RR 6+ weird issue: Twist Throttle and Brake Light comes on...

[Jack D]

Intermittently.  I.e.; sometimes the throttle works and not brake light comes on.  Sometimes I twist it and the brake light comes on, and no movement.

I disconnected both the brake and throttle connectors (per Rad support) and inspected them and put them back together again without any noticeable change in behavior.

Weird thing I did notice: The throttle and PAS both work as expected when the front brake connector is disconnected.  As soon as I reconnect the front brake connector - the intermittent issue begins again.

Yet another bad controller?  Thoughts?

Thanks for any input / advice

Jack

 

[inoxa]

It might be a setting, but as long as you use both brakes at the same time I would keep it disconnected until you can find the issue.  The purpose of the brakes being connected is to turn the motor off so you can come to a stop without the bike continuing along. 

[Jack D]

Rad is thinking it's a bad controller.

[John Rose]

I would focus on the brake handle switch before shelling out for a new controller, especially if the misbehaviour only happens when operating the throttle. It suggests a mechanical issue to me, and the throttle is in the same vicinity as the brake handle. Maybe something is bumping into something else.

There is a procedure for adjusting the cut-off switches in the brake handles, but I cannot find it at the moment.

[John Rose]

... Weird thing I did notice: The throttle and PAS both work as expected when the front brake connector is disconnected.  As soon as I reconnect the front brake connector - the intermittent issue begins again.

Oh, wait - that's the wrong side from the throttle for my theory to work. 
Still, it wouldn't hurt to make the adjustments and be sure.

[Jack D]

John - you're not far off of the mark.  The Rear Brake Lever and the Throttle control are basically on top of each other.

Rad asked me to loosen the throttle mechanism screw and rotate it until the cable from it was pointed directly down, vs. crimped against the cable from the brake lever.  I was (very) skeptical, but it actually worked.  No more issue. 

Thanks for chiming in.

[John Rose]

Thanks for chiming in.

No problem. I developed my troubleshooting process working (most recently) on 250 kiloWatt shortwave transmitters. Lotsa moving parts and high voltages there. Now that I'm retired it's difficult not to speculate what might be wrong with something.