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Honda CM400C - User Manual

Honda CM400C
317 pages
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MANUAL

Table of Contents

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Summary

General Information

General Safety

Safety precautions for engine operation and fuel handling.

Service Rules

Guidelines for servicing the motorcycle, including parts and tools.

Maintenance Schedule

Recommended maintenance intervals and tasks for the motorcycle.

Specifications

Torque Values

Special Tools; Common Tools

Wiring Diagrams

Cable and Harness Routing

Lubrication

Engine Oil & Filter Change

Steps for changing the engine oil and filter.

Inspection and Adjustment

Valve Clearance Adjustment

Steps for adjusting valve clearance.

Carburetor Synchronization

How to synchronize carburetors for optimal performance.

Drive Chain

How to check and adjust drive chain tension.

Fuel System

Carburetor Removal

Steps for removing the carburetors from the engine.

Float Level Adjustment

How to adjust the float level in the carburetor.

Engine Removal & Installation

Engine Removal

Detailed steps for removing the engine from the motorcycle frame.

Engine Installation

Steps for installing the engine back into the motorcycle frame.

Cylinder Head;Valve

Rocker Arm and Camshaft Removal

Procedure for removing rocker arms and camshaft.

Cylinder Head Removal

Steps for removing the cylinder head.

Cylinder;Piston

Piston Removal

Steps for removing the piston pin and piston.

Piston;Piston Ring Inspection

Inspecting piston rings and grooves for clearance and wear.

Clutch;Oil Pump

Clutch Removal

Procedure for removing the entire clutch assembly.

Oil Pump Inspection

Measuring clearances for oil pump tip, body, and end.

Crankcase

Crankcase Disassembly

Procedures for disassembling the crankcase into halves.

Crankcase Assembly

Steps for assembling the crankcase halves.

Crankshaft;Balancer

Connecting Rod Removal

Checking connecting rod side clearance and removing rods.

Main Bearings Inspection

Inspecting main bearing inserts and measuring oil clearance.

Transmission

Transmission Disassembly

Procedures for disassembling the transmission.

Transmission Assembly

Assembling transmission main and countershafts.

Front Wheel;Brake;Suspension

Front Wheel Removal;Disassembly;Assembly

Steps for removing the front wheel from the motorcycle.

Front Fork Removal

Steps for removing the front fork assembly.

Front Fork Assembly

Steps for assembling the front fork components.

Rear Wheel;Brake;Suspension

Rear Wheel Removal;Disassembly;Assembly

Steps for removing the rear wheel from the motorcycle.

Shock Absorber Removal

Steps for removing the shock absorbers.

Shock Absorber Assembly

Assembling the shock absorber components.

Hydraulic Disc Brake

Brake Fluid Replacement;Air Bleeding

Detailed steps for bleeding the hydraulic brake system.

Brake Master Cylinder

Information on brake master cylinder disassembly and inspection.

Brake Caliper

Steps for removing and assembling the brake caliper.

Battery; Charging System

Troubleshooting

Troubleshooting guide for power and charging system failures.

Charging Output Test

Testing charging system output with voltmeter and ammeter.

Ignition System

Troubleshooting

Troubleshooting guide for engine start and running problems related to ignition.

C.D.I. Unit Inspection

Testing C.D.I. unit continuity and resistance.

Starter Motor

Brush Inspection

Inspecting starter motor brushes and measuring length/tension.

Magnetic Switch Inspection

Testing the magnetic switch continuity.

Technical Features

1. Balancer Mechanism

Explanation of the balancer mechanism and its function.

2. 3-Valve, Short-Stroke Engine

Description of the 3-valve, short-stroke engine design.

3. C.D.I. System

Explanation of the C.D.I. electronic ignition system.

Troubleshooting

Engine Does Not Start or Is Hard to Start

Troubleshooting guide for starting issues with possible causes.

Engine Lacks Power

Troubleshooting guide for lack of engine power.

Poor Performance at High Speed

Troubleshooting guide for poor performance at high speeds.

79 Addendum

Maintenance Schedule

Maintenance schedule for 1979 models.

Hydraulic Disc Brake

Specifications and troubleshooting for hydraulic disc brake.

80 Addendum

Model Identification

Model identification for 1980 models.

Specifications

Specifications for 1980 models.

Fuel System

Carburetor specifications and high altitude adjustment for CM400T.

81 Addendum

Model Identification

Model identification for 1981 models.

Specifications

Specifications for 1981 models.

Inspection and Adjustment

Carburetor synchronization procedure for 1981 models.

Hydraulic Disc Brake

Brake pad replacement for CB400T/CM400C.

Summary

General Information

General Safety

Safety precautions for engine operation and fuel handling.

Service Rules

Guidelines for servicing the motorcycle, including parts and tools.

