Okay, I give... PLEASE HELP!!!

PitbullKC

PitbullKC

Active Member
Okay guys & gals, I have done everything I can think of and still can't get her runnin'.

Here's a my bike specs and info:
2003 BigDog Pitbull
S&S 107"
S&S Super-G (shorty) Carb
EHC: BD4030-1B
Thunderheart Ignition module (B503)
Thunderheart Cam Sensor (Trigger Plate)
Starter Relay Module (BD4121-D '0733')
Ignition Coil: Dyna 0703-5

And the PROBLEMS:
Got a couple blocks away from the house and my bike suddenly died as if it were starving for fuel. Had a hard time starting it back up, but got it started and hauled back to the house.
Sometimes it will fire right back up. But usually just dies again.
This may be a whole other issue...But when initially cracking the throttle open it will stumble and most the time die.
If I slowly open the throttle (the first 1/4inch turn) I can quickly open it up the rest of the way with no problem.
I have taken it around the block a few times while trying to diagnose the problem.
When it is running, it idles fine.
I've done all the carb setup/tuning with the acc pump, fuel mixture, etc.
But it always ends up dying on me like its running out of gas.
Also, just recently while trying to check electrical stuff, the headlight started to flicker as I wiggled the EHC.
I hadn't lost any electrical/power (signals/lights/etc) when the bike died prior to this. So I was trying to stay optimistic that my EHC isn't failing.
With all that said.....

What I've checked (trouble-shooted):
ELECTRICAL
Tested with multimeter:
Ignition switch(key)
Ignition coil (*UPDATE:Replaced coil)
Ignition module (*UPDATE:Tested "good" by Thunderheart)
Starter Relay Module BD4131-D '0733'
Cam Sensor (*UPDATE:Replaced)
I replaced the battery with a Braille.
Replaced Spark plugs and tested for spark (good spark)

FUEL/AIR
Drained fuel tank.
Checked fuel tank-liner.
Checked Gas Cap for venting
Pulled off and inspected hose that connects split tanks
Pulled and inspected petcock
Checked for any air/vacuum leaks.

CARB
Pulled off my carb, inspected it, cleaned it, inspected it again.
Checked:
float
diaphram
accelerator pump
jets
aux bowl vent plug
main jet air bleed


I followed the "No Spark Troubleshooting Tree" as well. http://www.bigdogbiker.com/forums/technical/11514-no-spark-troubleshooting-tree.html#post359195

By the way...It may sound like I know what I'm talking about and I am mechanically inclined....
I assure you, I AM NOT!
And have only been able to do what I have by looking at all the awesome info that you all have shared!!!
So thank you for everyone who has helped me, even though you don't know you helped me! :D

I would GREATLY appreciate anyone's advice they can give me!
Thank you in advance.
God bless,
Jeremy
 
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RCAdd1ct

RCAdd1ct

JAFO
Next time it stalls pull the plugs.

If they are wet it indicates ignition.

Dry is fuel.

White porcelain at the tip is lean and you should be carefull to not burn up your engine.
 
Skydiver

Skydiver

Member
I just sent my ThunderHeart ignition module and cam sensor off to ThurnderHeart for testing.
Click to expand...
I think that is going to be your problem. I had the EXACT same problems with my 03 AIH Texas Chopper (S&S 107), I installed a new Daytona Twin Tec ignition and coils and it solved the problem. The bike runs great now.
 
Little-Boo

Little-Boo

Well-Known Member
Troop Supporter
Skydiver said:
I think that is going to be your problem. I had the EXACT same problems with my 03 AIH Texas Chopper (S&S 107), I installed a new Daytona Twin Tec ignition and coils and it solved the problem. The bike runs great now.
Click to expand...
X 2 :2thumbs:

Carlos :D
 
PitbullKC

PitbullKC

Active Member
I did check gas cap for venting, it's good.
Same with petcock screen.

SkyDiver- Did you have to replace your ignition module or cam sensor too?
Was it ThunderHeart?
Or did you just replac the coils?
 
outdoorsman26

outdoorsman26

Well-Known Member
sounds like when your coils get hot they quit working, get a spare plug and go out riding when it quits take that spare plug and check for spark.
 
firedog19

firedog19

Active Member
I wondered why I havent seen you around town lately. If I can help I will be glad to put in my 2 cents.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Well since you sent off your parts to Thunderheart, will have to see what they come back with.

