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Honda CM400T Manuals Manuals and User Guides for Honda CM400T. We have 1 Honda CM400T manual available for free PDF download: Shop Manual

Honda CM400T Shop Manual (318 pages)

Brand: Honda | Category: Motorcycle | Size: 29 MB

Table of Contents

• Introduction 2
• How to Use this Manual 2
• Table of Contents 2
• Model Identification 3
• Identification Number 3
• General Information Contents 4
• General Safety 4
• Service Rules 4
• Specifications 5
• Torque Value 7
• Standard Torque Specifications 8
• Special Tools 9
• Common Tools 9
• Wiring Diagrams CB400T Type I 10
• CB400T Type II 11
• Cable and Hardness Routing 12
• Maintenance Schedule 15
• Lubrication Diagram 17
• Lubrication Contents 18
• Service Information 18
• Troubleshooting 18
• Engie Oil and Filter Change 19
• Engine Oil Level 19
• Swingarm Pivot 20
• Drive Chain 20
• Miscellaneous Lube Points 21
• Inspection and Adjustment Contents 22
• Spark Plugs 23
• Ignition Timing Check 23
• Engine 23
• Valve Clearance Adjustment 24
• Cam Chain Adjustment 24
• Idle Speed Adjustment 25
• Throttle Operation 25
• Carburetor Synchronization 26
• Choke Mechanism Maintenance 27
• Fast Idle Adjustment 27
• Adjustment 27
• Balancer Chain Adjustment 28
• Air Cleaner Maintenance 28
• Fuel Line Inspection 29
• Compression Test 29
• Clutch Adjustment 30
• Brake Fluid Inspection 31
• Chassis 31
• Front Brake Drum 31
• Front Brake Disc 31
• Rear Brake 32
• Brake Pedal Height 32
• Brake Pedal Free Play 33
• Stoplight Switch 33
• Brake Shoe Inspection (Wear Indicator) 33
• Side Stand 34
• Wheel Spoke Retightening 35
• Wheels/Spokes 35
• Tire Pressure 35
• Battery Electrolyte 35
• Fuel System 37
• Fuel System Contents 38
• Carburetor Removal 39
• Carburetor Separation 39
• Vacuum Cylinder Disassembly 41
• Float Chamber Disassembly 42
• Air Cutoff Valve Disassembly 43
• Craburetor Assembly 44
• Float Level Adjustment 44
• Component Assembly 44
• Craburetor Installation 45
• Fuel Tank 46
• Air Cleaner Case Removal/Installation 46
• Crankcase Ventilation System 46
• Engine Removal and Installation 48
• Cylinder Head/Valve 53
• Rocker Arm and Camshaft Removal 54
• Rocker Arm Inspection 55
• Cam Bearing Surface Inspection 56
• Camshaft Holder Rocker Arm Shaft Hole Inspection 56
• Rocker Arm Shaft Inspection 56
• Camshaft Oil Clearance 57
• Cylinder Head Removal 58
• Camshaft Runout 58
• Cam Lobe Inspection 58
• Cylinder Head Disassembly 59
• Cylinder Head Inspection 60
• Valve Spring Free Length Inspection 60
• Valve Stem-To-Guide Clearance 61
• Valve Guide Replacement 62
• Valve Seat Inspection and Grinding 63
• Cylinder Head Assembly 64
• Rocker Arm Assembly 65
• Cylinder Head Installation 65
• Camshaft/Rocker Arm Installation 66
• Cylinder/Piston 71
• Cylinder/Piston Contents 72
• Cylinder Removal 73
• Cylinder Inspection 73
• Piston Removal 74
• Piston/Piston Ring Inspection 74
• Piston Ring Installation 76
• Cylinder Installation 78
• Piston Installation 78
• Clutch/Oil Pump 81
• Clutch/Oil Pump Contents 82
• R-Crankcase Cover Removal 84
• Clutch 84
• Clutch Lifter Removal 84
• Clutch Lifter Plate Removal 84
• Clutch Removal 85
• Clatch Center, Plate and Disc Removal 85
• Clutch Disc Inspection 86
• Disc Spring Inspection 86
• Clutch Spring Inspection 86
• Plate Inspection 87
• Clutch Outer and Outer Guide Inspection 87
• Clutch Installation 87
• Clutch Lifter and Right Crankcase Cover Installation 90
• Oil Pump 92
• Oil Pump Removal 92
• Oil Pump Disassembly 92
• Oil Pump Inspection 93
• Oil Pump Assembly 94
• Oil Pump Installation 94
• Oil Pressure Relief Valve 95
• Right-Crankcase Cover Installation 96
• Crankcase 97
• Crankcase Contents 98
• Crankcase Removal of Parts 99
• A.C. Generator Removal 99
• Crankcase Disassembly 100
• Crankcase Assembly 100
• Installation of Parts 102
• A.C. Generator Installation 102
• Crankshaft/Balancer 103
• Crankshaft/Balancer Contents 104
• Balancer Removal 106
• Balancer Inspection 108
• Connecting Rod Removal 109
• Crankshaft/Starter Clutch Removal 110
• Starter Clutch Inspection 110
• Starter Drive Gear Inspection 110
• Crankshaft Inspection 110
• Electric Starter Idle Gear Removal 111
• Electric Starter Idle Gear Inspection 111
