Honda 1978 CB400A Shop Manual Download Page 1

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Summary of Contents for 1978 CB400A

Page 2: ...ction 18 If you don t know the source of the trouble see section 19 TROUBLESHOOTING Refer to the addendum at the back of the shop manual for 1978 and subsequent years service information ALL PHTOGRAPH...

Page 3: ...erial number is stamped on the right side The legal vehicle identification number WIN is on of the steering head the left side of the steerins head The engine serial number is stamped on the top of th...

Page 4: ...moke or allow flames or sparks near the battery especially while charging it SERVICE RULES 1 Use geniune HONDA or HONDA recommended parts and lubricants or their equ valent Parts that do not meet HOND...

Page 5: ...CO LTD Bore and stroke Displacement Compression ratio Valve train Oil capacity Lubrication system Cylinder head compression pressure 70 5 x 50 6 mm 2 776 x 1 992 in 395 cc 24 1 cu in 9 3 1 Chain driv...

Page 6: ...aHONDA GENERAL INFORMATION Date of Issue September 1977 0 HONDA MOTOR CO LTD 1 3...

Page 7: ...x 33 UBS bolt Caliper set bolt 10 x 32 flange bolt Front brake caliper bleeder valve Rear brake stopper arm nut 8 mm nut Front axle nut Front axle holder nut 8 mm nut Rear axle nut Final driven sprock...

Page 8: ...uts 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 mm screw 6 mm screw 6 mm flange bolt and nut 8 mm flange bolt and nut 10 mm flange bolt and nut Torque...

Page 9: ...socket 26 x 29 mml Extension bar Universal holder Rotor puller Valve guide remover 5 5 rnml IN1 Valve guide remover 6 6 mml EX1 Bearing driver outer 42 x 47 mml Bearing driver pilot 15 mm Bearing dri...

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Page 12: ...MATION CABLE AND TYPE I HARNESS ROUTING CLUTCH CAB BRAKE CABLE HROTTLE CABLE CLOSE THROTTLE CABLE OPEN MAIN WIRE HARNESS THROTTLE CABLES SPEEDOMETER CABLE WlRE BANDS CLUTCHCABLE Date of Issue February...

Page 13: ...aHONDA GENERAL INFORMATION TYPE 11 CLUTCHCABLE BRAKE HOSE CHOKE CABLE OTTLE CABLE OPEN1 CHOKE CAB1 BRAKE CABLE E CABLE 1 1 0 Date of Issue February 1979 O HONDA MOTOR CO LTD...

Page 14: ...HONDA C B 4 0 0 T GENERAL INFORMATION RECEPTACLE BLACK Date of Issue February 1979 O HONDA MOTOR CO LTD 1 11...

Page 15: ...nance period I INSPECT CLEAN ADJUST OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST NOTES 11 More frequent service may be required when riding in dusty areas 2 For higher odometer readings repeat a...

Page 16: ...HONDA C B 4 0 0 T M E M O...

Page 17: ...LUBRICATION HONDA C B 4 0 0 T LUBRICATION DIAGRAM Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 18: ...l leaks 3 Worn piston rings 3 0 liters 3 2 qt at engine assembly 2 5 liters 2 6 qt 1 at oil change HONDA 4 strpke oil or equivalent rated SE 1OW 40 11 i 1 liters 4 000 rpm Oil Contamination 1 Oil or f...

Page 19: ...may be left in the recesses of 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...

Page 20: ...d cleaned prio ic to lubrication Carefully remove the master link retaining clip with pliers Do not bend or twist the clip Remove the master link Remove the drive chain from the motorcycle Clean the d...

Page 21: ...end of the clip will face the direc I tion of forward wheel rotation The master link is the most critical part affecting the security of the drive chain Master links are reusable if they remain in ex...

Page 22: ...alve clearance IN 0 10 i 0 02 mm 0 004 0 0008 in EX 0 W 0 02 mm 0 006 i 0 0008 in Throttle free play 2 6 mm 0 08 0 24 in Idle speed 1 200 100 rpm Synchronizationvacuum 200 240 mmHg Fast idle speed 2 5...

Page 23: ...GAP 0 6 0 7 mm 10 024 0 028 in RECOMMENDED SPARK PLUG NGK D8EA ND X24ES U Reinstall the spark plugs and reconnect the spark plug caps NOTE First tighten the spark plug finger tight then tighten with a...

Page 24: ...on the compression stroke The rockers should be loose VALVE CLEARANCE IN 0 10 0 02 mm 0 004 i 0 0008 in EX 0 14 t 0 02 mm 0 006 i 0 0008 in Adjust by loosening the lock nut and turning the screw unti...

Page 25: ...m fully closed to fully opened positions a t all steering positions Adjust or replace if necessary IDLE SPEED ADJUSTMENT 2 6 mm 118 714 in NOTE Adjust idle after synchronizing carbure tors The engine...

Page 26: ...fuel valve OFF and remove the fuel tube and fuel tank Prepare a longer fuel tube and reconnect it to the fuel tank and carburetor Position the tank higher than the carburetors Remove the plugs from c...

Page 27: ...eat CHOKE MECHANISM MAINTEMIBEMAMQ Check for smooth choke knob operation Pull the choke knob to fully closed and make sure that the choke i s fully closed When adjustment is necessary loosen the choke...

Page 28: ...lbs ft is lowered so that the groove contacts Remove the 10 mm and 8 mm nuts remove the stopper plate 1 Install the stopper plate with different spline engagement Reinstall 8 mm and 10 mm nuts and ti...

Page 29: ...engine Remove the spark plugs Insert the compression gauge Open the choke and throttle valves fully Crank the engine electrically or operate the kick starter stops rising The maximum reading is usual...

Page 30: ...located at theclutch housing Loosen the lock nut and turn the clutch cable adjust ing nut Minor adjustments can be made with the clutch cable adjuster located on the clutch lever Loosenthe lock nut an...

Page 31: ...tay with one fluid as they are not compatible Do not remove the cap until the handlebar has been turned full right so that the reservoir is level Avoid operating the brake lever with the cap removed B...

Page 32: ...the adjusting nut Minor adjustments can be made with the brake cable adjuster located on the brake lever Loosenthe lock nut and turn the adjuster Recheck the brake operation REAR BRAKE BRAKE PEDAL HEI...

Page 33: ...TCH Adjust the stoplight switch so that the stop light will come on when the brake pedal is depressed 20 mm 314 in where the brake just starts to engage Adjust by turning the switch adjusting nut BRAK...

Page 34: ...l number of turns until the correct drive chain tension is obtained Be sure that the index mark aligns with the same graduation on the scale on both sides Tighten the axle nut and install a new cotter...

Page 35: ...with skin or eves WHEELS SPOKES a TIRE PRESSURE NOTE Tire pressure should be checked when the tires are COLD Check the tires for cuts imbedded nails or other sharp objects a WHEEL SPOKE RETIGHTENING T...

Page 36: ...HONDA C B 4 0 0 T M E M O...

Page 37: ...FUEL SYSTEM HONDA C 8 4 0 0 T Date of Issue September 1977 HONDA MOTOR CO LTD...

Page 38: ...lay Engine Cranks But Won t Start 1 No fuel in tank 2 No fuel to cylinders 3 Too much fuel getting to cylinders 4 No spark at plugs ignition malfunction 5 Air cleaner clogged Engine Idles Roughly Stal...

Page 39: ...etor carburetor engine Push down on the carburetors while carefully pulling them back evenly Unscrew the lock nuts and disconnect the throttle cables at the carburetors Remove the clamp holding the ch...

Page 40: ...lief spring from the choke lever Unscrew the four screws attaching the rear stay to the carburetors and remove the rear stay Remove the four screws attaching the front stay and remove the front stay D...

Page 41: ...r wear nicks scratches or other damage Make sure that the piston moves up and down freely in the cvlinder Remove the full open stopper Remove the needle set screw Separate the jet needle from the pist...

Page 42: ...e float chamber body Remove the secondary main jet Remove the primary main jet Remove the slow jet plug NOTE The slow air jet cannot be removed since it is a tight press fit in the carbure Take out th...

Page 43: ...t and float valve Inspect the float valve and seat for grooves nicks deposits or other defects AIR CUTOFF VALVE DISASSEMBLY Remove the air cutoff valve cover and pull out the spring Removethe diaphrag...

