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Discussion Starter #1
Hi everyone I am new here. I have been working on a trx200sx that has spark issues. It will fire some times and not others. I tried drying out cdi box. it seemed like it helped but I am not sure. it would run for 15 to 20 minutes then die no spark. I put a new coil on it, it fired and ran great for about 5 min and then died. Now I am looking for ideas to get this going. Should I replace the cdi box? I hate to just keep buying parts without knowing what is bad. Does the neutral switch affect spark? the battery is dead. I am pull starting this. I have been told it could be the stator? Any info would be great! Does it run without battery? or does it need a good battery to run long term?
 

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It needs a good battery installed. A junk/shorted battery can overheat the alternator windings and the regulator/rectifier and destroy either of them quickly.

Put a good battery in it, then pull apart all of the plugs on the wiring harness and look for loose or corroded connections. Use some dielectric grease on each plug after cleaning them and make sure each and every wire terminal is snapping together firmly.

If the motor is still losing spark after replacing the battery and fixing up all of the harness connectors, try tapping on the CDI when the spark fails and the motor dies. If that tapping fixes it briefly, it likely has some cold/cracked solder joints inside the CDI. Replace the CDI (or fix it if you know how to) if thats the case.

You can get a copy of the FSM for your bike HERE.

Enjoy your work... and welcome to the forums!
 

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Discussion Starter #3
Thanks for the help! I am charging the battery overnight to see if it will take a charge. Do you know of any low cost cdi boxes that interchange with this bike? The trx250r cdi is much cheaper?
 

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You're very welcome! The CDI interchange list shows that 86-88 TRX200SX CDI's are the only ones that fit. They are obsoleted as you probably know... so used ones would be your only option if yours turns out to be failing. Don't try to buy an aftermarket because any of those will be china garbage, which will only force you to spend again for a used one.

I'd certainly go over the wiring harness (including grounds) first, before deciding to spend for one.
 
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