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Author Topic: CB400F Cafe Racer Project  (Read 4593 times)

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Offline EtienneZA

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CB400F Cafe Racer Project
« on: July 25, 2012, 11:15:40 PM »
Dear Members,

After some dabling with British twins, I finally got tired of oil leaks and decided to build a Japanese 4 cyl Cafe Racer!!

I was delighted to find this somewhat molested 400f on Gumtree. It was an ex racer and I believe the perfect base for my custom build. The motor is excellent although somewhat stripped from basic electrics.

Also found a friendly breaker around the corner with a host of second hand parts available. Already bought a full bank of carbs (ZAR 350), Charging system, coils, stator, rectifier and regulator (R500) of him and I am sure there is many more to come.

Thanks for all the info on the forum, I pretty much found everything needed and required for this build.
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Offline Gurp

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Re: CB400F Cafe Racer Project
« Reply #1 on: July 25, 2012, 11:30:19 PM »
Cant wait to see it. Atleast in its condition it saves you the teardown lol
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slow Progress 74 cb550.

Poor boy chop 73 CB500 chop

Future project 77 Cb750 Amen Savior

Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #2 on: July 26, 2012, 12:21:19 AM »
Ordered the new spokes from David Silver................and received my new Bumbox..............the journey begins
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #3 on: July 26, 2012, 12:25:32 AM »
Here is a run down of the planned electronic ignition system......

The advancer unit is made up of CB750K5 ATU and GL500 trigger lobe pick-ups are CB750/900F units fitted to a modified base plate  the ignition unit is a GSX1100 unit ignition coils are CBR 400. Previous owner recon this works........MMMMMMM..........will have to see how this pans out.
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Offline Kevin

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Re: CB400F Cafe Racer Project
« Reply #4 on: July 26, 2012, 07:00:21 AM »
Hello EtienneZA!
Welcome to the forum!!
I think you will find the SOHC's to be much more fun than those Brit bikes :-)
Since you are in SA you should get in touch with TTR400, he is in Pretoria and has a garage full of CB400F parts and is cleaning house!
Good luck on your build!!
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A couple of 400F's and a
'98 Suzuki Intruder VS1400 ~ for long rides

Offline Kwality

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Re: CB400F Cafe Racer Project
« Reply #5 on: July 26, 2012, 05:54:46 PM »
Subscribed!  Welcome - looks like a fine project!

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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #6 on: July 26, 2012, 11:51:26 PM »
Well, started the stripping process last night, went quick and easy. Planned for this weekend - finish off the frame and remove all unwanted bits and pieces and coat with high gloss 2k black paint. Frame is in beautifull condition with very little rust although some brackets have been welded on and others cut off.

Herewith the planned basic run down od what it will look like:

Black rims and hubs with new spokes
Silver std tank with bumbox, black stripe running through center
Tomaselli clip ons onto std polished forks with HRC top yoke
Black engine with polished covers
custom 2 into 2 into 1 zorst
Lighting - TBD
Custom / homemade wiring harness

More pics to follow
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Offline jackseattle

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Re: CB400F Cafe Racer Project
« Reply #7 on: July 28, 2012, 05:13:33 PM »
your build sounds great.  This will be a fun one to follow.
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1976 400F
1971 450

Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #8 on: July 31, 2012, 07:15:55 AM »
Well, thought this would be an easier build but alas no way! On starting preparing the frame, which was supposedly in good condition, it cleary came to light that it was butchered instead of being "worked". Where brackets were removed there are bad grinding marks causing thinning in the tube. Main area of concern would be where the stand brackets were once attached.

I would suppose that these sections of tube would need to be replaced.......any suggestions please.

On a lighter side the new spokes from David Silver arrived. It took a mere three working days to arrive. Now that is definitely good service and also reliable. I will probably use them a lot in future. Rims and hubs have been delivered for sandblasting and powdercoating. Lets see how long a few days are, no commitment here from the coater! Holding thumbs.

Any good suggestions on a good polishing compound to use for the engine covers and forks? Maybe I should first ask if these can be polished successfully. Not fully familiar yet with the Jap stuff. Have had some good results with Brit bits.

Thanks again for all the info on this site. Also must comment the tricks bits from TTR400, wow very very inviting to see how you can stretch you credit card limits.

