Honda cb400 super four Owner'S Manual Download Page 95

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Troubleshooting

Electrical Trouble

Blown Fuse

❙

Main Fuse

Remove the left side cover.

P.46

Disconnect the wire connector of the

starter magnetic switch.

Pull out the main fuse and check for a

blown fuse. Always replace a blown fuse
with a spare of the same rating.

Spare main fuse is provided under the
starter magnetic switch.

Connect the wire connector of the starter

magnetic switch.

Install the left side cover.

NOTICE

If a fuse fails repeatedly, you likely have an electrical
problem. Have your motorcycle inspected by your dealer.

Starter magnetic

switch

Main fuse

Wire connector

Spare main fuse

Starter magnetic

switch

Wire connector

Main fuse

Spare main fuse

(CB400)

(CB400A)

32MFM630.indb 92

2010/12/14 15:44:42

Summary of Contents for cb400 super four

Page 1: ...on information available before printing Honda Motor Co Ltd reserves the right to make changes at any time without notice and without incurring any obligation No part of this publication may be reprod...

Page 2: ...ations on your purchase of a new Honda motorcycle Your selection of a Honda makes you part of a worldwide family of satisfied customers who appreciate Honda s reputation for building quality into ever...

Page 3: ...n good judgement You will find important safety information in a variety of forms including Safety labels on the motorcycle Safety Messages preceded by a safety alert symbol and one of three signal wo...

Page 4: ...Contents Motorcycle Safety P 2 Operation Guide P 12 Maintenance P 29 Troubleshooting P 72 Information P 94 Specifications P 106 Index P 109 Contents 32MFM630 indb 1 2010 12 14 15 43 47...

Page 5: ...P 6 Riding Precautions P 7 Accessories Modifications P 10 Loading P 11 Motorcycle Safety This section contains important information for safe riding of your motorcycle Please read this section carefu...

Page 6: ...ng Make sure that you are physically fit mentally focused and free of alcohol and drugs Check that you and your passenger are both wearing an approved motorcycle helmet and protective apparel Instruct...

Page 7: ...let your friends drink and ride either Keep Your Honda in Safe Condition It s important to keep your motorcycle properly maintained and in safe riding condition Inspect your motorcycle before every ri...

Page 8: ...ide Hazard Exhaust contains poisonous carbon monoxide a colourless odorless gas Breathing carbon monoxide can cause loss of consciousness and may lead to death If you run the engine in a confined or e...

Page 9: ...oad conditions Helmet Safety standard certified high visibility correct size for your head Must fit comfortably but securely with the chin strap fastened Face shield with unobstructed field of vision...

Page 10: ...Brakes Observe the following guidelines Avoid excessively hard braking and sudden shifting to a lower gear a Sudden braking can reduce the motorcycle s stability a Where possible reduce speed before...

Page 11: ...BS operation ABS does not reduce braking distance In certain circumstances ABS may result in a longer stopping distance ABS does not function at speeds below 10 km h 6 mph The brake lever and pedal ma...

Page 12: ...Stop the engine 2 Push the side stand down 3 Slowly lean the motorcycle to the left until its weight rests on the side stand 4 Turn the handlebars fully to the left a Turning the handlebars to the rig...

Page 13: ...llegal to operate on public roads and highways Before deciding to install accessories on your motorcycle be certain the modification is safe and legal WARNING Improper accessories or modifications can...

Page 14: ...and keep within specified load limits Maximum weight capacity P 106 Tie all luggage securely evenly balanced and close to the centre of the motorcycle Do not place objects near the lights or the muff...

Page 15: ...Throttle grip P 66 Front brake lever P 68 Front brake fluid reservoir P 55 Engine oil filter P 51 Coolant reserve tank P 53 Rear suspension spring preload adjuster P 70 Engine oil fill cap P 49 Engine...

Page 16: ...ster P 69 Fuse box P 91 CB400A Crankcase breather P 67 Shift lever P 23 Fuel fill cap P 24 Left side cover P 46 Rear suspension spring preload adjuster P 70 Fuse box P 90 Main fuse P 92 FI fuse P 73 E...

