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General| Engine Type | Air-cooled, four-stroke, parallel twin |
|---|---|
| Displacement | 395 cc |
| Compression Ratio | 9.3:1 |
| Cooling System | Air-cooled |
| Transmission | 5-speed |
| Front Suspension | Telescopic fork |
| Front Brakes | Single disc |
| Rear Brakes | Drum |
| Front Tire | 3.25-19 |
| Seat Height | 780 mm (30.7 in) |
| Ignition | CDI |
| Rear Suspension | Dual shocks |
| Wheelbase | 1, 410 mm (55.5 in) |
| Bore x Stroke | 70.5 mm x 50.6 mm |
Identifies Type I model for CB400T, showing its location and starting frame number.
Identifies Type II model for CB400T, showing its location and starting frame number.
Details safety warnings for operating the engine and handling gasoline.
Provides essential rules for servicing the motorcycle and using correct tools.
Lists key dimensional, frame, and engine specifications for the CB400T.
Lists torque values for various engine bolts and nuts.
Lists torque values for various chassis bolts and nuts.
Lists specific tools required for particular maintenance tasks.
Lists general tools that can be used for various maintenance tasks.
Illustrates the electrical system for the CB400T Type I model.
Shows the routing of cables and wiring harnesses for the Type I model.
Details the recommended maintenance intervals for various motorcycle components.
Illustrates the engine's lubrication system flow.
Provides working practices and specifications for lubrication.
Lists common lubrication problems and their possible causes.
Explains how to check and maintain the engine oil level.
Details the steps for changing engine oil and replacing the oil filter.
Describes lubrication points for the swingarm pivot.
Provides instructions for lubricating and maintaining the drive chain.
Lists engine specifications and outlines inspection points.
Lists chassis specifications and outlines inspection points.
Details how to inspect, gap, and install spark plugs.
Step-by-step guide for adjusting valve clearance.
Instructions for adjusting the cam chain tension.
Details how to check and adjust throttle grip free play.
Explains how to adjust the engine idle speed.
Guide for synchronizing the carburetors for optimal performance.
Details on adjusting carburetors, including vacuum balance.
Instructions for maintaining the choke mechanism operation.
Explains how to adjust the fast idle speed setting.
Procedure for adjusting the balancer chain tension.
Steps for cleaning and maintaining the air cleaner element.
Guide for inspecting the fuel lines for damage or leaks.
Details on how to perform a compression test on the engine.
Explains how to adjust the clutch lever free play.
Covers inspection of the front disc brake fluid and pads.
Details on checking the front drum brake lever free play.
Covers adjustments for the rear brake pedal height.
Explains how to check and adjust rear brake pedal free play.
Details on adjusting the stoplight switch for proper operation.
Guide for inspecting brake shoes using the wear indicator.
Procedure for checking and adjusting drive chain tension.
Check the side stand for wear, damage, and freedom of movement.
Instructions for checking and maintaining battery electrolyte levels.
Guidance on checking wheels and spokes for condition.
Working practices and special tools for fuel system service.
Lists common fuel system problems and their causes.
Details on how to remove the carburetors from the motorcycle.
Instructions for separating the carburetors.
Procedure for disassembling the vacuum cylinder.
Steps for disassembling the float chamber.
Procedure for disassembling the air cutoff valve.
Instructions for assembling fuel system components.
Guide for adjusting the float level in the carburetor.
Instructions for assembling the right and left carburetors.
Steps for reinstalling the carburetors onto the engine.
Checks and maintenance for the fuel tank and strainer.
Covers air cleaner case removal/installation and crankcase ventilation.
Details on parts needing removal and working practices.
Procedure for removing the engine from the motorcycle frame.
Steps for removing exhaust components and the drive chain.
How to disconnect the AC generator coupler.
Steps for disconnecting breather tubes and carburetor bands.
How to disconnect clutch, tachometer, and starter motor cables.
Disconnecting oil pressure and neutral switch wires.
