Topic: CB400F 1977 (1st build)

[marting100]

Hi guys, 1st thing I would like to say is: BIG thanks to all of you that are posting very valuable information for a noob like me! Thanks!!!
I am new to the Honda CB4 world, I am from Quebec, Canada, (please pardon my bad English writing, I am french ;-). I did ride motocross when I was younger (42 now) and this year I decided to get my moto license and found myself a project. I was not really looking for it but from mouth to ears I have found something nice.
In April I have purchased a CB400 1977 with 22300 miles, from there this forum along with shop manuals and a few videos have been of the greatest help.
Mainly the reason I am posting this is to say thank you to you all, because without all of you this CB400F would probably not be running at the moment.
(even if it was in fairly good shape)
I dont have much time to continue on today but I will post everything I did to it since then. Not in great detail but you never know, it might help someone someday!
(here's a few pics of the bike in April)
Cheers!
M

[Jore]

Salut Marting100, T’habite oú à Québec? (excusez mon mauvais québécois mais je suis Mexicain)

That's a nice looking bike you have, welcome and i hope to see more of your project.

[MoMo]

welcome, nice looking bike you have....Larry

[marting100]

Thanks guys!!

HI Jore, not bad french at all. I am from Québec Province, living in the town of Granby.
Thanks!
M

[marting100]

So, when I went to check the bike at the PO's place, it as been sitting in a dry garage for 3 years (i was please seing that), the PO purchased the bike in 2004 with 20422 miles on it from a motocycle shop in Granby. (I have all the papers). The gas tank was empty (happy about that) with no rust in it.
I have to say that I did my research before the 1st visit, I dig the internet to know what where the bad things or the things to check on those bikes (since I ad no idea).
Overall the bike was clean from all the other built I saw on the web. The clutch cable was totally jam, the front brake piston was seize and there was an impact mark with a broken casing piece at the magneto. (see image). We manage to start the bike for a couple of minutes, that was nice to know that the motor was actually working.

My original plan was to make a cafe racer but after some research I have learn that those bike are rare and I was lucky to found one. So my plan change, I was going to go over the entire bike without splitting the case if it's not needed (remember that I did not test the bike) and take out what I dont like without cutting anything. This way if for some reason I want to go back I can. For me, those big turning lights and rear brake light are not something I like, the great thing is that they are easy to take out and replace without being a permanent change. But one thing at the time. I started on the left side of the bike with the broken casing, then make my way around.

After inspection, nothing was leaking from the impact at the broken casing area, so I did the repair with metal epoxy. Since the gasket was BO at 4into1.com I use the old one to cut myself a new one + a little bit of gasket maker putty. My goal here is not to make a show room or resto project, I want something that show is age and scares but in great running condition. Spend a great amount of time buffing the casing and also replacing the old screws that strip easy for some allen.
M

[marting100]

I proceeded to an oil change, nothing bad in there. I did not strip the filter bolt either (was happy about that).
Took out the gauges, they needed a fresh coat of paint and some new gaskets. The idiot light box was crack,
repaired it with some epoxy and some new paint. Buffed all the chrome and nuts and put everything back in place.
I did took out the light mounting bracket and replace it with some simple Drag S. light brackets.

After reading about electrical issues some were having, I did go over all connections, brushed/sanded and apply dielectric grease.
I took apart the front light, buffed the chrome, and painted everything else with Tremclad flat black.
M

[marting100]

Next step was the front brake. The piston was pitted with rust, purchased a new one, clean and buff everything
and re-install. Bring the front wheel to a mechanic since I dont have the tool for alignment. Did replace the
wheel bearings and tube, the wheel was aligned and balanced.
M

[marting100]

At this point the dog was fed up of looking at me working on that weird thing and was like "wtf!, build me my pool"
So I did... the water could not fill fast enough for him
M

[marting100]

Carb clean up, overall they where not bad. All needles where fine, I just give them and ultrasonic bath + compressed air
to make sure everything what clear and clean then replaced all o-rings. I bench sync them and later on, sync them on the bike
with the Motion Pro tool I have purchased online.
M

[marting100]

I am not the type of guy that will check the point gaps and make sure they are all good so I decided to go with the Dyna S ignition system.
Installation was simple (for my late version of CB400F, I needed to contact Dynatek to get the bigger center hub piece that have the little magnet on. They send the piece FREE by Fed-Ex and it was at my place 2 days later) I did make sure my valve gaps were all set set and then proceeded with the advanced timing as per Dynatek instruction using the test light method.
I was missing the point cover gasket, I got it from BikeBandit.com along with a clutch cable and a new clutch lever switch.
M

[marting100]

Next was the seat, the cover needed to be replaced, it have been repaired in the past and after taking it apart I have found that the seat pan was crack due to water infiltration. Since I do not have a welding machine and I did not feel like source the job out I proceeded doing the job myself with metal epoxy and aluminum plates
that I have riveted in place. The seat pan end up very strong and not so bad looking with the new cover.
M

[marting100]

