SHOP MANUAL .. HONDA CB400T .400A/CM400T. 400A-400E -400C , TABLE OF CONTENTS INTRODUCTION This Shop Manual is for these models: '78: CB400T, CB400A '79: CB400T. CM400T, CM400A A, '80: CB400T, CM400T, C M ~ ~ O CM400E '81 : CB400T. CM400T, CM400A. CM400E, CM400C PART I CB4OOTIA GENERAL INFORMATION LUBRICATION INSPECTION AND ADJUSTMENT HOW TO USE THlS MANUAL The first part of this shop manual contains all information and procedures common to the CBICM: : 400's. After section 19, part two begins and it . contains information and procedures for the Honda. . matic models. A 78% Emissions Addendum follows the second part and it applies to all CB and CM400 models manufactured after December 31, 1977 (USA only). Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 17 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to ,, the table of contents on page 1 of that section. Most sections start with an assembly or system .' / illustration and all the specifications, torque values, .'. .:.working practices, tools and materials required for "&.. the. section. The subsequent pages give detailed .. . . .. ------procedures. ' I f you are not familiar with this motorcycle, read TECHNICAL FEATURES, section 18. If you don't know the source of the trouble, see section 19, TROUBLESHOOTING. Refer to the addendum at the back of the shop manual for 1978% and subsequent years service information. 5 CYLINDER HEADIVALVE 6 CYLINDERIPISTON 7 '.,' CLUTCHIOIL PUMP 8 . . I 1 CRANKCASE F' NO PART OF THlS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. Service Publications Office Date of Issue: December, 1980 O HONDA MOTOR CO.. LTD. ... , 9 I 1 CRANKSHAFTIBALANCER. I lo 11 12 ,I S S I S FRONT WHEELIBRAKEI SUSPENSION REAR WHEELIBRAKEI SUSPENSION HYDRAULIC DISC BRAKE 14 I L BATTERYICHARGING SYSTEM 15 E 1 R I C A L l IGNITION SYSTEM STARTER MOTOR ~. TECHNICAL FEATURES TROUBLESHOOTING A L L PHTOGRAPHS ARE BASED ON THE TYPE II MODEL. A L L INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THlS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES A T ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. 4 TRANSMISSION ' , FUEL SYSTEM ENGINE REMOVAL 81 INSTALLATION . i I 16 17 / l8 l9 PART I1 CB400A ONLY 1 ,I I '78% CB400T.CB400A EMISSIONS ADDENDUM 20 '79 CB400T ADDENDUM 21 7 9 CM400T.CB400A ADDENDUM 22 '80 CM400T.CM400A ADDENDUM 23 '80 CB400T ADDENDUM 24 8 0 CM4OOE ADDENDUM 25 '81 CBlCM400'S ADDENDUM 26 1 I i ;I 1 PART 11 @ HONDA CB400T MODEL lDEMTlFlCATlON TYPE I CB400T (I) BEGINNING FIN 2000001 TYPE II i CB400T (11) BEGINNING FIN 4000032 The frame serial number is stamped on the right side of the steering head. The legal vehicle identification number WIN) i s on the left side of the steerins head. The engine serial number is stamped on the top of the crankcase. The carburetor identification number is on the left side of the carburetor body. Data of Issue: August, 1980 . O HONDA MOTOR CO., LTD. @ RAL INFORMATION 3 HONDA CB400T GENERAL SAFETY 1-1 SPECIAL TOOLS 1-6 SERVICE RULES 1-1 WIRING DIAGRAMS 1-7 SPECIFICATIONS 1-2 CABLE & HARNESS ROUTING 1-9 TORQUE VALUES .I -4 MAINTENANCE SCHEDULE 1-12 ! GENERAL SAFETY Ifthe engine must be running to do some work, make sure the area is well-ventilated, Never run the engine in a closed area. The exhaust containspoisonous carbon monoxide gas. Gasoline is extremely flammable and is explosive under certain conditions. Do n o t smoke or allow flames or sparks in your working area. 0 The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case o f contact, flush thoroughly with water and call a doctor ifyour eyes were exposed. The battery generates hydrogen gas which can be highly explosive. Do n o t smoke o r allow flames or sparks near the battery, especially while charging it. . SERVICE RULES Use geniune HONDA or HONDA-recommended parts and lubricants or their equ~valent.Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for this product. 3, Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. 4. When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten t o the specified torque diagonally, unless a particular sequence 1s specified. 5. Clean parts i n cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6. After reassembly, check a l l parts for proper installation and operation. 7. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. 1. Date of issue: September, 1977 O HONDA MOTOR CO., LTD. 1-1 ~. HONDA CB400T GENERAL INFORMATION SPECIFICATIONS Bore and stroke Displacement Compression ratio 70.5 x 50.6 mm Lubrication system Cylinder head compression pressure 24.1 cu-in. 9.3 : 1 Chain driven over head camshaft Valve train Oil capacity 2.776 x 1.992 in. 395 cc / 3.2 U.S. qt., 2.6 Imp. qt. 3.0 lit. Forced pressure and we1 4 psi 13 1.0 kg/cm2 * Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. .. aHONDA GENERAL INFORMATION Date o f Issue: September, 1977 0 HONDA MOTOR CO., LTD. 1-3 HONDA CB400T GENERAL INFORMATION TORQUE VALUES ENGINE Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Cylinder head cover bolt Tappet adjusting nut Cylinder head bolt Cam sprocket knock bolt, 7 x 12 hex. bolt Spark plug Drive gear fixing bolt, 12 x 25 flange bolt Clutch eenter lock nut 20 mm Balancer, 8 mm nut Balancer, 10 mm nut A.C. generator rotor set bolt, 12 x 40 flange bolt Crankshaft holder bolt, 10 mm bolt Connecting rod nut Starting clutch bolt, TORX bolt Oil filter center bolt Oil drain plug Exhaust pipe flange nut. 6 mm Muffler chamber clamp bolt, 8 x 35 flange bolt Gear shift pedal, 6 x 32 flange bolt - Torque Values Q'ty 2 6 8 2 2 1 1 1 1 1 6 4 3 1 1 4 4 1 kg-m Ibs-ft 0.8-1.2 1.2-1.7 3.0-3.3 1.8-2.2 1.5-2.0 4.5-5.0 4.5-5.0 2.0-2.5 3.0-3.5 10.0-12.0 3.3-3.7 2.5-2.9 1.2-1.4 2.8-3.2 2.5-3.5 0.8-1.2 1.872.5 0.8-1.2 6-9 9-12 22-24 13-16 11-14 33-36 33-36 15-18 22-25 70-90 24-27 18-21 9-10 20-23 18-25 6-9 13-18 6-9 . CHASSIS Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 1-4 Steering upper holder bolt. 8 x 36 flange bolt Steering lower holder bolt Steering stem nut Front fork bolt Front fork bottom bridge bolt, 8 x 40 hex. bolt Front brake disc bolt, 8 x 33 UBS bolt Caliper set bolt, 10 x 32 flange bolt Front brake caliper bleeder valve Rear brake stopper arm nut, 8 mm nut Front axle nut Front axle holder nut. 8 mm nut Rear axle nut Final driven sprocket, 10 mm nut Rear fork pivot nut. 14 rnm nut Rear shock absorber upper bolt, 10 x 45 flange bolt Rear shock absorber lower bolt, 10 x 32 hex. bolt Foot peg bolt. 10 mm flange bolt Drive chain adjusting nut Fuel tank set bolt. 8 x 28 flange bolt Rear brake pedal pivot bolt, 8 x 65 flange bolt Engine hanger, 10 mm flange nut Q'ty 4 4 1 2 2 5 2 1 2 1 4 1 4 1 2 2 4 2 1 1 5 Torque Values Ibs.ft kg-m 1.8-2.5 2.3-3.0 9.0-12.0 7.0-9.0 1.8-2.5 2.7-3.3 3.0-4.0 0.7-0.9 1.5-2.3 5.0-8.0 1.8-2.5 7.0-10.0 6.0-7.0 5.5-7.0 3.0-4.0 3.0-4.0 5.5-6.5 0.8-1.2 1.5-2.3 1.8-2.5 4.5-6.0 13-18 17-22 65-87 51 -65 13-18 20-24 22-29 5-7 11-17 36-58 13-18 51-72 43-51 40-51 22-29 22-29 40-47 6-9 11-17 13-18 33-43 Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. HONDA CB400T \ a GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS Bolts and Nuts 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 mm screw 6 mm screw 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm flange bolt and nut Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. Torque Values kg-m 0.45-0.6 0.8-1.2 1.8-2.5 3.0-4.0 5.0-6.0 0.35-0.5 0.7-1.1 1 .O-1.4 2.0-3.0 3.0-4.0 - Ibs.ft 3-4 6-9 13-18 22-29 36--43 3-4 5-8 7-10 14-22 22-29 - HONDA CB400T GENERAL INFORMATION SPEC1AL TOOLS /COM MON TOOLS SPECIAL TOOLS Part No. Tool Name Snap ring pliers 07914-3230001 Hollow s e t wrench ( 6 mml Ball race driver - Bottom Steering Race* 07945-3330300 Ball race driver - T o p steering Race* 07946-3290000 Ball race remover Valve guide reamer (IN1 07953-3330000 Valve guide reamer (EX1 07984-61 10000 TORX driver bit (T-30) Piston ring compressor (21 Piston base (2) 07703-001 0200 07958-2500000 Tool case 07797-2920300 07917-3230000 07984-2000000 07954-2830000 COMMON TOOLS I Tool Name I part NO. I Float level gauge Lock nut wrench socket (30 x 32 mml Pin spanner Lock nut wrench socket (26 x 29 mml Extension bar Universal holder Rotor puller Valve guide remover (5.5 rnml (IN1 Valve guide remover (6.6 mml (EX1 *Bearing driver outer (42 x 47 mml Bearing driver pilot (15 mm) Bearing driver pilot (17 mml "Bearing driver outer 152 x 55 rnm) Bearing driver pilot (20 mml Front fork oil seal driver body Front fork oil seal attachment ( D l Bearing driver handle (A1 Valve spring compressor Rear shock absorber compressor Apropriation List (Common tool - Special tool1 1 t - Pin spanner Flywheel holder Flywheel puller Valve guide driver Valve guide driver "Bearing driver 'Bearing driver 1 077470010100 07747-0010500 07749-0010000 07757-0010000 07959-3290001 } ,or, seal driver - Driver handle attachment Valve spring compressor 07949-61 10000 07957-3290001 The tools asterisked ("I are t o be used with the Handle-PIN 07749-0010000 or 07949-61 10000 (also listed above). 1-6 Date of Issue: September, 1977 0 HONDA MOTOR CO., LTD. HONDA CB400T GENERAL INFORMATION CABLE AND HARNESS ROUTING TYPE-I CLUTCH CAB BRAKE CABLE HROTTLE CABLE (CLOSE) THROTTLE CABLE (OPEN) MAIN WIRE HARNESS THROTTLE CABLES SPEEDOMETER CABLE WlRE BANDS CLUTCHCABLE Date of Issue: February, 1979 0 HONDA MOTOR CO., LTD. 1-9 aHONDA GENERAL INFORMATION TYPE-11 CLUTCHCABLE BRAKE HOSE / CHOKE CABLE OTTLE CABLE (OPEN1 CABLE CHOKE CAB1.E BRAKE CABLE 1-10 Date of Issue: February, 1979 O HONDA MOTOR CO., LTD. .. HONDA CB400T GENERAL INFORMATION RECEPTACLE (BLACK) Date of Issue: February, 1979 O HONDA MOTOR CO., LTD. 1-11 .. HONDA GENERAL INFORMATION CB400T MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Manual at every maintenance period. I: INSPECT, CLEAN, ADJUST, OR REPLACE I F NECESSARY. C: CLEAN R: REPLACE A: ADJUST NOTES: (11 More frequent service may be required when riding in dusty areas. (2) For higher odometer readings, repeat at the frequency interval established here. (3) Initial service period: 200 miles. 1-12 Date of Issue: September. 1977 @ HONDA MOTOR CO.. LTD. HONDA CB400T M E M O HONDA LUBRICATION CB400T LUBRICATION DIAGRAM Date of Issue: September. 1977 O HONDA MOTOR CO..LTD. 2. LUBRICATION HONDA CB4OOT -- -- 1 SERVICE INFORMATION 2-1 ENGINE OIL 81 FILTER CHANGE 2-2 TROUBLESHOOTING 2-1 SWINGARM PIVOT 2-3 11 I ENGINE OIL LEVEL 2-2 DRIVE CHAIN 2-3 1 \ SERVICE INFORMATION WORKING PRACTICE Refer t o Section 8. Oil pump: Oil pressure relief valve: Refer t o Section 8. Oil filter screen: Refer t o Section 10. SPECIFICATION Oil Capacity 3.0 liters (3.2 qt.) at engine assembly, 2.5 liters (2.6 qt.1 at oil change. Oil HONDA 4-strpke oil or equivalent rated SE 1OW-40 Oil Pump Delivery 11 i. 1 liters/4,000 rpm TROUBLESHOOTING Oil Level Too Low: 1. Normal oil consumption 2 External oil leaks 3. Worn piston rings High Oil Pressure: 1. Pressure relief valve stuck closed 2. Plugged oil filter, gallery, or metering orifice 3 Incorrect oil being used Oil Contamination 1. Oil or filter not changed often enough 2. Faulty head gasket No Oil Pressure 1 Oil level too low 2. Oil pump drive chain broken 3. Faulty oil pump Low Oil Pressure 1. Faulty warning light switch 2. Pressure relief valve stuck open 3. Plugged oil pick-up screen 4. Oil pump worn Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. HONDA CB400T LUBRICATION ENGINE OIL LEVEL Stop the engine and support the motorcycle on the center stand or hold it upright. Check the oil level with the filler cap dipstick after 2-3 minutes. Do not screw in the cap when making this check. If the level is below the lower level mark on the disptick, fill to the upper level mark. ENGINE 011 & FILTER CHANGE engine at normal operating temperature and vehicle upright or on center stand t o assure com~leteand r a ~ i ddrainino. Remove the oil filler cap after the engine is warm. Remove the drain plug and oil filter case t o drain oil from the engine. Operate the kick starter several times t o drain any oil which may be left i n the recesses of the engine. Check operation of the bypass valve i n the oil filter bolt. Make sure that the sealing washer on the drain 'plug and the O-rings on the oil filter bolt and the oil filter case are in good condition. Tighten the oil filter bolt securely. TIGHTENING TORQUE: 2.8-3.2 kq-m - (20-23 lbs-ftl ~ i i i l s t a lthe l drain plug. TIGHTENING TORQUE 2.5-3.5 kg-m (18-25 ibs-ftl OIL FILTER BOLl TORQUE: 2.8-3.2 kg-m (20-23 lbs-ftl Fill the crankcase with the recommended oil. Ol L CAPACITY: APPROXIMATELY 2.5 liters (2.6 U.S.qt.) SPECIFIED OIL: HONDA CSTROKE OIL OR AN EQUIVALENT Reinstall the oil filler cap. Start the engine and allow t o idle for a few minutes. Stop the engine, make sure that oil level is at the upper level mark with the motorcycle upright, and there are no oil leaks. 