CB400 F PDF

Honda CB400 / CB-1 Service Manual
http://www.motorcycle.in.th
INTRODUCTION CONTENTS
Thi:i 3crvice manuel d.scribe~ the servicu procedures
for the Ctl4OOF, GENERAL INFORMATION
Th l~
MOl:l61 Specif ic ManllRI inr:l\.deli every service pro-
cedure that is of & specific nature to this particular FRAME/BODY PANELS/ EXHAUST SYSTEM
model. Basic service procedures that afe common t o
other Honda Motorcycles/Motor Scooters Common
Service Manual. This Model Specif ic Service Manual MAINTENANCE
shuuhJ lat used t oget her with the Common Service
Manual in order to provide complete service information LUBRICATION
on all S5pects of this motorcycle. z
;;: COOLING SYSTEM
Follow the Maintenance Schedule (Section 31 recom-
mendattons to ensure that the vehicle is in peak operat-
....0::
W
ing condition and the emission levels are within the > FUEL SYSTEM
standards set by the U.S. Environmental Pr'!tection ;;:
Agency i!lnd t he CalirUlllitt Air Resources Board.
o ENGINE REMOVAL/INSTALLATION
Performing the first scheduled maintenau{;1:t ill very im- o
portant . It compensates for the initial wear that occurs
z
<0: CYLINDER HEAD/CYLINDER/ PISTON
during the break-in period _ w
z
Section 1 and 3 apply to t he whole mot o rcycle, section az CLUTCH/GEARSHIFT LINKAGE
r 2 illustrates procedures for removal /installation of com - w
ponents that may be required to perform service de- CRANKSHAFTITRANSMISSION
scribed in the followi ng sections .
While 3ection 4 through 1 B d8sclibe parts of the motor-
r.yr.lA, ornllrA'" at;t;ording to locations.
FRONT WHEEL/SUSPENSION/STEERING
Find the sect ion you want on this page. then turn to the REAR WHEEL/SUSPENSION
table of contents on the first page of the section.
BRAKES
Most sections desCribe the service procedure through a
3",3tcm iUustrlltion. n.f.r
to thlt m,,,,,'
paye fu r details on
how to use thi6 manual. CHARGING SYSTEM/ALTERNATOR
....
If you don't know the ,source of the trouble. go to SAr.- <0: IGNITION SYSTEM
tion 19, TROUBLESHOOTING. u
;;:
....
u
ELECTRIC STARTER/STARTER CLUTCH
w
All INFORMATION , ILLUSTRATIONS, DIREC- ....w LIGHTS/METERS/SWITCHES
TIONS AND SPECIFICATIONS INCLUDED IN
T HIS PUBLICATION ARE BASeD ON THE LATEST
PRODUCT INFORMATION AVAILABLE AT THE WIRING DIAGRAM
TIME OF APPROVAL FOR PRINTlNG . HONDA
M OTOR CO .• LTD . RESERVES THE RIGHT TO
TROUBLESHOOTING
MAKE CHANGES A T ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBlI-
OATION WH ATEVER . NO PART OF T HI S "UBlI- INDEX
CATION MAY BE REPRODUCED WITHOUT
WRITIEN PERMISSION . THIS MANUAL IS WRIT-
TEN FOR PERSON S WHO HAVE A CaUIRED
BASIC KNOWLEDG E OF MAINTENANCE ON
HONDA M OTORCYCLES OR MOTOR SCOOT-
ERs .
Date of Issue: January. 1989 http://www.motorcycle.in.th

~ I-In",.,.,,I\. "~nTnl) rn 'T ....
HOW TO USE THIS MANUAL

FINDING INFORMATION YOU NEED
ThiS manual Is divided Into sections whleh eover each of

the major components of the motorcycle.
To quickly find the section you ere interested in, the first
page of 8ach section is marked with 8 black tab that lines
up with one of the thumb index tabs before this page.
The first page of 8ach section lists the table of contents
within the section .
Read the service information end troubleshooting related
to the section before you begin working.
An indol( of the entire book is provided in the Illst chapter
to directly locate the Information you need.
NOT E ON THE EXPLANATION METHOD OF THIS MANUAL
The removal and Installation of parts are f or the most part illustrated by large and cloar illustrations that should provide the
reader with visuol oid In understanding the major point for servicing. .
The system iIIulltnnionli ure uugmented by catlouts whose numbefs Of letters indicate the order in which the parts should
be removed or installed .
f' The seQulnee of steps represented numerically are differentiated from the ones represented alphabetically to notify the
reader tt'lat tt'ley must perform tt'lese steps separately.
For example, if tt'le steps prior and up to camst'laft removal are performed with the engine installed, but tt'le subsequent
steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alpt'labetical orders.
The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be
taken . Refer to the next page fOr the meaning of each symbol mark.
Also in tt'le illustration is a ct'lart tt'lat lists information such as thl! order in whict'l the part is removed/ installed, the name of
thc port , and 1I0mo Olltro notO:l that may be needed.
Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces-
sary or illustrations alone would not suffice,
Service procedures required before or after the procedure described on that particular page, or inspection/ adjustment pro-
tl
cedures required following the instellation of parts, are described under tt'le title Requisite Service.
Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual.
Detailed description
Symbol mark illustration the procedure
.-' -
.... -"""' ...' .....
-------_
c= _______ ,
---.... __-------
,- --_ . __....-- ..
I -!""--"-~"----.- ,
_._-----.-,-
I
-_._--
.1
Step
sequence
I ....-_--'
_--- .........-
--------
(numerals
"' "'ph',bot'lr---
-.~
_ ___ I
_.
'- - - ' "
...
.1
---.----
,--------,.-
Part
- - .... "...-...
--". -"' '' - ' . ~
~
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Symbols
The symbols used throughout this manual show specific service procedures . If supplementary information is required pertain-
ing to these symbols, it would be explained specifically in the t8xt without the use of the symbols.
ell Repl<lce the paills) wilh IUIW one(s) before assembly .
[$ 7"000.. 1 Use special tool
lu'7_1 U"" optional tool. Thli:l!:lll tuuls are obtained 8S you order parts.
C
10 (1.0,7.2)
Torque specification. 10f.,l·m (1.0 kg -m, 7.2 ft-Ib)
71 UIHI rtll::ummended engine 011, unless otherwise specltled.
, 11.
-"7J Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1
-w=- Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NlGI #2 or
~
equivalent)
Exomple : Molykote~ en-2 plUA manufac.tured by Duw Cuming, U .S. A .
Multi-purpose M -2 manufactured bV Mitsubishi Oil Japan
UI!I!I molybd~llulli tli\iulfitlw p<lste (containing more than 40% molvbdenum disulfide, NLGI #2 or
equivalent)
...-riD FVi'f11pI9: MolVko19~ G-n Paste manufooturcd by Dow Corning, U,S.A.

Honda Moly 45 (U .S.A. onlv )
Roeol ASP manufactured bv Rocollimited, U .K.
Rocol Paste manufactured by Sumico Lubricant, Japan
~ Use silicone grease
a..... Apply a locking 81lotlnL. UI>B the agent of the middle strength , unll't.'lS otherwise specified.
J'0Jl! Applv sealant
t
..
Use brake fluid, DOT 3 or DOT." Use the recommended brake fillin, unless otherwise spedfittd •
Use Fork or Suspension Fluid.
1. GENERAL INFORMATION
GENERAL SAFETY ,-, LUBRICATION AND SEAL POINTS ,-,B
MODEL IDENTIFICATION '-3 CABLE AND HARNESS ROUTING
'-'9
SPECIFICATIONS '-4 EMISSION CONTROL SYSTEMS ' -25
• '-'4
TORQUE VALUES EMISSION CONTROL INFORMATION
LABELS (U .S.A. Only) '-28
TOOLS
'-'6
GENERAL SAFETY
• Carbon Monoxide
If the engine must be running to do some work, make sure
the area is well ventilated . Never run the engine in an en-
c lUl:itnJ ttrYl:I.
Und Englne/Transmlsslon Oil
Used engine all (or transmission oil In two-strokesl

may causa skin cance, if reptlatadly left in contact
with the skin tor prolonged periods. Atthough this is
Th. IIXhaust contains poisonous carbon monoxide unlikely unless you handle used oil on II daily baal•• it
gao that oon cause lou of cOllln:iuuanass and may is stilladvi sabl. to thoroughly wash your hands with
lead to death. soap and water liS soon .8 possible aftar handling
used 011. KEEP OUT OF REACH OF CHILDREN.
Run the engine in an open area or with an exhaust evacua-
t ion liv stem in an onclo3ed eree. Brake Dust
Never use an air hose or dry brush to clean brake assemb-
•
Gasoline lies. Usc on OSHA-l'Ipproved va cuum cleaner or alternate
W o rk in a well v entilated area. Keep cigarettes, flames or method approv ed by OSHA, designed to minimize t he
sparks away from the w o rk area or where !:IBsoline is hazard cl'lused by " irborne asbestos fiber6.
stored .
to cause
Gasoline Is extremely flammable and is explosive respiratory disease and cancer.
under certain conditions . KEEP OUT OF REACH OF
CHILDREN . Brake Fluid
Hot Components CAUTION

Spilling fluid o n painted, plastic or rubber parts will
damaAe them . Place a clean .hop towel over these
Engine and exhaust system parts become very hot parts whenever the system is serviced. KEEP OUT
and remain hot for some time after the engine is run. OF REACH OF CHILDREN.
Weer Insulated glov98 or walt until the engine end
exhaust system have cooled before handling these
GENERAL INfORMATION
Coolant Nitrogen Pressure

Under some c onditions, the ethylene glycol In engine cool- For shock absorbers with a gas-filted reserv oir:
Iml lw cumbustlble and ItS fl ame is not vi sible . If the ethyl-
ene glycol does ignite, you will not see any flame , but y ou
c;;an be burned .
•
I
Use only nitrogen to pressurb:e the shock absorber .
The usa of an unstabla gas can causa a fire or explo·
sian reaulting m &anous injury.
Avoid spilling engine coolant on the exhaust system The shock absorber contains nitrogen under high
or engine plIn __ They may tM hot enough to oause pre..ure. Allowing fire or heat near the shock abo
the coolant to ignlt. and bum without • visible sorber could lead to an explosion that could result in
flame . serious injury.
Coolant (ethylene glycol) can cause some skin Irrita- Failure to release the pressure from a shock absorber
tion and is poisonous If swallowed. KEEP OUT OF before disposing of it may lead to a possible explo·
REACH OF CHilDREN . sian and serious injury if tt Is heated or pierced.
Do not remove the radiator cap when the englna is
hot. The coolant is unde, pl1n~.ur" 1Ind could scald
To prevent the pou ibility of an explosion, rel ease t he ni- •
you.
Keep hands and clothing away from the COOling fan.
trogen by pressing the valve c ore. Then rem ove the v alv e
stem from the shoc k absorber reservoir. Dispose of the oil
•
as it .tarts I
in a manner acc eptable to the Environment al Protection
Agency I~"'AI .
If it contacts your skin, was h the affected areas immedi-
ately with SORr Anrl w~ter . If it con1acts your eyea, flush Before disposal of the shock. absorber , ItlltlllSIl the nitrogen
them thoroughly with fresh water and get immediate medi- by pressing the valve core . Then (emove the valve stem
cal attention. If It Is swallowed, the vict im must be fo rced from the shock ahsorber.
t o vomit then rinse m outh and throat w ith fresh water
before obtaining medical attention. Because of these dan- Battery Hvdrogen Gall & Electrolvte
gers, always 1>tore coolant in a safe place, away from the
reach of childr en .
The battery gives off explosive gases; keep sparils,
flames and cigarettes away. Provide adequate venti· t
lation when charging.
The battery contains sulfuric acid lelecttolvte) . Can·
tact wtth skin or eyes may cause HveTe bums . Wear
protective clothing and a face shield .
If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water
for at least 16 minutes and call a physici.n .
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or
milk and follow with milk of magnesia or vegeta-
ble oil and call a physician. KEEP OUT OF REACH
OF CHILDREN .
.j
GENERAL INFORMATION
MODEL IDENTIFICATION
•
•
• The frame serial number is stamped on the right side of the
steering head .
' (21 ENGINE"SERIAl"NUMBER
The Angi nA serial nl.lmber i6 stamped on the right side of T he Vehicle Identification Number (VIN) is located on the
the crankcase. safety certification label on the right side of the frame
tube .
(4 ) CARBURETOR
IDENTIFICATION
NUMBER
The carburetor identification number is on the reef side of The color code label is attached on the left frame tube
ooch carburetor. under the seat. W:len ordering a color coded part, always
specify its designated color code.
GENERAL INFORMATION
SPECIFICATIONS
Generel
ITEM SPECIFICAT IONS
DIMENTIONS Overall length 2.035 mm (80.1 in)
Overall width 705 mm (27.8 in)
Uverall height 1,025 mm (40.4 in)
Wheel base 1.370 mm (53.9 in)
Seet height 775 mm (30.5 In)
Foot peg height 335 mm 113.2 in)
Ground clearance 130mm(5.1 in)
Dry weight 170 kg (375 Ibs)
Curb weight 183 kg (403 Ibsl
Maximum weight cepacity 157 kg (347 Ibsl
FRAME Frame tYpe niflmond
Front suspension Telescopic fork
Front wheel travel 130 mm 15.1 in)
Rear suspension Swingarm
Rear wheel travel 110 mm (4.3 in)
Rear damper Gas· filled damper
Front tire size 110/ 70 - 1754H
Roar tire size , 40/70 - 17 66H
Tire brand (Bridgestone) Front/Rear G547/G548
Tire brand lDunlOp) Front/ RfIllU K505F/K50 5
Tire brand (Yokohama) Front/Rear --
Tire brand IIRC) Front/Rear --
Front brake Hydraulic disc brake
Rear brake Hydraulic disc brake
Custer angle :.151,)30'
Trail length 99 mm (3.9 in)
Fuel tank oapacity 11.5 lit 13.04 US gal. 2.53 Imp gal)
Fuel tank reserve c apacity 3 .5 lit (0.92 US gal. 0 .77 Imp gal)
ENGINE Bore .!lind stroke 55 .0 )( 42.0 mm (2.17 )( 1.65 in)
Displacement 399 cm 3 124.3 cu in)
r:nmru""_<l$ion r8tio 11.6 : 1
Valve train Gear driven OOHe , 4 valves per cylinder
Intake valve opens at 1 mm lift 5° ATOC
Intake valve close at 1 mm lift 33 ° ABDC
Exhaust valve opens at 1 mm lift 33° BBOC, 38° BBDC (California)
Exhaust valve close at 1 mm lift 50 BTDC, 10 ° BTDC (California)
lubrication system Forced pressure and wet sump
Oil pump type TrochOid-type
Cooling system liquid cooling system wi th cooling fan
Air filtr(ltioll" Paper filter
Crankshaft type Unit-type, 6 main journals
Engine weight (dry) 57 kg 1126 Ibsl
Firing order 1 - 2 - 4 -3
Cylinder arrangement Vertical 30° in lino four
Front
fr
J \.
~~~O~0)
J
1-4
GENERAL INFORMATION
r Gene rallCont'dl
ITEM SPECIFICATIONS
• CARBURETOR
DRIVE TRAIN
Carburetor type
Thro ttle bore
Clutch system
Clutch oporation 3vstem
Transmission
VG06
32 .6 mm 11 .28 in)
Wet, multi-plate
Mechanical tVPQ
6-speed constant-mesh
•
Primary reduction 2 . 181 (96/44)
Secondary reduction --
Third reduction --
Final reduction 2.733 (41 / 15)
Gear ratio 1 st 3.307 (43 /13)
GotH ratio 2nd 2.352 (40/17)
Gear ratio 3rd 1.875 (30/16)
• ELECTRICAL
Gear ratio 1th
Gear ratio 5th
Gear ratio 6th
Gear ratio reverse
Gears hift pattern
Ignition system
Starting syste m
1.590
1.434
1.333
--
(3G/22)
133/23)
(32/24)
Left foot operated return system l - N- 2 - 3 - 4 - 5-6

Full transistor ignition
Starter motor
Charging system Triple phase output alternator
Regulator/ rectifier type SCR shorted/ triple phase full -wave rectification
lIghtmg system Battery
A C regulator t y pe --
GENERAL INFORMATION
Unit: mm lin)
Standard Service limit

Engine all capacity 8t draining 2.9 t 13.06 USqt, 2.55 Imp qt)
at disassembly 3.5t (3.70 US qt, 3.08 Imp qt)
at oil filter change 3 .1 t (3.28 US qt, 2.73 Imp qt)
IItr10inerO~;~llO~I':L:!:!:~::=~~
HONDA 4-stroka oil or equivalent.
API service classification SE or SF.
RecOmmfIJnrlArI
The viscosities shown in the chart may

be used when the average temperature in
your riding area is within the indicated
ra nge.
-20 -10 0 on 10 so 'tQ" t

Oil pressure at oil pressure switch 490 kPa (5 kg/cm 2 , 71 psi)
Oil pump roter tip clearance CD 0.10 (0 .004) 0. 15 (0.006)
body clearance @ 0.15 - 0 .22 (0.006-0.009) 0,35 (0.014)
end clearance (iJ 0.02 - 0.07 (0.001-0.003) 0.10 (0.004)
' <:I>
?@
(j)
I
Fuel,y.tem
Carburetor identification number VG06B
(California) VG06C t
Main jet #105
(High altitud81
(2,3)
f1 , 4)
(Front)
(Rear)
Slow iet #35
Jet needle crip position
Pilot scrElw illiliHI opening 2- 1/4 turns out
(California) 2- 1/ 2 turns out
Pilot screw adju6tment finol opening 1 turn out
Pilot screw high altitude adjustment 1/2 turn in from initial opening
Air screw initial oeening
Air screw high altitUde adjustment

Hoat level
(California)
8 .0 {0.311
I
Carburetor vacuum difference Within 30 mmHg (1.2 inHg)
Ba.e callJUHllor (For carburetor synchronization) No. 2 carburetor
Idle speed 1,300 ~ 100 rpm
(California) 1,400 ± 100 rpm
Throttle grip free play 2 - 6 {0.08-0.241
Accelerator pump clearance
Secondary air supply system Reed valves are built into the ASV
Air injection control valve vacuum pressure 360 mmHn (14 .2 inHg)
1-6
GENERAL INFORMATION
Unit ' mm lin)

- Cylinder head
Item Standard Service limit
Cylinder compression 1,280 - 1,320 kPa 112.8 - 13.2 kg/cm 2,
182 - 188 psil/400 rpm

Cylinder compres sion difference Within 30 mmHg (1. 2 inHg) of each other
Valve clearance IN 0 .12 - 0 .18 (0.005 - 0 .007)
(cold) EX 0.17 - 0 ,23 (0.007 - 0,009)
Cylinder head warpege 0 .1 (0.0041
Cam lobe height <D IN 33.070-33. 230 (1 ,3020 - 1 .3083) 33.02 (1. 3001
IN (California model)
EX 33 .120 - 33.280 (1.3039 - 1.3102 ) 33.07 (1.302)
EX (California model)
Camshaft runout @ 0.05 (0.002 )
Camshaft oil clearance 0.020-0.062 (0.OOO8 - 0.0024) 0.10 (0.004)
r
Camshaft journal 0 .0 . 22 .959 - 22.980 (0.9039-0. 90471 22.96510.9041 )
Camshaft holder 1.0.
Valve stem 0 .0. IN 3 .775 - 3 ,790 (0. 1486 - 0 , 14921 3.70 (0.1461
EX 3.755 - 3.770 10. 1478 - 0 .1484) 3.69 (0.145)
Val V!! guide 1.0. IN 3.800-3.812 (0, 1496 - 0 .1253 ) 3.89 10.1531
EX 3.800 - 3 .B12 (0. 1496 - 0. 1253 ) 3.89 (0.153)
Stem-ta-guide cleernnce IN 0.04 10 .002)
EX 0.05 (0.002 )
Valve guide projer: t inn ~i)ove ~ylinder head (h) IN 13.37 -13. 77 (0.526 - 0.542)
EX 11 .52 - 11 .92 (0.454 - 0 .4 69)
Before guide installation:

h 1. Chill the valve guides in the freez -
er section of a refrigerator for
about an hour.
2 . HeillllllJl.:yllnder head to 1UO -
150° C (2 12-300 o Fl.
Valve seat width 0 .9 - 1.1 (0,035 - 0 .0 43) 1.5 (0 .06 )

Valve spring free length IN 39.4011 .661 ) 38.6 (1.52 )
EX 39.40 (1 , 551) 38.6 (1.52)
inner IN
inner EX
o uter IN
a utel EX
Rocker arm 1.0. IN
EX
Rocker arm shaft 0 .0 . IN
EX
Aocker arm-te -r ocker arm shaft clearance
Valve lifter 0 .0.
Vulva lifter bOre I.U.
Hydraulic lash adjuster assist spring free length
Hydraulio I03h adjuster CO mpHlIl!:llon strokb with kerosene
GENERAL INFORMATION
r- Cylind.r/ pJ&lon
Cylinder to .
Cylinder out of round
Item Standard
55.000 - 55.010 (2.16 54 - 2.1657)

--
- -
Unit' mm (in)
Service limit
55.10(2.169)
0 . 10 (0.004)
,
,
Cylinder taper 0.10 (0.004)
Cvlinder warpage -- 0.10 (0.004)
Piston mark direction With " IN" mark facing to the intake side - -
Piston 0 .0 . to) 54.960 - 54.990 (2 .1638 - 2.16501 54 .90(2 .161 '
Piston 0 .0 . measurement point (HI 10 (0. 4 ) --
Piston pin hole 1.0. (d) 14.002 - 14.008 (0.55 13 - 0 .5515) 14.05 (0.5531
~
Cylinder-te-piston clearance
0 )) 01
0 .
T
I"
,-'-
-- 0 .10 (0.004 )
,
Piston pin 0 .0 . 13.994 - 14.000 (0.5509 - 0.55121 13.98 (0.550)
Piston-te-piston pin clearance 0.002 - 0.014 (0.0001 - 0 .0006) 0.04 (0.002 )
Connecting rod -te-piston pin c learance 0.0 16 - 0 .040 (0.0006-0.0016) 0 .06 (0.002 )
Top ring-ta-ring groove clearance 0.015 - 0.050 (0.0006 -0.0020) 0 .08 (0.003)
Second ring·ta-ring groove clearance 0.015 - 0 .050 (0 .0006 - 0 .0020) 0 .08 (0 .003)
Top ring ond gop 0.18 - 0.28 (0 .00/ - 0.0 11) 0.5 (0.02)
Second ring end gap 0.18-0.33 (0.007 -0.0 13) 0 . 5 (0.02)
Oil rint., Iside raill end (J;!r 0 .2 0 .7 (0.01-0.0J) 1. 1 10.04)
Top ring mark Install with the marked side up --
Second ring mark Install with thA mArked side up --
Crank'haft
Connecting rod small end 1.0. 14.016 - 14.034 (0.5518 - 0 .5525) 14.07 (0.554)
ConnectinQ rod big end side cllummr.A 0.05 - 0.2010 .002 - 0 .008 ) 0 . 30 (0.012)
radial clearance
CranksMft runout <D 0.05 (0.002 )
H O LO~-,-,
o
Crankpin oil clearance 0 .020 - 0.052 (0.0008-0.0020) 0 .06 (0.002 )

Crankoin bearing selection See pago 107
Main journal oil clearance 0 .022 - 0 .04610.0009 - 0 .0018) 0 .05 (0 .002)
M ain journal bearing selection See page 10-6
- Kic:k"itilrtor - - -
Kickstarter pinion gear 1.0.
Kickstarter spindle 0 .0 .
Ki ckstarter idle gear 1.0.
Countershaft 0.0. at kickstarter idle gear
Kickstarter idle gear bushing 0 .0 .
1.0.
1-8 http://www.motorcycle.in.th
GENERAL INFORMATION
Unit : mm Unl
TrllnsmlssJon
Item St andard Service limtt
Transmission gear 1.0 . MS 25.000 25 .021 (0.9843 - 0 .98511 25.05 (0.986)

M6 25.000 - 25.021 (0.9843-0.9851) 25.05 (0.986)
C2 28.000-28 .02 1 (1 .1024-1.1032) 28.05(1 .1041
C3 28 .000- 28 .021 (1.1024-1.1032) 28.05 ( 1. 104)
C4 28.000 - 28.021 (1.1024 - 1.1032) 28.0511 .104)
Tron~mission gear bushi"y 0.0 . M5 24.959 - 24.980 (0.9926 - 0 .9835) 24.9210.981)
M6 24.959 - 24.980 (0.9826 - 0.98351 24.9210.981)
C2 27.959 - 27.980 11.1007-1.10161 27.92 11 .0991
C3 27.959 - 27 .980 (1. 1007-1.10161 27.92 (1.099)
C4 27.959 - 27 .980 (1. 1007- 1.1016) 27 .92 (1.099)
Transmission gear busing 1.0. M5 2 1.985 - 22.006 (0.8655-0.86641 22.07 (0. 869)
C2 24.985-25 .006 (0.9837-0.9845) 25 .07 (0.987)
GMr-to-bushing clearance at M6 gear 0.020 - 0.062 (0.0008-0.0024 1 0 .10 (0.0041
at M6 gear 0.020 - 0.062 10.0008 - 0.0024) 0 .1010.0041
et C2 gear 0 .020 - 0.062 (0.0008 - 0.00241 0 .10 (0.004)
at C3 gear 0 .020 - 0.062 (0.0008-0.0024 ) 0 .10 10.004)
tit C4 gear 0 .020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
Mainshah 0 .0 . at MS gear bushing G) 21.959 - 21 .980 (0.8645-0.86541 21 .93 (0.863)
at clutch outer guide ® 21.967 - 21 .980 (0.8648-0 .8654) 21 .93 (0.863)
(j) (j)
IIII!§:· ~~ I [13;* .
Coutershaft 0.0. at C2 goar bushing CD 24.967 - 24 .98010.9830 - 0.9835) 24.93 (0.9811
•
Gear-to-shah clearance
Gear bushing-to-shaft clearance at M5 gear 0.020- 0.06210.0008 - 0.00241 0 .10 (0 .004)
at C2 gear 0 .005 - 0.03910.0002 - 0.0015) 0 .06 (0.002)
Shift fork claw thickness l 5.93-6.00 (0.233-0.236) 5.60 10 .2201
C 5.93 - 6.00 (0. 233 - 0 .236) 5.60 {0.2201
5.93 - 6.00 (0.233-0.236) 5.60 (0.2201
r Shift fork 1.0. L 12.000 -12.018 (0.4724-0.47311 12.06 (0.4751
C 12.000- 12.0 18 \0.4724-0.47311 12.0610.475)
R 12.000 - 12.018 (0 .4724-0.47311 12.0610047S)
Shih fork shaft 0.0. 11.969 - 11.980 (0.4712-0.47171 11 .90 (0.469)
- GENERAL INFORMATION
r Clutch system
Clvtch lAver free play

Recommended clutch fluid
Item Standard
10 - 20 (0.4 - 0.8)
--
--
Unit· mm Onl
Service limit
--
--
,
,
Clutch master cylinder 1.0.
Clutch master piston 0.0. -- --
Clutch outer 1.0 . 37.005 - 37.030 (1.4569 - 1 .4579) 37 .08 (1.460)
Clutch outer guide 0.0. 29.994-30 .007 n .1809-1 .1814) 29.96 (1.1791
1.0. 21.980 - 22.007 (0.8654-0.8664) 22.05 (0.868)
Mainahoft 0 .0 . at clutch outer guide 21.967 - 21 .980 (0.8648 - 0.8654) 21.93 (0.8631
Oil pump drive sprocket 1.0. 30.025 - 30.075 (1.1821 - 1.1841) 30.13/1 .186)
,
Clutch spring fre8 height -- --
Clutch spring free length 37.50.48) 36 .0 (1.42)
Clutch disc thickness A 3.22 - 3.38 (0.127-0.133) 2.910.11)
•
C . 3 .22 - 3.38 (0.127 - 0.133)
3.42 - 3 .58 (0.135 - 0.141)
2.9 (0 .11)
3.1 (0.12)
Clutch plate warpage -- 0.3 (0.01)
Centrifugal clutch drum 1.0. -- --
--
bU(lhing 0 .0. --
Centrifugal c lutch center guide 1.0 . -- --
D.O. -- --
Centrifugal clutch center guide collar height -- --
Centrifugal clutch weight lining thickness -- --
Centrifugal clutch spring free length -- --
Clutch lining thickness -- --
Cran)(SMft 0.0. at clutch center -- --
r Cooling system
Coolant capacity (Radiator and enginel 1.5 t (0.40 US gal. 0.33 Imp gal)
(Reserve tank)
Radiator cap relief pressure
0 .3 t (O.OI::J US gal , 0.07 Imp gal)
93- 123 kPa (0.95 - 1.25 kg/cm l , 14 - 18 psi) I
Thermostat bogins to OP4:!1l BO-84" C (176-183° F)
Thermostat fully open 950C (203° F)
Thormostat valve lift 8 .0 (0 .315) min .
r Drive treln
Recommended final drive oil
Fillul uTiv", 1:1"'1011 uil l.:uvadty aL disassembly
at draining
Final drive gear backlash
Ring gear-to-stop pin clearance (AI
Stop pin shIm
Ring gear spacer
Pinion spacer
Output gear backla sh
Output gaar 1.0.
OUl)JUL \:11;1'" lJullhil1\:1 0.0.
1.0.
OutPul drive shaft 0 .0 .
Output gear damper spring free length
Output shaft adjustment shim
Countershaft drive shaft adjustment shim
I
GENERAL INFORMATION
Unit- mm (in)
r Wheel./tlre.
Item Standard Service limit
M inimum tire tread depth (FA) 1.6 (0.06 )
(HRI -- 2 .0 (0.08)
Cold tire pressure Up to 90kg t200lb) load (FA) 225 kPa 12.25 kg /em:, 33 pail --
Up to 90kg (200llJ) luud (RA) 225 kPa (2.25 kg / cm z• 33 psi) --
Up to maJO:imum weight capacity (FA) 225 kPa 12.25 kg! cm Z, 33 psi) --
--
•
Up to mmtimum weight capaoity (AR) 250 kPa (2.S0 kgf cm J , 36 psi)
Front and rear axle runcut -- 0 .2 (0 .01 )
Front and reer wheel rim runcut (Radial) -- 2.0 (0.08)
(Axiall - - 2.0 (0.08)
Front wheel hub-to-rim distance -- - -
F.ol1t wheel nub ~tandard surface -- - -
Rear wheel hub-te -rim distanc e - - --
•
Aear whoel hub standard surhll:tl
. -- --
Wheel balance weight FrontJRear -- 60 9 (2.1 0')
Drive chain stack 15 - 25 (5/8 - 1) --
Drive chain si7e/ llnk (DID ) DID525VB / l04 --
- -
(RK) RK525SM4 / 104
r Front au:.pen.ion
Fork spring free length 324 .5 (1 2 .18) 318(12 .5)
Fork spring free length A
8
Fork spring direction With tightly wound coil end facing down
Fork tube runout 0.2 (0 .01 1
Recommended fork oil Fork Fluid
Furk uil level 95 (3 .1)
Fork oil level (R)
III
Fork oil capecity 510 cc (11 .2 US OZ , 11.9 Imp oz)
Fork oil capecity (R )
IL)
Fork air pressure
Steering bearing preload 1 .0 - 1 .6 kg
r Ree, suspension
Shock absorber spring hflR Iflnoth 110 .0 (7.011 174 (6 .9 )
Shock absorber spring free length (AI - - -- --
(8) - -
Damper gas pressure -- - -
Damper compressed gas -- - -
DampVI IUU compresSM force at 10' mm 10.4 in) compressed -- --
Damper drilling point
~
t 20 mm (0 .8 inl
Shock absorber spring installed length (Standard) Adjuster position III - -
(Adjust8ble r8nge) Position 1- VII --
3hul:k Ilbsorbor spring direction With the taper end facing to adjuster - -
Recommended shock absorber oil - - --
$ ho~k absorbor oil capec ity -- --
air pressure -- --
• ••
GENERAL INfORMATION
r Brakes
Front brake fluid

brllke lever '!'!!IiI play
brake pad wear indicator
Item
DOT4
--
--
StandD,d
--
--
Unit - mm (in)
Service IImft
to the groove <D

,
~ (J)
brake disc thickness 5 .6 - 6.0 (0.22-0.24\ 5 .0 (0.20)
,
brako disc ,unout --
11.000 -
11 .043 (0.4331 - 0.4348)
0 .4 (0.02)
11.055 10.4352)
master cylinder 1.0.
10.967 10.994 (0.4314 0.4324) 10.945 (0.4309)
•
maotcr pioton 0.0.
caliper cylinder 1.0. 27.000-27.050 (1.0630 - 1.0650) 27.06 (1.065)
caliper cylinder I.D.IUpper) --
--
--
--
(Lower)
caliper piston 0.0. 26.918 - 26.96811.0598 - 1.0617) 26.91 11.0591
caliper piston D.D.tUpper)
(lower)
--
--
--
--
r brake drum 1.0 . -- --
brake tining thickness -- --
Roar broko fluid DOT4 --
brake pedal height -- --

brake pedal free play -- --
br8!,8 ~ w~r indicator -- to the step ®
i~ ;
i~ 1 :
1
brake d~C thickness
(unout
4 .8 - 5 .2 (0.19 - 0.20)
--
4.0 (0.16)
0.4 (0.02)
mester cylinder 1.0. 14.000 - 1 4.043 (0.5512 - 0.5529) 14.06 (0.554)
master piston 0.0. 13.957 -13.984 (0.5495 - 0 . 5506) 13.95 (0.549)
cahper cylinder 1.0. 38 .180 - 38 .230 (1.5031 - 1. 5051) 38.24 (1.506)
caliper piston 0.0. 38.098 - 38.148 (1.4999 - 1.5019) 38 .09 (1.500)
brake d,'urn 1.0. -- --
brake lining thickness -- --
- Battery/charging system
Alternator charging cOil reslst8~ce (At ~wuC /68U F) 0.1-0.50
Regulator/rectifier regulated voltage/amperage
Battery capacity
14.0- 16.0 VIO- B A at 5.000 rpm
12 V-8 AH f
Battery specific gravity (Fully charging)
(NAAn !! r."""OinOI
Battery charging rate (Normal) 0.8 A (5 - 10 hours)
(Quick) 4 A (1 hour)
Battery voltage (Fully charged 20°C/68°F) Over 12.8 V
(Needs charging 20° C/68°F) Below 12.5 V
Alternator IJghting cod resistance (At :w u C/6B " FJ
,
AC regulator regulated voltage (With analogue type)
(With digitsl type)
r Starting system
Starter driven gear 0.0. 42 .175 - 42 .200 11.6604 - 1.66141 42.12 (1.6581
~tllrte r clutch outer 1.0.
Starter motor brush spring tension 920 :t 140 9 (32.4 :t 4 .9 ozl
brush length 12.5 (0.49) 8.5 (0.33)
GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
Torque Torque
Item N·m (kg-m. tHb)
Item
N·m (kg-m, ft·lbl
5 mm bolt and nut 510.5,3.5) 5 mm screw 4 (0.4 , 3)
6 mm bolt and nut 10 (1.0,71 6 mm screw 910.9,7)
8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0 .9 , 7 )
10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 12 (1.2, 9 )
1 2 mm bolt and nut 55 (5.5, 40) 6 mm flange bolt and nut 27 (2.7, 20)
10 mm f lange bolt and nut 40 (4.0, 29)
Torque specifications listed below are for Important fasteners. Others should be tightened to standard torque values hsted
above.
NOTES :
1. Apply II locking agent to the threads.
2 . Apply sealant to the threads.
,
3 . StRkA.
4 . Apply silicone grease to the sliding surface.
~ ENGINE
Thread Torque
Item Q ' ty Remarks
dialmml N' m kg m ft -Ib
lubricat ion:
Oil pump drivcn 3procket bolt 1 6 15 1.5 11 NOTE 1
Oil pressure switch 1 -- 12 1.2
• NOTE 2
'.
Oil drain bolt 1 12 35 3.5 25
Oil filter boss 1 20 18 1.8 13
Oil filter 1 20 10 1.0 7
Cvlinder headfcvllnder/ plston:
Cylinder head cover bolt 8 6 10 1.0 7
Camshaft hOl~er bolt ,"2 6 12 1.2 9
Cylinder head cover breather plate bolt
Cylindor hood 3pcciol nut 12
6
6
12
30
1.2
3.0 22
• NOTE 1
Cylinder head mounting bolt

Cylinder mounting bolt
2
1
6
6
12
10
1.2
1.0
•
7
Cylinder stud bolt 12 6 26 2.6
Spark plug
• 10 11 1 .1 "8
Clutchfgearahift linkage :
Crankshaft hole cap
TIming hOle cap
. 1
1
30 7
10
0.7
1.0
5
7
Clutch center lock nut 1 "
20 85 8.5 61 NOTE 3
Gearshift 3pindlc return sprIng pin 1 8 23 2.3 17
Crankcase/cran kshaft/transmission:
Connecting rod nut 8 7 2' 2.' 17
Crankcase bolt (8 mml 12 8 2' 2.' 17
(8 mm x 65) 1 8 27 2.7 20
(6 mm)
Sealing bolt UOWflr r.rAnkr.A !O<A)
SIJYt:iyl bolt (lower ertlnkcase)
Neutral switch
I.
,
1
1
,.
6
20
10
12
30
2S
18
1.2
3.0
2.S
1.8
22
16
'3
•
NOTe 2
NOTE 2
'I
Orive sprookot bolt 1 10 55 5.5 40
Altemator:
Flvwheel bolt 1 10 85 8.S 6'
Starter clutch:
Start 81 clulI•.:h bolt , 10 85 B.5 61
1_ 14
GENERAL INFORMATION
FRAME
Item
Thread Torque
a'W Remarks
dio(mm)
N'm kg-m ft-Ib
Frame/exhaust _vstem:
EJllhau~t pipe Joint nut 6 12
Muffler mounting bolt
Side &land pivot bolt
"
2
1
8
10
22
10
1.2
2.2
1.0
9
16
7
Side stand pivot lock nut 1 10 27 2.7 20
Side stand switch mounting bolt
Gearshift pedal joint bolt
1
1 •
6
30
12
3.0
1.2
22
9
Gearshift pedal mounting bolt 1 8 27 2.7 20 NOTE 1
footpeg stay bolt 4 8 27 2.7 20
Cooling .y.tem:
TI;lI11I)UII:HUrlJ sensor
. 1 -- 10 1.0 7 NOTE 2
Fan motor switch 1 16 18 1.8 13 NOTE 2
Fual system :
Fuel valve nut 1 22 23 2.3 17
Fuel tank cap mounting bolt 3 4 3 0.3 2
Engine mount:
Engine mount nut (frontl 2 10 40 4.0 29
Engine mount nut (rear/ upper) 1 10 50 5.0 36
Engine mount nut hear/lower) 1 10 50 5.0 36
AdjUSting bolt 1 20 15 1.5 11
Adjusting bolt lock nut 1 20 65 6.5 47
Engino oub frome nut 4 10 45 4.5 33
Engine bracket bolt 6 10 40 4.0 29
Front:
Handlebar pinch bolt 2 8 27 2.7 20
Handlebar weight screw 2 6 10 1.0 7 NOTE 1
Axle bolt 1 14 60 6 .0 43
Axle pinch bolt 4 8 22 2.2 16
fork I)lncl'l Mit (upper) 2 7 11 1.1 8
Fork pinch bolt (lower) 2 10 50 5.0 36
Fork oap bolt 2 37 23 2.3 17
Fork socket bolt 2 6 20 2.0 14 NOTE 1
Steering stem nut 1 24 105 10.5 76
Steering head bearing adjustment nut 1 26 25 2.5 18
Ignition switch mounting bolt 2 8 25 2.5 18 NOTE 1
Re ar:
Axle nut 1 16 90 9.0 65
Driven $procket nut 5 10 65 6 .5 47
Shock absorber mounting nut (upper) 1 10 45 4 .5 33
Shook ab30rbcr mounting nut (low4r) 1 10 45 4.5 33
Shock absorber lower joint lock nut 1 14 68 6.6 49 NOTE 1
Swingarm pivot nut 1 14 110 11 .0 80
Braka :
Front caliper pad pin pluQ 1 10 2.5 0 .25 1.8
pad pin 1 10 18 1.8 13
bracket bolt 2 8 27 2.7 20
pin bolt 1 -- 23 2.3 17 NOTE 1, 4
bracket pin bolt 1 -- 13 1.3 9 NOTE 1, 4
Front m03tcr cvlinder reservoir cover ,craw 2 4 6 0.6 4
Front brake disc bolt 6 8 30 3.0 22
Rear caliper pad pin plug 1 10 2.5 0 .25 1.8
pad pin 1 10 18 1.8 13
mounting bolt 1 8 23 2.3 17
pin bolt 1 -- 23 2.3 17 NOTE 1, 4
Rear master cylinder push rod joint lock nut
P\oor I)r81<e di~e bolt
1 -- 17 1.7 12
4 8 40 4.0 29
Brake hose bolt 4 10 35 3.5 25
GENERAL INFORMATION
TOOLS
The tools for the boll bearing removal and instollotion ore not contained in this list.
Refer to section " 8all Bearing Replacement. of the Common Service Manual.
Tnfl nftwly d"!ligned tools are indicated with· mark in the list. 1
Description Tool number Alternative tool Ref. sectionlsl
Oil fitter wrench 07HAA - PJ70 100 3
Var:uum gauge 07404 - 0030000 3
I-r or equivalent commer-
Oil pressure gauge
Oil pressure gauge attachment
07506 - 3000000
07510-4220100 cially available in
4
4
4 , 14 , 16
t
Rotor holder 07725-0040000 U.S.A.
Antifreeze tester Commercially available 5
Cooling system tester Commercially available 5
Float level gauge 07401 - 00 10000 6
Vacuum pump ST - AH - 260 - MC7 - U .S.A. only 6
Pressure pump , ST - AH - 2S5 - MC7 - U.S.A. only 6 • I
·Volve guide driver (guide removal '
installtion) 07JMD - KY20 100 8
·Valve bucket hole protector 07JMG - KY20100 8
Valve spring compressor 07757 - 0010000 8
·Valve spring compressor attachment 07JME-KY201OQ 8
·Valve guide reamer, 3.8 mm 07JMH - KY20100 !- 07JMH-KY2010A 8
(U,S,A, only)
Valva seat euner, 22 mm (4!5° IN, EX) 07780 - 0010701 or tlquivaltmt l:ommer- 8
Valvo Ilat cuttor. 22 mm (32 0 INI 07780-0012601 cially available in 8
Volvo flat outtor. 21.6 mm (32 0 EX) 07780-0012800 U .S.A, 8
Valve interior cutter, 22 mm (60 0 IN , EX) 07780 - 0014202 8
• Cutter holder 07JMH-KY202oo 8
Piston ring compressor 07954 - 2500000 1-07954 - 2350000 8
Piston base 0795B - 413oooo 1-07958 - 250000 1 8
Compression gauge 07305 - 0010000

(U.S.A. only)
p- ~r equivalent commer- 8
I
• Com~'asslon gouge ottachment 07JMJ - KY201OQ Chilly available in 8
U .S.A.
• Clutoh oontor holdor 07GMB - KTB01OQ - Not available in U.S.A. 9
07HGB - 00l000A
(U.S.A. only)
GENERAL INFORMATION
(Cont'd)
DescriptIon Tool number Alternative tool Ref. section!s)

Bearing remover head, 20 mm 07746 - 0050600 11
Bearing remover shaft 07746 - 0050100 11
Driver 07749 - 0010000 11. 12
Attachment, 42 )( 47 mm 07746-0010300 11 , 12
Attachment, 52 x 55 mm 07746 - 0010400 11
Pilot, 20 mm 077415 - 0040500 11 , 12
Fork S8al driver 07947 - KA50100 11
Fork jl;;8(11 driver attachment 07947 - KFOO100 11
Lock nut wrench, 30 x 32 mm 07716 - 0020400 11
Steering 5t801 socket 07916 - 3710100 11
Boll rsce remover 07953 - MJ10000 B ~ttachm.nt 107953 - 11
•
- attachment 07953-MJ10100 MJ1000A) , Driver 111 )
- dnver 07953 - MJ 10200 (07949 - 3710001) 1111
and Attachment,
37 x 40 mm (07746 -
0010200)
B9aring race remover 07946-3710500 11
Driver 07949 - 3710001 11
Attachment, 37 x 40 mm 07746 - 0010200 11
r Steering st8m driver 07946 - MBOOOOO 11
Bearing remover head . 17 mm 07746 - 0050500 12
Attachment. 24 x 2.6 mm 07746-0010700 12
PlIot, 17 mm 07746 -0040400 12
Pilul, 22 11 1111 07746 - UU4 1OO0 12
Shock absorber compressor 07GME - 001oooo \-- Not available in U.S.A. 12
07959 - 3290001
•
- screw assembly 07GME - ool01OO 1121
Shock absorber compressor attachmAnt 07~fiR - MB10000 12
.. Driver pin 07GMD - KT80100 - Not available in U.S.A. 12
Pilot, 22 mm 107746 -
0041000) and Driver
(07749 - 0010000)
Dliv",r !llr:lft U/!::l46 - MJ00100 - Not available in U .S.A. 12
Driver (07949 -
3710001)
.. Needle bearing remover attachment 07GMO - KT702oo - Not available in U .S.A. 12
Bushing remov er
(M967X - 038 -
XXX XXI
Anac hment. 28 x 30 mm 07946 - 1870100 t2
Attachment , 32 x 35 mm
Pilut. 15 mm
. 07746 - 0010100
U7746 - 0040300
12
12
Snap ring pliers
RQtQr puller
07914 - 3230001
07733-0020001 - 07933 - 2160000
(U .S.A. only)
,.
12, 13
Christie battery charger

Ollll~1 y t~litl:lr
Digital multitester (KOWA)
MC 1012/ 2
BM - 21U
07411 - 0020000 KS - AHM-32 - 003
,."
14. 15, 16.
(U .S .A . only) 17
Analogue tester 07308 - 0020001 (SANWA) 14,15,16,
or TH-5H (KOWA) 17
T orx bit IT4 0) 07703 - 0010100 - or equivalent commer- 17
clally available in
~
U.S.A .
. .....
GENERAL INFORMATION
LUBRICATION AND SEAL POINTS

ENGINE
Point Material Remarks

t
• Intake and Exhau~t v~lve stem sliding 8urfaoe Molybdenum Soluliun (mixture
• C8mshaft journal of the engine oil and molybde-
• Connecting rod small end-piston pin sliding surface nllm disulfide grease with the
• Transmission gear shifter groove ratio 1 : 1)
• Crankshaft main journal bearing sliding surface
• Connecting rod bearing sliding surface
t
• Upper crankcase mating surface liquid sealant Do not apply sealant to the
oil passages and near the
main journal bearings
• Oil pressure switch
• Fan motor switch
• Thermo sensor
• Neutral switch
• Gear teeth
•
Sealant
Engine o il
Do not apply sealant to the
oil pressure switch thread
head as shown. •
• Shaft journals
• Sliding surface
FRAME
Point M aterial Remarks

• Center stand pivot Multipurpose grea se
• Side st and pivot
• Brake pedal pivot
• Gcor3hltt ped81 pivot
• Steering head bearings
t
• Dust SAl'll lip ..
• Clutch lever pivot
• Throttle cable ands
• Swingarm pivot bearings
• Seat locking tab
• RelIr wheel driven flange bearing
• Wheel bearings
- Speedometer geal
• Brake caliper sealS DOT 4 Brake fluid
• C .. liper-plston $liding surtace
• Master cylinder piston cups
• Master cylindcr phton sliding sui"facl:I
• Brake caliper pivots Silicone grease
• Br8kfl ctlliper pivot !.roots
• Rear brake master cylinder push rod head
• SlJlIlIdometer cable Light weight oil
• Throttle coble
• Choke coblo
• Clutch cable
• Handlebar grip insiull I>urface Honda Bond A or
Honda Hand Grip Cement
(U.S.A. only)
-1
----------------------_........... Honda CB400 / CB-1 Service Manual
GENERAL INFORMATION
CABLE AND HARNESS ROUTING

(1) 6P-WHITE CONNECTOR (2) 6P-AED CONNECTOR
(METER)
, - -(:3) 6P-BLACK CONNECTOR

(TURN SIGNAL SWITCH)
•
(6) 3P-BLACK CONNEc-rOl' /
(IGNITION SWITCH)
11'11i1--..., 6P-GREEN CONNECTO R
(TURN SIGNAL SWITCH)
SP.RED CONNECTOR
(STARTER SWITCH, ENGINE STOP SWITCH)
(7) BRAKE HOSE la) CLUTCH CABLE
(15) THROTILE LEFT

L:AHLE HANDLEBAR
SWITCH
WIRE
(14)
HANnLE6AR
SWITCH I~~2~~lJ~l:""-~ 0) CHOKE CABLE
11 IGNITION SWITCH WIRE
WIRE
~~~~
( 12) SIGNAL
WIRES
GENERAL INFORMATION
111 MAIN
WIRE
(2 ) CHOKE
SET THE W IRE HARNESS SECUAEl Y
,
';;;~_~.' THROTTLE
~ CABLES
~~t~zA~~~_-451
~
) HOSE
BRAKE ,
(8) 2 &
No. 3
SPARK SET THE No.2 & No.3 SPARK PLUG
PLUG WIRES SECU RE LY
WIRES
1
) SET THE No . 1 &
No.4 SPARK
PLUG WIRES
(9) I r--+- SECURELY
CABLE
(15) 2) SIPHON
CABLE TUBE
) SPEEDOMETER
CABLE
GENERAL INFORMATION
(2) DIODE BATTERY

