Fault Code Ingition

[Rottweiler]

Ok it is getting warmer snow is finally gone. Time to see if the bike will start. Turn on the key, looks good so far head light is on with no flashing lights, Hit the run button then the start button bike turn over then a fault light comes on. I get the manual out and it is the Ignition fault light. the manual says open or short condition in the Ignition circuit. Will light when the run button is push may flash while motorcycle is running. If I rev it up sometimes the light goes out. Is this the key switch or something else? Key switch reed good with a ohm meter. Does this mean Ignition coils? Thanks in advance

 

[KaptinAmerika]

That light means you have short or open condition somewhere in the ignition circuit
Break out your electrical schematic and start troubleshooting
It may well be a rubbed wire under the tank

 

[Rottweiler]

udate

ok multi meter in hand. No Alcohol Yet There is only six wires in the ignition circuit can't be that hard. disconnect neg. EHC wire before unplugging 50 pin connector. All six wire read open to ground. Checked all 50 pins and the only ones that read to ground, all go to the Headlight about 965 ohms on all? Bike does run with 2007 EHC but has ignition fault light. Installed the correct 2004 EHC SAME FAULT bike will not start. I cannot believe a open circuit with the bike starting and running? It's time to look for a good shop. There was a thread on here somewhere.

 

[DRBarnhart]

I'm a little confused with your troubleshooting...

Turn on the key, looks good so far head light is on with no flashing lights, Hit the run button then the start button bike turn over then a fault light comes on. I get the manual out and it is the Ignition fault light. the manual says open or short condition in the Ignition circuit. Will light when the run button is push may flash while motorcycle is running.

So far so good...

If I rev it up sometimes the light goes out.

So you're saying it starts and runs? Or not?

There is only six wires in the ignition circuit can't be that hard.

Do you have a wiring diagram? Actually there are 8... 3 from the ignition module to the cam sensor, 3 from the EHC to the ignition module, 1 from the ignition module to the coil, and 1 from the EHC to the other post of the coil.

All six wire read open to ground.

Only the black wire going from the EHC to the ignition module should have continuity to ground assuming the ground wire from the battery to the EHC is connected!

Checked all 50 pins...

Since everything gets its ground from the EHC you won't have any wires showing ground after you disconnected the negative lead from the EHC. Anyway, why would you check ALL of the wires? You need to stick with the problem at hand and not measure stuff that has no bearing on it. Just creates confusion... in my pee brain anyway!

Installed the correct 2004 EHC SAME FAULT bike will not start. I cannot believe a open circuit with the bike starting and running?

So back to my question of whether the bike starts or not?

Dennis

 

[Rottweiler]

Bike will start with the 2007 EHC. Bike will not start with the 2004 EHC. When the run button is pushed I get a Ignition fault with both EHC's.

 

[Rottweiler]

I have been checking for grounds from the 50 pin connector with EHC disconected from the battery. How should I be checking?

 

[DRBarnhart]

Bike will start with the 2007 EHC. Bike will not start with the 2004 EHC.

And when it's running... how does it run? Meaning "perfect", "stalls", "shuts down when it feels like it", etc.?

When the run button is pushed I get a Ignition fault with both EHC's.

Here's what the book says about the ignition LED on the EHC...

"There are times when a fault light coming on is actually normal.
One of the LED's that will be on normally is the one labeled "ignition". Since the ignition circuit
is constantly being switched on and off the red LED for the ignition circuit will always be on and it
will flash at the same rate as the plugs are being fired. This indicator is a good way to check to
see if the ignition module is getting power. The Ignition LED will only come on when the
"RUN" button has been pushed."

Dennis

 

[DRBarnhart]

I have been checking for grounds from the 50 pin connector with EHC disconected from the battery. How should I be checking?

Would I be correct in assuming you mean you're checking the connector side, not the EHC?

Like I said before... stick with the problem at hand. One thing at a time. If you're only issue is ignition then stick with checked the few wires that could actually be causing you grief!

Dennis

PS Since the '04 and '07 EHC's are different, I'm again assuming you must have the adapters to allow it to plug in?

 

[Rottweiler]

Dennis
Yes I have a adapter plate. Today I turned the key and four ways flash with no headlight. 12.4 vdc on battery. Then after a while of turning key off then on bike starts. Took it for a short ride. Yes it does miss sometimes other times runs like a raped ape. FYI I did buy a new back bone harness and replaced last year when my original EHC died. I got a 2007 EHC first with adapter but would get the flashing four ways 50% of the time. So I got another 2004 EHC thought it might be looking for something it the power up test that was different between 2007 and 2004. YES I bought a new battery also. I bought the bike last year the previous guy had a open primary installed. The only problem he told me was wires going to the left rear light got rubbed though by the read tire. Fixed them then the EHC started acting up. It's been a long down hill slope from there. I have only put 105 miles on bike since I had it. Looking for a good BIG DOG shop in Eastern PA.

