SHOP MANUAL CB/ CM400’s 1978-81 CB / CM400’S HONDA CMOO'I' - 400A/CM400T - 400k 400E 400C INTRODUCTION TABLE OF CONTENTS This Shop Manual is for these models: PART I CB400T/A '78: ce4oor, CB400A '79: ce4oor, CM4DDT, CM400A GENERAL '“FDRMAT'ON 1 '80: CB4OOT, CM400T, CM4OOA, CM4ODE '81: CB400T, CM4ODT, CM4OOA, CMAOOE, CM4OOC LUBRICATION 2 INSPECTION AND ADJUSTMENT 3 HOW TO USE THIS MANUAL FUEL V E The first part of this shop manual contains all infor- 8 ST M 4 mation and procedures common to the CB/CM» ENGITIESI‘I'TATEX‘I‘IION 5 400's. After section 19, part two begins and it E contains information and procedures for the Honda— N CYLINDER HEAD/VALVE 6 matic models. G ." A 78% Emissions Addendum follows the second I! CYLINDER/PISTON 7 part and it applies to all CB and CM400 models E manufactured after December 31, 1977 (USA only). CLUTCH/OIL PUMP 8 ' Sections 1 through 3 apply to the whole motor CRANKCASE 9 cycle, while sections 4 through 17 describe parts of i the motorcycle, grouped according to location. CRANKSHAFT/BALANCER‘ 10 Find the section you want on this page, then turn to TRANSMISSION 11 , the table of contents on page 1 of that section. . Most sections start with an assembly or system H FRONTWHEEL/BRAKE/ 12 1 ‘ illustration and all the specifications, torque values, A REAR WHEEE7§§§I2§ _ I 'working practices, tools and materials required for g SUSPENSION 13 [ the section. The subsequent pages give detailed I 1 -- \ procedures. 5 HYDRAULIC DISC BRAKE 14 - If you are not familiar with this motorcycle, read E BATTERY CH R I STE TECHNICAL FEATURES, section 18. E I A G "6 SV M 15 I If you don't know the source of the trouble, see ‘cl' IGNITION SYSTEM 15 section 19, TROUBLESHOOTING. T STARTER MOTOR 1., Refer to the addendums at the back of the shop C ; manual for 1978% and subsequent years service A TECHNICAL FEATURES 18 information. L TROUBLESHOOTING 19 ALL PHTOGRAPHS ARE BASED ON THE TYPE PART II CmDA ONLV ll MODEL. ALL INFORMATION, ILLUSTRATIONS, DIREC- 78% CB400T'CB400A EMISSIONS 20 TIONS AND SPECIFICATIONS INCLUDED IN THIS ADDENDUM PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE 3 79 0340‘" ADDENDUM 2‘ I TIME OF APPROVAL FOR PRINTING. HONDA D I MOTOR co., LTD. RESERVES THE RIGHT TO E 799M400T‘CB409A ADDENDUM 2 MAKE CHANGES AT ANY TIME WITHOUT , NOTICE AND WITHOUT INCURRING ANV 3 3° CMMT'DMWOA ADDENDUM 23 HA EVE . “UGAT'oN w T R . [If '80 ceaom ADDENDUM 24 NO PART OF THIS PUBLICATION MAV BE REPRO- I DUCED WITHOUT WRITTEN PERMISSION. '30 CM4ODE ADDENDUM 25 \ '81 CB/CM400'S ADDENDUM 26 HONDA MOTOR CO., LTD. Service Publications Office Date of Issue: December, 1980 © HONDA MOTOR CO., LTD PART I MUIIL IDENTIFICATION TVPE I HONDA C B4OOT YVPE II CMOOT (II BEGINNING F/N 2000001 The flame scriil number is slampad on me right side 01 the steering head. .- V The engine serial number is stamped on the top cf the crankcase. CB400T III) BEGINNING F/N 4000032 The loge! vehicle identification number [VIN] is on (he left side of flu: stealing heade _- \: . a Yhe carbumor idemifiution number is on (he left side of the carburetor bodv. IDENTIFICATION NUMBER Daia of Issue: Augusx, 1980 ‘© HONDA MOTOR C0., LTD. $3333 I. GENERAL INFORMATION GENERAL SAFETY 1—1 SPECIAL TOOLS 1—6 SERVICE RULES 1—‘I WIRING DIAGRAMS 1—7 SPECIFICATIONS 1—2 CABLE & HARNESS ROUTING 1-9 TOROUE VALUES 1—4 MAINTENANCE SCHEDULE 1—12 ‘ (ENERAL SAFETY I! m engine must be mnnins to do some work. make u m battery electrolyte contains sulfuric acid. Protect sure the m is Mil-vrntilmd Never run III! engine your eyes, skin and clothiny. In use of contact. flush in a closed am. The exhaust contains poisonous urban thoroughly with water and call a doctor ,1 your eyes monoxide yes m exposed. H _ H I The battery generates hydrogen gas which can be highly eXpInsiva. 00 no! smoke or allow flames a! spark: Gasoline is extremely flammable and is explosive under "9-77 the battery. arm/ally will/E Margin! 17- - certain mfldifions. Do not smoke or allow flames ar sparks in your working am. SERVICE RULES 1. Use geniune HONDA or HONDA-recommended parts and lubricants or their equivalent Parts that do not meet HONDA'S design specifications may damage the motorcycle. Use the special teal; designed (or this product. Install new gaskets. Ovrings, cotter pins, lock plates, etc. when reassemoling. When turquing balls or nuts, begin with Iarnerdiameter or inner bolt first, and tighten to the specified torque diagonally, unless a particular sequence ts specified. Clean parts In cleaning solvent upon disessemblv. Lubriute any sliding surlecos before reassembly. Alter reassembly, check all parts for proper installation and operation Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws an.- not interchangeable with English lesteners. The use at incorrect tools and fasteners may damage the motorcycle. #54.” >193" Data of Issue: September, 1977 © HONDA MOTOR Co. LTD. 1 - 1 HONDA GENERAL INFORMATION c B40 01' SPECIFICATIONS Illlll Metric English Dimensions Overall length 2,130 mm 83.1] in. , Type I 830 mm 32.7 in. mm" “"d‘" Type II 340 mm 33.1 in. 0",." height Type I 1.150 mm 45.3 in Type II 1.100 mm 46.5 In. Wheel base 1,390 mm 54.7 in. Seat height 800 mm ' 31.5 in. Right 315 mm 12.‘ in. Fm“ ”a“ Mgr" Left 325 mm 12.3 in. Ground clnrence 185 mm 6.5 in. Dry weight Type I 159 kg 351 lbs. Type II 168 kg 370 lbs. Frame Type Diamond Type F. suspension and travel Telescopic fork, 139.5 mm (5.5 in.) R. suspension and travel Swing arm. 96 mm (3.3 in.) ~ F. tire size 3.505194"! R. tire size 4.IOS18—4Pfi up m 90 kg Front v.75 kg/cm‘ 24 psi Cold me I203 lbs.) hid Rur 2.25 kg/cm2 32 psi ”"55”" Up to Vlhicle Front 1.75 kg/I:m= 24 psi “PEI” I‘ll" Hear 2.5 Isa/om2 36 psi Type I Internal expanding shoes F' brake Type II Disk brake R. brake Internal expanding shoes . Type I 14 lit. 3.7 U5. gal., 3.1 Imp. gal. F". “Dam" Type II I: lit. 3.4 u.s. 93L, 2.9 Imp. gal. Fuel reserve clpacilv Type I 3.1 lit. 0.8 U.S. 9]., 0.7 Imp. gel. Type II 3.0 In. 0.8 U5. 9“,, 0.6 Imp. gel. Caster angle 63 degrees Trlil length 100 mm 3.9 In. Front iork oil capacity 140 1 3 cc 4.9 2 0.1 015. Engine Type Air cooled 4 stroke 0.H.C. engine I Cylinder arrangement Vertical twin parallel ' sure and stroke 70.5 x 50.6 mm 2.776 x 1.992 in. Displacement 395 cl: 24.1 eu-in. Comprasion ratio 9.3 : 1 VIIVI train Chain driven over head camshaft Oil capacity 3.0 lit. I 3.2 us. at. 2.6 Imp. ql. Lubrication system Forced nrnssura and Wei sump Cylinder head compression pressure 131 1.0 Isa/cm: I wanna; 1-2 Date oi Issue: September, 1977 ® HONDA MOTOR C0,, LTD. HONDA C 34007 GENERAL INFORMATION Item Metric English Engine — Opens 57'BTDC (AID liltl, 5°BTDC [At 1.0 mm lihl Intake valve . . . , Class 87 ABDC (At 0 lift). 35 ABDC (At 1.0 mm llhl Opens 90°BBDC (At 0 lift), 40°EBDC (At 1.0 mm lift) Exhaust value Claus 55°ATDC (At 0 rim, 5°A'roc (At 1.0 mm Iihi Valve clearance m 0.10 mm t 0.02 mm 0,006 X (LWOB in. EX 0.14 mm 3: 0.02 mm 0.006 2 0.0008 in. ldla speed 1.200 t 100 rpm Carbureticn Carburetor tvpe CV type. 32 mm l1.26in.l vanturi bore ; Selling number VBZIA Pilot screw 1-1/2 turns out flat level 15.5 mm | 0.61 in. Drive train Clutch Wat multl plate type _Tran‘sini;srioini 7 , _,. . '— 5-speed constant mesh ~lirri Irv reduction ratio __ 3.!25 GeaLratjo | 2.733 Gear ratio II 1.350 _ Gear ratio Ill 1.410 ' Gear ratio IV 1.148 Gear ratio V 0555 Final re'rfiarion ratio 2.312 Gear shilt pattern Lelt foot Operated rewm system Electrical Ignition Capacitive discharge ignition mm“ liming i "F" mark 15“ a‘roc at 1.200 rpm idll mud Full advanca 43° amc 2 2' at 4,500 to 5.350 angine rpm Starting “sum Type I Kick starter Type II Starting molar and kick starter Alternator A.c. ganaratot, 0.17 kwl5,000 rpm aumy capacity Type I 12V. 9 amure-hours Type II 12V. 12 ampere-hams Spark plug NGK-DBEA, ND-XZdESU Spark plug gap 0.6 ~ 0.7 mm ] 0.024 ~ 0.028 in. Lights Headlight (low/high beam) 35/50 W Tail/stoplighl 3/32 0p SAE NO. 1157 Turn “ENE!" "rant/rear) 32/32 cp SAE NO. F. 1034. R. 1073 ipeedomater light 2 cp SAE NO. 57 Tachometer light (Type II only) 20;: SAE NO. 57 Nautral indicator light 2 cp SAE NO. 57 Turn signal indicator light 2 cp SAE NO. 57 jigflJeam indicator light 2 cp SAE No. 57 Position light 3 cp SAE NO. 1034 Dale 0! Issue: September, 1977 0 HONDA MOTOR CO” LTD. 1-3 HONDA GENERAL INFORMATION CB4OOT TllllllllE VALUES e ENGINE . Torque Values "9'“ a w kwn lbs-ft 1. Cylinder head cover bolt 2 0.8—1.2 6-9 2. Tappat adjusting nut 15 1.2—1.7 9—12 3. Cylinder head bolt 8 3.0—3.3 22—24 4. Cam sprocket knock bolt. 7 x 12 nax. bolt 2 1.6—2.2 13-16 5‘ Spark plug 2 1.5—2.0 11—14 6. Drive gear lixing bolt, 12 x 25 flange bolt 1 4.5-5.0 33-36 7. Clutch cantor lock nut 20 mm 1 4.5—5.0 33—36 8. Balanur, 8 mm nut 1 2.0—2.5 15—13 9. Balanoar, 10 mm nut 1 3.6—3.5 22—25 10. AC. generator rotor set bolt, 12 x 40 flung: bolt 1 10.0—12.0 70—90 11. crankshaft holder bolt, 10 mm bolt 6 21.3—11.7 24—27 12. Connecting rad nut 4 2.5—2.9 18—21 13. Starting clutch boll. TORX bolt 3 1.2—1.4 9—10 14. Oil liltel center bolt 1 2.8-3.2 20—23 15. Oil drain plug 1 2.5—3.5 18—25 16. Exhaust pipe llanga nut, 5 mm 4 0.3-1.2 6—9 17, Muffler chamber clamp bolt, 3 )1 351mm: bolt 4 1.8—2.5 13—18 IE. Gear shift pedal, 6 x 32 flange bolt 1 0.8—1.2 8—9 0 CHASSIS ' Torque Values ""n a 'V kg-m mm 1 Steering upper holder bolt, 8 x 36 flange bolt 4 1.8—2.5 13—18 2 Steering lower holder bolt 4 2.3—3.0 17—22 3 Steering stem nut 1 9.0—12.U 65—87 4. Front lork bolt 2 7.0—9.0 51—65 5. Front lurk bottom bridge bolt, 3 x 40 hex. bolt 2 1.8—2.5 13—18 6 Front brake disc boll, B x 33 USS bolt 5 2.7—3.3 20—24 7 Caliper set bolt, 10 x 32 flange bolt 2 3.0—4.0 22—29 8 From brake ullpar blaedar valve 1 0.7—0.9 5—7 9 Hear brake stopper arm nut, 8 mm nut 2 1.5—2.3 11—17 10. Front axle nut 1 5.0—8.0 36—58 11. Front axle holder nut. 8 mm nut 4 1.8—2.5 13—18 12. Rear axle nut 1 7.0—10.0 51—72 13. Final driven sprocket. 10 mm nut 4 5.0—7.0 43—51 14, Rear lork pivot nut. 14 mm nut 1 5.5—7.0 40—51 15. Rear shock absorber upper bolt, 10 x 45 flange bolt 2 3.0—4.0 22-29 16. Rear shock absorber Iowar bolt. 10 x 32 hex. bolt 2 3.0—4.0 22—29 17. Foot peg bolt, 10 mm flange bolt 4 55—65 40—47 18. Drive chain adjusting nut 2 0.8—1.2 6—9 19. Fuel tank set bolt, 8 x 28 flange bolt 1 1.5—2.3 11—17 20, Rear brake pedal pivot bolt, 8 x 65 flange bolt 1 1.8—2.5 13-13 21. Engine hanger, 10 mm flange nut 5 4.5-6.0 33—43 1 - 4 Date of Issue:5aptember, l977 © HONDA MOTOR (20., L10. HONDA C 54007 GENERAL INFORMATION I STANDARD TORQUE SPECIFICATIONS Torque Values Bulls and Nuts __ kg-m lbs" I. 5 mm bolt and nut OAS—0.6 3—4 2. 6 mm bolt and um DIE—L2 6—9 3, 8 mm bolt and nut 13—15 13 48 4, 10 mm bolt and nut 3.0—4.0 22—29 5. 12 mm bolt and nut 5,0 —6‘0 36 43 6. 5 mm screw 035—05 3~4 7‘ 6 mm screw 0.7—1 1 5—8 a. 6 mm flange bolt and nut 1.0—1.4 7—l0 9. 3 mm flange bolt and nut 2D—3.0 ”>22 10‘ 10 mm flange bolt and flu! 3.0—4.0 22-29 Dan: 09 Issue: Saplembar, 1977 0 HONDA MOTOR CO.. LTD‘ 1-5 GENERAL INFORMATION SPECIAL TOOLS /OOM MON TOOLS I SPECIAL TOOLS Tool Name Part No. Snap ring plilrs 07914—3230001 Hollow set Wrench (6 mm] 079174230000 Ball race driver — Bottom Steering Race' 07945—3330300 Ball race driver —- Top sleering Ham’ 07Bd$3290000 Bell race remover 07953—3330000 Valve guide reamer llN) 07954—2000000 Valve guide relmer lEXl 07934—61 10000 TORX driver bil lT-30) 077034010200 Piston ring compressor (21 . 