No Spark

[verynonchalant]

I am working on a 2004 Chopper that has had a Wires Plus kit installed, the bike ran fine before installing the kit, the problem was a bad contact in the EHC and the only fix was a Wires Plus, After installing the wires plus the bike would not fire, after doing all the tests it was determined the Ignition module was bad, borrowed a friends module til the new one was delivered, the bike ran fine, the new Ignition module comes in and installed and again the bike will not fire, so do more tests, the cam plate sensor is bad, replace with a new one, still will not fire, now not even getting power to the module, when I do a voltage test for power it is spurratic jumping all over the place no constant battery power, unplug the Wires Plus and it goes to normal battery voltage

Any Ideas from the Big Dog Lovers out there, I am not happy with Wires Plus since I have had 3 Ridgebacks and 2 K-9s have problems with the switch modules after the kit has been installed, I have done 9 total wires plus jobs and my first 2 and the 5th one have NEVER had a problem and I have done 6 Thunderheart installs that have never had a problem

Maybe I am doing it wrong but as far as the install instructions go I have istalled it exactly how they instruct and nothing is wrong with the wires

PLEASE HELP

 

[Little-Boo]

I am working on a 2004 Chopper that has had a Wires Plus kit installed, the bike ran fine before installing the kit, the problem was a bad contact in the EHC and the only fix was a Wires Plus, After installing the wires plus the bike would not fire, after doing all the tests it was determined the Ignition module was bad, borrowed a friends module til the new one was delivered, the bike ran fine, the new Ignition module comes in and installed and again the bike will not fire, so do more tests, the cam plate sensor is bad, replace with a new one, still will not fire, now not even getting power to the module, when I do a voltage test for power it is spurratic jumping all over the place no constant battery power, unplug the Wires Plus and it goes to normal battery voltage

Any Ideas from the Big Dog Lovers out there, I am not happy with Wires Plus since I have had 3 Ridgebacks and 2 K-9s have problems with the switch modules after the kit has been installed, I have done 9 total wires plus jobs and my first 2 and the 5th one have NEVER had a problem and I have done 6 Thunderheart installs that have never had a problem

Maybe I am doing it wrong but as far as the install instructions go I have istalled it exactly how they instruct and nothing is wrong with the wires

PLEASE HELP

Put your friends ignition module back in and see if it works. Just because you installed a new one doesn't mean it is good. The thing could be defective and have you chasing you tail forever. :2thumbs:

Carlos

 

[Oscar Maldonado]

I agree with Carlos.

It can also be that you got a faulty Wire Plus assembly. If you've done several installations like you've mentioned then you really shouln't have the issues you're having, unless the unit is bad or you missed a step in the directions. I think I have another cam sensor at the house if you want to try another one. I wish I had another ignition module you can try. Try posting up to see if someone has a spare you can use for testing.

 

[BadBrad]

Post a pic of your ignition module. I have a spare off of Rocky's '03 Mastiff but I think something may have changed on the '04 models. But, if it's the same, you're welcome to it.

 

[RRRUFF]

I have read on here somewhere that someone post they had some problems with the key switch that was supplied with the WirePlus. If that voltage is spiking around like that then might be a faulity WirePlus module. You can send it back to them and they can test if for you. I also agree with Carlos put you friends ignition module back on and see if the problem goes away.

 

[verynonchalant]

Put your friends ignition module back in and see if it works. Just because you installed a new one doesn't mean it is good. The thing could be defective and have you chasing you tail forever. :2thumbs:

Carlos

tired it and nothing even put the new one in the buddys bike and it worked

 

[verynonchalant]

I agree with Carlos.

It can also be that you got a faulty Wire Plus assembly. If you've done several installations like you've mentioned then you really shouln't have the issues you're having, unless the unit is bad or you missed a step in the directions. I think I have another cam sensor at the house if you want to try another one. I wish I had another ignition module you can try. Try posting up to see if someone has a spare you can use for testing.

thnx but I have brand new cam sensors and ignition modules in stock and that is 100% not the problem

I am not ruling out that i installed wrong even tho the instructions are so simple a monkey could install them, i have triple quadruple checked all the wires it is installed as per the install instruction provided by wires plus

 

[verynonchalant]

Post a pic of your ignition module. I have a spare off of Rocky's '03 Mastiff but I think something may have changed on the '04 models. But, if it's the same, you're welcome to it.

yes the 03 and the 04 are different

thnx for trying tho

 

[verynonchalant]

I have read on here somewhere that someone post they had some problems with the key switch that was supplied with the WirePlus. If that voltage is spiking around like that then might be a faulity WirePlus module. You can send it back to them and they can test if for you. I also agree with Carlos put you friends ignition module back on and see if the problem goes away.

with the 6 bikes i have had problems with so far 4 has been the switch module and 1 has been the key switch and then this one i have no clue haha i am seriously getting sick of the wires plus kits, the big dog wiring is way to simple to have this many problems, i am stumped

 

[BadBrad]

I know the WP kits for '05 and newer require a different style keyswitch but I'm pretty sure the '04 is somewhat different. Have you installed an '04 WP in all your installations? Jake, aka bdmridgeback sold WP units at one time and is what I would consider to be the WP expert on this forum. You may want to contact him concerning the keyswitch for an '04 WP and possible solutions.

