2004 chopper

[04BDCHOPPER]

Hey guys! I have a 2004 chopper that will not shut off with the kill switch. The switch is telling the ECH to stop the engine but nothing happens. I cleaned the connections on the coil and still nothing. Could it be a broken wire from the ECH to the coil?

 

[Rottweiler]

How did you test the EHC is getting the signal from the kill switch? I would think if it was a broken wire to the coil it wouldn't run.

 

[Mr. Wright]

It could be the key switch. The key switch in the older bikes, weren't strong enough to hold up to the vibration. check the continuity across the switch wires whiler they are disconnected.

 

[Mikeinjersey]

Welcome from NJ,
This will help you troubleshoot the PCB

 

[04BDCHOPPER]

How did you test the EHC is getting the signal from the kill switch? I would think if it was a broken wire to the coil it wouldn't run.

The light on the EHC comes on when I hit the stop button but doesn’t shut the bike off.

 

[04BDCHOPPER]

Welcome from NJ,
This will help you troubleshoot the PCB

I have done this already and everything seems to be in working order unless I missed something

 

[04BDCHOPPER]

It could be the key switch. The key switch in the older bikes, weren't strong enough to hold up to the vibration. check the continuity across the switch wires whiler they are disconnected.

I will have to try that and see what happens

 

[Rottweiler]

The light on the EHC comes on when I hit the stop button but doesn’t shut the bike off.

That's not good. The output should be shutting off. You might have a wire rubbed through and is grounding.

 

[Rottweiler]

Do you have a good wire diagram

 

[04BDCHOPPER]

Do you have a good wire diagram

No I have not found anything

 

[Rottweiler]

 

[04BDCHOPPER]

Awesome. Thanks I’ll have to trace these wires tomorrow and see what I find out

 

[Rottweiler]

You are talking about the OFF button on the right handle bar?

 

[04BDCHOPPER]

Yeah

 

[Rottweiler]

Sounds like you may have a bad EHC.
Does the key switch still shut off the bike. If so ride it, but I believe a new EHC is in your future.

 

[Rottweiler]

Over winter send it out to get tested.

 

[04BDCHOPPER]

Sounds like you may have a bad EHC.
Does the key switch still shut off the bike. If so ride it, but I believe a new EHC is in your future.

Ok thanks and Yes I can shut the bike off using the key

 

[Mr. Wright]

Well this is different information. Ok, note to those that don't know. The first try at these type of controls back in 04, had some problems making connections. Mostly with the start button, because it was used the most.
If you still have the original circuit boards in the handle bar controls that is where your problem is.

 

[Rottweiler]

The light on the EHC comes on when I hit the stop button but doesn’t shut the bike off.

He said the light on the EHC comes on with the stop button but bike keeps running. so I think the handle bar board is functioning?

 

[Mikeinjersey]

Ok thanks and Yes I can shut the bike off using the key

The key sw turns on the EHC. The Run button turns on the ignition to make the bike ready to start. The off button turns off the ignition and stops the engine.
Follow Eric's instructions exactly ( 04 only lights the ignition module momentarily). Let the bike start (safety first) and then hit the off connector as he does to see if the bike continues to run. If the engine turns off (means wiring is good) your problem is with the switch and if it continues to run that means the EHC is not responding to the signal. Could be wiring to EHC or EHC itself.
Pull the connector off the EHC and check that all the wires are good and not backed out of the connector. Check for continuity between the PCB off wire and the EHC . Replace and re-grease the connector ( dielectric grease). If all wiring seems good your EHC is most likely the failure.
If you can't get to the bottom of the issue you could install a separate switch to power the ignition module. Less expensive than a new EHC. Although, I believe I have read somewhere (not sure why) that the EHC does like the ignition to be turned off by the off button and not the key switch. Good Luck