Topic: 1977 CB400F2 Reassembly Project

[MaaseyRacer]

It has been a while since I have posted a project on this forum, I have sold off my Honda fours and have only been working on twins until the other day. A buddy called me up and long story short I would be doing him a huge favor taking his fully disassembled 1977 CB400F2 off his hands. The price was right, and even though I am in the middle of a few (to say the least) other projects I bit.

When the bike showed up at my door, I was pleasantly surprised to see that the frame had been powder coated, along with the kick stand, center stand, and triple tree. Clear title was handed to me (this might be a first). I was also handed a NOS 400F seat. All of the engine parts look to be in clearly labed bags and boxes. I figured this was going to be a pile of parts I would regret, so far we look to be off to a good start.

Now the bad that I can see right off the bat, is that the tank has a nasty dent in it with plenty of paint removed. in the dent. With only 5,000 F2s sold in the states finding another tank might prove to be a pain in the butt. Also the NOS seat appears to be for the earlier 75 and 76 400Fs. Along with the dented tank the stock seat cover appears rough, but with some new seat rivets, and a new cross strap I might be able to clean it up.

If anyone has a Yellow F2 tank in usable condition let me know otherwise I may try to fix this one. Also if anyone is interested in an NOS 400F seat please let me know.

[MaaseyRacer]

I am looking a little more closely at the seats in the daylight. I have two very distinctly different seat covers. The NOS seat has the standard looking 400F seat cover (same as the early models). However, the seat that appears to be originally on the bike does not have the seat pattern. My vin # show this bike is one of the last 1000 imported in 77 (according to http://cb_400f.tripod.com/page5.html ). Does anyone have any info on late 77 seat covers? I am looking to find out which one is the correct one for this bike?

[MaaseyRacer]

400F is now a roller. The Powder Coated parts look great. I am debating getting a remanufactured tank and side covers instead of pulling dents and paint the tank. My stud welder is struggling to pull the dents out on the tank, I would hate to see this tank go as the inside of it is spotless, but that dent is not budging yet. I will put a few more days on it and see where I can get. I am starting to see what I am missing on the frame of the bike, but I think it is best to get the engine fully assembled and then get back to the frame and bits.

I inspected the carbs today, they look like they should be frozen (covered in dirt), but move freely and easily. Very happy and pleasant surprise.

Once I get the bottom end assembled I will figure out what I am going to do with the top end. I also need to sort out which is the correct seat for this bike, anyone have any info on this?

[MaaseyRacer]

Quick update the bottom end on the engine is built. Feel pretty good only used the manual once for the starter gear. Luckily the guy I bought it from labeled the parts bags well. Made my life so much easier. The last time I bought a bike in pieces it came with one bag of bolts...

I took a ton of measurements today. Everything seems to be in spec, granted the bike only has 15,000 miles on it. Gears look to have zero wear on them, crank and bearings are in spec as well. The cylinders were the interesting bit, I use a micrometer to make sure they were round and within spec. All of the cylinder were within 0.0005" round and they all measured well with in spec. I removed the glaze with a ball hone and I think it all came out well.

[MaaseyRacer]

Engine is together now, and I have sourced a gas tank more photos to come this weekend. Shifter assembly is giving me a headache, but I have a feeling if I read the book a few more times I will have it sorted. If anyone has any insight on this matter it would be appreciated.

[NobleHops]

It has been a while since I have posted a project on this forum, I have sold off my Honda fours and have only been working on twins until the other day. A buddy called me up and long story short I would be doing him a huge favor taking his fully disassembled 1977 CB400F2 off his hands. The price was right, and even though I am in the middle of a few (to say the least) other projects I bit.

When the bike showed up at my door, I was pleasantly surprised to see that the frame had been powder coated, along with the kick stand, center stand, and triple tree. Clear title was handed to me (this might be a first). I was also handed a NOS 400F seat. All of the engine parts look to be in clearly labed bags and boxes. I figured this was going to be a pile of parts I would regret, so far we look to be off to a good start.

