Author Topic: IrishGuy's Cafe Project Has Begun... [Updated and frustrated!]  (Read 13857 times)

0 Members and 1 Guest are viewing this topic.

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #50 on: October 04, 2007, 05:21:52 PM »
Well...  An old biker at work has made a comment that got me concerned about my tank.  I told him what I did with the $1 tank cleaning in the coffee room, and he asked me what I was going to coat the tank with.  I told him nothing and he seemed to think that the tanks were "acid etched" from the factory to prevent rust.  Is this true?  And if so should I do anything else?  I figure as long as the tank is clean and not leaking what should I have to worry about.  I plan on keeping gas in the tank and riding the bike regularly.

Any comments?

Offline dagersh

  • "A country attempting to tax itself into prosperity is akin to a man standing in a bucket attempting to lift that bucket by its handle. - Winston Churchill"
  • Expert
  • ****
  • Posts: 1,010
    • Photos
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #51 on: October 04, 2007, 05:33:14 PM »
IG,

You should be fine, as long as you don't let old gas sit in there for too long a period.  It sounds like you did a great job protecting it after you cleaned the rust out, so you should be fine there as well.

If you do run ino rusting problems in the future, you can always seal the tank at that point with POR-15 (don't use Kreem).

No stress man, keep up the great work.

Gersh
1962 CA95
1966 Black Bomber
1966 CA77 Dream
1967 Superhawk
1970 CB750K0
1972 CL350
1972 CB450/500 Custom
1972 CB500K1
1975 CB550F
1976 CB400F
1975 CB750 Future Restoration
1976 CB750K6
1976 CB750F
1976 GL1000


1968 Suzuki T500 Cobra
1990 BMW K1
2001 'Busa
2003 RC 51
Bunch of Guzzi's

http://www.sohc4.us/gallery/v/members/personal/dagersh/

Offline motomotard

  • Enthusiast
  • **
  • Posts: 130
    • GoGo Garage
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #52 on: October 04, 2007, 06:11:46 PM »
wow, i cant believe how well the "works and bolts" cleaned the inside of that tank. good job

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #53 on: October 04, 2007, 07:37:33 PM »
wow, i cant believe how well the "works and bolts" cleaned the inside of that tank. good job

Yeah...  I was pretty pleased and pleasantly surprised.  I heard about it from someone here on the group so they deserve the credit  [And my girlfriend for finding it at the Dollar Store]...  For a buck it is a pretty sweet deal.  It sure beats the other solutions I have read about.

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #54 on: October 18, 2007, 02:38:30 PM »
Well... I'm almost there if i can track down a few electrical gremlins...

1.  The blinkers don't work.

2.  The fuse is getting hot.

I have checked all of the connectors, cleaned them off and put a little dielectric grease on all of them.  At this point I am pretty bummed out.  I really want to get this bike running and all the little bugs worked out.  It was running when I got it, except for the number 4 cylinder pipe not getting as hot as the others.

So anyway I decided since I needed some motivation I would just put it all together and see what she looks like.  I still haven't decided on the paint so for now she is just in primer.  I may leave her in primer and just clear coat over it.  It is kind of growing on me.

PS:  If any electrical gurus are coming to the Barber's Vintage Festival...  I have beer, food and a spare bedroom for you if you can help me get my bike trouble shot...   ;D
« Last Edit: October 18, 2007, 02:41:39 PM by Irishguy »

Offline Sam Green Racing

  • Really Old Timer ...
  • *******
  • Posts: 16,068
  • I REALLY? hate black rims.
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #55 on: October 18, 2007, 02:50:10 PM »
Turned out quite nice Mark, well done mate. 8) 8) 8) 8) 8) 8)

Sam. ;)
C95 sprint bike.
CB95 hybrid race bike
CB95 race bike
CB92
RS 175. sprint/land speed bike
JMR Racing CB750A street ET drag bike

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #56 on: October 18, 2007, 03:07:39 PM »
Turned out quite nice Mark, well done mate. 8) 8) 8) 8) 8) 8)

Sam. ;)


Thanks, butt...

It will be well done when I am actually riding it down the road trouble free.  Don't hold your breath.

I have decided that whenever I get it all sorted out I am going to buy me an old vintage leather motorcycle jacket as a reward.  Some stuff on old bikes is fun, but some stuff is a pain in the ass.   ;)


Offline Dennis

  • Hot Shot
  • ***
  • Posts: 721
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #57 on: October 18, 2007, 04:21:45 PM »
Well... I'm almost there if i can track down a few electrical gremlins...

