Dropped my Stella...bashed the throttle

[slotrod65]

I dropped my Stella in my Sister in law's driveway today. The bike was not running, and I set it on the center stand but I guess the driveway was uneven. The next thing I knew it rolled over onto the right side. I am so upset at myself I could spit nails.

The Prima rear crash bars saved the cowl from any damage, although the bars themselves were pretty well scratched up. This was not the worst unfortunately. The scoot also landed on the right handlebar end, and the grip was ripped up. No biggie. But the front brake handle was bent outward, and the worst: the throttle tube was pushed into the headset about 1/2".

At first, I noticed the throttle would not turn at all, so I pulled off the grip, and the throttle tube pulled back out. The stop ring (circled below) was bashed up and had been pushed into the headset. It is now bet over in several places, and now the jagged edges were catching on the headset housing. A little rough screwdriver work made it sorta drivable, and I got her home (only 2 miles).



Not only am I very upset at myself, but I am concerned about what I could have broken inside the headset. It is too dark for photos of the scooter, but I will take and post them tomorrow.

Has anyone ever replaced a throttle tube before? Is opening the headset a snake's nest? How about swapping in a new brake handle, that should be pretty straight-forward no? Or should I just try to bend this one back?

[JohnKiniston]

I've only changed cable operated brakes, Since the Stella is hydraulic it might be a bit of work to do but it should be possible.

Both The Top and Bottom of the headset can be purchased if you need to replace one or the other.

4 screws under the headset and off comes the top, You'll have to unscrew the speedometer cable from the base of the speedometer but the rest is easy with plugs that only fit one way.

[Spud]

Don't be mad at yourself...stuff like this happens.

I dropped my motorcycle so many times...eventually my frame got bent and had to be straightened.

That poor bike...it was my first, and I made a lot of mistakes that it suffered for.

[Tam Tam]

I pulled her up on her stand, and turned to pick up something and heard CRUNCH! She fell on her right side. Like yours, the cowl crash bar saved the day, and thank god it fell into dirt grass rather than concrete. The brake lever on that side was bent back, but it was such a gentle curve it almost looked like it was bent on purpose. But the throttle was completely stuck.
Online, I looked up the pieces and parts of the throttle, got choked up at the cost of the bar, and got a bit sick thinking about labor costs. The headset did come off (not all the way, but enough that I could see inside - I was not gonna even try to disconnect any wires or cables). The stop ring had been completely forced into that space.
So, I used WD40 on the throttle bar, letting it soak in for about 30 mins. Then, with pliers and my strongest grip, i pulled the throttle bar back out from it's stuck position - I did not remove the whole throttle bar, just pulled it back out.
Then with needle nose pliers and a very small hammer, I kinda bent and hammered the stop ring back into it's former shape. It didn't go back exactly, but I repaired it to about 80% of what is used to be.
After that I put it all back together, and gave it a test drive. One year later and no troubles from it at all.

By all means, if you feel like replacing the throttle bar, then that may be your best course of action. I didn't want to unhook the throttle cable for fear of it falling down into the scooter itself...This post was just to share how I was in the same situation, and was able to resolve without even having to remove the whole throttle bar.

p.s. - I kept the bent brake handle on. It bent in such a perfect arc that it looks like it was made that way. And oddly, I have come to like how it seems to hold my hand in place as I apply the brakes. It's bent shape has not interfered with my throttle control nor my braking control. And I think it looks kinda cool, kinda like a cool dog with one floppy ear lol

[slotrod65]

Thanks for the re assurances everyone. As I was lolling off to sleep last night, the idea of tapping the stop ring back into shape worked itself out in my head and I am hoping that should do it. If Nothing is busted inside the headset, I should be able to live without replacing the throttle tube. Today I am calmer, and am concentrating on fixes. I have already ordered another pair if Vespa grey grips, but I am not sure about the bent brake handle yet. I may try to bend it back, or replace it with a new one.

[slotrod65]

OK, Here is the damage:

[BuddyRaton]

If you don't have any scratches then you aren't riding enough!