Page 17: ...meter red zone excessive engine rpm range Tachometer NOTICE Do not operate the engine in the tachometer red zone Excessive engine speed can adversely affect engine life A button Speedometer B button 3...

Page 18: ...meter Distance ridden since tripmeter was reset press and hold A button to reset to 0 0 km continued Display Check When the ignition switch is turned ON all the mode and digital segments will show If...

Page 19: ...ruments Continued A button B button Fuel gauge Remaining fuel when the display lights as shown in the illustration approximately 4 0 litres 1 06 US gal 0 88 Imp gal Clock 12 hour display 32MFM630 indb...

Page 20: ...he desired hour and AM PM are displayed a Press and hold to advance the hour fast 4 Press B button until the desired minute is displayed a Press and hold to advance the minute fast 5 Turn the ignition...

Page 21: ...gnition switch is turned ON Goes off when your speed reaches approximately 10 km h 6 mph If it comes ON while riding P 76 High coolant temperature indicator If it comes ON while engine is running P 74...

Page 22: ...eutral HISS indicator P 73 Comes on briefly when the ignition switch is turned ON with the engine stop switch in the RUN position Goes off if the ignition key has the correct coding Flashes every 2 se...

Page 23: ...es the high beam headlight Hazard switch Switchable when the ignition switch is ON Engine stop switch Should normally remain in the RUN position a In an emergency switch to the OFF position to stop th...

Page 24: ...also recommended 1 Ignition key Push Turn 2 ON Turns electrical system on for starting riding LOCK Locks steering OFF Turns engine off Locking 1 Turn the handlebars all the way to the left 2 Push the...

Page 25: ...1 Make sure the engine stop switch is in the RUN position 2 Turn the ignition switch to the ON position 3 Shift the transmission to Neutral N indicator comes ON Alternatively pull in the clutch lever...

Page 26: ...ifting Gears Your motorcycle transmission has six forward gears in a one down five up shift pattern If you put the motorcycle in gear with the side stand down the engine will shut off 32MFM630 indb 23...

Page 27: ...and explosive You can be burned or seriously injured when handling fuel Stop the engine and keep heat sparks and flame away Handle fuel only outdoors Wipe up spills immediately Fuel filler opening Fil...

Page 28: ...met Holder 1 Insert the ignition key and turn it clockwise to unlock 2 Hang your helmet on the holder hook 3 Turn the key counterclockwise to lock the holder hook and then remove the key WARNING Ridin...

Page 29: ...above the rear fender by the rubber band a Use the helmet holder only when parked a Some U shaped locks may not fit in the compartment due to their size or design Removing the Seat P 45 WARNING Ridin...

Page 30: ...seat Maximum Weight Limit 3 0 kg 6 6 Ib Centre compartment Centre compartment CB400 CB400A a The centre compartment may become heated by the engine Do not store any items that are flammable or suscep...

Page 31: ...down Hooks This motorcycle is equipped with the retractable luggage tie down hooks below the seat of both sides Luggage tie down hook a Never use the tie down hooks to tow or lift the motorcycle 32MFM...

Page 32: ...s P 55 Side Stand P 58 Drive Chain P 59 Clutch P 63 Throttle P 66 Crankcase Breather P 67 Other Adjustments P 68 Brake Lever P 68 Front Suspension P 69 Rear Suspension P 70 Headlight Aim P 71 Brakelig...

Page 33: ...mmendations and schedules in this owner s manual Importance of Maintenance Maintenance Safety Always read the maintenance instructions before you begin each task and make sure that you have the tools...

Page 34: ...nts Keep an accurate record of maintenance to help ensure that your motorcycle is properly maintained Make sure that whomever performs the maintenance completes this record All scheduled maintenance i...

Page 35: ...gine Oil Filter R R R R 51 Radiator Coolant 4 I I R 53 Cooling System I I I Secondary Air Supply System I I I Maintenance Level Intermediate We recommend service by your dealer unless you have the nec...

Page 36: ...ight Aim I I I 71 Clutch System I I I I I I I 63 Side Stand I I I 58 Suspension I I I 69 70 Nuts Bolts Fasteners I I I I Wheels Tyres I I I 41 Steering Head Bearings I I I I Notes 1 At higher odometer...