07954—2830000 Piston base l2) mass—2500000 Tool case 07797—2920300 0 COMMON TOOLS Tool Name Part No. Aprvprlilion List (Common tool — Special tool) Float level gauge 07401—0010000 Lock nur wrendi socket (30 x 32 mm) 07716-0020400 Pin spanner 07702—0010000 Pin spanner 07902—240000!) Lock nut wrench sucker (26 x 29 mm) 07716—0020201 Extension bar 07716-0020500 Universal holder 07725—0010101 Flywheel holder 07823—0400000 Ruler puller 07733—0020000 Flywheel puller 07933-3959000 Valve guide remover (5.5 mm) (IN) 07742—0010100 Valve guide driver 07942—329010!) Valve guide remover (6.6 mm) (EX) 07742—001020!) Valve guide driver 07942—6110000 'Bearing driver outer (42 x 47 mm) 07745—0010300 'Beering driver 07945—3330100 Bearing driver pilol [15 mm] 07746—004030!) Bearing driver pilot [17 mm] 07746—0040400 ' 3 no drivar out-r l52 x 55 mm) mus—0010400 - Bearing driver {M‘s—37‘0”" Bearing driver pllol (20 mm) mus—0040500 “79‘5‘329°°°° Front lnrk oil seal driver body 07747—0010100 ‘ From lnrk oil sell ltliehmenl (D) 0770—0010500 } Fm “" “m" 079474330000 Bearing driver handle IA] 07749—0010000 Driver handle Illlchmenl 07949—611000!) Valve spring compressor 0775741010000 Valve spring compressor 07957—3290001 Rear shock absorber compressor 07959—3290001 «— The tools asterisked l') ire to he used with the HenleP/N 07749—0010000 or 07949—6110000 (also listed above). 1 6 Date 01 issue: September, 1977 ' G) HONDA MOTOR COO. LTDt bur ..z..:.. 5 u .8 u .r h... u a.“ u u 923:. : :3: . .. wln.v|~fis 35.2.5 6:8 8:2... 5:3 1!. .5. u.- .S 5 s5 .3 3 x: 5.935 3...... .eE...!.3.io.. .5. E. a :5 .. In . u.- .. .2 i i... . 55 .- 9335. : .9. E329. .. 3.... ii. 3!: 6.... I: 9.33:3 as. .3 .5. .3. fix..- 5.5 is. 3:5! 3:5 Q .......:E_ E... «I... E: 59. . 3:... :33. 33...! 3:51.55 3: a: a: a: :HB/ .- 53.1.5... 5.1.1:... 5.3.5.» _ . .350... _ . _ g! 5:. ,5... 8:2! 5...... .6 $2.33 5.1! 5 5.... :9. IE... inn :3. it: .3 8...... S. 55...... .5... $23 5.3.5. .5: . 5:... 3: end... .95 .52 a... El. h 5:... .5: a... .3. .51.... .8: Son .5. 3. x 5.... 0:0 Pa. 5:: .5 5.. :8 u E 538 £555: 25:; $83 .2: = 4 5:15. :59 :55." 5.! 3:59;? . _ w a :64 \ flwfl ,, V w = . . . . “Eggs. 3;“. .. .,. . ; ‘ an... E. .59 a m :59 In! a gun OIIO x... m: x... . oz 9. 01:0 5.. 2s:- ufis in 2:9. 538.9: A G I. E! < 4!! .3 a... is. s: E; /4 u a \ 362.1 5...»... u E . I L? .5: ”:6. M" n 9: a .5 . . r _ . .85: 950‘ mu. fix 5:3? 5:4": _ agi‘ rr :9. U; r- P.‘ II _ .. r. 3 vi . a v! . I u 5.3:! :3. 5:72:35: m .. .....§..? _ 62.5 is. 558.9. _, |.|v BUB-:HLS. .3 wl=nx Ind ham 4?. 4r» .0 n rill. 1.. ‘ h % .rmH can , 9.IO I2 . ‘ . .sznohub‘ H. 19!: 0:10 0.10 .. awn . I. v n 0 0'0. film 3:: . v E. a 7;. : HONDA CB4°°T GENERAL CABII AND HARNESS ROUTING TVPE-I HOOK Hoax CLUTCH CABLE BRAKE CABLE INFORMATION TH ROTTLE CABLE (OPEN) CHOKE CABLE MAIN WIRE HARNESS BRAKE CABLE Dita of Issue: February, 1979 @HONDA MOTOR 00., LTD. HONDA CB4OOT GENERAL INFORMATION TVPE—II CLUTCH CABLE BRAKE HOSE TH ROTTLE CABLE (CLOSE) THROTTLE CABLE (OPEN) TACHOMETER CABLE HOOK TH ROTTLE CAB LE CHOKE CABLE CLUTCH CABLE \ \ Dale 0' Issult Fthrnlrv. 1979 1 - 1 0 © HONDA MOYOR CO” LTD. é HONDA CB4OOT GENERAL IN FORMATION COUPLER (RED) Date of Issue: Fabvuarv, 1979 ' a HONDA MOTOR (20., LTD. 1 ' 1 1 GENERAL INFORMATION HONDA CB4OOT MAINTENANCE SCHEDIIE Perform the PfiE-RIDE INSPECTION in the Owner‘s Manual n every maintenance period. I: INSPECT, CLEAN, ADJUST‘ OR REPLACE IF NECESSARY. c: CLEAN R: REPLACE A: ADJUST FREDUENCY WHICH EVER Q ODOMETER READING [NOTE (2)] CW“ 3 . E e E E I 5 FIRST J, gg ‘E’ 5;; if §§* N’ Baler In ”W EVERV §:‘ 0% 4%" 5%; 3'0" 3% ENGINE DIL YEAR R REPLACE EVERv 1,900 mi (3,000 km) Page 2.2 ENGINE OIL FILTER VEAR R R R R R R Page 2-2 AIR CLEANER NOTE (1) c c c c C Pane 3-7 FUEL LINES I I 'l I I Page 3-7 SPARK PLUGS I R I R I Page 3-2 VALVE CLEARANCE I I I I I I Page as cAM CHAIN TENSION A A A A A A Page 3-3 THROTTLE OPERATION I I I I I I Page 34 CARSURETDRS IDLE SPEED I I I I I I Page 3-4 GARaURETORS CHOKE I I I I I Page SS CARBUR ETORSASYNCHRONIZE I I I I I I Page 3-5 aALANCER CHAIN TENSION A Page 3-7 DRIVE CHAIN NOTE Ia) INSPECT EVERV Goo mI (1.000 ml Page fix GATTE RY ELECTROLYTE MONTH I I I I I I Pege 3-14 BRAKE FLUID LEVEL MONTH I I I I I I PageSID BRAKE FLUID 2 YEARS R Page 14-2 BRAKE SHOE/PAD WEAR I I I I I Pege :IID BRAKE SYSTEM I I I I I I Page 31‘; BRAKE LIGHT SWITCH I I I I I I pm 342 HEADLIGHT AIM I I I I I I CLUTCH FREE PLAV I I I I I I Page 3.9 SIDE STAND I . I I I I Pege 3-13 SUSPENSION I I I I I I NUTS, aOLTs, FASTENERS I I I I I I WHEELS/SPOKES I I I I I I Pege 3.14 ' STEERING HEAD BEARING I I I NOTES: (I) Mare lvaquenl servlce mlv I": required when riding in dusty grease (2) For higher Odometer readings. repeat at Ihe Frequency inlerval established here (3) lnixial Service period: 200 miles. 1-12 One Of lame: September, 1977 © HONDA MOTOR CO., LTD. HONDA CB400'I' MEMO II(JIRII)IL CB4OOT LUBRICATION LUBRICATION DIAGRAM ~ ROCKER ARM I \ <—l—> 1 ROCKER ARM r ‘\ l 'l CAMSHAFT I FRdNT BALANCER . I ORIFICE OHIFICE OIL PRESSURE I SWITCH . ‘I CRANKSHAF REAR BALANCER ORIFICE l OIL FILTER 1332 OIL PUMP TRANSMISSION MAIN SHAFT II I W OIL STRAINER C0 UNTERSHAFT PRESSURE : : RELIEF VALVE l I Dalo of Issua: Samember, 1977 2' 0 © HONDA MOTOR ‘30.. LTD. HONDA CB4OOT 2. LUBRICATION SERVICE INFORMATION TROUBLESHOOTING ENGINE OIL LEVEL 2-1 ENGINE OIL & FILTER CHANGE 2—1 SWINGARM PIVOT 2—2 DRIVE CHAIN 2—-2 2—3 2—3 SERVICE INFllRMATIllII ' WORKING PRACTICE diluump: Oil lilter screen: I SPECIFICATION Refer to Section 8. Oil pressure reliel valve: Reler to Section 8. Reler to Section II]. Oil Capacity 10 liters (32 at.) It engine assembly, 2.5 liters (2.6 qr.) u oil change Oil HONDA 4-stroke oil or equivalent rated SE IOWA“) Oil Pump Delivery 11 t 1 IirersMDDO rpm TRIJIIBLESHNTIIIE Oil Level Too Low: 1. Normal ail consumption 2 External oil leaks 3. Worn piston rings Oil Contamination 1. Oil or filter not changed often enough 2. Faulty head gasket Low Oil Pressure 1. Faulty warning light switch 2. Pressure and valve stuck open 3. Plugged oil pick-up screen 4. Oil pump worn High Oil Pressure: 1‘ Pressure relief valve stuck closed 2. Plugged oil filter, gallery. or metering orifice 3 Incorrect oil being used Na Oil Pressure 1 Oil level too low 2. Oil pump drivi- chain broken 3. Faulty oil pump Date ol Issue: September, 1977 9 HONDA MOTOR COT, LTD. 2-1 LUBRICATION ENGINE BIL 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 alter 2—3 minutes. Do not screw in the can when making this check. ll the level is below the lower level mark on the disptick. fill to the upper level mark, *UPPER LEVEL MARK ENGINE llll & FILTER mun: Willi" “V“ NOTE Engine oil change is periormed with engine at normal Operating temperature and vehicle upright or on center stand to assure complete and rapid draining. Remove the oil filler cap after the engine is warm. Remove the drain plug and oil filter case to drain oil lrorn the engine. Operate the kick starlet several times to drain any oil which may be left in the recesses ol the engine. Check operation of the bypass valve in 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 ere in good condition Tighten the oil filter bolt securely. TIGHTENING TORQUE: 2.8—3.2 kg-m (20—23 lbs-ft) V OIL FILTER BOL‘I TORQUE: 2.5—1? kg-m (20—23 lbs-ll) h \ Reinstall the drain plug. TIGHTENING TORQUE 2.5—3.5 kfl-m (18—25 Ills-ft) OIL FILTER Fill the crankcase with the rewmmended oil. O'R‘NG SPRING OIL CAPACITY: APPROXIMATELY 2.5 liters (2.8 U.S.qt.l SPECIFIED OIL: HONDA 4-STROKE OIL OR AN EQUIVALENT Reinstall the oil filler cap. COVER Start the engine and allow to idle for a few minute: WASHER Stop the engine, make sure that oil level is at the upper level mark with the motorcycle upright, and there are no oil leekst 2 2 Date of Issue: September, 1977 - 9 HONDA MOTOR (30.. LTD. HONDA C 34007 LUBRICATION SWINGAIIM PIVOT Two lubrication points are located as shown Use multipurpose grease, Type NLGI No. 2. DRIVE CHAIN Commercially prepared drive chain lubricants should be used in prelerenoe to motor oil or other lubricants. Normally drive chain lubrication is performed without removing the chain, at the time of chain adjustment, Saturata each chain link ioint so that the lubricant penetrates bemeen the link plates, pins, bushings and rollers‘ When the drive drain becomes extremely dirtv, it should be removed and cleaned prior;- to lubrication. Carefully remove the master link retaining clip with pliers. Do not bend or twist the clip. Remove the master link. Retrieve the drive chain from the motorcycle, Clean the drive chain in solvent and allow to dry. Inspect the drive chain Ior possible wear or damage. Replace any chain that has damaged rollers, loose fitting links, or other wise appears unservioaable. Inspect the sprocket teeth for possible wear or damage, Replace il neoessarv. CAUTION Never install a new drive chain on badly worn sprockets or a badly worn chain on new sprockets Bath chain and sprokels must be in good condition, or the new replacement chain or sprockets will wear rapidly. Dateol Issue: September, 1977 © HONDA MOTOR CO.. LTD. Lubricete the drive chain. Pass the chain over the sprockets and Iain the ends of the chain with the master link. For ease of assembly. hold the chain ends against adlacent rear sprocket teeth while inserting the master link. Install the master link retaining clip m that the closed end of the clip will face the direc- tion of forward wheel rotation. The master link is the most critical part affecting the security oi the drive chain. Master links are reusable, if they remain in excellent condition, but it is recommended that a new master link be installed when~ ever the drive chain is reassembled. Adiust the drive chain to the proper tension. 0 MISCELLANEOUS LUBE POINTS Lubricate the central cables, levers, and pedal pivots. LUBRICATlDN HONDA C 34007 2-4 Date al Issue: September, 1977 © HONDA MOTOR CO” LTD. HONDA 3 INSPECTION AND CB4°°T - ADJUSTMENT AIR CLEANER MAINTENANCE 3—7 SPARK PLUG ADJUSTMENT 3—2 FUEL LINE INSPECTION 3-7 IGNITION TIMING INSPECTION 3—2 COMPRESSION TEST 3—8 VALVE CLEARANCE CLUTCH ADJUSTMENT 3-9 ADJUSTMENT 3-3 Spark plug gap. type: GIG—0.7 mm (OHM—0.028 inJ ND X24ES~U, NGK DBEA Ignition liming "F" mark: 15n BTDC n 1,200 rpm Full advance: 43° ETDC a! 44500—5350 rpm Valve clearance IN: 0.10 t 0.02 mm (0.004 t 0.0008 lrl.I EX: 0,14 2 0.02 mm (0.006 2 0.0008 in.) Thrunle free play: 2—6 mm (0.06—0.24 in.) Idle speed: 1.200 .t 100 rpm Synchronixauon vacuum: 200—240 rang Fast Idle speed: 2.500 t 500 rpm Compresslon: 13 t 1 kg/cm’ (185 t 14 psi) Clutch lree play: 10—20 mm (3/8—3/4 in.) I TORQUE VALUES Balanur adjuster mu (3 mm]: 2.0—2.5 kg-m “5—“! 1mm Balanur Divot nul (10 mm): 3.0-215 kg-m (22-25 lbs~fll From axle nut: 5.0—8.0 kym (36—58 lbs-It) Front axle holder nut: 1.8—2.5 kg~m (13—18lbs-m Rear axle nul:7.0—10.0 kg-m (51—72 I054!) Spoke nipples: 0.2—0.5 kg-m [1.4—2.5 lbs-ll) From brake [drum] fr“ play: 20—30 mm l3/4—l-1l4 in.) Rear brake lree play: 20—30 mm (3/4—1-1/4in1) ‘ Drive chain play: 20 mm (3/4 in.) Tire pressures: Up to 90 kg (2001bsl load From 1.75 kg/cm’ (24 p5.) Rut 2.25 kg/cm’ 132 psi) Up [0 vahiclil capacity luad From 1.75 kg/cm‘ 124 psi) filar 2.5 kg/cn‘l2 (36 psi) Date al Issue: Seplember. 