2-2 COVER Date of Issue: September. 1977 @ HONDA MOTOR CO.. LTD. HONDA CB40OT LUBRICATION SWINGARM PIVOT Two lubrication points are located as shown. Use multipurpose grease, Type NLGl No. 2. DRIVE CHAIN Commercially prepared drive chain lubricants should be used in preference to motor oil or other lubricants. Normally drive chain lubrication is performed without removing the chain, at the time of chain adjustment. Saturate each chain link joint so that the lubricant penetrates between the link plates, pins, bushings and rollers. When the drive chain becomes extremely dirty, i t should be removed and cleaned prio'icto lubrication. Carefully remove the master link retaining clip with pliers. Do not bend or twist the clip. Remove the master link. Remove the drive chain from the motorcycle. Clean the drive chain in solvent and allow to dry. Inspect the drive chain for possible wear or damage. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. lnspect the sprocket teeth for possible wear or damage. Replace if necessary. CAUTION Never install a new drive chain on badly worn sprockets or a badly worn chain on new sprockets. Both chain and sprokets must be in good condition, or the new replacement chain or sprockets will wear raoidlv. Date of Issue: September, 1977 MOTOR co., LTD. o HoNDA 2-3 .. HONDA CB400T LUBRICATION Lubricate the drive chain. Pass the chain over the sprockets and join the ends o f the chain with the master link. For ease o f assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip so that the closed end of the clip will face the direction o f forward wheel rotation. The master link is the most critical part affecting the security of the drive chain. Master links are reusable, if they remain in excellent condition, but it i s recommended that a new master link be installed whenever the drive chain is reassembled. Adjust the drive chain t o the proper tension. P I t i I-. . ' MISCELLANEOUS LUBE POINTS Lubricate the control cables, levers, and pedal pivots. i . . .. , ~ ':. .< . f i <7 -. 12: : r.: ,.' ._ 2-4 Fc .;: -. . , .:. .-a'.' Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. ( I HONDA 3. CB400T i ( I I I i AIR CLEANER MAINTENANCE 3-7 1 SPARK PLUG ADJUSTMENT 3-2 FUEL LINE INSPECTION 3-7 IGNITION TIMING INSPECTION 3-2 COMPRESSION TEST 3-8 ( VALVE CLEARANCE ADJUSTMENT 3-3 CAM CHAIN ADJUSTMENT 3-3 THROTTLE OPERATION 3-4 IDLE SPEED ADJUSTMENT 3-4 1 CARBURETOR SYNCHRONIZATION 3-5 ( INSPECTION AND AmUSTMENT CLUTCH ADJUSTMENT FRONT BRAKE (DISC) FRONT BRAKE (DRUM) REAR BRAKE DRIVE CHAIN CHOKE MECHANISM MAINTENANCE 3-6 SIDE STAND FAST IDLE ADJUSTMENT 3-6 BATTERY ELECTROLYTE 3-14 BALANCER CHAIN ADJUSTMENT 3-7 WHEELSISPOKES 3-14 SPECIFICATIONS Spark plug gap, type: 0.6-0.7 mm (0.024-0.028 in.) ND X24ES-U, NGK DBEA Ignition timing "F" mark: 15' BTDC a t 1,200 rpm Full advance: 43" BTDC a t 4.500-5.350 rpm Valve clearance IN: 0.10 i 0.02 mm (0.004 + 0.0008 in.) E X : 0.W + 0.02 mm (0.006 i 0.0008 in.) Throttle free play: 2-6 mm (0.08-0.24 in.) Idle speed: 1,200 + 100 rpm Synchronization vacuum: 200-240 mmHg Fast idle speed: 2,500 i 500 rpm Compression: 13* 1 kg/cm2 (185 14 psi) Clutch free play: 10-20 mm (318-314 in.) * Front brake (drum) free play: 20-30 mm (314-1-114 in.) Rear brake free play: 20-30 mm (314-1.114 in.) Drive chain play: 20 mm (314 in.) Tire pressures: Up to 90 kg (200 lbs) load Front 1.75 kg/cm2 (24 psi) Rear 2.25 kg/cm2 132 psi) Up to vehicle capacity load Front 1.75 kglcmZ 124 psi) Rear 2.5 kg/cm2 (36 psi) TORQUE VALUES Balancer adjuster nut (8 mm): 2.0-2.5 kg-m (15-18 lbs-ft) Balancer pivot nut (10 mm): 3.0-2.5 kg-m (22-25 lbs-ft) Front axle nut: 5.0-8.0 kg-m (36-58 lbs-ft) Front axle holder nut: 1.8-2.5 kg-m (13-18 lbs-ft) Rear axle nut: 7.0-10.0 kg-m (51-72 lbs-it) Spoke nipples: 0.2-0.35 kg-m (1.4-2.5 lbs-ft) Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. 3-1 I ! 1 1 I HONDA INSPECTION AND ADJUSTMENT CB4OOT (ENGINE) SPARK PLUGS Disconnect the spark plug caps and remove the spark plugs. Visually inspect the spark plug electrodes for wear. The center electrode should have square edges and the side electrodes should have a constant thickness. Discard the spark plug if there i s apparent wear or if the insulator is cracked or chipped. If the spark plug deposits can be removed by sandblasting, the spark plug can be reused. Adjust the spark plug gap by bending the side electrode. SPARK PLUG GAP: 0.6-0.7 mm 10.024-0.028 in.) RECOMMENDED SPARK PLUG: NGK D8EA N D X24ES-U 0.6-0.7 m m (0.024-0.028 in.) Check : gap : deposit : dirt : wear Check : sealing : damage Reinstall the spark plugs and reconnect the spark plug caps. NOTE First tighten the spark plug finger tight. then tighten with a spark plug wrench. Check : damage : crack IGNITION TIMING CHECK NOTE The C.D.I. (Capacitive Discharge Ignition) ignition timing i s not adjustable. I f the ignition timing is incorrect, check the C.D.I. unit and A.C. generator and replace any defective parts. See Section lfi Remove the left crankcase cover. Check the ignition timing using a strobe light (07308-0070000). Timing is correct if the index mark aligns w i t h the "F" mark at idle. Also check that the index mark is between the advance marks at 5.350 rpm. 3-2 Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. HONDA CB4QOT INSPECTION AND ADJUSTMENT VALVE CLEARANCE ADJUSTMENT NOTE Inspect and adjust valve clearance while the engine is cold. (Below 3 5 ' ~ . 9 5 ' ~ ) Remove the seat. Turn the fuel valve "OFF" and remove the fuel tube and fuel tank. Remove the left crankcase cover and cylinder head cover. Rotate the flywheel counterclockwise and align the rotor "T" mark with the crankcase index mark. Check the intake and exhaust valve clearance by inserting the feeler gauge between the clearance adjusting screw and the valve stem. Before checking, make sure that the piston is at TDC on the compression stroke. (The rockers should be loose.) VALVE CLEARANCE: IN: 0.10 0.02 mm (0.004 i. 0.0008 in.) EX: 0.14 t 0.02 mm (0.006 i. 0.0008 in.) Adjust by loosening'the lock nut and turning the screw until there is a slight drag on the feeler gauge. Tighten the locknut and recheck clearance. Rotate the flywheel counterclockwise one full turn and align the "T" mark with the index mark. Check the intake and exhaust valve clearance for the opposite cylinder. * CAM CHAIN ADJUSTMENT Start the engine and allow it to idle. Loosen the cam chain tensioner lock nut. When the cam chain tensioner lock nut is loosened, the tensioner will automatically position itself to provide the correct tension. Retighten the lock nut. . Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. . 3-3 HONDA INSPECTION AND ADJUSTMENT CB4OOT THROTTLE OPERATION Make sure that there is no deterioration. damage, or kink in the throttle cables, and that the throttle grip free play is 2-6 mrn (118-114 in.) on the outer edge of the thrott l e grip flange. Check for smooth throttle grip rotation from fully closed to fully opened positions a t all steering positions. Adjust or replace, if necessary. 2--6 mm (118-714 in.) Throttle grip free play can be adjusted at either end of the throttle cable. Major adjustments must be made a t the lower adjuster. To adjust, loosen the grip play adjuster lock nut and turn the adjuster In either direction. Minor adjustments must be performed at the upper adjuster. IDLE SPEED ADJUSTMENT NOTE Adjust idle after synchronizing carburetors. The engine must be warm for accurate idle adjustment. Ten minutes of stop-and-go driving should be sufficient. Warm up the engine, shift to NEUTRAL, and put the motorcycle on i t s centerstand or hold it upright. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,200 + 100 rpm If pilot screw adjustment i s required, turn each pilot screw to find the highest idle speed. Reset idle speed with the throttle stop screw. Repeat this sequence once. fuel mixture; turning out produces a rich fuel mixture. Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. HONDA CB400T INSPECTION AND ADJUSTMENT CARBURETOR SYNCHRONIZATION with engine at normal operating temperature and motorcycle on the center stand or uoriaht. Remove the seat. Turn the fuel valve OFF and remove the fuel tube and fuel tank. Prepare a longer fuel tube and reconnect it t o the fuel tank and carburetor. . . Position the tank higher than the carburetors. Remove the plugs from cylinder head and install the adapters. Connect vacuum gauges to the adaptors. Start the engine and set the idle speed at 1,200 i I00 rpm. Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. 3-5 HONDA CB4QQT INSPECTION AND ADJUSTMENT ADJUSTMENT Loosen the lock nut. Check the vacuum balance between the left and right cylinders and adjust with the adjusting screw. Turning adjusting screw to right: Vacuum on right carburetor decreases. Turning adjusting screw t o left: Vacuum on right carburetor increases. TOR INCR and vacuum on left carburetor. Make sure that the difference in vacuum readings is within 40 mmHg. SPECIFIED VACUUM:200-240 mmHg (At idle) Retighten the lock nut securely. Recheck synchronization and idle speed. Reinstall the fuel tank and seat. CHOKE MECHANISM MAINTEMIBEMAMQ Check for smooth choke knob operation. Pull the choke knob t o "fully closed" and make sure that the choke i s fully closed. When adjustment is necessary, loosen the choke wire clamp and adjust the choke wire. Retighten the clamp, holding the choke lever fully closed. FAST IDLE ADJUSTMENT DRUM ABOUT 1.2 rnm SPECIFIED FAST IDLE: 2,500 ? 500 rpm If adjustment o f the fast idle is necessary. remove the carburetor, return the throttle stop screw, and close the throttle valve. Adjust by opening or closing the fork end o f the fast idle lever until the clearance between the fast idle lever and throttle drum is about 1.2 mm (0.047 in.) FAST IDLE LEVER OPEN OR CLOSE 3-6 Date of Issue: September. 1977 O HONDA MOTOR CO., LTD. HONDA CB40OT INSPECTION AND ADJUSTMENT BALANCER CHAIN ADJUSTMENT Drain oil from the engine. Remove the tachometer and clutch cables. Remove the right foot peg and kick starter arm. Remove the right crankcase cover. Loosen the 8 mm adjuster nut. will position itself to provide proper Retighten the 8 mm nut. TORQUE: 2.0-2.5 kg-m (15-18 lbs-ft) is lowered so that the groove contacts 1 the shaft is below the horizontal line. Remove the 10 mm and 8 mm nuts; remove the stopper .. .plate. Install the stopper plate with different spline engagement. Reinstall 8 mm and 10 mm nuts and tiohten to specified torques: TORQUE: 8 mrn: 2.0-2.5 kg-m (15-18 lbs-ft) 10 mm: 3.0-3.5 kg-m (22-25 lbs-ft) NOTE I Install the 8 mm nut first. AIR CLEANER MAINTENANCE Remove the seat. Remove the air cleaner cover by removing the attaching screws. Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. 3-7 (&I HONDA Remove the air cleaner element. Wash the element i n non-flammable or high flashpoint solvent and allow the element t o dry. Submerge the air cleaner element i n clean gear oil (SAE80-90) or engine oil. Squeeze out excess oil. Reinstall the element and air cleaner cover. FUEL LINE INSPECTION Marke sure that there is no deterioration, damage, or leaks in fuel tube and joints. I f there is any deterioration, damage or leakage, install new parts. COMPRESSION TEST Warm up the engine. Remove the spark plugs. Insert the compression gauge. Open the choke and throttle valves fully. Crank the engine electrically or operate the kick starter. stops rising. The maximum reading is usually reached i n five or six revolutions (kick pedal) or several seconds (electric starter). COMPRESSION PRESSURE: 13 + 1 kg/cm2 (185 ? 14 psi) I f the compression pressure is low, check the following items: Leaky valves Improper valve tappet clearance Blown cylinder head gasket Worn pistonlcylinder I f the compression i s high, it indiates that carbon deposits have accumulated on the combustion chamber wall or on the piston top. - 3-8 Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. .. HONDA dB400T INSPECTION AND ADJUSTMENT CLUTCH ADJUSTMENT Measure the clutch lever free play. CLUTCH LEVER FREE PLAY: 10-20 mm (318-314 in.) Major adjustments should be made using the adjuster located at theclutch housing. Loosen the lock nut and turn the clutch cable adjusting nut. Minor adjustments can be made with the clutch cable adjuster located on the clutch lever. Loosen the lock nut and turn the adjuster. NOTE Do not allow the threads at the adiuster to come out by more than 8 mm (0.3 in.). I I Recheck the clutch operation. Date of Issue: September, 1977 0 HONDA MOTOR CO.. LTD. 3-9 MONDA CB4OOT INSPECTION AND ADJUSTMENT (CHASSIS) FRONT BWAKE(DISC) 8 BRAKE FLUID INSPECTION UPPE Check that the brake fluid reservoir is filled to the level mark engraved inside the reservoir. If the level is lower than the level mark, fill the reservoir with DOT-3 BRAKE FLUID up to the level mark. Check the entire system for leaks, if the level is low. .,. , CAUTION Do not mix different brands of fluid in the reservoir. Stay with one fluid as they are not compatible. Do not remove the cap until the handlebar has been turned full right so that the reservoir is level.. Avoid operating the brake lever with the cap removed. Brake fluid will flow out if the lever is pulled. - BRAKE PAD Remove the cap from the caliper and check for brake pad wear. Replace the brake pads if the red line on the top of the pads reaches the edge of the brake disc. (Refer to Section 12). to assure even disc pressure. FRONT BRAK~DRUM) Meas~rethe brake lever free play. BRAKE LEVER FREE PLAY: 20-30 mm (314-1.114 in.) 3-10 Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. 0 HONDA % csseooa 3 , INSPECTION AND ADJUSTMENT Major adjustments should be made using the adjuster located at the front wheel hub. Loosen the lock nut and turn the adjusting nut. Minor adjustments can be made with the brake cable adjuster located on the brake lever. Loosen the lock nut and turn the adjuster. Recheck the brake operation. REAR BRAKE BRAKE PEDAL HEIGHT Loosen the lock nut. Adjust the brake pedal height by turning the stopper bolt. Tighten the lock nut. Date of Issue: September, 1977 o HONDA MOTOR co., LTD. 3-61 HONDA INSPECTION AND ADJUSTMENT 68400T BRAKE PEDAL FREE PLAY Check the brake pedal free play. FREE PLAY: 20-30 mm (314-1.114 in.) I f adjustment is necessary, turn the rear brake adjusting nut. INCRE. STOPLIGHT SWITCH Adjust the stoplight switch so that the stoplight will come on when the brake pedal is depressed 20 mm (314 in.) where the brake just starts to engage. Adjust by turning the switch adjusting nut. BRAKE SHOE INSPECTION (WEAR INDICATOR) Replace the brake shoes if the arrow on the brake arm aligns with the reference mark "A" on full application of the rear brake. 3-1 2 Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HONDA CB4OOT INSPECTION AND ADJUSTMENT DRIVE CHAIN Place the motorcycle on i t s center stand (or a support block) and shift the transmission into neutral. Check the drive chain tension. PLAY: APPROXIMATELY 20 mm (314 in.) Adjust as follows: Remove the cotter pin from the rear axle nut, and loosen the nut. Loosen the lock nuts on both adjusting bolts. Turn both adjusting bolts an equal number of turns until the correct drive chain tension i s obtained. Be sure that the index mark aligns with the same graduation on the scale on both sides. Tighten the axle nut and install a new cotter pin. TORQUE: 8-10 kg-m 158-72 lbs-ft) Tighten both adjusting bolt lock nuts. Lubricate the drive chain. SIDE STAND Check the rubber pad for deterioration or wear. Replace if any wear extends to wear line as shown. Check the side stand spring for damage and loss of tension, and the side stand assembly for freedom of movement. Date of Issue: September, 1977 o HONDA MOTOR co., LTD. 3-13 HONDA CB400T INSPECTION AND ADJUSTMENT BATTERY ELECTROLYTE Remove the right side cover. The electrolyte level must be maintained between the upper and 'lower level marks. If the electrolyte level is low, remove the battery filler caps. Add distilled water. i " Use only distilled water in the battery. Tap water will shorten the service life of the battery. - Avoid contact with skin, eyes or clothing. Flush with water and get prompt medical attention when in contact with skin or eves. WHEELS/SPOKES a TIRE PRESSURE NOTE Tire pressure should be checked when the tires are COLD. Check the tires for cuts, imbedded nails, or other sharp objects. r Coldtire pressures kg/cm2 (psi) Up to 90 kg (200 ib) load U p to vehicle capacity load Front: Rear: Front: Rear: 1.75 (24) 2.25 (32) 1.75 124) 2.5 (36) Vehicle capacity load 150 kg (330 lbs) limit Front: 3.60S19-4PR -Tire size Rear: 4.10S18.4PR Front: YOKOHAMA Y-992 BRIDGESTONE 5702 Tire brand Rear: YOKOHAMA Y-983 BRIDGSTONE 5302 . - a WHEEL SPOKE RETIGHTENING (TYPE I) Retighten the wheel spokes periodically. TlGHTNlNG TORQUE: 0.2-0.35 kg-m (1.4-2.5 lbs-hl 3-14 Date of Issue: September, 1977 , O HONDA MOTOR CO., LTD. HONDA CB400T M E M O HONDA C8400T FUEL SYSTEM - Date of Issue: September. 1977 @ H O N D A MOTOR CO.. LTD. HONDA CB400T I I1 SERVICE INFORMATION 4-1 TROUBLESHOOTING 4-1 CARBURETOR REMOVAL 4-2- CARBURETOR SEPARATION 4-2 AIR CUTOFF VALVE DISASSEMBLY 4-6 COMPONENT ASSEMBLY 4-7 FLOAT LEVEL ADJUSTMENT 4-7 CARBURETOR ASSEMBLY 4-7 4-8 ~ VACUUM CYLINDER DISASSEMBLY 4-4 CARBURETOR INSTALLATION FLOAT CHAMBER DISASSEMBLY 4-5 FUEL TANKIAIR CLEANER CASE 4-9 1 1 SERVICE INFORMATION WORKING PRACTICE Use caution when working with gasoiine. Always work in a well-ventilated area and away from sparks or open flames. When disassembling fuel systemparts, note the locations of the O-rings. Replace them with new ones on reassembly. The float bowls have drain plugs that can be loosened to drain residual gasoline. SPECIAL TOOL Common Tool FLOAT GAUGE 07401-0010000 ! SPECIFICATIONS - Venturi dia. 32 rnm Setting mark VB21A Float level 15.5 mm 10.61 in.) Pilot screw opening 1,112 Idle speed 1,200 + I 0 0 rpm Fast idle 2,500 i- 500 rpm Vacuum (at idle speed1 200-240 mmHg Throttle grip free play 2-6 rnrn (0.08-0.24 in.) 1 I I 1I ! 1 TROUBLESHOOTING Engine Cranks But Won't Start 1. No fuel in tank 2. No fuel to cylinders 3. Too much fuel getting to cylinders 4. No spark at plugs (ignition malfunction) 5. Air cleaner clogged Engine Idles Roughly, Stalls, or Runs Poorly 1. ldle speed incorrect 2. Ignition malfunction 3. Low compression 4. Rich mixture 5. Lean mixture 6. Air cleaner clogged 7. Air leaking into manifold 8. Fuei contaminated 9. Carburetors not synchronized Date of Issue: September, 1977 0 HONDA MOTOR CO., LTD. Lean Mixture 1. Carburetor fuel jets clogged 2. Vacuum piston stuck closed 3. Fuel cap vent blocked 4. Fuel filter clogged 5. Fuei line kinked or restricted 6. Float valve defective 7. Float level too low Rich Mixture 1. Choke stuck closed 2 . Float valve defective 3. Float level too high 4. Carburetor air jets clogged 4- 1 HONDA FUEL SYSTEM 654OOT CARBURETOR REMOVAL Remove the fuel tank. NOTE I Turn the fuel valve to OFF. I Loosen the screws securing the carburetor bands. Remove the carburetor. engine. Push down on the carburetors while carefully pulling them back evenly. Unscrew the lock nuts and disconnect the throttle cables at the carburetors. Remove the clamp holding the choke cable and disconnect the choke cable. CARBURETOR SEPARATION Loosen the synchronize adjust screw, 4-2 Date of Issue: September, 1977 0 HONDA MOTOR CO.. LTD. .. HONDA CB400T FUEL SYSTEM Disconnect the choke relief spring from the choke lever. Unscrew the four screws attaching the rear stay to the carburetors, and remove the rear stay. Remove the four screws attaching the front stay, and remove the front stay. Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. I .< , 4-3 .. HONDA CB400T FUEL SYSTEM Separate the carburetors. VACUUM CYLINOER DISASSEMBLY Remove the vacuum cylinders from the carburetor bodies. Carefully lift the vacuum piston out with its needle and compression spring. I for wear, nicks, scratches or other damage. Make sure that the piston moves up and down freely in the cvlinder. Remove the full open stopper. Remove the needle set screw. Separate the jet needle from the piston. NEEDLE SETSCREW \,~ - -- -<._ 10-65 HONDA CRANKSHAFTIBALANCER NOTE Rotate the stopper fully. CB40OT plate clockwise Torque the 8 mm nut. Install the cam chain tensioner. Assemble the rear chain guide and oil orifice. NOTE Be sure the oil orifice is not clogged. Align the front balancer "TC" mark and crankshaft aligning mark with the end of the crankcase. Install the chain so that the rear balancer "TH" mark is flush with the end of the crankcase. 10-16 Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. HONDA CB400T CRANKSHAFTIBALANCER Be sure the dowel pins and bearinu inserts are in place in the holder Install the rear balancer on the bearing holder with the shaft. balancer chain on the sprocket during Install the front chain guide. Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. 10-17 HONDA CB4OOT CRANKSHAFTIBALANCER Lay the bearing holders over the crankshaft main journals. With the front balancer "TC" mark flush with the end of the crankcase, check that the rear balancer "TH" mark i s in line with the bearing holder shoulder and that the crankweight mark i s flush with the end of the crankcase. FRONT BALANCER Torque bearing holder bolts: TORQUE SPECIFICATIONS: 10 rnrn bolt: 3.3-3.7 kg-m (24-27ibs-ft) 6 mrn bolt: 1.0-1.4 kg-m ( 7-1OIbs-ftl TORQUE: 10 mm bolt: 3.3-3.7 kg.m (24-27 lbs-ft) 6 rnm bolt : 1.0-1.4 kg-m ( 7-10 lbs-ft) more steps and in the cross pattern shown. Make sure the crankshaft rotates freely without binding. 