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Author Topic: 550F/K Free Bird The FINAL STRETCH mark  (Read 11690 times)

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Offline straat-toe

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Re: 550F/K Rebuild and Bug fixing
« Reply #50 on: July 07, 2015, 06:15:52 AM »
Ok.

I have been busy cleaning up my wiring. I have everything that I need to refresh the black circuit and some bad connectors so i thought I might as well do that while tracking down the short. I'll report back on that once it's done.

In other news, when fitting my Fork brace I noticed that the wheel isn't sitting in the middle of the 2 forks. I always thought my fender bracket was a bit bent. Turns out my wheel isn't centered. I have all the pieces on the axle including the collar and bearing seal . I never noticed the bike feeling misaligned when riding. Could the wrong collar be fitted on my axle. The gap on the brake side of the wheel between wheel and fork lower is about 9mm. The gap on the left side is 15mm. 

Is this normal?
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Offline straat-toe

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Re: 550F/K Rebuild and Bug fixing
« Reply #51 on: July 07, 2015, 06:27:36 AM »
And what's a thread without photos. I also moved my bike into the house while my Girl is on a business trip....no one will ever know.
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Offline straat-toe

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Re: 550F/K Rebuild and Bug fixing
« Reply #52 on: August 25, 2015, 07:16:44 AM »
Greetings and salutations! So it's been a while since I posted once again.
My Car project has been sucking funds and time out of the bikes. But here's a couple of pics of wiring that I did and what my dogs did to my seat. I've been meaning to redo the seat. I guess the mutts just helped me along!

I fitted a new reg/rec from David Silver and I replaced the entire black circuit with all new vintage connectors and cleaned up all the dodgy looking old connectors and crap aftermarket ones I had put on as a stop gap. And after being inspired by Cal's clean Polyester braided loom work i decided to go the same route.

If the problems are still there I'm towing the bike to a shop to get it the electrics sorted out. I've been meaning to get a professional to go over everything I did anyway before I take it for it's roadworthy test.

 
« Last Edit: August 25, 2015, 07:35:52 AM by straat-toe »
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #53 on: August 27, 2015, 11:31:25 PM »
Ok so after trying my hand at wiring and electrics. I still cant find the dead short. Main Fuse is still popping as soon as Ignition gets turned. I've done it all. Even tried to see the spark in a darkened room and I still couldn't see the light. Only the warm glow of a fuse heating up and then...Darkness.

So I'm doing what I should've done from the start. I'm taking it to a pro. It's probably going to be something stupid that is as clear as day. But hey I cant wait anymore. This bird was meant for flying, and summer's here. Here's some pics of my seat pan after my dogs did me the favour of removing the old foam. I reckon a new one is on the cards. I started derusting it to use the original as a mold to make my plug. I'll be making a new pan with mostly glass and maybe 2 layers of Carbon for strength. Once I've learned from my inevitable mistakes I will move on to making a Carbon Fender to fit under the Tarozzi fork brace.   

Peace!
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Offline calj737

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Re: 550F/K Free Bird
« Reply #54 on: August 28, 2015, 06:45:53 AM »
Quote from: straat-toe on August 27, 2015, 11:31:25 PM
Ok so after trying my hand at wiring and electrics. I still cant find the dead short. Main Fuse is still popping as soon as Ignition gets turned. I've done it all. Even tried to see the spark in a darkened room and I still couldn't see the light. Only the warm glow of a fuse heating up and then...Darkness.
Come now, you've done so much by yourself, you can solve this too! A little logic and process is all you require...

From battery POS, RED wire traverses the Main fuse, then goes to key switch. At the key switch,
Red transfers power to BLK, BR and BR/WHT

If simply turning the key to position 1 pops the Main fuse, you are grounding out the RED wire between the battery POS and the key switch. You need to insure that the power being sent to BLK, Br, and BR/WHT is not being tripped. Pull the fuses for those colors (stock has Br and Br/Wht) and turn the key. Does the Main fuse pop? If so, then your issue is on BLK circuit. If not, replace 1 of the Br circuit fuses and test again. Pop? No? remove Br, and replace Br/Wht. Pop? Yes? Now trace that circuit.

I suspect the problem is along your BLK. It leaves the key and heads towards the handlebars. If you have inadvertently tied stock BLK to a device ground (industry standard is BLK=ground, except in Honda its switched 12v) then you'll find your problem.

