Dog Down - Need Info

Energy One

Ryan

New Member
I'll apologize in advance if this is not the right place to post this, but I need to know of any recommended BDM service places in the St Louis, MO, or Metro East area. Here's the problem.

My 2003 Chopper died on a poker run today. Thankfully, my wife was riding our trike at the time so I had a way to get home to get my truck and trailer ~ 3 hours later my dog is home.

Shortly after making a turn onto a remote country road the clutch lever snapped while shifting into 3rd and about 1 mile later all the electronics took a dump. My odometer is a Dakota digital and it started flashing on and off and the motor was spitting and sputtering at the same time. Luckily, I found neutral (light was out) before I was jerked to a sudden stop and was able to coast to the shoulder safely.

When I say the lever snapped, it was the piece about 1/2 inch wide that the cable attaches to that snapped completely away from the lever. The cable remained attached to that piece so nothing was dangling. I thought I could limp to the nearest town which was maybe 7 miles away but no such luck. Less than a mile later, the electronics went bizarre and there was no way to stop it. Shortly after crapping out on the side of the road, I called insurance (Allstate) for a tow but they couldn't find my policy (I'll be discussing that with my worthless agent). So I pushed the Chopper to the nearest farm house and luckily the biker-friendly resident was gracious enough to let me stow the bike behind his barn while I road with my wife on the trike to get my trailer.

Now I need to get the bike somewhere for diagnostics and repair. My gut tells me that the clutch is toast and maybe the transmission, too. As for the electronics, I'm hoping it's just a case of the speed sensor in the transmission tacking a beating from no tension on the clutch cable. That could be naive but I'm hopeful.

So this brings me back to the reason for this post. I need to know where to take my bike for reliable service; hopefully, someplace within 100 miles of Fairview Heights, IL. Thanks in advance for any help offered or directing me to a better place to post this plea for help.
 

titus722

Active Member
Personally I think just a clutch cable ,, and something to do with either the battery or battery connections , iv had my clutch cable let go twice so far ,
 

chubs

Guru
I'll apologize in advance if this is not the right place to post this, but I need to know of any recommended BDM service places in the St Louis, MO, or Metro East area. Here's the problem.

My 2003 Chopper died on a poker run today. Thankfully, my wife was riding our trike at the time so I had a way to get home to get my truck and trailer ~ 3 hours later my dog is home.

Shortly after making a turn onto a remote country road the clutch lever snapped while shifting into 3rd and about 1 mile later all the electronics took a dump. My odometer is a Dakota digital and it started flashing on and off and the motor was spitting and sputtering at the same time. Luckily, I found neutral (light was out) before I was jerked to a sudden stop and was able to coast to the shoulder safely.

When I say the lever snapped, it was the piece about 1/2 inch wide that the cable attaches to that snapped completely away from the lever. The cable remained attached to that piece so nothing was dangling. I thought I could limp to the nearest town which was maybe 7 miles away but no such luck. Less than a mile later, the electronics went bizarre and there was no way to stop it. Shortly after crapping out on the side of the road, I called insurance (Allstate) for a tow but they couldn't find my policy (I'll be discussing that with my worthless agent). So I pushed the Chopper to the nearest farm house and luckily the biker-friendly resident was gracious enough to let me stow the bike behind his barn while I road with my wife on the trike to get my trailer.

Now I need to get the bike somewhere for diagnostics and repair. My gut tells me that the clutch is toast and maybe the transmission, too. As for the electronics, I'm hoping it's just a case of the speed sensor in the transmission tacking a beating from no tension on the clutch cable. That could be naive but I'm hopeful.

So this brings me back to the reason for this post. I need to know where to take my bike for reliable service; hopefully, someplace within 100 miles of Fairview Heights, IL. Thanks in advance for any help offered or directing me to a better place to post this plea for help.
You have replies from Mr. Wright, and I personally will recommend him for your problem. Shannon "KNOWS HIS STUFF!"on these bikes! :old2::old2:
 

Bdm4ever

Well-Known Member
Troop Supporter
Definitely worth a trip to see Shannon my friend. If the clutch cable is broken off into the clutch lever, the cable would be the culprit but it may be both just doesn't sound like it as you described.. :2cents:
 

HMAN

I just like my Freedom
Supporting Member
Welcome from Kansas. Do yourself a favor and go see Shannon. Your Dog will be barking again.
 

Ryan

New Member
Thanks for all the quick replies and suggestions. I'll go check the tires as soon as I get off the computer.;)

Mr. Wright thanks for sending your number! I'll give ya a shout shortly. The cable may have contributed to the lever breaking. When I bought the bike there was a nasty burr in the cable about a foot below the adjuster -- almost like it was melted or crushed on one side. The seller didn't know how it got there as he was the second owner. Anyway, from my experience with my other Big Dogs, the stiffness in the lever seemed normal. Now I'm thinking it probably wasn't normal.

