Testing Ignition Module

03BigPit

03BigPit

Member
Hello from the cuse. I am chasing a potentioal electrical issue on my 03 pitbull (bike will shut off while driving and sometimes start back up and sometimes not). Some of the guys on this forum have already helped me on checking for a gas issue (caps, draining tank and new fuel filter and air filter, cleaning carb). Coil has been tested good, wires good new plugs.
Some of the guys on the forum mention putting heat gun to my cm sensor and ignition sensor to see if they will cut out under heat. I'm alittle afraid they may be good and if I apply too much heat I will burn some thing out.
I would like to get my volt meter and check them electronically.
I have already reeived what the voltage levels should be on the cam sensor wires but I do not know how to check the Thunderheart Ignition module under the seat. I should probably check the resistor next to it but dont know what that is for.
Any help would be appreciated. The bike fires up know I just dont feel like getting stranded again
 
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drbalazo

Member
I just had this issue 2 days ago. I have the thunder heart ignition module also and my bike would start when cold but would shut of when warm. As per someone on this forum, I took a hair dryer directly to the module when it was cold and as soon as it got warm, the bike died. I spoke to Keith at thunder heart and explained what happened and he told me that it was 99% chance it was the ignition module. I ordered through them, $223.00 and I'll get it today. Hope this helps.
 
03BigPit

03BigPit

Member
Dan,
I tested the cam sensor and it was within spec (300 - 750 ohms). I put a hair dryer to the ignition module until it was hot to the touch and the bike shut down a minute later. I could also smell a burning wire smell. The light is not flickering when I try to restart and no spark to the plugs as well. Unpluged the wires that go to the cam sensor and it is still sending the proper ohms.
I think I have narrowed it down to the ignition module as well. Do you have Kevin's number at thunder heart so I can give him a call?
 
03BigPit

03BigPit

Member
Thanks. I gave her a call and placed the order. They wanted an extra $65 to ups overnight to NY. I passed on that and went standard 2-3 day ship. I will get it Mon/Tues
 
03BigPit

03BigPit

Member
OK - here we go. I received the new ignition module. Installed in 5 minutes. Interesting thing now - when I turn the ignition key on the red light on the module is supposed to light up for about a second or so and go out. It doesn't. It stays on when the bike starts up though. I'm going for a test ride - keep your fingers crossed :)
 
03BigPit

03BigPit

Member
Well Danny the test ride sucked ass. I made it about 1 effin mile and it quit again. Same exact problem. Bike would turn over like a champ but wouldn't fire. $200 bucks down the drain. I pushed the bike home and not a happy camper right about now. I should have put a "free to a good home" sign on the bike and left it at the side of the road!
I need to calm my nerves before deciding what to do with it next.
 
03BigPit

03BigPit

Member
My patience and knowledge gave up. I just brought it to a professional shop to figure it out. Hopefully I won't get bent over too much
 
grizfish

grizfish

Active Member
I don't like doing things twice, but.....on the checks you did before, did you do them when the bike was cold and running fine? Maybe you should try getting the scoot warmed up until it fails again, then check things. Especially the wiring near the engine. Something to consider.

Had a coil on a HD that was bad only when hot. Just tryin' to help.
 
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drbalazo

Member
I tested the bike when it was cold and ran just fine. Rode it for about a mile and it shut off. I let it cool off and it started back up again. I put a hair dryer o the module and it shut off. I installed the new ignition module the Same day you did and have been running just fine since then. Have ridden it for about 100 miles with no problem.


Maybe the cam sensor?
 
Last edited:
Gatlin5

Gatlin5

Active Member
drbalazo said:
I tested the bike when it was cold and ran just fine. Rode it for about a mile and it shut off. I let it cool off and it started back up again. I put a hair dryer o the module and it shut off. I installed the new ignition module the Same day you did and have been running just fine since then. Have ridden it for about 100 miles with no problem.
Click to expand...
Great Job! Thanks for the update! Good riding!:2thumbs::cheers:
 
03BigPit

03BigPit

Member
grzfish - yeah I checked both when the bike was cold and running and again when the bike got hot and shut down. I checked the coil: good. The cam sensor:good.
drbalazo - glad to hear your new ignition module fixed our problem.
I'll keep the post going when I hear back from the bike shop
 
big A

big A

Member
hey dave, im having the exact same problems that ur having. scoot just shuts down without any warning. i have checked alot of things and it still shuts down. mine doesnt seen to be a heat issue. ive ridden on some hot days and bike runs perfect. i checked the cam sensor using a meter and it checked good. of coarse this is when the ignition light is working. my scoot always fires right up after it dies so the chance to check everything when the prob occurrs is slim to none. sorry to hear you spent 200 bucks for the module. that is exactly what i cant afford. so im at a loss. please, please let us know what the mechanic finds. good luck.
 
03BigPit

03BigPit

Member
Hey Aaron,
I know the feeling of chasing an electrical gremlin -it sucks. Well after spending the $200 on a new thunderheart ignition module which still did not eliminate the problem I lost patience in trying to figure it out. I ended up towing it to a shop that works on Big Dogs, and of coarse while the bike sat there they could not duplicate the problem. So after loosing another week and a half of not riding this is what my options were-choice 1 was pay the mechanic his hourly rate to go through the entire electrical system and "if" he found the issue I would have and expensive hourly labor rate plus parts. Choice 2 is what I did - Installed a new Crane Hi-4 ignition system (which also replaced my cam sensor) and had it direct wired to the starter, coil and ignition key switch. This way I bybassed connecting into the EHC and also bypassed the inition module. This way bypassing the EHC if and when I have an issue with it I will always have spark and wont be left stranded on the side of the road(lights, signals and horn different issue -lol)
 
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