 

[Th3InfamousI]

I know the WP kits for '05 and newer require a different style keyswitch but I'm pretty sure the '04 is somewhat different. Have you installed an '04 WP in all your installations? Jake, aka bdmridgeback sold WP units at one time and is what I would consider to be the WP expert on this forum. You may want to contact him concerning the keyswitch for an '04 WP and possible solutions.

Keyswitches are same on 04 & 05 you can use any standard harley sportster keyswitch. Hell I think someone actually found that an old keyswitch from a tractor worked.

now not even getting power to the module, when I do a voltage test for power it is spurratic jumping all over the place no constant battery power, unplug the Wires Plus and it goes to normal battery voltage

Let's go back to the first question, where you doing the voltage test and seeing spikes? Ignition module in or out? or the WP module in or out?

Unplug WP? Disconnect from hot battery lead? or somewhere else?

Normal battery voltage when disconnected? Again where are you testing that?

 

[verynonchalant]

I know the WP kits for '05 and newer require a different style keyswitch but I'm pretty sure the '04 is somewhat different. Have you installed an '04 WP in all your installations? Jake, aka bdmridgeback sold WP units at one time and is what I would consider to be the WP expert on this forum. You may want to contact him concerning the keyswitch for an '04 WP and possible solutions.

I have done 1 other one on a 2004 and it is one of the 3 I have never had problems with yet, they key switches are the same for those years, i just installed a brand new out of the box wires plus power and switch modules and got no power at all, so went back to the one i installed and got power back but still no spark still no voltage getting to the ignition module, i do have power going into the wires plus modules, nothing coming out

 

[Th3InfamousI]

I have done 1 other one on a 2004 and it is one of the 3 I have never had problems with yet, they key switches are the same for those years, i just installed a brand new out of the box wires plus power and switch modules and got no power at all, so went back to the one i installed and got power back but still no spark still no voltage getting to the ignition module, i do have power going into the wires plus modules, nothing coming out

Man this is a lot of parts of changing....

Power to the module no power out to ignition...fine. What about power to anything else? According to the below diagram plug #3 runs power to your ignition, it also runs power to the horn and turn signals do those work?

 

[verynonchalant]

Man this is a lot of parts of changing....

Power to the module no power out to ignition...fine. What about power to anything else? According to the below diagram plug #3 runs power to your ignition, it also runs power to the horn and turn signals do those work?

yes everything else has power, good voltage, good ohms, just nothing out on the white/black to the ignition module, checked resistance on the wires and rechecked connection and both are good, I am leaning toward the power module somehow being bad, however i cannot get an answer from wires plus directly

I really appreciate every ones help, i am trying everything and definitely taking in every ones advice, I have been a factory yamaha and factory kawasaki tech for the past 3 years, the past 9 months is when i started working on harleys and big dogs and other customs, for some reason i have been having nothing but problems with big dogs as simple as they are and the manufactures of the parts are being no help so thank you guys so much for trying and hopefully being patient with my naiveness when it comes to these bikes

 

[BadBrad]

Are you getting power from the #8 pin from the #1 plug? Looks like it feeds power to the #5 pin on the #3 plug that powers the ignition module. Also, do you have power at the ignition switch that is fed directly from the power module? Just trying to track down the culprit here.

 

[verynonchalant]

no that is where it is wierd, with everything plugged in I get a flucuation in the reading from 380 mVDC to 0.8 VDC, but when I unplug the #3 Plug then I get a flat 0.0 VDC

 

[verynonchalant]

Also the white wire that feeds power when the key switch is on has battery voltage at pin #2 on plug #1 just like it should, so voltage is goin into the power module, but nothing coming out, so honestly I believe it is the power module even tho wires plus told me it is not possible and when i replace it with a brand new power module it doesn't fix anything so i really just don't know i am so stumped, going on a week of not being able to trace the problem is getting super frustrating

 

[verynonchalant]

I attached a block diagram of the ignition system and my readings, if this helps put a visual on things

 

[verynonchalant]

sorry its really small and idk how to make it bigger on here, maybe you can save it and zoom in idk, thnx for your help

 

[bearman]

I read here somewhere that someone had a couple of the wires installed in the wrong place in the connector to the wire plus module.