Now the bad that I can see right off the bat, is that the tank has a nasty dent in it with plenty of paint removed. in the dent. With only 5,000 F2s sold in the states finding another tank might prove to be a pain in the butt. Also the NOS seat appears to be for the earlier 75 and 76 400Fs. Along with the dented tank the stock seat cover appears rough, but with some new seat rivets, and a new cross strap I might be able to clean it up.

If anyone has a Yellow F2 tank in usable condition let me know otherwise I may try to fix this one. Also if anyone is interested in an NOS 400F seat please let me know.

Pick me!

[NobleHops]

Engine is together now, and I have sourced a gas tank more photos to come this weekend. Shifter assembly is giving me a headache, but I have a feeling if I read the book a few more times I will have it sorted. If anyone has any insight on this matter it would be appreciated.

This would explain the trouble I am having with the shifter too I guess.

[NobleHops]

Ladies and gentlemen, please allow me to introduce my bike, before I bought it. The one with the rebuilt engine, bronze swingarm bushings, rebuilt front brake caliper and master cylinder, rebuilt carbs and more.

[NobleHops]

400F is now a roller. The Powder Coated parts look great. I am debating getting a remanufactured tank and side covers instead of pulling dents and paint the tank. My stud welder is struggling to pull the dents out on the tank, I would hate to see this tank go as the inside of it is spotless, but that dent is not budging yet. I will put a few more days on it and see where I can get. I am starting to see what I am missing on the frame of the bike, but I think it is best to get the engine fully assembled and then get back to the frame and bits.

I inspected the carbs today, they look like they should be frozen (covered in dirt), but move freely and easily. Very happy and pleasant surprise.

Once I get the bottom end assembled I will figure out what I am going to do with the top end. I also need to sort out which is the correct seat for this bike, anyone have any info on this?

Not me!

[NobleHops]

Quick update the bottom end on the engine is built. Feel pretty good only used the manual once for the starter gear. Luckily the guy I bought it from labeled the parts bags well. Made my life so much easier. The last time I bought a bike in pieces it came with one bag of bolts...

I took a ton of measurements today. Everything seems to be in spec, granted the bike only has 15,000 miles on it. Gears look to have zero wear on them, crank and bearings are in spec as well. The cylinders were the interesting bit, I use a micrometer to make sure they were round and within spec. All of the cylinder were within 0.0005" round and they all measured well with in spec. I removed the glaze with a ball hone and I think it all came out well.

I hope so!

[nvr2old]

That's a pretty nasty set of dents, for sure.  Looks very similar to the ones that were on my 400F tank, only more severe.  I used a stud gun, too.  Did you start at the outside edges and work to the middle and deepest part of the dent, or did you start at the deepest point?  Working from the outside first and moving to the deepest as you go is the way it works best.  I apologize if that is one of those "duh" recommendations.  Are the fork stops broken off, too..?  Would hate to see the tank get slapped again after the repair..

The engine looks great, with only 15K you might have a good runner on your hands.

[NobleHops]

That's a pretty nasty set of dents, for sure.  Looks very similar to the ones that were on my 400F tank, only more severe.  I used a stud gun, too.  Did you start at the outside edges and work to the middle and deepest part of the dent, or did you start at the deepest point?  Working from the outside first and moving to the deepest as you go is the way it works best.  I apologize if that is one of those "duh" recommendations.  Are the fork stops broken off, too..?  Would hate to see the tank get slapped again after the repair..

The engine looks great, with only 15K you might have a good runner on your hands.

Yeah, that tank is pretty gnarly, I have it with a half-dozen studs welded to it, before the PO gave up.  I ended up buying a repro tank for David Silver for the bike. Steering stops are fine. I am hopeful on the engine, although it won't run till I can get the shifter sorted out.

This thread is from the previous owner of my bike, BTW. I just unearthed it last night.

[inv3ctiv3]

Very cool build can't wait to see where it goes and that is a huge bummer about the tank.

[nvr2old]

This thread is from the previous owner of my bike, BTW. I just unearthed it last night.
[/quote]

Ahhh..that makes more sense now..