• Bearing Inspection 112
• Connecting Rods 112
• Main Bearings 113
• Bearing Selection 114
• Connecting Rod Bearing Inserts 114
• Main Bearing 115
• Starter Idle Gear Installation 116
• Starter Clutch/Crankshaft Installation 116
• Connecting Rod Intsallation 117
• Balancer Installation 118
• Transmission 123
• Table of Contents 124
• Transmission Contents 124
• Troubleshooting 125
• Gearshift Linkage Disassembly 126
• Transmission Disassembly 126
  • Gear Dog Minimum Clearance at End 127
  • Transmission Inspection 128
  • Gearshift Drum/Shift Fork Removal 129
  • Gearshift Drum and Shift Fork Inspection 129
  • Kick Starter Inspecction 131
• Kick Starter Disassembly 131
  • Kick Starter Assembly 132
  • Gearshift Drum/Shift Fork Installation 133
• Transmission Assembly 134
• Gearshift Linkage Assembly 136
  • Front Wheel/Brake/Suspension 137
  • Front Wheel/Brake/Suspension Contents 138
  • Troubleshooting 139
  • Headlight 140
    • Headlight Case Removal 140
    • Headlight Installation 140
    • Wiring Connection in Headlight Case 140
    • Cluster Disassembly 141
    • Indicator Lamp/Combination Switch Replacement 141
  • Instruments 141
  • Meter Lamp/Meter Replacement 141
  • Handlebar 142
    • Handlebar Installation 142
    • Handlebar Removal 142
  • Front Wheel Removal/ Disassembly/Assembly 143
    • Axle Inspection 144
    • Wheel Bearing Inspection 144
    • Wheel Inspection 144
    • Wheel Disassembly 145
    • Front Wheel Assembly 146
    • Brake Rod Adjustment 147
    • Brake Shoe Replacement 147
    • Front Brake Lining Thickness 147
  • Front Brake Panel 147
  • Front Wheel Installation 148
  • Front Fork 149
    • Front Fork Removal 149
    • Front Damper Spring Free Length Inspection 150
    • Front Fork Disassembly 150
    • Fork Tube/Fork Slide/Piston Inspection 151
    • Oil Seal Removal 151
    • Front Fork Assembly 152
    • Filling with Fork Oil 153
    • Oil Seal Installation 153
    • Front Fork Installation 154
    • Fork Top Bridge Removal 155
  • Steering Stem 155
    • Steering Head Adjuster Removal 156
    • Steering Lock Removal/Installation 156
    • Steering Head Adjuster Installation 157
    • Top Bridge Installation 157
    • Rear Wheel/Brake/Suspension 159
    • Rear Wheel/Brake/Suspension Contents 160
  • Service Information 160
  • Troubleshooting 161
    • Axle Shaft Bend Inspection 162
    • Rear Wheel Bearing Play Inspection 162
    • Rear Wheel Removal/Disassembly/Assembly 162
    • Rear Wheel Rim Runout Inspection 162
    • Damper Rubber Inspection 164
  • Final Driven Sprocket 164
    • Final Driven Sprocket Inspection 164
    • Rear Wheel Hub Inspection 164
    • Brake Drum I.D. Inspection 165
    • Rear Brake Lining Thickness 165
  • Rear Brake Panel 165
  • Rear Brake Shoe Replacement 165
  • Rear Wheel Installation 166
  • Shock Absorber 167
    • Shock Absorber Disassembly 167
    • Shock Absorber Removal 167
  • IIV 168
    • Shock Absorber Assembly 168
    • Shock Absorber Installation 168
    • Shock Absorber Spring 168
    • Swing Arm Removal 169
    • Swingarm Disassembly/Assembly 169
    • Swingarm Installation 169
    • Brake Pedal Removal/Installation 170
    • Rear Brake Pedal 170
    • Rear Brake Pedal Height 170
    • Hydraulic Disc Brake 171
    • Hydraulic Disc Brake Contents 172
    • Air Bleeding 173
    • Brake Fluid Draining 173
    • Brake Fluid Filling 173
    • Brake Fluid Replacement/Air Bleeding 173
    • Brake Pad Replacement 174
    • Brake Pad Wear Check 174
    • Brake Pads/Disc Plate 174
    • Brake Disc Warpage 176
    • Disc Thickness 176
    • Brake Master Cylinder 177
    • Master Cylinder I.D. Inspection 177
    • Matser Cylinder Disassembly 177
    • Master Cylinder Assembly 178
    • Matser Piston O.D. Ispection 178
    • Brake Caliper 179
    • Brake Caliper Disassembly 179
    • Caliper a Removal 179
    • Caliper Assembly 179
    • Caliper Carrier/Carrier Assembly 180
    • Caliper Carrier/Carrier Disassembly 180
    • Caliper Cylinder I.D. 180
    • Caliper Piston O.D. 180
    • Caliper Installation 181
    • Battery/Charge System Contents 182
    • Battery Removal 184
    • Testing Specific Gravity 184
    • Battery Charging 185
    • Charging Output Test 185
