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9 Posts
Hi guys. Leave it to me to have a strange issue...I have a 1980 200 Twinstar. It has been starting and running since I got her, but ran bad, would only give me about 40 mph. I decided this winter to put her on the operating table. The carb/fuel system was absolutely nasty and contaminated. Got all that corrected. Check...The bike didn’t have a horn installed. I have a 6V Honda horn, so I put it on there. Once connected, my electrical system went to hell in a hand basket. With the horn connected, when I turn the key on, I BARELY get a dim neutral indicator, and nothing else. No spark, no run, no horn, etc. disconnected the horn black wire, and lights, starter, etc work as they should, but now still no spark. I stripped the bike down, exposed the entire wiring harness, and checked that everything was connected where it should be per the wiring diagram, cleaned all the ground connections with a scotch-brite pad on a die grinder, Ohmed the grounds with a VOM, installed new plugs, cleaned the points, and using a small battery charger, my battery is holding 7.14 volts during all my checks. Before all this, it would start the instant the button was pushed, or with one kick. Main fuse is good to go, all wiring was checked visually from end to end, connectors checked for corrosion. I can’t figure out what I’m missing, and I can’t imagine that connecting a horn (without even pushing the button) would kill my coil. I felt confident that cleaning the fuel system, would give me good running bike to enjoy remembering my childhood memories, it’s deflating to say the least. I have an aircraft shop, and am no stranger to odd electrical gremlins, but this thing has me floored! Any help is greatly appreciated.