Topic: 1978 Honda CB550k

[Onelesscar83]

So, this is my first post and hopefully not my last.  Since March, I have been rebuilding a 1978 Honda CB550k.  This is my first build of this extent and has been a HELL of a ride.  So much fun, agony, learning, processing, failure, and success. 

You can see all the pictures here

https://briankillmore.smugmug.com/1978-CB550K-REBUILD/

starting point was decent with a bit of a cafe racer look, but EVERYTHING was barely attached/working.  What I've done so far:

rebuilt/cleaned carbs and replaced all jets/seals/most screws/pod filters

cut and welded frame to flatten the back end

rebuilt wiring harness, previous owner extended the wires but nothing was soldered together.  Everything was just twisted and tapped......it was a mess. 

built box to hold all the wiring, and replaced the reg/rec unit with new combo unit.

new firestone tires, new seat from tuffside

new signals and tail lights

redid ALL connection points on the bike.  they were ALL corroded to the point of no return. 

modified rear fender

rebuilt master cylinder and front caliper

rebuilt fuse box and found places to hide wiring harness components

cleaned up connections at the coils with new bullet connections

added mac 4 into 1 exhaust- not shown in pictures yet

I'm currently stuck on the charging system.  Just doesn't want to work for me.  I replaced the original rusted out one with a used stator that was supposedly working when it left their junk yard.  From what I've read they are pretty hard to destroy, but according to the manual the 3 yellow wires from the stator should have a 3.5 ohm resistance between each pair.  I'm getting 1.9 on each pair.  Does that mean the stator I bought as a replacement is also shot?  Are there replacement parts I can find NEW?

[SOHC4 Cafe Racer Fan]

Not a fan of Firestone tires, but welcome Brian.

I am not sure if you need new electronics but if you do (you might want to hit up Cal Jeffrey on the forum), you can get new parts: http://ricksmotorsportelectrics.com/

[calj737]

Dang, you're right down the road too! I'm heading down to Statesville Weds to drop off some stuff for another member, and then riding thru Friday-Sun for the races at Rockingham. Might have to stop in and give you hell for the Firestones and for redoing your harness in all the same color (WTF were you thinking???!!!) 

There's some decent pictures on your link, but let's start at the beginning:

- Voltage of battery at rest (no key, no motor)
- Voltage of battery with key ON
- Voltage it idle?
- Voltage at 3k RPMs?
- Voltage at 5k RPMs?

Let's have those and then see if we can sort out which piece is giving you grief.

[Onelesscar83]

This being my first build I'm flying by the seat of my pants.  To be honest I had close to no experience with engines and or motorcycles besides the little tw200, I messed with before this.  So I'm sure to mess up a bunch of things.  As for the firestones what do you guys dislike about them? 

The harness wiring would have been close to $60 to get all the colors I needed to extend the harness that had been chopped up by the previous owner.  25ft of black was $6, so budget won there. I made sure to keep sections on either side of the splice that were of the correct color.  I wasn't in love with my decision to add all black wires, but my pockets were empty.  On a plus side they are all soldered and heat shrunk now instead of twisted together and black electrical tapped.....it was a disaster in there.     

moving forward to make SURE everything is right I went out and bought a second multimeter.....$5 from harbor freight....nbd....the other one i have was close to $50 so we get both ends of the spectrum
                     
                               mm1           mm2
No key               = 12.86v  and 12.87v
key                    = 12.46v  and 12.47v
idle (1500rpm)  = 12.46v  and 12.47
3000rpm           = 12.47v  and 12.48
5000rpm           = 12.47v  and 12.48

yellow wire combos from stator in ohms

mm1=    1.1  1.1  1.1
mm2=    1.4  1.4  1.4

spec should be 3.5.....I'm thinking this stator is also shot.....

green to yellow wires in reg/rec

mm1     -to green + to yellow      5.03     5.24      5.4
            +to green - to yellow         .483     .478      .5

mm2    -to green + to yellow         no readings
           +to green - to yellow          no readings


Only other thought I have is the Dyna S ignition is sucking all my power?  I have read a bunch of not so great things about these things, but it came with the bike and is an expensive upgrade so I wasn't going to complain.