Page 37: ...and lubricate as needed P 40 59 Check the following items if you are carrying a passenger or cargo Combined weight is within load limits P 106 Cargo is secured properly Suspension spring preload is ad...

Page 38: ...mponents specify the model name colour and code mentioned on the colour label The colour label is attached to the frame under the seat P 45 Colour label WARNING Installing non Honda parts may make you...

Page 39: ...product must not be treated as household waste NOTICE An improperly disposed of battery can be harmful to the environment and human health Always confirm local regulations for battery disposal WARNING...

Page 40: ...cessories can overload the electrical system discharging the battery and possibly damaging the system Fuses Fuses protect the electrical circuits on your motorcycle If something electrical on your mot...

Page 41: ...use non Honda engine oil check the label to make sure that the oil satisfies all of the following standards JASO T 903 standard 1 MA SAE standard 2 10W 30 API classification 3 SG or higher 1 The JASO...

Page 42: ...he drive chain must be inspected and lubricated regularly Inspect the chain more frequently if you often ride on bad roads ride at high speed or ride with repeated fast acceleration If the chain does...

Page 43: ...rive chain lubricant designed specifically for O ring chains Do not use a steam cleaner a high pressure cleaner a wire brush volatile solvent such as gasoline and benzene abrasive cleaner chain cleane...

Page 44: ...can be seen in the transparent section of the drain tube Tyres Inspecting Replacing Checking the Air Pressure Visually inspect your tyres and use an air pressure gauge to measure the air pressure at l...

Page 45: ...ing you should replace the tyres when the minimum tread depth is reached Wear indicator location mark WARNING Riding on tyres that are excessively worn or improperly inflated can cause a crash in whic...

Page 46: ...is installed Do not install a tube inside a tubeless tyre on this motorcycle Excessive heat build up can cause the tube to burst Use only tubeless tyres on this motorcycle The rims are designed for tu...

Page 47: ...d parts replacement with the tools contained in the kit Pin spanner 8 mm Open end wrench 10 x 12 mm Open end wrench 14 x 17 mm Open end wrench Pliers Standard Phillips screwdriver Screwdriver handle E...

Page 48: ...lock lever downward to unlock the seat 3 Pull the seat back and up Installation 1 Insert the front prong into the front stay and the rear prongs into the rear stays on the frame 2 Push forward and the...

Page 49: ...be removed for fuse maintenance The right and left side covers can be removed in the same manner Removal 1 Remove the seat P 45 2 Remove the bolt 3 Remove the prongs from the grommets Installation 1...

Page 50: ...Body Components a Battery Battery CB400 Battery cover Bolt CB400A Bolt Battery cover Removal Make sure the ignition switch is OFF 1 Remove the seat P 45 2 Open the battery cover by removing the bolt 3...

Page 51: ...arts in the reverse order of removal Always connect the positive terminal first Make sure that bolts and nuts are tight The clock will be reset AM 1 00 if the battery is disconnected To set the clock...

Page 52: ...on switch OFF stop the engine and wait 2 to 3 minutes 3 Place your motorcycle in an upright position on a firm level surface 4 Check that the oil level is between the upper and lower level marks in th...

Page 53: ...hen checking the oil level a Do not overfill above the upper level mark a Make sure no foreign objects enter the oil filler opening a Wipe up any spills immediately 2 Securely reinstall the oil fill c...

Page 54: ...idle the engine for 3 to 5 minutes 2 Turn the ignition switch OFF stop the engine and wait for 2 to 3 minutes 3 Park on a firm level surface and lower the side stand 4 Place a drain pan under the dra...

Page 55: ...nd tighten Torque 30 N m 3 1 kgf m 22 lbf ft 10 Fill the crankcase with the recommended oil P 38 and install the oil fill cap Required oil When changing oil engine oil filter 3 2 litres 3 4 US qt 2 8...

Page 56: ...le in an upright position 3 Check that the coolant level is between the UPPER and LOWER level marks in the reserve tank LOWER level UPPER level Reserve tank cap Reserve tank If the coolant level is dr...

Page 57: ...nitoring the coolant level a Do not overfill above the UPPER level mark a Make sure no foreign objects enter the reserve tank opening 4 Securely reinstall the cap 5 Install the right side cover WARNIN...