10-1 8 Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. HONDA CB400T CRANKSHAFTIBALANCER Slide the O-ring over the oil strainer pipe. Aligh with the bolt hole by rotating the rear balancer shaft. Torque the front chain guide bolts. NOTE p h e rear bolt should be t 1 5 n e Lthe oil strainer installed. Loosen the 8 mm n u t UOTE The balancer chain tension will be adjusted automatically by loosening the 8 mm nut. I f the balancer chain slack is excessive so that no further adjustment i s possible, follow the steps on Daae 3-7. . . Torque the 8 mm nut first. TORQUE SPECIFICATION: 2.0-2.5 kg-m 115-18 lbs-ftl Torque the 10 mm nut last. TORQUE SPECIFICATION: 3.0-3.5 kg-m (22-25 lbs-ft) Install the lower case. (Section 91 Date o f Issue: September, 1977 O HONDA MOTOR CO.. LTD. 10-19 HONDA CB400T TRANSMISSION 11 -0 Date of Issue: September, 1977 HONDA MOTOR CO., LTD. I .. HONDA CB400T 1 1. TRANSMISSION SERVICE INFORMATION 11-1 TROUBLESHOOTING 11-2 GEARSHIFT LINKAGE DISASSEMBLY 11-3 TRANSMISSION DISASSEMBLY 11-3 GEARSHIFT DRUMISHIFT FORK REMOVAL 11-6 KICK STARTER DISASSEMBLY 11-8 KICK STARTER ASSEMBLY 11-9 GEARSHIFT DRUMISHIFT FORK INSTALLATION 11-10 TRANSMISSION ASSEMBLY 11-11 GEARSHIFT LINKAGE ASSEMBLY 11-13 SERVICE INFORMATION WORKING PRACTICE The gear shift linkage can be serviced with the engine in the frame. For internal transmission repairs, the engine cases must be separated. (See Section 9) SPECIFICATIONS C1 Gear bushing Countershaft O.D. Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. 11-1 .. HONDA TRANSMISSION CB400T TROUBLESHOOTING Hard to Shift 1. Improper clutch adjustment: too much free play 2. Shift forks bent 3. Shift shaft bent 4. Shift fork claw bent 5. Shift drum cam grooves damaged Transmission Jumps Out of Gear 1. Gear dogs worn 2. Shift shaft bent 3. Shift drum stopper broken 4. Shift forks bent Date of Issue: September, 1977 0 HONDA MOTOR CO.. LTD. .. HONDA CB400T TRANSMISSION GEARSHIFT LINKAGE BPSASSEMBLK Remove the gearshift pedal. Remove the clutch. (Section 8) Remove the gearshift spindle and gearshift return spring. Remove the shift drum stopper arm. Remove the stopper plate bolt. Remove the drum stopper plate, gearshift drum pins and collar. Remove the drum plate and dowel pins. Inspect a l l parts for wear or damage. TRANSMISSION DISASSEMBLY Separate the crankcases, (Section 9) Inspect each gear for backlash. SERVICE LIMIT: 0.02 mm 10.008 in.) Remove the crankshaft bearing holders. (Section 10) Date of Issue: September, 1977 o HONDA MOTOR co.. LTD. 11-3 HONDA TRANSMISSION CB400T Remove the rear balancer chain guide. Place gears into neutral, and check each gear dog for minimum clearance a t end. SERVICE L I M I T : 0.30 mm (0.012 in.) Remove the main- and countershafts. Lift out the oil orifice and dowel pin. rATEND4, 1 GEAR D O G M I N I M U M CLEARANCE ,, Date of l r s ~ e September. : 1977 0 HONDA MOTOR CO.. LTD. HONDA C5400T TRANSMISSION TRANSMISSION INSPECTION Check gear dogs for excessive or abnormal wear. Inspect the 1.0. of each gear. SERVICE LIMIT: M4,M5 and C3 gears: 25.10mm (0.988in.) C1 gear : 24.10 mm (0.949in.1 Measure the I.D. and O.D. of the countershaft low gear (C1) bushing. SERVICE LIMITS : 1.0. : 20.06 mm (0.790 in.) O.D. : 23.95 mm (0.943 in.) Measure the O.D. of the main- and countershafts. SERVICE LIMITS: A: 24.93 mm (0.981 in.) B: 24.93 mm (0.981 in.) C: 19.96 mm (0.786 in.) Calculate the clearance between the gear and gear shaft or bushing. SERVICE LIMIT: 0.15 mm (0.006 in.) Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. O.D. "A" MAIN SHAFT 11 - 5 HONDA TRANSMISSION CB400T GEARSHIFT DRUM/SHIFT FORK REMOVAL Remove the bearing stopper plate. Pull the gearshift drum out of the case. Remove the shift fork shafts. shift forks and guide pins. GEARSHIFT DRUM AND SHIFT FORK INSPECTION Measure the shift drum 0.0.. 11 - 6 Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. .. HONDA CB400T TRANSMISSION Measure the case I.D.. O.D. SERVICE LIMIT: 12.95 mm (0.510 in.) Measure the shift fork 1.0. and claw thickness. SREVICE LIMITS: ID.: 13.05 mm (0.514 in.] Claw thickness: 5.50 mm (0.217 in.) ESS Date of Issue: September, 1977 0 HONOA MOTOR CO., LTD. 11 -7 HONDA TRANSMISSION CB4OOT KlCK STARTER DISASSEMBLY Remove the E-ring Remove the kick starter spindle and kick starter pinion. Remove the kick spring collar, kick spring. drive ratchet and washer off the spindle. KlCK STARTER INSPECTION Measure the pinion gear I.D.. 11 - 8 1.0. SERVICE L I M I T : 18.54 m m (0.730 in.) Date of Issue: September, 1977 O H O N D A MOTOR CO.. LTD. HONDA C8400T TRANSMISSION Measure the kick starter spindle O.D.. & O.D. .ER".E LIMIT: 18.44 rnm (0.726 in.) SPINDLE \ STARTER PlNlOF 'ID R I V E RATCHET - t \ SPRING COLLAR KICK SPRING Install the spindle and pinion gear. Hook the end of the kick spring over the abutment on the case. Date of Issue: September. 1977 @ HONDA MOTOR CO., LTO. . . KIC 11-9 HONDA TRANSMISSION CB400T GEARSHIFT DRUM/SHIFT FORK IMSTALLATIOM Install the shift drum. Install the guide pins, shift forks and fork shafts. Install the bearing stopper plate. Stake the end of each screw against the groove in the stopper plate. Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. HONDA CB4QOT TRANSMISSION TRANSMISSION ASSEMBLY Assemble the main- and countershafts. movement or rotation on the shaft. Examine that the c i r c l i ~is seated in Install the dowel pin -and oil control orifice Date of Issue: September. 1977 0 HONDA MOTOR CO., LTD. 11 - 1 1 ~. HONDA TRANSMISSION CBLCQOT Assemble the main shaft. Install the shaft with the needle bearing hole facing down. bearing are flush with the end of the crankcase. lnstall the countershaft. Align the marks on the needle roller bearing with the end of the case, and then f i t the hole i n the bearing over the dowel pin. Assemble balancer chain guide. Install the bearing holder (Section 10). Install the lower crankcase (Section 9). 11 - 1 2 Date o f Issue: September, 1977 O HONDA MOTOR CO., LTD. HONDA CB400T TRANSMISSION GEARSHIFT LINKAGE ASSEMBLY Install the drum plate and dowel pin. Assemble the drum pins, collar and drum stopper plate. NOTE ( A p p l y a locking agent to the bolt threads and underside of bolt heads I durina assemblv. I I I 1 A Install the neutral stopper arm. Assemble the gearshift sp~ndleand gearshift return spring. APPLY LOCKING AGENT TORQUE: 0.8-1.2 kg-m (6-9 lbs-ftl After installing, check the linkage for smooth operation by rotating the gearshift spindle. Install the clutch (Section 8) Date of Issue: September, 1977 LTD. o HONDA MOTOR CO., 11-13 HONDA FRONT WHEEL/BRAKE/SUSPENSION CB400T Date of Issue: September, 1977 O H O N D A MOTOR CO., LTD. HONDA CB400T 7 12. SERVICE INFORMATION 12-1 TROUBLESHOOTING 12-2 HEADLIGHT 12-3 INSTRUMENTS 12-4 HANDLEBAR 12-5 FRONT WHEEL /BRAKE / SUSPENSION FRONT WHEEL REMOVAL/ DISASSEMBLY/ASSEMBLY 12-6 FRONT BRAKE PANEL 12-10 FRONT WHEEL INSTALLATION 12-11 FRONT FORK STEERING STEM SERVICE INFORMATION WORKING PRACTICE Do not remove rivets, nuts and pins from the rim, spoke plate and hub, since they cannot be disassembled Never ride on the spokes or try to bend the wheel. Avoid damaging the aluminum alloy rim. SPECIAL TOOLSICOMMON TOOLS Special Tools HOLLOW SET WRENCH ( 6 mm) BALL RACE DRIVER (BOTTOM) BALL RACE DRIVER (TOP) BALL RACE REMOVER Common Tools PIN SPANNER LOCK NUT WRENCH SOCKET (32 x 30 cm) EXTENSION BAR BEARING DRIVER HANDLE (A) BEARING DRIVER OUTER (42 x 47 mm) BEARING DRIVER PILOT (15mm) FRONT FORKOILSEAL DRIVER BODY FRONT FORK O I L SEAL ATTACHMENT (13) SPECIFICATIONS Front wheel rim runout Front fork tube bend Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. HONDA FRONT WHEELIBRAKEISUSPENSION CB400T TROUBLESHOOTING Head Steering 1. Steering stem nut too tight 2. Faulty steering stem bearings 3. Damaged steering stem ball race and/or cone race 4. lnsufficient tire pressure Steers to One Side or Does Not Track Straight 1. Unbalanced right and left shock absorbers 2. Bent front forks 3. Bent front axle; wheel installed incorrectly Front Wheel Wobbling 1. Distorted rim 2. Worn front wheel bearing 3. Distorted spokes 4. Faulty tire 5. Axle not tightened propel;ly 12-2 Soft Suspension 1. Weak fork spring 2, lnsufficient fluid in front forks Hard Suspension 1. Incorrect fluid weight in front iorks Front Suspension Noise 1. Slider binding 2. lnsufficient fluid in forks 3. Loose front shocks or springs Date of Issue: September. 1977 O HONDA MOTOR CO., LTD. HONDA CB400T FRONT WHEEL/BRAKE/SUSPENSION HEADLIGHT HEADLIGHT CASE REMOVAL Remove the headlight and disconnect all wires at their couplers and connectors. NOTE Hold the connectors with pliers to prevent the wires from being cut. To remove the headlight case, unscrew the right and left turn signal mounts. WIRING CONNECTION IN HEADLIGHT CASE Route the wires into the headlight case through the headlight case hole. Route the wire harness into the headlight case through the headlight case lower hole. Connect the wires color-to-color. Set each coupler in i t s correct holder in the headlight case. For wiring procedure, see page 1-9. HEADLIGHT INSTALLATION Align the punch marks on the headlight case with the punch marks on the headlight case brackets. Position the turn signals parallel to the ground. NOTE Check each component for operation after assembling. Date of Issue: September, 1977 o HONDA MOTOR co., LTD. 12-3 HONDA FRONT WHEELIBRAKEISUSPENSION CB400T INSTRUMENTS CLUSTER DISASSEMBLY Separate the instrument cluster by removing the four screws. Remove the instrument s e t plate by removing the two bolts. INDICATOR LAMPICOMBINATION SWITCH REPLACEMENT After installing a new bulb, check for continuty. I f the bulb does n o t light, inspect the wiring for open or short circuits. The ignition switch wire i s connected t o the wiring harness inside the headlight case. METER LAMPIMETER REPLACEMENT TO replace a meter lamp or meter, it is necessary t o separate the cluster. Remove the set plate and cable. Check the meter cable i f the needle swings abnormally. Date of Issue: September. 1977 O HONDA MOTOR CO., LTD. HONDA CB400T FRONT WHEEL/BRAKE/SUSPENSION HANDLEBAR HANDLEBAR REMOVAL Disconnect the front brake stoplight switch wires and remove the master cylinder. NOTE Do not loosen the brake hose unless necessary. Loosen the two screws attaching the throttle grip switch housing. Remove the two screws holding the left grip switch housing. Remove the four switch wire bands. Remove the handlebar upper holders and take out the handlebar with the throttle grip and switch housing. HANDLEBAR INSTALLATION Coat the throttle grip area of handlebar with clean grease. Position the handlebar on the lower holders with the punch marks on the handlebar in line with the top of the holders. Place the upper holders on the handlebar with the punch marks facing the front. Align the punch marks on the handlebar with the split in the switch housings. Tighten the forward bolts first, then tighten the rear bolts to the same torque. Turn the handlebar fully left, then install the master cylinder so that the fluid level of oil in the reservoir i s parallel to the upper level line inside the reservoir. Connect the front brake stoplight switch wires. Install the four switch wire bands on the handlebar. NOTE Bleed the brake system i f the hose was disconnected. Date of Issue: September. 