1977 © HONDA MOTOR CO., LTD. 3-1 HONDA. CB400‘I' INSPECTION AND ADJUSTMENT (ENGINE) SPARK PLUGS Disconnect the spark plug caps and remove the spark plugs, Visually inspect the spark plug electrodes lor wear. The center electrode should have square edges and the side electrodes should have a l constant thickness. Discard thu spark plug it there is apparent wear or ii the insulator is check :qap cracked or chipped. II the spark plug deposits 0-5-0] mrn_ / : deposit can be removed by sandblasting, the spark (04024—0.023in4l— :dirt plug can be reused. - :wear Adiust the spark plug gap by bending the side electrode. SPARK PLUG GAP: 0.6—0.7 mm (0024—0323 in.) RECOMMENDED SPARK PLUG: NGK DBEA Check :sealing ND X24ES% HONDA FRONT WHEEL/BRAKE/SUSPENSION E}; (234001 INSTRUMENTS 0 CLUSTER DISASSEMBLY / ‘ ’ fl...) “will”, Separate the Instvument cluster by removing - TI! ‘0‘ 5 I {”4” A e | the low screws. Remove [he instrument set plate by removing the two bolts. 0 INDICATOR LAMP/COMBINA- TION SWITCH REPLACEMENT After installing a new bulb, chedr lot now tinutv. If the bulb does not light, inspect the wiring for open or shun circuits. The ignition switch wire is connected to the wiring harness inside the headlight use. I METER LAMP/METER REPLACEMENT To replace a motor lamp or motor, it is neces- serv to separate the cluster. Rem the sat plate and cable Check the meter able ii the needle swings abnormally. 1 2 4 . Date ni Issue: September, 1977 ' © HONDA MOTOR 00., LTD. HONDA C34°°T FRONT WHEEL/BRAKEISUSPENSION HANDLEBAR o HANDLEBAH REMOVAL Disconnect the iront brake stoplight switch wires and remove the master cylinder. NOTE Do not loosen the brake hose unless "BWSSHYY. Loosen the two screws attaching the throttle grip switch housing. Remove the two screws holding the left grip switch housing. Remove the tour switch wire bands. Remove the handlebar upper holders and take out the handlebar with the throttle grip and switch housing. a HANDLEBAR INSTALLATION Coat the throttle grip area oi handlebar with clean grease. Position the handlebar on the lower holders with the punch marks on the handlebar in line with the top at the holders. Pllce the upper holders on the handlebar with the punch marks lacing the front. Align the punch mlrks an the handlebar with the split in the switch housings. Tighten the lorward bolts lirst, 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 is parallel to the upper level line inside the reservoir. Connect the front brake stoplight switch wires. Install the lam switch wire bands on the handlebar. NOTE Bleed the brake system if the hose was disconnected. Date oi Issue: September, 1977 © HONDA MOTOR CO, LTD. FRONT WHEEL/BRAKE/SUSPENSION FRONT WHEEL REMOVAL/ DISASSEMBLY/ ASSEMBLY o FRONT WHEEL REMOVAL Raise the front wheel off the ground by placing a block or safety stand under the engine. Disconnect the speedometer cable lrom the speedometer gearbox. Disconnect the hunt brake uhlel (Drum type onlvl Remove the front brake torque linki (Drum type only). Remove the cotter pin and loosen Ihe axle nul. Remove the axle holder from the fork and. Withdraw the axle and remove the wheel. NOTE Du not open!» the front brake lover after removing the front wheel. To do so will cause difficulty in lining the brake disc between the brake pods. 12-6 Date of Issue: September, 1977 ® HONDA MOTOR CO., LTD HON DA C 3400‘! e AXLE INSPECTION Set the axle in V blacks and measure me runoul. The actual runoul is 1/2 al TIR (“Total Indicator Reading). 0 WHEEL BEARING INSPECTION Chuck (he whul heaving play by placing the wheel in a (wing stand Ind spinning the wheel by hand, Replace lhe hearings with new ones if they lfl noisy or have excessive play. 0 WHEEL INSPECTION Chuck the rim runoul by placing the wheel in a (ruins stand. Than spin the wheel by hand, and read me mnoul using a dial indicamr. N TE The COMSTAR WHEEL cunnot be rep-Wed and must be replaced wlth a new one if lhe service limits are ex- needed. FRONT WHEE L/BRAKE/SUSPENSION SERVICE LIMIT: 0.2 mm (0.008 in.) PLAV SERVICE LIMITS: RADIAL RUNOUT:2.0 mm (0.08 in.) AXIAL RUNOUT: 2.0 mm (0.98 in.) , .\ Dale 0! Issue: September, 1977 © HONDA MOTOR CO., LTD. 12-7 HONDA FRONT WHEEL/BRAKE/SUSPENSION CB4OOT 0 WHEEL DISASSEMBLY Ali-6.5 kg-m (33-47 lbs-ft] Dm of Issul: September. 1977 1 3' O G) HONDA MOTOR 60., LTD. HONDA. CB400'I' 13 REAR WHEEL/BRAKE/ SUSPENSION SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL REMOVAL] DISASSEMBLY/ASSEMBLY FINAL DRIVEN SPROCKET REAR BRAKE PANEL REAR WHEEL INSTALLATION SHOCK ABSORBER SWINGARM BRAKE PEDAL 14—1 14—2 14—4 14—6 14-7 14—8 14—10 14—11 14—12 SERVICE INFORMATION 0 WORKING PRACTICE Du nm remove me rivets, nuts and pins ham "1: rim, spoke plan-s and hub, since they cannot he disassembled, Do not ride on the vim or try [0 bend [he wheel‘ Handle wilh care since the rim is made 0! aluminum alloy. 0 SPECIAL TOOLS Common Tools BEARING DRIVER HANDLE (AI BEARING DRIVER OUTER (42 x 47 run” BEARING DRIVER OUTER I52 x 55 mm] BEARING DRIVER PILOT 120 mm) BEARING DRIVER PILOT (17 mm) REAR CUSHION COMPRESSOR 0774943010000 0774641010300 07746-0010400 07746—0040500 07746—0040400 07959—3290001 Dal: oi Issue: Seplember, 1977 © HONDA MOTOR 60.. LTD, 13-1 R EAR WH EEL/BRAKEISUSPENSION - SPECIFICATIONS HONDA C 34001 STANDARD SERVICE LIMIT Axle bend 0.2 mm(0.008in.l ——A d W V ”7 Radial 2.0 mm (0.08 in.) Rear wheel rumul Axial 2.0 mm (0.03 in.) Final ngEn sprucke‘F—LBZ—“fi 65.00~ 65.09 mm (2.560~2.563 in.) 65.16 mm (0.565 in.l finr wheel huh 0.0:E— 64.94~ 64.97 mm (2.557~2.568 in.) 64.87 mm (2.554 in.) Brake lining thickness 4.9 ~ 5.0 mm (0.19 ~0.20 in.) 2.0 min (0.08 in.) Rear brake drum |.D. 140.0 ~14IJ.3 mm (5.51 ~55? in.) 141.0 mm (5.55 inJ Rear cushion spring free lenglh 208.3 mm (8.20 in.) 198.0 mm (7.50 in.) TRIIIBLESHOIITING Wobble or Vibrarian in Motorcycle I. Dlslnrred rim 2. Lease wheel hen-n9 3. Loose or disloued swkes 4, Faulty live 5. Loose axle SoIl Suspension I. Weak spring . 2. Shock absorbers improperly adjusted 3. Week rear damper Hard Suspensian l, Shock “isomers impcrperly adiusted Suspension Noise 1. Shock case binding 2. Loose fasteners Poor Brake Perinrmanne lmprnper brake ediuumenr Fouled brake linings Worn brake shoes Worn bake shun cam consuming laces Worn brake drum Improper engagement belween imke arm and shah serrations 99:59.”? 13-2 Dale of Issue: September, 1977 © HONDA MOTOR CO., LTD. HONDA CB4°°T REAR WHEEL/BRAKEISUSPENSION REAR WIIEEI. IIEMUVAL/ DISASSEMBlY/A SSEMBLY o REAR WHEEL REMOVAL Support the motorcycle on the main stand or - a stand placed under the engine. Disconnect the brake rod. Pry off the cutter pin and separate the brake Iorque link. Loosen the drive chain adjusting baits. Remove the cutter pin and loosen the axle nut. Remove the drive chain retaining clip. Withdraw the axle and remove the rear wheel. O AXLE SHAFT BEND INSPECTION SERVICE LIMIT: Set the axle in V blocks and read the axle 0'2 nun “1‘00st bend. The actual axle bend is 1/2 at TIR. (total indicator readingi. I REAR WHEEL BEARING PLAY INSPECTION Check the wheel bearing piay’bv rotating the wheel by hand. Replace the bebrings with new ones if they are noisy or have excessive play. , - REAR WHEEL RIM HUNOUT INSPECTION RADIAL AXIAL Check the rim for runuut by placing the wheel SERVICE LIMITS: in a truing stand. Spin the wheel by hand‘ RADIAL RUNOUT:2.0 mm l0.03in.l and read the when: using a dial lfldICaID' gauge, OTE The COMSTAR WHEEL cannot be serviced and must be replaced if the above limits are exceeded. Date oi Issue: September. 1977 © HONDA MOTOR cot, LTD. 1 3' 3 HONDA. REAR WHEEL/BRAKE/SUSPENSION (234001“ BEARING DRIVER HANDLE IAI BEARING DRIVER PILOT (20 mm) o HEAR WHEEL DISASSEMBLY (TYPE-I) FIXING BOLTS LR Remnva me right bearing first. DISTANCE BALANCE WEIGHT_ COLLAR CIRCLIP :1 I . . \ .r.’ A / FWD ALIGN BALANCE MARK WITH TIRE VALVE BEARING DRIVER HANDLE IA) DISTANCE FIXING BOLT COLLAR Ramon 1h: right bearing first. DAMPER COVER FINAL DRIVEN BALANCE WEIGHT SPRDCKET ° 1 o 00@ Apply adhesiva during DUST C/O‘VER innallnion DAMPER COLLAR DAMPER RUBBER NOTE The CDMSTAR WHEEL has no rim bind. ‘ BEARING DRIVER HANDLE IA) . REAR WHEEL ASSEMBLY BEARING DRIVER OUTER (42 x 47 mm): RIGHT BEARING DRIVER PILOY (17 mm) SIDE Pack all bearing nvitias with grease. Puss the dinanee collar lnlo place from "I: left side. Drive the right ball burinn firsl. Drive the left bl“ bearing last. CAUTION Drive m. blaring: squanly, BEARING DRIVER OUTER (52 X 55 MW Install the bearings with th: salad and B9‘ka DRIVER I'll-OT I20 rnmI (Icing out. Data of Issuu: Sepxember, 1977 1 3" 4 0 HONDA MOTOR CO. LTD HONDA. C34°°T REAR WHEEL/BRAKE/SUSPENSION FINAL DRIVEN srnocxn ‘c°”?-T-f‘f‘-~V!'15‘L°"”’ can 0 FINAL DRIVEN SPROCKET (COMSTAR WHEEL ONLYI Remove the dust cover. Pry of! the snap tinge NOTE Install the snap ring and dust mver Draperly during assembly‘ Coat the inside diameter at the sprocket hunting with grease. NOTE Make certain that the fixing bolts are seated snugly on the sprocket. 1 FINAL DRIVEN SPROCKET INSPECTION Measure the linaldriven sprocket l.D.. SERVICE LIMIT: 65.15 mm (15$an Check the condition of the final driven sprocket teeth. Replace the sprocket il worn or distorted. NOTE The drive chain and drive sprocket must also be inspected if the driven sprncket is worn or distorted O REAR WHEEL HUB INSPECTION Measure the rear wheel hub 0.0. on the I!“ side. SERVICE LIMIT: 64.87 mm (2.554 in.) O DAMPER RUBBER INSPECTION Replace the damper rubbers iI they are damaned or deteriorated. NOTE Note the damper collar location. Date 0! Issue: September, l977 © HONDA MOTOR C0.. LTD. REAR REAR BRAKE PANEL 0 REAR BRAKE LINING THICKNESS Maasuve the rear blaka lining thickness. WH EE L/BRAKE/SUSPENSION HONDA. C 34001 SERVICE LIMIT: 2.0 mm (0.08 in.) O REAR BRAKE SHOE REPLACEMENT Pry on the cutter pin. Inslall naw brake shoes‘ Apply grease to the fat: 0' the brake cam. m— Contaminaled brake linings reduu stopping pawn. Keep grass! off the hrako linings Wipe [he excess grease oil the cam. NOTE Make sure the me punch mark on ma brake arm aligns with [he punch mark an the shoe. GREASE GREASE o BRAKE DRUM |.D. INSPECTION Measure the brake drum LD‘. 