[SOHC4 Cafe Racer Fan]

I doubt it's your Dyna S.  There have been some issues with the Dyna 2000, but the S is pretty reliable.

[calj737]

Its NOT your DYNA.

Try using this diagram to troubleshoot your charging system:
http://www.electrosport.com/media/pdf/fault-finding-diagram.pdf

And I completely understand about budget building and wire colors.  No offense intended. You did all the important things well, like solder and heat shrink those connections.

[Onelesscar83]

Oh none taken just explaining my thinking and situation. 

According to the tests on this fault finding diagram my battery is shot.....its brand new.....I went through everything twice.....I guess I'll take it back and try again?

 

Its NOT your DYNA.

Try using this diagram to troubleshoot your charging system:
http://www.electrosport.com/media/pdf/fault-finding-diagram.pdf

And I completely understand about budget building and wire colors.  No offense intended. You did all the important things well, like solder and heat shrink those connections.

[calj737]

 Double check the terminal connections at the battery and especially where the negative terminal connects to the frame/engine on the right side  The ground gets punched between the engine and frame on the upper bracket. It needs to be very clean, bare metal there.

[Onelesscar83]

So I took the battery to Advanced auto and had it tested.  Battery is good.  I went through and double checked the ground and sanded the CRAP OUT of every connection and they are all clean....no changes....

What next?  I'm so at a loss here.  I was debating replacing the starter solenoid cause it looks pretty beat up....

[calj737]

Look under the left side engine cover, that's where the stator output wires plug into some inline bullet connectors. Then, they work their way out to a large plastic connector. Are you taking measurements at the plastic plug on the Yellow wires? If so, go towards the stator and clean the insides of the bullets.

It is possible your stator is shot. Not very common. Are the rest of the electrics stock or did yu have to re-wire all that (I know you posted a bunch of pictures, but I don't remember seeing the Reg and Rec wiring)

[Onelesscar83]

Yeah I replaced both the reg/rec with a combo unit, and all the bullet connections/block connections on the entire bike. 

[calj737]

I wonder if you have possibly crossed up a wire from the stator to your "new" harness. Got any detailed shots of your Reg/Rec connections? By the way, I am heading to Statesville today. I'm happy to bust a bit farther down and drop in and see if I can identify the issue. It would need to be early afternoon, but if that's of interest, let me know.

[Onelesscar83]

If you want to come by that would be AMAZING.  I'm about as stuck as I can be.

 

I wonder if you have possibly crossed up a wire from the stator to your "new" harness. Got any detailed shots of your Reg/Rec connections? By the way, I am heading to Statesville today. I'm happy to bust a bit farther down and drop in and see if I can identify the issue. It would need to be early afternoon, but if that's of interest, let me know.

[Onelesscar83]

Ok, latest update.  After about 3 and a half hours with calj737 we decided the reg/rec is at fault, even though the diodes were in spec......fingers crossed there as I already ordered a new part.  Also as we were messing with things the seal behind my drive sprocket started leaking, so add that to the parts list. 

While waiting on those parts I think I need to tackle these wheels.  The previous owner decided plastidip would be a good fix for everything on the bike, including both rims and all the spokes.  The rear wheel is pretty untrue and has a big hop in it.  I tried taking it to be trued but no one will touch it with the plastidip on there. 

Here are my options: 

1) replace both wheels.....suggestions on what would fit with minimal work/money even if they are used.  I love the mag wheels just not sure if there is a swap out option for the 550k? 

2) pull both wheels apart clean the plastidip off and rebuild.....WAYYYYYY out of my comfort zone/ have no idea what I'm doing here.  Youtube could most likely help and A TON of labor.   Plus either buying a truing stand or building one.....from wood?  not sure about that either.....I'd also have to re-finish the rims.....sounds expensive.

Basically looking for the cheapest option here, thats not going to look like a disaster....

[calj737]

Acetone on a rag. Leave them in place and wipe/hose them down. Should come right off.

When you come to your senses and replace those Firestones, deal with wheel bearings 

[Bankerdanny]

Period Lester wheels, like the ones on my bike in my profile picture, area a direct bolt up. But they are fairly rare and generally expensive. Yamaha and Kawasaki both had Lester style wheels on some of their bikes that come in the right size, but you would need to fab up adapters.