Repaired the bike after an electrical fire - no spark.

[smcd]

Hello all.

I have an '03 Bulldog that has no spark. This problem originated many months back when I started the bike and smoke began to appear under the seat. I flipped the kill switch and turned off the ignition, but the bike kept running. It finally died when several wires burned and the battery terminals melted.

I finally replaced the burned wires (with Big Dog wiring) and installed a new battery. Everything on the bike works - signals, lights, horn - but I have no spark. I tested the cam sensor, and it appears to be ok. All the burned/melted wires have been replaced. I opened up the Thunderheart ignition module, and though I did not test it, it doesn't look or smell bad.

I have power to the coil. I replaced the Dynatek coil with a HD coil of similar specs, and it made no difference. Does anyone have any ideas? It seems the only culprits left are the Thunderheart ignition module or the EHC unit.

 

[bearman]

Check to see if you have power to the Ignition module. if you do, then your problem is your ignition module or your cam sensor.

 

[smcd]

Check to see if you have power to the Ignition module. if you do, then your problem is your ignition module or your cam sensor.

Thanks bearman. I'll try that this afternoon.


I followed the cam sensor check procedure outlined below. Everything seemed to check out as it should. Is it safe to assume my cam sensor is ok?

1. Disconnect the cam sensor from the ignition module.
2. Take out your trusty multimeter and set it to the RX1 scale.
3. Now while touching the sensor backing plate with the negative meter lead touch the positive meter lead on each of the three wires of the sensor connector (red, black, & green). If you get continuity from the backing plate to any of them the sensor is bad.

If it passes the first test...
1. With your meter still at the same settings touch the positive meter lead to the green wire and the negative meter lead to the black wire. If you get an "open" it's good.
2. Then take the positive meter lead and touch the black sensor wire while touching the negative meter lead to the green wire. In this case an "open" is bad. A reading somewhere around 300 - 750 Kohms is what you're looking for.

 

[smcd]

Well, I installed a new Thunderheart ignition module, and I still don't get a spark. Any other thoughts? What is that small black box that sits on top of the battery?