POSITIVE
TERMINAL
•
• GUIDE
• IGNITION COIL WIRE
• NEUTRAL SWITCH
& Oil PRESSURE
SWITCH WIRE
• PULSE GENERATOR
WIRE
• SIDE STAND
SWIT CH WIRE
171 CLAMP • ALTERNATOR WIRE
• MAIN WIRE HARNESS
• AEAR BRAKE UGHT SWITCH
I
1) SIDE STAND
SWITCH (3P)
CONNECTOR
CRANKCASE
BREATHER
TUBE
• No.2 & No.3

SPARK
PLUG
WI RES
ALTERNATOR
(3P) CONNECTOR
(1 REAR
BRAKE
Hn~F
RESERVE TI\NK (16) FUEL TANK ) IGNITION COIL

OVERFLOW TUBE DRAIN TUBE /4PI CONNECTOR
http://www.motorcycle.in.th . ...
GENERAL INFORMATION
I FUEL FUEL CUT -OFF

FILTER RELAY
SIGNAL
•
•
I '
I COIL WIRE
• NEUTRAL SWITCH
& OIL PRESSURE
SWITCH WIRE
• PULSE GENERATOR
WIRE
(8) NEUTRAL sIDe STAND (61 FUEL PUMP
• sloe STAND
•
SWITCH WIRE SWITCH WIRE
SWITCH WIRE
• ALTERNATOR WIRE
11) MAIN WIRe

HARNESS
(10) C"IM"/'
(1
1-22
GENERAL INFORMATION
• Calif om la M odel Only
(3) TO AVCV
. 4 'u" </~
1')"10, 15
(1) FUEL TANK
(8) No.
TUBE
m No. 4"~
TUBE
(6) No.
TUBE
IS} RADIATOR
RESERVE
TANK
OVERFlOW
TUBE
(12) NO.3 INTAKE

(11) No. 41
1 (18) TO PCV
( 19) TO AVe V
(10) No . 10
TUBES
(91 No. 15
TUBE
o
15) AIR
HOSE
(171 A~'~';;;--...;1C~
HOSes
(21) No . 10 (20) TO CANISTER

TUBE
(16) AIR SUCTION
(AVe V )
VALVE
GENERAL INfORMATION
•
(1) No.5
TUBES
•
•
,-
) AIR
INJECTION
TUBE (No. 15)
(3) No.1 TUBE
(6) pev
(5) AVCV_1:~::>~
(9) No. 10
TUBE
----Ii
H~----"(7) No.4 TUBE ,

"
GENERAL INFORMATION
EMISSION CONTROL SYSTEMS

The U.S. [n vironmenUd P,utllction Agency and ClIhtornia Air Resources Board (CARB) require manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained
according tn the 'I'lstru'"tions ~rovided , ond thet motorcycles built after January " 1983 comply with applicable noise emis-
sion standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchassr, when operated and
maintained according to the instructions provided . Compliltnce with the terms of the Distributor's Warran ties for Honda
Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect .
SOURCE OF EMISSIONS
ThC combustion proce66 produces carbon monoxide and hydrocarbons . Control of hydrocarbons is very important because ,
under certain conditions. they react to form photochemical smog when subjected to sunlight. Carbon mono)(ide does not
rea ct in the ,,!'me way, but it is toxio.
Honda Motor Co .• Ltd. utilized lean carburetor settings as WAil 1'$ other systemli , to reduce oarbon mono)(ide end hydro-
carbons.
CRANKCASE EMISSION CONTROL SYSTEM
The crenkca se emi6sioll culltrol system routes crankcase emissions through the air cleaner end into the combustion chamber.
Condensed crankcali8 vapors are accumulated in nn airfoil separatol and urain tube whIch must be emptied periodically. Refer
t o the MAintenance Schedule (page 3-41. Thc drain tube needs to be checluHJ rur oil accumulation more frequently if the ma-
chine has been ridden mostly at high speeds or in rain.
1) AIR CLEANER
J-~----'2ICARBURETOR
(3)
__ : BLOW·BY GAS
(4)
¢:l : FRESH AIR
1 "'0=
GENERAL INFORMATION
EXHAUST EMISSION CONTROL SYSTEM (SECONOARY AIR SUPPLY SYSTEM)
•
(EJU':lIpl Cillifulllia modul)
The exhaust emission control system is composed of lean carburetor settings and no adjustment should be made except idle
8peed adjl.llitment with the throttle stop screw.
(California model)
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust
gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust
system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of •
hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
This model hilS th~ llir sut:tiun valva; it consists of read valves built into the air injection control valve.
A reed valve prevents reverse air flow through the system. The air injection control valve reacts to high intake manifold
vacuum and will cut off the liupply of fralih air during engine deceleration, thereby preventing afterburn in the exhaust sys-
tem .
No adjustments to the secondary air supply system should be made , although periodic inspection of the components is rec-
ommended. •
•
(lI INTAK' PORT
AIR SUCTION
VALVE ASSEMBLY •
CARBURETOR
(6)
PORT
¢:l (7): FRESH AIR

(
,
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)
Thili vehiole complies with th9 Cillifornia Air Resources Board requirements for evaporative emission regulations.
_ Fuel vapor from thlt fue l tank lind carburetors is routed into the charcoal canister where it is absorbed and stored while the
engine is stopped. When the engine is running and the purge contro l diaphragm v alve is open f uel vapor in the charcoal canis~
ter is drawn into the engine through t he carblifAt or . At the same t ime, t he air vent cont rol ... al\l'6 is open and air is drawn into
the carburetor through the valve.
PURGE~~~I~b
111 CONTROL
VAILV E tPCVI
FUEL
TA NK
• ~
14 1 CA'NIIS,"'R
~ : (5) FRESH A lA
..... : (6) FUEL VAPOR
AIR VENT
CONTROL
VALVE IAVeV)
I
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED : Federal law prohibits the following acts or the causing
I thereof: 111 The removal or rendering inoperative by any person. other than for purposes of maintenance. repair of replace-
m"nt. of any device or clement of desigll incorporatfld into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has
ooen removed or renderAil inoperative by any pcr30n.
AMONG THOSE A CTS PRESUMED TO CONSTITUTE TAMPERING ARE T HE A CTS LISTED BELOW :
,. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2 . Remov al of . or puncturing of any part of the intake system.
J . La!.:k of prO~~r mtllntenance.
4 . Replac ing any moving parts of the vechile , or parts of the exhaust or Intake system. with parts other than those specified
by the monufocturer.
GENERAL INFORMATION
EMISSION CONTROL
INFORMATION LABELS
(U.S.A. Only)
An Emission Information label is located on the rear fender
as shown. The s8at must be removed to r8C1d it.
It gives basic tune-up specifications.
(1) EMISSION INFORMA
LABEL
(2) UP DATE
•
•
VEHICLE EMISSION CONTROL INFORMATION
UPDATE LABEL
After making a high altitude carburetor adjustment, attach an

update label on the rear fender as shown.
•
(3) HOSE
ROUTING DIAGRAM
LABEL
(California modal
only)
VACUUM HOSE ROUTING DIAGRAM LABEL

(California model only)
VACUUM HOSE ROUTING DIAGRAM
•
The Vacuum Hose Routing Diagram label is on the rear E~GI"'''FA 1.\1 LY~KHN0 3DD"" YB
EVAPORA,TIVE FA, M llY-SII 'Z K
fender as shown. The seat must be removed to read it.
CA' IFO~NIA VEHICLE
Route the vacuum hoses as shown on this label. FRONT OF

VEHICLE
----- W
, •
u
~I
I~
ANI TEA
KAF - 750
2. FRAME/BODY PANELS/EXHAUST SYSTEM

SERVICE INFORMATION 2- 1 SIDE COVER REMOVAU INSTALLATION 2-3
T ROUBLESHOOTING
SEAT REMOVAL/INSTALLATION
2-1
2-2
EXHAUST SYSTEM REMOVAL/
INSTALLATION 2-3 IfJ I
FUEL TANK REMOVAU INSTALLATION 2-4
•
REAR FAIRING REMOVAL/
INSTALLATION 2-2
SERVICE INFORMATION
• When remO\llng a cover, be careful not to damage any tab or groove .
while it is hot.
NOTE
Re place the exhaust pipe gaskets if the exhaust system is removed .
• Tighten the exhaust pipe joint nuts first. then the mounting bolt!>,
• Although it is possibl9 to wAlrl "'"me cracked frames and straighten some frames that 8fe slightly bent it is best to replace
the frame with a new one when it is damaged.
• Generally speaking, plastic body panels cannot be repaired and therefore mu!\t he replaced.
• It is possible that a front end callastan will bend the steering head of the frame , but not the fork, wheel or even the axle .
TROUBLESHOOTING
Failure of the front suspension , steering or rear suspension mav damage the frame enough to require replacement.
R.f.r to lhe section 18 of thc Common Service Manual fUi frullt suspension and Steering inspectrons.
Refer to the section 19 of the Common Service Manual for rear suspension inspection.
Abnormal engine vibration

Cracked or damaged anQine mounts
Cracked, damaged or bent welded portions
Bent or damaged frame
t;ng rne problems
Abnormal nolS8 when IhJiny (bunglng ' or cracking)

Damaged or bent engina mounts
DltmltOAri w elded points
Damaged or bent frame
Steers to on8 sKie when under acceleration or deceleration

Bent frame
8ent lark
_ Bent swingarm
FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT REMOVAL/INSTALLATION
I') SEAT LOCKI
Insert the ignition key into the seat lockJhelmet holder and HELMET HOLDER
turn the key clockwise and push down the lever; release the
seat locking.
Pushing the seat as shown, remove lhe seat rearward.
Align the seat hooks with lhy fryme hooks and push the seat
forward.
Prl!l$$ tnli' reaf of the seat down and look the scot securel y.
LEVER ~~IWJ1
CAUTION
(2)
I
Apply grea.e to the . e.t locking .
Be candul not to pinch the wire harnos6 botween the
•• at and the frame .
REAR FAIRING REMOVAL/

INSTAllATION
(2) BOLTS
Remove lhe seat (above).
Remove the bolts and collars.
Release the fa iring front bosses from the grommets .
Remove the rear fairing rearward.
(11 COLLARS "''':::::::-_-1
Install the rear fa iring in the reverse order of removal.
•
(4) REAR
FAIRING
2·2 http://www.motorcycle.in.th
FRAMEJBOOY PANELS/EXHAUST SYSTEM
SIDE COVER REMOV ALI 11) FRONT SIDE COVER

INSTALLATION
t FRONT SIDE COVER
Remove the bolts.