1.  The blinkers don't work.

2.  The fuse is getting hot.

I have checked all of the connectors, cleaned them off and put a little dielectric grease on all of them.  At this point I am pretty bummed out.  I really want to get this bike running and all the little bugs worked out.  It was running when I got it, except for the number 4 cylinder pipe not getting as hot as the others.
.............................................

PS:  If any electrical gurus are coming to the Barber's Vintage Festival...  I have beer, food and a spare bedroom for you if you can help me get my bike trouble shot...   ;D


GREMLINS????????????????

Not really, just the usual stuff for an old Honda (or probably any old motorcycle for that matter).

1.  The blinkers don't work.
I notice that you have aftermarket turn signals installed. (Note: I didn't read through the entire 4 pages before this so you may have mentioned this.) I suspect that they have substantially lower wattage bulbs than the OEM Honda indicators. The original flasher will never work with smaller (less wattage = lower current) bulbs since it requires a minimum amount of current to flash. I usually replace them with the automotive (2 terminal) "heavy duty towing flasher" usually numbered "552" (I think) which has always worked for me. Some people prefer the electronic type, however I don't know which selection would work for those. Does anyone reading this know?
If they still don't flash after changing the flasher a poor ground will also reduce the current and cause a flashing problem so check your ground connections -- on second thought, maybe you ought to do that first.

2.  The fuse is getting hot.
Two strong possibilities here. Most likely a high resistance connection somewhere in the fuse holder. I'm thinking that the "500" has only one fuse in an in-line style fuse holder. I would examine the fuse holder for corrosion or other signs of a poor connection and clean the contacts where it contacts the fuse element. You could also remove the fuse and measure the current at that point with a meter to be sure that the system is not drawing excessive current (though my thoughts are that would more likely blow the fuse than cause it to be noticeably hot). I'm suspecting a poor connection in the fuse holder.

I hope this helps to solve your electrical problems. No, I'm not coming to Barber's Vintage Festival, but next time I pass through Ohio (it is Ohio - isn't it?) I'll take you up on the free beer.

Good luck!

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #58 on: October 18, 2007, 07:08:10 PM »
1.  The blinkers don't work.
I notice that you have aftermarket turn signals installed. (Note: I didn't read through the entire 4 pages before this so you may have mentioned this.) I suspect that they have substantially lower wattage bulbs than the OEM Honda indicators. The original flasher will never work with smaller (less wattage = lower current) bulbs since it requires a minimum amount of current to flash. I usually replace them with the automotive (2 terminal) "heavy duty towing flasher" usually numbered "552" (I think) which has always worked for me. Some people prefer the electronic type, however I don't know which selection would work for those. Does anyone reading this know?
If they still don't flash after changing the flasher a poor ground will also reduce the current and cause a flashing problem so check your ground connections -- on second thought, maybe you ought to do that first.

2.  The fuse is getting hot.
Two strong possibilities here. Most likely a high resistance connection somewhere in the fuse holder. I'm thinking that the "500" has only one fuse in an in-line style fuse holder. I would examine the fuse holder for corrosion or other signs of a poor connection and clean the contacts where it contacts the fuse element. You could also remove the fuse and measure the current at that point with a meter to be sure that the system is not drawing excessive current (though my thoughts are that would more likely blow the fuse than cause it to be noticeably hot). I'm suspecting a poor connection in the fuse holder.

I hope this helps to solve your electrical problems. No, I'm not coming to Barber's Vintage Festival, but next time I pass through Ohio (it is Ohio - isn't it?) I'll take you up on the free beer.

Good luck!

Thanks for the reply...

Regarding the blinkers...  I had searched this forum and thought the same thing, but from what I remember most people who have trouble with the after market blinkers the problem is that they won't blink.  They come on and stay on.  Mine, on the other hand, won't light up at all.  I even hooked up one side of the bike to the original OEM blinkers and they still won't come on.  I have replaced the winker with one from the auto parts store also.  So I am still at wits end regarding this one.

Regarding the fuse...  Yes it is only one fuse on the whole bike.  The fuse holder is like new, but I cleaned the contacts anyway.  I re-spliced the wires where it connects to the red and white striped wires with new bullet connectors.  I have pulled apart, cleaned and coated each connection with dielectric grease too...  Yet I am still at wits end regarding this one too.


Offline Dennis

  • Hot Shot
  • ***
  • Posts: 721
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #59 on: October 18, 2007, 07:49:53 PM »

Thanks for the reply...

