Honda CB-1 89 Service Manual Download

Page: 1 / 178

Honda CB400 / CB-1 Service Manual

http://www.motorcycle.in.th

Summary of Contents for CB-1 89

Page 1: ...Honda CB400 CB 1 Service Manual http www motorcycle in th ...

Page 2: ...nI lf Arl ccorcling to locat ions Find th e section you want on this page then turn to the table of contents on the first page of the section Most sec clonsoeseribe the service procedure through a oyotom illunrntion nefer to the 111 xtvay11 for details on how to use thi6 manual If you don t know the source of the trouble go to sP r tion 19 TROUBLESHOOTING ALL INFOR MA TION ILLUSTRATIONS DIREC TION...

Page 3: ...t the subsequent steps like cylinder head removal require engine removal the callouts are grouped In numerical and alphabetical order s The illustration s may conta in symbol marks to indicate necessary service procedures and precautions that need to be tak en Reft lr to the next page for the mean ing of each symbol mark Also in the illustrat ion Is e chart that lists information such as the order...

Page 4: ...r Use 111ulll µurpose grease Lithium basedmu lti purp ose grease NLGI 2 or equivalent UM molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Exomol o Molykote jll BR 2 plus manufa ctured by Ouw Cum ing U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Un molybl l1 t11u111 uisulntJo paste contalnfng more than 40 molybdenum disulfide NLGI 2 or equi...

Page 5: ... wait until the engine and exhaust system have cooled before handling these parts LUBRICATION AND SEAL POINTS 1 18 CABLE AND HARNESS ROUTING 1 19 EMISSION CONTROL SYSTEMS 1 25 EMISSION CONTROL INFORMATION LABELS U S A Only 1 28 Uaed Engine Tran smission Oil Used engine oll or transmission oil in two strokes may cause skin cancer if repeatedly left in contact with the skin for prolonged perio ds AJ...

Page 6: ...o pressurize the shock absorber The use of an unstable gas can cause a fh e or eJ1 plo sion resulting In serious injury The shock absorber contains nitrogen under high pressure Allowing fire or heat near the shock ab sorber could lead to an explosion that could resutt In seriousinjury Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explo sion and...

Page 7: ...r i on the roar side of ooch corburetor GENERAL INFORMAT ION The frame seria l number is stamped on the right side of the steerlng head The Vehicle Identification Number VIN Is located on the safety certification label on the right side of the frame tube 15 COLOR CODE LABEL The color code label is attached on the left frame tube under the seat w 1en ordering a color coded pan alway s specify its d...

Page 8: ...ns at 1 mm lift l xhaust valve close at 1 mm lift Lubrication system 011pump type Cooling system Ai fil tr 1tio1l Crankshaft type Engine weight dry Firing order Cylinder arrnngement Front 1f 2 035 mm 80 1 lnl 705 mm 27 8 in 1 025 mm 40 4 in 1 370 mm 53 9 inl 775 mm 30 5 inl 335 mm 113 2 in 130 mm 5 1 in 170 kg 375 lbs 183 kg 403 lbs l 157 kg 347 lbs Oiamond Telescopic fork 130 mm 5 1 in Swingarm 1...

Page 9: ... Third reduction Final reduction 2 733 41 15 Gear ratio 1st 3 307 43 13 Goar ratio 2nd 2 352 40 17 Gear ratio 3rd 1 875 30 16 t Gear ratio 1th 1 590 35 22 Gear ratio 5th 1 434 33 23 Gear ratio 6th 1 333 32 24 Gear ratio reverse Gearshift pattern Left foot operated return system 1 N 2 3 4 5 6 ELECTRICA L Ignition system Full transistor ignition Start ing system Starter motor Charging system Triple ...

Page 10: ...um difference BHe ca11 Ju1 1a1LU r For carburet or synchronization Idle speed Califo1nial Thronle grip free play Accelerator pump clearance Secondary air supply system A ir inject ion control valve vacuum pressure Standard 2 9 l 3 06 US qt 2 65 Imp qt 3 5 i 3 70 US qt 3 08 Imp qt 3 1 I 3 28 US qt 2 73 Imp qt HONDA 4 stroke oil or equivalent API service classification SE or SF The viscosities shown...

Page 11: ...r tN inner EX o uter IN oute1 EX EX Rocker arm shaft 0 0 IN ex Rock er arm to rock er arm shaft clearance Valve lifte r 0 D Vu lva fitter bore I U Hydraulic lash adjuster assist spring free length Hydraullo I03h adjust er comµ11 1i i ion str ol e with kerosene GENERAL 1NFORMA TION Standard 1 280 1 320 kPa 12 8 13 2 kg cm2 182 188 psi 400 rpm Within 30 mmHg 1 2 lnHy of each other 0 12 0 18 0 005 0 ...

Page 12: ...ing selection Ki klnar1or Klckstarter pinion gear I D Kickstarter spi ndle 0 D Kickstarter idle gear 1 0 Countershaf t 0 0 at kickstarter idle gear Kid starter Idle gear bushing 0 D I D 1 T Standard 55 000 55 010 2 1654 2 16571 With IN mark facing to the intake side 54 960 54 990 2 1638 2 1650 10 0 4 14 002 14 008 0 5513 0 5515 13 994 14 000 0 5509 0 55121 0 002 0 0 14 0 0001 0 0006 0 0 16 0 040 0...

Page 13: ... 980 1 100 7 1 10161 27 959 27 980 1 1007 1 1016 27 969 27 980 1 1007 1 101 6 21 985 22 006 0 8655 0 8664 24 985 25 006 0 9837 0 9845 0 020 0 062 0 0008 0 00241 0 020 0 062 0 0008 0 0024 0 020 0 062 0 0008 0 00 24 0 020 0 062 0 0008 0 0024 0 020 0 062 0 0008 0 002 4 21 959 21 980 0 8645 0 8654 21 967 2 1 980 0 86 4 8 0 8654 24 9 67 24 980 0 9830 0 9835 0 0 20 0 0 62 0 00 08 0 00241 0 005 0 039 0 0...

Page 14: ...s to open Thermostat fully open TharmoGtat valve lift Drivet aln Recommended flna l drive oil Fim1I uliv1 1 1 11 1111 uii l aµal ity iL cJisassemb ly at draining Final driv e gear backlash Ring gear to stop pin clearance IAI Sto p pin shim Ring gear spacer Pinion spacer Outp ut gear backlash Output gear 1 0 Ouq 1uty1a1111 1Ju11hh1y O D LD Output drive shaft 0 0 Out put gear damper spring tree leng...

Page 15: ...y R L Fork air pressure Steering bearing preload Rear suspension Shook absorber spring hee hmoth Shock absorber spring free length IAI Bl Dampe r gas pressure Damper compressed gas Oampa uucompressed force at 10 1 mm 0 4 1n compressed Damper drilling point 20 mm 10 8 in Shock absorber spring installed length Standard Adjustable ran ge 31Ju1 k 1 1usorberSl rfng directi on Recomm ended shock absorbe...

Page 16: ... roin J Battery ch arg ing rate Normal Quick Battery voltage Fully charged 20 C 68 F Needs charging 20 C 68 FI Alternator hght1ng COIi resistance At 20 C 68 UFI AC regulator regulated voltage With analogue type With digit al type Staning system Starter driven gear 0 D Starter clutch outer I U Starte r motor brush spring tension brush length Standard DOT4 5 6 6 0 0 22 0 24 11 000 11 043 0 4331 0 43...

Page 17: ...Honda CB400 CB 1 Service Manual http www motorcycle in th ...

Page 18: ... 5 11 NOTT 1 Oil pressure sw i ch 1 12 1 2 9 NOTE 2 Oil drain bolt 1 12 35 3 5 25 Oil filter boss 1 20 18 1 8 13 Oil f ilte r 1 20 10 1 0 7 Cylinder head cyllnder platon Cyli nder head cov er bolt 8 6 10 1 0 7 Cam Mft hOlder bolt 16 6 12 1 2 9 Cylinder head cove r breather plat e bolt 2 6 2 1 2 9 NOTE 1 Cylinder hood 3pccio l nut 12 8 30 3 0 22 Cylin der head mount ing bolt 2 6 12 1 2 9 Cylin der ...

Page 19: ... 27 2 7 20 Hand lebar weight sc rew 2 6 10 1 0 7 NOTE 1 A xle bolt 14 60 6 0 43 Axle pinch bol t 4 8 22 2 2 16 Fork c lnePI bo lt upperl 2 7 1 8 Fork pinch bolt lower 2 10 50 5 0 36 Fork oop bolt 2 37 23 2 3 17 Fork soc ket bolt 2 6 20 2 0 14 NOTE 1 SteerlnQ stem nut 21 105 10 5 76 Steering head bearing adjustmen t nut 26 25 2 5 18 Ignition swit ch mounting bolt 2 8 25 2 5 18 NOTE 1 Rear Axle nut ...

Page 20: ...T A H 260 MC7 U S A only 6 Pressure pump ST AH 255 MC7 U S A only 6 I Valve guide driver guide removal instellt ion 07JMO KY20100 8 Valve bucket hole protector 07JMG KY20100 8 Valve spring compressor 07757 0010000 8 Valve spring compressor attachment 07JME KY20100 8 Valve guide reamer 3 8 mm 07JMH KY20100 07JMH KY201 OA 8 U S A only Valve seatcuner 22 mm 1 4 5 IN EXl 07780 0010701 or equivahml com...

