Chopper won't start

[Cyrus]

I have a 2005 Chopper. Over the weekend while doing about 70 down the freeway, I heard a big clunk and the bike just shut down (almost sounded like I throw the belt). I checked the battery wires and they are tight. It had it hauled to a nearby HD dealer and they checked the battery and output, and the battery is fine. They also charged it for a while just to make sure fully charged.

The headlight & everything comes on when I turn the switch, but when I hit start, it clicks but doesn't start (just like a battery issue). It can't be the starter, can it? Why would it just clunk and die suddenly going down the freeway.

Long expensive weekend with a tow of 150 miles. Hoping this is not anything major.

Appreciate any suggestions guys.

 

[Zachusmc]

I would check the starter first and see if it will turn over manually

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[awg]

Get it up on a jack rear wheel off the ground put it in gear and see if you can get the motor to turn over. Maybe its locked up??

 

[Cyrus]

After it shut down, it rolled to stop. So don't think it is locked up. Even before I came to a stop, I tried starting it back up manually in gear while running, but it wouldn't. I didn't hear any grinding or anything. I will check both the starter and see if it is locked up. Thank guys.

 

[RRRUFF]

As said above get the rear wheel off the ground and then remove the spark plugs. Put it in third gear and roll the tire and see if the engine turns without binding or making any unusual noises. How many miles do you have on it? You may want to also pull the valve covers and check to see if you dropped a valve, start with the rear valve cover first. The big clunk has me concerned.

 

[Cyrus]

Okay, will check that. It has about 16000 on it.

 

[Cyrus]

Bad news. You had the right hunch. We first tested the starter and it is okay. Then jacked it up, put her in gear and it is locked up. The front plug came right out but the rear plug was jammed. Got the rear plug out and it is half chewed up. Looks like the piston jammed right into the plug.

Hard to see how this could happen on a S&S 117 with 16,000 miles on it!

I wonder if something got in there? or as you suggested, may be dropped a valve? Only hope I am not looking at a complete rebuilt and it is something simpler on the top end.

Any further advise is greatly appreciated - Thank you guys

 

[Cyrus]

Also, just to make sure it is locked up, we took the primary cover off, took the chain off and checked to see if it turns. It is locked up.

 

[wolfen]

Same thing happined to me.

Hi, Same thing happined to me on my 2005 chopper. Was going 80 down the new jersey parkway when i heard a clunk ,then the bike wouldn`t run. Lost the front exhaust valve. Chewed the front head and cylinder up. Bent the rod, I had to get the whole thing rebuilt. Cost 4500.00. When it goes back together it will have larger valves , manual compression releases, a 640 S&S cam. Acually i`m still waiting on the motor. It`s been 7 months so far ,but,thats another story.
Good luck

 

[Cyrus]

Hi, Same thing happined to me on my 2005 chopper. Was going 80 down the new jersey parkway when i heard a clunk ,then the bike wouldn`t run. Lost the front exhaust valve. Chewed the front head and cylinder up. Bent the rod, I had to get the whole thing rebuilt. Cost 4500.00. When it goes back together it will have larger valves , manual compression releases, a 640 S&S cam. Acually i`m still waiting on the motor. It`s been 7 months so far ,but,thats another story.
Good luck

Did you figure out what the cause was? I still don't know if something got in there, heated up or something else.