Regarding the blinkers...  I had searched this forum and thought the same thing, but from what I remember most people who have trouble with the after market blinkers the problem is that they won't blink.  They come on and stay on.  Mine, on the other hand, won't light up at all.  ................  So I am still at wits end regarding this one.

Regarding the fuse...  Yes it is only one fuse on the whole bike.  The fuse holder is like new, ..........................  Yet I am still at wits end regarding this one too.



Seeems like I missed something(s) before I replied to you ...... 

Regarding the blinkers...  Mine, .... won't light up at all.

Kind of sounds like no power or an open circuit somewhere. Do You have a test light? Do you know how to use it?
Clip one end to the negative battery terminal, probe the supply side of the flasher - light or no light? If it lights, turn on flasher switch and follow wiring diagram until you get to the lamp and lose the light somewhere along the way. If no light do the same thing in the opposite direction until you find power. Remember to turn the key on first.

Regarding the fuse...  The fuse holder is like new,..........................  Yet I am still at wits end regarding this one too.

I would remove the fuse, replace with an ampmeter and see how much current is flowing there just to make sure ......
You could try to measure the voltage drop from one bullet to the other, that should give you an idea of how much resistance you are seeing in the fuse holder.


Offline droopy

  • Hot Shot
  • ***
  • Posts: 281
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #60 on: October 18, 2007, 09:36:24 PM »
sounds like the 2 problems maybe related. I would disconnect the signals and see if the fuse heats up. I think you have a short to ground in the turn signal wiring.
2007 lifan 200cc sport ohc thumper

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #61 on: October 19, 2007, 02:13:25 AM »
sounds like the 2 problems maybe related. I would disconnect the signals and see if the fuse heats up. I think you have a short to ground in the turn signal wiring.

Thanks for the help...

Yeah...  I have been thinking that is what I am going to try tonight.  I've got to charge the battery now it ran down yesterday goofing with the electrical system.

Offline Dennis

  • Hot Shot
  • ***
  • Posts: 721
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #62 on: October 19, 2007, 08:53:04 AM »
sounds like the 2 problems maybe related. I would disconnect the signals and see if the fuse heats up. I think you have a short to ground in the turn signal wiring.
 

...... definitely worth a try!!!
« Last Edit: October 19, 2007, 12:21:28 PM by Dennis »

Offline motomotard

  • Enthusiast
  • **
  • Posts: 130
    • GoGo Garage
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #63 on: October 19, 2007, 12:31:29 PM »
Irishguy,

I tried the works and bolts thing on the inside of my tank to remove rust like you did.  i did it exactly like your post says you did. after about a day or two sitting the entire inside of he tank has begun to tarnish and  turn a brown rusty color, i dont think its rust but it may be, it looks like just tarnish to me. when i put gas in the gas comes out brown. did you have this problem? i can post pics also if anybody wants to see them.

Offline volthause

  • Enthusiast
  • **
  • Posts: 165
    • gallery
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #64 on: October 19, 2007, 01:52:13 PM »
If left dry, I'm sure the inside of the tanks will flash rust within a couple days. It's usually only superficial, and I'd imagine it will disappear after a few tanks of fuel have been through it.
scott - 1974 CB550
Project Thread - http://forums.sohc4.net/index.php?topic=122740.0

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #65 on: October 19, 2007, 03:33:41 PM »
Irishguy,

I tried the works and bolts thing on the inside of my tank to remove rust like you did.  i did it exactly like your post says you did. after about a day or two sitting the entire inside of he tank has begun to tarnish and  turn a brown rusty color, i dont think its rust but it may be, it looks like just tarnish to me. when i put gas in the gas comes out brown. did you have this problem? i can post pics also if anybody wants to see them.

Oh hell yes it will rust back if you don't put something in it.  Did you not fog it with WD-40 or coat it with some oil or something?  I put 2 stroke oil in mine, mixed with gas and it still re-rusted on the upper hump where the oil didn't pool.  I am going to do it again fight before I start to use it.  And then I think I am going to add a little 2 stroke oil in each tank full.

An old biker enthusiast at work told me that those tanks were originally acid etched from the factory to prevent rusting.  I would imagine "The Works" is an extreme alkali and it basically strips everything off the inside of the tank and any bare carbon steel will rust if exposed.

Offline TwoTired

  • Really Old Timer ...
  • *******
  • Posts: 21,805
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #66 on: October 19, 2007, 06:51:24 PM »
What size fuse are you using?

Does it get hot when you have all the electrics on or just when the turn signals switch is engaged.

