Honda CB400A - Shop Manual

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SHOP

MANUAL

Main Page

Introduction2
How to Use this Manual2
Table of Contents2
Model Identification3
Identification Number3
General Information Contents4
General Safety4
Service Rules4
Specifications5
Torque Value7
Standard Torque Specifications8
Special Tools9
Common Tools9
Wiring Diagrams CB400T Type I10
CB400T Type II11
Cable and Hardness Routing12
Maintenance Schedule15
Lubrication Diagram17
Lubrication Contents18
Service Information18
Troubleshooting18
Engie Oil and Filter Change19
Engine Oil Level19
Swingarm Pivot20
Drive Chain20
Miscellaneous Lube Points21
Inspection and Adjustment Contents22
Spark Plugs23
Ignition Timing Check23
Engine23
Valve Clearance Adjustment24
Cam Chain Adjustment24
Idle Speed Adjustment25
Throttle Operation25
Carburetor Synchronization26
Choke Mechanism Maintenance27
Fast Idle Adjustment27
Adjustment27
Balancer Chain Adjustment28
Air Cleaner Maintenance28
Fuel Line Inspection29
Compression Test29
Clutch Adjustment30
Brake Fluid Inspection31
Chassis31
Front Brake Drum31
Front Brake Disc31
Rear Brake32
Brake Pedal Height32
Brake Pedal Free Play33
Stoplight Switch33
Brake Shoe Inspection (Wear Indicator)33
Side Stand34
Wheel Spoke Retightening35
Wheels/Spokes35
Tire Pressure35
Battery Electrolyte35
Fuel System37
Fuel System Contents38
Carburetor Removal39
Carburetor Separation39
Vacuum Cylinder Disassembly41
Float Chamber Disassembly42
Air Cutoff Valve Disassembly43
Craburetor Assembly44
Float Level Adjustment44
Component Assembly44
Craburetor Installation45
Fuel Tank46
Air Cleaner Case Removal/Installation46
Crankcase Ventilation System46
Engine Removal and Installation48
Cylinder Head/Valve53
Rocker Arm and Camshaft Removal54
Rocker Arm Inspection55
Cam Bearing Surface Inspection56
Camshaft Holder Rocker Arm Shaft Hole Inspection56
Rocker Arm Shaft Inspection56
Camshaft Oil Clearance57
Cylinder Head Removal58
Camshaft Runout58
Cam Lobe Inspection58
Cylinder Head Disassembly59
Cylinder Head Inspection60
Valve Spring Free Length Inspection60
Valve Stem-To-Guide Clearance61
Valve Guide Replacement62
Valve Seat Inspection and Grinding63
Cylinder Head Assembly64
Rocker Arm Assembly65
Cylinder Head Installation65
Camshaft/Rocker Arm Installation66
Cylinder/Piston71
Cylinder/Piston Contents72
Cylinder Removal73
Cylinder Inspection73
Piston Removal74
Piston/Piston Ring Inspection74
Piston Ring Installation76
Cylinder Installation78
Piston Installation78
Clutch/Oil Pump81
Clutch/Oil Pump Contents82
R-Crankcase Cover Removal84
Clutch84
Clutch Lifter Removal84
Clutch Lifter Plate Removal84
Clutch Removal85
Clatch Center, Plate and Disc Removal85
Clutch Disc Inspection86
Disc Spring Inspection86
Clutch Spring Inspection86
Plate Inspection87
Clutch Outer and Outer Guide Inspection87
Clutch Installation87
Clutch Lifter and Right Crankcase Cover Installation90
Oil Pump92
Oil Pump Removal92
Oil Pump Disassembly92
Oil Pump Inspection93
Oil Pump Assembly94
Oil Pump Installation94
Oil Pressure Relief Valve95
Right-Crankcase Cover Installation96
Crankcase97
Crankcase Contents98
Crankcase Removal of Parts99
A.C. Generator Removal99
Crankcase Disassembly100
Crankcase Assembly100
Installation of Parts102
A.C. Generator Installation102
Crankshaft/Balancer103
Crankshaft/Balancer Contents104
Balancer Removal106
Balancer Inspection108
Connecting Rod Removal109
Crankshaft/Starter Clutch Removal110
Starter Clutch Inspection110
Starter Drive Gear Inspection110
Crankshaft Inspection110
Electric Starter Idle Gear Removal111
Electric Starter Idle Gear Inspection111
Bearing Inspection112
Connecting Rods112
Main Bearings113
Bearing Selection114
Connecting Rod Bearing Inserts114
Main Bearing115
Starter Idle Gear Installation116
