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CB400 Project
Chris400F:
Hi beemsquar,
Good luck with the project - looks like you have made a good start already.
Here's another alternative for the exhaust. Original style, stainless so no rot and looks a reasonable price (cheaper than others).
http://www.ebay.co.uk/itm/Honda-CB400-4-4-1-Stainless-steel-pipes-and-collector-by-Motad-/161768793224
I have one of their non-stainless systems on my own 400, it's OK for the money.
If you find other bits you need you can always try a 'Desperately Seeking' post on here, someone may have what you need gathering dust.
beemsquar:
Day 17 to 19
I have now removed the engine from the frame, which was not fun on my own!
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I'm not sure this is normal but , I struggled to remove the front engine bracket as there were a stack of washers on the crankcase bolts that made those bolts and the bracket bolts so close I couldn't get a spanner on them. should this have been like this?
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And while I was taking that picture I noticed this!!!!
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Not sure if this is fixable or not???
The last few days I have been slowly working on dismantling the engine, ready for a deep clean and overhaul, I sprayed all the bolts with a penetrating liquid over a few days. I started to remove the rocker cover when snap! the first bolt I touched with hardly any pressure broke off in the head, there are screws and bolts on my rocker cover and I'm unsure if that is standard or other bodge on this poor old girl??? But the inevitable happened and a screw also snapped in the head with the lightest of turns.
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Hopefully they can be drilled out!!
Cheers for the link Chris, I will have a look at that good to keep your options open.
I looked at an original on 400fourbits, so might get an original used one yet, He's got a lot of parts I need so might doing a bulk order soon!
beemsquar:
Day 20
So I removed the Rocker cover yesterday and found this nasty surprise, just plain lazy if you ask me!
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It removed OK, but will need replacing. when I get to put this back together should I replace the copper washers?
I removed the sprocket, cam chain slipper and tensioner and then proceeded with the removal of the head, which was surprisingly simple and got my first site of the pistons a little cruddy, but I was expecting worse, I guess it's been running too rich???
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I proceeded with the removal of the block yesterday as I want to clean everything in one go so again it came off quite easily.
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As soon as the block was off piston number four gave up a piston ring to the crankcase! Definitely about time this thing had a tear down!
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Saisei:
A nice variety of bolts you have there ;). With care and patience those sheared bolts should repair. Give them a good soak with penetrating oil plus heat the surrounding alloy before drilling. Try using left hand drills incrementing in size. If you are real lucky the stub might free off and spin out on the drill tip leaving you to just clean up the case thread with a tap.
http://www.ebay.co.uk/itm/LEFT-HAND-STUB-DRILLS-65MM-7-4MM-/281739868990?pt=LH_DefaultDomain_3&var=&hash=item4199013b3e
As mentioned earlier, I do have one complete exhaust set left if interested. Yes, the downpipes are single skinned but this should not be an issue if the carbs are set up correctly.
http://www.saisei-europe.com/Shop/Products/c/exhaust/p/new-cb400f-silencer
Good luck with the project, I will watch this one with interest :)
beemsquar:
Day 21
Cheers for the advice saisei, I will check out the link and have a think about the exhausts, they do look good!
Today I wanted to get the pistons off the conrods and measure and inspect everything before I go any further.
I removed the pistons again not as hard as I thought, but when I removed the gudgeon pins they felt slightly ridged and marked, is this normal wear or a thrashed motor?
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I measured all the pistons and bores (with my cheap digital calipers mind), they were all slightly out from each other but the worst measurements were these....
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I am going by a clymer and haynes manual, but from what they recommend, I think I could be in for a set of oversized pistons and a rebore?! Not what I wanted to hear.
There is also a slight gouge down bore number 2 that I couldn't get in a photo, so what are the options for me guys? By a used block and pistons or rebore and replace with oversized? What sort of cost am I looking at?
The other thing I had two pistons marked with the number 4 and 2 marked number 3, is that normal??? All four were original honda mind, thought maybe they were already oversized???
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So thats where I'm at at the moment, I was going to split the crank and order a gasket set, replacement stainless steel bolts and all the engine seals today, but I might wait and see what responses I get first!
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