Electrically cutting out

[shansel88]

So 2004 chopper, have had issue where bikes dies, electrically, usually at during acceleration, higher rpm. Have replaced speedo and cable as it had shorted and melted wire back through annunciator cable- maybe related-maybe not???
Everything works now with new speedo-tach ring- starter- left and right control boards - even replaced EHC with Axles unit.

Still, have inconsistent electrical kill- bike dies- have to reset stop button and it will repower speedo and start back up.

My guess is short somewhere still??
Maybe losing ground - though I have verified tight connection to frame.

Also, maybe important, I think my cam sensor or something - small dia wire traveling under bike - has drug at one time and could be issue/related?? maybe- just haven't cut and spliced it up all nice and neat yet. But any other thoughts/ideas or troubleshooting ideas would be appreciated.

Thanks,
Sam

 

[HMAN]

Key switch vibrating under acceleration?

 

[05chop]

Could be cam sensor get your wife's hair dryer apply heat to the nose cone area with a cold engine. Cycle key switch with ohm meter. Could be heat related to coil

 

[shansel88]

thanks for advice. its definitely not the key switch as I've gone as far to bypass that, and replace. I will have to look into this cam sensor testing or possibly coil. I know this will also occur sometime when I start the bike and just rev in garage. Now that I am thinking, I am not sure its ever happened after the bike has been ridden more then 5 min or so, but i'm not positive on that or could be coincidence?????

 

[bdm7250]

Did you replace the backbone harness when you replaced the EHC? If not, my guess would be damaged wire causing problems when vibrating. Had similar problem back when I had PDM in mine.

 

[shansel88]

I did not replace the backbone harness and am definitely concerned that it the issue. I'll likely replace that this off-season, just because, what the hell, why not, lol.
Backbone is my number 1 thought, just curious to hear opinions of others as to what condition or even short would really cause me to lose electronics in this manner and force a reset of the run/stop button to power the system back up.

Is it mor elikely loss of ground or s short on power side and current overload??

 

[Th3InfamousI]

I did not replace the backbone harness and am definitely concerned that it the issue. I'll likely replace that this off-season, just because, what the hell, why not, lol.
Backbone is my number 1 thought, just curious to hear opinions of others as to what condition or even short would really cause me to lose electronics in this manner and force a reset of the run/stop button to power the system back up.

Is it mor elikely loss of ground or s short on power side and current overload??

Could just be a loose connection in the right hand PCB board. Although I'd expect that to happen while riding as well...

This one is kinda strange if after 5 min it never dies.

Sent from my SM-G925P using Tapatalk

 

[shansel88]

Could just be a loose connection in the right hand PCB board. Although I'd expect that to happen while riding as well...

This one is kinda strange if after 5 min it never dies.

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yeah - it seems that way for timing, but i need to verify that. i know that connection for the right hand board is extremely tight - to say the least. And ive had issues with that wiring previously because of that - but for some reason even when that connector came unpluged (under tank) the bike kept running with no issues - and I only knew because i lost the turn signal. Then when I shut it down i couldnt restart and had no function over there.
This made me believe that the reset/run condition the computer is looking for was only momentary?? or locked in until it saw a change of the condition either the kill pressed or the computer shut off and looked for another reset sequence??
Can anyone confirm this - Axel maybe??

 

[Th3InfamousI]

yeah - it seems that way for timing, but i need to verify that. i know that connection for the right hand board is extremely tight - to say the least. And ive had issues with that wiring previously because of that - but for some reason even when that connector came unpluged (under tank) the bike kept running with no issues - and I only knew because i lost the turn signal. Then when I shut it down i couldnt restart and had no function over there.
This made me believe that the reset/run condition the computer is looking for was only momentary?? or locked in until it saw a change of the condition either the kill pressed or the computer shut off and looked for another reset sequence??
Can anyone confirm this - Axel maybe??

Yes it is momentary switch.

Could be anything from a bare wire, to a loose PCB screw or a bad coil.

Intermittent issues are always the worst to fix. Most of the time i'd rather just have it never work than work sometimes at least that way you can isolate the issue.

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[shansel88]

I'm thinking bare wire. Found one wire shorted/melted from high beam indicator the entire way down annunciator cable to the backbone harness connection, and even the connector was melted internally. Bike was still running though. Maybe I need to track that wire back through the backbone cable??

But, second or thrird time somebody has mentioned coil. Will a shorted/bad coil cause a condition that kills bike/EHC?? If so, this might be my next step prior to replace backbone harness.

Thanks,
Sam

 

[HMAN]

Change out ur headlamp plug to a ceramic one like WSW has. The plastic ones have melted and screwed with a lot of folks....jm .02

 

[shansel88]

Change out ur headlamp plug to a ceramic one like WSW has. The plastic ones have melted and screwed with a lot of folks....jm .02

Might open that up and get it done this weekend. I bought and LED buld - though wished I'd had waited and bought the daymaker light itself, but that's what inpatients gets me -smh. I will be checking out the plug when I open it up as I dont have any idea what is in there, but i'll definitely change it if its plastic after hearing all the feedback on this particular issue.