2005 Chopper Found Dead Today

[BDMike]

Planned for a nice SOCAL solo ride today on my chopper. I havent been riding much lately but did get a short ride in yesterday and she ran great as usual. Pulled her out of the garage, cleaned her up just a little, grabbed my helmet and gear and…..the bike is dead. Nothing, I turn the key on and off but nothing. Pulled out my meter and the battery reads 12.8 VDC.

An hour of troubleshooting (thank you to the member that provided the wiring diagram). I found one of the wires had pulled from the small connector from the key switch. I was able to use a small pair of needle nose pliers and re-inserted into the connector and it seems to be holding. I actually found that the wires had somewhat pulled back, causing a strain on the connector. I was able to pull the wires through (around the coil and switch to better position the ignition switch connector.

With all the info I have been reading on this website, I probably should replace my battery as it is the original since 2005. I have 4800 miles and really have not had any problems, and always keep it on a tender.

Anyway, I thought I would share what the root cause issue was just in case some of you may be experiencing similar issues.
Mike:flag:

 

[BBChopper]

Get a new battery (a good one) and a battery tender!
My local shot that I bought a Drag Specialty’s batter from six months before kept telling me the battery was good. I also had a new starter I got from them and kept the battery on a tender. I finally got a Big Bore 350 and have had no issues since. The battery they sold me didn’t have the CCA needed and it had a bad cell!

 

[Oldhvymetal]

Over time I've personally become fond of the Yuasa batteries. To me they seem more reliable. Battery preference might be something the other members want to comment on. Glad you found the open connection- kudos to the member that sent the diagram!
Respect,
OHM

 

[Brew]

Glad that you found the issue and got the scoot back on the road...:2thumbs:

 

[Doctor of Power]

Having same problem with my 06 Chopper. I disconnected the keyswitch and shorted the connector. Still nothing. Was bad connection @ key switch or harness wire? if on harness wire that could be my prob. Gonna check it either way, just curious.

 

[Mickeetwo]

Good info Mike.....thanks for posting :2thumbs:

 

[BDMike]

The bad connection was between the switch and the harness at the connector (21/22). There is also a pigtail running from 21/22 to 23/24 (I have attached the diagram for reference). I also re-routed the harness and connectors (21/22 and 23/24) to reduce the strain that I believe caused the pulled connection.

Mike:flag: