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Honda CM400A - User Manual

Honda CM400A
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MANUAL

Table of Contents

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Summary

General Information

General Safety

Essential safety precautions for operating and maintaining the motorcycle, including ventilation and fire safety.

Service Rules

Guidelines for proper service procedures, including using genuine parts and tools, and maintaining cleanliness.

Specifications

Detailed technical specifications for the motorcycle's dimensions, frame, engine, and other key components.

Torque Values

Specific torque values for engine and chassis bolts and nuts to ensure correct assembly and prevent damage.

Lubrication

Lubrication Diagram

Schematic illustrating the oil flow path throughout the engine for proper lubrication.

Engine Oil Level and Oil & Filter Change

Procedures for checking engine oil level and performing oil and filter changes for engine longevity.

Drive Chain Lubrication

Instructions for lubricating the drive chain, including cleaning and proper saturation techniques.

Inspection and Adjustment

Spark Plug and Ignition Timing

Procedures for inspecting spark plugs and checking ignition timing for optimal engine performance.

Valve Clearance and Cam Chain Adjustment

Steps for inspecting and adjusting valve clearance and cam chain tension for engine timing accuracy.

Throttle Operation and Idle Speed

Guidance on checking throttle operation and adjusting idle speed for smooth engine running.

Carburetor Synchronization

Procedure for synchronizing carburetors using vacuum gauges for balanced engine operation.

Brake Inspection and Adjustment

Inspection and adjustment procedures for front (disc and drum) and rear brakes for safety.

Wheels and Spokes

Information on checking tire pressure, wheel spoke tightening, and tire inspection for safety.

Fuel System

Carburetor Removal and Assembly

Detailed steps for removing, separating, and assembling the carburetors for maintenance.

Vacuum Cylinder Disassembly

Procedure for disassembling the vacuum cylinder, including inspection of internal parts.

Float Level Adjustment

Instructions for adjusting the float level in the carburetor for correct fuel delivery.

Engine Removal & Installation

Engine Removal Procedures

Step-by-step guide for safely removing the engine from the motorcycle frame for servicing.

Engine Installation Procedures

Guidance for reinstalling the engine, emphasizing proper routing of wires and cables.

Cylinder Head;Valve Service

Rocker Arm and Camshaft Removal

Instructions for removing rocker arms and camshaft, emphasizing careful handling to prevent damage.

Valve Clearance Inspection

Procedures for measuring valve spring free length and checking valve stem-to-guide clearance.

Valve Guide Replacement

Detailed steps for removing and installing new valve guides, including reaming and cleaning.

Cylinder Head Assembly

Steps for assembling the cylinder head, including valve stem seals, springs, and keepers.

Cylinder;Piston Service

Cylinder Removal and Inspection

Procedure for removing the cylinder and inspecting cylinder bores for wear and damage.

Piston Removal and Inspection

Guide for removing pistons and inspecting them for wear, damage, and ring groove condition.

Piston Ring Installation

Instructions for installing piston rings, ensuring correct placement of end gaps and orientation.

Clutch;Oil Pump Service

Right Crankcase Cover Removal

Steps for removing the right crankcase cover to access clutch and oil pump components.

Clutch Removal and Inspection

Procedures for removing clutch components and inspecting discs, springs, and plates for wear.

Oil Pump Removal and Inspection

Guide for removing and inspecting the oil pump, including tip, body, and end clearances.

Crankcase Service

Removal of Parts

Overview of parts to be removed before crankcase disassembly, including engine and generator.

AC Generator Removal

Instructions for removing the AC generator rotor, stator, and pulser for service.

Crankcase Disassembly and Assembly

Steps for disassembling and reassembling the crankcase halves, including sealant application.

Crankshaft;Balancer Service

Connecting Rod Removal and Installation

Procedures for removing and installing connecting rods, including bearing inspection and clearance checks.

Crankshaft Inspection

Methods for inspecting crankshaft runout and starter clutch components for wear or damage.

Bearing Inspection and Selection

Guide to inspecting main and connecting rod bearings, including clearance measurement and selection.

Transmission Service

Transmission Disassembly and Inspection

Steps for disassembling the transmission and inspecting gears for backlash and wear.

Gearshift Drum;Shift Fork Service

Procedures for removing, inspecting, and installing the gearshift drum and shift forks.

Kick Starter Assembly

Instructions for assembling the kick starter mechanism, including spindle and pinion gear.

Front Wheel;Brake;Suspension

Front Wheel Removal and Assembly

Detailed steps for removing and installing the front wheel, including axle and bearing checks.

Handlebar Inspection and Installation

Procedures for removing and installing the handlebar, including throttle and switch housing.

Front Fork Disassembly and Assembly

Guide to disassembling and assembling front forks, including spring inspection and oil filling.