Page 21: ...17 mm 07746 0050500 12 Attachment 24 x 26 mm 077 46 00 0700 12 Pilot 17 mm 07746 0040400 12 PiluL 22 111111 07741 UU41UOO 12 Shock absorber compressor 07GME 0010000 Not available in U S A 12 07959 3290001 screw assembly 07GME 0010t00 12 Shock absorber compressor attac hment 07 lfi l MB10000 12 Driver pin 07GMO KT80100 Not available in U S A 12 Pilot 22 mm 077 46 00 4 1000 and Driver 07749 0010000 ...

Page 22: ...e Fan motor switch oil pressure switch thread t Ther mo senso r head as shown Neutral switch Gear teelh Engine oil Shaft journals Sliding surface FRAME Point Material Remarks Center stand pivot Mul tipu rpose grease Side stand pivot Brake pedal pivot Goor3hift pedal pivot Steering head bearings I Dust seal Hr Clutch lever pivot Throttle cable ends Sw ingarm pivot bearing s Seat locking tab Rear wh...

Page 23: ...TION SWITCH METER GENERAL INFORMA TION 12 SP RED CONNECTOR METER t6 1 3 SP BLACK CONNECTOR TURN SIGNAL SWIT CH 4 6P GREEN CONNECTO R ITURN SIGNAL SWITCH 5 9P RED CONNECTOR 151 TH ROTTL E CAl 3LE 14 1 RIG HA SW WI STARTER SWITCH ENGINE STOP SWITCH 7 BRAKEHOSE 13 MAIN WIRE HARNESS I12 TURN SIGNAL WIRES 9 LEFT HANDLEBAR SWIT CH WIRE ...

Page 24: ...N 8 No 3 SPARK PLUG WIRES 7 Cl IIT C H CABLE Y CHOKE CABLE 1 5 CLUTCH CABLE 31 SET THE WIRE HARNES S SECURELY 4 T HROTTLE CABLES 6 SET THE No 2 No 3 SPARK PLUG WIRES SECURELY no ffiROTTLE CABLES SET THE No 1 No 4 SPARK PLUG WIRES ECURELY 112 SIPHON TUBE 113 SPEEDOMETER CABLE I ...

Page 25: ...ESERVE T NK OVERFLOW TUBE 8 PULSE GCNCRATOA 2 P CONNECTOR 161 FUEL TANK DRAIN TUBE GENERAL INFORMAT ION IGNITION COIL WIRE NEUTRAL SWITCH OIL PRESSURE SWITCH WIRE PULSE GENERATOR WIRE SIDE STAND SWITCH WIRE ALTERNATOR WIRE 11 SIDE STAND SWITCH l3PI CONNECTOR 12 CRANKCASE BREATHER TUBE 13 No 2 No 3 SPARK PLUG WIRES 14 ALTERNATOR _ 3P CONNECTOR 115 IGNITION COIL 4 PI CONNECTOR ...

Page 26: ... MATION IGNITION COIL WIR E NEUTRAL SWITCH OIL PRESSURE SWITCH WIRE PULSE GENERATOR WIRE SIDE STAND SWITC H WIRE Al TERNATO R WIRE 2 FUEL FILTER 3 FUEL CUT OFF 4 REGULATOR 8 NEUTRAL SWITCH WIRE RELAY RECTIFIER 7 SIDE STAND SWITCH WIRE 6 FUEL PUMP 111 MAIN WIRE HARNESS t t ...

Page 27: ...ornia Model Only 9l No 15 TUBE 8 No 2 TUBE 7 No 4 TUBE 6 No 1 TUBE 12 No 3 INTAKE MAN IFOLD 5 RADIATO R RESERVE TANK OVERFLOW TUBE 15 AIR HOSE 161 AIR SUCTION VALVE GENERAL INFORMA TION 4 AIR SUCTION VALVE 18 TO PCV 1191TO A VCV 2 1 No 10 TUB E AVCV 20 TO CAN ISTER ...

Page 28: ...Honda CB400 CB 1 Service Manual http www motorcycle in th GENERAL INFORMATION 1l No 5 TUBES 4 No 4 TUBE 5 AVCV 8 3 WAY JOINT 3 No 1 TUBE 2 AIR INJECTION TUBE No 15 t t ...

Page 29: ...o keep the emissions system warranty in effect SOURCE OF EMISSIONS Th o combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain cond itions they react to form photochemical smog when subjected to sun light Carbon monoxide does not react In the 11meway but it is toxic Honda Motor Co Ltd utilized lean carburetor settings as w11II u...

Page 30: ...ge of fresh air promotes burning of the unburned exhaust gases and changes a cons iderable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor t This model has lh J air suction valve it consists of reed valves built into the air injection con trol valve A reed valve prevents reverse air flow through the system The air injectio n control valve reacts t...

Page 31: ...OR 7 AIR VENT CONTROL VALVE AVCV TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other tha n for purposes of maintenance repair of repta ce m nt of any dovioo or element of design inco rporated into any new vehicle for the purpose of noise control prior to its sale or del iver...

Page 32: ...r adjustment attach an update label on the rear fender as shown VACUUM HOSE ROUTING DIAGRAM LABEL California model only The Vacuum Hose Rout ing Diagram Label is on the rear fender as shown The seat must be removed to read it Route the vacuum hoses as shown on this label 1 EM ISSION INFORMATION LABEL 3l VACUUM HOSE ROUTING DIAGRAM LABEL California model only VACUUM HOSE ROUTING DIAGRAM ENGI N E FA...

Page 33: ...e frame with a new one when it is damaged Generally speaking plastic body panels cannot be repaired and therefo re must he replaced It is possible that a front end collosion will bend the stee ring head of t he frame but not the fork wheel or even the axle TRO UBLESHOOTING Failure of the front suspension steering or rear suspe nsion may damage the frame enough to requ ire replacement Ref9r to the ...

Page 34: ...ward Align the seat hooks wilh llttt frame hooks and push the seat forward PrAsS the rear of the seat down and look the scot secure ly CAUTION Apply grease to the seat locking Be careful not to pinch the wire harness botwoon tho seat and the frame REAR FAIRING REMOVAL INSTALLATION Remove the seat above Remove the bolts and collars Release the fairing front bosses from the grom mets Remove the rear...

Page 35: ... of removal NOTE It is not necessary to remove the bolt as shown EXHAUST SYSTEMREMOVAL INSTALLATION Remove the radiator lower mnuming bolts and loosen the upperMounting bolt nut page 5 5 Swing the radiator for ward Remove the following exhaust pl joint nuti muffler mounting bolts and exhaust pipe muffler gaskets NOTE Replace the exhaust pipe gaskets if the exhaust system is removed Install new gas...

Page 36: ...sparks in the work area or where gasoline is stored can cause a fire or explo sion Remove the seat page 2 2 Turn the fue l valve OFF Remove the fuel tank mountf119 bolts and lift the ta nk up Disconnect the tubes and remove the fuel tank Install the fuel tank In the feverse order of removal After installation turn the fuel valve ON and check the fuel line for leakag e Install the seat page 2 2 2 4...

Page 37: ...ESS GUIDE MAINTENANCE SCHEDULE AIR CLEANER SERVICE INFORMATION 3 1 3 2 3 4 3 5 SPARK PLUG VALVE CLEARANCE CARBURETOR SYNCHRONIZATION SIDE STAND Refer to the Common Service Manu al for ite ms not incl uded in th is manual Refer to the spec1 hcations Section 1 for maintenance service dat a 3 5 3 5 3 8 3 8 ...

Page 38: ...rvice item Fuel t ank parts required to be removed for servi ce Reserve Tonk Cap Coolal t fllter Seat Brake Pedal Air bubb les in system Brake Hose Leakage degradation damage Brake Reservo ir Level check fluid rcploccmcnt Caliper Pc1u w1 ta1 Tire Wear dsmege pres3ure Wheel Damage runout corrosion Brakefight Switch Operation Oil filler Cap Level Gauge level check replacement Throttle Grip Operation...

Page 39: ...aulty hose page 6 13 Spark Plug Wear damage coloration Front side cover Radiator Hose Leakage degradation damage Engine Oil Drain Bolt Oil replacement Synchronization Adjusting Screw Carbureto r synchronization page 3 8 Fuel tank MAINTENANCE PCV and AICV Damage faulty hose page 6 13 Reserve Tank Coolant level Drive Chain Suspension tLoose wear damag el Free play lubrication replacement Side Stand ...

Page 40: ... SYSTEM w I BRAKE LIGHT SW ITCH w HEADLIGHT AIM a 7 CLUTCH SYSTEM Q en SIDE STAND en SUSPENSION w z NUTS BOLTS FASTENERS 0 z WHEELS TIRES STEERING HEAD BEARINGS FIRST J x 1000 km 6 NOTE x 1000 mi 0 6 4 NOTE 2 R I R R NOTC 3 NOTE 4 NOTE 4 12 18 24 30 36 8 12 16 20 24 I R R R R R R R R H R R A R R Refer to page NOTE 5 NOTE 5 NOT E 6 3 5 3 5 NOlE 6 3 5 NOTE 6 NOTE 5 3 8 NOTE 6 NOTE 5 NOTE 5 NOTE 5 NO...

Page 41: ...front side cover Remove the front side covers page 2 31 The spark plug wrench Is Included In the tool kit Insert the plug wrench between the heat guard plate and cvl inde r head cover as shown and set the wrench onto the spark plug Turn the plug wrench and remove the spark plug Then lift 1 1p the wrench with the plug through the heet guerd cross hole Pull th e wr ench out of ths cvlim l tl1 htidtl...