13-6 Dale of Issue: September, 1977 © HONDA MOTOR CU. LTD, HONDA CB4OOT REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL INSTALLATIIIN Insert the axle through the wheel hub. NOTE Install the long axle collar on the right side. lnstalI the brake torque link. Connect the brake rod. install the drive main retaining clip. NOTE Note the retaining clip direction. Adjust the drive chain tension. CHAIN SLACK: 10~20 mm (0.4%.8 in.) NOTE Rotate the adjusters so that the index marks are aligned with the same scale number on both sides. Torque the axle nut, and install ('1! wmr pin. Spread the ends of the cutter pin. TORQUE SPECIFICATION: B.0~10.0 Ito-m (SS-72 "154!) Lubricate the drive chain with engine oil at grease. Date 0! Issue: September, 1977 © HONDA MOTOR CO" LTD. 1 3 " 7 HONDA. C 3400‘! REAR WH E E LIBRAKE/SUSPENSION SHOCK ABSORBER uSHOCK ABSORBER REMOVAL To remove the left shock absorber, remove the chain cover. Remove the upper bolt first, then remove the lower bnlt. NOTE Belore removing the shock absorbers rotate the adjuster to the weakest position, 0 SHOCK ABSORBER DISASSEMBLY _ Using a hacksaw blade, cut a groove in the head or the damper bolt to receive thl flat end 01 e screwdriver as shown. NOT E Remove burrs thoroughly. Remove the lock nut. Screw in the rod by applying a screwdriver to the groove in the rod end. NOTE Do not damage the upper joint threads with the end of the screwdriver‘ SPRING UNDER SEAT SPRING ADJUSTER 0‘/ LOCK NUT 9 [gal UPPER JOINT REAR DAMPER SHOCK ABSORBER COMPRESSOR 1 3 8 Date 0! Issue: September, 1977 - @ HONDA MOTOR C0,, LTD. REAR WHEEL/BHAKE/SUSPENSION o SHOCK ABSORBER SPRING FREE LENGTH "_ “““ SERVICE LIMIT: 19m mm(7.801nJ W A» I SHOCK ABSORBER ASSEMBLY When the damper is to be replaced with a SERVICE UMIY: 198.0 mm (7.80 In.) new one, it is necessary to cut a slot in the top and of the rod. NOTE Avoid damaging the rod threads. Enend the rod fully so [hit the stopper rubber is at the bottom of the rod, Compress the spring until the slatted end at STOPPER RUBBER the rod mntacts the upper joint. Applying the end of a screwdriver to the rod UPPER JOlNT slot, turn the rod into the upper joint iullv. Install the lock nut on the end at the rod and tighten securely. NOTE Replace the lock nut it it is crass threaded. iii JUL / SHOCK ABSORBER COMPRESSOR C SHOCK ABSORBER INSTALLATION Torque the bolts. TORQUE SPECIFICATION: 3.0—4.0 kn~rn (22-29 lbs-ft) Adjust the cushion springs with the spring 't SPH ING ADJUSTER adjuster. I Ii Ill lV V STANDARD: ll Data 0! Issue: September. 197] Q HONDA MOTOR (30., LTD. 1 3' 9 HON DA C B4OOT HEAR WHEEL/BRAKE/SUSPENSION SWING ARM I REMOVAL Remove the rear wheel. Remove the right and la" shack Ibsorbers. Withdraw the rear lurk pivot boll. o SWINGARM DISASSEMBLY/ ASSEMBLY NOTE Drive the bushings imn plane thraugh a pad making sure lhal they are not damaged Lubricale with grease after installation. ‘ :e’ _ ,@ figs?- 0 SWINGARM INSTALLATION Torque (he swingarm pivot bolt. TORQUE SPECIFICATION: 5.5—7‘0 kg-m (40—51 lbs-"I Install [he shock absorbers. Install the rear wheel, 1 3- 1 0 Dale 0' lssuc:Seplemher. 1977 © HONDA MOTOR Col, LTD. HON DA C 3400‘! REAR WHEEL/BRAKEISUSPENSION REAR BRAKE PEDAL a REAR BRAKE PEDAL HEIGHT Adjust the pedal height so that the distance betwnn the pedal and upper Inc: a! the lootpeg is 10 mm. Turning th: adjusting halt until the correct pedal height is obtained‘ NOTE Alter adiusting lhl pedal Might, adjust the pad-l Iran play and stoplight switch. D BRAKE PEDAL REMOVAL/ INSTALLATION Disconner. the brak: rod and loosen the brake pedal bolt. Ramona KM buka return spring. NOTE Note the Iacatton of the stoplight switch spring. Date 0' Issue: Septamber, 1977 © HONDA MOTOR CO» LTD. 1 3' 1 1 HONDA. HYDRAULIC DISC BRAKE ‘ CB400'I’ 3.0—4.0 kg-m (22—29 lbs-fl) Dam of lssul: Seplember. 1977 1 4' o Q HONDA MOTOR 60., LTD. HONDA 1 4 HYDRAULIC “4°07 DISC BRAKE SERVICE INFORMATION 14-1 TROUBLESHOOTING 14-1 BRAKE FLUID REPLACEMENT/ AIR BLEEDING 14.2 BRAKE PADS/DISC PLATE 14-3 BRAKE MASTER CYLINDER 14—6 BRAKE CALIPER 14—8 SERVICE INFIIIIMATIOII I SPECIAL TOOL SNAP RING PLIERS 07914-3230001 o SPECIFICATIONS STANDARDS SERVICE LIMIT Disc lhinknass 4.94.1 mm (0.194120 in.) 4.0 mm [0.16 in) Disc rumu! —— 0.3 mm (001210.) Masler cylinder LD, M.000~14.043 mm (05512-415529 in.) 140.55 mm (0.5533 in.) Master piston 0D. 13.957~13.984 mm (0.5495~05506 in.) 13.940 mm (0.5488 in.) "JIIMr pislon OD. 38.115~ZB.180 mm115006~15031 in.) 33.105 mm 11.50021") Caliper cylinder |.D. 33.18%33200 mm lI.5031-1,5039 in.) 38.215 mm (1.5045 in.) Four Brake Performance - Air bubbles in hydraulic svsrum — Worn brak: p-ds — Pads louled or glazed - Hydraulic svslem leaking Dale of Issue: Septemhln 1977 1 4 1 © HONDA MOTOR 00.. LTD. HONDA HVDRAULlc Disc BRAKE (234001“ BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the fluid level with the fluid reservoir parallel with the ground. DIAPHRAGM BRAKE FLUID RESERVOIR CAUTION Install the diaphragm on the 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 sur- laoes. Place a reg over the fuel tank whenever the system is serviced. I BRAKE FLUID DRAINING Loosen the aliper bleeder valve and pump the brake lever. Stop operating the lever when no fluid flows out af the bleeder valve. 0 BRAKE FLUID FILLING CAU‘HON ' BLEEDER VALVE Do not mix different brands of fluid since they are not compatible BRAKE FLUID DOT 3 Clnsa the bleeder valve, fill the reservoiry and install the diaphragm. To prevent piston cvertravel 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 at the reservoir small hole [until lever resistance is felt)- a AIR BLEEDING NOTE check the fluid level often while bleed ing 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 blender valve about 1/2 turn, and retighten. NOTE Du not release the lever until the bleeder valve has been closed. Release the lever gradually and wait several seconds eftar It reaches the end of its 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. Check the entire system for leaks by operating the lever. A mnmrrine ted brake disc or pod: reduces stopping power. Replace mnraminated pads, and clean a contaminated disc with agoodquellty determine agent. Date of Issue: September. 1977 1 4- 2 © HONDA MOTOR CO" LTD. HONDA CB4OOT HYDRAULIC DISC BRAKE BRAKE PADS/DISC PLATE 0 BRAKE PAD WEAR CHECK The front brake pads require replacement if the led line an the top of the pads rushes the edges of the brake disc. 0 BRAKE PAD REPLACEMENT Remove the wiper cover. Pull off the clip. Push the caliper toward the right Ind push the piston all (M way in to Illow Installation of new bake pads. Data at Issue: Szptamhev, 1977 © HONDA MOTOR 60.. LTD. HONDA CB4OOT HYDRAULIC DISC BRAKE Ramon the pin win: I pair 0' pliers. Install the new brake pads and th: shim on the plsion side pad. Insert the pin with the pin hole lacing am as shnwn. 1 4 Dale of Issue: Saplember, 1977 - 4 © HONDA MOTOR co.. LTD. HONDA CB4°°T HYDRAULIC DISC BRAKE lnsen the clip into place In the pin hola‘ Install (ha calipev cover. o DISC THICKNESS Measure the disc mickness, o BRAKE DISC WARPAGE Measura the brake disc warplge. Dale of Issue: September, 1977 Q HONDA MOTOR CO., LTD. 1 4' 5 HONDA C B400'I' HYDRAULIC DISC BRAKE BRAKE MASER CYLINDER 0 MASTER CYLINDER DISASSEMBLY Drain brake fluid from [he hydraulic svslem. Remove (he brake lever from the master cylinder. Disconnem the brake hnsa. CAUTION Avoid spilling brake Iluid on painted surIacesl Place a rag over the fuel rank whenever the brake system is serviced. Remove the mane! cvlinden Remove the snap ring. SNAP RING PLIERS 07914—3230001 0 MASTER CYLINDER |.D, INSPECTION Measure the master cylinder LD" Check the masler cylinder for scores, scrub Chas, nicks or other defects. SERVICE LIMIT: 14.055 mm (05533 in.) 1 4 6 Dale a! Issue: September, 1977 ' ® HONDA MOTOR CO., LTD, HONDA CB4°°T HVDRAULIC DISC BRAKE 0 MASTER PISTON O.D4 INSPECTION Measure the master pIsIon 0.0.. SERVICE LIMIT: 13.940 mm (0.5488 inJ 0 MASTER CVLINDER ASSEMBLY CAUTION Handle the muster cylinder piston, cylinder and spring as a set. DIAPHRAGM MASTER PISTON SILICON GREASE OR BRAKE FLUID DOT-3 FRONT BRAKE Dip the piston mm in brake fluid or Doll with STOFLIGHT SWITCH silicon grease before ammbly. Insnll the maswr cylinder on the handlebar. Connecx the bake hose and install the brake lever, Bleed the from brake system, Dale oI Issue: September, 1977 © HONDA MOTOR CO. LTD. 1 4' 7 HONDA CB4001’ HYDRAU LlC DISC BRAKE BRAKE CALIPER C CALIPER A REMOVAL Drain the brake hydraulic system. Disconnect the brake hose. Remove the inspection cover. NOTE Avoid spilling brake liuid on painted surlaoes. To remove caliper A, loosen the two caliper shells gradually ln several steps while pressing them against the caliper. e BRAKE CALIPEFl A DISASSEMBLY Place a shop towel or rag over the piston to prevent the piston lrom coming out, and position the caliper With the piston down Apply a small amount ol air pressure to Ihe llutd inlel, Do not use high pressure air or bring the nozzle too name to the inleL Examine the piston and cylinder lD' scoring, scratches or other delects and replace il necessary. Lift out lhl nil seal by lirst pushing it into the cylinder as shown‘ Clean the caliper grooves with brake fluid. 0 CALIPER A ASSEMBLY The oil seal must be replaced with a new one whenever disassemblldt Coat the oil seal with silicon grease or brake fluid before assembly, Install the caliper A with the dished end ol the piston on the brake pad side. 1 4 8 Date of Issue: Septenbcr, 1977 ' © HONDA MOTOR C04, LTD. HONDA CB4OOT HYDRAULIC Disc BRAKE o CALIPER PISTON 0.0. Check the piston for scoring, scratches or other detects. Measure the piston diameter with a micrometert SERVICE L|MIT: 38.105 mm (15002 in.) o CALIPER CLYINDER |.D, Check the caliper cylinder for scoring, scratches or other defects. Measure the inside diameter of the caliper cylinder bore. - SERVICE LIMIT: 38.215 mm (1.5045 in.) O CALIPER CARRIER/CARRIER B 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 bootst e CALIPER CARRIER/CAMPER B ASSEMBLY Wash all the removed pars. Coat the O-rings with silicon grease or brake fluid and install into place in the shaft center grooves. NOTE Replace the O‘rings with new ones whenever disassembled. Replace the boats with new ones it damaged. Install the boots on the carrier. Date cl Issue: September, 1977 © HONDA MOTOR CO., LTD, 1 4' 9 HONDA. C B40 0 'I' HYDRAULIC DISC BRAKE Assemble caliper B Ind caliper carrier loge- ther, making sure (has ma bum is salad in [he caliper shah groove properlyl Install the carrier on the from fork. TORQUE SPECIFICATION: 3.04.0 kg-m I22~23 lbs-fl] CALIPER COVER fie CALIPER SHAFT SHIM PIN CLIP RING PISTON BOOT OIL SEAL BLEEDER VALVE © CALI PER PISTON CALI PER E RETAINING PIN SILICDN GREASE SHAFT BOOT SILICON GREASE OR BRAKE FULID DOT-3 CALIPER CARRIER 0 CALIPER A INSTALLATION Tighten (he caliper shafts evenly while push- ing them against wiper 8. NOTE Tighten the shafts rarelully, noting the mating faces of calipers A and B. Connect thu brake hose. Install the inspection covers Bleed file brake svstam. 1 4 1 0 Date of Issue: September. 1977 - © HONDA MOTOR CO” LTD. BATTERY ‘13:? I5. cHARGINE SYSTEM SERVICE INFORMATION 15—1 TROUBLESHOOTING 15—2 BATTERY 15—3 CHARGING SYSTEM 15—5 A.C. GENERATOR REMOVAL/ INSTALLATION 15—5 SERVICE INFORMATION I WORKING PRACTICE Emery acid level should be checked regularly and filled with disfillad water when nnoessary. When charging rho bartary, quick-charging should only be done In an emergency; slow-charging is preferred. Remove The burery from the motorcycla for charging whenever possible. If hmarv must be charged on the motorcycle, discount! 1h: barrery cables, . Kaep fire or sparks away from a charging battery because it produce: hydrogen. All charging svstem components can be mm! on The mororcycle. I SPECIFICATIONS Capacity 12V, 12 amoerahnurs (TYPE 1 : 12V, 9 nmperwhours) Emery Specific grlvilv TYPE n: 128, TYPE I: T.27/20°c (68°F) Charging rate 1.2 ampere; mlximum (0.9 ampere; maximum) Ac generator Capacity NIGHT: 5 amperes minimum/5,000 rpm (14.5 volts) Voltage regulator Transistorizud nomadiusublo regulltor Date oI Issue: September. 