Steering Stem Service

Procedures for removing and installing the steering stem, including head adjuster and ball bearings.

Rear Wheel;Brake;Suspension

Rear Wheel Removal and Installation

Steps for removing and installing the rear wheel, including axle and bearing checks.

Rear Brake Panel Service

Inspection and replacement procedures for rear brake lining thickness and brake shoes.

Shock Absorber Service

Instructions for removing, disassembling, and installing shock absorbers, including spring length.

Swingarm Service

Procedures for removing, disassembling, and installing the swingarm, including pivot bolt torque.

Hydraulic Disc Brake Service

Brake Fluid Replacement and Air Bleeding

Steps for draining, filling, and bleeding the hydraulic brake system for optimal performance.

Brake Pad Replacement

Guide for checking and replacing front disc brake pads, ensuring proper caliper piston movement.

Brake Master Cylinder Service

Procedures for disassembling and inspecting the master cylinder, including piston and cylinder dimensions.

Brake Caliper Service

Instructions for removing, disassembling, and assembling the brake caliper, including piston and seal checks.

Battery;Charging System

Battery Service and Charging

Guidelines for checking battery specific gravity, removing, and charging the battery safely.

Charging System Testing

Procedures for testing the charging system output using a voltmeter and ammeter.

Stator Coil and Voltage Regulator Tests

Methods for testing stator coil continuity and voltage regulator/rectifier resistances.

Ignition System

Spark Plug and Ignition Coil Service

Instructions for servicing spark plugs and ignition coils, including performance testing.

CDI Unit Inspection

Procedure for inspecting the CDI unit's continuity using an electrical tester.

AC Generator Inspection

Methods for inspecting AC generator stator coils and related wiring for continuity.

Starter Motor Service

Starter Motor Removal and Brush Inspection

Steps for removing the starter motor and inspecting brushes and commutator for wear.

Field Coil and Assembly;Installation

Inspection of field coils and procedures for assembling and installing the starter motor.

Magnetic Switch and Starter Clutch

Testing the magnetic switch and referencing starter clutch service information.

Technical Features

Balancer Mechanism Overview

Explanation of the balancer mechanism's role in counteracting inertia forces for smooth power.

Operating Principle of Balancer

Detailed explanation of how balancers create centrifugal force to neutralize engine vibration.

3-Valve, Short-Stroke Engine Design

Description of the engine's 3-valve design and short-stroke characteristics for improved performance.

CDI System Features

Overview of the CDI ignition system's benefits, including maintenance-free operation and improved spark.

Troubleshooting

Engine Starting Issues

Diagnostic guide for troubleshooting engine starting problems, from fuel to ignition issues.

Engine Power and Performance Issues

Troubleshooting steps for engine power loss, poor performance at low/high speeds, and handling problems.

1979 Addendum

Maintenance Schedule (1979)

Scheduled maintenance intervals for the 1979 models, detailing inspection and service items.

Balancer Chain Tension Adjustment

Procedure for adjusting balancer chain tension if the chain is noisy, ensuring proper tension.

Hydraulic Disc Brake Specifications

Specifications for the hydraulic disc brake system, including measurements and service limits.

1980 CB400 T Addendum

Model Identification (1980 CB400 T)

Visual identification of the 1980 CB400T model, showing key features and serial number information.

Specifications (1980 CB400 T)

Detailed metric and English specifications for the 1980 CB400T model.

Inspection and Adjustment: Carburetor Synchronization

Procedure for synchronizing carburetors, including idle speed and vacuum difference checks.

Fuel System: High Altitude Adjustment

Instructions for adjusting carburetors for improved performance at high altitudes.

1980 CM400 E Addendum

Model Identification (1980 CM400 E)

Visual identification of the 1980 CM400E model, showing key features and serial number information.

Specifications (1980 CM400 E)

Detailed metric and English specifications for the 1980 CM400E model.

Maintenance Schedule (1980 CM400 E)

Scheduled maintenance intervals for the 1980 CM400E, detailing service items and frequencies.

1981 CB;CM400 S Addendum

Model Identification (81 CB;CM400 s)

Visual identification of the 1981 CB400T/CM400 models, including frame numbers.

Specifications (81 CB400 T;CM400 T-A-E-C)

Detailed specifications for 1981 CB400T and CM400T models, covering dimensions and engine details.

Inspection and Adjustment: Carburetor Synchronization

Procedure for synchronizing carburetors, including idle speed and vacuum difference checks.

Front Air Forks Service

Instructions for removing, disassembling, and filling front air forks with appropriate pressure.

Hydraulic Disc Brake Pad Replacement

Steps for replacing front disc brake pads, including caliper and pad pin procedures.

Summary

General Information

General Safety

Essential safety precautions for operating and maintaining the motorcycle, including ventilation and fire safety.

Service Rules

Guidelines for proper service procedures, including using genuine parts and tools, and maintaining cleanliness.

