Author Topic: 1979 CB650 (Read 3753 times)

CaptainCory · « **on:** September 26, 2016, 11:36:49 PM »

Hey guys im very new to the bike scene. Im basically going in blind lol but i picked up a 79 CB650 project bike. So fat i have put in a new wire harness and a starter solenoid. I replaced the harness because when i installed the new starter solenoid it burned up my wire harness. SO i replaced it and thought it was a short or being grounded out somewhere. I tracked it down to what i think is the crank case. The wire goes beyond that tho. Dose anyone know how i could replace that wire or even how to fix the problem.

All help is appreciated, thanks

calj737 · « **Reply #1 on:** September 27, 2016, 04:26:31 AM »

If you replaced the solenoid and suffered a significant electrical short, then you simply connected it up wrong. There should be 2 large diameter wires connected to the solenoid. One leads straight to the starter motor, the other to the battery positive terminal. They appear to black in color, and on your Honda, BLACK wires are NOT grounds; they are 12v powered wires. Solid GREEN is ground. This causes lots of new owners issues...

There are numerous smaller gauge wires that run down the left side of the bike, from underneath the electric panel on the left side. Some of these slide under the left shift cover. These are your Alternator/stator wires, plus a NEUTRAL switch and OIL PRESSURE switch. The 3 yellow, 1 white (solid) and 1 black are involved in the charging of your bike. To access their connections under the cover, remove the shifter level, then the screws holding the cover on. Pry it off carefully and they will be revealed in their bullet style connectors.

Just always connect color-to-color on these bikes to insure the correct sequence and polarity. And here's your color wiring diagram for reference:
http://www.cmsnl.com/classic-honda-fansite/honda_wiring_diagrams/CB650(79).jpg
If you look at this diagram, look at the right side. See the alternator? Thats under the left front of the motor. The Regulator/Rectifier is under the left body panel. Top of the page, center, Starter Magnetic switch is your solenoid. That should help get you oriented...

CaptainCory · « **Reply #2 on:** September 27, 2016, 07:02:20 AM »

I'm pretty sure I put it on correctly , I put the key in and the neutral light popped up , when I shifted the bike into first to lock the wheels in place thats when it started to smoke and burn my wires.

calj737 · « **Reply #3 on:** September 27, 2016, 07:05:59 AM »

Quote from: CaptainCory on September 27, 2016, 07:02:20 AM

I'm pretty sure I put it on correctly , I put the key in and the neutral light popped up , when I shifted the bike into first to lock the wheels in place thats when it started to smoke and burn my wires.

Sorry, but that is an indication that it, or something related, is NOT installed correctly. Its quite possible that the NEU switch is improperly connected to the solenoid (if thats the only component you altered and this problem resulted).

Perhaps you can snap a clear picture of the solenoid, its wiring, and that of the battery? Post those and maybe some forum eyes can spot the issue?

CaptainCory · « **Reply #4 on:** September 27, 2016, 07:09:33 AM »

I'm pretty sure this is the problem but I will take a pic of the starter solenoid and post it as well.

calj737 · « **Reply #5 on:** September 27, 2016, 07:14:49 AM »

One thing is for sure; that bare exposed copper wire touching the engine case is NOT good.

CaptainCory · « **Reply #6 on:** September 27, 2016, 07:31:37 AM »

Yeah lol so I'm sure that's why it started to smoke lol. How do I fix that tho :/

calj737 · « **Reply #7 on:** September 27, 2016, 08:07:54 AM »

Remove the stator cover (the round one to the left and forward). Identify which wire that is exactly, and it may be after the bullet connector so the section to be repaired is very short (no electrical pun intended). Replace with proper gauge wire, proper color, and use a proper connector type.

(I am assuming from the little that picture shows) That wire carries lives voltage, AC current likely. Touching the case will "ground it out" and that is no doubt why its tripping the bike. But without knowing the exact color of that wire, its a little difficult to tell-

CaptainCory · « **Reply #8 on:** September 27, 2016, 08:30:26 AM »

Here is better pictures of what I'm looking at currently

calj737 · « **Reply #9 on:** September 27, 2016, 08:48:41 AM »

Lets start with a little bit of spray degreaser on the cases, especially in the area where that bare wire is. Also, I see the repaired case from the stator boss being crunched. That is an indication that cover has been off, and some amount of prior damage to the wiring is possible. I'd pull that cover and trace all the wires back to the alternator as a precaution. Lord knows what lurks below the grease and covers

The green plug on top of the solenoid also looks heat damaged. Might want to investigate replacing that soon too.

CaptainCory · « **Reply #10 on:** September 27, 2016, 08:58:08 AM »

Okay so when I take all that stuff off should I be careful , meaning like is stuff gonna fall out and I have to remeber where it was ?

calj737 · « **Reply #11 on:** September 27, 2016, 11:06:48 AM »

Nope, you're fine.

marting100 · « **Reply #12 on:** September 27, 2016, 02:00:16 PM »

Hey Captain!, remember to take pictures of what you take apart, it will be much easier to go back and look at them when you put it back together.
Nice project!!
Cheers
M

CaptainCory · « **Reply #13 on:** September 27, 2016, 04:14:01 PM »

That's the wire for one , two it looks like this was repaired in some way . Tbh I'm a little iffy about taking it off. And also the screws are stripped to hell :/

calj737 · « **Reply #14 on:** September 27, 2016, 05:30:55 PM »

Because of the damage, evidence of improper repairs, and the issue you're having, I really encourage you to bite the bullet and fix it now, once, completely and properly.

Drill the head off the stripped screws. Pull the cover. Remove the shank with your fingers (they're really easy to extract with the head off). Fix the wiring, and use new metric screws or socket head cap screws. Simple and a right of passage for new owners. (Might as well give up your chastity now and get it over with

)

CaptainCory · « **Reply #15 on:** September 27, 2016, 06:47:23 PM »

Okay lol , do you know what the wire name is , on the wire I need to replace ?

calj737 · « **Reply #16 on:** September 27, 2016, 07:48:22 PM »

I can't tell from the pictures. I see two colors in that bundle that don't look stock, so if you can show me where it connects (towards the rear tire) that will help identify it. Does it run completely under the stator cover?

I see what looks to be 3 yellows, and a blue (odd?) and what looks like a BLACK. That should make that raw wire GREEN but not sure yet.

grcamna2 · « **Reply #17 on:** September 27, 2016, 08:01:12 PM »

subscribed

CaptainCory · « **Reply #18 on:** October 01, 2016, 12:01:46 PM »

Also , I was replacing my wire harness and for some reason it isn't long enough to go to my tail lights , I made sure I bought the right year and everything.

grcamna2 · « **Reply #19 on:** October 01, 2016, 05:48:54 PM »

Quote from: CaptainCory on October 01, 2016, 12:01:46 PM

Also , I was replacing my wire harness and for some reason it isn't long enough to go to my tail lights , I made sure I bought the right year and everything.

You may need to plug-in another rear fender wire harness extension,check an online parts description break-down picture for your model year and see if they used one.

CaptainCory · « **Reply #20 on:** November 24, 2016, 11:21:41 AM »

Alrighty lol , I'm back . I put a new stator on the 650 and got power to the bike , I only saw my signal lights turn on but hey it's better then nothing. Now my only problem is when I got the bike I didn't see how my throttle cables and choke cable connected . I can't find any pictures online to help me :/ .

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Author Topic: 1979 CB650 (Read 3753 times)