Procedure for removing the foot peg and kick starter pedal.
Instructions for removing the front engine mounting bracket.
Removing upper engine hanger plates and rear mount bolts.
Steps for installing the engine, including torque specs.
Detailed procedure for removing rocker arms and camshaft.
Instructions for removing the camshaft.
Guide for inspecting rocker arms for wear or damage.
How to inspect rocker arm shafts for wear or damage.
Measuring the I.D. of camshaft holder shaft holes.
Checking cam bearing surfaces for scoring or damage.
Procedure for measuring camshaft oil clearance using Plastigage.
How to check camshaft runout using a micrometer.
Guide for inspecting cam lobes for wear or damage.
Procedure for removing the cylinder head.
Steps for disassembling the cylinder head, including valve components.
Checking cylinder head for cracks and warpage.
Measuring the free length of valve springs.
Procedure for measuring valve stem-to-guide clearance.
Steps for replacing valve guides.
Procedure for inspecting and grinding valve seats.
Detailed instructions for assembling the cylinder head.
Procedure for assembling rocker arms.
Steps for installing the cylinder head.
Procedure for installing the camshaft and rocker arms.
Guide for aligning timing marks on the rotor and sprocket.
Steps for installing dowel pins and camshaft holders.
Adjusting cam chain tension and valve tappet clearance.
Procedure for installing the cylinder head cover gasket.
Working practices and special tools for cylinder/piston service.
Common cylinder/piston problems and their causes.
Detailed procedure for removing the cylinder.
Guide for inspecting cylinder bores for wear.
How to check cylinder warpage.
Procedure for removing pistons from the cylinder.
Guide for inspecting piston rings and grooves.
Checking the end gap of piston rings.
How to measure the piston's outside diameter.
Measuring the inside diameter of the piston pin hole.
Steps for correctly installing piston rings onto the piston.
How to space piston ring end gaps correctly.
Procedure for installing pistons, pins, and clips.
Instructions for installing the cylinders.
Steps for installing the cam chain guide.
How to install the cam chain tensioner.
Working practices for clutch/oil pump service.
Lists key specifications for clutch and oil pump components.
Common issues and solutions for clutch and oil pump systems.
Steps for removing the right crankcase cover.
Procedure for removing the clutch lifter.
Instructions for removing the clutch lifter plate.
Detailed procedure for removing the clutch assembly.
Instructions for removing clutch center, plates, and discs.
Measuring clearance between clutch center and plate B.
Checking the free length of clutch springs.
Guide for inspecting clutch discs for wear or discoloration.
Checking clutch plates for warpage using a surface plate.
Inspecting slots in clutch outer drum and measuring I.D./O.D.
Instructions for installing clutch components.
Steps for assembling the clutch parts into the clutch outer.
Installing the thrust washer and outer guide on the transmission shaft.
Installing and torquing the lock washer and lock nut.
Installing clutch springs, lifter plate, and bolts.
Installing clutch lifter and right crankcase cover.
Illustrates the various parts of the oil pump.
Steps for removing the oil pump.
Procedure for disassembling the oil pump.
Details on measuring oil pump clearances.
Instructions for assembling the oil pump.
Steps for installing the oil pump onto the engine.
Covers removal, checking operation, and location of the relief valve.
Steps for installing the right crankcase cover, clutch, and cables.
Working practices for crankcase repair.
Lists specialized tools needed for crankcase disassembly.
Steps for removing parts before crankcase disassembly.
Detailed steps for removing the AC generator.
Instructions for disassembling the crankcase into halves.
Steps for reassembling the crankcase halves.
Torque values for crankcase assembly bolts.
Procedure for installing the AC generator and rotor.
Sequence for installing remaining parts like gearshift spindle and engine.
Working practices and bearing selection advice.
Identifies the Torx driver bit needed for specific tasks.
Lists standard and service limit measurements for components.
Common issues like excessive noise and their causes.
