1976 CB400 Four

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Have been working away for the last few days, so have only managed to get back to this today - had a few hours this afternoon/evening to have a look at it again.

First job was that cylinder head and the cylinder - and the fact that they were stuck fast.

Decided to be logical about it and had a good look around to see what was what.

Well, it's off:

https://i.imgur.com/Zg7L2mT.jpg

How? I hear you all cry in desperation.. (hah).

Well, there's these little tabs - sort of raised bits right in the middle front and back which are strong enough to get a decent flat head screwdriver on, and with a very very light pressure you can just get enough leverage on to break the seal holding the two dowels in:

https://i.imgur.com/6pWwoCV.jpg

https://i.imgur.com/ZEBC7ip.jpg

If anyone is attempting this and the head is stuck fast - have a look for the raised bits and give it some very gentle leverage. Gasket came off as one and the mating surfaces are untouched.. Phew!

Next job was to take the pistons off. There is one split clip missing - I reckon I'm going to find it in the crank case:

https://i.imgur.com/fRnFPPL.jpg

More bits then came off - connecting rod was locked off with a 'stout bar' (as per haynes) and a gear puller used to pop the alternator rotor off:

https://i.imgur.com/Tpytf6J.jpg

Clutch cover was then popped off - needed some liberal rubber mallet to release the gasket on it.. Then out came clutch spider, springs etc..

https://i.imgur.com/OGVnJlw.jpg

All was looking pretty good:

https://i.imgur.com/ZMSL0FQ.jpg

And then I noticed this abortion of a mess:

https://i.imgur.com/x148RL0.jpg

That's the castellated retaining nut for the clutch basket. Yeah, right - castellated. Mutilated more like.

Tomorrow is going to start with a head scratch and trying to work out how to get that bugger off after it was utterly mangled when last put on..

Hope you are all enjoying the ride!
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

chickenstrip · Super Spammer Joined: 06 Dec 2013 Karma :

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Pistons are showing no sign of blow-by yet there's heavy staining on the head. I wonder if the 50 on the pistons means it's been over-bored 0.5mm?
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Although I doubt anyone has missed me posting, apologies for the gap - I've been rather busy, and I've been waiting for Mr Postman to deliver one of these:

https://i.imgur.com/8En8Vgm.jpg

It's the first tool I've had to buy for the CB400f - a special socket for the clutch basket nut, and spanner to hold the basket whilst trying to remove the nut. If you remember, the nut itself is somewhat shagged - but it was worth getting the tool - came off like a dream and I can use it to get a new one back on!

Here's the offending item:

https://i.imgur.com/LjxBRjQ.jpg

And once off, I could disassemble the clutch, and the gear change linkage with some ease. It's a bit fiddly to get everything off, but nothing that 45 mins and some patience didn't stop:

https://i.imgur.com/q0AR4cX.jpg

And that leaves the side of the casing free for the next stage - at the weekend I'm going to split the casings.

https://i.imgur.com/06DNywL.jpg

Had a bit more time left tonight, so started to strip the front wheel. The tyre was so old that there just wasn't any play left in it. Every time I tried to get an iron onto it, the rubber cracked and split. Had to resort to a hacksaw to get the bugger off.

Anyway, once off, it was a simple case of getting the spacer off and the spindle out, removing the disc, then knocking off the bearing cover:

https://i.imgur.com/6u08vBx.jpg

Leaving me with the bearings to do next:

https://i.imgur.com/eEAGrd3.jpg

On the other side there is a castle nut that holds the bearing in and the rubber seal as well. I could invest in something to get it out, or I could knock it out with a drift. It's very soft aluminium alloy so if I knock it out it will be wrecked. I'll decide tomorrow.

https://i.imgur.com/pYaZIPN.jpg

As an aside - remember I said I found some bits in the sump? Well I drained it out tonight, and here they are. Anyone want to guess what they are?

https://i.imgur.com/o2Sh3ar.jpg
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Looks like the neutral light switch pin.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good Very Happy

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

S1417 · Nitrous Nuisance Joined: 30 Apr 2014 Karma :

Enjoying this, looks like good work so far Thumbs Up

Ed Case · World Chat Champion Joined: 01 Mar 2009 Karma :

You're in for shifting a few quid before you're finished !.

bladeblaster · Trackday Trickster Joined: 19 Jan 2015 Karma :

great thread, keep it up Thumbs Up

Shaft · World Chat Champion Joined: 27 Dec 2010 Karma :

.Chris. · World Chat Champion Joined: 09 Jun 2007 Karma :

A new one is just over £7 from David Silver. Looks like it screws in so you might need the tool to put a new one in anyway.

Keep up the good work Thumbs Up

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Chris
1985 Kawasaki Z550F

Shaft · World Chat Champion Joined: 27 Dec 2010 Karma :

Fizzer Thou · World Chat Champion Joined: 06 Aug 2011 Karma :

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Cheers for the suggestions folks - been away this weekend, but tomorrow night I will have a closer look and see what would be best to use.

It's going to be replaced anyway, so I'm not too fussed if it gets mauled. However, the idea of having a tool to get the new one in is a good one!
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

Bridgehouse · Renault 5 Driver Joined: 11 Dec 2015 Karma :

Guys - sorry about the lack of activity. Ground to a halt due to work and a shed refurbishment for the missus workshop.

I'm back on the case by the end of the week though!
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

Suntan Sid · World Chat Champion Joined: 07 May 2009 Karma :

There is a similar "nut" on the rear wheel of my XL125.
To get mine out and back in I took a length of flat steel bar, drilled two holes in it, tapped the holes and screwed in two, appropriately sized, bolts and used that.
The "nut" has a very fine thread on it, if it's been in there for a long time you'll need a lot of force to get it moving. I used a meter long bar to get plenty of leverage, it worked for me.
I don't think I'd have got it out with pin pliers mentioned above!
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