1977 ©HONDA MOTOR CO” LTD. 1 5' 1 l I YELLOW AC. GENERATOR TROUBLESHOOTING No Power — Key Turned On: I. Deed battery —Battey not charged —Battery electrolyte evaporated —Battery run down —Charging system lailure 2. Disconnected battery cable 3. Main luse burned out 4. Faulty ignition switch Low Power — Key Turned On: 17 Week battery —Low battery elecuolyte level —Blttery run down —Charging system leilure 2, Loose battery connection Low Power — Engine Running: 1. Battery undercnerged —Low battery electrolyte level —0ne or more dead cells 2. Charging syflem lailure BATTERY/CHARGING SYSTEM RED/WHITE HONDA Cid-001' l u: b: EFUSE 15A _ >' —K _ ll] .. _ l- _( _ m MAIN SWITCH BLACK REGULATOR/RECTIFlER Intermittent Power: 1. Loose battery connection 2, Loose charging system connection 3. Loose starting system connection 4 Loose connection or short circuut in ignition system 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 recti er 4. Faulty AC generator 5-“ 15-2 Date of Issue: September, WW 6 HONDA MOTOR CO.” LTD. HONDA CB4OOT BATTEHV/CHARGING SVSTEM BATTERY e REMOVAL Diswnnect the ground cable at the trame, Remove the battery strap. Disconnect the positive (H cable at the battery, Remove the battery. o TESTING SPECIFIC GRAVITY Test each cell by drawmg eleclrulvle rnro Ihe hvdramater. SPECIFIC GRAVITY [20°C. 68"” TYPE I TVPE l| HVDROMETER 1.26—1.28 1.27429 Fullvchargcd L 125 1.25 Underchargcd NOTE The battery mus! be recharged if the specific gravity is below 1.23 (TYPE I : 1.22). The specific gravity varies with the temperature as shawn in the accom» ‘ partying table. Replace the battery il sultation Is I. 29 evident. The battery must be replaced it there are pastes settled on the bottom of each cell. The battery remains sill/uric acid. Amid contact with skin. syn. DI elm/tiny. Antidote: Flush with water and get pmmpt medial attmtiarr. SPECIFIC GRAVITY .25 ——-- TYPE I — TYPE ll r r l I r l r 1 0' 5' I0~ 15' 20' 25' 30' 35' ‘0' ELECTROLYTE TEMPERATURE 5mm: gravily chinges by 0.007 tor every 10°C Date oi Issue: September‘ 1977 © HONDA MOTOR C0., LTD. 1 5' 3 BATTERY/CHARGING SYSTEM HONDA CB400‘I’ o BATTERY CHARGING Hookup instructinn: Connect the charger positive (+l cable to the battery pnsitive I+I terminal. Connect the charger negative (—I able to the battery negative i—I terminal. Charging current: L2 ampere: maximum (TYPE I 20.9 lmmres maximum) Charging: Charge the battery until specific gravity is 1.27~1.29 at 20'C (68°F) (TYPE I: 1.26—1.28) ' Before charging a battery, remove the cap from each cell. - Keep fire and sparks away [mm a charging battery. - Turn power ON/DFF at the allergen not at the battery terminus. - Discontinue charging if thee/ectrnlyte temperature exceed: 45°C (117W. CAUTION Quickscharging shuuld only be dune in an emergency; slowdrarging is prelerred. After installing the battery, coat the terminals with clean grease. CAUTION Route the breather tube as shown an the battery caution label. BHAREIIIG SYSTEM 0 CHARGING OUTPUT TEST Warm un the engine belore liking readings. Disconnect the regulator/rectifier black wire. Connect a voltmeter and an altimeter to check charging system output. NOTE Use a Iully charged battery to check the charging system output. TECHNICAL DATA: CAUTION BATTERY BREATHER TUBE CARBURETCIR OVERFLOW TUEE CATCH TANK DRAIN TUBE MAIN SWITCH LIGHTING SWITCH CHARGING RPM 5,000 rpm ON ON (High beam) 1,200 rpm 5 amperes minimum/14.5 volts) 15-4 Data M Issue: September, 1971 © HONDA MOTOR (20., LTD. HONDA. CB4°°T BATTERY/CHARGING SYSTEM I STATOR COIL CONTINUITY TEST NOTE It is not necessary to remove the statur to make this test. Check the yellow lands to 1'1! AC generamr stator for continuity with each other. Replace . the stator El my yellow lead is not continuous BROWN with the others. or il any lead has continuity ‘ lo ground, LIGHT BLUE . /_ PINK /' WHITE BLUE GREEN fin YE LLOW e VOLTAGE REGULATOR/ RECTIFIER TEST Check the resistances helmen the leads with an nhmmeler. Do not use a high voltge source such as insulation resistance raster since it may damage the rectifier and yive you a shock. RESISTANCES IN NORMAL DIRECTION GREEN LEAD AND ANY YELLOW LEAD: 540 Q RED/WHITE LEAD AND ANY YELLOW LEAD: 540 n RESISTANCES IN REVERSE DIRECTION RED/WHITE LEAD AND ANV VELLOW LEAD: 20009 minimum GREEN LEAD AND ANY YELLOW LEAD: 200m minimum NORMAL DIRECTION §_> YELLOW YELLOW RED/WHITE YELLOW GREEN <_§ REVERSE DIRECTION Date at Issue: Sentember, 1977 QHONDA MOTOR C0,, LTD 1 5' 5 BATTERY/CHARGING SVSTEM I VOLTAGE REGULATOR PERFORMANCE TEST n, Tasting with a voltmeter cannent a voltmeter Icross the battery. Check regulator perfarmanue with the engine running. Regulator must divert current to around when battery voltage reaches 14.0~15.0 V. b. Testing with a variable resistor Connect a variable resistor (0-100m across the battery with a son resistor in between. Test lamp must come on when voltage roads M to 15 V on the voltmeter by HONDA. C 34001 VELLOW YELLOW VELLOW GREEN BLACK REGU LATCH/RECTIFIER TWO FULLY CHARGEDT 12V BATTERIES I adjusting the variable resistor. VARIABLE RESISTOR CONNECTED IN same: GREEN RED/WHITE A. B. IENEIIATIIR REMOVAL/ INSTALLATIIIII Far removal and see Section 9. installation proudure, {r-—-|.l 12V BATTERIES B 15-6 Date 0! mus: September. 1377 © HONDA MOTOR (20.. LTD. 1:333“ IE. IGNITION SYSTEM SERVICE INFORMATION 16—1 TROUBLESHOOTING 16—2 SPARK PLUG 16—3 IGNITION COIL 15—3 C.D.|. UNIT 16-4 A.C. GENERATOR 16—4 SERVICE INFORMATION 0 WORKING PRACTICE Ignition timing cannot ha adIusted since the C.D.|. ICapacitiva Discharge Ignition) unit is nomadiusubia. If ignition timing is incorrect, check the CL“. unit and AC generator and raplac: any daizctive part. 0 SPECIFICATIONS Spark plug ND XZQES-U NGK DSEA Spavk plug can DIM] mm (0.024~o.oza in.) Ignition timing Initial 15° Full adv-nae 43° Engine spend (initial) I,600~2,000 rpm Engine speed (lull advanu) a.soo~5,3so rpm Ignition coil 3-point spark test 6 mm (0.24 in! minimum S‘iafléi"ibs€$;"c"&ff$37 1 6- 1 IGNITION SYSTEM HONDA C 340 O 'I' TROUBLESHOOTING Engine Cranks but Will Not Start: — Engine stop switch OFF — No spark at plugs — Defective CD.L unit — AC generator faulty No Spark at Plugs — Engine stop switch DFF — Poorly connectedl broken or shorted wires Between AC generator and ignition coil Between C.D.l, unit and engine stop switch Between C.D.IV unit and ignition coil Between ctD.|. unit and ignition switch ‘ Between ignition coil and plug — Delectiv — Defective ignition coil — C.D,I. unit faulty — Defective AC generator Engine Suns but Runs Poorly — Ignition primlry circuit Delective ignition coil Loose or here wire Intermittent short-circuit in I switch — Secondary circuit Defective plug Defective high tension cord — Secondary circuit De lective AC generator Detective C.D.I. unit 16-2 Date of Issue: February, 1979 Q HONDA MOTOR (20., LTDt /T\ I 2 %% FIXED PULSER (SIGNAL GENERATING COILI HONDA C B40 0 T IGNITION SYSTEM ACG ROTOR ADVANCER PULSER CONDENSER # ‘J . r I L g: I : o O Q U ; vSPARK sca ; q PLUG < a GATE E g if E 3 I I U} I j IGNITION COIL SPARK PLUG For spark pIug gap Inspacnon and adjusmenx procedure, sea Semen 3, IGNITION CIJII. o REMOVAL Ramove (he Iuel unkv D‘scunnec‘ Ihe wue leads. flamoxe [I19 co-I auachmg cows and cow 0 PERFORMANCE TEST Perform m: 3-poml spark us: With a cud (25m. SERVICE LIMIT: 6 mm (0.24m) minimum NOTE For wire connecnons, Iollow the Innrucuons suophed with the cor! teslar. Data at Issue: Februarv, 1979 © HONDA MOTOR CO.. LTD. SCHEMATIC DIAGRAM OF C D l SYSTEM .IFA .1} ‘II—" , FIGMWI'U‘II‘I £13) L 6 mm (0.24 In) MINIMUM u—fi SECONDARY ELECTRODE PRIMARY ELECTRODE SPARK THIRD ELECTRODE 16-3 HONDA. C B4OOT IGNITION SYSTEM 0, D. l. UNIT 0 INSPECTION Disconnect wiring. Set the tester at xkn or x1009 and check continuity DI C.D.|. terminals. Replace the C.D,I. unit it the readings do not tall within the limits shown in thatable. NOTE The C.D.L unit is Iullv lransistarized. For accurate testing, it is necessary to use a specified electrical taster. - Use of an impropev tester nrmeasuta- merits in improper range may give Ialse rendings‘ v U58 SANWA ELECTRICAL TESTER (SPAIODI PIN 07303—002000!) 0r KOWA ELECTRICAL TESTER (TH- 5H5. Discharge the capacitor belore testing. \ "NEEDLE SWINGS AND FIE- TURNS” indicates that a capacitor is being charged with the tester. The tester needle will stay at infinity in subsequent tests unless the capaci- tor is disthargedt UPPER ROW: MEASURING HANGE (SANWA TESTER) xkfl LOWER ROW: MEASURING RANGE (KOWA TESTER) x1009 The resistances shown in the table indicate thuse to be read an the tester, not at specific circuits or parts, The Specifications in Fig. I are ”pliable to (Fig. 1) the C.D.l. unit (connectors on the blue and Huron-i whit: wins) used on followlng mndels: burnt:- < caaon‘r > 3 F.Na.CB400T—20XXXXX _ "°"" F No. CBAMT—ZI XXXXX léilght F.Na. C8400T—40XXXXX ua FND. CEdDOT—MXXXXX While F.Nu, ~NCDS-ZOU17B1 — Green Pink ‘7 I is . ___B|"° IK” ix“ ma- IK~A IK—u _ Black] iM—- ’imzo IM~‘ 1~a 7—15 souou - 3 vynue 5 ~20 15—40 loo—sou \_ 7 it“; v 'v "x "v A" "v; Needle swings and back to W. a Date of Issue: Deumber, 1980 1 6- 4 © HONDA MOTOR CO., LTD. HONDA CB4OOT IGNITION SYSTEM The Specification: in Fig. 2 Ir: lwlluble to the C.D.l. unit (Coupler on blue Ind W'IIII wire ends) used an 01. followlng models; < CMOOT > F.No. ~ Nous—2001782 < CMWUT > F.No. NCD1—20XXXXX F.No. ~ MGM—2110251 2'? COUPER Thu Specific-lion: in Fly. 3 Ira nwliclblu to the C.D,I. unit ("0" mark stamped on tho cover) usud on the lalluwing models; < caaom’ > F.No. NCO3—2w1783~ < CMdODT > F.No. NCO'l—2110252~ < CMMXJE > F.No. NCO1—4000009~ Z-P COUPLER (Fla. 2) rm- 1-! MM to) \ Imm- Phi mm! mm- “an '9 : Naedla swings and luck lo 3‘. (Fig. 3) mm (-1 3mm Whit- Gmn Flnk Inn Mm- Vlllwl Imo- M I'm Liv-t alu- mt lino l—kl wal- Vila-4 x‘: Naadla swings and Ind m °-. Dm of lssul: Deunbcr. 1930 0 HONDA MOTOR CO., LTD. 16-5 HONDA C 3400‘! A. II. ENERATOR NOTE: Grnund the pulsar to m: stator wnzn bench mucking mu Graan to Light Blue and Green lo Brown wires. 0 INSPECTION Disconneu rho stator wires a (hair connec- lions. Measure rasistanus betwuan (ha terminals. PULSER NOTE - TESTER MEASURING RANGE: xlofl . g - Use [ha HONDA SERVICE TESTER ' " BROWN I07308-00200m) to perlnrm thIs mt. For generator removal ind instillatinn pro- UGHTBLUE cadure, ralar to Slclian 9. WHITE BLUE GREEN ‘laacoeL ‘wgwcr GR EEN-WHITE 400~500f2 ‘ BLUE-WHITE 75~130S2 GREENEROWN 75-4309 GREEN-LIGHT BLUE 75-1303 GREEMPINK 120~180S1 The specifications are applicable to the A.C. generator used on ma following models; < (234001’ > E .No. CB4OOTE—20XXXXX E.Nu, CBAUOTE-4OXXXXX WIRE COLOR RESISTANCE GREEN~WHITE 315—3853 BLUE-WHITE 77-459 GREEN-8 ROWN 79-9231 GREEN-LIGHT BLUE 95~116fl GRE EN-PINK 1294549 Thu specifications are applicable to ma A.C. generamr (Screws painted with yellow) and on ma lollnwinn models; < CEMJOT > E.No‘ CB4DDTE—210594D~ E,No. CB4OOTE-4103395~ YELLOW PAINT E‘No. NC03E—20XXXXX E‘No. NCOQE—ZIODUO‘I~ < CM400T > E‘N0.NC01E—2UXXXXX E‘Nu.NC01E—21XXXXX E.NolNC01E—2200001~ Dun 0! Issue: December. 1980 1 6 ' 6 0 HONDA MOTOR 00.. LTD. HONDA CB400'I' 17. STARTER MOTOR SERVICE INFORMATION TROUBLESHOOTING STARTER MOTOR MAGNETIC SWITCH STARTER CLUTCH 17—1 17—1 17—2 17—4 17—4 SERVICE INFIITMATIIII 0 WORKING PRACTICE The starter motor an be removed with the engine in the tram. See Section 10 for sterter clutch repairs. 