This is why I always re-wire with BLK through its own fuse. Not because it requires it from a current draw, but because when you blow a fuse due to a device ground, it kills the MAIN fuse. Dead bike  :-\

Another way of doing this is: key OFF. Check with your meter for continuity to ground on these 4 colors from the KEY switch. None should have a path to ground. You can do it from the harness connector of the key switch. This method saves you blowing fuses...

Spend 15 minutes, and you'll find it. Meters don't lie. And they have X-ray vision  ;)
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #55 on: August 31, 2015, 12:47:37 AM »
Thanks for the encouragement Cal.
 I've tried it all done all of these tests. Replaced entire black and red circuits. New terminals even replaced the reg/rec with a new japanese unit(that I probably didn't need) So as much as I hate admitting defeat. I took it to a man over the weekend. I think I'll be able to live with the shame while going down the Freeway at speed.  ;)
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Offline Restoration Fan

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Re: 550F/K Free Bird
« Reply #56 on: August 31, 2015, 03:02:08 AM »
Never seen a motorcycle carrier that attaches like that to the trailer hitch.  Pretty cool.
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Offline calj737

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Re: 550F/K Free Bird
« Reply #57 on: August 31, 2015, 05:15:42 AM »
yup, you just need to remove the chain when you tow that way.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline straat-toe

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Re: 550F/K Free Bird
« Reply #58 on: August 31, 2015, 06:49:02 AM »
First time you tow like that it's Nerve Racking. The bike has a tendency to lean into corners...... And that just freaks me out.
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Offline SOHC4 Cafe Racer Fan

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Re: 550F/K Free Bird
« Reply #59 on: August 31, 2015, 07:52:28 AM »
Quote from: straat-toe on August 31, 2015, 06:49:02 AM
First time you tow like that it's Nerve Racking. The bike has a tendency to lean into corners...... And that just freaks me out.

I don't know if I'd be so comfortable seeing that.
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #60 on: September 01, 2015, 03:01:47 AM »
Yes. I nearly Shat myself the first time. Definitely better to be riding the bike than towing it.
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #61 on: September 18, 2015, 03:11:55 AM »
Quick little update guys.

The short has been fixed. The sparky's couldn't find it either, so he redid a bunch of stuff and now the fuse is no longer popping. Still need to finish the seat up before I can take it out and give it a test run. I also took the opportunity to paint my air-box with Rustoleum plastic paint. Checked the Carb boots for damage. Found none. I ordered Honda S clamps for the boots. Hopefully that stops the jump to high revs when I shift into N. 

I also managed to get the old seat-lock working. So i'll be refurbing the Plunger to attach to my new Carbon seat pan.

So here's my first ever attempt at mold making and laying up. . 

It came out pretty good in the end. Don't judge me too harshly on the top of the pan.....all i can say is if you think you have enough releasing agent in the mold...give it another 3 layers of wax. I had to break the mold off so it's a bit messy. But that will get foam over it anyway.  It fits really well and weighs a 3rd of what the metal pan did. 

So now with Carbon-fibre lessons learnt I will be tackling a shorter fender to fit under the Tarozzi brace...Hell I might get carried away and make a carbon rear fender! But i'm going to try not to. ha ha.

Parts on order from Honda:
 Missing Seat rubbers.
Carb boot clamps.
New Rubbers for Seat lock plunger.                                           

PS. Screw Fiber Glass.
« Last Edit: September 18, 2015, 03:15:53 AM by straat-toe »
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Offline calj737

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Re: 550F/K Free Bird
« Reply #62 on: September 18, 2015, 03:49:17 AM »
Nicely done. A little hint for you, on a seat pan that needs some structural connection, lay some thin strips of aluminum between the layers of carbon fiber and they will become bonded internally to it. Won't add any weight and will prevent cracking or tear out of the fasteners. (Should be helpful for your front fender bracketry)
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #63 on: September 18, 2015, 05:54:38 AM »
Thanks for the hint Cal.
 I think I'll do that where the hinge bolts and plunger mounting points are. Is it to late to lay some more carbon for support on the underside now that it's cured?
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Offline calj737

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Re: 550F/K Free Bird
« Reply #64 on: September 18, 2015, 07:48:01 AM »
Never too late with Carbon or FG. Thats a huge reason auto manufacturers like the stuff; it can be repaired endlessly.
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"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline straat-toe

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Re: 550F/K Free Bird
« Reply #65 on: September 21, 2015, 12:13:46 AM »
Cool. I'll get onto strengthening it up a bit more before I get it recovered.
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #66 on: November 27, 2015, 03:27:50 AM »
Hi all.  Just a quick update. I have reinforced my C/fibre seat pan and had the bike running and getting the idling dialed in again. Just waiting for the last few bits from Honda(for almost 2 months already :( ) before I get the seat redone.

