200 big red issues

[newfiebullet]

brother inlaw just grabbed a 200 big, hi/lo/rev...the 200es maybe? anyway its rough as hell but he bought it to beat on and the motor is solid. but were haveing some issues getting it to run good. after 1/4 throttle it just spits and sputters...progressively speed up a bit but not great...the more you shove on it the worse it gets. we did the usual tonight, cleaned carb spotless cleaned airfilter . then we put in a new plug and cleaned the petcock and gastank. slight improvement but nothing much. then pulled the muffler to make sure it wasnt the problem, screams nice but still sputters bad and can be heard much more easily haha. next on my list to try is a coil and plug wire...where to go from here?

[newfiebullet]

so an update, carb has been cleaned 3 times now, tank and all components twice, air filter again plug rechecked. finding today are much the same, plug wire has seen better days for sure...also what is the factory setting on the pilot screw it was set at 3.5 turns back so i put it there again also the little o ring inside was broken..still thre but broken...and to make sure the order...o ring washer spring screw?. i took a video..maybe it will help...sounds the same when driving.

http://youtu.be/uFhHzKlMSOk?list=UUjjR-IhwUd0s2oUgBjIry0A

[danbur55]

Try removing airbox lid. If that fixes anything youll have to chase out the varmint nest in the backbone

[newfiebullet]

so i pulled the "harness" apart...man what a hack job...deadends and bad connections everywhere and the wires coming from the head by the cam cover were reversed(green and blue)...cleaned and tided with new connectors and finished in split loom ...looks great and the bike now runs great, idles great and no more spittin and sputtering....however could use some info for 2 other issues, whats the process for adjusting the clutch( screw in tight and back 1/8 or the opposite) and gas is steady pouring out of the overflow, which part do i need to replace the floats or float needle or both?

[oscarmayer]

i would get a good sued harness off feebay for around $30 shipped or so and call it a day on the harness.
mixtgure screw shoudl onyl be 1-1/4 to 1-1/2 turns out 2 at max.
the jets coudl be worn. is there a reason you never rebuild the carb? the firs tthing I always do is rebuild the carb to all older bikes I get and then start from there with getting it running. for $15 you cna ge a rebuild kti with new jets and everything and then you can be 100% sure the carb is good and not worn includng orings and all.

[newfiebullet]

i have the harness cleaned up real nice and workin good now....previous owner had it butchered....no carb rebuild because he only got it the day i orignally posted, at that point we were trying free fixes lol. he said the hell with it and is ordering one of those zoomzoom carbs on ebay and entire rearend assembly...his goal now seems to be a mint drivetrain/engine with a bike that looks like crap lol. he only payed 100 bucks for it cause it was running like crap and the rear axle bearing are toast and the hubs are welded on..motor is nice, no smoke or ticks and dont leak a drop of oil.

[newfiebullet]

all the wire diagrams i look at show the regulator as a 4 pin , yellow X2 red and green, mine also has a black...where abouts would this go to? also i think the regulator is shot..on full throttle im getting 55-65 volts and 17-18 at idle...looking to add a headlight

[oscarmayer]

look at my sig you will find a link to factory service manuals for it there.

[thcowboy]

There is a user on here that makes harnesses i forgot his name at the moment but if its the 200 engine with a shaft and reverse its a 1984

[newfiebullet]

it is indeed a 84, managed to cleaned the frame tube enough to find it...this black wire is throwing me off lol

[thcowboy]

The guys name that makes harnesses is ps2fixer

[clmeue37]

it is indeed a 84, managed to cleaned the frame tube enough to find it...this black wire is throwing me off lol

Got my manual out and the only diagram showing the regulator with 5 wires is an 85 200m. Here's a pic of the diagram for the m if it helps any.

210228

[oscarmayer]

i see it showing 5 wires.
br= brown
b= black (missing this one?)
y= yellow
y= yellow
DG = Dark Green (usually grounding wire)

so the black does show on the photo and it apparently terminates to a BR/B wire.

[newfiebullet]

the regulator and the part of the harness that goes to the base must have come from a 200m...either way its throwing out 60 volts so i gotta find another one...harness is non issue now got it fixed and kill switch working. gas pours from the overflow on the carb as well...which part is the issue at hand? hes suppose to have a carb comming but it could be a few weeks to get it.

[newfiebullet]

ok peeps new problems lol...hard to narrow down with no spare parts to try....he managaed to get a 10 min ride, running good. then it slowly died and shut down and rolled to a stop. now it has 0 spark...where should i start looking?