Steps for removing the balancer assembly from the crankcase.
Removing balancer nuts, stopper plate, clip, and spring.
Checking balancer components like damper rubbers and clearances.
Procedure for removing connecting rods and pistons.
Steps for removing the crankshaft and starter clutch.
Checking the starter clutch roller for smooth rotation.
Inspecting the starter drive gear for damage or wear.
Checking crankshaft runout using a dial indicator.
Procedure for removing the electric starter idle gear.
Checking the idle gear for tooth damage and measuring clearances.
Procedure for inspecting connecting rod bearing inserts.
Steps for inspecting main bearing inserts and measuring oil clearance.
How to select replacement connecting rod bearings.
Inspecting and selecting main bearings based on codes.
Procedure for installing the starter idle gear.
Steps for installing the starter clutch and crankshaft.
Instructions for installing connecting rods and bearing caps.
Procedure for installing the balancer assembly.
Steps for installing the cam chain tensioner.
Adjusting the balancer chain tension.
Procedure for installing the rear balancer.
Instructions for installing the front chain guide.
Steps for installing bearing holders onto the crankshaft journals.
Installing oil strainer pipe and front chain guide bolts.
Adjusting balancer chain tension by loosening the 8 mm nut.
Working practices for transmission servicing.
Lists backlash, gear I.D., bushing, and shaft dimensions.
Common issues like hard shifting and jumping out of gear.
Steps for disassembling the gearshift linkage.
Procedure for separating crankcases and inspecting gears.
Checking gear dog clearance at the end.
Steps for removing main and countershafts.
Checking gear dogs for wear and inspecting gear I.D.
Procedure for removing gearshift drum, forks, and pins.
Checking the shift drum O.D.
Measuring the inside diameter of the transmission case.
Measuring the outside diameter of the shift fork.
Measuring shift fork I.D. and claw thickness.
Steps for disassembling the kick starter mechanism.
Checking the pinion gear I.D.
Procedure for assembling the kick starter.
Steps for installing gearshift drum, forks, and stopper plate.
Procedure for assembling the main and countershafts.
Instructions for assembling the main shaft.
Procedure for installing the countershaft.
Installing the balancer chain guide.
Steps for assembling the gearshift linkage.
General instructions and warnings for front end service.
Lists necessary tools for front wheel, brake, and suspension service.
Lists specifications for axle, wheel, and fork.
Common issues related to steering, wheel, and suspension.
Procedure for removing the headlight case.
Guide for routing and connecting wires in the headlight case.
Procedure for installing the headlight assembly.
Steps for separating the instrument cluster.
Procedure for replacing indicator lamps and switches.
Instructions for replacing meter lamps or meters.
Steps for removing the handlebar assembly.
Instructions for installing the handlebar.
Procedure for removing the front wheel.
Checking the axle for runout.
Checking wheel bearing play.
Checking the wheel rim for runout.
Steps for disassembling the front wheel (Drum and Disc types).
Procedure for assembling the front wheel.
Installing bearings, distance collar, and speedometer gear.
Checking brake lining thickness and drum I.D.
Procedure for installing the front wheel.
Steps for removing the front fork assembly.
Procedure for disassembling the front fork.
Measuring the free length of front damper springs.
Checking fork tubes, sliders, and pistons for wear.
Measuring fork tube runout.
Steps for assembling the front fork.
Procedure for installing the fork oil seal.
Instructions for filling front forks with ATF.
Steps for installing the front forks.
Steps for removing the fork top bridge.
Procedure for removing and installing the steering lock.
Steps for removing the steering head adjuster.
Procedure for installing the steering head adjuster and bearings.
Instructions for positioning and installing the top bridge.
Installing fork covers and tightening the steering stem nut.
Torque specifications for fork bolts and bottom bridge.
General instructions and notes for rear end service.
Lists specialized tools for rear wheel, brake, and suspension.
Lists axle bend, wheel runout, sprocket I.D., and brake specs.