Page 44: ...s assembly procedure FLOAT LEVEL ADJUSTMENT To adjust the float level bend the float arm carefully until the float tip just contacts the float valve FLOAT LEVEL 15 5 mm 10 61 in pry CARBURETOR ASSEMBL...

Page 45: ...on is the reverse of the removal PUSH cables After assembly perform the follow ing adjustments Throttle grip free play Section 3 Carburetor synchronization Sec tion 3 Idle adjustment Section 3 Fast id...

Page 46: ...ed asoline at once I Check that fuel is flowing out of the fuel valve freely If the fuel flow is restricted clean the fuel strainer NOTE Do not overtighten the fuel valve lock 1 nut Make sure there ar...

Page 47: ...N C B 4 0 0 T TIGHTENING TORQUES 10 m m FLANGE BOLT AND NUT 4 5 6 0 kg m 33 43 Ibs ft 8 m r n FLANGE BOLT AND NUT 2 0 3 0 kg m 15 22 lbs ftl 8 m m BOLT 1 8 2 5 kg m 13 18 Ibs ft 5 0 Date of issue Sept...

Page 48: ...Transmission Shift drum and shift fork Kick starter Starter gear To remove and install the engine place a jack under the engine to support its weight Engine weight 60 kg I132 lbs approx ENGINE REMOVAL...

Page 49: ...haust pipe clamp bolts Remove the L and R muffler chamber and muffler mounting bolts Remove the L and R exhaust pipes muffler chamber and mufflers Remove the chain clip Remove the master link Remove t...

Page 50: ...sconnect the breather tube Remove the spark plug caps Loosen the carburetor bands Disconnect the clutch cable at the lower adjuster Disconnect the tachometercable type 11 1 Disconnect the starter moto...

Page 51: ...ssure switch and neutral Remove the right foot peg Remove the kick starter pedal Remove the front engine mounting bracket NOTE I Place a jack under the engine to support I the engine weight while remo...

Page 52: ...tion sequence is essentially the reverse of removal Date of Issue September 1977 O HONDA MOTOR CO LTD 5 5 Do not damage parts during installation Perform the following inspections and ad Route the wir...

Page 53: ...HONDA CYLINDER HEADIVALVE CB40OT 0 8 1 2 kg m See pages 6 3 and 6 14 6 0 Date of Issue September 1977 0 HONDA MOTOR CO LTD...

Page 54: ...ylinder head hold down bolts in the sequence shown in 2 3 steps Remove the cylinder head hold down bolts I the head are exposed When removing them use care to keep dirt from enter ing the cylinder hea...

Page 55: ...t from the right side wire to keep it from falling into the ROCKER ARM INSPECTION Inspect the rocker arms for damage wear or I D SERVICE LIMIT clogged oil holes Measure the I D of each 12 03m m 10 474...

Page 56: ...ER ARM SHAFT HOLE INSPECTION Measure the I D of the rocker arm shah hole of the camshaft holders 8 CAM BEARING SURFACE INSPECTION Inspect the cam bearing surfaces for scoring scratches or evidence of...

Page 57: ...the sequence shown NOTE IDo not rotate the camshaft when usins 1 Plastigage Remove the camshaft holders and measure the width of each Plastigage The widest thickness determines the oil clearance SERV...

Page 58: ...OBE INSPECTION Using a micrometer check each cam lobe for wear or damage CYLINDER HEAD REMOVAL Remove the upper engine brackets cam chain tensioner bolt and exhaust ioes Disconnect the carburetors fro...

Page 59: ...ings cvlinder head gasket dowel pins CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs and valves NOTE I Do not compress the valve springs more than necessary to remove the v...

Page 60: ...N Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge VALVE SPRING FREE LENGTH INSPECTION Measure the free length of the in...

Page 61: ...ract each valve stem 0 0 from the cor responding guide I D to obtain the stem t o guide clearance SERVICE LIMIT IN 0 10 mm 0 004 in EX 0 10 mm 0 004 in O D SERVICE LIMIT IN 5 44 mm 0 214 in X 6 54 mm...

Page 62: ...driving out the valve guide do I I not damase the head I Install a new oversize valve guide from the top of the head Ream the new valve guide after installation NOTE Use cutting oil on the reamer duri...

Page 63: ...he valve face is rough worn unevenly or valve must be re laced Ins ect the valve seats If the seat is too wide too narrow or has low spots the seat must be ground a power grinder is recommended for go...

Page 64: ...retainers NOTE lnstall the valve springs with the tightly wound coils facing the cylinder head lnstall the valve keepers To prevent loss o f tension do not com press the valve spring more than Tap the...

Page 65: ...bling Wave washers replace springs at indicated locations on the engine with the frame number starting with the following CYLINDER HEAD INSTALLATION Clean the cylinder head gasket surfaces of any gask...

Page 66: ...all the O ring cam chain bolt collar and CAMSHAFT ROCKER ARM INSTALLATIBN Lubricate the camshaft bearings with molyb denum disulfide grease lnstall the camshaft and camshaft sprocket NOTE I Install th...

Page 67: ...ce the timing chain on the sprocket while holding the sprocket Tighten the sprocket mounting bolts to specified torque NOTE I Do not allow the bolts to fall into the I crankcase Apply liquid sealant t...

Page 68: ...ce Coosen each tappet adjusting screw fully and install the camshaft holders Torque in the sequence shown TIGHTENING TORQUE 3 0 3 3 kg rn 22 24 lbs ft NOTE 1 Torque in 2 3steps 1 Clean excessive seala...

Page 69: ...Adjust valve tappet clearance Section 3 Inspect the cylinder head cover gasket for damage or deterioration Install the cover Tighten the bolts Install the right and left exhaust pipes and upper hange...

Page 70: ...HONDA C B 4 0 0 T M E M O...

Page 71: ...HONDA C B 4 0 0 T 7 0 Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 72: ...ed and that the O ringsand dowel pins are in place before installing the cylinder head SPECIAL TOOLS Piston Base 07958 2500000 Piston Ring Compressor 07954 2830000 SPECIFICATIONS TROUBLESHOOTING Compr...

Page 73: ...crankcase Remove the tensioner lock nut washer and O ring Remove the tensioner base Remove the cam chain guide Remove the cylinder Clean the bare of the cylinder head CHAIN GUIDE Remove the cylinder...

Page 74: ...case Press the piston pin out of the piston NOTE I Mark the pistons to indicate the cvl I I inder positions I PISTONIPISTON RING INSPEG TlON lnspect the piston ring to groove clearance Remove the pist...

Page 75: ...008 0 016 in SECOND 0 2 0 4 mm 0 008 0 016 in OIL Side rail 0 2 0 9 mm 10 008 0 035 in Measure the piston O D at the skirt NOTE Measurements should be taken 7 mm 0 28 in from the bottom Calculate the...

Page 76: ...NG INSTALATION O D SERVICE LIMIT 16 98 rnrn 0 669 in Install the piston rings NOTE Avoid piston and piston ring damage during installation SECOND All rings should be installed with the markings facing...

Page 77: ...HONDA CYLINDERIPISTON C B 4 0 0 T Space the piston ring end gaps 120 degrees apart Do not align the gaps in the oil rings 7 6 Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 78: ...on the intake valve side as for the piston marked with IN Install the pistons in their original CYLINDER INSTALLATION Install the oil control orifices dowel pins and cylinder gasket NOTE I Check that...

Page 79: ...ase on the cylinder with plain washer and lock nut Tighten the lock nut with the tensioner base pulled up fully Install the tensioner on the tensioner base with the pin and clip NOTE Do not drop the p...

Page 80: ...HONDA CBlCOOT M E M O...

Page 81: ...CLUTCH OIL PUMP HONDA CB40OT Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 82: ...tion of the gearshift linkage Section 111 adjustment of the crankshaft balancer and removal and installation of the oil pressure switch should also be performed by first removing the right crankcase c...

Page 83: ...n Accelerating Motorcycle Creeps With Clutch Disengaged 1 No free play 1 Too much free play 2 Discs worn 2 Plates warped 3 Springs weak Excessive Lever Pressure Clutch Will Not Disengage 1 Clutch cabl...

Page 84: ...adjuster Remove the right foot peg Remove the kick starter arm Remove the right crankcase cover CLUTCH CLUTCH LIFTER REMOVAL Remove the lifter piece circlip spring clutch lever and O ring CLUTCH LIFTE...