Specifications

Detailed technical specifications for the motorcycle's dimensions, frame, engine, and other key components.

Torque Values

Specific torque values for engine and chassis bolts and nuts to ensure correct assembly and prevent damage.

Lubrication

Lubrication Diagram

Schematic illustrating the oil flow path throughout the engine for proper lubrication.

Engine Oil Level and Oil & Filter Change

Procedures for checking engine oil level and performing oil and filter changes for engine longevity.

Drive Chain Lubrication

Instructions for lubricating the drive chain, including cleaning and proper saturation techniques.

Inspection and Adjustment

Spark Plug and Ignition Timing

Procedures for inspecting spark plugs and checking ignition timing for optimal engine performance.

Valve Clearance and Cam Chain Adjustment

Steps for inspecting and adjusting valve clearance and cam chain tension for engine timing accuracy.

Throttle Operation and Idle Speed

Guidance on checking throttle operation and adjusting idle speed for smooth engine running.

Carburetor Synchronization

Procedure for synchronizing carburetors using vacuum gauges for balanced engine operation.

Brake Inspection and Adjustment

Inspection and adjustment procedures for front (disc and drum) and rear brakes for safety.

Wheels and Spokes

Information on checking tire pressure, wheel spoke tightening, and tire inspection for safety.

Fuel System

Carburetor Removal and Assembly

Detailed steps for removing, separating, and assembling the carburetors for maintenance.

Vacuum Cylinder Disassembly

Procedure for disassembling the vacuum cylinder, including inspection of internal parts.

Float Level Adjustment

Instructions for adjusting the float level in the carburetor for correct fuel delivery.

Engine Removal & Installation

Engine Removal Procedures

Step-by-step guide for safely removing the engine from the motorcycle frame for servicing.

Engine Installation Procedures

Guidance for reinstalling the engine, emphasizing proper routing of wires and cables.

Cylinder Head;Valve Service

Rocker Arm and Camshaft Removal

Instructions for removing rocker arms and camshaft, emphasizing careful handling to prevent damage.

Valve Clearance Inspection

Procedures for measuring valve spring free length and checking valve stem-to-guide clearance.

Valve Guide Replacement

Detailed steps for removing and installing new valve guides, including reaming and cleaning.

Cylinder Head Assembly

Steps for assembling the cylinder head, including valve stem seals, springs, and keepers.

Cylinder;Piston Service

Cylinder Removal and Inspection

Procedure for removing the cylinder and inspecting cylinder bores for wear and damage.

Piston Removal and Inspection

Guide for removing pistons and inspecting them for wear, damage, and ring groove condition.

Piston Ring Installation

Instructions for installing piston rings, ensuring correct placement of end gaps and orientation.

Clutch;Oil Pump Service

Right Crankcase Cover Removal

Steps for removing the right crankcase cover to access clutch and oil pump components.

Clutch Removal and Inspection

Procedures for removing clutch components and inspecting discs, springs, and plates for wear.

Oil Pump Removal and Inspection

Guide for removing and inspecting the oil pump, including tip, body, and end clearances.

Crankcase Service

Removal of Parts

Overview of parts to be removed before crankcase disassembly, including engine and generator.

AC Generator Removal

Instructions for removing the AC generator rotor, stator, and pulser for service.

Crankcase Disassembly and Assembly

Steps for disassembling and reassembling the crankcase halves, including sealant application.

Crankshaft;Balancer Service

Connecting Rod Removal and Installation

Procedures for removing and installing connecting rods, including bearing inspection and clearance checks.

Crankshaft Inspection

Methods for inspecting crankshaft runout and starter clutch components for wear or damage.

Bearing Inspection and Selection

Guide to inspecting main and connecting rod bearings, including clearance measurement and selection.

Transmission Service

Transmission Disassembly and Inspection

Steps for disassembling the transmission and inspecting gears for backlash and wear.

Gearshift Drum;Shift Fork Service

Procedures for removing, inspecting, and installing the gearshift drum and shift forks.

Kick Starter Assembly

Instructions for assembling the kick starter mechanism, including spindle and pinion gear.

Front Wheel;Brake;Suspension

Front Wheel Removal and Assembly

Detailed steps for removing and installing the front wheel, including axle and bearing checks.

Handlebar Inspection and Installation

Procedures for removing and installing the handlebar, including throttle and switch housing.

Front Fork Disassembly and Assembly

Guide to disassembling and assembling front forks, including spring inspection and oil filling.

Steering Stem Service

Procedures for removing and installing the steering stem, including head adjuster and ball bearings.

Rear Wheel;Brake;Suspension

Rear Wheel Removal and Installation

Steps for removing and installing the rear wheel, including axle and bearing checks.

Rear Brake Panel Service

Inspection and replacement procedures for rear brake lining thickness and brake shoes.

