My 04 Chopper is chappin my arss!

[bigdoghogz]

Hey guys and gals.....I have an 04 Big Dog Chopper and I've had some electrical issues lately with it dying during a ride. this is what Ive done thus far...

Replaced the coil
Replaced the Ignition switch
Replaced the Thunder Heart Module
Replaced the Battery
checked all ground connections----looks good
Unplugged the the speedometer because it looks like its getting burned inside the unit and tach was acting weird!
Installed a new Ignition Sensor which was what was causing the problem all along. or was it? Ill explain.....

Once I installed the the HD ignition sensor and hooked everything back up including the speedometer It ran Fantastic. For two days. went out to start it at work and the new sensor went bad. went to HD and got another sensor and installed it. unplugged the speedometer because I think it has a short or the EHC has a short or both. I also Bypassed the EHC power to the Thunder Heart Ignition Module and hooked up directly to battery with a fusable link. Bike is again running. My Question is...could a short in the EHC and Or the Speedometer be causing the problem? I'm hoping to avoid going to through yet another ignition sensor. Any wisdom you can add to this issue would be greatly appreciated. On another note...I vote that we tar and feather the dumb dumb that designed the electrical system for these bikes! im just sayin lol.

Kirk

 

[bigdoghogz]

And yes I am making plans to do a WP install asap. where's the line for all the free stuff? lol. When I do a WP install I am going to take the EHC out to a vacant lot and do a video recording of me demolishing the old crud! just given you all a heads up on that event! not goin to be pleasant.

Kirk

 

[Nukeranger]

I don't know about an 04. But, the newer EHC gets grounded to turn on and it doesn't take but a few milli seconds to shutdown the system if the connection is interrupted. I would believe it is important to find the problem prior to replacing the EHC.


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[Th3InfamousI]

You seem to have installed quite a few parts.

When the bike dies do you lose power. Just riding along and all of a sudden a quick loss of all power?

FYI there was a recall in 2004 for the below

Big Dog is recalling certain 2004 Chopper, Bulldog, Ridgeback, Mastiff, Boxer and Pitbull motorcycles. There is a possible loose connection between the harness connector and the electronic harness controller. This condition may cause the motorcycle to experience intermittent loss of electrical power to various components, which can lead to, among other things, a loss of headlamp function or a vehicle stall, increasing the risk of a crash. Big Dog will notify owners and dealers will repair the motorcycles free of charge. The safety recall began on May 24 2010. Owners may contact Big Dog at 316-219-9121. NHTSA campaign ID no. 10v180

 

[MyDogPete]

And yes I am making plans to do a WP install asap. where's the line for all the free stuff? lol. When I do a WP install I am going to take the EHC out to a vacant lot and do a video recording of me demolishing the old crud! just given you all a heads up on that event! not goin to be pleasant.

Kirk

Blow that MF up with a couple of sticks of dynamite or C4.

 

[bigdoghogz]

Yes. Like I said it was the ignition sensor in the nose cone. I replaced it twice. Something is making it blow. Im hoping that by bypassing the EHC module to the thunder heart that this will keep it alive until I do the complete rewire.

 

[Th3InfamousI]

Yes. Like I said it was the ignition sensor in the nose cone. I replaced it twice. Something is making it blow. Im hoping that by bypassing the EHC module to the thunder heart that this will keep it alive until I do the complete rewire.

What kind of exhaust you got on your dog? Does it run around the nose cone? Lot of guys have problems in the summer killing the sensors with the exhaust routed around it.

Guy last week on here said he replaced it twice and got only about 200 miles out of it. I then mentioned the heat to him and sure enough his exhaust sits right under the nose cone. He rode with the cam sensor cover off after installing the new one and said he rode 500 miles with no issue. I wouldn't recommend riding with the plate off though.

http://www.bigdogbiker.com/forums/technical/37179-cam-sensor-no-spark-2003-chopper.html