I ordered the seat rubbers and a new seat lock plunger and original S clamps for the air intake rubbers. I should just have ordered from the 4into1 store. Would have had the parts a month ago already.

Goddamn you HONDA!   
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #67 on: July 10, 2016, 06:01:25 AM »
Ok so I'm probably the most infrequent poster on here.

So on the 550.... I finished the seat but didn't measure the distances correctly.So there was a huge gap between the seat and tank that was keeping me up at night.mI've fixed that now with some brackets at the bottom of the seat so I can move the seat lock and hinge to get the right placement. The seat also came out with a bit of a fuller figure than I wanted. But it's been growing on me.

I upgraded the front brakes with some phenolic pistons from Godferrys Garage. Braided hoses and a double banjo bolt/switch combo. Bike stops on a penny now.

On the front fender I have been trying my hand at shaping ABS plastic. I just haven't been able to get it  just right. So I sourced a old Suzuki fender that I started cutting. Just need to finish that and I'm of to the races. I have figured out a system for mounting the fender under the Tarozzi brace.

I also had my Exhaust and Caliper's ceramic coated. Woop.

And I'll be giving her a fresh lick of paint in the next month or so....and when I say me I mean a professional painter.

Here's some pics.
« Last Edit: July 10, 2016, 06:21:29 AM by straat-toe »
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #68 on: July 10, 2016, 10:45:58 PM »
So here is the new and improved seat position.

I can sleep at night. I do think the hump on the back of the seat is too pronounced though....
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Offline Bankerdanny

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Re: 550F/K Free Bird
« Reply #69 on: July 11, 2016, 11:05:15 AM »
The seat looks good. Well done.
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Current: '76 CB750F. Previous:  '75 CB550F, 2007 Yamaha Vino 125 Scooter, '75 Harley FXE Superglide, '77 GL1000, '77 CB550k, '68 Suzuki K10 80, '68 Yamaha YR2, '69 BMW R69S, '71 Honda SL175, '02 Royal Enfield Bullet 500, '89 Yamaha FJ1200

Offline straat-toe

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Re: 550F/K Free Bird
« Reply #70 on: July 11, 2016, 01:06:14 PM »
Thanks. I'm finally kinda happy with it.
Onwards and upwards. I'm waiting on a Ignition system from Honda-man for the 550 currently.
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Offline straat-toe

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Re: 550F/K Free Bird
« Reply #71 on: July 13, 2016, 10:59:51 AM »
3 Posts in 3 days.
I'm setting personal records here.

So I bobbed my Fender. Just need to clean it up a bit now and get it mounted on the fork brace.

It doesn't look half bad....even if I say so myself.

All Hail DREMEL! 
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Offline Bankerdanny

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Re: 550F/K Free Bird
« Reply #72 on: July 13, 2016, 11:07:29 AM »
That turned out very nice. I am not a fan of the no-fender look.
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Offline straat-toe

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Re: 550F/K Free Bird The FINAL stretch mark
« Reply #73 on: July 13, 2016, 11:22:18 AM »
Yeah Totally. I'm not a fan of my brake hoses and speedo cable chaffing against the tyre either.

I really wanted the fork brace. But the 76's fork lowers are the short kind. So the stock fender wont fit under the Brace. Hence ABS experiments and finally the Suzuki fender that I cut. I wasn't keen on cutting the original 550 fender as it is still in pretty good nic. I'm thinking of making a bracket out of some alu for the two hoses to mount to top of the Fork brace. I kinda drilled and tapped 2 holes into it for mounting the fender before I came to my final solution. 

Coming along nicely now.
« Last Edit: July 13, 2016, 11:32:37 AM by straat-toe »
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Offline straat-toe

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Re: 550F/K Free Bird The FINAL STRETCH mark
« Reply #74 on: July 17, 2016, 01:28:58 PM »
Update

So I have successfully mounted the fender. It clears the tyre and the brake lines clear the sidewalls. It all lines up rather nicely. I think it looks the tits. Just need to clean up around the edges a bit more and clear coat the cuts holes and underside to prevent rusting.

On a side note. I scratched my fork-brace during mouunting so I'm going to have to repaint it now...maybe a gloss black....
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