Now..back to your question. Throttle tube replacement is pretty easy. I don't know how mechanically inclined you are but if you can change you oil you can change a throttle tube. Order a new grip at the same time

[slotrod65]

Thanks BuddyRaton, I will replace the tube if necessary, but I think I have been able to dodge that one:

I headed out to the shed at break time this morning, and worked on the throttle stop ring. I used a stainless steel ruler as an anvil: wedging it in between the ring and the headset. Then a 6" long 1/4" drive extension made a makeshift punch. A few gentle love taps brought the stop ring back into shape. Once the new grips arrive, you won't be able to tell there was any problem with the ring.

I was thinking of trying to bend the brake lever back into shape... has anyone ever tried this? Has anyone ever replaced one? The level is functional, and usable I guess, but is a bit of a stretch. I do not want to have to get into bleeding the brakes as my dealer is 2 hours away... any thoughts?

[BuddyRaton]

Nice job on the tube! OK...now we know that you're pretty handy!

The lever might bend back...but it might snap also. I've never seen one bend like that...usually they break.

Lever replacement is easy too. No need to bleed brakes to replace lever. The lever just "activates" the master cylinder. In other words you pull the lever, the lever pushes against the MC actuator( that tab below the lever screw in your photo), actuator moves in reducing volume making calipers squeeze together. There is no direct connection between the lever and the fluid. When replacing the lever remember to put the washers back in.

[Spud]

In my opinion, while you could try bending the brake lever back, it probably would be a lot easier to buy another one. I don't think it should cost more than $10 or so (that's what a brake lever would cost for the bike I used to have, so I'm basing my estimate off that)

[slotrod65]

Yeah, I came to the same conclusion. I have a 14" section of pipe I use for all sorts of brute force jobs, and so I knew I could get the leverage, but I figured I had a 50/50 shot of just breaking the lever rather than bending it. Or worse yet, bending or breaking another part of the scoot... namely the master cylinder, which would surely cost more.

So I just called Scooterworks, and ordered me one. $41 plus shipping. The high cost, I was advised, is that this is a handle for a disc brake model, rather than the older cable brake. Less demand = fewer sold = higher costs to produce. Oh well. I found out the master cylinder was about $200, so if I broke that I would have been really screwed.

So I am out $20 for a new (new) set of grey Vespa grips, and $46 incl shipping for the brake handle. All-in-all, it could have been worse.

[BuddyRaton]

Glad the $ damage isn't too bad.

And yeah that newfangled disc set up for P series Vespas has only been around for what....30 years or so?

[slotrod65]

I received the new brake level from Scooterworks, and installed it this morning. It was a snap. Just one bolt, one screw, and don't lose the washers! The only hold up was wiggling the lever around a bit to get the screw to thread in cleanly, and that took only a few minutes. Pics are below. Once my new grips arrive, you will never know there was a problem...

Bent brake lever:



Comparison of bent and new:



More details: bent (bottom) and new lever (top)

[BuddyRaton]

Nice job!

We'll have you splitting cases on a vintage 2T soon!

[slotrod65]

I am not afraid of wrenchin' on anything. But I am afraid of drilling holes in my legshield for my Cuppini front crash bars....

[Spud]

Glad you got it fixed.

If new brake levers for the Stella are around $40...I might try to buy one second-hand and just keep it, as a prophylactic measure!

[slotrod65]

Just remember: the Left and Right are different, as the Right handles the disc brake. Also, just don't buy a PX right lever, make sure it fits a disc brake.

[Spud]

Just remember: the Left and Right are different, as the Right handles the disc brake. Also, just don't buy a PX right lever, make sure it fits a disc brake.

Thanks for the reminder.

[BuddyRaton]

I am not afraid of wrenchin' on anything. But I am afraid of drilling holes in my legshield for my Cuppini front crash bars....

I'm with you on that. I've had to do it...and will need to do it to convert my GT to oil injected...but I HATE drilling any body parts!

[Spud]

I don't think I will ever get any accessories that require drilling. It seems like exactly the kind of thing I'd mess up.

