Topic: 1974 CB550 Cafe Build

[Simon96Taco]

Well, it's time to start this thread.

I picked up the bike while I was working overseas (actually, thanks to my sis and her fiancee for actually picking it up) for what seemed to be a reasonable price.  Bike was running and came with a spare engine and a box full of random parts.  Looked pretty good stock, and from what I'd seen (I'd had my eyes on kijiji for months) I wasn't going to pass it up.  Here are a few pics:











Fast forward a few months and I'm back in Calgary and the bike is mine.  I've been so busy unfortunately, and my priority has been on finding a house, so the bike hasn't got much attention.  I also have no garage to work in, and the place I'm renting is not a place I want to keep the bike, so she (hmm.....wonder what I should name her.  Maybe...Cybil?) sits at my parents house, about a half hour drive away.

I tried starting her up a while back and no go.  I figured a dead battery from sitting outside all winter and tried jumpstarting her from my truck.  No go.  I also hooked the damn thing up backwards....suspected I might have blown something.  Couple weeks later I got back to her to try again and found this:



Yup, I blew the fuse.  I looked around a little more and found this under the seat:



That could explain the lack of a tail light (and other lights) I’m thinking...so....I reconnect this wire and replace the fuse and try again.  Immediately blow the fuse again.  After some head scratching, it dawned on me that the previous owner had told my brother-in-law-to-be that there were some known “intermittent” electrical problems.  I wondered if this was one of them.  I unplugged the wire again, put in a new fuse, and tried jumping the bike again.....VROOOOOMMM!!!!  She finally ran, though very rough.  Idled erratically, would only run with the choke on, revved wildly if I touched the throttle etc.

I’m thinking she needs at the very least, fresh gas, clean carbs, oil & spark plug change.  I also got some smoke coming out of and some melting of the left turn signal up front.  More electrical gremlins.

So this is the beginning.  I’m not 100% sure where I want to go with her, but I have a general idea.  I’d love to have her up and running with enough time to rip around a bit before the short season ends here.  I know almost nothing about bikes/engines etc though, so it might be a stretch.

Look forward to seeing all of your projects and the coming months!

[Simon96Taco]

So I think the first thing I want to tackle is the wiring/electrics.  The bike runs (bro in law test drove it for me) so engine isn't my #1 concern.  The fact that smoke started pouring out of the signal lights and many/most of the wires/connectors look cracked, corroded and even burnt. 

Ideally I'd like to replace ALL of the wiring but I have no idea how to go about doing this.  Not sure if I can buy factory replacements of everything (expensive?) or just buy different types/colours of wire and connectors and go about it that way.  I'm also a little worried about pulling the whole thing apart and having no clue how to wire it up again (with our without wiring diagrams).

Hoping to attack it this weekend if possible, so I'll do some reading/searching of the forums for the best way to tackle the wiring.

[Simon96Taco]

Wonering if buying wires and replacing them (and buying connectors as well) is a good way to go, or if I'd just be better off buying something like this:

http://cgi.ebay.ca/1974-honda-cb550-cb-550-four-h109-wiring-harness-/250676672297?cmd=ViewItem&pt=Motorcycles_Parts_Accessories&hash=item3a5d7e7729

Any comments??

[Dieselbegood]

IMO a new harness is the way to go, unless you are doing custom wiring. My buddy had to buy 2 harnesses off of ebay to get a working one. Just less of a hassle to know everything is fine. Its not too difficult to re-wire the entire bike as well, just takes patience and a beer or three.

http://www.davidsilverspares.co.uk/CB550K0-1974-USA/part_43400/ - quite expensive 

[Simon96Taco]

IMO a new harness is the way to go, unless you are doing custom wiring. My buddy had to buy 2 harnesses off of ebay to get a working one. Just less of a hassle to know everything is fine. Its not too difficult to re-wire the entire bike as well, just takes patience and a beer or three.

http://www.davidsilverspares.co.uk/CB550K0-1974-USA/part_43400/ - quite expensive 

Ouch, that is quite expensive.  However, given the frustration it may avoid not to mention wasted time, it might be the best way to go! I'm going to have a look to see if I can find something similar in Canada or the USA.

Thanks for your advice.
Simon

[Tintop]

IMO a new harness is the way to go, unless you are doing custom wiring. My buddy had to buy 2 harnesses off of ebay to get a working one. Just less of a hassle to know everything is fine. Its not too difficult to re-wire the entire bike as well, just takes patience and a beer or three.

http://www.davidsilverspares.co.uk/CB550K0-1974-USA/part_43400/ - quite expensive 

+1 on the new harness.

if you are planning on leaving the major electricals in the stock locations its your easiest, and least expensive move.  $160 is cheap when you figure your time to swap harness' into it.  I'll easily have that it my custom harness, and 20+ hours to build it.

[Simon96Taco]

Well, it's been almost one year, and I just finally got the bike running (last weekend) again.  I had trouble starting it, but after pulling out the carbs and blasting with a bit of cleaner, reassembling, new battery, new gas, and several attempts...she fired up!

Got to rip around for a few minutes on her until I heard the loud clatter coming from the engine.  I'm no mechanic - the best I could describe it is as fairly loud banging sound that gets louder as the rpm's increase.  It doesn't matter if it's in gear or parked. 

