Dead Chopper

Utopiapga · Dec 10, 2013

First thought was you had some bad plugs! Have you changed them? I would start there before you go on............

Welcome aboard from NC!!

RCAdd1ct · Dec 10, 2013

Light flash at the ignition module?

KaptinAmerika · Dec 10, 2013

The very first thing, based on your notes, I would check is the red LED on the ignition module. If this light is not on while cranking the motor then you have a bad cam sensor. Its a quick easy analysis to rule out major components.

Cam Sensor Replacement

If you have the light then start where Utopiaga suggested with plugs and then start looking at your carb settings.

ELDWARDO said:
Just Purchased an 03 Chopper and she's beautiful!
Oh and I've never posted on a thread like this so if I don't respond it's probably because I don't know what i'm doing.

Got her for a good price, that being said the bike does have at least one issue. It has about 3400 miles and had obviousley been riden very little.
I started and rode the bike home with some backfiring and cutting out mid throttle. Also it didn't want to start (it would turn over but no fire). Then started with some pretty serious backfiring and misses, but seemed to smooth out after a short ride. The next time I tried to start the bike it would turn over but no fire. Switches and wiring seem to be in operating order, lights work, speedo lights up but doesn't function. The coil reads 3.3 ohms from pole to pole but i'm getting no fire to the plugs. Does any of this sound remotely familiar to anyone?
Any ideas?
Ignition? Electrical?
Help! :|

KaptinAmerika · Dec 10, 2013

Yes the ignition module is generally on the back fender above the EHC except on Mutts and pitbulls I believe

If the LED does not flash when cranking the engine and you have no spark then you have a bad Cam Sensor. It is a somewhat common thing, not that it happens excessively, on the 03 and older bikes.

ELDWARDO said:
Is the Ignition Module the silver box under the seat? The red led comes on prior to attempting to start but does not flash..

Also I did change and propperly gap the plugs. Thank you though.

KaptinAmerika · Dec 11, 2013

The only other possible issue I can think of is the starter.
03 did not come with compression releases so its harder on the starter.
But I wouldn't worry to much about that one as it is not very common.
The real issue is usually a bad battery or poor connections.

Cam Sensor

Diesel Dan · Dec 11, 2013

Hahahaha Curtis was thinkin the same thing as I was.............Sounds like a possible Cam sensor..........I would also check/change spark plugs and look inside the fuel tank,check for any ca-ca floating in there such as a bad tank liner breaking apart, and pull a fuel sample in a clear bottle.......Check out the quality and condition of the fuel........Good Luck Bud!!!!!!!!!

JR03CHOPPER · Dec 11, 2013

Other concerns...just little things here and there. Clean the end of your speed sensor in the trans...that tends to cause the speedometer to foul. I had to replace the ignition module on mine. It is the little rectangle box that was sitting on my battery between the terminals. It was a BDM part. AmyLuLu at Strokers in Dallas got it for me. It has two LED lights (yellow & red) on one end and two wires (red and black) on the other. It would make the starter engage while riding down the road. Tons of Fun!!! Definately replace your fluids. Check for glitter!! My bearings were shot in my Trans, which sent shards through the gearset. Had to rebuild it. Other than that...Enjoy!!!

ZeDevil · Dec 12, 2013

Ed, here's a few things I'd like to add from my personal experience with a 2003 Chopper.

1. Cam sensor goes bad in very hot weather conditions + if your fuel mixture is very lean = engine runs hot => then cam sensor melts. Tried and tested :bang: That being said, if you replace your cam sensor make sure your carb is set right, otherwise you might replace a sensor every week.

2. The following issue is unlikely, but again, it happened to me. The 2003 Chopper used two different frame manufacturers. If yours is DT (Daytec), then there's no reason to worry.
I have RT (Rolling Thunder) without the revision on the backbone - where it tends to crack if you're riding really hard . Yes, mine cracked and it was right under the fuel tank where the service bulletin said it would be.
Most of these bikes were recalled for a reinforcement or a frame replacement.

How to check:
1. If your frame is RT - then it's easily visible on the other side of the top engine mount (on the side with the exhaust pipes) - you shold see their logo and name stamped. If it's DT, there's nothing stamped.

2. Assuming it's a RT frame, empty your fuel tank and take it off the bike.
The backbone should be reinforced (on the down side) by a single piece of tube connecting both the neck and top motor mount, and not two tubes leaving a gap somewhere in between - where it usually tends to crack.

If you're not sure what I mean, take a picture of your frame after you have the fuel tank off and we'll point out really easy which type it is.

Again, don't get alarmed - some of these early frames still ride to this day without a single problem and will continue to do so, but you might want to know what you're riding, right?

Good luck and sorry for the long post! :cheers:

PS: What did I do when my frame cracked? Duct tape that sucker and rode it for another 25k miles :loony: :roll:
No, seriously, a good welder fixed it up and made it even stronger than it was.

8ball · Dec 12, 2013

Eldwardo, backfiring issues can also be because of exhaust and or intake gaskets leaking, check for tightness of nuts on exhaust and intake for no leakage. As old as the bike is and so few miles the intakes could have dried out and cracked or the exhaust gaskets could just be loose and it could be sucking air.

NZBigDog · Dec 12, 2013

Cam sensor would be what I would look at first....Ive only worked on two Big Dogs but have had to replace sensors on both of them.
You don't have to use a BD one, a Harley one will be fine, you just have to cut and solder the wires.

JR03CHOPPER · Dec 12, 2013

ZeDevil said:
The 2003 Chopper used two different frame manufacturers..

This is true except the two manufacturers were Daytec (DT) and Rolling Thunder (RT).

pknowles · Dec 15, 2013

test appears to be working properly

Diesel Dan · Dec 15, 2013

No problem bud!!!!!!:up: thats why were all here anyways right??? Gotta help eachother out man:2thumbs:!! Glad your up and running buddy.........Cam sensors are a common failure on our bikes.......I keep 3 or 4 in stock in my shop at all times.......and carry one ON ME on a long ride just incase

......Glad your running again :cheers:

!!!!!!!!

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