Broken wire in handlebar control board, cause of ignition cutting out?

Energy One

Moespeeds

Well-Known Member
I'm riding my friend's 2005 Chopper today, and out of the blue his ignition starts cutting out. It's totally random, ignition goes dead with no warning. His tach will flash when it happens, but this may not mean anything since his speedo is totally screwed. All I need to do is hit the run button and the bike will fire back up every time. No need to cycle the key or anything. I opened up his right side control, and found that a wire connected to the control board was broken and hanging. There are actually two wires here, one is still connected but just barely. The other has broken loose. What do you guys think? Here is a pic:



 

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
That's the brake light swith wire. A new board is $45 or you can try soldering it back on. Shouldn't effect the ingition though.

:cheers:
 

Moespeeds

Well-Known Member
I just ordered him new boards off ebay. The plug in there is also loose, didn't seem to be locking properly. What else would cause the ignition to cut out like that? Like I said, as soon as I press run it comes back on. It's almost like someone is hitting the off switch when I'm riding. When you hit RUN, the bike backfires and starts right back up if you're still rolling, or I hit the RUN then starter if I'm stopped.
 

narow37

Angry Southern White Man
could be the key switch. those have been known to go bad and cause this kind of problem
 

BigDogBro1

Made in the USA
Does he have a lot of junk on the keyring? If so it causes the ignition switch to wear out quickly and loose contact connections.
 

Moespeeds

Well-Known Member
He did have a long assed good luck thing his girl's kid made for him, but I ripped it off. If the key switch is the issue, why isn't there a need to cycle the switch to get it started again?
 

BigDogBro1

Made in the USA
Maybe if the key contacts temporarily break contact and then make contact again, isn't that like cycling the switch ready for the start button to be pressed?

not sure, just asking.
 

Moespeeds

Well-Known Member
Actually Big Dog Bro that does make sense, because the tachometer runs up as if you had just turned on the key. I'll look at it tomorrow. Lucky him, I just ripped a perfectly good key switch out of my '04.
 

Gas Man

Cool isn't cheap
Calendar Participant
make sure all the connections to the battery, back bone wiring, and coil wiring are tight.
 

Moespeeds

Well-Known Member
Just to close this out, I threw my 2004 key switch in this guy's bike, and it looks like the problem is solved. Thanks for the help guys.
 
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