0 SPECIFICATIONS STANDARD SERVICE LIMIT Starter motor Brush spring tension 0.495416% kg 400 9 Brush length 1|.0~12.5 rnm (0.43-0.49 in.) 5.5 mm (0.21 in.) STA RTE R MOTOR L_‘RE°TT Qfl '3‘“ A sausnes V STARTER Ll, MAGNETIC SWITCH ‘— "GREEN/RED FUSE iSA YELLow/ 9'0“; GREEN/RED RED 1 STARTER é Ei a 5 l a RELAY COIL - I: FIELD COIL “MATURE: swncu. EemcK—A {.5 E5 3 E MAIN swrrcu 9: 2' 1 4° “5 IE 2 NEUTRAL 5 D ‘” FIELD MAGENT ‘9 LAMP 5’ d g BATI'ERY 3" TRIIIIILESIIIIIITIIIG Starter Motor Will Not Turn: - Deed buttery — FaulW ignition switch Faulty start switch Faulty neutral switch Feuity 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 oirwit — Binding in stener mutnr. Starter Motor Turnsl Hut Engine Does Not Turn: —- Faulty starter clutch - Faulty starter motor nears - Faulty starter motor or idle our Starter Motor and Engine Tum, But Engine Does Not Start: — Faulty ignition system — Engine problems Data of Issue: Decemblf. 1980 9 HONDA MOTOR (20., LTD. 17-1 STARTER MOTIIII e REMOVAL lMlh me ignition swiich OFF, remove lhe negative labia It the banery beiore servicing the starter moror. Disonnect the starter able. Remove the starter mounting bolts and pull the molar out of the engine use. 0 BRUSH INSPECTION Remove ma starter motor case scrwas. Inspect the brushes and measure brush length. Measure brush spring tension with a spring scale. SERVICE LIMITS: Brush length: 55 mm (0.21 in.) Brush spring nmion: 400g 0 COMMUTATOH INSPECTION Remove the user NOTE Regard (he Iooerion and number ol the Khrusr washers, lnspect the oommumur burs for disculore~ rion. Bars discolored in pairs indicate grounded armature coils. NOTE Do no! use emery or sand paper on the DDMMUKBIOY. HONDA C B4001 STARTER MOTOR BRUSH LENGT ”I BRUSH LENGTH COMMUTATOR 17-2 DIII of Issue: December, 1980 © HONDA MOTOR 00.. LTD. HONDA (234007 STARTER MOTOR Cheek lor continuity between pairs 01 com- mumar burs, end also bum-en mmmumor 9 COMMUTATDR 8A IRS bars and armature shaft. CONTINUITV: Norm Replica mmr motor If armature coils are COMMUTATOR BAR open, or shorted to Irmalure shaft. ARMATURE SHAFT N0 CONTINUITY: No o FIELD COIL INSPECTION CABLEYERMINAL‘MOTOR V . , CASE - 352': KSEflXd'f'LTni'L: :21: $2522: ”0 °°“T'“”'"= “W" CABLE TERMINAL-BRUSH to the brush wire. WIRE Replace the sinner motor if the field coil is _ not continues or il it is shorted (o the molar CONT'NU'TY‘ "mm“ cm, ‘ I ASSEBMLYIINSTALLATION Assemble the starter motor. NOTE Align the punch mark on “I: case to the punch mark on Illa cover. Insull the inner molar on I’ll engine. Connect the slaner rumor cable. Dale of lawn: December, 1980 9 HONDA MOTOR (20.. LTD. 1 7 ' 3 HONDA C 34007 STARTER MOTOR MAGNETIC SWITDII I INSPECTION Ya test it the switch wimary coil is HolmBI, depress the switch button. The coil is normal if the switch clicks into position. Cnnnect an ohmrnutcr to the switch terminals. Connact n 12V battery to the switch cable terminals. The switch is normal if there is continuity. STARTER CLUTCH See Section 10. 1 7 4 Date of Issue: December. 1980 ' G) HONDA MOTOR C0,. LTD. $33? 18. TECHNICAL FEATURES 1. BALANCER MECHANISM The Iron! and rear bahnours counteracr large inertia lore“ inherent in the 2cylinder. in-IiM. 350mg". crank engine, allowing it to produce smooth powere FRONT BALANCER SHAFT The eccentric shah allows balancur chain tension adiust- mam. HALANCER wemm’ /sPnoo(Er O 0/ 0 ..%en DAWEns / / RUBBER DAMPERS The sprofltlks are connected to their respective halamrs through rubber dampers to absorb shadts lor lonnar chaln lile. Due 01 Issue: September. 1977 0 HONDA MOTOR CO. LTD. 18-1 HONDA. C B4001 TECl'NchL FEATURES - OPERATING PRINCIPLE 0F BALANCER ' INERTlA FORCE AT TDC ‘ INERTIA FOFICE AT BBC The source of vbrslion in a reciprwling angina is the "inertia" lore: mind by "I: roming or reciprocating misses. For example. ihu inmia lures which am on (ha main buying; of a ringlu cylinder, l-cycle, 200 cl: engine at TDC will be: 400 kql 682lbslapprnx. . . . a16.000rpm 1000 kg (2,205Ibs) approx . ‘ M 100li rpm INERTIAF RCE 1/ 0 lNERTIA FORCE CENTHIFUGAL FORCE 0N CRANK WEIGHT "—CENTRIFUGAL FORCE ON CRANK WEIGHT [BDC] [TDC] Imrxia lore: malld by the rotating mass is general unwind by eoumarwcighls. Their use will mince vibration caused by the primary inania fore. which occur! one: avorv cmkshln mvolutioni (Hero-fur, inertin forge raters lo rhis primary inertia force). 1 8 2 Dale 0' Issue: Seplzmher, 1977 - © HONDA MOTOR 60., LTDi HONDA C 34001“ TECHNICAL FEATURES (4) » 1: ' 15 50 25 The centrifugal lnrce on the counterweight is ha|anced bv the belancers. Although the countlrwelghts will belance the Inerti- inrce at T.DtC. and ED. , they will create a corresponding horizontal imbalance of heir awn at 90' BTDC and 90° ATDC due to centrifugal force. The balancers are dosimed to counteract this larce including the inertia lorce united by the reciprocating. CENTRI FUGAL FORCE ON COUNTERWEIGHTS (I) YDC The counterweight creates a centrifugal force to neutralize one«half oi the inertia force The remaining inertia will be totally belenced by two balance". Each belancer counteracts one- founh of the lot-l Inertia. => 25 50 25 i3) 306 The inertia force is balanced by the counterweight Is in (1). However. the centrifugal farce acting on the counterweight is still present. The 25 centrifugal force an the belencers cancel: this remaining larce. The centrifugal force on the counterweight neutr 'zes oneJ’Iaii oi the downward inertia force. The balancers counteract the remainder. Dltcoi Issue: Septemberl 1977 © HONDA MOTOR 00‘. LTD. 18-3 HONDA. CB400'I' TECHNICAL FEATURES 2. 3-VALVE, SHORT-STROKE ENGINE INTAKE VALVE The duel verve arrangement in- sures eflective breathing et high speeds without floating. Two smllllr valves instead oi one lerge valve allow large overall part one with low re- ciprouting weight for each valve spring. EXHAUST VALVE The exhaust valve is oflset in the combustion chamber. The result is a spark plug that centers in the combustion chamber for optimum combustion. Easy access to the spark plug is another important design leeture resulting from this erringernent. e SHORT-STROKE ENGINE The 0.72 oversguare design reduces piston speed end minimizes 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. It is loo-ted at the must Ideal position without sacrificing spec- between the engine end the ground due to reduced engine height. The exhaust geses from one cylinder expand in the power chamber and heve .1 auction effect on the other cylinder. 1 Date nl Issue: September, 1977 8' 4 Q HONDA MOTOR 00.. LTD. HON DA (3400' TECHNICAL FEATURES 3. C.D.|. SYSTEM The C.D.I. lcapacmve discharge ignit-unl electronic lgfllllOl’l system is designed to provide a powerlul spark, especially at high rpm. With no scheduled maintenance. 7 c D.L UNIT 7 The unit consists of diode transistors, condenser. SCR and pressed steel caslng filled with epoxy resin compound. SPARK ADVANCE PULSER l’he pulser is inspected and adjusted at the lactoty and must never be disassembled. The ignition coil. battery charging mil \ and spark advance pulsar are assembl- ed inside the 12-pale stator. 0 FEATURES There are no contact points since the C.D.l. system employs an inductive buildup by capacitive discharge. - The C.D.I. can develon greater voltage at the spark plugs than conventional systems and is less sensitive to spark plug louling. Working on AC‘ the semndary energy produced to lire the spark plugs is stable regardless of the battery's charge. The electronic ti ‘ng advance is virtually lree lrorn troubles which occur in mechmiul sdvancers. The overall design eliminates initial and periodic adjustments and maintenance services. Den: of Issue: Flbllllfvl 1979 V QHONDA MOTOR Co.. LTD. 1 8- 5 0 OPERATING PRINCIPLE TECHNICAL FEATURES FIXED PULSER [SIGNAL GENERATING COIL) CONDENSER SPARK ADVANCE PU LSER IGNITION COIL DI ll Cr SCH GATE EJI'nd )IUVdS 1. As the AC generator rotor turns, wrrent is induced in the AC generator (AC generat- ing will This current is rectified as it passes through the diode D, and is stored in the condenser C.‘ During this process, the SCR is kept OFF. 2. An electric pulse is generated by the fixed pulsar when the pickup reaches the point where ignition must start. This is due to changes in the flux. The pulse is rectified by the diode 2 and is applied to the gate oi SCH. As this happens, SCH [UNIS 0N which in turn discharges the energy stored in the condenser through the primary coil. Sufficient potential is lhen developed at the spark plug to ignite lit-fuel mixture in the combustion chamber. 5 c, 18-6 Dale ul Issue: September, 1977 © HONDA MOTOR CO‘, LTD. HONDA (34°07 TECHNICAL FEATURES 3, To advance timing, the signal from the fix- ed pulsar is replaced by the output signal I from the spark advance pulser. The output signal applies to SCH gate through diode C, 3 and fires the splrk plug. plrlormlnq the same lunction as the conventional system. The taster the engine speed, the (ester the SCH is triggered to advance the D: SCR timing. 4. The negative pulse lrom the fixed pulser balances the positive pulse from the spark advance pulset when the maximum ed- vtnce is reached. This limits timing 0‘ advance. . .1 I D] scn I ADVANCEFl OPERATION In C.D.l. ignition. timing advance depends on the buildup time of voltage on the adv-nee pulsar, which beams tester Is the engine speed increases. The SCR acts like a switching deuce, but there is a definite voltage at which it turns on. The overall operation at the C.D.I. system stems from theta two lacts. The faster the voltage buildup. the earlier the SCR is triggered. allowing the system to perform the same function as the conventional system. The lixed pulser controls timing until the advance pulsar comes into ooerttion. N4 N1 N: N: SCR TRIGGER VOLTAGE (ON) 92m: ~.(1l CARBURETOR (1) I3) [4) I1) (2) (3) (4) I5) (6) (7) WEAK OR NO SPARK ————o COMPRESSION LOW —> (1) (ll (3) Mi (5) [Si ENGINE FIRES BUT —-I1l STOPS I?) I3) (4) WET PLUG ‘—‘.Ill (2) (3) Fuel tank empty Clogged luel tube or luel filter Clogged fuel inlet Clogged fuel tank cap breather hole Faulty spark plug Fouled spark plug Faulty C.D.I, Unit Broken or shorted high tension cord Faulty A,C. generator Broken or shorted ignition coil Faulty main switch Kick pedal slipping . Inadequate valve clearance Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Valve timing innorrecl Misuse of choke Carburetor pilot screw setting incorrect Air leaking past manifold Ignition timing incorrect iC.D.I. unit or A.C. genflator at laultl Carburetor Hooded Carburetor choke closed Throttle valve opened Date ol Issue: September, 1977 © HONDA MOTOR C0,. LTD. 19-1 TROUBLESHOOTING HON DA C B4007 ENGINE LACKS POWER 5. , Raise wheels and spin them by hand. WHEELS SPIN FREELY Check tire pressure PRESSURE NORMAL t Accelerate rapidly Irom low to second. ENGINE SLOWS WHEN CLUTCH RELEASED Accelerate Iighlly SPEED INCREASES Check ignition timing TIMING CORRECT Check valve clearance . Test cylinder compression COMPRESSION NORMAL Check carburetor for clogging CARBURETOFI CLEAN Possible Cause WHEELS DO NOT ———-> (1) SPIN FREELV (2) I3) I4) PRESSURE LOW ———* II) I?) ENIGNE SPEED UNCHANGEO —’ (1) WHEN CLUTCH RELEASED I2) I3) NO SIGNIFICANT —>III INCREASE IN ENGINE (2) SPEED I3) (4) I5) TIMING INCORRECT ~———> (1| (2) CLEARANCE INCOR RECT —— (I) I2) COMPRESSION LOW —. (II (2) l3) (4) CARBUREYOR CLDGGED —. II) Brake dragging Worn or damaged wheel bearing Wheel bearing dry Drive chain too right Puncturad lire Faulty lire valve Clutch slipping Worn clutch disc Clutch disc warped Carburetor choke closed Clogged air cleaner Restricled Iuel flaw Clogged fuel tank breather cap hole Clagged mulller Faullv C‘DJ. unit Faulty AC generator Improper adjustment Worn valve seal Valve stuck open Worn cylinder and piston Blown cylinder head gasket Valve timing incorrect Carburetor not servlned frequently enough 19-2 Data 00 Issue: Summer. 