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

[Sesman]

Plus one on plugs out using the “big nut”.

I tend to adjust using 1thou more on the feeler gauge when nipping up. It seems to result in a nice sliding fit at the specified clearance.

Just saying what works for me.

[Bryanj]

The reason i say dont use the big nut is i have seen too many where turning with the plugs in(be all right just this once!)breaks the ears off the advancer cam, its easier to say dont than explain it ever time and as i am getting older and crotchetier thats just me!

[Oddjob]

I knew that was the reason Bryan, I just say remove the plugs. Strange that Honda don't mention doing that, you'd think they'd be more proactive.

[Bryanj]

Well we all know Honda aint infalable, i have one of the very early small workshop manuals which can read odly shall we say, and the parts book does say there are 4 gear selectors

[McCabe-Thiele (Ted)]

Thanks everyone for your input on adjusting the valve clearances - today I have given it some looking at plus I found this chart in one of the Manuals  that came with the bike.`

I hope to report the job has been completed soon depending on my energy levels and the "To Do" list from the Gaffer before I go into the garage again!

.valve clearances by Macabe Thiele, on Flickr

[Oddjob]

TBH Ted, you rotate the crank once for that method. You need something to remind you which of the inner cylinder valves you can do, the other way you don't need to think what valves to do and you rotate the crank 1/2 a turn more. Seriously it's a no brainer, even in the trade we never did them like the Honda method, just not worth the bother for 1/2 a turn.

Don't over think it, just do the easiest thing.

[McCabe-Thiele (Ted)]

Over thinking me?

Guilty in the first degree.

[McCabe-Thiele (Ted)]

I have now adjusted the eight valve clearances - I had forgotten what a fiddly task it is. Its about 35 years since I adjusted a set as my more recent cars have had hydraulic ones - got easier with practice. No doubt I may have to make some minor adjustments after the engine has been run.

I'm looking at minor tweaks to the wiring loom routing having made some changes on my speedometer & rev counter routes near the headlamp area. Handy having lots of photos to check against.
Currently fitting new male connectors to the small loom from the left side of the handlebars as they were all the wrong size. The PO had added some wiring in this area but what had been fitted I am not sure as some wires had been cut off to remove the item or items - possibly a DTRL or some sort of relay arrangement?

[McCabe-Thiele (Ted)]

Major leaps forward on the wiring front just a few minor things to resolve like the clutch switch that was missing so need to work out where the connections go. I assume the switch is standard in the UK. Last task on the wiring will be trying to sort out the bunch in/behind the headlamp. A quart into a pint pot.

[Bryanj]

Cant remember the colours but they connect in the headlamp, gree/red is one that comes to mind.
You can use a front brake light switch from a drum braked cg125 or similar, wires are different colour but fittings same.

EDIT

ebay item 300184704803

[Oddjob]

35360-341-000 superceded to 35360-329-003 Ted, colours are green/yellow and black. Costs £18.48 from DS.

The ones Bryan has listed are much cheaper, shame the pic is so blurred as the connectors don't look great but could just be the pic.

[Bryanj]

Front brake switch is 35340-401-681 which has superceeded.
Only difference is wire colour and price

[Oddjob]

The parts book says the 35360 number Bryan, although why Honda would produce another almost identical part is beyond me, even the wire colours look the same. Price is about the same as well, depending where you buy. In fact the proper part is cheaper at CMS. Maybe the wires are shorter on the 125 one?

[McCabe-Thiele (Ted)]

Cant remember the colours but they connect in the headlamp, gree/red is one that comes to mind.
You can use a front brake light switch from a drum braked cg125 or similar, wires are different colour but fittings same.

EDIT

ebay item 300184704803

You are spot on Bryan it was Geen/red on the loom - my patern switch had Dark Green/light green trace.

[McCabe-Thiele (Ted)]

Nice warm day so started connecting more electrical bits - horn mini loom now fitted so horn works as do all the indicators & side lights.

Fitted 4 way connector where rear brake lamp loom connection feeds the rear brake light switch to enable power supply to my electronic ignition. Fitted an additional earth cable between battery and existing loom earthing point on regulator mounting bolt to hopefully generally improve earthing.

Painted inside of rear chain guard with Zinc Primer prior to final painting before fitting.