Author Topic: Anyone with a unbent 400 gear lever, need some pics  (Read 349 times)

Offline Oddjob

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Anyone with a unbent 400 gear lever, need some pics
« on: April 28, 2022, 12:47:35 AM »
I'm trying to restore an old 400 four gear lever, replacing the rose joints, removing all the pitting on the chrome etc.

However this lever was really given to me as scrap for mucking about with and it's as bent as a Brighton resident, the linkage mount on the rear of the lever is really bent out of shape, the arm where the rubber goes is also bent backwards and the lever itself seems to be not only bent but twisted as well. I need some really good top down shots showing how the lever is shaped when it's on the bike. They need to show the mounting bush point as that's my reference point. The arm coming up from this bush mount for the rose joint etc. Some side on pics would also be good so I can ensure it's the right shape before modding it.

If it turns out ok and the recipient Ted on here gives the thumbs up on how it performs and feels I'll explain how it was done and where to get the parts to do it if anyone is interested.
Don't play stupid with me, I'm better at it

Offline Laverda Dave

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #1 on: April 28, 2022, 09:04:30 AM »
Give me until the end of the day Ken and I'll get some photos over to you.
1976 Honda 400/4
1981 Honda CB250RSA
1977 Rickman Honda CR750
1999 Honda VFR 800FX
1955 750 Dresda Triton
1978 Moto Morini 350 Sport
1982 Laverda 120 Jota
1924 Triumph 550SD
2012 Stanley Battery Drill

Offline McCabe-Thiele (Ted)

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #2 on: April 28, 2022, 09:38:12 AM »
I'm trying to restore an old 400 four gear lever, replacing the rose joints, removing all the pitting on the chrome etc.

However this lever was really given to me as scrap for mucking about with and it's as bent as a Brighton resident, the linkage mount on the rear of the lever is really bent out of shape, the arm where the rubber goes is also bent backwards and the lever itself seems to be not only bent but twisted as well. I need some really good top down shots showing how the lever is shaped when it's on the bike. They need to show the mounting bush point as that's my reference point. The arm coming up from this bush mount for the rose joint etc. Some side on pics would also be good so I can ensure it's the right shape before modding it.

If it turns out ok and the recipient Ted on here gives the thumbs up on how it performs and feels I'll explain how it was done and where to get the parts to do it if anyone is interested.

Would it be better if I posted you my old one Ken?
Would need your address again.
Cheers Ted
Honda CB400 four super sport

Offline Laverdaroo

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #3 on: April 28, 2022, 12:56:44 PM »
Told you it was shagged Ken ;D

Looking forward to seeing what you do with it......
Mornings are the invention of the devil!
1977 CB550F (new money pit!!)
2002 VFR800 VTEC
1977 CB400F (current money pit!)
1998 Ducati 748\853 conversion
1980 ish CB750KZ in a billion bits (need to get rid!!)

Offline Laverda Dave

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #4 on: April 28, 2022, 02:11:24 PM »
Here you go Ken. I couldn't get any closer without the image going fuzzy on the mobile camera.
1976 Honda 400/4
1981 Honda CB250RSA
1977 Rickman Honda CR750
1999 Honda VFR 800FX
1955 750 Dresda Triton
1978 Moto Morini 350 Sport
1982 Laverda 120 Jota
1924 Triumph 550SD
2012 Stanley Battery Drill

Offline Oddjob

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #5 on: April 28, 2022, 02:48:22 PM »
Cheers Dave, those are a great help. Honda really dropped the ball designing that. The angle of the link rod is obscene, why not extend the bush housing and bend the lever inwards to compensate. That way the link arm would run straighter and cause less wear on the rose joints, it's no wonder they failed quickly.

Ted, the real thing in my hand is always better than pics. I'll PM you my address again. Don't you keep your PMs, I have 50 pages of them so I can read them again if I need to.

Roo, there's shagged and then there's shagged. This one is beyond shagged, it's like a pretzel it's so twisted out of shape. The gear shaft end is all done, all corrosion gone, the linkage arm is still ok on that one.

I've got a CB1300 gear lever lying around and the 400 looks almost the same, I'm wondering if the 1300 gear lever setup would fit the 400. I'll compare lever lengths, bush diameters etc and see. The 1300 lever is really nice, if it fits you'd just need to swap over the link rod as the 400 one is much shorter.
Don't play stupid with me, I'm better at it

Offline Oddjob

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #6 on: April 28, 2022, 03:05:35 PM »
To show you what I'm working with I took some pics before starting work.

Have a look at these babies.

Front of lever. Chrome almost extinct. What you can't see is how twisted it is.