Maintenance Schedule

Recommended maintenance intervals and tasks for the motorcycle.

Specifications

Torque Values

Special Tools; Common Tools

Wiring Diagrams

Cable and Harness Routing

Lubrication

Engine Oil & Filter Change

Steps for changing the engine oil and filter.

Inspection and Adjustment

Valve Clearance Adjustment

Steps for adjusting valve clearance.

Carburetor Synchronization

How to synchronize carburetors for optimal performance.

Drive Chain

How to check and adjust drive chain tension.

Fuel System

Carburetor Removal

Steps for removing the carburetors from the engine.

Float Level Adjustment

How to adjust the float level in the carburetor.

Engine Removal & Installation

Engine Removal

Detailed steps for removing the engine from the motorcycle frame.

Engine Installation

Steps for installing the engine back into the motorcycle frame.

Cylinder Head;Valve

Rocker Arm and Camshaft Removal

Procedure for removing rocker arms and camshaft.

Cylinder Head Removal

Steps for removing the cylinder head.

Cylinder;Piston

Piston Removal

Steps for removing the piston pin and piston.

Piston;Piston Ring Inspection

Inspecting piston rings and grooves for clearance and wear.

Clutch;Oil Pump

Clutch Removal

Procedure for removing the entire clutch assembly.

Oil Pump Inspection

Measuring clearances for oil pump tip, body, and end.

Crankcase

Crankcase Disassembly

Procedures for disassembling the crankcase into halves.

Crankcase Assembly

Steps for assembling the crankcase halves.

Crankshaft;Balancer

Connecting Rod Removal

Checking connecting rod side clearance and removing rods.

Main Bearings Inspection

Inspecting main bearing inserts and measuring oil clearance.

Transmission

Transmission Disassembly

Procedures for disassembling the transmission.

Transmission Assembly

Assembling transmission main and countershafts.

Front Wheel;Brake;Suspension

Front Wheel Removal;Disassembly;Assembly

Steps for removing the front wheel from the motorcycle.

Front Fork Removal

Steps for removing the front fork assembly.

Front Fork Assembly

Steps for assembling the front fork components.

Rear Wheel;Brake;Suspension

Rear Wheel Removal;Disassembly;Assembly

Steps for removing the rear wheel from the motorcycle.

Shock Absorber Removal

Steps for removing the shock absorbers.

Shock Absorber Assembly

Assembling the shock absorber components.

Hydraulic Disc Brake

Brake Fluid Replacement;Air Bleeding

Detailed steps for bleeding the hydraulic brake system.

Brake Master Cylinder

Information on brake master cylinder disassembly and inspection.

Brake Caliper

Steps for removing and assembling the brake caliper.

Battery; Charging System

Troubleshooting

Troubleshooting guide for power and charging system failures.

Charging Output Test

Testing charging system output with voltmeter and ammeter.

Ignition System

Troubleshooting

Troubleshooting guide for engine start and running problems related to ignition.

C.D.I. Unit Inspection

Testing C.D.I. unit continuity and resistance.

Starter Motor

Brush Inspection

Inspecting starter motor brushes and measuring length/tension.

Magnetic Switch Inspection

Testing the magnetic switch continuity.

Technical Features

1. Balancer Mechanism

Explanation of the balancer mechanism and its function.

2. 3-Valve, Short-Stroke Engine

Description of the 3-valve, short-stroke engine design.

3. C.D.I. System

Explanation of the C.D.I. electronic ignition system.

Troubleshooting

Engine Does Not Start or Is Hard to Start

Troubleshooting guide for starting issues with possible causes.

Engine Lacks Power

Troubleshooting guide for lack of engine power.

Poor Performance at High Speed

Troubleshooting guide for poor performance at high speeds.

79 Addendum

Maintenance Schedule

Maintenance schedule for 1979 models.

Hydraulic Disc Brake

Specifications and troubleshooting for hydraulic disc brake.

80 Addendum

Model Identification

Model identification for 1980 models.

Specifications

Specifications for 1980 models.

Fuel System

Carburetor specifications and high altitude adjustment for CM400T.

81 Addendum

Model Identification

Model identification for 1981 models.

Specifications

Specifications for 1981 models.

Inspection and Adjustment

Carburetor synchronization procedure for 1981 models.

Hydraulic Disc Brake

Brake pad replacement for CB400T/CM400C.

Honda CM400C Specifications

General IconGeneral
Displacement395 cc
Bore x Stroke70.5 mm x 50.6 mm
Compression Ratio9.3:1
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Rear SuspensionDual shock absorbers
Front BrakeSingle disc
Rear BrakeDrum
Engine TypeAir-cooled, parallel twin
IgnitionCapacitor Discharge Ignition (CDI)
Seat Height780 mm (30.7 inches)
CarburetionTwin Keihin carburetors

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