Happy Times "no start" - "hard start" possible fix

arceeguy

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May 20, 2008
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Central New Jersey, USA
Hey guys,

Just finishing my 4th build with a "Happy Times" bicycle engine and experienced my first "no start" condition from a brand new engine.

I was getting a "no spark" condition and swapped out a new CDI, which didn't do any good. The magneto coil measured continuity from ground to the white wire, and blue wire. It would light up a night light bulb (dim, but lit) connected to the blue and black wires, so there was output.

Turns out the problem was the air gap between the rotor magnet and the magneto frame. It was too wide, and the magneto output wasn't high enough to trigger the CDI. I used a business card and a large pair of vice grips to close the gap on the magneto coil.

Now, the engine starts with just a momentary "popping" of the clutch lever at slow speeds. I made the adjustment to my other bike, and it starts a lot easier. I would have to pedal to a pretty high speed and pp the clutch before it would start, and now I can just pedal at a slow pace and pop the clutch to get it started with little effort. The same night light now glows a bit brighter when connected to the magneto, so the output went up a lot by closing the air gap.

Hope this helps others!

Ciao!
 
Well, how about that? Something new.

That coil "frame" looks fairly beefy. You can close that gap with vice grips? Or did I miss something?
 
Yup - I used a pair of vise grips clamps. The coil frame isn't hard to deflect the 10-15 thousands of an inch that was required to get it running. The new owner picked it up a couple of hours ago and it started up in an instant.

No more Moon Doggies at Walmart, either online or in stores. Woof........
 
hmmm, wonder if that was my problem.....seemed to replace them every time it rained. :???:
 
Yup - I used a pair of vise grips clamps. The coil frame isn't hard to deflect the 10-15 thousands of an inch that was required to get it running. The new owner picked it up a couple of hours ago and it started up in an instant.

No more Moon Doggies at Walmart, either online or in stores. Woof........

Moon Doggy problems?
 
They are sold out of the puppies.
I have a brand new Huffy Cranbrook that will be my next build. Single speed with coaster brake - should be interesting.

ibdennyak - I have no idea why a coil would fail if it got wet. The copper wire is enameled, and it looks like they dip the whole assembly in some sort of varnish.
 
They are sold out of the puppies.
I have a brand new Huffy Cranbrook that will be my next build. Single speed with coaster brake - should be interesting.

ibdennyak - I have no idea why a coil would fail if it got wet. The copper wire is enameled, and it looks like they dip the whole assembly in some sort of varnish.

That was my thought too, espexially after all the wsterproofing measures I took. Of course, the climate here is kind of extreme......I've seen rain 24/7 for 61 days already. Put it this way...couple years ago, I saw something on the chrome bumper of my truck. There was a mushroom growing on it. :eek: Never saw that before. Thought maybe the constant moisture causes a partial short somewhere. Oh well.
 
That was my thought too, espexially after all the wsterproofing measures I took. Of course, the climate here is kind of extreme......I've seen rain 24/7 for 61 days already. Put it this way...couple years ago, I saw something on the chrome bumper of my truck. There was a mushroom growing on it. :eek: Never saw that before. Thought maybe the constant moisture causes a partial short somewhere. Oh well.

I guess cars up there don't last too long either.

Maybe try giving the magneto and magnet a shot of Mercury Marine "Corrosion Guard" spray, or Boeshield T9. Might not be a bad idea to spray the CDI where the high voltage wire screws in. People coat their entire outboard engines with this stuff to keep the electronics from failing.
 
You know, turning to marine products is a good idea. They must have to deal with water issues (of course) but it wouldn't occur to us land-lubbers.

thanks.
 
You know, turning to marine products is a good idea. They must have to deal with water issues (of course) but it wouldn't occur to us land-lubbers.

thanks.

Every year, I wash the underside of my cars and give them a coat of Boeshield T9 on every visible square inch. I also clean the engine compartment and do the same. Makes it a lot easier to work on an old car where the fasteners aren't all corroded and frozen. Stuff is great weather you live by the ocean or in the "rust belt".
 
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