Release the boss from the frame grommet and remove the
front side cover. (2) BOLTS
Install the side cover in the reverse order of removal.
t NOTE
14)
80LT ®-"1"~~
• It is not necessary to remove the bolt ® as shown.
• REAR SIDE COVER

Remove the following:
s8at (page 2-2),
Release the reaT fairing front bosses from the grommets
(page 2-2) ,
Remove the bolts and rear side cover.

~~~!...- (1) RE AR
Install the side cover in the reverse order of removal. SIDE
13) COVER
NOTE BOLT 11\1 - -
!;;:::==-' 121 80LTS
• It is not necessary to remove the bolt ® 8S s ho w n .
• EXHAUST SYSTEM REMOVALI

INSTALLATION 11) RAn"" Tn,"
Remove the radiator lower mOllnting bolts and loosen the
UDDer mounting bolt/nut !page 5-5', Swing the radiator for-
ward.
Remove the following :

- exhaust ripA joint nuts,
- muffler mounting bolts and exhaust pipe/ muffler.
- gaskets.
• NOTE
Replace the exhaust pipe gaskets if the exhaust system
is removed.
Install new gaskAt!: ;md exhauu pipe/ muffler.
•
Tighten the exhaust pipe joint nuts first.
T Orto.UE: 12 N·m 11.2 kg-m . 9 ft-lbJ
Tlum tighten the mutfler mounting bolts.
TORQUE: ZZ N·m (2 .2 kg -III, 1 e ft-Ib) (3) JOINT

14) EX)<AlJST NUTS
PIPE/MUFFLER
--
FRAME/BODY PANELS/EXHAUST SYSTEM
FUEL TANK REMOVAL! (1)BQlT (2) FUEL

TANK
INSTALLATION
Gasoline is extremely flammable and is explosive under

<:~u1ftin (!Qn(iiti(ln$. Wl)rk in II w(IIlI vtmtilatAd Ilrllil.
Smoking or allowing flame. or sparks in the work area
(3 ) BOLTI
NUT
•
or where gasoline is stored can cause 8 fir. or explo-
Remove the seat (page 2-21.

Turn the fuel velve OFF.
Remove the fuel tank mounting bolts and lift the tank up .
Disconnect the tubes, and remove the fuel tank.
•
Install the fuel tank in the reverse order of removal.
After installation, turn the fuel velve ON and check the fuel
line for leakage.
Install the seat (page 2 -2).

(5)
TUBE
•
3. MAINTENANCE
SERVICE INFORMATION 3- 1 SPARK PLUG 3-5
SERVICE ACCESS GUIDE 3-2 VALVE CLEARANCE 3-5
MAINTENANCE SCHEDULE
AIR CLEANER
SERVICE INFORMATION
3-4
3-5
CARBURETOR SYNCHRONIZATION
SIDE STAND
3 -B
3-8
•
• Refer to the Common Service Manual for items not included in this manual.
• AeMr to th e specIfications (Section 1) for maintenance service dats .
M AINTENANCE
SERVICE ACCESS GUIDE

The following shows the locations of the maintenance items listed below and the parts required to be removed for that
mainHmttrlC9 service. Refer to the Common Service Manual for items not instru cted in this manual. ,
Refer to section 2 (Frame/Body panels/Exhaust system), the perts required to be remove for service.
For example: AIR CLEANER (Contaminat ion, clogging. replacement) maintenance parts (service item)
• Fuel tank perts required to be removed for service
Reserve Tank Cap (Coolant filler)

Throttle • free
•
•
Master Cylinder
Brake Pedal (Air bubbles in 1;
Brake Hose
Brake Reservoir
(Level • fluid
•
Brake Hose
(Leakage. degradation, damage)
Caliper
Tire Tire (Wear,
Wheel Wheel (
runout,
Switch Oit Filter
Oil filler I Gauge Timing Hole Cap/Cr ankshaft Hole Cap

(Level 1
MAINTENANCE
Air Clea ner Synchroni1;8tion Adjusting Screw

(Contamination, clogging, repla cement page 3-5) (Carburetor synchronization page 3· 8)
Fu",1 tAnk
Choke (Operation) PCV and AICV 6-13)
Clutch lever (Free Reserve Tank (Coolant
(Aim )
• Steering Head
(Damage)
Valve
Suspension
(loose, weer .
• Suspension
Drive Chain
(Free play ,
floose. wear.
ASV hose 6 · 13)

Side Stand 3·8)
Spark Plug (Wear, damage. coloration)
• Front sIde cover Fuel Filter (clogging)
leakage)
Hose
Oil Drain Bolt (Oil Throttle Screw (Idle
MAINTENANCE
MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's M anual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate. or Replace if necessary.
R: Raplae., I.: LubriCate
The following items require some mechanical knowledge. Certain items (particularly those marked· and··) may require
more tochnioal information and tools. Consult your authorized Honda dealer.
=~
WHICHEVER . .
ODOMETER READING (NOTe 1)
COMES
FIRST
... x 1000 km 1 6 12 ,. 2. 30 36
Refer
ITEM
• FUEL LINE
NOTE x 1000 mi 0 .6 4
•
I
12 16
I
20 2'
I
to page
NOTE.
• LE I I I NOTE'
I I I NOTE 5
I~
AIR CLEANER NOTE 2 R R 3 -'
'"w $PARK PLUG R R R R R R

•
'" • I I 3-'
•
t:
0 , OIL R NOTE.
w
0-
:sw OIL FILTER
H
R
H
R "
R R NaTE 5
-
• CARBURETOR
'"0z SYNCHRONIZATION
I I I 3-B/NOTE 5
in • "DLE SPEED I I I I I I I NOTE.

'!1
nADIATon COOLANT NOT[ 3 I I R NOTE 5
"
w
• I I I NOTE.
• SECONDARY AIR
NOTE 4 I I I NOTE 5
SUPPLY SYSTEM
• EVAPORATIVE EMISSION
NOTE 4 I I NOTE 5
CONTROL SYSTEM
DRIVE CHAIN
, NOTE'
'"w
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t:
c
~ · •
BRAKE FLUID
' PAD WEAR
; LIGHT' I
g:r I'
, I , I ,
j
,
A
,
,,
I
,
,J,
NOTE 5
NOTE.
NOTE 5
NOTE 5
•
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HEADLIGHT AIM
,
,', , NOTE 5
W" ,I I I
7 .j . , ,
Q
SIDE
" "
. " I
NOTE 5
'"'":! I 3-8
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Z •
0
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· SUSPENSION
NUTS, BOLTS, FASTENERS
'~
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,
I
" ,I
I
NOTE 5
NOTE'
I· • , HEAl I I, ,I NOTE.
NOTE 5
• Should be serviced by an authOrized Honda dealer, unless the owner has proper tools and service data and IS mechanically
4ualHilild .
• • In the Interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES : 1. At higher odometer readings , repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3 . Replace every 2 years, or at indicated odometer interval . whichever comes first .
Replacement requires mechanical skill.
4. Californial type only.
5 . Refer to the Common Service Manual.
3-4
MAINTENANCE
AIR CLEANER
- fuel tank (page 2 -4).
- air cleaner case covar (page 6-31 ,
Discard the air cleaner element in accordance with the moin

tenonee schedule.
•
Also, replace the element any time it is excessively dirty or
~
damaged.
Install the air cleaner element with the il' mark. forward and
the TOP mark facing up.
Install the wiru l umnuls into the wire herness clam p on the
(21 lt TOP MARK
cover securely.
• SPARK PLUG
NOTE
For detailed instructions, refer to saction 2 of the
• Common !;flrvlce Manuel. Instruction for femova ll

installation of only the No.2 end No.3 spark plugs is
given here. No.1 and No.2 plug can be removed easilv
only to remove the front side cover.
Remove the front side covers (page 2-3).

The spark plug wrench Is Included in the tool kit.
Insert the plug wrench between t he heat guard plate and cyl-
• inder head cover as shown, and set the wrench onto the
spark. plug.
Turn the plug w rench and remove the spark plug.
Then lihl.lp 'he wrench with tho plug, through the heat guard
cross-hole.
r'ull the wrench out of th8 cvlindtl'l tl~ittl.
Remove the spark plug from the wrench.
Install is new spark plug Into the cylinder In the reverse order
of removal.
Tighten th~ !;~itrk IJluy 112 turn with en open end wrench to
• compress the plug sealing washer.
• VALVE CLEARANCE 111 TIMING HOLE
• INSPECTION
NOTE
Inspect and adjust valve ctearance while the engine is
cold (Below 35 0 C/95°FI.

- timing hole cap (page 9-2J.
- crankshaft hole cap cover (page 9 -21.
- crankshaft hole cap (page 9-21.
- Ilir cleaner case (page 6-3).
MAINTENANCE
Aemove the radiator lower mounting bolts and loosen the

upper mounting bolt/nut.
•
Swing the radiator forward.
Remove thQ cylindor head co ....er Ipogo 8-21.
•
Rotate the crankshaft clockwise.
Align the T mark (Yellow colored line I on the flywheel with
the index mark on the right crankcase cover. Each timing
mark lEX and INion the camshaft Q88rs should be aligned
with the cylinder head upper surface.
(1) T MARK
I •
•
If each timing mark is facing outside, No .4 cylinder piston is
at TOC (Top Dead Center) on the compression stroke. go to
Step 1 .
If each timing ma,~ Is faciny ilu.h.h:!. Nu. 1 cylinder piston Is at
TOC (Top Dead Center) on the compression stroke, go to
~tAP ?
Step 1:
Insert the feeler gauge between the cam lobe and valve
bucket.
(')INIAKE
CAM SHAFT
(2) EXHAUST
CAM SHAFT
•
Measure the valve c learance as follow:
- No. 2 (IN)
- Nu. 3 (I!X)
- No.4 (IN/EX)
Step 2:
Insert the feeler gauge between the CRm InhA ;tno valve
• bucket .
Measure the valve clearance as follpw :
- No.1 (IN /EX)
- No.2 (EX)
- Nu. 3 (IN)
(3) TIMING MARKS
!facing outside)
I RIGHT VIEW I
•
,
VALVE CLEARANCES :
IN : 0 . 12-0. 18 mm (0.005 - 0 .007 In) (llINTAKE (2) EXHAUST
EX: 0 . 17 - 0 .23 mm 10.007 -0.009 In) CAM SHAFT CAM SHAFT
Rotate the crankshaft 360 degrees and align the T mark with
,
the index mark again and go to Step 2 or 1 to check other
valve clearances.
(3) TIMING
MARKS
(facing Inside)
I RIGHT ViEW I
MAINTENANCE
SHIM SELECTION
If the clearance is not correct:

Remov e the camshafts (page 8-21 .
Remove the \(8lve buckets and shims (page 8-6).
NOTE
00 not allow shims to fall into the crankcase.
Tlla shlmls) may Occasionally stick to the bucket.
Mark t he positions of all buckets and shims to ensure
correct reassembly.
It is easy to remove the valve bucket with 8 valve
lePDing tool or magnet .
Remove the shims with tweezers or a magnet .
~ Clean the valve buckets with compressed air.
III SHIM
Measure the shim thickness with a mir.rnmeter and record it.
NOTE
Si)(ty-five different shims Bre 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 fo llowing

formula:
• - (b-c)+d
III: new shim thickness
b : racorded valve clearance
c : specified v.lve c leaulIIl.:u UN: 0 . 1!5 mm EX : 0 .20 mml
d : old shim thickness
e.ample:
b : recorded valve claarance: 0 . 18 mm
d : old shim thickness: 1.850 mm
c: speCified valve clearance : 0 . 15 mm
a - 10.18 - O.1~1 + 1.850 1.BO mm 1.825 mm 1.85 mm 1.875 mm

• - 1 .880
now :shim thickne .. _ 1.876111111
NOTE
If the required thickness of the new shim is more than
2,800 mm , thc valve seat is probable IItluvily carboned.
Reface the seat, recheck valve clearance and reselect
the shim.
http://www.motorcycle.in.th . , '"7
MAINTENANCE
CARBURETOR SYNCHRONIZATION
•
NOTE
For detailed instuctions, refer to section 2 of the
Common Service Manuel. The information here only in-
dicates locations of the plugs for the adapters and the
synchronlzstlon adjusting screws .
Before inspection, remov e the f uel tank mounting bolts
•
(page 2-4) and move tho tonk rearward with the fuel
tube connected.
CARBURETOR VACUUM DIFFERENCE:

Within 30 mmHg (1.2 InHgl
flA!ie CARBURETOR : NO. 2 CARBURETOR
(1) SYNCHRON IZATION SCREWS

•
•
(4) No.1 (3) No.3 (2) No. 4
SCREW SCREW SCREW
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.
•
- Th'l '1"olne should stOp as the sida stand is lowered.
If there is a problem with the system, check the side stand
swit ch (Section 15).
Check the side stand switch mounting bolts for looseness. 121 SIDE STAND
3-8
4. LUBRICATION SYSTEM
SERVICE INFORMATION 4-1 OIL PUMP REMOVAUINSTALLATION 4-3
TROUBLESHOOTING 4-1 OIL PUMP DISASSEMBLY/ASSEMBLY 4-4
LUBRICATION SYSTEM DIAGRAM 4-2
SERVICE INFORMATION
Used engine oil lor transmission 011 In two-strok••) may cau •• skin cance, If repeatedly left In contact with the skin for
prolonged period,. Atthough this Is unlikely unl••• you handle used ofl on a dally basis, h I. Itill advluble to thoroughly
wash hands whh and water a. soon afte' used oil. KEEP OUT OF REACH OF CHILDREN .
• The oil pump can be serviced with the engine installed in the f rame.
• Replace the oil pump as an assembly .
• For oil pressure check, refer to sect ion 4 of the Common Service Manual; for the switch location, see page 17-2 of this
manual.
For oil pressur. warning light inspection. refer to section 25 of the Common Service Manual.
When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
• After the oil pump ho.! been installed, check. that ttum! are no 011 teak s and that oil pressure is correct.
TROUBLESHOOTING
Oil tevellow No oil pressure
Oil consumption Oil level too low
External oil leaks Oil pump drive chain or oil pump drive/driven sprocket
Worn piston ring or incorre ct piston ring installation Oil pump damaged (pump shaft)
WOIIl vidv", yultJl;I or sesl Internal oil leaks
Oil <;.ont.min.tign (White appoarance) all prellure werning light does not work well
From coolant mixing with oil • Refer to section 25 of the Common Service Manual
faulty water pump mechanical seal
- faulty cylinder head gasket
High all pressure

Pressure relief valve stuck closed
tit . Plugged uil fihl:H, gallery or metering ontlce

Incorrect oil being used
low oil pressure

Pressure relief valve stuck open
Oil pump worn or damaged
Internal oil leaks
Incorrect oil being used
l ow oil level
/I 1
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM
•
~rf.11==1lr.r1.__<1IEXHAUST
CAMSHAFT
•
J~~==~~~ ___,.'INTAKE
- CAMSHAFT
(3) PISTON
•
• ~~:;;;;I---(4) CONNECTING
!!I! ROD
"t'_-.-~(5) CRANKSHAFT
(6) Oil
PRESSURE
(14) OIL ORIFICE

SWITCH
•
(7) OIL ORIFICE
113) MA.IN"HA,FT -------l
(12) COIUN'-'R- ---~flIoI!l

SHAFT
• (111 OIL
FilTER
---.I.
OIL PUMP
(9) OIL STRAINER

I
11 0 ) Oil _~~E SS\J~

RELIEF VALVE
LUBRICATION SYSTEM
OIL PUMP REMOVAL/INSTALLATION

n. DRAIN
~
BOLT
35 13.5, 25)
(6)
C
15 (1.5,11)
• CLUTCH
OUTER ROIT in U .S . A .
(9 1· 1S)
REQUISITE SERVICE
Engine oil dreining (loc8tion: page 3-3, step : section 2 of the Common Service Ml:mu,!!)
Exhaust system removal/installation (page 2-31 • Clutch disassembly (page 9-41!assembIY (page 9-8)
PROCEDURE O'tv REMARKS

~!MOVAL ORDER • Installation is in the reverse order of removal.
111 Oil pan bolt 12 At installation, tighten the bolts in a gradual, crisscross
pattern .
(2) Oil pan 1
)3) Gasket 1
)4) Relief valve 1
IS) D-ring 1
• 161 011 strainer 1 Clean with the non-flammable solvent.

171 O-ring 1
)8) Oil pump driven sprocket bOIt~ 1 NOTE:
• Install the clutch outer onto the mainshaft temporarily
• )9) Washer 1
(page 9-t:ll . hold the flywheel with the rotor holder and
remove (or torque) the bolt.
o Apply a locking agent to the tip of the threads (approK .
6 mmfO.2 in)
( 10) 011 pump driven sprocket 1 At Installation, install with the grooves facing inside.
(111 Oil pump mounting bolt 2
(12) Oil ~UIl1P I
(13) Dowel pin 2
4-3
LUBRICATION SYSTEM
OIL PUMP DISASSEMBLY/ASSEMBLY
PUNCH MARK
14 1
GROOVE
•
I
I
I
I
I
I
I
(21
131
•
161
.'
• WATER
PUMP
SlOE
151
NOTe
Defore installing them, clean 811 removed P8rt5 thoroughly with clean engine oil.
Refer to section 4 of the Common Service Manual for inspection information.
R",fAr tn P"O'" 1 _R fn. "r~r.ifir:II'inn .
«
REQUISITE SERVICE
• Oil pump removal linstalil'ltion (page 4 -3\
PROCEDURE Q'ty REMARKS

DISASSEMBLY ORDER • Assembly is in the reverse order of disassembly .
•
111 Oil l1ump cover attaching screw 2 NOTE:
• Install the dowel pins , then tighten the screws.
121 Dowel pin . 2
13) Oil pump cover 1
14) Outer rotor 1 Install with its punch mark facing the cover.
151
16)
Inner rotor
Drive pin
1
1
Install the rotor, aligning its groove with the drive pin. «
17) PUIIIIJ !ilIH;dl 1 Install with the tab side fa cing the cover (water pump
,
side).
IBI Washer 1
19) Oil pump body 1
./I ./I
5. COOLING SYSTEM
SERVICE INFORMATION 6-' THERMOSTAT REMOVAU
TROUBLESHOOTING 5-1 INSTALLATION 5-4
SYSTEM FLOW PATTERN 5-2 RADIATOR REMOVAUINSTALLATION 5-5
COOLANT DRAINING 5-3
RADIATOR DISASSEMBLY' ASSEMBLY 5-8
WATER PUMP DISASSEMBLY'
RESERVE TANK REMOVAL'
INSTALLATION 5-3 ASSEMBLY 5-7
SERVICE INFORMATION
Wait until the englna is coof before slowly remoylng the radiator cap. Removing the cap while the angina is hot and the
~.nt Is under pre •• ur. may cause Hrious scalding.
Radlator coolant I. toxic . Keep it away from ay••• mouth. skin and clothe •.
- If any coolant gets In your ay ••• rin.. them with wat., and consult. doctor immediately .
- If a ny coolant I. s wallowed. Induce vomiting, gargla and consult II physician Immediately.
_ If any coolant gAU on your akin or r.loth(ls. rinM thoroughly with planty of watar.
KEEP OUT OF REACH OF CHILDREN
• Add coolant at the reserve tank . Do not remove the radiator cap except to refill or drain the system.
• All coolin ... system service can be done with the anginA In 1hA frtlme .
• 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 proce-
dUre is described.
• After servicing the system, check for leaks with a cooling system tester.
• flur fun motor switCh and thermo seMOr Inspections, refer to section 25 of the Common Service Manual; for the switch
and sensor locations, see page 17-2 of this manual.
TROUBLESHOOTING
Engine temperature too high Coolant leaks
Faulty temperature gauge or thermo sensor Faulty oil pump mechanical seal
Thermostat stuck closed Deteriorated O-ring
Faultv raoiator cap Faulty radiator c ap
• -_ Insufficient coolant Damaged cylinder gasket
PaoGago5 blocked in rodiotor, hoses or weter jacket loose hose connection 01 clamp
Air in system Damaged or deteriorated hoses
Faulty cooling fan motor
I Faulty fan motor switch
Faulty water pump
Engine temperature too low

Faulty temperature gauge or thermo sensor
Thermostat stuck open
I Foulty fon motor switch
COOLING SYSTEM
SYSTEM FLOW PATTERN
•
(3) RADIATOR
12, THIER"'IOS"rAT
•
(4) THERMO
(1) COOLING SIPHON

•
FAN TUBE
•
•
1'1 RA')lA"rCR
•
17, WAT'R
PUMP
,
COOLING SYSTEM
COOLANT DRAINING ( 1) RADI ATOR
NOTE
For coolant f9\Jil;lt:ument , refer to section 5 of the
Common Service M anual .
CAUTION
Wah until the engine Is cool before servicing the cool·
Ing system. Removing the radiato r c ap while the anglne
'Shot and the coolant Is under pr••• ure may cause • • ri-
ous scalding.
121 I
SEALING WASHER
To drain the coolant, remove the f ollowing:
- rut/I umk {page 2-4 1.
- heat rubber and radiator cap.
- wllter pump drain bolt and sealing w asher.
Remove the cylinder drain bolts and sealing washers end
•
drain the coolant completely from the syst em .
NOT
~E~______~__~__~~~~~____--,
• Calif ornia model has the only left drain bott.
SEALING
Place 8 suitable tray under the siphon t ube joint of the re-
serve tank and disconnect t he siphon tube f rom the reserve
tenk.
Drain the coolant from the reserve tank.
Install the water pump drain bolt and cylinder drain bolts with
new sealing wA",hers., and c;:onnect tho :liphon tube to the rQ-
serve tank .
•
RESERVE TANK REMOVAL!
INSTALLATION
111 BOLT (3) RESERVE
Drain the coolant from the reserve tank (see above).
TANK
ReMove the follOWIng :
- shock absorber (page 12-4).
- rC3erve tank: muullting bolt .
- collar and reserve tank.
Install the reserve tank in the reverse order of removal.
COOLING SYSTEM
THERMOSTAT REMOVAL/INSTALLATION
FRONT
HOLE~
t 17)
t - -_
15)
['\-::;/"9=--- MARK
Q~~ :----(3)
• MARK
REQUISITE SERVICE
Fuel tank removal/installation (page 2·4) Coolant refill (section 5 of the Common Service Manual)
Coolant dr~ill;'lij (page !)'3) Air cleaner t:ASA removal/installation (paRs 6 ·31

REMOVAL ORDER • Installation is in the reverse order of removal.
111 1hermostSt eover mountll1\:1 uull 2
(2) Siphon tube 1
(3) nadil!ltor h03C 2 Install them with "0" marks facing up.
14) Thermo sensor connector 1
•
16) ThflrmnstAt cover 1
16) O· ring 1
17)
16)
Thermostat
Thermo sensor
. 1
1
Install the thermostat with its hole side forwards .
At InStaliatioll, apply sealant to the threads.
10) ThermOlltl'lt housing 1
COOLING SYSTEM
RADIATOR REMOVAL/INSTALLATION
•
REQUISITE SERVICE
• Coolant draining !page 5-3) • Coolant refill (secti on 5 of the Common Service Manual)

REMOVAL ORDER • Installation is in t he reverse order of removal.
11) Radiator hose 2 Inst all them with "0" marks facing up.
•
IL.l t-an motor sWitch connector 1
13) Radiator lower mounting bolt 2
14) Redietor upper mounting bolt/nut 1/1
•
15) Fan motor connector 1
IR) Cnlhu 4
•
....................------------------
COOLING SYSTEM
RADIATOR DISASSEMBLY/ASSEMBLY
•
•
FAN MO"rOR
•
• J'IllIiIl!'" 18 (1 .8.13)
REQUISITE SERVICE
• Radiator removal/installation (page 5· 51

DISASSEMBLY ORDER • Assembly is in the reverse order of disassembly .
/11 Radiator shroud attaching screw 4
• (2)
(3)
(41
Left and right radiator shroud
Radiator grille
.
Fen motor shroud lTluul1liny bolVnut
2
1/2
At installation, align the grille tabs with the shroud
grooves .
At Installation, align four grille grooves with the radiator
lugs.
At installation, instoll the fan motor ground wire terminal
properly as shown.
(6 ) Fan motor mounting nut 3
(6) Fan motor 1 Install the fan motor , with the motor wireharness facing
down .
(7) Cooling fan 1 At installation, align the fan groove with the motor shaft.
(8) Fan motor s witr:n 1 At installation, apply sealant to the threads.
CAUTION :
• 00 not ove r-tighten the fan motor s w itch, or the radia-
tor may be damagod.
(9) O-ring 1
_a------------------------......... Honda CB400 / CB-1 Service Manual
COOLING SYSTEM
WATER PUMP DISASSEMBLY/ASSEMBLY
•
•
•
•
NOTE
• If the mechanical s8al is damaged. the water pump must be replaced as an assembly.
REQUISITE SERVICE
Coolant drtllnmg (page 5-3) Gearshift spindle joint removal/installation (page 9 -6 )

Engine oil draining (drain bolt location: page 3-3, step: Water pump side cover removal/installation (page 7- 21
Gcetion 2 of the Common S8'\li~w Manual)
Coolant refill (section 5 of the Common Service Manual)
•
DISASSEM8l Y ORDER • Assembly is in the reverse order of disassembly .
(1)
12)
Radiato r hose
Willer pump mounting bolt . 2
2 NOTE ~
• Before removing bolts, loosen the pump cover bolts{3 ,.
• 13)
14)
15)
16)
17)
Water pump cover bult
Water pump side cover stay
Water pump cover
O-ring
Water pump body
,,
2
,,
At installation, align the pump shaft slot with the oil
18) O· ring , pump shaft.
6. FUEL SYSTEM
SERVICE INFORMATION 6-1 CARBURETOR DISASSEMBLY/
ASSEMBLY 6-B
TROUBLESHOOTING 6-2
CARBURETOR COMBINATION 6-10
AIR CLEANER CASE REMOVAl!
INSTALLATION 6-3 FUEL PUMP/FILTER 6-13
CARBURETOR REMOVAL/ EMISSION CONTROL SYSTEMS
INSTALLATION 6·4 (California Model Only) 6-13
CARBURETOR SEPARATION 6·6
SERVICE INFORMATION
Gunline I, extremely flammable and Ie 8X.pioalvO under certeln condidon6. Work in a well ventilated .fea. Smoking or al-
lowing flame. or sparks in the work .re. or where gasoline Is stored can causa fir. or explosion.
Bending or twisting the control ClIble. will impair smooth operation _ could cause the cables to stick or bind. r.sultlng
~ L--Cln
~ lo~.~._o
~f_v
~.~h~lc
~I~
.~c~o~
n~ I .____________________________________________________________________J
t,~o~
CAUTION
To provont damago , be :SUf. to remove the di ...llIayms before cleaning air and fuel passages with compr....d air. Th.
diaphragms might be damaged.
NOTE
If vehicle is to be stored for m ore than one month , drain the float chambers. Fuel left in the flo at chambers may cause
clogged jets resulting in hard starting or poor driveability .
• When dis8sli9mbling fuel system ports, note the locations of the O-rings. Replace them with new ones on reassembly.
• Hatore removing the carburetors , place a suitable container under the carburetor drain tube, loosen the drain bolts and
drain the carburetors.
• After removiny lilt! l!arLJuH!tors, cover 1he intake port at the engine with a shop towel or cove t it with pieces of tape to pre-
vent any foreign material from dropping into the engine.
• The vacuum c:hamber and floot ohambcr con be serviced with the carLJurtltors assembled .
• Fo r fuel tank rem oval/installation, sea page 2-4 .
• California M odel Onlv :
All hoses used in the secondary air supply and evaporative em ission control systems are numbered for identification. When
~ connec ting one of these hoses, cQmpare the hose number with the Vacuum Hose Routing Diagram Label, page 1-29, and
carburetor tubes, page 6- 12 .
FU EL SYSTEM
TROUBLESHOOTING
Engine w on 't start l ean mixture
Fuel iets clogged
•
No fuel to carburetors
- fuel strainer clogged Float valve faulty
- fuel tube clogged Float level too low
- float velve stuck Fuel tine restricted
- float level misadjusted Carburetor air vent hole (or tube) clogged
- fuel tank cap breather hole clogged California Model Only: air vent control valve IAVeV)
- fuel pump malfunction faulty
Too much fuel getting to the engine
- air cleaner clogged
- flooded carburetors
Intake air leak
Fuel pump malfunction
Vacuum piston faulty
•
Intake air leak Throttle valve faulty
Fuel contaminated/deteriorated
Slow clreult or bystener circuit clogged Rich miAt urv
Ignition malfunction Bystarter valve in ON position
Float valve faulty
I
Engine stalls. hard to start. ro ugh Idling Float level too high
Fuel line restricted Air jets dogged
Ignition malfunction Air cleaner element contaminated
Fuel mixture too lean/rich Flooded carburetors
• Fuel contaminated/deteriorated
Intake air leak
Idle speed misadjusted
Fuel pump malfunction
Pilot screw misodjusted
Slow circuit or bystarter circuit clogged
Float level misadjusted
Fuel tank bre8ther tube dogged
Emission control system malfunction (California Model
Onlyl
- air vent control valve (AVCV) faulty
- purge control valve (peV) faulty
- loose. disconnected or deteriorated hoses of the
emission control system
Afterbum o n deceleration
Lean mixture in slow circuit
Only)
- secondary air supply system faulty
•
- loose. disconnected or deteriorated hoses of the
Backfiring or misfiring during acceleration

Ignition system faulty
• Fuel mixture too lean
Poor performance Idriveabilityl and poor fuel economy

Fuel system dogged
Ignition malfunction
Only)
- air vent control valve (AVCV) faulty
- loose, disconnected or deteriorated hoses of the
FUELSVSTEM
AIR CLEANER CASE REMOVAL/INSTALLATION
•
•
•
REQUISITE SERVICE
t . Fuel tenk removal/installation (page 2-4)
PROCEDURE U'ty REMARKS
AIR CLEANER CASE REMOVAL ORDER • Installation is in the reverse order of removal.
11) Main wire harness 1 Install it into the wire harness clamp of the csss cover.
12) Heat guard plate 1
13) Air el&IU'Ier case cover 1
14) Air cleaner element 1 Install it with the {t mark forwards and with the TOP
IIlIlIk facing up.
15) Air cleaner case bolt/collar 2/2
161 Crankcase breathflf fuhA 2
••
17) Air hose 1 Except California Model
(8) Air injection tube {No. 15' , 1 California Model Only
19, Air cleaner case 1 • Align the holes of the connecting tubes with the air jets.
• Install the spark plug wires as shown.
SUB AIR CLEANER CASE REMOVAL
ORDER • Installation is in the reverse order of removal.
(Except California Model)
1101 Attaching screw 1
111 ) Sub ail cit:l<II 1I;:II r.:<lSlI cover 1
1l2) Sub air cleaner element 1 NOTE :
• for element cle~ning , refer to ~\:Ir.:tion 2 (AIR CLEANER :
Oiled Urethane Foam Element) of the Common Service
. Mltnual.
113) Sub air cleaner case 1
. http://www.motorcycle.in.th
FUEL SYSTEM
CARBURETOR REMOVAL/INSTALLATION
17)
•
California Model Only
•
(
FUEL SYSTEM
Gasoline Is IIIIx"..m9Iy flammabl. and io oMplo31vo under carteln condftion5. Work In 8 well ventilated ara•. Smoking or al_
lowing flames or spa"'" In the work area or where ga.ollne is .tored can causa 8 fir. or explosion.
REQUISITE SERVICE
Fuel tank removal/ installation (page 2-4) • Carburetors draining

Air cleaner case removal/installation (paSJII 6-3)
PROCEDURE a'ty REMARKS
REMOVAL ORDER • Installation is in the reverse order of removaL

11)
12)
Insulator band
Choke cabl. ,
4 Only loosen the screws.
13)
14)
Throttle cable
t-uel tube ,,
2
15) No . 10 vacuum tube (from the AVCVl • California M odel Only

16)
17)
No.4 tUUt:1 Ifrom the AVCV and PCV)
Carburetors ,
2 California Model Only
18) Insulator 4 Each Insulator has the identification number as sho wn.
