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  #1 (permalink)  
Old 11-06-2020, 09:36 AM
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ignition module or something else?

Hello all,

I'm trying to repair a friend's 2002 Tejas Rigid that just dies randomly, seemingly only on hot days.

I tore into the switch housing and found what looks like an ignition component of some kind bolted to the inside. It has a 6pin connector coming out of it and also has 3 wires all crimped to one ring connector that gets wired to the ignition switch.

It looks like it has a relay attached...what is this and is there any way to test it?
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ignition module or something else?-1.jpg   ignition module or something else?-2.jpg  
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  #2 (permalink)  
Old 11-06-2020, 01:24 PM
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During the chopper craze that spawned a ton of A/M chopper companies, some of the companies foolishly used proprietary electrical components.
The companies now out of business , means that their proprietary electrical components are now unobtainable.
Ask anyone with a Big Dog , one came into the shop I worked at with electrical issues , by the time we diagnosed the problem and id'd the component failure , it was determined that the electrical system was unworkable. A complete re-wire with standard easily gotten and replaced components was the best thing to do.
Thats what I suggest to you on this problem. Strip off alla the existing wiring that is enslaved to the proprietary components and install a generic harness or even better , do what I do and fabricate a custom harness.
USE STOCK COMPONENTS FOR EASY REPLACEMENT
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Old 11-06-2020, 03:05 PM
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Thanks for the input James.

That's ultimately what the guy wants to do, and have read of other success stories once they rewired them. More time in the garage is fine by me

Bob
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Old 11-06-2020, 03:38 PM
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Best plan.
Why waste time on a system with proprietary components?
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Old 11-09-2020, 08:17 AM
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The responses here are correct. They outthunk themselves.
Happens all the time.
The issue with IronHorse is they designed an interrupt into their
igniter. I have lost my schematic but the trick is to cut the BLK wire
going to igniter to defeat that interrupt.
It is a frustrating run error because any short - like the infamous tail lite short -
will cause a stop which then resets in to run.
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Old 11-10-2020, 04:25 AM
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Thanks for the replies guys

This being a 2002 Tejas, does it have an igniter?

It has a TwinTec 1005 ignition module (stock item?) and dual fire coil.
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Old 11-10-2020, 04:28 AM
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just to add - i have the black wire/white stripe going to one side of the coil (coming from kill switch?), and a red wire and black wire (not sure what this feeds) on the other.

With the key on, I have 12v on both sides of the coil, which I was sure was wrong...but rode the bike 40 miles yesterday with no issues.
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