1975 Honda CB400f cafe bike.

This is my second 400f project and it will be built for the road.  I built the race bike first to setup a sharp handling chassis.  Now, the road bike will be simply a street legal version of the race bike, using many of the same parts.

09-06-03:

Here is the chassis now being built up with the same 550f forks and 79 cbx triples.  The clip-ons are now Spec II Telefix fully adjustable items.  They are a little higher and will be more comfortable due to adjustability for street use.  Out back, I have the same length 14" rear shocks, but this time from a CB900f. They are fully adjustable with separate compression and rebound settings.  Also, the reservoir gives them a cool vintage racer look!

Here is a set of NOS Koni shocks which are the same as the race bike.  I'll try these on as well later when I road test the bike.

10-06-03:

I've now built up both rims on newly polished and anodized DID alloy rims.  They are plus one sizes over stock at 1.85 front and 2.15 rear.  The hubs are tumbled and clear powdercoated just like the racers.

I also picked street versions of the same Avon tires, sized 90-90 front and 110-90 rear.  The rear is a little taller.

03-19-04:

My friend Jeff made a set of aluminum axle spacers.  So, the back end is bolted up.  With the forks slapped together and both rims with new Avons spooned on, I was able to get the rolling chassis!  The adjustable 36mm clip-ons have to be cut back to fit the 35mm forks.  Also, I was able to finish up the seat pan with a hump back from a Guiliari seat!  Nice!

Stay tuned while I move the motor from the racer back to this bike.  I'm waiting on a set of bored out carbs and a quick throttle cam.  I should have the seat re-upholstered soon.   The front end is still being re-engineered with the help of Jeff C.  Since I laced the rim on a 400f hub and the forks are from a 550f, there lies the problem of mating a proper brake rotor system.  The 400f rotors bolt on but don't mate to the calipers.  So, I either adapt 550f rotors to the 400f hub or use 400f rotors and lower the calipers to match.  I'm pursuing 550f rotors.   Other than making adapters, I have to see if the machine shop can properly bore a set of holes in the hub of the completed wheel.

4-09-04:

I've decided to use the racers rims to solve the front brake rotor issue.  I've already switched them.  The backend is all done, except for the brake cable brackets.  I've scored a set of Dyna 3 ohm coils.  I've modified them for 4 or 5 ohm loads.  I'm waiting for the rotor patterns so I can drill them.  I'm also waiting on a set of the bored out carb bodies, quick throttle cam and the right side rotor (being machined for the speedo drive).  I still need to buy the front SS brake lines, a Dyna S trigger unit, a brake light and a set of rearset adapters (currently being machined).

Here are some recent shots minus carbs, rotors and brakes:

How do you like that custom cafe seat, eh??!!  I took apart a 500f Guiliari seat pan and welded it to the 400f seat pan, then just re-assembled it.  Turned out great!  Looks and feels like a different bike, but still retains the 400f classic lines - though updated a bit.  Can't wait to fire it up!

Here is the shot of the Dyna 3 ohm coil setup.  I added a couple of 1 ohm power resistors with taps at 4 ohm or 5 ohm loads.

4-29-04:

The bike is now in the garage awaiting final details.  Today, I've installed the SS brake lines and bled them.  I hate brake fluid!  The puzzling problem now is that there is a lot of brake drag.  It could be the mating of the 900rr master cylinder and the vintage calipers.  There may not be enough travel to allow the piston to back off enough.  I'll look into changing the master cylinder with one from a GL1000 and try again.  The missing items at this point are the ignition trigger from Dyna, the plug wires and a set of carbs.  Today, I got the bored out (22mm to 24mm) bodies and quick throttle cam from Rick Denoon (www.denoonsp.com) and will be assembling the carbs next.  Here are the pictures of the bike today.  

Notice my new rearset brackets?  I designed them myself on Autocad and had the local machine shop make a few prototypes.  I had to use a few washers to space things out.  I also requires a longer swingarm axle, 954/929 footpegs and shifter linkages and a longer shift rod.  I had to make a custom brake rod from 5/16" stock and bent it.  It is drilled and threaded on both ends.   For a longer shift rod, I added a short extension.   The footpegs are mounted in the most rear position in order to clear the kickstarter.   For the kickstarter to clear the brake pedal, I made a swingout tab to hold up the brake pedal during starting.  This is the best solution so far.   I decided to use a brake rod instead of the brake cable I had planned earlier.  

Check out the small tail light and the Italian designed cafe seat.  I cut it from a 500f pan and welded it to the 400f pan!

Here are some brake hub detail shots.

Here is a shot of the headlight and control sections.