Two Gen-6 questions: Valves and harness

Hey all-
I'm preparing to do the 'big teardown' on my '02. The valve adjustment is coming due and I thought I'd go through the complete machine for cleaning, inspection, and any other fixes I can work in.
So the questions:
1) My manual refers to a "tool" (I'll add the p/n when I get home today) for retaining the V-tech valve pin actuators that looks like a small disc of rubber (?- hard to tell with the B&W photos) that one jams in the bucket while it's out of the engine. Is this all that it is? Precision die cut, etc. I'm sure! I'll order a part from Honda if there is value in it, but this seems pretty basic.
2) I need to address the wiring harness ground problem seen with under-rated connectors on early Gen 6 machines. The closest dealer hasn't returned my calls or emails regarding the recall service, (no surprise) but I'd just as soon do the replacement myself (properly soldered in- not just crimped on) as the service department gorillas can't even change a tire with out trashing my rims.
Is there a part number for the replacement connector available? Would I be better off purchasing a GoldWing or ST1300 connector as a replacement as they are designed to support extra accessory power loads?
I appreciate any comments or information- I'll definitely document and post whatever I end up doing to the bike.
Cheers!

 

Hey,
my 2004 has a factory recall for the wiring harness-not sure if your '02 does. I've read the documentation at the dealer - it calls for inspecting the harness, and replacing part of it, and some additional parts if burning/melting is seen at one of the connection points. They've ordered the part they will replace, and call me to bring it in for inspection when that part gets here. Mine has shown no problems yet, that I can tell.
I'll let you know how it goes if you want.
BTW, my first bike was a '76 CB400F. I sold it to buy an '82 sabre, which I drove and maintained myself for 14 years and 50,000 mi. Both were great bikes, but I wish I had the CB400F back.

 

I believe that you will also need a special tool to remove the cam chain tension. The service manual specifies the dimensions somewhere, as the tool is not available from Honda (according to my book).

 

You WILL want ALL tools associated with disabling the Vtech lifters in order to inspect valve clearance. No improvising on this one. The right small screwdriver will work fine to relax the cam chains when removing and replacing the cams.

Geronpg is totally right regarding the recall. The first step is to inspect the blue multi-pin connector on the left side of the bike. If it's OK... the whole front subharness is replaced with a new one that has an additional section that connects to the RR on the right side of the bike...this much is automatic. If the left side blue connector shows any sign of melting...the dealer calls Honda Tech and they ship out a complete new main wiring harness. No cutting and soldering is done in this recall.

I understand your "wanting to do it yourself". But in the case of the recall, it's best left to a dealer (pick one you think is best) for a couple reasons aside from the actual work itself. Begin by bringing your VIN into the dealer so they can ID it as needing the recall or not.

 

Thank you for the input- I knew asking here would yield good information! :thumb:
I did get a letter from Honda Corporate and had a rather long conversation with someone there about the harness problem. He told me that the weak link was the connection, but the ground wire gauge was up to the task. That's why I assumed that it was a connector only swap. :ranger: Hmmmmm.....
The tool I was asking about is the "Slide Pin Stopper" (07XMZ-MCE0100) and yes, the cam chain tensioner stopper is a custom chunk of steel that is dimensioned in the service manual.
I guess I'll have to bring doughnuts to the machinist at work.

I do appreciate that Honda has given us information to fabricate the stopper and the Tappet Hole Protector (07HMG-MR70002), which can be had by modifying a 35mm film canister.

Now.... it's been mentioned on one of these threads that the newer Gen6 engines transition to 4-valve mode at a lower RPM. I'd love to change this on my bike to avoid the minor lurch when I shift just as the Vtec is kickin' in. Not a problem when riding by myself, as I'm spinning up the mill pretty good before the next gear, but I usually short shift with the wife on the back and we end up knocking helmets. (can't stand that) I take some pride in riding smoothly (and safely!) with passengers and it would be easier with an earlier transition point.
Should this be a whole different discussion? :nod:

Anyhow, thanks again for the help and I'll start looking for a dealer who wants my business- If nothing else, I'll be buying parts.

Ciao!

 

You'll want at least four of those little slide pin stoppers otherwise you'll have to remove and install the cams on each bank four times to inspect the valve clearance. With four you can do a bank at a time in one step, keeping cam removal and installation to a minimum.

You could just inspect the blue connector yourself...to make sure it's sound in the meantime...and wait a month or two 'til the Honda shops slow down a bit. There's no time limit on recalls.

It's not that you're not totally capable of doing the recall work yourself, but if you can't find a Honda dealer to claim the work without doing it you'll continue to get letters and your bike will be on record as not having the recall done. Could be a source of confusion in the future should you decide to sell the bike. Also, you would have no way of contacting tech services for a main wire harness should you need one. And often when many recalls are being done, Honda doesn't allow "open" ordering of the part in question. In other words, you may not be able to get one for awhile.