Topic: I think I got a good deal.... we'll see

[TwoTired]

The Honda shop manual has all the wire diagrams or the 550's
The 76K is on page 172 (in a supplement)
The K0 (74) is on page 145
Since there isn't one a separate one for the K1 (75), it must be the same as the K0.

Anyway, the 76 doesn't have that safety box, it has a simpler diode and less complicated wiring, two wires instead of the earlier model's 5.

I don't think the harness is going to fit cleanly into your bike, in that area.  If you are going to use the simple diode that the 76 has, then you only need the LG/R and G/R wires in that Red plug.  Your are going to have to NOT use the Black wire (insulate) going to the Stater solenoid and run the G/R wire over to it in its place, to get the electric start to work as before.
Oh wait, it gets worse. The starter button control is different, too.  The G/R to that switch needs to be connected to a Black wire in the harness, and separated from the clutch switch...

I think...

I looked at the Clymer diagram on the old man Honda site.  Typical of Clymer, it only covers early 550 models and ignores changes made on later models, like your 76.

Why, exactly, can't your repair your original Harness?  Is there more headaches there than grafting the wrong harness onto it?

Cheers,

[MgMt CB550K]

So I have a attached a picture of the wiring panel after I have gotten some of the wires from the old harness out of there.  I don't think I can use the original wiring harness because the PO totally mangled it by splicing in a toggle switch to somehow cut the ignition out of the loop.  So the two wires coming out of the little diode for the starter motor are spliced into the toggle switch.   

[TwoTired]

So I have a attached a picture of the wiring panel after I have gotten some of the wires from the old harness out of there.  I don't think I can use the original wiring harness because the PO totally mangled it by splicing in a toggle switch to somehow cut the ignition out of the loop.  So the two wires coming out of the little diode for the starter motor are spliced into the toggle switch.   

I'm afraid this is going to sound harsh.  But, I think the observation is valid anyway.  So, here goes.  Put on your thick skin, OK?

When you're done, what wire diagram will be valid for your bike?  The 75?  The 76?  Or, a hybrid that only you, if anybody knows how to manipulate/follow?

I'm skeptical your old harness is really "totally mangled".  I can believe it is modified in a way you don't understand.  If you get the correct wire diagram for the bike and then restore the modified sections, you have a bike that is easily understandable by anybody that can read stock wire diagrams.  If you do make a hybrid, you are going to have to figure out how it all works correctly, anyway.  Why not understand and make something serviceable in the future?

I suspect you are trying to evade wiring understanding by changing parts wholesale.  But, in the time you have finally adapted the older harness into something functional, you could have simply mended and reversed the changes made by the P.O.

It's your call, of course.  Maybe my observations/guesses are wrong.

Anyway, you should know that the diode you mentioned is not for the starter motor.  It's function on the stock (76) bike is to keep the neutral light from coming on when the clutch lever is pulled in.

Your bike (76) originally activated the starter solenoid by placing 12v to one solenoid terminal from the starter button, and applying 12V return (neg) on the other terminal via either the nuetral switch or the clutch switch.
The 75 put 12V on one starter solenoid terminal whenever the Key switch is activated.  12v(neg) was applied to the other solenoid terminal, when the starter button was engaged AND the Starting Safety Unit enabled the starter button after either the clutch or neutral switch was active.

By the way, Honda changed the function of the Y/R wire from providing 12V(Neg) to the solenoid in 75 to providing 12V (pos) in 76.  What bar controls do you plan to use? 

Have you found the 76 wire diagram in the shop manual yet?

Cheers,

[troppo]

I'm skeptical your old harness is really "totally mangled".  I can believe it is modified in a way you don't understand.  If you get the correct wire diagram for the bike and then restore the modified sections, you have a bike that is easily understandable by anybody that can read stock wire diagrams.  If you do make a hybrid, you are going to have to figure out how it all works correctly, anyway.  Why not understand and make something serviceable in the future?

I suspect you are trying to evade wiring understanding by changing parts wholesale.  But, in the time you have finally adapted the older harness into something functional, you could have simply mended and reversed the changes made by the P.O.

+1

[MgMt CB550K]

I'm afraid this is going to sound harsh.  But, I think the observation is valid anyway.  So, here goes.  Put on your thick skin, OK?

I'm a big boy I can handle it 

But seriously you are probably right about the wiring harness not being totally manged.  But for someone that has never wired anything it sure as hell looked mangeled to me.  The reson I said that it was was because there were numerous wires sliced into other wires, and I don't understand what was done with the toggle switch.  Im just not sure if I can figure it all out.

Have you found the 76 wire diagram in the shop manual yet?

I still haven't bought a shop manual.  I have a couple electronic ones but I just checked and it doesn't say what year it is for.  I got it from http://www.sohc4.net/index.php?title=CB550#Wiring_Diagrams.

So at this point  what I am hearing is that I should either try to use the original harness or if I'm not able to due to it's condition or my lack of knowhow try to find a harness off of a 76.

