Honda-SOHC

SOHC.co.uk Forums => Project Board => Topic started by: trek97 on November 22, 2018, 01:38:26 PM

Title: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on November 22, 2018, 01:38:26 PM
Hello, My name is Eric Im an Elevator Repair Mechanic at the University of Illinois, USA
First off I want to thank you for allowing me to enter your circle.

I already own a a few vintage bikes that meet all my needs. 
And was not looking for another project. 
Then a 1975 CB400F appeared on Craigslist.  Here in the States the 400F is pretty rare compared to other Honda models.
I wasn't going to pass up the opportunity to have a "Holy Grail" parked in my garage.

(http://www.dotheton.com/gallery/11494-221118064949.png)

It was located about 6 hours away in Iowa.  So I took off work early and started my adventure.

I found it in rough non-running condition without a title.  However the price was right so I made the deal and she followed me home.

(http://www.dotheton.com/gallery/11494-210618050312-39322086.jpeg)

(http://www.dotheton.com/gallery/11494-210618050311-39312084.jpeg)

(http://www.dotheton.com/gallery/11494-210618050311-39301167.jpeg)

(http://www.dotheton.com/gallery/11494-210618050311-39231958.jpeg)

I got busy w the usual preliminary checks...looking to find why she was parked in 1998.

I did leak down and compression checks and all four came out to be about the same..

Not the best.  But, good enough to run, for now.

(http://www.dotheton.com/gallery/11494-190818105719-4258173.jpeg)

(http://www.dotheton.com/gallery/11494-190818105719-42591238.jpeg)

The previous owner had told me the coils were bad, it had no spark.

I found it was just dirty points.  So I got them cleaned up, set static time and found spark on all 4 plugs.

(http://www.dotheton.com/gallery/11494-230618051431.jpeg)

Dumped gas into her dirty tank, cracked the overflows, and found it made its way to the filthy carbs.

(http://www.dotheton.com/gallery/11494-210618200533.jpeg)

(http://www.dotheton.com/gallery/11494-190818193031.jpeg)

So I took a chance...

https://youtu.be/Dd7ojJyVNSw

Then of course my wife Rachel wanted her turn on the throttle...haha

https://youtu.be/WTzr3MzEZ5M

Next I oiled the chain, added some air to the rotten tires, etc etc...  then on 1 1/2 maybe 2 clogged carbs I went for a ride.

https://youtu.be/6TxcUfywY9g

(http://www.dotheton.com/gallery/11494-220618043255-393417.png)

I now knew I had something I could work with...

So got busy ordering parts and parts and more parts.

(http://www.dotheton.com/gallery/11494-010718063550.jpeg)

(http://www.dotheton.com/gallery/11494-130918192304-43282316.jpeg)

(http://www.dotheton.com/gallery/11494-080918084326.jpeg)

(http://www.dotheton.com/gallery/11494-131018063330.jpeg)


















Title: Re: 75 CB400four, A tale from the Black Knight
Post by: taysidedragon on November 22, 2018, 01:51:22 PM
That looks like a good starting point for a resto. Some of us start with a frame and boxes of parts!
The old plate has my initials GJ, I don't suppose it's for sale, is it? 😎
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: trek97 on November 22, 2018, 01:54:51 PM
That looks like a good starting point for a resto. Some of us start with a frame and boxes of parts!
The old plate has my initials GJ, I don't suppose it's for sale, is it? 😎

Thanks, and YES, let me do some digging.  If I still have the plate I will be happy to send it your way.
Please PM me your address.   
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: taysidedragon on November 22, 2018, 02:00:22 PM
That looks like a good starting point for a resto. Some of us start with a frame and boxes of parts!
The old plate has my initials GJ, I don't suppose it's for sale, is it? 😎

Thanks, and YES, let me do some digging.  If I still have the plate I will be happy to send it your way.
Please PM me your address.

Cheers. 😊
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: Nurse Julie on November 22, 2018, 02:09:26 PM
Hey, you found us Eric....great to have you with us. We are getting quite a few new forum members from the USA with CB400/4's which is nice to see.
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: trek97 on November 22, 2018, 02:20:10 PM
Hey, you found us Eric....great to have you with us. We are getting quite a few new forum members from the USA with CB400/4's which is nice to see.

Thanks so much, Julie.
(http://www.dotheton.com/gallery/11494-200816163635.png)
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: Davelu88 on November 22, 2018, 02:42:06 PM
welcome & good luck with the restoration the 400/4 is a great bike .
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: trek97 on November 22, 2018, 03:16:11 PM
welcome & good luck with the restoration the 400/4 is a great bike .

Thanks so much.
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: paul G on November 22, 2018, 03:32:08 PM
Welcome Eric from another 400/4 owner.
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: Seabeowner on November 22, 2018, 04:42:23 PM
Welcome Eric. The 400/4 was a (relatively) big seller in the UK. I think there are more 400/4s on the forum than any other SOHCs. That's quite some investment in parts you have there.
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: Laverda Dave on November 22, 2018, 06:16:35 PM
Welcome to the forum Eric. A 400/4 a very wise choice of sohc. Keep us all updated of progress.
Title: Re: 75 CB400four, A tale from the Black Knight
Post by: trek97 on November 22, 2018, 06:50:24 PM
Thanks all.   :)

Though not finished, I am considerably further along w the build than I have posted.

I posted what I could this morning, busy getting ready for our Thanksgiving holiday.

So more to come as I get the time.

Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: trek97 on November 23, 2018, 12:33:49 PM
Picked up some necessities on ebay...

Ebay (almost like new) 4" Supertrapp megaphone complete w 18 SS tuning discs.

And a SS Wool/fiberglass blanket kit from International Steel Wool.

(http://www.dotheton.com/gallery/11494-100818202902.jpeg)

Sand blasted and fireproof coating

(http://www.dotheton.com/gallery/11494-110818093201-42101607.jpeg)

single layer Masking tape wrap help keeps the packing in place for easy install.

(http://www.dotheton.com/gallery/11494-110818093201-4232494.jpeg)

The kickstand had rotted off the original No-Title frame.

 (http://www.dotheton.com/gallery/11494-231118070155.jpeg)

Picked up a really nice frame with a Title.

(http://www.dotheton.com/gallery/11494-250818155922-42761227.jpeg)

Found a good deal on a spare engine with 11k kilometers on it.

(http://www.dotheton.com/gallery/11494-260818143050-4286622.jpeg)

At least the numbers are better.

(http://www.dotheton.com/gallery/11494-260818143049-42831196.jpeg)

(http://www.dotheton.com/gallery/11494-260818143049-4282655.jpeg)

Both rims were bent.

(http://www.dotheton.com/gallery/11494-210818183354-42611388.jpeg)

Super nice NOS front complete w disc.