At installation, align the insulator groove with the engine
•
lug, with the 1} UP mark facing upwards Icarbttitor side).
••
http://www.motorcycle.in.th ". ...

FUEL SYSTEM
CARBURETOR SEPARATION
•
•
•
•
•
• I
,
,
FUEL SYSTEM
REQUISITE SERVICE
Fuel tank removal (page 2-4) Carburetor removal (page 6-4)

Air cleaner case removallpage 6·3) California Model Only : AVCV and PCV tubes removal from
carburetors

Sepa,ata Nn. ~/NO . 4 carbo from No. 1/
(1)
No.2 earb ..
Byst&rter arm shaft ,,
(2) Spring
(3)
(4)
Bystarter arm
CtlCkc coble holder
3
,,
(5) Rear bracket
16) Front bracket ,,
.
•
17) No . 3 carbo synchronization spring
181 Air joint pipe 13-way)IO-ring 112
19) Fuel joint pipe 13-way)/ O-ring 112
(10)
Sep.rata No .3 Club. from No. 4 car b ..
No.4 carbo synchronization spring ,,
,
•
(11 ) Thrust spring
(12) Air joint pipe (rubber)
(13) Air vent pipe/Doring 112
1141 Fuel joint pipe 12-way)/O-ring 112
,,,
Separate No.1 carb o from No. 2 carb ..
(15) AVCV and PCV 8S an assembly California Model Only
(161 No. 1 corb . synchronization spring
1"171
(1 B)
Thrust spring
Air joint pipe (rubber) ,
(1 DI Air vent pipe/ O-lillg 112
(201 Fuel jOint pipe (2-wayI /O-ring 1/2
•
•
FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY
I
111
DOWEL
PIN
SIDE
" 12)
I
•
(3)
• (4)
19) ---__<
(15)
) ~'9
) ~~'8)
~
( 17 )
.t(' (16)
• " ""--
o &
•
\
(1 3)
114)
ALIGN
~ ( 10)
R-R
FUEL SYSTEM
NOTE
The vacuum chamber and ftnl'lt chamber can be serviced with the carburetors lI5sembled.
The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled. Turn each pilot
screw in and carefully count the number of turns before it seats lightly. Mske a note of this to use 8S 8 reference when
reinstalling the pilot screws. If new pilot screws are installed, turn pilot screws out to the initial opening (page 1-6),
REQUISITE SERVICE
Fuel tank removal/ inst ellation (page 2-41 Carburetor separation (page 6-61/combination (page 6 - 10)
Air cleaner case removaltinstaliation (page 6-3) Carburetor synchronization (page 3 -81
CarlJurator rem oval/Installation (page 6-4)
PROC[DURE O'tv REMARKS

DISASSEMBLY ORDER • Assembly is in the re .... rse order of disassembly.
• (11
(21
(~)
141
(51
V acuum Chamber
Vacuum chamber co.... r screws
Vacuum chamber co ... er

Srrlno
Diaphragm/...acuum piston
Jat needle holder
. 4
,,
,,
At installation, first tighten the two screws on the dowel
pin side.
Turn the holder 90 0 counterclockwise while pushing it In
• 161
171
(61
101
Spring
Spring holder
Jet needle
W •• h.r
Float Chamber
,,
,,
and remo ...e it .
At installation, align holder claws with piston groo...es.
(10) float chamber eo.... r screws 4 At installation, first tighten the two screws on the dowel
Ill) Float pin , pin side.

NOTE:
• For remo ...al of the No. 1 (or No.3) carburetor float pin
with the carburetors assemlJl\!d, first remo.... e the No.2
(12) Float , (or No.4) carburetor float chamber.

For float le ...el in!;ipection, ref.r to the section B of the
,,
Common Ser...ice Manual .
(13) Float ...al ....
(14) Vat ... \! ~I;HJt
(15)
(16)
Sealing washer
Fuel filer ,1
(17)
1181
Main jet
Needle jet ,,
1
•
(19) Slow jet
.
(20)
By.tartar Val ...e
Val ...e nut ,,
~ (21)
(221
Spring
Bystarter ... al ... e ,
(23)
Pi~t Screw
Pilot screw , Caneda model : No.1 end No. 4 carburetor pilot screws
are shorter thAn those for No.2 and No.3.
1241
(25)
Spring
Washer ,
t
120) O-ring t
Co O
FUEL SYSTEM
CARBURETOR COMBINATION
•
•
(14)
•
•
I
(20) 0-
I I
• I
6-10
FUEL SYSTEM
REQUISIT E SERVICE
• Carburetor assembly (page 6-BI

A ...m ble No. 1 cerb. w ith No.2 carb .. Nn. 1 carburetor is the base carburetor.
(1 Fuel joint pipe 12-way)/O-ring 112
:~:
Air vent pipe /3 -way)/O-ring 112
Air jomt pipe (rubber) 1
:::
(61
Thrust spring
No . 1 carb o synchronization spring
Front bracket
1
1
1
:~:
Front br81':kAt screw
Fuel joint pipe 13-wayI/ O-ring
•
112
The shorter. Do nut tighten screws yet.
Onto the No.2 carburetor.
191 AI, joint pip. 112 Onto the No.2 carburetor.
A ssemble No. 3 carbo w ith No. 4 carb .. •
(10) Fuel joint pipe 12-wayj/ O-ring 112
(11) Air vent pipe 13-weyI/O-ring 112
(12) Air joint pipe (rubber) 1
(131 Thrust spring 1
(14) No.4 carbo synchronization spring 1
(Hi) FlUnt bracket screw 2 T he shorter. Do not tighten screws yet. Do not install
two screws of the front t cable holder yet.
A ...m ble No. 1 /No. 2 carb o w h:h No. 3/

No. 4 carb .•
nO) No . 3 corb o synchroniution ,,~rirIY I
(17) Rear bracket 1
1181 Rear brackRt Jlr.rew B Tighten them.
(19) Front bracket screw 6 Tighten them.
(20) Choke cable holder 1 U!IIa two longer front bracket screws.
121 ) Bystarter arm 3
(22) Spring 1
1231 Bystertar arm shaft 1 •
I:~::
AVCV and PCV as an assembly 1 Callifornia Model Only
AVCV ond rev tubo , Mod.1 Only, p.g. 6-1 2
•
I
c: 1 1
FUEL SYSTEM
CALIFORNIA MODEL ONLY:

AVCV AND PCV TUBES ROUTING
,
(2) No. 1
(3) No.2
(4) No . 3
(5) No.4
,
(lINo. S
TUBE
I
\ll __~(;/:?rbl TUBES
\. NO.5
• No. 6 TIIRES
(13) No. 6
(14) AVr.V TUBES
. (15) No. 6 TU~I::S (16) No . 5 TUBES

(8) No.5
TUBES
•
(19) AVCV I1B) PCV (17) No . 10 TUBE
FUEL SYSTEM
FUEL PUMP/FILTER
Turn the fuel vslve OFF.
Remove the reaf· left side cover (page 2-31.
Remov", Ih~ 'utll pump and 1uel tllter to the left.
Install the fue l filter and pump in the reverse order of removal.
NOTE
• Fuel lilhill ulil:lll(Ylilm 1:11' shown .
•
EMISSION CONTROL SYSTEMS (2) PCV
(California Model Only) (1) AVCV
EVAPORATIVE EMISSION CONTROL SYSTEM
PURGE CONTROL VALVE fPCV) AND AIR VENT CONTROL

VAlVEfAVCV)nCMOVAl
Remove the fnllnwino :

- fuel tank (page 2-4 )
• - air cleaner case (page 6-3)
- carburetors (page 6·4)
(4) SET PLATE (3) TUBES
Disconnect tho tubes trom I-'t:V and AVCV, and remove the
set plate from the No. 1 carburetor float chamber cover .
Remove the PeV and AVCV .
Inspect the PCV ",ntt A VCV (refer to netian 7 of the

Common Service Manual) .
Install the PCV and AVCV in the reverse order of removal.
NOTE
• For PCV and AVCV tubes routing, see previous p8j:l8.
FUEL SYSTEM
SECONDARY AIR SUPPLY SYSTEM
NOTE
I· The ASV hes reed val .... es built Into the A ICV.
Remove the fuel tank (page 2·4).

Disconnect the air Injection tube (No. 15 tubel from the air . - _ -- - -). (1) No. 15 TUBE
l:leaner ease. ~--tL'--- uuumm,
Disconnect the vacuum tube (No. 10 tube) from the ASV.
Install the plug onto the No. 1 0 vacuum tube and connect the
··I"2,··P,:sv······!j
vacuum pump to the ASV. ~
Perform the secondary air supply system (refer to section 7
of the Common Service Manuall .
SPECIFIED VACUUM : 360 mmHg 11 4.2 1nHgl
AIR SUCTION V A LVE (ASVI REMOVAL
•
Remove two bolts and air suction valve 8S an assembly.
Disconnect the follo w ing from the ASV .
- No. 10 vacuum tube . (5 ) VACUUM
- No. , 5 air injection tube . PUMP
- air supply hoses .
Remove bolts, air injection pipes and gaskets.
Remove the reed valve covyn ••mu II:II;I\J valv@s.
In3toll tho air auotion valve in the reverae order of removal.
( 1) No . 15 TUBE (2) GASKET
g
(9) REED VALVE
7. ENGINE REMOVAL/INSTALLATION
• SERVICE INFORMATION
SERVICE INFORMATION
7·' ENGINE REMOVAU INSTALLATION 7·2
~ • A floor jack or other adjustable support is required to support end maneuver the engine.
CAUTIO N
• Do not Jack up the motorcycle using the oil filter .
•
• The following components can be serviced with the engine installed in the frame:
~ alternator (Section 14)
- camshaft (Section B)
- carburetors (Section 6)
- clutch (Sectiun 9)
- gearshift linkage (Section 9)
• -
-
-
oil pump (Section 41
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 (Section 10)
- crankshaft (Section 10)
- r.ytin~e' (Section 6)
- c ylinder head (Section 8 )
- piston (Section 8)
- transmission (Section 10)
•
•
"7 ..
ENGINE REMOVAL/INSTALLATION
ENGINE REMOV AL/lNSl ALLA liON
4014 .0,291
A 'U 50 (5.0, 36) •
0 65 (6 . 5, 47)
•
0 1511 .5 ,11)
(21 )
I
•
(27)
40 (4 .0, 29)
SPROCKET
0 40
• SPEEDO-
. 291
SP EDOMETER
GEAR BOX JOINT
METER
CABLE
- Honda CB400 / CB-1 Service Manual
ENGINE REMOVAL/INSTALLATION
NOTE
• Turn the ignition switch orr and divcullllln:t lhld bllttllry ground I I cable.
CAUTION
• Do not jack up the motorcycle using the oil filter.
REQUISITE SERVICE
E)(haust system removal/ installation (page 2-3) Engine oil draining (location; page 3 -3 , step: section 2 of
FUI:l1 lank ramovai/installation (page 2-41 the Common Service Manual)
Air cleaner case removal /installation (page 6-3) Remove the radiator lower mounting bolts and loosen the
Carburetol f8'1'10VIII/in!:ltullatlon (I)&go 6 -41 upper mounting boltlnut (page 5·5). Swing the radistor
Coolant draining (page 5-3) forward.
Coolant refill (section 5 of the Common Service Manual)
REMOVAL ORDER • Installation is in the re verse order of removal .

111 Spork plug cep 4
,21 Pulse generator 2P mini (blue) connector 1
• 131 Alt!!rn~tor 3P (black) connector

141 Neutral switch/oil pressure switch 2P mini
,51
161
171
(bl~ck) connector
Starter motor cable
Engine ground cable
WAter hose Jomt/U-rlng
1
1
1
1
2/2
On the starter motor
181 Clutch cable 1

101 Geor5hih 5pindle joint 1 At Insta1lation. align the punch marks on the joint and
spindle.
11m Water pump !lirlA r.nwtr 1
( 11) Speedometer cable 1
(12) Drive sprocket cover 1 CAUTION:
• Make sure the drive sprocket bolt Is aligned with the
speedometer gasr box joint securely as shown .
(13) Urlve cham guide 1
(14)
(1 5 )
Dowel pin
Weter ho.,e
2
,
(16) Drive sprocket bolt 1 NOTE:
- Hold the motorcycle on its side stand and shift the
transmission in 6th gear. With the brake pedal applied,
remove (m install) the drive sprocket bolt.
•
~
(17)
(18)
Washer
Drive sprocket
(Un I::ngme mount bolt (rear/ lower)
(20) Adjusting bolt lock nut
(21) Adjusting bolt
(22 ) Special washer
1
1
1
1
I
1
Loosen the drive chain.
With its tab fac ing down .

(n) FnOin", mount bolt (Front)! washer 2/2
(24) Engine sub frame bolt 4
(25) Engine sub hame 1
(26) Engine bracket bolt 2 Only remove the lefUlower and right/lower bolts .
(27) Bolt cap 2
(21:1) Engine mount bolt (rear/upper)!collar 1/1 In stall the collar on the left side.
(29) Engine assemblv 1 Move the engine out of the frame to the leh.
CAUTION:
• Carefully align mounting points with the jack to prevent
damage to mounting bolt threads. wire harness and ca -
bles.
8. CYLINDER HEAD/CYLINDER/PISTON
SERVICE INFORMATION B-1 CYLINDER HEAD DISASSEMBLY/
ASSEMBLY 8-6
TROUBLESHOOTING B-1
CYLINDER/ PISTON REMOVAU
CAMSHAFT REMOV A U INSTALLATION 8-2
INSTALLATION 8-8
CYLINDER HEAD REMOVAU
INSTALLATION 8-4
SERVICE INFORMATION
•
• Camshaft service can be done with the engine in the frame.
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cyl-
inder head . Fill the cylinder head oil pockets with the clean engine oil of the proper type and viscosity.
• Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspec-
tion.
• Hetor!!! reassembly, lubricate the camshaft journals and cam lobes with a molybdenum oil solution.
• Wk8n dhuissemblino, mark and store the disassembled parts to ensure th.t they are reinstalled in their proper locations.
• • Be cereful not to damage the mating surfaces by using a screwdriver when removing the cylinder. Do not strike the cylin·
der too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder
fins .
• Take care not to damage the cylinder walls and pistons .
• Store the valve and piston components in the same order they were installed so they can be reinstalled in the original posi-
t ions .
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down test, or
by tracinQ noises in the top-end with a sounding rod or stethoscope.
If performance Is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokey, check for
seized piston rings .
NOTE
• For cylinder compression and leak-down test procedures, refer to section 3 of the Common Service Manual.
Rough Idle Excessive smoke

Worn valve stem or valve guide
•
• Low cylinder compression
Damaged stem seal
Low compression , Worn cylinder, piston or piston rings
•
Incorrec t valve shim adjustment (page 3-5) Improper installation of piston rings
Burned or bent valves Scored or scratched piston or cylinder wall
IIlCOllect valva til11illij
Broken valve spring Excessive noise
Uneven valve slilatin" Incorrect valve shim adjustment (page 3·5 )
leaking or damaged head gasket Sticking valve or broken valve spring
Warped or cracked cylinder head Damaged or worn cemsheft
loose spark plug Damaged camshaft drive gear
Worn , stuck or broken piston rings
Worn or damaged cylinder and piston Abnormal noise (plstonl
Worn cylinder and piston
CUlllpnnndun too high Worn piStOn pin or piston pin hole
Exce ssive carbon build-up on piston top or combustion Worn connecting rod big end bearing
chamber
8 -1
CYLINDER HEAD/CYLINDER/ PISTON
CAMSHAFT REMOVAL/INSTALLATION
(1)
(.,
"" .J ---;7D
~' II
•
P'"
REQUISITE SERVICE
• 91
Fuel tank removal /installation (page 2-4) Remove the radiator lower mounting bolts and loosen the
Air cleaner case removal/installation (page 6-3) upper mounting boltlnut (page 5-5). Swing the radiator
forward.
PROCEDURE O'ty REMARKS
•
REMOVAL ORDFR • InstallatiQn is in the reverse order of removal.
111 Heat guard plate 1
12, Cylinder head cover bolt . • At installation, tighten the bolts in a gradual , crisscross
pattern.
(31 Washer
• Install them with the " UP" mark facing up.
,5,
(41 Cylinder head cover
Gasket
1
1
Install with the
NOTE:
" ¢:>" mark forward .
• Apply Thl ge Bond 1 521 or equivalent to the head cover

and install the gasket onto the cover with tab s facing
forward.
,61 Camshaft holder bolt 16 NOTE:
• Before removing bolts, turn the flywheel clockwise and
insert suitable pins into the cam gear holes to ease the
installation of camshaft serrated gears. Take care not to
drop pins into the crankcase and that the pins do not In·
terlere with the cylinder head .
(.,
17' Camshaft holder
( A)
Dowel pin
Fxhl'lll!it (EXt camshl'lft
4
B
Camshaft installation (page 8 ·3)
1
(10) Intake (IN) camshaft 1
CL?
CYLINOER HEAD/CYLINDER/PISTON
CAMSHAFT INSTALLATION

- c rankshaft hole cap cover (pagB 9-2).
121 EXHAUST
- c rankshaft hole cap (page 9 -21. III INTAKE CAMSHAFT
- timing mark hole cap (page 9-21. CAMSHAFT
Rotate the crankshaft clockwise and align the flywheel "TOO

mark (Yellow colored line) witll tln:t cover Index mark.
lubricate the camshaft journals and cam lobes with 8 molyb·
denum oil sohlriQn,
:lI
lay the EX marked (Exhaust) camshaft onto the cylinder (3) "EX"
MARK
head with EX mark line 85 shown and lay the IN marked (In·
tak e) camshaft with IN mark line 8S shown.
( LINE
In this pOSition, the No.4 piston is at TOe on the compres-
~ion stroke .
(5) T MARK
(Yellow colored
•
Install the dowel pins onto the camshaft holders and install 111 PINS
the camshaft holders in their original positions.
NOTE
Each holder has identification marks.
EXL: Ellhaust camshaft- EXR: Exhaust camshaft-
L~h Hight
INL: Intake camshaft- INR: Intake camshaft-
•
I.eft night
BOLT
Tighten the c81llsll<lh huillar bOlts In a gradual, Crisscross
DC'W'~P~'~N~S-~
•
pattern . (31
TORQUE: 12 N·m 11 .2 kg -m, 9 ft-Ib)
Turn the crankshaft counterclockwise so 8S not to interfere
•
the camshaft serrated gear holder pins with the cylinder
h.~d, Removu tho holder pins from each carnsh.,U gear .
NOTE
• Take care not to drop the pins into the crankcase.
Recheck the valve timing.
Honda CB400 / CB-1 Service Manual a
CYLINDER HEAD/CYLINDER/PISTON
CYLINDER HEAD REMOVAL/INSTALLATION

0 30 (3.0, 22)
111
c
0 '21,.2,91
CC
" " · ...-". 0

•
REQUISITE SERVICE
• • Engine removal / installation (page 7-2)
111
REMOVAL ORDER
PROCEDURE
Cylinder head special nut

Q'ty
12,
• Camshaft removal/ installation (page 8-2)
Installation (page a-51

REMARKS
• Installation is in the reverse order of removal.
121 Cylinder head mounting bolt 2~
131 Cylinder head assembly 1

141 Gasket 1 Install with the UP mark facing up and rearward.
15) Dowel pin 2
161 Camshaft idle gear case bolt 5
17) C:mmtlllft idle gear ease dowel pin 2 t- Installation (page 8-5)
18) Sealing washer 1-
Camshaft idle gear 0860
1_
191
(10) Carburetor insulator 4 At installation, align the insulator groove with the engine
lug, with the ft UP mark facing upwards (carburetor side).
CAMSHAFT IDLE GEAR CASE INSTALLATION ( 1) IDLE (4) INCORRECT

Install the camshaft idle gear case dowel pins properly . GEAR "-:0\"0,,-
CASE ""
NOTE ~
Wit ....out the dowe' pins instaUed properly, the camshaft
Idle gear may not be able to be installed onto the crank· {}
(5 CORRECT
shaft timing gsar.
Install the camshHft kll", !Jesf case onto the cylinder. (2) DOWEL
M
While moving the idle gear lightly with the gear case held , the PI N S """,""
gesr casa should be lifted up slightly from the cylinder. (3) TIMING
GEAR
•
Install 8 new sealing washer and mounting bolts. Tighten
bolts in a gradual. 88 shown .
•
CYLIN DER HEA D NUT/BOLT INSTALLATION (1) SPECIAL NUT
Install the cylmder head speCial nuts 8S shown .

00 not tighten them yet.
•
Install the cylinder head mounting bolts.
Tiyhll:lll llll;! ~lJtH.:lal I1Ut~ and mounting bolts In a gradual,
crisscross pattern .
TORQUE:
Special nut : 30 N·m (3.0 kg-m. 22 ft-Ibl
Mounting bolt: 12 N·m (1.2 kg·m. 9 ft·lb)
•
CYLINDER HEAD DISASSEMBLY/ASSEMBLY

HAND·
,-(2)
LAPPING
TOOL
&-(071
~ (3) [~ ;oo..l(page B·7)
16,:-. -(71 _
..
~ (5)
(4)
@
, !""......,g'l -
[lfOot. ! (page 1-71
• DOWN
(61
NOTE
Store the valve components in the same order they were installed so they can be reinstalled in the original positions.
• Refer to section 9 of the Common Service MantlAl for VAlvA Ollirte in.spectionJreplacement.
REOU ISIT E SERVICE
Engine removal/installation (paQe 7· 2) • Cylinder head removal/in!ltRIIRtion (page 8 ·4)

Camshaft removal/installation (pege 8· 2)
• (1) Valve bucket

PROCEDURE
DISASSEMBLY ORDER
Q'tv
16 NOTE:
REMARKS
• Assembly is in the reverse order of disassembly.
• Remove usin!:! a handlapping tool. Do not damage the

cylinder head ·bucket sliding surface.
(21 Valve shim 16
(31 Valve cotttlr 32 Removal/Installation (page 8· 7)
(41 Retainer 16
(61
(6)
(7)
(8)
Vulvc :Jprlng
Valve
Stem seal
Spring seat
,.,.
10
16
Install thtlnl with the narrow pitCh end facing down.
(91 Valve guide 16 Be sure to duplicate the proper valve guide installed
length (page 1-7)
VALVE COTTERS REMOVAL/INSTALLATION
Remove the valve buckets and shims.

Insu.lI lhe cylinder r.ead protector into the cylinder head·
bucket sliding surface.
VALVE BUCKET HOLE

PROTECTOR 07JMG-KY20100
(11 vALV e BUCKET HOLE PROTECTOR
Il1l;1tall t"e VAl ve spring compressor onto the valve and com-
press the valve spring . (1) An"ACHMI'NT
Romove {or install! the va lv~ cotters .
VALVE SPRING COMPRESSOR

ATTACHMENT 07JME- KY20100
4tYAlVE SPRING COMPRESSOR 07767-0010000
http://www.motorcycle.in.th 8-7
CYLINDER/PISTON REMOVAL/INST ALLATION
C10
11. 0,71
NOTE
• Refer to section 'Oaf the Common Service Manual tnr pi!lltnn ~nd piston ring inspection.
J REQUISITE SERVICE
Engine removal /installation (page 7-2) • Cylinder haHn removal /installation (page 8-4)
Camshaft removal/installation (page 8· 2)
•
PHOCEDURE Q 'ty REMARKS
(1 ) Water joint bolt 3
(7) Water joint 1
(3) O-flng 1
(4) Cylinder mounting bolt 1
•
(5) Cylinder 1
(6) Gasket 1 Install with the UP mark facing up and forward.
(7) Dowel pin 2
(8) Piston pin clip 8
(9) Piston pin 4
(10) Piston 4 Install them with the IN mark facing t o the intake side .
• :I
(11 ) Piston top ring • Install the top and second rings with the markings
(12) Piston second ring facing up.
1131 Piston all ring set ('ide rails and spacer) • Space the ring end gaps 120 0 apart.
• Space the side rail gaps 20 mm (0.8 in) or more apart.
•
••
•
•
9. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 9-1 CLUTCH REMOVAL 9-4
TROUBLESHOOTING 9-1 GEARSHIFT LINKAGE REMOVAU
INSTALLATION 9-6
RIGHT CRANKCASE COVER REMOVAL'
INSTALLATION 9-2 CLUTCH INSTALLATION 9-8
• Clutch and gearshift linkage maintenance can be done with t he engine in the f rame.
• Engine oil viscosity and level have an effect o n clutch operation. When the clutch does not disengage or the vehicle creeps
with clutch disengaged, inspect the engine oil and oil level before servicing t he clutch system.
• Clean any gasket off the crankcase cover·'crankcase mating surface.
• 00 not damage the cover-cese mating surface.
• Never allow foreign materials to get into the engine.
• If tho 3hift forks. drum end transmi5$ion Is quill;' 1>l:Ilvicing, remove t he engine and separat e the crankcase (Section 10).
• If it is no longer clear which bolt belongs in which hole, insert all bolts in the holes and check the exposed length; each
• should be elCpn!lAri 'hI'! !l;IIme ~mount.
TROUBLESHOOTING
Clutc h lever tOO M rd Hard to shift
Damaged, kinked or dirty clutch cable Misadjusted clutch cable
Improporly routcd clutch cable Dam aged or bent shift fork
•
Damaged clutch lifter mechanism Bent shift fork shaft
Faulty clutch lifter pllltA hAArino Worn gear dogs
Incorrect engine oil viscosity
Clutch will not disengage or motorc ycle creeps w ith c lutch Incorrect gearshift linkage guidl'! plate installation
d isengaged
Too much clutch lever free play Jumps out of ge8r
Warl)M I)ltl t elsl Damaged or bent shift fo rk
Oil level too high, improper oil viscosity or oil additive Bent shift fork shaft
uGod Damaged stopper arm
Worn gear engagement dogs or slots
Clutch slips Damaged shift drum cem groov8s
Clutch lifter sticking
Worn clutch discs
• Weak clutch springs

No clutch lever free play
•
•
0 "
CLUTCHIGEARSHIFT LINKAGE
RIGHT CRANKCASE COVER REMOVAL/INSTALLATION

,
• . , ,.".- -1/
C
v-.:::::.....,; 41
10 !1.0, 7)
. , 1101
C
1 (0.7, 5) ~'-'~(
''''----e
•
CLUTCH/GEARSHIFT LINKAGE
REQUISITE SERVICE
• Engine oil draining (drain bolt location: page 3-3, step : section 2 of the Common Service Manual)
PROCEDURE Q'tv REMARKS
REMOVAL ORDER • Installation is in the reverse order of removlIl.

fl) Clutch cable I
f2) Alternator wire connector I
f3) Flight crankcase cover bolt NOTE:
" • At installation, applV 8 locking agent 10 the two bolt
threads.
f') Right crankcase cover I Disconnect (or connect) the Alternator 3P connector .
f5) Ga8ket I
f5) Dowel pin 2
f7) Clutch lifter pin 1
fB) Return spring • 1
f9) Spring pin I NOTE:
• Drive in a new spring pin using 8 pin driver until the pin
does not interfere with the lifter arm 85 shown.
(101 Clutch lifter arm I
•
( 11) Oil seal I
1121 Crankshaft hole cap cover I
Crankshaft hole cap/O-ring
(13)
fl4) Timing mark hole cap/O-ring '"
'"
•
•
0 ':)
CLUTCH REMOVAL
•
REQUISITE SERVICE
• Right crankcase cover removal (page 9-2)
(11 Cll.ltch lifter plilt" bolt 4 Remove them in a gradual, crisscross pattern.
(21 Clutch lifter plate 1
(31 Clutch lifter plate bearing 1
(41 Clutch spring 4
(51 Clutch center lock nut 1 Removal (page 9-5)
(61 lock washar 1
- Refer to page 1- 10 for specification.
•
(71 Clutch assembly
(8, - clutch center 1
(91
(WI
-
-
spring seat
Judder sprmg
. 1
1
(11 ) - clutch friction disc C 1 Larger I.D. disc/ Color: black
(12) - dutch plate B 1 Color: gray
(13) - clutch frictin disc B 4 Smaller LD . disc
(14) - dutr:h plAtA A 4 Color: silver
(15) - clutch friction disc A 1 Smaller I.D. disc/Color: black
(16) - pressure plate 1 Refer to section 11 of the Common Service Manual for
inspection information.
(17) Oil pump driven sprocket 1 Removal (page 4 -3)
(18) Clutch outer 1 NOTE :
• Turn the crankshaft clockwise and face the flywheel
"T" mark up so as not to interfere the primary driven
gear with the crank weight .
• Du not still remove the needle bearing and outer guide.
(19) Needle bearing 1
(20) Oi) pump drive liproc;:ket/d rive c;:hain 1/1
(2 1 ) Clutch outer guide 1
• Honda CB400 / CB-1 Service Manual
CLUTCH CENTER LOCK NUT REMOVAL

111 CLUTCH
CENTE R
If you have the universal type of the clutch center holder. you
wilt be able to use it.
Unstake the nut.

Set the clutch center holder to the pressure plate bosses and
loosely install the nuts .
CLUTCH CENTER HOLDER 07HGB-001000A

(U.S .A . only) CLUTCH
LIFTER
PLATE BOLTS
Temporarily remove the 1001 and tighten nuts; then reinstall
the clutch center holder ontn the oosses. Use at least two
clutch lifter plate bolts to secure the tool to t~e clutch.
Hold the c lutch center holder and remo ve the lock nut as
shown .
•
If you do not have the above holder, use the below holder.
111 CLUTCH CENTER
Unstake the nut.
Remove the clutch center lock nut as shown.
CLUTCH CENTER HOLDER 07GMB - KT80100

(Nut avallubls In U.S.A.)
GEARSHIFT LINKAGE REMOVAL/INSTALLATION
ALIGN
GUIDE PLATE/ DRUM SHIFTER

ASSEMBLY
NOTE
• Make sure the gearshift linkage can be operated properly after assembly .
REQUISITE SERVICE
• Right crankcase cover remo val/installation (page 9· 2) • Clutch removalfinstallation (page 9 -4 , 9-8)
PAOCEOURE O'ty REMARKS

REMOVAL ORDER • Installation Is In the reverse ordar of removeL
(11 Gearshift spindle joint bolt 1
(21 Gearshift s pindle joint 1 At installation, align the punch marks on the joint end
spindle.
(31 Gearshift spindle 1
(41 Spindle return sDrlng 1
(51 Washer . 1
(61 Shifter collar 1
171 Guide plate mounting bolt 2
(01 Guide plete/dlulli !!.ilill",. olil>l:ITIIUly - Assembly : as Illustrated
(91 - guide plsts 1 InstaU onto dowel pins properly, or shift to hard .
• (10)
(111
(12)
(13)
(14)
11 bl
- ratchet pawl
- plunger
- spring
- drum shifter
Collar
Dowel pin
2
2
2
1
1
1
Pawl orientetion as ahown .
1161 Stopper arm spring 1

(17) Spring collar 1
(18) Stopper arm 1
119) Washer 1
(20) Shift drum center bolt 1 At installation, torque after applying a locking agent to
bolt thl tlinJI>.
(21 ) Shift drum center 1 At installation, align the drum center groove with the
dowel pin .
122) Dowel pin 1
•
•
CLUTCH INSTALLATION
0 15 .5, 11)
•
1151_ ";
(221 ~23)
,~
_.----------------------.............. Honda CB400 / CB-1 Service Manual
REQUISITE SERVICE
• Gearshift linkage installation (page 9-6) • Right crankcase cover installation (page 9-21

{ll Clutch outer gUide 1
{2) Oil pump drive sprocket/drive chain 111
(J) Oil pump driven 3pro<:ket 1 At installation, install with the grooves facing inside.
{O) Washer 1
16) Oil pump drive spmckMI bolt 1 Apply a locking agent to the threads . Installation (pag8
4·3).
16) Needle bearing 1
17) Clutch outer 1 Installation (see below)
{el Clutch assembly -
(10)
{SI - pressure plate
- clutch friction disc A
. 1
1 Smaller 1.0 . disc/ Color : black
(11) - clutch plst8 A 0 Color: silver
(12) - clutch friction disc B 0 Smaller 1.0. disc
(13) - clulch plate B 1 Color: gray
(14) - clutch friction disc C 1 larger 1.0 . disc/ Color: black
•
115) - judder spring 1 Faee the dished side of the judder spring to the outside.
(161 - spring seat 1
1171 - eluteh center 1
(181 Lock washer 1 With the OUTSIDE mark facing up.
(19) Clutch center Inck no I' 1 In5tlllliltion (paya 9 - 10)
(20) Clutch spring 0
(21) Clutch lifter plate 1
122) Clutch lifter plate bearing 1 Install it with the marked side facing out.
Clutch lifter plate bolt 0 Install them in a gradual. cri sscross pattern.
•
(23)
CLUTCH OUTER INSTALLATION

( 1) CLUTCH
Turn tne crankshaft clockwise and face the flywheel " T "
mark UP so that the primary "riven oear doeli not interfere
willi lila L:IClI1k weight.
Align the nrratod tooth of the primary dlivI:1I1 yI:I IH with the
~~~::;:IUP
drive gear teeth , as shown, and temporarily install the clutch
outer onto the mainshaft.
~
•
T MARK
While holding the clutch outer and pushing in on it lightly,

