Motorcycle Repair: 1977 cb550f, hairline cracks, clutch lever

Question
Hi Bill,
Had this bike for a month and a half now. started and ran well the first two starts.  Then had a rough start the third time but ran well after running a bit. Fourth time no electric.  1/2 hour later electricity and a rough start then sputtered out.  I put in brand new battery. Got it started once and no electricity since. Seems as if there is a loose connection somewhere. Battery is fully charged but no lights come on at all. (what would cause no lights at all.) I have meter reads at the regulater, rectifier and solenoid but when I bypassed the solenoid and connected the battery directly to the starter it wanted to start. Does this mean I need a new solenoid or are there other possibilities? Maybe the ignition? How do I proceed?  Thanks for your help.  

Answer
In case you need some illustrations... go here
http://www.powersportspro.com/partsfish/login.asp
Sign up, log in and select HONDA motorcycle, then your CB550F.

The most common problem like this is that the base of the ignition switch has come loose. There are repair kits for them.. I think I have one leftover in the garage! When the forks get moved back and forth the wiring connector to the ignition switch will work the connector back and forth until it pops loose. Pull the headlight loose to access the bolts, unless you have a nice long 1/4" extension and socket to try and get it from the bottom.

Assuming that all the fuses are okay.. and check them for hairline cracks, even when they seem good, then probably it is the ignition switch.

The headlight sometimes will quit due to disintegrating switch contacts inside. Pushing the starter button IN will disable the headlights momentarily. When it is released, the starter disengages and the headlight comes back on. When you have problems with either function, just about always it is the starter switch assembly. Common problem and the switches are similar in many of those 400-750s, from that era.

There should also be a clutch lever switch to disable the starter system, unless the clutch lever is pulled in. Check the condition of the plunger and the wiring.

Bill Silver