You should report any electrical mods from stock, as we can only refer to a stock wire diagram to make suggestions.  Creative adaptations on your part leave us no clue for rendering aid.

I have a CB500 and a CB500 K2 wire diagram.

Are you aware that the black wires are switched +12v ?

The signals are powered through the flasher relay from a black wire located there.  The flasher routes power onto the grey wire.
The grey wire runs up to the left bar control where the selector routes it to the Orange or Light Blue wires depending on switch selection.

The Orange or Light Blue wires route to power the signal lamps.

The lamps need a solid 12V return connection to battery NEG.  This is done with the Green wires in the loom.  The loom Green connections need a solid path to the frame near the coil mount.  This must be to bare metal (not paint).  Also, the motor and battery neg cable must have a clean, no paint, connection to the frame.

For testing you could bridge the grey and black at the flasher relay.  The lamps should illuminate with the key switch on and the turn switch selected.  Once you have that, then it is a matter of selecting a flasher unit that meets your signal load needs.


Cheers,

Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline motomotard

  • Enthusiast
  • **
  • Posts: 130
    • GoGo Garage
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #67 on: October 19, 2007, 11:59:47 PM »
Irishguy,

I tried the works and bolts thing on the inside of my tank to remove rust like you did.  i did it exactly like your post says you did. after about a day or two sitting the entire inside of he tank has begun to tarnish and  turn a brown rusty color, i dont think its rust but it may be, it looks like just tarnish to me. when i put gas in the gas comes out brown. did you have this problem? i can post pics also if anybody wants to see them.

Oh hell yes it will rust back if you don't put something in it.  Did you not fog it with WD-40 or coat it with some oil or something?  I put 2 stroke oil in mine, mixed with gas and it still re-rusted on the upper hump where the oil didn't pool.  I am going to do it again fight before I start to use it.  And then I think I am going to add a little 2 stroke oil in each tank full.

An old biker enthusiast at work told me that those tanks were originally acid etched from the factory to prevent rusting.  I would imagine "The Works" is an extreme alkali and it basically strips everything off the inside of the tank and any bare carbon steel will rust if exposed.

yeah i did the same thing, some 2 stroke oil in gas. dont know what happened, maybe i didnt do enough.  i hit it again with some Evapo rust tonight, and then i think im gonna coat it w/ a sealer, probably por-15. how much will having that "flash rust" grim in your gas hurt your engine or carbs? is it that big a deal?

i let some gas sit in the tank and it came out brown w/ a bunch of crud in it.

thanks

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #68 on: October 20, 2007, 07:07:40 AM »
What size fuse are you using?

Does it get hot when you have all the electrics on or just when the turn signals switch is engaged.

You should report any electrical mods from stock, as we can only refer to a stock wire diagram to make suggestions.  Creative adaptations on your part leave us no clue for rendering aid.

I have a CB500 and a CB500 K2 wire diagram.

Are you aware that the black wires are switched +12v ?

The signals are powered through the flasher relay from a black wire located there.  The flasher routes power onto the grey wire.
The grey wire runs up to the left bar control where the selector routes it to the Orange or Light Blue wires depending on switch selection.

The Orange or Light Blue wires route to power the signal lamps.

The lamps need a solid 12V return connection to battery NEG.  This is done with the Green wires in the loom.  The loom Green connections need a solid path to the frame near the coil mount.  This must be to bare metal (not paint).  Also, the motor and battery neg cable must have a clean, no paint, connection to the frame.

For testing you could bridge the grey and black at the flasher relay.  The lamps should illuminate with the key switch on and the turn switch selected.  Once you have that, then it is a matter of selecting a flasher unit that meets your signal load needs.

Cheers,


TwoTired,

Thanks for your response.  After searcing on this subject for quite a while and reading various posts, I have come to consider you sort of a guru on the subject.  In response to your post:

I am using a 15A fuse.

The only real modifications to my system are the turn signals.  I have the black and white striped wires connected to the green ground wires on all four.  I have the right side black wires connected to the blue and the left side black wires connected to the orange.  [I'm not at my bike now, but I double checked all of that stuff a couple of days ago.]

I looked into the winker connections and went a bought a 3 pronged winker, because some PO had only a 2 prong hooked up and the green wire was not connected to anything.

There is a green ground to the chassis up by the coils I took it off and cleaned the connection up, but it looked pretty good to begin with.  I will check the other chassis grounds that you mentioned.

I will also try bridging the grey and black wires, and see what that does.