Back of lever. Chrome was already poor from the factory but it got worse.



Yay!! a good part. Gear shaft end.



Reverse side. The rose joint is SO knackered it moved back and forth by 3-6mm, that would have rattled it's head off on the bike. I'm not 100% sure if that's the alignment dot or just a deep pit in the chrome.



What the hell happened here.





And to show you how badly damaged this section was, check out the alignment of the rose joint bracket. Not only is it bent inwards but backward as well and like a nice Cocktail, it comes with a twist.

Don't play stupid with me, I'm better at it

Offline taysidedragon

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #7 on: April 28, 2022, 04:00:46 PM »
It'll polish out!  ;D
Gareth

2010 Street TripleR
1977 CB400F
1965 T100SS

Offline Johnny4428

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #8 on: April 28, 2022, 06:22:00 PM »
I can see it being sanded and buffed into submission.🤣
1952 Cymoto on Triumph bicycle.
1961 Matchless G3
1978 Honda CB550K3.
1999 ST1100 Pan European 50th Anniversary.
1975,1980,1984,1986 Honda C90’s
1973 Honda CB750K3

Offline Laverdaroo

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #9 on: April 28, 2022, 06:57:16 PM »
You can undferstand why it was replaced Ken, saying that a bit of OCD thrown at it and it'll be as good as new ;D


Interested to see how your fiddling goes with the 1300 changer, that could be a really good fix mate. Keep at it mate.

I've an evening in the shed tonight as Bristol Badger is coming over to get his engine finished off. Cases are back together now so its getting all buttoned up tonight with a bit of luck. Im working on my frame so I'm banished outside so I dont blather him in sparks ::) ;D
Mornings are the invention of the devil!
1977 CB550F (new money pit!!)
2002 VFR800 VTEC
1977 CB400F (current money pit!)
1998 Ducati 748\853 conversion
1980 ish CB750KZ in a billion bits (need to get rid!!)

Offline Oddjob

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #10 on: April 28, 2022, 08:14:47 PM »
Did you remove the oil gallery bungs and look down the oil gallery Roo?
Don't play stupid with me, I'm better at it

Offline Laverdaroo

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #11 on: April 29, 2022, 01:31:56 AM »
Yup all of that, anything that coul;d be opened up and cleaned through was done with a fine tooth comb and pretty confident its a s clean as a whistle. Nick did snap and arm off the clutch holder cover plage putting it back on so he's in the market for one of those this week.......eek!
Mornings are the invention of the devil!
1977 CB550F (new money pit!!)
2002 VFR800 VTEC
1977 CB400F (current money pit!)
1998 Ducati 748\853 conversion
1980 ish CB750KZ in a billion bits (need to get rid!!)

Offline Oddjob

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #12 on: April 29, 2022, 06:37:11 PM »
I may have 90% finished the gear lever mod.

The end part where the rubber mounts isn't finished yet, needs some tidying up and I think it's not quite in the right position yet, it's close enough for the moment but I think it needs to angled down a little more.

Not chromed yet, just sanded and even that's not done completely. It's only on it's 2nd of 6 sandings, so it will get better each time. Going to pick up my chroming parts on Tuesday so I may drop this off at the same time if it's ready.

Just assembled it and there is zero movement in any direction, the rose joints are really nice and snug and they are in the same place and alignment as the originals.

As for the 1300 lever, it's very close. The bush point however is bigger but I think the best way to solve this would be to cut off the pivot point off the footrest and flatten that out, drill a 5mm hole and tap to 6mm as that's how the 1300 is fixed, which is better as if the bush wears it's replaceable. The part where the rubber fits is the same distance from the bush housing, the gearshaft part is slightly different but may not be a problem, spline holes are the same. It's doable except for maybe one thing. The 1300 lever isn't arched like the 400, in fact it hangs down, whether it would foul the kick stand is the problem. I don't think so but who knows until it's tested.

Here's the result, up to now of course. Sorry not the best pics.





Don't play stupid with me, I'm better at it

Offline Oddjob

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #13 on: April 29, 2022, 06:42:14 PM »
Just noticed I fitted the gearshaft end upside down. There are no alignment dots anymore so that why it fooled me, not a problem, easy to change it over.

Which was does the pinch bolt fit, head up or head down?
Don't play stupid with me, I'm better at it

Offline smoothoperator

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Re: Anyone with a unbent 400 gear lever, need some pics
« Reply #14 on: April 29, 2022, 08:04:16 PM »
Head down.
Steve
2017 Triumph Bonneville T100
1977 Honda 400 Four Restored April 2022

 

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