Performance problems on a 83 Big Red 200E

[frenchy]

I have a Honda Big Red 200E that I've put a used engine in. The engine is the 200 with High/Low. I kept the same carb on the bike as it seemed ok.

I have boiled the carb, cleaned the jets, adjusted the pilot to factory, changed the coil, and even tried 2 different jet combos. I started with the standard 35 low and 95 high, then tried a 38 and 100. No difference. I have also verified and corrected the timing according to the manual. That improved the performance, but not to where it should be.

It idles fine, but when you jam the throttle it bogs down. If you slowly push the throttle, it revs up fine.

I'm at my wits end on this one. I won't even get into the issues with my 1984 200S at this point!

Can anyone help me get on the right track?

[3Wheeler]

Have you touched your Spark advancer? Set your valve lash?

[tripsvids]

Filter? No filter? Could be valves like 3wheeler said.

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[polaris_dave]

Check the intake manifold (carb boot) for cracks. Could be running lean. How about needle clip position?

[frenchy]

Originally Posted by 3Wheeler

Have you touched your Spark advancer? Set your valve lash?

I didn't try to advance the pulser (if that's what you mean) and I've done one valve (I screwed around with it before putting the engine in.) the other one is going to be hard to get to, but I"ll check it.

Originally Posted by tripsvids

Filter? No filter? Could be valves like 3wheeler said.

I have the mesh filter on with no foam. I've tried with the cover right off and doesn't make a difference.

Originally Posted by polaris_dave

Check the intake manifold (carb boot) for cracks. Could be running lean. How about needle clip position?

I put the carb boot from another engine on and it was crack free. I didn't look at the clip, but a buddy did and he said it was in the center gap. I'll check again though.

[frenchy]

Another item worthy of noting: it seemed to backfire a bit when I pump the throttle in and out fast

A bit more background information: I had previously installed a 200S engine on this chassis with the same carb and it seemed to work like a champ. So valves and timing are the only things that I can think of that could be screwing this up...

[TRX 500]

on some I can't remember which ones there is a screen filter in the fuel on/off/reserve switch under fuel tank which comes apart with 3 philips screws I believe, sometimes get plugged up...a little more info..is it bogging, revving out..sputtering??? Right spark plug?

[3Wheeler]

I also check the O-ring between the intake and the cylinder head.

[polaris_dave]

I would try dropping the e-clip on the needle one step, which will raise the needle up and make it richer. If it runs better, then you know that you have a lean condition. Throttle response as you describe sounds like a lean condition.

[frenchy]

Originally Posted by TRX 500

on some I can't remember which ones there is a screen filter in the fuel on/off/reserve switch under fuel tank which comes apart with 3 philips screws I believe, sometimes get plugged up...a little more info..is it bogging, revving out..sputtering??? Right spark plug?

I was thinking about the petcock valve last night. I'll try that tonight. Plug is right, just replaced.

Originally Posted by 3Wheeler

I also check the O-ring between the intake and the cylinder head.

This is good, ring is still round and protrudes the face of the carb

Originally Posted by polaris_dave

I would try dropping the e-clip on the needle one step, which will raise the needle up and make it richer. If it runs better, then you know that you have a lean condition. Throttle response as you describe sounds like a lean condition.

Sounds good, i'll move that tonight.

[timmytorco]

You do a compression test?

[frenchy]

Originally Posted by timmytorco

You do a compression test?

Not formally. We found it was a bit weak, but after we adjusted the valve it improved a lot. I need to get a tester...

[3Wheeler]

Originally Posted by frenchy

Not formally. We found it was a bit weak, but after we adjusted the valve it improved a lot. I need to get a tester...

If it idles fine, then it will run. I've seen them run in pretty rough shape. Where do you live? I might come check it out.

[frenchy]

Originally Posted by 3Wheeler

If it idles fine, then it will run. I've seen them run in pretty rough shape. Where do you live? I might come check it out.

I fired you a PM

[frenchy]

So I tried everything in this thread. Nothing has seemed to make a difference. I'm tempted to put in the other 200 engine that I have just cause I know it worked fine. Now i'm concerned that I've messed with the carb so much that even that engine won't work.

[frenchy]

UPDATE: So I was looking through the manual and notice that there was a key piece of my camshaft/CDI that was missing... there is a little dowel that prevents the pulse generator from spinning. So I grabbed one from another engine that I had and put everything back together. Now, it idles nice but running it full out I need to have it at half choke. Any ideas for that? The jets in there right now are the standard 35/95. Thinking I better do a real compression test and make sure I don't have issues internally.

[tripsvids]

Originally Posted by frenchy

UPDATE: So I was looking through the manual and notice that there was a key piece of my camshaft/CDI that was missing... there is a little dowel that prevents the pulse generator from spinning. So I grabbed one from another engine that I had and put everything back together. Now, it idles nice but running it full out I need to have it at half choke. Any ideas for that? The jets in there right now are the standard 35/95. Thinking I better do a real compression test and make sure I don't have issues internally.

If you have to run it at half choke full throttle to get it to run right then your jets are plugged. Clean the carb as well as making sure its getting the right amount of fuel.

[frenchy]

Originally Posted by tripsvids

If you have to run it at half choke full throttle to get it to run right then your jets are plugged. Clean the carb as well as making sure its getting the right amount of fuel.

It's compression. I had boiled the carb, cleaned the jets with cleaner and a wire... I just did a compression test and i'm reading 95 psi consistently and the spec is 156 psi for that. Shit.

[polaris_dave]

Originally Posted by frenchy

It's compression. I had boiled the carb, cleaned the jets with cleaner and a wire... I just did a compression test and i'm reading 95 psi consistently and the spec is 156 psi for that. Shit.

Wow, I didn't think the compression was that high. I guess that explains the decompression lever for starting. Well at least you finally found the problem!

[frenchy]

Originally Posted by polaris_dave

Wow, I didn't think the compression was that high. I guess that explains the decompression lever for starting. Well at least you finally found the problem!

A friend of mind thinks that I should try some bigger jets. I might give that a shot or drill out the spare ones I have and see if that does anything before I rebuild the valves.