Topic: CB400F project, where to start?

[Flyin900]

Just fill the hole in the front of the case with JB Weld, as you won't be using that anymore to lock the slipper rod in there. The adjustment and locking is now done all from the new bolt in the top. I would play with getting the tension adjusted while the motor is out and the valve cover is off. You can see the tensioner moving and get a good feel for it first by adjusting it while the motor is out of the bike.
Just a warning on that new bolt assy it only needs very minor adjustments and you can easily over do it, so go easy if you are adjusting it when the motor is installed and running. I used the bolt to adjust a CB350F that I restored and just get a better idea of how the tensioner was working overall. I didn't leave it in the bike, as the original lock bolt was good and I only used it to apply some tension. It can be hard to get at once the motor is in there with a 4 into 1 header (clearance) so I had to remove the one motor mount front bracket to get room to not burn myself while the engine was running.
I would also consider pulling the head as suggested to check that everything is good and clean up the cam lobes and valve springs and install some new valve seals. I used a EBay seller in Poland for the complete gasket set and it was really inexpensive around $50US and reasonable shipping. You get everything you need including the oil seals for the oil pipes in the head and all the gaskets etc. I think he was called Klassen Motorwerks???

[spuds]

Hey Alaxy,

Good to see you making some progress!!  Coming along nicely.

[Flyin900]

To put the new seal and piston into the caliper just use some fresh brake fluid to lube the seal and the outside of the piston and push it into the caliper.

[Alaxy Galaxy]

To put the new seal and piston into the caliper just use some fresh brake fluid to lube the seal and the outside of the piston and push it into the caliper.

I *was* going to do that, but man-oh-man, there are some very polarizing opinions here on the forum regarding that. I got pretty paranoid while reading two threads, namely

Topic: Brake assembly lube for caliper piston seal
and
Topic: To grease the caliper piston & seal... or to not grease
(couldn't figure out how to link the threads).

Anyway, I ordered a proper sized handlebar and will concentrate on assembling that first along with rebuilding the master cylinder. I'll get to installing the piston later...

Also, maybe this thread should be moved to the "projects shop;" what do you think, mods?

[Alaxy Galaxy]

Last night I dove into my sidecovers.

As the bits I got were mostly from a '77 CB400F and I'm aiming for a '76 parakeed yellow bike, I went ahead and decided to change my Antares red covers to black.

The right one had a very long crack and was missing some plastic too, so I filled that in with 24hr epoxy backed with some application-specific epoxy mesh (*ahem* drywall screen tape). I tried every trick in the book to remove the decal. Heat we the most effective, but it would only remove the decal and not the glue behind it. I ended up block-sanding it away with 80 grit, followed by 200, then 320.

The LH cover was in good shape and only needed the decal removed. I found something odd while sanding it away: under the candy red and metallic silver paint was a coat of varnish blue. I mean, I know car manufacturers sometimes re-shoot parts a different colour, but what I find odd is that, not only did these colours not coexist, they never even overlapped! There was a full model year between them...

Anyway, now both covers are coated with a grainy layer of primer and I'm mostly pleased with the result. I have to do some slight correction on the rounded edge above the filled-in hole on the RH cover (and respray some primer there), and after that, I'm going to... - wait for it - Paint it Black.

[MoMo]

I see a red cover and I want it painted black?   or was that red door ..Larry

[Alaxy Galaxy]

I see a red cover and I want it painted black?   or was that red door ..Larry

 

LOL! I hadn't even though of that! Okay. It's really late.

[Alaxy Galaxy]

Just to give folks here a general idea of where the bike is at, here 'tis:



I've been pretty lucky scurrying the 'net and finding good parts on the cheap. My biggest hurdle to that is finding a muffler because I don't want to pay 300$ for a re-pop. I think I can borrow a friend's muffler to pass the inspection here, but after that, he's gonna want it back! I was thinking getting an Emgo, but they just don't look quite right. 

[FuZZie]

I don't recognize it without the blue tarp and crates! 

[Flyin900]

The fellow bobbing a CB 400F from Ottawa (Spuds) has a DSS reproduction from his pictures and sounds like he is interested in selling. He has posted here on your blog.

[Alaxy Galaxy]

I don't recognize it without the blue tarp and crates! 

 

[spuds]

I don't recognize it without the blue tarp and crates! 

 

Thanks Flyin'-----contact has been made!!

[Alaxy Galaxy]

Back from vacation, and back to workin on the bike.

Two engines are better than one, right? (and to Fuzzie's delight, the return of the blue tarp!) The left-hand engine is a 1975 and in better shape (albeit dirtier) than the 1977 I got with the parts lot. It's missing a lot of stuff, but I already have all the stuff on the other motor.