Page 85: ...ioninto gear Block the drive sprocket to prevent it from turning Remove the lock nut and washer The clutch can then be taken out a s a unit CLUTCH CENTER PLATE AND DISC REMOVAL Removethe clutch center...

Page 86: ...sc spring and spring seats SERVICE LIMIT 0 1 0 5 mm 0 004 0 020 in CLUTCH SPRING INSPECTION Check spring free length a CLUTCH DlSC INSPECTION Replace the clutch discs if they show signs of scoring or...

Page 87: ...in the outer drum for nicks cuts or indentations made by the friction discs Measure the I D of the clutch outer and the 0 0 of the outer guide CLUTCH INSTALLATION Install the spring seat disc spring...

Page 88: ...s in the clutch outer in the order listed Pressure plate Discs A and plates A 6each alternately one after the other Disc B Clutch center CLUTCHCENTER Align the splines by rotating the clutch 7 7 4 3 c...

Page 89: ...the transmission main shaft Install the clutch on the transmission a s a unit Apply the universal holder to the drive sprocket UNIVERSAL HOLDER Install the lock washer and lock nut Torque the lock nu...

Page 90: ...and in a criss cross pattern CLUTCH LIFTER AND RIGHT CRANKCASE COVER INSTALLATION Install the O ringon the clutch lever Install the clutch lever on the crankcase Secure the lever with the spring and...

Page 91: ...HONDA CLUTCH OILPUMP C B 4 0 0 T 8 10 Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 92: ...holder Remove the primary drive gear bolt Remove the circlip Removethe sprockets and chain Remove the oil pump OIL PUMP DISASSEMBLY Remove the oil pump cover and thrust washer Pull out the drive pin...

Page 93: ...MP INSPECTION Measure pump tip clearance Measure pump body clearance Measure pump end clearance SERVICE LIMIT 0 10 mm 0 004 in SERVICE LIMIT 0 35 mm 0 014 in SERVICE LIMIT 0 10 mm 0 004 in 8 12 Date o...

Page 94: ...ft into the pump body Install the pump shaft Install the thrust washer and pump cover NOTE Install the pump cover after installing the dowel pins OIL PUMP INSTALLATION Install the oil pump with the ga...

Page 95: ...UE 4 5 5 0 kg m 33 36 IbS h OIL PRESSURE RELIEF VALVE Remove the valve as an assembly and check operation NOTE Beginning with the following engine numbers the location of the pressure relief valve has...

Page 96: ...alve as a unit if the spring is broken PLUNGER SPRING RIGHT CRANKCASE COVER IMSTALLATlON Install the right crankcase cover clutch cable tachometer cable kick starter arm and right foot peg Adjust the...

Page 97: ...CRANKCASE HONDA C B 4 0 0 T 8 rnrn BOLT 2 0 3 0 kg rn 6 mrn BOLT x 14 1 O 1 4 kg rn 7 10 ibs ft 9 0 Date of issue September 1977 6 3 HONDA MOTOR CO LTD...

Page 98: ...ved before disassembling the crankcase all photos illustrations and step by step proceduresfor these parts are described a s single parts or units for simplicity SPECIAL TOOLS Items to be serviced Cra...

Page 99: ...C GENERATOR REMOVAL alled without removing the engine from the frame Removethe A C generator rotor bolt If the cylinder head is off be carful not to pinch the cam chain while removing Remove the A C g...

Page 100: ...mm bolt and the fourteen 6 mm bolts NOTE I Remove the bolts in two or more steos I and in a cross pattern to prevent war page Remove the lower case CRANKCASE ASSEMBLY Before assembling apply liquid s...

Page 101: ...ten the bolts to the specified torques TORQUE SPECIFICATION 8 mm bolt 2 0 3 0 kg m 15 22 lbs ft 6 mm bolt 1 0 1 4 kg m 7 10 lbs ft NOTE Tighten the bolts in two or more steps and in a cross pattern Re...

Page 102: ...rotor Install the A C generator rotor TORQUE SPECIFICATION 10 0 12 0 kg m 70 90 lbr ft GENERATOR ROTOR INSTALLATION OF PARTS 10 0 12 0 kg m 70 90 lbs ft Install the following parts Gearshift spindle...

Page 103: ...HONDA CRANKSHAFTIBALANCER C B 4 0 0 T 10 mrn BOLT x 6 3 3 3 7 kgm 124 27 lbs ft 6mmBOLTx3 1 0 1 4 kg m 1 7 10 lbs ft APPLY LOCKING AGENT 10 0 Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 104: ...D INSTALLATION 10 14 BALANCER INSTALLATION 10 15 SERVICE INFORMATION WORKING PRACTICE All bearing inserts are a selective fit and are identified by color code Select replacement bearings from the colo...

Page 105: ...cer Connecting rod big end side clearance Crankpin oil clearance TROBLESHOOTING I D Shaft O D Balancer to shaftclearance Electric starter gear Excessive Noise 1 Crankshaft Worn main journal bearing Wo...

Page 106: ...Section 9 Remove the oil strainer Remove the bearing holder bolts Remove the front chain guide Remove the rear balancer shaft and rear balancer Remove the oil orifice and rear chain guide Remove the...

Page 107: ...480T Remove balancer the 10 mm nut 8 mm nut and stopper plate Remove the clip and spring Remove the front balancer shaft and balancer chain Remove the circlip and ride plate 10 4 O Date HONDA of Issue...

Page 108: ...he damper rubbers for weakness or damage Replace rubbers a s a set Measure the balancer I D Measure the balancer shaft O D Measure the clearance between the balancer and balancer shaft SERVICE LIMIT 0...

Page 109: ...nnecting REMOVAL rod side clearance SERVICE LIMIT Remove the rods and pistons and to indicate the cylinder position mark them NOTE Mark the rods bearings and bearing caps to indicate the cylinder posi...

Page 110: ...local wear a STARTER DRIVE GEAR INSPECTION Inspect the starter drive gear for damage or local or excessive wear O D SERVICE LIMIT 54 15 mm 2 132 in DOWEL PIN o D I OVERRUNNING CLUTCH STARTER DRIVE GE...

Page 111: ...gear shaft and take out the idle gear INSPECTION r Inspect Measure the idle gear for tooth damage the idle gear I D Measure the idle gear shaft O D Measure the idle gear to shaft clearance SERVCE LIM...

Page 112: ...avoiding the oil hole Install the bearing caps on the correct crank pins and torque them evenly SPECIFIED TORQUE 2 5 2 9 kg m 18 21 lbs ft NOTE Do not rotate crankshaft during inspec tion 2 5 2 9 kg...

Page 113: ...l the main bearings on the correct journals and torque them evenly in a cross 3 3 3 7 kg m 24 27 lbs ft parttern and in two or more steps SPECIFIEDTORQUE 3 3 3 7 kg m 24 27 lbs ft NOTE Do not rotate t...

Page 114: ...Determine and record the corresponding rod 1 13 code number Determine and record the corresponding crankpin O D code number LEFT SIDE R I G T SIDE L CRANKPIN CODE NO 2 R CRANKPIN CODE NO 3 Cross refer...

Page 115: ...d case I D code numbers Determine and record the corresponding main journal O D code letters LEFT SIDE RIGHT SIDE JOURNAL CODE C L CENTER JOURNAL CODE B Cross reference the case and journal codes to d...

Page 116: ...curely STARTER CLUTCH CRANKSHAFT INSTALLATION Install the springs plungers and rollers I Align the hole in the starter clutch with the dowel pin on the crankweight and install the starter clutch Tight...

Page 117: ...he connecting rods and bearing caps NOTE Besure connecting rods are installed in their correct position and the oil holes point to the rear Cross reference the rod and cap I D codes to insure the orig...

Page 118: ...lancer chain and front balancer shaft Position the punch mark on the end of the shaft at about 10 o clock as shown and install the spring Rotate the shaft clockwise to 6 o clock BALANCER WEIGHT SPROCK...

Page 119: ...ner Assemble the rear chain guide and oil orifice NOTE Be sure the oil orifice is not clogged Align the front balancer TC mark and crankshaft aligning mark with the end of the crankcase Install the ch...

Page 120: ...the dowel pins and bearinu inserts are in place in the holder Install the rear balancer on the bearing holder with the shaft balancer chain on the sprocket during Install the front chain guide Date of...