Shock Absorber Service

Instructions for removing, disassembling, and installing shock absorbers, including spring length.

Swingarm Service

Procedures for removing, disassembling, and installing the swingarm, including pivot bolt torque.

Hydraulic Disc Brake Service

Brake Fluid Replacement and Air Bleeding

Steps for draining, filling, and bleeding the hydraulic brake system for optimal performance.

Brake Pad Replacement

Guide for checking and replacing front disc brake pads, ensuring proper caliper piston movement.

Brake Master Cylinder Service

Procedures for disassembling and inspecting the master cylinder, including piston and cylinder dimensions.

Brake Caliper Service

Instructions for removing, disassembling, and assembling the brake caliper, including piston and seal checks.

Battery;Charging System

Battery Service and Charging

Guidelines for checking battery specific gravity, removing, and charging the battery safely.

Charging System Testing

Procedures for testing the charging system output using a voltmeter and ammeter.

Stator Coil and Voltage Regulator Tests

Methods for testing stator coil continuity and voltage regulator/rectifier resistances.

Ignition System

Spark Plug and Ignition Coil Service

Instructions for servicing spark plugs and ignition coils, including performance testing.

CDI Unit Inspection

Procedure for inspecting the CDI unit's continuity using an electrical tester.

AC Generator Inspection

Methods for inspecting AC generator stator coils and related wiring for continuity.

Starter Motor Service

Starter Motor Removal and Brush Inspection

Steps for removing the starter motor and inspecting brushes and commutator for wear.

Field Coil and Assembly;Installation

Inspection of field coils and procedures for assembling and installing the starter motor.

Magnetic Switch and Starter Clutch

Testing the magnetic switch and referencing starter clutch service information.

Technical Features

Balancer Mechanism Overview

Explanation of the balancer mechanism's role in counteracting inertia forces for smooth power.

Operating Principle of Balancer

Detailed explanation of how balancers create centrifugal force to neutralize engine vibration.

3-Valve, Short-Stroke Engine Design

Description of the engine's 3-valve design and short-stroke characteristics for improved performance.

CDI System Features

Overview of the CDI ignition system's benefits, including maintenance-free operation and improved spark.

Troubleshooting

Engine Starting Issues

Diagnostic guide for troubleshooting engine starting problems, from fuel to ignition issues.

Engine Power and Performance Issues

Troubleshooting steps for engine power loss, poor performance at low/high speeds, and handling problems.

1979 Addendum

Maintenance Schedule (1979)

Scheduled maintenance intervals for the 1979 models, detailing inspection and service items.

Balancer Chain Tension Adjustment

Procedure for adjusting balancer chain tension if the chain is noisy, ensuring proper tension.

Hydraulic Disc Brake Specifications

Specifications for the hydraulic disc brake system, including measurements and service limits.

1980 CB400 T Addendum

Model Identification (1980 CB400 T)

Visual identification of the 1980 CB400T model, showing key features and serial number information.

Specifications (1980 CB400 T)

Detailed metric and English specifications for the 1980 CB400T model.

Inspection and Adjustment: Carburetor Synchronization

Procedure for synchronizing carburetors, including idle speed and vacuum difference checks.

Fuel System: High Altitude Adjustment

Instructions for adjusting carburetors for improved performance at high altitudes.

1980 CM400 E Addendum

Model Identification (1980 CM400 E)

Visual identification of the 1980 CM400E model, showing key features and serial number information.

Specifications (1980 CM400 E)

Detailed metric and English specifications for the 1980 CM400E model.

Maintenance Schedule (1980 CM400 E)

Scheduled maintenance intervals for the 1980 CM400E, detailing service items and frequencies.

1981 CB;CM400 S Addendum

Model Identification (81 CB;CM400 s)

Visual identification of the 1981 CB400T/CM400 models, including frame numbers.

Specifications (81 CB400 T;CM400 T-A-E-C)

Detailed specifications for 1981 CB400T and CM400T models, covering dimensions and engine details.

Inspection and Adjustment: Carburetor Synchronization

Procedure for synchronizing carburetors, including idle speed and vacuum difference checks.

Front Air Forks Service

Instructions for removing, disassembling, and filling front air forks with appropriate pressure.

Hydraulic Disc Brake Pad Replacement

Steps for replacing front disc brake pads, including caliper and pad pin procedures.

Honda CM400A Specifications

General IconGeneral
Bore x Stroke70.5 mm x 50.6 mm
Compression Ratio9.3:1
Transmission2-speed automatic
Final DriveChain
Cooling SystemAir
Front SuspensionTelescopic fork
Rear SuspensionDual shocks
Front BrakeSingle disc
Rear BrakeDrum
Engine TypeAir-cooled, 4-stroke, parallel twin
Wheelbase1, 410 mm (55.5 in)

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