1577 © HONDA MOTOR 00., LTD. HONDA C 3400‘! TROUBLESHOOTING 9r Ramove sperk plug PLUG IS NOT FOULED OR DISCOLORED 10. Check all level and condition. OIL LEVEL CORRECT l 1. Remove cylinder held cover and check lubrication. VALVE TRAIN SUFFICIENTLY LUBRICATED 12. Check for engine overheating ENGINE DOES NOT OVERHEAT 13, Accelerate or run u high speed. Poiible Cause PLUG IS FOULED OR — [1) OR DISCOLORED (2i 13l OIL LEVEL INCORRECT —. l1) (2) (3| VALVE TRAIN ———>l1) INSUFFICIENTLV i2) LUBRICATED ENGINE OVERHEATS _——o (I) I2) (3) I4) ENGINE KNOCKS *> (1) (2) (3l (4) (5 Plugs nor serviced frequemly enough Spark plug heal range incorrect Wrong Iuel Oil level too high Oil Ievel [on law Conlaminated oil Clogged oil passage Clogged oil cnnrrnl orifice Excessive urban build-up on oom- buslion chamber wall Wrong lvpe of fuel Clutch slipping Fuel air mixture too rich Worn piston md cylinder Fuel air mixlure loo lean Wrong [we oi luel Excessive carbon buildup in combus‘ lion chamber Ignixion timing loo early (Deiective C.D.l. unit or A.C. senemur) Dale oi Issue: September, 1977 © HONDA MOTOR CO.. LTD‘ 19-3 TROUBL ESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing CORRECT 2. Check carburetor pilnt screw adiustment, CORRECT 3. Cheat for air leaking NO LEAK l 4. Try spark test. HONDA C340 01' Possible Cause INCORRECT —. (U (2) INCORRECT —> (1) l2) LEAKING ——> (1) (2) WEAK DR INTERMITTENT —. l1) SPARK l2) (3) (4| Valve clearance incorrect Ignition timing incnrmcl (Defective C,D.l. unir or A.C. generator) Fuel air mixture too lean [To correct, screw out) Full air mixture too rich (To correct, screw in] Deteriorated insulator O-ring Loose carburetor Faulty or louled spark plug Faulty C‘DJ. unu AC generator at lault Ignition Doll out of order 19-4 0an al Issue: September, 1977 © HONDA MOTOR cot. LTD. HONDA CB4°°T TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible Cause: INCORRECT —_. l1) l2) l3) it Check ignition timing and valve cleeranoe. CORRECT FUEL FLOW “o [1) RESTRICTED l2) l3] l4) 2. Disconnect luel tube at carburetor. FUEL FLOWS FREELY 3. Remove carburetor and JET CLDGGED * in check for clogged iel. NO CLOG 4, Check valve timing. INCORRECT ——p (1) CORRECT 5. Cheri valve spring tension WEAK —-> [I POOR HANDLING 4 check tire pressures Valve ciearenoe incorrect C,D.I. unil out of order AD, generator at fault Fuel tank empty Clogged luel line Clogged luel tank can breather hole Clogged luel valve Clean Cam sprocket is not installed properly Faulty spring Possible Cause: It I! steering is heavy ——-—-——. l1) l2) 2. If either wheel is wubbling —————-> [1) l2) l3) l4) l5) l6) 3. ll the motorcycle pulls to one side ——————» (1) l2) l3) (4) Steering cone races too tight Damaged steering steel bells Excessive wheel bearing play. Distorted rim Improperly installed wheel hub Swingarm pivot bushing excessively WOI’" Distorted fume Improper drive chain tension or ediustmenl Unbalanced shock absorbers Front and rear wheels not aligned Bent lrant lork Bent swingerm Dale 0! Issue: September, 1977 © HONDA MOTOR CO., LTD 19-5 HONDA C B40 0 'I' MEMO MEMO MEMO HONDA. CB400T 21. ’79 ADDENDUM INTRODUCTION This HONDA 1979 CB4ODT Shop ManuaI Addendum comains information pertinent to th91979 CBdOOT. Refer to the base shop manual for setvice pro- cedures and data not included in this addendum. TABLE OF CONTENTS MAINTENANCE SCHEDU LE BALANCER CHAIN TENSION III. HYDRAULIC DISC BRAKE BRAKE FLUID MASTER CYLINDER ALL PHOTOGRAPHS ARE BASED ON THE TYPE IIMODEL. ALL INFORMATION, ILLUSTRATIONS. DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING, HONDA MOTOR 00‘. LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAV BE REPRO- DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR C0., LTD. Service Publications Office ll. INSPECTION AND ADJUSTMENT 21—2 21—3 21—3 21—4 21—5 21—6 Date nI Issue: August, 1978 9 HONDA MOTOR (10., LTD. 21-1 HONDA '79 ADDENDUM CB4°°T I. MAINTENANCE SBHEIIJLE ' CB4ODT Periorm the Pre~ride Inspection In the Owner's Manual at each scheduled maintenance period. I: INSPECT, CLEAN. ADJUST, LUBRICATE OR REPLACE IF NECESSARY, (RE stir-5331c: A: ADJUST L : LURRICATE FREQUENCY WHICHEVERQ ODoMETER READING [NOTE (3)) COMES ‘ FIRST 5 Ruler lo we '75” EVE RY S mAiflifiSSJ.‘ ENGINE oIL _VEAR 00k Page In ENGINE OIL FILTER YEAR R R R R R R Page In E CRANKCASE BHEATHER NOTE In C C C c C Page 11 :5 AIR CLEANER NOTE (2| C C C C C Page ‘2 E ' FUEL LINES I I I I I Page I: E SPARK PLUGS I R I R I Page 12 d ' VALVE CLEARANCE I I I I I I 939213 : ‘ CAM CHAIN TENSION A A A A A A Page l3 5 ' THROTTLE OPERATION I I I I I I Page 14 g ' CARaURETOR IDLE SPEED I I I I I I Page 14 “J ~ cARaURETOR CHOKE I I I I I Page 15 ' CARBURETOR SYNCHRONIZE I I I I I I Page Is " BALANCER CHAIN TENSION A Page 17 DRIVE CHAIN I, L EVERv 300 mi. (500 km) P3918 aATTERv MONTH I I I I I I Pop 29 E BRAKE FLUID (Front) 332125,; I I I 'R I I Page 20 E BRAKE SHOE/PAD WEAR I I I I I Page 22 E BRAKE SYSTEM mean I I I I I I Pm 2: d ' BRAKE LIGHT SWITCH I I I I I I Page a i ' HEADLIGHTAIM I I I I I I Plunge 9 CLUTCH FREE PLAY I I I I I I Page as g SIDE STAND I I I I I Plan 27 g ‘ SUSPENSION I I I l I I Page 29 g ' NUTS. BOLTS, FASTENERS I I I I I I Page so ~ ' WHEELS/SPOKES I I I I I I Pew so "STEERING HEAD BEARING I I I Page so Should be serviced by an authorized HONDA dealer. unless the owner has proper tools and service date Ind is mechani- Cally qualiliede In the interest of safety, we ucornmend these items be serviced ONLY by an authorized HONDA dealer. NOTE: (1) Service more lrequentlv when riding in rain or at lull throttle. or elm being washed or overturned. (USA only) (2) Service more frequently when riding in dusty areas. (3) For higher odometer readings, repeat at the {requeney interval establirhed here. Date of Issue: August, 1978 21 ' 2 OHONDA MOToR co., LTD. (. )2? HONDA é"; €34007 '79 ADDENDUM ||. INSPECTION IINI] ADJUSTMENT BAlANDER CHAIN TENSION Perform the iollowt'ng iI the balanoer chain is noisve Remove lhn adjuster can on the right crank- case EDVQL Loosen the H mm adjuster nut, When this nut is loosened, the balancer will position itsell to provide proper chain tension. Retignten the 8 mm nut, TORQUE: 2.0—2.5 kg-m (15—18 helbs) CAUTION Readjust as Inflows H the end of the stopper plate groove contacts the stud balls Drain the engine otl. Remove the tachometer and clutch cables. Remove the right iontpeg and kickstarter lever. Remove the right crankcase covert Remove the 10 mm and 8 mm nuts; remove the stopper plate. Install the stopper plate moving it over one SFIIHE to move the end ol the stopper plate groove away from the stud boll Reinstall the 8 mm nut lrrst and than the 10 mm nut and llghlen to the specified lorques: TORQUE: 8 mm: 2.0—2.5 k9,,“ I15—18h4bsI 10 mm: 3.0—3.5 kg-m (22—25 It‘lbsI W Replace the chain if the punch mark on the shaft is below the horizontal line. (Refer to the base shop manual Section 10. l \ OPUNCH MARK REPLACE CHAIN Date 0' Issue: August, 1978 © HONDA MOTOR CO.. LTD. 2 1 ' 3 ’79 ADDENDUM HONDA CB400'I' Ill. HYDRAULIC DISC BRAKE SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID BRAKE MASTER CYLINDER 21—4 21—4 21—5 21—6 SERVICE INFORMATION 0 SPECIAL TOOL SNAP RING PLIERS o SPECIFICATIONS 07914-3230001 STANDARDS SERVICE LIMIT Dlsc thicknass 4.9~5.l mm (0.194120 in) 4.0 mm [0.16 in) Disc runoul 0.3 mm (0.012 Inl Master cylindu I.D. 14.noo~14.043 mm (05512-415529 in) (4.055 mm (0.5533 in) Mm" piston 0.D. 13.957~13.984 mm (05495-435506 in) 13.965 mm (0.5490 in) Caliper piswn OD. 3B.115~38.1EO mm (1.5006~1,503l in) 38.105 mm (1.5002 In) Caliper cylinder LD. 36. IMF—33.200 mm (1.5031~1.5039 in) 38.215 mm (1.5045in1 TROUBLESHOITIINC Poor Brake Plrformunee — Air bubbles in hydraulic system — Worn brake pads — Pads foulad or glued — Hydraulic sysnm lukinu 21-4 Date of lawn: August, 1978 9 HONDA MOTOR 00.. LTD. <_ 2,: HONDA “Ia C34001' '79 ADDENDUM II. INSPECTION AND ADJUSTMENT BALANCER CHAIN TENSION Perform the lollowing if the balancer chain is noisy, Remove thu adjuster cap on the right crank- case COVEI. Loosen the B mm adjuster nut. When this nut is loosened, the halanuer will position itself to provide proper chain tension. Retighten the 8 mm nut. TORQUE: 2.0—2.5 kg-m (15—18 h-lhsl C’AUTION Readiust as follows ii the end of the stopper plate groove contacts the stud bolt. Drain the engine oil. Remove the tachometer and clutch cables. Remove the right loutpeg and kickslarter levere Remove the right crankcase covert Remove the 10 mm and 8 mm nuts; remove the stopper plate. Install the stopper plate. mov-ng it over one spline to move the and 0' the stopper plate groove away lrom the slud bolt, Reinstall the 8 mm nut lirsl and then the IO mm nut and tighten to the specified IOIQUESZ TORQUE: 3 mm: 2.0—25 kn-m (15—18 IHbsI 10 mm: 3.0—3.5 kg»!!! (22—25 ft-lbs) CAUTION Replace the chain it the punch mark on the shaft is below the horizontal line. (Refer to the base shop manual Section .,\\\/\K 10.) OPUNCH MARK REPLACE CHAIN Date of Issue: August, 1978 Q HONDA MOTOR 00., LTD. 2 1 ' 3 HONDA '79 ADDENDUM C34°°T Ill. HYDRAULIC DISC BRAKE SERVICE INFORMATION 21—4 TROUBLESHOOTING 21—4 BRAKE FLUID 21-5 BRAKE MASTER CYLINDER 21—6 SERVICE INFIIIMATIIII 0 SPECIAL TOOL SNAP RING PLIERS 07914—3230001 . I SPECIFICATIONS STANDARDS SERVICE LIMIT Dim mickness 4.9~€L'l mm (0.19~0.20 in] 4.0 mm (0.16 in) Disc runoul 0.3 mm (0.012 in) Master cylinder LD. 14.000~14.043 mm (0.5512~0.5529 in) 14.055 mm (0.5533 in) Musuu piston OD. 13.957~13.9M mm (0‘5495~O.5506 inl 13.945 mm (05490 lnI Caliper plslon 0.0. 38.11.543.150 mm (1.5006~1.5031 in) 38,105 mm (1.5002inl Callpar cylinder |.D. 30. IBO~38100 mm I1.6031~l.5039 in) 38.215mm (1.5045inl TROUBLESHIIIITING Poor Brake Perlormamx — Alr hubhlzs in hydraulic svmm — Worn braka pads - Pads fouled or gland — Hydraulic svsum leaking 21-4 Dam uf Issue: August, 1976 © HONDA MOTOR C0,. LTD. HON DA. CB400'I' '79 ADDENDUM BRAKE FLUID (TYPE-II) a FLUID LEVEL Check the fluid level with the reservoir level. II the level Is below the UDDBr level mark, add DOT-3 BRAKE FLUID up to the upper level mark. Check the entire system Ior leaks, It the level is low. CAUTION ' Do not mix different brands of fluid ‘ in the reservoir as they may not be compatible. ' Do not remove the cap until the handlebar has been Inmed full right so that the reservoir is level. . Avoid operating the bake lever with the cap removed. Brake fluid with flow out if the lever is pulled. BRAKE FLUID REPLACEMENT CAUTION - Install the diaphragm on the reservoir when operating the brake level. Failure to do so vvlll allow reservoir during brake lever uperetlon. Avoid spilllnn fluid on pointed sup feces. Place a rag over the fuel tenk whenever the system is serviced. 