1976 CB400 Four

[pompousporcup...]

good work. initfortheupdates

[.Chris.]

Keep it coming!

It's funny how people have such different standards. Here's me looking at a lot of that thinking it doesn't look too bad .
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Chris
1985 Kawasaki Z550F

[Bridgehouse]

[Bridgehouse]

Got a good few hours in this evening.

Plan was to strip as much as possible ready to get the engine out of the frame.

Got a number of ancillaries off.. as you can see:

https://i.imgur.com/ntN6uYj.jpg

https://i.imgur.com/jFH0Hjb.jpg

https://i.imgur.com/Hr4fqLl.jpg

Now it starts to get interesting. What should have been a simple job.. oil filter and spark plugs...

https://i.imgur.com/sFF1EfB.jpg

Notice something a bit unusual? Yep - the 3rd plug from the left..
Sheared off and left me a present behind to remove with the thread remover later:

https://i.imgur.com/b6NVFEY.jpg

https://i.imgur.com/te1BgBZ.jpg

Then turned her on her side to get the sump pan off. Came off no problem. Noticed a couple of little bits of shiny in the bottom - had a dig around and there's some gubbins in there. Will investigate later in the week and let you know what it might be!

https://i.imgur.com/iCdII52.jpg

All the engine bolts came off bar one.. at the front. Tried just about everything on it. I may have to invest in a big breaker bar and if not then it's going to get ground off.

Here's the bugger:

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

So there she sits, looking a bit sorry for herself, one more bolt and then the engine is out and it's time to prep the frame.. so close!

https://i.imgur.com/crdEI4Z.jpg
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[grr666]

My dad had one of these with a white wedge shaped squire sidecar. I used to 'borrow' it when he was on nights and in bed asleep

It was a death trap DIY job but still a hoot to ride as a combination, nearly killed myself on it with my lack of skill
many times when I was about 17. I'll never forget that noise it made though. Watching with interest.
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Currently enjoying products from Ford, Mazda and Yamaha
Ste wrote: Avatars are fine, it's signatures that need turning off.

[Bridgehouse]

Some days it happens, some days it just doesn't.

Luckily, today it did. I had a meeting in London all day so I dispatched the good lady off to Machine Mart with a little list.

Got home, and there were some goodies waiting for me. Included in these goodies was a 36" breaker bar.

Tackled that dodgy unmoveable nut and after the most almighty crack, off she pops. My faith in physics and mechanics are restored. And that was that. Just one nut today - sounds pathetic, but the time it took was quite unbelievable. I had to jury rig up a hold with blocks of wood and ratchet straps and other random crap just to get one wrench firm whilst the breaker bar did its magic.

Thinking of doing a project yourself? Buy a breaker bar. It will be the best 20 notes you ever spend.

The culprit:

https://i.imgur.com/1EmH2TS.jpg

And the resultant freed up engine ready to come out tomorrow:

https://i.imgur.com/7ab2gNI.jpg

With any luck there will be a rather different view tomorrow!
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[Bridgehouse]

Well, it actually feels like I'm getting somewhere now.

Engine is out. Frame is being prepped (slowly).

Engine came out pretty easy, and it's on the stand ready for stripping:

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

https://i.imgur.com/4I6xfiB.jpg

And of course that left me with a bare frame ready for prepping!

https://i.imgur.com/BGeX2yB.jpg

https://i.imgur.com/4O21d3U.jpg

Centre stand had to come off first - and it seems that the pivot pin was well and truly rusted and corroded to the stand itself. After much hammering and swearing, the hacksaw came out and it was hacked off.. (bit like me!)

https://i.imgur.com/CN4eAM6.jpg

I was going to get a new one anyway, so meh.

Took the frame number plate off the frame as I don't want to risk it getting destroyed during blasting or powdercoating. I've heard horror stories of them being masked but still wiped out. The plan is to use drive screws to put it back on (it's what was used originally)

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

There's two small tabs that need sorting out on the frame - they were retaining clips for the loom, but one had snapped and the other was hanging on by a thread. Took one off, ground it down and drilled a pilot reminder hole as I'm going to fabricate a new pair in thicker metal sheet and pop rivet them on - it's only holding cable, under the tank, and so a pop rivet will be fine. TBH I think that will look neater anyway (specially given my welding!) as it will be put on before powdercoating which will cover the whole lot.

