DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Integra99 on Sep 22, 2017, 04:44:53

Title: My CB400f Supersport project
Post by: Integra99 on Sep 22, 2017, 04:44:53

Hi, plan to share a bit of my CB400 build project on here.. I picked this bike up a couple of years ago.. in good condition and ran really well,  tank was an awful blue and it needed some tidying. But while purists will disagree I felt my CB400 although cool.. for me needs bringing into 2017 just a little so there will be no frame cutting.. I'm keeping her standard and some nice gentle mods.

Of course on taking the bike apart I start to notice problems, and poor repair work by previous owners and 3 hours later I have a frame and a bag of bits..  So finally the frame is done and I've started the rebuild .. !

Anything that I can reuse I will, had to buy new stanchions which hurt but so far going ok..  I have custom wheels being made, hopefully I can fit a 130/140 rear tyre.

(http://www.sohc.co.uk/gallery/14623_21_09_17_8_56_14.jpeg)

She doesnt look to bad.. but underneath so many bad fixes...

(http://www.sohc.co.uk/gallery/14623_21_09_17_8_56_37.jpeg)

The tank was done in cellulose ... and the wiring.. omg.

(http://www.sohc.co.uk/gallery/14623_22_09_17_8_41_14.jpeg)

(http://www.sohc.co.uk/gallery/14623_22_09_17_8_42_21.jpeg)

(http://www.sohc.co.uk/gallery/14623_21_09_17_8_56_53.jpeg)

(http://www.sohc.co.uk/gallery/14623_21_09_17_8_57_11.jpeg)

(http://www.sohc.co.uk/gallery/14623_22_09_17_8_24_22.jpeg)

Won't get much done this weekend.. thanks to selfish friends who have invited us to their wedding... lol! !


Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 22, 2017, 08:37:30
Looking good.  That's a pretty big tire for the 400.  Any performance plans in mind?   I'm running a 110 on mine and love it.  What's your plans for the bike?


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Title: Re: My CB400f Supersport project
Post by: SONIC. on Sep 22, 2017, 09:46:17
I ran a 130 on my 400f and never liked it. It's too wide and throws the handling off. I was much happier when I switched back to a 110
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 25, 2017, 06:39:56

Thanks all, now I've got them back I think 130 is optimistic and I'll be looking at a 120, rear and 100 front.

Engine is staying std apart from electronic ignition.. carbs fettled and a Delkevic exhaust. I want to be able to carry a pillion on this bike so I may use the std seat.. or have a trimmed down one made in the same style just a nit more modern.

Fenders will be given a trim, but building as I go on this one..

(http://www.dotheton.com/gallery/107242-250917043818.jpeg)

(http://www.dotheton.com/gallery/107242-250917043503.jpeg)



Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 25, 2017, 10:49:13
what size wheels are those you are running? 
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 25, 2017, 11:10:34

They are 18", 2.1" front and 2.5" rear
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 25, 2017, 11:16:24

Innovative.. I just noticed your build!! Very nice! Are the rear sets custom made? 
Title: Re: My CB400f Supersport project
Post by: 1fasgsxr on Sep 25, 2017, 13:27:04
Nice !!  Cant wait to see this thing finished.
Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 25, 2017, 16:57:46
Innovative.. I just noticed your build!! Very nice! Are the rear sets custom made?

Thank you!  I'm slowly working to get all of the build loaded up.  The bike is almost done.  Those rearsets are made my ttr400.com  His products are amazing!
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 26, 2017, 07:07:29

Thanks.. I dont think it will be as gorgeous as Innovative.. I dont have the skills but she will be a nice ride. Innovative you may have just cost me some money, those rear sets are lovely.. I'm emailing him now!
Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 26, 2017, 11:33:57
Thanks.. I dont think it will be as gorgeous as Innovative.. I dont have the skills but she will be a nice ride. Innovative you may have just cost me some money, those rear sets are lovely.. I'm emailing him now!

You won't regret it.  Kevin is amazing to deal with.  Being in south africa does take the items alittle bit to get here but it's well worth the weight.  all of his parts are top notch, i'm runing his lower triple, 20mm race front axle, engine mounting plates, oil cooler, tach blockoff, cam chain tensioner, oil drain plug, and wheel spacers.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 26, 2017, 11:45:47
Great I've emailed.. the inspection covers are a must as well.

I have plenty of time.. and thoroughly enjoying this build! What width Excel rims and tire sizes are you using?
Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 26, 2017, 17:52:17
Great I've emailed.. the inspection covers are a must as well.