The exhaust was not so bad except for the collector that have been welded in the past by PO and after inspection had some major holes in it.
Since I did not have the $ to change it this year (yes I was on a budget) I decided to use (again) some aluminum plates with Spider patch exhaust repair wrap for gasket
+ rivets. Once installed, I have patch the little rivets heads with Spider Patch putty (I left on clear for the condensation to go out and hopefully stop the rust)
I sanded all the pipe to give them a brush finish and coated them all with some VHT clear. I am not a big fan of chrome so overall I like the dull metal finish.
M

[marting100]

I have to say that I have pass a lot of time cleaning everything and a couple of brush wheels is a must have 
For the rear fender I brush most of the rust out and painted the inside with Tremclad matte black. (also did all the frame paint retouch with Tremclad semi-gloss)
I found some double filament lights for the front turn signal lights to keep them as running light. For the back I have found some heavy duty lights in a similar shape that allowed me to use them to secure the frame with the fender and leaving enough space for the seat.

One of the bigger problem I got was when I broke the cam chain adj. bolt. I did manage to drill it out, threaded a new hole and put a plug bolt. I made myself a new adjusting bolt that push directly on the top of the rod. You need to take out the motor mounts to adj. it but once it's done it work like a charm, when the horse shoe is working that is  .

Overall I must have spend 90++ hrs on the bike and I loved it. So far I went on the road 3 time for a total of 500 miles without any problem. In Québec once you get your apprentice license you have to ride with someone for 11 months (someone that have is license since at least 2 years), then next year I can pass my final test and be free.

I am still playing with the air mix ratio, from Hondaman great advise on this forum I am now running the Denso spark plugs and have been doing great on the last 150 miles run.

So in a nut shell that's pretty much it. If you guys have any questions/comments/suggestions, please let me know.
Thanks!
M

[Restoration Fan]

Very nice job! 
You said the bike is running.  Is it running well and have you been riding it?

Ron

[marting100]

Very nice job! 
You said the bike is running.  Is it running well and have you been riding it?

Ron

Thanks Ron!
So far I went on the road 3 time for a total of 500 miles without any problem. In Québec once you get your apprentice license you have to ride with someone for 11 months (someone that have is license since at least 2 years), next year end of July I can pass my final test and be free (and put a lot more miles on the bike anytime I want)

I am still playing with the air mix ratio, from Hondaman great advise on this forum I am now running the Denso spark plugs and have been doing great on the last 150 miles run. The bike is great on all rpm, no power loss, the only thing I am thinking of doing is replacing the clutch plates, they are not skipping but I am thinking the clutch could work a little better on low gears.
Cheers!
M

[hondamad]

Nice one , great to see another honda rescued

[marting100]

Nice one , great to see another honda rescued

Thanks!

[Jore]

Thanks guys!!

HI Jore, not bad french at all. I am from Québec Province, living in the town of Granby.
Thanks!
M

La belle province, I've actually been around your land, but mostly I was around Saint-Jean-sur-Richelieu and Montréal.

You're doing and excellent job on the bike, keep it up.

[marting100]

Thanks guys!!

HI Jore, not bad french at all. I am from Québec Province, living in the town of Granby.
Thanks!
M

La belle province, I've actually been around your land, but mostly I was around Saint-Jean-sur-Richelieu and Montréal.

You're doing and excellent job on the bike, keep it up.

Thanks man, I appreciate
M

[marting100]

Nothing really special happening lately, wanted to cut the front fender but not the original.
Found an old 350 1972 on ebay for 20$. Clean the inside and painted with Rustolium rubber paint (cant remember the exact name).
Here's what it look like.
M

[marting100]

Cold weather is setting in, winter is coming 
I took out the oil pan just to make sure nothing special went in there during summer riding/initial tune-up, everything look good, clean it up and put a new gasket.
I did not check the clutch plates this summer when I got the bike and did the initial tune-up, the bike was slipping a little this summer.
I open it up and from what I could see, the plates where long gone. Ordered some new EBC clutch plates, springs, gasket and the special tool to remove the basket center nut.
End up using my impact screwdriver and it came loose easily. New plates, springs, gasket and oil _ DONE!
I will make a quick test run and put it to bed this week-end probably (not happy about that).
M 

[przjohn]

I like the Yellow 400s. Looks like you are doing a great job, nice bike.

I think I've been through Granby snowmobiling. We use to go to Quebec quite a bit snowmobiling. We would leave out of Newport VT and spend a week touring through Quebec. It  has been about 7 years since we have been up there but we always had a great time. Big fan of poutine and the Women of Quebec. I don't know why, but as soon as your cross that border from VT there seems to be an abundance of fine ladies. Kudos I say, Kudos, to our Northern neighbors on that front!

[marting100]

Thanks dude!
Québec city and up north is an awesome place for Snowmobile, ...ur not the 1st one saying we have fine ladies, I believe it's true 

[Jore]

Marting100, how hard was it changing the clutch? I'm about to tackle that same job.

[NobleHops]

Bravo man, you did a great job using the parts you had and repairing and not replacing where you could. Well done!