Time to play name that electrical problem

[matchless1069]

So here's what's going on with my 2004 Chopper DT:
A couple of weeks ago I went out to start my bike and everything was dead, no headlight no speedo nothing. I took the seat off and tried to jump my bike using a battery charger, nothing. So I bought a new Interstate battery, charged it fully for 1 day before putting it in the bike, nothing. I now assume I have a grounding issue but it appears that all grounds are connected and tightened. There are no lights on the EHC. I bought a new circuit breaker to put in the bike to see if that's my problem (figured it's best to replace a $12.00 part than a $563.00 part first). If I still get no power does anyone have any suggestions? Is it my EHC? If it is I'm following Bdmridgebacks ditch the bitch thread and would seriously consider doing the same rewire rather than replacing a part that seems to have a high rate of failure. It's Bikefest here in Las Vegas this week and it sucks to be bikeless :down:

 

[ChopperJeff]

I had a similar problem occur on my 2005 Chopper, except it would go dead while idling, and it was as if someone took the battery out as NOTHING was working... no lights, speedo, zilch. But then if I just waited a few minutes it would magically come back to life and run fine.

So, it may be a different problem than yours, but the dealer replaced the ignition switch and claimed that they are known to go bad. After that, the bike ran fine for almost a year, until it happened again.

Is there any way you can bypass the ignition switch just to see if that's the culprit?

Hopefully GasMan will chime in as he appears to be the resident expert, but thought I'd throw out to you my experience and suggestion.

Good luck!

 

[barhopper]

See ya in Vegas Matchless, leaving Friday am.

 

[matchless1069]

See ya in Vegas Matchless, leaving Friday am.

Hopefully my bike will be running! Still gonna have a good time though bike or no bike. See ya at the Fremont Experience!

I'll have to check out my ignition switch......that's one area I have not checked yet.

 

[matchless1069]

Put in a new circuit breaker and still no luck. Is there a way to test the EHC to confirm that it is bad?

 

[Gas Man]

So the old battery died completely out of no where?
You installed a new battery and it died just sitting in the garage?

Do you have a service manual?

Sounds like your voltage regulator is smokin your battery. I had this happen to me before and that was the problem. Killed my new battery within 4 hrs.

The reason why I ask if you have the manual is it tells you how to test it. It has been posted here before but not sure where.

 

[Vegas]

It's not battery related. You need a wiring diagram. The ignition switch should be hot all the time. You can verify voltage there, then on the other side of the switch. If you have power to the EHC but no juice anywhere else it's done. Need to know which pins do what on the EHC connector.

 

[matchless1069]

So the old battery died completely out of no where?
You installed a new battery and it died just sitting in the garage?

Do you have a service manual?

Sounds like your voltage regulator is smokin your battery. I had this happen to me before and that was the problem. Killed my new battery within 4 hrs.

The reason why I ask if you have the manual is it tells you how to test it. It has been posted here before but not sure where.

Hello Gas, the old battery was from '06 so it was probably time for it to go anyway but yes it was completley dead and would not accept a charge. The new battery is fully charged and is not being drained by the bike. The bike is not getting any power from a fully charged battery. There are no lights powered on the EHC. When i turn the key in the ignition there is no headlight or speedo, and the run and start switches don't work. I do have a service manual but I did not see any info on testing the EHC in there (maybe I need to look harder).

 

[matchless1069]

It's not battery related. You need a wiring diagram. The ignition switch should be hot all the time. You can verify voltage there, then on the other side of the switch. If you have power to the EHC but no juice anywhere else it's done. Need to know which pins do what on the EHC connector.

Hello Vegas, It doesn't seem to have any power to the EHC...all lights are dark on it. I probably need to check my ignition switch next with a volt meter. Do you know any local shops that would be reputable for a rewire if it comes to that?

 

[Vegas]

I really don't. It needs done right if you decide to rewire the whole bike. Solder and shrink wrap. Not a fun job. Just got done wiring my whole restoration project. You can do it right once or half ass it multiple times. Unfortunately it's not as simple as wiring on these change overs.

 

[bdmridgeback]

I had about 10-12 hours total into doing my re-wire.

I would start with the ignition switch for sure. They are known to fail and easy to test.

 

[Raywood]

Hello Vegas, It doesn't seem to have any power to the EHC...all lights are dark on it. I probably need to check my ignition switch next with a volt meter. Do you know any local shops that would be reputable for a rewire if it comes to that?

Have you ensured all the wires got installed back on the battery lugs? Don't think it's your EHC cause even if it was you would have a headlight and power to the speedo and such. So, seems you have another issue whether it's the ignition switch or a missing wire on the battery.
Also, if you have a tender on the battery then whether the battery is good or bad it still supplies light to the headlight and other things if it's wired up correctly.

 

[N8KAM]

I'll take connectors for a Thousand Match.....

Chk the wire ends..... even though the connectors are secure to the battery the wire might have broken just after the metal portion of the connector and is being held in place by the shrink wrap.... wiggle the connectors and see how flexible they feel... maybe a slight tug also...

 

[Gas Man]

I would pull the tank and hot wire the ignition key wires... see if that helps. BDM key switches are known to being POS

 

[BBChopper]

First thing I would check is the ignition switch and plug.

 

[matchless1069]

Thanks guys. I'll try the ignition sugestions next.