!OtClte the 011 I)ump driven sprocket bolt. (1) CLUTCH OUTER
Install the clutch outer properly , aligning the clutch outer HOLE
holes with thc oil pump drive sprocket iJUIUUIS.
CLUTCH CENTER LOCK NUT INSTALLATION (11 CLUTCH

CENTER
If you have the universal type of the clutch center holder. you
will be able to use it .
Position the tools as shown and use at leest two clutch lifter
plate bolts to secure the tool to the clutch.
CLUTCH CENTER HOLDER 0 7 HGB - 001 000A

(U.S.A. only)
Hold the clutch center holder end torque the clutch center
lock nut 8S shown .
TORQUE: 85 N·m {S.6 kg·m. 6 1 ft-Ibl
• Stake the lock nut onto the mains haft .
If you do not have the above holder. use the below holder.
(1) CLUTCH
•
Hold the clutch center as shown and torque the clutch center
CENTER
IOt k nut .
HqL.~.E!! /'
I- ;:"." I
CLUTCH CENTER HOLDER 07GMB-KT80100
INot .vailable in U.S.A.I
TORQUE: 85 N·m IS.5 kg·m. 61 ft-Ibl
e Stake the lock nut onto the mains~8ft .
10. CRANKSHAFT/TRANSMISSION
SERVICE INFORMATION 10-1 TRANSMISSION REMOVAL/
INSTALLATION 10-B
TROUBLESHOOTING 10-1
TRANSMISSION DISASSEMBLY/
CRANKCASE SEPARATION 10-2
ASSEMBLY 10-10
CRANKSHAFT/CONNECTING ROD
REMOVAUINSTALLATION
CRANKCASE INSTALLATION 10-12
10-4
CRANKSHAFT BEARING
REPLACEMENT 10-6
SERVICE INFORMATION
• Remove the engine and separate the crankcase to inspect the crankshaft , connecting rod and transmission.
• S.rvic. p..,in\$
Service Item Removed Components

~ ~-c-o-n-n-.-ct-i-ng~'O~d~~~~----------~----C-Y-lin-d-.-'-h-e-'-d-'-P.-9-.--B--4~)~~~~~~~~------------------~
Cylinder/Piston (page 8-8)
Crankcase separation (page 10-2)
Starter clutch (page 16-8)
Flywheel (page 14-7)
Crank.case separa tion (page 10-2)
Connecting rod bearing cap (page 10-4)
Transmission Crankcase separation (page 10-2)
Gearshift linkage (page 9-6)
• Prior to assembling the crankcase halves, apply 8 sealant to their mating surface. Wipe off excess sealant thoroughly _
.. Mark and storo th o bearing insert s to be sure of their correct Iuc!ltions for reassembly. If the inserts are improperly installed
they will block the oil holes, causing insufficiant lubrication and eventual engine seizure.
• If it is no longer clear which bolt hP.lnno!'! in which hole, insert all bolts in the holcs ond c heck the exposed lengths; each
should be exposed the same amount .
TROUBLESHOOTING
• Excessive noise Transmission jumps out of gear
• Worn oonnooting rod beorings Worn gear engagement dogs or slots
Bent connecting rod Bent shift fork shaft
Worn c rankshaft main bearino Damaged shift drum stopper arm
Damaged or bent shift fork
Hard to shift Broken shif t linkage fl'tturn spring
Improper clutch operati on Da maged shift drum cern grooves
Incorrect engine oil viscosity
Incorrect clutch adjustment
Bent shift fork s
Bont ohift fork 3hoft
Bent shift fork claw
Damaged shift drum cam oron vA~
Bent shift spindle
•
CRANKSHAFTITRANSMISSION
CRANKCASE SEPARATION
11----1-12)
•
15)
11)
------------------------------------... Honda CB400 / CB-1 Service Manual
REQUISITE SERVICE
•
Engine (page 7· 2) Starter motor (page 16-5)
Clutch/oil pump drive chain (page 9-4) Oil pan (page 4-3)
Left crankcase cover /page 16-B)
PROCEDURI:: O'ty REMARKS

(1) Upper crankcase bolt (6 mm) 6 Bolts 12 psc/markAd ll. on the crankcase) have sealing
•
washers.
(2) lower crankcase bolt (6 mml 13 Botts 12 psc/ marked I::. on the crankcase) have sealing
washers.
(3) lower crankcase bolt (8 mm) 13 Bolts (12 psc) have sealing washers.
(4) Lower crankcase (
(5) Dowel pin 3
(6)
•
Oil nrifir.R 2
•
CRANKCASE BOLTS LOCATION (1) BOLTS: 26 psc
Loosen all bolls ill .. \:jnuJuul, crisscross pattern. r'I

rgr 0 o 0 0 o
Bolts location: 8S shown
.. : bolt with a 5uling washer o 9Y 0
Clean an.,. liquid sealant off the crankcase mating surface. o· @ o 0 0
~
l----JiC-.r:;..' '-...
• l. )~~;~J' . . .
tel" ~ ~
~ (2)
LOWER
CRANKCASE
• (1) BOLTS: 6 psc
'-
~(' o
" o
o
~~o
o 0
( ) UPPER CRANKCASE
CRANKSHAfTlTRANSMISSION
CRANKSHAFT/CONNECTING ROD REMOVAL/INSTALLATION
• Ie 24 12.4. 17) - ,
• •
Oil HOLE
FACING TO
INTAKE
SIDE
NOTE
Determine the replaCenltll1l bl:lllring color eode aecording to the main bearing selection table (page 10-6) or the connect-
ing rod bearing selection table (page 10-7).
M6rk and store the bearing inserts to be sure of their correct locations for reassembly.
At installation, apply molybdenum solution to the main journal bearing and connecting rod bearing surface.
Refer to page 1-8 for crankshaft and rod specific ation.
Refer to section 14 of the Common Service Manual for bearing inspection.
REQUISITE SERVICE
• Refer to Service Information (page 10- 11

REMOVAL ORDER
(1)
(2)
Connecting rod bearing cap nut
Bearing cap
. 8
4
(3) Connecting rod 4
(4) Connecting rod bolt 8 Do not remove them without necessary .
(0) Conneetlno rod beanng 8 Wipe all oil from the bearing seating areas.
(6) Crankshaft 1
• (7)
(7)
(6)
Crankshaft main journal bearing
INSTALLA TION ORDER
Clanll.shalt main journal bearing
Crankshaft
12
12
1
Wipe ell oil from the bearing seating arees.
The bearing tabs should be aligned with the grooves in

the crankcases.
instaU it onto the upper crankcase with the flywheel side
facing to the clutch side .
(5) ConneetinQ rod bearing • NOTE:
• The bearing oil hole should be aligned with the oil hole
in the connecting rod.
(4) Connecting rod bolt 8
(3) Connecting rod 4 NOTE :
• Face the oil ho les to the Intake side.
(2) Bearing cup 4 Install them with the code letters reed properly.
(1) Connecling rod beering oop nut 0 Apply oil Lu tilli nut threads and torque them in gradual .
crisscross pattern .
•
•
CRANKSHAFT BEARING
REPLACEMENT
MAIN JOURNAL BEARING SELECTION
Record the crankcase 1.0. code letters from the pad on the
left flitiA nf the crankcase.
NOTE
letters (A, B or C) on the upper crankcase are the
Cod8 !l fnr the main jOurnall .O.s from the left .
(1) CRANKCASE I.D . CODE
Record the corresponding main journal O.D. code numbers

from the crank weight.
NOTE
Numbers (lor 2) on the crank weight are the codes for
•
the main journal O.O.s from the left .
(1) MAIN JOIJR"ALO.D.CODE
Cross reference the case and journal codes to determine the

rlflJlUClfl11unt bearing color code. (1) MAIN JOURNAL BEARINGS
.............. Cr.n ... u .... A , C
~.- 33.000-
33.008 mm
33.009
33.018 mm
33.017 -
33.024 mm
M,in !g.yrnll ... ~ 11 . Z99Z_ (1 .2998- t 1.2999-
0 .0 . code 1.2995 inl 1.2998 In) 1.3002 inl
, 29.992 30.000 mm
(1 . 1808 _ 1.181111'1)
Pink YQlIow a"",,,
2
29.984 _ 29. 992 mm
11.1805 - 1.1808 Inl
Yellow G
._ ",0_
• Bearing thickness
Brown: Thick
Green: t
Yellow : +
Pink : Thin
CONNECTING ROO BEARING SELECTION
Record the connect ing rod 1.0. code numbers on the rod .
~ ~:~
NOTE
Numbers ( l o r 21 on the connecting rod are the codes 0=~ G
tor the connecting rod 1.0.5. ~," -
i
(1) CONNECTING ADO
1.0. CODE
t Record the crankpin 0 .0 . code letters from the crank weight.
NOTE
Leners (A or BI on the upper crankcase are the codes
for the crankpln 0 .0 .5 from the~I:
.CftC._ __ _ __ .-J
•
11 1 CRANK PIN
• Cross referlln(;8 t hllt I.:Hmk1J111 and rod codes to determine the

replacement bearing color code.
,
( 1) CONNECTING ROD BEARINGS
(2 ) COLOR CODE
;;;:~
2
1.0. cod ... 32 .99 2 33.001
33.000 mm aa.ooa nvn
C. ...kpin 11.2989 - 11.2992 -
0.0 . coo. 1.2992 inl , .2995 In)
~O.OOO mm
A 29.992
(1.1808- 1.1811 in)
Yellow Green
•
29 .884 2!UI!'il ..........
• (1. 1805 1, 1807 in)
I.l,een Bro wn
Bearing thickness
• Brown : Thin
Black :
Blue : Thic k
t
•
'In ...
CRANKSHAFT/TRANSMISSION
TRANSMISSION REMOV AL/INST ALLATION
c:w 51
•
(4 1
131
n
iIiii
1 -8
REQUISITE SERVICE
• Refer to Service Information (page 10-11
PROCEOURE O'W REMAAKS

REMOVAL ORDER • Installation is in the feWIr." order of removal.
11) Countershaft assembly I At installation, align the bearing groove with the set ring
and align the oil seal with the case groove.
(:l ) t.:ountershatt bearing set ring I
)3) Mainshaft bearing set plate bolt 2
14) Mainshaft bearing sst plate I
15) Needle bearing I
16) Wtlsl"ler I
17) Malnshaft M2 gear/spline washer/M6 gear - At installation, face the M6 gear engagement dogs for-
ward the M4 gear.
18) Mainshaft assembly I
19) Center shift fork bolt • I Remove after bending down the lock washer tab. Install
and bend new lock washer tabs 8S shown.
110) Lock washer I Install a new lock washer.
(11) ShiH rurk Ilhaft 1 At installation, face the shatt flatted surface side forward
•
the drive sprocket.
~j
(12) Right shift fork Install them with the identification marks (R: Right, C:
(13) Center shift fork Center, l : Left) facing forward the clutch side.
(14) Left shift fork
(15) Shift drum bearing set plate bolt 1
(16) Dowel pin 1
1171 Shift drum bearing set plate 1
(18) Shift drum bearing 1 Install with the bearing stopper near the outside.
(19) Shih drum I
•
•
•
Honda CB400 / CB-1 Service Manual a
TRANSMISSION DISASSEMBLYI ASSEMBLY

• MAINSHAFT
ALIGN OIL HOLES
(2) (3)
(1J~@~d~. (A~)----1
(16)
1121
~ : SHIFTER GEAR
. • GROOVE
• ( ) (4) (7) (8) (10) (1' I (14)

--:7Il : GEAR SLIDING
- . SURFACE
NOTE
Apply molybdenum ,olution to the shiher gear grooves. Apply oil to ail sliding surface of the mainshaft. countershaft
and bU6hings.
Inslall the thru!;t WAf;.hAr" "nd snap rings with the chamfered edge facing to the thrust IOl.'ld side.
Refer to section 13 of the Common Service Manual for inspection information.
----------------~
REQUISITE SERVICE
• Transmission removal/installation (page 10-8)
PROCEDURE O'ty REMARKS
,
•
MAINS HAFT OISASSEMBLY ORDER • Assembly is in the reverse order uf disassembly.
(1) Needle bearing
( 2)
(3)
Thrust washer
M2 gear 117T)
, 1
,,
(4)
(5)
Splino washor
M6 gear (24T) ,,
,,
(6) M6 spline bushing Align the oil holes of the bushing and mainshaft .
(7) S~lil\Y w"!lhllr
(8)
(0)
Snap ring
M3 (16T)/M4 (22T) shifter geor ,,
,,,
(10) Snap ring
(11 ) Spline washer (
(12) M5 gear (23T)
,,,
(13) M5 bushing
(141 Thrust washer
(15) Meinshaft bearing Install it with the bearing stopper near the outside.
(10) Malnshaft 1M I gear/ 13TI
t
10....-1141
: SHIFTER GEAR
e l\---1'=) GROOV E
: GEAR SLIDING
SURFACE
rnOCEOUAE Q 'ty REMARKS
,,
COUNTERSHAFT DISASSEMBLY ORDER • Assembly is in the reverse order of disassembly.
Bearing Install with the sealed side facing outside.
"121I Thrust washer
• 131 C1 g.,,1:11 (43T)

141 Needle bearing ,,
1
161 Thrust wuher

IBI C5 shifter gear 133TI ,,
,,,
171 Snap ring
181 Spline washer
191 C3 gear (30n
(101 t:3 spline bushing
(11) Lock washer ,, Align the oil holes of the bushing and countershaft.
• ,,
(12) 3pline washel
(13) C4 gear 135T1
l U I Cd. spline bUlihing . ,, Align the oil holes of the bushing and countershaft .
(151 Spline washer
116 ) Snap ring
(1 7) C6 shifter geer (32T) ,,
(18)
\1 !:J)
Snap ring
Spline washer ,,
(20) C2 bushing
(21)
(22)
C2 geal (40T)
Thrust wash er
1
,,
(2::1)
(24)
Oil s~al
Bearing ,, Install with the bearing stopper neer the outside.
(25) Countershaft
CRANKCASE INSTALLATION
012
(1.2. o
12(1 .2. 91
•
(
Itt 1211 .2 , 91
• •
(7) 0 '12 n .2, 9)
_a----------------------__________.... Honda CB400 / CB-1 Service Manual
REQUISITE SERVICE
• Crankshaft/connecting rod installation (page 10·4) • Transmission installation (page 10-8)

(1) Oil orifIce 2
(2) Dowel pin 3
13) Lower crankcalll ,-
14)
15)
16)
lower crankcase bolt IS mml
lower t:rl'lnkt::I'I$e bolt (6 mm)
lower crankcase bolt (8 mm :II: 65)
,.-
' 3-
,-
Crankcase installation (see below)
11) Upper crankcase bolt (6 mm) 6-
•
• CRANKCASE INSTALLATION
Apply a light but thorough coating of s8alant to the upper

~
•
crankcase mating surface except to the m ain bearing journal
bOlt Mating areas and the 011 passage area as shown . =
0;;' ~=
• L
111 SEALANT
A RE AS
Set the mainshaft and countershaft into neutral position first , I C6 SHIFTER GEAR
then slide the l:ti shitter gear onto the C2. gear /2nd gear po-
•
sition) as shown, 10 8ase upper crankcase installation.
C2 GEAR n
Set the shih drum in the 2nd gear position as shown.

(2) , , FORK
NOTE
The shifter-pin of the left shift fork (marked "L") l
should be located as shown.
(1) " l " 'u'''_,
Align the left shift fork (marked "l") with the C6 shifter
gear, and the right shift fork (mark ed "A") with the C5 shift- (7,
er gear first, then lowering the lower crankcase, align the
center shift fork (marked "C") with the M3/M4 shifter gear. POSITION
Assemble the crankcases.

(6) C6 ."'FTFR
Make sure each crankcase is assembled securelv .
•
Inatoll the Cf"nkcose bo lill ~nd 59alln9 washers as shown. (1) BOLTS : 26 psc
NOTE
Four 6 mm bolts (marked 6 on the crankcase) have
sealing waGhcr:'!.
Twelve 8 mm bolts (for the crankshaft main journals)
have sealing washAfl':. ,2,
Four 8 mm bolts (marked f:J. on the crankcase, ®. @, lOWER-__.j
® and @) is black in color.
II~:j~~~t:~3) SEALING
CRANK-
• Tighten all c rank case bolts in ~ orttdual. crisscross pottern,

beginning with larger diameter bolts first as shown.
TORQUE,
8 mm crankcase bolt : 24 N'm 12.4 kg-m, 17 ft-Ib)
CASE WASHERS
8 mm A ee cranKcase bolt @ :
27 N·m 12.7 kg-m, 20 ft-Ibl (11 BOLTS : 6 pSC
e mm Gt8nko03c bolt: 12 N'm (1.2 kg -m . 9 ft-Ib)
J
o-r=~~
'-='
. •
(;) ~
'~
--" 0
•
,2,
UPPER
CRANKCASE
• .r.~
I 0
I
V
, 3) SEALING
WASHERS
10-14
11. FRONT WHEEL/SUSPENSION/STEERING
• SERVice INFORMA nON

TROUBLESHOOTING
".,
".,
RIGHT HANDLEBAR REMOVALI
INSTALLATION
VI
"·5
,,·6
"·2
FRONT WHEEL OISASSEMBL
ASSEMBLV
FORK REMOVAL/INSTALLATION
FORK DISASSEMBLV " ·8
• LEFT HANDLEBAR REMOVAU

INSTALLATION
FRONT WHEel REMOVAU
INSTALLATION
11·3
" ·4
FORK ASSEMBL V
STEERING STEM REMOVALI
INSTALLATION
"·'0
,,·,2
SERVICE INFORMATION
Riding on damaged ,ims impairs safe operation of the vehicle.
• A contamlnnted brake disc or pad reduee. stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake dagre.sing agant.
Inhaled asbestos flh.us have bean found to causa resplrutory disease and cancer. Never use an air hose or dry brush to
claan brake ....mblie•. Use an OSHA-approved vacuum cleane, or alternate method approved by OSHA designed to
minimb:e the hazard caused by airborne asbestn" fiber •.
• A.fer to the section 1 3 fnr hrake sYlitem information.

• Refer to the section 17 for light, meter and switch information.
• Tubeless tire removal, repair, and remouting prnl':P.rtllres are co vered In the section 16 of the Common Service Manual.
• It the motorcycle has been involved in an accident, inspect the frame very carefully at the steering head and at the engine
mounts.
TllliIs~ alll the arMs most likely to suffer demage. It is possible to bend the frame steering head without bending the f ork
tubes or even the front axle.
• For wheel, fork or steering !itlllll Il:Imoval , a jack or other support is required to support the motorcycle. Do not use the oil
filter as an jack point.
TROUBLESHOOTING
Hard steering Wheel turns hard
3te~lhl\l head bMring adjustment nut too t ight Faulty wheel bearing
. ,' Faulty steering head bearings Brake drag (page 13-1)
Dlilmaged t1t ccring stem ,aCt/tO Bent front axle
Insufficient tire pressure
FaUlty tirc Suft suspension
Weak fork spring
Steers to one side or does not track straight Insufficient fluid in fork
Bent fork low fluid level in fork
Bent front axle: wheel installed incorrectly low tire prp.~sure
Fc.ulty steering head bearings
Bent frame Hard suspension
Worn whool bcoring Incorrect fluid weight
Worn swingarm pivot Bent fork tubes
Clogged fork fluid passage
Front wheel wobbling High tire pressure
Bent rim
Worn front wheel bearings Front suspension noisy
FaUlty tire Insufficient fluid in fork
U"lJ<llanced t ire and wheel • loose fork fasteners
FRONT WHEEl/SUSPENSION/STEERING
RIGHT HANDLEBAR REMOVAL/INSTALLATION