1977 MOTOR co., LTD. o HoNDA 6 2-5 FRONT WHEELIBRAKEISUSPENSION @ HONDA CB400T FRONT WHEEL REMOVAL/ BISASSEMLY/ASSEMBLY FRONT WHEEL REMOVAL Raise the front wheel off the ground by placing a block or safety stand under the engine. Disconnect the speedometer cable from the speedometer gearbox. Disconnect the front brake cable. (Drum type only) Remove the front brake torque link. (Drum type only). Remove the cotter pin and loosen the axle nut. Remove the axle holder from the fork end. Withdraw the axle and remove the wheel. after removing the front wheel. To do so will cause difficulty in fitting the brake disc between the brake pads. Date of Issue: September, 1977 @3 HONDA MOTOR CO., LTD. ~ ~ HONDA CB400T FRONT WHEEL/BRAKE/SUSPENSION AXLE INSPECTION Set the axle in V blocks and measure the runout. The actual runout i s 112 of TIR (Total Indicator Reading). SERVICE LIMIT: 0.2 mm 10.008 in.) WHEEL BEARING INSPECTION Check the wheel bearing play by placing the wheel in a truing stand and spinning the wheel by hand. Replace the bearings with new ones if they are noisy or have excessive play. PLAY I WHEEL INSPECTION Check the rim runout by placing the wheel in a truing stand. Then spin the wheel by hand. SERVICE LIMITS: RADIAL RUNOUT:2.0 mm (0.08 in.) AXIAL RUNOUT: 2.0 mm (0.08 in.) and read the runout using a dial indicator. repaired and must be replaced with a new one if the service limits are exceeded. Date of Issue: September, 1977 CO., LTD. o HONDA MOTOR 12-7 HONDA FRONT WHEELIBRAKEISUSPENSION CB400T WHEEL DISASSEMBLY TlRE BALANCE MARK LOCATION BALANCE WEIGHT LOCATION ITH TlRE VALVE DISTANCE COLLAR Remove the right hearing first. 12-8 APPLY ADHESIVE Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. .. HONDA CB4OOT FRONT WHEEL/BRAKE/SUSPENSION FRONT WHEEL ASSEMBLY Pack all bearing cavities with grease. Drive in the right bearing first. Press the distance collar into place. Drive in the left bearing. I I BEARING DRIVE HANDLE A BEARING DRIVER OUTER (42 x 47) BEARING DRIVER PILOT (15) NOTE Drive the bearing squarely. Drive the bearing into position, making sure that it is fully seated and that the sealed side is facing out. Lubricate the inside of the dust seal with grease. Install the dust seal and collar in the hub on the right side. no retightening since they are secured with lock pins. Do not remove these lock oins. Install the speedometer gear retainer in the hub from the left side. Lubricate the inside o f the oil seal and install. Disassemble the speedometer gear box and lubricate the gears and sliding faces. Install the speedometer gear in the wheel hub, aligning the speedometer gear box tangs with the notches in the retainer. Date of Issue: September, 1977 o HONDA MOTOR co.. LTD. 12-9 HONDA FRONT WHEEL/BRAKE/SUSPENSION FRONT BRAKE PANEL (Type I ) CB400T THICKNESS FRONT BRAKE LINING THICKNESS Measure the brake lining thickness. BRAKE SHOE REPLACEMENT NOTE Do not loosen the brake rod unless necessary. I 1 Pry off the cotter pin and remove the washer. Replace the shoes with new ones. Appty grease to the cam contacting faces of the shoes. stopping PO wer. Keep grease off the brake linings. Wipe BRAKE ROD ADJUSTMENT Adjust the brake rod length a t i t s threaded ends so that both shoes start to hold a t the same time, while observing the cam and shoe movement. brake arm aligns with the punch mark BRAKE DRUM INSPECTION Measure the brake drum 1.0.. 12-10 I.D. SERVICE L l M l 181.0 mm (7.13 in.) Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. ~. HONDA CB400T FRONT WHEEL/BRAKE/SUSPENSION FRONT WHEEL INSTALLATION Insert the axle through the wheel hub from the right side. Torque the axle nut, noting the installation direction of the speedometer gearbox. TORQUE SPECIFICATION: 5.0-8.0 k g m (36-58 lbs-h) zontally, being careful not t o bend the speedometer cable. Position the axle holder on the fork end with the arrow mark facing the front. Tighten the forward nut to the specified torque first, then tighten the rear hut to the same torque. TORQUE SPECIFICATION: 1.8-2.5 k g m (13-18 ibs-ftl remove load from the front fork. Keep Connect the speedometer cable to the speedometer gearbox while rotating the wheel by hand. Install the brake cable and adjust the brake (Drum type only). With the front brake applied, pump the front fork u p and down several times to check for proper operation. Recheck the installation of the axle holder and adjust, if necessary. Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. 1 2 - 11 HONDA FRONT WHEELlBRAKE/SUSPENSlON C8400T FRONT FORK F R O N T FORK REMOVAL Remove the front wheel. Remove the brake caliper by unscrewing the attaching bolts. NOTE Do not loosen the brake hose unless necessary. Remove the front fender. Unscrew the right and left fork bolts. Loosen the front fork attaching bolts a t the bottom fork bridge. Remove the fork tubes from the bottom fork bridge, rotating them by hand if necessary. 12-12 Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. HONDA CB4OOT FRONT WHEELIBRAKEISUSPENSION FRONT FORK DISASSEMBLY Hold the fork tube in a vise Loosen the cushion spring inner bolt. I CAUTION / SOFT' JAWS Do not damage or bend the sliding surface. - I Use care when loosening [ the spring willpop out. ~p the b o l t br 1 Pour out any remaining fork fluid by pumping the fork up and down several times. FRONT DAMPER SPRING FREE LENGTH INSPECTION Measure the front damper spring free length. Date of issue: September, 1977 MOTOR co., LTD. o HoNDA FREE LENGTH SERVICE LIMIT: 480.0 mm 118.90 in.) 12-13 HONDA CB4OOT FRONT WHEEL/BRAKE/SUSPENSION Remove the socket from the bottom of the fork leg. Remove the fork tubes and piston " NOTE I . H o. U~.the fork slider i n a vice, beinsca?eful not to tighten excesrively. >. .. HOLLOW SET WRENCH 791 7-3230000 (6mm) SHOP I Temporarily install the spring and fork ,bolt should difficulty be encountered in rernovina the bolt. O I L SEAL REMOVAL Carefully lift out the oil seal with a screwdriver. NOTE Avoid damaging the inner and outer surfaces of the slider when removing the seal. FORK TUBEIFORK SLIDER /PISTON INSPECTION O I L SEAL Check t h e fork tubes, fork sliders and pistons for score marks, scratches, or excessive or abnormal wear, replacing those which are damaged. SHOP TOWELS OR SOFT JAWS FORK TUBE INSPECTION Set the fork tube i n V blocks and read the runout. Take 112 TIR t o determine the actual runout. 12-14 0.2 rnm (0.008 in.) Date o f issue: September, 1977 . . - O HONDA MOTOR CO., LTO. HONDA CB480T FRONT WHEELIBRAKEISUSPENSION FRONT FORK ASSEMBLY NOTE Clean a l l parts with solvent and wipe off. I 1 OILSEAL SNAP RING FORK SLIDER SOCKET BOLT (APPLY LOCKING AGNETTO BOLT THREADS AND UNDERSIDE OF BOLT) 3 OIL LOCK PIECE Install the piston and fork tube. Apply a locking agent to the bolt threads and underside of the bolt, then torque to specified tension. SHOP TOWEL OR SOFT JAWS NOTE Do not tighten the fork slider excessively in a vise. I Date of Issue: September, 1977 o HONDA MOTOR co.. LTD. I 12-15 HONDA FRONT WHEELIBRAKEISUSPENSION CB400T OIL SEAL INSTALLATION Drive the oil seal into position until the snap ring groove appears. Install the snap ring and dust cover. FILLING WITH FORK OIL Use ATF (Automatic Transmission Fluid) to fill the front fork. NOTE Pour the specified amount of ATF. Do not overfill. Slide the front cushion spring and spring s e a t into position and tighten with the inner bolt. SHOP TOWEL OR SOFT JA Place the fork tube in soft jaws. avoiding the sliding surface. Note the spring direction. Date of Issue: September. 1977 @ HONDA MOTOR CO., LTD. HONDA CB40OT FRON FRONT FORK INSTALLATION Install the fork tubes i n the fork top and bottom bridges while rotating them by hand. Ensure that each tube bears against the fork top bridge. .I I: I :'. Tighten the right and left fork:'dolts to the specified torque. TORQUE 7.0-9.0 kg-m (51-65 lbs-ftl Torque the front fork bolts at the fork bottom bridge. TORQUE SPECIFICATION: 1.8-2.5 kg-m (13-18 lbs-ft) SPECIFICATION;'.^ Install the fender. Install the brake caliper. Secure the brake hose. Install the front wheel. Date of Issue: September. 1977 @ HONOA MOTOR CO.. LTD. 1 2 - 17 HONDA FRONT WHEELIBRAKEISUSPENSION CB4OOT STEERING STEM FORK TOP BRIDGE REMOVAL Remove the headl~ght. Remove the instruments. Remove the handlebars. Unscrew the steering stem nut. Loosen the right and left fork bolts. Remove the fork cover. Loosen the bottom bridge fork bolts. Pull off the front fork. Date of Issue: September. 1977 0 H O N D A MOTOR CO., LTD. HONDA CB400T *'I FRONT WHEEL/BRAKE/SUSPENSION STEERING LOCK R.EMOVAL/ INSTALLATION r 7 Removb the steering lock dover. Insert the key, turn counterclockwise, and remove the lock. b 4.- STEERING HEAD ADJUSTER REMOVAL NOTE Do not allow the steel balls to fall. STEEL BALLS (19) BOTTOM BALL RACE DUST SEAL WASHER i DISASSEMBLY: BALL RACE REMOVER 07953-3330000 ASSEMBLY: BALL RACE DRIVER 07945-3330300 07946-3290000 Date of Issue: September. 1977 o HONDA MOTOR CO.. LTD. 12-1'9 HONDA FRONT WHEELIBRAKEISUSPENSION CB400T STEERING HEAD ADJUSTER INSTALLATION Grease thetop race and install 18 ball bearings. Grease the lower cone race and install the 19 ball bearings on the race. Install the adjuster in the frame neck and tighten it until snug against the top cone race. Then. back it out 118 turn. Make sure that there is no vertical movement and the stem rotates freely. TOP BRIDGE INSTALLATION Install the front fork legs NOTE Do not mix the right and left fork legs. Position the fork tubes so that the upper ends are even with the steering head adjuster. Temporaily hold the front fork legs by tightening the bottom bridge fork bolts. 12-20 Date of Issue: September, 1977 Q HONDA MOTOR CO., LTD. HONDA CB400T -3 FRONT WHEELIBRAKEISUSPENSION Install the fork covers and fork cover cushions. Install the right and l e f t fork bolts, but do not tighten at this time. Torque the steering stem nut. TORQUE SPECIFICATION: 0.0-12.0 kg-m (65-87 lbs-ft) Tighten the fork bolts to the specified torque. TORQUE SPECIFICATION: 7.0-9.0 kg-m (51-65 lbs-ft) Torque the bottom bridge fork bolts. TORQUE SPECIFICATION: 1.8-2.5 kg-m (13-18 lbs-ft) Install the following: HANDLEBARS INSTRUMENTS HEADLIGHT FRONT FENDER FRONTWHEEL Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. 12-21 HONDA REAR WHEELIBRAKEISUSPENSION 13-0 C840OT Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. 13. HONDA CB400T REAR WHEEL /BRAKE-/ SUSPENSION r--. SERVICE INFORMATION 14-1 TROUBLESHOOTING 14-2 REAR WHEEL REMOVAL1 DISASSEMBLY/ASSEMBLY 14-4 FINAL DRIVEN SPROCKET 14-6 REAR BRAKE PANEL 14-7 REAR WHEEL INSTALLATION 14-8 SHOCK ABSORBER 14-10 SWINGARM 14-11 BRAKE PEDAL 14-12 SERVICE INFORMATION W O R K I N G PRACTICE Do not remove the rivets, nuts and pins from the rim, spoke plates and hub, since they cannot be disassembled. Do not ride on the rim or try to bend the wheel. Handle with care since the rim i s made of aluminum alloy. SPECIAL TOOLS Common Tools BEARING DRIVER HANDLE (Al BEARING DRIVER OUTER (42 x 47 mml BEARING DRIVER OUTER (52 x 55 mm) BEARING DRIVER PILOT (20 mm) BEARING DRIVER PILOT (17 mm) REAR CUSHION COMPRESSOR Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. HONDA CB400T REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS Axle bend -....- . . SERVICE LIMIT STANDARD --...-.--- 0.2 mm (0.008 in.) --Radial - - 2.0 mm (0.08 in.) Axial - - 2.0 Rear wheel runout Final driven sprocket I.D. mm (0.08 in.) 65.00- 65.09 mm 12.560-2.563 in.) 65.16 mm (0.565 in.) 64.94- 64.97 mm (2.557-2.558 in.) 64.87 mm (2.554 in.) -. Rear wheel hub O.D. ( L l Brake lining thickness Rear brake drum I.D. 4.9 - Rear cushion spring free length - 5.0 mm (0.19 -0.20 140.0 -140.3 mm (5.51 -5.52 208.3 mm (8.20 in.) in.) 2.0 mm (0.08 in.) in.) 141.0 mm(5.55 in.) 198.0 mm (7.80 in.) TROUBLESHOOTING Wobble or Vibration in Motorcycle 1. Distorted rim 2. Loose wheel bearing 3. Loose or distorted spokes 4. Faulty tire 5. Loose axle Soft Suspension 1. Weak spring , 2. Shock absorbers improperly adjusted 3. Weak rear damper Hard Suspension 1. Shock absorbers imporperly adjusted 13-2 Suspension Noise 1. Shock case binding 2. Loose fasteners Poor Brake Performance 1. Improper brake adjustment 2. Fouled brake linings 3. Worn brake shoes 4. Worn brake shoe cam contacting faces 5. Worn brake drum 6. Improper engagement between brake arm and shaft serrations Date of Issue: September. 