Page 121: ...nd that the crank weight mark is flush with the end of the crankcase FRONT BALANCER Torque bearing holder bolts TORQUE SPECIFICATIONS 10 rnrn bolt 3 3 3 7 kg m 24 27ibs ft 6 mrn bolt 1 0 1 4 kg m 7 1O...

Page 122: ...the 8 mm nut UOTE The balancer chain tension will be adjusted automatically by loosening the 8 mm nut If the balancer chain slack is ex cessive so that no further adjustment is possible follow the st...

Page 123: ...TRANSMISSION HONDA C B 4 0 0 T 11 0 Date of Issue September 1977 HONDA MOTOR CO LTD I...

Page 124: ...STARTER ASSEMBLY 11 9 GEARSHIFT DRUMISHIFT FORK INSTALLATION 11 10 TRANSMISSION ASSEMBLY 11 11 GEARSHIFT LINKAGE ASSEMBLY 11 13 SERVICE INFORMATION WORKING PRACTICE The gear shift linkage can be servi...

Page 125: ...stment too much free play 2 Shift forks bent 3 Shift shaft bent 4 Shift fork claw bent 5 Shift drum cam grooves damaged Transmission Jumps Out of Gear 1 Gear dogs worn 2 Shift shaft bent 3 Shift drum...

Page 126: ...pper arm Removethe stopper plate bolt Remove the drum stopper plate gearshift drum pins and collar Remove the drum plate and dowel pins Inspect all parts for wear or damage TRANSMISSION DISASSEMBLY Se...

Page 127: ...lace gears into neutral and check each gear dog for minimum clearance at end SERVICE LIMIT 0 30 mm 0 012 in Remove the main and countershafts Lift out the oil orifice and dowel pin GEAR DOG MINIMUM CL...

Page 128: ...ure the I D and O D of the countershaft low gear C1 bushing SERVICE LIMITS 1 0 20 06 mm 0 790 in O D 23 95 mm 0 943 in Measure the O D of the main and counter shafts SERVICE LIMITS A 24 93 mm 0 981 in...

Page 129: ...L Remove the bearing stopper plate FORK Pull the gearshift drum out of the case Remove the shift fork shafts shift forks and guide pins GEARSHIFT DRUM AND SHIFT FORK INSPECTION Measure the shift drum...

Page 130: ...Measure the case I D O D SERVICE LIMIT 12 95 mm 0 510 in Measure the shift fork 1 0 and claw thickness SREVICE LIMITS ID 13 05 mm 0 514 in Claw thickness 5 50 mm 0 217 in ESS Date of Issue September...

Page 131: ...the kick starter spindle and kick starter pinion Remove the kick spring collar kick spring drive ratchet and washer off the spindle KlCK STARTER INSPECTION Measure the pinion gear I D 1 0 SERVICE LIM...

Page 132: ...e O D O D ER E LIMIT 18 44 rnm 0 726 in STARTER PlNlOF I SPINDLE DRIVE RATCHET Install the spindle and pinion gear Hook the end of the kick spring over the abutment on the case t SPRING COLLAR KICK SP...

Page 133: ...IFT FORK IMSTALLATIOM Install the shift drum Install the guide pins shift forks and fork shafts Install the bearing stopper plate Stake the end of each screw groove in the stopper plate against the Da...

Page 134: ...MISSION ASSEMBLY Assemble the main and countershafts movement or rotation on the shaft Examine that the c i r c l i is seated in Install the dowel pin and oil control orifice Date of Issue September 1...

Page 135: ...e end of the crankcase Assemble balancer chain guide Install the bearing holder Section 10 Install the lower crankcase Section 9 lnstall the countershaft Align the marks on the needle roller bearing w...

Page 136: ...bolt I I threads and underside of bolt heads I A I durina assemblv 1 Install the neutral stopper arm Assemble the gearshift sp ndleand gearshift return spring APPLY LOCKING AGENT TORQUE 0 8 1 2 kg m 6...

Page 137: ...HONDA FRONT WHEEL BRAKE SUSPENSION C B 4 0 0 T Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 138: ...since they cannot be disassembled Never ride on the spokes or try to bend the wheel Avoid damaging the aluminum alloy rim SPECIAL TOOLSICOMMON TOOLS Special Tools HOLLOW SET WRENCH 6 mm BALL RACE DRIV...

Page 139: ...shock absorbers 2 Bent front forks 3 Bent front axle wheel installed incorrectly Front Wheel Wobbling 1 Distorted rim 2 Worn front wheel bearing 3 Distorted spokes 4 Faulty tire 5 Axle not tightened p...

Page 140: ...ires into the headlight case through the headlightcase hole Route the wire harness into the headlight case through the headlight case lower hole Connect the wires color to color Set each coupler in it...

Page 141: ...ter installing a new bulb check for con tinuty I f the bulb does not light inspect the wiring for open or short circuits The ignition switch wire i s connected to the wiring harness inside the headlig...

Page 142: ...n grease Position the handlebar on the lower holders with the punch marks on the handlebar in line with the top of the holders Place the upper holders on the handlebar with the punch marks facing the...

Page 143: ...r cable from the speedometer gearbox Disconnect the front brake cable Drum type only Remove the front brake torque link Drum type only Remove the cotter pin and loosen the axle nut Remove the axle hol...

Page 144: ...blocks and measure the runout The actual runout is 112 of TIR Total Indicator Reading WHEEL INSPECTION SERVICE LIMIT 0 2 mm 10 008 in Check the rim runout by placingthe wheel in a truing stand Then s...

Page 145: ...4 0 0 T WHEEL DISASSEMBLY DRUM BRAKE TYPE TlRE BALANCE MARK LOCATION BALANCE WEIGHT LOCATION ITH TlRE VALVE DISTANCE COLLAR DISC BRAKE TYPE Remove the right hearingfirst APPLY ADHESIVE 12 8 Date of Is...

Page 146: ...Install the dust seal and collar in the hub on the right side BEARING DRIVE HANDLE A BEARING DRIVER OUTER 42 x 47 BEARING DRIVER PILOT 15 no retightening since they are secured with lock pins Do not r...

Page 147: ...the shoes with new ones Appty grease to the cam contacting faces of the shoes stopping PO wer Keep grease off the brake linings Wipe BRAKE ROD ADJUSTMENT Adjust the brake rod length a t its threaded...

Page 148: ...acing the front Tighten the forward nut to the specified torque first then tighten the rear hut to the same torque TORQUE SPECIFICATION 1 8 2 5 k g m 13 18 ibs ftl remove load from the front fork Keep...

Page 149: ...the attaching bolts NOTE Do not loosen the brake hose unless necessary Remove the front fender Unscrew the right and left fork bolts Loosen the front fork attaching bolts a t the bottom fork bridge Re...

Page 150: ...the sliding surface p I Use care when loosening the bolt br 1 the spring willpop out Pour out any remaining fork fluid by pumping the fork up and down several times FRONT DAMPER SPRING FREE LENGTH INS...

Page 151: ...seal with a screw driver NOTE Avoid damaging the inner and outer surfaces of the slider when removing the seal FORK TUBEIFORK SLIDER PISTON INSPECTION Check the fork tubes fork sliders and pistons fo...

Page 152: ...BOLT APPLY LOCKING AGNETTO BOLT THREADS AND UNDERSIDE OF BOLT Install the piston and fork tube Apply a locking agent to the bolt threads and underside of the bolt then torque to specified tension NOTE...

Page 153: ...G WITH FORK OIL Use ATF Automatic Transmission Fluid to fill the front fork NOTE Pour the specified amount of ATF Do not overfill Slide the front cushion spring and spring seat into position and tight...

Page 154: ...rk top bridge I I I Tighten the right and left fork dolts to the specified torque TORQUE SPECIFICATION 7 0 9 0 kg m 51 65 lbs ftl Torque the front fork bolts at the fork bottom bridge TORQUE SPECIFICA...

Page 155: ...REMOVAL Remove the headl ght Remove the instruments Remove the handlebars Unscrew the steering stem nut Loosen the right and left fork bolts Remove the fork cover Loosen the bottom bridge fork bolts P...

Page 156: ...key turn counterclockwise and remove the lock 4 b STEERING HEAD ADJUSTER REMOVAL NOTE Do not allow the steel balls to fall STEEL BALLS 19 BOTTOM BALL RACE DUST SEAL WASHER i DISASSEMBLY BALL RACE REM...