    • Charging System 185
    • Stator Coil Continuity Test 186
    • Voltage Regulator/Rectifier Test 186
    • A.C. Generator Removal/Installation 187
    • Voltage Regulator Performance Test 187
    • Ignition System Contents 188
    • Ignition Coil Performance Test 190
    • Ignition Coil Removal 190
    • Schematic Diagram Od C.D.I. System 190
    • Spark Plug 190
    • C.D.I. Unit 191
    • A.C. Generator Inspection 193
    • Starter Motor Contents 194
    • Brush Inspection 195
    • Commutator Inspection 195
    • Starter Motor Removal 195
    • Field Coil Inspection 196
    • Magnetic Switch Inspection 197
    • Starter Clutch 197
    • Balancer Mechanism 198
    • Front Balancer Shaft 198
    • Rubber Dampers 198
    • Technical Features 198
    • Operating Principle of Balancer 199
    • 3 Valve, Short Stroke Engine 201
    • C.D.I. System 202
    • Features 202
    • Operating Principle 203
    • Advancer Operation 204
    • Engine Does Not Start or Is Hard to Start 206
    • Engine Lacks Power 207
    • Poor Performance at Low and Idle Speeds 209
    • Poor Handling 210
    • Poor Performance at High Speed 210
    • '79 Addendum Table of Contents 214
  • A L L Information, Illustrations, Direc 214
  • Duced Without Written Permission 214
  • MAKE CHANGES at any Tlme WITHOUT 214
  • Motor Co., Lto Reserves the Right to 214
  • NO PART of Thls PUBLICATION MAY be REPRO 214
  • Notice and Without Incurring any 214
  • Obligation Whatever 214
  • PRODUCT INFORMATION AVAILABLE a T the Tlme of APPROVAL for PRINTING. HONDA 214
  • TIONS and SPECIFICATIONS INCLUDED I N Thls 214
    • Maintenance Schedule CB400T 215
    • Inspection and Adjustment Balancer Chain Tension 216
    • Brake Fluid 220
    • Brake Fluid Replacement 220
    • Brake System Draining 220
    • Fluid Level 220
    • Brake Master Cylinder Disassembly 221
    • I.D. Inspection 221
    • Master Piston O.D. Inspection 222
  • Model Identification 225
  • Specifications 226
  • Ill. TORQUE VALUES 229
    • Wiring Diagrams CM400T 232
    • Wiring Diagrams CM400A 233
    • Cable and Harness Routing CM400T 234
    • Cable and Harness Routing CM400A 236
  • Emission Control Label 238
    • Maintenance Schedule CM400T 239
    • Maintenance Schedule CM400A 240
    • Air Cleaner 241
    • Inspection and Adjustment 241
  • Hydraulic Disc Brake 242
  • Fuel System 243
    • High Altitude Adjustment 243
    • '80 Adendum Contents 244
    • Maintenance Schedule CM400T 249
    • Control Cable Lubrication 251
    • Engine Oil Recommendation 251
    • Oil Viscosity 251
    • Recommended Spark Plug 251
    • Carburetor Assembly 252
    • Carburetor Specifications 252
    • Float Level Inspection 252
    • Accelerator Pump Adjustment 253
    • Accelerator Pump Inspection 253
    • Pilot Screw Adjustment Idle Drop Procedure 254
    • Pilot Screw Removal/Installation 254
    • Wiring Diagram CM400T 256
    • Wiring Diagram CM400A 257
    • '80 CB400T Addendum Contents 258
  • Inspection and Adjustment 258
  • Specifications 258
    • Cable Routing 262
    • Spark Plug Replacement 265
    • High Altitude Carburetor Specifications 269
    • Limiter Cap Installation 269
    • Cylinder Head/Valves 270
    • Oil Pressure Relief Valve Removal 270
    • Wiring Diagram '80 CB400T Addendum 272
    • '80 CM400E Addendum Contents 274
    • Maintenance Schedule CM400E 278
    • Cable and Harness Routing 279
    • Battery 283
    • Wheel Spoke Tightening 283
    • Wiring Diagram CM400E 284
    • '81 CB/CM400'S Addendum Contents 286
    • CB400T, CM400C: Front Disc Brake Pad 297
  • Front Air Forks 297
    • Recommended Tire Pressures and Sizes 298
    • Wheels 298
    • Front Air Forks Removal 299
    • Front Air Forks Disassembly 300
    • Bushing/Back-Up Ring Inspection 302
    • Fork Tube/Piston Inspection 302
    • Spring Inspection 302
    • Assembly 303
    • Installation 305
    • CB400T/CM400C: Hydraulic Disc Brake 307
  • Cb400Tlcm400C 307
    • Caliper Removal 308
    • Caliper Disassembly 309
    • Caliper Carrier Assembly 311
    • Caliper Carrier Disassembly 311
  • Cable and Harness Routing 313
• Wiring Diagram CM400T/C 316

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