Honda Twins banner

1 - 14 of 14 Posts

·
Registered
Joined
·
37 Posts
Discussion Starter #1
I have just rebuilt a 1980 CD 200 Benly, 6volt points ignition, trying to get it going again, worked before I stripped it.

here is what I have done so far. please bear with me.

1. connected up all wires, in the headlight bucket, and the rectifier ,stator, lights, when I turn on the ignition I get neutral light, no indicators working, when I press the start button I get nothing, no click or anything, I shorted the started solenoid, and the bike turns over, but no spark.

2. I have fitted a new solenoid, new 6 volt battery (fully charged) , but this has made no difference. no joy from the start button, or spark when it turns over with the solenoid shorted.

3. I have fitted a new coil, to try to get spark, no difference.

4. I have used the Haynes manual to try and read the diagram , I think I've wired it correct, but obviously not. this it where I need some pointers.

5. fuse is ok.

6. I have checked the rectifier with a meter, and it seems to be ok.


is there anything obvious that I'm missing, is there a safety switch anywhere for the kickstand or the clutch, I didn't see anything in the manual, where do I go from here?
 

·
Sensei
Joined
·
27,018 Posts
Give me a bit to type up a step by step troubleshoot for the UK version bike......Will post it here....Meanwhile, verify that your headlight/starter (right hand unit) is getting power to the Black wire.....and verify for me the two wire colors to the flasher module...Should be a GRAY and a BLACK......
 

·
Sensei
Joined
·
27,018 Posts
Is the grounding link from bottom of one handlebar riser to the meter bracket re-installed?
(~4 1/2 inches of black wire with an 8mm ring terminal on one end, a 6mm ring on the other..)
 

·
Registered
Joined
·
37 Posts
Discussion Starter #6
horn . works, sticky switch, ok so i have power to the right side switch, headlight works neutral light works ,rear light works, no starter still?



james
 

·
Sensei
Joined
·
27,018 Posts
James,
Unplug Yellow/red stripe wire back at the solenoid.....bike in neutral, key on ....ground solenoid end of that Y/R wire...
Does grounding it activate solenoid?... Does the starter crank?
IF Yes to both: wire from there to (and including) start button and its ground has the problem...Ground SHOULD be good as horn works.......
IF solenoid activates but starter doesn't, Faulty contacts within solenoid.... Repair or Replace....
If solenoid fails to activate (clunk) verify battery power to black solenoid wire......If power, bad solenoid......If no power, trace black wire connections.....
 

·
Registered
Joined
·
37 Posts
Discussion Starter #8
Ground the yellow and red wire does start the starter. Where do I check next?
 

·
Sensei
Joined
·
27,018 Posts
Ground the yellow and red wire does start the starter. Where do I check next?
Well, you now know the solenoid works properly when the Yellow/red wire is grounded..... Plug it back into the harness and check it at its next juncture point inside the headlight shell (where it Might just be unplugged/dislodged) in the same manner, grounding the end coming from/leading back to the solenoid.... If it still works then the problem lies in the last wire leg (in the handlebars/up to the button), or the button switch itself........If NOT, there's a break in that yellow/red wire within the harness (maybe pinched/cut/broken at or by the fork stop)......
 

·
Registered
Joined
·
37 Posts
Discussion Starter #10
Testing continuity from the red \ yellow wire from the solenoid side to the switch ground beeps. So ground is good.

Yellow/red from the loom side to the yellow / red at the switch continuity beeps here also. So no breaks here


I had one of the solenoid wires connected to the rear lights switch. Damn fool I am.

Getting it turning over now. And getting spark at plugs. But still not starting. Wondering if the new coil ht leads are round the wrong way. Waiting for battery to charge up to test this
 

·
Sensei
Joined
·
27,018 Posts
Both plugs spark simultaneously on both the compression and exhaust strokes, so there is NO wrong way for the HT leads......
Points should be opening (breaking contact) and plugs should fire at EXACTLY the F line to index line alignment.......
 

·
Registered
Joined
·
37 Posts
Discussion Starter #12 (Edited)
just seen the post about the wire at the handle bars, there was never one of these on the bike? however i do get earth on handlebars, should i fit one?

only then battery is full, i get a splutter from the engine, but thats about it, has fuel, points open and close, spark seems ok. not sure if i need new point and condenser or not. set to F line and
cleaned, i feel like were getting there as well, but obviously something still not quite right.

holy ****, you come from Roanoke, seen it on american horror story, was that true?
 

·
Sensei
Joined
·
27,018 Posts
just seen the post about the wire at the handle bars, there was never one of these on the bike? however i do get earth on handlebars, should i fit one?....There SHOULD be a short (4" or so) wire with ring terminal ends connecting a handlebar riser to the bridge (top triple) at the meter bracket ...IF you have rubber isolated risers...You DO already have a ground as horn works.....

only then battery is fully charged...(Battery MUST be fully charged as this is a battery powered ignition)... i get a splutter from the engine, but thats about it, has fuel, points open and close, spark seems ok. not sure if i need new point and condenser or not. set to F line and
cleaned, (Plugs MUST fire at EXACTLY the F line to index line alignment)....... i feel like were getting there as well, but obviously something still not quite right.

holy ****, you come from Roanoke, seen it on american horror story, was that true?
No idea, never watched it.....
 

·
Registered
Joined
·
37 Posts
Discussion Starter #14
Update. And I feel silly. I have a known good plug that I use to test for a spark. So spark was looking good. Took one of the real plugs out and tested this. Spark seemed to jump to the side of the electrode which I found odd. So cleaned both of them again and gave them a scuff with a piece of sandpaper. Regapped them. And hey presto it fired up. Should have been the first thing I checked. But as I was so far deep into it. I missed the obvious. However new plugs on the way. As these were the original ones. I will also make a ground lead and fit this as well. Just the indicators to sort out and its golden . So I cant thank you enough for your help. Hopefully I will be able to help someone else with this post in future. Your the man.
 
1 - 14 of 14 Posts
Top