Page 42: ...is raciny irn itllf No 1 cylinder piston Is at TDC Top Dead Center on the compression stroke go to r Step 1 Insert the feeler gauge between the cam lobe and valve bucket Measure the valve clearance as follow No 2 IN Nu 3 11 X No 4 IN EXI Step 2 Insert the fee ler gau9e between the cam lobe mc f valve buck et Measure the valve clearance as foll pw No l IN EX No 2 EX No 3 IN VALVE CLE RANCE6 IN 0 12...

Page 43: ... mir rnmet er and record it NOTE Sixty fi ve different shims are available In thickness in tervals of 0 026 mm The thinnest is 1 200 mm the thickest is 2 800 mm To confirm your shim choice you may use the following formula a lb cl d 6 new shim thickness b recorded valve clearance c specified valve clearance IN 0 1 5 mm EX 0 20 mm d old shim thickness example b recorded valve clearance 0 18 mm d ol...

Page 44: ...ed CARBURETOR VACUUM DIFFERENCE Wfthln 30 mmHg 1 2 lnHg l BA f CARBURETOR No 2 CARBURETO R SIDE STAND Check the side stand ignition cut off system Place the motorcycle on its center stand and raise the side stand Start the engine with the transmission in neutral then shift the transmission Into gear with the clutch lever squeezed Move the side stand full down Thl l t1nglne should stop os the sldt ...

Page 45: ...rnmg hght inspectio n refer t o section 25 of the Common Servic e Manual When removing and inst alling the oil pump use care not to allo w dust or dirt to enter the engine After t he oil pump hos been inst alled check that llntre are no oil leaks and that oil pressure is correct TROUBLESHOOTING OiJlevel low No oil pressure Oil co nsumpt ion Oil level too low Extern al oil leaks Oil pum p drive cha...

Page 46: ...UBRICATION SYST EM LUBRICATION SYSTEM DIAGRAM 131 MA1NSHAFT 12 COUNTER 4 IIHHflllll 111 Oil FILTER SHAFT fl 0 OIL PRESSURE RELIEF VALVE 1 EXHAUST CAMSHAFT 1 ____ 2 INTAKE CAMSHAFT 3 PISTON t 4 CONNECTING 1 3 ROD 15 CRANKSHAFT 6 OIL PRESSURE SWITCH 7 OIL ORIFICE ...

Page 47: ...llation is in the reverse order of removal l 011pan bolt 12 At installat ion tighten the bolts In a gradual crisscross pattern 2 Oil pan 1 3 Gasket 1 4 Relief valve 1 S O rlng OUst rainer 1 Clean wit h the non flammab le solvent 71 O ring 1 8 Oil pum p driven sprocket bolt I NOTE Install the clutch outer onto the mainshaft temporarily poge 9 8 hold the flywheel with the rotor holder and remove or ...

Page 48: ...ifir suinn REQUISITE SERVIC E Oil pump removal installation page 4 31 PROCEDURE O ty REMARKS DISASSE MBLY ORDER Assembly is in the reverse orde r of disassembly 11 Oil pump cover attaching crew 2 NOTE Install the dowel pins then tighten the screws 12 Dowel oin 2 3 OIi pump cover 1 4 Outer rotor 1 Install with its punch mark facing the cover 5 Inner rotor 1 Install the rotor aligning its groove wit...

Page 49: ...ank Do not remove the radiator cap except to refill or drain the system All cool ing system service can be done with the enginn in ThP fr iml Avoid spilling coolant on painted surfaces For coolant replacement refer to section 5 of the Common Service Manual in this manual only the coolant draining pro ce dure is described After servicing the system check for leaks with a cooling system tester fur f...

Page 50: ...Honda CB400 CB 1 Service Manual http www motorcycle in th COOLING SYSTEIVI SYSTEMFLOWPATTERN 8 FAN MOTOR SWITCH 3 RAD IATOR CAP Pl WATER PUMP G SIPHON TU BE ...

Page 51: ...system NOTE I _ C _a_li_fo_ r _n_la_ m _o_d _ e_ l _ h_ a_ s_ t_ he _ o_ n_ ly le ft_d _r _ a_ in _ b_ o_ lt Place a suitable tray under the siphon tub e joint of the re serve tank and disconne ct the siphon tube from th e reserve tan1 Drain the coolant from the reserve tank Install the water pump drain bolt and cylinder drain bolt s wit h new sealing wA hAr and connec t th o oiphon tu be to the r...

Page 52: ... 2 Siphon tube 3 nad iator hose 4 Thermo sensor connector fi Thn rmo stat cover 6 0 ring 7 Thermost at 8 Thermo sensor 9 The rmostat housing MARK CL s 3 81 0 1011 0 11 Coolant refi ll section 5 of the Comm on Service Manual Ai r cleanRr case removal installation page 6 3 O ty REMARKS Installation is in the reverse order of removal 2 1 2 Install them with O marks fac ing up 1 1 1 1 Install the ther...

Page 53: ... draining page 5 3 Coolant refill section 5 of the Common Service Manual PROCEDURE Q ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 1 Radiator hose 2 Install them with O marks facing up I an motor switch connector 3 Radiator lower mounting bolt 2 4 Radiator uppar mounting bolt nut 1 1 5 Fan motor connector 1 fi Coll u 4 ...

Page 54: ...1 7 Cooling fan 8 S anm oto r s wlt r h 1 9 0 rlng FAN MOTOR GROUND TERMINAL REMARKS Assembly is in the reverse order of disassembly At insta llat ion align the grille tabs with the shroud grooves At installation align f our grill e grooves with the radiator lugs At insta llati on insta ll the tan motor ground w ire terminal proper ly as shown Install the fan mot or w it h the motor wireharness fa...

Page 55: ...ion page 3 3 step Weter pump side cover removal installation page 7 2 Gection 2 of the Common Se vi1 uManual Coolant refill section 5 of the Common Service Manual PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Assembly is in the reverse order of disassembly 11 Radiator hose 2 2 Water pump mounting bolt 2 NOTE Before removing bolt s loosen the pump cover bolts 3 3 Weter pump cover bolt 2 41 Water pump si...

Page 56: ... diaphragms might be damag ed NOTE If vehicle is to be stored for more than one month drain the float cham bers Fuel left in the float cham bers may caus e clogged jets result ing in hard st arting or poor driveability When disa56embling fuel system port s note the locations of the 0 rings Replace them w ith new ones on reassembly etore removing the carbureto rs place a suitab le cont ainer under ...

Page 57: ...ol valve PCV faulty loose disconnected or deteriorated hoses of the emission control iystem Afterburn on deceleration Lean mixture in slow circuit Emission control system malfunction California Model Only secondary air supply system faulty loose disconnected or deteriorated hoses of the emission control system Backfiring or misfiring during acceleration Ignition system faulty Fuel mixture too lean...

Page 58: ...me nt Inst all It with the fJmark forwards and with the TOP rm11kfacing up 16 Ai r clea ner case bolt co llar 2 2 16 Crankcase breather t11hfll 2 7 Air hose 1 Except California Model 8 Air injection tube No 15 1 California Model Only 9 Air cleaner case Align the hol es of th e connecti ng tubes with th e air jets Install the spark plug wire s as shown SUB AIR CLEANER CASE REMOVAL ORDER Installatio...

Page 59: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FUEL SYSTEM CARBURETOR REMOVAL INSTALLATION 7 Califo rnia Model Only f 2 ...

Page 60: ...rs draining Air cleaner case removal installation pas e6 3 PROCEDURE O ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 1 Insulator band 4 Only loosen t he screws 2 Choke cable 1 3 Throttle cable 2 14 t uel tube 1 16 No 10 vacuum tube from the AV CVI 1 California Model Only 6 No 4 Lul Je from the AVCV and PCV 2 California Model Only 7 Carburetors 1 8 Insulator 4 Each insu l...

Page 61: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FUEL SYSTEM CARBURETOR SEPARATION 1 4 No 3 CARBURETOR 6 119 ...

Page 62: ...3 way 0 ring Separato No 3 carb fro m No 4 carb 10 No 4 carb syn chronization spri ng 11 Thrust spring 12 A ir joint pipe rubber 13 Air vent pipe 0 ring 1141 Fuel joint pipe 2 w ay 0 ri ng Separate No 1 carb from No 2 carb 15 AVCV and PCV as an asse mbl y 16 No 1 carb synchronization spring 17 Thrust spring 18 Air joint pipe rub ber 19 Air v ent pip e 0 riny 20 Fuel joint pipe 2 way O ring O ty 1 ...

Page 63: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FUEL SYSTEM CARBURETOR DISASSEMBLY ASSEMBLY 4 26 25 2 4 1230 7 17 DOWEL I PIN SIDE t 91 a 16 14 13 12 11 I DOWEL PIN SIDE 10 1 13 t ...

Page 64: ...um cha mber cove r screws 4 At install ation first tighten the two screw s on the dowel pin side 2 Vacuum chambe r cove r 1 3 Srr lnQ 1 4 Diaphragm va cuum piston 1 5 Jet needle holder l Turn the hold er 90 countercloc kw ise while pushing It in and remove it 6 Spring 7 Spring holder 1 At insta llation align holder claws with piston grooves 8 Jet needle l 8 W1uher 1 Float Chamber 10 Float chamber ...

Page 65: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FUEL SYSTEM CARBURETOR COMBINATION 14 10 11 23 15 19 1 l c t I 7 119 6 10 t 7 No t CARBURETOR f ...

