Trial and error fun

[Re4peR26]

Well as some of you know, Ive been having a couple issues with my ignition system.. I'm going to start replacing stuff within the week but before I do i figured id check with the pros...It all started with a bad battery, I replaced it and it was all good for quite a while.. Then my headlight started messing up again So i jumperd it from the tail light wire, Then my nutrual light stopped working and now my oil ( assuming EHC failure ) Sometimes my tach will work perfectly normal or not work at all.. Very strange

Heres what I've done! Ive pulled tach apart checked all connections all look great and nice and tight, Pulled the controls apart checked those aswell.. They look nice and clean. Pulled tank off to check those connecters aswell all nice clean and tight. So i fiddeled with my ehc plug and that was cleaned and Dielectric grease installed. So as you can see connections have been very throughtly checked and re-checked.. Ive had the multi-meter out for weeks now battery is perfect brand new less then a week old. Connecters all have good power.. I re-did some of my grounds the one on the battery and the one leading the the frame. So now that we have that out of the way here is what Ive done.. I purchased a cam sensor from bigdog, I got it rode for about 15 mins started doing the same old stuff... Had to get it towed wouldnt run long enough to even concider getting it home.. It would run for 3 seconds then die, So i sent that cam sensor back they sent me a new one, Ive since installed it have not rode anywhere but let it idle for a while, It didnt die but im sure it would...So this week I will be ordering my Dyna 2k ignition and getting that installed hoping that fixes my issues.. Suggestions thoughts comments?

 

[ringo]

looking at your issue's and what they have in common could point to a number of things such as, ignition module, EHC, wiring etc. Sounds like your own the right path with all the trouble shooting efforts. I hope you have a manual to look at

 

[Th3InfamousI]

You got an 04, there was a recall on the power harness on the EHC. I would go ahead and watch this video.
It might not be it, but it's a free check. I posted a picture of my fix.

Big Dog is recalling certain 2004 Chopper, Bulldog, Ridgeback, Mastiff, Boxer and Pitbull motorcycles. There is a possible loose connection between the harness connector and the electronic harness controller. This condition may cause the motorcycle to experience intermittent loss of electrical power to various components, which can lead to, among other things, a loss of headlamp function or a vehicle stall, increasing the risk of a crash. Big Dog will notify owners and dealers will repair the motorcycles free of charge. The safety recall began on May 24 2010. Owners may contact Big Dog at 316-219-9121. NHTSA campaign ID no. 10v180

It might not be it, but it's a free check. I posted a picture of my fix.

[ame=http://www.youtube.com/watch?v=GIO8xd5Ps9s&feature=youtube_gdata_player]O4rigid ehc connection issues - YouTube[/ame]

 

[Re4peR26]

looking at your issue's and what they have in common could point to a number of things such as, ignition module, EHC, wiring etc. Sounds like your own the right path with all the trouble shooting efforts. I hope you have a manual to look at

I do not have a manual, I just couldnt justify paying 100+ for something that didnt have all of the bikes info in it, Well I hear the newer manuals are actually worth it??

You got an 04, there was a recall on the power harness on the EHC. I would go ahead and watch this video.
It might not be it, but it's a free check. I posted a picture of my fix.




It might not be it, but it's a free check. I posted a picture of my fix.

O4rigid ehc connection issues - YouTube

Haha, Yeah I call her old faithful the bike has had a zip tie around the plug since the day I bought it, and now even cleaned connecters and dieelctric grease.. I noticed this its really strange, Cranking if it doesnt fire right away (its been real cold here) that the Tach will not work.. once its gets started.. However if I cycle the key and it does fire first time tach will work.

 

[Re4peR26]

Every connection was double checked today and re-dielctric greased, Tach, Under tank, coil, back bone, and misc going down near starter.. Ran it for about 45 mins today then boom just shut off.. Go to restart no light on thunderheart.. Wait 5 comes back to life for a lil.. So i have to say after a month of digging around is has to be.... Ignition module and maybe ignition switch.. I have dyna 2ki on the way and soon will order a keyswitch once i find a direct replacement or a good quality one.

The symtoms are what seems to be a weak tach signal sometimes, and its almost as if power is lost to ignition module..

 

[Re4peR26]

Yikes, After reading countless threads it could very well be my EHC, Which im beginning to think it is No oil light, Headlight function, Neutral light isnt working... I just dont understand how It could be running fine for say 10 mins, Then all the sudden just die with everything still on besides thunderheart.. Perhaps a pin is broke?

 

[dingo]

Deven - I experienced the exact same symptoms and found that the positive terminal bolt was tight but also just a hair too long resulting in a poor connection - changed to a shorter bolt, cleaned and dialectric greased each terminal and the problems resolved. Worth checking at least - good luck !

 

[BigDogBro1]

Sounds like a EHC power interruption problem possibly caused by a loose wire crimp, poor connection etc.

Wire brush/sand paper the battery terminals and harness conections to clean them. Check you headlight bulb connection for melting and causing a short.

 

[Re4peR26]

Deven - I experienced the exact same symptoms and found that the positive terminal bolt was tight but also just a hair too long resulting in a poor connection - changed to a shorter bolt, cleaned and dialectric greased each terminal and the problems resolved. Worth checking at least - good luck !

Sounds like a EHC power interruption problem possibly caused by a loose wire crimp, poor connection etc.

Wire brush/sand paper the battery terminals and harness conections to clean them. Check you headlight bulb connection for melting and causing a short.

I've checked all battery connections, Re did the ones that were bad, cleaned all of them aswell with sander, They are all clean and making good contact! I've talked with a few people around my neck of the woods... and some of them are saying I have all the signs of a bad coil... I'm going to go ahead and order a new coil and see where that takes me.

The bike will start and idle just fine, and when i go to ride it runs even better doesnt miss a beat then after a short while just boom dies and has to cool down before restarrting, but even then dies quite a bit.. I have a brand new cam sensor, So next thing down the line I would say is the Coil... Im guessing its original becasue it says 04 on it. So im going to try that before I sink any more kinda money in it.