ATC200ES CDI Replacement, Sticky?? Been asked a lot lately.

[kb0nly]

This has come up a lot lately, so i will document it quickly here so i don't have to post this over and over anymore... LOL

Here is a picture on this page with a wiring diagram for changing the plug over to the newer style. You can buy the connector from him but it doesn't have the correct latch on it, i have a better source for those, the CDI unit from his is $19.99 but they can be had a lot cheaper as well, or order from him as i have bought a couple of his and they are just as good quality.

http://dratv.com/cdiunatseeap.html

Ok for the connector go here...

http://www.vintageconnections.com/

On the left side click Price List, then on the right scroll down about half way and look for HP6L Latching Set
White Nylon, its the 6 pin connector. Order a set of those and now you have the correct connector.

The CDI is called a 5 Pin CDI, yes there is six positions but only five contacts, the picture at DR ATV explains the wiring just wire the connector as he has it, the one wire is no longer used and so just gets pinned into the open position.

Here is the cheap ones i buy, they have been VERY reliable and durable. No problems.

EDIT: The previous seller's CDI's seem to be having issues now, the ones with the Green connector seem to have become unreliable. The ones i am trying now have a Brown connector, tested one today it works great. So not sure whats going on, bad batch maybe, or they changed somehow. These Brown connector ones are Shindengen brand, name molded into the bottom, and these are the brand i have seen on many Honda products. So for now i am changing my supplier!

http://www.ebay.com/itm/151107921202?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

If you have any questions or problems feel free to ask. I have put these cheap CDI units on a few 200ES's including my own i use almost daily. It will work on virtually any ATC model or year that has the square connector or can be changed over to the correct connector. I have put these on 185s, 125M's, and a multitude of 200 models. I think the CDI is going to be a common failure point due to age of the components inside it, electrolytic capacitors don't last that long with the conditions these see, and 20+ years is a good stretch for sure!

[tripledog]

I hereby nominate this info for a sticky. Saved me a bunch of cash and frustration!

[GTO]

I hereby nominate this info for a sticky. Saved me a bunch of cash and frustration!

+1

All 4 of my 200es now run beautifully after fitting chinese CDI units.

[Scootertrash]

I third the nomination for a sticky. The plug and connector kits info handy for many electrical applications besides three wheelers too. Excellent info!

Thanks kb!!

[tripledog]

I discovered that there is no need to use the new crimps on the 200es wiring harness if the originals are still in good condition. Merely hammer a piece of wire or a paper clip flat enough to fit into the stock wiring harness connector, release the barbs that hold the stock crimps into the stock connector, and re-insert the crimps into the Vintage Connections connector. Works like a charm!

[tri again]

The way things are going, I'd perfer to beg KB to make one for me.
or sell kits.
Net connection here runs through fence wire and my close vision
soldering days are over.
Just a thought.

[tripledog]

What I was trying to say in my previous post is that there is no need to cut, crimp, or solder anything. And if you need the harness connector, I have a new one (bought an extra to make the minimum $10 purchase from Vintage Connections) that you can have. Then simply go to ebay and buy a cheap cdi box (mine was under $6, including shipping), and you are on your way.
Pm me your address if you want the connector. And I feel your pain regarding the slow internet connection!

[Scootertrash]

I discovered that there is no need to use the new crimps on the 200es wiring harness if the originals are still in good condition. Merely hammer a piece of wire or a paper clip flat enough to fit into the stock wiring harness connector, release the barbs that hold the stock crimps into the stock connector, and re-insert the crimps into the Vintage Connections connector. Works like a charm!

Funny you should mention this. I've done the exact thing many times on various vehicle connectors, mostly bikes and ATVs

[kb0nly]

Yes you can move the contacts to the new connector, very good point! Usually the ones i have been working on the contacts are corroded or dirty or someone has tried tightening them up a couple times thinking it was just a bad connection, etc.. So i generally just remove all the contacts from the original plug so i can cut them off leaving the max amount of wire left.

I was thinking of making a sort of kit for sale on here and ebay but i don't know how many units i would sell, the other problem is how do you make it any easier? If i could find the male round connector on the CDI as an inline connector i guess i could make an adapter to plug onto the stock harness and plug into the new CDI but that would add a lot of wiring bulk. Another option might be a pigtail with the new connector on it, so you could cut off the original plug and splice the wires, but i don't feel thats as good as just replacing or reusing the crimps into the new connector.

So i figured the best option was show everyone how to do it so they can go forth! LOL

Thanks guys!

[tripledog]

The cdi swap seems like a daunting task at first, but is actually is quite simple (especially if you have someone else do the work for you, as I did). I read and re-read kbOnly's post several times, drew out a sketch, and gave it and the connectors to my friend. He told me that he removed the trunk to gain access to the cdi, but the actual cdi swap took less than 15 minutes to complete. I can't take credit for the info on being able to reuse the contacts, that was my friend's mind at work. And thanks again, kb! You are a credit to this forum.

[kb0nly]

You are welcome, just glad i could help as i get a lot of good info off here as well!

[ps2fixer]

if someone can find the male adapter for the cdi plug on the OEM harness, they could make quite a bit of money selling "kits" on ebay since anyone can plug in a connection, not many are willing to cut into wires on their beloved machines. I know there are a lot of amazing people on here that makes new parts, is anyone in the connector end business? I bet someone could sell the kits for easy $50 as new units with the adapter plug.

[kb0nly]

If someone can find a source for the CDI side of the round connector i can make the adapters, i have all the crimping tools here and it literally would take me a few minutes a unit to make them. I will start doing some research.......

[kb0nly]

Please note the edited link to the cheap CDI's in my first post along with the note about the change. Thanks!

[kb0nly]

Reviving an old post from the dead!!!

7 years later and today my CDI died... It was the one i put on this machine when i wrote this post. 7 years out of a cheap part is not bad in my book!! I had another in my spare parts so i swapped it and it started right up and i took off again. However, its not as easy to find more of these now. DR ATV still has them, but i don't see the exact same ones i bought on eBay anymore. I will see if i can find a more current source of these. In the mean time, if you need one DR ATV is your best bet, the ones he has work every single time i have bought one. The eBay ones are a crap shoot to get one that works right.