Page 157: ...until snug against the top cone race Then back it out 118 turn Make sure that there is no vertical movement and the stem rotates freely TOP BRIDGE INSTALLATION Install the front fork legs NOTE Do not...

Page 158: ...teering stem nut TORQUE SPECIFICATION 0 0 12 0 kg m 65 87 lbs ft Tighten the fork bolts to the specified torque TORQUE SPECIFICATION 7 0 9 0 kg m 51 65 lbs ft Torque the bottom bridge fork bolts TORQU...

Page 159: ...HONDA REAR WHEELIBRAKEISUSPENSION C 8 4 0 O T 13 0 Date of Issue September 1977 O HONDA MOTOR CO LTD...

Page 160: ...NFORMATION WORKING PRACTICE Do not remove the rivets nuts and pins from the rim spoke plates and hub since they cannot be disassembled Do not ride on the rim or try to bend the wheel Handle with care...

Page 161: ...41 0 mm 5 55 in 198 0 mm 7 80 in Suspension Noise 1 Shock case binding 2 Loose fasteners Poor Brake Performance 1 Improper brake adjustment 2 Fouled brake linings 3 Worn brake shoes 4 Worn brake shoe...

Page 162: ...ar wheel AXLE SHAFT BEND INSPECTION Set the axle in V blocks and read the axle bend The actual axle bend is 112 of TIR total indicator reading REAR WHEEL BEARING PLAY INSPECTION Check the wheel bearin...

Page 163: ...w SPOKE PLATE MARK Apply adhesive during installation NOTE The COMSTAR WHEEL has no rim band BEARING DRIVER HANDLE A REAR WHEEL ASSEMBLY BEARING DRIVER OUTER 42 x 47 mm BEARING DRIVER PILOT 17 mm Pac...

Page 164: ...INAL DRIVEN SPROCKET INSPECTION Measurethe final driven sprocket I D SERVICE LIMIT 65 16 mm 2 565 in Check the condition of the final driven sprocket teeth Replace the sprocket if worn or distorted mu...

Page 165: ...OE REPLACEMENT Pry off the cotter pin Install new brake shoes Apply grease to the face of the brake cam stopplng power Make sure the the punch mark on the brake arm aligns with the punch mark on the s...

Page 166: ...ip NOTE Note the retaining clip direction Adjust the drive chain tension CHAIN SLACK 10 20 rnrn 0 44 8 in Rotate the adjusters so that the index marks are aligned with the same scale number on both si...

Page 167: ...SORBER DISASSEMBLY Using a hacksaw blade cut a groove in the head of the damper bolt to receive the flat end of a screwdriver as shown NOTE Remove burrs thoroughly Remove the lock nut Screw in the rod...

Page 168: ...of the rod Compress the spring until the slotted end of STOPPER RUBBER the rod contacts the upper joint Applying the end of a screwdriver to the rod UPPER JOINT slot turn the rod into the upper joint...

Page 169: ...WINGARM DISASSEMBLY1 ASSEMBLY I Drive the bushings into place through a I pad making sure that they are not Idamaged 1 A Lubricate with grease after installation SWINGARM INSTALLATION Torque the swing...

Page 170: ...Turning the adjusting bolt until the correct pedal height is obtained NOTE After adjusting the pedal height adjust the pedal free play and stoplight switch BRAKE PEDAL REMOVAL1 INSTALLATION Oisconnec...

Page 171: ...HONDA HYDRAULIC DISC BRAKE C 8 4 0 0 T 14 0 Date of Issue September 1977 HONDA MOTOR CO LTD...

Page 172: ...inder I D Master piston O D r3liper piston O D Caliper cylinder I D Poor Brake Performance Air bubbles in hydraulic system Worn brake pads Pads fouled or glazed Hydraulic system leaking Date of Issue...

Page 173: ...ravel 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 flowi...

Page 174: ...e replacement if the red line on the top of the pads reachesthe edges of the brake disc 8 BRAKE PAD REPLACEMENT Removethe caliper cover Pull off the clip Push the caliper toward the right and push the...

Page 175: ...C BRAKE Remove the pin with a pair of pliers Install the new brake the piston side pad pads and the shim on Insert the pin with the pin hole facing out as shown 14 4 Date of Issue September 1977 HONDA...

Page 176: ...lSC BRAKE Insert the clip into place Install the caliper cover in the DlSC THICKNESS Measure the disc thickness BRAKE DlSC WARPAGE Measure the brake disc warpage pin hole Date of Issue September 1977...

Page 177: ...sconnect the brake hose Avoid spilling brake fluid on painted surfaces Place a rag over the fuel tank whenever Remove the master cylinder Remove the snap ring MASTER CYLINDER I D INSPECTION Measure th...

Page 178: ...ASTER CYLINDER ASSEMBLY MASTER PISTON MASTER CYLINDER Dip the piston cup in brake fluid or coat with STOPLIGHT SWITCH silicon grease before assembly Install the master cylinder on the handlebar Connec...

Page 179: ...with the piston down Apply a small amount of air pressure to the I fluid inlet 6 1 Do not use high Dressure air or brino I I the nozzle too close to the inlet I Examine the piston and cylinder for sc...

Page 180: ...LIMIT 38 215 rnrn 1 5045 in CALIPER CARRIERICARRIER DISASSEMBLY Remove the speedometer cable clamp Remove the carrier with caliper B Remove the caliper shafts off the carrier and caliper B while rota...

Page 181: ...04 0kg m 22 29 lbs ft CALIPER COVER q8 LEEDER VALVE CALIPER PISTON SILICON GREASE OR CALIPER CARRIER BRAKE FULlD DOT 3 CALIPER A INSTALLATION Tighten the caliper shafts evenly while push ing them aga...

Page 182: ...le for charging whenever possible If battery must be charged on the motorcycle disconnect the battery cables Keep fire or sparks away from a charging battery because it produces hydrogen All charging...

Page 183: ...se battery connection Low Power Engine Running 1 Battery undercharged Low battery electrolyte level One or more dead cells 2 Charging system failure Intermittent Power 1 Loose battery connection 2 Loo...

Page 184: ...ed NOTE I The battery must be recharqed if the I I specific gravity is below 1 3 TYPE 1 I 1 22 The specific gravity varies with the temperature as shown in the accom panying table Replace the battery...

Page 185: ...nue chargingif theelectrolyte temperature exceeds 45 C 117 FJ CAUTION I 0uick charging should only be done 1 In an emergency slow charging i s preferred I After installing the battery coat the termina...

Page 186: ...the resistances between the leads with an ohmmeter o not usea high voltage source such as I insulation resistance tester since it may damage the rectifier and give you RESISTANCES IN NORMAL DIRECTION...

Page 187: ...voltage reaches 14 0 15 0 V b Testingwith avariable resistor Connect a variable resistor 0 100CZ across the battery with a 50a resistor in between Test lamp must come on when voltage reads 14 to 15 V...

Page 188: ...unit is non adjustable If ignition timing is incorrect check the C D I unit and AC generator and replace any defective part I SPECIFICATIONS Date of Issue September 1977 HONDA MOTOR CO LTD ND X24ES U...

Page 189: ...switch Between C D I unit and ignition coil Between C D I unit and ignition switch Between ignition coil and plug Defective ignition switch Defective ignition coil C D I unit faulty Defective AC gene...

Page 190: ...i Disconnect the wire leads Remove the coii attach ngbolts and coil PERFORMANCE TEST Perform the 3 point spark test with a coil tester 7 SERVICE LIMIT li 6 mm 0 24in minimum 6 rnm 10 24 n i MlNlMllM...

Page 191: ...0000 or KOWA ELECTRICAL TESTER TH 5H 1 Discharge the capacitor before testing 1 NEEDLE SWINGS AND RE I TURNS indicates that a capacitor is being charged with the tester The tester needle will stay a t...

Page 192: ...No NC03 2001782 CM400T F No NCO1 ZOXXXXX F No NC01 2110251 The Specifications in Fig 3 are applicable to the C D I unit C mark stamped on the cover used on the following models C8400T F No NC03 200 17...