Starter Clutch/Crankshaft Installation116
Connecting Rod Intsallation117
Balancer Installation118
Transmission123
Table of Contents124
Transmission Contents124
Troubleshooting125
Gearshift Linkage Disassembly126
Transmission Disassembly126
- Gear Dog Minimum Clearance at End127
- Transmission Inspection128
- Gearshift Drum/Shift Fork Removal129
- Gearshift Drum and Shift Fork Inspection129
- Kick Starter Inspecction131
Kick Starter Disassembly131
- Kick Starter Assembly132
- Gearshift Drum/Shift Fork Installation133
Transmission Assembly134
Gearshift Linkage Assembly136
- Front Wheel/Brake/Suspension137
- Front Wheel/Brake/Suspension Contents138
- Troubleshooting139
- Headlight140
  - Headlight Case Removal140
  - Headlight Installation140
  - Wiring Connection in Headlight Case140
  - Cluster Disassembly141
  - Indicator Lamp/Combination Switch Replacement141
- Instruments141
- Meter Lamp/Meter Replacement141
- Handlebar142
  - Handlebar Installation142
  - Handlebar Removal142
- Front Wheel Removal/ Disassembly/Assembly143
  - Axle Inspection144
  - Wheel Bearing Inspection144
  - Wheel Inspection144
  - Wheel Disassembly145
  - Front Wheel Assembly146
  - Brake Rod Adjustment147
  - Brake Shoe Replacement147
  - Front Brake Lining Thickness147
- Front Brake Panel147
- Front Wheel Installation148
- Front Fork149
  - Front Fork Removal149
  - Front Damper Spring Free Length Inspection150
  - Front Fork Disassembly150
  - Fork Tube/Fork Slide/Piston Inspection151
  - Oil Seal Removal151
  - Front Fork Assembly152
  - Filling with Fork Oil153
  - Oil Seal Installation153
  - Front Fork Installation154
  - Fork Top Bridge Removal155
- Steering Stem155
  - Steering Head Adjuster Removal156
  - Steering Lock Removal/Installation156
  - Steering Head Adjuster Installation157
  - Top Bridge Installation157
  - Rear Wheel/Brake/Suspension159
  - Rear Wheel/Brake/Suspension Contents160
- Service Information160
- Troubleshooting161
  - Axle Shaft Bend Inspection162
  - Rear Wheel Bearing Play Inspection162
  - Rear Wheel Removal/Disassembly/Assembly162
  - Rear Wheel Rim Runout Inspection162
  - Damper Rubber Inspection164
- Final Driven Sprocket164
  - Final Driven Sprocket Inspection164
  - Rear Wheel Hub Inspection164
  - Brake Drum I.D. Inspection165
  - Rear Brake Lining Thickness165
- Rear Brake Panel165
- Rear Brake Shoe Replacement165
- Rear Wheel Installation166
- Shock Absorber167
  - Shock Absorber Disassembly167
  - Shock Absorber Removal167
- IIV168
  - Shock Absorber Assembly168
  - Shock Absorber Installation168
  - Shock Absorber Spring168
  - Swing Arm Removal169
  - Swingarm Disassembly/Assembly169
  - Swingarm Installation169
  - Brake Pedal Removal/Installation170
  - Rear Brake Pedal170
  - Rear Brake Pedal Height170
  - Hydraulic Disc Brake171
  - Hydraulic Disc Brake Contents172
  - Air Bleeding173
  - Brake Fluid Draining173
  - Brake Fluid Filling173
  - Brake Fluid Replacement/Air Bleeding173
  - Brake Pad Replacement174
  - Brake Pad Wear Check174
  - Brake Pads/Disc Plate174
  - Brake Disc Warpage176
  - Disc Thickness176
  - Brake Master Cylinder177
  - Master Cylinder I.D. Inspection177
  - Matser Cylinder Disassembly177
  - Master Cylinder Assembly178
  - Matser Piston O.D. Ispection178
  - Brake Caliper179
  - Brake Caliper Disassembly179
  - Caliper a Removal179
  - Caliper Assembly179
  - Caliper Carrier/Carrier Assembly180
  - Caliper Carrier/Carrier Disassembly180
  - Caliper Cylinder I.D.180
  - Caliper Piston O.D.180
  - Caliper Installation181
  - Battery/Charge System Contents182
  - Battery Removal184
  - Testing Specific Gravity184
  - Battery Charging185
  - Charging Output Test185
  - Charging System185
  - Stator Coil Continuity Test186
  - Voltage Regulator/Rectifier Test186
