Help with this problem please

[Chopperdave70]

Hello, i am a new member. I did the introduction thing but not sure it ended up in the right place. My name is dave, i bought a 2004 big dog a couple of months ago and have been trying to get in as many miles as possible before it turns cold. All was well except the speedo was not working. I tried to reset it but each time it displayed error. I figured who needs a speedo anyway. When i got the bike the front brakes also did not work, i rebuilt the front master cylinder btw a 5/8" jay brake kit will work perfectly plus easy to find and cheaper than the big dog kit. After i fixed that i decided to go for a ride, i get only an 1/8 mile or so and the bike starts to miss and backfire so i turn around and try to get back home. It dies and i coast to a stop on the side of the road and notice smoke. I notice the speed sensor wire on the trans is on fire so i turn off the key and it goes out. At this point the bike will not start. I bought a new sensor for a bigdog and put it in, all wires look fine on the old one except near the sensor itself. After installing the new one i noticed the positive battery cable was loose so i tightened it. I have no headlight, turn signal lights come on but do not blink, bike will not turn over, i looked at the ehc no obvious problems, doesnt smell burnt, does have one yellow light lit up when the key is on. I have worked on many bikes but big dog electricals are really a pain. Sorry for such a long post but i figure it helps to be very detailed. Thanks in advance for any help getting my dog going again

 

[BadBrad]

The loose positive wire may have caused your EHC to take a dive. I know! Everyone is quick to blame the EHC on any electrical issue, but when you have several electrical problems occur at the same time, it's likly to be related to the EHC. Something definitely caused your speedo harness to catch fire! First, I would make sure the battery is still good by having it load tested or you can just check the voltage with a meter, both while it is sitting and also while you push the start button to crank the bike. Also, you should have a breaker under the seat. The electrical fire could have cause your breaker to disconnect. I'm not sure if the breaker being bad would still let your tail lights come on. Do you hear any "click" or any kind of noise when you try to crank it? Check (with a meter) to see if you're getting fire to the starter when you push the start button. Also, check the green wire going to the starter for a good connection. If the battery, breaker and starter check out ok, then I would look at your EHC. I'm not sure what the yellow light indicates on that year model, but someone should be able to tell you.

 

[Th3InfamousI]

Hello, i am a new member. I did the introduction thing but not sure it ended up in the right place. My name is dave, i bought a 2004 big dog a couple of months ago and have been trying to get in as many miles as possible before it turns cold. All was well except the speedo was not working. I tried to reset it but each time it displayed error. I figured who needs a speedo anyway. When i got the bike the front brakes also did not work, i rebuilt the front master cylinder btw a 5/8" jay brake kit will work perfectly plus easy to find and cheaper than the big dog kit. After i fixed that i decided to go for a ride, i get only an 1/8 mile or so and the bike starts to miss and backfire so i turn around and try to get back home. It dies and i coast to a stop on the side of the road and notice smoke. I notice the speed sensor wire on the trans is on fire so i turn off the key and it goes out. At this point the bike will not start. I bought a new sensor for a bigdog and put it in, all wires look fine on the old one except near the sensor itself. After installing the new one i noticed the positive battery cable was loose so i tightened it. I have no headlight, turn signal lights come on but do not blink, bike will not turn over, i looked at the ehc no obvious problems, doesnt smell burnt, does have one yellow light lit up when the key is on. I have worked on many bikes but big dog electricals are really a pain. Sorry for such a long post but i figure it helps to be very detailed. Thanks in advance for any help getting my dog going again

Yellow is the Power Light, Here is a the EHC Fault Light Diagram. I Also included a electrical schematic. As the guy above states get your batt tested. Just an FYI I have an 04 and the Yellow "Main Power" Light is never on.

 

[Chopperdave70]

I will check those things and see whats up, i can get a new EHC for $200 but i hate to buy one. Thanks for the info i will let you know what i figure out

 

[TimNY]

Dave
Don't get discouraged. You will figure it out.
I'm a big fan of the 03 04 Choppers.
I'm not too keen on the eletrical end of the stock wiring.
But I'm shure you will find the help you need here from knowledgeable members.
Keep us posted

 

[BadBrad]

Go back with a Wire Plus if you go back with anything and save yourself the headache long term. It's tried and proven! May cost a little more initially, but it will save you on down the road. Nothing worse than being left stranded.

 

[Chopperdave70]

Update... I checked the battery and it is ok, i checked the relay and it is ok and then i hit the start button and for reasons i cant begin to understand it started, it was running very rough and wanted to die when i twist the throttle. I did notice now there are 2 red lights and one yellow on the ehc while running and the red light on the ign module was on. Still no headlight. Do you think it may be the ehc causing it to run rough and no headlight?

 

[Nomad2day]

No...
Is the bulb good and the connector plugged in good..

 

[DRBarnhart]

Update... I did notice now there are 2 red lights and one yellow on the ehc while running and the red light on the ign module was on. Still no headlight.

And this is the part where we guess which lights are lit?

:bang:

Dennis

 

[Chopperdave70]

The episode may have blown low beam because it has high beam and the turn signals are working

 

[Chopperdave70]

Ign, main power, and low beam are whats lit up according to the diagram posted

 

[Chopperdave70]

Thanks for the diagrams they have been helpfull

 

[Th3InfamousI]

Ign, main power, and low beam are whats lit up according to the diagram posted

Maybe my 04 is weird but when my bike is on and running only ignition light is on, main power is off.

Low beam fault light being on is bad check your headlight connector some users have melted theirs. Does the headlight even turn on with the key?

 

[DRBarnhart]

Maybe my 04 is weird but when my bike is on and running only ignition light is on, main power is off.

Low beam fault light being on is bad check your headlight connector some users have melted theirs. Does the headlight even turn on with the key?

:iagree:
Sounds like there's a problem (open) in the power up circuit. I'd recheck that speed sensor...

Dennis

 

[Chopperdave70]

The headlight will turn on with the key if left on high beam, low beam is not working i will check it to see if it blew low beam or if its the connector. I put the new speedo sensor in however when i got it i noticed they sent the wrong one, they sent the shorter one. My transmission has two places for speedo sensors which seems strange but i put it in the other place because it appears that they are at different heights to allow the use of either. Anyone else have this on theirs?

 

[DRBarnhart]

My transmission has two places for speedo sensors...

Got a pic?

Dennis

 

[Slick-Dog]

CHECK the ground wires to your headlight... On my 03 chopper there on the - side ..hooked to the frame .... Turn key on (dont start) and move those wires around....now see if your low beam comes back.....

 

[Chopperdave70]

I noticed when i got my new speedo sensor it was the wrong one, i needed the longer one and got the shorter one. I noticed to places on the trans where a speedo sensor could go. So i used the place that would seem to place it closer therefore maybe making up for it being shorter. I have noticed that the speedo only cycled up to about 40 mph when the key is turned on instead of all the way over. Also i checked and for the headlight to come on i have to turn it on high beam. Im thinking of buying another sensor and go from there

 

[Chopperdave70]

Switched the speedo sensor back with no change the part number is the same on both except there is an R at the end of the new one. If anyone has the correct one for my bike i will be happy to buy it and whatever i have left from this misadventure i will post and give to someone on here in hopes that i may save them some money.

 

[Chopperdave70]

Btw the part number of the one i need is BD4122 04