SOHC.co.uk Forums > CB500/550
Partially Restored 74 CB550
davidcumbria:
After this fascinating debate back to something more prosaic,I’m afraid. I took photos when disconnecting all the connections in the headlight but find them difficult to follow in reverse order. I have never been this deep into bike electrics before. I have got the wiring diagram and understand how it shows the connectors and where the loom ends. I have a strong feeling the wiring has been modified - there are some snap connectors in there. There were lots of unconnected bullets from the pattern switchgear.
So any tips on a good process to get it all connected up again. I assume I have to shove all the loom, switchgear, tachometer/ speedo, idiot lights leads into the headlight shell first and then try to make the connections. This is going to take awhile….
I have also found the section in Teds thread that has some useful stuff
http://www.sohc.co.uk/index.php/topic,28541.540.html
Johnny4428:
Sometimes you can make the connections before packing into headlight shell. More room to work.
Bryanj:
David, as far as i know there is only one wire that is not connected colour to colour and that is one from the rh switchgear and i cant remember if it is the power from fuse box or the power back fot lights
Oddjob:
Dave, if the handlebar switches are pattern it's well known that some use different coloured wires to the Honda switches, you could look inside the switchgear and make notes of what colour wires are used to connect to the horn for instance. There are at least one wire used by Honda where the colour of the wire is wrong, to get around that Honda used small tubes of the correct colour to connect to next to the connector. Spotted one the other day on the brown/blue wire coming out of the kill switch switchgear, it has a yellow tube on the wire, most likely meaning it's to be connected to the brown/yellow instead. There's another by the horn IIRC.
On PDI the first job we did was remove the headlight and connect all the wires up, none were connected by Honda, just a huge mess of spaghetti when you took off the headlight, good job I wasn't colour blind, getting some of the headlights back in afterwards was sometimes hard, the CX500 was a bitch to do. Make a sort of doughnut shape with the wires so the bulb holder can fit inside the hole, easier on the CB550 than on the 500 as the handlebar switches don't connect in the headlight but down by the coils so far less in the bowl than the 500.
Bryanj:
As Ken said most Hondas were shipped with handlebars not fitted but switches were on bars.
Ken was also correct about the brown/blue/ yellow thing, i just couldnt rememer the colours
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