EHC/BRAKE LIGHTS/WTF!!!

[BadBrad]

I had the same problem on my 05 chopper.After going crazy for a week and then getting the run around from the dealer I just said the hell with it and installed a new module #374 from wire plus and a wp-148 ignition switch.This solved everything and will elimate other electrical problems down the road.
GOOD LUCK

There ya go. Grand daddy wouldn't lie.

 

[2004BC]

that is the thing. I have the electrical schematic, and we have good continuity from the levers. We used a volt meter (my uncle is very electrically inclined) and when we pulled the front brake lever and pushed the rear pedal, he put a setting on the meter so that when we pulled the levers, it would make a buzzing sound from all levers so i can tell we have good continuity from the switches.
and then i used jumper wire which is pointing to the ehc. I will pull the switches and replace them in case they are tricking me somehow.

FYI a continuity test is a coarse way of measuring connections. It will just tell you if electricity will flow but nothing about the characteristics of the electricity that is flowing. Also if your testing live and your buzzer is telling you that 12vdc threshold has been reached then again that is a coarse measurement. Good luck!:up:

 

[2004hdfxsti]

alright I am back at this. Before I change to WP module, does anyone know what the HD part numbers are on the brake switches for the 03?

 

[BigDogBro1]

"When I turn the key on, the brake lights come on solid and then they will flicker to running lights, and then go back to brake lights. I have checked the switches in the controls and they are all good. I also have checked and have good continuity TO the EHC Module. All 3 modules seem to do the same thing. Could it be that all 3 are bad, or am I missing something? Do the Big Dog dealers have a way of bench testing them? My understanding is that some of the EHC modules have lights on them to indicate faults in them if there is a problem. These EHC modules do not have these lights. "

This is redundant but I thought it may help focus.

Let's knock this out..one at a time. You need to elliminate each piece and wire section.

Not having a wiring diagram is harder for me, but... I'll try to help out.

Make sure all connector pins are properly seated in connector housings.

1. Disconnect the front brake switch and turn on key to see if problem still exists.
If it does......

2. Disconnect the front brake harness to EHC if possible to see if problem still exists.
If it does......

3. Disconnect the rear brake switch and turn on key to see if problem still exists.
If it does......

4. Disconnect the rear brake harness to EHC if possible to see if problem still exists.
If it does......

5. Remove one taillight bulb, Check bulb contacts for cleanliness and see if problem still exists. If it does......

6. Reinstall old bulb.

7. Remove other taillight bulb Check bulb contacts for cleanliness and see if problem still exists. If it does......

8. Remove both old bulbs again.

9. Disconnect rear harness from EHC if possible and OHMS test end to end all conductors.

10. Now OHMS test between all conductors for a high resistance short.

11. Need to elliminate it all, back to the EHC box.

Can't think of anything else to try at the moment other than the Wire+.

 

[DRBarnhart]

ok so i went at it and checked some stuff out anyway. I ran a jumper from where the taillight wire connects coming out of the EHC. I connected both rears to the jumper wire and the problem is still there which rules out a damaged wire underneath the fender.

So currently I have good continuity at the J4 plug and the brake levers from the meter test, and now i have no broken wires under the fender.

Based on the stuff you've already told us I'm starting to think that there may be a wire out of place somewhere. Did the previous owner do any mods or even admit to trying any? On a 2003 a wire chaffed to the frame would pop a breaker and lights wouldn't turn on at all if you had a broken wire.

Anyway, with that in mind..
With everything still connected is there power at pin 5 of the J-4 connector when you turn on the ignition switch? If there is that's what's causing your problem since there shouldn't be power there until you step on the brake pedal or squeeze the brake lever.

Assuming for minute that there is power where/when there shouldn't be you're going to need to find out where it's coming from. (Installing a WP unit would be a waste of money if this is your problem.)

This is getting frustrating......

Take a deep breath my friend, there's enough knowledge on this site to get you up and running in no time!

Let us know what you find after BDB1's suggestions and my suggestion to check for voltage at pin 5 and we'll go from there...

Dennis

 

[thexaulted]

Hey Mike a couple things for you, they may be rudimentary but hey! I have an 03 Chopper also that I would have sworn was possessed by demons. I had gone off on several horrible rants in the past lol! 1. It is an absolute must that you do away with the ehc and replace it with the wire plus set up, that is if you ever want to have any peace with the bike! As I have said in the past in one of my rants, I've had a lot of different motorized toys over the years but never experienced anything like this! Get rid of the ehc now, or in my opinion sell the bike!
2. As far as flashing lights, (like I said I'm gonna be rudimentary) are you aware that the 03 Chop has the back off lights, when you hit the brakes they should flash 3 times and then return to the running lights when you come off of the brake!

One more story for you: My 03 was at the dealer for one of the 1,000,000+ electrical issues that I was having with it when they called me and said that it was fixed. So I go over to pick it up and they guy starts explaining to me what he did, we are inside the building with the bike. We turn the ignition switch on and everything lights up and works the way it should. As soon as he starts the bike every lighted thing on the bike goes into a discotheque strobe effect:lol: "It wasn't doing that before," he tells me and I said yea it wasn't doing it when I dropped it off. "Must be some type of short or another EHC problem":angry: A week later, after tracing wires and taking the tank off because, "those wire's under the tank are usually some type of problem," he tells me that nobody can figure it out and they are waiting for a call from "The Factory!" Yea, it was bad plug wires!