Page 66: ...carbu retor Assemble No 3 carb with No 4 carb 110 Fuel joint pipe I2 way 0 ring 1 2 l 1 Air vent pipe I3 way O ring 1 2 1121 Air joint pipe rubber 1 13 Thrust spring 1 1141 No 4 carb synchronization spring 1 1161 F1011t bracket screw 2 The shorter Do not tighten screws yet Do not install two screws of the front bracket choke cable holder yet AHenible No 1 No 2 carb with No 3 No 4 carb 1161 No 3 co...

Page 67: ...le in th FUEL SYSTEM CALIFORNIA MODEL ONLV AVCV AND PCV TUBES ROUTING 14 AVf V l No 5 TUBE 3 No 2 51 No 4 CARBURETOR CARBURETOR 2 No 1 4 No 3 CARBURETOR CARBURETOR 11 AVCV 10 PCV 15 No 6 TU l S 16 No 5 TUBES 19 AVCV 18 PCV 171 No 10 TUBE Bl No 5 TUBES ...

Page 68: ...URGE CONTROL VALVE PCVI ANO AIR VENT CONTROL VALV E IAVCV RCMOVAL Remove the fnllnwin13 fuel tank page 2 4 air cleaner case page 6 3 t carbu retor s page 6 4 Dlseonneetthe tube s trom Pt V and AVCV and remove the set plate from the No 1 car buretor float chamber cover Remove the PCV and AVCV Inspect the PCV 11nrl AVCV refer to section 7 of the Common Service Manual Install the PCV and AVCV in the ...

Page 69: ...nnect the vacuum pump to the ASV Perform the secondary air supply system refer to section 7 o1 the Common Service Manual SPECIFIED VA CUUM 360 mmHg 14 2 lnHg AJR SUCTION VALVE ASV I REMOVA L Remove two bolts and air suction valve as an assembly Disconnect the follo w ing from the ASV No 10 vacuum tube No 15 air injection tube air supply hoses Remove bolts air injection pipes and gaskets ReMove tl ...

Page 70: ...lt er The fo llowing components can be serviced with the engine installed in the frame alternator Section 14 camshaft Section 8 carbureto rs Section 6 clutr h Secliu11 9 gearshift linkage Section 9 oil pump Section 4 pulse generator Section 15 starter clutch Section 16 starter motor Section 16 water pump Section 5 The following components require engine removal for service connecting rod Sect ion ...

Page 71: ...Honda CB400 CB 1 Service Manual http www motorcycle in th ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION c40 4 0 29 261 C65 6 S 47 201 c s 1 5 11 21 c40 4 o 291 SPEEDO METER CABLE 27 ...

Page 72: ...ial washer n Fnoine mo Int bolt Frontl washer 24 Engine sub frame bolt 25 Engine sut frame 26 Engin e bracket bolt 27 Bolt cap 2ij l ngine mount bo lt rear upper collar 29 Engine assembly O ty 4 1 1 1 2 2 1 1 1 1 1 1 2 1 1 1 I 1 2 2 4 1 2 2 1 1 1 Engine oil draining location page 3 3 step section 2 of the Common Service Manua l Remo ve the radiator lower mount ing bolts and loosen the upper mounti...

Page 73: ...the valve and piston componen ts in the same order they were Installed so they can be reinstalled in the original posi tions TROUBLESHOOTING Engine top end problems usually affect engine performance These can be diagnosed by a compression or leak down test or by tracing noises In the top end with a sound ing rod or stethoscope If perfor ma nce is poor at low spee ds check for white smoke in the cr...

Page 74: ... radiator lower mounting bolts and loosen the upper mount ing bolt nut page 5 5 Swing the radiator forward REMARKS ln tallation is in the reverse order of removal At installation tighten the bolts in a gradual crisscross pattern Install them with the UP mark facing up Install with the mark forward NOTE Apply Th ee Bond 1521 or equlvalent to the head cove r and install the gasket onto the cover wit...

Page 75: ... is at TDC on the compres lon stroke Install the dowel pins onto the camshaft holders and install the camshaft holders in their original positions NOTE Each holder has Identificat ion marks EXL Exhaust camshaft Lull INL lnta e camshaft Left EXR Exhaust camshaft Hight INR Intake camshaft nigtn Tighten the r am I fl hultJur bolts In a gradual cqsscross pat1em TORQUE 12 N m 1 2 kg m 9 ft lb Turn the ...

Page 76: ...ead assembly 4 Gasket 15 Dowe l pin 6 Cams haft idle gear case bolt 7 Camshaft idle gear easedowel pin 8 Sea lin g washer 9 Camshaft idle gear oam1 10 Carbureto r insulator n A Camshaft removal installation page 8 2 Q ty REMARKS Installation is in the reverse order of remova l 1 Installation page 8 5 1 1 Install with the UP mark facing up and rearwa rd 2 5 2 Installat io n jpage 8 5 1 1 4 At insta...

Page 77: ... the gear case held the gear c899 should be lifted up shghtly from the cylinder Install a new sealing washer and mounting bolts Tighten bolt s In a gradual as shown CYLINDERHEADNUT BOLTINSTALLATION Install the cylinder head special nuts as shown Do not tighten them yet Install the cylinder head mounting bolts Tlijltllm lh1 11 I nIcial nut anc1 mounting DOits In a gradual crisscross panem TORQUE Sp...

Page 78: ...E SERVICE Engine removal installation paQe 7 2 Cylinder head remo val installati on page 8 4 Camshaft removal installation page 8 2 PROCEDURE Q ty REMARK S DISASSEMB LY ORDER Assembl y is in the reverse orde r of disassembly r11 Valve bucket 16 NOTE Remov e using a handlapp lng tool Do not damage the cylinder head bucket sliding surface 2 Valve shim 16 3 Vatve cottef 32 Removal Inst allat ion page...

Page 79: ...inder head bucket sliding surface VALVE BUCKET HOLE PROTECTOR 07JMG KY2010 0 Install the valve spring compresso r onto the valve and com press the valve spring Remove or Insta ll t he valv cotte rs VALVE SPRING COMPRESSOR ATTACHMENT 07JME K V20 100 ALVE SPRING COMPRESSOR 07757 0010000 CYLINDER HEAO CYU NDER PiSTON 1 VALVE BUCKET HOLE PROTECTOR 1 ATTACHME NT 21 COMPRESSOR 8 7 ...

Page 80: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CYLIND R HEAD CYLINDER PISTON CYLINDER PISTON REMOVAL INSTALLATION C10 1 0 11 4 its Bl fl 8 8 ...

Page 81: ...der mounting bolt 5 Cylin der 6 Gasket 7 Dowe l pin 8 Piston pin clip 91 Piston pin 10 Piston 11 Piston top ring 112 Piston second ring 131 Piston oil ring set side rails and spacer Cylinder hear removal installation page 8 4 Q ty REMARKS Installation is in the reverse order of removal 3 1 1 1 Install with the UP mark facing up and forward 2 8 4 4 Install them with the IN mark facing to the intake...

Page 82: ...ove the engine and separate the crankcase Section 10 If it ii no longer clear wh ich bolt belongs in which hole insert all bolts in the holes and check th e exposed length each should be expoMd t hP Ami amount TROUBLESHOOTING Clutc h leve r too hard Damaged kinked or dirty clutch cable Improperly routed clutch cable Damage d clutch lifte r mechanism Faulty clutch litte r plate h1111rino Clutch w i...

Page 83: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL INSTALLATION 10 J 17 I 1 1 11 2 _ _ 7 _cZ 2 C o o 1 14 Ow ...

Page 84: ...nnecto r 1 3 Alght crankcase cover bolt 14 NOTE At instaJlation apply a tock ing agent to the two bolt threads 4 Right crankcase cover 1 Disconnect or connect the Alternato r 3P connector 5 Gasket 1 6 Dowel pin 2 7 Clutch lifte r pin 1 8 Return spr ing 9 Spring pin 1 NOTE Drive in a new spring pin using a pin drive r until the pin does not interfe re with the lifter arm as shown 110 Clutch lifter ...

Page 85: ...g seat 1 10 Judder spring 11 clut ch frict ion disc C Larger l D disc Color black 112 clutch plate B 1 Color grey 13 clut c h frictin disc B 4 Smaller I D disc 14 clutch plate A 4 Color silver 15 clutch friction disc A 1 Smaller I D disc C olor black 16 pressure plate 1 Refer to section 11 of the Common Servfce Manual for inspection information 17 Oil pump driven sprocket 1 Removal page 4 3 18 Clu...

Page 86: ...01 000A U S A only Temporarily remove the tool and tighten nuts then reinstall the clutch center holder onto thl bosses Use at least two clutch lifter plate bolts to secure the tool to th e clutch Hold the clutch center holder and remove the lock nut as shown If you do not have the above holder use the below holder Unstake the nut Remove the clutch center lock nut as shown CLUTCH CENTER HOLDER 07G...

Page 87: ...a CB400 CB 1 Service Manual http www motorcycle in th CLUTCH GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL INSTALLATION ALIGN GUIDEPLATE ORUMSHIFTER ASSEMBLY 12 1 2 9 0 lo 9 10 11 m SPINDLE ASSEMBLY 3 12 131 ...

Page 88: ... on the joint and spindle 13 Gearshift spindle 1 4 Spindle return spring 6 Washer 1 61 Shifte r collar 1 71 Guide plate mounting bolt 2 0 Guide plate d1u111 SlliH1 11 a1a 0mllly Assembly as Illustrated 9 guide plate 1 Install onto dowel pins properly or shift to hard 10 ratchet pawl 2 Pawl orientation as shown 11 plunger 2 121 spring 2 13 drum shifter 1 14 Collar 1 11b Dowel pin 16 Stopper arm spr...

