multiple ignition module failures
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,196
Likes: 3,085
From: NW AR
And the more current it draws, to the point that it could (possibly) fry a stock ignition module.
Thread Starter
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Cruiser
Joined: Jan 2014
Posts: 147
Likes: 61
From: Mulkeytown, IL
I did check the coil. Ohmed out perfectly. That is the frustrating part, nothing tests even remotely bad! I have been wrenching on bikes for 50 years and it's s... like this that drives us all crazy!
I have another Ebay used module on the way. I will replace the key switch first since I have one on the way. I need to check the amperage output of the charging system. Voltage is within specs. I also need to do a voltage drop test on the whole system. Just because something ohms out properly doesn't mean it can carry the required current (iffy connectors/broken wire strands). I even went through and cleaned all of the connectors and tightened them back up.
If all of this fails, I will probably go with the Ultima dual fire so I can keep my coil. I can't rely on the bike anymore. Sucks, because it has been very reliable for 11 years.
Thanks for all of the feedback!
I have another Ebay used module on the way. I will replace the key switch first since I have one on the way. I need to check the amperage output of the charging system. Voltage is within specs. I also need to do a voltage drop test on the whole system. Just because something ohms out properly doesn't mean it can carry the required current (iffy connectors/broken wire strands). I even went through and cleaned all of the connectors and tightened them back up.
If all of this fails, I will probably go with the Ultima dual fire so I can keep my coil. I can't rely on the bike anymore. Sucks, because it has been very reliable for 11 years.
Thanks for all of the feedback!
Thread Starter
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Cruiser
Joined: Jan 2014
Posts: 147
Likes: 61
From: Mulkeytown, IL
Thank you very much for the offer. If I need another one I'll let you know. If the one I test next fails, I think it will be on to an Ultima system.
Grand HDF Member
Joined: Apr 2007
Posts: 3,723
Likes: 3,063
From: Brighton, MI
I did check the coil. Ohmed out perfectly. That is the frustrating part, nothing tests even remotely bad! I have been wrenching on bikes for 50 years and it's s... like this that drives us all crazy!
I have another Ebay used module on the way. I will replace the key switch first since I have one on the way. I need to check the amperage output of the charging system. Voltage is within specs. I also need to do a voltage drop test on the whole system. Just because something ohms out properly doesn't mean it can carry the required current (iffy connectors/broken wire strands). I even went through and cleaned all of the connectors and tightened them back up.
If all of this fails, I will probably go with the Ultima dual fire so I can keep my coil. I can't rely on the bike anymore. Sucks, because it has been very reliable for 11 years.
Thanks for all of the feedback!
I have another Ebay used module on the way. I will replace the key switch first since I have one on the way. I need to check the amperage output of the charging system. Voltage is within specs. I also need to do a voltage drop test on the whole system. Just because something ohms out properly doesn't mean it can carry the required current (iffy connectors/broken wire strands). I even went through and cleaned all of the connectors and tightened them back up.
If all of this fails, I will probably go with the Ultima dual fire so I can keep my coil. I can't rely on the bike anymore. Sucks, because it has been very reliable for 11 years.
Thanks for all of the feedback!
If your coil has been the common denominator through all the different modules, then change it (as mentioned earlier). It may test out fine, but change it anyways. YD
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
Coil ohmed out fine but no spark.
Here is the thread if you're interested
https://www.hdforums.com/forum/evo-c...r-8-miles.html
Thread Starter
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Cruiser
Joined: Jan 2014
Posts: 147
Likes: 61
From: Mulkeytown, IL
Update. I replaced the ignition switch and coil and installed another Ebay used module. I don't want to jinx myself, but so far so good. Several rides in really hot weather and no issues! I sure hope the coil was it and I can rely on my bike again.
We had a problem with V-6 outboards in the Navy that would have electrical problems after the engine got hot. Of course when they cooled down back at the shop we couldn't find the problem. I started putting the stators in an oven and then testing them. The heat would short the windings. I'll have to test my old coil the same way one day and see if it shorts.
Thanks for all of the feedback guys!
We had a problem with V-6 outboards in the Navy that would have electrical problems after the engine got hot. Of course when they cooled down back at the shop we couldn't find the problem. I started putting the stators in an oven and then testing them. The heat would short the windings. I'll have to test my old coil the same way one day and see if it shorts.
Thanks for all of the feedback guys!
Seasoned HDF Member
Joined: Mar 2010
Posts: 38,416
Likes: 6,366
From: Honah Lee
Put your Volt Ohm meter on 120 AC. Hook it to your battery and run it up to apx 2000 RPM. Do you see any AC voltage leaking across the diodes in the voltage regulator?
Have seen it numerous times on older cars of the 70 and 80s. Takes out the electronic ignition systems dwell to fire the coil. Before the OB2 system. The ECM bikes protect itself against reversing the DC. Probably AC. Your's probably does not even do DC let alone AC protection.
Have seen it numerous times on older cars of the 70 and 80s. Takes out the electronic ignition systems dwell to fire the coil. Before the OB2 system. The ECM bikes protect itself against reversing the DC. Probably AC. Your's probably does not even do DC let alone AC protection.
Last edited by Jackie Paper; Jul 16, 2017 at 05:27 AM. Reason: added protection to last sentance
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Seasoned HDF Member
Joined: Mar 2010
Posts: 38,416
Likes: 6,366
From: Honah Lee
Make sense now above? When the diodes in the regulator get old from heat, they usually short out. However, sometimes they short thru and then rather than just allow DC across, they let the AC from the AC alternator on our Harleys come thru.
Last edited by Jackie Paper; Jul 16, 2017 at 05:31 AM.