Author Topic: 1977 CB400F Cafe Project (Read 3117 times)

dclarson · « **on:** March 13, 2015, 12:50:02 AM »

Been saving parts for this bike for a long time and got started on it seriously more than a year ago. It's my 5th CB400F since 1981. I initially wanted to do a Yoshima replica race bike (what I dreamed about when I was 17 years old) but my taste has evolved and so now I'm doing a street legal cafe racer with a vintage look and major upgrades to suspension, brakes, and engine while shedding a lot of weight.

The bike - purchased in 1996 with 8k miles. It had been in storage for 13 years and had some missing parts, oxidation here and there, bad rust on the front fender, but most of the bike was like new. I immediately ditched the high handlebars and forward pegs, replacing with OEM '75-76 bars and rearsets.

dclarson · « **Reply #1 on:** March 13, 2015, 01:18:36 AM »

And this is where I am so far. Will post pics of various stages of the project when I have time.

Link to my pics on Flickr for this project: https://www.flickr.com/photos/dclarson/sets/72157605065321490/

dclarson · « **Reply #2 on:** March 13, 2015, 01:56:38 AM »

Build sheet (what I can remember):

ttr400 swingarm
Woodcraft spindle sliders
ttr400 rear hub
Brembo Serie Oro rear disc
Brembo rear caliper
Brembo rear master cylinder
Denoon rearsets with Tarozzi hardware
2008 SV650 forks and triple with modified top clamp
Tarozzi clip-ons
Woodcraft bar-end sliders
SV650 front calipers
Brembo radial front master cylinder
CRG clutch perch
All Balls steering stem tapered roller bearing kit
Active Japan Type 2 throttle kit
Vintage BMW style 1/4 fairing with custom paint
Marzocchi AG Strada rear shock rebuilt and powder coated. Custom fabricated brass hardware.
Storz Harley front hub
Harley floating rotors
Takasago Excel aluminum rims
Buchanan stainless spokes and nipples
Bridgestone BT-45 tires
Polished alloy front fender
Vintage polished alloy fuel tank
Legendary Motorcycles polished alloy seat
Custom fabricated seat pan
Leather seat by Pirate Upholstery
Oil breather catch can by V-Twin Mfg
Ducati Monster headlight and mounting bracket
520 chain and sprockets
Antigravity 4 cell lithium battery
Rick’s regulator/rectifier
MC-Again upgraded stator kit with cover (charges at 1k rpm)
Dyna III electronic ignition
Dyna coils
Barnett clutch and springs
Ontario Moto Tech (Kaz Yoshima) 4-1 exhaust.
Active Earl’s curved oil cooler kit
Takegawa oil thermostat
ttr400 oil cooler bracket
Dime City Cycles frame hoop

Engine build still to come:

54.5mm pistons, balanced
Performance rods with 13mm small end
Crank: balanced and lightened
APE heavy duty cyl studs
Full porting job on cyl head
bronze guides, valves (modified std valves std size)
Kibblewhite valve springs, with Ti retainers
Webcam profile 3
hardwelded Webcam rockers
New OEM inlet rubbers matched the inlet port
CR26 carbs
TTR cam chain adjuster, replace all other related parts with OEM.
Heavy Duty cam chain
Uprated oil pump (self modified with instructions from Kevin Bidgood)

calj737 · « **Reply #3 on:** March 13, 2015, 05:59:27 AM »

Pretty neat bike and project. Definitely should be a major upgrade on its performance. The BMW fairing looks a bit "upright" for the length of the bike. Perhaps a Daytona style might fit the bike better?

What are your plans for instrumentation and electronics?

knowsnothing · « **Reply #4 on:** March 13, 2015, 11:49:38 AM »

Awesome, can't wait to see this finished.

dclarson · « **Reply #5 on:** March 13, 2015, 12:44:23 PM »

Quote from: calj737 on March 13, 2015, 05:59:27 AM

Pretty neat bike and project. Definitely should be a major upgrade on its performance. The BMW fairing looks a bit "upright" for the length of the bike. Perhaps a Daytona style might fit the bike better?

