200 cc starting issue

bucannon · 02-02-2014, 11:34 AM

so my bike was sitting outside under a buddies porch for about a year with a flat tire. i finally replaced the tube and got it rolled into my garage. I bought a new battery and rebuilt the carb.

so when i go to crank it with carb cleaner to see what its going to do after a year, the main ground wire melted off the insulation. i quickly turned off the key and replaced the ground with a wire of the same gauge.

only when i hit the starter button does the circut get hot. otherwise all my lights, horn, etc still work. I assume it is a bad starter solenoid but not sure yet.

anyone have any suggestions? I have a Fluke multimeter and lots of other electrical diagnostic equipment to use, i dont know what else i can test.

bucannon · 02-05-2014, 06:44 PM

I was able to fix it!

The issue was a corroded ground to the battery box. so i took it off and cleaned up everywhere that the bracket contacted the frame. then i tested it by only connecting the ground wire to the battery, then using the multimeter, i placed the red probe on the positive battery terminal and the black probe on various places on the frame/ engine block.

I had 12.7 volts all around. and it cranks and runs with no hot wiring!

now i have to tune the carb..........

SpudRider · 02-05-2014, 09:29 PM

Good work!

FastDoc · 02-05-2014, 09:41 PM

Good work. No better feeling than a free fix!

Weldangrind · 02-06-2014, 11:04 AM

Nicely done.

02-02-2014, 11:34 AM	#1
bucannon Join Date: Nov 2011 Location: Galveston, TX Posts: 63	200 cc starting issue so my bike was sitting outside under a buddies porch for about a year with a flat tire. i finally replaced the tube and got it rolled into my garage. I bought a new battery and rebuilt the carb. so when i go to crank it with carb cleaner to see what its going to do after a year, the main ground wire melted off the insulation. i quickly turned off the key and replaced the ground with a wire of the same gauge. only when i hit the starter button does the circut get hot. otherwise all my lights, horn, etc still work. I assume it is a bad starter solenoid but not sure yet. anyone have any suggestions? I have a Fluke multimeter and lots of other electrical diagnostic equipment to use, i dont know what else i can test. __________________ 2008 200cc dirtbike
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02-05-2014, 06:44 PM	#2
bucannon Join Date: Nov 2011 Location: Galveston, TX Posts: 63	I was able to fix it! The issue was a corroded ground to the battery box. so i took it off and cleaned up everywhere that the bracket contacted the frame. then i tested it by only connecting the ground wire to the battery, then using the multimeter, i placed the red probe on the positive battery terminal and the black probe on various places on the frame/ engine block. I had 12.7 volts all around. and it cranks and runs with no hot wiring! now i have to tune the carb.......... __________________ 2008 200cc dirtbike
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02-05-2014, 09:29 PM	#3
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Good work! __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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02-05-2014, 09:41 PM	#4
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Good work. No better feeling than a free fix! __________________ Happy to serve.
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02-06-2014, 11:04 AM	#5
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Nicely done. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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