However in the mean time, just incase equipment checks out good. Can you elaborate on what happens when the bike dies? Just completly dies or sputters out? It starts right back up? Everytime?




I agree it sounds like the igntion, if its a true stumble like you state. Anways the below doesn't cost anything and will rule out a known issue. You should be able to still do the below without the igntion module too :up: Two birds 1 Stone!

Just one more thing to check since I do not know the service history of the bike, there was a recall in 2004 in regards to the EHC main power harness becoming loose and bike will shutdown. This happened to me and bike would occassionally stumble and I could catch it with throttle. The main connector finally got so bad from constant vibrations that it would completly shut down, and I couldn't stop it. I spent a lot of time chasing it, as the issue originally fairly intermittent.

Easy test is to put the key in and turn ignition on and hit the RUN button. The Red LED for Power should light up on your EHC and try just lightly wiggling the top of the harness left and right and see if the light goes on and off on the EHC. If you search I posted a video on the board of my EHC issue.
 
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PitbullKC

PitbullKC

Active Member
Th3InfamousI said:
Well since you sent off your parts to Thunderheart, will have to see what they come back with.

However in the mean time, just incase equipment checks out good. Can you elaborate on what happens when the bike dies? Just completly dies or sputters out? It starts right back up? Everytime?

I agree it sounds like the igntion, if its a true stumble like you state. Anways the below doesn't cost anything and will rule out a known issue. You should be able to still do the below without the igntion module too :up: Two birds 1 Stone!

Just one more thing to check since I do not know the service history of the bike, there was a recall in 2004 in regards to the EHC main power harness becoming loose and bike will shutdown. This happened to me and bike would occassionally stumble and I could catch it with throttle. The main connector finally got so bad from constant vibrations that it would completly shut down, and I couldn't stop it. I spent a lot of time chasing it, as the issue originally fairly intermittent.

Easy test is to put the key in and turn ignition on and hit the RUN button. The Red LED for Power should light up on your EHC and try just lightly wiggling the top of the harness left and right and see if the light goes on and off on the EHC.
Click to expand...
When it dies it sounds/feels like its not getting fuel.
It feels like it stumbles/sputters like its not getting fuel, but it happens quickly and dies right away. Not a long drawn out stumble or anything.
When its dying/dies, all my electrical components still work fine.

It starts right back up about 50% of the time. I can usually get it started within a few minutes. But it only runs for another minute or so before it dies again.

Last week I checked the main EHC power harness and didn't have any loose wires or grounds. I'm out of town for work right now, but will try and turn the key with 'RUN' button down and wiggle it to see if thats it.
 
PitbullKC

PitbullKC

Active Member
outdoorsman26 said:
sounds like when your coils get hot they quit working, get a spare plug and go out riding when it quits take that spare plug and check for spark.
Click to expand...
I will definitely do this too when I get my module back from ThurnderHeart.
I see you are a hunter:2thumbs:
I've been bow hunting for about 10yrs myself & love it!
Going elk hunting this September in Colorado and can't wait.
You'll have to send me some pictures of your kills.

FireDog-I may be calling for some help if I can't get it going.
And if I do get it going, I will be calling to go ride!
 
PitbullKC

PitbullKC

Active Member
Just got a call from (Larry) at ThunderHeart.
Everything tested good with my ignition module & cam sensor/trigger.
He said they tested it hot & cold & worked fine, never failed.
Although he did smell the cam sensor/trigger burning???
And said potting & encapsuling(?) is cracked.
 
Skydiver

Skydiver

Member
SkyDiver- Did you have to replace your ignition module or cam sensor too?
Was it ThunderHeart?
Or did you just replac the coils?
Click to expand...
American Ironhorse used an ignition from a company in England called Gills. They were not very good ignitions and from what I have read a lot of people had problems with them. Daytona Twin Tec makes an entire repalcement kit for the AIH bikes. This is what I installed.

Internal Ignition Kit for 1999-2003 American IronHorse® Motorcycles (includes special Model 1005-IH ignition, timing rotor, VOES switch, and two 3 ohm mini coils). Not legal for sale or use on pollution controlled vehicles.



 
PitbullKC

PitbullKC

Active Member
I've replaced the cam sensor (trigger plate) & ignition coil.
Still will not stay running!
 
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