Reintroduction/New 2005 Chopper/Fried EHC/Advice!

[2004BC]

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

John recommended to a local tuner he trusts in Boynton Beach since he just moved up to Deltona and that's where I was headed until this happened. Figures!!! Thanks for the info. I forgot there is a separate ignition module and the EHC to deal with.

 

[Rottweiler]

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![/QUOTE]

If you checked out you wiring and it is ok Axel replacement is quick and easy way to be back on the road again. 2 year warranty also.

 

[BadDawg Bill]

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!

You don't even need a fuse panel just 1 30 amp relay for the battery/starter and one 15 amp relay for the rest.

 

[bigkelk9]

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!

Yeah.. it was simple and painless really. The only thing I changed in the harness was I switched to deutsch connectors, other then that it was very simple. Plugged right into the lights, can't use factory controls either.. which I'm not a fan of the factory controls n e ways so didn't hurt my feelings much. But however you go.. the best of luck

 

[bigkelk9]

You don't even need a fuse panel just 1 30 amp relay for the battery/starter and one 15 amp relay for the rest.

I found a nifty little fuse panel with a clear cover that housed 5 or 6 fuses.. maybe 8.. idk, but I ran everything through it just for extra protection and easier diagnostics for future reference

 

[2004BC]

Ok, I think I'm going to take the easy road for now and buy the Alex controller from Curtis. Hate to sound lazy but I'm being lazy so I roll the dice. Just to finish up here's the offending part:

And here is the Crane ignition....

AND last question, dumb maybe, but what is the big aluminum block? I can't find unmarked giant aluminum block on the electrical schematic. My 2004 Ridgeback had something similar but it said Thunderheart so it was the ignition module connected to the cam sensor under the timing cover. Thanks!

 

[BWG56]

Ok, I think I'm going to take the easy road for now and buy the Alex controller from Curtis. Hate to sound lazy but I'm being lazy so I roll the dice. Just to finish up here's the offending part:

And here is the Crane ignition....

AND last question, dumb maybe, but what is the big aluminum block? I can't find unmarked giant aluminum block on the electrical schematic. My 2004 Ridgeback had something similar but it said Thunderheart so it was the ignition module connected to the cam sensor under the timing cover. Thanks!

Donna and Derek sell it for $499

 

[2004BC]

Ok, Last last last question. Here are the champion plugs in the bike. Marc the tuner suggested Iridiums. For a S&S 117 11:1 compression high performance BD motor what plug works best. Thanks and I appreciate the help!

 

[2004BC]

Do you know what caused the ehc to burn up? Possible voltage spike from the vr?

No, it was kind of typical I think. I tried to start the bike but it was popping through the carb (seperate issue, sat for a long time so I'm seafoaming it and cleaning out the carb) so it ran then died. I kept trying to start it but probably flooded it. Battery ran down quick so it would barely turn over. I gave it one more shot and held the starter button down but it didn't have enough juice to turn over. Thants when flashing lights, then horn, then smoke.

 

[2004BC]

Donna and Derek sell it for $499

Sorry I've been out of the loop for awhile but who are Donna & Derek? Thanks!

 

[2004BC]

Looks like running rich

No doubt not running right. Ran ok when I bought it but like crap the one time I fired it up when I got it home. Figures! but it's my issue, the seller is a great guy. Sometimes you just get lucky and other times you don't!

 

[2004BC]

Ah that's what got the ehc hot makes sense donna and Derek are bigdogpartskingpin and shovelheadkicker they have loads of big dog parts from the original big dogs surplus

OH! I've bought a boat load of stuff from both and had no idea who they were. I just bought a bunch of odds and ends for this bike too. Small World!!!

 

[2004BC]

Shoot donna a text or call and tell her your in need of a replacement ehc

(620) 257-2009

Thanks!

 

[Rottweiler]

AND last question, dumb maybe, but what is the big aluminum block? I can't find unmarked giant aluminum block on the electrical schematic. My 2004 Ridgeback had something similar but it said Thunderheart so it was the ignition module connected to the cam sensor under the timing cover. Thanks!

Did you ever get the answer?

 

[2004BC]

Did you ever get the answer?

Not yet. I guess it's a mysterious part. I didn't look to see if wires were coming out of it or not so I'll grab a flashlight and check. Here's some pics. Connector port, looks like red and green led, and wires coming out the side. Looks like an ignition control module but I'm just a hair confused how it works with the Crane. Crane acts as a cam sensor with more adjustability than the original? Is this an original oem part? Now I'm confused!

 

[bdm7250]

Not yet. I guess it's a mysterious part. I didn't look to see if wires were coming out of it or not so I'll grab a flashlight and check. Here's some pics. Connector port, looks like red and green led, and wires coming out the side. Looks like an ignition control module but I'm just a hair confused how it works with the Crane. Crane acts as a cam sensor with more adjustability than the original? Is this an original oem part? Now I'm confused!

That's your ignition module.

 

[Th3InfamousI]

Not yet. I guess it's a mysterious part. I didn't look to see if wires were coming out of it or not so I'll grab a flashlight and check. Here's some pics. Connector port, looks like red and green led, and wires coming out the side. Looks like an ignition control module but I'm just a hair confused how it works with the Crane. Crane acts as a cam sensor with more adjustability than the original? Is this an original oem part? Now I'm confused!

If you have a crane in the nose cone that ignition module might not be hooked up. Trace the wires.

Also strangely that is a 05+ ignition module not a 2004. 04 was dual fire, whereas 05+ was single fire.

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[2004BC]

That's your ignition module.
View attachment 39919

Aha! Confirmed! Thanks!

 

[2004BC]

If you have a crane in the nose cone that ignition module might not be hooked up. Trace the wires.

Also strangely that is a 05+ ignition module not a 2004. 04 was dual fire, whereas 05+ was single fire.

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My last BD was a 2004 Ridgeback, this ones a 2005 Chopper. I did trace the wires and they go to 2 connectors that are hooked up. I'll look closer tonight to see where they go. I thought the Crane replaced it but I'm not sure now.

 

[Th3InfamousI]

My last BD was a 2004 Ridgeback, this ones a 2005 Chopper. I did trace the wires and they go to 2 connectors that are hooked up. I'll look closer tonight to see where they go. I thought the Crane replaced it but I'm not sure now.

I'm actually confused 2005 should have been a crank sensor model. You must have gotten a leftover 04 engine. You can't even fit a ignition in the nose cone of the 05 engines. The Cam cover isn't built for it.

I'm wondering if someone swapped engines?


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