,
11ul-~./..... r
•
• (111
11.0,7)
NOTE
Using wires . hang the front brake master cylinder at least es high as the position it was originally installed 8t to prevent
air from getting into the master cylinder. Do ont twist the brake hOGo.
Aoute the cables and wire harnesses properly (page 1·19).
Adjust the throttle cable after installation.
~~~~--------------------------------~
rnOCEDURE U'ty INSTALLATION REMARKS
REMOVAL ORDER • Installation is in the reverse order of remollal.
• III
12)
131
(4)
Front brakelight switch connector
Master cylinder
•
Right hRndlebar switch housing 5crcw

Right handlebar switch housing
2
2
1
1
Align the holder end with the punch mark on the htlndle-
bar and face the holder UP mark upward. Tighten the
upper bolt first, then the lower bolt.
Tighten the front screw first, then the rear screw.
IS) Thronle cable nut 1

16) Throttle calbe 2 Don't bend or distort the cables.
(7) Handlebar weight 1 Align its boss with the inner weight.
(8 ) Tl'lrottle pipe 1
(9) Throttle grip 1 Applv Honda Bond A or Honda Hand Grip Cement (U.S.A.
only) to the inside surface of the grip.
{lOI Stop ring 1 Install int o the fork groove properly.
(1 , I HandlebM pinch bolt 1 Tiyhten with the handlebar pushing forward.
(12) Right handlebar 1 Align the handlabar boss with the top bridge slot.
Honda CB400 / CB-1 Service Manual ----_.._ - - - --
LEFT HANDLEBAR REMOVAL/INSTALLATION
, 12.7,20)
•
,
p1'i''''----.:~(9) (l 27 12.7, 20)
NOTE
Route the cables end wirll hllmesses prOPQrly (page 1-1 9).
• Adjust the clutch cable after installation .
PROCEDURE a ' ty INSTALLATION REMARKS

f--
" )
12)
Clutch switch connector
Clutch lever assembly ,
2
Align the holder end with the punch mark on the handle-
bar and face the holder UP mark upward . Tighten the
upper bolt fi rst. then the lower bolt.
(3) Le ft handlebar switch ho using screw 2 Tighten the front screw first, then the rear screw .
,,,
(1) Loft handlebar switch hou~illY 1
(5) Choke cable
(6) Handlebar wp.ioht . Align its bou with the Inner weight.
(7) Handle grip Apply Honda Bond A or Honda Hand Grip Cement (U.S.A .
,,,
only) to the inside surface of the grip.
18) Stop ring Install into the fork groove properly .
19) Handlebar pinc:h bolt nghten with the handlebar pushing forward.
(10) Left handlebar Align the handlebar boss with the top bridge slot.
.. -
FRONT WHEEUSUSPENSION/STEERING
FRONT WHEEL REMOVAL/INSTALLATION
11 )
C 60 (8.0, 43)
• 12)
C 22 12.2, 1S)
16)
A contaminated brake disc or pad reduced stopping power. Discard contaminated pads and clean 8 contaminated disc
WltP\ ,. high quality brake degreaslng agent.
Inhaled asbestos fiber. heve been found to caus. respiratory dis.ase and cancer. Nave' use an .Ir ho•• or dry brush to
oleon brake ...embli.6 . UIJlI HI! OSHA-approved VaCuum cleaner or alternate method approved by OSHA designed to
minimize the hazard caused airborne asbestos fiber •.
CAUTION
I· Do not use the oil filtar as 8 jack point.
NOTE
e 00 not depress the brako lever when the caliper is rellluvl:!d, ur it will be dlltleuh to refit the disc between the brake
pads.
REQUISITE SERVICE
• Raise the front wheel off the ground by placing a jack or other support under the engine.
PROCEDURE Q ' tv REMARKS

REMOVAL onom • Installation is in the re verse order of rem oval.
11) Axle bolt 1
12) Axie pinch holt 4 Only loosen the bolts .
13) Axle shaft 1
)4) Front wheel assembly 1
15) Left side collar 1 Shorter one
16) Right side collar 1 longer one
11-4
» Honda CB400 / CB-1 Service Manual
FRONT WHEEL DISASSEMBLY/ASSEMBLY
13....-~~~
• C
3013.0, 221 11)
• A conta minated braka disc or pad reduce s stopping powe, . DIscard contaminated pad s and clean 8 contamlna tad disc
with 8 high quality brake degr.ulng age nt.
NOTE
Alwavs replace wheel bearinRS as a set.
• For wheel bearing replacement, refer to the section 1 of the Common Service Manuel .
• REQUISITE SERVICE
•
• Front wheel remo val/ installation (page 11 -4)
PROCEDURE O'ty ASSEMBLY REMARKS

DISASSEMBLY ORDER • Assembly is in the reverse order of disassembly.
11) Right side coliar 1 longer collar
12) Left side collar 1 Shorter collar
•
13) Brake disc bolt 6 Wipe off all the grease on the bolt surface.
14 ) Brake disc 1 Install with the stamped side outward as shown.
(5) Dust seal 2 Apply grease to t he dust seal lips lind install them wi th
the lip side facing inside .
(6) Right whcel bearing 16004 UUI 1
(7) Distance collar 1
18) left wheel bearing 16004 UUI 1 NOTE:
• Drive in the left side bearing fir st, then the right side
bearing.
19) Front wheel /tire 111
11-~
FORK REMOVAL/INSTALLATION
• 1111 .1,8)
C
50 (5.C, 35)
C 27 12.7, 20)
CAUTION
Support the removed caliper with" piftcill of wire so that It does not hang from the brake hos • . Do not twist the brake
hose.
NOTE
Do not depress the brake lever when the cliliptl f fl> lemoved, or it will be difficult to refit the disc between the brake
pads.
!5ufure II:II11oving the fork , loo3cn tho fork cap bolt; but still do not rAmove it .
REQUISITE SERVICE
Right handlebar remo'iol/in!Jtoliation (page 11 -21 • Fron! wheel removal/ installation (page 11-4)
Left handlebar removal installation (page 11 -3)
PROCEDURE
. Q'tv REMARKS
,,
(1) Front fender bolt 4
(2) Front fender
(3) Brake hose clamp Install it with the front fender as shown .
f' )
(5)
C811per bracket bolt
Caliper assembly ,
2
f61 Meter mounting bolt 2 Move the meter assembly forwerd.

f7I Fork pinch bolt Uower) 2 Only loosen the bolts.
fS) Fork pinch bolt (upper) 2 Only loosen the bolts.
NOTE;
• Be careful not to let the fork leg drop when loosening
the pinch bolt .
f" Fork assembly 2 At installation, align the fork grooves with t he top bridge
upper surfaces .
11-7
FORK DISASSEMBLY
111 14
( 10)
1 -- 131
• 112~
~ 141
1181-B~
1171- t S a
131
o
~(6)
~(71
• ~ 1151
g . ( 16)
.... 0
FRONT WHEEUSUSPENSIONISTEERING
REQUISITE SERVICE
• Fork removal (Plige 11 · 61
PROCEDURE Q' ty REMARKS

,
I ~.p bolt is ynde r high pressure. Use car.
111 Fork cap bolt
when
(2) O-ring ,, loosening the bolt .
,,
i31 Spacer
(4) Spring seat
(5) Fork splng After removing, pour out any remaining fork oil .
(6) Dust s9al
'-. When removing them , do not damage the fork tube .
(7)
(8)
Stoppor ring
Fork socket bolt . ,
,~
NOTE:
• Temporarily install the spring end fork cap bolt if
(9) Seeling washer , difficulty is encountered in rem oving the socket bolt.
(10) Fork p iston 1

,
•
f111 Fork piston ring NOTE :
(12) Rebound spring ,, • Do not remove it unless it is necessary to repl ace.
(13)
(14)
Fork tube
Oil s8el ,,
115)
(16)
Back up rino
Slider bushing ,,
(17) Fork tube bushing NOTE:
• Do not remove it unless it is necessary to replace.
(18)
119)
Oil lock piece
FOrk slider ,
1
FORK ASSEMBLY
0 . 23 (2 .3 , 17)
I
14 )
(17 1
~18)
.,
• (16 1 ~
(1
(7
( 141~
(11---+/
t '13 ) ~
•
( 1 2 ~~
[I;-~I __. ~
IP.g. ,~
~,,( jf
~1101
(
::11?At
()1--.
0 . 20 12.0 , 14)
0: 2 2 (l .:.! , 1 ti l
NOTE
I·
•
Clean all disassembled parts.
REQUISITE SERV ICE
• Fork installation (page 11 -6)
PROCEDURE
•
Q'ty REMARKS
111 Fork slider 1
(2) Fork piston ring 1 Replace with 8 new one if it was removed from the pis-
ton.
(S) Rebound spring 1
(4 1 Fork piston assembly 1 Insert into the fork tube (10).
•
( 5) Oil luck pIece 1 Install onto the piston (4).
(6) Fork tube bushing 1 Replace with a new one if it was remo ved from the fork
tulll!.
(1) Fork tube 1
(8) Sealing washer 1
(91 Fork socket bolt 1 NOTE :
•
• Temporarily instaH the fork spring and fork cap bolt so
that the piston is held in place when the socket bolt is
t ightened .
(101 Slider bushing 1
(11) Back up ring 1
(12) CU6eei 1 NOTE:
• Wrap vinyl tape around the fork tube top end to avoid
damaging the oil scol during the oil s8al installation .
• Orive in it securely. using fork seal driver f07947 -
KA50100) and attachment (07947 - KFOO100).
•
(13) Stopper ring 1 Install into the slider groove securely.
(14) Oust seal 1 NOTE :
• After installing it , compress the fork tube fully and pour
the specified amount of fork fluid (page 1-1 1) into the
fork tube.
(15) Fork spring 1 NOTE :
• Wipe oil off the spring thoroughly using a clean lint free
cloth and install with tightly wound coil end facing
down.
(16) Spring seat 1
(17) Spacer 1
• (18)
(19)
O-ring
Fork cap bolt
,
1
1 Tighten lightly. being careful not to cross -thread the bolt;
after installing the tork into the steering stem, torQue the
bolt.
STEERING STEM REMOVAL/INSTALLATION
€X: 105 110.5, 76)

(1J
(page 1- 171
• 0 2512 .5, lSI
71
31
141
[.~ I
I 71
~(91
~(11)
__ (121 _ 5ijjjjj.,
~-- (16)
(page ' · 17)
o ~(pagel - 17)
'-
(81
~=tV-
(( ~ '-=--==
~.
•
SHORTER T 1\8S:
r-- . Bend down
LONG.ER TABS;
• Send up (10)
NOTE
81:llllill\j1l IIhuuld always be re~U~eed as a set- inner and outer races.
Remove the fork, after loosening the steering stem nut.
Check the &teering head bearing preload (page 1- 111 ofter torquing the stem nut.
REQUISITE SERVICE
• Frcmt wheel removal/inlitallation (pago 11 4) - Fork rcmo,,"ol/instollotion (poge 11-6)
REMOVAL ORDER
(11 Steering stem nut 1 After removing, remove the fUl k.
,21 Washer 1
•
(:'\) 'onitinn .c:witr.h r.Qnnec tor 2 Disconnect inside the headlight case (page 1-191.
141 Top bridge
151 Headlight/Stay assembly
. 1
1 Support with a piece of wire so that they do not hang
from the cables or wire harnesses.
161 lock nut 1 NOTE:
• Remove. after straightening the lock washer tabs.
•
171 Lock washer 1
tol Steering head bearing adjustrlltrnt nut 1
,91 Dust seal 1
(10) ~t"''''rinD .q;t",m 1
111 ) Upper inner race 1
(12) Upper bearing 1
( 13) lower bearing 1
(14) lower inner race 1- Replace if they were removed.
(1 b) Dust seal 1- • Use race remover attachment (07953 - MJlOOOA) with
116) Upper outer race 1- driver (07949 - 3710001) and attachment,
(17) lower outer race 1 37 J, 40 Illlll (07746 - 0010200) for upper outer race
removal.
• Use race remover (07946 - 3710500) with driver
(07949 - 3710001) and attachment, 37 )( 40 mm
(07746 - 00 10200) for lower outer race removal.
INSTAllATION ORDER
(17 ) lower outer race 1- Rep[ace as a set, if necessary .
(16) Upper outer race 1- • Use attachment, 52 )( 55 mm (07746 - 0010400) and
(15) Dust seal 1- driver (07749-0010000) for [ower outer race installa·
1141 lower inner race 1- t[on.
(13) lower bearing 1- • Use attachment, 42)( 47 rnm (07746 - 0010300) and
•t
(12) Uppm tmaring 1- driver (07749 - 0010000) for upper outer race install a-
( 11 ) 1- tion .
Upper inner race
. • Usc stcering stem driver (07946-MBOOOOO) for lower
inner race installation.
(101 Steering stem 1
191 Dust seal 1
,81
~j
Steering head bearing adjustment nut [nstallation: refer to section 1 8 of the Common Service
,71 lock washer Manua[ !Retainer-Type Ball Bearings).
,.,
161 lock nut
•
Headlight Stay assembly I
141 Top bridge 1
131 Ignition owitoh connc ctor 2 Connect them (page 1·19).
121 Wesher 1
111 Steering stem nut 1 TJlmpnrRrily inst<tll fork and torque the nut.
11 1 .,
12. REAR WHEEL/SUSPENSION

SERVICE INFORMATION 12-1 SHOCK ABSORBER DISASSEMBLYI
ASSEMBLY 12-5
TROUBLESHOOTING 12-1
SWINGARM REMDVAU
REAR WHEEL REMOVAU
INSTALLATION 12-7
INSTALLATION 12-2
•
SWINGARM DISASSEMBLYI
REAR WHEEL DISASSEMBLYI
ASSEMBLY 12-8
ASSEMBLY 12-3
SHOCK ABSORBER REMOVAU
INSTALLATION 12-4
The shock absorber contains nitrogen under high pressure. Do not allow fir. or heat near the shock absorber.
• 8810rll disposal of the shoc:k absorber. re'e.8. the nitrogen (Step: section 19 of the Common Service Manual: Drilling
point: page 1·111
A contaminated brake disc or pad reduc •• stopping power. DI.eard cant.min.tAd ptMts and clean 8 contaminated disc
with. high quality brake degr.aslng agent.
Inhaled asbestos fibers have been found to cause r••piratory disease and cancer. Nava, use 8n air hose or dry brush to
el.6'" brake ass.mbli••• U.. an OSHA·approved vacuum cleaner or alternate method approved bV OSHA designed to
m inimize the hazard caused by airborne a.bestos fibers .
I on rims uf. uf the vehicle.
• • Refer to the section 13 for brake system information .

• Tubeless tire removal, rep air, and remounting procedures are covered in the section 16 of the Common Service Manual.
TROUBLESHOOTING
Rear wheel wobbling Hard suspension
Bent rim Damaged shock absorber upper or lower bearings
Worn reaf wheel bearings Incorrect suspension adjustment
FaultY tire Bent damper rod
Unbalanced tire and wheel Damaged swingarm pivot bearing
•
low tiro prC33ure High tint pressure
Faulty swingarm pivot bearing{sl
Rear suspension noisy
• l oose fa steners
•
Wheel turns hard
Faulty wheel bearing{51
Brake drag {page 13-11
Bent rear axle
Soft suspension
Weok spring
Incorrect suspension adjustment
Oil laaksaB from d<lmper unit
l ow tire pressure
•
~ - ~
REAR WHEEL/SUSPENSION
REAR WHEEL REMOV AL/INST ALLATION

(31
• I
( : : 90 (9 .0, 65)
A contaminated brekfl dhu: nr pad r"ducAl'II IItnpplno power. Discard contaminated padl and clean a contaminated disc
with. high quality brake degre.sing agent.
Inhaled asbestos fiber. have been found to cause r•• plratory disease a nd cancer. Navar usa an air hose or dry brush to
clean brake assembUel . U •• an OSHA-8pJ)fOved vacuum cieaner or alternate method approved by OSHA designed to
minimize the hazard caused by airborne asbestos fiber •.
NOTE
·· Put the motorcycle on its center stand .

Do not depress the brake pedal when the caliper is remnvarl, or it will hft rlifficult to refit the disc between the brake
pads.
· Support the removed caliper with a piece of wire so that it does not hang from the brake hose . Do not twist the brake
• ·
hose .
Adjust the drive chain free play adjustment after installing the wheel.
PROCEDURE O' t y REMARKS
REMOVAL ORDER • Installation is in the reverse order of removal .

(1 1 RAAr Avle n~lt 1
(21 Drive chain adjusting nut 2 loosen the lock nuts end loosen the adjusting nut fully.
(31 Drive chain 1 Move the rear wheel forward, and disengage the drive
chain from the driven sprocket.
(41 Rear axle 1
(b l Hear wheel assembly 1
(6 1 left side collar
(7 1 night side collar
-- Honda CB400 / CB-1 Service Manual
REAR WHEEUSUSPENSION
,
REAR WHEEL DISASSEMBLY/ASSEMBLY
C 40 f4.0, 29)
@
(21
~
(11 )
•
•
21
A contaminat"d lmlke disc or pad redUl:.AA Atnpping power. Dlscllrd pods ond clean 8 contaminated disc
with. high quality brake degreasing agent.
NOTE
ror driven SIJIUL:t..l:Il rl:llT1ov al, loosen tM Sprocket nuts wIth the driven flange installed into the wheel hub.
Replace wheel bearings 8S 8 set.
For wheel bearing replacement . refer to the lIection 1 of the Common Stlfvicl;! Manual.
REQUISITE SERVICE
• Rear wheel removallinstallation (pagtt 12-2)
• PROCEDURE
DISASSEMBLY ORDER •
a ' ty ASSEMBLY REMARKS
• Assembly is in the reverse order of disassembly .
•
111 Right side collar 1
(21 left side collar 1
(31 Right dust ~1:1I11
~ ::::r
Apply grease to the dust seal lips and install them with
141 left dust seal the lip side facing inside.
(51 Driven flange aU81ll1Jly 1
(61 - driven flange collar 1
(71 - driven flanQ8 bearing /6204 UJ 1 Inltall with the sealed side facing out .
•
,.1 - driven sprocket nut 5
(91 - driven sprocket 1
(10) - dlivon rh:ll1Yo 1
(11 ) O-ring 1
(12) near wheel dampel 4
(13) Brake disc bolt 4
(14) Brake disc 1
(15) left wheel bearing (6303 UU) 1
(16) Distance collar 1
(17) FliQhl whtlttl bttaring (6303 UUI 1 NOTE:
• Drive in the right side bearing first, then the left side
bearing.
(1 B) Rear wheel/tire 1/1
SHOCK ABSORBER REMOVAL/INSTALLATION
111
""'2..---'10; 45 (4.5, 33)
•
NOTE
Put the motorcycle on it center stand .
Before removing the shock absorber for disassembly. adjust the shock absorber to position I (for lightest loads) before
removing the shock absorber f rom the frame.
REQUISITE SERVICE
Fuel tank removallinstallation (page 2-4)

•
III Shock absorber mounting bolt (upper) At installation, install them from the left side.
(2) Shock absorber mounting bolt (lower)
(3) Shock absorber assembly. NOTE:
• Remove it upwards from the frame.
• Install with the drain tube forward.
SHOCK ABSORBER DISASSEMBLYIASSEMBLY
•
•
Tho shock absorber contains nitfOUlln un('ter high pr... ure. Do not allow flre or heat near the shock absorber.
Befor. disposal of the shock absorber. re lease the nitrogen
(Step: section 19 the Common Service Manual; Drilling point: page ' ·11)
NOTE
Adjust the shock absorber to position I (for lightest loads) before removing the shock absorber from the frame.
• For lower jnint needle bvaring replacement, 3ee next page.
REQUISITE SERVICE
•
• Shock absorber rAmnv~I'in8taliation (page 12-")
PROCEDURE . Q ' ty REMARKS
•
1') Lower joint 1 NOTE:
• Removal /Installation (page 12·6)
• At instollation, align the lower joinl with the seat stop-
per pin .
(2) Seat stopper 1
,~) Spring seet 1
• (4)
{51
{61
(7)
{.I
Spring
Adju~llill
Lower joint lock nut
Damper rubber
Damper
.
1
1
1
1
1
Install with the taper end fac ing to the adjuster .
•
~- -
REAR WHEEUSUSPENSION
LOWER JOINT REMOVAL/INSTALLATION

( 11 ATTACHMENT
Install the shock absorber compressor and attachment on the
rear shock absorber as shown.
t
SHOCK ABSOR8ER COMPRESSOR 070ME-0010000
INot available in
U.S.A. I or
079~9 - 3290001
- screw assembly 07GME-0010100 t
ATTACHMENT 07959-MB10000
(2) COMPRESSOR
Turn the compressor handle and slowly compress the spring.
Hold the lower joint and loosen the lock 'nut (turn the nut I
clockwise), (1) LOCK NUT
Remove the lower joint and clean off any locking agent from
the threads .
•
(2) LOWER
Installotion: JOINT
Apply a locking agent to the damper threads.
Install the lower joint securely onto the damper rod.
Hole the lower joint and torque the lock nut.
TORQUE: 68 N·m 16.8 kg-m, 49 ft-Ibl
Make sure the lower Joint Is aligned with the seat stopper pin
and remove the compressor.
LOWER JOINTS NEEDLE 8EARING (1) DRIVER

REPLACEMENT PI
Remove the dust seals.

Hold the joint with ~ sl Jitable tool
Press the needle bearing out of the joint. .....{2 1 NEEDLE
(s -;00.. ) ~~~~~\\~?Jr~"" BEARING
DRIVER PIN 07GMD-KT80100
• ".PILOT, 22 mm
DRIVER
(Not available
In U.S.A.)
07746-0041000
07749 - 0010000
~
(3 ) SUITABLE
TOOL
Pack a new bearing w ith grease .

Pren th ~ b~ a rin9 into th", joint llntil th", b",,,rinO surf;;ace ( 1) DRIVER (2) NEEDLE BEARING
flushes w ith the jo int surface as shown .
!$i'oO... l
DRIVER
ATTACHMENT, 24 )( 26 mm
PILOT, l ' mm
07749 - 0010000
07746-0010700
07746 - 0040400
e I
( 3) ATTACH-
MENT
14) PILOT
SWINGARM REMOVAL/INSTALLATION
110 (11.0, 80)
• :"""'--;' - (4 ) C 4 5 (4.5, 33)
•
NOTE
• Put the motorcycle on its center stand .

Do not depress the brake pedal when the caliper is removed, or it wi ll be difficult t o refit t he disc between the brake
pads.
Support the removed caliper with a piece of wire so that it does not hang from t he brake hose. Do not twist the brake
hose.
If necessarv, loosen the rear engine mounting nut near the swingarm pivot to ease the swingarm removal/installation.
REQUISITE SERVICE
neer wheel remavlli/instlllintion Ipnge 12-2)
•
•
(1) Rear brake caliper
(2) Brake hose clamp
(3) Shook abuorber lower mounting bolt
(4) Swingarm pivot nut
151 SwinQarm oivot shaft
(6) Swingarm assembly
•
SWINGARM DISASSEMBLYIASSEMBLY
10;7"1>01.. 1 (paga 1-17)

(9) .. c-: I
5t;\:::::f~(61 (2)
(4)
• (5)
NOTE
• For pivot bearing replacement, see next page .
(
REQUIS ITE SERVIC E
• Rear wheel removalfinstatlation (page 12-2) • Swingarm removal/installation (page 12-7)
PROCEDURE Q'ty ASSEMBLY REMARKS

(1) Drive chain adjuster 2 Install them with the UP mark facing up and the index
(2) Right pivot collar ,, mark facing out.
• (3)
(4)
(5)
(6)
)7)
Left pivot coltar
Drive chain cover
Drive ehaln slider
Right dust seal
loft duat Goal
. ,,
,,, Apply grease to the lip.
(8)
(9)
Distance collar
Snap ring , Install it into the groove securely.
(10)
(11 )
Ball bearing
Needle bearing ,
2 Replacement (page 12-9)
SWINGARM PIVOT BEARING REPLACEMENT

(1) DRIVER SHAFT
Press the right pivot bearings (ball bearings) out of the swing-
arm .
Is~ 1
DRIVER SHAFT 0794G-MJ00100
(Not available in U.S.A.)
o.
DRIVER 07949-3710001
• Set the needle bearing remover onto the left 'pivot bearing
(needle bearing) as shown.
Press the bearing out of the swingarm.
I' TOOL I
(1) DRi'VER
SHAFT
(2) NEEDLE
• NEEDLE BEARING REMOVER ATTACHMENT
DRIVER SHAFT
o.
BUSHING REMOVER
DRIVI!R
07GMD-KT70200-, (Not available
07946 - MJ00100-1in U.S.A.J
M967X -038-XXXXX
07949 - 3710001
- (3) BEARING
REMOVER ATTACHMENT
PrOGll tho noodle boaring into the Bwingarm with the marked
(1) DRIVER
side facing out. 14i NCCULC BE'\R"JG
(2) ATTACHMENT
NOTE
Th$ be. ring ~\.Irfa~8 IOhol.lld fll.lih with the pivot in"ide
\\ \
surface as shown .
(s TOOl. )
•
ORIVER 07749-0010000
ATTACHMENT. 28 x 30 mm 07946 - 1870100
PILOT. 22 mm 07746-0041000
• Press one ball bearing (inner bearing) into the swingarm first,
then press in another on top of it (outer bearing). (2 ) ATTACH -
•
(1 ) DRIVER
MENT
(~ ;:.,. I (4 ) BALI.
UHIVI::H 07749-0010000 BEARINGS_
ATTACHMENT, 32 x 35 mm 07746-0010100
PILOT, 15 mm 07746-0040300
•
13. BRAKES
TROUBLESHOOTING
FRONT BRAKE PAD REPLACEMENT
REAR BRAKE PAD REPLACEMENT
13- 1
13- 1
13-2
13-3
FRONT MASTER CYLINDER
REMOVAL/INSTALLATION
REAR MASTER CYLINDER
REMOVAL!INSTALLATION
FRONT MASTER CYLINDER
13-B
13-9
FRONT BRAKE CALIPER REMOVAL! DISASSEMBLY/ASSEMBLY 13-10

INSTALLATION 13-4
REAR MASTER CYLINDER
REAR BRAKE CALIPER REMOVAL! DISASSEMBLY/ASSEMBLY 13- 11
INSTALLATION 13-5
BRAKE PEDAL REMOVAL!
•
FRONT BRAKE CALIPER INSTALLATION 13-12
DISASSEMBLY/ASSEMBLY 13-6
REAR BRAKE CALIPER DISASSEMBLY/
ASSEMBLY 13-7
A r.nntAn1in ... t,,(ll)rake di,,, or palil radU GOD 6topping power. Discard contaminated pads and claan 8 contaminated disc
with a high quality brake degreasing agant.
Inhaled asbestos fiber. have been found to causa respiratory dbutluuJ and canear. Navar use an air hose or dry brush to
clean brake assemblies. Us. an OSHA·approved vacuum cleane r or altem ate method approved by OSHA designed to
•
minimize the hazard caused by 8irbome asbestos fibers.
• Spilled brake fluid will severely damaQ8 instrument lenses and painted su rflu~eJII. . It is also harmful to 100me rubber parts. Be
very careful whenever you remove the reservoi r cap: make sure the front reservoir is horizontal first.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• Once the hydraulic system has been opened, or jf the brakes feel spongy, the system must be bled .
• Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid
as they may not be compaliiJlli:!.
• Always check brake operation before riding the motorcycle.
TROUBLESHOOTING
e Brake lever/ pedal sof t or spongy •
Air bubbles in the hydraulic system
Brake lever/pedal hard
Clogged / restricted brake system
Leaking hydraulic system Sticking/ worn caliper piston
Contaminated br6ke pad/ diSC Caliper not sliding properly
Worn caliper piston seal Clogged/ restricted fluid passage
Worn meotar oylindcr piston cups Wurn caliper piston seal
Worn brake pad Sticking/ worn master cylinder piston
Contaminated caliper Bent brake lever/ ped;)1
Caliper not sliding properly
Worn brake pad /disc Brakes drag
low fluid level Contaminated brake pad /disc
Clogged fluid passage Misaligned wheel
Warped/deformed brake diSC Worn brake pad/diSC
Sticking/ worn caliper piston Warped /deformed brake disc
Sticking/worn master cylinder piston Caliper not sliding properly
Worn brake disc
Contaminated master cylinr1l1r
Bent brake lever/ pedal
1" 1
BRAKES
FRONT BRAKE PAD REPLACEMENT
•
• C
1)
2.5 (0.25, 1 .81
c
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean 8 contamlnat&d disc
with 8 high quality brake degr88sing agent.
Inhaled asbestos fiber. have bean found to caus. , •• piratory di•••se and cancer. Na"'ar UN an air hose or dry brush to
clean brake assemblies. U•• an OSHA-approved vacuum daana, or alternata method approved by OSHA d.,lgned to
minimize the hazard caused by airborne asb.stos tiber •.
Aftar I the brake lever to .eat the the
NOTE
• -=
D-o- n- o- tCC
pods.
d-'-P-"-'-'- tCh-.-C
Replace brake pads 8S a set.

b-"c,-.-c
,.-,-.-, -"-C
h-. n
-CtCh-. - c-,C"Cp-. -, C',- -,.
Apply 8 thin of silicone grease onto t he pad pin so as not to ru st it .

--m-o-,-, C
dC,-o-,c"c-..c,c"Cb-.-CdC"O
" -c-uC
It- t-o- ,- .C,C
" - tCh-.- dC'C,-cCb-.-t-..-.-.- n-C
th-.-Cb-"c,-.-;
REQUISITE SERVICE
• Pushing the caliper against the disc, push the caliper pistons all the way in to allow the installation of new brake pads.
PROCEDURE Q'ty INSTA LLATION REMARKS
REMOVAL ORDER • Installation Is in the reverse order of removal.

111 Pad pin plug 1
121 Pad pm I Insen the pin, pushing the pads against the pad spring .
(31 Sraka pad 2 Align the pad lug with the pad retainer as shown.
1 -:t .,
BRAKES
REAR BRAKE PAD REPLACEMENT
•
• _~_121
~/
0 ' 2.5 (0.25, 1.8)
• 1 /
0'18 (1.8, 13)
0 ' -2312.3, 17)
A contaminated brake disc or pad raduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high quality brake degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to
cleM breke assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to
minimize the hazard caused by airbome asbestos fibers.
After I'fIplacement, operate the braka pedal to seat the tho
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
• • Pu~hillY lim l:ali~tJI
REMOVAL ORDER
ayaim;l lim (Jist:,
PROCEDURE
~usl1 thll caliper piston all the way in to allow the Installation of new brake pads.
Q'ty
,,
REMARKS
11) Caliper mountmg bolt Remove the bolt and swing the calipar upward.
121 Pad pin plug
131 rad pin t
141 Brake pad 2
INSTALLATION ORDER
111 Brake pad 2 Align the pad lug with the pad retainer as shown .
121
131
Pod pin
Pad pin plug ,
1 Inscrt thc pin, pushing thc pods against the pad spring.
141 Caliper mounting bolt 1
BRAKES
FRONT BRAKE CALIPER REMOVAL/INSTALLATION

C 35 (3. 5, 25)
11)
•
,
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a hlVh quality brake dagrfl8$lno agent.
Inhaled asbestos fiber. have been found to caus. respiratory disease and cancer. Naye, use an air hose or dry brush to
e l.an brake 8888mbl"" Use an OSHA-approved vacuum c leaner or alternate method approved hy OSHA designed to
minimize the hazard caused by airborne asbestos fiber•.
NOTE
•
If yo" ,emove tha calipor pioton3. remove the C81iper brack.et bolts (41 belult! IJisconnecting the brake hose 13); and
place a pan under the caliper to catch the draining flu id and squeeze the brake lever slowly to push out the pistons .
REQUISITE SERVICE
Brake pad removal/installation (page 13-2)

Broke fluid replecement/llir bleeding (sticliull 17 of the Common Service Manual)

REMOVAL ORDER • Installation is in the reverse order of remove!.
(1) Brake hOM~ bolt 1
(3 ) Brake hose 1 At installation, press thfl hose end against the stopper
while tightening the hose bolt .
(.) Caliper bracket bolt 2
(S) Front brake caliper assambly 1
BRAKES
REAR BRAKE CALIPER REMOVAL/INSTALLATION

C 35 (3.5, 25)
)
•
12.3, 17)
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads a contaminated disc
with . high q\181rtV hrllkll filigree sing agent.
Inhaled .. bestos flber. have been found to causa r.spiratory dlse... and cancer. Naver us. an air hos8 or dry brush to
c l••n brake assemblies . Use an OSHA-approved vacuum cleaner or alternata method approved by OSHA d.slgned to
minimize the hazard caused airborne asbestos flber • .
NOTE
•
Before dkloonnooting the brakli hO$8 t 1), place a pan under t he r.Ali('W'r t o catch the draining f luid and squeeze the brake
levar slowly to push out the piston .
Brake pad removal/in stallation (page 1 3-3)

Brake fluid replacement/ air bleeding (section 17 of the Common Service Manual)

REMOVAL ORDER • Installation is in t he reverse o rder of removal .
(1) 8f"~1<", nn~p. holt 1 Temporarily install t he caliper onto the bracket .
(3) Brake hose 1 A t installation, press t he hose end against the stopper
while tightening t he hose bolt.
(4) Rear brake caliper assembly 1
13-5
BRAKES
FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY

...-'iSiIi
C 13 11.3, 9)
'~
C
2.5 (0.25, 1.8)
~\~BI
\~ ~ €:X: 18 (1.8, 13) •
(31
(9~
• : 18 1 OUST SEALS
: (9) PISTON SEALS
'nhaled asbesto. fibers have been found to cau •• respiratory diulI8e and cancer. Never use an air hose or dry brush to
cl••n brake assemblies. Use an OSHA -approved vacuum cle.ner or anemate method approved by OSHA designed to
mlnlmlzo tho Mt-ard CNlu:IOd airborne 03003108 fiberll .
ReQUISITE SERVICE
Front brake pad removal/ in6tallation (page 13~ 2) • Front broke caliper rcmovollinstallation (page 13-4)
Brake fluid replacement/ air bleeding (section 17 of the
Common Service M anual)
• "'
(21
(3,
(41
(51
DISASSEMBLY ORDER
PRd "pring
Caliper bracket
Bradet pin bolt boot
Caliper pin bolt boot
Bracket pin bolt
. ,
,,
,
• A ssembly is in the reverse ord er of disassembly.
Note the spring direction 8S shown.
Install into the bracket g roove securelv.

Apply 8 locking agent to the threads and torque it. Apply
161 Caliper pm bolt "
, ..J silicone grease t o the pin.
(71 Caliper piston 2 Install them with the concaved side away from the pad.
(BI OU3t 3eel 2 , CAUTION :
(91 Piston seal 2 ..J • Be careful not to damage the piston sliding surface
when removing n811 .
¥ Honda CB400 / CB-1 Service Manual
BRAKES
.,..
REAR BRAKE CALIPER DISASSEMBLY/ASSEMBLY