1977 O HONDA MOTOR CO.. LTD. HONDA CB400T REAR WHEELIBRAKEISUSPENSION REAR WHEEL REMOVAL/ DISASSEMBLY/ASSEMBLY REAR WHEEL REMOVAL Support the motorcycle on the main stand or a stand placed under the engine. Disconnect the brake rod. Pry off the cotter pin and separate the brake torque link. Loosen the drive chain adjusting bolts. Remove the cotter pin and loosen the axlt nut. Remove the drive chain retaining clip. Withdraw the axle and remove the rear wheel. A X L E SHAFT BEND INSPECTION Set the axle in V blocks and read the axle bend. The actual axle bend is 112 of TIR. (total indicator reading). SERVICE LIMIT: 0.2 mrn (0.008 in.) REAR WHEEL BEARING P L A Y INSPECTION Check the wheel bearing play by rotating the wheel by hand. Replace the bearings w i t h new ones i f they are noisy or have excessive play. REAR WHEEL RIM RUNOUT INSPECTION RADIAL AXIAL Check the r i m for runout b y placing the wheel i n a truing stand. Spin the wheel by hand, and read the runout using a dial ind.icator gauge. serviced and must be replaced i f the Date of Issue: September, 1977 LTD. o H o N D A MOTOR co.. 13-3 HONDA CB400T REAR WHEELIBRAKEISUSPENSION REAR WHEEL DISASSEMBLY BEARING DRIVER HANDLE (A) BEARING DRIVER PILOT (20 mm) Remove the right bearing first. D I S T ~ N c E FINAL DRIVEN SPROCKET DAMPER BUSHING BEARING DRIVER HANDLE (A) BEARING DRIVER PILOT 120 mm), WITH TIRE VALVE DAMPER COVER BALANCE WEIGHT w SPOKE PLATE MARK Apply adhesive during installation NOTE The COMSTAR WHEEL has no rim band. REAR WHEEL ASSEMBLY BEARING DRIVER HANDLE (A) BEARING DRIVER OUTER (42 x 47 mm) BEARING DRIVER PILOT (17 mm) Pack a l l bearing cavities with grease. Press the distance collar into place from the left side. Drive the right ball bearing first. Drive the left ball bearing last. Install the bearings with the sealed end BEARING DRIVER OUTER (52 x BEARING DRIVER PILOT (20 mm) -. 1 3-4 Date of Issue: September, 1977 0 HONDA MOTOR CO., LTD. ~. HONDA CB40OT REAR WHEEL/BRAKE/SUSPENSION FINAL DRIVEN SPROCKET (COMSTAR WHEEL ONLY) (COMSTAR WHEEL ONLY) F I N A L DRIVEN SPROCKET Remove the dust cover. Pry off the snap ring. properly during assembly. Coat the inside diameter of the sprocket NOTE Make certain that the fixing bolts are seated snugly on the sprocket. F I N A L DRIVEN SPROCKET INSPECTION Measure the final driven sprocket I.D.. SERVICE LIMIT: 65.16 mm (2.565 in.) Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or distorted. must also be inspected if the driven REAR WHEEL HUB INSPECTION Measure the rear wheel hub O.D. on the left side. SERVICE LIMIT: 64.87 mm (2.554 in.) DAMPER RUBBER INSPECTION Replace the damper rubbers if they are damaged or deteriorated. NOTE ( Note the damper collar location. Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. ~ HONDA CB400T REAR WHEEL/BRAKE/SUSPENSlON REAR BRAKE PANEL REAR BRAKE LINING THICKNESS Measure the rear brake lining thickness. REAR BRAKE SHOE REPLACEMENT Pry off the cotter pin. Install new brake shoes. Apply grease to the face of the brake cam. stopplng power. i " " Make sure the the punch mark on the brake arm aligns with the punch mark on the shoe. BRAKE DRUM I.D. INSPECTION Measure the brake drum I.D.. 1'3-6 SERVICE LIMIT: 141.0 mm (5.55 in.) / - Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HONDA CB4OOT REAR WHEELIBRAKEISUSPENSION REAR WHEEL INSTALLATION Insert the axle through the wheel hub. NOTE Install the long axle collar on the right side. Install the brake torque link Connect the brake rod. Install the drive chain retaining clip. NOTE Note the retaining clip direction. Adjust the drive chain tension. CHAIN SLACK: 10-20 rnrn ( 0 . 4 4 . 8 in.) r Rotate the adjusters so that the index marks are aligned with the same scale number o n both sides. Torque the axle nut, and install the cotter pin, Spread the ends of the cotter pin. TORQUE SPECIFICATION: 8.0-10.0 kg-rn (58-72 lbs-ft) Lubricate the drive chain with engine oil or grease. Date of Issue: September, 1977 0 HONDA MOTOR CO.. LTD. 13-7 HONDA REAR WHEEL/BRAKE/SUSPENSION CB400T SHOCK ABSORBER SHOCK ABSORBER REMOVAL To remove the left shock absorber, remove the chain cover. Remove the upper, bolt first, then remove the lower bolt. rotate the adjuster to the weakest SHOCK ABSORBER DISASSEMBLY Using a hacksaw blade, cut a groove in the head of the damper bolt to receive the flat end of a screwdriver as shown. NOTE Remove burrs thoroughly. Remove the lock nut. Screw in the rod by applying a t o the groove in the rod end. screwdriver ..-.Do not damage the upper joint threads with the end of the screwdriver. SPRING UNDER SEAT / / SPRING ADJUSTER SHOCK A ~ S O R B E RCOMPRESSOR Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HONDA C8400f REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER SPRING FREE LENGTH SERVICE LIMIT: 198.0 mm (7.80 in.) SHOCK ABSORBER ASSEMBLY When the damper is t o be replaced with a new one, it i s necessary to cut a slot in the top end of the rod. C SERVICE LIMIT: 198.0 mm (7.80 in.) NOTE Avoid damaging the rod threads. LOCK NUTExtend the rod fully so that the stopper rubber is a t the bonom of the rod. Compress the spring until the slotted end of the rod contacts the upper joint. Applying the end of a screwdriver to the rod slot, turn the rod into the upper joint fully. Install the lock nut on the end of the rod and tighten securely. STOPPER RUBBER UPPER JOINT NOTE Replace the lock nut if it is cross threaded. SHOCK ABSORBERCOMPRESSOR SHOCK ABSORBER INSTALLATION Torque the bolts. TORQUE SPECIFICATION: 3.0-4.0 kg-m (22-29 lbs-ft) Adjust the cushion springs with the spring adjuster. .>, 1 SPRING ADJUSTER I 11 Ill IV STANDARD: I1 Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. v HONDA CB400T REAR WHEEL/BRAKE/SUSPENSION SWING ARM REMOVAL Remove the rear wheel. Remove the right and left shock absorbers Withdraw the rear fork pivot bolt. - SWINGARM DISASSEMBLY1 ASSEMBLY I @ - I Drive the bushings into place through a I pad making sure that they are not damaged. Lubricate with grease after installation. 1A SWINGARM INSTALLATION Torque the swingarm pivot bolt. TORQUE SPECIFICATION: 5.5-7.0 kg-m 140-51 lbs-ftl Install the shock absorbers. Install the rear wheel. Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HONDA CB40OT REAR WHEELIBRAKEISUSPENSION REAR BRAKE PEDAL REAR BRAKE PEDAL HEIGHT Adjust the pedal height so that the distance between the pedal and upper face of the footpeg is 10 mm. Turning the adjusting bolt until the correct pedal height is obtained. NOTE After adjusting the pedal height, adjust the pedal free play and stoplight switch. BRAKE PEDAL REMOVAL1 INSTALLATION Oisconnec the brake rod and loosen the brake pedal bolt. Remove the brake return spring. NOTE Note the location of the stoplight switch sprins. Date of Issue: September, 1977 o HONDA MOTOR co.. LTD. 13-11 HONDA HYDRAULIC DISC BRAKE 14-0 C8400T Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. 14 HYDRAULIC' DISC BRAKE HONDA CB4OOT SERVICE INFORMATION 14-1 TROUBLESHOOTING 14-1 BRAKE FLUID REPLACEMENT1 AIR BLEEDING 14-2 BRAKE PADSIDISC PLATE 14-3 BRAKE MASTER CYLINDER 14-6 BRAKE CALIPER 14-8 SERVICE INFORMATION SPECIAL TOOL SNAP RING PLIERS 07914-3230001 SPEC1FICATIONS Disc thickness STANDARDS SERVICE LIMIT 4.9-5.1 mm (0.19-0.20 in.) 4.0 mm (0.16 in.) Disc runout 0.3 mm (0.012 in.) Master cylinder I.D. 14.000-14.043 mm (0.5512-0.5529 in.) 14.055 mrn (0.5533 in.) Master piston O.D. 13.957-13.984 mrn (0.5495-0.5506 in.) 13.940 mm (0.5488 in.) r3liper piston O.D. 38.115-38.180 mm (1.5006-1.5031 in.) 38.105 mm (1.5002 in.) Caliper cylinder I.D. 38.180-38.200 rnm (1.5031-1.5039 in.) 38.215 mm (1.5045 in.) TROUBLESHOOTING Poor Brake Performance - Air bubbles in hydraulic system - Worn brake pads - Pads fouled or glazed - Hydraulic system leaking Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. . , HONDA CB400T HYDRAULIC DISC BRAKE BRAKE FLUB0 NPLACEMBEMT/AIR BLEEDING Check the fluid level with the fluid reservoir parallel with the ground. BRAKE FLUID RESERVOIR when operating the brake lever. Failure to do so will allow brake fluid to squirt out of the reservoir during brake lever operation. Avoid spilling fluid on painted surfaces. Place a rag over the fuel tank B R A K E FLUID D R A I N I N G Loosen the caliper bleeder valve and pump the brake lever. Stop operating the lever when no fluid flows out of the bleeder valve. BRAKE FLUID DOT 3 B R A K E FLUID F I L L I N G Do not mix different brands of fluid Close the blseder valve, fill the reservoir, and install the diaphragm. To prevent piston overtravel and brake fluid seepage, keep a 20 mm space to the handlebar grip when bleeding the front brake system. Pump up the system pressure with the lever until there are no air bubbles in the fluid flowing out of the reservoir small hole (until lever resistance is felt). AIR BLEEDING i " ' Check the fluid level often while bleeding the brake, to prevent air from being pumped into the system. Pull the brake lever all the way back to the handlebar grip. Loosen the bleeder valve about 112 turn, and retighten. NOTE Do not release the lever until the bleeder valve has been closed. NEVER REUSE Release the lever gradually and wait several sewnds after it reaches the end of i t s travel. Repeat the above steps until there are no air bubbles in the fluid flowing out of the bleeder valve. Fill the reservoir to the UPPER FLUID LEVEL. C d disc with agood quality degreasing 14-2 Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HONDA CB400T HYDRAULIC DISC BRAKE BRAKE PADS/DISC PLATE 8 BRAKE PAD WEAR CHECK The front brake pads require replacement if the red line on the top of the pads reaches the edges of the brake disc. 8 BRAKE PAD REPLACEMENT Remove the caliper cover. Pull off the clip. Push the caliper toward the right and push the piston all the way in t o allow installation of new brake pads. Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. HYDRAULIC DISC BRAKE Remove the pin with a pair of pliers. Install the new brake pads and the shim on the piston side pad. Insert the pin with the pin hole facing out as shown. 14-4 Date of Issue: September. 