I am rewiring the handle bar controls and headlight for my 1974 CB550 K0 and I'm running into a few electrical issues and after reading through the Electrical section in FAQs (which if I understand correctly I am just a few splices away from having a fully working bike) and looking over a few wiring diagrams I am a little uncertain of my wiring.
I rebuilt the front and rear end over the winter and I have switched over to clip-ons, with all new parts. I am replacing the old stock honda switches with two K&S switches that I purchased from Dime City Cycles and I am no longer running gauges, gauge lights, clutch switch, or turn signals. On the left clip-on I am using
http://www.kandstech.com/pimages/12-0050.html (picture 1) this is used as my headlight/tail light on/off, high beam, and low beam, and the kill button is now my horn. On the right I am using
http://www.kandstech.com/pimages/12-0203.html (picture 2) this is my electric start and kill switch. I have the horn and electric start working but I don't have power to the headlight or headlight fuse and I can still turn the engine over even with the kill switch in the off position. I tested the headlight and bulb outside of the wiring harness, Hi and Lo Beam work.
To make matters more confusing the PO had the fuses mixed up or he was an electrical genius. On my bike the fuse panel from left to right reads 5A (Tail Light) 7A(Headlight) 15A(Main) on the fuse block. the PO had a 7A fuse in the 5A (Tail Light) and 14A in the 7A(Headlight) and some screwy wiring on the ignition switch (picture 3) but I ran the bike like this all last season with all stock honda parts and I had no problems. Started right up, all lights and switches worked not one problem. While wiring this time I noticed the 7A fuse in the 5A (Tail Light) location was blown (my guess is a short somewhere) I have checked the battery, the fuse panel, the grounds, no disconnected wires, no signs of a short or any other problems found yet other than the screwy ignition wiring.
To make things easy I referenced the Haynes electrical diagram and made my own as I wired.
K&S Switches ----------------> CB550 HarnessLEFT SWITCH
HORNWHITE----------------------------------LIGHT GREEN
BLACK----------------------------------GREEN
HEADLIGHT - no power to headlight or to headlight fuse
YELLOW (Hi Beam)--------------------BLUE (Hi Beam)
GREEN (Lo Beam)---------------------WHITE (Lo Beam)
RED (Power)---------------------------BROWN/RED (Headlight to fuse)
BLUE (Tail Light)-----------------------BROWN/WHITE (to IGNITION and to Headlight Fuse)
RIGHT SWITCH
ELECTRIC STARTBLUE/WHITE---------------------------YELLOW/RED
BLACK----------------------------------GREEN/RED
RUN/KILLRED/BLACK----------------------------BLACK
RED/WHITE----------------------------BLACK/WHITE