Topic: cb400f "Project Resurrection"

[DarcyCB400F]

Hi Jamie,
The "spring" could very lilely be a heli coil... you want to be very careful of this repair in a brake caliper. It has been placed there becasue the threads were stripped by a PO. If that heli coil fails, it will fail under pressure...from your brake lever. This won't be a good thing to have it fail when you need it the most.
Is there any options? can you find a larger blead screw perhaps? Tap it out and replace it? Check around for a "Time Sert" repair. This method uses a solid sleeve that is permantly installed.
Maybe a replacement caliper is in your future.
Take care with that heli coil. If it lets go, you might be in trouble!
Darcy

p.s. Nice work on the entire project!!!!

[-CB-Jamie-]

Thanks Darcy that was my main worry exactly that it could fail under pressure, I have a spare caliper too but there's a broken bleeder in that so I might try get that out with an easy out or if that fails I might go scouring ebay for one, ah well.

Jamie

[-CB-Jamie-]

Ok so it's been a while since I've updated, don't think I said it before but I was unemployed for a while but I now have a job so I can start spending money on my bike again 
So out of my first weeks wages I decided to treat myself and this is what I got.





Its the replica header collector box assembly from DSS, haven't seen anyone else on the forum try one of them yet so thought I'd be the guinea pig. Have to say I'm quite happy with it so far. The four pipes just slide into the collector box and thens there's a pinch bolt on one of the pipes. The chroming and everything seems up to standard as well. I know they're only single walled unlike the originals but I don't really care.

I finally also got my Hondaman ignition, I was waiting about 6-7 weeks and it never arrived so I contacted Mark and he was good enough to send a second one and that arrived very fast then, so looks like there's a hondaman ignition floating around out there in the mail somewhere Got it installed neatly attached to the back of the battery box by the plastic rear fender thing. and all wires neatly hidden. You can kinda make it out in this pic.


Having a problem with one of my carbs overflowing so have them off now trying to sort that so hopefully should be putting them back on tomorrow and will be able to check out the header assembly with the bike running to make sure alls ok.

Jamie

[strynboen]

fine kollektor..have rebuild mine. old orginal.just the same vay..with loose exhost lines..and reused the pipes..but mine orginal are not that stright..under engine..have more snake arraund..but they looks fine
have ds have that type for 550

[-CB-Jamie-]

Don't think he has them for the 550 as far as I know Strynboen

[-CB-Jamie-]

I finally started the bike yesterday for the first time with the new header and was just checking to make sure each header pipe was getting hot to make sure it was running on all four. Anyway as I was checking the number 4 pipe I felt what seemed like air escaping from somewhere and I just thought I hadn't clamped it back on to the block properly or something. But then I investigated further and it looks like there's a seam that runs down the length of the pipe and it has little splits every now and again along the seam. Pretty pissed I'm just in the process of emailing DSS about it now. I'd say there'll be no problem getting it sorted though.

Here's a pic of the splits

[maduncle]

Bummer - and here I was scrolling down the page admiring that sweet header set up.

Let us know what the supplier has to say...

[strynboen]

ferdamte scheise..vhy use bad tubing..on exhostings systems..with heat and vibrations problems..happely they are broke before you have uset it for 1 year..and garentee vas lost..think they are made in taivan or beleruss

[gsnorcal]

I'm sure you're bummed, but I get the sense that DSS is a stand-up organization. Give them a chance to make it right, and let us all know how it goes.

[Syscrush]

Very, very nice work.

[-CB-Jamie-]

OK thanks guys for all the support so just got an email back from DSS, they are sending me out a replacement pipe number 4 first thing tomorrow, they don't even want the one I have back to check it or anything. Turns out Motad is actually their supplier for these replica headers, Motad are an English company I believe Strynboen if I'm not mistaken.

[gsnorcal]

OK thanks guys for all the support so just got an email back from DSS, they are sending me out a replacement pipe number 4 first thing tomorrow, they don't even want the one I have back to check it or anything. Turns out Motad is actually their supplier for these replica headers, Motad are an English company I believe Strynboen if I'm not mistaken.

Awesome!!!

[strynboen]

ds are nice peapel,,,they ewen understand my english.. ..they send vrong plates for my 550 chlucth..but sent replasments ..even it vas 1,5 year since i bay them..and let me keep the vrong ones..they fit in my other procjekt..very ok service

[-CB-Jamie-]

Hello everyone,
Well it's been a while again since I've updated. Haven't had much time to work on the bike over the last few months but now I've gotten back into it in the last few weeks again. I have since sold my Honda Rebel 250 and got myself a 2009 Honda cbf600 (big power difference) as my daily driver and also got my full motorcycle driving license on it a few weeks ago here it is in all it's glory. Also been having too much fun on this bike so that's another reason I haven't been working on the 400




So here's what I've done since my last update.
Ordered some bits from DSS, mainly rear brake linkage, mirrors, grips chain and sprockets and lots of other bits and pieces that somehow really seem to bring up the cost a lot  Have ordered a new seat also from DSS and am expecting that tomorrow.

So I now have my rear brake and brake light all hooked up and working properly, fitted the chain this morning after removing a few links from the chain as I'm guessing it's just a universal chain they sent me that does a few different bikes.



I also got a new clutch cable installed but seem to be having a bit of a problem with the clutch, I put the bike on the centre stand, started it and put it into gear. the rear wheel went around as expected but if I pull in the clutch it doesn't stop and if I press the rear brake with the clutch pulled in the bike just cuts out, so basically the clutch just doesn't seem to be working. I'm 99% sure it's adjusted properly going by the workshop manual and also I removed it ages ago to measure the clutch plates and they were all well within tolerance, anybody any ideas???