What are your plans for instrumentation and electronics?

The bars are above the triple clamp for comfort so you're not crouched as low as you might think. Of course I might change my mind once I get it out on the road

I haven't completely decided on instrumentation yet. Was hoping to use a GPS speedometer but the only ones I've found so far don't have a matching tach (or integral tach) that goes high enough. I may have to go with the Motogadget and put a magnet and sensor on the wheel. You can get a tach from them up to 14k which is perfect. I'm not keen on the wheel sensor because I wanted to keep things as clean as possible but I may not have a choice.

calj737 · « **Reply #6 on:** March 13, 2015, 01:16:09 PM »

Use a magnetic sensor installed on the front sprocket bolt under the left side cover. Magnet on bolt, sensor rigged from underside of cover. Wiring tucks into the loom with stator bundle (oil, neutral wiring for instruments).

They're Chrono series in a 14k band could be just the trick for you. Integrated speedo, voltmeter, gear position, odometer and of course, and classic analog needle tach displayed. Also, you can integrate oil pressure and temp since you're using the external cooler.

dclarson · « **Reply #7 on:** March 13, 2015, 03:07:20 PM »

Quote from: calj737 on March 13, 2015, 01:16:09 PM

Use a magnetic sensor installed on the front sprocket bolt under the left side cover. Magnet on bolt, sensor rigged from underside of cover. Wiring tucks into the loom with stator bundle (oil, neutral wiring for instruments).

They're Chrono series in a 14k band could be just the trick for you. Integrated speedo, voltmeter, gear position, odometer and of course, and classic analog needle tach displayed. Also, you can integrate oil pressure and temp since you're using the external cooler.

Excellent idea, why didn't I think of that? I was checking out their Chrono series, it's the only tach/speedo I could find with a tach that goes that high. This engine should be capable of running up to 14k. Will just have to see where the power tops out, I'm guessing I will probably only run it up to about 12,500 or so but will have to wait and see. I've been asking a few people for advice on the engine build and I'm pretty much going with what Kevin Bidgood (ttr400) recommends.

calj737 · « **Reply #8 on:** March 13, 2015, 07:41:16 PM »

You'll be hard pressed to find someone more knowledgeable about the 400 than Kevin. Plus, he's an absolute gentleman and top class guy. I have his swing arm on my 550 too.

thirsty 1 · « **Reply #9 on:** March 13, 2015, 08:22:06 PM »

Very nice man! I did one last winter and I love that thing. Good on ya for your fifth. Do you still have that pimp scarf?

dclarson · « **Reply #10 on:** March 18, 2015, 02:11:26 AM »

Years ago I picked up a a set finned stator cover and points cover from eBay and put them on a shelf for future use. Here I am now and it turns out I never looked at the stator cover carefully because it does not fit. It looks like it may fit a CB550 but I'm not sure. Long story short I've had a heck of a time finding a nice stator cover and at the same time I've had concerns about the OEM charging system since I am going to a small 4 cell Lithium battery. I found a nice stator kit from Again Co. LTD in Japan http://www.mc-again.com/

It comes with a cover of their design with Honda internals from a more modern bike. It was not cheap but I'm glad I got it.

You have to use a new regulator/rectifier, the OEM Honda one won't cut it. I got one from Rick's http://ricksmotorsportelectrics.com/

MC-Again recently started taking international orders but you have to email them directly. The email address is on their News page. They take PayPal.

calj737 · « **Reply #11 on:** March 18, 2015, 05:32:03 AM »

That's a very trick looking stator. What output is it rated for?

SOHC4 Cafe Racer Fan · « **Reply #12 on:** March 18, 2015, 09:53:25 AM »

Shazam. The website is not so English friendly, but that stator looks slick. I bet the power output is much higher given modern tech.

dclarson · « **Reply #13 on:** March 18, 2015, 11:54:50 AM »

I honestly don't know what it's rated for, just that it will produce 14 V at 1,000 RPM, which was really my only concern. I don't plan on connecting my heated gear and installing fog lights etc so I didn't even ask about output.