Page 58: ...level and UPPER level marks If the brake fluid level in either reservoir is below the lower level mark or the brake lever and pedal freeplay becomes excessive inspect the brake pads for wear If the b...

Page 59: ...pad is worn to the groove 1 Front Inspect the brake pads from in front of the brake caliper a Always inspect both left and right calipers 2 Rear Inspect the brake pads from the rear right of the moto...

Page 60: ...caliper a Always inspect both left and right calipers 2 Rear Inspect the brake pads from the rear right of the motorcycle If necessary have the pads replaced by your dealer Always replace both left an...

Page 61: ...ck the spring for damage or loss of tension 3 Sit on the motorcycle put the transmission in Neutral and raise the side stand 4 Start the engine pull the clutch lever in and shift the transmission into...

Page 62: ...r 1 Place your motorcycle on the side stand on a level surface 2 Stop the engine place the gear in Neutral 3 Check the slack in the lower half of the drive chain midway between the sprockets Drive cha...

Page 63: ...g 1 Place your motorcycle on the side stand on a level surface 2 Stop the engine Place the transmission in Neutral 3 Loosen the rear axle nut Adjusting bolt Rear axle nut Index mark Scales 4 Turn both...

Page 64: ...xle is misaligned turn the right or left adjusting bolt until the scales are aligned and recheck chain slack 6 Tighten the rear axle nut Torque 88 N m 9 0 kgf m 65 lbf ft 7 Tighten the adjusting bolts...

Page 65: ...proper slack the chain is excessively worn and must be replaced Chain RK 525SMOZ5 If necessary have the drive chain replaced by your dealer Red zone Index mark Checking the Drive Chain Slider Check t...

Page 66: ...ay at the clutch lever 10 to 20 mm 0 4 to 0 8 in Clutch lever Freeplay Check the clutch cable for kinks or signs of wear If necessary have it replaced by your dealer Lubricate the clutch cable with a...

Page 67: ...t 2 Turn the upper clutch cable adjuster until the freeplay is 10 to 20 mm 0 4 to 0 8 in 3 Tighten the upper lock nut and check the freeplay again Upper clutch cable adjuster Upper lock nut Lower Adju...

Page 68: ...mm 0 4 to 0 8 in 4 Tighten the lower lock nut and check the clutch lever freeplay 5 Start the engine pull the clutch lever in and shift into gear Make sure the engine does not stall and the motorcycl...

Page 69: ...ove smoothly close automatically or if the cable is damaged have the motorcycle inspected by your dealer Freeplay at the throttle grip flange 2 to 6 mm 0 1 to 0 2 in Freeplay Adjusting the Throttle Fr...

Page 70: ...aning the Crankcase Breather 1 Remove the crankcase breather tube plug from the tube 2 Drain deposits into a suitable container 3 Install the crankcase breather tube plug Crankcase breather tube plug...

Page 71: ...Adjustment method Turn the adjuster until the index mark aligns with the arrow while pushing the lever forward in the desired position After adjustment check that the lever operates correctly before r...

Page 72: ...ad surface Turn clockwise to increase spring preload hard or turn counterclockwise to decrease spring preload soft The standard position is the third groove from the top aligns with the top surface of...

Page 73: ...oad soft or turn the position 4 to 5 increase spring preload hard The standard position is 3 Extension bar Adjuster Pin spanner 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage...

Page 74: ...ht case loosen the bolts Obey local laws and regulations Headlight case Bolts Up Down Adjusting the Brakelight Switch Check the operation of the brakelight switch Turn the adjusting nut in the directi...

Page 75: ...Oil Pressure Indicator P 75 PGM FI Programmed Fuel Injection Malfunction Indicator Lamp MIL P 75 ABS Indicator CB400A P 76 Troubleshooting Other Warning Indications P 77 Fuel Gauge Failure Indication...

Page 76: ...turn the ignition switch to the ON position If the indicator still stays ON check the following Check if there is no another HISS key including spare key close to the ignition switch Check if there ar...

Page 77: ...n switch to the ON position 2 Check that the radiator fan is operating and then turn the ignition switch to the OFF position If the fan is not operating Suspect a fault Do not start the engine Transpo...

