Hi all,
been meaning to update the thread for a while but just so happens that work schedule has taken most of my time and the internet connection has been quite erratic in this part of the country. Regardless, time has come to get things rolling and i hope the following rants of an OCMD rider will add something more to this thread if you know what i am saying!

My riding has become limited to just 940 kms last month thanks to hectic schedule and periodic field visits. The 4th round of Rimula 4 HDEO oil has been holding up well. The engine oil has changed its colour of dark amber but so far the response, smoothness and gear shifts has been extremely sublime. I shall monitor the health of the engine for another 800 - 1000 kms (if time permits) and report my observations here. However, i would give a detailed update on that in another post. For now, let us carry on with the big one

INSTALLATION OF TAPERED ROLLER BEARINGS & SERVICING OF FRONT FORKS WITH CUSTOM PRELOAD
WARNING: The items i am about to describe and use are based on my discretion and my own need to experiment and learn. The products mentioned below are after-market in nature and i donot advocate any of them. It is merely to understand, learn, for the sheer joy of personalising my vehicle, sharing my experiences here as i clock more kms and review/post the net results for knowledge sharing. Should someone decide to follow my footsteps, know this: you are doing so with your own free will.
I have been delaying the process of replacing the worn out OEM steering bearings and the much needed fork oil change for a while thanks to the hectic work schedule and also due to the reluctance & in-experience of the local SVC mechanic. Understandably, CBR by nature is relatively trouble free and most of the owners don't harass their local SVC mechanics like i do!!
Me and a bunch of OCMD riders belong to such a group: who are never satisfied with their respective steeds. Any noise, vibrations or even a minute deviation will send jitters down our spine... something a generic - everyday rider will never ever bother with...only to later realise that when we test ride a similar vehicle of a fellow rider: our respective steeds are in far better health, refined and well kept than theirs!! Well what can i say... it is a medical condition!! 
So i finally managed to get hold of free time and decided it was wise to approach a bigger SVC with experienced mechanics who have at least carried out fork oil changes and complete rebuilds of accident vehicles. I came to know of a good mechanic through a referral of a common friend and then fixed my appointment with the SVC. Now i must be clear: given the choice i would any day go for a hydraulic set up to get the outer race and bearing installation done like it was carried out by Mr. Vikram & Vijay: Motozone Performance, Mumbai & Pune on @abhimanyu31 's Ninja san (thread link:http://www.xbhp.com/talkies/general-...ml#post1069542) as from any manner one looks at it: it is the right way to do things. Given the circumstances of me living in a remote location and due to unavailability of such services: add to that in-experienced hands, i had to make do with what i had. Bearing installation is not a hatchet job! So one can definitely understand the sheer reluctance to carry out the installation of the same with "chalta hain" attitude: as a result i had been stalling this, trying to find out alternative ways to get hold a custom hydraulic press shop or create some sort of custom jig to install the tapered roller bearings like it should be. However, after exhausting all options i consulted Mr. Vikram and @gopakumar s pillai and decided to go ahead with traditional method while keeping few safeguards. The good thing about the All Balls tapered roller bearings is that the manufacturer supplies the bearings with everything: outer races for CBR 250R and rubber dust seals for both the top and bottom bearings.
After i reached the SVC, the mechanic first dismantled the front fairing, MID instrument panel in order to gain easy access to the front forks and also in the due process have more free room to carry out the work easily.


Pic 1 & 2: Front fairing removed from my CBR 250R. The mechanic releasing the clamps and slowly removing the front forks from the fixtures/mounts and the clip ons.
Once, the front forks were removed from their given location, we then began dismantling the triple tree clamp: top lock nut and the holding nut for accessing the top and bottom steering bearings. Once the top cover was removed the top bearing was initially inspected to do a kind of autopsy behind the bearing failure and also assess the damage that has been done over a period of usage. As the pictures will suggest, both the top and bottom bearings were covered with a concoction of grease mixed with dust and dirt: understandably due to exposure to the elements with over 26,000 kms of usage. The outer race for the top bearing had visible damage and the inner part of the race had metal flaking off (not visible in the pics). The top bearing balls were also damaged, the bottom bearing was relatively in good shape though.



Pic 3, 4 & 5: The OEM bearings being removed. Post inspection the top bearing was found to have taken a severe beating along with the outer race. the bottom bearing was found to be relatively in good shape post 26,000 kms.
We then took out the OEM bearings and began with the process of removing the OEM outer races. Once, the outer races were removed we then started installing the supplied outer races by All Balls Racing for both top and bottom for the tapered roller bearings. I was monitoring the whole progress at all the time in order to ensure that the mechanic doesn't have a gala time hammering his way to the glory. The races were tapped uniformly from all sides to ensure that they seat properly. I then followed a method suggested by the vendor which made things easy for me. Once, the installation was done, we then measured to confirm that the seating has been done within the specs recommended by Honda. One good thing about these races were than they have been precision manufactured. If one notices the images below the outer races are angled compared to the OEM ones for the ball bearings. The fit was exceptionally snug and there was no play observed even when the final installation of the lower triple tree was done to the chassis.