Common issues like wobble, soft suspension, and poor brake performance.
Steps for removing the rear wheel.
Steps for disassembling the rear wheel (Type I and Type II).
Procedure for assembling the rear wheel bearings.
Steps for removing, inspecting, and installing the final driven sprocket.
Measuring the rear wheel hub O.D.
Checking damper rubbers for damage or deterioration.
Checking brake lining thickness and replacing brake shoes.
Procedure for installing the rear wheel, including chain and brake adjustments.
Steps for removing the left shock absorber.
Procedure for disassembling the shock absorber.
Measuring the free length of shock absorber springs.
Steps for assembling the shock absorber.
Procedure for installing the shock absorber.
Procedure for removing the swing arm.
Instructions for disassembling and assembling the swingarm.
Steps for installing the swingarm.
Adjusting the rear brake pedal height.
Steps for removing and installing the brake pedal.
General info and special tools for hydraulic disc brake.
Common issues like air in system and worn pads.
Lists specs for disc thickness, runout, and cylinder/piston dimensions.
Procedure for replacing fluid and bleeding air from the system.
How to check front brake pads for wear using the red line indicator.
Steps for replacing front brake pads.
Installing new brake pads, shim, and pin.
How to measure the disc thickness.
Checking the brake disc for warpage.
Steps for disassembling the master cylinder.
Measuring the master cylinder's inside diameter.
Measuring the master piston's outside diameter.
Steps for assembling the master cylinder.
Steps for removing the brake caliper.
Procedure for disassembling Brake Caliper A.
Measuring caliper piston O.D.
Measuring caliper cylinder I.D.
Steps for disassembling caliper carrier and carrier B.
Procedure for assembling caliper carrier and caliper B.
Assembling caliper B and installing caliper onto the front fork.
Common issues with power, engine running, and charging system.
Procedure for removing the motorcycle battery.
How to test battery specific gravity using a hydrometer.
Instructions for charging the motorcycle battery.
How to test the charging system output.
Checking stator coil continuity.
Checking resistances of the voltage regulator/rectifier.
Testing voltage regulator performance with a voltmeter.
Procedure for removing and installing the AC generator.
Common issues with starting, running poorly, and no spark.
Refers to Section 3 for spark plug gap inspection.
Steps for removing and testing the ignition coil.
Details on testing CDI unit continuity.
Lists CDI unit specifications for different models.
How to test AC generator stator coil continuity.
Working practices for starter motor removal.
Procedure for removing the starter motor.
Checking starter motor brushes and spring tension.
Procedure for inspecting the starter motor commutator.
Checking field coil continuity.
Steps for assembling and installing the starter motor.
Procedure for testing the magnetic switch.
Refers to Section 10 for starter clutch repairs.
Describes how the balancer mechanism counteracts inertia forces.
Explains the operating principle of the balancer system.
Illustrates centrifugal force acting on counterweights and balancers.
Details the 3-valve, short-stroke engine design features.
Describes the CDI system's design and features.
Explains the operating principle of the CDI ignition system.
Details how the ignition timing advance works.
Illustrates pulser wave forms and SCR trigger voltage.
Diagnosing issues when the engine lacks power.
Troubleshooting starting issues like no fuel or no spark.
Diagnosing problems related to fouled or discolored spark plugs.
Troubleshooting incorrect oil levels.
Diagnosing problems with insufficient valve train lubrication.
Troubleshooting engine overheating causes.
Identifying causes of engine knocking.
Diagnosing poor performance at low and idle speeds.
Diagnosing poor performance at high speeds.
Troubleshooting issues related to steering and wheel wobble.
Scheduled maintenance intervals for CM400T.
Procedure for adjusting balancer chain tension.
Specifications for hydraulic disc brake components.
Common issues with hydraulic disc brakes.
How to check and maintain brake fluid level.
Steps for replacing brake fluid.
Procedure for disassembling the brake master cylinder.