(http://www.dotheton.com/gallery/11494-250818155922-42731119.jpeg)

(http://www.dotheton.com/gallery/11494-250818155922-42721830.jpeg)

(http://www.dotheton.com/gallery/11494-250818155922-427110.jpeg)

and nice new rear.  I Installed new bearings, sprocket and tires.

(http://www.dotheton.com/gallery/11494-090918184238.jpeg)

The weathered spokes on the rear wheel polished up as nice as the front spokes. 
Ceramabrite glass cooktop cleaner is the stuff to brighten old finishes including chrome.

(http://www.dotheton.com/gallery/11494-180918190017-4361767.jpeg)

(http://www.dotheton.com/gallery/11494-180918190017-4362774.jpeg)

New shocks to complement.

(http://www.dotheton.com/gallery/11494-060918201316-4310343.png)

I was a little disappointed to see the new Hagons come w these ill-fitting, cheap looking collets.

I sent an email to Hagon.  A few days later...They sent me the a set of the old style collets w new bushings.

(http://www.dotheton.com/gallery/11494-151018183249-45571769.jpeg)

(http://www.dotheton.com/gallery/11494-151018183249-45582277.jpeg)

(http://www.dotheton.com/gallery/11494-151018183250-4561846.jpeg)

Out w old fork seals in w new seals and pipes.

(http://www.dotheton.com/gallery/11494-100918202514-4311376.jpeg)

(http://www.dotheton.com/gallery/11494-130918192304-43432341.jpeg)

Tapered bearings kit installed.

(http://www.dotheton.com/gallery/11494-130918192304-43441816.jpeg)

3 days soaking tank w apple cider vinegar, water rinse, alcohol rinse then Marvel Mystery to prevent flash rust.

(http://www.dotheton.com/gallery/11494-180918185549-43581988.jpeg)

Worked a treat on the rust.

(http://www.dotheton.com/gallery/11494-180918185549-4356450.jpeg)

(http://www.dotheton.com/gallery/11494-160918044909-4355515.jpeg)
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: paul G on November 23, 2018, 12:45:02 PM
Wow your not hanging around  :o
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: trek97 on November 23, 2018, 12:56:25 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.
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: paul G 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
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: trek97 on November 23, 2018, 01:07:04 PM

Phew ;D


Haha, Ill post more later.  gotta get busy installed the airbox.   8)
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: Laverda Dave 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.
Title: Re: 75 CB400four, Black Knight, Cleaning up
Post by: trek97 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
Title: Re: 75 CB400four, Black Knight, Prep and Paint engine
Post by: trek97 on November 25, 2018, 03:23:31 AM
Loading bike on service table.

(http://www.dotheton.com/gallery/11494-150718132400-40601099.jpeg)

(http://www.dotheton.com/gallery/11494-150718132400-4064127.jpeg)

Video...

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



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

(http://www.dotheton.com/gallery/11494-220918102723-4382287.jpeg)

(http://www.dotheton.com/gallery/11494-220918102723-43811541.jpeg)

(http://www.dotheton.com/gallery/11494-220918103410-43891492.jpeg)

(http://www.dotheton.com/gallery/11494-220918103410-43901803.jpeg)

(http://www.dotheton.com/gallery/11494-220918104035.jpeg)

Cleaning...

(http://www.dotheton.com/gallery/11494-230918062157-44001708.jpeg)

New discs and springs and stuff....

(http://www.dotheton.com/gallery/11494-230918062157-4402567.jpeg)

(http://www.dotheton.com/gallery/11494-230918125416-44122436.jpeg)

(http://www.dotheton.com/gallery/11494-230918125416-4413910.jpeg)

New ignition

(http://www.dotheton.com/gallery/11494-240918200145-44252329.jpeg)

(http://www.dotheton.com/gallery/11494-240918200145-4422526.jpeg)

(http://www.dotheton.com/gallery/11494-031018191023.jpeg)

(http://www.dotheton.com/gallery/11494-041018165735.jpeg)

(http://www.dotheton.com/gallery/11494-061018165844-44631235.jpeg)

More cleaning...

(http://www.dotheton.com/gallery/11494-280918210854.jpeg)

a quick coat of paint.

(http://www.dotheton.com/gallery/11494-300918064342-4454324.jpeg)

(http://www.dotheton.com/gallery/11494-290918125703-4435586.jpeg)

(http://www.dotheton.com/gallery/11494-300918141730-44551938.jpeg)

(http://www.dotheton.com/gallery/11494-300918141731-4458525.jpeg)
Title: Re: 75 CB400four, Black Knight, Prep and Paint engine
Post by: Davelu88 on November 25, 2018, 10:46:00 AM
Looking really good & that's a nice big workshop :)
Title: Re: 75 CB400four, Black Knight, Prep and Paint engine
Post by: trek97 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

(http://www.dotheton.com/gallery/11494-251118055808.jpeg)
Title: Re: 75 CB400four, Black Knight, Prep and Paint engine
Post by: Davelu88 on November 25, 2018, 12:13:27 PM
That will keep you busy just moving that lot around :)
Title: Re: 75 CB400four, Black Knight, Prep and Paint engine
Post by: trek97 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.   ::)
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 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

(http://www.dotheton.com/gallery/11494-061018165845-44731465.jpeg)
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: taysidedragon on November 27, 2018, 12:57:57 AM
Oh bigger! 😣
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 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
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 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.

(http://www.dotheton.com/gallery/11494-061018210235.png)

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

(http://www.dotheton.com/gallery/11494-081018122816-44901261.jpeg)

(http://www.dotheton.com/gallery/11494-081018122816-44911218.jpeg)

(http://www.dotheton.com/gallery/11494-081018122816-4492907.jpeg)

(http://www.dotheton.com/gallery/11494-101018064719-45052290.jpeg)

All the brass soaking in carb cleaner.

(http://www.dotheton.com/gallery/11494-081018122816-44941144.jpeg)

(http://www.dotheton.com/gallery/11494-081018122816-449360.jpeg)

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

(http://www.dotheton.com/gallery/11494-081018122816-44952160.jpeg)

(http://www.dotheton.com/gallery/11494-081018133043-44971399.jpeg)

(http://www.dotheton.com/gallery/11494-081018133043-44982415.jpeg)

(http://www.dotheton.com/gallery/11494-081018185418-45012293.jpeg)

Ensuring all holes are clear and clean.

(http://www.dotheton.com/gallery/11494-081018185418-45021078.jpeg)

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.

(http://www.dotheton.com/gallery/11494-081018193546-4503944.jpeg)

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

(http://www.dotheton.com/gallery/11494-101018064719-45081882.jpeg)

Floats straightened and properly adjusted.

