Topic: CB500K1 Cafe to Stock (well more or less!)

[AndyH]

Hi all,

I haven't posted much about my restoration since getting the bike so I guess it's time to provide some info.
I'm in Perth, Western Australia and acquired a CB500K1 which was converted to cafe racer style some 4 or 5 years ago.  The bike was in overall good nick but obviously some things needed to change to bring things back to original.

The duck-tail seat, lo-rise handlebars and mini speedo and tacho needed to be replaced.  Fortunately there were quite a few useful odds and ends that I got with the bike, and a subsequest purchase of a box of bits from another Perth local. 

So as it stands now, I have a seat (original base and foam covered with a DSS cover), a new set of RHS and LHS switches (another story... ) , a new handlebar and a bunch of other things like rear footpegs, new headlight and surrounds and a new 2-stay front fender.

I've been cleaning up the wiring loom and connectors, along with some other bits.

A close friend is restoring the instrument faces for me, so they'll be ready before long. 

And now to today! 

I removed the “sub-frame” containing the reg, rectifier, blinker relay and solenoid in order to clean things up.
The sub-harness turned out to be an absolute dog’s breakfast….one of the multipin connectors was missing altogether!
Thanks to the CMSNL diagrams I soon figured out that the rectifier module no longer had a multipin connector on it.  Instead, it was sloppily spliced into the sub-harness, with some of the connections just twisted together (no solder) and wrapped with cheap electrical tape.

Once I realised that refurbishment was going to be difficult, I took a heap of photos.  They’ll help with putting things back together, along with the wiring diagrams. 

I tinkered with the idea of getting hold of a replacement harness (which isn’t available anyway!) but then I’d have to source a multi connector for the rectifier.

I’ll strip the paint off the sub-frame tomorrow, respray same then set about putting things back together.  Won’t be too difficult, just not original….oh well!! 

I'll try to remember to take more photos in future.  If you want to see what the bike looked like when I bought it,  here ya go! 

[AndyH]

For whatever reason, the 6-pin spade connector on the rectifier was removed, and the wires then spliced into the loom after removing the female bulkhead connector.  I have a source for the 6-pin spade connectors and will restore the loom.

[calj737]

You can fully replenish all those connectors: http://vintageconnections.com

Here's a full repro harness for you: https://www.cmsnl.com/honda-cb500k1-four-general-export_model14659/harness-wire-non-oe_32100323040p/#.WSf7ScZ-K3U
Or another source: https://www.davidsilverspares.com/CB500K1-FOUR-1972/part_61799/

I realize shipping to AUS isn't always cheap, but if you do seek the originality you can source the components to get there.

[AndyH]

Thanks Cal but it's the sub-harness which has been butchered, and a replacement is unobtanium. 
And Vintage Connections don't have a 9-pin.

[calj737]

Is this what you need? If so, PM me and I'll post it out to you

[AndyH]

PMed Cal!

[AndyH]

Things move slowly in WA (Wait Awhile!) 

Recently returned from a trip up into the Pilbara and Kimberley regions of Western Australia.  Now back in the cold hole that is Perth in Winter!! 

Installed the replacement wiring harness, fitted the electrics panel (refurbished & thanks to Cal  for the sub-harness!  ), rear blinkers fitted/wired and took the front wheel and caliper off in preparation for removing the forks, polishing them and mounting the fork ears.  They've been chromed and ready to go on, but waiting for delivery of top rubber "cushions" from DSS which are now back in stock and should arrive in the next week or so. 

The 1st two pics show the original sub-harness and electrics panel before refurbishing.

The 3rd pic shows some of the harness wiring, including the crap connection for the electronic ignition.

The last pic shows the bike in its current state, with new wiring harness provisionally fitted, along with several other bits n pieces.

[seanbarney41]

Was that a real Giuliari seat on there? Or maybe the Vietnamese copy?...somebody is gonna want that.

[AndyH]

Was that a real Giuliari seat on there? Or maybe the Vietnamese copy?...somebody is gonna want that.

I have no idea whether it's a Giuliari or a copy, but it's going to my mate who's building a cafe racer.

[seanbarney41]

Was that a real Giuliari seat on there? Or maybe the Vietnamese copy?...somebody is gonna want that.

