Booo electrical gremlins..

Energy One
Chong

Chong

U-238
I have 3 bikes ..

All are giving me electrical issues :/

04 Bullbog Stator no output ..
This has been known .. got a new one here Saturday.. need to start wrenching :p

02 Electra Glide.. went out Saturday for a 350 mile overnighter ... Sunday on way home last fuel stop .. Cranked it twice .. second time then it stopped!
Been looking at it .. no signs of 12v and batt drops about 6v with key on.
I've un hooked starter and batt and heavy starter wire .. Jump pack still showing short with all that unhooked:p

03 Chopper .
Now today .. Ride to store .. no crank .. jump pack got it going .. New battery put in yesterday ( i was down one battery since I am fixing to put stator in the Bulldog and getting it road worthy too) .. haven't looked at it other then to glance for any leads left of battery . Haven't been riding it cause i had a gas tank leak .grrrr.

Okay that's it I'm done venting ..
Bwahaha.
 
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Jusme

Jusme

‘05 BDMC
I remember thinking just before retirement, it was going to be nice to do my vehicle maintenance at my pace, rather than having to cram it in somewhere. Yeah right, always trying to be a dreamer. I don’t know about the psychology of it because psychology is pretty much a crapshoot, but venting helps. Doesn’t it? I’m listening and feel it man.
 
Chong

Chong

U-238
03 Chopper..
Need to clean some wires .. did it again .
This time jump pack didn't succeed.
Started after about 3 mins using the hand control switch. ( for total transparency I forgot this bike has a slam switch LMAO)

Before riding .. had it on charger for about 35 mins .. but a volt check showed 13.65 , and running I had 14.78 .. Forgot to check voltage before charger was connected. But that battery must have been in pretty good shape.
Too lazy to fetch the meter .. :p

Yeah eliminates a couple potential things.
 
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Mikeinjersey

Mikeinjersey

Well-Known Member
Chong said:
03 Chopper..
Need to clean some wires .. did it again .
This time jump pack didn't succeed.
Started after about 3 mins using the hand control switch. ( for total transparency I forgot this bike has a slam switch LMAO)

Before riding .. had it on charger for about 35 mins .. but a volt check showed 13.65 , and running I had 14.78 .. Forgot to check voltage before charger was connected. But that battery must have been in pretty good shape.
Too lazy to fetch the meter .. :p

Yeah eliminates a couple potential things.
Click to expand...
IF your meter is correct 14.78 is too much charge and your battery may not like it. Your VR may be getting ready to crap out and beginning to overcharge. I believe 14.5 is max to not fry your battery.
 
Chong

Chong

U-238
Cables are tight on the 03 .. I'm leaning towards hand control wiring... yesterday it had a episode of self cranking .. seemed like I just put my hand on throttle and wasn't turning it ..went for about 5-6 seconds . Due to stories I've seen on things burning - getting hot it was a tedious event .Gotta look under seat for rodent signs too. Yeah I was thinking that 14.78 was high.

02 .. that bike has the starter cable only on the battery. Down at the starter is a second wire on the solenoid connection. I'm thinking that's where the electrical system ties to the battery . I've taken that wire off that which gets the starter, battery and starter out of the curcuit.. disconnected. Hooked jump pack to that removed wire .. jump pack still shows a short .

It's 95 + humidity now here .. probably be tomorrow lol

PS Warning I have a tendency to overtime things .
 
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Mickmorris

Mickmorris

Well Known Member
Supporting Member
Chong said:
I have 3 bikes ..

All are giving me electrical issues :/

04 Bullbog Stator no output ..
This has been known .. got a new one here Saturday.. need to start wrenching :p

02 Electra Glide.. went out Saturday for a 350 mile overnighter ... Sunday on way home last fuel stop .. Cranked it twice .. second time then it stopped!
Been looking at it .. no signs of 12v and batt drops about 6v with key on.
I've un hooked starter and batt and heavy starter wire .. Jump pack still showing short with all that unhooked:p

03 Chopper .
Now today .. Ride to store .. no crank .. jump pack got it going .. New battery put in yesterday ( i was down one battery since I am fixing to put stator in the Bulldog and getting it road worthy too) .. haven't looked at it other then to glance for any leads left of battery . Haven't been riding it cause i had a gas tank leak .grrrr.

Okay that's it I'm done venting ..
Bwahaha.
Click to expand...
It’s not really that hard. Just takes time and much patience. Will you need to remove the inner primary to swap the stator? I’ve not had to replace that yet. I just checked the one on the Ironhorse and it looks fine & the charging system wasn’t the problem. But I had the inner primary off so I figured it made sense to check it. Luckily you are retired and have loads of time!! Lol :oldhardlaugh:
:cheers: :chopper:IMG_8703.jpegIMG_8872.jpeg
 
Chong

Chong

U-238
Mickmorris said:
It’s not really that hard. Just takes time and much patience. Will you need to remove the inner primary to swap the stator? I’ve not had to replace that yet. I just checked the one on the Ironhorse and it looks fine & the charging system wasn’t the problem. But I had the inner primary off so I figured it made sense to check it. Luckily you are retired and have loads of time!! Lol :oldhardlaugh:
:cheers: :chopper:View attachment 118838View attachment 118839
Click to expand...
Yea, read the write ups on here .
 
Chong

Chong

U-238
Mickmorris said:
It’s not really that hard. Just takes time and much patience. Will you need to remove the inner primary to swap the stator? I’ve not had to replace that yet. I just checked the one on the Ironhorse and it looks fine & the charging system wasn’t the problem. But I had the inner primary off so I figured it made sense to check it. Luckily you are retired and have loads of time!! Lol :oldhardlaugh:
:cheers: :chopper:View attachment 118838View attachment 118839
Click to expand...
No on the inner primary..
From what I've read clutch stays on ..
So ..
cover off .
Tensioner off
Big nut off.
Bell off. May require puller tool. Like crochet hooks.
Seems like stator output pigtail is tedious .