(http://www.dotheton.com/gallery/11494-101018203230-45091652.jpeg)

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

(http://www.dotheton.com/gallery/11494-101018203230-45111486.jpeg)

(http://www.dotheton.com/gallery/11494-101018203230-4510463.jpeg)

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

(http://www.dotheton.com/gallery/11494-101018203230-4512203.jpeg)

(http://www.dotheton.com/gallery/11494-101018203230-45131460.jpeg)

And finished polishing the spokes...

(http://www.dotheton.com/gallery/11494-081018090137-4475421.jpeg)
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 02:09:55 AM
Case arrived right on time.

(http://www.dotheton.com/gallery/11494-121018093659-45161262.jpeg)

(http://www.dotheton.com/gallery/11494-121018093659-45181703.jpeg)

Along w some new toys.

(http://www.dotheton.com/gallery/11494-121018124150.jpeg)

(http://www.dotheton.com/gallery/11494-230918062157-44071207.jpeg)

(http://www.dotheton.com/gallery/11494-121018125618-45191224.jpeg)

my buddy loaned me his nice caliper.

(http://www.dotheton.com/gallery/11494-181018120104.jpeg)

(http://www.dotheton.com/gallery/11494-121018125618-45191224.jpeg)

New blades and aluminum tensioner arm from DSS

(http://www.dotheton.com/gallery/11494-201018114702.jpeg)

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. 

(http://www.dotheton.com/gallery/11494-181018181006-45672352.jpeg)

(http://www.dotheton.com/gallery/11494-181018181006-45681010.jpeg)

(http://www.dotheton.com/gallery/11494-181018181006-45692206.jpeg)

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

(http://www.dotheton.com/gallery/11494-181018181006-45692206.jpeg)

(http://www.dotheton.com/gallery/11494-201018070038.jpeg)

(http://www.dotheton.com/gallery/11494-201018073450-4570893.jpeg)

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

(http://www.dotheton.com/gallery/11494-201018093829.jpeg)

(http://www.dotheton.com/gallery/11494-201018174439.jpeg)

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

(http://www.dotheton.com/gallery/11494-211018172644-4579446.jpeg)

(http://www.dotheton.com/gallery/11494-211018172644-45811057.jpeg)

Then took my daughter to visit the Reindeer.  haha

(http://www.dotheton.com/gallery/11494-211018172644-4580592.jpeg)

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

(http://www.dotheton.com/gallery/11494-231018174001.jpeg)

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

(http://www.dotheton.com/gallery/11494-231018200958.jpeg)

Amateur cross hatching.

(http://www.dotheton.com/gallery/11494-271018171711-45981614.jpeg)

New rings gapped perfectly at .040  :)

(http://www.dotheton.com/gallery/11494-271018171711-46001438.jpeg)

Pisotns cleaned up nice w the fresh rings installed.

(http://www.dotheton.com/gallery/11494-271018171712-4601400.jpeg)

Used the Dremel to remove the casting marks on intakes.

(http://www.dotheton.com/gallery/11494-281018131955-46022094.jpeg)

(http://www.dotheton.com/gallery/11494-281018131955-46041359.jpeg)

One million new O-rings and oil unit.

(http://www.dotheton.com/gallery/11494-011118174021-4608484.jpeg)

Valve lapping, Being careful not to over do it.
before
(http://www.dotheton.com/gallery/11494-011118174021-46132126.jpeg)
after
(http://www.dotheton.com/gallery/11494-011118174021-46152291.jpeg)
before
(http://www.dotheton.com/gallery/11494-011118174021-46141905.jpeg)
after
(http://www.dotheton.com/gallery/11494-011118174022-4616816.jpeg)

(http://www.dotheton.com/gallery/11494-011118174022-46171530.jpeg)

leak test w alcohol 30 minutes or so.

(http://www.dotheton.com/gallery/11494-031118094009-462054.jpeg)

(http://www.dotheton.com/gallery/11494-031118094009-46221419.jpeg)








Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 02:37:27 AM
Ready to make the swap.

(http://www.dotheton.com/gallery/11494-101118140334-46452348.jpeg)

Found all shift forks in great condition.

(http://www.dotheton.com/gallery/11494-101118140334-46471235.jpeg)

(http://www.dotheton.com/gallery/11494-101118224519-46512477.jpeg)

(http://www.dotheton.com/gallery/11494-101118224519-46521102.jpeg)

Pistons w new rings were a snug fit.

(http://www.dotheton.com/gallery/11494-101118224519-4653933.jpeg)

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

(http://www.dotheton.com/gallery/11494-101118224519-465464.jpeg)

Back in frame for finishing.

(http://www.dotheton.com/gallery/11494-111118115904-46572442.jpeg)

Out w the old in w the new.

(http://www.dotheton.com/gallery/11494-111118115903-46561452.jpeg)

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!!!

(http://www.dotheton.com/gallery/11494-121118105644-46591390.jpeg)

WRONG!!!

(http://www.dotheton.com/gallery/11494-121118105644-466044.jpeg)

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

(http://www.dotheton.com/gallery/11494-121118105644-46611419.jpeg)

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

(http://www.dotheton.com/gallery/11494-121118105644-4662805.jpeg)

Back into frame again. LOL.  ;D

New O-rings for the pipes.

(http://www.dotheton.com/gallery/11494-121118105644-46632289.jpeg)

Liberal coat of Zpaste.

(http://www.dotheton.com/gallery/11494-121118105644-4664647.jpeg)

(http://www.dotheton.com/gallery/11494-121118105644-465815.jpeg)

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.... ;)

(http://www.dotheton.com/gallery/11494-171118054458.jpeg)

Static time adjusted

(http://www.dotheton.com/gallery/11494-171118075843.jpeg)

Coated all bolts w teflon thread sealant to prevent galling.

(http://www.dotheton.com/gallery/11494-171118192404-46701804.jpeg)

valves adjusted

(http://www.dotheton.com/gallery/11494-171118192404-46791523.jpeg)

And back to where I was.

(http://www.dotheton.com/gallery/11494-171118210036.jpeg)
















Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: Trigger on November 27, 2018, 07:22:22 AM
Interesting large amounts of Hondabond. It only needs to be a light smear on the parts of the cases that need sealing from oil to the outside world not, all the mating surfaces  ;) Hondabond is a sealant and it looks like you have tried to create a gasket with letting it go off before closing the cases :o This could give you problems very soon from string blocking the oil strainer and jets.
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: SteveD CB500K0 on November 27, 2018, 07:37:14 AM
On a lighter note, I notice that you use the word "gudgeon" pin - I would have expected "wrist" pin?
Or are you self-censoring  8)

On the .net site, I once started a "divided by a common language" thread. It was astonishing how quickly it filled up.
I might go and see if I can find it...

Also, we seem to be better off here as most of us don't need licence "tags" or annual MOT tests any more.

