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TLR200 CDI and Coils Replacements

Posted: Sat Apr 29, 2017 7:40 am
by Julz
Our TLR200 has no spark. Mechanic has checked with multi meter and says that the primary coil is dead (no reading at all) and that the CDI unit is possibly fried (low ohm reading on a swapped out coil). I know very little about this stuff, so looking for recommendations please. Are there aftermarket solutions that work? XR200 parts seem far more readily available - would they work? It all seems a bit strange that all 3 core ignition wiring components have died at the same time. We are in New Zealand, so fewer classic parts suppliers.

Re: TLR200 CDI and Coils Replacements

Posted: Sat Apr 29, 2017 8:17 pm
by joey
Hi
I fitted TLR200 engine into an xr200 frame had to change all electrics xr 12volt TLR 6 volt. bought the engine and all the electrics through Import Monster https://www.importmonster.com.au/

Re: TLR200 CDI and Coils Replacements

Posted: Tue May 16, 2017 8:53 pm
by sharvie
You can get all sorts of used tlr200 parts here

https://auctions.yahoo.co.jp/search/sea ... =0&fixed=0

Re: TLR200 CDI and Coils Replacements

Posted: Thu May 25, 2017 4:21 am
by Julz
Our mechanic advises that the pulse generator (pick up coil) next to the stator has died. I have contacted wreckers across the UK, USA and New Zealand with no luck. People in western countries just don't seem to wreck TLR's. Apparently the part (no. 30300-kj2-154 or 30300-kj2-671) is unique to TLR's or TL125's with CDI, so other Honda or generic pit bike won't fit). I have also searched through every listing on Yahoo.jp and importmonster.com.au, but I have not found any listings with stator parts of any sort.

Any other ideas please?

Re: TLR200 CDI and Coils Replacements

Posted: Thu May 25, 2017 6:56 am
by David Lahey
get the pulse coil rewound

Re: TLR200 CDI and Coils Replacements

Posted: Sun Jun 04, 2017 11:49 am
by Julz
We have struggled to find a rewinder in NZ who does smaller sized motorbike coils. Most of the contacts that our mechanic (who specialises in older bikes) has used have passed away. We have found a guy who does rewinding for vintage machinery, but the pulse coil is a lot smaller than he is used to working on. He says he will give it a go, so wish us luck.

Re: TLR200 CDI and Coils Replacements

Posted: Sun Jun 04, 2017 12:35 pm
by tat ty
July

Small Coil Rewinds in Geelong Victoria. That's what they do.

Google it.

Alastair

Oh ... look back at a few of Gregs clues.

Re: TLR200 CDI and Coils Replacements

Posted: Sun Jun 04, 2017 3:19 pm
by Julz
Thanks for that Alastair

Re: TLR200 CDI and Coils Replacements

Posted: Mon Jun 05, 2017 10:43 am
by Tony27
Closer to home Julz there is a guy in Auckland who may be able to help, can't remember his details but when I talked to him about a Sherco stator he said he'd done a lot of other trials stuff
From memory we didn't proceed due to him saying whichever coil was the problem had the thinnest wire he'd ever seen & he couldn't justify attempting a repair due to how busy he was
I'll see if I can find his details

Re: TLR200 CDI and Coils Replacements

Posted: Tue Aug 01, 2017 7:12 pm
by Julz
An update on our :Honda: TLR200...

We contacted Small Coil Rewinds in Geelong, but they said that they had never done one like that before. At the same time we had been researching other options and found a couple of threads online that suggested that we could swap out the camshaft for one off an ATC200 with the pulse trigger on the end.

Sure enough the cam and trigger bolted straight in and with a small re-wire for the different location of the pulse trigger (and using the CDI unit from the ATC) it ran. The slightly larger cover on the end of the camshaft was not noticeable when riding.

It would seem that the cam profile is slightly different - and this may contribute to a slight hesitation when giving the bike a fistful of throttle off idle. However, it was good enough to be ridden at our classic trial on Sunday.

We will also look at stripping the carb down and checking the jets, as the bike has not run for dome months.