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

Here's the other one I haven't done yet..

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

Finally the rubber stopper for the centre stand had to come off. It's perished and the nut/bolt is rusted to buggery... As it happens, it snapped off after very little applied torque..

https://i.imgur.com/8x831Pf.jpg

Not sure if there will be any work tomorrow, but there definitely will be on Saturday - plan is rest of frame prep, including a jolly good wire brushing for the whole lot, and removal of races, bushes and other such bits. I'd like to get the full pile of bits for powdercoating done and ready by the end of the weekend so they can go next week.
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[DrDonnyBrago]

Loving the project!

Getting a minor lob on over your garage though. So empty. So deliciously empty.

Think I need to hire a skip.

[Bridgehouse]

[Bridgehouse]

Full day to tackle some of the jobs I've been avoiding in the evenings.

On the agenda:

- Headstock bearing races
- Swingarm pivot bushes
- Swingarm shock absorber rubber encapsulated bushes
- Steering lock
- Degreasing the frame

Not much then!

Steering lock was first. Nothing to show really - had to grind off the pin to get the retainer off, and then internet said to use a punch and give it a good whack to knock the retaining screw off and then lever it out.

Was sceptical, but that's exactly what I did, and out it popped. Wanted it out mainly as I don't have the key, so new lock required anyway.

Headstock races came out with the good old blind bearing puller. Nice and easy.

Swingarm. Now, there's a thing. The pivot bushes are made of a composite material. Most bikes of this era use phosphor bronze I'm led to believe, but the CB400f used composite. 40 years of rust and 65k miles of abuse meant they were well and truly knackered. Common wisdom is to hacksaw through carefully, then knock them on the edge to get them to fold and collapse.

Hacksawed my way through, knocked the top in and it just broke off. So an hour later and much swearing as I had to knock them out piece by piece till they did finally collapse. One was actually much better than the other. Not too much marking on the swingarm either


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

The rubber encapsulated bushes that the shocks sit on were also buggered. Nothing I tried would pop them out - so I had to drill round the rubber, knock and pull the centre metal collet out and then gently hacksaw round the outer ring to weaken it, before a good whack freed them out.

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

Here's the accumulated bits from the endeavour! (including the greasing nipple for the swingarm pivot which I also managed to get off (eventually)

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

Started the first pass of degreasing on the frame - it's really mucky and is going to take another session tomorrow to finish it off

https://i.imgur.com/0b8eZQi.jpg

That's it for now folks!
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[paddlesat16]

I think David Silvers Spares will be your new best friend
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I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[Bridgehouse]

[Bridgehouse]

Today's first job was sorting out all the parts for degreasing and cleaning/prepping ready for the powdercoating.

I have one part that's broken and will need replacing - headlight/indicator bracket:

https://i.imgur.com/e36WFzy.jpg

A new one is £69 so I'll be getting one rather than attempting to repair!

All parts are going through a good wash/degrease and wire brushing. Here's the collective bits that will eventually be powder coated:

https://i.imgur.com/0WEpdBe.jpg

Frame, Swingarm, Triple Trees, Engine mount brackets, Footage hangers, Airbox/Battery Box and associated bits, instrument bracket, rear light bracket, and rear brake torque arm.

On to the engine - decided to give it some love/attention today.

Breather cover came off, and then rocker cover:

https://i.imgur.com/MXgh7VD.jpg

https://i.imgur.com/B9vWx5a.jpg

https://i.imgur.com/TDmf2Uk.jpg

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

Then rocker arm covers, rockers and springs and other bits and bobs stripped out of the cover:

https://i.imgur.com/KRq7Xl9.jpg

I've left the tacho worm gear in - apparently it's a bitch to get out, and it should cope with the media blasting anyway.

