Kill switch repair. yellow button

[tinkerfinger]

If your yellow button kill switch never worked, and you would like to kill your motor and save $$ on the down hill runs, Check out my repair.
Getting it out is simple. I suggest removing wires with soldering gun to make this easier. The switch is a simple snap together. Just slip an exacto blade, or supper thin small screwdriver between parts and pop it apart. be carefull not to brake it.
The issue is the spring loaded metal contact that sits in the yellow swith button. As you can see, it is stuck in the yellow plastic. It is not only too wide for the slots its supposed to fit in, but it also is simply not bent to fit the holes. Rebend it to make it fit. I used a dremmel to make the legs thinner. now it floats the way it should. making contact with the two copper contacts on the black cover plate. The smaller spring goes under the contact. the big one is behind the button. Reassemble with copper contacts closest to front of switch. Check continuity with voltmeter. You should now have a good switch.

 

[deacon]

I used a toggle switch and a house type electrical switch to replace my kill switches. But I can see how this would be nice.

 

[Tj Bunch]

What about a better Throttle assem? Are there any that will fit handle bars?

 

[deacon]

I converted a gear changer to a thumb throttle.

 

[Tj Bunch]

ok like an atv has......good idea.

Thanks

 

[stude13]

throttle and kill switch @ scootercatalog.com

 

[Dave31]

ok like an atv has......good idea.

Thanks

I've used a ATV thumb throttle....I've gone back to the twist throttle but for really long ride's I will use the ATV throtttle...I have a wrist that has more metal then a junk yard and for long ride's the thumb throttle is more comfortable for me.

http://motorbicycling.com/f3/different-throttle-563.html

 

[motor_head]

they sell push button toggle switches at menards in the electric aisle

 

[rgd48]

am i supposed to hold the kill switch in while i ride. i used to didn't have to. what may be wrong/

 

[2door]

am i supposed to hold the kill switch in while i ride. i used to didn't have to. what may be wrong/

Depending on how you have it wired, check the soldered connections on the core of the magneto coil. If one of them is broke it will give you the problem you have. They aren't easy to see; some are covered with a glob of brown stuff (insulation).
A simple test for this is to disconnect the kill switch wires and see if the engine runs. If it doesn't then you have a broken solder connection on the mag coil.
Also the recommended way to wire the kill switch is to connect it to the blue & black wires from the CDI...not the white wire and frame.

Tom

 

[rgd48]

thanks tom. now i think i've ran into another problem. i think. riding last night i heard this poof and felt something on my forward leg. i again rode to work and i got to noticing a piece of head gasket stuck on the front motor mount bracket. it's 1to 1-1/2" long. will this damage my motor?