I'm using bigdog parts 32 amp . Other things like using harley stator or some of the 40 amp system may require grinding a tad off the cover bolt bosses ..

I'll find out if it's that straight forwards !
 
Jersey Big Mike

Jersey Big Mike

100K mile club
Chong said:
Cables are tight on the 03 .. I'm leaning towards hand control wiring... yesterday it had a episode of self cranking .. seemed like I just put my hand on throttle and wasn't turning it ..went for about 5-6 seconds . Due to stories I've seen on things burning - getting hot it was a tedious event .Gotta look under seat for rodent signs too. Yeah I was thinking that 14.78 was high.

02 .. that bike has the starter cable only on the battery. Down at the starter is a second wire on the solenoid connection. I'm thinking that's where the electrical system ties to the battery . I've taken that wire off that which gets the starter, battery and starter out of the curcuit.. disconnected. Hooked jump pack to that removed wire .. jump pack still shows a short .

It's 95 + humidity now here .. probably be tomorrow lol

PS Warning I have a tendency to overtime things .
Click to expand...
03 - Max would normally be 14.4v 14.8 is the start of the danger zone especially where low voltage electroncs are used for the controls.

02 - starter has 2 connections to 12v - the main one that spins the starter and goes direct to the battery.
The green wire that goes to the solenoid that activates the solenoid and which engages the starter motor.


12v (heavy wire from battery) starter bolt, solenoid contacts, starter motor - other end to the case/ground.
green wire (to solenoid) think of this as a relay, when powered it pushes arod forward that makes contact so that the 12v from the heavy wire connects to the motor.

Where do you see the short - green wire to ground or heavy wire to ground.

You're better off using a DVM to check for a short than a jump box.
 
Chong

Chong

U-238
knothead said:
The 4 stator screws that are 10-24 bolts torques at 45 INCH pounds with blue loctite

Engine sprocket nut torques at 150 FOOT pounds with red loctite.

On your 03 and 04 bike the transmission nut torques at 90 FOOT pounds with red loctite...remember the transmission is left handed threads
Click to expand...
Awesome
Thanks!
 
Chong

Chong

U-238
Jersey Big Mike said:
03 - Max would normally be 14.4v 14.8 is the start of the danger zone especially where low voltage electroncs are used for the controls.

02 - starter has 2 connections to 12v - the main one that spins the starter and goes direct to the battery.
The green wire that goes to the solenoid that activates the solenoid and which engages the starter motor.


12v (heavy wire from battery) starter bolt, solenoid contacts, starter motor - other end to the case/ground.
green wire (to solenoid) think of this as a relay, when powered it pushes arod forward that makes contact so that the 12v from the heavy wire connects to the motor.

Where do you see the short - green wire to ground or heavy wire to ground.

You're better off using a DVM to check for a short than a jump box.
Click to expand...
Hi Mike ,

Thanks for your replies ..
That 03 I'll rerun the meter reading ..
May have miss reported the tenth and hundredths values .. Regardless needs rechecked and evaluated.. And I still need to get it all sorted out ..

The 02.
It's a Harley .. so wiring I'm seeing is not consistent with a Bigdog . That jump pack deal . I was powering up bike with battery removed to see if anything changed . It won't send power if it thinks there is a problem. So the warning indicator kicked on . Wasn't really using to find a short ..

But seriously thanks for the info your sending me !
 
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Chong

Chong

U-238
Okay ..

Wire schematics.. I though I saw a thread on them .. can't find it .. I'll keep looking .

Checking things out on the 03 Chopper.
Yeah 14.76v running with about 2k revs .
Actually saw a blink at 14.80. Maybe 2.5k revs .

Took handle bar controls off .. didn't find any chafing.. but cleaned it out ..dust etc . Pointing out this is a 03 .. so not circuit board 5v switch conf. Recon they are 12v of harley type heritage.

See below .. found this little pigtail coming out of the EHC . ?

20230824_114055.jpg20230824_114034.jpg20230824_114040.jpg
 
Jersey Big Mike

Jersey Big Mike

100K mile club
Chong said:
Hi Mike ,

The 02.
It's a Harley .. so wiring I'm seeing is not consistent with a Bigdog . That jump pack deal . I was powering up bike with battery removed to see if anything changed . It won't send power if it thinks there is a problem. So the warning indicator kicked on . Wasn't really using to find a short ..

But seriously thanks for the info your sending me !
Click to expand...
The wiring I describe is how virtually ALL motorcycle starters are wire. The starter is a high power motor Large wire to battery - the power is interrupted internally in the stater bu the solenoid circuit. When the solonoid is activated (green wire gets power) the circuit for motor connects and the engine is suppose to spin.
 
Jersey Big Mike

Jersey Big Mike

100K mile club
Chong said:
Hi Mike ,

The 02.
It's a Harley .. so wiring I'm seeing is not consistent with a Bigdog . That jump pack deal . I was powering up bike with battery removed to see if anything changed . It won't send power if it thinks there is a problem. So the warning indicator kicked on . Wasn't really using to find a short ..

But seriously thanks for the info your sending me !
Click to expand...
What type of jump pack are you using? Is it a small Lithium Ion jump pack?
Many of the small jump packs require some life left in the battery in order to work properly.
Remember - this is a booster pack(LiOn units) not a battery replacement/substitute.
 
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