Making Progress on My 1978 CB400T II

Through late fall I was able to make enough progress on the bike to actually get it on the road and ridable.  The goal was to get some runs in to see how the engine is performing. Needless to say after sitting for close to 15 years, it needs some work - valve and carb adjustments from what I can tell. Otherwise it starts right up, and runs.

After rebuilding the front end and replacing the blinkers, headlight, and rear brake/tail light; the last item I needed to address in order to start riding was the front disc brake. The old caliper was so caked with dried brake fluid that it needed to be disassembled, cleaned, and rebuilt. After assessing the master cylinder, it was actually cheaper to replace it entirely then rebuilding it. I purchased a cheap, spare, used caliper off eBay to cannibalize some parts - brake pads, brake pad pins, pad pin clip, and other parts. This worked out really well for the price and it saved me a bunch of money. All the other boots, seals, and the bleeder valve I purchased new from my local Honda dealer, those parts were expensive; was just happy I didn't have to replace the piston, it was pitted in spots but nothing bad enough to keep me from reusing it.

Purchased a replacement brake hose, I should have ordered a shorter hose to accommodate the lower handle bars and the lowering of the front forks; but I was able to make it work. Purchased off eBay pretty cheap.

DCC Master Cylinder

Like I said, I also replaced the master cylinder with (SKU: 717-652) from Dime City Cycles. It bolted right on the bike and included the brake light switch (some do not). Note, the MC requires and does not include the bolt to hold the fluid reservoir bracket in position; you'll need a short bolt or a mirror, I used a mirror. I also needed to replace the female flag spade terminal ends on the bike's harness to accommodate the brake light switch on the MC. DCC did not have them, I was able to find suitable connectors at RadioShack, those connectors are the 3/16th type. You can also purchase after market brass connectors at www.cycleterminal.com.

Click here to view the video showing speed bleeding with a vacuum pump. I purchased a cheap one from Harbor Freight; you get what you pay for. It worked out fine, but I should have purchase the MityVac for a few more dollars. HB carries the MityVac as well. I was able to do this work on my own, did not need a second person to do any pumping; and even though the Clymer's Manual calls for DOT3 brake fluid, the dealer recommended and sold me DOT4 brake fluid. Building the seat is next.

The Beast Update

So it's now going into November here and I've been busy finding the right parts for the bike, making the modifications, finalizing the DMV paperwork for the title, and completing motorcycle basic rider class so I can get my license. So I've been busy. Here are some pics.

The Beast Broken Down & Forks Off

So far I was able to lower the front forks using a spacer in the lower. Got this trick from the Ryca videos on YouTube. Not sure if it's going to work out or not; probably won't know until I take the bike for a test ride, we'll see how the  front end performs. While I had the forks off the bike, I was able to get the fork gaiters, clip-on handle bars, new halogen headlight, and the headlight ears installed. The gaiters are a little too long since I lowered the forks, but they will do for now.

Online videos and online forums have been very helpful in pointing me in the right directions, however they usually do not provide enough detail to avoid pitfalls, not sure that they could.



The Clymer manual was the best money I spent so far. Also looking to find and purchase the original product brochure and owners manual.

Also had fun fabricating a mounting bracket for the gauges out of some aluminum sheet I purchased at ACE Hardware. Not great considering I was using a jig saw with a metal cutting blade and a Dremel Tool. Serves its purpose for now, will reproduce a better one based on this when I replace the fork gaiters and the front wheel goes to paint.

I sorted out some of the electrical while replacing the rear tail/brake light. The electric has been the most challenging part of the project, but I have a friend pointing me in the right direction as I go along. Also replaced the winkers, front and back.

Nice Looking Seat

Next items to complete will be the chopping and modifying the seat pan, and also replacing the rear shocks. Here's the seat look I am going for. Probably more of a bobber/rat bike seat type than cafe. It looks like my old  broke in catchers mitt.

Found the foam I need online, and also found a British company online that manufactures replacement seat cover spikes for under the seat. You basically pop-rivet the strips on the underside if the seat and then you you hook the seat cover material to it to tighten the cover over the foam. In concept it works like tackless does with  carpet. P & K Classic Bikes

I also spent time fixing the left light controls and I am in the process of rebuilding the front disc brake caliper and replacing the front brake master cylinder.

Introducing "The Beast from The East"

So...I picked up this bike from a family friend for free. The catch? No title! It is a 1978 Honda CB400TII that starts easily, only has about 7,000 original miles,  has some leaks, and probably needs a good tune-up. I removed the chrome trimmings - grab bar, luggage rack, and highway bars. I have also replaced the engine oil and spark plugs, and ran some carburetor cleaner through the fuel tank. Running a little rough right now. My next steps are to remove the valve cover, torque the head bolts, and adjust the intake and exhaust valves. Right now I am waiting for a replacement headlight bucket. Once I receive this part, I'll start the front end part of the project. This will include lowering the front forks, replacing the handle bars with clip-on handle bars, bolting on new headlight ears, and the the replacement headlight. I will also replace the front end blinkers as well. I don't want to get much further than that until I figure out whether or not I am going to be able to the title for the bike. A lot of people are telling me to part the bike on eBay, but I am going bang forward on trying to get the title first. It would be a shame to chop this bike up. Other than a few dents and dings, it's pretty clean for a 30+ year cycle. Click here to take a video walk around of the bike here on YouTube.