Honda 1981 CM400A Manuals

Manuals and User Guides for Honda 1981 CM400A. We have 1 Honda 1981 CM400A manual available for free PDF download: Shop Manual

Honda 1981 CM400A Shop Manual (318 pages)

Brand: Honda | Category: Motorcycle | Size: 29.89 MB

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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Honda 1981 CM400A Shop Manual (318 pages)

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