As far as the electronics go, the battery is brand new and has been staying charged on recent rides (plus I use a tender). I haven't tried to start the bike since it died so I can't rule out a coincidental charging system failure happening less than two minutes after the clutch lever broke. The bike turned over strong when I left the last poker stop and I only rode about 7 miles before the electronics crapped. Of course, I don't have a clue what the clutch lever and the electronics have in common either. Just doesn't make any sense.

Anyway, thanks again to everyone!
 

Ryan

New Member
The dog is in the pound.

After talking to Shannon (big thanks to you Shannon!) about what to check and what to replace, I decided it's time to take the dog for a trailer ride. My exhaust is mounted to the transmission housing so to replace the clutch cable (more on that later) I'd have to remove the pipes and since those have to be removed, I figured the tranny needs a good checkup, too. It's been down-shifting into false neutral which as Shannon pointed out could be an oil problem or could also be a bent fork. Anyway, I'd rather be certain and not have to tear it all down again. Also, I've been wanting to get the dog dyno tuned. So since I'm going into debt anyway... in for a penny, in for a pound.

No offense to Shannon but rather than drive 2 1/2 hours one way I searched for the old Gateway Cycles BDM dealer that used to be off Dorset in ST Louis and discovered that a few of the techies set up shop in St Charles, MO, which is just 40 minutes away. Upon unloading at Ross Gateway Cycles in St Charles the tech helping me, Josh, recognized my bike. He knew the original owner and turns out that Josh did all the maintenance and some of the customization on the bike for that dude.

When Josh saw the clutch lever he showed me that the lever was fine and what I mistook for a piece of lever was actually part of the ring on the end of the cable. So in addition to 1. replacing the cable and adjusting the clutch, I gave Josh a shopping list of things that needed to be done:
2. neutral light (I tested the switch using directions on this site and I think it's working but wasn't enough slack in the wiring to re-crimp the leads without first removing the exhaust so I could use both hands.)
3. tranny shifting problems
4. EHC
5. dyno tune

I'm hoping to hear back from Josh in a couple weeks.
 

BWG56

Guru
The dog is in the pound.

When Josh saw the clutch lever he showed me that the lever was fine and what I mistook for a piece of lever was actually part of the ring on the end of the cable. So in addition to 1. replacing the cable and adjusting the clutch, I gave Josh a shopping list of things that needed to be done:
2. neutral light (I tested the switch using directions on this site and I think it's working but wasn't enough slack in the wiring to re-crimp the leads without first removing the exhaust so I could use both hands.)
3. tranny shifting problems
4. EHC
5. dyno tune

I'm hoping to hear back from Josh in a couple weeks.
So it was the cable and not the clutch lever, huh, what do ya think of that Little-Boo?:oldconfused: :oldhardlaugh::sorry::oldlaugh:
 

Mr. Wright

Knows some things
Supporting Member
The dog is in the pound.

After talking to Shannon (big thanks to you Shannon!) about what to check and what to replace, I decided it's time to take the dog for a trailer ride. My exhaust is mounted to the transmission housing so to replace the clutch cable (more on that later) I'd have to remove the pipes and since those have to be removed, I figured the tranny needs a good checkup, too. It's been down-shifting into false neutral which as Shannon pointed out could be an oil problem or could also be a bent fork. Anyway, I'd rather be certain and not have to tear it all down again. Also, I've been wanting to get the dog dyno tuned. So since I'm going into debt anyway... in for a penny, in for a pound.

No offense to Shannon but rather than drive 2 1/2 hours one way I searched for the old Gateway Cycles BDM dealer that used to be off Dorset in ST Louis and discovered that a few of the techies set up shop in St Charles, MO, which is just 40 minutes away. Upon unloading at Ross Gateway Cycles in St Charles the tech helping me, Josh, recognized my bike. He knew the original owner and turns out that Josh did all the maintenance and some of the customization on the bike for that dude.

When Josh saw the clutch lever he showed me that the lever was fine and what I mistook for a piece of lever was actually part of the ring on the end of the cable. So in addition to 1. replacing the cable and adjusting the clutch, I gave Josh a shopping list of things that needed to be done:
2. neutral light (I tested the switch using directions on this site and I think it's working but wasn't enough slack in the wiring to re-crimp the leads without first removing the exhaust so I could use both hands.)
3. tranny shifting problems
4. EHC
5. dyno tune

I'm hoping to hear back from Josh in a couple weeks.
It's good to find a doctor that knows your kids.
 
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