Honda CL175 from hell.

[kdotlowe]

Making a start on the part that I've been dreading most - wiring. I've never scratch built a loom before so I'm still getting my head around understanding the original wiring diagram and creating my own to suit my needs. 

These old Honda Twins have pretty shitty charging systems that only charge above a certain RPM or when the headlights are on (I think). Decided to change out the rectifier to a rectifier/regulator which will allow the battery to be charging at all RPMs. $11 unit from a lawnmower which is a common upgrade on these 175s. Just need to bridge 2 wires and then it will plug n play just like the old one!

Starting to mock up an electronics tray to keep everything tidy. Making sure everything fits. Still need to fit a flasher relay in there, but I'll make it work. The standard loom only had one main fuse but I'm going to run the ignition/lighting/main/aux all of their own fuse.

Mint! Now to make it out of sheet metal. 

[kdotlowe]

New bits! Including possibly the tiniest switch block ever. Not sure how to wire up the ridiculously small wires or if they'll even handle the right amperage. 

But hey. They look good.

[Raizer]

Nice looking switchgear!

 

I'm dealing with tiny gauge wires on switches too, I think I'm just going to add relays to everything as I really don't want to run headlights etc through them.

[kdotlowe]

8 hours ago, Raizer said:

Nice looking switchgear!

 

I'm dealing with tiny gauge wires on switches too, I think I'm just going to add relays to everything as I really don't want to run headlights etc through them.

Yeah looking at it last night, I think this will be my only option also. Relay for horn and highbeam, and have the main headlight switch on with ignition. LED indicators should be sweet through the switches I think. 

[Raizer]

Good idea with the led indicators, as long as you're running them on a DC circuit.

[z18et1200coupe]

Bike is looking rad dude!

Also, I've got those same mini switch clusters (from Modern Motorcycle Company?), and I've run everything through them without relays and they seem to be holding up fine. All of my bulbs are LED but the horn and kill switch would draw plenty of current. Everything still seems to be sweet! 

 

[Abarth]

My Honda has same equally as bad charging system but after changing over to the new reg/rectifier and LEDs (brakes, dials, park light) I can drive round with the headlight on 100% of the time without the battery going flat. Definitely worth doing. 

Are you running the 35w headlight? Mine still does, its not great, thinking of switching to 55w but again back to power issues. 

[kdotlowe]

On 11/18/2017 at 16:42, z18et1200coupe said:

Bike is looking rad dude!

Also, I've got those same mini switch clusters (from Modern Motorcycle Company?), and I've run everything through them without relays and they seem to be holding up fine. All of my bulbs are LED but the horn and kill switch would draw plenty of current. Everything still seems to be sweet! 

 

Yeah mine are from MMC also. That's good to know! Did you use the same gauge wire to run to the lighting? Or did you step up to a larger one? The wires are tiny!

20 hours ago, Abarth said:

My Honda has same equally as bad charging system but after changing over to the new reg/rectifier and LEDs (brakes, dials, park light) I can drive round with the headlight on 100% of the time without the battery going flat. Definitely worth doing. 

Are you running the 35w headlight? Mine still does, its not great, thinking of switching to 55w but again back to power issues. 

Rad. That's the result I'm hoping for. Haven't actually received my headlight yet... I think it's a 55w one however.

[kdotlowe]

Oh yeah, also bought (another) distraction. 1979 XL100s. Was so cheap I couldn't say no. 

[63Ragtop]

GIZ!

[SOHC]

Where did you get that regulator / rectifie from?

[kdotlowe]

@SOHC it's this one here: https://www.ebay.com/itm/232418635440

Keep in mind I haven't tested it yet. But I hear good things. 

[SOHC]

On 11/24/2017 at 08:02, kdotlowe said:

@SOHC it's this one here: https://www.ebay.com/itm/232418635440

Keep in mind I haven't tested it yet. But I hear good things. 

If its not suitable for you bike I will swap you for another one witch is witch has 3 wires for the stator,  one to bat+ one to earth on the frame.

[kdotlowe]

Awesome! I'll keep that in mind @SOHC. Cheers!

[kdotlowe]

Eletcronics tray all folded out of steel. Now just need to source a battery and I'm a ready to run all the wiring. 

[kdotlowe]

Been a little slow on the updates but I've been painting, polishing and reassembling while I procrastinate finishing the wiring. Pretty stoked with how she's looking.

[kdotlowe]

New year, new motivation. 

Bike now has power. Need to find a suitable battery that will fit the little space I have left. 

Also found a place where I can hide a coil. The coil wont fit in the original position due to the new tank. Just need to whip together a little mount or drill another mounting hole. 

Next plan is to get the new air filters, coil and wire the ignition. That should be the bare minimum I need to get the bike running...

[kdotlowe]

Headlight fitted thanks to a friend who has access to a water cutter. Bracket still needs to be painted but it's got me excited for how the whole build is coming together.

[kdotlowe]

I'm lucky enough to have a friend who just purchased an ultrasonic cleaner. Cleaned a whole lot of small bits including the original carbs. I should've taken before & after shots, but it did a bloody good job of making everything look like new again.

[kdotlowe]

Some ghetto ass cardboard mockups to give an idea of how high the seat will be. I hope to get the seat pan off to Greg at Midnight Upholstery to work his magic.