Page 89: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CLUTCH GEARSHIFT LINKAGE CLUTCH INST ALLA TlON 7 15 0 0 8 15 1 6 11 6 ...

Page 90: ...v m oear does not interfere will ll11 1l limk weight Align the serrated tooth of the prlmn ry d1 Ive 1 IJl llH with The drive gear teeth as shown and temporarily install the clutch outer onto the mainshaft Wh ite hold ing the clutc h outer and pushing in on it lightly 1utata the OIi pt Jrnpdriven sprocket bolt Install the clutch outer properly aligning the clu tch outer holes with th e oil pump dr...

Page 91: ...ool to t he clutch CLUTCH CENTER HOLDER 07HGB 001000A U S A only Hold the clutch ce nte r holder and torque the clutch cente r lock nut as shown TORQUE 85 N m 8 6 kg m 61 ft lb Stake the lock nut onto the mainshaft If you do not have the above holder use the below holder Hold the clutch center as shown and torque the clutch center loek nut l I CLUTCH CENTERHOLDER 07GMB KT80100 Not avallable in U S...

Page 92: ...to assembling the crankcase halves apply a sealant to their mating surface Wipe off excess sealant tho roughly Mark and store tho bearing Inserts to be sur e of the ir cot eel luoatlons for reassemb ly If the inserts are improperly installed they will block the oil holes causing insufficien t lubrication and eventual engine seizure If it is no longer clear wh ich bolt hAlnno iin whi ch hQle Insert...

Page 93: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CRANKSHAFT TRANSMISSION CRANKCASE SEPARATION ...

Page 94: ...l nrifir A CRANKCASE BOLTS LOCATION Loosen all bolls i11c1 yrm lu1 1I crisscross panern Bolt s locat ion as shown _ bolt with a naling washer O w 6 13 13 1 3 2 Clean any liquid sealant off the crankcase mating surface CRANKSHAFT T RANSMISSION Starter motor page 16 5 Oil pan paQe 4 3 REMARKS Bolts 2 psc mar kert t on the crankcase have sealing washers Bolts 2 psc marked A on the crankcase have seal...

Page 95: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CRANKSHAFT TRANSMISSION CRANKSHAFT CONNECTING RODREMOVAL INSTALLATION 3 10 4 l C 24 2 4 17 OIL HOLE FACING TO INTAKE SIDE ...

Page 96: ...ring cap nut 8 2 Bearing cap 4 3 Connecting rod 4 4 Conne cting rod bolt 8 Do not remove them without necessary I Conneet lng rod bearing 8 Wipe all oil fr om the bearing seating areas 6 Crankshaft 7 Cranksh aft main jo urnal bearing 12 Wipe all oil from the bearing seating areas INSTALLAT ION OAOEA 71 C1ank sln1fl 1111 tin journal bearing 12 The bearing tabs should be aligned w ith the grooves in...

Page 97: ...e crank weight NOTE Numbers 1 or 2 on the crank weight are the codes for the main journal 0 D s from the left Cross reference the case and journal codes to determine the 1 1 1uu1 1ment bearingcolor code c enl case A II C code 33 000 33 009 33 017 33 008 mm 33 016 mm 33 024 mm M1m j1111mal 11 2992 1 2996 1 2999 0 0 oode 1 2995 in 1 2998 int 1 3002 lnl 1 29 992 30 000 mm Pink Yollow Green 1 11108 1 ...

Page 98: ...the upper crankcase are the codes for the crankpin 0 0 s from the left _ _ __ _ _ _ _ J Cron re fe1ence tl1 e cr mlqlln and rod codasto determ ne the replace ment bearing color code n 11 e A 29 992 30 000 mm 1 1808 1 1811 lnl 8 29 984 29 9 H mm 1 1805 1 1807 inl Bearing thickness Brow n Thi n Bl lCk Sloe Thick 1 2 32 992 33 001 33 000mm aa ooamm 1 2989 11 299 2 1 29 92 in 1 29 95 lnl Yellow Green ...

Page 99: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CRANKSHAFT T RANSMISSION TRANSMISSION REMOVAL INSTALLATION BENO THE lF B l ...

Page 100: ...16 Dowel pin 17 Shift drum bearing set plate 18 Shift drum bearing 19 Shirt I Jrum CRANKSHAFT TRANSMISS ION Q ty REMARKS Insta llation is in the revArse order of removal 1 At insta llation align the bearing groove with the set ring and align the oil seal with the case groove 1 2 1 1 At installation face the M6 gear engagement dogs for ward the M4 gear 1 1 Remove after bending down the lock was her...

Page 101: ...o section 13 of the Common Service Manual for inspection Information ______ _____ ___ REQUISITE SERVICE Transmission removal instatlation page 10 8 PROCEDURE Q ty REMARKS MAINSHAFT DISASSEMBLY ORDER Assembly is in the reverse ordt1r of disassembly 111 Needle bearing 1 2 Thrust washer 1 3 M2 gear 17T 1 4 Spline washer 1 5 M6 gear 24 TI 1 6 M6 spline bushing Align the oil holes of the bushing and ma...

Page 102: ... C3 gear 30Tl t spline bushing Lock washer 5pline wasli1 J1 C4 gear 35T Cd spline bushing Spline washer Snap ring CS shifter gear 32T Snap ring Spline washer C2 bushing C2 gear 40T Thrust washer Oil seal Bearing Countershaft 6 5 4 o w 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1 1 l 1 1 1 1 1 1 2 3 1 REMARKS SHIFTER GEAR GROOVE GEAR SLIDING SURFACE Assembly is in the reverse order of disassembly Install with the...

Page 103: ...Honda CB400 CB 1 Service Manual http www motorcycle in th CRANKSHAFT TRANSMISSION CRANKCASE INSTALLATION 4 0 121 1 2 91 I fi C24 2 4 111 4 a c 12 1 2 s 41 C 12 1 2 9 ...

Page 104: ... 6 mm 6 CRANKCASE INSTALLATION Apply a light but thorough coating of sealant to the upper crankcase mating surface except to the main bearing journal bolt Mating areas and the 011 passage area as shown Set the mamshaft and countershaft into neutral position first th en slide the C Bshitter gear onto the C2gear 2nd gear po sition as shown to ease upper crankcase installation CRANKSHAFT TRANSMISS IO...

Page 105: ...e is assembled securelv lnatoll the cronkcase b1Jlli11md sealing washers as shown NOTE Four 6 mm bolts marked l on the crankcase have sealing waoh cr3 Twelve 8 mn I bolts for the cranks haft main journals have sealing washers Four 8 mm bolts marked t on the crankcase and is black Incolor Tighten all crankcase bolts in it Q Rdual crisscross pattern beginning with larger diameter bolts first as show...

Page 106: ...s ire covered rnt he s ectlon 16 of the Common Servi ce Manu al It the moto rcycle has been involved in an accide nt inspect the frame very carefully at the stee ring head and at the engine mounts Tl11 1i 1 1 1 1r e the areaamosl likely to suffer damage It is possible to bend the frame steering head without bending the fork tubes or even the front axle For wheel fork or 3teering ste11111 1move1 a ...

Page 107: ...ligh t swit ch connector 2 2 Master cy linder 1 Align the holder end with the punch mark on the handle bar and face the holder UP mark upward nghten the upper bo lt first then the lower bolt 13 Right hRnrllebar sw it h housing ocrew 2 Tighten the front screw first then the rear screw 14 Right handlebar switch housin g 51 Throttle cab le nut 1 6 Throttle calbe 2 Don t bend or distort th e cables 7 ...

Page 108: ...th the punch mark on the handle bar and face the holder UP mark upward nghten the upper bolt first then the lower bolt 3 left handlebar sw itch housing screw 2 Tighten the front screw first then the rear screw 11 Loft hond lebor sw itch housin1 1 I 6 Choke cable 1 16 Handlebar weight 1 Align its boss w ith Lhe Inner weight 71 Handle grip 1 Apply Honda Bond A or Honda Hand Grip Cement U S A only to...

Page 109: ...vacuum cleaner or alternate method approved by OSHA desig ned to minimize the hazard caused by airborne asbestos fiber s CAUTION Do not use the oil filte r as a jack point NOTE Do no t depress t ho brake lever when the caliper is remove tl or it will be dlff lcu lt to refit the disc between the brake pads REQUISITE SERVICE Raise the front whe el off the ground by placing a jack or other support un...

Page 110: ...ERVICE Front wheel removal installa tion page 1l 4 PROCEDURE O ty ASSEMBLY REMARKS OISASSEMBL Y ORDER Assembly is in the reverse order of disassembly Right side collar 1 Longer collar 2 Left side collar 1 Shorter collar 3 Brake disc bolt 6 Wipe off all the grease on the bolt surface 4 Brake disc 1 Install with the stamped side outward as shown 151 Dus seal 2 Apply grease to the dust seal llps and ...

Page 111: ...Honda CB400 CB 1 Service Manual http www motorcycle in th AONT WHEEL SUSPENSION STEERING FORKREMOVAL INSTALLATION 4 l c 27 2 7 20 1 1 R 6 GROOVE ...