[troppo]

G`day Mg
First up you need to know how to solder, then you need to know how to read a wiring diagram  (not hard really when you get the basics down) and then you have to make sure your not colour-blind (really important with honda as they seem to be so nice in the way they wire their bikes).
Most wires connect to wires of the same colour, if you have a decent diagram it shouldnt be hard to find the matching wire. Try to find matching wire colours  for replacement wires or at least something close to avoid confusion.
Just remember to ask plenty of questions, the guru`s here just love to help.
Cheers
Troppo

[MgMt CB550K]

Well I'm trying to find the easiest way to do this.  I already have matched most of the wiring up in the front with all the hand controls.  So I am going to try and find a harness off of a 76 or would a 77 work?  Let me know if you think the easy way out isnt the right way to go.

[MgMt CB550K]

Since the wiring panels seem very similar does anyone know if a wiring harness off of a 77 would work on a 76?

[TwoTired]

The link you posted also has a service manual pdf.  There is a wire diagram for your bike in it.

The 77 won't plug and play either I'm afraid.  They used different bar control connectors.  So, you are back to making modifications.


I'm surprised you were able to hook up the bar controls functionally, using 76 bar controls and the 75 harness.  The 75 has a Headlight switch on the control.  The 76 does not.  I haven't worked it out for sure, but you may have some lighting issues with the harness adaptation, too.

Look, I'm not saying, you can't adapt the harness.  It's moderately challenging for me, and I understand how it needs to be to work.  I'm just saying you aren't going to get it to work without a much better understanding of how it is supposed to work.

So at this point  what I am hearing is that I should either try to use the original harness or if I'm not able to due to it's condition or my lack of knowhow try to find a harness off of a 76.

I think that is the fastest/easiest way.  And, I'm not too sure finding a 76 harness will be fast or easy.

Can you show a picture of the harness mods?  With the proper wire diagram, it shouldn't be too hard to undo them. Can you solder, if needed?  Surely you can wrap electrical tape!

Cheers,

[MgMt CB550K]

I'm surprised you were able to hook up the bar controls functionally

I never said I hooked it up functionally!!  But I hooked it up as good as I could with matching colors and using the diagrams that I had.  But it could be completely wrong at the same time.

I can take some pictures of the original harness tonight when I get home and start tinkering again.

As far as finding a harness from a 76 I will start looking around eBay and see what I can find.  It sounds like adapting the 75 wiring harness is out of my league.  But if that's the case it's not that big of a deal since I got the harness for a steal on eBay 

[MgMt CB550K]

so here are some pictures of my wiring that was on the bike.  After looking at the pictures they are pretty crappy.

I did find a wiring harness on eBay that ends in 4 days so I can try to work with what I have for 4 days but at that point I might just buy another.

[TwoTired]

Well, I understand why you were intimidated.

Did you remove the outer wrapping of the Harness?  Or, was this done for you?

If you want to put that harness back together, you're going to need the proper wire diagram.

The splayed wires can be made to resemble a harness by using twist ties to bind it into a bundle again.  Get a spool of twist ties at the garden center.  They use them for holding plants to stakes.  But, they work well for creating harnesses where you can still trace wires inside them.  After you get everything wired and working you can tape the harness and remove the ties as you put on the tape.

The twist ties make the wires look less "explosive", and more like a harness.  Using the wire diagram pick a wire color and follow where it is supposed to go.  Just keep doing this until you have them all done.  Make a copy of the wire diagram and mark each wire done with hi-lighter.  When all the wires on the diagram are hi-lighted, your bike should run and operate as predicted.  Then tape up the harness.

It's a divide and conquer routine.

Cheers,

[troppo]

G`day again MG
I hear what your saying about the spagetti you got now. As we have said, get a good wiring diagram so you know what wire does what and its colours, then start somewhere simple like the front left indicator, trace it to the headlight bucket then to the loom, then to the flasher and the switch.
It can be a royal pain in the arse to fix dodgey wiring but it is well worth it in the "i did it" factor.
This is what i removed from the wiring of my bike just after i bought her,I didnt need to do too much repair work to the original harness luckily, only a couple of replacements here and there, thank god for this forum, couldnt find a large clear diagram till i joined here. The PO had a power feed for the flasher unit running from the rear brake switch!!!!!!

Cheers mate
Troppo

[MgMt CB550K]

Did you remove the outer wrapping of the Harness?  Or, was this done for you?

HAha someone was nice enough to do all of this for me  .  As far as tracing the wiring goes I am gona give it a try.  My main concern is in the back near the panel there are a good amount of wires cut off of one of the male connectors so and I am not sure if all of those wires are still there.  But I guess a silver lining is that there is enough wiring left sticking out of the plug that I can tell what color wire was there. 

Thanks for all your help guys.  My girlfriend is coming down this weekend and she needs to do a bunch of studying so that means I get to work on the bike for a few hours.  So I will let you guys know if I make any progress.

It can be a royal pain in the arse to fix dodgey wiring but it is well worth it in the "i did it" factor.

That is what I am really going for.  Even though i haven't finished any of the wiring I still feel like I have learned A LOT.  Plus once I am done with this I feel like I will know enough to rip into my '77 and clean all the connections without fear of screwing it up.  Thanks again guys, I'll keep you posted.

[MgMt CB550K]

So some good news, I won a wiring harness off of a '76 cb550 on ebay last night 29.99 shipped to my door isn't bad if it all plugs right in as it should.  Hopefully everything hooks up and I can move along on this project.  I just hope I can move away from the electrical and get into more familiar ground.