Page 78: ...ause the low oil pressure indicator to come ON especially if the oil is at or near the low level If the low oil pressure indicator stays ON when the oil level is at the proper level stop the engine an...

Page 79: ...or starts flashing while riding Indicator does not come ON when the ignition switch is in the ON position Indicator does not go OFF at speeds above 10 km h 6 mph If the ABS indicator stays ON your bra...

Page 80: ...ndications Fuel Gauge Failure Indication If the fuel system has an error the fuel gauge indicators will be displayed as shown in the illustration If this occurs see your dealer as soon as possible 32M...

Page 81: ...uctions provided with the emergency tyre repair kit Riding your motorcycle with a temporary tyre repair is very risky Do not exceed 50 km h 30 mph Have the tyre replaced by your dealer as soon as poss...

Page 82: ...or cloth Brake caliper assembly Fixing bolts 3 Remove the right and left caliper assemblies from the fork leg by removing the fixing bolts a Support the brake caliper assembly so that it doesn t hang...

Page 83: ...our motorcycle securely and raise the front wheel off the ground using a maintenance stand or a hoist Front axle bolt Axle pinch bolts 7 Loosen the left axle pinch bolts 8 On the left side withdraw th...

Page 84: ...inch bolts to hold the axle 5 Tighten the front axle bolt Torque 59 N m 6 0 kgf m 44 lbf ft 6 Loosen the left axle pinch bolts 7 Tighten the right axle pinch bolts Torque 23 N m 2 3 kgf m 17 lbf ft 8...

Page 85: ...e brake 13 Check the clearances between each surface of the brake disc and the brake caliper body not the brake pads are symmetrical If the clearances are not symmetrical loosen the left axle pinch bo...

Page 86: ...e rear axle nut and turn the adjusting bolts so the rear wheel can be moved all the way forward for maximum drive chain slack 3 Remove the rear axle nut washer Adjusting bolt Rear axle nut 4 Remove th...

Page 87: ...ot Swingarm 6 Remove the rear axle shaft side collars and rear wheel a Support the brake caliper assembly so that it doesn t hang from the brake hose Do not twist the brake hose a Avoid getting grease...

Page 88: ...ling the wheel apply the brake pedal several times then recheck the disc for caliper holder to disc clearance Do not operate the motorcycle without adequate clearance If a torque wrench was not used f...

Page 89: ...ging contact your dealer NOTICE Jump starting using an automobile battery is not recommended as this can damage your motorcycle s electrical system Burned out Light Bulb Follow the procedure below to...

Page 90: ...tabs Screw Screw Connector Tabs Headlight 4 Remove the dust cover 5 Unhook the pin and remove the bulb 6 Install a new bulb in the reverse order of removal a Install the dust cover with its TOP mark...

Page 91: ...s packing 3 Slightly press the bulb and turn it counterclockwise Turn signal lens Screw Bulb Lens packing 4 Install a new bulb in the reverse order of removal Brake Tail light Brake Tail light The bra...

Page 92: ...out Light Bulb License Plate Light 1 Remove the screws 2 Remove the license light cover 3 Pull out the bulb without turning Screws Bulb License light cover 4 Install a new bulb in the reverse order o...

Page 93: ...7 Fuse Box Fuses CB400 Fuse box cover Spare fuses 1 Remove the left side cover P 46 2 Open the fuse box cover 3 Pull out the fuses one by one to check for a blown fuse Always replace a blown fuse with...

Page 94: ...Close the fuse box cover 5 Install the seat Beside left rear suspension 1 Remove the left side cover P 46 2 Open the fuse box covers 3 Pull out the fuses one by one to check for a blown fuse Always r...

Page 95: ...e rating a Spare main fuse is provided under the starter magnetic switch 4 Connect the wire connector of the starter magnetic switch 5 Install the left side cover NOTICE If a fuse fails repeatedly you...

Page 96: ...the left side cover CB400 Fuse holder FI fuse CB400A 1 Remove the left side cover P 46 2 Open the fuse box cover located beside the left rear suspension 3 Pull out the fuse and check for a blown fuse...

