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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...

Good article on Mater cylinder ratios. http://www.vintagebrake.com/mastercylinder.htm

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.

I think the first pic looks more period correct. The Corbin looks like it came form an 80's bike. It looks good with the Norman Hyde's.

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...

I don't know if you found your answer yet but it is 14mm.

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

I picked the bike up a few months ago, got it running and then tore it apart for a restomods.