[jimmbomb]

Find yourself an arbor press somewhere and slowly work your original brake lever over.
Then you'll have a backup for when you bend your replacement one!
Good job fixing things!

[slotrod65]

Find yourself an arbor press somewhere and slowly work your original brake lever over.
Then you'll have a backup for when you bend your replacement one!
Good job fixing things!

Yeah, I thought about trying to refurb the bent handle, but I did not want to bust it and not be able to drive. Fixing it up as a spare is just the ticket. Thanks!!

[Hapgator]

Yikes. I'm suffering from the same problem of the Vespa toppling over and the right handle being jammed into the throttle housing. Alas, I'm so mechanically uninclined. I am unable to tap the ring part that keeps the handle from sliding into the throttle housing. I tried the needle nose plier route and, well, I can't tap the thing back into place. Is there a part I need to buy and have a mechanic do it?

I goofed and bought a throttle tube online but that's not what's broken, I think. It's the thing on the handle or whatever that attaches itself to the throttle tube. Unfortunately, the only place nearby that will touch a Vespa (in NW Chicago burbs) has a real attitude against Italian bikes, and especially Vintage ones (1980). Scooterworks is a pretty long drive and, unfortunately, I've had shoddy service from them in the past.

Is there some kind of easy fix. I wish I could knock the battered, bent ring or whatever you call it into place. Perhaps, I need to hire somebody who can do that. Would appreciate your advise. Thanks.

hapagator

[Robbie]

Yikes. I'm suffering from the same problem of the Vespa toppling over and the right handle being jammed into the throttle housing. Alas, I'm so mechanically uninclined. I am unable to tap the ring part that keeps the handle from sliding into the throttle housing. I tried the needle nose plier route and, well, I can't tap the thing back into place. Is there a part I need to buy and have a mechanic do it?

I goofed and bought a throttle tube online but that's not what's broken, I think. It's the thing on the handle or whatever that attaches itself to the throttle tube. Unfortunately, the only place nearby that will touch a Vespa (in NW Chicago burbs) has a real attitude against Italian bikes, and especially Vintage ones (1980). Scooterworks is a pretty long drive and, unfortunately, I've had shoddy service from them in the past.

Is there some kind of easy fix. I wish I could knock the battered, bent ring or whatever you call it into place. Perhaps, I need to hire somebody who can do that. Would appreciate your advise. Thanks.

hapagator

Although I cannot vouch for their service dept. Arlington Motorsports on RT.14 in Arlington Heights is also a Stella dealer.....they service all brands though.

They are open on Saturdays.....Sorry though, I don't have the number.

Rob

[BuddyRaton]

Yikes. I'm suffering from the same problem of the Vespa toppling over and the right handle being jammed into the throttle housing. Alas, I'm so mechanically uninclined. I am unable to tap the ring part that keeps the handle from sliding into the throttle housing. I tried the needle nose plier route and, well, I can't tap the thing back into place. Is there a part I need to buy and have a mechanic do it?

I goofed and bought a throttle tube online but that's not what's broken, I think. It's the thing on the handle or whatever that attaches itself to the throttle tube. Unfortunately, the only place nearby that will touch a Vespa (in NW Chicago burbs) has a real attitude against Italian bikes, and especially Vintage ones (1980). Scooterworks is a pretty long drive and, unfortunately, I've had shoddy service from them in the past.

Is there some kind of easy fix. I wish I could knock the battered, bent ring or whatever you call it into place. Perhaps, I need to hire somebody who can do that. Would appreciate your advise. Thanks.

hapagator

Photos and a location are a must. We gotta see it and if you tell us where you are someone nearby might be able to help.

[Spiffy]

I did the exact same drop last year... only I was loading mine up with heavy stuff on a slope... dumb thing to do...

I pulled the throttle back out (yanked really hard, it popped back into place), straightened the stop ring with some needle-nose pliers, and never looked back...

haven't had any problems with it in all the time since then...

in fact, it used to have a sticky throttle sometimes, now it's smoother than ever... and I've never lubed it...