Steve
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: taysidedragon on November 27, 2018, 09:50:31 AM
Looking good so far Eric. 👍
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: Seabeowner on November 27, 2018, 10:03:24 AM
Wow what a lot of great pics.

"New rings gapped at 0.040"  Is that 0.040 in. correct, seems large? Or is that 0.4mm, 0.016"?
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: Laverda Dave on November 27, 2018, 11:34:13 AM
Looking good Eric. You obviously don't sleep for long each day at the speed you are going! Are you going to repaint the frame as part of the build?
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 12:25:57 PM
Interesting large amounts of Hondabond. It only needs to be a light smear on the parts of the cases that need sealing from oil to the outside world not, all the mating surfaces  ;) Hondabond is a sealant and it looks like you have tried to create a gasket with letting it go off before closing the cases :o This could give you problems very soon from string blocking the oil strainer and jets.

Oh I dont know about all that, Sir.  Im definitley not a pro engine builder.  But, thank you for the good info.

Time will tell. 

Its pretty thin and you can see per the photo virtually nothing squeezed out upon torquing to specs.

Just following the recommendation as per the Official Honda workshop manual. 

Occasionally I have a bit of trouble interpreting exactly what they are meaning.

(http://www.dotheton.com/gallery/11494-271118062023.jpeg)

(http://www.dotheton.com/gallery/11494-121118105644-466044.jpeg)
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 12:41:21 PM
On a lighter note, I notice that you use the word "gudgeon" pin - I would have expected "wrist" pin?
Or are you self-censoring  8)

On the .net site, I once started a "divided by a common language" thread. It was astonishing how quickly it filled up.
I might go and see if I can find it...

Also, we seem to be better off here as most of us don't need licence "tags" or annual MOT tests any more.

Steve

haha nope here in my garage its a "gudgeon" pin.

Also nice that you dont need tags or tests. 

Here individual states have their own sets of rules.  And all of them seem to differ.

In some States if a vehicle is more than 25 years old it doesn't need a Title. 

In Illinois doesn't matter what it is.  If it ever had a VIN # then it has to have the original Title to get license tags for the street.  There are other types of Titles available but they are $$$$ and take up to 3 years to receive. 

So its just easier and cheaper to buy a frame w a Title.
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 12:56:40 PM
Wow what a lot of great pics.

"New rings gapped at 0.040"  Is that 0.040 in. correct, seems large? Or is that 0.4mm, 0.016"?

Looking good so far Eric. 👍

Looking good Eric. You obviously don't sleep for long each day at the speed you are going! Are you going to repaint the frame as part of the build?

Thanks so much everyone.   :)

Honda assembly standard on ring end gap is 0.15 - 0.35,  Mine is 0.254. Honda device limit is 0.70.  As best as my bifocals can see it.  Ha

Also yea this was over a couple weeks time.  And we have no kids in the house.  So that makes it easier to find spare time.

Also, Yes I sleep a lot.  My wife says too much napping.  haha

Im getting really close to having this thread caught up to where Im sitting presently.  Ill try to get it caught up in real time tonight.

Gotta run to my "Real Job" now.  Ugh! 
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 02:30:44 PM
Am I reading this correctly?

You swapped crankcases and used the same shell bearings from the old case to transfer into the new case? I can see you using plastiguage but is that on the new case or the old one. You'd be very very lucky to find 2 different sets of cases with the exact same bore for the crank to sit in.

Also wondering why when you had the cases fully dismantled and cleaned up you didn't spray them before you started to assemble the engine?

Yup, I believe the reason they make different thickness bearings available for purchase.  If they had been outside of spec I would have replaced them with the size necessary to bring it back to proper spec.  Either due to wear, utilizing original case or replacing the case, as I did.  I was happy to find All the bearings plastigauged the same, within spec. 

And yeah, to paint the major components individually it would have required a bunch of extra work masking.  The painted covers (clutch, alternator, etc.  I just fit loosely without gaskets.  Then removed and wiped gasket surfaces w lacquer thinner and a paper towel to clean before gasket installation.
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 27, 2018, 02:40:07 PM
And if they had been too tight, I could’ve taken the case to be bored to fit at a machine shop.  Or just ended up getting the broken kickstart support pillar welded and fixed in the original case.

As it is , it worked out so I’m a happy camper
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 28, 2018, 12:30:19 AM
Did you compare the crankcase markings on both cases? they should be on the back of the bottom crankcase and are the journal sizes as marked and measured by Honda when it was new.

It's quite easy to get a false reading from Plastigauge IMO, too much torque, too little torque and you get a different result.

Wow thanks, I had no idea.  But I will see what I can find.

How have you measured them for rebuild or replacement if not trusting plastigauge to be accurate, enough?

"Too much or too little torque"?  Im Not exactly sure why someone would purposefully set up the torque wrench wrong when checking bearings w plastigauge?  But this is your reasoning not mine.

Again, Im just using Hondas preferred technique as per manual.

Stamped Or do you mean hand written numbers?  If so, long long gone. haha  :P

Ill look through my pics.  Maybe caught them by random chance.

This kind of info is why I like these forums.  And why I was excited to join this U.K. forum, 

Just wishing I knew about it earlier.  As there is more knowledge on the 400F here than I found in the States.
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: Deano400 on November 28, 2018, 08:34:11 AM
Hi trek97.
I think this is what you are looking.
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 28, 2018, 11:58:40 AM
Hi trek97.
I think this is what you are looking.

Thank you sir.  And yes I will check them out.   8)
Title: Re: 75 CB400four, Black Knight, The good, bad and ugly.
Post by: trek97 on November 29, 2018, 10:35:20 AM
Plus some people seem to think that any torque wrench is fine, like the ones which use a bending rod and a scale under the handle, very easy to misread one of those for instance.


Now your going "old school". I have one of those at work, (in the bottom of the work box". haha

Happy to find all 3 of mine are the same.

(ps, you made an old man w bad knees roll around on the cold concrete to get a shot up and under the bike. )

This is the "new case" currently installed in the bike.

(http://www.dotheton.com/gallery/11494-291118042718-4708326.jpeg)

Old broken case...

(http://www.dotheton.com/gallery/11494-291118042719-47261453.jpeg)

and my complete spare engine, saving for another project...

(http://www.dotheton.com/gallery/11494-291118042719-47271016.jpeg)
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: trek97 on November 29, 2018, 10:51:12 AM
Here is where I get all caught up to the present with this thread.

Still got a long way to go before its "finished".  HAHA LOL  ;D

Last weekend was our Thanksgiving holiday.  I got a 4 day weekend at home w the machine.

I was excited to hear this thing run...

So I made myself a 2 wire harness.  A 12+ from battery to the kill switch to feed coils and the neg to engine cover bolt.

