Reintroduction/New 2005 Chopper/Fried EHC/Advice!

Energy One

2004BC

FREEDOM!!!
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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I don't know. I wasn't told that. Tonight I'll locate the vin number and see if they match the title. Thanks for the heads up and I'll let you know. I was told it's a 117 also. I'll try to decipher the vin as well. That should tell the tale.
 

Th3InfamousI

Administrator
Staff member
I don't know. I wasn't told that. Tonight I'll locate the vin number and see if they match the title. Thanks for the heads up and I'll let you know. I was told it's a 117 also. I'll try to decipher the vin as well. That should tell the tale.
Cool yea check the engine numbers. Also the 05 was called a Super Sidewinder Plus. Vs an 04 which was just a Super Sidewinder. You should see the + sign on the engine. The fins are shaped different too, you can tell in the sparkplug side, square fins are super sidewinder and more round are super+


This is an 05+ Cam cover that nose is just a beauty cap. If you take it off it's just a solid aluminum behind it. Unlike the EVO with an ignition in the nose

New



Old



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2004BC

FREEDOM!!!
OK you BDM knowledgeable detectives! Here's what I've found. The title numbers match the neck and sticker numbers. The title says 2005 BDM Chopper with 1930cc motor which is about 117 ci. Sticker on down tube also says 9/04. The following are the pictures of all of the identification numbers I can find on the engine. Can someone decipher them? Thanks!















Thanks! I believe I read where there was some grey areas between the introduction of the 117 in late 2004 early 2005 models. Anyways, if you could decipher all of the markings it would help me understand the bike better. Thanks!

PS Ordered the Alex EHC replacement and new plugs. Should be here in a day or two and I'll reassemble and see how it goes. Thanks again!
 

Th3InfamousI

Administrator
Staff member
OK you BDM knowledgeable detectives! Here's what I've found. The title numbers match the neck and sticker numbers. The title says 2005 BDM Chopper with 1930cc motor which is about 117 ci. Sticker on down tube also says 9/04. The following are the pictures of all of the identification numbers I can find on the engine. Can someone decipher them? Thanks!















Thanks! I believe I read where there was some grey areas between the introduction of the 117 in late 2004 early 2005 models. Anyways, if you could decipher all of the markings it would help me understand the bike better. Thanks!

PS Ordered the Alex EHC replacement and new plugs. Should be here in a day or two and I'll reassemble and see how it goes. Thanks again!
There is some grey area....yep. looks like you might have an old stock bottom end and they put the 117 cylinders and heads on it.

I dont know how to read the numbers...but for what it's worth the first letter E on the engine matches my 04 and my 07 has a G which makes sense it was bought in 06. take a pic of the bottom right side near the oil filter. This will tell you if it's crank or cam. Only one has to be working haha.

This is a pic of the Cam sensor plug on the left.





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2004BC

FREEDOM!!!
There is some grey area....yep. looks like you might have an old stock bottom end and they put the 117 cylinders and heads on it.

I dont know how to read the numbers...but for what it's worth the first letter E on the engine matches my 04 and my 07 has a G which makes sense it was bought in 06. take a pic of the bottom right side near the oil filter. This will tell you if it's crank or cam. Only one has to be working haha.

This is a pic of the Cam sensor plug on the left.





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Here's what I have. Looks like 104 crankcase and 117 top end. Could very well be original with 4.000 miles on the bike and a build date of 9/04. Any way to get the original build sheets from BDM with your vin #? Thanks!









 

Th3InfamousI

Administrator
Staff member
Here's what I have. Looks like 104 crankcase and 117 top end. Could very well be original with 4.000 miles on the bike and a build date of 9/04. Any way to get the original build sheets from BDM with your vin #? Thanks!









Haha well dang it you got the crank sensor and the cam sensor plugged in. Only one of them has to be working. You are going to have to figure out which one is working.

The ignition module has a red light on it when the run button is pressed and blinks when starting. Will be solid red when bike is running.

I'd check the light, and trace the wires. And remove which ever one you are not using.

Whoever put both those in was very lazy and never removed the old stuff.

Quite frankly the crank sensor and ignition module would be ideal to run. The Cam sensor is old school and not as easy to tune. I'd run the crank sensor If I were you. Raywood also just converted his to a crank sensor and said it started quicker.

