Topic: Air box internals

[SohRon]

Sweet! Very nicely done; it looks factory made!

The foam piece is a 3"X4"X1/4"  sheet of medium density open cell polyurethane foam and, as suggested above, something usable can probably be obtained from your local garden or farm supply store. It should be dipped in ATF and wrung dry, just like the filter for your mower. It's important because it filters oil vapors from the blow-by that would cause the engine to run lean, smoke, and misfire. I don't have a pic of the filter itself, but here's one with it installed in the CB550 version of what you're working on, just so you can get an idea of what it looks like

Two other important parts in this setup are the drain hoses (18 & 22 ), especially #22. It drains condensation from the airbox, but has a special tip on the end that keeps extraneous air from entering the scavenging system. Be sure the hose either has the special tip, or rig some type of plug that can be removed occasionally for draining purposes.

Glad to see you're being so meticulous in restoring your bike; it seems like they always run better in stock configuration (duh!).

[txterror]

Thanks Sohron, so would it be fine to run a rubber hose with a plug. What does the special tip look like. The piece i made isnt identical but i think it just might get the job done.

[txterror]

Is there any tips you guys may have for installing the air/battery box onto the bike, or is it pretty self explanatory . Also any tips on attaching electronics to it. Never done it before and never seen it stock. I will be tackling this tomorrow and I will be playing the guessing game again. Pics would help, where box mounts to frame as well as electronics. Thanks again guys for all the help along the way.

[oldbob]

When I pulled the battery box/air box out of my 400, the only way that I could get it out was by removing the rear wheel and fender. The box then came out through the rear of the frame. That answered my question of how the intake manifold was installed at the factory. On reassembly, I'll attach pieces in the following order.
1) carburetors to cylinder head
2) intake manifold to carburetors
3) air box to intake manifold
4) rear fender
5) rear wheel

[SohRon]

Here's a pic of the special tip on the CB550 filter box, but I'm sure it's the same one you should have on yours.

Before I got it from a fellow forum member, I just plugged the hose with a small plastic plug

The drain hoses can still be had from BikeBandit, and a little more info can be found here:   
http://forums.sohc4.net/index.php?topic=86697.msg1216567#msg1216567

This thresd covers a CB550, but if you scroll down the page there's a discussion of the hoses and how thry're used.

[txterror]

awesome, thanks guys.

[txterror]

Also, whats ATF?

[txterror]

Sears sells 1/16 rubber gasket set.rubber/cork/and fiber.

[oldbob]

Very nice. And you don't have to wait until next month to ride.

[goofy3392]

Also, whats ATF?

AutoMatic transmission fluid.  Used in the automatic transmission of an automobile. 

Sent from my DROID RAZR using Tapatalk 2

[txterror]

Alright guys i need your help on these wires. Where does the excess wires go? In the pic i hav them coming out the back towards rear tire. Also how does the electronics connected to the box look, am i on the right track? Also what is the bracket right above the number 4 line for in diagram. And also the little tab in the middle of electronic side of box, whats that for

[txterror]

When i bought the bike it didnt have signal lights, so the signal light relay is missing. Guess im not done buying things. sux too cause i just bought some signal lights to install, guess not.

[txterror]

Not sure bout the wire with the bracket. PO had it attached to negative terminal. Its the blk wire spliced to the green wire, can i just ground this to a bolt or does it have to go back on neg terminal. It reaches the term but the wire is pretty close to the positive term. Air box and electronics are on. I just need to get a couple of hoses and solve these wires.. Also what are the rest of the wires for in the pic, blinkers? Help me finish this up guys, i appreciate all help so far and any in the future.

[txterror]

OldBOB, Sohron, anyone please..........need your help guys

[KennyRedman]

OldBOB, Sohron, anyone please..........need your help guys

Looks like that whole rear electrical is all buggered up.  Basically all three green wires (from each turn signal and brake light) are connected to the green wire heading up stream.

I thought it looked funky when I stripped mine, so I took a picture to remind myself.

[oldbob]

Where to start?

The bundle of wires passes by the left side of the airbox, partially supported by hooks near the top.


My electronics have a HondaMan fuse box. In this photo, there is non-standard turn-signal flasher which the PO secured using tie-wraps. I need to get the correct one, or just eliminate the gigantic turn signals.


I'm not quite sure of what is happening with the wires feeding your bike's rear lights. Mine look like this. The right rear signal's non-ground wire (black with a lt blue collar) is disconnected from the lt blue wire that feeds it.

[txterror]

Thanks again OldBob. PO cut off two of the green wires, and left one with that extension on it (in pic) and connected it to negative terminal on battery. Do you think i have to connect it back to battery terminal or can i just ground it to a bolt.

[txterror]

also, thanks homebrew

[oldbob]

Thanks again OldBob. PO cut off two of the green wires, and left one with that extension on it (in pic) and connected it to negative terminal on battery. Do you think i have to connect it back to battery terminal or can i just ground it to a bolt.

I don't know, but it makes me wonder why Mother Honda ran dedicated ground wires.

[txterror]

update: Intake system back to normal
Got both side covers for $65 off flea-bay!