Author Topic: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.  (Read 45022 times)

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #180 on: March 05, 2021, 07:34:11 AM »
I wouldn't be happy about those 2 marks on the L/H footrest hanger.

Got to be honest Ted and say the paint looks a little thick, around the lower engine hanger bolt hole it looks like they didn't mask those off and it's possible the bolt won't go through now.
The marks on the footrest hangar are an odd reflection from where the steel frame profile changes there is no physical mark. I agree the coating thickness is certainly not thin. At £155 incl VAT I think it was good value. I expect that I will need to probably clean out some of the bolt holes for a free fit but threaded sections appear good. Presumably a little abrasive action with some wet & dry using a circular profile dowel will not be too difficult - tbh had I painted it myself I might face similar issues.

Hope I don't sound too defensive - I mostly accept your comments.
PS
What I have discovered on closer examination is that the rear offside footpeg frame bracket has a bit of a bend in it - tbh had I noticed it beforhand I would hve applied some heat to straighten it. As I will never have a passenger anyways it's not the end of the world but shows the importance of a thorough inspection beforehand - now I think about it the rear footpeg was at an odd angle when folded back - I dismissed it as wear in the bolt/spring mechanism.
« Last Edit: March 05, 2021, 10:39:33 AM by Macabethiele (Ted) »
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Offline smoothoperator

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #181 on: March 05, 2021, 09:58:58 AM »
Great progress Ted, looking really good. Now you get to start putting it all back together. I'm just starting to get the paint off mine so it's inspiring to see what lies ahead.
Steve
2017 Triumph Bonneville T100
1977 Honda 400 Four Restored April 2022

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #182 on: March 05, 2021, 10:47:33 AM »
Great progress Ted, looking really good. Now you get to start putting it all back together. I'm just starting to get the paint off mine so it's inspiring to see what lies ahead.

Aside from fitting the steering shaft I was going to leave the frame alone until the engine has been further inspected. Should I need a rebore or any other major work I can then fall back on frame assembly to fill in any waiting time.  I need to plan my work space out better as I was going to have my engine on the bike lift and put the frame at the end my garage. I might have to reclaim my work bench behind our car in the garage for engine work.

Main lesson I have learnt so far is to check your frame fully before painting - see my post about the bent rear foot peg bracket. Not sure yet whether to live with it or sort it now.

Still very cold here just 6 deg C.
« Last Edit: March 05, 2021, 10:49:25 AM by Macabethiele (Ted) »
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Offline Bryanj

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #183 on: March 05, 2021, 10:53:11 AM »
First thing to fit is the rear brae pedal pivot!!

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #184 on: March 05, 2021, 11:15:49 AM »
First thing to fit is the rear brae pedal pivot!!

Okay is there a reason for this ?
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Offline Bryanj

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #185 on: March 05, 2021, 11:18:53 AM »
Yup, you cant get it in after you fit the swingarm!!

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #186 on: March 05, 2021, 11:28:10 AM »
Yup, you cant get it in after you fit the swingarm!!

Thanks for that I didn't know. Still dealing mentally with the bent rear foot peg bracket!
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Offline Bryanj

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #187 on: March 05, 2021, 11:38:00 AM »
Its the thing you discover just before you throw something at the wall in frustation!!

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #188 on: March 05, 2021, 06:14:24 PM »
Its the thing you discover just before you throw something at the wall in frustation!!

As you can imagine I'm well annoyed I didn't spot it beforehand - the colour blue makes it obvious!
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #189 on: April 12, 2021, 06:14:48 PM »
Today I have dropped of my upper crankcase to have the cam chain tensioner repair/upgrade fitted of the type shown below that I read about here. The local place I was going to use were not happy about tackling it as its at an angle not horizontal or vertical so they recommended a nearby firm called "Croft Engineering" that I am using. I was encouraged when I visited as there was a customer there that was having a pair of engine blocks made for an old 2 cylinder Velocette

This is my Stage 1  inside clean of the lower crank case using initially some engine degreaser, followed by petrol done outside when it was warmer last week. The majority of the paint has been removed just need to fettle it up a bit where the stripper / and or me has missed it.

.Adjust Bolt Kit by Macabe Thiele, on Flickr

.ower casing first clean by Macabe Thiele, on Flickr
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #190 on: April 26, 2021, 10:34:42 AM »
As I am waiting for my order of Plastigauge & some main shells I have decided to start cleaning up the light surface rust on parts of the gearbox - I don't want the rust deposits to end up in the engine oil so I have dismantled the rear gearshaft first and cleaned the components affected in Evaporust. Photo taken before cleaning the crankcase.



.surface rust by Macabe Thiele, on Flickr


Below are two cleaned items courtesy of Evaporust.


.Evaporusted by Macabe Thiele, on Flickr
« Last Edit: April 26, 2021, 03:52:35 PM by Macabethiele (Ted) »
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #191 on: April 26, 2021, 01:41:49 PM »
When re-assembling the gear shaft I checked where parts 250 & 249 fitted - I was begining to think the parts manual was wrong as I just could not get them to fit together in situ despite many attempts. I checked my photos taken when dismantling - yes the parts manual is correct - one last try & it fitted perfectly!

I have no idea why my previous attempts failed !!

.parts 250 & 249 by Macabe Thiele, on Flickr
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #192 on: May 26, 2021, 05:18:51 PM »
Still waiting for the weather to warm up a bit - had a suspicious mole thingy removed from my side last week following a routine Dermatology 6 month check up -don't want to pull the sutures before they are removed next week.

We've just had a weekend break at Eye Kettleby for a relaxed view of the wind & lashing rain - great timing again - now I remember why we used to go abroad.

If the forecast is true a heatwave is on it's way - I just need to get my finger out and Plastigauge the big ends so I can start putting the engine back together soon. I will be glad to see the crankcase halves bolted back  together - hopefully all buttoned up by the end of June.
« Last Edit: May 27, 2021, 02:51:37 PM by Macabethiele (Ted) »
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

Online Laverda Dave

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #193 on: May 27, 2021, 08:50:30 AM »
At least you are making progress Ted.
Maybe do some light jobs whilst you recover, the sort of jobs that creep up on you as you are putting the bike back together like cleaning the wiring loom (stick it in the dishwasher, works a treat) and cleaning anything plastic and rubber like the half rear guard, all the grommets etc. All easy sitting at the table stuff and nice to get out of the way before assembly begins.
1976 Honda 400/4
1977 Rickman Honda CR750
1999 Honda VFR 800FX
1955 750 Dresda Triton
1978 Moto Morini 350 Sport
1978 Honda CB400/4 'Rat' bike
1982 Laverda 120 Jota

Online McCabe-Thiele (Ted)

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Re: OAP Ted's CB400F2 rebuild - engine not run for about 12 years.
« Reply #194 on: May 27, 2021, 02:55:00 PM »
At least you are making progress Ted.
Maybe do some light jobs whilst you recover, the sort of jobs that creep up on you as you are putting the bike back together like cleaning the wiring loom (stick it in the dishwasher, works a treat) and cleaning anything plastic and rubber like the half rear guard, all the grommets etc. All easy sitting at the table stuff and nice to get out of the way before assembly begins.

Good idea Dave - I have started with clearing the bike lift of all tools put back where they should be then I'm going to clean the half rear guard.
Honda CB500 K1 (new pit dug out ready)
Honda CB400 four super sport (first money pit)
Link to my full restoration http://www.sohc.co.uk/index.php/topic,23291.0.html

 

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