I have plenty of time.. and thoroughly enjoying this build! What width Excel rims and tire sizes are you using?

The side covers i got from a place out of japan via ebay.  crazy how fast shipping is from japan to the states.  I'm running a wm2 on the front and wm3 on the back.  a 90 on the front and 110 on the rear.  Rocking Avon roadrider tires and have been pretty impressed with the grip.  I need to dial in my suspension still
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 27, 2017, 06:10:13

cheers mate thats really helpful, 110 on the rear it is then!

I'm loving this project.. but trying to keep costs down as my track bike is wanting repairing lol
Title: Re: My CB400f Supersport project
Post by: Integra99 on Sep 27, 2017, 07:24:42

Finished a few more items ready for Install last night, Side panels off for paint and engine getting prepped for paint as well. I'll pop the tank in primer over the weekend.

Tonight's job is to polish up the rear wheel spacers and start prepping all the bits for the rear links and rear brake assembly.

Tires fitted on Saturday.. and then I should have a rolling bike with brakes and a center and side stand.

(http://www.dotheton.com/gallery/107242-270917043656.jpeg)
Title: Re: My CB400f Supersport project
Post by: innovativems on Sep 30, 2017, 11:09:56
Looking good!


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Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 03, 2017, 08:47:09

My lads been racing so little progress but Tyres fitted ok, 120 rears, 100 up front .

Polished up the rear axle spacer too.. what a difference!!

(http://www.dotheton.com/gallery/107242-031017064010.jpeg)

(http://www.dotheton.com/gallery/107242-031017063909.jpeg)

[imghttp://www.dotheton.com/gallery/107242-031017064556.jpeg][/img]

Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 09, 2017, 07:55:25

Slow progress this week due to work, but managed to get side panels painted, engine off to be painted and I have a rolling bike finally.

One the engine is in next weekend we can really start to crack on, custom sprockets are being made too!  Then I can focus on mudguards but we are problem solving as we go..

(http://www.dotheton.com/gallery/107242-091017054812.jpeg)

(http://www.dotheton.com/gallery/107242-091017054830.jpeg)

Title: Re: My CB400f Supersport project
Post by: innovativems on Oct 09, 2017, 08:21:23
Looking good!


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Title: Re: My CB400f Supersport project
Post by: SONIC. on Oct 09, 2017, 17:07:42
Of the 30+ motorcycles I have had, my 400F is the only one I regret selling.
Title: Re: My CB400f Supersport project
Post by: irk miller on Oct 09, 2017, 20:53:29
You're not the first person I've heard say that.  Seems to be a common feeling.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 10, 2017, 06:33:34

Just skimmed your build Sonic.. lovely bike!!

I've just had a full Delkevic system arrive today.. I'm now getting very excited about this bike... its sounds crazy as its my 3rd build but its suddenly dawned on me when its finished I will have a brand new CB400f SS with a twist!

This bike will be my ride to work and around town bike next spring.. and finally a bike that I intend to carry a pillion as my son and daughter are desperate to come to my local bike night!!
Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 11, 2017, 10:26:25
Bit more work last night, finished restoring the rusty old airbox, and chuffed with the rubber mounts bought from china for 2..  they took 4 weeks to arrive but can't fault them.

Sprayed up the foot rest mounts so a few more coats later tonight.

New rear pads arrived but still waiting on the custom sprockets!

(http://www.dotheton.com/gallery/107242-111017081625.jpeg)

(http://www.dotheton.com/gallery/107242-111017081648.jpeg)
Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 11, 2017, 10:27:08
Also my Delkevic arrived.. a big deliberation over the beautiful OEM pipes vs the Delkevic but I wanted to create a bike that was different and I'm very happy!

(http://www.dotheton.com/gallery/107242-111017082141.jpeg)

(http://www.dotheton.com/gallery/107242-111017082125.jpeg)
Title: Re: My CB400f Supersport project
Post by: innovativems on Oct 11, 2017, 10:32:34
Looking great!  You will be happy with the delkevic system.  I have one on my cb550 and cb350f.  Very happy with them


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Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 11, 2017, 10:38:38

Thanks.. I cant wait to build it up once I have the engine back!

I'm a bit unsure about the back of the bike.. I really want to carry a pillion so my girlfriend can hop on but want to make it look better than the huge stock seat.. so lots of tea drinking looking at the bike with some mates this weekend.. and a few beers!
Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 17, 2017, 06:57:29

Friends down for the weekend so not huge progress but finally got all the 2 pack paint off the tank an into primer, needs filling and sanding but its just nice to get in into a workable stage!

