04 117 / No Spark

[BDRider]

2004 Chopper, 117ci. No spark. No light flashing on the Thunder Heart ign module. Bad sensor plate? If so, what would you replace it with. Another from Big Dog, HD or what aftermarket? Ohm test on coil checks out.
What, if any problem would a broken wire to the front brake switch cause? It's broken at the circuit board. I'd rather it didn't work anyway.
Since this is actually an aftermarket system, what years do I look at for components. Pre 99 or 2000 and later? The S&S Sidewinder would be like an Evo motor, correct, as far as configuration and parts?
I forgot to log in. Sorry if this shows up twice.
Thanks guys.

 

[mobsta]

you can get the cam sensor from harley,as far has the wire being broken i can only tell you what happened to mine,when the wire broke on my 04 it was shorten the system and my bike would shut down while riding but would fire back up!just sayn

 

[mobsta]

ok just looked at your other post,when did this problem start?was it after the ehc replacement?was it after cam sensor replacement?i have been told by the factory,dealers and guys right here that the timing is locked.

 

[BDRider]

last fall, replaced cam sensor with HD part. Got about 100 miles, died, no start since.

 

[BDRider]

Sorry, EHC replacement was 2 yrs ago.

 

[mobsta]

that hand control could be an issue,let me go check something on my bike,also did you fill the ehc with dielectric grease?

 

[mobsta]

i always forget when the thunder heart lites up,when you hit run the light should com on,since you already replaced ehc and cam sensor,i would wonder about that control board,do you have the cruise mate installed

 

[mobsta]

one other thing,you got 100 miles after the cam sensor replacement so im guessing you rechecked your cam sensor install to make sure a wire or something didnt come loose

 

[BDRider]

Replaced Thunderheart ignition along with the cam sensor.
The light comes on, but dosn't flash when cranked over. Dealer installed EHC. Haven't done anything with it since.
No cruise.
What is locked timing?

 

[mobsta]

the timing cant be adjusted so i have been told,i havent tried to since i havent the need too.pull your ehc connector and fill it with dielectric grease.that control board keeps popping in my head,is your ehc yellow or black

 

[mobsta]

do you have the little breaker or starter relay box on your fender?try pushing the little black button if you havent already

 

[BDRider]

Gold updated EHC.
Main Power breaker on fender works. Power in, power out.
What would dialectric grease do to the EHC other than protect it from moisture.
Service manual does say that the timing can not be adjusted, yet the sensor plate can be moved.
Wiring being the main issue on these, I've gone over everything. the old cam sensor had a broken wire when I took it out. Replaced it with the new HD sensor, so I hooked up the old sensor plate to try and still no spark.

 

[mobsta]

the grease acts as a conductor,i am just shootn ideas here that pop into my head,did you try wiggling the key,these switches have problems also,did you remove the broken wire from the control board,i just got around to replacing my board,i got it from rc cycles out of tennesse it was 69 bucks

 

[BDRider]

Oh yeah, another replaced part. New Ignition switch last spring. Everything worked after that.
The wire broke off flush at the control board. I just have the board hanging free from the handle bar.
All lights work, horn works, everything seems to do what it's supposed to except fire.

 

[mobsta]

have you tried grounding a test light and checking the wires to the board to see if the lite on the thunder heart lites up

 

[BDRider]

The light on the ign module comes on like it's supposed to when you push the run button. It just doesn't flash when the bike is turned over.
I actually just tried the other Thunder heart module. Same thing.

 

[Big Daddy Woo Woo]

I grounded my thunderbox with a Test light and it lite up Sooo I guess that's good new's after replace'n the Cam Sensor it light's up to, Just no spark, I'm still thinking it's the wrong Cam Sensor that I used from HD though??? Anyway I'll be watch'n and learning and Welcome to the No Spark Club!!!! Now I'm really going Hmmmm..... The light on my module comes on when I turn the key on and goes off when I hit the Run button if I hit the Run button again it comes back on????

 

[mobsta]

im outa ideas at the moment,if something comes up i will be sure to let you know but it sounds like your hittn everything.try the grease for shits and giggles.

 

[BDRider]

Thanks.

 

[DRBarnhart]

What would dialectric grease do to the EHC other than protect it from moisture.

That's all it does... If it were a conductor it would short all the pins together.

Service manual does say that the timing can not be adjusted, yet the sensor plate can be moved.

The fact that the mounting holes are slotted means that if you turn the plate either direction you're changing the timing. I don't give a shit what the manual, factory, or anyone else says!

The light on the ign module comes on like it's supposed to when you push the run button. It just doesn't flash when the bike is turned over.
I actually just tried the other Thunder heart module. Same thing.

If the light comes on like it does with two different TH modules but doesn't blink when the engine turns over then your problem is in the cam sensor or wiring...

Dennis