop was the Cam Chain Tensioner and the Chain Rail but they are just peachy. Other than that the bike is in good shape, she sounds like a monster. Still want to replace the radiator, fairing, grips, etc, etc.

If anyone out there took on a similar challenge, let me know, keen to hear how it went down. I'm not a mechanic and don't claim to know it all. In my mind, this is a adult version Lego and I'm going to take my time taking it apart, fixing and putting it back together.

My engine knowledge two weeks ago was limited to doing the maintenance service.

Will let you all know how it goes along.

Heading towards the valve clearance checkpoint

My 2002 Honda Blackbird (BB)

 

Welcome to the forum, sound like you're having fun sorting the bikes out.

I'd love to hear how you get on with the engine fix. Back in the 70s and 80s I used to do all my own spanner work but more time with family and work commitments out paid to that until couple of years ago when I swapped my VFR800 for a 1993 CBR600. So far she's had complete mechanical stripdown but I've yet to open the engine up.

 

Thank you. This is my first engine operation but at this stage I'm more excited than worried. I'm taking the Santa approach, checking the list twice before I remove anything and labelling each connector. The intention with this project is to learn more about the engine and for my 'graduation' I have a up and running Blade. If the engine operation fails then graduation will take longer than planned, but I'm in no rush.

Once I have sorted out the engine then I will start replacing the normal items like levers, mirrors, etc. My wife is a artist, so the respraying is entirely her department. But given the condition of this fairing, I will rather buy a new fairing kit which has all the decal done.

My wife thinks I'm selling the Blade when she's done. hehehe

 

The very best of luck - remember, your camera is your friend :-)

 

So I managed to sneak away from the office to spend some time on the rebuild. Got the radiator out and to the point where I can check the valve clearances. Which is my next destination on the journey to resolve the engine knocking noise. There is definitely some work that needs to be done here, the valve clearances are all over the place. Full disclosure, this process is taking me much longer than it probably should but I'm enjoying the process and look forward to firing her up after this checkpoint.

Hopefully I can escape the office tomorrow to tinker further, I want to confirm the valve clearances and then it's onto the shims.

Will keep you posted.

 

Sooo I got to tinker a bit further today. Double checked the valve clearances this morning and pulled all the shims to measure them.

I made a spreadsheet to keep track of all the sizes and safe to say they all need to be adjusted. Thankfully I can swop 10 around to other spots but still need to hunt for 6 shims. The Honda dealer in is a waste of time, lead time is 2 - 5 months. That's not happening. So tomorrow I'm swopping the 10 shims and hunting for the other 6. I found the biggest variance on the 4th valve (0,12 intake and 0,13 exhaust) which is also where I hear the knocking noise. Fingers crossed this will be the end of the knocking sound.

 

Latest update, I managed to get my hands on a box of Shims which thankfully had the six that I needed. Manage to replace the shims, install the camshafts, timing chain and onto to the camshaft covers.

And that is when it happened..... the snapping sound of a bolt giving up on life. At first I thought it was the torque wrench.....it wasn't.

Thankfully I was left with 1mm+ of thread and stuck a bolt on there with Pratley Steel. Left the little f#cker for 24 hrs and was able to just unscrew the remaining piece......unfortunately the bolt that I attached was slightly too big to turn, unless I removed the camshafts again. Which is what I had to do.

So there has been some back and forth, picked up a replacement bolt this morning, next step is to get the camshaft covers bank on and start reassembling.

On the respraying side, my mrs finished the engine cover, clutch cover, fuel tank, slip on exhaust and random bits and bobs on the bike.



Soo this happened....

Solution - small nut with Pratley Steel

 

Nice fix.

I've had some success with stud extractors but that can leave swarf in the engine