0 BRAKE SYSTEM DRAINING Loosen the caliper bleeder velve end pump the brake lever. Stop operating the lever when no fluid flows out of the bleeder valve. To prevent piston evertrevel and brake fluid seepage, meintlin a 2|) mm (3/4 in.) distance lrom the hendleber grip when bleeding the Iront brlke system. I BRAKE SYSTEM FILLING CAUTION Do not mix brands of fluid since they may not be compatible. Close the blender valve, fill the reservoir, and install the diaphragm Pump up the system presure wlth the lever until there are no air bubbles in the lluld flowing out of the small hole In the reservoir (until lever resisunee is felt). UPPER LEVEL‘. LOWER LEVEL—' NEVER R E-USE Dete oi Issue: August, 1978 © HONDA MOTOR 00.. LTD. 21-5 HONDA C B400T '79 ADDENDUM BRAKE MASTER CYLINDER 0 DISASSEMBLY Drain brake fluid lrom the hydraulic system. Remove the brake lever and rear view mirror from the master cvlinden Disconnect the brake hose. CAUTION Avoid spilling brake fluid on painted surfaces. Place a rag over the fuel tank whenever the brake system is serviced. NOTE Whln removing the brake hose bolt, cover the end of the hose to prevent contaminafian and secure the hose. Remove the master cylinder. Remove the snap ring, SNAP RING PLIERS 07914—3230001 a I.D. INSPECTION Measure the master cylinder I.D.. Check the cylinder inr scores, scratches, nicks or Other demige. SERVICE LIMIT: 16.055 mm (0.5533 in) Date of Issue: August, 1978 2 1 ' 6 © HONDA MOTOR co., LTDe HONDA C34001 '79 ADDENDUM 0 MASTER PISTON O.D. INSPECTION Measure "1: master cylinder piston OD" SERVICE LIMIT: 13.945 mm (0.549 in) I MASTER CYLINDER ASSEMBLY CAUTION Handle me I'l'lisll' cylinder piston, cylinder and spring as a set. Assemble the masrer cylinder. Coal all parts /\ with clean brake fluid before assembly, / \ Place the spring an the check valve. Install x ‘ [he spring and valve logelher, ~ \ 0 Dip me piston cup in brake fluid before MASTER PISTON} essemhlv- SILICON GREASE on CAUTION Don enAKE FLUID When insulling the cups. do not allow PRIMARY CUP the lips to turn inside am. Be certain . III- circlip is seated firmly in the groove. Insxall the boot, washer and clip, CYLINDER Insull the reservoir on the master cylinder ‘@ making sure mat the O-ring is in good con- I dilion. (9 e FRONT BRAKE A LIGHT SWITCH ane 0! Issue: August, 1973 0 HONDA MOTOR COT. LTD. 21 " 7 MEMO 33%: 22. ’79 ADDENDUM INTRODUCTION TABL E OF CONTENTS This HONDA 1979 CMAOOT-CMAOOA Shop Manual I. MODEL IDENTIFICATION 22—2 Addendum contains information pertinent to the 1979 CM4DOT-CM400A. Refer to the base shop manual for service pro- I" SPECIFICATIONS 22—3 cedures and data not included in (his addendum. III. TORQUE VALUES 22—6 IV. WIRING DIAGRAMS 22—9 CABLE AND HARNESS _ V' ROUTING 22 " VI. EMISSION- CONTROL LABEL 22—15 cmooT MAINTENANCE _ VII. SCHEDULE 22 16 CM4ODA MAINTENANCE 22_17 SCHEDULE . VIII. INSPECTION AND ADJUSTMENT 22—18 IX. HYDRAULIC DISC BRAKE 22—19 ALL INFORMATION. ILLUSTRATIONS, DIREC- . TIONS AND SPECIFICATIONS INCLUDED IN THIS X. FUEL SVSTEM 22_20 FUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR 60., LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. N0 PART OF THIS PUBLICATION MAV BE REPRO‘ DUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR C0., LTD. Service Publications Office Date 0! Issua: February. I979 O HONDA MOTOR (20.. LTD. 22 ' 1 HONDA '79 ADDENDUM $5; CM400T- 400A I. MIIIIEL IDENTIFICATION } I CMAODA BEGINNING F/N 2000001 2 2- 2 Dam of Issue: February, 1979 © HONDA MOTOR C0,. LTD. HONDA CM4OOT' 400A ll SPECIFICATIBNS I Specifications listed are for both T and A models unless otherwise noted. ’79 ADDENDUM Item Metric English Dimensions Over-II length 2,110 mm 83.1 in. Ovarall width 870 mm 34.3 in. Over-II heith 1,150 mm 45.3 in. Wheal base 1,425 mm 56A in. Seat height 750 mm 29.5 in. Foot my height 310 mm 12.2 in. Ground clearnnu 140 mm 5.5 in. - D'vweism 23:33}; 33:: 333.15%? Fume Tvpe Diamond F. suspension and travel Talescouic lork, l35,5 rnrn l5.5 insl R. suspension Ind travel Swing arm. 75.5 mm (3 in] F. tlr! size 350518~4PR ‘ R. tits size 460316—51??? Up to go kg From L75 lisp/cmI 24 psi Cold lire ‘200 'st load Rear 2.0 kg/cm‘ 23 psi ”9‘5”"; Up to vaniclc Front L75 Isa/cml 24 psi “DEW '0“ Rear 2.5 kg/cm’ 36 psi F. brake Disk brlk: R. brake lntarnal expanding shoes Fuel capacity It) ”L 2.6 U5. gal._ 2.2 Imp. gal. Fuel reserve capacity 3.0 lit. 0.8 U.S. 9.1L. 0.7 Imp. qal, Caster angle 60°30‘ lrom horizontal Trail length 103 mm 4.3 in Front lorlr oil capacity 140 cc 4.9 oz. Engine Type Air cooled 4 stroke O,H.C. engine Cylindsr arrangement Vertical twin parallel Born and struk: 10.5 x 50.6 mm 2.776 x 1.992 in. Displacement 395 cc 24.1 cu-in. Compassion ratio 9.3 : 1 Valve train chain driven over hurl camshaft WWW 53:88}; 33:2: i:§3:§:3§::§:31$2‘2§: Lubrication system Forced pressure and wet sump Cylinder head compassion prlssure 13 : Ll! lug/cm2 135 : )4 psi Data of Issun: Febru-ry, 1979 6 HONDA MOTOR C0,. LTD. 22-3 '79 ADDENDUM HONDA CMAOOT- 400A Item Metric ] English Engine Opens 5° BTDC (At 1,0 mm mm, 57° BTDC (At 0 lihl Intake valve 3 l n . C|oses 35 ABDC (At 10 mm Mt), B7 ABDC (At 0 Mil Opens 40' aauc (At 1.0 mm lilt), 90° aeoc lAl 0 lim Exhaust valve . . a . Closes 5 AYDC (A! L0 mm Ml). 55 ATDC (A! D lull) Valve clearinc! IN 0,10 mm 0.0!“ in. EX 0,14 mm [1006 in, minim 832231; 1:323:123123 {2:253:23 CMGOOT: Carburetor type CV type, 32 mm (126 in,) venturi bore °°'b“'°“°" ldentifiuatl'an number va 21c Pilot screw 2 turns out (see Emissions Addendum page 3!) Float level 155 mm 1 0.61 in. CMAODA: Carburetor typo CV type, 28 mm (1,10 in.) venturi bore C""‘""i°" Identification number vazaa Pilot screw initial setting 2 turns out (see Emissions Addendum page 31) Float level 15.5 mm | 0.61 in. CMADOT: CluICh We! mulli-plat: type ' 0”" "ii" Transmission 5-speed constant mesh Primary reduction ratio 1125 Gear ratio 1 2,733 Gear ratio H 1.850 Gear ratio Ill 1.417 Gear ratio iv H48 Gear ratio V 0.966 Final reduction ratio 2.188 Gear shirt pattern Left loot operated return system cMaooA: Transmission 2~speed semi-automatic transmission with torque converter 9"" "3‘" Primary reduction ratio 1.463 Gear ratio | 2923 Gear ratio II 2.059 Final reduction ratio 2.133 Gear shift pattern Left loot operated return system Electrical Ignition Capacitive discharge ignition amour: "F" mark is" lame at 1,200 rpm idle speed IsnIIion “mini: Full advance 43' BTDC 2 2” at 4.500 to 5,350 angina rpm "FM” mark 75' BTDC at 1250 rpm idle speed (Transmi 'on in neutral) gwggofiiming "r" mark 15“ BTDC at 1,250 rpm idle speed (Transmission in gear) Full advance 43° BTDC 2 2" at 4,500 to 5,350 rpm 22-4 Date of Issue: July, 1979 9 HONDA MOYOR 00., LTDe HONDA CM4001°400A 79 ADDENDUM Item Metric English Electrical Starting wslem Stming motor and kick slarler Alternator AtC, generator, 0.17 kWI5.lJOO rpm Battery rapidly 12V‘ 12 amnara-hours rigglga'gfgf'fi‘fim ND xzzss‘u or NGK D7EA U.S.k modal Standard ND X24ESvU m NGK DBEA 59"" ”'“9 Sitar/m? “W" ND x27es‘u or NGK 095A gm” ND xzassn-u n1 NGK DnsEs-L Spark plug gap 0,6417 mm [ 0.024~o.oza in. Lights Headlight (low/high helm) 35/50W Tall/smplioht 3/32 cp SAE NO. 1157 Turn signal light (Front/Ram) 32/32 cp SAE NO. F.1034 RAMS Speedometer light 2 cp SAE N0. 57 CdeA: Plrking brika warning light 2 cp SAE NO‘ 57 Tum signal Indicator light 2 cp SAE NO. 57 High burn Indicator light 2 cu SAE N0, 57 ' Position llgh! 3 ED SAE NO. 1034 CM4DOA: Shlfl position light (3) 2 cp SAE N0. 57 Oil pussur: light 2 cp SAE NO. 57 CM4MT: Tachormter light Zcp SAE N0. 57 3':Jl$i“l§:3’:'€a.ff¥3 22-5 HONDA CM‘IOOI" 400A ’79 ADDENDUM Ill TIJRlllE VALIES - E N6 | N E 0' Torque Values "5'" W kgm mt: 1. Cylinder head cover bolt 2 0.8—1.2 6—9 2. Valve adjusting nut 15 1.2—1.7 9—12 3. CylindEr head bolt 8 3.0-3.3 22—24 4. Cam sprocket knock bolt, 7 x 12 hex. bolt 2 1.B~2.2 13—16 5. Spark plug 2 1.5—2.0 11—14 6. Drivr: gear fixing bolt. 12 x 25 “any! bolt 1 4.5-5.0 33-35 7. Clutd’t center lock nut 20 mm 1 4.5—5.0 33—36 8. Balancer, 8 mm nut 1 2.0-2.5 14—18 9. Balanuer, 10 mm nut 1 3.0—3.5 22—25 10. AC. generator rotor set bolt. 12 x 40 flange bolt 1 10.0—12.0 72—87 11. Crankshaft holder bolt, 10 mm bolt 6 3.3—3.7 24-27 12. Connecting rod nut 4 2.5—2.9 18-21 13. Starting clutch boll, TORX bolt 3 1.2-1.5 9—12 14, Oil filter center bolt 1 2.8—3.2 20—23 ‘ 15. Oil drain plug 1 25—35 18—25 I6. Exhaust plpo flange nut, 6 mm 4 0.0—1.2 6—9 17, Mulfler chamber clamp bolt, 8 x 35113nge ball 4 1.5—2.5 13—13 18. Gear shill pedal, 6 x 32 flange bolt 1 0.8— 1.2 6—9 0 CHASSIS Torque Values Item O'ty kg-m ft-Ib 1 Steering upper holder bolt, 3 x 36 flange halt 4 1.8—3.0 13—22 2 Steering lower holder nut 4 2.0—3.0 14—22 3 Steering stern nut 1 9.0410 65—37 4. Front fork bolt 2 7.0—9.0 51 —65 5. Front lork bottom bridge bolt. 8 x 4D hex. bolt 2 1.8—3.0 13—22 6 Front brakl disc bolt, 0 x 33 USS bolt 5 2.7-3.8 20-27 7 Caliper set bolt. 10 x 321mm bolt 2 3.0—4.5 22—33 8 Front brake caliper bleedar valve 1 0.7—0.9 5—7 9 Rear brake stopper arm nm, 8 mm nut 2 1.5—2.5 11—18 10. Front axls nut 1 5.0-3.0 36—58 11. Front axle holder nut, 3 mm nut 2 1.5—3.0 13-22 12. “Ear axle nur 1 7.0—1D.D 51—72 13. Final driven sprocket, 10 mm nut 4 6.0-7.0 43—51 14. Swing arm pivot nut 1 6.0—8.0 43—58 15. Rear shock absorber uwer ball, 10 x 45 flange bolt 2 3.0—4.0 22—29 16. Rear shock absorber lower bolt, 10x 32 hex. Doll 2 3.0—4.0 22—29 17. Foot peg bolt, 10 mm flange bolt 4 5.5—6.5 40—47 18. Drlve chain adiuning nut 2 0.8—1.2 6—5 19. Fuel tank set hall, 3 x 28 Hanna bolt 1 15—25 11—13 20. Rear brake pedal pivot bolt, 5 x 65 flange bolt 1 1.8—2.5 13—18 21. Engine hanger. 10 mm flange nur 5 4.5—7.0 33—51 22. Muffler band 4 1.8—2.8 13—20 23. Rear brake pedal 1 13—18 13—20 2 2 6 Dale of Issue: February, 1979 " © HONDA MOTOR (20., LTD. HONDA. CMMT'MA '79 ADDENDUM I STANDARD TORQUE SPECIFICATIONS N Torque Values Bah: and ms ka‘m fl-Ib I. 5 mm hall and nut OAS—0.6 3—4 2. 6 mm bolt and nut 0.8—1.2 6—9 3. 8 mm bolt and nut 1.8—2.5 13~IE 4. 10 mm bolt Ind nu! 3.0—4.0 22—29 5. ‘2 mm bolt and nut 5.0—6.0 36—43 5. 5 mm screw 035—0.!) 3-4 7. 6 mm swew 0.7—1.1 5—3 a. 6mm Hinge bolt and nu: 1.0—1.4 7—10 9. ‘ 8 mm Hang: bolt and rum 2.0—3.0 [4—22 10. ' ID mm flange bull and nul 30-4.!) 22—29 One of Issue: February, 1979 © HONDA MOTOR 00.. LTD. 22-7 $153 / CM4OOT-4OOA MEMO m-- .. m flawhfififlfin 5H0 ‘ , . . i . l. i Ono-0 . . ETEINOE . _ ., , . . . , I Io boat 5.0 35.3.: 2.2.: .2 cowoNl #3 I 38 on: S .5! 1.92.? 33 o .65» .33.. no; :6. HONDA CM400T‘4OOA '79 ADDENDUM V. CABLE AND HARNESS ROUTINE - CM400T CLUTCH CABLE BRAKE HOSE TACHOMETER CAELE ,, . BRAKE HOSE TACHOMETER CABLE Dale of Issac: Februnry, 1979 0 HONDA MOTOR 00., LTD. 2 2' 1 1 @ HONDA CM4OOT- 400A '79 ADDENDUM COUPLER (BLACK) (CM400T 8| CM4OOA) 2 2_ 1 2 Dan nf Issua: February, 1979 O HONDA MOTOR C0,, LTD. HONDA CM400'F400A '79 ADDENDUM o CM400A PARKING BRAKE CABLE BRAKE HOSE THROTTLE CABLES 1 'Txv )\ ¥ "1 V K OKE CABLE BRAKE HOSE PARKING BRAKE CABLE Dale of Issul: February, 1979 © HONDA MOTOR CO‘, LTD. 2 2 ' 1 3 HONDA " '79 ADDENDUM CM4001-400A _o 26-31 Dam of [sum Dmmbgr, I980 O HONDA MOTOR C0,, LID. MEMO