2004 BD CHOPPER , turn key no power

[Jusme]

Welcome to the site John. Just a thought from my experience. On my ‘05 chopper, I found a headlight wire had frayed from rubbing inside the headlight housing and fried the bulb. I chased down the rest of the wires and found one of the starter wires had frayed from rubbing the drive belt. This may not be your issue, but I have patched, shielded and secured all loose wires. Just a note, the headlight ring unscrews after removing the allen screws. Just like a jar lid.

 

[Mikeinjersey]

Update: went a few days with hands off the bike. So had got the bike running a few days ago after pulling the solenoid and cleaning it up and putting back together and replacing a new battery… i leave the GREEN wire disconnected from the starter otherwise the bike tries to start even with key in OFF position…

So a few days have gone by and went to work in it last night.. Now it would not start and brand new battery was dead.. So exchanged it for a replacement. Put in new battery and then the inline fuse it has between the circuit breaker to the EHC now keeps popping..
So i disonnected the main power cable off the battery. Replace the inline fuse and then just reattach the line from the battery to the circuit breaker and as soon as it touches the inline fuse blows…

so no power from the battery to the starter because i have that main positive disconnected…So now power until I connect power to EHC and each time is blows that inline fuse… Have not done anything else to the bike since I got it running days ago…previous owner said he had the RIP kit installed. But not sure if this EHC is the RIP kit ir what. If anyone knows what type if system this is installed? I attached a pic

This has been a little hard to follow but it seems as though you may have mixed up some wires when you changed out the battery. The bike only needs the circuit breaker when the bike is running and charging. It serves to protect the battery from a short or over-current from the VR. A fuse between the CB and the positive side of the battery serves no purpose. The fuse should be placed between the positive side of the battery and the EHC in order to protect the EHC.
For now, just remove the lead off the CB on the battery side and see what happens. If it was indeed connected correctly to the positive side of the battery it could blow the fuse/CB if the VR or wiring is shorted to gro
Maybe take a pic or two of your wiring, it may help us figure out what's up. You definitely have a short we just need to locate it.

 

[ARBNRANGER]

Going to say. The ECH is fried…

So i will try to paint the picture of how the wiring was done… coming off the positive terminal of the battery a wire goes to the CB on one post. Then coming off the 2nd post is a wire going to the EHC that wire has an in-line fuse before it reaches the ECH…

So with the starter completely disconnected from the battery so the starter had no power. I put the wire on the positive terminal that goes to the CB to out power to the ECH…

I turned the key on. The directionals flashed and some LEDs came on on the EHC

Suddenly there was a snap noise and a stream of smoke coming out from inside the EHC

I will attach pics. But a safe assumption is the EHC is fried

 

[Rottweiler]

Ouch
Yeah that magic smoke needs to stay in.

 

[Rottweiler]

You need to check for shorts. Also verify all wiring before installing a new one.

 

[HMAN]

With Axel's EHC, He recommends to change out the charging system, ie: stator and VR. They can cause the brain to overload n fry. Little late for this knowledge it looks like. His EHC's are rock solid with that exception.

 

[Mikeinjersey]

Going to say. The ECH is fried…

So i will try to paint the picture of how the wiring was done… coming off the positive terminal of the battery a wire goes to the CB on one post. Then coming off the 2nd post is a wire going to the EHC that wire has an in-line fuse before it reaches the ECH…

So with the starter completely disconnected from the battery so the starter had no power. I put the wire on the positive terminal that goes to the CB to out power to the ECH…

I turned the key on. The directionals flashed and some LEDs came on on the EHC

Suddenly there was a snap noise and a stream of smoke coming out from inside the EHC

I will attach pics. But a safe assumption is the EHC is fried
[

 

[Rottweiler]

Update: went a few days with hands off the bike. So had got the bike running a few days ago after pulling the solenoid and cleaning it up and putting back together and replacing a new battery… i leave the GREEN wire disconnected from the starter otherwise the bike tries to start even with key in OFF position…

So a few days have gone by and went to work in it last night.. Now it would not start and brand new battery was dead.. So exchanged it for a replacement. Put in new battery and then the inline fuse it has between the circuit breaker to the EHC now keeps popping..
So i disonnected the main power cable off the battery. Replace the inline fuse and then just reattach the line from the battery to the circuit breaker and as soon as it touches the inline fuse blows…

so no power from the battery to the starter because i have that main positive disconnected…So now power until I connect power to EHC and each time is blows that inline fuse… Have not done anything else to the bike since I got it running days ago…previous owner said he had the RIP kit installed. But not sure if this EHC is the RIP kit ir what. If anyone knows what type if system this is installed? I attached a pic

If a new battery went dead in 3 days, you need to start disconnecting wires until you find the problem.

 

[ARBNRANGER]

Yes. Everything is disconnected…. Going to order all new wiring harness and requre entire bike. This way. Now that its in my hands can be a fresh start…. Having no clue what was done by previous owner to get it to this condition….

I see guys have said it is an EHC from
axel? Who is Axel?

 

[Mikeinjersey]

Yes, I agree pic 6006 kind of affirms that. Pic 6007 looks like the CB is connected to the battery on the top lug and the VR and Fused wire is connected to the EHC on the bottom. If that is so, I don't believe that is correct. The fused wire should have come from the same top lug back to the positive side of the battery. That being said , I don't think that would cause your EHC to smoke by just turning on the key. Is it possible you switched the Pos & Neg wires from the EHC ? Could the battery have an internal short? Maybe someone else can weigh in on what they think.
One thing is for sure before your plug in a new EHC is making sure you have solved the shorting issue.

Yes. Everything is disconnected…. Going to order all new wiring harness and requre entire bike. This way. Now that its in my hands can be a fresh start…. Having no clue what was done by previous owner to get it to this condition….

I see guys have said it is an EHC from
axel? Who is Axel?

He is a member from Germany who manufactures electronics.
You can purchase his EHC from https://www.wildsteedworx.com/

https://www.bigdogbiker.com/members/axel.12812/

 

[ARBNRANGER]

UPDATE. GEN1 RIP kit arrived. Removed entire old wire harness and replace with new. Got everything in.
the smaller separate wire harness that goes from the key ignition switch/ coil back to battery tray. One plug goes into the thunderheart and no idea where this 2nd plug on the harness goes.

then. I realize the bike has a S&S HI-4N ignition module snd that is wired directly up to the coil.

So am told i dont need and remove the thubderheart module.

Now I am playing stump the chump. Cause i am at a mental block rightnow….. do i need to disconnect the S&S ignition from up behind thecoil and tie it into tge RIP KIT harness where it was going to pluginto the original thunderheart module??

in the pic thatis the 2 plugs coming off new ignition harness and 1 goes to thunderheart but not sure where the other plug goes