Page 193: ...the following models CB400T E No CB400TE 20XXXXX E No CB400TE 40XXXXX WIRE COLOR I RESISTANCE GREE N WHITE 315 385S2 BLUE WHITE 77 950 GREEN BROWN 76 92 Q GREEN LIGHT BLUE 95 1 16S2 GREEN PINK 126 154...

Page 194: ...length I J u I NEUTRAL FIELD MAGENT I ha0 o r a SERI ICE LIMIT 4009 5 5 mm 0 21 in IIBATTERY L TROUBLESHOOTING Starter Motor Will Not Turn Dead battery Faulty ignition switch Faulty start switch Faul...

Page 195: ...and measure brush length Measure brush spring tension with a spring scale SERVICE LIMITS Brush length 5 5 mm 0 21 in Brushspring tension 400g COMMUTATOR INSPECTION Remove the case NOTE Record the loca...

Page 196: ...rom the cable terminal to the brush wire Replace the starter motor if the field coil is not continuos or if it is shorted to the motor case Assemble the starter motor NOTE Align the punch mark on the...

Page 197: ...the switch button The coil if the switch clicks into position normal i normal Connect an ohmmeter to the switch terminals Connect e 12V battery to the switch cable terminals The switch i s normal if t...

Page 198: ...n line 360 degree crank engine allowing it to produce smooth power FRONT BALANCER SHAFT RUBBER DAMPERS The eccentric shaft allows balancer chain tension adjust The sprockets are connected t o their re...

Page 199: ...gs of a single cylinder Ccycle 200 ccengine at TDC will be 400 kg 1 882 lbs approx a t 6 000 rpm 1000 kg 2 205 lbs approx a t 10 000 rpm INERTIA FORCE INERTIA FORCE ON CRANK WEIGHT Inertia force creat...

Page 200: ...alf of the inertia force The remaining inertia will be totally balanced by two balancen Each balancer counteracts one fourth of the total inertia 9 25 50 z c3 C e 25 50 25 The centrifugal force on the...

Page 201: ...e valves in one combustion chamber The power chamber adds extra torque at low and medium speeds It is located at the most ideal position without sacrificing space between the engine and the ground due...

Page 202: ...e assembl ed i nside the 12 pole stator FEATURES There are no contact points since the C D I system employs an inductive buildup by capacitive discharge The C D I can develop greater voltage at the sp...

Page 203: ...he SCR is keot OFF 2 An electric pulse is generated by the fixed pulser when the pickup reaches the point where ignition must start This is due to changes in the flux The pulse is rectified by the dio...

Page 204: ...imum ad vance is reached This limits timing advance ADVANCER OPERATION In C D I ignition timing advance depends on the buildup time of voltage on the advance pulser which becomes faster as the engine...

Page 205: ...GNAL FROM FIXED PULSER SCR TRIGGER VOLTAGE T D C SIGNAL FROM ADVANCE PULSER SIGNAL FROM FlXED PULSER THROUGH Dq 3 PULSER WAVE FORMS DURING TIMING ADVANCE 4 PULSER WAVE FORMS AT END OF ADVANCE With fur...

Page 206: ...PLUG I I 6 Restart with choke applied WEAK OR NO SPARK 11 Faulty spark plug 2 Fouled spark plug 31 Faulty C D I Unit 4 Broken or shorted high tension cord 51 Faulty A C generator 6 Broken or shorted...

Page 207: ...elerate lightly SPEED INCREASES 5 check ignition timing NO SIGNIFICANT 1 Carburetor choke closed INCREASE IN ENGINE 21 Clogged air cleaner SPEED 3 Restricted fuel flow 4 Clogged fuel tank breather cap...

Page 208: ...ug heat range incorrect 31 Wrong fuel OIL LEVEL INCORRECT 11 Oil level too high 21 Oil level too low 31 Contaminated oil VALVE TRAIN 11 Clogged oil passage INSUFFICIENTLY 21 Clogged oil control orific...

Page 209: ...buretor pilot INCORRECT 9 1 Fuel air mixture too lean To correct screw adjustment screw out 2 Fuel air mixture too rich To correct CORRECT screw in 3 heck for air leaking LEAKING 9 I Deteriorated insu...

Page 210: ...e JET CLOGGED r 1 Clean INCORRECT c 1 Cam sprocket is not installed properly 5 check valve spring tension WEAK 1 Faulty spring POOR HANDLING Check tire pressures Possible Cause 1 If steering is heavy...

Page 211: ...HONDA CB4OOT M E M O...

Page 212: ...M E M O...

Page 213: ...M E M O...

Page 214: ...PHOTOGRAPHS ARE BASED ON THE TYPE I1MODEL ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED IN THlS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TlME OF...

Page 215: ...y an authorized HONDA dealer unless the owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HOND...

Page 216: ...t Drain the engine oil Remove the tachometer and clutch cables Remove the right footpeg and kickstarter lever Remove the right crankcase cover Remove the 10 mm and 8 mm nuts remove the stopper plate I...

Page 217: ...pads Pads fouled or glazed Hydraulic system leaking SERVICE LIMIT 4 0 mrn 0 16 in 0 3 mm 0 012 in 14 055 mm 0 5533 in 13 945 mm 0 5490 in 38 105 mm 1 5002 in 38 215 mm 1 5045 in Disc thickness Disc r...

Page 218: ...er and clutch cables Remove the right footpeg and kickstarter lever Remove the right crankcase cover Remove the 10 mm and 8 mm nuts remove the stopper plate Install the stopper plate moving it over on...

Page 219: ...ouled or glazed Hydraulic system leaking SERVICE LIMIT 4 0 mm 0 16 in 0 3 mm 0 012 in 14 055 mm 10 5533 in 13 945 mm 10 5490 in 38 105 mm 1 5002 in 36 215 mm 1 5045 in1 Disc thickness Disc runout Mast...

Page 220: ...kelever operation Avoid spilling fluid on painted sur faces Place a rag over the fuel tank BRAKE SYSTEM DRAINING Loosen the caliper bleeder valve and pump the brake lever Stop operating the lever when...

Page 221: ...rom the master cylinder Disconnect the brake hose NOTE When removing the brake hose bolt cover the end of the hose to prevent contamination and secure the hose Remove the master cylinder Remove the sn...

Page 222: ...r cylinder Coat all parts with clean brake fluid before assembly 1 Place the spring on the check valve Install the spring and valve together Dip the piston cup in brake fluid before assembly DOT3 BRAK...

Page 223: ......

Page 224: ...MAINTENANCE I SCHEDULE CM400A MAINTENANCE SCHEDULE 22 17 VIII INSPECTION AND ADJUSTMENT 22 18 ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED I N THlS PUBLICATION ARE BASE0 ON TH...

Page 225: ...HONDA 79 ADDENDUM CM400T 400A I MODEL IDENTIFICATION BI CM400T BEGINNING FIN 2000001 CM4OOA BEGINNING FIN 2000001 22 2 Date of Issue February 1979 O HONDA MOTOR CO LTD...

Page 226: ...HONDA CM4QQT 400A 7 9 ADDENDUM 11 SPECIFICATIONS Specifications listed are for both T and A models unless otherwise noted Date of Issue February 1979 HONDA MOTOR CO LTD 22 3...

Page 227: ...HONDA 79 ADDENDUM CM400T 400A Date of Issue July 1979 22 4 3 HoNDA MOTOR CO LTD...

Page 228: ...HONDA CM4OOT 400A 79 ADDENDUM Date of issue February 1979 o HONDA MOTOR CO LTD 22 5...

Page 229: ...36 14 18 22 25 72 87 24 27 18 21 9 12 20 23 18 25 6 9 13 18 6 9 Item Steering upper holder bolt 8 x 36 flange bolt Steering lower holder nut Steering stem nut Front fork bolt Front fork bottom bridge...

Page 230: ...bolt and nut 6 mm bolt and nut 8 mrn bolt and nut 10 mm bolt and nut 12 rnm bolt and nut 5 mm screw 6 rnm screw 6 mrn flange bolt and nut 8 mrn flange bolt and nut 10 rnrn flange bolt and nut Torque...

Page 231: ...HONDA CM400T 400A M E M O...

Page 232: ......

Page 233: ......

Page 234: ...C11114OQT 4 0 0 A 79 ADDENDUM V CABLE AND HARNESS ROUTING CM400T CLUTCHCABLE BRA5E HOSE THROTTLE CABLES SPEEDOMETER CABLE THROTTLE CABLES TACHOMETER CABLE Date of Issue February 1979 HONDA MOTOR CO LT...