You got a polished bottom end, so yep I believe it's an 05. I wouldn't worry about it. If you want buy that Cam cover from that eBay add, chuck the crane ignition in the rubbish and get the crank sensor working. Then it will look like it should!

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2004BC

FREEDOM!!!
Haha well dang it you got the crank sensor and the cam sensor plugged in. Only one of them has to be working. You are going to have to figure out which one is working.

The ignition module has a red light on it when the run button is pressed and blinks when starting. Will be solid red when bike is running.

I'd check the light, and trace the wires. And remove which ever one you are not using.

Whoever put both those in was very lazy and never removed the old stuff.

Quite frankly the crank sensor and ignition module would be ideal to run. The Cam sensor is old school and not as easy to tune. I'd run the crank sensor If I were you. Raywood also just converted his to a crank sensor and said it started quicker.

You got a polished bottom end, so yep I believe it's an 05. I wouldn't worry about it. If you want buy that Cam cover from that eBay add, chuck the crane ignition in the rubbish and get the crank sensor working. Then it will look like it should!

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Well surprise surprise! Maybe I have fuel injection too along with the Carb!!! Funny and thanks for the info! Now back to work for me sorting this out!
 

Rottweiler

Well-Known Member
Supporting Member
Wow :oldwtf: Nothing like having a back up system already installed. :oldhardlaugh: Just trace your coil wire back to either the Crane HI-4 or you big gray box? That will tell you witch is supplying the spark. Good Luck :chopper::patriot: My bet it now goes to your HI-4
 
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Th3InfamousI

Administrator
Staff member
Well surprise surprise! Maybe I have fuel injection too along with the Carb!!! Funny and thanks for the info! Now back to work for me sorting this out!
Does the bike currently run? I don't think I read if it didn't so I've been just assuming it is it did run?


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2004BC

FREEDOM!!!
Does the bike currently run? I don't think I read if it didn't so I've been just assuming it is it did run?


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Yes, but I only started it twice then the original EHC went up in smoke. Will be putting it back together tonight and tomorrow. I'll let you know the outcome.
 

2004BC

FREEDOM!!!
Well, all installed but no start. I emailed Alex in Germany and Curtis from Wild Steed Works where I bought the Alex EHC58. Here's what I wrote, maybe someone has an idea what to check next and how to. Thanks!

I installed it tonight but the bike won't click or turn over when I press the start button. Everything else works, horn, turn signals, hi/low beam. When you turn on the key the first 2 led lights (HighB & LowB) blink a couple of times then 3 &4 ("Horn" and "Start") stay lit. When I press run 1 &2 blink a couple of times, 3 &4 stay light and 7 (Right) stays lit. When I start I hear a small weezing noise very faint below the battery area then thats it. Battery is fully charged. Any ideas??? Starter relay, fuse somewhere??? Thanks!
 

2004BC

FREEDOM!!!
UPDATE! 5 minutes after I emailed Curtis for advice he was on the phone and expertly walked me through the whole troubleshooting process. Starter, starter solenoid, wiring and ehc. New ehc is on the way. The man is standup, honest, and has my respect, thanks and business. Faulty ehc on the starter circuit voltage. Now on to changing one of the compression releases and other odds and ends so when the new part gets here I'm ready to ride! Thanks Curtis!!!!
 

Th3InfamousI

Administrator
Staff member
UPDATE! 5 minutes after I emailed Curtis for advice he was on the phone and expertly walked me through the whole troubleshooting process. Starter, starter solenoid, wiring and ehc. New ehc is on the way. The man is standup, honest, and has my respect, thanks and business. Faulty ehc on the starter circuit voltage. Now on to changing one of the compression releases and other odds and ends so when the new part gets here I'm ready to ride! Thanks Curtis!!!!
Super! Great!

So it was determined the new EHC was bad out of the box? Is that right? Y'all sure its not wiring that fried the last one and this one? Did you mention to Curtis you just fried your last EHC?

I'm just saying its quite suspect youve blown through 2 EHC and wanted to make sure you let Curtis know that part. Since your wiring is already been bastardized it just makes me wonder if you don't have an underlying problem.

Did you ever figure out which ignition System is plugged in?

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Axel

Active Member
Hi Bruce,

Sorry, I was some weeks not in this forum due to (too) much work here and just have read parts of this thread.

It would be also a good idea to check if a short circuit is at the decompression valves, cause these parts are hanging parallel with the starter solenoid. So, a short circuit at one valve will pull down the power at the starter solenoid as well. Let´s see...