 

[Rottweiler]

I was checking for grounds at the 50 pin plug and none read to ground for the Ignition pins 38 & 18 key switch, 13 &14 coil power and module power, 20 & 37 cam signal and ground. I get the red Ignition light after the run button is pushed before the start is pressed. It has the stock Ignition and coil. Another question should the headlight wires read about 965 ohms to the frame / ground? Both the hi and low even the ground wire reads the same?

 

[Sven]

Bike will start with the 2007 EHC. Bike will not start with the 2004 EHC. When the run button is pushed I get a Ignition fault with both EHC's... the previous guy had a open primary installed. The only problem he told me was wires going to the left rear light got rubbed though by the read tire. Fixed them then the EHC started acting up. It's been a long down hill slope from there.

3wV (think out 3 variables to a wire/jobber:

1. Wire out of connector.
2. Connectors not connected.
3. Short to ground-out of range signal. <<<< Ding-Ding-Ding! We have a winner!

There is no (1) when the EHC's are swapped.
There is no (2) happening when the EHC's are plugged in.
There she blows (3) signal out of range. Why? Because you swap boxes it says all wires are up and running. One box is out of range because the other box starts the bike, therefore, no 1-2 wire variables are out of some pin you are searching for. Make sense?

4th Variable: I'd disconnect the taillight assembly connector as far up the main harness I can. In fact, disconnect as many connectors you can find on the bike. This eliminates the last wire job repair or a question of integrity of the wire repair. A (2) move may shut the box's light off. Then, with a better signal or the signal it runs as it was designed to run within that range, the lights are offandango. Get it?

A short still sends 1 number in as an electrical signal. The box can measure it and the truth tables find the 'Best' binary number so the box understands machine language: it keeps running or not/keeps running or throws a code = Signal out of range outside or [inside a jobber] meaning a black box.

 

[Rottweiler]

Thanks for the reply. I will unplug all rear tail light wires at the main harness and see what happens. The rear lights do work fine. could it be the type of wire I used??

 

[Rottweiler]

Same thing with rear light disconnected.

 

[Rottweiler]

Took it for another ride about 15 miles ran fine. Will keep it on tender and only short rides for now.

 

[Rottweiler]

(That light means you have short or open condition somewhere in the ignition circuit
Break out your electrical schematic and start troubleshooting
It may well be a rubbed wire under the tank)



Had some time on Sunday. Worked on bike for about 10 hours. Think I found the short. It is only there with power on and it brings down the voltage to the Thunder Heart module to about 6-7 volts. Tach / Annunciator ring. One of the reasons I replaced the backbone harness was a bad pin at the 50 pin connector. Pin 21 Yellow wire to tach. I cut it off and the 2004 Ehc works now. What a pain to find!! Red light on Thunder Heart module would not light up after run button pushed. Took connector apart and stuck pins in the red and black applied 12 vdc and light lit. Checked power at EHC side of connector and had 12 vdc. with module unplugged. Since I could not find any shorted wires any where else and that pin was corroded and not making a connection with the old backbone harness I cut it off the new harness. I already had the speedo and tach ring out and every thing look ok. Don't really need a tach but would like to have the other lights on that ring work. Looking for a tach / Annunciator ring if anyone has one. Thanks

 

[Rottweiler]

(And when it's running... how does it run? Meaning "perfect", "stalls", "shuts down when it feels like it", etc.?)


Sometimes runs great and sometime it misses. Tach was bringing voltage down at the ignition module. Tach read good with no power on it.

 

[DRBarnhart]

Sounds like you're hot on the trail!!! :2thumbs:

Dennis

 

[Rottweiler]

Yea I think this is what fried the ehc? When i got the bike that pin #21 was push up and coroted. That is why i replaced the back bone harness, when i fixed the cut wires going to the left rear light. They got rubbed through by the rear tire. Because the rear tire was not center of fender. I could go on for hours. My question now is while the starter is turning i get tach lights? This is happening with the yellow tach wire cut off!!! WTF Would like to replace the tach ring soon before it fries another ehc.

 

[Th3InfamousI]

You sure it's the physical tach ring and not the wire shorting out under the tank going to the tach ring?

 

[Rottweiler]

Yes had the tank off and the tach ring out wires are good to tach. Also the black ground wire from tach read to ground with speedo mounted on the bike. Ground goes away by lifting speedo off mounting bracket. The ring is shorted to the speedo cone. Can not figure how the tach lights up, about the first 4 or 5 lights come on when the starter is turning with the yellow tach single wire going to it cut off. The turn signals, oil and neutral lights all work ok. Can not think of any connection with the speedo or tach when the starter is turning. WTF