•
• C
15
...-
• ~
• PAD SPRING
ORIENTATION AS SHOWN
• Inhalud asbestos fib81S have beall found to cause respiratory disease and cancer. Naver use an air hose or dry brush to
clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSAH designed to
minlmiu the hazard cau..d
REQUISITE SERVICE
airbQrne •• beltos fiber ••
Rear brake pad removal/installation (page' 3-3) • Rear brake caliper removal /installation (page 13-5 )
Brake fluid replacement/ air bleeding (section 17 of the
Common Service Manual)
•
111
DISASSEMBLY ORDER
PAd spring . 1
Note the spring direction as shown.
12) Pivot collar 1 Apply silicone grease to the sliding surface .
13 1 Pivot boot 1
14 1 Caliper pin bolt boot 1 Install into the bracket groove securely.
151 Caliper pin bolt 1 Apply a locking agent to the threads and torque it. Appl y
silicone grease to the pin.
16) Caliper piston 1 Install it with the opening toward the pad.
171 OU3t 3eol
::T CAUTION:
•
181 Piston seal • Be cafeful not to damage the piston 8lidlng 8urface
when removing s8at9 .
• http://www.motorcycle.in.th
BRAKES
FRONT MASTER CYLINDER REMOVAL/INSTALLATION
C 3513.5 , 251
«
(4(
•
REQUISITE SERVICE
• Air bleeding (section 17 of the Common Service Manual)
PROCEDURE Q'ty INSTALLATION REMARKS

(1) Right rearview mirror 1
(2 )
-
Brake lever pivot bott 1
(:J) Brake lever 1
(4) Brake hose bolt 1
(5) Sealing w3!:>lItlr 2
(6) Front brake light switch connector 2
•
(7) Mast.r cylinder holder bolt 2 Thighten the UpptH bolt first, then the lower bolt.
(8) Master cylinder holder 1 Fece the UP mark upward .
(9) Master cylinder assemblv 1 Alion the holder end with the punch mark no the handle-
bar.
BRAKES
REAR MASTER CYLINDER REMOVAL/INSTALLATION
•
REQUISITE SERVICE
• •
(1)
,2)
Brake fluid replacement/ air bleeding (section 17 of the Common Service Manual)
REMOVAL ORDER
PHUCEDURE
Brake hose bolt

Sealing washer
Q'ty
1
2
REMARKS
• Installation is in the reverse order of removal.
(3) Brake hose 1

(4) Master cylinder mounting bolt 2 Only loosen the bolts.
(!:'I) FOOtP8g bI3t.:~"'llJull 2
(6) Reservoir hose joint 1
•»
(7) O-ring 1
(8) Push rod joint 1 Install it from the footpeg side with a new cotter pin .
(9) Master cylinder assembly . 1 Remove the mounting bolts (4) and master cylinder.
BRAKES
FRONT MASTER CYLINDER DISASSEMBLYIASSEMBLY
•
(3)
(0)
~i"~/~
t
• (6)
I,T'_) (page 1-171 V

...
~(4) (
NOTE
Replace the ma!;ler piston, spring, c u ps, slOpp~r phlllf, smlp fillg and boot as 8 set.
• The master cylinder piston, cups and spring must be installed as a set.
REQUISITE SERVICE
• Air bleeding (section 17 of the Common Service M anual) • Front master cylinder removal/ installation (page 1 3·8)
• (11
(2)
(3)
PROCEDURE
DISASSEMBLY ORDER
Reservoir cover
Diaphragm plate
Diaphragm
.
Q'ty
,,
,,
ASSEM BLY REMARKS
(4)
(5)
Front brakelight switch
Boot ,,
(6) Snap ring CAUTION :
(7) Stopper plate , • Be c ertain the s na p rin g I. fully s eate d in the groove.
(.)
(9)
MUllt!!T piston assembly
Spring ,
(
Install it with its small coil end toward the piston.
13- 10
BRAKES
REAR MASTER CYLINDER DISASSEMBLYIASSEMBLY
• (6~
PUSH ROO INSTALLATION
LENGTH
• (5)
o
•
NU I i:
•
ReplacB the master piston, spring, cups, snap ring and boot as a set.
• The master cylinder piston, cups and spring must be installed as 8 set.
REQUISITE SERVICE
Brake fluid replacement/air bleeding (section 17 of the Common Service Manual)

Aear master cylinder rem ovaUinstaliation (page 13-9)
(1)
DISASSEMBLY ORDER
Push rod joint , • Assembly is in the reverse order of disassembly .
Adjust the joint installed length 8S shown. Face the joint
• ,, tab side as shown.

(2)
13)
Boot
.
•
Snap ring CAUTION:
(4) Pu p.h rod ,, • Be certain the snap ring Is fully ••• ted in the groove .
Apply silicone grease to the rod head.
(5)
16)
Master piston assembly
Spring , Install it with its small coil end toward the piston.
•
•
1 ~_11
BRAKES
BRAKE PEDAL REMOVAL/INSTALLATION
•
AS SHOWN
NOTE
• Adjust the brake pedal height after installation.

,,,
( 1) Footpeg stav bolt 2
• (2 1
(3 1
(41
(51
161
(71
PUSh rOC! Joint
FootP6g mounting bolt
Wavo w03hcr .
Reaf brakelight switch spring
Brake pedal return spring
Right footpeg
,,
,,
Install It trom the tootpeg side with a new cotter pin.
Apply a locking agent to the bolt threads .
Align the footpeg with the stay groove .

(8 1 Brake pedal Apply grease to the pedal pivot.
14. CHARGING SYSTEMIALTERNATOR

SERVICE INFORMATION 14-1 CHARGING SYSTEM INSPECTION 14-4
SYSTEM LOCATION 14-2 REGULATOR/RECTIFIER 14-5
CIRCUIT DIAGRAM 14-2 ALTERNATOR 14-7
•
TROUlll~SHOOTING 14-3
SERVICE INFORMATION
• The battery gives ott explosive ga ••• : keep spark,. flam •• , and cigarettes away. Provide adequate ventilation when
charging or using the battery In 8n enclosed space.
The battery contains sulfuric acid lelectrolyteJ. Contact with ,kin or ey•• may cau. . . .vere burns. We., protective
clothing and 8 fac8 shield.
- If ele<:trolyte oets on yo,,, skin, flush with watllr.
- If electrolyte gets In your eyes, flush with wat8r for at Jelilit 15 minutes and call a physician immediately.
• Electrolyte is poisonous. If swallowed. drink large quantltJes of water Of milk and follow with milk of magna.la or no.-
tabkt oil and call 8 physician.
KEEP OUT OF REACH OF CHILDREN.
• Always turn off the ignition switch before disconnecting any electrical component .
CAUTION
•
Some electrical components may be damaged If terminals or connectors are connected or diaconnected while the Igni-
tion switch is ON and currant is present.
• For extended storage. remove the battery. give it a full charge, and store it in a cool, dry place.
• For battery remaining in a stored motorcycle, disconnect t he negative battery cable from the battery terminal.
NOTE
• The maintenance free battery must be replaced when it reaches the end of its service life.
CI\UTION
The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the bat-
•
tIrry,
•
• aattary can be damaged .t overcharged or undercharged , or if left to discharge for long periods. These same conditions
contribute to shortening the " life span" of the battery. Even under normal use, the performance of battery deteriorates
after 2-3 years .
• Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually
diE' ovt For thi,!!, r"A'l''''' . thll r.hAroino iIIyilltAm iill nftAn illlIl'lpAr:tftn to be the problem. Battery overcharge often re sults from
problems in the battery it self, which may appear to be an overcharge symptom . If one of the battery cells is shorted and
•
battery voltage does not increase. the regulator/rectifier supplies excess voltage to the battery. Under these conditions,
tho electrolyte level goes down Quickly ,
• Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is
frequently under heevy loed , such as havmg the hetldllght and taillight ON for long periods of time without riding the motor-
cy cle .
• The battery will self-discharge when the motorcycle is not in use . For this reason, charge the battery every two w eeks to
prevent sulfation from form ing .
• Filling a new battery w ith elec trolyte will produce some voltage, but in order ttl ac:hieve its maximum performance, al w ays
c harge the battery. Al so , the battery life is lengthened when it is initial-charged .
• When checking the charging system, always follow the steps in the troubleshooting flow chart (page 14-3).
• Fo r battery testing/ charging, refer to section 22 of the Common Service Manual.
• For churging systum lu\,;atiQn , see page 14-2.
14-1
CHARGIN(; SYSTEM/ALTERNATOR
SYSTEM LOCATION
MAIN FUSE
(INTO STAR TER
• (4) BATTERY
REGULATORI
RECTIFIER
CIRCUIT DIAGRAM
e
(2) MAIN
FUSE
30 A
(4) BATTERY
• y y
(3) REGULATORI
RECTIFIER
(1) Al TEANATOA
14-?
CHARGING SYSTEM/ALTERNATOR
TROUBLESHOOTING
Battery overcharging
• Faulty regulator/rectifier
Battery undercharging
Measure the battery current leakage (leak test) Check the regulator/rectifier unit inspection
INCORRECT
(page 14-41 (page 14-6)
• CORRECT
IN CORRECT
L:
CORRECT
Shorted J ire harness
Faulty ignition switch
Faulty regulator/rectifier
• Inspect the charging voltage (page 14-4) •
NOT CHARGING
CORRECT Check the battery using a Honda Battery Tester
INCORRECT CORRECT
Electric
I
s~stem overloading
• Check the voltages of the regulator/rectifier bat-

tery charging line and ground line (page 14-5)
NORMAL
ABNORMAL_
1
Faulty battery
Open circuit in wire harness

Poorly connected connectors
Cl'lbtk the alternator (chargmg coill resistance at

ABNORMAL Check the charging coil at alternator (page 14-71
•
the regulator/rectifier connector (page 14-5)
ABNORM AL NORMAL
,
L:
Poorly connected alternator
NORMAL connector
Faulty alternator
Check the regUlatOr /rectifier unit Inspection

ABNORMAl _ " Faulty regulator/rectifier
(page'4-6)
NORMAL
~.~" Faulty battery
•
LI_ _ _ _ __ _ _ __ _ _ _ _ _ _ _ _
•
•
•
1/L ~
CHARGING SYSTEM INSPECTION

LEAK TEST
Turn off the ignition switch , and disconnect the ground (-)
cable from the battery.
Connect the ammeter (+) probe to the ground cable and the
ammeter I-I probe to the battery 1-) terminal.
With the ignition switch off, measure the leakage current.
NOTE
When measuring cu rrent using a tester, set it to a high
range, and then bring the range down to an appropriate
level. Current flow larger than the range selected may
blowout the fuse in the tester.
While measuring current, do not turn the ignition on.
A !lI Inn A n .IIllrOI'l of
tester .
~llrrA n' mAy hl('\w O~lf the fuse In the
•
e SPECIFIED CURRENT LEAKAGE: 0 .01 rnA 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.
I
CHARGING VOLTAGE INSPECTION
NOTE
Before performing thia teat, be cure that the battery is
fully charged whose voltage between its terminals is
Qreater than 12.8 V.
•
Start the engine and warm it up to operating temperature,
then turn the ignition switch OFF . ••
Connect a multitester between the battery terminals .
DIGITAL MULTITESTER 07411-0020000 or

KS - AHM - 32 - 003
(U .S.A . onlv)
.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
Disconnect t he starter relay switch connector and remove

the main fuse (~O A). Aeconnect the connector onto the relay
•
(1) MAIN
switch .
FUSE
Connect the ammeter as shown.
CAUTION
(4) AMME TER
B8 uandul lIut tu uhun any tester probes.
•
Although the current could be measured when the am- rr==t\~-'I
m.'.r i. fOonnected between the battery positive! termi-
nal and the positive cable. 8 sudden surge of current to
the s tarter motor could damage the ammeter. fB'A
Always tum the ignition off when conducting the test.
Disconnecting the ammeter or wires when current is
•
flowing may damage the ammetsr.
Start the engine and increase t he engine speed gradually.
hEGULATED VOLTAGE: 14 .0 - 16.0 V / S,DOO rpm
•
CHARGING CURRENT: 0-8 A / 5 ,OOO rpm
• REGULATOR/RECTIFIER
WIRE HARNESS INSPECTION
Remove the rear fairing (page 2-2) .

Disconnect the regulator/rectifier connector and measure the
following between connector terminals of the wire harness
side .
•, Item
B&Ttery
charging line
Ground line
Terminels
AM/White I + ) and'
ground (-I
Ureen and ground
Specification
Battery voltage
should resister.
Continuity exist.
Charging coil Y~lIuw ilnd Yellow 0.1-0.50
line (20 0 C/68°F)
•
UNIT INSPECTION
Remove the regulator fre ctifi er.
Inspect the regulator/rectifier unit by measuring the resis -

tance between the terminals.
NOTE
There are two types of the regulator/rectifier as shown.
Select the proper resistance chart.
Resistance value will not be accura te if the probes
touch your finger.
Uw thu fonow ing recommended multlte$ter.
Using another manufacturer' s equipment m ay not
allow you t!l obtain tho opaoified valuc3. This Is due t o
Unit· kO
t he characteristic of semiconductors,. which have dif-
l~
ferent resistance value depending on the appli9d volt-
(j) (j) (j) (j) ®
age .
SPECIFIC MULTITESTER:
(j) ~- ~ ~ ~ ~
(j) 0 . 5 - 10 30- 500 30- 500 10 200
•
- 07411 - 0020000 (KOWA Digital type)
- KS - AHM - 32-003 (j) 0 .5 - 10 ------ '---..
30- 500 30 - 500 10 - 200
(KOWA Dlgltlll type; U .S .A . only)
- 07308 - 0020001 (SANWA Analogue type)
(j) 0.6 - 10 30- 500 30- 600 --.... 10 - 200
- TH - 6H IKOWA Analogue type) ® 1 20 0.' 10 0 .' 10 0.' 10
Select the following range. ------

SANWA t • • ter: x kG
KOWA teater: x 100 G
When using the KOWA multitester, remember that all

IIftHJil1YIO IOhuuld be multlplleCiby 100.
An old, weak multitester battery could cause Inaccu-
rille readings. Check tho battory if t ho multitc3tcr regis-
ters incorrectly .
Replace the regulatorlrectifi er unit If the resistance value be-

the terminals is abnormal.
t W ll'll'n
Install the regul ator/rectifier in the reverse order of removal.
• NOTE
Install t he ground wire onto ttUt r AOLlI~tor/r ect; fie r
lower mo unting bolt properly as shown.
Unit· kO
~, (j) (j) (j) (j) ®

(j) ---.. ~ 00 00 00
(j) 0 .' 10 ---.... 30 '00 30 .00 10 - 200

(j) 0 . 5 - 10 00 00 00
(j) 0 . 5 - 10 00 ------00 00
@ 1 20 0.' 10 0 .' 10 ------

0.5 - 10
-------
ALTERNATOR
•
CHARGING COIL INSPECTION
NOTE
It i3 not necessary to remove tillil atl911l8tor (rum lin:!
engine.
• Disconnect the alternator 3P black connector and measure

th e resbtancc between connector terminals (Yellow and Yel-
low),
STANDARD: 0 . 1 - 0 .5 0 (20 0 C/68°FI

( 11 ALTERNATOR
CONNECTOR
•
Check for continuity between the Yellow wire terminal and
ground. There should be no continuity.
STATOR COIL/FLYWHEEL REMOVAL/
•
INSTALLATION
Remove the following :

- right cumkc.I!I!I1.fI r.nvAr (ptt{J8 9 - 2) ,
- flywheel bolt.
- washer.
- flywheel.
- woodruff key.
• Remove the bolt and stator wire harness clamp.

Remove the bolts and stator.
Apply a locking agent to the stator mounting bolt threads.

Install tM SUtOr and tighten the bolts securely.
Set the wire harness grommet into the cover groove and in-
otoll tho c lomp .
•,
Clean any material off the crankshaft.
Install the following:

- woodruU l\.Iily .
- flywheel.
- \Nt'Os t'le r .
- flywheel bolt.
TURQUE : 85 N'm (8.5 kg-m. 61 ft-Ibl
- right crankcase cover /page 9 · 2)

(4) FLYWHEEL
15;;:;0... 1 (page 1· 17) [.;:0.. ) (page 1-17)
15. IGNITION SYSTEM

SERVICE INFORMATION 15-1 IGNITION COIL 15-6
SYSTEM LOCATION 16-2 PULSE GENERATOR 15-8
CIRCUIT DIAGRAM 15-2 SIDE STAND SWITCH 15-8
TROUBLESHOOTING 15-3 IGNITION TIMING 15-9
• IGNITION SYSTEM INSPECTION
SERVICE INFORMATION
15-6
• When checking the ignition system, always. follow the steps in the troubleshooting flow chart (page 15-3).
• The transistorized ignition system use an electrically controlled ignition timing system. No adjustments can be made to the
ignition timing .
• A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect.
• The spark unit may be damaged if dropped . Also, if the connector is disconnected when current is flowing, the excessive
• voltage may damage the unit. Always turn off the ignition switch before servicing .
• A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
• Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine crank-
ing speed !IS well !IS no spark at the spark plugs.
• Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine .
Refer to section 2 of the Common Service Manual.
• For neutral switch inspection, refer to section 25 of the Common Service Manual; for switch location, see page 15-2 of
this manual (SYSTEM LOCATION).
• For the ignition switch and engine stop switch inspection , check for continuity on the continuity chart of the WIRING DIA·
GRAM, page 18- 1. Disconnect each switch connector inside the headlight case (page 1-19) and check it.
• For side stand inhibitor system instructions, see page 15-5 "NOTE" of the troubleshooting.
m
•
•
• http://www.motorcycle.in.th
IGNITION SYSTEM
SYSTEM LOCATION
I
:j~~::::lID STOP SWITCH UNIT
• (1 1) SPARK
PL.UG '1 PULSE
GENERATOR
CIRCUIT DIAGRAM
(4) MAIN (12) IGNITION (5) FUSE
3,iiii-FU:::S~E~3~O~A~ SWITCH 10 A 111 SIDE STAND
-Ie -. A - - i fO-R/BI-'---<V'C>- BUBr~ SWITCH INDICATOR
(2) CNGINE down
STOP (5) FU SE
(6) BATTERY SWITCH 10 A V/ SI (8) SIDE
To T.ch
r B11W--¢""'""o - SI
up
STANO
SWITCH
• (10) PULSE
GENERATOR
(3) IGNITION
COILS (7) SPARK
(9) NEUTRAL
UNIT
SWITCH
( 11) SPARK PLUGS
1 -2
IGNITION SYSTEM
TROUBLESHOOTING
•
No spark at all plugs (Faulty input system )
If there is no spark at all plugs, the problem could be at the input of the ignition system (pulse generator. power input circuit
of the spark unit, neutrel swit ch, side stand switch or spark unit) .
eh."k for loose or poorly connooted 3pork unit

ABNORMAL _ " Poorly connected connector
connector.
• NORMAL
Check f or loose or poorly connected ignit ion coil

4P mini connector.
NORMAL
ABNORMAL _ _ Poorly connected connector
•
t
Check If banery voltage is measured bet"{een
power input line (Black/White) and ground
(G reenl at the spark unit connector with the igni- r--- NO VOLTAGE __ Faulty ignition switch or engine stop switch
tion swit ch ON and the engine stop switch at Open circuit in wire harness
RUN (page 15-6). loose or poor contact of related circuit con-
•
nectors
I
BATTERY VOLT AGE MEASURED
Measure the pulse generator resistance at the

unit connec tor fpaoe 15-61 , ABNORMAl~~C~h~eC~k~th~e~PU~I~,~e~g~e~n~e,~.~to~'r(~P~.~g~e~'~5~-~8~).______"
I I
NORMAL ABNORMAL
' Faulty pulse gener-
• 1 ator
NORMAL
Open circuit between the unit and pulse gener-
otor
loose or poor contact of the pulse generator
connector
Check the neutral switch for continuity at the

ABNORMAl_! Chcck the neutral switch ,
spark unit connector !page 15-61,
I I
NORMAL ABNORMAL
' Faulty neutral
•» 1 switch
NORMAL
Open circuit between the unit and neutral
switch
l oose or poor contact of the neutral switch
connectors
Ch1ilcl!.. tim \lh..le !:It .. IIU !:lwitch al l im spark unit ABNORMAl--.1L~C~h~e~Ck"Tth~e~"~d~e~'~t~.n~d~'w~;t~C~h~l~p~.g~e~'~5~-8~)~.____"

connector (page 15-61. I I
•
NORMAL ABNORMAL
GOOD
"
,
Faulty 6par~ unit
t Faulty side stand
,w<tch
1
Open Circuit between the unit end side stand
switch
loo!'ll'! or poor contact of the side st and switch
connectors
1 1'>_ ~
IGNITION SYSTEM
No spark at either Ignition group

If there is no spark at either group, the r"roblem is liuspected in the primary t:oil side of the ignition system (ignition coil, or
unit and ignition coil circuitl.
" No Spark"
Switch the ignition coil primary terminal
condition Remove the faulty pair ignition coil and check.
connection between the faulty pair and good
-remains with th~ ignition coil resistance (page' 5· 7) .
pair. Try spark lest aua1n.
faulty pair
I
" No Spark" condi tion
ABNORMAL
t Faulty ignition coil
shUts to other pair Faulty spark plug
wire
OUT OF
MeaSure resistance of the ignitiOn primary coil at
STANOAAD_ Poor or loose contact of ignition coil 4P m ini
spark unit connector (page 15-61 .
VALUE cunnector
Open circuit between the unit and ignition coil
G~OO
• Faulty spark unit
No ~park at one pluy (Trouble In secondary coil alde)

• Faulty spark plug is most likely .
• r~R~.;p;'~.cie~I'~U~'~P~.~c~t!.;d~b~'~d:';'P;";'~k~P~';U~O~'~w;;;th~k~n=o~W~nj___
good spark plug and conduct spark
NO SPARK
fe !!!t .
SPARK ___.... Original spark plug no good,
Put the spark plug wire on and measure re sis- NORMAL Conduct spark test on good ignition coil.
tance of ignition 3econdery coil (page 15-7) .
OUT OF STANDARD VALUE SPARK
Remove the spark plug wire , and measure the

resistance o f the ignition secondary coil (page
nUT OF
STANDARD _ _ Faulty ignition coil
I
15-7), VALUE
GOOD
~oor contact of spark plug wire

• Faulty spark plug wire
1 !;-4
IGNITION SYSTEM
,
Engine starts, but aide stand switch does not function at all.
NOTE
The side stand switch should function as follows:
When the transmission is shifted into It gear from neutral with the side stand down, the ignition shuts off and the engine
will stop.
, When in neutfal , the neutral switch line (a) of the spark unit is connected to ground via the side stand switch.
When the ,ide stand is up, the side stand switch line (b) of the spark unit passes to ground via the side stand switch.
The spark unit monitors lines (8) and (b)' and provides spark only when one or both of those lines is connected to ground
vill the neutr91 switch or the side stand switch.
,
Check the side stand indicator for function . NORMAL _ " Open circuit in GreenlWhite wire
ABNORMAL
Check the side stand switch (page 15-81. NORMAL _ " loose or poor contect of releted connectors
Open circuit in GreenIWhite wire
A8NORMAl Burnt indicator bulb
•
" Fatlty side stand switch
IGNITION SYSTEM
IGNITION SYSTEM INSPECTION

CIRCUIT INSPECTION
NOTE
Follow the steps in the troubleshooting flow chart for
servicing.
Re move the seat .

Disconnect the connector from the spark. unit and conduct
these tests at the connector.
Item Terminals Specification

Power source input line Black/White 1+1 and ground I I Benery voltage should resister with the ignition
switch ON and the engine stop switch at RUN .
• Pul!lA oenerator coil

Ignition primary coil
Neutral switc h line

Yellow and White/ Yellow
No. 1- 4: Black/White and Yellow/Blue
No. 2 - 3 : Black/ White and Bluy/ Vellow
Ught Green/Red and ground
GreenIWhite and ground

340- 420 n (20 a C/68°F)
2-4 [) (20 0 C/68°F)
Continuity into neutral

No continuity in any gear except neutral
Continuity with the side stand up
Side stand switch line
No continuity with the side stand down
Ground line Green and ground Continuity
•
IGNITION COIL
INSPECTION
Ulsconnect the ignit ion coli 4P m ini connector under the fuel
tank and measure the primary coil resi stanc e betwe en the
termin.lt. IJtjluw .
No. 1 - 4 primary coil : Black/White end Yellow /Blue

No. 2 - 3 primary coil : Black/White and Blue/ Yellow
STANDARD: 2 - 4 n 120° C/ 68 ° F) II I IGNITION

CO NNECTOR
15-6
IGNITION SYSTEM
Disconnect the spark plug caps from the spark plugs and
mco~ure the secondary coil tEllilivllilll;U wi t h the ~park plug
•
wire at each ignition pair;
No.1 -4 secondary coil: between ENG 1 and ENG 4 wire

No . 2 - 3 secondary coil: between ENG 2 and ENG 3 wire
STANDARD: 23-27 kO (20 o C/68°F)
•
• Remove the ignition coli, disconnect the spark plug wires and
measure the primary and secondary coil resistances as
shown. III SECONDARY COIL
•
STANDARDS:
Primary coil: 2-411 (20 D C/6S D F)
Secondary coil : 13-17 kO (20°C/68°F)
(2) PRIMARY
COIL
» REMOVAUINSTALLATION
(2 1 IGNITION COIL
ASSEMBLY
Disconnect the ignition coil 4P mini connector under the fuel
tank. t
(31
R\l1IIuvt:l lht:! bolts and collars .
Oi~ i::onn.ct tho ignition primory terminals from the coils and
rem ove the ignition coil as an assembly .
•
RAmnVA holts and No . 2 - 3 ignition coil first. then remove
bOltS an(! NO. I - 4 ignition CO IL
) No. 2~3
Inotoll the ignition coils in the reverse order of reillovai. IGNITION
COIL
NOTE
Connect the spark plug wire properly 8S shown (right).
Conncct the ignition coil priml!ry terminals properly !:IS
shown above .
131 BOL
IGNITION SYSTEM
PULSE GENERATOR
INSPECTION
NOTE
It is not necessary to remove the pulse generator from
the engine.
Disconnect the pulse generator 2P mini blue connector under

the fuel tank and measure the resistance between Whitel
Yellow and Yellow terminals.
STANDARD : 340 - 4200 (20°C/68°FI
REMOVAL/INSTALLATION 11) BOLTS ,

Remove the left crankcase cover (page 16-Bl.
fit/move the bolts and pulse generator.
• Install the pulse generator and wire clamp, ond tighten the
bolts securely .
Set the wire harness Qrommet into the cover groove.
Install the left crankcase cover (page 16-8),

(2) GROMMET~~~~o;::::=;=""~O~
SIDE STAND SWITCH

INSPECTION
Disconnect the side stand 3P mini grp.f'Jn connector under the

fuel tank and check for continuity between each terminals as
below.
There should be continuity between the 0--0 positions on (1) SIDE <T',"" SWITCH
the continuity chart .
• Side stand
down
Side stand
Green/White Yellow/Black Green
~up
up
(3) DOWN
» Honda CB400 / CB-1 Service Manual
IGNITION SYSTEM
REMOVAl/lNSTAlLATION
•
Disconnect the side stand connector.
Remove the wotor Dump side cover.
With the side stand up. remove the side stand switch mount-
ing bolt and side stand switch.
Install the switch in the reverse order of removal.
• TORQUE:
NOTE
Side st.nd sw itch mounting bolt:
3 0 N·m 13 .0 kg-m . 2 2 ft-Ib)
Align the switch pin with the side stand hole and align
5==;---' '"' ALIGN
SIDE STAND SWITCH
• the switch groove with the side stand return spring

holding pin.
(11 SIDE
STAN D
e Route the side stand switch wire harness properly as shown.
SWITCH
W IRE
HARNESS
• IGNITION TIMING
Warm up the engine.
Stop the engine and connect a timing light to the No .3 cylin-
der spork plug wire.
NOTE
• Read the instructions for timing light for operating.
•, Remove the following:

- crankshaft hOle ca!:l toyer (page ~-21.
- crankshaft hole cap (page 9- 21.
- timing mark hole cop (poge !J-21.
o~
(1) TIMING LIGHT
Start the engine and let it idle.

The timing is correct if lila F rmlfk aligns Wit h thO crankcase
cover index mark. -
(3 ) ADVANCE START
NOTE
If the correct timing could nOl ut! ubsarved, connect a
t iming light to the No. 2 cylinder spark plug wire and re-
check the ignition timing.
""
InorooGO the engine 3peed by rotating the lllruLUa stop screw
(2)
on the carburetor, make sure the F mark begins to move
counterclockwise lit Rrrrnl!im9tely 1,700 rpm,
, Honda CB400 / CB-1 Service Manual
16. ELECTRIC STARTER/STARTER CLUTCH
SYSTEM LOCATION
CIRCUIT OIAGRAM
TROUBLESHOOTING
16-1
16-2
16-2
16-3
STARTER MOTOR DISASSEMBLY!
ASSEMBLY
STARTER CLUTCH REMOVAU
INSTALLATION
16-6
16-8
• STARTER MOTOR REMOVAU

INSTALLATION
SERVICE INFORMATION
16-5
• Always tum the ignition switch OFf before servicing th" .tarter motor. The motor could s uddenly start. causing ••rious
Injury.
• • A weak battery may be unable to turn the st arter motor quickly enough. or supply adequate ignition current .
• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor
mAy bI! dJlmllQfHL
• For the following component inspections, refer to the following pages; for the parts loeations, see page 16· 2 of this
manuel (SYSTEM LOCATION) .
Clutch switch diode Section 24 of the Common Service Manual.

Starter motor Section 24 of the Common Service Manual.
•
Starter relay swi tch SI!r.tinn 24 of the Common Service Manual ("A" circuit type'.
Clutch switch Section 25 of the Common Service Manual .
Neutral swltel"l Section 25 of the Common Service Manual.
Ignition switch Check for continuity on the continuity chart of the WIRING DIAGRAM, page 18· 1.
Disconnect the switch connector inside the headlight case (page 1· 1 9) and check it .
(page 15·8)
m
Side stand switch
... I:." ..
SYSTEM LOCATION
(6) BATTERY
SWITCHI __
FUSE 30 A
.?----:7""
• fl21 ClIJTC:H
SWITCH 111) IGNITION
SWITCH
110)
MOTOR
(9) NEUTRAL
SWITCH
(8) SIDE STAND
~WITCH
CIRCUIT DIAGRAM
(11) IGNITION
SWITCH
(6) BATIEAY
141 STARTER
RELAY
SWITCH
•
f1 RIBI A
~51
(101 STARTER
MOTOR
(5) '"USE - (4) MAIN '1-+1'
lOA US
I -
FUSE VIR
10 A
Sl/Br BL.a--o-- VIR ------IT
30 A
J
• (2) NEUrHAl
INDICATOR
SWITCH
13) STARTER
:~'"'I~ ,~. SWITCH

o.
fl21 CLUTCH
,,'-'"
•
DIODE
( i) SIDE STANO
SWITCH 't::._ _ _ _ _ _ _ __ _ _ _ _ y /BI
INDICATOR
181 SIDE
STAND
SWITCH
TROUBLESHOOTING
Start.r motor w ill not tum
Check for a blown out main or sub fuses before servicing.
• Make sur. the battery is fully charged and In good eondltlon.
C:hAr.k fm IOOIS(t or poorly connected battery ter-

ABNORMAL _ " Poorly connected battery terminals
minals, and opened or shorted battery cable.
Open or short circuit in battery cable
NORMAL
Che~k fOr loose or poorly connected starter

relay switch terminals and 4P connector.
ABNORMAl_" Poorly connected terminals or 4P connector
NORMAL
Check for loose or poorly connected starter

motor cable , end opened cable. ABNORMAl_" Poorly connected motor cable
Open circuit in motor cable
With the ignition switch " ON" . push the starter Connect the starter motor terminal to the bat-
switch and check for a "click" 30und from the - CliCKS - - . j tery positive Huminat tJinlctlv. (Because 8 large
• L:."
t.,rt~·'CC,·,I".,Yc·""~;t"c"hc·____________________--, amount of current flows, do not use thin wires)
I I
Starter Starter motor
motor does not turn
turns
NO CUCK ! Faulty starter motor
j
Loose or disconnected starter motor cable
Faulty starter relay switch
Disconnect starter relay switch connector. and

che c ~ lhl:t I l;IliclY cull yround wire lines 8S below
for continuity:
1. Green/Reel terminal -clutch Dwitoh diode-
neutral switch line (with transmission into
neutral and clutc h lever released .1
f- NO CONTINUiTY...... Faulty neutral switch
Faulty clutch switch diode
2. Green/Red terminal-clutch switch-side stand
Faulty clutch switch
switch line (in any gear except neutral, and
Faulty sida stand tlwitch
with the clutch lever pulled in and the side
stand up.)
loose or poor contact of connector
•
I
CONTINUITY
•
Connect the starter relay switch connector .
With the ignition switch ON and the starter
switch pushed, measure the starter relay volt- NO VOLTAGE_· Faulty ignition switch
age at the starter switch connector (between Faulty starter switch
Yellow/Red 1+1 and ground HI. Blown out main or sub fu ses
Loose or poor contact of connector
VOLTAGE APPEARED Open circuit in wire harness
