1978 Honda 400 Build

[loudbeard]

Did a simple spray wax on the tank, and I think it looks great for a 1978

But there is some chipping on the bottom. I'm not really worried about it cosmetically, I am more worried about it rusting. Any way to repair this without painting the whole tank?

I'm thinking find some Rustoleum that's a close match and carefully painting it on?

Get some automotive pinstriping tape to mask off the border, it is really good about working around contours and bends. Then back mask from there and blast it. You can probably get this color in a rattle can if you have the paint code.

[RandyO]

I'm thinking find some Rustoleum that's a close match and carefully painting it on?

based on a couple tanks I've had in similar condition, I'd cream the inside of the tank, and paint the vertical seam with POR15 before covering with matching color

[xrocket21]

Battery and swingarm to shock bushings arrived



Rear tire arrived, no front, tracking says both delivered

[Kurlon]

based on a couple tanks I've had in similar condition, I'd cream the inside of the tank, and paint the vertical seam with POR15 before covering with matching color

Why would you want to guarantee tank problems down the line by ruining it with Kream? That crap is useless and when it fails is a mess to get rid of.

[xrocket21]

Went to a friend with a tire machine and got the new rubber mounted! Old tires were STIFF!

[csmutty]

So you finally got the front tire then haha?

[xrocket21]

So you finally got the front tire then haha?

HA! Yes, after calling fed ex and the company, it came a few days later.

[xrocket21]

Another update.

Long ago from @MATTR302 I bought some moose bars to use on my Honda TRX90 and they never worked, been sitting on the shelf ever since. Maybe they will go on this project???

Moose Aluminum handlebar

Been working slowly on cleaning/polishing parts while my son skates the ramp. Got the rear drum ready to go, shoes look fine, I won't replace them.





Aaaaaaaaaaaaannnnddddd, the big news..... GOT THE FRAME, SWINGER, AND CENTER STAND BACK FROM POWDER COAT!!!!!!!!!!!!!



It looks brand new. I believe I can start assembly now!

[xrocket21]

You think I should do engine in the frame first, then attach swinger and rear tire and front forks and front tire? Or get the suspension and tires on, then put the engine in after?

[loudbeard]

Easiest to install the engine into the frame first, particularly if the swing arm pivot isn’t integral. Caveat is having a lift to get the engine/frame off the floor. Much easier to install the forks when the chassis is elevated, same with the swing arm.

[xrocket21]

Easiest to install the engine into the frame first, particularly if the swing arm pivot isn’t integral. Caveat is having a lift to get the engine/frame off the floor. Much easier to install the forks when the chassis is elevated, same with the swing arm.

Thanks! I've only rebuilt dirt bikes where I can easily lift the engine, this engine is pretty damn heavy.

Having the center stand will be handy during assembly I think. I hate to grind up all that new powder coat on the bottom though!!!!

[FriskyDingo]

I hate to grind up all that new powder coat on the bottom though!!!!

Not saying it will keep the weight of the engine from scratching it, but may be worth temporarily wrapping the frame with some cheap e-bay PPF film while doing the rebuild, keep any other little scratches from happening...just a thought, may be more work than its worth.

[loudbeard]

I just take some cloth towels and place them between the frame/lift. And be careful.

[nhbubba]

Watched a video the other day of a guy who laid the motor on its side and slipped the frame over it, loosely bolted it in place and then righted the whole assembly. Looked clever to my eye.

[xrocket21]

Not saying it will keep the weight of the engine from scratching it, but may be worth temporarily wrapping the frame with some cheap e-bay PPF film while doing the rebuild, keep any other little scratches from happening...just a thought, may be more work than its worth.

Ahh, I meant the bottom of the center stand. There's no real way around it, its gonna touch pavement.

[loudbeard]

Can’t you just put it on after you have a rolling chassis?

[xrocket21]

Can’t you just put it on after you have a rolling chassis?

the bottom of the stand will have to touch the ground someday

[TheIglu]

That bike is relatively easy to jack the engine up into the rolling frame using some wood scraps, a jack, and a second set of hands.

Did it when I was 16.

Still have some brand new clutch disks and springs for that thing in the basement somewhere....

[csmutty]

Ahh, I meant the bottom of the center stand. There's no real way around it, its gonna touch pavement.

Could you spray the bottom area with undercoating to protect that?

[xrocket21]

Got the bushings pressed into the swingarm without scratching it.



Found a single kick stand, I thought the center stand was your only option!

[loudbeard]

Now you’ll have to get it powder coated

[xrocket21]

[xrocket21]

Nhbubba did an incredible job saving everything and packing everything!

[xrocket21]

Making some good but slow progress on the bike. Definitely tough putting something together that not only did you not take it apart, but you have never even seen in person to know what it looks like lol. I am using a combo of photos of the bike from online, the parts exploded diagrams from Honda Parts House, and the repair manual I have. The swingarm assembly gave me a few issues, but I got it figured out and installed. Got the shocks on, but I believe I need to take them back off already in order to get the airbox in. I also need to order a new air filter, the one in it turned to dust lol. I also had to grind away some powdercoat in a few spots to get things to fit, but that is to be expected, the powder coat is VERY thick (and strong!)



One question I have is on the steering head bearings, I need 37 of them, #19 (96211-08000) in this parts explosion:

https://www.hondapartshouse.com/oemp...ring-stem-horn

These appear to be $3 each, give or take

https://www.ebay.com/sch/i.html?_nkw...023.m570.l1313

But they are #8 1/4" steel bearings, would these work?

https://www.ebay.com/itm/29140794816...3Avlp_homepage

It says for bicycles, casters, slides, etc. no mention of motorcycles, but its just steel bearings, it should be fine unless I'm missing something?

Also, for what it is worth, going by the VIN number I figured out that this is a Hawk 2, not a Hawk 1.

[TheIglu]

I'd see if All Balls Racing has a tapered roller set of steering head bearings for this thing.