. By rosiemoto (Read 11,403 times)

[Alleyoop]

Great! so the problem is the brake switchs YOUR SOLENOID is good. Getting this puppy up to everything working just a little TLC is and replacing old worn out parts is all.

The way the electric start works is:
1. When you squeeze EITHER BRAKE it sends voltage to the STOP LIGHTS and the SOLENOID(the wiring from the brake switch YELLOW and GREEN SPLITS) one to the SOLENOID and one to the STOP LIGHTS.
2. When you Push the Start Button it GROUNDS out the SOLENOID and the SOLENOID then allows VOLTAGE to GO TO THE TERMINAL that is connected to the STARTER.

What happens inside the SOLENOID is JUST LIKE YOU JUMP IT WITH THE SCREWDRIVER but it happens inside.

Alleyoop

[Alleyoop]

If your stop lights and solenoid work when you push that switch in TAPE THE SUCKER UP PUSHED IN or out which ever position it works. A temp fix until you can get a new one.
Alleyoop

[damin69]

Rosie, I know on at least one of your Videos you had mentioned Lighting issues also. I had mentioned in the comments on one of your last videos. Make sure that your Break Light bulbs are working also. Blown bulbs will act like an open circuit and react the same way as an open/bad switch. So make sure your bulbs are good also.

[rosiemoto]

.

[damin69]

rosiemoto It is the brake light you have to worry about being burned out or the starter will not engage. I should have been a bit more clear on that.... Did you find a bad brake switch? If so did you find the style you need? I have a couple from my Old scooter that you can have if they will work for you. I no longer have a need for them as the scooter they fit I no longer own.

If it is like this one that Alley Posted? If so that is the ones I have. Both Left and Right side.
They are probably this type, the two wires plug in and one screw holds the switch:

[damin69]

Here is an way to get that nut off without an impact drive. Though there is always a chance of damaging Variator fins doing it this way but atleast chino Variators are cheap.

[Alleyoop]

[rosiemoto]

Would it be possible to hold it steady with the strap wrench (what size would I need?) and use adjustable wrench on the nut? I don't have the 17mm socket.
So these two tools...

Adjustable wrench: www.amazon.com/TEKTON-23005-12-Inch-Adjustable-Wrench/dp/B00FFUPTVK/ref=sr_1_2?s=power-hand-tools&ie=UTF8&qid=1444701760&sr=1-2-spons&keywords=adjustable+wrench&psc=1

Strap wrench: www.amazon.com/gp/product/B0011E4QU4?keywords=strap%20wrench&qid=1444701657&ref_=sr_1_1&sr=8-1

edit: or Alleyoop's tool + adjustable wrench? Trying to go the cheapest effective route

[damin69]

rosiemoto Should have looked at the Adjustable wrench..... Stay away from the Knuckle busters when working with the variator nut. Stick with a good 6 pt socket and a breaker bar. you would not be able to loosen it with that anyway not without a cheater and would probably mess up the nut.
Not sure about the 150cc but I know I tried on my 250 before I got my impact wrench and was not able to get the nut loose using a strap wrench. Those that Ally posted would do a much better job.

[Alleyoop]

Here this will work and not expensive and you can use it on the Clutch Bell as well. You may be able to find it cheaper than that I think I saw it on aliexpress for 14.95 + free shipping.
Alleyoop

www.amazon.com/REMOVER-PULLER-VARIATOR-SCOOTER-MOTORS/dp/B0117MI0G0

[damin69]

If you have a harbor Freight near you you can probably get this stuff at a good price also. If you go cheap on your Sockets Make sure they are 6 pt so you have less play. That way you will have less chance of rounding off the nut if it slips.
Cheap set of 1/2" sockets
www.amazon.com/TEKTON-4815-Shallow-11-24mm-Sockets/dp/B000JL9I5I/ref=sr_1_4?s=automotive&ie=UTF8&qid=1444703219&sr=1-4&keywords=1+2+metric+socket+set
Breaker bar for decent leverage.
www.amazon.com/Neiko-Heavy-Duty-24-Inch-Chrome-Vanadium-Breaker/dp/B001222378/ref=sr_1_2?ie=UTF8&qid=1444703137&sr=8-2&keywords=1+2+breaker+bar

[Alleyoop]

You can also use a hammer on your adjustable wrench hitting the handle while holding the Variator Fan with something acts like an IMPACT wrench.

[rosiemoto]

Here is a picture of my adjustable wrench from Ace Hardware. Do you think this will work with the hammer? The handle is rubber and the tool feels pretty heavy. I have a hammer and also a rubber mallet that might help to not hurt the rubber handle on this wrench...?



If this looks suitable, I think I'll use it and hammer/mallet combo, and order that lock tool.

[rosiemoto]

I just took apart my front end and got to the brakes. I took off the front brake switch to inspect it, and the problem is it's got no springyness or click to the switch; it's just loose and falls whichever direction you hold it. The connectors were also pretty rusted when I unplugged it.

My back brake switch.. not sure how to explain it so I made an illustration out of the picture you showed me before, Alleyoop. When I pulled it out, some plastic or rubber pieces fell out. Does it just maybe need a good push so it pops through to the other side or something?

[cyborg]

Unless i missed it in the text,,,engine still reving and bike decelerating,,,and as you stated (Alley) rollers worn out,,,but i didn't see that the belt was changed,,,that could be the cause of the strange rpm problems? (along with the rollers being worn),,,,