Reintroduction/New 2005 Chopper/Fried EHC/Advice!

[2004BC]

I had to sell my 2004 Ridgeback a few years ago to fix up my house in New York. Hated to do it but you know you do what you have to do! I still checked in here on occasion but it's not the same when you don't have a Big Dog anymore. Fast forward to 2017 my job relocated to Pompano Beach, FL, sold my house in NY, bought a house west of West Palm Beach, and finally got back to the thrill of riding by buying another members worked 2005 BD Chopper. Just got done cleaning and customizing a bit and adjusting the carb when the classic EHC bonfire started. Flashing lights, beeping horn and smoke coming from under the seat. Now I know I have the original EHC. Strike that, had. So, to all of you that have switched, what is the best, easiest, system to replace the Thunderheart? I remember Wire Plus, and now I read Doc's, etc etc. Also to consider the bike came with a Crane Ignition and the engine was highly worked by John Sachs. In talking to a tuner he recommended I would need a new EHC anyways so he can dyno tune the engine to get to 145 to 155 HP which it should make instead of the 125hp it's making now. Thanks and I appreciate your help!

Old

New

BURNED EHC

 

[bdm7250]

I had to sell my 2004 Ridgeback a few years ago to fix up my house in New York. Hated to do it but you know you do what you have to do! I still checked in here on occasion but it's not the same when you don't have a Big Dog anymore. Fast forward to 2017 my job relocated to Pompano Beach, FL, sold my house in NY, bought a house west of West Palm Beach, and finally got back to the thrill of riding by buying another members worked 2005 BD Chopper. Just got done cleaning and customizing a bit and adjusting the carb when the classic EHC bonfire started. Flashing lights, beeping horn and smoke coming from under the seat. Now I know I have the original EHC. Strike that, had. So, to all of you that have switched, what is the best, easiest, system to replace the Thunderheart? I remember Wire Plus, and now I read Doc's, etc etc. Also to consider the bike came with a Crane Ignition and the engine was highly worked by John Sachs. In talking to a tuner he recommended I would need a new EHC anyways so he can dyno tune the engine to get to 145 to 155 HP which it should make instead of the 125hp it's making now. Thanks and I appreciate your help!

Old

New

BURNED EHC

I have DOC's ESC on mine, very straight forward install, Jeff has complete instructions that come with the ESC. I have put on about 6k trouble free miles. There are many options, Axel's ehc is a great option as well (from what I've heard from other members). I could not use a direct replacement ehc as I had the PDM installed, so the wire harness would not work. So from personal experience, I would recommend DOC's ESC, but if you're looking for simple plug and play (and your wire harness is in 100% condition) you may want to check Axel's unit. I'm sure dentdude will chime in on this.

 

[BWG56]

X2 on DOC's

 

[Hirter6Pack]

Bdm7250 Doug gave you the best advice you're going to get. I went with the RIP, that was before Axel's. I no problem with the installation and it is a solid unit. Your just going to have to pick one.
Welcome back.

__________

 

[BadDawg Bill]

Old school wire it and be done with all the problems....

 

[2004BC]

I have DOC's ESC on mine, very straight forward install, Jeff has complete instructions that come with the ESC. I have put on about 6k trouble free miles. There are many options, Axel's ehc is a great option as well (from what I've heard from other members). I could not use a direct replacement ehc as I had the PDM installed, so the wire harness would not work. So from personal experience, I would recommend DOC's ESC, but if you're looking for simple plug and play (and your wire harness is in 100% condition) you may want to check Axel's unit. I'm sure dentdude will chime in on this.

Thanks! I appreciate your advice!

 

[2004BC]

X2 on DOC's

Guess I'll do some research on Doc's. Thanks!

 

[2004BC]

Bdm7250 Doug gave you the best advice you're going to get. I went with the RIP, that was before Axel's. I no problem with the installation and it is a solid unit. Your just going to have to pick one.
Welcome back.

__________

Thanks and glad to be back! Rocky start with burned EHC but better in my driveway than out on the road. I can't believe there was zero short circuit protection. It would have just kept burning if I hadn't unbolted the negative battery cable. My garage smells like burnt florescent ballasts!!!

 

[BWG56]

Thanks and glad to be back! Rocky start with burned EHC but better in my driveway than out on the road. I can't believe there was zero short circuit protection. It would have just kept burning if I hadn't unbolted the negative battery cable. My garage smells like burnt florescent ballasts!!!

DOC's unit has this fuse link in it to prevent that from happening

 

[2004BC]

Old school wire it and be done with all the problems....

I know you rewired your bike that way and I have wired many bike builds in the past from scratch as simple as possible. In fact first thing I would do in making an HD chopper is throw out the entire oem wiring harness and go simple. The catch is I kept it super simple, running lights, high beam, brake light switch, hidden on/off switch, alternator, voltage regulator, battery, 1 main 30A relay for short circuit protection, and MAYBE a starter relay and hidden switch but most were kick only. No turn signals, no electric start, no horn, no handle bar controls, nothing but the bare essentials. Just more things to vibrate, break, or short out.

Now with the BD it is a different story. I'm not starting from a frame and all of the existing wiring is perfect. In fact the whole bike was perfect until the craptastic EHC decided it was time to fumigate my garage. So while my inclination would be to do what you've done, I do not want to do all of the work to gut the bike and start over.

HOWEVER, if someone could email me an electrical schematic of a stock 2005 BD Chopper or has a service manual to sell me with the electrical schematic in it, I am interested in taking a close look at exactly what I would have to do to redesign the electrical system to eliminate the EHC and "old school" the wiring so that the main systems are functional. If I can just work "under the seat" and not touch any of the rest of the branch circuit wiring I might just do as you suggested but I would need to thoroughly analyze the electrical schematic and it's components.