New pads arrived too so rear brake set up all working, awaiting custom sprockets and chain plus the engine so I can get that installed ASAP.

(http://www.dotheton.com/gallery/107242-171017043214.jpeg)
Title: Re: My CB400f Supersport project
Post by: Integra99 on Oct 31, 2017, 08:50:22

Been busy.. engine now in... delkevic headers on and a lovely machined bush made for my gear linkage slop problem. 

(http://www.dotheton.com/gallery/107242-311017064404.jpeg)

(http://www.dotheton.com/gallery/107242-301017035052.jpeg)

(http://www.dotheton.com/gallery/107242-301017035113.jpeg)

(http://www.dotheton.com/gallery/107242-311017064836.jpeg)

The build cost has lost the plot..and I have so much left to do but its a lovely distraction from work.. I'm not planning another build for a while, once this is done I can finish the next stage of my XS750.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Nov 15, 2017, 07:04:02

Well a quick update on the build... like all projects.. I've now gone back two steps.. the engine paint isnt fuel proof it seems, so its back out again and 4 bolts in the head need helicoils. Also the front mudguard bracket is causing me trouble... as lowering it by taking a section out simply isnt going to work..  The bracket is good so I'm going to leave it for now , it sits a little too high for my liking but we can address later.

On the positive the carbs have turned out amazing and are as good as new internally.

The Delkevic exhaust it seems was designed for a 75 - 77 , they are going to help with the issue or I'll make a bracket of some sort. I've now shorted the seat base.. which has turned out well... CB400f owners will curse me.. but the std seat is sooo long!

It was good to get the bike out in daylight.. still unsure on tank color.. so it can stay as is until I decide. Next job, modify the airbox to hold the new regulator. Once the engine is back from paint we can get cracking and back together at start to make progress as most of the work is now done, but run out of funds till next month now so electronic ignition will have to wait.. I can at least get the wiring loom in place.

A few pics...

(http://www.dotheton.com/gallery/107242-151117025341.jpeg)

(http://www.dotheton.com/gallery/107242-151117025316.jpeg)

(http://www.dotheton.com/gallery/107242-151117025208.jpeg)

Just when I was getting a bit demotivated at the cost and time of this build I found this old picture of the carbs and engine at strip down and realised how far we've come..!

(http://www.dotheton.com/gallery/107242-151117025112.jpeg)
Title: Re: My CB400f Supersport project
Post by: briandk on Nov 15, 2017, 16:01:04
Looking really good. The stock headers are beautiful of course, but these are not bad at all.
Had a CB400F about 15 years ago and loved it, this almost makes me want to look around for another :)
Title: Re: My CB400f Supersport project
Post by: tattoo on Nov 15, 2017, 18:40:28
Oh my.....quickly skimmed through the thread, and this one's gonna be a looker for sure!!

Title: Re: My CB400f Supersport project
Post by: Integra99 on Nov 17, 2017, 08:13:05

Thanks.. well I hope so, just going through the wiring loom while the engine is getting painted again then off to Delkevic next weekend and we can look at getting the engine running!
Title: Re: My CB400f Supersport project
Post by: Integra99 on Nov 27, 2017, 06:58:00
Been busy this weekend, finally re painted the engine.. came out really well.

Delkevic exhaust now all fitted, carbs and airboxes in and I made a bracket for the rectifer/regulator which fits perfect.

This week its all about getting the loom in and secured, along with making plans to perhaps have it running next weekend!! A lot of the hardwork has been done so feels good to see it coming together finally!

(http://www.dotheton.com/gallery/107242-271117045126.jpeg)

(http://www.dotheton.com/gallery/107242-271117045157.jpeg)

(http://www.dotheton.com/gallery/107242-271117045221.jpeg)

(http://www.dotheton.com/gallery/107242-271117045246.jpeg)

Title: Re: My CB400f Supersport project
Post by: Integra99 on Nov 27, 2017, 06:59:00
(http://www.dotheton.com/gallery/107242-271117045838.jpeg)
Title: Re: My CB400f Supersport project
Post by: Pete12 on Nov 27, 2017, 08:15:00
Wow, clever idea on the regulator/rectifier mounting.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Nov 27, 2017, 10:37:57

I cant claim full credit... lol, I saw something similar done on a forum so adapted the idea.. worked a treat.
Title: Re: My CB400f Supersport project
Post by: tattoo on Nov 30, 2017, 11:45:05
Tidy, crisp, clean and neat.   Nice attention to detail!

