Author Topic: The Black Knight...Dialed in and ready to ride.  (Read 2675 times)

Offline paul G

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Re: 75 CB400four, Black Knight, Cleaning up
« Reply #15 on: November 23, 2018, 12:59:20 PM »
Wow your not hanging around  :o

Yeah, sorry but Im late to joining the forum.  This all happened throughout the summer.

Just trying to catch up to present.

Phew ;D
Honda CB400 4
Honda CB550 K3
Honda CB750 UK K1 restoration
Kawasaki Z650 C2
Kawasaki Z650 cafe racer (bitsa) ongoing

Offline trek97

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Re: 75 CB400four, Black Knight, Cleaning up
« Reply #16 on: November 23, 2018, 01:07:04 PM »

Phew ;D


Haha, Ill post more later.  gotta get busy installed the airbox.   8)

Offline Laverda120

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Re: 75 CB400four, Black Knight, Cleaning up
« Reply #17 on: November 24, 2018, 10:34:10 AM »
Slow down, you are embarrassing the rest of us 😳.
Great progress and photos. It should be finished by Sunday evening at the speed you are going👍.
I met Martin Hagon last Tuesday at the NEC motorcycle show, very helpful and talkative. He is doing a lot to help youngsters break into speedway with his academy.

Offline trek97

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Re: 75 CB400four, Black Knight, Cleaning up
« Reply #18 on: November 25, 2018, 02:25:30 AM »
Slow down, you are embarrassing the rest of us 😳.
Great progress and photos. It should be finished by Sunday evening at the speed you are going👍.
I met Martin Hagon last Tuesday at the NEC motorcycle show, very helpful and talkative. He is doing a lot to help youngsters break into speedway with his academy.

Thanks, but Im just catching up w the build thread Im actually a little further along than this.
Cool fun, Tell him I said Thanks.   ;D

Offline trek97

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Re: 75 CB400four, Black Knight, Prep and Paint engine
« Reply #19 on: November 25, 2018, 03:23:31 AM »
Loading bike on service table.





Video...

https://www.youtube.com/watch?v=seNk7NI2qGQ.



Then got busy prepping the engine...Everything appeared to be in good order.











Cleaning...



New discs and springs and stuff....







New ignition











More cleaning...



a quick coat of paint.







« Last Edit: November 29, 2018, 10:56:14 AM by trek97 »

Offline Davelu88

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Re: 75 CB400four, Black Knight, Prep and Paint engine
« Reply #20 on: November 25, 2018, 10:46:00 AM »
Looking really good & that's a nice big workshop :)

Offline trek97

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Re: 75 CB400four, Black Knight, Prep and Paint engine
« Reply #21 on: November 25, 2018, 12:04:13 PM »
Looking really good & that's a nice big workshop :)

Thanks so much.

And yeah my garage is OK.  At 22x22 feet, Kinda small by American standards.
When I try to fit all 7 bikes in here AND get a working mess going. 
It feels really small really fast.
For the winter I store my K75 and Honda 360 in my neighbors garage, and my wifes CM200 and daughters scooter go into my dads garage.

Keeping my wifes 400 Hondamatic and my 72 CL100 in here.

Then I will have room to move my Garden Tractor in, for plowing snow from driveway.   :P

« Last Edit: November 25, 2018, 12:06:18 PM by trek97 »

Offline Davelu88

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Re: 75 CB400four, Black Knight, Prep and Paint engine
« Reply #22 on: November 25, 2018, 12:13:27 PM »
That will keep you busy just moving that lot around :)

Offline trek97

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Re: 75 CB400four, Black Knight, Prep and Paint engine
« Reply #23 on: November 25, 2018, 02:58:13 PM »
That will keep you busy just moving that lot around :)

Ha yes, just keeping current tags on all them is a chore.   ::)

Offline trek97

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #24 on: November 27, 2018, 12:36:56 AM »
I was fitting the clutch cover with its new gasket and noticed the kickstarter shaft felt a little "TOO WIGGLY".

I'm expecting maybe the snap ring had broke or some how popped off the kickstarter shaft.

So I gave it a tug.  And that when I found THIS.... :P


Offline taysidedragon

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #25 on: November 27, 2018, 12:57:57 AM »
Oh bigger! 😣
2010 Street TripleR
1977 CB400F

Offline trek97

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #26 on: November 27, 2018, 01:03:51 AM »
Oh bigger! 😣

YES!!!  To put it nicely.  LOL.  ;D

But it actually went more like this....

