Help!!! What ya think problem is??

[HuskerChop]

I just started getting this problem on my 07 Chopper. Riding along and bam, motor shuts down just like you hit the kill switch. Sometimes I can cycle the ignition switch at speed, rehit the run switch and it will take off. Sometimes it might not take off first time but after several tries of doing this it will. Sometimes runs perfect and sometimes its off n on off n on, just like it is only firing on one cyl every other time. Really weird is the motor at low rpm, and throttle roll on, the motor sounds like it is pinging terribly. Very tinny noise that seems to go away with as rpm climbs. Running same gas as last year and no problems then, 91 or 92 octane. I am running the aftermarket thunderheart adjustable ignition and it is set moderately in the middle of the range. I have not pulled over and removed seat to see if the ignition LED is still on, will try that but I still have all my lights and speedo, all else is normal. I did install the dakota digital speedo this past winter. Let me know ur thoughts! Thanks

 

[narow37]

sounds like the ignition switch to me. anyone else got an idea

 

[HuskerChop]

Ok heres the latest. I checked all wiring and connections, removed connectors from ECM and cleaned and covered with fresh Dow DC4, cleaned battery connections (kinda corroded), disassembled r/h control and inspected. All seemed fine. Test drove and the POS quit 11 times in about a mile. Every single time the Ign LED on the EHC was lit at all times, here's the weird part, the ignition pulse light on the Thunderheart would be on when the motors quit and leaving the motor in gear and still rolling, as I would slow down you could see it start to pulse with the #1 cylinder, but motor still would not run. When bike came to a stop, the ignition box LED would be on solid. The other times when the bike quit, the thunderheart light would go out and remain out till I cycled the run/stop switch. I made it home, changed the battery to an 9 year old harley and after finally got enuff juice to turn over and start, the bike ran perfect. No quitting, sputtering, backfiring, pingin, etc. The old battery would start the bike fine but had an issue running the bike. I know on aircraft magneto's we can run on a bench and when you install, run aircraft and starting pulling power, combustion pressure increases and that same magento will fail. anyway, hopefully got it with a battery! Let me know your thoughts still! Thanks!

 

[HuskerChop]

Sorry my reply was so garbled! Tryin to hurry and post as the ole lady was b1tchin me out for making alot of noise at this hour in the neighborhood!

 

[HuskerChop]

Well I changed the battery and same thing. When I hit start button, motor tries but will not turn over. Battery draws so low that alarm chirps. Alarm is wired directly to battery so I am changing starter. Hoping that starter soleloid possibly shorting internally causing problems. Dumbfounded at this point. Pulled spark plugs and motor turns over fine. Anyone ever have a thunderheart ign go bad? Almost like I have about 40 degrees adv at start.

 

[HuskerChop]

The latest, First I wired the power wire to the thunderheart direct to the battery completely bypassing the EHC circuit. Test rode, same thing bike died under heavy load accelerating, Thunderheart light extinguished and could not get back on. Unhhoked power wire(direct wire added to thunderheart) and reconnected to battery light came back on and started fine. This time also direct wired Thunderheart ign ground wire to battery negative. The Thunderheart is totally bypassing the EHC for both power and ground. Test rode same thing, died. Sometimes thunderheart light stays on, sometimes not. I spliced in my old stock ignition, test rode and bike ran perfect. No dying, sputtering and above all, no pushing back home! Couple questions has anyone ever had any trouble like this with the ASM5012 Thunderheart ign system? I still have some doubt with the cam sensor although it ran fine. Whats your opinion? Hopin it is narrowed down to the Ign module! Thanks alot for the help and feedback!

 

[Raywood]

I still have some doubt with the cam sensor although it ran fine. Whats your opinion? Hopin it is narrowed down to the Ign module! Thanks alot for the help and feedback!

No help as I haven't installed my adj ignition yet. But just wanted to state you don't have a cam sensor!

 

[HuskerChop]

Hey Raywood! Great to hear from you! Hoping we can catch up again in Sturgis. Sorry you are correct, i mistakenly called it a cam sensor, my bad! Have you heard of the crank sensor ever going bad? I am hoping that I got it narrowed down to the ign box but it threw so many inconsistent weird things at me. Thanks again for your input, always much appreciated!

 

[Raywood]

I would ask what battery did you replace yours with? Our bikes take a lot of battery to start. Still sounds to me like it's not strong enough.

 

[HuskerChop]

I just put in a new interstate yesterday, thought had it whipped and same darn thing. I have never had the alarm chirp when starting. Changed starter as the old one had water get in it and the brush holder was corroded bad. I did a 30 minute overhayul on it last year with new bearings and bead blasted the brush holder. New starter on it spins a ton better but sometimesmy headlight completely dies when i hit start button. after putting my old ignition box on last night, all seems to be fine. Gonna talk to thunderheart tomorrow and see if I can get some warranty. Only bout a year and half old. Weird!! Thanks again!

 

[Raywood]

I just put in a new interstate yesterday, thought had it whipped and same darn thing. I have never had the alarm chirp when starting. Changed starter as the old one had water get in it and the brush holder was corroded bad. I did a 30 minute overhayul on it last year with new bearings and bead blasted the brush holder. New starter on it spins a ton better but sometimesmy headlight completely dies when i hit start button. after putting my old ignition box on last night, all seems to be fine. Gonna talk to thunderheart tomorrow and see if I can get some warranty. Only bout a year and half old. Weird!! Thanks again!

Many on here have had experiences with the Interstate batteries not being charged properly. I think they have it posted on there site. But you should pull it and give it a good charge anyway.
The headlight is supposed to go out when you hit the start switch. That is part of the starting procedure on our bikes to help start the bike.
Through a multi-meter on the battery and find out for sure what voltage it has and what it drops to when you hit the start button.

 

[lowrider47]

I have same problem, only I have Dynatek 2000i ignition. Tore it down last night to check and run light on ignition stayed on while turning engine over. then when light went out engine would try to fire. Sucks, going to do the wire plus as long as i'm down. Good luck with your problem as it sucks to sit along the road with problems

 

[HuskerChop]

When I got the bike home all that was in the frame was the powertrain and rear tire. Everything else was either broke, tore off or stolen at the insurance auction house. Before I tore it down I wanted to run engine to warm up for leak down and comp test. I then press washed all the guck off and the rubber boot was torn on the start motor. Didn't know but I filled the starter with water. Bike done, tried to start and nuthin. Pulled starter apart and found brushes, armature and brush holder all corroded into one piece. now with new starter all that is fine. With old ign box all seems ok and I beat on it hard thru the gears and no failure. Gonna call thunderheart 1st thing in the am. Definitely next winter the WP is goin in! Thanks everyone for you input!

 

[HuskerChop]

Quick Update! Sent my Thunderheart ignition in to thunderheart with a very lengthy explain of troubleshooting and problems. They called me back today and after reading my explanation they immediately heated it to 180 degrees and tested. It failed!!! They warrantied unit even tho it was 5 months outta warranty and they were great to deal with! Tid bit of info for everyone. Thanks!