Video, First fire and First ride.

https://youtu.be/BVIBqSZlQKM. 
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: taysidedragon on November 29, 2018, 11:00:23 AM
Getting there. 👍 Just got to make it pretty now. ☺
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: Bryanj on November 29, 2018, 12:01:56 PM
You were real jammy with those cases being coded the same!!!
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: trek97 on November 29, 2018, 12:44:40 PM
You were real jammy with those cases being coded the same!!!

I dont even know what "jammy" means.   :)
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: taysidedragon on November 29, 2018, 02:44:24 PM
You were real jammy with those cases being coded the same!!!

I dont even know what "jammy" means.   :)

Lucky x 100!
Title: Re: 75 CB400four, Black Knight, First fire - First ride video.
Post by: trek97 on November 29, 2018, 06:35:53 PM
You were real jammy with those cases being coded the same!!!

I dont even know what "jammy" means.   :)

Lucky x 100!

I’d like to say it worked out because I know what I’m doing.   ;D

I had no idea about those letters.

Thanks for the info and advise.
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: trek97 on November 30, 2018, 11:23:31 AM
Hey guys,

None of the other carbs Ive any experience with, didn't have anything like the 2 "vent" tubes located adjacent to the fuel line.

What exactly are these two vents doing?

The reason I ask is,  After turning fuel on there are a few drops of fuel leaking from 'somewhere' in there.

I was thinking it might be the o-rings on the fuel pipes connecting the rack together. 

But, maybe its one or both of these vents.
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: Nurse Julie on November 30, 2018, 11:32:18 AM
They vent fumes to atmosphere. If everything is ok in the carbs there should be no fuel coming out of tem.
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: trek97 on November 30, 2018, 11:45:13 AM
They vent fumes to atmosphere. If everything is ok in the carbs there should be no fuel coming out of tem.

Ten 4 Julie thanks.

I will dig back in and get the o-rings replaced.

I was trying to avoid separating them.  But gotta do what I gotta do.   :)

any tips or tricks to this o-ring replacement?

After the first couple leaking drops the leak stops and they hold fuel fine.
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: trek97 on December 01, 2018, 02:32:25 PM
Taking a break now, cleaning, re-organizing so I can get the tractor w snowplow in here for the winter. UGH

Also got the new stove piped up and warming garage nicely.   :)

(http://www.dotheton.com/gallery/11494-011218082853.jpeg)

(http://www.dotheton.com/gallery/11494-011218082824.jpeg)
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: taysidedragon on December 07, 2018, 11:09:00 PM
Hi Eric,  Christmas came early today, your plate arrived, thanks very much. 👍

It's going on the garage wall next to a couple of other plates from California and New Jersey. 😎

Cheers, Gareth
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: SteveD CB500K0 on December 08, 2018, 07:19:59 AM
Hey Gareth.

My son in law has a Street Triple R. We swap sometimes.

I find the Street too small/fast/focused. I do like the TFT instruments though.

He says my Tiger 800 is slow and like an armchair “it’s got heated seats!” 

He rode my 500 round the block and was terrified that he’d crash it due to no brakes/handling/power.

Steve



Sent from my iPhone using Tapatalk
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: taysidedragon on December 08, 2018, 11:22:39 AM
Hi Steve. I love my Street Triple R. Best bike I've ever owned. (said in a whisper on a Honda forum!)
It is fast but only when you want it to be! 😉
I've had it for 8 years now and not planning to sell it anytime soon. My 400 will be on the road in the spring so I'll have difficult decisions on which one to ride each day.
Title: Re: 75 CB400four, Black Knight, Carb question
Post by: trek97 on December 11, 2018, 01:10:35 AM
Hi Eric,  Christmas came early today, your plate arrived, thanks very much. 👍

It's going on the garage wall next to a couple of other plates from California and New Jersey. 😎

Cheers, Gareth

Haha Hooray.  Im quite surprised it made it there.  And you're very welcome.
Title: Re: The Black Knight...Side job
Post by: trek97 on December 17, 2018, 12:39:42 PM
Working to get a few Christmas gifts ready.

(http://www.dotheton.com/gallery/11494-171218063320-4759198.jpeg)

(http://www.dotheton.com/gallery/11494-171218063320-47601494.jpeg)

(http://www.dotheton.com/gallery/11494-171218063320-47611588.jpeg)

Managing to get a bit done whilst waiting for new cordage and switches and stuff.

Fresh brake buttoned up and fender fitted.

(http://www.dotheton.com/gallery/11494-171218063320-47621351.jpeg)
Title: Re: The Black Knight...Side job
Post by: trek97 on December 17, 2018, 01:01:32 PM
The pivot was seized hard.

Boiling penetrant w heat gun.  It finally freed.

(http://www.dotheton.com/gallery/11494-141018074808-4536970.jpeg)

(http://www.dotheton.com/gallery/11494-141018074808-45381834.jpeg)

I decided to make a quick change for ease of servicing ...

(http://www.dotheton.com/gallery/11494-141018102912-4548777.jpeg)

(http://www.dotheton.com/gallery/11494-141018102912-45491405.jpeg)

(http://www.dotheton.com/gallery/11494-141018102912-45502425.jpeg)

While the tools are out...why not do the rear pivot too?

(http://www.dotheton.com/gallery/11494-141018102913-4553392.jpeg)




Title: Re: The Black Knight...Side job
Post by: trek97 on December 20, 2018, 02:33:37 AM
Heres the first one finished, for Rachels Christmas to go in our bathroom.

Thought Id give the 2k primer a go.  It goes on and sands just like primer. 

Rach really likes the new Subaru color, Jasmine green, so that came from Harpy's motors. 

My 2nd fan, going in the garage, will be House of Kolor, Candy Blue.

And all finished w 2k clear.

(http://www.dotheton.com/gallery/11494-191218202241-4766776.jpeg)

(http://www.dotheton.com/gallery/11494-191218202241-4763776.jpeg)

(http://www.dotheton.com/gallery/11494-191218202241-47671988.jpeg)

(http://www.dotheton.com/gallery/11494-191218202242-4768509.jpeg)

(http://www.dotheton.com/gallery/11494-191218202242-4769473.jpeg)

https://youtu.be/sh5cXv0uS0A
Title: Re: The Black Knight...Side job
Post by: Laverda Dave on December 20, 2018, 08:01:06 PM
Nice job with the fan, you can't beat home made Christmas presents.
I have an old electo/mechanical signaling relay I recovered from a skip, it's in as new condition, has clear glass on every side to show the internal workings, is a cube 12 inch square and weighs a ton! I'd like to fit a bulb inside it to highlight the workings but have no idea how to do it!
Title: Re: The Black Knight...Side job
Post by: trek97 on December 21, 2018, 12:00:31 AM
Nice job with the fan, you can't beat home made Christmas presents.
I have an old electo/mechanical signaling relay I recovered from a skip, it's in as new condition, has clear glass on every side to show the internal workings, is a cube 12 inch square and weighs a ton! I'd like to fit a bulb inside it to highlight the workings but have no idea how to do it!

