04 chopper stalling

[Blessed American]

My 2004 chopper is stalling after it warms up I didn't have spark at plugs so I traced back to ehc found that there is only 8vdc going to thunder heart with run button pushed).after a few min of cooling down 12 volts is back and red lights come on bike starts again for a short time .Tested stator , battery both good replaced VR. Anything else I can do before bypassing ehc .

 

[Th3InfamousI]

Take a look at this post...my issue a while back...

http://www.bigdogbiker.com/forums/technical/30808-rookie-wrencher-troubled-dog-lengthy-post.html

 

[Blessed American]

Infamous thank you for you reply. I checked the connection out just like in the thread there don't seem to be any loose wires or anything I figured out the bike doesn't even have to be running. There is 12vdc going into the EHC at all times and when I hit run there is 12v coming out of the EHC going to the thunder heart but then after a few min the ignition led on the EHC goes off and then there's only 8v coming out of the EHC . I can let it sit a few min and it comes back on and back to 12v. It doesn't seem to matter whether I jiggle the wires, Ehc , push down on Ehc, or do nothing and just let it sit.

 

[Blessed American]

Since the bike doesn't have to be on to get the lack of 12v coming out of the ehc to the thunderheart I assume no it's not a heat related issue.

 

[Blessed American]

After messing some more with the 50 pin connector and the ehc I was able to zip tie the harness just like you did infamous I had to use three zip ties though. Initially I didn't think this was the problem because when I pushed on the ehc it didn't matter it still stalled but after continuing to look at it I could see I needed to squeeze the harness and ehc together really tight . It works so I put the three zip ties on and it's working perfect. Thanks infamous..... Guess I need to order that wire plus and just replace that POS ehc

 

[Th3InfamousI]

After messing some more with the 50 pin connector and the ehc I was able to zip tie the harness just like you did infamous I had to use three zip ties though. Initially I didn't think this was the problem because when I pushed on the ehc it didn't matter it still stalled but after continuing to look at it I could see I needed to squeeze the harness and ehc together really tight . It works so I put the three zip ties on and it's working perfect. Thanks infamous..... Guess I need to order that wire plus and just replace that POS ehc

Glad it worked and got you on the road. I did about 1,000 miles like that and it was still going strong when I replaced it with the WP over the winter. Ride the bitch carry a few extra zip-ties just incase one comes loose and fix it this winter. Happy motoring!

Oh... make sure you tighten those 2 bolts holding the EHC in place. I think that is the root cause of the issue the EHC bolts come loose which then shakes the harness loose. Just not a solid enough piece on a rigid motorcycle with a solid mounted engine.

This was a recall in 04 they came out with an updated harness that wasn't supposed to come loose.

 

[Blessed American]

Heck yeah ill be carrying some zip ties . I've had great luck with this bike so far and really been learning a lot with this problem I had. Guess that's how it goes gotta take care of the easy things in life.

 

[Th3InfamousI]

Heck yeah ill be carrying some zip ties . I've had great luck with this bike so far and really been learning a lot with this problem I had. Guess that's how it goes gotta take care of the easy things in life.

That post was about 2 years ago almost exactly. With the help of this forum I have done a lot of maintence and I swore a lot and said nasty things but in the end great sense of satisfaction. Now there isn't much I haven't taken apart on the bike 2 years later and not much I wouldn't hesitate doing.

 

[Blessed American]

Almost went two days without a stall .Now I can't get it to stop irratically work and then not work no matter how much I try to push down or manipulate the harness. I will buy the wire plus but in the mean time is it safe to say I should bypass the ehc and change my ignition switch to a 12v ??? Or is there anything else I could check that might be my problem ?? Frustrated