Page 112: ...in3ta llat ion page 11 2 Front wheel removal installat ion page 11 4 Left handlebar removal installation page 1 1 31 PROCEDURE Q ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 11 Front fender bolt 4 2 Front fender 1 3 Brake hose clamp 1 Insta ll it with the front fender as shown 41 Caliper brack el bolt 2 5 Caliper assembly 1 6 Meter mounting bolt 2 Move the meter assembl...

Page 113: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FRONT WHEEL SUSPENSION STEERING FORK DISASSEMBLY 1Yl 10 13 4 61 71 8 14 15 5i 3 1161 ...

Page 114: ...remaining fork oil 6 Dust seal J When removing them do not damage the fork tube 7 Stopper ring 8 Fork socket bolt 1 NOTE Temp orarily install th e spring and fork cap bolt if difficulty is encountered in rem oving the soc ket bolt 9 Sealing washer 1 10 Fork piston 1 111I Fork piston ring NOTE Do not remove it unless it is necessa ry to repla ce 12 Rebound spring 1 13 Fork tube 1 14 Oil seal 1 1151...

Page 115: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FRONT WHEEL SUSPENSION STEERING FORKASSEMBL V 4 151 6 621 7 1r t 17 16 Tight er Coils_ Dow n T ...

Page 116: ... In place when the socket bolt is tightened 10 Slider busl llng 1 11 Back up ring 1 1 21 0116081 NOTE Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal during the oil seal installat ion Drive in it securely using fork seal driver 07947 KA50100 and attachment 07947 KF00100 131 Stoppe r ring Install into the slider groove secu rely 14 Dust seal 1 NOTE After Installing it co...

Page 117: ...Honda CB400 CB 1 Service Manual http www motorcycle in th FRONT WHEEL SUSPENSION STEERING STEERING STEMREMOVAL INSTALLATION 5 er SHORTER TABS Bend down LONGFR TABS Bend up 10 c os 1 0 s 761 11 6 mS ...

Page 118: ...ed 11bl Oust seal 1 Use race remover attachment 0 7953 MJ 1OOOA with 16 Upper outer race _ driver 07949 3710001 and attachment 17 Low er outer race _ 37 x 40 mm 07746 0010200 fo r upper outer race removal Use race remo v er 07946 3710500 with driver 079 49 371000 1 and attachment 37 x 40 mm 077 46 0010 200 for lower outer race removal INSTALLATION ORDER 17 lower outer race _ Replace as a set if ne...

Page 119: ...hose or dry brush to t lean brake assemblies Use an OSHA appro ved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airbo rne asbesto s fibers __ _ RJ _d _I_ n_ g_o_n _d _o _m _ a_ g_ ad _ ri_m _s _lm _p _a _n _ sa _ f_ e_ o _ pe _ ra _u _ u _n _of _ th _e _ve _h _l_ cl _ e_ _________ _ ___ _ ___ ___ __ m Refer to th section 13 for brake system Informat...

Page 120: ...rne asbestos fiber NOTE Put the motorcycle on its center stand Do not depress the brake pedal wh en the calip er is removed or it will hP rfiffi cult to refit the disc bet ween the brake pads Support the removed caliper with a piece of wire so that i I does not hang from the brake hose Do not twist the brake hose Adjust the drive chain free plav adjustment after Installing the wheel PROCEDURE Q ty...

Page 121: ...SITE SERVICE Rear wheel removal installation page 12 2 PROCEDURE O ty ASSEMBLY REMARKS OISASSEMBL Y ORDER Assembly is In the revers e order of disassembly Right side collar 1 2 1 l eft side collar 1 31 Right du l svul tr Appl y grease to the dust seal lips and install them with 4 1 Left dust seal the lip side facing inside 51 Drive n flange assemli ly l 6 driven flange collar 1 7 driven flan Qe be...

Page 122: ...os ition I for lightest loads before removing the shock absorber from the frame REQUISITE SERVICE Fuel tank removal installation page 2 4 PROCEDURE Q ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 1 Shock absorber mountinQ bolt upper At installation install them from the left side 2 Shock absorber mounting bolt lowe r 3 Shock absorber assembly 1 NOTE Remove it upwards fro...

Page 123: ...k absorber to position I for lightes t loads before removing the shock absorber from the frame For lower joint nAedle b11aringreplacement ace next page REQUISITE SERVICE Shock absorbe r remnv J inc tallation page 12 1 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Assembly is in the reverse order of disassemb ly I1 l lower joint 1 NOTE Remova l Installation page 12 6 t instollat ion align the lower join...

Page 124: ...tall the lower joint securely onto the dampe r rod Hole the lower joint and torque the loc k nut TORQUE 68 N m 6 8 kg m 49 ft lb Makesurethe Lower Joint Is aligned with th e seat stop per pin and remo ve the compressor LOWER JOINTS NEEDLE BEARING REPLACEMENT Remove the dust seals Hold th joint with a suita bl e tool Press the need le bearing out of the joint s fOOL l DRIVER PIN ur PILOT 22 mm DRIV...

Page 125: ...ved caliper with a piece of wire so that it does not hang from the brake hose Do not twist the brake hose If necessary loosen the rear engine mounting nut near the swingarm pivot to ease the swingarm removal installati on REQUISITE SERVICE neer wh eel removel instelletion pege 12 2 PROCEDURE Q ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 1 Rear brake cauper I 2 Brake ho...

Page 126: ...Right pivot co llar 3 Left pivot collar 41 Drive chain cover 5 Drive eMln slider 6 Right dust seal 7 Loft duet eeal 8 Distance collar 19 Snap rin 10 Ball bearing Needle bearing 12 8 I oq Ipaya 1 17 9 c u O ty 2 1 1 1 1 1 2 1 4 1 0 ls L I p e 12 9 Swingarm removal installation page 12 7 ASSEMBLY REMARKS Assembly is in the reverse order of disassembly Install them with the UP mark facing up and the ...

Page 127: ...ble DRIVER SHAFT 07946 MJ00100 in U S A or BUSHING REMOVER M967X 038 XXXXX DRIV R 07949 3710001 Pross the needle bearing into the swingarm w ith the marked side facing out NOTE The b11aring s1 1rface sho1 1fd flush with the pivot inside surface as shown STOOL DRIVER ATTACHMENT 28 1130 rnm PILOT 22 mm 07749 0010000 07946 1870100 07746 0041000 Press one ball bearing inner bearing into the swingarm f...

Page 128: ...rmful t o some rubber parts Be very careful whenever you remove the reservoir cap make sure the front reservoir is horizontal first Never allow contamin ants dirt w ater etc to get into an open reservoir Once the hyd raulic sys tem has been opened or if t he brakes feel spongy the system must be bled Always use fresh DOT 4 brake fluid fr om a sealed containe r when servicing the system Do not mix ...

Page 129: ...irbor ne asbestos fibers After replacement operate the brake lever to seat the caliper pistons against the pads NOTE Do not depress the brake lever when the caliper ls removed or it will be difficult to refit the disc between the brake pads Replace brake pads as a set Apply a thin of silicone grease onto the pad pin so as not to rust it REQUISITE SERVlCE Pushing the calipe r against the disc push ...

Page 130: ...edal to seat the caliper piatons againat the pads NOTE Do not depress the brake pedal when the caliper is removed or it will be difficult to refit the disc between the brake pads Replace brake pads as a set Apply a thin coating of silicone grease onto the pad pins to prevent rust and allow easy pad movement REQUISITE SERVICE Pusl1i11ylh l calipl lr ayai11sl lh1 1 uisc pui h the caliper piston all ...

Page 131: ...to minimize the hazard caused by airborne asbestos fibers NOTE If you remove the caliper piatono remove the caliper bracket bolts 4 belor1 1disconnect ing the brake hose 3 and place a pan under the caliper to catch the draining fluid and squeeze he brake lever slowly to push out the pistons REQUISITE SERVICE Brake pad removal ins tallat ion page 13 2 Brake fluid reolecement air bleeding St1Ctio11 ...

Page 132: ...ed by OSHA designed to minimize the hazard caused by airborne asbestos fibers NOTE Before di oonnocting the brake hoH 1 place a pan unde r th r AlipAr to catch the draining fluid and squeeze the brake lever slow ly to push out the piston REQUISITE SERVICE Brake pad removal installation page 13 3 Brake fluid replacement air bleed ing section 17 of the Common Service Manual PROCEDURE O tv REMARKS RE...

Page 133: ...tallation jpage 13 21 Front brake collpor removal installation page 13 4 Brake fluid replacement air bleeding section 17 of the Common Service Manuel PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Assemb ly is in the reverse orde r of disassembly 111 Ped S lrlno Note the spring direction as shown 2 Caliper bracket 1 3 Bracket pin bull bout 4 Caliper pin bolt boot 1 Install into the bracket groove secure...

Page 134: ... Rear brake caliper remo val installation page 13 5 Brake fluid repla cement air bleeding section 17 of the Common Service Manual PROCEDURE O ty DISASSEMBLY ORDER 1 Pad spring 1 m Pivot collar 1 31 Piv ot boot 1 4 Caliper pin bolt boot 1 5 Caliper pin bolt 1 6 Caliper pisto n 1 m Du3t seal i 8 Piston seal REMARKS Assembly is in the reverse order of disassembly Note the spring direction as shown _ ...

Page 135: ...ARKS REMOVAL ORDER Install ation is in the reve rse order of removal I1I Right rearview mirror 1 2 Brake lever pivot bolt l Brake lever 1 4 Brake hose bolt 1 5 3el llng was I 2 6 Front brake light switch connector 2 7 Maner cylinder holder bolt 2 Thighten the uµµar uolt first then the lower bolt 8 Master cylinder holder 1 Face the UP mark upward 91 Master cylinder assembly 1 Align the holder end w...