1977 @ HONDA MOTOR CO.. LTD. HONDA CBlaOOT HYDRAULIC DlSC BRAKE Insert the clip into place in the pin hole. Install the caliper cover. DlSC THICKNESS Measure the disc thickness. B R A K E DlSC WARPAGE Measure the brake disc warpage. , Date of Issue: September, 1977 o HONDA MOTOR co.,LTD. 14-5 HONDA HYDRAULIC DISC BRAKE CB4OOT BRAKE MASTER CYLINDER MASTER CYLINDER DISASSEMBLY Drain brake fluid from the hydraulic system. Remove the brake lever from the master cylinder. Disconnect the brake hose. Avoid spilling brake fluid on painted surfaces. Place a rag over the fuel tank whenever Remove the master cylinder Remove the snap ring MASTER CYLINDER I.D. INSPECTION Measure the master cylinder I.D.. Check the master cylinder for scores, scratches, nicks or other defects. SERVICE LIMIT: 14.055 mm 10.5533 in.) Date of Issue: September, 1977 O HONOA MOTOR CO., LTD. HONDA CB4808 ', HYDRAULIC DISC BRAKE MASTER PISTON O.D. INSPECTION Measure the master piston O.D.. SERVICE LIMIT: 13.940 mm (0.5488 in.) MASTER CYLINDER ASSEMBLY MASTER PISTON MASTER CYLINDER Dip the piston cup in brake fluid or coat with silicon grease before assembly. Install the master cylinder on the handlebar. Connect the brake hose and install the brake lever. Bleed the front brake system. Date of Issue: September, 1977 o HONDA MOTOR co., LTD. STOPLIGHT SWITCH 14-7 HONDA HYDRAULIC DISC BRAKE CB4OOT BRAKE CALIPER CALIPER A REMOVAL Drain the brake hydraulic system Disconnect the brake hose. Remove the inspection cover. NOTE I Avoid ( spilling brake fluid on painted surfaces. ( I To remove caliper A, loosen the two caliper shafts gradually in several steps while pressing them against the caliper. BRAKE CALIPER A DISASSEMBLY Place a shop towel or rag prevent the piston from position the caliper with Apply a small amount of fluid inlet. over the piston to coming out, and the piston down. air pressure to the I., 6' 1 Do not use high - .Dressure air o r brinothe nozzle too close to the inlet. I Examine the piston and cylinder for scoring, scratches or other defects and replace i f necessarv. I I ' >x- L i f t out the o i l seal bv first o u s h i n - ~it into the cylinder as shown. Clean the caliper grooves with brake fluid. CALIPER A ASSEMBLY The oil seal must be replaced with a new one whenever disassembled. Coat the oil seal with silicon grease or brake fluid before assembly. Install the caliper A with the dished end o f the piston on the brake pad side. 14-8 Gate o f Issue: September, 1977 O HONDA MOTOR CO., LTD. HYDRAULIC DISC BRAKE C A L I P E R PISTON O.D. Check the piston for scoring, scratches or other defects. Measure the piston diameter with a micrometer. SERVICE LIMIT: 38.105 rnrn (1.5002 in.) C A L I P E R C L Y I N D E R I.D. Check the caliper cylinder for scoring, scratches or other defects. Measure the inside diameter o f the caliper cylinder bore. SERVICE LIMIT: 38.215 rnrn (1.5045 in.) CALIPER CARRIERICARRIER DISASSEMBLY Remove the speedometer cable clamp. Remove the carrier with caliper B. Remove the caliper shafts off the carrier and caliper B while rotating them by hand. Avoid damaging the boots. CALIPER CARRIERICALIPER B ASSEMBLY Wash all the removed parts. Coat the O-rings with silicon grease or brake fluid and install into place in the shaft center grooves. whenever disassembled. Replace the Install the boots on the carrier. Date of Issue: September, 1977 LTD. o HONDA MOTOR co., 14-9 HONDA HYDRAULIC DISC BRAKE CB400T Assemble caliper B and caliper carrier together, making sure that the boot is seated in the caliper shaft groove properly. Install the carrier on the front fork. TORQUE SPECIFICATION: 3.04.0 kg-m (22-29 lbs-ft) CALIPER COVER q8 LEEDER VALVE CALIPER PISTON CALIPER CARRIER SILICON GREASE OR BRAKE FULlD DOT-3 CALIPER A INSTALLATION Tighten the caliper shafts evenly while pushing them against caliper B. NOTE I Tighten the shafts carefully, noting the I [ mating faces of calipers A end B. Connect the brake hose. Install the inspection cover. Bleed the brake system. Date of Issue: September, 1977 O HONDA MOTOR CO., LTD. HONDA CBLaQOT SERVICE INFORMATION 15-1 TROUBLESHOOTING 15-2 BATTERY 15-3 CHARGING SYSTEM 15-5 A.C. GENERATOR REMOVAL1 INSTALLATION 15-6 SERVICE INFORMATION a WORKING PRACTICE Battery acid level should be checked regularly and filled with distilled water when necessary. When charging the battery, quick-charging should only be done in an emergency; slow-charging is preferred. Remove the battery from the motorcycle for charging whenever possible. I f battery must be charged on the motorcycle, disconnect the battery cables. Keep fire or sparks away from a charging battery because it produces hydrogen. All charging system components can be tested on the motorcycle. SPECIFICATIONS Battery AC generator Capacity 12V. 12 ampere-hours (TYPE 1 : 12V, 9 ampere-hours) Specific gravity TYPE ll: 1.28, TYPE I: 1 . 2 7 / 2 0 ~(~1 3 8 ~ ~ ) Charging rate 1.2 amperes maximum (0.9 amperes maximum) Capacity NIGHT: Voltage regulator Date of Issue: September. 1977 @ HONDA MOTOR CO.. LTD. 5 amperes minimum/5,600 rpm (14.5 volts) Transistorized non-adjustable regulator HONDA BATTERYICHARGING SYSTEM CB4OOT TROUBLESHOOTING No Power - Key Turned On: 1. Dead battery -0attey not charged -Battery electrolyte evaporated -Battery run down -Charging system failure 2. Disconnected battery cable 3. Main fuse burned o u t 4. Faulty ignition switch Low Power - Key Turned On: 1. Weak battery -Low battery electrolyte level -Battery run down -Charging system failure 2. Loose battery connection Low Power - Engine Running: 1. Battery undercharged -Low battery electrolyte level -One or more dead cells 2. Charging system failure 15-2 Intermittent Power: 1. Loose battery connection 2. Loose charging system connection 3. Loose starting system connection 4. Loose connection or short circuit i n ignition system 5. Loose connection or short circuit in lighting system Charging System Failure: 1. Loose, broken, or shorted wire or connection 2. Faulty voltage regulator 3. Faulty silicon rectifier 4. Faulty AC generator Date of issue: September. 1977 O HONDA MOTOR CO., LTD. HONDA CB4OOT BATTERYICHARGING SYSTEM BATTERY REMOVAL Disconnect the ground cable at the frame. Remove the battery strap. Disconnect the positive (+I cable at the battery. Remove the battery. TESTING SPECIFIC GRAVITY I I Test each cell by drawing electrolyte into the hydrometer. . 8"~) SPECIFIC GRAVITY ( 2 0 " ~ 6 I TYPE I 1.26-1.28 1.25 I TYPE II 1 1 1.27-1.29 1 Fullycharged 1 1.26 1 Undercharged NOTE I. I The battery must be recharqed if the specific gravity is below 1.?3 (TYPE I : 1.22). The specific gravity varies with the temperature as shown i n the accompanying table. Replace the battery if sulfation i s evident. The battery must be replaced if there are pastes settled on the bottom of each cell. I 1 Avoid contact with skin, eyes, o r clo thing. Antidote: Flush with water and get promot medical atten tion. I 0' I I I I 5' 10' 15' 20' I 25' I 30' I I 4V 35- ELECTROLYTE TEMPERATURE - ~ Specific gravity changes by 0.007 for every 1 0 " ~ Date of Issue: September, 1977 MOTOR co., LTD. o HoNDA 15-3 HONDA C5400T BATTERYICHARGING SYSTEM BATTERY CHARGING a Hookup instruction: Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. Charging current: 1.2 amperes maximum (TYPE I : 0.9 amperes maximum) Charging: Charge the battery until specific gravity is 1.27-1.29 a t 20°C (6B°F) (TYPE I : 1.26-1.28) . . Before charging a battery, removs the cap from each cell. Keep fire and sparks away from a charging battery. Turn power ON/OFF at the charger, not at the battery terminals. Discontinue charging if the electrolyte temperature exceeds 45'C (117"FJ. I I CAUTION . 0uick.charging should only be done In an emergency; slow-charging i s preferred. CAUTION 1 BATTERYBREATHER TUBE CARBURETOR OVERFLOW TUBE After installing the battery, coat the terminals with clean grease. Route the breather tube as shown on CMWR68#6 SYSTEM a CHARGING OUTPUT TEST Warm up the engine before taking readings. Disconnect the regulatorlrectifier black wire. Connect a voltmeter and an ammeter to check charging system output. NOTE Use a fully charged battery to check the charging system output. TECHNICAL DATA: MAIN SWITCH LIGHTING SWITCH CHARGING RPM 5,000 rpm ON ON (High beam) 1,200 rpm 5 amperes minimum/l4.5 volts) 15-4 Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. HONDA CB400T BATTERYICHARGING SYSTEM STATOR COIL CONTINUITY TEST NOTE It is not necessary to remove the stator to make this test. Check the yellow leads to the AC generator stator for continuity with each other. Replace the stator if any yellow lead i s not continuous with the others, or if any lead has continuity to ground. 2 WHITE/ . - 4 PINKBLUE i t GREEN VOLTAGE REGULATOR1 RECTIFIER TEST Check the resistances between the leads with an ohmmeter. o not use a high voltage source such as insulation resistance tester since i t may damage the rectifier and give you I RESISTANCES IN NORMAL DIRECTION GREEN LEAD AND ANY YELLOW LEAD: 5-40 REDIWHITE LEAD AND ANY YELLOW LEAD: 5-40 R RESISTANCES IN REVERSE DIRECTION REDIWHITE LEAD AND ANY YELLOW LEAD: 2000R minimum GREEN LEAD AND ANY 2000R minimum YELLOW LEAD: I I NORMAL DIRECTION I YELLOW ^ YELLOW REDIWHITE YELLOW t REVERSE DIRECTION I Date of Issue: September, 1977 LTD. o HONDA MOTOR co., 15-5 HONDA BATTERY/CHARGING SYSTEM CB4OOT VOLTAGE REGULATOR PERFORMANCE TEST a. Testing with a voltmeter Connect a voltmeter across the battery. Check regulator performance with the engine running. Regulator must divert current to ground when battery voltage reaches 14.0-15.0 V. b. Testing with a variable resistor Connect a variable resistor (0-100CZ) across the battery with a 50a resistor in between. Test lamp must come on when voltage reads 14 to 15 V on the voltmeter by adjusting the variable resistor. TWOFULLYCHARGED 12V BATTERIES CONNECTED I N SERIES A. C. GENERATOR EMOVAL/ l WSTALLATBQM For removal and installation procedure, see Section 9. 15-6 Date of Issue: September, 1977 @ HONDA MOTOR CO.. LTD. SERVICE INFORMATION 16-1 TROUBLESHOOTING 16-2 SPARK PLUG 16-3 IGNITION COIL 16-3 C.D.I. UNIT 16-4 A.C. GENERATOR 16-4 SERVICE INFORMATION a WORKING PRACTICE Ignition timing cannot be adjusted since the C.D.I. (Capacitive Discharge Ignition) unit i s non-adjustable. If ignition timing is incorrect, check the C.D.I. unit and AC generator and replace any defective part. I SPECIFICATIONS Spark plug ND X24ES-U NGK D8EA Spark plug gap 0.6-0.7 mm (0.024-0.028 in.) Ignition timing Ignition coil Date of Issue: September, 1977 @ HONDA MOTOR CO., LTD. Initial 15' Full advance 43" Engine speed (initial) 1.600-2.000 rpm Engine speed (full advance) 4.500-5.350 3-point spark test 6 mm (0.24 in.) minimum rpm HONDA CB400T IGNITION SYSTEM TROUBLESHOOBlMG Engine Cranks but Will N o t Start: - Engine stop switch OFF - No spark at plugs - Defective C.D.I. unit - AC generator faulty No Spark at Plugs - Engine stop switch OFF - Poorly connected, broken or shorted wires , Between AC generator and ignition coil . Between C.D.I. unit and engine stop switch Between C.D.I. unit and ignition coil . Between C.D.I. unit and ignition switch Between ignition coil and plug - Defective ignition switch - Defective ignition coil - C.D.I. unit faulty - Defective AC generator . Engine Starts but Runs Poorly - Ignition primary circuit . Defective ignition coil . Loose or bare wire Intermittent short-circuit i n a switch - Secondary circuit Defective plug Defective high tension cord - Secondary circuit . Defective AC generator Defective C.D.I. u n i t . . . . . 16-2 Date o f Issue: February, 1979 O HONDA MOTOR CO., LID. - m, . HONDA ~ ~ 4 0 z ,% &. .-. .,. ~. 0 ~ IGNITION SYSTEM . . For spark Plug gap inspection and adjustmenr procedure. see Section 3. IGNITION COIL REMOVAL -. Remove the fuel tank. Disconnect the wire leads. Remove the coii attach~ng bolts and coil. I I i PERFORMANCE TEST Perform the 3-point spark test with a coil tester. SERVICE LIMIT: 6 mm (0.24in.) minimum instructions supplied with the coil %/li,&- .. -7 - ~.... .- 6 rnm 10.24 n i M l N l M l-l M.. SECONDARY ELECTRODE PRIMARY ELECTRODE THIRD E L E C ~ R O D E Date of issue: February, 1979 @ HONDA MOTOR CO., LTD. 16-3 @ 3 IGNITION SYSTEM HONDA CB4OOT C. D. I.UNIT INSPECTION Disconnect wiring. Set the tester at xkS2 or x l Q 0 i 2 and check continuity of C.D.1. terminals. Replace the C.D.I. unit if the readings do not fall within the limits shown in the table. NOTE . 1. 1. The C.D.I. unit is fully transistorized. For accurate testing, it is necessary t o use a specified electrical tester. Use o f an improper tester or measurements in improper range may give false readings. Use SANWA ELECTRICAL TESTER (SP-1OD) PIN 07308-0020000 or KOWA ELECTRICAL TESTER (TH5H). Discharge the capacitor before testing. "NEEDLE SWINGS AND RETURNS" indicates that a capacitor is being charged with the tester. The tester needle will stay a t infinity in subsequent tests unless the capacitor 1s discharged. / I UPPER ROW: MEASURING RANGE (SANWATESTER) xkS2 LOWER ROW: MEASURING RANGE (KOWATESTER) x100.Q The resistances shown in the table indicate those t o be read on the tester, not o f specific circuits or parts. in Fia. 1 are a.