Help!!! Nothing but problem after problem with 04 BDM Chopper

[Hradek]

So we traded the Harley FatBob for the 04 BDM Chopper almost a year ago.
Since then, the Chopper has had one problem after another...
-front shock mount bolt busted
-back shock mount bolt busted
-Clutch cable problems... even after clutch cable was replaced
-replaced base and head gasket
-replaced clutch basket bearing
-did the rebuild kit for the starter sloenoid
-retuned carb
-changed the acc. pump diaphram
After doing all that we still have a few problems with the bike... This is what we need help on!!!!!!
-headlight is stuck on highbeam will not switch to lowbeam... light flashes when trying to switch to lowbeam.
We took headlight apart and replaced bulb... no change. We have noticed that a lot of the BDM's have problems with the EHC and was wondering if this was our problem too? The chopper currently has a Type 2 EHC (176-000003-00 REV J). A guy at ft worth harley gave us a spare EHC... it too is a Type 2 (171-000010-00 REV C). Our question is... if the current EHC is what is causing the headlight problem, can we remove the current EHC and replace it with the spare we were given? OR is there something else causing the headlight problem?

 

[Sven]

http://wildsteedworx.com/docs/2005 & later EHC Information Sheet.pdf

I was reading this and did not refresh. Let me introduce you to franco. BTW, that left switch reset might enable the right switch back to ROM... you hope.

 

[Hradek]

http://wildsteedworx.com/docs/2005 & later EHC Information Sheet.pdf

I was reading this and did not refresh. Let me introduce you to franco. BTW, that left switch reset might enable the right switch back to ROM... you hope.

I have the wildsteedworx/ehc information website... bookmarked it.
1.) who is franco?
2.) please explain in further detail your left switch/right switch comment

 

[francoblay1]

Check THIS out too!

 

[Hradek]

Check THIS out too! View attachment 25338

Sorry, hope we didnt offend anyone. Being new to the site and not checking the whole site out first... we didnt know about the introduction thread... i have since added our introductory thread... happy reading
P.S. Nice to meet you franco

 

[FrankBDPS]

You could not possibly offend anyone on this site. To work on electrical issues you need two things. First is a volt ohm meter. You don't need a fancy one. Just the basics. Then you need a wiring diagram. If you're bike has a Thunderheart EHC or electronic harness controller the wiring diagrams are on their web site. I have an older bike so mine may be different than yours. You're issue could be the controller or the switch or in the wires themselves. With the right stuff it is not too hard to figure out. Good luck and don't be afraid to ask questions.

 

[liferider]

You could not possibly offend anyone on this site. To work on electrical issues you need two things. First is a volt ohm meter. You don't need a fancy one. Just the basics. Then you need a wiring diagram. If you're bike has a Thunderheart EHC or electronic harness controller the wiring diagrams are on their web site. I have an older bike so mine may be different than yours. You're issue could be the controller or the switch or in the wires themselves. With the right stuff it is not too hard to figure out. Good luck and don't be afraid to ask questions.

I don't know Frank, Gary is pretty picky about his females!

 

[Th3InfamousI]

I was thinking I'm offended for Frank thinking I can't get offended ! Haha

 

[pauldeepsea]

So we traded the Harley FatBob for the 04 BDM Chopper almost a year ago.
Since then, the Chopper has had one problem after another...
-front shock mount bolt busted
-back shock mount bolt busted
-Clutch cable problems... even after clutch cable was replaced
-replaced base and head gasket
-replaced clutch basket bearing
-did the rebuild kit for the starter sloenoid
-retuned carb
-changed the acc. pump diaphram
After doing all that we still have a few problems with the bike... This is what we need help on!!!!!!
-headlight is stuck on highbeam will not switch to lowbeam... light flashes when trying to switch to lowbeam.
We took headlight apart and replaced bulb... no change. We have noticed that a lot of the BDM's have problems with the EHC and was wondering if this was our problem too? The chopper currently has a Type 2 EHC (176-000003-00 REV J). A guy at ft worth harley gave us a spare EHC... it too is a Type 2 (171-000010-00 REV C). Our question is... if the current EHC is what is causing the headlight problem, can we remove the current EHC and replace it with the spare we were given? OR is there something else causing the headlight problem?

