Re-wire bike?

[ChopperFred]

Seeking a little wisdom from the Forum. I've got a 2004 BDM Chopper DT that I had since new. Many of the problems I've had have been electrical in nature (EHC, connectors, etc.). I'm thinking about re-wiring the bike for better reliability (I hope, anyway). Here's some questions for anyone who's done this or thought about it.
1) Are there any after market harnesses that are compatible or closer than others?
2) The handlebar switches are nonstandard (momentary contact rather than rocker style). How do you get around the fact with BDM switches?
3) If you re-wire, would you include connectors or just splice and solder?
4) Would you use relays for some components like starter or a direct push button on the solenoid?
5) Would you increase the wire size one knotch for better current draw when it's needed?
I'd love to see my EHC with some .223 rounds through it. That would make the voltage regulator nervous.:angry:

 

[CCRainman]

Fred, you need to get new bars and controls. You can use the HD type controls to make things easy or you can use other controls such as PM or Jaybrake etc etc. I used a Thunderheart Micro harness which is the closes thing to stock for me, but I have an 03 which is a little different then the 04's. You can also get a harness from the guy on Clubchopper that is out of Florida. He make great harnesses that are easy to install. You need a lot of patient and some good friends that know what they are doing. If not a shop will probablt charge you about $500 to $700 to do the work not including the parts. When you do rewire you can use connectors or you can solid wire them. It's your choice. I use connectors for the switches and everything else was soldered.
The Thunderheart comes with built in relays, some of the harnesses you need to use relays. It all depends on the harness. I hope this answers all your questions.


By the way welcome and introduce yourself to the rest of the dog pound in the intro section and pin the map.

 

[ChopperFred]

Rainman,
Thanks for the input. I've thought about new bars and controls. That might also require a standard clutch lever - one that doesn't have the long leverage that BDM uses and thus more force on the clutch lever. Always trade-offs.

 

[CCRainman]

Rainman,
Thanks for the input. I've thought about new bars and controls. That might also require a standard clutch lever - one that doesn't have the long leverage that BDM uses and thus more force on the clutch lever. Always trade-offs.

Yes, but nothing is impossible if you have the time or money. I heard a guy in England did it. He was on here and never finished the post about the rewire on the newer dogs. Good luck.

 

[lee]

I think wireplus is supposed to be another option worth looking at

Wire Plus

 

[bdmridgeback]

Looks like Wire Plus has some cool latching modules for momentary switches that would allow us to eliminate the EHC and keep the BDM hand controls!!!:2thumbs: :2thumbs:

They have a module that works with momenary run/start buttons and also momentary high/low beam switches!!! Buy their self cancelling turn signal module and we are home free with the stock controls!!

I'll have to bookmark that site for my future EHC execution!!!

 

[lee]

Jake - I have absolutely no idea what any of that means but I can draw from it that it looks promising!

 

[barhopper]

Jake - I have absolutely no idea what any of that means

:roll: :roll: :roll: :roll:

 

[Nomad2day]

I am really interested in this thread myself and would like to convert my 07 EFI Bulldog over to a 12v system. In the long run, I think it is in my best interest to go this route. I would like some links or talk to some who have done this already. Looks like a good winter project to do....
Ping me offline if you want too with any suggestions or thoughts on this..
Neil in Tenn