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Don't know what has become of this but it sounds like primary chain slapping from out of sync carbs. If you are resourcefull you can make a test kit for cheap.
FYIW... Most dirt bike mc's are 11mm. You can find 12.7mm ones on some street bikes. Stock on most CB's is 14mm. I have tried nearly everything on my cb400f. Smaller gives better feel, more travel but it easier to modulate and bites harder. I would try a dirt bike mc if you want small. 12.7mm...
Getting it welded would be a PITA as you would have to bring atleast the front end to them. If you do go that route I used compressed air on an old banjo fitting to align the caliper with the rotor. I only tacked my bracket in place ( mig with spool gun) and had a friend finish welding it with...
I hated the stock brakes too. If any one has ridden a modern sport bike they would know how much these old CB's brakes are a joke. This is kind of right up that I did.
http://forums.sohc4.net/index.php?topic=101234.25
On my 400 I shaved the seat. I bought an extra for $40 off Ebay. I too could not cut up a good one. I also lowered my front forks 1". I don't run a center stand. I am running some SW (?) 12.75" rear shocks. I weigh about the same as you. With just me, leaning pretty good, not quite to the edge...
Large bore MC with single caliper? If so it will be on the firm side. I too painted my stock MC and got just a little paint on it. I then stripped it and polished it.
I hate the skinny look on the 400's too. I used the 400 rear (1.85) rim up front and found a 2.15 rear from a GS for the rear. I run a 90 f and 110 r. The fit is good but the rear still looks skinny. To do again I would run a 2.15 on the front and a 2.5 on the rear and a 120 on the rear.
Look at a 650 Ninja caliper. They are a 2 piston sliding caliper but modern. Not as nice as 4 piston but there is a lot of room on the back. It's the only thing I could find that I can run a spoked wheel. There are good pics here...
Re: 75 CB400F SS stuck in 4th gear. any wisdom before tear down??!!
There's a factory CB400f PDF manual here.
http://www.honda4fun.com/man_officina/man_officina.html
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