EtienneZA
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #9 on: June 27, 2013, 08:07:04 AM »
Well after a very long absence, due to an injury from dirtbike riding, I can now start working on my project again.
So far.........
Rims and hubs e-coated black and laced up
Frame modified and e-coated black
Forks and brake parts polished and ready to assemble
Exhaust headers fabricated

Next up.......
Turn up some bushes and fabricate new shock mounts in order for the new aluminum swing arm to fit and function. The swing arm is from an 80's IT 200 and stretches the wheelbase by 120mm

Post some pics soon
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #10 on: June 27, 2013, 10:50:06 PM »
Refurbished wheels, tank and tailpiece,  new swingarm
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Offline kyre

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    • CB400F / 466 Build Thread
Re: CB400F Cafe Racer Project
« Reply #11 on: June 28, 2013, 06:22:26 AM »
Nice one. Will be watching!
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CB400F / 466 Build Thread (currently in progress)
http://forums.sohc4.net/index.php?topic=105027.0

Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #12 on: June 28, 2013, 08:45:17 AM »
Chaps, I am in a bit of a predicament. I have  one set of complete carbs, one semi complete and two sets stripped to pieces. How do I identify which carbs are the correct ones for a 400? Are the any markings or numbers? Sorry for this silly question but I am learning about the Honda specifics as I go along and don't have a shop manual.
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Offline braveg

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Re: CB400F Cafe Racer Project
« Reply #13 on: July 05, 2013, 01:49:18 PM »
Do you mean you have one entire set for the bike (ie one carb per cylinde) then another three sets in different stages or do you mean you have four carbs in different states of disassembly?
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #14 on: July 16, 2013, 10:26:07 PM »
After some nights of serious effort my bike is finally on its wheels. I have managed to clean, repair and fit the carbs. Although they were filthy on the outside, the insides were sparkling. I still gave them a good boil in vinegar to make sure all passages are clean. After figuring out that fitment was not going to be easy, I heated the rubber boots with a heat gun and it popped in fairly easy.

You can also see that the aluminium swingarm is now fitted and I aligned the track with a laser tool.

I have also constructed a stand on castors to elevate the bike and make working easier.

More pics later.
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Offline Mugen_Stumpo

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Re: CB400F Cafe Racer Project
« Reply #15 on: July 17, 2013, 09:20:38 AM »
looks great!!! 8)
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #16 on: July 18, 2013, 12:21:44 AM »
Thanks for your comment.

She fired up last night on the second attempt and runs like clockwork!!!! I am very chuffed. Now need to complete the wiring, paint it up and then ready to go!  ;D 8)
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Offline straat-toe

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Re: CB400F Cafe Racer Project
« Reply #17 on: July 18, 2013, 01:23:21 AM »
Hi Etienne .

Great build so far man. Interesting  swing arm tactic. I'm also rebuilding a 75 400f in Cape Town, so I'll be watching your's closely.
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #18 on: July 18, 2013, 02:10:16 AM »
Thanks, Straat-toe. the swinging arm is from an IT200. It extends the WB by 180mm. I have kept the twin shock arrangement and machined to brackets out of billet aluminium. Must say that the effort was worth the while.
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Offline straat-toe

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Re: CB400F Cafe Racer Project
« Reply #19 on: July 19, 2013, 03:25:44 AM »
Yea good work. You going drag racing with it?  ;) What rearset are you fitting on there?
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #20 on: July 19, 2013, 05:22:02 AM »
Rear Sets are home made!
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #21 on: July 07, 2014, 06:58:50 AM »
Hello Guys,

Sorry long absence but some progress. Attached is a picture of the latest status. The motor is at least running.

https://www.youtube.com/watch?v=KlXmtr8HFtE&feature=youtu.be
« Last Edit: July 07, 2014, 07:05:25 AM by EtienneZA »
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Offline EtienneZA

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Re: CB400F Cafe Racer Project
« Reply #22 on: July 07, 2014, 07:09:41 AM »
I am in the middle of restoring my KTM 640 Adventure and have sidelined the CB for the moment.

Still quite a bit to do to get her going. I have to repaint the tank of my KTM the standard metallic orange and I am sure that I will have some paint left. What do you guys suggest, orange tank and black bumbox or should I keep it as per my original plan of silver tank with black bumbox? Obviously if I go with the orange the front fairing will have to go.
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Offline Blackfin5

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Re: CB400F Cafe Racer Project
« Reply #23 on: July 10, 2014, 07:04:18 AM »
Welcome, Etienne.  Where are you in ZA?  If in Capetown, I can send parts if needed with my SAF buddies in late August.

Cheers.
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Offline straat-toe

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Re: CB400F Cafe Racer Project
« Reply #24 on: August 04, 2014, 11:34:06 PM »
Nice one Elliot. She sounds good. I'm also standing still due to other bike commitments at the moment.
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