200es

[MisterRoboto]

so i had another post about a specific thing on my es but im just gonna make this thread about the entire trike.

i picked up an 84 trx200 and was wondering if the wiring is the same as the 84 200es?

[MisterRoboto]

putting my engine back together and i need to know how this washer that is behind the flywheel goes in? seems to be tapered. thanks

[Nason]

Might be able to get a look here. http://www.bikebandit.com/houseofmotorcycles/1984-honda-atc200es-left-crankcase-cover/o/m1891sch11888

[MisterRoboto]

i did look at that diagram on a dif site, my washer is shown behind the rotor there and i think the tapering on it is from wear from the starter driven gear bearings pushing out into it

appreciate the help nason.

[barnett468]

there are no tapered washers in there.

[MisterRoboto]

ya i figured it was worn from that roller bearing popping out and hitting it as the 2 washers that i have from my engines both have this wear to them

[MisterRoboto]

So im using a 84 trx200 bottom end and the wiring/controls/key from the trx200 on my 84 200es. when i pulled the engine over the lights on the dash will both light up just as im pulling and then go back off but i do not have spark. now when i was putting the wiring on there i found a mate for all the wires accept for this pink wire and the yellow wire i have plugged into it now that comes from the controls.

http://i1127.photobucket.com/albums/l632/Adam_Button/100MEDIAIMAG0875_zps3fb41cbf.jpg (http://s1127.photobucket.com/user/Adam_Button/media/100MEDIAIMAG0875_zps3fb41cbf.jpg.html)

the other odd thing is that one of the wires that plug into the cdi wires isnt the same as the cdi wire being blue and yellow

http://i1127.photobucket.com/albums/l632/Adam_Button/100MEDIAIMAG0878_zpsd895c0ee.jpg (http://s1127.photobucket.com/user/Adam_Button/media/100MEDIAIMAG0878_zpsd895c0ee.jpg.html)

anyway just thought id see if anyone knew about this pink wire specifically, or have any other suggestions to look at
thanks guys

[wonderboy]

The pink wire on your machine is power to the accessory outlet next to the headlamp. It shouldn't interact with the handlebar controls. There is an in-line connection along with all the others, but it should just connect to a pink wire coming up the main harness along the frame.

The pulse generator is what is under that cover. The Big Red harness that runs to the pulse generator has the blue/yellow wire and green. Green is ground, and as far as I know, Honda has kept this pretty constant on most machines. So match up the green wire. Like you already did, the blue/yellow harness wire should just connect to the other wire coming out of the pulse generator cover. I think you've done it right.

For what it's worth, my machine never seems to want to start with the recoil starter unless I have a battery installed. I don't think this is the way it is supposed to be, but mine does like yours if I pull it over.

[MisterRoboto]

The pink wire on your machine is power to the accessory outlet next to the headlamp. It shouldn't interact with the handlebar controls. There is an in-line connection along with all the others, but it should just connect to a pink wire coming up the main harness along the frame.

For what it's worth, my machine never seems to want to start with the recoil starter unless I have a battery installed. I don't think this is the way it is supposed to be, but mine does like yours if I pull it over.

wondered if you would happen to know where the solid yellow wire that i have plugged into the pink wire coming out of the dash belongs?

also will definately try putting my good battery in there see how she responds.

really appreciate the help thanks

[cap]

Here is the trx200 schematic

[wonderboy]

Yellow is the common feed to the headlamp switch. This lead should plug into a Yellow with Red stripe wire from the main harness.

[cap]

It looks like you have the YR (yellow with red strip) from the harness plugged into something other than the Y from the controls?

[MisterRoboto]

well there are 2 yr coming from harness one of them has a 2 prong female and the other yr is a male there are 2 YR and a Y coming from the dash.

[MisterRoboto]

i plugged the yellow into that YR with 2 ports and found the accesory outlet on my parts trx frame and hooked that up, however now i dont even get the light on the dash lighting up when i pull it over, even after i took my bike battery which is known to be good before and after putting it on the trike. so i need to start diagnosing the individual components but not sure how to start. when i jump the starter it turns the engine over.

[cap]

The single R/Y comes from the harness to the IGN switch R/Y
The double R/Y comes from the harness to the REV indicator light R/Y and the headlight switch/dimmer Y

It's very confusing but I think you will get it and it will work.
I added the 200ES wiring diagram to the 200trx diagram post above.

[MisterRoboto]

very helpful cap thank you.

i have all the wires hooked up correct now i believe. but still nothing

[MisterRoboto]

well, im not too sure where to go from here. any advice would be appreciated. should i strip the tape off the wires and check for broken wires or is there a way to check the pulse generator and alternator with multimeter?
thanks guys

[cap]

If you don't have spark then it might be the on/off or key so unplug all the wires from the controls and pull it over to see if you have a spark.