Measuring the master cylinder's inside diameter.
Measuring the master piston's outside diameter.
Procedure for assembling the master cylinder.
Shows the CM400T model with its beginning F/N.
Shows the CM400A model with its beginning F/N.
Lists metric and English specifications for T and A models.
Lists torque values for various engine bolts and nuts.
Lists torque values for various chassis bolts and nuts.
Lists torque values for common bolts and nuts.
Electrical wiring diagram for the CM400T model.
Illustrates cable and harness routing for CM400T.
Shows cable and harness routing for CM400T and CM400A.
Location and purpose of the emission control label.
Scheduled maintenance intervals for CM400T.
Scheduled maintenance intervals for CM400A.
Procedure for inspecting, replacing, and gapping spark plugs.
Instructions for lubricating throttle and clutch cables.
Specifies recommended engine oil type and viscosity.
Notes on CM400T carburetor bore and accelerator pump.
Lists specs for idle speed, float level, and venturi size.
Procedure for separating carburetors.
Steps for assembling carburetors.
How to measure float level using a float gauge.
Checking diaphragm for cracks and rod for bends.
Adjusting clearance between pump rod and adjusting arm.
Procedure for removing and installing pilot screws.
Steps for adjusting pilot screws for idle drop.
Installing limiter caps after pilot screw adjustment.
Adjusting carburetors for high altitude riding.
Electrical wiring diagram for the CM400T model.
Illustrates cable and harness routing for CM400T/CM400 Custom.
Shows routing of wires and cables.
Provides maintenance intervals for CM400T.
Procedure for inspecting, replacing, and gapping spark plugs.
Instructions for lubricating throttle and clutch control cables.
Specifies recommended engine oil type and viscosity.
Notes on CM400T carburetor bore and accelerator pump.
Lists specs for idle speed, float level, and venturi size.
Procedure for separating carburetors.
Instructions for assembling carburetors.
How to measure float level using a float gauge.
Checking diaphragm for cracks and rod for bends.
Adjusting clearance between pump rod and adjusting arm.
Procedure for removing and installing pilot screws.
Steps for adjusting pilot screws for idle drop.
Installing limiter caps after pilot screw adjustment.
Adjusting carburetors for high altitude riding.
Procedure for installing the cylinder head.
Steps for removing the oil pressure relief valve.
Lists backlash, gear I.D., bushing, and shaft measurements.
Shows the CB400T model with its beginning F/N.
Shows the CM400A model with its beginning F/N.
Shows the CM400E model with its beginning F/N.
Shows the CM400C model with its beginning F/N.
Lists metric and English specs for CB400T/CM400T.
Lists specifications for various electrical and light components.
Lists metric and English specifications for CM400A/CM400E.
Lists metric and English specifications for CM400 CUSTOM.
Illustrates cable and harness routing for CM400T.
How to check front disc brake pads for wear.
Procedure for measuring front fork air pressure.
Notes on wheels and recommended tire pressures/sizes.
Steps for removing front air forks.
Procedure for disassembling front fork tubes.
Steps for removing dust seal, snap-ring, and backup plate.
Checking free length of fork springs.
Checking fork tubes, sliders, and pistons for wear.
Visually inspecting slider and fork pipe bushings.
Steps for assembling the front fork.
Procedure for installing front forks and tightening bolts.
Installing air hose connector and filling fork tubes with air.
Steps for replacing brake pads.
Procedure for removing the brake caliper.
Procedure for disassembling the caliper.
Measuring caliper piston O.D.
Measuring caliper cylinder I.D.
Steps for assembling caliper parts.
Procedure for assembling the caliper carrier.
Procedure for installing the caliper onto the front fork.
Illustrates cable and harness routing for CM400T/CM400 Custom.
Illustrates cable and harness routing for CM400A.
Illustrates cable and harness routing for CB400T.
Illustrates cable and harness routing for CM400E.
Electrical wiring diagram for CM400T/C models.
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