chopper dies after about 3 miles, sets for 5 minutes and starts back up

[8ball]

looking for opinions , I am thinking possible brake in coil winding that cools and reattaches till it heats up again. Electrical is not my strong suit.I'm gonna start it up with some fans on the motor and let it idle till it quits and see if I can prove my theory am looking at all connections for looseness.going to check the kill switch for possible damage, that's a longshot but grasping. Any input will be well recieved. Thanks in advance.

 

[Rottweiler]

Sounds like you are on the wright path. Probably the coil.

 

[Mr. Wright]

I belive your bike may have a crank sensor. Located front of the engine, next to where the stator plug is. If I remember correctly, you have a 117, but I don't recall if the 04 117's still have a cam sensor, or crank sensor.
Your problem sounds like a crank sensor over heating.

 

[8ball]

I belive your bike may have a crank sensor. Located front of the engine, next to where the stator plug is. If I remember correctly, you have a 117, but I don't recall if the 04 117's still have a cam sensor, or crank sensor.
Your problem sounds like a crank sensor over heating.

I will investigate that first, not much to change that, thanks for the input

 

[Mikeinjersey]

I will investigate that first, not much to change that, thanks for the input

Mr. Wright is leading you in the correct direction. If you have a crank sensor try cleaning it and look for damage like cracks. Do the same if you have cam sensor. If you see no obvious damage unfortunately, the best way to troubleshoot this issue is to replace the crank/cam sensor with a known good one or last choice a new one.

 

[8ball]

I belive your bike may have a crank sensor. Located front of the engine, next to where the stator plug is. If I remember correctly, you have a 117, but I don't recall if the 04 117's still have a cam sensor, or crank sensor.
Your problem sounds like a crank sensor over heating.

I looked the motor over and don't see a crank sensor so I don't think it has one. Not sure about the cam sensor would it be seperate from the pick_up inside the cone?

 

[Jersey Big Mike]

Cam semsor is more prone to failure than a crank sensor is in my experience.
The cam sensor IS the PICK UP in the cone.

 

[Mikeinjersey]

I looked the motor over and don't see a crank sensor so I don't think it has one. Not sure about the cam sensor would it be seperate from the pick_up inside the cone?

You most likely have a cam sensor. If you inspect it make sure you mark it's location as you will see it's adjustable.

CAM SENSOR [000-00175-22] - $59.99 : WSW, Rule Your Ride!

WSW CAM SENSOR [000-00175-22] - Cam Sensor for all 04 and older BDs with. JST connector installed for direct connection.

wildsteedworx.com

https://wildsteedworx.com/index.php?main_page=product_info&cPath=68_173_82_295_298&products_id=1411

 

[Jersey Big Mike]

I looked the motor over and don't see a crank sensor so I don't think it has one. Not sure about the cam sensor would it be seperate from the pick_up inside the cone?

If you want an easy test, start bike and run intil it dies.
Immediately put a bag of ICE on the cone where the cam sensor is and it it restarts sinificantly sooner (less delay) then thats it.
We used freeze spray to pinpoint heat failures on computer boards back when I did production testing of computer memory systems meant for large machines.

 

[8ball]

wished I would have seen this earlier, ordered the coil wasn't it ordering the sensor now new coil can.t hurt, was in Minnesota for my brothers wifes funeral is why I haven't been back on about this. As always thanks for all comments and advice enjoy whats left of the summer

 

[SCC007]

Condolences on the loss! It's not bad to replace the coil anyway...one more thing to check off the culprit list. Out of curiosity have you checked the fuel when it dies...something plugging the petcock screen (liner failing etc.)?

 

[Sven]

Crank sensor. This creates the spark to occur. Cam sensor would run, but more turns of the crank to override the sequence of who's on first.

 

[Chief Boomer]

Condolences on the loss! It's not bad to replace the coil anyway...one more thing to check off the culprit list. Out of curiosity have you checked the fuel when it dies...something plugging the petcock screen (liner failing etc.)?

To be honest when I read the beginning of this thread I fuel flow was my first thoughts. If he has a carb.

 

[tcrowelljr]

I belive your bike may have a crank sensor. Located front of the engine, next to where the stator plug is. If I remember correctly, you have a 117, but I don't recall if the 04 117's still have a cam sensor, or crank sensor.
Your problem sounds like a crank sensor over heating.

04 117's have Cam Sensor

 

[Savage 1]

Just another round of BS - how to test cam sensor?

Well, tidied up the last bit and tried to fire up the dog and just cranks. I think it is in the ignition. New RIP 04 107 stock TH ignition with CAM sensor (not crank). When you turn the power on the ignition module red LED goes on and stays on. If memory was correct the red LED should go...

www.bigdogbiker.com

 

[Savage 1]

I can't verify accuracy of the above information.

I can share, my sensor was melted and visible. Had the same symptoms.

There is a bunch of information in the thread listed above. Hopefully, something will be helpful and be applicable to your issue Boss.

 

[Savage 1]

Keep in mind, resistance testing often produces inaccurate results. However, generally speaking, sometimes an obvious open circuit will confirm the issue.

I prefer dynamic testing. I believe it is a hall effect sensor. If I were testing, I would be looking for voltage most likely a (5 volt reference) on the signal wire while engine is turning.

Like Big Mike mentioned, the fastest and easiest method is use one off the shelf. However, sometimes we don't have a spare.

The service manual doesn't provide a lot of detail in these situations, so we have to rely on information from friends here or past experience.

Hopefully, these ideas spark ideas from others and they may have better specifications or feedback.

 

[Jersey Big Mike]

Keep in mind, resistance testing often produces inaccurate results. However, generally speaking, sometimes an obvious open circuit will confirm the issue.

I prefer dynamic testing. I believe it is a hall effect sensor. If I were testing, I would be looking for voltage most likely a (5 volt reference) on the signal wire while engine is turning.

Like Big Mike mentioned, the fastest and easiest method is use one off the shelf. However, sometimes we don't have a spare.

The service manual doesn't provide a lot of detail in these situations, so we have to rely on information from friends here or past experience.

Hopefully, these ideas spark ideas from others and they may have better specifications or feedback.

When I return from Arkansas I will be working on a cheap to build test device that will test wiring, handlebar switches and cam/crank sensors
I am open to any other testing people need/want.
I will be releasing this as an open source hardware/software project -- I don't want to be in business building these although I might do a initial run of 10-20 if there is interest and I can keep the cost down low enough.

 

[Savage 1]

Sounds great Mike! Let us know if ya need any input. Like you, I'm so busy working on things, time is the issue.

However, the need is there for testing devices. Most people don't go down the electrical rabbit hole. They just want to ride.

Anything we could do to help them save a few bucks would be an awesome contribution.

I know there are some members that have electrical engineering degrees that could also contribute to the cause.

Great idea Boss!

 

[JohnBoy]

You could also rent the tester out for either a fee or for shipping costs. Businesses would benefit from this that would be your main market but I for one would like to have one.