Here is the manual it has a trouble shooting and checking of the electrical system, I would recommend checking everything.

http://www.oscarmayer.net/atc/manuals/honda/1984_200es_bigred.pdf

[MisterRoboto]

unplugged the control wires and still no spark. tried putting my known good pulse generator from my 200s and still no spark, but i left it in there. wasnt sure if i wanted to aim at wiring or the stator / flywheel next, but my brother told me to try to rewire it temporarily to see if its the wire harness. so i took the original 200es harness which is a mess with basically everything cut accept for the wires for spark and sure enough i got spark :D

so now i have to tackle this trx harness to find the weak spot and fix it :( wish me luck

[MisterRoboto]

untaped the trx harness and looked around
cut and soldered one kink i thought might be bad
didnt see anything wrong
so i put it on the trike it sparked 1 time and then nothing.
pretty sure its in the ground wires, but wiring gets me so frustrated i think ima wire it simple with the crappy harness just to run it

[cap]

Good job finding the problem! Wiring can be a real nightmare.

[kb0nly]

I dont know if it was already answered... But that washer on the crank goes on first between the timing chaing gear and the starter gear. If you put it on the front side of the starter gear against the flywheel then the starter gear wanders back and rubs against the front edge of the timing chain gear. I had to take my 200ES back apart after putting that washer in the wrong place and hearing weird scraping sounds.

[MisterRoboto]

alright, so i did end up wiring it up with my original crappy wiring and it did indeed start and run. however that harness is just awful and i ended up finding a complete harness at my local atv shop in a parts bin, wasnt going to buy it at first i was going to try to make the trx harness work but decided to take a shot and bought it.
i got it home and hooked up just the wires to get spark and nothing :X so frustrating... cleaned up the ground and everything and still nothing

wasnt sure where to go from there again but decided to try to fix up the crappy wiring harness that i had the trike running with(soldering in new wire to each of the 10 or so hacked ones) but after trying to start the repairs i felt there had to be a better way with the other harness i had just got. so i checked continuity in it and got the same readings on the few wires that matter just to get it to run so i didnt understand what the heck the problem could be.
not knowing what the proper ohms reading should be i figured id check the chopped harness that had been running the machine and the ground had the same reading as the complete harness i have so i went on to check the red and black wire that connects to the stator red black wire and as i was finding the red black spot on the cdi connector i noticed that it wasnt in the same hole as on the full harness and is infact swapped with the solid black wire ><;;
Sure enough looking at the trx200 harness it is the same way as my complete 200es harness with where the blackred wire is.
So im hoping if i just clip these wires and swap them i should be in business, but wish me luck!


when i first got the trike i was told it was a big red but was a bit of a frankentrike so im assuming this harness and cdi are off of a different year trike all together -.-

[MisterRoboto]

just went out and snipped the wires and put some connectors on there incase i ever have to switch to an actual 84 cdi and it started up! :D

[MisterRoboto]

i got a battery for it and hooked it up and it makes the dash lights shine bright but when i hit the start button nothing happens no clicks or anything
the wire was crimped so i cut it and reconnected them and tested for continuity through the wire and it had continuity

[MisterRoboto]

so i was having a heck of a time finding the problem... switched out the solenoid and tested each on off switch and most wires for continuity. still nothing
so i started following wires back from the bars and when i got to the reverse indicator wire i looked under the rubber boot and the wire came completely off of the hoop that connects to the engine. i repaired it and it now will turn over with the start button, which is awesome!:D

my next problem is that my original carb kept flooding and i think just needs a rebuild kit after all, but when i put my brand new 24mm mikuni on it revs like hell and even with choke off its really revving fast... im bad at wiring but even worse at carb tuning so if anyone knows where to start let me know!?

the carb i have is a 24mm and i believe the original was a 22mm

[cap]

why are you using that carb? not sure that will work. I would rebuild the original or by one these 18$ carbs.

http://www.ebay.com/itm/270920908086?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

[MisterRoboto]

was using that carb cause i had it on hand and my local shop isnt open on sunday. going to put original back in or ya get a normal size new carb for it if i need to and use this one for my 200s

got it together and it starts right up but the idle goes up and down and seems to be really high idle too. i took the lil needle washer and moved it up a notch i think im going to move it up some more but i dont think this is the cause of my up and down idle... might have to do the timing again -.-;

[MisterRoboto]

i got a new carb for it and now the starter doesnt wanna turn everytime i push the button... i had disconnected the wire on the starter to do something and now its acting up ><