All the best!
Axel
 

2004BC

FREEDOM!!!
Super! Great!

So it was determined the new EHC was bad out of the box? Is that right? Y'all sure its not wiring that fried the last one and this one? Did you mention to Curtis you just fried your last EHC?

I'm just saying its quite suspect youve blown through 2 EHC and wanted to make sure you let Curtis know that part. Since your wiring is already been bastardized it just makes me wonder if you don't have an underlying problem.

Did you ever figure out which ignition System is plugged in?

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I disconnected the harnesses from the EHC this morning and wrung out the wiring to ground or shorts and visually inspected. Perfect. Connected back up and had continuity to ground through the EHC to the stater solenoid (green) wire, indicating short through circuit board. Also powered up and hitting start switch DC voltage test 3.5vdc for a millisecond then down to millivolts. Manual (slam) actuation of the starter works perfectly.

I mentioned the fried EHC to both Curtis and Axel and included a link to this thread as well.

Strangely enough both the original ignition module powered up (red light) and the Hi4 Crane (red light). Both are live. I haven't followed the coil wire back through the harness to see whose connected. Will do a little later.

Both guys felt the EHC starter circuit wasn't allowing 12vdc through to activate the starter solenoid. New one on the way so we'll see.
 

Th3InfamousI

Administrator
Staff member
I disconnected the harnesses from the EHC this morning and wrung out the wiring to ground or shorts and visually inspected. Perfect. Connected back up and had continuity to ground through the EHC to the stater solenoid (green) wire, indicating short through circuit board. Also powered up and hitting start switch DC voltage test 3.5vdc for a millisecond then down to millivolts. Manual (slam) actuation of the starter works perfectly.

I mentioned the fried EHC to both Curtis and Axel and included a link to this thread as well.

Strangely enough both the original ignition module powered up (red light) and the Hi4 Crane (red light). Both are live. I haven't followed the coil wire back through the harness to see whose connected. Will do a little later.

Both guys felt the EHC starter circuit wasn't allowing 12vdc through to activate the starter solenoid. New one on the way so we'll see.
Cool...well that's good just wanted to make sure.

definitely sort out that ignition issue you shouldn't have both units plugged in. Gotta have a wire spliced somewhere to have them both on.

While your in there have you taken the tank off and inspected all the wiring under there in case the tank rubbed against the wiring? Just something to do while you wait for the EHC that will pay dividends down the road.

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2004BC

FREEDOM!!!
Hi Bruce,

Sorry, I was some weeks not in this forum due to (too) much work here and just have read parts of this thread.

It would be also a good idea to check if a short circuit is at the decompression valves, cause these parts are hanging parallel with the starter solenoid. So, a short circuit at one valve will pull down the power at the starter solenoid as well. Let´s see...

All the best!
Axel
AHA!!!! Thank you Axel! The rear decompression valve does not work electrically and only works manually. I have a whole new assembly from Curtis here with the installation tool. I will change it out and check the wiring for a short to ground. Once I finish the installation I will test the bike again step by step and see if it works. I see on the original electrical schematic of the EHC that indeed the circuits are connected internally through the board. That is possible. I will let you know! Thanks!
 

Th3InfamousI

Administrator
Staff member
AHA!!!! Thank you Axel! The rear decompression valve does not work electrically and only works manually. I have a whole new assembly from Curtis here with the installation tool. I will change it out and check the wiring for a short to ground. Once I finish the installation I will test the bike again step by step and see if it works. I see on the original electrical schematic of the EHC that indeed the circuits are connected internally through the board. That is possible. I will let you know! Thanks!
Just FYI a quick test you can do is pull your spark plug and disconnect your compression releases and recheck voltage when you try and start. I believe there is a JST connector under the tank for the compression releases. This will at least isolate if it's a short where it is. Could be down the backbone for example. At least you will know with confidence what the issue is before replacing the compression release.

Heck the compression release may be fine and just needs new wiring.

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2004BC

FREEDOM!!!
Just FYI a quick test you can do is pull your spark plug and disconnect your compression releases and recheck voltage when you try and start. I believe there is a JST connector under the tank for the compression releases. This will at least isolate if it's a short where it is. Could be down the backbone for example. At least you will know with confidence what the issue is before replacing the compression release.

Heck the compression release may be fine and just needs new wiring.

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GOOD POINT!!!! I'm on it!!!! THANKS!!!
 
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