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Discussion Starter #1
Hi all,
I'm taking on my biggest project on my cbr so far by breaking the engine apart to replace the piston rings and the head gasket. I have been forced to replace the head gasket but decided to do the piston rings as well. I have a manual and have the scope of the job figured out and pretty confident in being able to do it. I just wanted to know how far i really need to go to do the job? do the pistons have to come out or is simply getting to them sufficient enough to be able to replace the rings? The manual i have is a bit fuzzy on this.
 

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The pistons have to come out to replace the rings.

You might be able to do all this with the engine in the bike but it would probably be easier to just drop the motor. On my old CBR600 f2 I had to drop the motor to fix a blown out spark plug thread. It wasn't that bad. I would recommend you look for a clymers service manual. I had one for my f2 and it was way more helpful than the service manual I have for the RR now (I got the pdf for free though so I can't complain too much...)

Let us know if you have questions. Take your time and take notes/pictures upon disassembly. Trust me they will come in handy.

EDIT: How did you manage to blow a head gasket and what makes you think you need new rings?
 

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Discussion Starter #4 (Edited)
The pistons have to come out to replace the rings.

You might be able to do all this with the engine in the bike but it would probably be easier to just drop the motor. On my old CBR600 f2 I had to drop the motor to fix a blown out spark plug thread. It wasn't that bad. I would recommend you look for a clymers service manual. I had one for my f2 and it was way more helpful than the service manual I have for the RR now (I got the pdf for free though so I can't complain too much...)

Let us know if you have questions. Take your time and take notes/pictures upon disassembly. Trust me they will come in handy.

EDIT: How did you manage to blow a head gasket and what makes you think you need new rings?
Well after hitting 120mph on the interstate and finding that my motor had 1.5 quarts more oil than it was supposed to have after getting an oil change i spoke to a few people and mechanics about the black smoke coming out of the tailpipe for a mile or so followed by white smoke and the two most likely culprits i was supplied with were the head gasket and or piston rings so i decided i may as well go ahead and do both since i have to take the whole upper portion of the bike apart anyways. The most likely issue being the head gaskets but i decided i may as well do both so i dont have the issue down the road after i put the bike back together.
 

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OK don't get ahead of yourself.

Did you drain the oil to within the acceptable range? If yes is it still smoking black/white smoke when you ride it?

Your bike is probably 100% OK. Check your coolant for oil and your oil for coolant. Keep on eye on fluid levels. Don't dive into this major project until you are 100% sure it needs it.

EDIT: Now that I think about it there is a crankcase breather that goes into the airbox. With the oil as overfull as you had, excess oil most likely went into the airbox, and got burned along with the air fuel mixture. This would cause the smoke you were seeing. Hopefully this was the cause of the smoke, and not bad piston rings or a blown headgasket. GET OIL TO PROPER LEVEL AND RIDE THE DAMN THING. You will know soon enough
 

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Discussion Starter #8
OK don't get ahead of yourself.

Did you drain the oil to within the acceptable range? If yes is it still smoking black/white smoke when you ride it?

Your bike is probably 100% OK. Check your coolant for oil and your oil for coolant. Keep on eye on fluid levels. Don't dive into this major project until you are 100% sure it needs it.

EDIT: Now that I think about it there is a crankcase breather that goes into the airbox. With the oil as overfull as you had, excess oil most likely went into the airbox, and got burned along with the air fuel mixture. This would cause the smoke you were seeing. Hopefully this was the cause of the smoke, and not bad piston rings or a blown headgasket. GET OIL TO PROPER LEVEL AND RIDE THE DAMN THING. You will know soon enough
I did as you said and my bike was still spitting white smoke. I rode it for about 15 miles and it still constantly spit white smoke. I have already bought the gasket and piston rings but i probably can still return the piston rings.
 

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Discussion Starter #10
OK don't get ahead of yourself.

Did you drain the oil to within the acceptable range? If yes is it still smoking black/white smoke when you ride it?

Your bike is probably 100% OK. Check your coolant for oil and your oil for coolant. Keep on eye on fluid levels. Don't dive into this major project until you are 100% sure it needs it.

EDIT: Now that I think about it there is a crankcase breather that goes into the airbox. With the oil as overfull as you had, excess oil most likely went into the airbox, and got burned along with the air fuel mixture. This would cause the smoke you were seeing. Hopefully this was the cause of the smoke, and not bad piston rings or a blown headgasket. GET OIL TO PROPER LEVEL AND RIDE THE DAMN THING. You will know soon enough
did you clean out the airbox?
Yes I cleaned the airbox as well.
 

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Well **** you shouldn't still be blowing smoke then.

Did you do the oil change or did you have a shop do it? If a shop did it you should go to them and demand they fix the damages caused by their mistake.
 