Pic 6, 7 & 8: Outer races for both the top and bottom part getting installed onto the chassis. Note the angular nature of the races compared to the OEM ones. These have been precision machined specifically for this application by All Balls Racing.
For any readers who are on the lookout for an alternative bearing from another manufacturer do bear this in mind: getting hold of an outer race (for tapered bearings) designed to match the specs for a Honda CBR 250R will be the first priority as simply purchasing a matching tapered roller bearing from another manufacturer will be a worthless exercise. As far as i am aware of no other indian manufacturer (SKF/FAG etc.) provides outer race for similar application for motorcycles manufactured in India. If one can custom build it using a VMC/CNC machine then this will open up doors for a lot of riders who are on the lookout for an alternative bearing in place of the OEM one... just a thought!!
The next step literally made me sweat throughout the process as we were now progressing towards installation of bottom bearing onto the lower triple tree. Since, i didn't have any access to hydraulic press we had to route for the traditional "hammering" method. Thanks to Mr. Vikram & @gopakumar s pillai for giving me useful pointers on the same, the installation was relatively made easy though i was on the edge throughout.

Pic 9: installation of bottom bearing onto the lower triple tree
Once the installation was complete, i started looking for a good grease to lubricate the bearings. Thanks to a weekend, all the oil & lubricants selling shops were shut. I was very adamant and made it clear to the SVC mechanic that using dust & grime mixed lithium grease which was lying outside and used on other motorcycles & vehicles in their SVC will simply not do. The mechanic then suggested going for Honda supplied high grade, high temperature resistant & waterproof silicon grease. A mere 30 - 40 gms tube costs whopping 260 bucks! I then decided what the heck, let us go for the best and not compromise on such a critical component. So then we went ahead with smearing liberal gobs of silicon grease onto the bearing to ensure that it receives a good amount of lubrication and also forms a layer: creating a barrier for the bearing from interacting with the outside elements.


Pic 10 & 11: Honda High grade silicon grease. The silicon grease being liberally applied on the tapered bearing.
Both the top and bottom bearings were greased liberally and we also lubricated the outer races for the top and bottom bearing with the same Honda silicon grease. This was going to pinch my wallet a bit however, i didn't want to compromise on anything. Once, the lubrication work was completed we then installed the triple tree onto the chassis and the tightened the holding mechanism.
We then progressed onto dis-assembling and putting in fresh fork oil into the front forks. For those who are keen the learn a bit more about proper servicing/overhauling of front forks for Honda CBR 250R do check out the video link below:
Once, the front forks were disassembled, we then took out the fork spring, washers, preload OEM spacers from the fork and drained the old fork oil from the fork pipe. The old fork oil looked like dirty gutter water which was expected given non-preventive maintenance by the previous owner. The mechanic then started cleaning all the components using petrol. Since, the fork oil seal and the dust seal was in good health we didn't bother dis-assembling the whole fork unit and simply carried out the cleaning process of the innards of the fork tube using petrol. Once, all the components were cleaned and dried, the mechanic then poured the new fork oil into a measuring jug and the put in into the front forks.




Pic 12, 13, 14 & 15: The front fork components being removed and cleaned using petrol. The innards of the fork tube getting cleaned by pouring in petrol and then sloshing around, pumping the fork tube a couple of times and then draining the contents.
Once, the fork oil was put in the mechanic then started pumping the fork tube a number of times in order to ensure that any residual air remaining inside is removed completely. We then wen ahead with putting the fork spring, washers and the OEM spacer inside in the order we had taken them out. However, one more thing was added into the recipe. I had got hold of a 1" spacer in order to test out a high pre-load setting with the OEM forks. Honda CBR 250R has been traditionally softly sprung into order to provide a much more compliant ride. However, this same OEM set up is also the "achilles heel" for Honda as it doesn't provide confidence for any rider who wants to do a bit more of corner carving. Also with the OEM set up, the front forks have a tendency to dive in too much during hard braking which i felt at times lead to the front tire losing a bit of grip and also the feeling on the front brake lever was not consistent.




Pic 16, 17, 18 & 19: The mechanic pumping the forks to let out any residual air from inside. The 1" spacer getting installed for custom suspension set up test.
I wanted to try out a custom set up with 1" spacer and using 340 ml of fork oil instead of 331ml to see if this floats my boat. I will have to do some extensive runs on the moon cratered roads of the North East and then see if the set up feels more stiff then what other combinations can be tried out to get a set up of my preference. Once, the front forks were re-assembled, the mechanic then put them back onto the triple tree and then began re-assembling the fairing back on my CBR. Well then the money was paid off and the mechanic was tipped (quite well!!). The top locknut of the steering bearings have been kept slightly lose in order to see how much tightening will work best for my CBR. I wanted to be sure that the mechanic didn't end up over tightening the locknut which may damage the tapered bearings and prove to be an costly affair for me.
Anyways, i will provide an initial experience with the new set up in a separate post as due to time constraints i will have to wrap this one rather quick.
Till then watch out more on this space...
Cheers,





Couldn't resist the temptation so manage to procure 3 bottles of Shell Advanced Ultra 10W 40 FS oil for the future engine oil change. I already had about 500 ml remaining from the 1st round of Ultra run on my CBR 250R. I believe this stock is good enough for the next 10,000 kms eh?? Anyways, i am really hopeful that post the completion of Shell Rimula R4 HDEO oil treatment, the internals by the end of the 4th round would have more than enough ZDDP coating. The moment i put in Shell Advanced FS oil, it will maintain the ZDDP coating even though it has comparatively lesser ZDDP content PPM and also being FS oil, i may witness further increase in smoothness just like rider @




















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