Page 136: ...ice Manual PHUCl DURE O ty REMARKS REMOVAL ORDER Installat ion is in the reverse order of removal 1 Brake hose bolt 2 Sealing washer 2 3 Brake hose 4 Ma ster cylinder mounting bolt 2 Only loosen the bolts G Foolpey bt IL l lJull 2 6 Reservoir hose joint 1 71 0 ring 1 8 Push rod jo int 1 Install it from the footpeg side w ith a new cotter pin 9 Master cylinder asse m bly Remove the mount ing bolts ...

Page 137: ... SERVICE Air bleeding section 17 of the Common Service Manual Front maste r cylinder removal i nstallation page 13 8 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMB LY ORDER Assembly is in th e reverse order of disassembly t1 Reservoir cover 1 2 Diaphragm plate 3 Diaphragm 4 Front brakelight switch 1 6 Boot 6 Snap ring CAUTION Be certain the snap ring la fully seated in the groov e 7 Stopper plate 1 8 M...

Page 138: ...ake lluid replacement atr bleeding section 17 of the Common Service Manual Rear master cylinder removal installation page 13 9 PROCEDURE O ty ASSEMB LY REMARKS DISASSEMBLY ORDER Assemb ly is in the reverse order of disassembly Push rod joint 1 Adjust the joint installed length as shown Face the joint tab side as shown 2 Boot 1 J Snap ring 1 CAUTION Be certain the snap ring Is fuUv seate d in the g...

Page 139: ...ush roe JOll lt 3 Footpeg mounting bolt vn Wava woohor 5 Rear brakelight switch spring 6 Brake pedal return spring 7 Right footpeg 8 Brake pedal 13 12 Q ty 2 1 1 1 1 1 1 27 2 7 20 REMARKS Installation is in the reverse order of removal Install tt trom the tootpeg side with a new cotter pin Apply a locking agent to the bolt threads Align the footpeg with the stay groove Apply grease to the pedal pi...

Page 140: ...ot be removed Attemptin g to remove the sealing caps from th e ce lls may damag e the bat l1 ny Hattery can be damaged t overcharged or undercharged or if lett to discharge for long periods These same cond lt lons contribute to shortening the life span of the battery Even under norma l use the performance of battery deter iorates after 2 J years Battery voltage may recover after battery charging b...

Page 141: ...vice Manual http www motorcycle in th r I CHARGING SYSTEM Al TERNA TOR SYSTEM LOCATION CIRCUIT DIAGRAM 11 ALTERNATOR 14 MAIN FUSE INTO STA E _ LA Y _ __ __ Y Y Y G R W 3 REGULAT OR RECTIFIER 2 MAIN FUSE 30 A 8 1 41 BATTERY ...

Page 142: ...ector page 14 5 NORMAL Cheek the regulator rectifier unit 1nspect1on page 14 6 NORMAL INCORRECT CORRECT CHARGING SYSTEM ALTERNATOR Check the regulator rectifi er unit inspect ion page 14 6 INCORRECT CORRECT L Shorted Jire harness Faulty ignition switch Faultv regulator rect ifier Check the battery using a Honda Battery Tester I CORRECT Electric sJstem over loa ding INCORRECT I Faulty battery ABNOR...

Page 143: ...out the fuse in the tester While measu ring current do not turn the ignition on A urlrlAn 11ro F1 nf r urrP nT m9y hlow out th fuse in th tester SPECIFIED CURRENT LEAKAGE 0 01 mA max If current leakage exceeds the specified value a shorted cir cuit is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLT AGE INSPECTION NOTE Before performing this t...

Page 144: ...t ing the ammeter or wires when current is ilowing may damage the ammeter Start the engine and increase the engine speed gradually REGULATED VOLTAGE 14 0 1 6 0 V 5 000 rpm CHARGING CURRENT 0 8 A 5 000 rpm REGULATOR RECTIFIER WIRE HARNESS INSPECTION Remove the rear fairing page 2 2 Disconnect the regulator rectifie r connecto r and measure the following between connector terminals of the wire harne...

Page 145: ...2 003 KOWA Dlg11altype U S A only 07308 0020001 SANWA Analogue type TH SH KOWA Analogue type Select the following range SANWA tester x kO KOWA tester x 100 0 When using the KOWA multitester remember that all H H lt li11yi i huuld be multiplied by 100 An old weak multitester battery could cause Inaccu rate reading Check the battory if the multitc3tcr rcgis ters incorrectly Replace the regulator rec...

Page 146: ...ALLATION Remove the following right crankcase cover IP OE 9 2 flywheel bolt washer flywheel woodruff key Remove the bolt and stator w ire harness clamp Remove the bolts and stator Apply a locking agent to the stator mounting bolt threads Install tl e tat or and tighten the bolts securely Set the wire harness grommet Into the cover groove and in atoll the clomp Clean any material off the crankshaft...

Page 147: ...y damage the unit Always turn off the ignitio n switch befo re servicing A faulty ignition system is often related to poo rly connecte d conn ectors Check t hose con nections before proceeding Make sure the battery is adequate ly charged Using the starter motor with a weak battery results in a slower engine crank ing speed as wall as no spark at the spark plugs Use spark plugs of the correct heat ...

Page 148: ...H CIRCUITDIAGRAM 31 IGNITION COILS 1111 SPARK PLUGS 4 MAIN 12 IGNITION FUSE 30 A SWITCH Sl FUSE 10 A A 7 o R 81 2 CNGINE STOP 5 FUSE 6 BATTERY SWITCH 1o A 1 SIDE STAND Bl Br SWITCH INDICATOR u_ v fv down Y Bla iG1 8 SIDE 1 s1tw O o BI To Tachometer B1 W __ y IBu i Y G 7 SPARK UNIT STAND G W SWITCH W Y o 9 NEUTRAL SWITCH up 101 PULSE GENERATOR ...

Page 149: ...e ne1 1tralswitch for continuity at the spark unit connector page 15 6 NORMAL Cl11 11 k LIiia sille Sl 111 Jswiluh l ll l111 1 spark unit connector page 15 6 GOOD Faulty 5pa1to u11 lt ABNORMAL Poorly connected connector ABNORMAL Poorly connected connector NO VOLTAGE _ Faulty ignition switc h or engine stop switch ABNORMAL ABNORMAL ABNORMAL Open circuit in wire harness Loose or poor contact of rela...

Page 150: ...re Measure resistance of the Ignitio n primary coil at spark unit connector page 15 6 STANOARO_ Poor or loose contact of ignrtlon coil 4P mini GOOD Faulty spark unit No spark at one plug Trouble Ii secondary coil sidel Faulty spark plug is most likely VALUE i onnector Open circuit between the unit and ignit ion coil Replace suspected bad spa rk plug with known SPARK good spark plug and conduct spa...

Page 151: ...cted to ground via the side stand switch When th o aide atond is up the side stand switch line bl of the spark unit passes to ground via the side stand switch The spark unit monitors lines al and bl and provides spark only when one or bot h of those lines is connected to ground vis the neutra l switc h or the Ide tand switc h Check the side stand indicator for function NORMAL Open circuit in Green...

Page 152: ... Light Green Red and ground Side stand switch line Green White and ground Ground line Green and ground IGNITION COIL INSPECTION U1sconnect the Ignition coil 4P mlnl connector under the fuel tank and measur e the primary coll resistan ce between the terminalf IJ1 1luw No 1 4 primary coil Black Wh ite and Yellow Blue No 2 3 primary coil Black White and Blue Yellow STANDA RD 2 4 0 20 C 68 F Specifica...

Page 153: ...ARDS Primary coil 2 4 0 120 C 68 F Secondary coll 13 17 kO 120 C 68 F REMOVAUINSTALLA TION Disconnect the ignition coil 4P mini connector under the fuel tank Remuvti thH lm lts and collars Oiac onnect the ignition primary terminals from the coils and remove the ignition coil as an assembly RemnvA hnlts and No 2 3 ignition coil first t han remove bOltS and NO I 4 lgmtion co I lnotoll the ignition c...

Page 154: ...ove the left crankcase cove r page 16 8 R1m1ove the bolts and pulse generator Install the pulse generator and wire clamp and t ighten the bolts securely Set the wire harness arommet into the cover groove Install the left crankcase cover page 16 8 SIDESTANDSWITCH INSPECTION Disconnect the side stand 3P mini greP n r onnector under the fuel tank and check for continuity between each terminals as bel...

Page 155: ...e and connect a timing light to the No 3 cylin der ipork plug wire NOTE Read the instr uction s for tim ing light for operating Remove the following crankshaft Mle eap cover page 9 1 J crankshaft hole cap page 9 21 timi ng mark hol e cop page 2 Start the engine and let 1tidle The timing is correct if the F 111c1rk aligns With the crankcase cove r index mark NOTE If the correct timing could not u1 ...

Page 156: ...t is kept flowing through the starter moto r to turn it whi le the engine is not cranking over the starter motor may bfl damage d_ For the following component inspections refer to the follo w ing pages for the parts locations see page 16 2 of this manual SYST EM LOCAT ION Clutch switch diode Section 24 of the Common Service Manual Sta rt er moto r Section 24 of the Common Servi ce Manual Sta rter ...

