OAP Ted's CB400F2 rebuild - engine not run for about 12 years.

[smoothoperator]

I've contacted DS - they are posting all but a few parts out to me (including the tensioner clips) to arrive on Friday with the remainder being sent at a later date. I was slightly annoyed that the wanted an extra  £3.54  postage to split the order. A bit mean spirited I thought as I have spent around £1100 with them in the last 10 months - business is business I guess.

Probably depends on who you get to talk to. I made an order on Friday and then added an inlet valve on Monday which was offered free of postage if the other parts were already picked. First package arrived Tuesday and the valve arrived with free post yesterday. Now I've concluded I need 2 tensioner dampers, doh.

Build looking great Ted, good luck with the rest of the engine build.

[Sesman]

Thanks Ted. Bottle on order. Keep the build progress coming please.

[4wDaz]

Out interest, can you recommend an assembly lube. I normally use graphogen, but I’ve just finished the tube. That red stuff looks good?

I use this https://www.jdmgarageuk.com/catalogsearch/result/?cat=0&q=Clevite+Bearing+Guard+

[McCabe-Thiele (Ted)]

Whilst waiting for DS delivery decided to strip & re-paint the front steering column - the Rustoleum paint has amazing cover almost too much!

In the photo the underside has been painted just about to paint the top side.

For the environmentalists note the re-purposed bog roll tubes & recyclable spray booth.

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steering stem by Macabe Thiele, on Flickr

[McCabe-Thiele (Ted)]

So here is the upper crankcase before I fit the top half - second picture after it's bolted together.

ready for assembly by Macabe Thiele, on Flickr

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fastnened up  again by Macabe Thiele, on Flickr

[philward]

Top job Ted

[McCabe-Thiele (Ted)]

Top job Ted

Thanks Phil but I've had to split the crankcase halves this morning as the lateral travel on the mainshaft is worrying me (see my other post) all was correctly assembled but I need to address the movement issue that I have now measured as 1.016 mm of what is effectively end float between the bearings.

[philward]

Ah well, it's piece of mind - have done similar myself in the last few years - it's an age thing!

Sent from my moto g(7) power using Tapatalk

[Sesman]

Hang in there Ted. All the effort will be worth it in the end. Sorry I can’t offer any help or guidance on the end float issue.

[McCabe-Thiele (Ted)]

Still in thinking mode about the gearbox end float so fastening the crankcase halves up again is in pause mode.

I have been doing some frame work again.

Front forks in position & fitted front brake caliper & DS mudguard. The mudguard went in okay will not really know if it's skewiff until I fit the front wheel.
As the steering is tilted to one side and the frame is not completely level on the bike stand base any out of kilter looks are hopefully just the camera angles




mudguard 1 (1) by Macabe Thiele, on Flickr

mudguard 1 (2) by Macabe Thiele, on Flickr

Plus rear forks & stand fitted last week with nice Brass bearings from NJ.

rear forks by Macabe Thiele, on Flickr

[McCabe-Thiele (Ted)]

A brief recap about my previous crankcase assembly fails.

Groundhog Day 1 - sticking conrod so seperated  them again.
Groundhog Day 2 - gearshaft endfloat so seperated them again.

After a fitful night sleep dreaming about a potential groundhog day 3 on the crankcase halves assembly today I went for it and assembled the cases again.
I ensured there was some Hondabond on the places where the gearbox bearings sit in the casings - ensured bearings were pushed inwards from the outside to reduce excess movement.
All bolted together like a well practiced routine - everything is hunk dorey so then came to fitting the primary gear shaft - never had any issues previously until this time when the shaft did not want to pass into the primary gear hub centre. (I'm starting to think - the new primary bearing is just making everything a bit tighter fit)

After much sweating and making no progress I decided to try to rotate the crank a little to ensure the primary chain was seated nicely on the crank end. Then as if it was all a bad dream it slotted in nicely. Spacer - second new bearing pushed in place - end circlip - end spacer & gear all fitted.

The only real casualty of my previous failures is the nice paint finish on the crankcase halves has been removed in paces when taking off the Hondabond with thinners.
I will do some masking up and get the cases re-painted before I fit the casing unit into the frame.

I will sleep soundly tonight lol

[taysidedragon]

Well done. Progress at last. 👍

[Sesman]

Stick with it Ted. Nothing in life worth having comes easily.

[philward]

Your getting there Ted - it will all be worth it!

[McCabe-Thiele (Ted)]

This afternoon I fitted the pistons making sure it was impossible to drop a circlip into the engine as I progressed. Trigger had numbered the positions 1,2,3 4 on the tops with his marker pen.

Fitted innermost circlip on the bench then worked my way outwards fitting number 2 & 3 pistons so that the second clip could be accessed from the ends. Then lastly fitted numbers 1 & 4 all have the letters "IN" facing the inlet side of the engine.

Finally covered up the top of the engine to keep out dust etc finally placing an inverted cardboard box in place ready for Monday when my brother will help me fit it into the frame.
Just noticed a small run in the engine paint I'll get that sorted next - turned out to be an oil drip!.

pistons fitted to rods by Macabe Thiele, on Flickr

wrapped ready for fitting in frame by Macabe Thiele, on Flickr