Two things: you replaced the bulb how did the connections look? The plastic connectors have been known to melt.
It could also be you have a bad switchboard in the handlebar controls. Start simple and work your way back don't assume it the ehc

 

[Hradek]

Two things: you replaced the bulb how did the connections look? The plastic connectors have been known to melt.
It could also be you have a bad switchboard in the handlebar controls. Start simple and work your way back don't assume it the ehc

Connectors looked fine...gonna look into the switchboard today.

 

[woodbutcher]

under the tank there is a little JST connector for the headlight that is known to go bad. keep it in mind. but that definitely sounds like a bad bulb.

 

[Th3InfamousI]

under the tank there is a little JST connector for the headlight that is known to go bad. keep it in mind. but that definitely sounds like a bad bulb.

While you got the handle bars apart take the tank off and the headlight out and grab your multimeter and figure out where the voltage is going.

First I'd take the headlight out and put a meter on your headlight harness and see If you 12v on both terminals when you press high beam. Then work your way backwards could be a rubbed wire under the tank too. That sure as hell wouldn't be the first time.

 

[FrankBDPS]

I don't know Frank, Gary is pretty picky about his females!

I was thinking I'm offended for Frank thinking I can't get offended ! Haha

Give this couple a break guys! Quit hijacking her thread. And I am sorry if I offended a couple of thin skinned bikers. Now go back to your mommies. It is feeding time again! And as far as Gary's women go give me a break.

 

[liferider]

Come on Infamous, we shit in Franks sand box again. Hradek get a OHM meter and check for continuity on switch from high & low. also check it with a volt meter that reads 12 volts. If your getting continuity hook the power back to the switch and see if you are getting voltage on low & high beam. this will verify if you have a short.

 

[Hradek]

Update... The ehc that was on the bike was a 176-000003-00 rev j...the spare we were given was a 171-000010-00 rev c. After looking into the ehc info i have received i noticed it said that the 176 was a replacement for the 171. So out of curiosity...we pulled the 176 out and put the 171 in. It totally fixed the headlight issue, and after starting the bike to make sure all was operational... We both agreed that the bike even sounded better. Go figure!

 

[Th3InfamousI]

Update... The ehc that was on the bike was a 176-000003-00 rev j...the spare we were given was a 171-000010-00 rev c. After looking into the ehc info i have received i noticed it said that the 176 was a replacement for the 171. So out of curiosity...we pulled the 176 out and put the 171 in. It totally fixed the headlight issue, and after starting the bike to make sure all was operational... We both agreed that the bike even sounded better. Go figure!

Glad you got it up and running.


There was a recall on 2004 EHC electrical harness it self, in which the plug would unseat itself from the EHC and the bike would lose either a headlight or all power, mine would just shutdown and die. Im Not aware of a new or updated EHC however for 04 but plausible?

For the recall The harness was replaced under that recall, mine never had it done before BDM went under (first time) and therefore I replaced with a WP.

For a while I did ziptie the harness around the EHC to help hold it in place which got me to winter when I did the WP. If you search the recall you'll find my post from way back then. Should have been back in 2011 I think.

 

[liferider]

Glad it had a great ending. Thanks for sharing that. Damn tap talk messes half of what I say up. Glad your up and running. If you feel like a road trip a couple of the guys in Dallas area are heading to Jefferson TX Sunday the 28 to meet up with some of us from east Texas, southwest Arkansas and Louisiana. Ya'll come on!

 

[FrankBDPS]

Good news. Enjoy the ride!

 

[Keith S]

Got here late. I have posted the wiring diagram for the 04 Chopper before. If you can't find it with a search, let me know and I will find another copy I can e-mail you. Glad the EHC fixed it.

 

[francoblay1]