Topic: '78 550K headlight ear/turn signal questions... PICS ADDED

[Scott S]

 I picked up a set of stock headlight ears and signals for my 550 (bet that makes you happy, TwoTired!) and, of course, the P.O. cut the wries..  No biggies, I can fix that.

 The left ear has a bend in it at the end, where it would bolt to the headlight. It looks to clean to be damage. Is it supposed to be this way?

 Also, I see how the signals mount to the ears and, I assume, the wires run inside the stalks. What then? Do I wrap them around the forks or ? ? ?

[zackblack]

There should be one wire grounded to the inside of the winker housing and another wire that travels down the stalk.

You screw the stalk through the ear and into the headlight bucket.  Inside the bucket is a pair of nuts attached to green ground. The wire that is through the stalk attaches to a blue or orange wire (depending on which side the winker is on).

See the schematic I attached if my directions aren't clear.

[Scott S]

 Well, I wasn't asking about how to plug in the wires, really. I wanted to know more about the routing.

 My bike came with aftermarket headlight and front turn signals. I have acquired the stock stuff, but I don't see how the wires go around the forks/triple tree when installed. I'll get some pics later today. Maybe I'm missing something.

[willbird]

The signals bolt right onto the headlight bucket, with a nut inside, the wires then plug into the wire harness which is inside the headlight bucket, the wires never exit the headight bucket.

[Scott S]

 Not on the '77-78 550's. They go on a stalk on the bottom of the headlight ears. Pics coming...

[Scott S]

 Here's the bent ear I was asking about. My guess is that it's not supposed to be this way, but the angles are so clean and there are no marks on the chrome. Is this stock or damaged?

[Scott S]

 On the late 550K's, the front turn signals mount on these stalks...




 Like so...

[Scott S]

 But then how do I route these wires? It seems like there'd be no room around the forks/bottom triple tree.  Once I get inside the headlight bucket, I have no problem figuring out the wiring harness. But where do the wires go on their way TO the harness, from the stalks?

[Tom in Newcastle......Ontario]

Run them around the back of the fork tubes.........I put some thin black tubing around mine from where they exit the ear and almost to the connectors.......... the ears should both be straight,with only a slight bend like the right one in your pic ,compare it too your bucket.

[Scott S]

 Thanks, tjjkc. I must be missing a spacer or something....what stops the ears from bottoming out on the triple tree?

[Scott S]

 Yep...looks like I'm missing #16. I winder if I can fab up a spacer of some sort?

[Bankerdanny]

here's the stock ear and wire routing from my '77

[Scott S]

 It all makes sens now. I'm just missing the spacer. Can one of you guys give me an eyeball measurement of the spacer thickness? Maybe I can make something out of radiator hose or something.

[Bankerdanny]

The spacer is hidden between the ear and the lower triple clamp, so I'm not sure I can get a good look at it, but I will see what I can do.

[Scott S]

 Thanks, Danny. I contacted the guy I got the ears from and he's going to check to see if he still has the spacers.

 I installed fork gaitors on my CB500 and have the stock dust seals....I wonder if I could modify them to be used as spacers?

[willbird]

Not on the '77-78 550's. They go on a stalk on the bottom of the headlight ears. Pics coming...

I'm sorry Scott I foolishly ASSUMED assumed it was a similar layout to my earlier 750's.

[Bankerdanny]

Yes, I suspect that you could. They have the tapered top that you need.

[Scott S]

 It looks like I'm missing #17 as well. I hope the guy that sold me the ears has them, but they just serve to keep the ears in place between the triple tree clamps, right?
 Push comes to shove, I can find something that works.

[Tom in Newcastle......Ontario]

Scott........PM me your full name and address..........I will try to get them out in the morning....that is if you want a set.........talk price after I get a shipping cost.......don't worry it will be cheap

[Scott S]

 Tjjkc, you have a PM.

[Scott S]

 The front signals have two wires. I think one is a ground to the bolts that hold the headlight bucket.

 The rear signals are one wire. I guess they're grounded through the tail light circuit.

 Can I use the one wire signals from the rear on the front? I found a nice pair with uncut wires.

[Tom in Newcastle......Ontario]

Front signals are joined together in the head light bucket,also fronts are running lights and signals....and grounded through the ears to the bolts in the bucket

rear signals are just turns so only one wire with the ground mounted to the stem...........so I guess the answer is no unless you change the internal bulb holders from a single filament to a duel

[vance]

the front signals have two wires because one circuit is your running lights which should be on all the time and the other is your blinkers. for safety you should use the stock front signals with the running lights.

[Scott S]

 You know, I typed that question and walked out in the garage and then remembered about the running lights.

 I guess running lights are safer than NOT having running lights, but I can use the rear signals, right?

[mjstone]

You should be able to just hook up the single wire to the proper turn signal connection in your headlight bucket.  The earlier bikes didn't have the running light, just a turn signal and somehow we survived.  I'm sure you will too.

MJ