Anyway check those plug wires and ditch that EHC before its too late and you go crazy like me:loony:

 

[2004hdfxsti]

I will check out these ideas and see what is going on. It does have power at the pin 5 of the J4 when the brake lever is pressed. I will go through this and eliminate them as I can. I guess I just want to rule everything out before going Wires Plus because I fear that I will put in that module and still have the problem.
I do not believe the previous owner did much, however they did ditch the front turn signals by cutting the wire and putting it under the seat. I did solder on new wire and attach new turn signals. I am going to go to Wires Plus, but I do want to try to eliminate this issue prior to doing that, assuming it is not the same issue with the 3 EHC modules that I have.

Thanks for all the help everyone. I will make sure to check all of these issues and report back to you with my findings.

 

[DRBarnhart]

It does have power at the pin 5 of the J4 when the brake lever is pressed.

But does it have power before you press the brake lever?

I guess I just want to rule everything out before going Wires Plus because I fear that I will put in that module and still have the problem.

Absolutely true! The WP setup will only fix a bad EHC. If your problem is somewhere else it'll still be here after the install...

I do not believe the previous owner did much, however they did ditch the front turn signals by cutting the wire and putting it under the seat.

Which wires were cut? And where?

I did solder on new wire and attach new turn signals.

Stock turn signals? Have you tried the bike with the new signals disconnected?

I am going to go to Wires Plus, but I do want to try to eliminate this issue prior to doing that, assuming it is not the same issue with the 3 EHC modules that I have.

Smart! :2thumbs:

I will make sure to check all of these issues and report back to you with my findings.

We'll be waiting...

Dennis

 

[TLB08K9]

Click on the photo, Is it doing this?

 

[2004hdfxsti]

With regards to that photo, it is similar, however the brake lights will stay on, and then flicker and go back to solid as if the brakes were pressed.
THe turn signals I picked up were out of a catalog, look exactly the same, but they did come with their own circuit board.

The front turn signal wires were cut, it looks like under the tank about half way. I did solder on new wire and continued routing the turn signal wires to the signal

 

[BigDogBro1]

Did you have this problem prior to installing the new aftermarket front turnsignals?

Are the new lights from Bigdog or aftermarket?

Are the specifically for Bigdog?

Do you have to RUN the engine to get the problem?

You might try disconnecting the fronts and see what happens.

Are the new fronts LED or bulb? Where was this circuit board on the new lights?

 

[2004hdfxsti]

the new lights are out of a catalog, but not Big Dog. the board is inside the housing, just like on the big dog ones. they are LED...so essentially, they are aftermarket LED signals out of a catalog

i got them here....

VIEWING TUCKER ROCKY PUBLICATION PAGES

they are the ones on the bottom left P/N 48-9855

 

[DRBarnhart]

The front turn signal wires were cut, it looks like under the tank about half way. I did solder on new wire and continued routing the turn signal wires to the signal

What do the front signals do when you turn the bike on?

Dennis

 

[BigDogBro1]

Did you have this problem prior to installing the new aftermarket front turnsignals?

Are the front signals working?

You might try disconnecting the fronts and see what happens.

Do you have to RUN the engine to get the problem?

 

[TLB08K9]

Ok mine while riding would stay solid, but at times flicker like this. I had a cracked board in my handle bar controls. So small you could not see it. The shop in BR did something to test it and found out what it was. Replaced the board and 8k miles later no issues "knock on wood"

 

[DRBarnhart]

Ok mine while riding would stay solid, but at times flicker like this. I had a cracked board in my handle bar controls.

This makes me think of another question (Thanks Henry!)...

Has a Cruise-Mate been installed on your bike Mike? I'm not thinking as much about there being a crack in the control board as there being a small metal sliver left behind. I've read where that's happened...

Dennis

 

[2004hdfxsti]

The front turn signals seem to work fine. I do not think it was doing it prior to installing them, however I only put about 10 miles on it due to my injury.

I do not know if the bike has cruise mate as i am not sure what that is, however if it is a sort of thumbscrew cruise control or something, it does not have it

 

[BigDogBro1]

The front turn signals seem to work fine. I do not think it was doing it prior to installing them, however I only put about 10 miles on it due to my injury.

I do not know if the bike has cruise mate as i am not sure what that is, however if it is a sort of thumbscrew cruise control or something, it does not have it

I understand the agony of this troubleshooting but it could save you a bundle. Hang in there!

You may want to revisit the prior front turnsignal times and disconnect all wires to the front signals and see if the rears still have the problem.

 

[DRBarnhart]

The front turn signals seem to work fine. I do not think it was doing it prior to installing them...

You may want to revisit the prior front turnsignal times and disconnect all wires to the front signals and see if the rears still have the problem.

Ditto! :up:

I do not know if the bike has cruise mate as i am not sure what that is, however if it is a sort of thumbscrew cruise control or something, it does not have it

Instead of the thumbscrew "cruise control" it's a lever that many members on this forum have installed.

Dennis

 

[2004hdfxsti]

allllllllllllllllllrighty.....same problem still going on after WP install. hooked the taillights up to volt meter, and with the brake levers NOT pushed, it is reading 6v. Should be at 0. Any ideas what could be causing this?