No Power

Energy One

DoubleZAB

New Member
I have a 04 Boxer. Started the up fine yesterday, backed it out of the garage and it died. The bottom of the seat broke off the main negative terminal off the battery. Has this ever happen to anyone else? I replaced the negitive terminal and thought I would be up and running. Still no power. Battery has good charge.
Any Suggestions?

Thanks,
Joe
 

Little-Boo

Well-Known Member
Troop Supporter
You should do an introduction first and then ask for help. I know you need help and you will get the help you need, however we would like to know a little about you. :2thumbs:

I don't know much about the 04 bikes and don't know if they have a circuit breaker (CB), but if it does it may have tripped if you shorted out the battery. It's a little black & Gray box about 1/2 inch by 1 inch that has the VR (voltage regulator) attached to it. Should be located under the seat close to the battery. If it doesn't you may have fuse 40 (amp) in place of the CB, check make sure it's not blown.

So others will pop on here and help you out, but don't forget to tell us a little about you.

Carlos :whoop:
 

DoubleZAB

New Member
Carlos,

Thanks for the reply.
I don't think this model has a circuit breaker. There is a fuse that is not blown from my basic knowledge. I will continue to do more checking.

This is my first big V twin. Purchased it this winter. It only has 3300 miles and is in near new condition. Been riding sport bikes for a long time. Riding in Wisconsin is only a 1/2 year past time so every day that goes by not riding is not enjoyable. (unless I can play golf)

Looking forward to getting some help and helping and meeting others on the message board.

Thanks again.

Joe
 

Brew

Troop Supporter
Welcome from Washington State, hope you enjoy the site. Someone will be along to give some assistance. I like Carlos was thinking along the same lines. If I remember correctly, a member had the terminal short against the seat. Not sure if it was on a Boxer though. Perform a search, that may help you out. Do any of you guys remember who posted that?...:cheers:
 

mobsta

Well-Known Member
i have an 04 that has a relay mounted on the fender that connects to the battery.it has alittle black button on it to reset it.might try that,what ehc do you have?when you say negative terminal are you talking the actual battery terminal or the wire connector?you maybe missing a wire.i have heard of guys melting or breaking the terminal off the battery and causing the ehc to go south.do you have power to anything?just sayn,good luck:cheers:
 

DoubleZAB

New Member
Thanks for the help.
I will take a closer look tomorrow and let you know how things work out.
I would hate to have the ECM shorted out some of the discussions on the cost and availability.
Joe
 

DoubleZAB

New Member
The EHC is:
Big Dog CARB EHC
176-000010-00 rev F
176-000003-00 rev H
01-0476-00 rev M

I have power thru the 30 amp fuse into the EHC but no power coming out.
The EHC does not light up. It does have a USB connector.

The main ground wire broke off the negative terminal on the battery. Not sure if it could have shorted the system.

Any suggestions?

Thanks,
Joe
 

mobsta

Well-Known Member
my positive cable broke off on a ride,i had to stick it between the post and it came out a few times tryn to get it home,bike died but didnt hurt the ehc,i have read on here where some guys had terminals melt and fried the ehc so anything is possible.sure all the wires are tight and not shorten?joe
 

DoubleZAB

New Member
I double checked all of the connections to the battery. Everything is tight.
The battery has 13.2 volts so low voltage doesn't seem to be the issue.
Also disconected the EHC and reconnected it.
Power to both sides of the 30 amp fuse. Still not luck.

Thanks for all of the suggestions.

Joe
 

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
I double checked all of the connections to the battery. Everything is tight.
The battery has 13.2 volts so low voltage doesn't seem to be the issue.
Also disconected the EHC and reconnected it.
Power to both sides of the 30 amp fuse. Still not luck.

Thanks for all of the suggestions.

Joe
Is the fuse good? :D
 

BadBrad

2005 Pitbull
Seems like I recently read a post from Night Train about the '04s ECM not lighting up until you press the run button. Then one light should come on the ECM. He's a certified Big Dog mechanic that once worked for Big Dog if I remember right. Can't remember shit anymore. :job: Also, just because your battery is reading 13+ volts does not make it good. Take a reading while pressing the start button. Can you hear any "click" sounds while trying to start your bike?
 

