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

[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

 

[philward]

Progressing well Ted - cant wait to see the finished bike

[McCabe-Thiele (Ted)]

Progressing well Ted - cant wait to see the finished bike

Thanks Phil I'm planning to get the cylinder block fitted early next week then I'll start stripping down the cylinder head.
I'm thinking all I need to do before I fit the block is fit the bottom gasket, cylinder O rings, block dowels then feed the pistons into the bores.
 
Not sure until I check the manual etc if there are any O rings or Doughty washer at this stage -am hoping they are between the head & the top of the block.

[smoothoperator]

Really making progress now Ted, well done. 3rd time lucky with putting the cases together, guess the end float problem has gone away now or you've decided that it is normal. Only dowty washers I am aware of are 2 that go on 2 of the head bolts, I've bought some but they look too small on the outside diameter, I'll have to check.

[McCabe-Thiele (Ted)]

Really making progress now Ted, well done. 3rd time lucky with putting the cases together, guess the end float problem has gone away now or you've decided that it is normal. Only dowty washers I am aware of are 2 that go on 2 of the head bolts, I've bought some but they look too small on the outside diameter, I'll have to check.

At the moment the end float has gone - as the bike is used the Hondabond might not hold everything as it is but I'm happy to proceed.
So no Doughty washers between the cylinder block & crankcase - keep me up to speed when you find the right washers as mine are a mess.

(I have a spare engine for a reason.lol)

[McCabe-Thiele (Ted)]

My brother Paul gave me a lift in with the engine base unit this morning - I had blocks of wood under the sumpless engine so when we positioned lifted it in it was by a combination of forethought and luck within a few mm of the right height. Hardest bit was getting the rear long bolt in position - thwarted for a couple of minutes by what turned out to be bubble wrap getting in the way.
Not much thread to work with on the front bolts so might have to select  thinner washers - at present there is a spring washer plus a flat washer - I'll check if both need to be there in the parts manual.



.engine in frame by Macabe Thiele, on Flickr

[Deano400]

Front bolts are spring washer only on the head end of the bolt.

[Johnny4428]

Looking good Ted! Not much room getting in past these rear mounting lugs if I remember, at least with the complete engine.

[McCabe-Thiele (Ted)]

Looking good Ted! Not much room getting in past these rear mounting lugs if I remember, at least with the complete engine.

With having my blocks just at the right height it all went in like I had planned  for a change.

 

[McCabe-Thiele (Ted)]

This afternoon (Tuesday 24the Aug) I fitted the gear linkage bits in the clutch case housing - it was not too fiddly in the end just hope the gears work okay.
I'm forever removing dog hairs that seem to blow in - need to use a cardboard box to cover up the engine rather than a clean(ish) old towel.

Out of interest is it possible for me to test the gear selection as the top wheel rotated as I tightened the bolt and it is now in a gear?

It would be good to know that the selection system works presumably I will have to fit the nearside cover and connect the gear shift?


..gear mechanism by Macabe Thiele, on Flickr


.

[taysidedragon]

You can try gear selection and put it back in neutral without putting the left hand cover on. Clamp a mole grip on the gearchange shaft and change gears with that. Don't damage the splines though. 🙂

[Nurse Julie]

I've pinched this photo off of a FB page as someone was asking the same question the other day and I haven't got one of my own photos to hand.
Lift the arm marked red above the spot marked green, turn the shaft too and fro whilst selecting the gears.

[McCabe-Thiele (Ted)]

I've pinched this photo off of a FB page as someone was asking the same question the other day and I haven't got one of my own photos to hand.
Lift the arm marked red above the spot marked green, turn the shaft too and fro whilst selecting the gears.

When you say turn the shaft to & fro do you mean the top wheel that is the selector drum?