Topic: 1976 CB550 electrical problems posted photos for help

[zizzonuts]

I have inherited my fathers 1976 CB 550K. He had it worked on through one dealership but it will not start do to electrical problems. The fuse holder is melted on the right side (15amp), and someone spliced in a wire from one point and connected it to two other points of two different wires. I have attached photos of the wire any thoughts as to why or how I can fix this? The bike had a major overhaul because it would not shift out of 3red gear. If anyone has any thoughts as to what to do I would greatly appreciate it.

[goldarrow]

Seems like wires are spliced to bypass fuse, not a good thing todo. I would look for shorts, get new fuse holder, stock replacement should be fine but others may recommend blade type fuse. Can't shift out of gear could indicate tranny issues, but before that try to go through proper adjustments and/or new clutch pack.  Download manual in the FAQ section

[Parkwood60]

I can't tell from the pictures, they are too small. No competent shop would have wired around a fuse. Sticking a piece of foil in the fuse holder is a trick for getting home when you short out miles from home, but you should never eliminate the only thing that stops an electrical fire from starting in the event of a short.

[calj737]

Amen on replacing the fuse holder! From the pictures, it appears the bike had a problem with the ignition switch and someone tapped into the 12v wire (red from the block connector) and wired it directly to the 12v switched (black wire) to indeed bypass the switch. The result? A melted fuse block.

This bike will need a decent amount of maintenance to all the electrical connections (handle bar controls, headlight bucket, block connectors, etc) to be electrically reliable. You may also discover other "melted" wire sections indicating a replacement loom/harness to be required. Best to be thorough with all this stuff.

I don't believe any bike shop would have performed the "splice" as it really could have caught fire. Perhaps someone spliced it, then took it the shop, where they said $$$$$ and the repair ended there. Either way, it can be fixed but will take some effort to do so properly.

[rb550four]

Red to black, looks like the browns....Looks like someone made a poor attempt at hotwiring the bike.
Do you have the key?

[MoMo]

Red to black, looks like the browns....Looks like someone made a poor attempt at hotwiring the bike.
Do you have the key?

That was my interpretation too

[zizzonuts]

Thanks for the advice and info everyone. The Background to this bike is this. My dad bought it new and the only place it has had work done was called don and roy's in new berlin Wisconsin. I know that my dad did not do this because he never touched  electrical only just regular maintenance . This bike was at there shop for almost a year because the gearing was shot and one day he could not get it out of 3red coming home. I belie they did a engine rebuild and I was told that Honda had to make parts for the bike that where not available anymore. I have not contacted dealership to find out the work history on the bike but I have a better place to go to. If anyone lives in Milwaukee I suggest "The Shop" they have been nothing but helpful with advise and even explaining in great detail how to work on the bike. I rebuilt the carburetors myself with their help and now its the electrical. If Im correct from your advise I should follow the wires to each component and check it all. I have the key, the first position on the  ignition switch did work light horn and directional signal signal did work. I did discover that one of the ignition coils connections where week and I have to repair with soldering. In short should I invest in a new wire harness because of the age of the bike or do it peace by peace.

[MoMo]

New harness would be nice but you can repair what is there using patience along with connectors and crimping tool from www.vintageconnections.com  At least I think that is the correct link...Larry


If you only need a handful of connections I can send some to your gratis as I bought a rather large kit and have only used a minimal amount up till now.

[zizzonuts]

Just an update and thanks.
I have replaced the wire harness, plug heads, wires, and fuse box. After putting it all back together along with the cleaned and reassembled carburetor I was still not able to get the bike to start. So I started to think as to what everyone said on this thread and looked at the ignition switch and to my surprise the geniuses at Don and Roy’s removed one of the wires, Confirming that they were trying to bypass the ignition switch instead of simply replacing the part. Once that and a new starter solenoid arrives I will be back on the road, hopefully. Thankyou for your help.
Matt