Topic: 1977 cb550f cafe-brat build

[Cafe_Brat]

I just bought my first Honda sohc, a 1977 cb 550f, and am looking to build a quasi cafe racer / brat.   It doesn't currently run but I was told that the electrical was the issue.   It appears that a previous owner ripped most of the electrical out and then they or someone else tried to piece it all back together.   I have been looking around for a wiring harness but haven't been able to find one any tips for making my own?

[Toxic]

Hang tight and someone will be along shortly with the answer.  There are lots of hardcore 550 guys on here.

Very knowledgeable

[cafevee]

I just bought my first Honda sohc,...  It doesn't currently run but I was told that the electrical was the issue.   It appears that a previous owner ripped most of the electrical out and then they or someone else tried to piece it all back together... 

I feel your pain. Im in the exact same boat... chk it out..
http://forums.sohc4.net/index.php?topic=107576.0

Also, there is a simplified wiring diagram online. I found it once and for the life of me could not find it again to post it for you. My buddy said it should be easy to do just match up the coloured wires. Im sure if you search the forum in a bit more detail this diagram will come up.

Good luck and post some pics of your progress.

Vee

[steakCB550K]

I found this here and this might be what you are talking about.  I am not sure how different it is for the cb550. 
http://www.sohc4.net/index.php/cb750-simplified-wiring-diagram/

You can find a lot of info on this site from here:
http://www.sohc4.net/index.php/cb550/

Good luck!

[kerryb]

I was stumped by wiring too until I got the color diagram from the back of the clymer manual, then took the black wrapper off my wiring harness (removed from bike) and physically followed each wire by colore to where it ended up.  I referenced each color and wire to the diagram while cleaning it.  It took a few hours, but now I "aint sceered" by anything electrical on my bike.  I've started mixing 750 and 550 parts when needed and it still appeatrs to be working fine. Get the book, My cb750, it is the best reference for lots of stuff.

[Cafe_Brat]

Yeah my haynes manual is still in the mail, should be here soon.   But despite that I wnt ahead and strpped most of the electrical out already.

[kerryb]

That's good, now you can test each wire for continuity to see which ones have a break in them.  It is easy to miss a broken wire inside the colored plastic insulation.  When you test with a test light or ohm meter ($3.00 at harbor freight) you will be sure to find the hidden gremlins.  I had several wires that were broken inside the insulation right next to the plug-in connector.  The intermittent problem drove me nutty till I learned what to look for.  Now it's easy, just a matter of time spent.

good luck...someone here says "if you can't fix it with a hammer, it must be electrical"!

[Cafe_Brat]

Well I got a little impatient and have stripped the bike down to a rolling frame, figured I could put off the wiring a little longer and get some paint on her.

[Cafe_Brat]

here is a link to some pictures http://www.flickr.com/photos/79614564@N05/sets/72157629962164056/

[Cafe_Brat]

I am going to put the electronics in a custom "pan" under the seat and upgrade the battery; http://www.ballisticparts.com/products/batteries/8cell.php

and upgrade the fuses using the new auto style fuses  and combine the the regulator and rectifier into using the VRREM7 @ http://www.oregonmotorcycleparts.com/Reg_rec_units.html

[Cafe_Brat]

Found this regulator/ rectifier for cheaper

http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-electronics-parts-honda-cb350f-cb400f-cb500-cb550-cb750-rectifier-864218.html

[goldarrow]

looks like someone is on a shopping spree!

[Cafe_Brat]

looks like someone is on a shopping spree!

just dreaming right now... gotta wait for the next pay check then I can blow it on the bike

The project is at a strange phase where I need to order a bunch of things in order to see how they are going to fit into my design before I can have some custom welding done and a seat made.

[Cafe_Brat]

Got the bike down to the frame and have stripped most of the paint off.   Got some new parts in and have designed an electrical pan to go under the sear.   Taking it to the shop tomorrow for some welding.   Check out this site for my progress photos. 


http://www.flickr.com/photos/79614564@N05/sets/72157629962164056/

[Finksies]

Looks good brother.

[minimo]

Got the bike down to the frame and have stripped most of the paint off.   Got some new parts in and have designed an electrical pan to go under the sear.   Taking it to the shop tomorrow for some welding.   Check out this site for my progress photos. 


http://www.flickr.com/photos/79614564@N05/sets/72157629962164056/

Awesome! I like your approach of, oh well, let's just strip it all down anyway while we're at it. I also like your cardboard mockup of the under-seat compartment. Are you going to fiberglass it as is?

[SOHC4 Cafe Racer Fan]

Two suggestions:

(1) If you are going to modernize the wiring, get rid of the tube fuseblock and replace it with a blade fuseblock.  You can get a weather-proof model for about $6 that will carry extra fuses, just in case.

(2) You might want to mount your reg/rectifier outside of the box, so the cooling fans can do their work in dissipating heat.  Keeping it in an enclosed area will create a hotbox for your electronics to cook themselves.

[cafesnrods]

I am also working on the wiring on my build (pics & thread to come soon...). Could you tell me where I might find a weatherproof blade style fuse box?

Thanks

[calj737]

Member Hondaman sells plug-and-play units. Or, Abec electronics, or eater beaver.com or... about any type of automotive supplier will have these..

[SOHC4 Cafe Racer Fan]

Hondaman's unit is plug and play with the original style socket connector. You can also find them for under $10 on amazon.

[cafesnrods]

Great! Thanks.