Should likely ask this question/search in the "electrics" topic, but what's the skinny on going with (if I'm reading this right?) a combined voltage regulator/rectifier?    There are obviously benefits?    What else has to be done to make that "upgrade"?   

Sorry if this is a thread hijack.....

Title: Re: My CB400f Supersport project
Post by: Integra99 on Jan 12, 2018, 05:53:40

Its been a while.. loads of issues and other projects taking up time. Main issue is it appears the cam tensioner is stuck. For now I have a new cam chain on and everything is where it should be, she runs sweet so I'll crack on for now but at some stage I'm going to need to split the cases. With 2 months to the bike show and the fact she runs beautifully and I won't be doing more than a 1000 miles in a year I'll carry on with the build. So loom is now in, gauge in and all warning lights working. Cut down the front guard, it needs to be lower but cutting the original bracket down is not as easy as thought.

New chain and sprockets on.. really pleased and huge improvement over the stock chain!

Next jobs;

Sort why my new rectifer/regulator is not charging?

Investigate the gears... return spring may have gone? Worked fine before the strip down.

Fit rear indicators and cut down the mounts.

(http://www.dotheton.com/gallery/107242-120118033153.jpeg)

(http://www.dotheton.com/gallery/107242-120118033236.jpeg)

(http://www.dotheton.com/gallery/107242-120118033750.jpeg)

Title: Re: My CB400f Supersport project
Post by: teazer on Jan 12, 2018, 11:02:05
So much attention to detail.  So much shine and perfection and then I see that red tape wrapped bundle  where a wiring loom should be.  WTF? 

We have all used those crappy red crimp on connectors but they have a horrible habit of coming apart, and they look like crap (IMHO).  Do yourself a favor when you get a moment and order a bunch of waterproof multipin connectors.  You will be happy you did.  I usually use Sumitomo connectors from Eastern Beaver in Japan, but I believe that Sonreir now has taken over Vintage Connections and can supply connectors of the type that were commonly used when our bikes were built. That would take a lot of bulk out of that harness and would look more professional.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Jan 12, 2018, 11:35:10

Ah well that's just temporary to hold the loom together.. I'm not wrapping it up yet as I have a problem getting charge to the battery and still need to finish some wiring! As for the connectors I've used slim gold OEM type connectors in most places.. the ones you see are for the horn and the new gauge of which I'll be replacing as totally agree and I made a mistake using them they are total crap. The reason it looks bulky is well... there are a lot of wires to sort.. as I have no wiring jumble behind the headlight so this will be neatly wrapped up and hidden under the tank keeping it clean and tidy around the front of the bike..  thats the plan.



Title: Re: My CB400f Supersport project
Post by: The Limey on Jan 12, 2018, 20:37:30
I love the hand finished patina this bike has.  By that I don't mean scrappy or second rate, but rather that the finish on everything is spot on and has that lovely warm finish that can only be achieved with love.  A production bike would look equally pristine, but would somehow look too sharp, too industrial.  This thing looks luvverly, and I can't wait to see it finished.
Title: Re: My CB400f Supersport project
Post by: Integra99 on Jan 15, 2018, 09:39:58

Thanks very much.. !! Its slow progress, I could probably finish it in a day with some time off work.. but it would be rushed.

I have just gone ahead with the custom seat .. the original frame has been cut and welded to simply be a bit shorter than original and I hope my design comes out in what they produce. Being done this week!

New throttle cable arrived today so I can get that fitted along with the new horn. Tonights job is to cut down the rear indicator stalks so we can fit those and sort the rear mudguard.
Title: Re: My CB400f Supersport project
Post by: tattoo on Jan 15, 2018, 09:45:46
I agree.  This bike has a great "look and feel" to it.

Title: Re: My CB400f Supersport project
Post by: Integra99 on Jan 22, 2018, 05:38:27

Phew, some work over the weekend and found a poor fitting kick start seal was preventing the return spring from working!

So all good! Next up are the rear indicators, on my XS750 I don't have any but for this bike its a must, I cut down the original mounts as too long and I think they turned out ok.

Seat is back this week and then I can try and decide on the rear mudguard and light and number plate mounting!

(http://www.dotheton.com/gallery/107242-220118033349.jpeg)

(http://www.dotheton.com/gallery/107242-220118033312.jpeg)