Thanks so much bud.
Title: Re: The Black Knight...Side job
Post by: paul G on December 21, 2018, 08:02:08 AM
Nice job with the fan, you can't beat home made Christmas presents.
I have an old electo/mechanical signaling relay I recovered from a skip, it's in as new condition, has clear glass on every side to show the internal workings, is a cube 12 inch square and weighs a ton! I'd like to fit a bulb inside it to highlight the workings but have no idea how to do it!
Is that how to get into it or fit the bulb ! any pictures.
Title: Re: The Black Knight...Side job
Post by: Laverda Dave on December 21, 2018, 10:32:43 AM
This is it Paul. It's a piece of railway history and much to good to be left in a scrap skip. I could go in with a cord via one of the 'Chinese Hats' (as we used to call them at work) on the top but that would look terrible especially as I want to install lamp inside the case to highlight the workings inside.
Thinking about it I may have to drill into the underside of the case. Any ideas of what type of lamp I should fit. It doesn't have to be bright it's just to highlight the workings, copper and brass etc. It will need to be 240v mains feed though.
It will be kept in the garage as my workshop lamp, somehow I cannot see the o/h allowing this in the house even if it will be a talking point to old railway grissers who may visit!
Apologies Trek97, I don't wish to hijack your thread🤐!
Title: Re: The Black Knight...Side job
Post by: Bryanj on December 21, 2018, 10:43:18 AM
I would suggest a 3watt led available in bc or ses fitting
Title: Re: The Black Knight...Side job
Post by: taysidedragon on December 21, 2018, 10:46:55 AM
This is it Paul. It's a piece of railway history and much to good to be left in a scrap skip. I could go in with a cord via one of the 'Chinese Hats' (as we used to call them at work) on the top but that would look terrible especially as I want to install lamp inside the case to highlight the workings inside.
Thinking about it I may have to drill into the underside of the case. Any ideas of what type of lamp I should fit. It doesn't have to be bright it's just to highlight the workings, copper and brass etc. It will need to be 240v mains feed though.
It will be kept in the garage as my workshop lamp, somehow I cannot see the o/h allowing this in the house even if it will be a talking point to old railway grissers who may visit!
Apologies Trek97, I don't wish to hijack your thread🤐!

Why not route the cable up through the bottom near a corner and fit one or two led lighting strips. Either at the top of the case or vertically in the corner angle.
Title: Re: The Black Knight...Side job
Post by: Bryanj on December 21, 2018, 11:59:52 AM
Do the do led strips in 240v?
Title: Re: The Black Knight...Side job
Post by: trek97 on December 21, 2018, 12:55:43 PM
Apologies Trek97, I don't wish to hijack your thread🤐!

Ha, think nothing of it.  No idea what it is...but its cool.   8)
Title: Re: The Black Knight...Side job
Post by: taysidedragon on December 21, 2018, 09:04:58 PM
Do the do led strips in 240v?

The transformer is usually in the plug, so yes.  :)
Title: Re: The Black Knight...Side job
Post by: trek97 on December 25, 2018, 12:52:31 PM
Happy Holidays Everyone.

Nothing like last minute Christmas gifts.  ::)

Gotta make some new rubber feet this morning (Christmas morning here now) and they will be ready to gift.

(http://www.dotheton.com/gallery/11494-251218064643-4783913.jpeg)

(http://www.dotheton.com/gallery/11494-251218064643-4784818.jpeg)
Title: Re: The Black Knight...Side job
Post by: MCTID on December 26, 2018, 01:41:16 PM
Reminds me of that old Ken Dodd quip.........'My fan Club has swollen..........my Wife has the Mumps' !
Title: Re: The Black Knight...Side job
Post by: Laverda Dave on December 26, 2018, 02:45:55 PM
 😁👍
Title: Re: The Black Knight...Wired up and Charging properly
Post by: trek97 on January 09, 2019, 08:37:13 PM
Back to the bike..

The original harness was toast, so had sparckmoto.com build me a fresh custom.

Complete w LED's, turn flasher and R/R.  Everything went perfectly.

Until I found the old stator had a bad leg, got a new emgo.  and ALL GOOD

Charging 13.5vdc at idle.

(http://www.dotheton.com/gallery/11494-090119142418-47852377.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-4804953.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-48051657.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-48061161.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-48071879.jpeg)


Cut old reflector and riveted it to new so the original would fit in stock bucket w LED.


(http://www.dotheton.com/gallery/11494-090119142418-48081149.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-4809820.jpeg)

(http://www.dotheton.com/gallery/11494-090119142418-48102496.jpeg)

Charging properly at idle

https://youtu.be/IAZ2YkY6PFQ
Title: Re: The Black Knight...Wired up and charging properly
Post by: taysidedragon on January 10, 2019, 12:25:19 PM
Happy New loom!  8) I like the led warning bulbs. 👍
Title: Re: The Black Knight...Wired up and charging properly
Post by: Bryanj on January 10, 2019, 01:10:21 PM
I would love to check out the original stator if you dont want ir as i have only ever seen them fail due to mechanical damage.
Title: Re: The Black Knight...Wired up and charging properly
Post by: trek97 on January 10, 2019, 06:09:25 PM
Happy New loom!  8) I like the led warning bulbs. 👍

Thanks bud

I would love to check out the original stator if you dont want ir as i have only ever seen them fail due to mechanical damage.

I’m planning to keep going w it to see if the solder joint cracked.
Title: The Black Knight...Complete and ready for spring.
Post by: trek97 on February 04, 2019, 12:05:35 AM
The Black Knight lives to fight another day...

(http://www.dotheton.com/gallery/11494-220618042444.png)

https://www.youtube.com/watch?v=U5cNF0C0R9s&feature=youtu.be

(http://www.dotheton.com/gallery/11494-030219175256-49101671.jpeg)

(http://www.dotheton.com/gallery/11494-030219175256-4913492.jpeg)

(http://www.dotheton.com/gallery/11494-030219175256-49142404.jpeg)

(http://www.dotheton.com/gallery/11494-030219175256-4911160.jpeg)

(http://www.dotheton.com/gallery/11494-030219175256-4912485.jpeg)

(http://www.dotheton.com/gallery/11494-030219175257-49161440.jpeg)

(http://www.dotheton.com/gallery/11494-030219175257-49191382.jpeg)

(http://www.dotheton.com/gallery/11494-030219175256-49151029.jpeg)

(http://www.dotheton.com/gallery/11494-030219175257-4918172.jpeg)

Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: Laverda Dave on February 04, 2019, 09:18:24 AM
Well done, another one on the road 👍. The Supertrap sounds great and especially on the overrun.
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: Nurse Julie on February 04, 2019, 09:23:28 AM
We'll done Eric 👍
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: Moorey on February 04, 2019, 10:05:14 AM
Love the feed sack seat cover. :)
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: Rob62 on February 04, 2019, 06:17:43 PM
Cool 8)
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: trek97 on February 04, 2019, 11:52:41 PM
Cool 8)
Love the feed sack seat cover. :)
We'll done Eric 👍
Well done, another one on the road 👍. The Supertrap sounds great and especially on the overrun.

