**HELP**!! Bike won't start
 

I recently replaced the stock handlebars with 16" bars on my '04 FXDWG. Assembled new cables, wires, bars over the weekend. I was VERY meticulous with the solder work on the new wires - got everything hooked up properly - or so I thought. But once everything was back on (bars, tank, battery, etc.) - the starter motor will turn over but the spark plugs have no spark. I have check for broken/crimped wires but all is laid out smoothly. The headlight, turn signals, security system works great - everything powers up fine. But the bike won't fire up!!! The carb is getting fuel (throttle works) and all wires going to the ECM and fuse box are connected and tight. I put new plugs on but they don't have spark either. Fuses are good. Spark plug cables are good. Can someone please help????

Welcome to the Forum.
I'm not an expert, but... see if you have 12 volts supplied at the coil.

Sounds like you have a problem with the kill switch, I know on my 05 WG there is a spliced wire that goes to the kill switch, not the way it shows on the wiring diagrams. Only reason I caught it was through carefully documenting before I cut any wires loose. Sorry to say I did not keep the diagram I created. As I recall the Gray wire and the White/Black wire were spliced in the harness.
If you can open up the controls, check with a multi-meter to make sure the kill switch is connected properly.

Thanks - checked with multimeter (good) and also reconnected switch from old bars - same thing - engine turns over but no spark from spark plugs. Could it be a bad wire/connected somewhere else? I have checked the connections to the ECM/coil and all wires are connected. Also - battery is 100% charged. I have reset the security system - that didn't fix the ignition problem either.

Sorry to say but if the bike ran before you cut and spliced the wires and now it doesn't run the only possibility is you have made a mistake somewhere. I'd say the kill switch could be a possibility but the fact the starter engages tells me there is a chance you shorted out your ecm during the process.

did you, by any chance, not disconnect the battery before you began your work?

Thanks sniper77 for the reply. Battery was disconnected during all work. Perhaps it is a bad crank position sensor (CPS) or coil? Not sure why it would be as the bike ran fine before I changed the handlebars. I've tested the coil and it reads 0.6 ohms on the primary side and 11,260 ohms on the secondary side. Not sure this is within spec or not? Also, checked the start button on the handlebar and it's getting 12 volts from the battery so the wiring to the bars is intact. I still can't get this one figure out. I have read that the if the CPS goes bad the spark plugs will not fire. But I don't want to start buying parts that I can't afford if that's not the problem.

check the wiring at the switches. If anything is pinched or frayed and crossed it could be your problem right there.

Did you take pics of everything before you took it all apart? Maybe when you put it all back you croosed up some wires somewhere.

Yes - checked the switches. I'm thinking its a bad coil or CPS? Any thoughts? Coincidental - but maybe that's the issues. Any way to test coil or CPS to determine if they are good?

The electrical diagnostic manual for the 2003 Dyna Models says:

"Normal resistance range for the Ignition Coil Primary Circuit Test is 0.5-0.7 ohms; for the Secondary Circuit Test normal resistance range is 5.5-7.5K ohms....

A high resistance value might indicate that there is some corrosion/oxidation of the termionals. Clean the terminals and repeat resistance test. If resistance is still high after cleaning terminals, replace coil........."

I'm not sure if these values are the same for your 2004 WG; if they are it seems to me you will have to clean/replace the coil (for 2003 models p/n 31655-99, US$ 63.65 at Zanotti.com)

Furthermore it says:

"...Also check condition of spark plug cables. Insulation on cables may be cracked or damaged allowing high tension current to short to metal parts. This problem is most noticeable when cables are wet..."

I hope this info will help you solve your problem..

FXD2003Rider

Thanks. If anyone reading this can verify that an 11k ohm reading on the secondary side of the coil will prevent spark - please chime in............. :icon_worthy: