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Author Topic: CB400 Four to XR400 Four  (Read 54061 times)

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pennswoodsed

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Re: CB400 Four to XR400 Four
« Reply #25 on: November 24, 2009, 08:21:39 AM »

     very nice , is frame top narrow ? if so ,plastic tank ? many ,many avail here ,may be there as well ?
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #26 on: November 25, 2009, 01:46:55 AM »
Quote from: pennswoodsed on November 24, 2009, 08:21:39 AM

     very nice , is frame top narrow ? if so ,plastic tank ? many ,many avail here ,may be there as well ?

It is but you dont have a lot depth to go down. I will have to put the front end on and then see if the XL tank will fit then look from there. I will be making bar risers to lift the bars higher and therefore more clearance.
« Last Edit: November 25, 2009, 02:34:45 AM by Pezz »
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #27 on: January 04, 2010, 02:10:59 PM »
Well it’s been a while since I updated this thread, so here goes.

I had a couple of friends from Advrider, Odeano and ATGreg over for a cup of tea and a chat to pull the head and barrel off to get bored and overhauled. We didn’t do much but it was good to catch up, Thanks Guys.





The motor looked like this inside



The head looks like it may need a clean


It now looks like this


I have the parts fische for the CB400Four and looked up some of the parts needed to get the bike built. It was amazing the price difference between here and Overseas. Mainly Gaskets and O-rings etc

David Silver Honda in the UK worked around $280 + freight
Service Honda in the USofA worked out $256 + freight
Honda Australia worked out $596

After some sourcing O-rings locally I got the US order down to $116 Aussie + freight.

It pays to shop around. One o-ring from Honda was $9.75 from CBC Bearings $0.17, when you need 4 it saved me close to $29.00. Another o-ring from Honda was $11.25 from CBC Bearings $0.30, when you need 4 it saved me close to $44.00.

The barrel has been bored and just need to gap the rings and wait for the parts to arrive. I decided to paint the barrel satin black, for heat dissipation. Looks nice too.
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Offline camelman

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Re: CB400 Four to XR400 Four
« Reply #28 on: January 06, 2010, 05:19:56 PM »
Good call on the black hole radiation effect.  Cool cylinders = happy engine.

How did you clean up the cylinder head?

Camelman
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #29 on: January 06, 2010, 07:18:06 PM »
It was soda blasted, very good on the alloy and you just wash off in water and it leaves no residue.

Highly recommended
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Offline bill440cars

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Re: CB400 Four to XR400 Four
« Reply #30 on: January 06, 2010, 08:42:23 PM »


           Ah, a Cool bike build AND an Excellent Cause to do it for! 8) ;)

                                         My Hat's off to YOU! :)
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #31 on: January 10, 2010, 05:38:53 PM »
Quote from: bill440cars on January 06, 2010, 08:42:23 PM


           Ah, a Cool bike build AND an Excellent Cause to do it for! 8) ;)

                                         My Hat's off to YOU! :)

If you want to follow it there is thread on Adventure Rider in the Australian forum.

http://www.advrider.com/forums/showthread.php?t=519541

I am waiting on a UPS Package to arrive from the UK with the Valve Stem seals along with some other essential o-rings. I also ordered a set of engine bars too.

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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #32 on: January 11, 2010, 03:11:19 AM »
Just trying to get my head around the rear end of this project. The top shock mounts are a fair way back and to get travel I will need to get different shocks to make it work. Im hoping for around 200mm or 8" of travel at the back. I am running a XL250 R swingarm which 100 mm longer than the CB400/4 one is.

I was given a set of stock shocks of a 'New' series 900 Triumph Thruxton. but they only have 75-80mm of travel.

I may be swinging back to the Pro-link option off the 250 . . . . .
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #33 on: January 12, 2010, 02:58:04 AM »
Well Im at a bit of a stalemate with the back end of this build . . . .

The front end will be a snack, I want to match the travel, front and rear. The XL steel swing arm is 540mm long. However the top shock mount is way too far back to make it work with what I have in the shed.

In wanted to be sympathetic to the little 'Supersports' and try to make everything reversible. But it just doesn't work the way it is????
If I butcher the frame I will condemn this bike to Off-Road for ever  ???

Probably not the worst fate . . . . but it will take a lot of time to get it right, and I only have 4 weeks to finish the build, with the parcel arriving any day from the UK with the Parts I ordered to finish the engine.

Decisions, decisions.

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Offline Ecosse

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Re: CB400 Four to XR400 Four
« Reply #34 on: January 12, 2010, 02:21:21 PM »
just a thought: how about making it a scrambler? almost like a big brother (sister?) to the little sl.

this triumph is on my lust list.
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #35 on: January 13, 2010, 01:28:10 AM »
Just picked these up on Flea-bay USofA

Husky Ohlins . . . . practically stole them, they were so cheap  ;D

Still think I will have to mod the subframe

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Offline HavocTurbo

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Re: CB400 Four to XR400 Four
« Reply #36 on: January 13, 2010, 11:22:50 AM »
Quote from: Pezz on November 23, 2009, 02:20:46 PM

I recently picked up an XL250R with an XR Disc brake front for $362 off ebay  ;D



What year? I might have a set of Progressive fork springs sitting sround that would fit. Might help with the feel.
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #37 on: January 14, 2010, 01:59:46 AM »
Quote from: HavocTurbo on January 13, 2010, 11:22:50 AM
Quote from: Pezz on November 23, 2009, 02:20:46 PM

I recently picked up an XL250R with an XR Disc brake front for $362 off ebay  ;D



What year? I might have a set of Progressive fork springs sitting sround that would fit. Might help with the feel.

To be honest I have no idea, it came on the bike, unsure what 'XR' the front end is off?

Thanks for the kind offer
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Offline HavocTurbo

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Re: CB400 Four to XR400 Four
« Reply #38 on: January 14, 2010, 02:50:53 PM »
Well of you ever set out to taking them apart.... measure the springs and let me know.
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #39 on: January 19, 2010, 05:38:29 PM »
Bit of engine work been happening.

Lapped the valves after refacing them.


The head reassembled. I had to deck the head as it was out by about 4 thou variation from the sides to the middle.


I picked up this Husky swing arm which is about 600mm long and suits the  Ohlins shocks picked up from Ebay USofA.




Now about to overhaul the carbies and reassemble
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Offline Holdingfast

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Re: CB400 Four to XR400 Four
« Reply #40 on: January 20, 2010, 09:19:37 AM »
way exciting, this is gonna be awesome!
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #41 on: January 23, 2010, 12:53:57 AM »
 :'(

Well I started to work on the carbies and to say they were filthy is an understatement. The stalest fuel I have ever smelt.

They were very difficult to get apart, corrosion everywhere, and in the process the piston lift linkage broke, soft alloy.

So I look up the part number and see that to replace the on link assembly will cost about £206.50 + freight  :o

The rest of the motor is ready to go back together again.

So the big question is where to from here?

Anyone have a spare set of carbies they would part out????

Open to any suggestions. Maybe other carbies that will do the trick? Its 460cc 's
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Offline Industrial Rat400f Killer

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Re: CB400 Four to XR400 Four
« Reply #42 on: January 23, 2010, 07:00:15 AM »
Hey man, sorry I never replied to your email, life's been real busy. I might have that part you're looking for. I'm not familiar with it by name though can you post a pic or a link to pic?
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #43 on: January 24, 2010, 12:43:21 AM »
No Worries Rat400F

Thank you Mr Ebay. I friend who read of my predicament on Advrider, found a set locally on ebay.   ;D

Well I now own a dusty old set of CB400 Carbies for the sum of $100 delivered. Now I just have to get them pulled down and make a good set out of the 2. PHEW!!!! I have the Carbie overhaul kits. Do the needles need replacing? as this is what brought me undone on the last set??

I am also going to pull the engine out of the frame to reassemble and whilst its out I will modify the sub frame to take the Ohlins and Husky swing arm.



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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #44 on: January 25, 2010, 04:29:27 PM »
This is the little linkage that nearly cost me $500, see screwdriver tip.
There sure are a lot of moving parts in these old Carbies





Lifted the engine out of the frame after removing the sump, its a pretty straight forward job.

This will make the fitting of the top end much easier, abd will make it easier allow for the sub frame mods to be carried out.



When I look at the engine out of the frame I felt like splitting the cases, but then I thought of the $$$  ???



One of the the things I battle with is not to get too carried away with the build, I said earlier I wanted it to be a scrapheap bike and not a 'Nice' bike. However I think it will look okay with all the old bling, especially the back end  ;D


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Offline Terry in Australia

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Re: CB400 Four to XR400 Four
« Reply #45 on: January 25, 2010, 05:15:59 PM »
Hey nice work Pezz, I've got you a cooler radiator now and have almost finished the adapter, I'll get it to you shortly. Are you going to use the XR front and rear wheels? If so, let me know, a mate of mine here is doing up a 400/4 and would love those wheels, swingarm etc and any leftover parts! Can you install the XR tank and seat as well? That'd be cool! Cheers, Terry. ;D
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #46 on: January 25, 2010, 06:46:37 PM »
G'day Terry

I intend to use the complete XR front end and was going to use the swing arm as well but its a lot of work to make the suspension fit and it became easier to run the Husky item and twin shocks.

However I am going to run the 18" 400 rear wheel. I will let you known what I have left when I finish. I was trying to build it so I could be made a 400/4 again . . . . But maybe not.

The tank wont fit as its too wide, it sits way too high to clear the bars etc.

Got a reply from a guy on another forum:
One from England




So Im not the only mad one in the world  8)
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Offline Terry in Australia

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Re: CB400 Four to XR400 Four
« Reply #47 on: January 26, 2010, 02:53:12 AM »
No worries Pezz, keep me in mind if you aren't going to use the 400F bits. How many spokes are the XR wheels, 36 or 40? Cheers, Terry. ;D
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I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #48 on: January 26, 2010, 04:47:08 AM »
They look to be 36 spoke wheels.

I will keep you in mind if and when the time comes to part out the rest of the bike
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Offline Pezz

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Re: CB400 Four to XR400 Four
« Reply #49 on: January 30, 2010, 12:04:15 AM »
Well in for a penny . . . . . decided to split the cases

Onto the operating table



Oil pump and alternator removed.



Clutch about to come out



Behind the clutch



All ready to split the cases



Open Heart



Fair amount of sludge in the bottom case



Now the lot has to go off to the Soda Blasters for a good clean, and I have to order some more seals.The gearbox looks great as does the crank. Peace of mind :)

The carbies arrived on Friday and after a thorough clean up look great, didnt get a chance to open them up but they are a much better place to start from than the other set.




 
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