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1975 CB400F "un-cafe"

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kartin:

--- Quote from: Bryanj on July 24, 2023, 11:27:14 AM ---As you are in US you may find it easier to get a 360G5 front end which is the same

--- End quote ---

Good know, thanks! Actually looking at some images of that model, the fuel tank looks suspiciously like the one that arrived on my bike!

kartin:
Steering as received had a very noticeable notch in the straight ahead position so new bearings required. For the steering tapers, I plumped for the All Balls kit. Maybe not the ultimate quality bearings but as a kit, it seemed to be the one people had fewest issues with in terms of the height. The thinner washer gave a lower stack height very, very close to the originals (18.6mm for lower washer plus complete bearing). In the first picture below, original washer plus seal plus bearing is on the left. The freezer trick for the outer races and the stem worked well and fitting was very easy. At the top, I chose not to use the extra washer between the new seal and the adjuster nut, just to get some extra thread as well as bring the dust cover closer to the headstock. The very top nut had plenty of thread to work with.

The forks themselves were dismantled, seals replaced (very stubborn!) and everything flushed with brake cleaner. One of the seal retaining clips was too corroded to re-use which is why you see shop towel wrapped around it until I can add it to my next parts order (ok, I could have used the rubber cover itself but I wanted a visible reminder!). The stanchions have a few blemishes but the chrome is complete so no immediate attention required.

kartin:
Just continuing to attach things to the frame. On the plus side, I'm very happy with the wiring loom. It came from classicjapanesemotorcycles.com and it looks almost brand new. The combined reg/rec came with the bike but it has zero markings so I'm not sure what brand. It was giving good voltage when I ran the bike briefly and I also metered the diodes so it seems good. It was originally wired in with a horrible rat's nest but I'll ditch all that and go straight into the loom regulator and rectifier locations. For now I'll use individual spade connectors but eventually I'd like to find the correct mating halves (source?). I have an alternator harness waiting in the UK for my next trip (from 400fourbits.co.uk).

On the downside, some more non-CB400F parts came to light. The coils don't look quite right (wires in different places) but they measure as 5ohm primary and 15k secondary and fit under the tank so that's fine. The handlebars only have a wiring hole on the left side and the clamp lines don't align with the clamps. I knew the switchgear was wrong. Neither side has anything related to the headlight and the horn wire goes to ground when pressed. I can also see that I'm missing various cable guides. So, more parts on the missing list!

kartin:
Few more pics that wouldn't fit on prior post:

kartin:
A bit of exhaust progress and it has some bearing on which way the project goes. From the beginning, I wasn't sure whether to aim for standard appearance or to try and mimic my old bike as it was when I finally sold it. The exhaust that came with the bike comprised standard downpipes but aftermarket muffler (without much muffling...). The downpipes are very rusty so either black paint or re-chrome would have been needed. But then what to do for a muffler? A repro in chrome might not look good with black downpipes?

Anyway, this dilemma was solved when I chanced on somebody selling one of the old Yoshimura pipes. These are the ones with the funky "crossover" arrangement and is exactly what I had on my old bike. The only photo I can find of the old bike is from the left side but you can just about make out the #4 pipe sticking further forwards than the others. The other pics are the seller's. Rust-wise it's not perfect, but it's probably going black anyway! Pipe is waiting for me in the UK so fingers crossed it will fit in our suitcases coming back!

So, for the rest of the bike, I won't go as radical on the colour scheme (it seemed like a good idea at the time and I obviously had an aversion to any chrome finishes!). But I still like the "high at the back" tail/fender look and the non-chrome front fender.

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