Issues with Bike Running /Dieing

[Dakotabos]

Posted by mariovitanza
Moved to own post by Dakotabos

I have an 04 Big Dog Chopper, a few weeks ago it shut down while I was cruising at 35 - 45 MPG for no reason, several times. Took it to a local bike mechanic and of course he could not get it to stall out. Got the bike back went on a good 500 mile road trip, ran beautiful !! I figured the problem was solved. P.S. While on this road trip the headlight went out, check old bulb (bulb checks good on bench check), put back on bike(does not work), bench checks good again, purchased new bulb, does not work on bike. Then all of a sudden the stalling problem is back, starts, runs a few seconds then cuts out, and does not start again after a few more starts and cutting out (battery is new !!). If I let it sit overnight it starts again a few mote times then refuses to start at all (no spark at spark plugs). The red light by the silver box where the troublrshooting plug is plugged in does not turn red until the bike is running, when it stalls out the red light on this box shuts off.......................Help what should I look for, most bike shops do not want to touch these bikes for some reason. HELP !! HELP !!

 

[Dakotabos]

mariovitanza

1st off welcome to the BDB Forum

OK Lets help you out.

1st off just cause the battery is new doesnt mean the battery is good.

Lets break down your issue

"I have an 04 Big Dog Chopper, a few weeks ago it shut down while I was cruising at 35 - 45 MPG for no reason"

There is always a reason so lets find it..... Its hot out so #1 reason it shuts down is fuel not getting to engine due to bad gas cap not venting I am taking a shot at this means the next time you ran it it ran fine.
Grab your gas cap turn left (The gas cap shouldnt be OH MY GOD Tight) 2nd look at the cap (Not the shinny side the white side) See the hole Thats your vent. Shit gets inside there and blocks it If its blocked your gas cap cant vent and Vapor locks your tank (No Gas flow = No Run)

Theres a how to on here how to remove the gutz on that fuel cap but I just dont put my cap on to Oh My God Tight and never have an issue


"While on this road trip the headlight went out"
You may have a lose wire or on the 04 it is know for bad EHCs (Brains)
Usually the head light and horn are 1st to go

Bike wont fire up
1st pop the seat off. See that black box mounted to the rear fender? Is it Black with white sticker? Two row of lights?

OK let me know due to some have been modded some have no Brains and wire plus has been installed some have been FUBARed by previous owners

The Silver box is your Thunder Heart The red light wont flash come on till the bike is running. What I need to find out about is the EHC.

If you have an EHC then you have two rows of lights. Turn the key on (While looking at the lights of the EHC) Did you see the lights come on and some go off? Ok Now hit the Stop Button. Anything change?
Now hit the Start button What happened?

It could also be a bad Cam Sensor but answer these questions and the guys from BDB with help out fast

 

[Nukeranger]

Welcome from Louisiana.

Dakotabos has provided some excellent info:2thumbs:

 

[francoblay1]

Welcome from Spain

 

[Th3InfamousI]

Welcome to the club!

mariovitanza
If you have an EHC then you have two rows of lights. Turn the key on (While looking at the lights of the EHC) Did you see the lights come on and some go off? Ok Now hit the Stop Button. Anything change?
Now hit the Start button What happened?

Just for clarification, the stock unit on a 04 only has one row of 10 lights. Not a big deal just trying to help.

 

[RRRUFF]

These intermittent problems can really be a pain. With head light failing and no spark I would start looking for some chaffed or broken wires. I am not as familiar with the 04s and earlier but 05 and up you should have a red light come on the ignition module with the ignition switch on and press the run button and should stay on. In failure condition red light on the ignition module not on, check the red wire going into the ignition module and see if you have power. If you have power but not red light ignition mocule may be bad. I would also start by checking the wiring harness with the wires coming from the ignition module in it. Since this problem seems to be heat related and you have multiple problems I suspect wire shorting out or EHC. Also check your connection and the battery and the ground wire at the starter. Hope this helps.

 

[Dakotabos]

Welcome to the club!



Just for clarification, the stock unit on a 04 only has one row of 10 lights. Not a big deal just trying to help.

damn its been sooooo long since I got my replacement i have forgoten a few things Thanks Infamous

 

[Mickeetwo]

Welcome