Honda TRX200 Help

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delling3
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Honda TRX200 Help

#1

Post by delling3 »

So not strictly a motorcycle, but a close relative. 1986 Honda TRX200SX quad. Just a little tiddler trail machine for use at the cabin. My son decided to take it out for a ride, and ended up seizing the motor. I decided to locate motor to swap into the thing instead of trying to rebuild.

Got the motor in, and everything seems good, except the electric starter. When I hit the button I get a loud click from the solenoid, but then silence. The motor turns over with the recoil starter, but nothing on the electric side. Thoughts. All the lights work as they are supposed to. I swapped the starter (which was working fine) from the old motor onto the donor, nothing else changed. I really want to get this thing buttoned back up and out of the garage - it's been here for far too long!

Any thoughts? Pulling the starter on this thing is a royal pain. Requires disassembly of half the engine. Would really like to avoid that if possible.

Thanks guys!
delling3

1979 Yamaha XS750SF

Previous:
1978 GL1000 - JUNE 2017 BOTM: Sold
2006 Kawasaki Concours: Sold
1995 Kawasaki Concours: Crashed/totalled.
1976 GL1000: LAST RESTORATION, sold
1981 Honda CB900F Supersport: 3rd restoration, sold.
1979 Yamaha XS-750F: 2nd restoration, sold.
1982 Honda FT-500 Ascot: First (only) new bike. Family forces sale.
1973 CB500 Four: First restoration, long gone.
1972 Suzuki TS-100: First bike, sold.

Only dead fish go with the flow . . .
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OCR
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Re: Honda TRX200 Help

#2

Post by OCR »

IS BATTERY FULLY CHARGED!
Will it crank over with a jump to another battery?
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delling3
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Re: Honda TRX200 Help

#3

Post by delling3 »

So, I am continuing to have issues, and could really use some troubleshooting help. The battery is nearly new, fully charged, and has been load tested: It isn't the issue. I checked the fuse - although unless I am mistaken with a blown fuse none of the electrical system would work, and everything works except the starter. I got some heavy gauge primary wire, and jumped between the positive battery terminal, and the lug on the starter - the starter spins and the engine turns over. So, it seems that the solenoid is bad, except:

1.) It was working fine prior to the engine swap, and
2.) I can hear a nice, solid "click" of the solenoid when I hit the starter button.

Can a solenoid fail in such a way that the relay still closes, but no power to the starter?

Here is a schematic of the starting system:
trx200SX Starting System.jpg
trx200SX Starting System.jpg (86.09 KiB) Viewed 110 times
Thanks for any help you can offer!
delling3

1979 Yamaha XS750SF

Previous:
1978 GL1000 - JUNE 2017 BOTM: Sold
2006 Kawasaki Concours: Sold
1995 Kawasaki Concours: Crashed/totalled.
1976 GL1000: LAST RESTORATION, sold
1981 Honda CB900F Supersport: 3rd restoration, sold.
1979 Yamaha XS-750F: 2nd restoration, sold.
1982 Honda FT-500 Ascot: First (only) new bike. Family forces sale.
1973 CB500 Four: First restoration, long gone.
1972 Suzuki TS-100: First bike, sold.

Only dead fish go with the flow . . .
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Track T 2411
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Re: Honda TRX200 Help

#4

Post by Track T 2411 »

Yes, the solenoid can 'fail' by having burned or corroded contacts. You can test the solenoid directly by jumping across the two terminals. I will caution you that sparks may fly and it will make some nasty marks on whatever you use to jump it with (I've used an old screwdriver). Not the best or safest, but works. You might also check the condition of the cable running from the solenoid to the starter. It might look fine but be corroded or otherwise compromised inside.
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Re: Honda TRX200 Help

#5

Post by desertrefugee »

It could also be working fine and supplying the positive voltage to the starter. But, if the ground side is somehow lacking, you'd get the same symptom. Check for any motor to frame ground "straps" or similar if the motor has been swapped. It'd be easy to miss something.
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delling3
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Re: Honda TRX200 Help

#6

Post by delling3 »

I’ve checked that there is a good ground to the starter housing. When I jumper. Direct from the battery positive terminal to the starter, the starter does turn.
delling3

1979 Yamaha XS750SF

Previous:
1978 GL1000 - JUNE 2017 BOTM: Sold
2006 Kawasaki Concours: Sold
1995 Kawasaki Concours: Crashed/totalled.
1976 GL1000: LAST RESTORATION, sold
1981 Honda CB900F Supersport: 3rd restoration, sold.
1979 Yamaha XS-750F: 2nd restoration, sold.
1982 Honda FT-500 Ascot: First (only) new bike. Family forces sale.
1973 CB500 Four: First restoration, long gone.
1972 Suzuki TS-100: First bike, sold.

Only dead fish go with the flow . . .
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