Page 157: ...AY SWITCH MAIN FUSE 30 A 5 FUSE 10 A 18 s1oe STAND ITCH f11 l IGNITION SWITCH 7 R 81 R 6 BATTERY 4 STARTER RELAY SWITCH 5 FUSE 5 4 MAIN I101 STARTEfl MOTOR 16 2 10 A US FUSE Y R 12 NEUIHAL INDICATOR 10 A Bl Br Bl o Y R L _____ _ _3 0 _ A 7 IG R _j I 1121 ig 13 STARTER SWITCH Lg R 9 Lg A NEUTRAL 7 CLUTCH WITCH SWITCH DIODE G R _JG R 0 1 GJW 1 SIDESTAND SWITCH INOICATOn down up Y Bt 18 SIDE STANO SW...

Page 158: ...ect starter relay switch connector and che1 the 1 t1 lay evil yruund wire lines as below for continuity 1 Grven Red terminal clutch sw itch diode neutral switch tine with transmission imo neutral and clut ch lever released 2 Green Red terminal clutch swi tch side stand switc h line in any gear except neutral and with the clutch lever pulled in and th e side stand up I CONTINU ITY Connect the start...

Page 159: ...e side stand switch page 15 8 ABNORMAL Faulty side stand switch NORMAL Open circuit in wire harness Loose or poor contact of connector Starter motor tums slowly Low specific gravity in battery lor Dead battery Poorly connected battery terminal cable Poorly connec ted starter motor cab le Faulty storte r motor Poorly connected battery ground cable Starter moto r tu ms but engine does not tum Starte...

Page 160: ... INSTALLATION Turn the iAniti on swit ch OFF REQUISITE SERVICE Fuel tank removal insta llation page 2 4 PROCEDURE O ty REMA RKS REMOVA L ORDER Installatio n Is In t he reverse order of removal 1 Starte r moto r cab le 1 2 Starter mot or moun t ing bolt 2 3 Ground cable on engine 1 4 Starter motor 1 5 0 ring 1 16 5 ...

Page 161: ...Honda CB400 CB 1 Service Manual http www motorcycle in th ELECTRIC STARTER STARTER CLUTCH STARTER MOTORDISASSEMBLY ASSEMBLY 111 ALIGN 1Q Q 13 141 2 15 16 5 11 18 6 19 ...

Page 162: ...5 O ring 1 6 Motor case 1 NOTE lnta ll with the groove side facing to the brushes Align the index marks on the rear cover and case 7 O ing 1 8 Lock washer 1 9 Insulated washer 1 10 Washer 1 11 Armature 1 12 Shims Record and store the shims in the seme order they were insta lled so they can be reinstalled in the original posi tions 13 Brush termina l holding nut 1 14 W1 1sl11 1 1 1 5 Insulated wash...

Page 163: ...400 CB 1 Service Manual http www motorcycle in th ELECTRIC STARTER STARTER CLUTCH STARTER CLUTCH REMOVAL INSTALLATION 12 ALIGN THE WIDE GROOVE AMONG THE CRANKSHAFT SPLINES AS SHOWN 1 5 0 1 page 16 9 C 85 8 5 61 ...

Page 164: ...the rotor holder onto the flywheel Q ty 7 1 1 1 1 1 1 1 1 1 ROTOR HOLDER 07725 0040000 o r equivalent commercially availab le in U S A Hold the roto r holder and remove the starter clutch bolt w it h a helper Set t he rotor ho lder and hold lt onto the engine bracket as sho wn Tlg ht eri the starter clutch bolt to the specified torque TORQUE 85 N m 8 5 lcg m 61 ft lb ELECTRIC STARTER STARTER CLUTC...

Page 165: ...equires proper battery voltage A continuity test can be made w ith the switches insta lled on the motorcycle For the following component locations see page 17 2 of this manual SYSTEM LOCATION for inspections refer to the applicable pages Component Inspection method Remarks Clutch 6Witch Section 25 of the Common Service Manual Coolant temperature gauge Section 25 of the Common Service Manual Temper...

Page 166: ...nual http www motorcycle in th LIGHTS METERS SWITCHES SYSTEM LOCATION 12 COOLANT TEMPERATURE GAUGE 3 FRONT BRAKELIGHT SWITCH 11 NEU RAL SWITCH 101 FUEL PUMP 9 FUl L CUT OFF 5 FUSE BOX RELAY SW ITCH Bl TURN SIGNAL RELAY t t f t t ...

Page 167: ...ght bulb as they may oreate hot spots on the bulb and ca use it to break If you touch the bulb with your bare hands clean It with a cloth moiste ned with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb PROCEDURE O ty REMARKS REMOVAL ORDER Installation is in the reverse order of removal 1 Screw 3 Ho idlight bulb GOOkOt l 3 Dust cover Install it with t...

Page 168: ...n signal case Turn the bulb socket counterc lockwise and remove it Turn tho bulb oounto rolookwiGc and remove it Insta ll a new bulb in the reverse order of removal TAILLIGHT BULB REPLACEMENT Remove the screws and lens from th e taillight case Turn the bulb counterclockwise and remove it Install a new bulb in the reverse order of removal 1 7 4 4 SOCKET 1 BULB ...

Page 169: ...REO CONNECTOR 1 Headlight assembly removal page 17 31 PROCEDURE REMOVAL ORDER 1 Meter mounting bolt 2 Speedometer cable 3 Meter con nector 4 Mete r ossembley O ty 2 1 2 1 LIGHTS METERS SWITCHES 1 41 11 REMARKS Installation is in the reverse order of removal 6P mini White connecto r and 6P mini Red connector ...

Page 170: ...mete r stay Disconnect t he meter termi nals and remove the wire har ness Remove the screw and meter front cover Remove the following two serawsand tachometer t rip meter reset knob four crcw3 3pe0dometer gear joint end 0 ring speedometer Assem ble the meter in the reverse order of disassembly NOTE Connect the proper color w ire to the meter terminals Y G Yellow Green B BR Black Brown G L Green Bl...

Page 171: ...re termi nals of the 6P mini White connector and spark unit connec tor Continuity exists at all times If there is no continuity replace the main wire harness If all checks are O K replace the tachome ter IG NITIONSWITCH REMOVAL INSTA LLATION fll lmovl l tlll l matar 1 111 1 111 umambly page 17 5 Disconnect the 3P Black conn ector and 2P mini connector inaida the headlight case Remove the bolts usi...

Page 172: ...Honda CB400 CB 1 Service Manual http www motorcycle in th 18 WIRING DIAGRAM 0 i 0 IIBIi I C hi ul I N 0 00 0 0 18 1 ...

Page 173: ...ose or disconnect ed fuel pump relay wire WEAK OR NO SPARK Faulty following page 15 3 ignition coi l pulse generator neutral switch spark unit side stand switch engine stop switch WET PLUG Mixture too rich Carburetor flooded Carburetor choke excessively closed Cylinder flooded Air cleaner dirty Faulty Purge Control Valve Calffornia model only l LOW COM PRESSION Improper voilve clP arance Ishim too...

Page 174: ...on Drive chain too tight Axle nut excessively tight PRESSURELOW Faulty tire valve CLUTCH SLIPS Faulty clutch lifter system Worn clutch disc plate Warped clutch disc plate Weak clutch spring ENGINE SPEED DOES NOT INCREASE Carburetor choke closed Clogged air cleaner Restricted fue l flow Clogged muffler Clogged fuel cap v ent hole Faulty fuel pump faulty fuel pump relay Loose broken or shorted wire ...

Page 175: ...ENGINE KNOCKS Worn piston and cyli nder Wrong type of fuel Excessive carbo n bu ild up in com bustion cham ber Ignition timing too advanced Fault y spark unit Lean fuel mixture POORPERFORMANCE AT LOWANDIDLESPEEDS 1 Check ignitil in timing and valve clearance CORRECT 1 2 Check carbu retor p1ot screw adjustmen1 CORRECT t 3 Check for leaking intake pipe NO LEAKAGE 4 Perform the spark test GOO D SPA R...

Page 176: ...r valve clearance Improper ignition timing Faulty spark unit Faulty pulse generator Fuel tank empty Clogged fuel line Clogged tuel cap vent hole Clogged fuel valve FaultY fu el pump or relay Clogged fue l filter Clogged jets Camshaft not insta lled properly Faulty valve spring POSSIBLE CAUSE Steering head bearing adjustment nut too tight Damaged steering head bearings Bent steering stem If eit her...

Page 177: ...l Installation Ignition Coil 13 4 13 2 13 10 13 8 11 5 11 4 11 1 6 13 6 1 2 4 9 6 1 1 1 1 17 3 15 6 20 INDEX Ignition Switch Removal Installation Ignition System Circuit Diagram Inspectio n location Ignition Timing Lett Handlebar Remova l Insta llation Lights Mete rs Switches System locat ion lubrication and Seal Points l ubr icatio n System Diagram Main te nance Schedule Meter disassembly assem b...

Page 178: ...ion Troubleshooting Hrakes Charging System Alternator Clutch Gea1 s11ifl Linkaijti Cooling System Crankshaft Transmission Cylinder Head Cylinder Piston Electric Starter Starter Clutch Frame Body Panels Exhaust system Front Wheel Suspension Steering Fuel System Ignition System Lul J11 1 al1u 11System Rear Wheel Suspension 16 6 16 5 11 12 12 8 12 7 17 7 17 4 5 4 1 16 1 14 10 10 10 8 19 1 13 1 14 3 9...

Search results

Summary of Contents for CB-1 89

Reviews:

Related manuals for CB-1 89

Brands by name

Popular brands

Honda CB-1 89, Service Manual

Search results

Summary of Contents for CB-1 89

Reviews:

Related manuals for CB-1 89

Brands by name

Popular brands