Quote from: calj737 on March 18, 2015, 05:32:03 AM

That's a very trick looking stator. What output is it rated for?

dclarson · « **Reply #14 on:** March 18, 2015, 11:57:39 AM »

If you use Google Chrome as your browser you can right-click and translate the page. Go to the news section where you can find the email link. They do speak English and welcome inquiries.

I don't know what the full output is, just that it will produce full charging voltage at idle.

Quote from: CB750 Cafe Racer Fan on March 18, 2015, 09:53:25 AM

Shazam. The website is not so English friendly, but that stator looks slick. I bet the power output is much higher given modern tech.

strynboen · « **Reply #15 on:** March 18, 2015, 12:29:39 PM »

is it a permanent magenet setup...?

dclarson · « **Reply #16 on:** March 18, 2015, 12:50:36 PM »

Not sure I understand the question. It appears to work the same as the OEM stator but it's using modern components. So you've got the coil fixed to the inside of the cover and the magnet hub is installed on the shaft.

Quote from: strynboen on March 18, 2015, 12:29:39 PM

is it a permanent magenet setup...?

SOHC4 Cafe Racer Fan · « **Reply #17 on:** March 18, 2015, 02:45:54 PM »

Found this system for a CB500/550 -- it's a drastic improvement but costs a bloody leg!

http://www.electrexworld.co.uk/acatalog/RPK-1550_Honda_CB500_CB550_-_Alternator_System.html

calj737 · « **Reply #18 on:** March 18, 2015, 05:47:01 PM »

Here's a better solution!

http://www.electrexworld.co.uk/acatalog/STK-550.html

SOHC4 Cafe Racer Fan · « **Reply #19 on:** March 18, 2015, 06:10:36 PM »

Quote from: calj737 on March 18, 2015, 05:47:01 PM

Here's a better solution!

http://www.electrexworld.co.uk/acatalog/STK-550.html

That one is pricey, too. Eliminates the battery though.

dclarson · « **Reply #20 on:** March 18, 2015, 06:19:57 PM »

That's more than what I paid and doesn't come with a cover! Just found out today that the internals are from the Japanese market CBR250RR (not the new CBR250R).

Quote from: calj737 on March 18, 2015, 05:47:01 PM

Here's a better solution!

http://www.electrexworld.co.uk/acatalog/STK-550.html

SOHC4 Cafe Racer Fan · « **Reply #21 on:** March 18, 2015, 07:26:25 PM »

It would be nice to find an improved charging system for the 550 and 750 that doesn't cost an arm or leg!

knowsnothing · « **Reply #22 on:** March 19, 2015, 06:40:46 AM »

Damnit man stop posting cool sh1t, my bank account can't take it!

strynboen · « **Reply #23 on:** March 19, 2015, 10:06:22 AM »

the back side of this system are intern friktion...you can aktuelly feell the resistens from the magenets..bu turning the engine...even it not deleveres power...suzuki have used it for many years...the orginal hondasetup.. are almost friktion free..vhen it not generate pover..or less power..permanent magenet are alvays heavy to rotate...and load kontroll can only be made bu bypass power to frame/and massive heat in a heat generating regulator
the honda set up are total regulating..from zero to full pover.

but it make a lot more power then the orginal set up...so if you have injektion/ pumps to drive it are a must...put it have a preis..the pover komes not free

this setup looks like a kokusan vho honda used in 1960..a lot of singel cylender bikes have integered ignision pick up coil..in a simular setup

dclarson · « **Reply #24 on:** April 12, 2015, 08:11:33 AM »

Got my seat back from the upholsterer. I made a mockup of the seat pan with a styrofoam backed board from a craft store. Then cut a sheet of 16 gauge aluminum with a rotary shear and bent it in my brake. I used a belt sander to shape it some more for a better fit. Here are some pics...

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Author Topic: 1977 CB400F Cafe Project (Read 3117 times)