As someone else suggested I will try to simpley unplug everything that is related to the turn signals from the system and see if the fuse still heats up with the switch on.

I have read another post about tracking down a positive power wire that is grounding out.  I just want to clarify something...  If I had a power wire grounding out on the chassis somewhere is that what could be causing both problems?

Thanks for the help.

Offline Bob Wessner

  • "Carbs Suck!"
  • Really Old Timer ...
  • *******
  • Posts: 10,079
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #69 on: October 20, 2007, 07:22:49 AM »
Quote
I am using a 15A fuse.

Is it a 1" fuse (correct length) or a 1 1/4" found at most auto parts stores? The longer fuse 'could' add some resistance as less of the fuse ends are in contact with the fuse holder contacts.
We'll all be someone else's PO some day.

Offline TwoTired

  • Really Old Timer ...
  • *******
  • Posts: 21,805
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #70 on: October 20, 2007, 09:37:21 AM »
Quote
I looked into the winker connections and went a bought a 3 pronged winker, because some PO had only a 2 prong hooked up and the green wire was not connected to anything.

Honda provided a two pronged flasher with the bike for US models.  The extra green wire nearby was for a 3 terminal flasher where lighting requirements of other countries mandated that type.

Fuses do get warm during use.  The heat from over current is what melts them when current rating is exceeded.  Depending on the actual fuse type, a 15 Amp fuse should part at about 125% of rating.  The Honda stock electrical load with everything on is about 10A.  So, the fuse should be warm to the touch but not cause discomfort while holding your thumb on it.
My 500 has a replacement fuse holder (non Honda) on it so I don't know what the original is like.  However, as Bob points out, the contacts to the fuse and the wire connections to those contacts can generate heat that conducts into the fuse, too.

Let me clarify an earlier statement.  Honda convention was that black wires in the loom were switched +12V.  Your replacement turn signals may follow a different convention.  If the packaging instructions don't state signal color codes, it is up to you to find out what they are.  You may have to dismantle the signal to learn this information.
1) determine bulb type, number.
2. verify exactly which wire color attaches to the base surround of the lamp and which drives the bulb center pin/nub.
The center pin/nub is what should connect to the Orange or Light Blue wires, whatever color code convention is used by the signal provider.
There are also bulb types that have different style of connections.  I can't see your signals from here.  What you have to determine is if either of the wire colors supplied attaches to a metal base of the fixture. This is important.

Quote
As someone else suggested I will try to simply unplug everything that is related to the turn signals from the system and see if the fuse still heats up with the switch on.

The Grey wire at the flasher and the Green ones in the loom, are what provides all power to the signals. If you have the proper color matched connections throughout the bike, you should get no signal illumination with the Grey disconnected.  If they don't light, they probably aren't drawing power.

Quote
I have read another post about tracking down a positive power wire that is grounding out.  I just want to clarify something...  If I had a power wire grounding out on the chassis somewhere is that what could be causing both problems?

A "positive power wire grounding out" will cause excessive current draw to melt the fuse in very short order.  To cause a slight over current that makes a fuse hot but not blow, such a condition would have to include a resistive connection only just severe as to add a small amount of extra current.  I believe this would be a very rare condition, albeit possible.  Such a condition is slightly more likely than all of the air molecules suddenly moving to the left side of the room.  I would view reports of this nature with skepticism.

Cheers,


Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.

Offline paulages

  • Old Timer
  • ******
  • Posts: 3,876
  • 1976 cb735
    • DOOMTOWN RIDERS P.R.M.C.
Re: IrishGuy's Cafe Project Has Begun... [Added Pictures!!!]
« Reply #71 on: October 20, 2007, 11:14:40 AM »
i was at a similar point when building my bike and my aftermarket blinkers wouldn't work with a mechanical relay (at least not with the stock one). i was tearing my hair out, and then TT suggested that it may be due to a load difference with the aftermarket lights, as the mechanical relays are load sensitive. bought an electronic blinker relay and they worked fine. now i always use them, because even with stock lights, i hate when they sometimes stop blinking at an idle.
paul
SOHC4 member #1050

1974 CB550 (735cc)
1976 CB550 (590cc) road racer
1973 CB750K3
1972 NORTON Commando Combat
1996 KLX650 R

Offline Irishguy

  • Enthusiast
  • **
  • Posts: 148
Re: IrishGuy's Cafe Project Has Begun... [Updated and frustrated!]
« Reply #72 on: October 29, 2007, 09:59:09 AM »
OK...  Where to start...