Thank you for your suggestion!

 

[2004BC]

DOC's unit has this fuse link in it to prevent that from happening

View attachment 39848

Well he's a boat load smarter than the guys who designed the original system. It's electrical design 101! SHORT CIRCUIT protection. So all of BDM's customers had to learn the hard way as EHC's burned through the years. Thanks for the information!!!

 

[BWG56]

If I can just work "under the seat" and not touch any of the rest of the branch circuit wiring I might just do as you suggested but I would need to thoroughly analyze the electrical schematic and it's components.

Thank you for your suggestion!

Try this
https://www.dropbox.com/sh/ng3saqa5a93gehp/AADK9gFSGaAG5oirsV17JO_Oa?dl=0

 

[bdm7250]

Hope you can see it.

 

[bigkelk9]

Old school wire it and be done with all the problems....

Can't preach it enough.. and all these knuckleheads just like knowing their bikes are gunna go down again.. lol

 

[2004BC]

Try this
https://www.dropbox.com/sh/ng3saqa5a93gehp/AADK9gFSGaAG5oirsV17JO_Oa?dl=0

HOLY SMOKES!!!! You guys are amazing!!! I go get a cup of coffee, take the cover off the pool, open the garage again and turn on the fan to get the burnt stench out, come back, ...and.....Here is everything I need! Hats off to you BWG56! I owe you one and I always repay a favor. Thank you!

 

[2004BC]

Hope you can see it.
View attachment 39850

Hi bdm7250, I can read it, I've printed it, and the super Bowl may have to wait today. I'm on it! Much much thanks for your help. This is what I missed when I sold my Ridge. Guys and ladies helping each other out in BDM community. Thank you! I owe all of you for helping me. I have to say I was a little discouraged when I got the Chopper and haden't even gotten a ride out of it yet when it fried. Now I'm good. Thanks!

 

[2004BC]

Can't preach it enough.. and all these knuckleheads just like knowing their bikes are gunna go down again.. lol

Solid state electronics have been a huge advancement for mankind obviously but the environment that they have to operate in in especially V-Twin motorcycles is harsh to say the least. Heat, Rain, and Vibration are all of the things to avoid in ss circuits. That being said they can be designed for harsh, high heat, wash down environments but you would need a backup component in case of failure the same as you would need a back up electromechanical or ss relay or fuse in an "old school" wired bike. BUT, after looking at the schematic, it's clear if you want complicated functionality then a "brain" is the only way to go. To much real estate to cover all of that control with relay logic.

Quick side question though, back to one of my original goals, what controller if I go that way allows a dyno tune to acheive it's optimal performance. The tuner said he couldn't with the oem EHC. Any thoughts? Thanks!

 

[bigkelk9]

Solid state electronics have been a huge advancement for mankind obviously but the environment that they have to operate in in especially V-Twin motorcycles is harsh to say the least. Heat, Rain, and Vibration are all of the things to avoid in ss circuits. That being said they can be designed for harsh, high heat, wash down environments but you would need a backup component in case of failure the same as you would need a back up electromechanical or ss relay or fuse in an "old school" wired bike. BUT, after looking at the schematic, it's clear if you want complicated functionality then a "brain" is the only way to go. To much real estate to cover all of that control with relay logic.

Quick side question though, back to one of my original goals, what controller if I go that way allows a dyno tune to acheive it's optimal performance. The tuner said he couldn't with the oem EHC. Any thoughts? Thanks!

Dyno tune for a carb bike? I'm not sure I've heard of such a thing. I hardwired my bike and it made a world of difference.. lol.. cuz I'm never on here asking about why this and that.. straight forward and to the point. An 8 fuse fuse panel, two relays and clean easy wiring. Best of luck to ya brother!

 

[BWG56]

Solid state electronics have been a huge advancement for mankind obviously but the environment that they have to operate in in especially V-Twin motorcycles is harsh to say the least. Heat, Rain, and Vibration are all of the things to avoid in ss circuits. That being said they can be designed for harsh, high heat, wash down environments but you would need a backup component in case of failure the same as you would need a back up electromechanical or ss relay or fuse in an "old school" wired bike. BUT, after looking at the schematic, it's clear if you want complicated functionality then a "brain" is the only way to go. To much real estate to cover all of that control with relay logic.

Quick side question though, back to one of my original goals, what controller if I go that way allows a dyno tune to acheive it's optimal performance. The tuner said he couldn't with the oem EHC. Any thoughts? Thanks!

Thunder heart makes a programmable ignition module that you can change the timing and the rev limiter, and you can also add your own program to it if you can write your program. I think its around $200 and is plug n play meaning it has the JST connectors on it.
I'm not sure if the 04' has the timing in the cam cover, in which case you can change the timing there

If John Sach's worked on it, he would be your go to guy

 

[2004BC]

Dyno tune for a carb bike? I'm not sure I've heard of such a thing. I hardwired my bike and it made a world of difference.. lol.. cuz I'm never on here asking about why this and that.. straight forward and to the point. An 8 fuse fuse panel, two relays and clean easy wiring. Best of luck to ya brother!

Dyno tune non-efi is pretty simple I guess. Just go at how much advance you can get on the timing and adjust the G Carb jets until you get smooth pull and max HP. Kind of trial and error on carb bikes. So you got everything you wanted with 2 relays and fuse panel. that's very appealing! Thanks!