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Discussion Starter #12
Well **** you shouldn't still be blowing smoke then.

Did you do the oil change or did you have a shop do it? If a shop did it you should go to them and demand they fix the damages caused by their mistake.
Nope, that one is all on me. I did the oil change so I dug my own grave here. I started doing the project today and I'm happy i am doing it because I'm finding parts that need replacing anyway so its gonna make my bike run better and last longer in the end...An issue i just ran into though has halted my progress.
I can't seem to get the crankcase right covers cap for the timing chain and manual piston movement piece off so that I can put the pistons in their correct orientation to begin removing the crankshafts...I tried the correct mm 6 point socket but it is so stuck on there that i stripped it, so next I tried getting flat head wedge on it and turing it but that didnt work, so i moved to pretty much hammering a smaller socket onto the 6 point but that didnt work, then i moved to a drill out set but the damn thing is so stuck on there i cant seem to get it off. I have a buddy coming over tomorrow to help me do the engine and remove the cap.
Is there anyway I could just remove the crankcase cover and worry about the cap later without moving anything in there prematurely? This would allow me to move the pistons to their correct setting but i dont want to mess up anything by doing this sooner than im supposed to as the manual shows removing the crankshafts and then removing the crank case cover then the timing chain...Is this a set order?
 

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You would also need new connecting rod bolts (8pcs) & main crankshaft bolts (10pcs, 8 short, 2 long) as they are torque to angle & one time use only.

You should use a thinner head gasket & squeeze more power from the engine, the CBR has low compression ratio compared to its rivals, check the head & cylinder deck for warpage, mill it flat if necessary.
 

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I don't see why it would be a problem to just take the whole cover off.
 

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Discussion Starter #15
You would also need new connecting rod bolts (8pcs) & main crankshaft bolts (10pcs, 8 short, 2 long) as they are torque to angle & one time use only.

You should use a thinner head gasket & squeeze more power from the engine, the CBR has low compression ratio compared to its rivals, check the head & cylinder deck for warpage, mill it flat if necessary.
The bolts are on the way :D. Well im just going to pull the whole case off honda power and go from there. Thanks guys
 

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Discussion Starter #16
So I did the full rebuild today ended up having not to use the piston rings and canceled the bolt order. The head gasket was blown and there was a mixture of oil and coolant still left on top of the pistons. Upon separating the crankcases and before removing the pistons and rods I noticed the rings looked hardly worn and very new compared to the rest of my engine. So I called up the previous owner. He originally told me he had some work done on the engine a few months before I got the bike from him. Apparently, some of that work consisted of a partial rebuild of the engine including new piston rings...Now the fact that they did not replace the head gasket has me completely baffled. After the previous owner gave me the shops info and the receipt I found that the shop has gone out of business due to multiple failures of customers bikes after rebuilds and work and has been sued into non-existence, go figure. At least I found my culprit and after an 8-hour long rebuild I now have peace of mind that my engine is in much better condition now, I understand more of how my bike works, and I will be back on the road in a week or so after a few cooling system parts come in.
Thanks all for your help.
On a side note if anyone needs a set of piston rings for an 06 cbr600rr and the job specific tools equaling about 160$ in value then I will be happy to bargain out a deal and save you some money. Will gladly ship if you cover the shipping costs.
 

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Way to go sir! You made pretty quick work of that.

Funny the bike had a ring job done to it with such low mileage. It is very uncommon for such work to be required at such a premature age. I hope the repair works out well for you. I take it you did not have the cylinder head checked for warpage? I guess because the bike did not overheat and the head gasket only blew because of the excess oil you should be fine, but keep an eye on it!

Did you check the valve clearance while you were in there and if so how far out of spec were they if at all? I've been putting off a valve check on my bike for too long haha.
 

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Way to go sir! You made pretty quick work of that.

Funny the bike had a ring job done to it with such low mileage. It is very uncommon for such work to be required at such a premature age. I hope the repair works out well for you. I take it you did not have the cylinder head checked for warpage? I guess because the bike did not overheat and the head gasket only blew because of the excess oil you should be fine, but keep an eye on it!

Did you check the valve clearance while you were in there and if so how far out of spec were they if at all? I've been putting off a valve check on my bike for too long haha.
Thank you sir! Had a bit of help from a friend but I've been working on my daily driver, my 2000 jeep wrangler for 6 years now and constantly, so I have a lot of hands on engine experience lol. I did not have the cylinder head checked because it seemed unnecessary due to the circumstances. The valves were just about dead on surprisingly for a bike with 27k miles on it I expected them to be off but it may have been done when the rings were. The receipt is very unclear as to exactly what was done.
 

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News rings would require at the very least honing the cylinders, meaning a complete engine tear down. You cant hone with a crankshaft sitting in the danger zone.
 
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