To be fair, the boat canvas and industrial sewing machine thing started out as a similar project. I was trying to repair some outdoor gear like backpacks and stuff, and just ruining home sewing machines in the process, while failing to actually repair them. Found an old 1960s Upholstery sewing machine, in somebody’s basement for 250 bucks. Had to learn how to work on that to make it sew right. Figured it out for the most part, and started taking on side work. Grew into a full-fledged business that supports my interests, I rather enjoy it compared to every other line of work that I’ve done. My office:

Dang man all I can think is you should be a writer or editor of something because your prose looks better than that puzzle you've undertaken lol. Well at least you won't be suffering boredom for the foreseeable future. This is the first time I've laid eyes on a blaster since I was a kid ogling the atv mags so I don't have any technical input other than generic 2-stroke knowledge which isn't helping me explain what might be hung in your gears. Are you building this for you or to flip? If it were for me I wouldn't sweat the back brakes since I always take those off to save weight and complexity and they're fairly useless anyway. Did I mention I can bunnyhop my 230 with the engine off in the garage? Are there cheap chinese alternatives to wiseco? If so I might be interested. If the frame is bent they're not that hard to straighten. I have a pic of that somewhere. Well I guess I'll follow you to the yamaha board for your search for life.

Here is the wiring diagram for that machine. It'll help you trace out the fault. You say there is continuity on the start button , but is there power to it when in neutral and ignition on ? If not , trace back from there, if there is then check switch to relay and beyond until you find the break. Honda TRX 200 service manual 1984 - B. 1984 TRX200(1).pdf