I also took a short video of it here today as I seem to be having a small problem with the running of the bike, for some reason it seems to me that it's a bit slow to come back to idle after it is revved up a bit. Again what's peoples opinions on this??

Cheers, Jamie

CB400Four

[assquatch20]

If the grip itself is slow to return to its stop, I'd think either the spring on the carb bank, the 'spring' on the grip, or the cable needs some slack let in. Outside of that, jetting or too much vacuum for some reason?

[strynboen]

hey have same trobbel vith my 550..that retyrn spring must be ok,,and the pull push kabes must be 100% right..to tight it be harder to mowe ,,to loose and it revvs up anytime ,,,,its a balance..but go on road and drive a day..and then adjust and syncro..all works better vhen it have run a long trip..even it not are perfekt adjusted..
sorry for my viking laungish..but think you get it...

[-CB-Jamie-]

No there's definitely nothing wrong with my return spring, the thottle snaps back to closed no problem and I'm pretty sure my cables are adjusted correctly but I'll have another check Strynboen, like you say maybe a long trip could help things settle down a bit. Sure this bike hasn't been driven in years, if only I could get that clutch sorted I could take it for a ride.

[Really?]

running lean, vacuum leak, sync carbs?

[-CB-Jamie-]

GODDAMMIT!! Was moving the bike out today to do a bit of work and as I was putting it back on the centre stand my foot slipped a little and the bike went over sideways, luckily enough though I managed to hold onto the left grip some bit and kept it partly up but my brand new mirror is damaged and I'd say not repairable, coulda been worse though I suppose there could have been a lot more damage.

My broken mirror


Anyway I got my new seat as well from DSS, the thing is mint and makes a big difference to the bike overall.

running lean, vacuum leak, sync carbs?

Ya I've synched the carbs and pretty sure I'm not running lean but I'll have a check for vacuum leaks, cheers.

[-CB-Jamie-]

Yes finally got the clutch sorted and took this thing for a quick ride up and down my street a few times. After stripping down the clutch I noticed the plates were just filthy and the clutch was just stuck, so I cleaned all the plates and put it back together and hey presto it worked. Unfortunately when I was reinstalling the clutch a bolt that holds the clutch springs and the bearing in sheared off but luckily I had another clutch around from the second engine and was able to swap out the whole part and use new bolts.


The clutch after removal


My cleaning efforts on the plates


The sheared off bolt in the bottom left lug

And so after all this I finally got a drive off the bike up and down my street a few times and I can't believe how well it's going. The bike pulled away evenly and steadily with no apparent flat spots or hesitation although I've only brought it up to about 6000 rpm so far, so I'm really happy with how this thing is going now. It's been a long time and a lot of work to get to here and I never though it would happen. So I think it's time for a before and after photo (even though it's not yet finished)


Before


As it stands now

I think the next thing I'm going to do is redo the spray job, I'm thinking of getting the Honda Milano Red for it. Also think I'm going to go for dyna coils, is it the 3 ohm or 5 ohm coils for these bikes could someone please tell me?
Jamie

[strynboen]

looks good..the hard work are done,,nov it are only opgrades..
mine 400 are in 1000 pieses..missing a gearbox to get it kompleted..but have both my cb 77 and cbx to do this vinter..so vaiting to find a spare engine for no money...it takes some time

[-CB-Jamie-]

So I got the 350f tank, side panels and fork covers back from being painted today and they have turned out brilliant. So after seeing them painted I've decided to get the 400 painted professionally as well as my painting isn't up to scratch. So I spent most of this morning stripping off the paint from the tank and side panels to save on the cost a little but unfortunately I came across a lot of filler at the front left of the tank, my guess is the forks came around into the tank at some stage. It should be ok though.

running lean, vacuum leak, sync carbs?

Think you might have been right Tipper, I think it was running a bit lean at idle as I had the screws 3 turns out and they are supposed to be 2 plus or minus a half. I noticed this while double checking everything. So adjusted them to 2 turns out and it seems much better at idle.

Here's a few pics of the 350f tank, the stripes are painted on at the painters suggestion so you wouldn't see any bulges over decals when lacquered over and it turned out perfect. He was able to match the colour from some paint that was still left on the tank. Should have wiped off the hand prints before taking the pics.






Here's the 400f tank stripped, don't think you can miss the filler 




Jamie

[-CB-Jamie-]

Got my tank and panels back from being painted and what can I say, delighted really happy with how the bike looks now, going from the black to the red has made a big difference to the overall look of the bike. The colour I went with is Honda Festival Red in case anyones interested and it looks pretty close to the original light Ruby Red from what I can tell. Got the decals on ebay and the painter put them on for me.

Also since last time I got a 6 3/8'' h4 headlamp from candlepower and that fitted perfect. Also got new HT leads and plug caps and joined onto the old leads using the NGK splicers, I've noticed a big improvement in how the bike is running now with just having changed the leads and caps especially at idle, it's ticking over now very smoothly with no inconsistent idle and no hang up when you rev it and release the throttle. I would recommend anyone who hasn't already changed the leads and caps to do so as it made a big difference for me.

So thats it I'm officially calling this project finished, only thing I have left to do is get the brake pedal, gear change pedal and chain gaurd re-chromed but there's plenty of time for that. Anyway here's some pics. Just noticed in my pics I still need to shorten my fuel hose to the carbs.

Jamie

Heres the candlepower headlamp


And the paint job

[rickmoore24]

Looks great in red, nice!

[gerryw]

Jamie, looks fantastic, well done!

question, is that a Honda seat or the pattern one from DSS?
It looks great.

gerry