I replaced the cheap a$$ fuse holder put in there by some PO with a nice one with thicker wires in hopes that the cheap fuse holder and thin wires may have something to do with the wires heating up.  I bought a fuse holder at Advanced Auto that was rated at 30 amps and it uses a small modern plug type fuse.  I wired it in with some new bullet connectors and installed a new 15A fuse which it promptly blew as soon as I switched on the ignition.  I unpluged about everything at one time and kept blowing 15A fuses until I was about out of them and then on a whim put in a 20A fuse and it didn't blow and the wiring didn't heat up either.

So I started plugging everything back up carefully following the wiring diagram and voila...  Everything now works and nothing is smoking or sizzling.  So I'm thinking that I must have accidentally had something hooked up backwards even though I call myself checking everything at least twice before.  Anyway...  I'm thinking "...cool, maybe everything is gonna be alright."

That was Friday night.  So Saturday morning I decide to see if I can get the thing running and on the road just so see what else needs to be done.  I clean the tank again, put in fresh gas and hook everything back up and she cranks up fine after a few tries.  I take off and it is pretty obvious that she is not running on all cylinders.  I get back after a short drive and sure enough the #4 pipe is not as hot as the others and I see the reason...  The #4 carburator is leaking gas pretty bad.  I take the float bowl off and probe around up in there hoping to see of anything looks stuck and try to manipulate everything to see if that frees anything up. 

I put it all back together and start off on another test ride.  She seems to be running better, until I get to the bottom of the big hill at the end of my neighborhood and she gos completely dead.  I realize that I have an extra fuse with me, but i don't have a phillips head screw driver for the aftermarket side covers.  I call the girlfriend and she brings me a phillips head and I discover that the fuse isn't blown,  it's the damn battery dead already. 

So now I'm pissed and decide in my frustration to push the bike home.  I soon discover a stark reality...  A non-running motorcycle gets really heavy really quickly when you are pushing it up a hill.  ;D.  So I pull it off the side of the road, have a mild heart attack  ;), and me and the girl friend [Seeing as she decides she wants me to live a little longer] go back to the house to get a rope.   :D  She pulls me the rest of the way back to the house.

So...  Here's what I'm thinking and tell me if you agree with my logic:

I have 2 problems:

1.  I have a short somewhere even though all the lights and everything are working that is causing the battery to drain so quickly.  I need to read up on trackin gdown a short and get busy on that.

2.  I have something sticking on the #4 carburator and I need to pull those suckers off and read up on rebuilding one of them of at least checking it out thouroghly.

Does that sound like a good plan?  I'm not going to let one of these old bikes whip me.  I'm going to keep learning and keep trying until I have this baby on the road running trouble free.  I will accept all help and advice.

Offline hcritz

  • Hot Shot
  • ***
  • Posts: 390
Re: IrishGuy's Cafe Project Has Begun... [Updated and frustrated!]
« Reply #73 on: October 29, 2007, 11:00:29 AM »
Hey Irish Guy!
Hate I missed you guys at Barber...we hung around until about 5 or so and then rode home.
The CB never missed a beat...nice shake down ride!
I'm pretty good with electricals...if you need help.
Hope maybe you got her sorted out by now!

Offline TwoTired

  • Really Old Timer ...
  • *******
  • Posts: 21,805
Re: IrishGuy's Cafe Project Has Begun... [Updated and frustrated!]
« Reply #74 on: October 29, 2007, 11:11:12 AM »
Since it appears your charging system isn't working, perhaps you could start there, a failure here could easily cause extra drain on your fuse.

Assuming you can use/have a multimeter, check the resistance across the white and green wires at the regulator (disconnected).  For the 500, it should be nearly 4.9 ohms.  If lower than this, you've found a problem that draws more current than expected.

Next, make sure the six diodes in the rectifier are working properly.


Carbs:
Since #4 is and end carb, it is fairly accessible.  I would first unscrew the drain plug on that bowl and observe the drainage in a clean vessel of some kind.  If it's nasty, then look to the source (gas tank?).
If reasonable, then remove the entire float bowl (4 screws) and have a peak inside.  You can then determine if the carbs indeed need to be removed or if some debris simply got stuck in the float valve, causing it to overflow.

Cheers,

Lloyd... (SOHC4 #11 Original Mail List)
72 500, 74 550, 75 550K, 75 550F, 76 550F, 77 550F X2, 78 550K, 77 750F X2, 78 750F, 79CX500, 85 700SC, GL1100

Those that learn from history are doomed to repeat it by those that don't learn from history.