DoubleZAB

New Member
Thanks for the suggestions.
I will double check the 30 amp fuse and double check with the start button.
Will keep you posted tomorrow.
Joe
 

BadBrad

2005 Pitbull
:lol: :lol: :lol:

NightTrain wasn't a certified BDM mechanic that I know of!

But he "WAS" an electrical engineer that worked for BDM for a while correcting a bunch of their electrical problems!

:zzdisappointed:

Only Bad "NEWS" Brad could dream this chit up!

:roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll: :roll:

Good try though! :2thumbs:

Thanks for this mornings little laugh! :2thumbs:

dead :D :lol: :cheers:
I didn't dream this shit up Dead. Well, maybe about the part of him being a mechanic, but I was close. Rocky says if I'm close, that's good enough for her.......except there was that one time I was off by a couple of inches and she don't play that shit! :spank: Here's Night Trains post about this. He's a little long winded, but seems to know what he's talking about. Here ya go:

I am sure I am going to repeat some of what you wrote in your original post, I just want to make sure I have it clear. You indicated the bike "died" while riding just like the key was turned off but from the way you write it, it sounds like the lights, speedo and other elctrical was still fine. So in reality was it more like the "Off" button was pressed? You also indicated that at one time you had the seat off and there were no LEDs on the EHC with key on. Did you press the "Run" key before you looked at it? None of the lights on a 2004 EHC will illuminate unless you have a fault on certain circuits or the Run button has been pressed (after run has been pressed the third LED will light). It is entirely possible the EHC is bad however lets check a couple more things out before you drop the money for a new module.

1. The cam plates are notorious for issues on 2004. Take the cam plate cover off and inspect. Some times you can see obvious damage. When you loose spark check to see if the light on the ignition module blinks when you have key on, run pressed and the starter is turning the motor over. It should blink as you crank.

2. As said the ignition diagnostic light on the EHC should not illuminate if the run button has been pressed. The EHC will default to Off when it is powered up. Next time you stall if it is safe do not touch the key, or any buttons on the hand controls. Pull off to the side of the road and take the seat off. See if the ignition LED is illuminated or if it is off. If it is on try to fire it back up and see if the ignition module light blinks. If the LED is not illuminated check your key switch to make sure it is not having an intermittent open. You should also check the wiring on your right side hand control. I have seen the wires damaged where the wires enter the bars under the hand controls and causes the EHC to think the bike was turned off. Take the hand control off and make sure none of the wires have been damaged.

3. There was a service bulliten that is now a recall on the 2004 EHC. It called to remove the dust seal from the ECH and fill the cavity with dielectric grease. The seal is too thick and does not allow the connector to fully seat and lock into place. The "seal" does nothing to keep out water anyway. Fill it with dielectric grease (not wheel bearing grease or assembly lube, don't laugh I have seen that). Fill the cavity with grease to about the top of the connector pins. When you put the connector back on some of the grease will squish out over the edge and help keep water out. All 4 locks should now engage and keep the connector connected. I have seen some people wire tie the connector as well.

I have not heard of any issues with the HID light on a 2004 EHC but I could not rule it out (Jake could probalby tell you if he has had anyone return an HID on a 2004). This is very unlikely but I will not pull anything off the table when I do not have any data to prove it one way or another.

Start with what I talked about above. Post any more observations, issue or questions you have and I and others will try to help ya out. Possible you have an EHC issue but I would lean towards one of the three items above. Worst thing that happens is you spend no money to look a little deaper and if it turns out to be the EHC you feel confident before you drop the coin.
 

mobsta

Well-Known Member
i read his post as his negative battery cable connector broke,fixed it and has no power at all to any thing so where does the cam sensor come into play?if he has no power hitting the run button makes no difference does it?now i'm confused.oh well i aint been on here much so i prolly forgot some stuff.:cheers:
 

mobsta

Well-Known Member
oh why do you have a 30 amp fuse?my 04 mastiff dosent.if this 30 amp fuse is in line with the ehc why didnt it blow before the ehc?are you sure you are not missing a wire that may have dropped down when you disconnected the wires to fix the broken one?just sayn.i am just a dumb ass and need to know i quess sorry.:lol::cheers:
 
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