OH HOLY &*$)  #@($(($)  &#@%&. &!)(#@@)#. !!!!!    ;D
« Last Edit: November 27, 2018, 01:24:03 AM by trek97 »

Offline trek97

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #27 on: November 27, 2018, 01:06:15 AM »
I jumped on this matched pair, top and bottom case.

Ive bought from this seller in the past and have never been disappointed.



So, now I have a few days waiting for the cases to ship, I dug into the carbs.









All the brass soaking in carb cleaner.





The bodies spent an hour in the heated ultrasonic bath with Pine-Sol









Ensuring all holes are clear and clean.



I prefer to keep and re-use all factory brass.

However, I found the kit brass to be sized differently than factory, so the new o-rings wont fit the factory stuff. 

I ended up fitting the new brass I needed to.  And keeping what factory brass I could.



All of the overflow tubes are in good shape, no cracks.  Thank goodness.



Floats straightened and properly adjusted.



Found I couldn't fit the new kit A/F adjusters as they were made improperly.  (threads too small diameter for a proper fit.)





Fresh and ready,  w new Stainless Steel bolts to compliment the engine.





And finished polishing the spokes...

« Last Edit: November 27, 2018, 01:36:33 AM by trek97 »

Offline trek97

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #28 on: November 27, 2018, 02:09:55 AM »
Case arrived right on time.





Along w some new toys.







my buddy loaned me his nice caliper.





New blades and aluminum tensioner arm from DSS



Got busy cleaning.  I was able to pull all but 3 of the head bolts.  Keeping them all labeled so I could replace them as original. 







And w enough flipping and turning gave them a full soak in the ultrasonic.   ;D







Chased all the threads to ensure they are in good shape and clean.





Now ready to disassemble the engine.

I had trouble breaking the jugs free.  So I used the old Indian trick.

move pistons 2 &3 to BDC.  Then add an inch of alcohol and light.

The alcohol will burn off after several minutes.  Then a couple taps w the dead blow...viola.  Easy Peasy.

Video...

https://www.youtube.com/watch?v=S0_rerU_Ymw





Then took my daughter to visit the Reindeer.  haha



Then, having some fun w it all.  Took a fancy ARTSY FARTSY  shot



Checking bearing fit with plastigauge.  Found it fill between .038 and .051mm.  Just inside factory build spec.   8)



Amateur cross hatching.



New rings gapped perfectly at .040  :)



Pisotns cleaned up nice w the fresh rings installed.



Used the Dremel to remove the casting marks on intakes.





One million new O-rings and oil unit.



Valve lapping, Being careful not to over do it.
before

after

before

after




leak test w alcohol 30 minutes or so.












« Last Edit: November 27, 2018, 02:13:02 AM by trek97 »

Offline trek97

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Re: 75 CB400four, Black Knight, The good, bad and ugly.
« Reply #29 on: November 27, 2018, 02:37:27 AM »
Ready to make the swap.



Found all shift forks in great condition.







Pistons w new rings were a snug fit.



It was a tight working space w the 4 cylinders, Fitted w new grudgeon clips.



Back in frame for finishing.



Out w the old in w the new.



AND thats when I find the tensioner arm had slipped from being fully compressed to fully sprung. 

Looking back through my pictures I found I had the tensioner bolt turned the wrong way and this let it slip past the lock bolt.  ARGH  >:(

Back out of the frame and apart. UGH!!!



WRONG!!!



CORRECT!!!  Woohoo.  The mark on the head MUST BE FACING OUTWARDS with engine upside down and bottom case pulled off.



Cleaned and re-applied the Hondabond.  Letting it dry about 30 minutes before reassmbly



Back into frame again. LOL.  ;D

New O-rings for the pipes.



Liberal coat of Zpaste.





Spinning with drill to ensure proper oiling.  And make sure transmission shifts through all gears smoothly.

Video...

https://www.youtube.com/watch?v=pSEuudpb48U

Another artsy fartsy.... ;)



Static time adjusted



Coated all bolts w teflon thread sealant to prevent galling.



valves adjusted



And back to where I was.


















« Last Edit: November 27, 2018, 02:44:56 AM by trek97 »