CM400A Project

ok, tomorrow I will be the semi-proud owner of this bike. I can't ride it yet because the mirrors are too low and I want to get a new handlebar for it, similar to the stock style but maybe not as much of a "chopper" style.
Suggestions of where to get the parts and any tips you may have are appreciated.

 

I think this is the stock handlebar style..

 

found one on ebay, $80. i also going to swap the controls on each end to chrome versions.

 

ok, i got the bars from the ebay guy. They are in decent shape exterior but show some rust inside. Whats the best way to clean out rust inside a handlebar? Will using water make it worse? I have long brushes available (from homebrewing).

 

I wouldn't bother with the rust inside.

 

I used some wd40 and some fine steel wool to clean it a little, thats good enough.

 

I get the bike tomorrow (finally - PO issues). Things to do:
1. swap handlebars (have) replacing mirrors (have)
2. change oil/filter and new plugs (have)
3. repair speedometer chrome lower case (ordered)
4. swap out all lights except headlight with LED's (ordered) when I do #3.
5. replace controls with chromed versions (ordered)
6. install new battery (ordered)
7. inspect tires - find new ones. need to see if current ones have tubes or not, they are a weird size. Fronts are 3.50S18-4PR, rear is 4.60S16-4PR tubeless according to manual
8. inspect chain, replace? (ordered)
9. find LED replacement headlight, stock one is useless at night
10. buy some riding armor. maybe knee/elbow pads
11. inspect front fork oil/replace seals
12. install analog fuel hydrostatic gauge (ordered) - inspect gas tank while empty and clean/install inline filter if needed
13. inspect/clean and synch carbs
14. see if balancer/cam chains tension needs adjusting

 

right side spark plug cap is cracked.
ordered a small fuse block. also ordered a new horn, original barely makes a peep. Cleaned the chain today, it was dirty but in good condition.

 

fixed speedometer housing today, also changed handlebars back to stock and rerouted cables.

 

https://www.youtube.com/watch?v=RA6xRKyiO7w

great video. the end of my cable came undone from the cable itself. ordering new cable

 

new lthium battery, rectifier and fuse box and relay today

 

new horn

 

new speedo cable works but needle is jumping, i'll take it off and put some lube in there.

 

added more oil to cable, added usb/meter..

 

replaced old taillight lens/socket with new one from 4-in-1. New one didnt have any rubber bumpers for shock so i chopped off some old foam bike handlebars i had and used pieces of that. Also replaced front day/turn lamps with the LED versions. everything tested and works.


Got all I need for my headlight casing replacement so thats next project once i get a nice day. This weekend is filled with CMSP safety course.

 

added luggage rack. used some old foam grips cut up to protect the u-bolt chrome. I'll add some red LED brake lights to the end in a week or so.

 

gonna stick these off the end/sides of the rack once i get them, slightly angled up.

 

Awesome project. I am looking to find a similar project to do this winter.

Keep posting you progress!

 

left my petcock open over the weekend, tank almost empty. i havent smelled the oil yet but i assume i'll need to change it to be safe. ordering a 12v fuel line valve to prevent future floods

 

fixed the missing seat lock chain link, now the seat is locked to the helmet lock. Also did a tank inspection and looks great. I do not see or smell gas in the oil so for now i'm leaving it as it since im not riding it in this 50 degree weather. Also got a blue smoked visor for my HJC i10, looks badass now.