  - A.C. Generator Removal/Installation187
  - Voltage Regulator Performance Test187
  - Ignition System Contents188
  - Ignition Coil Performance Test190
  - Ignition Coil Removal190
  - Schematic Diagram Od C.D.I. System190
  - Spark Plug190
  - C.D.I. Unit191
  - A.C. Generator Inspection193
  - Starter Motor Contents194
  - Brush Inspection195
  - Commutator Inspection195
  - Starter Motor Removal195
  - Field Coil Inspection196
  - Magnetic Switch Inspection197
  - Starter Clutch197
  - Balancer Mechanism198
  - Front Balancer Shaft198
  - Rubber Dampers198
  - Technical Features198
  - Operating Principle of Balancer199
  - 3 Valve, Short Stroke Engine201
  - C.D.I. System202
  - Features202
  - Operating Principle203
  - Advancer Operation204
  - Engine Does Not Start or Is Hard to Start206
  - Engine Lacks Power207
  - Poor Performance at Low and Idle Speeds209
  - Poor Handling210
  - Poor Performance at High Speed210
  - '79 Addendum Table of Contents214
- A L L Information, Illustrations, Direc214
- Duced Without Written Permission214
- MAKE CHANGES at any Tlme WITHOUT214
- Motor Co., Lto Reserves the Right to214
- NO PART of Thls PUBLICATION MAY be REPRO214
- Notice and Without Incurring any214
- Obligation Whatever214
- PRODUCT INFORMATION AVAILABLE a T the Tlme of APPROVAL for PRINTING. HONDA214
- TIONS and SPECIFICATIONS INCLUDED I N Thls214
  - Maintenance Schedule CB400T215
  - Inspection and Adjustment Balancer Chain Tension216
  - Brake Fluid220
  - Brake Fluid Replacement220
  - Brake System Draining220
  - Fluid Level220
  - Brake Master Cylinder Disassembly221
  - I.D. Inspection221
  - Master Piston O.D. Inspection222
- Model Identification225
- Specifications226
- Ill. TORQUE VALUES229
  - Wiring Diagrams CM400T232
  - Wiring Diagrams CM400A233
  - Cable and Harness Routing CM400T234
  - Cable and Harness Routing CM400A236
- Emission Control Label238
  - Maintenance Schedule CM400T239
  - Maintenance Schedule CM400A240
  - Air Cleaner241
  - Inspection and Adjustment241
- Hydraulic Disc Brake242
- Fuel System243
  - High Altitude Adjustment243
  - '80 Adendum Contents244
  - Maintenance Schedule CM400T249
  - Control Cable Lubrication251
  - Engine Oil Recommendation251
  - Oil Viscosity251
  - Recommended Spark Plug251
  - Carburetor Assembly252
  - Carburetor Specifications252
  - Float Level Inspection252
  - Accelerator Pump Adjustment253
  - Accelerator Pump Inspection253
  - Pilot Screw Adjustment Idle Drop Procedure254
  - Pilot Screw Removal/Installation254
  - Wiring Diagram CM400T256
  - Wiring Diagram CM400A257
  - '80 CB400T Addendum Contents258
- Inspection and Adjustment258
- Specifications258
  - Cable Routing262
  - Spark Plug Replacement265
  - High Altitude Carburetor Specifications269
  - Limiter Cap Installation269
  - Cylinder Head/Valves270
  - Oil Pressure Relief Valve Removal270
  - Wiring Diagram '80 CB400T Addendum272
  - '80 CM400E Addendum Contents274
  - Maintenance Schedule CM400E278
  - Cable and Harness Routing279
  - Battery283
  - Wheel Spoke Tightening283
  - Wiring Diagram CM400E284
  - '81 CB/CM400'S Addendum Contents286
  - CB400T, CM400C: Front Disc Brake Pad297
- Front Air Forks297
  - Recommended Tire Pressures and Sizes298
  - Wheels298
  - Front Air Forks Removal299
  - Front Air Forks Disassembly300
  - Bushing/Back-Up Ring Inspection302
  - Fork Tube/Piston Inspection302
  - Spring Inspection302
  - Assembly303
  - Installation305
  - CB400T/CM400C: Hydraulic Disc Brake307
- Cb400Tlcm400C307
  - Caliper Removal308
  - Caliper Disassembly309
  - Caliper Carrier Assembly311
  - Caliper Carrier Disassembly311
- Cable and Harness Routing313
Wiring Diagram CM400T/C316

Honda CB400A - Shop Manual

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