2005 Chopper Keeps Stalling

Energy One
CA Chopper

CA Chopper

Member
Has been in & out of the shop for the past year and we just can't find the problem. :bang: Dog will occassionally shut off while crusing. No sputtering - it just shuts off. Once the Dog stalls, turn off key and restart with no problems. May or may not happen again. Have already changed the coil and ignition module. Changed jets along with addition of Big Radius exhaust. Dyno shows fuel is mix is right. Carb was torn down and was clean. Did notice this time (as I was riding at dusk) the Tac would flash from dim to bright for a few minutes before it shut off. After I restarted, no flashing. I believe I have a good mechanic and he has been talking with BDM, but still no resolution. We're at a complete loss... Any ideas?
 
B

bushman

Active Member
Do a search for resistor on here. N8KAM and I had similar problems. Is your EHC an up to date one, if not there is an in-line resistor under the coil cover. N8KAM posted a pic of it in his thread. My bike would shut down like your describing, took the resistor out, no problems since.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
bushman said:
Do a search for resistor on here. N8KAM and I had similar problems. Is your EHC an up to date one, if not there is an in-line resistor under the coil cover. N8KAM posted a pic of it in his thread. My bike would shut down like your describing, took the resistor out, no problems since.
Click to expand...
That is what I would say

being its a 2005. You replaced your EHC. Did you check under your coil mount and see if you had the pigtail resistor still hooked up to the ignition key. See below link for more info
http://www.bigdogbiker.com/forums/technical/4664-little-diag-help.html#post74611


It was a fix for the older EHC but is suppose to be removed when you installed a new style. A repair or band aid for the old version that is not need and will cause problems with the new version. If you have this. I'll bet ya its the problem!
 
Roaddawg

Roaddawg

Well-Known Member
I had the same exact thing happening on my 2005 chopper last year. Cruising along and the engine dies out. Would usually start right back up by recycling key or just hitting the run button and letting it jump start. I spoke to my service tech at Fury Motorcycles in Saint Paul, and he knew what it was immediately.

It was a small short in the tachometer board. A tiny wire had broken off, but was still in contact with the board. The bike would start but for whatever reason, vibration just right, bump, the way the handlebars would be turned, the wire would lose contact for a moment and cause the stall. It was fixed under warranty (even though bike was 5 years old and 20K miles) quickly on the spot and haven't had a problem since.
 
RRRUFF

RRRUFF

Well-Known Member
Ignition switch baby!:D Mine did the exact same thing last summer. I put in a HD switch, problem gone.:2thumbs: Could be any of these other problems stated above but my $ is on the switch.
 
T.Byrd

T.Byrd

Well-Known Member
Do you all get the horn beep and the flashers flashing when yours dies like this, mine does. I tried finding mine for months and it has been in the shop for about 5 weeks now and they still havn't found it. Im ready to burn it down, and start over.
 
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