Page 235: ...HONDA 7 9 ADDENDUM CM4OOT 400A 22 12 Date of issue February 1979 0 HONDA MOTOR CO LTD...

Page 236: ...79 ADDENDUM CM400A PARKING BRAKE CABLE BRAKE HOSE F PARKING BRAKE CABLE EEDOMETER CABLE THROTTLE CABLES Date of Issue February 1979 HONDA MOTOR CO LTD 22 13...

Page 237: ...79 ADDENDUM HONDA CM400T 400A BANDS RKlNG BRAKE CABLE 22 14 Date of Issue February 1979 O HONDA MOTOR CO LTD...

Page 238: ...nformation Label attached to the frame on the left side below the seat as shown It contains basic tune up specifications for CM400T s and CM400A s Refer to the Shop Manual 78 Emissions Addendum for de...

Page 239: ...NDA dealer unless the owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTE 1 Se...

Page 240: ...owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTE 1 Service more frequently...

Page 241: ...ching screws Removethe air cleaner element Clean the element by tapping it lightly t o loosen dust Blow away the remaining dust by applying compressed air from inside the Date of Issue February 1979 O...

Page 242: ...to pages 14 3 through 14 10 for caliper and pad disassembly and inspection Refer to pages 21 6 and 21 7 for master cylinder disassembly and inspection 3 0 4 0 kg rn 22 29 ft lbl 3 014 0 kg m 22 29 ft...

Page 243: ...s follows CM400T Removethe float chambers and secondary main jets page4 51 Install 108secondary main jets Install the float chambers Turn each pilot screw in 112turn Adjust the idle speed with the thr...

Page 244: ...23 6 IV INSPECTIONAND ADJUSTMENT 23 8 V FUEL SYSTEM 23 9 VI WIRING DIAGRAMS 23 13 ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PROD...

Page 245: ...HONDA 80 ADDENDUM CM4OOt 400A I MODEL IDENTIFICATION CM 400T BEGINNING FIN 2100001 CM 400A BEGINNING FIN 2100001 23 2 Date of Issue July 1979 O HONDA MOTOR CO LTD...

Page 246: ...HONDA CM4OQT 400A 80 ADDENDUM II SPECIFICATIONS Specifications listed are for both T and A models unless otherwise noted tear rant Date of Issue July 1979 O HONDA MOTOR CO LTD...

Page 247: ...80 ADDENDUM HONDA CM400T 400A 23 4 Date of Issue July 1979 O HONDA MOTOR CO LTD Gear shift pattern Left foot operated return system...

Page 248: ...HONDA CM4QQT 400A 80 ADDENDUM Date of Issue July 1979 oHONDA MOTOR co LTD 23 5...

Page 249: ...unless the owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTE 1 Service more...

Page 250: ...ess the owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTE 1 Service more fre...

Page 251: ...6 0 7 mm 0 024 0 028 in RECOMMENDED SPARK PLUG CONTROL CABLE LUBRICATION Disconnect the throttle and clutch CM400T control cables at their upper ends Thoroughly lubricate the cables and their pivot po...

Page 252: ...ASSEMBLY Install a new O ring on each end of the accelerator pump and fuel joint pipes Assemble the right and left carburetors noting the compression spring location Install the front and rear stays...

Page 253: ...he accelerator pump rod is not bent Assemble the accelerator pump in the reverse order of removal ACCELERATOR PUMP ADJUSTMENT Loosen the throttle stop screw so the throttle valve is closed Measure the...

Page 254: ...against the seat Remove the pilot screw Inspect the pilot screw for wear and replace if necessary Install the pilot screw and return it to its original position as noted during removal Perform pilot...

Page 255: ...m in neutral1 5 Turn each pilot screw in or out to obtain the highest engine speed 6 Readjust the idle speed 7 Turn one of the pilot screws in gradually until the engine speed is lowered by 100 rpm 8...

Page 256: ......

Page 257: ......

Page 258: ...TING HONDA MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRO DUCED WITHOUT WRITTEN PERMI...

Page 259: ...HONDA 80 CB4OOT ADDENDUM C 5 4 8 O T I MODEL IDENT161CATION BEGINNING F N0 2000001 a I I 24 2 Date of Issue Sept 1979 HONDA MOTOR CO LTD...

Page 260: ...HONDA CB4QOT 80 CB400T ADDENDUM II SPECIFICATIONS Date of Issue Nov 1979 o HONDA MOTOR CO LTD 24 3...

Page 261: ...4 Date of Issue Nov 1979 O HONDA MOTOR CO LTD Valve clearance co Tachometer light Type ll only Neutral indicator Turn signal indicator High beam indicator Position light 2 C P SAE NO 57 2 C P SAE NO...

Page 262: ...HONDA C B 4 0 O T 80 CB4OOT ADDENDUM Ill CABLE ROUTING CLUTCHCABLE BRAKE HOSE HOKE CABLE CABLES SPEEDOMETER CABLE Date of Issue Sept 1979 3 HONDA MOTOR CO LTD 24 5...

Page 263: ...HONDA 80 CB4OOT ADDENDUM CB40OT WIRE BAND I CLAMP CLAMP 24 6 Date of Issue Sept 1979 O HONDA MOTOR CO LTD...

Page 264: ...in the Owner s Manual a t each scheduled maintenance period I INSPECTAND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN A ADJUST R REPLACE L LUBRICATE 3 For higher odometer readings repeat a...

Page 265: ...the plug washers attached thread the new spark plugs in by hand to prevent cross threading Tighten the spark plugs 2 turn with a spark plugwrench Connect the spark plug caps X22ESR U ND DR7ES NGK X27E...

Page 266: ...mm 0 61 0 02 in See page 24 1 1 13 mm 0 5 in 30 mm 1 2 in CARBURETOR SEPARATION Remove the carburetors page 4 21 Separate the carburetors page 4 2 noting that the accelerator pump joint pipe must be...

Page 267: ...lerator pump rod is not I bent Assemble the accelerator pump in the reverse order of removal ACCELERATOR PUMP ADJUSTMENT Loosen the throttle stop screw so the throttle valve is closed Measure the clea...

Page 268: ...ly Make a note of this t o use as a reference when reinstalling the pilot screw occur it the pilot screw is tightened against the seat Removethe pilot screw Inspect the pilot screw for wear and replac...

Page 269: ...10 Repeat steps 7 through 9 for rernain ingcarburetor LIMITER CAP INSTALLATION If a pilot screw is replaced a new limiter cap must be installed after pilot screw adjustment is completed After final a...

Page 270: ...the motorcycle is to be ridden below 1 500 m 5 000 ft do the following Install the standard size secondary main jets Adjust the accelerator pump adjusting arm and stopper clearance to 7 mm 114 in Tur...

Page 271: ...mm 1 1031 1 1040 in C1 24 020 24 041 mm 0 9457 0 9465 in Shift fork Gear bushing O D Refer to Section 11 for disassembly inspectionand installation procedures Gear bushing I D Main shaft O D Countersh...

Page 272: ......

Page 273: ......

Page 274: ...AILABLE AT THE TlME OF APPROVAL FOR PRINTING HONDA MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TlME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THlS PUBLICATION...

Page 275: ...80 ADDENDUM HONDA C M 4 0 0 E I MODEL IDEMTIFICAT10M CM400E BEGINNING FIN 4000009 4 25 2 Date of Issue Dec 1979 O HONDA MOTOR CO LID...

Page 276: ...HONDA k J C M 4 0 0 E SO ADDENDUM II SPECIFICATIONS Date of Issue Dec 1979 Q HONDA MOTOR CO LTD 25 3...

Page 277: ...HONDA 80 ADDENDUM C M 4 0 0 E 25 4 Date of Issue Dec 1979 O HONDA MOTOR CO LTD...

Page 278: ...DA gealer unless the owner has proper tools and service data and is mechani cally qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTE 1 Ser...

Page 279: ...HONDA 80 ADDENDUM C M 4 0 0 E IV CABLE AND HARNESS RQUTING CLUTCH BRAKE 1 CABLES CLUTCH CABLE I Date of Issue Dec 1979 25 6 HoNDA MOTOR co LTD...

