CB400/4 ENGINE STRIP, ASSESSMENT AND REBUILD BY JULIE - NOW COMPLETE

[Nurse Julie]

Just think to yourself. .. slowly, slowly,  catchee monkey and they'll go in nice and easy.

I hope so Mike.

[Clem2112]

Wide cable ties can be used to hold the new rings in their grooves if ring compressors are not available... a  bit fiddly and probably 2 ties are needed per piston.
Plenty of oil in the bores ( there may be something better out there that sticks to the cylinder walls for longer?). String and blocks to support the barrels helped too !
Worked for me and I was a newbie to the task having only ever fitted a new piston to a 2 stroke scooter !

[Bryanj]

Recently done a 1200 wing, now they are a real pain in the butt, if you get proper Jubilee clips and not cheap copies they are wider and just cover the 3 rings to make it easier

[Nurse Julie]

Fitted the new clutch lifter bearing. I had ordered the wrong one before. Even though there was nothing wrong with the clutch operation before I took the bike off the road, when I took this bearing out it and checked it, it sounded really scrunchy when moving it around so I decided to replace it. This is the only roller bearing I have changed throughout the build, the rest were fine and did not need changing.

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I also refitted the oil pump that I refurbed a few weeks ago. The oil pressure switch wire was not in a particularly good state so I made a new one and fitted it.

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And the engine is back in the frame. Unfortunately, at this stage I cannot put the front engine mounting brackets and bolts back on as I have engine crash bars fitted and the engine bolts act as the fitting points for the bars. If I fit the bars back on now, I cant get proper access to fit the side casings, ancillaries etc and it would be very close at the top when I put the barrels back on. I will fit all the side casings etc, the barrels and the rest of the top end and then bolt the engine in place with the crash bars. I have got the rear mounting bolt in place though.

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[Integra99]

Looks fantastic... !

[Clem2112]

Flying together now then....

I have the same bike ramp nowadays.... a bargain when MachineMart have their VAT free offer.
Wish I had got it a few years ago when I was rebuilding the 400/4.

[Nurse Julie]

Looks fantastic... !

Thank you.

[Nurse Julie]

Flying together now then....

I have the same bike ramp nowadays.... a bargain when MachineMart have their VAT free offer.
Wish I had got it a few years ago when I was rebuilding the 400/4.

Yes, I feel like I'm getting somewhere now. The stripping, diagnostics, cleaning, measuring, machine work and general prep seemed to have taken an age. I suppose it's still more efficient doing it that way instead of having a load of dirty bits laying around that you need to clean etc each time you want to fit something.

[Nurse Julie]

Just fitting bits and pieces this weekend. Leaving the barrels / head until I have plenty of time to concentrate on the job without having to rush off somewhere.

Fitted the oil strainer and sump back on.

The strainer has very fine metal mesh.

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The other side of the strainer where the big spring fits over.

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Once fitted the spring pushes the strainer down onto the lip in the recess of the oil separation plate.

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This is where the strainer and pipe fits.

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And finally, all in place.

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New sump gasket fitted and sump bolted in place.

Truth time. I had fitted the strainer and bolted up sump and saw the spring still sitting on the work bench, silly bitch I said to myself and set about undoing all those sump bolts and fitting the spring. Not concentrating !!!!!

[Spitfire]

Truth time. I had fitted the strainer and bolted up sump and saw the spring still sitting on the work bench, silly bitch I said to myself and set about undoing all those sump bolts and fitting the spring. Not concentrating !!!!!

It happens, you are feeling great, things are good and whoops how did I do that, never mind it's looking good and the photos are superb

Cheers

Dennis

[mike the bike]

If you leave most of the engine bolts out except the bottom two, you can jack the rear of the engine up as far as it will go.   That then gives an extra 20mm or so to get the carbs in.

[Nurse Julie]

If you leave most of the engine bolts out except the bottom two, you can jack the rear of the engine up as far as it will go.   That then gives an extra 20mm or so to get the carbs in.

Thanks Mike, that's worth bearing in mind. I usually don't have a problem fitting the carbs back on, I just push and compress the airbox back as far as it will go and then start wiggling them in. As always, it's not the easiest job in the world but I  usually manage.

[Nurse Julie]

Still finding myself short on time at the moment, but continuing with little bits of work.

Took apart this part of the clutch mechanism today to give it a good clean.

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On the back side it was full of old gritty, dirty grease and I'm sure not performing to it's best, although I never felt there was anything wrong with it.

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Looks a lot better after a good clean. I will re grease everything and re assemble and fit the casing to the bike.

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[Nurse Julie]

Fitted the front sprocket

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Cleaned the alternator up a bit and fitted it to the bike.

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And fitted the starter motor. You can see through the hole where the spline locates on the gear.

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[Clem2112]

Julie

Is that a new O ring on the starter motor spigot?
I doubt they ever leak ? .... just looks a bit flat in its groove.