Clutch Cable breaks

Yesterday, my clutch cable broke. Fortunately it broke with me 100 yards from my parking spot at home. I was able to find the broken end, it snapped at the cable clamp. 

Since I bought new cables 10 days ago, I count myself fortunate. But I left the cables at my friend's barn. The local motorcycle shop did not have a cable I could use, so I drove up to Petaluma to get the cables. By the time I got back, it was too dark to replace the cable.

After work today, I replaced the clutch cable, it was not that difficult, though it was a bit greasy messy. I drove around the parking lot and the clutch seems to be working fine. The real test will be when I drive into work tomorrow.

Electrical

I bought some new headlight bulbs and fiddled with the headlight and switch. All circuits seemed to be getting juice, but I blew out the pilot bulb. The larger bulb, only one filament of two works. So at least I have a light burning. 

Since I am going to replace the whole harness when I rebuild, I'm not going to put a lot of effort into tracking down this problem.

I did find out the headlight and switch is original SIEM equipment. The reflector is peeling, so it will need to be resurfaced.

When I bought the bulbs, I also got the correct taillight for my scooter, it being a clean but used SIEM unit. I also bought a cable set for the rebuild and in case one breaks before then.

Electrical Problems

Earlier this week I noticed my headlight was out. I was working late but left before it got too dark. When I started the scoot, the light was not shining on the wall where I park at work. 

The next evening I took of the headlight, having to cut one of the retaining screws, as it was buggered and frozen. I took the bulbs out, and finally found out for sure that my system is a 6 volt system. I used a old 6 volt wall wort transformer to test the bulbs. The main headlight bulb worked on both filaments but the pilot light looked like it has a tiny crack across the top and did not work.

I also found the headlight glass is a SIEM lens, so probably the original glass on the scooter. The bezel will need to be replaced though since it has some rust spots coming through the chrome.

Joy on the missing Horn Cast

I posted an inquiry on the Scoot.net classifieds looking for a horn cast for my Sprint. Within a day, I received a reply of someone who may have a NOS part (New Old Stock). This means a new part in the original packaging. Unfortunately he is out of town and won't be able to send me a picture and the part number for a couple weeks. 

If this the right part, this is great news. I did not think there would be any of these as NOS, only used taken from a wreck or a parted out scooter. Since the horn cast looks like is welded on, getting a good used one seemed like a slim proposition.