Check the starter relay switr:h npftflltinn NOAMAL_· Loose or poor contoct of thc startcr relay
switch connector
L - - - -- - - - -- - ---ABNOAMAL_· Faulty starter relay switch
EI.ECTRIC STARTER/STARTER CLUTCH
The sterter motor tllrnt; when the tranamission it} in neutral, but does not turn with the tran!lmission in any position except
neuttal, with the side stand up and the clutch lever pulled in.
Check the side stand indicator is properly oper-

ABNORMAL _ . Faulty side &.tand switch
ated with the ignition switch ON.
Burnt bulb
NORMAL
L':COh:eOc"kC,:h:e:..::cO'uO'"C,hC'CW",;'"Ch::..:o,poec,e:'e;oen'.:'-._____,--- ABNORMAL _ , Faulty clutch switch
NORMAL
Check the side stand switch (page 15·B). ABNORMAL _ , Faulty side stand switch
NORMAL
I • Open circuit ill wire harness

Loose or poor contact of connector
Starter motor tums slowly

Low speCific gra vity in battery tor Dead battery}
Poorly connected battery terminal cable
•
Poorly connected starter motor cable
Fautty :ttortsr motor
Poorly connected battery ground cable
Starter motor tums. but engine does not tum

Starter motor is running backwards
- Case assembled improperly
- Terminals connected improperly
• "aulty S1aner elutch
Damaged or faulty starter pinion
Damaged reduction geers
Starte, relay .wltch "click", !)tIt engine do•• not tum over
Crankshaft does not turn due to engine problems
, Excessive reduction gear friction
STARTER MOTOR REMOVAL/INSTALLATION
• (11
•
(3)
(4)
•
(5) " ,
•
•
REQUISITE SERVICE
• Fuel tank removal/ installation (page 2-41
REMARK S
,•
PROCEDURE Q'tv
11 \
(2 )
Starter motor cable . 1
Starter motor mounting bolt 2
(3 ) Ground cable on engine 1
(4 ) Starter motor 1
(5) O-ring 1
•
•
ELECTRIC STARTERISTARTER CLUTCH
STARTER MOTOR DISASSEMBLY/ASSEMBLY
• (191
•
I
REQUISITE SERVICE
•
• Starter motor removal/installation (page 16-5)

DISA5$EMBl Y ORDER • AS~>Illllbty is in the reverse order of disassembly.
(11 Set screw 2
(7) $1£'1 p1at'l' 2
•
(3) O-ring 2
(4) Front cover /D -ring
",, Align the index marks on the cover and case.
15)
16)
O-ring
Motor case , NOTE:
• Intall with the groov8 side facing to the brushes.
,, • Align the index marks on the rear cover and cese.
•
(7) O'liny
18) lock washer . ,,
19) Insulated washer
(10)
(11)
Washer
Armature ,
(12) Shims - Record and store the shims in the seme order they were
• (13)
(14)
(15 )
Brush terminal holding nut
WllsllI;I1
Insulated washer
- bigger
,,
3
111
installed so they can be reinstalled in the original posi-
tions.
- smaller (1)
(16)
- smaller
O-ring ,,
(1)
• ,,
(17) Brush holder assembly Align the holder tab with the rear cover groove .
(18) Brush and terminal
( 19) Rear cover
•,
•
STARTER CLUTCH REMOVAL/INSTALLATION
•
CLAMP
~
, •
• (2)
31 -, 11
• I
(
Is~ 1 (page 16-9)
(t 85 (8.5, 61)
ALIGN THE WIDE GROOVE I
AMONG T HE CRANKSHAFT
SPLINES AS SHOWN
•
REQUISITE SERVICE
•
• Right crankcase cover removal/installation (page 9 -21

11) left crankcase cover bolt
121 left cranKcase cover ,,
7 Install the pulse generator wire clamp properly 8S shown .
• ,,
131 Gasket
111 Dowel pin
,,
151 Starter clutch bolt Removal and installation (page 16-91.
IBI Washer
17) Pulse rotor Install it with the marked side facing out.
lal Starter clutch assembly -,
,,
•
191
(10)
- starter driven gear
- needle bearing
.
(1 1 ) - starter clutch At installation, make sure the starter clutch roller is In-
(12) Spline washer ,, stalled properly into the clutch housing.
,
•
(13) Starter drive gear shaft
(141 Starter drive gear
, STARTER CLUTCH BOLT REMOVAl!

INSTALLATION
CAUTION
j. Do not hold the pulse rotor.
Set the rotor holder onto the flywheel.
• ROTOR HOLDER 07725-0040000 o r

equivalent commercially
available in U.S .A.
Hold the rotor holder and remove the starter clutch bolt with
a helper.
Set the rotor holder and hold it onto the engine bracket as
shown.
t Tighten the starter clutch bolt to the specified torque .
TORQUE: 85 N·m (8.5 kg-m . 61 ft-Ibl
17. LIGHTS/METERS/SWITCHES
, SERVICE INFORMATION
SYSTEM LOCATION
17-1
17-2
METER REMOVAUINSTALLATION
METER DISASSEMBLY/ASSEMBLY
17-5
17-6
,
HEADLIGHT REMOVAL/ TACHOMETER INSPECTION 17-7
INSTALLATION 17-3
IGNITION SWITCH REMOVAU
TURN SIGNAL LIGHT 17-4 INSTALLATION 17-7
TAILLIGHT 17-4
SERVICE INFORMATION
• .
.
. Halogen h••dllght bulb become. vary hot while the headlight Is ON. and remain hot for
a ura to let It cool do wn bafor••arvicing.
II while atte, It I. turned OFF. Be
Use II flame a nd heated water/coolant mlxtur. for the thermo lIenlor Inapecticn. Keep 1111 flammable materials away
•
from the burner. We., . glov•• and a ye .
• Note the followings when replacing the halogen headlight bulb.

- Wea, clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, 8S they may crllate hot spots
on the bulb and cause it to break.
- I' you tOUeh t he bulb with your bare hands, clean It with II cloth moistened with alcohol to prevent its early failure .
- Be sure to install the dust cover after replacing the bulb.
• Chcck tho bottery oondition boforo porforming any inopoction that requires proper battery voltage.
•
•
A continuity test can be made with the switches instalied on the motorcycle.
For the following component locations. see page' 7 · 2 of this manuallSYSTEM LOCATION) : for inspections. refer to the
applicable pages .
Component Inspection method Remarks
Clutch switch Section 25 of t he Common Service Manual

Coolant temperature gauge/ Section 25 of the Common Service Manual Temperature gauge removal (page 17· 6) .
Thermo sensor Thermo sensor removal (page 5·4).
Fan motor switch Section 25 of the Common Service Munuul Removal (paga 5·6).
III
Front brekelight switch Section 25 of the Common Service Manual
Section 25 of the Common Service Manual Removal (page 6-13).
•
Fuel pump/Fuel cut·off relay
Horn Section 25 of the Common Service Manual
Handlebar 6witche6 Ctieck for continuity on the continuity chert Switch connectors ere located inside the
• of the WIRING DIAGRAM, page 18· 1. headlight case (page 1- 19).

Ignition switch
Neutral switch Section 25 of t he Common Service Manual TORQUE: 18 N-m (1.8 kg-m, 13 ft· lb)
Apply sealant to the threads.
Oil pressure switch / warning Section 25 of the Common Service Manual Oil pressure check : Section 4 of the
light Common Service Manual
•
Oil pressure switch torque:
12 N'm 11 ,2 kg·m, 9 ft·lb )
Rear brakelight switch Section 25 of the Common Service Manual
Turn signal URhts Section 25 of the Common Service Manual 3 terminals relay.
LIGHTS/METERS/SWITCHES
SYSTEM LOCATION
(2) COOLANT TEMPEAATUAE

•
•
(3) FAONT
BRAKELIGHT
(4) OIL PRESSURE
BATTERY
• ( 1) IGNITION
SWITCH (5) FUSE
BOX
115)
(14)
(13)
6EN60A
• 1121 1111
m REAR
f
BRAKEUGHT
SWITCH
(8 ) TURN SIGNAL
RELAY
" Honda CB400 / CB-1 Service Manual
,
HEADLIGHT REMOVAL/INSTALLATION
•
Halogen headlight bulb become. very hot while the headlight I. ON. and remain hot for a while aftar it is turned OFF . Be
) I Ut. to let it cool down before ••rvlcing .
CAUTION
· W~" r c1epft 010V8' while replacing the bulb. Do not put finger prints on the headlight bulb • • a they may create hot spots
on the bulb and causa It to break .
·· If you touc h the bulb with your bar. hands. claan it with a c loth moistened with alc ohol to prevent its earty failur • .
Ba s ur. to Install the dust cover oftar replacing the bulb.
PROCEDURE C 'ty REMARK S
• REMOVAL ORDER • Inst aliat ion is in the reverse order of removal.

11 )
\2 1
Scre w
Hoadlight bulb Gockot ,
3
13) Dust co ver 1 Install it w ith the TOP mark facing up .

14 ) Headlight bulb 1
15) Headlight assembly 1
16 ) Connectors - Connection (page 1- 19)
171 Headlight case 1 A lign the index marks on t he c ase and bracket.
TURN SIGNAL LIGHT

BULl! REPLACEMENT (1) BULB
ReMove the screw and lens from the turn signal ease.
Turn the bulb socket counterclockwise and remove it.
Turn tho bulb oountoroloakwiGo and removo it.
Install a new bulb in the reverse order of removal.
(4) SOCKET •
TAILLIGHT
BULB REPLACEMENT
III BULB
•
Remove the screws and lens from the taillight case.
• Turn the bulb counterclockwise and ramove it .
Install a new bulb in the reverse order of removal.

121 SCR1EWS
•
I
METER REMOVAL/INSTALLATION
•
6P-RED
•
• (2)
•
• Headlight assembly removal (page 17-3)
•
)
( 1)
(2)
(3)
(4)
REMOVAL ORDER
Meter mounting bolt
Speedometer cable
Meter connector
Meter o:uembley
. 2
1
2
1
• Installation is in the reverse order of removal .
6P mini White connector and 6P mini Red connector
. ~ -
METER OISASSEMBLYIASSEMBLY
Remove the five screws and the meter rear cover.
;;::~'""" 12) SCREW
•
Pull all Indicator bulbs OUt ot the Meier housing.
(1) CLAMPS
Remove the wire harness clamps, and remove the nuts,
washers and meter stlly.
• Disconnect the meter terminals, and remove the wire har-

ness.
Remove the screw and meter front cover.

I FRONT COVER
•
• (2) I

(1)
- tWO Mrews and tachometer.
- trip meter reset knob.
GEAR
four 3crCW3, 3peedometer gear joint end O -ring.
- speedometer.
JOINT I
Assemble the meter in the reverse order of disassembly.
(5) SP~('DO:~""'Tf!",
METER
NOTE
Connect the proper color wire to the meter terminals.
t
Y /G: Yellow /Green G: Green
B/ BR: Black/Brown G/ B: Green/Black
GIL: Green/Blue
$ Honda CB400 / CB-1 Service Manual
TACHOMETER INSPECTION
•
Remove the headlight assembly (page 17 -3 1. and disconnect
the 6P mini Red connect or and 6P mini White connector.
f":nnnAr:t II v nltm AtAr lIr.rn~$ the Black/R.nwn (+) IInr1 c:;,U'If'ln

(- ) terminals of the main wire harness side.
•
Turn the ignition switch ON and battery ..,0It8.98 should re-
sister .
It there is not O.K., the e lectric tachometer do not catch
power from the battery . Trace and repsir the related wiring,
sub fuse andlor connectors .
• Disconnect the spark unit connector (page 1 5-6).

Check f or continuity between the Yellow/Green wire termi -
nal6 of the 6P mini White connector and spark unit connec-
tor.
• Continuity exists at all times.

If there is no continui t y. replace the main wire harness.
If all checks afe O.K .. replece t he techometer.
(l( SP',RK
UNIT CONNECTOR
CONNECTOR
)
IGNITION SWITCH REMOVAL!
INSTALLATION
Al:!lI1uvl:! till:! II1l:Jtl:!r as an Clssl:!rnbly Ipagl:J 17- 5). (1) IGNITION
Disconnect the 3P Black connector and 2P mini connector SWITCH
inside the headlight oaso.
Remove the bolts using the torx bit (T40) (07703 -
•
0010100) and lenition switch.
Remove the screws and separate tJ1e con tact base from the
cylinder.
• NOTE
• You can separate the swit ch in all key position.
Apply a locking agent to the threads and install the ignition

------'
•
switc h in the reverse o rder of removal.
TURUUE :
Switch mounting bolt: 25 N·m 12.5 kg-f!"!. 18 ft -Ibl
•
(2) BOLT
1$;;"' 1 (page t - 17)
CU
18. WIRING DIAGRAM

I
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I
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II! \Ii
.. " ...
--..g
~
I
c
I
lh l , l N
-.
II . ....
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I:
• I
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I I II I
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II
• I , I
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• 1'.1
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•
•
~ • Ii t
http://www.motorcycle.in.th 18-1
19. TROUBLESHOOTING
ENG I N~ DOES NOT START OR IS POOR PERFORMANCE AT HIGH
HARD TO START 19-1 SPEED 19-4
ENGINE LACKS POWER 19-2 POOR HANDLING 19-4
POOR PERFORMANCE AT LOW AND
IDLE SPEEDS 19-3
ENGINE DOES NOT START OR IS HARD TO START

POSSIBLE CAUSE
1. Check fue l flow to carburetor NOT REACHING CARBURETOR •• Clogged fuel line or fuel filter
Sticking float valve
REACHING CARBURETOR Faulty fuel pump
Faulty fuel pump relay
Clogged fuel tank vent hole
Loose or disconnected fuel pump
re lay wire
2 . Perform spark test WEAK OR NO SPARK - - - - - _ •. Faulty following (page 15-3):

- ignition coil
GOOD SPARK - pulse generat or
- neutral switch
- spark unit
- side stand switch
1
- engine stop switch
3. Remove and inspect spark plug WETPLUG --------~ • Mixture too rich
Carburetor flooded
SPARKS Carburetor choke excessively
closed
Cylinder f looded
j
Air cleaner dirty
Faulty Purge Control Valve
(ClIlifornill model only)
• ••
4 . Te$t ey1inder compression LOW COMPRESSION - - - - - - _ Improper vcalve ciearl'lnce (shim too
thickl
COMPRESSION NORMAL Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket OJ
j
Seized valve
Improper valve timing
IrnplOper valve and seat contact
S. Start by following normal procedure ENGINE STARTS BUT STOPS - - - - •• Improper choke operation
Carburetor incorrectly adjusted
ENGINE DOES NOT FIRE Intake pipe leaking
Improper ignition timing
I
(Faulty spark unit or pulse gener-
atorl
Fuel contaminated
6. Start with choke on
TROUBLESHOOTING
ENGINE LACKS POWER

POSSIBLE CAUSE
I . Raise Whlllfl~ urf ijlUU1IU QIIU WHEELS DO NOT SPIN FREELY - - _ . . . Brake dragging
spin by hand Worn or damaged wheel bearings
W hAel hRAring needs lubriceotion
WHEEL SPINS FREELY Drive chain too tight
! A xle nut excessively tight
2. Check tire pressure
PRESSURE NORMAL
I
PRESSU RE lOW - - - - - - - - -.... Faulty tire valve
•
3. Check for clutch slippage CLUTCH S L I P S - - - - - - - - - _•• • Faulty clutch lifter system
Worn clut ch disc/plate
CLUTCH ENGAGED PROPERLY Warped clutch disc/plate
Weak clutch spring
l
4 . Accelerate lightly ENGINE SPEED DOES NOT INCREASE_· Carburetor choke closed
Clogged lIir cleaner
•
ENGINE SPEED INCREASES Restricted fuel flow
Clogged muffler
Clogged fuel cap vent hole
Faulty fuel pump
Faulty fuel pump relay
Loose, broken or shorted wire or
connection of pump relay
5. Chac ignition timing INCORRECT- - - - - - -- - -••• • Faulty spark unit

Faulty pulse generator
CORRECT
t
6. Check valve cleafance INCORRECT------ - -- - -•• • Improper valve adjustment
Worn valve seat
CORRECT
t
7. Test cylinder compression TOO LOW - - - - - - - - - - -_.· Valve stuck open
Worn cylinder and piston rings
NORMAL Improper valve timing
I
SaLI.QrJ valv9
Improper valve and seat contact
• B. Check carburetor for clogging
NOT CLOGGED
t
9. Check spark plug condition
CLOGGED - - - - - - - -- - -_ •• •
FOULED OR DISCOLORED----- •• •
Carburetor not serviced fr equantly
enou~h
Plugs not serviced frequently

enough
NOT FOULED OR DISCOLORED Spark with im.:orr~ct heat ranye
10. Choat oil leYol and oondition INCORRECT - - -- -- - -- _.. . 011 level too high
Oil level too low
CORRECT Contaminated oil
19·2
TROUBLESHOOTING
POSSIBLE CAUSE
•
11. Remove cylinder heed cover and VALVE TRAIN NOT LUBRICATED--~•• • Clogged oil passage
inspect lubrication PROPERLY Clogged oil control orifice
Contaminated oil
VALVE TRAIN LUBRICATED Faulty oil pump
PROPERLY
t
12. Check for engine overheating OVERHEATING --------~••• Coolant level low
• NOT OVERHEATING
Fan motor not working
(Faulty hm motor switch)
Therm ostat stuck closed
Excessive carbon build-up in com-
bustion chamber
Use of poor quality fuel
•
Clutch slipping
lean fuel mixture
13. Accelerate or run at high speed ENGINE KNQC K S - - - - - - - -_.. • Worn piston and cylinder
Wrong type of fuel
ENGINE DOES NOT KNOCK Excessive carbon build-up in com -
•
bustion chamber
Ignition timing t oo advanced
(Faulty spark unit)
Lean fuel mixture
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

POSSIBLE CAUSE
• , . Check ignilion t iming and valve

clearanco
CORRECT
t
2. Check carburetor pi'Iot screw
IN CORRECT-----------~.·
INCORRECT ----------.~"
Improper
Improper
- Faulty
- Faulty
valve clearance
Ignition timing
spark unit
pulse generator
See Fuel Syst em (Section 8) of the

adjustment Common Service Manual
CORRECT
t
3. Check for laaking intake pipe LEAKING - -- - - - - - - - - -_. " Loose carburetor
•
Damaged insulator
NO LEAKAGE
•
4. Perform the spark test WEAK OR INTERMITTENT SPARK _ " Faulty , carbon or wet fouled spark
plug
GOOD SPAflK Faulty following Ipage 15-3):
- ignition coil
- pulse generator
- neutral switch
•
- spark unit
- side stand switch
- engine stop switch
•
19-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEED

POSSIBLE CAUSE
Cnecic ignition timing and valve INCORRE CT - - - - - - - - - - "o. . Improper valve clearance
clearance Improper ignition timing
- Faulty spark unit
CORRECT - Faulty pulse generator
+
2. Disconnect fuel line at carburetor t-UI::L t-lUW RESTRICTEO ----_0.' Fuel tank empty
Clogged fuel line
FUEl FLOWS FREELY Clogged fuel cap vent hole
Clogged fuel valve
Faulty fuel pump or relay
1
3 . Remove carburetors and check for CLOGGED ----------~O.·
Clogged fuel fi lter
Clogged jets
clogged jets
NO COlGGED JETS
+
4 . Check valve timing
•
INCORRECT - - - - - - - - -- _.. Camshaft not installed properly
CORRECT
+
5 . Check valve spring tension W EAK - - -- - - - - - - - - _ . . Faulty valve spring
POOR HANDLING - - - Chilek lin:! etilU !:iut;pl;ll n;iun pressure
POSSIBLE CAUSE
1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - - . . • Steering head bearing adjustment

nut too tight
Damaged steering head bearings
Bent st eering stem
2 . If either wheel is wobbling o Excessive wheel bearing play

Bent rim
Improperl y installed wheel hub
Swingarm pivot bearing excessively
•
worn
Bent frame
3 . If tM motorcycle pulls to one side -----------------"00· Incorrect drive chain adjustment

Front and rear wheels not aligned
Bent fork legs
Bent swingarm
Bent frame
20. INDEX
• Air Cleaner .......................... ..... .... .. ....... ....... .. 3-5 Ignition Switch Removall1nstallation .................. . 17-7
Case Removal/Installation ............. ........... 6-3 Ignition System ....................................... ....... . 15-'
, Alternator •...................... . '........ ................... ... 14-7 Circuit Diagram ..................................... . 15-2
Brake Pedal Removal/Installation ........................ 13-12 Inspection ............................................. . 15-6
Brakes ............. ,................. ................... .......... 13- 1 Location .............................................. .. 15-2
Cable and Harness Routing ............................... 1-19 Ignition Timing .............................................. .. 15-9
•
Camshaft Removal/Installation .......................... 8-2 Left Handlebar Removal/Installation ...............•.•. , ' -3
Carburetor Combination.................................... 6-10 Lights/Me ters/ Switches .................................. .. 17-1
Disasscmbly/asscmbly ......................... .... 6 8 System Location .................................... . 17-2
Removaillnstallation ................................ 6-4 Lubrication and Seal Points .............................. . '-18
Separation ................ ............................. 6-6 Lubrication System ......................................... . 4-1
Synchronization ............................... ....... 3-8 Diagram .. ............................................ .. 4-2
Charging System/Alternator .............................. 14-1 Maintenance .................................................. . 3-1
• Circuit Diagram ...................................... 14-2

Inspection . ..................... ........ ..... : .......... 14-4
Location ...................................... .......... 14-2
Clutch Installation ............................................
Removel ................................................
Clutch/Gearshift Linkage ...................................
9-8
9 ·4
9-1
Schedule ....... ............ .......................... ..
Meter disassembly/assembly ........................... ..
Removaillnstallation .............................. ..
Model Identification ........................................ .
Oil Pump disassembly/assembly ....................... .
Removaillnstallation ............................... .
3-4
17-6
17-5
1-3
4-4
4-3
• Cool~ nt DrAining ......................................... .... .

Cooling System .............................................. .
Flow Pattern ......................................... .
Crankcase Installation .................................... . . 10-12
Separation .................................... ....... .. 10-2
Crankshaft Bearing Replacement ............ .. ........ . 10-6
5-3
5-1
5-2
Pulse Generator .............................................. .
Radiator disassembly/assembly ........................ ..
Removal/Installation ............................... .
Rear Brake Caliper disassembly/assembly ......... ..
Removaillnstallation ....... ........................ .
Pad Replacement .............. ..................... .
15-8
5-6
5-5
13-7
13-5
13-3
Crankshaft/Connecting Rod Removal/ Rear Fairing Removal /Installation .... .. ........ .. ... ... . 2-2
In:stalletion ........... ......................................... . 10·4 Reor Moster Cylinder diaassembly/assembly ....... . 13- 11
•
Crankshaft/Transmission ................................. . 10- 1 Removalflnstallation .............................. .. 13-9
Cylinder Head disassembly/assembly ................. . 8-6 Rear Wheel disassemblyfassemb ly ............... ..... . 12-3
Aemovaillnstallation ............................... . 8 -4 Removal/Installation .............................. .. 12-2
Cylinder Head/Cylinder/Piston .......................... .. 8- 1 Rear Wheel/Suspension .................................. .. 12-1
Cylinder/Piston Removal/Installation .................. . 8-8 Regulator/rectifier ..................... ..... ................ .. 14-5
Electric Starter Circuit diagram ........................ .. 16-2 Reserve TAnk RemOVAl/Installation .................. .. 5-3
System Location ......... ................... .... .... . 16·2 Right Crankcase Cover Removal/Installation ...... .. 9-2
Electric Starter/Starter Clutch ........................... . 16-1 Right Handlebar Removal/Installation ............ . .. .. . 11 -2
Emission Control Information Labels Seat Removalflnstallation ................................. . 2-2
(U.S.A. only) ............................ ... .................... 1-28 Service Access Guide ................ .................... .. 3-2
Syl':tAml': . ............ 1-25 Service Information Brakes ............................. .. 13-1
Systems (California Model Onlyl ............... 6- 13 Charging System/Alternator ................... . . 14-'
•
Engine Removaillnstallation ............... ..... ........... 7- 1, 2 Clutch/Gearshift Linkage ......................... . 9-1
Exhaust System Removaillnstallation ................. 2-3 Cooling System ................................. .... . 5-1
Fork Assembly ................................... .. ........... 11- 10 Crankshaft/Transmission ... .. ................... . 10-,
•
Uisassembly ..................: ........................ l1 -H Cylinder Head/Cylinder/Piston ... .. ............. . 8- 1
Removal/Installation ................................ 1 1-6 Electric Starter/Starter Clutch .................. . 16- 1
rrAmft/Dody rAnels /[xhAust System ....... . ........... 2-1 Engine Removalflnstallation . .................... . 7- 1
2-1
Front Brake Caliper disassembly/ assembly.......... 13-6
R~mOv'l'l/lnst'l'II'1'ti"n 13-4
Frame/Body Panels/Exhaust System ......... .
Front wheel/ Suspf!nsion/ Steering ............. . ,,-,
Pad Replacement .................................. .. 13-2 Fuel System ...... . .................................. .. 6 -1
Front Master Cylinder disassembly/assembly 13-10 Ignition System ................ ............... ... ... . 15-1
•
Removal/Installation ........ ............. .... ...... . 13-8 Lights/Meters/Switches .............. ............ . 17-1
Front Wheel disassembly/assembly .................. .. 11 -5 Lubrication System .............................. .. . 4-1
Removal/Installation .............. ................. . 11 -4 Maintenance .... ............... .... .................. . 3-1
Front Wheel/Suspension/ Steering ....................... . 11 - 1 Rear Wheel/Suspension ...................... ... . 12- 1
Fuel Pump/Filter .................... ... ...................... . 0-13 Shock Absorber disassemblY/ 8ssembly .............. . 12-5
Fuel System ................................ ......... .. ....... .. 6-1 Removal/Installation ............ .... .. .. . ....... ... . 12-4
•
FUIiI Tank Aemovill/lnstallation ........................ .. 2-4 Side Cover Removal/Installation ....... ................. . 2 -3
Gearshift Linkage Removalflnstallation .............. .. 9-6 Side Stand 3-8
General Information ........................................ . 1- 1 Switch ..................................... . .......... .. 15-8
General Safety ................................ ........ ..... .. . 1- 1 Spark Plug ......................................... . .. .. ... .... . 3-5
Headlight Removal/Installation .......................... . 17·3 Specifications ............................................... .. 1-4
Ignition Coil .... .... ........................................... . 15·6 Starter Clutch Removal/Installation ........ .......... .. 16-8
2 -1
£ Honda CB400 / CB-1 Service Manual
INDEX
Starter Motor disassembly/ assembly 16-6

Removaillnstallation .............. ..... ............ . 16- 5
Steering Stem Removal/Installation .................. . . 11 - 12
Swingarm disassembly/ assembly ............. ... .. . .. . . 12-8
Hemoval/lnstallation ............. .......... ........ . 12-7
Tachometer Inspection .. ................... ...... .....•.... 17-7
T8i11ight ...... ........ .. ...................... ................... . 17-4
Thermostat Remo val/Installation ........ ...... ......... . 5-4
Tnnl lt 1- 16
Torque Values ..... ..... ............... ............... .. .. .... . 1- 14
Transmission disassembly/ assembly ....... ........... . 10- 10
Removal/Installation ........... ... .... ............. . '0-8
Troubleshooting ...................... ... ......... .. ......... . 19- 1
Hrakes ...... ............................................ . 13-1
Charging System/ Alternator .................... . '4-3
Clutch/ G8ftl shih Lillll.ltijY .,., .. , .. , .. , .. , .. , .. , .. ,. 9- 1
Cooling System .. , .. , ......... ... ~ ....... , .. , .. , .. ,. 5- ,
CrankshaftlTransmission ,., .. , .. .. . ... .......... . 10- 1
Cylinder Head/ Cylinder/Piston .. .... ............ .
Electric Starter/ Starter Clutch .. ................ . 16-3
8-'
Frame/ Body Panels/ Ekhaust system ......... . 2-,
Front Wheel/Suspension/ Steering ..•........... 11 -1
Fuel System . .. .. .... , .. , ......... ......... .. , ....... .. 6-2
Ignition System , ... , .. ,., .... , .... , .. , .. , .. , .. , .. , .. , 15-3
LUlJllCClliuli SystlllTl .... , .... , .. ,." .. ,., .. , .. , .. , .. , 4-'
Reaf Wheel/Suspension , .. ,., .. , .. , .. , .. , .. , .. "., 12- 1
Turn SiRnal I"ight ''''".,'' , .. , .... ............... ........... . 17-4
Valve Clearance ........................... ....... ........... . 3 -5
Water Pump disassembly/ assembly ............. ...... . 5 -7
Wiring Diagram .............................. ................ . 18- 1

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Honda CB400 / CB-1 Service Manual

Date of Issue: January. 1989 http://www.motorcycle.in.th

HOW TO USE THIS MANUAL

ThiS manual Is divided Into sections whleh eover each of

NOT E ON THE EXPLANATION METHOD OF THIS MANUAL

ell Repl<lce the paills) wilh IUIW one(s) before assembly .

[$ 7"000.. 1 Use special tool

71 UIHI rtll::ummended engine 011, unless otherwise specltled.

...-riD FVi'f11pI9: MolVko19~ G-n Paste manufooturcd by Dow Corning, U,S.A.

~ Use silicone grease

J'0Jl! Applv sealant

Use Fork or Suspension Fluid.

Used engine all (or transmission oil In two-strokesl

Hot Components CAUTION

Coolant Nitrogen Pressure

' (21 ENGINE"SERIAl"NUMBER

Left foot operated return system l - N- 2 - 3 - 4 - 5-6

Standard Service limit

The viscosities shown in the chart may

-20 -10 0 on 10 so 'tQ" t

Air screw high altitUde adjustment

Unit ' mm lin)

182 - 188 psil/400 rpm

Before guide installation:

Valve seat width 0 .9 - 1.1 (0,035 - 0 .0 43) 1.5 (0 .06 )

55.000 - 55.010 (2.16 54 - 2.1657)

Crankpin oil clearance 0 .020 - 0.052 (0.0008-0.0020) 0 .06 (0.002 )

Transmission gear 1.0 . MS 25.000 25 .021 (0.9843 - 0 .98511 25.05 (0.986)

Clvtch lAver free play

Front brake fluid

to the groove <D

brake pedal height -- --

Cylinder head mounting bolt

Compression gauge 07305 - 0010000

DescriptIon Tool number Alternative tool Ref. section!s)

Christie battery charger

LUBRICATION AND SEAL POINTS

Point Material Remarks

Point M aterial Remarks

CABLE AND HARNESS ROUTING

, - -(:3) 6P-BLACK CONNECTOR

(15) THROTILE LEFT

(2) DIODE BATTERY

• No.2 & No.3

RESERVE TI\NK (16) FUEL TANK ) IGNITION COIL

I FUEL FUEL CUT -OFF

11) MAIN WIRe

• Calif om la M odel Only

(1) FUEL TANK

(12) NO.3 INTAKE

(21) No . 10 (20) TO CANISTER

(3) No.1 TUBE

H~----"(7) No.4 TUBE ,

EMISSION CONTROL SYSTEMS

CRANKCASE EMISSION CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM (SECONOARY AIR SUPPLY SYSTEM)

¢:l (7): FRESH AIR

EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

..... : (6) FUEL VAPOR

After making a high altitude carburetor adjustment, attach an

VACUUM HOSE ROUTING DIAGRAM LABEL

Route the vacuum hoses as shown on this label. FRONT OF

2. FRAME/BODY PANELS/EXHAUST SYSTEM