I noticed that the oil light was on (I can't remember if it was intermittent or not..) at times.  I would like to try again and post a video of the sound, but like a fool I drained the battery and have it on the charger right now.  Hope to post a vid once it's fired up again!

[paulh1282]

Did the bike run for long after the noise started or did it die out pretty quick? Glad your post brought this project back up. What did you do for wiring, anything? Post some pics of your work. Bike looks to be in good shape though.

[Simon96Taco]

Hi Paul,

Sadly, I've done basically no work to it yet besides the (now dead) battery, and quick carb cleaning.

It seems as though the bike is happy to continue running with the noise...went for several mini-rides (about 15 mins cumulative) after tinkering, adjusting idle etc.  Seems that the noise is only there when you open up the throttle.  It is so loud/sharp that I actually thought it might be something on the OUTSIDE of the engine case rattling....my friend disagrees - he says it sounds like "somthing is travelling too far" - disclaimer - neither of us are anything close to mechanics

I'm going to go see if I can kickstart her right now, and take a quick video!

S

[Simon96Taco]

OK, so I did kickstart her and manage to get a recording.  Here's what she sounds like:

CB550 running

It sounds worse in real life than it does in the video. 

[seaweb11]

I see the oil light on in the video. Your motor sounds bad. Why are you still running it?  Stop!

[strynboen]

red light= stop...tjek your oil pressure...with a extern gauge..before more bad happens

[Simon96Taco]

Crap ...I was really hoping it wasn't anything major.  I'll try and find an external oil pressure gauge.

For what it's worth, the light is intermittent....it was off for longer than it was on.

 

[Hotrodtrash]

Did you check to see how much oil was in the bike before you started it?

[Simon96Taco]

Hotrod,

I did take a look at the oil, to see the level and the condition (as it hasn't been changed in probably 2 years since the bike got parked).  The oil seemed like it was full, and clean.  Must have been changed fresh right before I took ownership of it.

S

[Simon96Taco]

Well, another winter passed by...along with a new job, a new house.....and a new BIKE!  Early this summer I picked up a new toy (Ducati S2R800) which has kept me rolling for the summer.  While I'm glad to have a shiny new bike, I'm also really glad that it lets me focus on the CB550 as a true project bike, whereas before I was starting to consider taking into a shop to let them have at it and get it running for me (as I was getting frustrated watcihng the riding season slip by and not having a bike to ride).

Regarding the external oil pressure gauge, can I just install something like this:

http://www.princessauto.com/pal/product/8400863/Miscellaneous-Surplus/Equus-Oil-Pressure-Gauge

using some of this:

http://www.princessauto.com/pal/product/4230075/Gauges/Mechanical-Oil-Pressure-Fitting-Kit

I did some searching about external pressure gauges, but I'm still a bit confused about what exactly to buy and exactly where I mount the thing.....and what it's going to tell me about the engine clatter sound after all is said and done.

Here's to hoping this revival gets a little busier in the near future!  I'm working next on getting my garage heated so I can really turn some wrenches in the coming fall and winter...and have a beautiful roadworthy CB550 for next spring!

Cheers all,
Simon

[rb550four]

   That looks like a fun little project....that could turn into a big project if you keep running that motor.
There are allot of parts that are no longer available, like bearings. Smoke those and either look for a different motor or try to sell the bike as parts. The  oil pump  is #1 concern, take it apart and see why it's failing or get a used one check it out and replace it.
 The wiring harness may be a concern but not as alarming as the oil pressure light was off more than it was on. Really? Don't know how old the oil is? 3.2 quarts @ $4 ea., change that and the filter and you'll know..
This machine can not heal itself, it will require your help, it won't be cheap, and it'll probably be more expensive if you don't get a manual,read it , and take an educated approach to the repair of your motorcycle.
 This forum is a wonderful place full of knowledgeable folks that are happy to share what they know, but 1st you'll need a manual so ya don't ask basic Q's that are fully covered in the manual, you will need to know that you will have to spend some $, and you will have to decide that you are truly ready to take on this project.
 Really, if the answer to any of this is no, save yourself the trouble ,expense, and aggravation. Sell it and buy some fun parts for the new bike.
            I say this with respect , please don't feel slighted.     RB

[Simon96Taco]

Appreciate the feedback, and I don't feel slighted at all.  I'd rather be warned than regretful

Regarding the second motor - I actually have one.  It came with the bike.  Maybe the second motor was to fix a known fault...?

Will get myself a manual, but please understand - to a total non-mechanic, it isn't the answer to all of life's questions. 

Thanks again for the feedback - I'll start by pulling the oil pump out and seeing if there's anything obviously wrong with that!

Cheers,
Simon

[FunJimmy]

Simon,

Congrats on the Ducati.
They're a ton of fun and like you said, it leaves you free to build your project without missing out.
Overall, the bike looks like a good candidate, especially with the spare engine. I've got a good spare harness and electrical panel, complete, if you need one.

Good luck
FJ

[Simon96Taco]

Jimmy,

Your bike is ridiculous!!  Great job!!  You really did it right with that one - very inspirational.

Yes, the Duc is a beauty - that S2R and a cafe of my own making are my dream bikes, so one down, one to go.

How much did you want for the harness/panel?

Cheers,
Simon