2004 Chopper Wires Plus Conversion Issue

[DJPaulyPaul]

Just bought this Chopper and the EHC went bad...only 3500 Miles total on the bike.
Headlight Low beam was not working initially then the whole bike went dead.
Bought the Wires Plus Kit after reading up on the problem here on the forum.

Installed it yesterday but have a few issues:
1. The new ignition switch that I got from wire plus also barely fits and barely lets the plug wires to be re-installed, after installation I could not get to last position...must have cranked to much on the set screw I installed, I ended up just wiring everything to position 2 and thta is working fine....Any better switch i could get for this?

2. After re-wiring the ignition switch to the 2nd position, I noticed the headlight comes on then immediately shuts off when the light on the billet "thunderheart" module comes on. After that I can toggle the headlight on using the switch but I dont think I'm getting a low or High beam just one light only. All other controls are working properly. Any ideas???


Any help or direction would be greatly appreciated...trying to get to Sturgis next week and show off my new bike!

Thanks

 

[Bobby Schulz]

Position 1 and 2.... I assume is ignition on (1) and (2) is for headlight on/ignition on. I doubt that the set screw is too tight. You may just have a bad switch. The switch is a common HD switch and you can get them at the dealer.

The 2nd question is easy...the wire plus will shut the high beam off on its on to the low beam. So when you toggle you are getting the high beam back on. Check the wiring to the low beam as well as the bulb.