Thanks so much everyone!!! 

And just a note to keep things real. 

My plan is to have fun with her 'as is' this summer. 

Collecting parts needed for the proper restoration next winter.

(http://www.dotheton.com/gallery/11494-040219174852.jpeg)
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: andy120t on February 21, 2019, 07:17:05 AM
Nice work - Enjoy the spring weather!
Title: Re: The Black Knight...Complete and ready for spring weather.
Post by: trek97 on February 26, 2019, 01:03:42 AM
Nice work - Enjoy the spring weather!

Thanks so much my man.
Title: Re: The Black Knight...Couple last minute mods.
Post by: trek97 on February 26, 2019, 01:07:25 AM
Making a few final tweaks.

Fit a British Bike fairing.  I dont recall BSA or Triumph maybe.

(http://www.dotheton.com/gallery/11494-240219161551-49802409.jpeg)

(http://www.dotheton.com/gallery/11494-240219161551-498154.jpeg)

And a new right side cover.

(http://www.dotheton.com/gallery/11494-240219190924-49821818.jpeg)

(http://www.dotheton.com/gallery/11494-240219190924-49841999.jpeg)
Title: Re: The Black Knight...A spin round the block for soup and bread.
Post by: trek97 on February 27, 2019, 03:31:01 AM
Went out for a nice little spin around the block and picked up a couple cans of soup and a loaf of bread at Caseys general store.

Along w a few (Ahem) umm "Beauty shots".  ::)

(http://www.dotheton.com/gallery/11494-260219185915-49851139.jpeg)

(http://www.dotheton.com/gallery/11494-260219185916-49911337.jpeg)

(http://www.dotheton.com/gallery/11494-260219185915-49891985.jpeg)

(http://www.dotheton.com/gallery/11494-260219185916-499346.jpeg)

(http://www.dotheton.com/gallery/11494-260219185916-4992863.jpeg)

(http://www.dotheton.com/gallery/11494-260219185916-49902054.jpeg)
Title: Re: The Black Knight...A spin round the block for soup and bread.
Post by: taysidedragon on February 27, 2019, 07:11:26 AM
That has to be the kookiest looking 400/4 around.

Or does anybody know different? 😄
Title: Re: The Black Knight...A spin round the block for soup and bread.
Post by: mattsz on February 27, 2019, 09:39:15 PM
Love it!  Can't wait to see the rest of the restoration!

Do you have specific parts vendors you like to use, or is it wherever you can find stuff?
Title: Re: The Black Knight...A spin round the block for soup and bread.
Post by: trek97 on February 28, 2019, 02:30:05 AM
That has to be the kookiest looking 400/4 around.

Or does anybody know different? 😄

Haha, thanks.  Inspired by this silly Rat Rod trend happening here now.  Plus I still get to ride while collecting clean parts.

As the weather is still pretty cold Ive only had the chance to take her out a couple short rides. 

I have restored several old Hondas now and this one was by far the most fun to do.

She has been nominated and currently in the running for Do The Ton, Bike of the Month contest.  haha

http://www.dotheton.com/forum/index.php?topic=76315.0
Title: Re: The Black Knight...A spin round the block for soup and bread.
Post by: trek97 on February 28, 2019, 02:34:23 AM
Love it!  Can't wait to see the rest of the restoration!

Do you have specific parts vendors you like to use, or is it wherever you can find stuff?

Thanks so much bud.  And I cant hardly wait to finish the proper restoration, next winter.

Most has come from David Silvers, these little machines are kinda, sort of rare here in the States.  (as Honda models go anyways.)

Most of the used parts for sale on Ebay here are for the most part junk and $$$.  So most has come from abroad.
Title: Re: The Black Knight...Seat and Rack re-DO.
Post by: trek97 on March 03, 2019, 11:49:19 PM
Tossed the chrome rack aside.
Made my own, then shortened seat and moved rack forward 7 inches.

(http://www.dotheton.com/gallery/11494-010319175505-49991192.jpeg)

(http://www.dotheton.com/gallery/11494-020319204116-5005596.jpeg)

(http://www.dotheton.com/gallery/11494-020319204116-5006342.jpeg)

(http://www.dotheton.com/gallery/11494-030319112449-5008432.jpeg)

(http://www.dotheton.com/gallery/11494-030319112449-500914.jpeg)

(http://www.dotheton.com/gallery/11494-030319112449-50101446.jpeg)
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: trek97 on March 17, 2019, 09:36:56 AM
I started getting fast idle issues.   Sorta like a vacuum leak but not really like a vacuum leak.

Julie and I compiled a list of things to check.  Thanks Lady.   ;)

First was plugs and caps.  They were fine.

So I made a pair of more substantial links, as the originals were bent.

Installed and re-synced then tuned A/F mix.  I found it too lean.  So with 3/4 turn in...

Viola, The fast idle calmed right down, now holds a smooth and steady 1200.

For fun, I installed a Dyna DS1-1, got her dialed in w my stroboscopic light and just like that she's done and ready for summer adventures.

Still need to flip that pesky #1 header clamp.   ::)

(http://www.dotheton.com/gallery/11494-170319042546-50581545.jpeg)

(http://www.dotheton.com/gallery/11494-170319042546-5060529.jpeg)

(http://www.dotheton.com/gallery/11494-170319042546-5061981.jpeg)

(http://www.dotheton.com/gallery/11494-160319091424-505460.jpeg)

(http://www.dotheton.com/gallery/11494-160319162233-50561991.jpeg)

(http://www.dotheton.com/gallery/11494-160319162233-50571.jpeg)
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: mattsz on March 17, 2019, 10:37:19 AM
I started getting fast idle issues.   Sorta like a vacuum leak but not really like a vacuum leak.

...

So I made a pair of more substantial links, as the originals were bent.

So the bent links were the cause of your fast idle problem?  Do you know how they got bent (I don't recall that you dismantled your carb rack enough to remove those links)?
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: trek97 on March 17, 2019, 11:15:11 AM
Yeah, sorry I ddnt bother to add the pics.

I took them completely down and changed all the o-rings on the fuel feed pipes.  Thank goodness, as I found the center T fitting still full of debris.   

