Bike Dies During Warm Up

[Randy Sigmond]

Seeking ideas…

2002 Mastiff, replaced all electrical components (Dyna 2000i, Digital Dakota Spd/Tach, coil, plugs, wires, battery, rotor / stator, voltage rectifier, and installed a VOES). Initial startup, seems to be timed properly, however, during warm up, the bike dies. I turn the power off then on and there is no power. After waiting for a 5-10 minutes, turn power on and everything seems normal. Fires up, and then dies again. Same symptoms. Any thoughts?

 

[Rottweiler]

When you say that there is no power. Try jumping around the key switch. Not sure but an easy test. It sounds like something is heating up.

 

[bikeone]

bimetall fuse is built in?

 

[HMAN]

Cam sensor is crap.

 

[Bigdog Ridgeback]

Cam sensor, been there done that!

 

[Rottweiler]

Dropbox

www.dropbox.com

This is a link to the 2002 manuals.
Do you still have the thunder heart controler?
When you say no power where are you checking?

 

[Mikeinjersey]

Seeking ideas…

2002 Mastiff, replaced all electrical components (Dyna 2000i, Digital Dakota Spd/Tach, coil, plugs, wires, battery, rotor / stator, voltage rectifier, and installed a VOES). Initial startup, seems to be timed properly, however, during warm up, the bike dies. I turn the power off then on and there is no power. After waiting for a 5-10 minutes, turn power on and everything seems normal. Fires up, and then dies again. Same symptoms. Any thoughts?

This file will help you diagnose your issue. HMAN and Big Dog Ridgeback are probably correct or at least have the most logical explanation for your failure. Page 3 will help you troubleshoot . Good luck.

 

[Randy Sigmond]

Dropbox

www.dropbox.com

This is a link to the 2002 manuals.
Do you still have the thunder heart controler?
When you say no power where are you checking?

No, the TH controller caught fire in the early days. Remove it an hardwired everything, fuses, circuit breaker, etc, to include push button on starter.

 

[Randy Sigmond]

Dropbox

www.dropbox.com

This is a link to the 2002 manuals.
Do you still have the thunder heart controler?
When you say no power where are you checking?

No, power, when the bike dies, there is nothing. I’m thinking the circuit breaker may be tripping, cause power comes back after a short while.

 

[Sven]

Main relay or any relay in the loop. Or say a HD kind of resetting relay/fuse. Can't be a crank or cam sensor being self supporting throwing AC out, so being DC would be loose ground cable/wires.

Got a temp gun to trigger hot spots at connecting points?

 

[knothead]

If your loosing power to everything then its 4 possible things.

Positive connection
Ground connection
Relay
Key switch

I leaning toward a relay getting hot

 

[chubs]

When you do get it to run, what voltage do you have going to the battery? Too much would probably trip the circuit breaker pretty shortly (I would think) Also, what is the circuit breaker rated for?

 

[Mickmorris]

If your loosing power to everything then its 4 possible things.

Positive connection
Ground connection
Relay
Key switch

I leaning toward a relay getting hot

 

[chubs]

Forgot to ask, what battery did you go with? AGM, lithium ion, or something else?

 

[Randy Sigmond]

Cam sensor, been there done that!

Main relay or any relay in the loop. Or say a HD kind of resetting relay/fuse. Can't be a crank or cam sensor being self supporting throwing AC out, so being DC would be loose ground cable/wires.

Got a temp gun to trigger hot spots at connecting points?

No temp gun, but that is a good idea.

 

[Randy Sigmond]

Forgot to ask, what battery did you go with? AGM, lithium ion, or something else?

Battery: CYLA 24HLBSXTA Xtreme 24HL-BS 12V 350CCA AGM Powersport

 

[Randy Sigmond]

When you say that there is no power. Try jumping around the key switch. Not sure but an easy test. It sounds like something is heating up.

No key switch, I have a power toggle and then the run button on the handle bar. Flick the toggle to get power and turn the run switch on, then push starter button. Not secure, but never to far away from it.

 

[Randy Sigmond]

When you do get it to run, what voltage do you have going to the battery? Too much would probably trip the circuit breaker pretty shortly (I would think) Also, what is the circuit breaker rated for?

when it is running, it was maintaining 13.5 approx.

 

[Randy Sigmond]

when it is running, it was maintaining 13.5 approx.

30amp circuit breaker.

 

[Mikeinjersey]

You need to start isolating the issue. Since you suspect the CB when the bike dies read it. If it's open, it could be a defective breaker or a short somewhere causing it to open. Also when the bike dies read the battery + to frame ground and verify you have 12.8vdc or more. We would need to see a wire diagram of how you wired your bike in order to help troubleshoot.
Just to be absolutely clear, when you say "no power" you mean nothing on the bike has power.