1984 200ES CDI Replacement, MythBusted..

[kb0nly]

Oops... Yes you are correct. I need to stop posting when i am tired!!! But yes the wire connected to that terminal.

[GTO]

I did ground the neutral wire and the light does come on.
If it is a bad neutral safety switch isn't it a mission to sort it out?

[kb0nly]

If its the switch, that is if you test it with a meter and it never grounds the wire then yes it is a pain to get to. The Neutral safety switch is towards the bottom of the case on that side, down between the flywheel and the sub-trans. I am not sure you could get to it without pulling apart the entire left side. I know for sure you would have to pull the recoil, the flywheel, the electric start and the entire left case, then you might have enough clearance to get to it without having to pull the sub-trans off as well but i don't know for sure as i haven't had to do one.

It's in a tight location, if you look at the neutral indicator and the shifter you will see the wire coming down for the neutral switch between the left case and the sub-trans, follow that wire down and you will see it, the neutral safety switch is installed into the case.

[GTO]

If its the switch, that is if you test it with a meter and it never grounds the wire then yes it is a pain to get to. The Neutral safety switch is towards the bottom of the case on that side, down between the flywheel and the sub-trans. I am not sure you could get to it without pulling apart the entire left side. I know for sure you would have to pull the recoil, the flywheel, the electric start and the entire left case, then you might have enough clearance to get to it without having to pull the sub-trans off as well but i don't know for sure as i haven't had to do one.

It's in a tight location, if you look at the neutral indicator and the shifter you will see the wire coming down for the neutral switch between the left case and the sub-trans, follow that wire down and you will see it, the neutral safety switch is installed into the case.

Thanks next time I am at our holiday place I will check it with a meter, I am not sure if feel like stripping it though if it is the switch!

[kb0nly]

http://www.ebay.com/itm/REVERSE-INDI...cf4a99&vxp=mtr

There is an example of what it looks like. The reverse switch is easier, thats on the top, the one i mentioned before that has the nut type terminal on the top of the sub trans, that one just screws out and looks like a spark plug really. The neutral safety switch is pushed into the case with an o-ring to seal it and a keeper that holds it.

[GTO]

http://www.ebay.com/itm/REVERSE-INDI...cf4a99&vxp=mtr

There is an example of what it looks like. The reverse switch is easier, thats on the top, the one i mentioned before that has the nut type terminal on the top of the sub trans, that one just screws out and looks like a spark plug really. The neutral safety switch is pushed into the case with an o-ring to seal it and a keeper that holds it.

Thanks for the link, nice to see what it looks like, I like the map the seller has on the areas he has shipped too.
4 items to South Africa!
But the transfer case has to be removed first right?

[kb0nly]

You would have to look at it, not really 100% sure if you could get it out without much teardown or not. I haven't had time to go look at mine.

[408Fairmont]

I know this is an old post, but it should be bumped. Thanks for the tips, I am going to try this on my 84 big red, the CDI is done, and I was just wondering why the hell they were so much more when I found this post.

Ill see if it works soon, I have another CDI from our 83.

[kb0nly]

Welcome!

The problem is they made the special one year CDI for the 84, thats what really made it hard to find and expensive. I have been running my cheap aftermarket CDI without problems.

[GTO]

Same here I have x4 200ES's I converted them all to Chinese CDI units a year and half ago and have had no problems since then.

[Dave_D]

Subscribed might have to do mine

[coolpool]

Just lost spark on my trusty 84 BR. Parked it one day fine, wouldn't start the next. Thought i'd seen a weak spark once? New plug didn't do it either as well as checking the boot connection. I subscribed to this thread a long time ago for the day i needed it, thanks kb, Time to go shopping!

[kb0nly]

Just lost spark on my trusty 84 BR. Parked it one day fine, wouldn't start the next. Thought i'd seen a weak spark once? New plug didn't do it either as well as checking the boot connection. I subscribed to this thread a long time ago for the day i needed it, thanks kb, Time to go shopping!

Sounds like how my CDI died... I started it and moved it across my yard to my shed to change the oil, came back later that afternoon and no spark and wouldn't start. Took the CDI off and smacked it hard on the concrete a few times and then it started right up. A few days later i was replacing the CDI... LOL

[honda200x1987]

Those big reds are bullet proof! Quick tip and it may have already been said, NEVER jump start your bike with jumper cables, that will damage the electrical system including the CDI unit, most common cause.

[kb0nly]

Those big reds are bullet proof! Quick tip and it may have already been said, NEVER jump start your bike with jumper cables, that will damage the electrical system including the CDI unit, most common cause.

Actually.... Jump starting can not, and will not, hurt the CDI. The CDI is in no way connected to the DC side of the system. The ignition has its own separate coil in the flywheel, it never crosses over with the lighting and starting side of things. Applying voltage to the battery to jump start it can damage the rectifier/regulator however, but it can't do anything to the ignition at all.