Tlr250 - Stator/flywheel/cover/pick Up Info Needed

[ttproducts]

Hi - and thank you for reading my desperate ramblings...

I've got a TLR250, the stator is missing.

The flywheel is 117mm o/d, 86mm i/d and 36mm deep.

The ignition cover has 2 stator mounting holes 40mm between centres. The stator mounting 'face' has a 30mm diameter lip, approx 4mm deep.

The bike had no stator when I got it so I have no idea what it should look like.

I have parts lists for the 200 Reflex (partzilla) but nothing at all for the 250 or trials version of the 200.

The 200 Reflex has stator coils with lighting and also has 3 mounting screws. That stator and matching engine case are available used from the USA.

The questions then:

1. Does anyone have a photo of the TLR250 stator set up and measurements (just to confirm I have the 250 flywheel fitted)

2. Does anyone know if the Reflex stator will fit inside the TLR250 flywheel (and work)?

3. Do the Reflex and Trials 200 have the same, 3 mounting screw, stator and side cover?

4. Has anyone used a different pulser coil or does anyone know where they're available? I'd prefer to use the crank trigger than mess about with the camshaft version.

5. Does the Reflex used the same, big flywheel with bigger crank taper size?

6. Has anyone changed the left crank half (or full crank) to a standard SOHC Honda version (XL etc) and how was the bike afterwards?

7. Has anyone discovered any other stator that fits - chinese engines, Honda ATV etc?

And on an aside - inlet stubs; is there another Honda version that'll fit the TLR head/carb?

Any help at all will be very much appreciated.

Cheers,

Clive.

Edited January 20, 2015 by ttproducts

[esteve]

Here is what I know:

 

1. Photos below and the measurements I have made are OD = 117mm (at the outside edge; the back of the flywheel steps up to a larger OD =122mm), ID = 86mm, internal depth = 40mm (from highest outer ridge to inside surface) - the flywheel is part filled with oil as I had turned the engine on its side and removed the cover. The maximum height from the centre boss is 168mm (from the edge is 165mm). The rear of the flywheel is stamped:

 

KOKUSAN JAPAN      FP5175  4E

 

• In a document entitled "On the problem of the XR200" (and#169;Nov 2002 Vincent Crabtree) - Google it - it states the Reflex Flywheel ID is 86mm and the OD is 126.8mm but the ID of the cover at the edge where it mates with the crankcase is 124.5mm which isn't consistent. In the same article it lists the weight of a Reflex flywheel as 2.4kg (I cannot confirm this) and the TLR200 as 2.85kg (my scales show 2.845kg)- . The article is however very interesting if you are interested in Honda singles of 100 to 250 cc based around the same design.

 

 

 

TLR200D and TLR250F stators are shown in the parts books as having 4 poles for windings; the Reflex has 8 poles. In the image above you can see the 4 poles but there are only 3 windings on this stator; the engine is an ME07E but of unknown provenance. Perhaps the absence of windings on one pole is because the TLR250F does not have a battery?

 

TLR200D and TLR250F only use 2 mounting screws (at 1 o'clock and 7 o'clock in the picture above) for the stator compared to 3 on the Reflex. You can see a screw head at 4 o'clock but that screw secures the wiring harness. The empty 4th hole in the stator is just that, an empty hole; there are only 2 stator mounting points in the side cover. The stator is stamped '4L' (or 4E?) by the screw at 1 o'clock.

 

N.B. the image of the cover and the stator is inverted; when I removed it I turned it over to photograph the stator so the top of the case in the image would be the bottom when mounted - in other words the pole with no winding will be at the bottom when the case is mounted on the engine.

 

3. No, 3 screws for Reflex and 2 for TLR200D and TLR250F. Below are images for a Reflex generator cover; they look the same as a TLR200D/250F from the outside!

 

 

 

5. The Reflex flywheel is different to the TLR250's. The TLR200D flywheel is the same as the TLR250's.

 

Reflex models (USA) have different part numbers for Flywheel, Stator and Pulse Generator compared to the TLR250F and TLR200D (the unrestricted/no emissions equipment model with 35mm forks and alloy rims commonly found in the UK). Part numbers for TLR200D and TLR250F Flywheel and Pulse Generator are identical.

 

                             Flywheel                Pulse Generator              Stator                    Generator side cover             C.D.I.                    Ignition Coil

TLR200 Reflex    31110-KJ2-671      30300-KJ2-670 or 671      31120-KJ2-671      11341-KR5-000  (3 screws)    30410-KJ2-670    30510-KJ2-670 or 405

TLR200D             31110-KJ2-003      30300-KJ2-154                 31120-KJ2-003      11341-KJ2-000  (2 screws)     30410-KJ2-003     30510-KJ2-000/3

TLR250F              31110-KJ2-003      30300-KJ2-154                 31120-KR9-003     11341-KJ2-000  (2 screws)     30410-KR9-003     30510-KJ2-000

 

This is a Reflex flywheel and stator:

 

Compare the back of the Reflex flywheel with a TLR200D's:

 

This is the front of a Reflex flywheel:

 

 

It appears (by looking at the headlight bulb voltages) that the electrics use different voltages for lighting depending on the model:

 

                                                               Rectifier

Reflex        12volt lighting

TLR200D     6volt lighting

TLR250F    12volt lighting

Edited April 20, 2015 by esteve

[ttproducts]

Thanks for all that info esteve

I've been busy with other stuff, just got back to this. I've just picked up a complete TLR200 engine so I'll do some more comparing. I now have 2 engines (a 200 and a 250) with only one stator but with the info you've put on here and the full engine I'll be able to figure what fits.

I'll add photos of what I have as and when I can.

Something I have noticed is that whilst there are a few stator/flywheel/cases for sale on ebay (USA) there's hardly ever a pulser coil - are they known to be problematic/prone to failure? Has anyone successfully fitted a pulser from a different bike? I have quite a few which I can tinker with but a known working solution would save a lot of faffing.