Page 280: ...HONDA C M 4 0 0 E 80 ADDENDUM RECEPTACLE BLACK BANDS Date of Issue Dec 1979 Q HoNDA MOTOR co LTD 25 7...

Page 281: ...HONDA 80 ADDENDUM CM4OOE WIRE HARNESS GUIDE CARBURETOR OVERFLOW TUBES BREATHER 25 8 Date of Issue Dec 1979 0 HONDA MOTOR CO LTD...

Page 282: ...ng and damage 4 mm 118 in Stopper clearance Adjust as follows Remove the carburetors page 4 2 Remove the float chambers and secondary main jets page4 5 Install I12 secondary main jets Install the floa...

Page 283: ...ad to psi vehicle capacity STONE brand K127 HAMA Check the tires for cuts imbedded nails 01 other sharp objects TORQUE 0 25 0 35 kg m 11 4 2 5 ft lb WHEEL SPOKE TIGHTENING Check spoke tighteness rim r...

Page 284: ......

Page 285: ......

Page 286: ...NG 26 28 11 SPECIFICATIONS 26 5 Ill INSPECTIONAND ADJUSTMENT 26 11 VIII WIRING DIAGRAM 26 31 ALL INFORMATION ILLUSTRATIONS DIREC TlONS AND SPECIFICATIONS INCLUDED IN THlS PUBLICATION ARE BASED ON THE...

Page 287: ...HONDA 81 ADDENDUM CB400T CM400T A E C I MODEL IDENTlFlCATlON D CB400T BEGINNING FIN NC030XBM100001 CM400T BEGINNING FIN NC010XBM200001 Date of Issue December 1980 26 2 O HONDA MOTOR CO LTD...

Page 288: ...HONDA CB4001 CM400T A E C 81 ADDENDUM CM400A BEGINNING FIN NC020 BM200001 CM400E BEGINNING FIN NC020 BM100001 Date of issue December 1980 o HONDA MOTOR co LTD 26 3...

Page 289: ...81 ADDENDUM HONDA CB40OT CM400T A E C CM400C BEGINNING FIN NC012 BM000001 26 4 Date of Issue December 1980 O HONDA MOTOR CO LTD...

Page 290: ...and CM4OOE Specifications begin on page 26 7 CM400 CUSTOM Specification begins on page 26 9 CB400T CM400T I CB4OOT I I Lubrication system Forced pressure and wet rump Cylinder comprerrian 13 1 0 kslcr...

Page 291: ...81 ADDENDUM HONDA CB400T CM400T A E C Exhaust valve High beam indicator A NO 57 AE NO 103 26 6 Date of Issue December 1980 O HONDA MOTOR CO LTD...

Page 292: ...HONDA CB400T CM400T A E C 81 ADDENDUM Date of Issue December 1980 o HONDA MOTOR CO LTD 26 7...

Page 293: ...81 ADDENDUM HONDA CB400T CM4001 AsE C CM401 CV 30 mrn I 7 5 BTDC at 1 250rpm idle speed Transrnirrion in neutral1 26 8 Date of Issue December 1980 O HONDA MOTOR CO LTD...

Page 294: ...e and stroke Diamond 28 psi I Disc brake Internal expanding shoes Displacement Comprerrion ratio Valve train 90 BBDC At 0 lift 40 BBDC At 1 0 mm liftl R Front Rear 13 0 lit 108 mm 3 4 U S gal 2 9 Imp...

Page 295: ...00 rpm idle Alternator 1 A C generator 170 W 5 000 rom Battery capacity I For cold climate I X22ES U lNDl X22ESR U lNDl Electrical Ignition I C a a c i i r1i rh m ioni inn 12 V 12 AH USA model Full ad...

Page 296: ...m gauges Disconnect the right carburetor overflow tube Position the throttle adjusting wrench on the balance adjusting screw lock nut from under the right carburetor 1 Start the engine The vacuum gaug...

Page 297: ...e 26 22 CAUTION I Always replace the brake pads in pairs to assure even disc pressure FRONT AIR FORKS NOTE This does not apply to the CM4OOE Place the vehicle on its center stand Remove the valve cap...

Page 298: ...mage or other faults When removing the tire from the rim use the special tools TIRE LEVER No 07772 0020100 and RIM PROTEC TOR No 07772 0020201 or an approved tire changer to prevent damage to the rim...

Page 299: ...VAL Remove the front wheel page 12 6 Remove the brake caliper attaching bolts and caliper assembly NOTE Do not loosen the brake hose unless necessary Remove the front fender Releaseair pressure Discon...

Page 300: ...e fork cap bolt Remove spring A washer and spring B from the fork tube Pour out fork fluid by pumping the fork up and down several times soft jaws being careful not to over tighten it Temporarily inst...

Page 301: ...is felt Then move it in and out tapping the bushing lightly until the fork tube separates from the slider The slider bushing seal and back up ring will come out with the fork tube Remove the oil seal...

Page 302: ...or scrat ches or if the teflon overlay is worn so that the copper surface appears on more than 314 of the entire surface Check the back up ring at the points shown and replace if there is any distort...

Page 303: ...t the fork tube Install the rebound spring and piston into the fork tube Apply a locking agent to the socket bolt and thread it into the piston Tighten with a hex wrench TORQUE 1 5 2 5 kg m 11 18fts l...

Page 304: ...p Drive the oil seal into position until the snap ring groove appears DRIVER 07947 3290000 Install the back up plate Install the snap ringand dust cover Use ATF Automatic Transmission Fluid to fill th...

Page 305: ...ith the upper sur face of the fork top bridge Tighten the fork pinch bolts TORQUE UPPER 0 9 1 3 kg m 7 9 ft lb LOWER 1 8 2 5 kg m 13 18 ft lbl Tighten the fork tube caps TORQUE 1 5 3 0 kg m 11 22 ft l...

Page 306: ...Fill the fork tubes with air to 0 8 0 2kg cm2 11 f 3 psi Use only a hand operated air pump to fill the fork tubes Do not use compressedair Do not exceed the specified air prer sure or fork tube compon...

Page 307: ...ACEMENT Remove the brake pad pin retainer TORQUE 0 8 1 3 kg rn 6 9 ft lb Push the caliper against the disc to push the pistons all the way in to facilitate new brake pad installation Remove Remove the...

Page 308: ...the pad pin retainer C A L I P E R R E M O V A L Drain the brake hydraulic system Disconnect the brake hose Remove the brake pads see page 26 22 NOTE Avoid spilling brake fluid on painted I surfaces...

Page 309: ...Remove the pad osition the with the piston down and 3p1ysmall spurts of air let Pressure to the fluid ING...

Page 310: ...O D Check the piston for scoring scratches or other faults Measurethe piston diameter with a micrometer STANDARD 30 20 mrn 1 189 in SERVICE LIMIT 30 14 mm 1 187 in CALIPER CYLIDNER I D Check the cali...

Page 311: ...the boots and collar making sure that the boots are seated in the collar grooves properly Install the brake pad spring BOOTS CALIPER CARRIER DISASSEMBLY Remove the speedometer clamp Remove the calipe...

Page 312: ...per onto the front fork TORQUE CALIPER SHAFT 2 5 3 0 kg rn 18 22 lbs ft CALIPER MOUNTING BOLT 2 0 2 5 kg m 14 18 lbs ft Make sure that the caliper shaft boot i in the shaft groove properly Install the...

Page 313: ...M400T A E C VII CABLE AND HARNESS ROUTING a CM400TlCM400 CUSTOM CLUTCHCABLE BRAKE HOSE HOKE CABLE MAIN WIRE HARNESS THROTTLE CABLES BRAKE HOSE SPEEDOMETER CABLE SPEEDOMETER 26 28 Date of Issue Decembe...

Page 314: ...HONDA CB4001 CM4001 A E C 81 ADDENDUM CM4OOA PARKING BRAKE CABLE BRAKE HOSE Date of Issue December 1980 HONDA MOTOR co LTD 26 29...

Page 315: ...HONDA 81 ADDENDUM CB400T CM4001 A E C CABLE SPEEDOMETER CABLE CLUTCH CABLE k4 26 30 Date of Issue December 1980 HONDA MOTOR CO LTD...

Page 316: ......

Page 317: ...M E M O...

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Summary of Contents for 1978 CB400A

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Honda 1978 CB400A, Shop Manual

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Summary of Contents for 1978 CB400A

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