Bike Runs Poorly... Sometimes - Page 5 - Honda Rebel Forum
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post #41 of 47 Old 01-02-2017, 11:17 PM
 
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Any manual is better than none. I have the Clymer and Honda manuals. The Honda manual is better IMO.

As Soaked Karma says, you need to remove the rings from the Piston and fit them into the cylinder bore in the unworn section near the bottom to check ring wear by measuring the end gap with a feeler gage. Make sure it is perfectly square with the cylinder. be careful not to break the rings or scratch the piston when removing and reinstalling them.
The maximum gaps allowed are .018, .024, .035 inches for the 3 rings from top to bottom.

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1996 Ducati 900SS CR (California Bike), 1973 Norton Interstate (in a box in the basement)
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post #42 of 47 Old 01-03-2017, 06:04 AM
 
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I get different specs out of my OEM shop manual than Duckster
Attached Images
File Type: jpg Piston_Rings.jpg (149.6 KB, 7 views)

96 VS800GL Suzuki Intruder, 87 CMX250C Rebel,
79 CB400 Hawk (sold 93), 75 CB350 (sold 83), 71 CB350 (stolen 74)
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post #43 of 47 Old 01-03-2017, 07:34 AM
 
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hmmm, interesting. If you go on 4 pages further you find this. Perhaps the OEM manual has a few inconsistencies as well.
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File Type: jpg manual.jpg (84.2 KB, 5 views)

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1996 Ducati 900SS CR (California Bike), 1973 Norton Interstate (in a box in the basement)
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post #44 of 47 Old 01-03-2017, 09:16 AM
 
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Interesting @Duckster No image like that exists in 85-87 OEM manual.
doesn't even mention how to measure end gap as yours does..

96 VS800GL Suzuki Intruder, 87 CMX250C Rebel,
79 CB400 Hawk (sold 93), 75 CB350 (sold 83), 71 CB350 (stolen 74)
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post #45 of 47 Old 01-03-2017, 10:06 AM
 
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My manual has the same table as you posted, but the numbers are different and do seem to be consistent with the later pages.
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File Type: jpg manual1.jpg (184.0 KB, 7 views)

2004 Rebel 250, 2003 BMW K1200GT (roadburner), 2004 BMW R1200GS(all purpose),
1996 Ducati 900SS CR (California Bike), 1973 Norton Interstate (in a box in the basement)
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post #46 of 47 Old 01-03-2017, 12:47 PM
 
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Interesting comparison between the two charts..
differences are infinitesimal

single graphic and instruction in measuring ring-to-grove clearance under Piston/Removal/Inspection
no end gap instruction or graphics..

Only other mention of rings in 1st Gen manual is following full page graphic


96 VS800GL Suzuki Intruder, 87 CMX250C Rebel,
79 CB400 Hawk (sold 93), 75 CB350 (sold 83), 71 CB350 (stolen 74)
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post #47 of 47 Old 02-27-2017, 06:49 PM Thread Starter
 
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Garage
The Shocking Conclusion

To conclude this thread,

First I'll summarize what has happened up until here. My engine was having intermittent problems and I found a broken cam chain tensioner bolt. I took the engine with me to fix up over winter.

Here is where the story continues. I put the engine back together and slapped it back on the bike. All was running well. I decided to go for a short ride, but while i was on the freeway I suddenly lost power. The reserve switch didnt fix it, so I pulled over to find a big puddle of oil under the engine. Turns out I didn't tighten the drain plug enough and it had come out on me after about ten miles.

After some pushing and some new quarts of oil, the bike was running again, but it would never run the same again. The intermittent running issue got worse, and the engine would sometimes not start altogether.

I thought through the different possible issues and approaches to this more severe problem. After about 4 weeks, I decided to swap out the engine if I could find a good enough deal.

I found a cheap running engine with low miles (about 14,000) on ebay. When it arrived, I swapped out the old engine and now the bike runs great. It has so far shown no signs of the old running issue.

Thank you all for your time and your help. The last few months were quite a journey, and now I can sleep easy knowing that my rebel is running strong. I wish everybody the best of luck with theirs! Safe riding!

1986 CMX250C
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carburetor, engine, fixes, problem, running bad, sputter, switch, valves

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