84 200ES puzzler

[scallop]

Have an 84 200ES that is giving me fits. Ran fine for awhile after I bought it then died on me. Tried to restart, but nothing. Fiddled with ignition key switch and refired. Ran fine for a week or so then died again. Bike would do nothing at all when elec. start was pushed. Replaced recoil rope, entire key ignition switch and ran down wiring, replaced quite a few bad splices and melted sections that had been repaired by previous owner just taping over the bare wires. Started just fine a few times then did same thing. Pulled recoil rope, started right up, so I shut off and hit elec start switch and started right up again. Now it does this on a regular basis. Turn on key and main power switch, hit the button and nothing, just like hitting button with key off. Pull recoil a time or two and electric start works just fine. Anyone have any pointers or quirks that I am over looking? Hate to have to replace entire wiring harness, ect. until I hit on the problem area. The ignition swich was replaced with a brand new switch from Honda.

[Mr.Jake]

start by checking all your grounds, if the key to on, and turn on your lights do they come on, but the start button does nothing? If this is the case maybe your starter fuse isn't seated properly, or check the wires coming out of the flywheel housing, i have a wire there on mine that rattles lose, and completely disengages the electric start.

[scallop]

well, the bugger did it again. and yes the light comes on and start button is dead. i will check the 2 wires coming off the flywheel but what do you mean by starter fuse. i am only aware of 2 fuses on my bike, both are at the rear on the lt side by battery. is there another one coming off the starter?

[Bryan Raffa]

so it fires by pull starting it..poss. bad brushes in the starter..

[scallop]

yes it fires by pull start, or if i pull it a couple times and it does not fire the start button will work, bike then starts and runs fine

[TeamGeek6]

"replaced quite a few bad splices and melted sections that had been repaired by previous owner just taping over the bare wires."

There you have it. more junk Honda wiring. Youll have to go through EVERY connection, especially on the CDi. "Cleaning" them is useless.