Actually I bent them, being a brute during the first sync.   ::)

The fast idle problem was the combination of Lean A/F mix AND the sync.  But mostly A/F mixture.

the first one I turned in #4.  the idle really took off, faster. 

(Which is exactly what you want it to do.  As A/F mix is properly tuned in at fastest idle.)

So I knew I was onto something.  Cranked in the others.  Then went through and dialed them all in/out for fastest idle properly.

Afterwards, I re-adjusted idle speed for 1200rpm.  Running smooth as silk.   :)





 
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: trek97 on March 17, 2019, 11:34:30 AM
Also mattsz, here's some pics I did take during.  Not the best as sometimes I get lazy about it.
 
(http://www.dotheton.com/gallery/11494-170319062559-50681898.jpeg)


Debris stuck in the T fitting, even after ultrasonic.

(http://www.dotheton.com/gallery/11494-170319062559-50671261.jpeg)


Rotten o-rings.

(http://www.dotheton.com/gallery/11494-170319062558-5064120.jpeg)


New on the left, old and flat on the right

(http://www.dotheton.com/gallery/11494-170319062558-50621738.jpeg)


Best to disassemble carbs as theres plenty of places for debris to get trapped in the fuel feed galleys.

(http://www.dotheton.com/gallery/11494-170319062559-50691567.jpeg)


I also found one float was a half gram heavier than the other three, so I replaced it w a spare that averaged same as the others.

(http://www.dotheton.com/gallery/11494-170319062559-50652159.jpeg)

(http://www.dotheton.com/gallery/11494-170319062559-50661272.jpeg)


Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: trek97 on March 17, 2019, 11:38:31 AM
Pulling and swapping that #1 clamp was a PITA!!!!    :P

Everything went back together as it should, but if theres any leaks I will probably have to drop that darned oil pan to get everything properly aligned and torqued.

(http://www.dotheton.com/gallery/11494-170319060402.jpeg)

Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: mattsz on March 17, 2019, 11:44:32 AM
Thanks for the details re. the carbs.  I'm going to do my best to clean mine "on the rack," then reassemble.  I haven't run the bike yet, so I still don't have a baseline performance.  The bowls and accessible bits within them are pretty clean, so I'm keeping my fingers crossed...
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: trek97 on March 17, 2019, 11:47:58 AM
Ten 4 man.

If I hadn't had the leaks I wouldn't have torn mine completely apart.

Keep me posted.  Im more active on Do the ton forum. Same trek97 over there.
Title: Re: The Black Knight...Dialed in and ready to ride.
Post by: mattsz on March 17, 2019, 11:51:01 AM
Ten 4 man.

If I hadn't had the leaks I wouldn't have torn mine completely apart.

Keep me posted.  Im more active on Do the ton forum. Same trek97 over there.

(https://advrider.com/f/styles/advrider_smilies/cooltu.gif)
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on March 24, 2019, 02:44:18 PM
Rach and I had our first sunny ride of the season.

It was almost a success.  The circlip popped off and my shifter was left dangling by the rearset linkage out on the breeze.

Got home, drilled a hole through the shaft and fixed that.

(http://www.dotheton.com/gallery/11494-240319093651-50751504.jpeg)

(http://www.dotheton.com/gallery/11494-240319093652-50771250.jpeg)
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: Laverda Dave on March 24, 2019, 06:21:06 PM
Looks like a nice sunny day where you are? Good to blow the winter cobwebs away. Shame about the circlip going AWOL, did you have the washer fitted between the circlip and the gear pedal?
It's been a great sunny day here as well, I'm just back from a 170mile ride out with the local institute of advanced motorcyclists. I've just joined them, a really great bunch.
That Hawk looks nice, imo they look so much better than a Superdream that followed it.
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: SteveD CB500K0 on March 24, 2019, 06:54:26 PM
Which group are you in Dave?


Sent from my iPhone using Tapatalk
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: petermigreen on March 24, 2019, 07:22:12 PM
Great thread Eric.
When I saw that you bought a new frame and a new engine (and then another one) I couldn't help thinking of this.

https://youtu.be/LAh8HryVaeY

Ride on Eric.
Peter
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: Nurse Julie on March 24, 2019, 07:46:59 PM
Eric is THE man......I really like it when people cobble a bike together and just ride it, regardless of what others may think. Keep yup the great work Eric x
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: Laverda Dave on March 24, 2019, 08:22:24 PM
I'm in the Middlesex branch Steve. I live just up the road from where they hold their social meets.
I've had my two theory lessons and went on my first social ride today, great bunch of people, glad I joined.
I need to book some observed rides now. Plan is to pass the test so I can join Blood Bikes as a volunteer. Only problem now is I'm currently undergoing training to be a tour guide in the Uxbridge RAF WW11 Operations Bunker.
And I thought retirement would involve winding down!
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on March 25, 2019, 10:18:41 AM
Looks like a nice sunny day where you are? Good to blow the winter cobwebs away. Shame about the circlip going AWOL, did you have the washer fitted between the circlip and the gear pedal?
It's been a great sunny day here as well, I'm just back from a 170mile ride out with the local institute of advanced motorcyclists. I've just joined them, a really great bunch.
That Hawk looks nice, imo they look so much better than a Superdream that followed it.

Thanks bud, and yes had the washer in place...its just the circle itself was the weak link,
one of the few parts left that was actually original to the bike..  ::)
My wife loves her Hondamatic.
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on March 25, 2019, 10:23:09 AM
Great thread Eric.
When I saw that you bought a new frame and a new engine (and then another one) I couldn't help thinking of this.

https://youtu.be/LAh8HryVaeY

Ride on Eric.
Peter

HAHA,  Yes its A LOT like that.  Thanks so much bud,  A chuckle is always a good way to start the day off right.   ;D
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on March 25, 2019, 10:24:51 AM
Eric is THE man......I really like it when people cobble a bike together and just ride it, regardless of what others may think. Keep yup the great work Eric x

Thanks so much for all YOUR help Julie.  YOURE THE BEST!!!   8)
Title: Re: The Black Knight...Sunny ride was ALMOST a success ;)
Post by: trek97 on March 25, 2019, 10:28:09 AM
I'm in the Middlesex branch Steve. I live just up the road from where they hold their social meets.
I've had my two theory lessons and went on my first social ride today, great bunch of people, glad I joined.
I need to book some observed rides now. Plan is to pass the test so I can join Blood Bikes as a volunteer. Only problem now is I'm currently undergoing training to be a tour guide in the Uxbridge RAF WW11 Operations Bunker.
And I thought retirement would involve winding down!

Sounds like awesome fun. 
I cant wait to retire...6-1/2 years til I turn 58yo. 
Then its nothin but bikes, booze and broads to the end.   ;)
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