[Flyin900]

Welcome back... hopefully you went somewhere both warm and restful!

Finally got the tank and side covers back from the painter on my CB400F (Varnish Blue) and so it is finished and waiting for some warm weather to move it outside.

[Alaxy Galaxy]

Welcome back... hopefully you went somewhere both warm and restful!

Finally got the tank and side covers back from the painter on my CB400F (Varnish Blue) and so it is finished and waiting for some warm weather to move it outside.

I was in Cuba, actually. First time further south than the States. It was great, actually. My wife loved the beach, I loved the cool cars.

I'm in the same boat as you for my 400/4. There's no more snow on the ground, but it's still mighty cold up here in Montreal. I can't wait to take the bike out of my basement so I can fit the engine and finally fire her up!

[Coredozer19]

I recently completed a similar project except the motor received a full rebuild which I did first

I agree with this. I would start with the engine. Without an engine the bike is no good. I started with my engine. And did everything else after I pulled the engine completely apart and accessed the damages

[b1jackson]

Happy to follow this thread and know that some fellow Canadians may have some spare parts kicking around.  I'll be starting my 400f rebuild this summer (77 parakeet yellow) and also attempting to rebuild a second bike with the spare parts.  It's a 75 frame.

Cheers and bring on summer!

[Don R]

 Good job on the restore of a challenging bike. For those still chasing parts, I've used the cb360 forks, they are the same. I'd assume other parts match up also. I think the 360 headlight bracket may be used to run the early turn signals and 450 rear signal brackets fit the frame and they look great. I wish I'd taken more pics of the ones I rebuilt.

 

[Alaxy Galaxy]

Thanks. I actually have most of the bike together now, sans engine. Other than what I'm going to purchase new (master cyl rebuild kit, battery, petcock, etc) I'm only missing the fusebox cover, the tool tray cover and a front fender stay. Actually, if anyone is looking for a '77 only Front fender without provisions for a front stay in excellent condition (also fits some CB360 models, I believe), I'll trade for one with two stays, in excellent condition. I'm the kind of guy that hates altering OEM parts, so despite my "disguising" my '77 as a '76, I'm unwilling to drill holes for that front stay. I'm still trying to figure out a way to get the stay to stay in place (<--- right? right?). So far I've had a few ideas:

-screw the two bolts on the fork tubes REALLY TIGHT
or
-add some small clips/wire that grab onto the fender and the stay
or
-use some sort of glue between the fender and the stay

[Flyin900]

Consider using the 77 front fender on the 76 with only the rear stay. Unless your trying to achieve a high level restoration the 77 will look fine and is supported without the need for another front stay on the 76 front end. As you know finding chrome parts that still look very good up isn't an easy task.
If you really what the front stay I believe I have a couple that would work from either the CB350F or the CB400F previous builds I did. Chrome maybe an issue or not I would have to check the parts condition.

[Stev-o]

Welcome back... hopefully you went somewhere both warm and restful!

Finally got the tank and side covers back from the painter on my CB400F (Varnish Blue) and so it is finished and waiting for some warm weather to move it outside.

I was in Cuba, actually. First time further south than the States. It was great, actually. My wife loved the beach, I loved the cool cars.

Very cool, I've always wanted to go to Cuba.  My sister was there a couple months ago, they toured the island in a classic old Chevy!

[Bodi]

Love those handlebars. I got a partly stripped "roller" where the bars were a piece of hockey stick bolted to the bar clamps, missing two bolts and the top clamp pieces of course. Good bunch of other spare parts on it though!
Looks like a fun project.

[Alaxy Galaxy]

Love those handlebars. I got a partly stripped "roller" where the bars were a piece of hockey stick bolted to the bar clamps, missing two bolts and the top clamp pieces of course. Good bunch of other spare parts on it though!
Looks like a fun project.

I kept the plastic pipe there for a long time only because the regular bars were too wide for the door frame that leads to my "shop" (laundry room). But I figured if I took the door out, I could leave the bars on.

Here it is now in the kids' playroom, waiting for fair weather and many friends to help bring it up a half flight of stairs!

[Alaxy Galaxy]

If you really what the front stay I believe I have a couple that would work from either the CB350F or the CB400F previous builds I did. Chrome maybe an issue or not I would have to check the parts condition.

Thank you Flyin, I'll think about that. In any event, I could always modify a back stay if one had the best chrome. Anyway, I'm not in a rush for that part.

[Flyin900]

I looks fine with the 77 front fender. That is what I am running on my 76 too as the PO supplied the project with an excellent front and rear fender set up with really nice chrome finishes on both pieces. As you know other that buying NOS fenders or reproduction pieces new it is almost impossible to find used fenders in excellent condition.