1975 400/4 project

[Sprocket]

Not a massive update, but I've had the front wheel off, painted the spokes individually with Chrome paint, and refurbished the disc. Also put the correct grub screw in the speedo drive cable hole, and put a new pinch bolt in the rear brake lever.

Next task is the abhorrence that is the brake caliper. There was a ton of gungy brake fluid all round the pad, to the extent I couldn't pull the pad out. Had to fill up the reservoir and attach the lever to the bar, and pump it for about 10 mins to get it to push it out. The piston has got loads of dents and rusty spots but I think the caliper might be salvageable.

[Nurse Julie]

Good progress.

[Bryanj]

Caliper is always fine BUT warm the body to uncomfortable temp before trying to undo the bleed nipple and clean the seal groove out scrupulously clean. Stainless Piston and seal kit about £30 on ebay and you only have 1 neck!!

[Sprocket]

So I'm up to the point where I want to put my replacement (Japanese sourced used and very good condition) loom on to the frame. And now I'm noticing all kinds of horrendous bodges, among the general clean and tidying.

The fuse box has no lid and has been chock blocked. I was about to use the connector from the rectifier when I thought it would be far, far less bother to just get a replacement.

The ignition switch works with the one extremely worn key, but as you can see it's not in great nick. After disassembly and reassembly it's much better, but I can still take the key out when it's in the 'ON' position. Anyone know what's up with that?

[Bryanj]

Ignition switches that have been used a lot get like that i'm afraid and if you fit new then the seat lock has a differentbkey.

[AshimotoK0]

I have a used 400/4 Ignition switch with non-original key that I was going to list on eBay. Would sell on here for £15 plus post if you or anyone else is interested. That's what I paid for it ages ago.
Would need to check it out electrically 1st though as been off the bike for yonks.

[Sprocket]

Thanks for the offer, but I've found a NOS key in the states for the one I have here. I'm hoping it's a worn key that's causing the issue where it can come out while the bike is 'on' but I'm really keen to retain as much as I possibly can from the pile of parts bike!

[Laverda Dave]

Ash, if you have no takers I would like the ignition switch please. I have a pattern one on my 400/4 and it looks like it so an original Honda item would be great 👍.

[AshimotoK0]

Ash, if you have no takers I would like the ignition switch please. I have a pattern one on my 400/4 and it looks like it so an original Honda item would be great 👍.

Tim (Rozabikes PM'ed me) a little while  you sent message about having itm so I really have to let him have 1st dibs on it. I also have one here to fix for Jeremy (Harold400) so if you need me to fix yours I could take a look at yours too.

[Laverda Dave]

No problem Ash. My pattern one is fine, I just wanted an original item but no hardship, Tim probably needs it more than I do.

[Sprocket]

So, the issue with being able to remove the key while the ignition is 'on', is down to the key being worn. I got my replacement in the post today and it operates exactly as it should.

[SteveD CB500K0]

So do you think that the key is designed to be “sacrificial” to wear before the lock?

Very forward thinking of the Honda engineers!


Sent from my iPhone using Tapatalk

[Sprocket]

Well I dare say the key must still meet some of the criteria originally set for it, but I don't think any Honda engineers would have designed a 43 year lifespan into any part of the bike, let alone the most used / abused part!

[Sprocket]

So current project status is as follows. Total spend is £2200. Still haven't started the engine, but 90% of the cycle parts are either done or in progress with a clear end in sight. I fitted the controls a couple days ago so the amount of 'brrmmm brrrmmm' noises from the garage have increased somewhat.

[Nurse Julie]

👍👍👍