Removed cam chain tensioner, cam chain guide and sprocket, and out came the cam:

https://i.imgur.com/tk8xNaf.jpg

So here's where we are at:

https://i.imgur.com/Rzk9mR9.jpg

I've taken the cylinder head bolts out, but it doesn't feel in the slightest bit loose. Tomorrow's job is a good look at it - it's going to be a job to get the cylinder head off without butchery.. hmmmm
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[chickenstrip]

[Bridgehouse]

[chickenstrip]

[Bridgehouse]

[Bridgehouse]

Decided to go tackle the stuck fast cylinder head with renewed aplomb today.

Started with no tools - just my hands giving everything a good shake about - eventually I felt a bit of movement. This is promising. Bit more rocking and giggling.. and a faint squish as oil was clearly released from a seal! Great I thought.. it's coming!

But then I look down, and as I do, up it pops. Not the cylinder head, but the whole bloody top end!

https://i.imgur.com/x5BesZs.jpg

Er, that wasn't what I expected. The cylinder to crank case joint is supposed to be nuclear-strength or something, but it just eased off.
Cylinder head didn't budge at all.

At least I know it's not the studs that are rusted in - it's clearly the gasket. Ugh. Had a good look around - seems to be all okay actually

https://i.imgur.com/tGoiGq1.jpg

https://i.imgur.com/rWVm1Bg.jpg

And the pistons seem alright as well

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

https://i.imgur.com/i9sHf20.jpg

Much internet research later, I decided to try oven cleaner on the gasket edge - followed by penetrating oil, and then finally some gunk engine degreaser. It's smothered in the stuff and I'm leaving it overnight

https://i.imgur.com/jUvV23T.jpg

Started to remove the studs - got a couple out then it was time to pack it in for the night

https://i.imgur.com/3PH6T1l.jpg

Missus came down armed with rubber gloves and set on degreasing and scrubbing the powdercoat parts pile whilst I was messing with the engine..

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

Domestic bliss huh?
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2015 Triumph Street Triple - 2015 Honda CB500F - 1976 CB400 Four (Stripped - and undergoing restoration)

[Pete.]

A carbide tipped flat scraper will sort the gasket faces. If you're going to make a habit of this you should buy a 8" bench grinder, fit a wire wheel one side and a scotchbrite wheel the other.

And watch that oven cleaner it eats aluminium.
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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

[Bridgehouse]

[Pete.]

Turn a slug of plastic to a loose sliding fit inside the bores. Turn the other end to fit over a scaffold tube. Put the tube in your vise so one end is on the floor and the other is a foot above the vise. Strap the cylinders to the head loosely and drop the barrel over the end of the tube and start bumping the head down onto the plastic protector, always closely monitoring for any adverse effects. Keep switching to different pots, eventually you'll break the bond on the dowels.
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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

[Pete.]

BTW a 6" grinder is not really powerful enough for polishing unless you use very small mops. My 8" grinder struggles and if I am ever going to do it again I'll be using a 1.5hp motor or something similar.

These people are not too far from you if you want a proper factory finish appearance to your engine cases.

https://www.aquablast.uk.com/what-is-aqua-blast.html
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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

[Fizzer Thou]

I know from previous experience that on the CB550 and CB750 fours that Honda had a habit of using small bolts to secure the barrels to the cylinder head,but after looking at the fiche for the CB400F I could not see any.

https://www.cmsnl.com/honda-cb400f-england_model14639/partslist/E01-1.html#results

I am amazed that the top end has come apart as easily as it appears to have done,and that the cam bearings and rocker pads are in such good condition.When you rebuild the engine,be sure to use genuine oil filters as I have had a pattern filter collapse and restrict the oil flow in the past,which ruined the top end of the CB550 that I was riding at the time

With that in mind,make sure that when you remove the old oil filter that the thin metal washer that faces against the spring on the oil filter bolt does not get thrown away with the old filter
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Just talk bikes.What else is there?

Always have a 'Plan B'

[chickenstrip]

[Bridgehouse]