~.~ l i c a btloe ,he Snerifications -r.-...--. the C.D.I. unit (connectors on the blue and white wires) used on following models: -~ (Fis. 1) '1.' : Needle swings and back t o -. . 16-4 Date o f k u e : December, 1980 Q HONDA MOTOR CO., LTD. HONDA C840OT The Specifications in Fig. 2 are applicable to the C.D.I. unit (Coupler on blue and white wire ends) used on the following models; IGNITION SYSTEM (Fig. 2) < C8400T > F.No. - NC03-2001782 < CM400T > F.No. NCO1-ZOXXXXX F.No.- NC01-2110251 '< L The Specifications in Fig. 3 are applicable to the C.D.I. unit ("C" mark stamped on the cover) used on the following models; > .. Needle swings and back to -. (Fig. 3) < C8400T > F.No. NC03-200 1783- < CM400T > F.No. NC01-2110252- <,CM4OOE > F.No. NC01-4000009- \ ' : Needle swings and back to -. BLUE WHITE Date of Issue: Decamber, 1980 LTD. o HONDA MOTOR CO., 16-5 HONDA CB40OT A. C. GENERATOR N0TE:Ground the pulser to the stator when bench cneckins- the Green to Light Blue and Green to Brown wires. INSPECTION Disconnect the stator wires at their connections. Measure resistances between the terminals. Use the HONDASERVICE TESTER (07308-0020000) t o perform this test. For generator removal and installation procedure. refer t o Section 9. GREEN-WHITE BLUE-WHITE GREEN-BROWN GREEN-LIGHT BLUE GREEN-PINK 400-5OOfZ 75-1 30S2 75-130.Q 75-1 30S2 120-18OS2 The specifications are applicable to the A.C. generator used on the following models; < CB400T > E.No. CB400TE-20XXXXX E.No. CB400TE-40XXXXX -WIRE COLOR GREE'N-WHITE BLUE-WHITE GREEN-BROWN GREEN-LIGHT BLUE GREEN-PINK I RESISTANCE 315-385S2 77-950 76-92.Q 95-1 16S2 126-154.Q The specifications are applicable to the A.C. generator (Screws painted with yellow) used on the following models: < CB400T > E.No. E.No. E.No. E.No. CB400TE-2105940CB400TE-4103395NC03E-20XXXXX NC03E-2100001- YELLOW PAINT < CM400T > E.No. NCOlE-20XXXXX E.No. NCOlE-21XXXXX E.No. NCOlE-2200001- 16-6 Date of Issue: December, 1980 HONDA MOTOR CO., LTD. O . STARTER MOTOR HONDA CB4OOT II II SERVICE INFORMATION 17-1 TROUBLESHOOTING 17-1 STARTER MOTOR 17-2 MAGNETIC SWITCH 17-4 STARTER CLUTCH 17-4 II II I I SERVICE INFORMATION *, WORKING PRACTICE The starter motor can be removed with the engine in the frame. See Section 10 for starter clutch repairs. SPECIFICATIONS STANDARD Starter motor SERI~ICE LIMIT . Brush spring tension 0.495-0.605 kg 4009 Brush length 11.O-12.5 mm (0.434.49 in.) 5.5 mm (0.21 in.) STARTER MOTOR BRUSHES MAGNETIC SWITCH / U Q \ARMATURE b STARTER'\ SWTCH. FIELD COIL I FIELD MAGENT BLACK [ II - GREEN/RED -" MAINSWITCH u JNEUTRAL BATTERY I ,,ha0 ] L,.,,",, - I % o r a - TROUBLESHOOTING Starter Motor Will Not Turn: Dead battery Faulty ignition switch - Faulty start switch Faulty neutral switch - Faulty starter magnetic switch - Loose or disconnected wire or cable - Neutral diode open - Faulty clutch switch Starter Motor Turns Engine Slowly: - Low battery - Excessive resistance in circuit - Binding in starter motor. - Date of Issue: December, 1980 o HONDA MOTOR CO., LTD. Starter Motor Turns, But Engine Does Not Turn: Faulty starter clutch Faulty starter motor gears Faulty starter motor or idle gear Starter Motor and Engine Turn, But Engine Does Not Start: Faulty ignition system - Engine problems - 17-g ~. HONDA C548OT STARTER MOTOR STARTER MOTOR REMOVAL With the ignition switch OFF, remove Disonnect the starter cable. Remove the starter mounting bolts and pull the motor out of the engine case. BRUSH INSPECTION Remove the starter motor case scrwes. Inspect the brushes and measure brush length. Measure brush spring tension with a spring scale. SERVICE LIMITS: Brush length: 5.5 mm (0.21 in.) 400g Brush spring tension: COMMUTATOR INSPECTION Remove the case. COMMUTATOR NOTE Record the location and number of the thrust washers. Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils. NOTE I Do not use emery or sand paper on the I commutator. 17-2 Date of Issue: Defflmber, 1980 Q HONDA MOTOR CO.. LTD. .. HONDA CB40OT STARTER MOTOR Check for continuity between pairs of commutator bars, and also between commutator bars and armature shaft. Replace starter motor if armature coils are open, or shorted to armature shaft. COMMUTATO CONTINUITY: COMMUTATO ARMATURE SHAFT NO CONTINUITY: No . .., FIELD COIL INSPECTION Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire. Replace the starter motor if the field coil i s not continuos or if it i s shorted to the motor case. CABLE TERMINAL-MOTOR CASE NO CONTINUITY: Normal CABLE TERMiNAL-BRUSH WIRE Assemble the starter motor. NOTE Align the punch mark on the case to the punch mark on the cover. MARKS Install the starter motor on the engine. Connect the starter motor cable. Date of Issue: December, 1980 LTD. o HONDA MOTOR CO., 17-3 .. HONDA STARTER MOTOR CB400T MAGNETIC SWITCH INSPECTION To test if the switch primary coil depress the switch button. The coil if the switch clicks into position. i normal. normal Connect an ohmmeter to the switch terminals. Connect e 12V battery to the switch cable terminals. The switch i s normal if there is continuity. STARTER CLUTCH See Section 10 17-4 Date of Issue: December, 1980 O HONDA MOTOR CO., LTD. @HONDA 18.TECHNIC8 C8400T \ 1. BALANCER MECHANISM The front and rear balancers counteract large inertia forces inherent in the 2-cylinder, in-line, 360-degree crank engine, allowing it to produce smooth power. FRONT BALANCER SHAFT The eccentric shaft allows balancer chain tension adjustment. Date of Issue: September, 1977 MOTOR co.,LTD. o HoNDA RUBBER DAMPERS The sprockets are connected t o their respective balancers through rubber dampers to absorb shocks for longer chain life. 18-1 HONDA CB40OT TECHNICAL FEATURES OPERATING PRINCIPLE OF BALANCER t INERTIA FORCE A T TDC 1 INERTIA FORCE AT BDC The source of vibration in a reciprocating engine i s the "inertia" force created by the rotating or reciprocating masses. For example, the inertia force which acts on the main bearings of a single cylinder, Ccycle. 200 ccengine at TDC will be: 400 kg 1 882 lbs) approx. . . . . . . . . . . . . . . a t 6.000 rpm 1000 kg (2.205 lbs) approx. . . . . . . . . . . . . . . a t 10.000 rpm +/INERTIA FORCE INERTIA FORCE ON CRANK WEIGHT Inertia force created by the rotating mass is general canceled by counterweights. Their use will reduce vibration caused by the primary inertia force which occurs once every crankshaft revolution. (Hereafter, inertia force refers to this primary inertia force). 18-2 Date of Issue: September, 1977 Q HONDA MOTOR CO.. LTD. HONDA CB4OOT TECHNICAL FEATURES Although the counterweights will balance the inertia force at T.D.C. and B.D.C., they will create a corresponding horizontal imbalance of their own at 90' BTDC and 90" ATDC due to centrifugal force. The balancers are designed to counteract this force including the inertia force created by the reciprocating. CENTRIFUGAL FORCE ON COUNTERWEIGHTS (1) TDC The counterweight creates a centrifugal force to neutralize one-half of the inertia force. The remaining inertia will be totally balanced by two balancen. Each balancer counteracts onefourth of the total inertia. 9 25 50 z The centrifugal force on the counterweight is balanced by the balancers. c3 25 (3) BDC C=, 50 e 25 The inertia force is balanced by the counterweight as in (1). However, the centrifugal force acting on the counterweight is s t i l l present. The centrifugal force on the balancers cancels this remaining force. 50 The centrifugal force on the counterweight neutralizes one-half of the downward inertia force. The balancers counteract the remainder. Date of Issue: September, 1977 o HoNDA MOTOR co., L I D . 18-3 HONDA TECHNICAL FEATURES CB400T 2. 3-VALVE, SHORT-STROKE ENGINE SHORT-STROKE ENGINE The 0.72 oversquare design reduces piston speed and mjnimizes friction. The bore is large enough to install three valves in one combustion chamber. The power chamber adds extra torque at low and medium speeds. I t is located at the most ideal position without sacrificing space between the engine and the ground due to reduced engine height. The exhaust gases from one cylinder expand in the power chamber and have an extraction effect on the other cylinder. 18-4 Date of issue: September, 1977 O HONDA MOTOR CO.. LTD. HONDA TECHNICAL FEATURES 3. C.D.I. SYSTEM The C.D.I. (capacitive discharge ignition) electronic ignition system is designed t o provide a powerful spark, especiallv at high rpm, with no scheduled maintenance. The unit consists o f diode transistors. condenser, SCR and ! ., ! I j SPARK ADVANCE PULSER The pulser is inspected and adjusted at the factory and must never be disassembled. The ignition coil, battery charging coil and spark advance pulser are assembled i'nside the 12-pole stator. FEATURES There are no contact points since the C.D.I. system employs an inductive buildup b y capacitive discharge. The C.D.I. can develop greater voltage at the spark plugs than conventional systems and is less sensitive t o spark plug fouling. Working on AC, the secondary energy produced to fire the spark plugs i s stable regardless o f the battery's charge. The electronic timing advance is virtually free from troubles which occur in mechanical advancers. The overall design eliminates initial and periodic adjustments and maintenance services. Date of Issue: February, 1979 a HONDA MOTOR co., LTD. 18-5 HONDA TECHNICAL FEATURES CB400T OPERATING PRINCIPLE CONDENSER 1. As the AC generator rotor turns, current is induced in the AC generator (AC generating coil). This current is rectified as it passes through the diode Dl and is stored in the condenser C,. During this process, the SCR is keot OFF. 2. An electric pulse is generated by the fixed pulser when the pickup reaches the point where ignition must start. This is due to changes in the flux. The pulse i s rectified by the diode 2 and is applied to the gate of SCR. As this happens. SCR turns ON which in turn discharges the energy stored in the condenser through the primary coil. Sufficient potential is then developed at the spark plug to ignite air-fuel mixture in the combustion chamber. 18-6 Date of Issue: September, 1977 O HONDA MOTOR CO.. LTD. HONDA CB4OOT TECHNICAL FEATURES 3. To advance timing, the signal from the fixed pulser is replaced by the output signal from the spark advance pulser. The output signal applies to SCR gate through diode 3 and fires the spark plug, performing the same function as the conventional system. The faster the engine speed, the faster the SCR is triggered to advance the timing. 4. The negative pulse from the fixed pulser balances the positive pulse from the spark advance pulser when the maximum advance i s reached. This limits timing advance. ADVANCER OPERATION In C.D.I. ignition, timing advance depends on the buildup time of voltage on the advance pulser, which becomes faster as the engine speed increases. The SCR acts like a switching device, but there i s a definite voltage at which i t turns on. The overall operation of the C.D.I. system stems from these two facts. The faster the voltage buildup, the earlier the SCR i s triggered, allowing the system to perform the same function as the conventional system. The fixed pulser controls timing until the advance pulser comes into operation. SCR TRIGGER VOLTAGE SPEED: N,