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Thread: CDI box relocation?

  1. #1
    Join Date
    Apr 2012
    Location
    Black HIlls
    --
    6

    CDI box relocation?

    So....just received a new CDI box for my 84 200S Honda ATC....Wondering if the heat off the head and no cooling air under the gas tank make these boxes fail quicker? Has anyone ever relocated their CDI box to a cooler location on the frame? I am really hoping that this fixes the "no spark" issue. All other aspects of the Ohms check and troubleshooting were correct. It would be easy to do, wonder what y'alls thoughts are?
    Also.....should the spark plug lead show continuity when ohms checked or will it show "open" since it may be a resitance wire?
    Thanks
    tz

  2. #2
    Join Date
    Mar 2010
    Location
    Pacific NW
    --
    4,255
    service manual
    should light up as a clickable link.

    You may try the search key for no spark or
    intermittent spark.

    We've ALL been through it but keep us posted.
    Oh, that service manual has the values for all your components and resistance values etc.

    If you do get it running, and you will,
    hit the cdi with a hair dryer while it's running and see if it kills it.

    Generally, most agree that cleaning ALL connections, especially
    grounds, coil to ground, frame grounds etc is the best place to start.

    Even a bad kill switch ground may keep it from running, oddly enough. on
    some models since it doubles as a run ground for the cdi.

    Please keep us posted.
    We all need to know how to fix this problem too.

    edit
    Sometimes those spark plug caps short out and also corrode inside the plug wire
    itself.
    Many a sleepless night has been cured by nipping off the last 1/4 inch of spark plug wire
    so the cap has fresh wire to bite into.
    Do you have spark directly from the wire to the case without the plug cap?
    Last edited by tri again; 04-21-2012 at 02:35 AM.

  3. #3
    Join Date
    Apr 2012
    Location
    Black HIlls
    --
    6
    Okay.....cleaned all the connectors with electrical DeOx and a small wire brush...still no go. Ohms checked everything again, the lighting coil failed while everything else passed (?) I trimmed the coil sparkplug lead and got good continuity. Decided to pull the rope starter and see what I would see.....WOW....lots of rust, fungus, dirt, crud and snarf. At some point water got into the alternator area and sat season in and out. Even tho the sprockets do not show any wear at all, this thing has been abused by letting it sit outside.
    I have ordered a flywheel puller off of Ebay for $15 and have been spraying the spindle and screws with WD-40 to help once I get the flywheel off. I have a feeling that once I clean the magnets and coils I will have "something" but plan on ordering a new exciter coil and lighting coil if I can find them.
    Does anyone have a favorite one stop shop for parts? I have found a bunch of neat sites but none seem to have everything I will need in one site.
    Thanks for the input!

  4. #4
    WJG1000W is offline At The Back Of The Pack Arm chair racerFirst time rider
    Join Date
    Mar 2012
    Location
    Amana Iowa
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    184
    ebay or bike bandit for parts
    1984 Honda 200M
    1984 Honda 200M
    1996 Yamaha 250 Timberwolf 4x4
    1990+ Xingfu Hunter
    1986 Suzuki SP200

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