I have no idea whether it's a Giuliari or a copy, but it's going to my mate who's building a cafe racer.

good!...just didn't want it to get thrown away or something

[RAFster122s]

Himble,  glad you found the mess now rather than later.  I found some PO nightmares as well just like those...
Makes you want to pummel them with a blunt object, lead pipe comes to mind...

You are making it look very nice.  You changed the Dyna 3 ohm coils for some 5 ohm coils?

Nice work, I am going to enjoy following your thread...

[AndyH]

Hi David, thanks for the positive remarks! 
The Dyna ignition was on the bike when I bought it, along with the 5 ohm coils.  It ran very nicely with that setup.
Hopefully it will still run nicely after I'm done with the resto! 

[AndyH]

Clutch and throttle cabling, and wiring routing more or less sorted now.

[RAFster122s]

Very tidy...
Your fork ears getting polished?  Nearly impossible to buy a used set that is not bent from a drop or chrome not pitted unless it spent most of its life inside.  If yours are straight count yourself lucky.  '74 US cb550 used same ears, they changed signal designs in '75 or was it '76 model year to the larger ones here in US.

[AndyH]

Yeah, the fork ears I had were in rather poor condition (the PO had sandblasted them to within an inch of their lives!  ) and that resulted in a small hole which my mate managed to fix.  I had them chromed and they've come up to reasonable condition.  Just waiting for the top rubbers to arrive from DSS and then I'll fit them and the headlight bucket etc.

I'll keep looking for replacements but I don't like my chances. 

[RAFster122s]

Very nice!
Chrome work here is not inexpensive...

David

[AndyH]

Very nice!
Chrome work here is not inexpensive...

David

Very expensive here too David!

[SOHC4 Cafe Racer Fan]

Nice. The stock plating wasn't so great.  These look nice. 

[AndyH]

I mucked around in my shed today, and rummaged in a parts bin and found some top fork ear rubbers in good condition!  So the ones coming from DSS will go into the "new parts" parts bin. 

I figured "What the hell", and went ahead with the fork ears, gaiters, caliper, front wheel and fender install today! 

Need to go to my local auto store tomorrow for some brake fluid, then bleed the brake and wheel the bike out of the shed for the 1st time in 3 months!

Getting ever closer to completion now. 

Last 2 pics show my messy bench, and my mate's "you beaut" meter crimp ring compressor. 

[AndyH]

Fitted the headlight bucket, blinkers and mirrors.  PO didn't use the original fork ears so I had no collets (#13 in the h/light schematic below).  Fortunately I had some tube stock in the shed of the right size so fabbed up a couple. 

Getting closer to completion.

[AndyH]

Finalised the wiring connections today.  Fitted the headlight and battery then carried out a couple of continuity checks.
When I turned on the ignition, lo and behold I had the neutral and oil pressure lamps come up!
No nasty burnt insulation smells either.
Tested headlight, park lights, blinkers and all good.
Will test F and R brake lights when I bleed the front brake.
Have mostly filled the tank, and run a couple of hoses down to a clear bucket to see if I've solved the petcock leak (screws leaking past the fibre washers).  If this is successful I'll put the carb hoses on and try a test fire! 

[AndyH]

No leaking!  So I've decided to change the fuel lines to the carbs....that was a challenge, but thanks to various threads on this forum I was able to do the business without too much drama.  As many have said, this resto business is a case of patience and beers, patience and beers....in my case, patience and red wine! 

Tomorrow I'll refit the tank, connect the (new) fuel lines and press the "Start" button! 
 

[AndyH]

We have a heartbeat! 

I mucked about a bit with the clutch cable as I wasn't happy with its routing.  After sorting that out, and fitting the fuel hoses to the tank I carried out a visual inspection to make sure I hadn't forgotten anything.  All good, so I turned the petcock "on" and went back inside for a coffee.  Suitably charged with caffeine ( ) I returned to the shed and turned the ignition key on and pressed the start button for just a few seconds to ensure that the starter motor would actually work!  It did, so I pressed the button for a few seconds more and she spluttered into life, then stalled.  I then realised I hadn't applied any choke ( ).  After a few more tries, things settled down and I was able to turn the choke off and enjoy a nice idle burble.

Happy?  You betcha!!     Just need to finalise the tacho and sidecovers then time to ride! 

[calj737]

  That's an ear-to-ear grin for you!

[SOHC4 Cafe Racer Fan]

Fantastic!