04 chopper wiring question

[dammit]

Well yes, I need a little help. Got a wire hanging loose. It is a black wire that comes from the ehc on the right side and had a spade connector on it. I think it is a ground, but don't know and don't want to ground a wire that isn't a ground. I had a starter problem and had it out so probably screwed it up myself. Now after starter is replaced headlights don't work, comp. releases aren't working, thunderheart lights up sometimes and not others?? Ain't sure but am hoping this wire is the reason. Out of the 5 wires coming out of the right side of the ehc it is the middle wire on the outside(right). A little help sure would be appreciated. Need this thing to run while weather is this great and got a couple days off. Thanks.....Dammit

 

[dammit]

Sorry guys, shoulda mentioned the wire hangs down between starter and rear fenderwell and is gray colored inside black shell. Thanks again

 

[DRBarnhart]

It is a black wire that comes from the ehc on the right side and had a spade connector on it.

Sorry guys, shoulda mentioned the wire hangs down between starter and rear fenderwell and is gray colored inside black shell. Thanks again

Now which is it? The black wire from the EHC (which is the ground to the battery) or is it grey (which goes to the horn)?

Dennis

PS And you're not talking about any of the wires going to the 50 pin harness connector, right?

 

[dammit]

it is the grey wire. thanks they all have a black outer shell. my bad

 

[dammit]

no, not 50 pin. wires on opposite side of ehc

 

[chacha]

Picture would be a BIG help. Given the symptoms, sounds like a ground.

 

[DRBarnhart]

Picture would be a BIG help. Given the symptoms, sounds like a ground.

And most likely the grey wire wouldn't be the cause of the problems unless it's touching a ground.

I'd recheck the battery connections...

Dennis

 

[dammit]

If this is only to the horn, then it's probably not responsible for compression release, headlight and other issues. thought if it was the main ground for the ehc it might be causing all this bs that wasn't happening til I pulled starter and also replaced battery. If I hold compression releases in it will turn over, but with a very large strain on battery and turning over very slow?? Think starter is ok, but battery cables getting very hot and motor rolls over, stops,rolls, stops?? Just trying to figure it out if not bad cables, battery, or starter??

 

[dammit]

I still have battery and starter off. Going to head out to have battery load tested even though it's new. Trying to absolutely rule out bad new battery. Far as posting pics, I'm screwed. Ex took all that stuff when she left. Thats why I described it as best as I could??

 

[dammit]

Don't know how you guys know that grey wire is horn, but you guys are great help!!

 

[DRBarnhart]

If this is only to the horn, then it's probably not responsible for compression release, headlight and other issues.

True.

...bs that wasn't happening til I pulled starter and also replaced battery. If I hold compression releases in it will turn over, but with a very large strain on battery and turning over very slow?? Think starter is ok, but battery cables getting very hot and motor rolls over, stops,rolls, stops??

Better make sure you got the right wires on the right battery terminals (new battery could have poles on the opposite sides as your old battery)!! And recheck the wires on the starter...

Just trying to figure it out if not bad cables, battery, or starter??

Cables - wouldn't think so.
Battery - probably not.
Starter - is it new or rebuilt? Never know.

Dennis

 

[DRBarnhart]

Don't know how you guys ...

"You guys"?

There's only one of me... :2thumbs: (And that's probably a good thing! )

... know that grey wire is horn

Wiring diagram!

Dennis

 

[dammit]

Thanks Dennis for your help. I am sure you're right on the grey wire. Horn never did work since I bout bike. That being said starter is original rebuilt by local starter guru. It turns over like a bitch on his bench, but that's with no load?? There also was a broken piece of wire I had never seen coming off frame below starter. Didn't want to connect that grey wire to it without checking on here. Don't have a wiring diagram. Makes me wonder what was grounded to the frame.

 

[DRBarnhart]

There also was a broken piece of wire I had never seen coming off frame below starter.

How big is that wire (gauge)?

Dennis

 

[dammit]

14 gauge. It is black and was broke off only bout three inches long. Bolted to right side on rear of frame crossmember below starter.

 

[aspen874]

Dennis, You obviously know a lot about the electrical systems on Bigdogs, I think it's great the way you have helped people here. :2thumbs:

P.S. When i start having electrical problems, I'm just going to ship my bike to you. :lol:

 

[Keith S]

If you are still struggling, here is a link that has the wiring diagram for an 04 Chopper in it.

Hope it helps.

http://www.bigdogbiker.com/forums/technical/8479-wiring-diagram.html

 

[dammit]

Yes that helps!!! thanks Keith!! Saved that in favorites and hope not to need it too many times.

 

[DRBarnhart]

Dennis, You obviously know a lot about the electrical systems on Bigdogs, I think it's great the way you have helped people here. :2thumbs:

Thanks! I do what I can. It would be a lot easier if I could work on problems in person 'cause troubleshooting on the internet sucks!!! (Photos do help!)

P.S. When i start having electrical problems, I'm just going to ship my bike to you. :lol:

And I'd be happy to do it too!!

Thanks again!

Dennis

 

[DRBarnhart]

If you are still struggling, here is a link that has the wiring diagram for an 04 Chopper in it.

Hope it helps.

http://www.bigdogbiker.com/forums/technical/8479-wiring-diagram.html

:2thumbs:

Dennis