Page 97: ...Fuels Containing Alcohol P 98 Catalytic Converter P 99 Caring for Your Motorcycle P 100 Storing Your Motorcycle P 102 Transporting Your Motorcycle P 103 You the Environment P 104 Serial Numbers P 105...

Page 98: ...ind drill or in any way alter their shape Do not expose to strong magnetic objects If you lose all keys and the key number plate the PGM FI unit ignition control module must be replaced by your dealer...

Page 99: ...n the read out exceeds 999 999 Tripmeter The tripmeter returns to 0 0 when the read out exceeds 999 9 HISS The Honda Ignition Security System HISS immobilizes the engine s ignition system if an improp...

Page 100: ...to R TTE Directive is provided to the owner at the time of purchase The declaration of conformity should be kept at a safe place When the declaration of conformity is lost or is not provided contact...

Page 101: ...e Gasohol Methanol methyl alcohol 5 by volume max that contain cosolvents and corrosion inhibitors to protect the fuel system Never use a blend containing more than 5 The use of petrol containing more...

Page 102: ...ive catalytic converter contributes to air pollution and can impair your engine s performance A replacement unit must be an original Honda part or equivalent Follow these guidelines to protect your mo...

Page 103: ...ther plastic components with extra care to avoid scratching them Avoid directing water into the air cleaner muffler and electrical parts 3 Thoroughly rinse your motorcycle with plenty of clean water 4...

Page 104: ...them Do not direct water under the seat a Water in the underseat compartment can damage your documents and other belongings Do not direct water at the air cleaner a Water in the air cleaner can preven...

Page 105: ...d Storing Your Motorcycle If you store your motorcycle outdoors you should consider using a full body motorcycle cover If you won t be riding for an extended period follow these guidelines Wash your m...

Page 106: ...ycle If your motorcycle needs to be transported it should be carried on a motorcycle trailer or a flatbed truck or trailer that has a loading ramp or lifting platform and motorcycle tie down straps Ne...

Page 107: ...ayer Recycle Wastes Put oil and other toxic wastes in approved containers and take them to a recycling centre Call your local or state office of public works or environmental services to find a recycl...

Page 108: ...o register your motorcycle They may also be required when ordering replacement parts The frame number is stamped on the right side of the steering head The engine number is stamped on the right side o...

Page 109: ...430 lb CB400A 200 kg 441 lb Maximum weight capacity 1 179 kg 395 lb Passenger capacity Rider and 1 passenger Minimum turning radius 2 6 m 8 53 ft Displacement 399 cm3 24 3 cu in Bore x stroke 55 0 x...

Page 110: ...mm 0 08 in Spark plugs standard CR8EH 9 NGK or U24FER9 DENSO Spark plug gap 0 80 to 0 90 mm 0 031 to 0 035 in Idle speed 1 400 100 rpm Recommended engine oil Honda 4 stroke motorcycle oil API Service...

Page 111: ...t turn signal lights SI type 12V 21 5W x 2 U type 12V 21W x 2 Rear turn signal lights 12V 21W x 2 License plate light 12V 5W Fuses Main fuse 30A FI fuse 20A Other fuses CB400 20A 10A CB400A 30A 20A 10...

Page 112: ...Caring for Your Motorcycle 100 Clutch System 63 Colour Label 35 Combined ABS 8 Compartment Centre 27 Luggage tie down hooks 28 Owner s Manual 26 97 Rear 26 Tool Kit 26 44 Coolant 40 53 Crankcase Breat...

Page 113: ...ight Aim 71 Headlight Dimmer Switch 20 Helmet Holder 25 26 High Beam Indicator 19 High Coolant Temperature Indicator 18 74 HISS Indicator 19 73 Horn Button 20 I Ignition Cut off System Banking Sensor...

Page 114: ...8 49 Other Warning Indications 77 Overheating 74 P Parking 9 Parts Location 12 Passing light control switch 20 Petrol 24 98 PGM FI Programmed Fuel Injection malfunction indicator lamp MIL 18 75 Protec...

Page 115: ...Engine 96 Storage Compartment 25 Owner s Manual 25 97 Storing Your Motorcycle 102 Switches 20 T Tachometer 14 Throttle 66 Tool Kit 44 Transporting Your Motorcycle 103 Tripmeter 15 96 Troubleshooting...

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