EHC replacement
- Thread starter Axel
- Start date
KaptinAmerika
Guru
I work with Electronik, Axel, because they are an excellent manufacturer and provide excellent warranty and customer service when issues arise. I have yet to have an issue when a warranty replacement was needed.
I have years of experience with Big Dog motorcycles and I can say with absolute certainty that a vast majority of the BDs have, have had, will have, take your pick, burned out or damaged electronic components and in some cases can't keep a battery in the bike for any real period of time without it getting damaged due to a poor choice in charging system selection by BD. So much so that the first thing we do with any new local customer is yank the stock charging system. In every case the damaged component issue went away. There are times when the cumulative damage from the OEM VR was great enough, in some components, that they still failed but there isn't anything one can do about that. There have been many other reasons for some of the damage but a huge portion of it was due to the OEM VR.
I have years of experience with Big Dog motorcycles and I can say with absolute certainty that a vast majority of the BDs have, have had, will have, take your pick, burned out or damaged electronic components and in some cases can't keep a battery in the bike for any real period of time without it getting damaged due to a poor choice in charging system selection by BD. So much so that the first thing we do with any new local customer is yank the stock charging system. In every case the damaged component issue went away. There are times when the cumulative damage from the OEM VR was great enough, in some components, that they still failed but there isn't anything one can do about that. There have been many other reasons for some of the damage but a huge portion of it was due to the OEM VR.
Freddiechopperrider
Member
I purchased my 05 chopper brand new from Dorschele a big dog Harley and iron horse dealer in Rochester NY, when I took
Mine in for the recall they never mentioned the charging system being bad just the possibility of a failing circuit breaker in the case if the voltage regulator shorted out. The dealer installed a fuse link in place of the circuit breaker and I’ve had no issues with the stock regulator nor the stator and I’m approaching 37,000 miles. I’m fairly certain I kept the recall notice and repair order of more info is needed on this topic I’ll be glad to share it with the forum https://images.app.goo.gl/fooxeVaoe2sC1Pzf9
mjsk9
Well-Known Member
I too purchased my 2006 K9 new and have 33,000+ miles on mine. I have done all of the recalls also. I would assume most owners performed the recalls when they came up? The one in question is captured below:
| Corrective action | DEALERS WILL REPLACE THE EXISTING CIRCUIT BREAKER LOCATED BETWEEN THE VOLTAGE REGULATOR POSITIVE BATTERY LEAD (B+ LEAD) AND THE POSITIVE BATTERY TERMINAL WITH AN ALTERNATIVE CIRCUIT PROTECTION DEVICE THAT WILL PREVENT A THERMAL EVENT IF THERE IS A SHORT TO GROUND. THE RECALL BEGAN ON OCTOBER 1, 2007. OWNERS MAY CONTACT BIG DOG AT 1-316-219-9129 OR EMAIL TO CUSTOMER.SERVICE@BIGDOGMOTORCYCLES.COM. |
In addition, for the newer members, thought the table below with the live links to model specific recalls might be beneficial from an historical perspective.....
| BIG DOG BIG DOG - (1 Recalls) | BIG DOG HUSKY - (1 Recalls) |
| BIG DOG BOXER - (6 Recalls) | BIG DOG K-9 - (7 Recalls) |
| BIG DOG BULLDOG - (16 Recalls) | BIG DOG MASTIFF - (23 Recalls) |
| BIG DOG CHOPPER - (23 Recalls) | BIG DOG MOTORCYCLE - (2 Recalls) |
| BIG DOG CHOPPER - DT - (1 Recalls) | BIG DOG MUTT - (1 Recalls) |
| BIG DOG CHOPPER DT - (4 Recalls) | BIG DOG N-CHOPPER - (1 Recalls) |
| BIG DOG DAYTEC CHOPPER - (2 Recalls) | BIG DOG PITBULL - (15 Recalls) |
| BIG DOG DT CHOPPER - (1 Recalls) | BIG DOG RIDGEBACK - (14 Recalls) |
pknowles
RETIRED
I'm still running stock on my 07 K9 and the 2010 Bulldog, interested in their reply.
Axel
Active Member
Hi Kobi and pknowles,
I had here in Germany about 6 - 8 times a customer with charger problems within the last 2 years. I know it sounds not much but we have not so many Big Dog bikes here. I´ll look for my old memories and try to find out what bikes had the problems or try to reach the customers. I don´t know if it was a problem with all OEM regulators within 2004 and 2011 or only within a small time period. I think it would be fine if everybody who had (overvoltage) issues with his charging system can send a short message and we can make a small table with the models and years and post it here. Maybe it´s good for a new thread? What is your opinion?
All the best!
Axel
I had here in Germany about 6 - 8 times a customer with charger problems within the last 2 years. I know it sounds not much but we have not so many Big Dog bikes here. I´ll look for my old memories and try to find out what bikes had the problems or try to reach the customers. I don´t know if it was a problem with all OEM regulators within 2004 and 2011 or only within a small time period. I think it would be fine if everybody who had (overvoltage) issues with his charging system can send a short message and we can make a small table with the models and years and post it here. Maybe it´s good for a new thread? What is your opinion?
All the best!
Axel
KaptinAmerika
Guru
As I stated, not all have the issue but a vast majority do.
It's up to an individual owner to determine if they want to risk losing their expensive components or just change the charging system. We recommend all owners having issues and any new owners change they're charging system asap. If your one of the lucky ones that's great but we're not basing our recommendation on one BD or being one of the lucky owners. Our recommendation is based on directly working on hundreds of BDs and assisting thousands of owners with their electrical issues.
It's up to an individual owner to determine if they want to risk losing their expensive components or just change the charging system. We recommend all owners having issues and any new owners change they're charging system asap. If your one of the lucky ones that's great but we're not basing our recommendation on one BD or being one of the lucky owners. Our recommendation is based on directly working on hundreds of BDs and assisting thousands of owners with their electrical issues.
I think we should all be cognizant that these bikes are now at almost minimum 10 years old. A VR and stator will eventually wear out, and I think while people are working on their bikes it just makes sense to replace your 10+ year old part regardless of issues. It's just cheap insurance to do now, especially as these bikes have changed hands many times, and entire new system will only cost you about $300.
Think about alternators on cars, slightly different system but theory is similar they usually wear out right around 10-12 years, and guess what people replace them...haha. Not to mention these are mounted on the front of a solid mount frame to motor so the circuit board and potting in these VR has been vibrating for however many years/miles.
I've replaced mine when I had the bikes torn down, while I was in there I rather NOT be stranded on the side road because of $300 I was trying to save. End of the day, it will cost me a hell of a lot more to rent a uhaul and haul it home.
Kobi
Member
A complete charging system replacement seems overkill in my case since I have under 3000 miles on my bike. I can see it being an option on higher mileage situations. I am thinking replacing the VR if it is thought that the OEM VR was of poor quality and may be the root cause to all our EHC issues. Seems two VR's are suggested by Axel, Compu fire and Cycle Electric. Researching these show they are 32 amp units and my manual says I have a 40 system. I see BD sells a VR that has no specs listed to know what amp it is. They are all in the $100 range. I'm hoping someone can help me with using a 32 amp VR on a 40 amp stator is appropriate. Thanks.
KaptinAmerika
Guru
Doesn't matter how many miles are on the bike.
What matters is if the bike has electrical issues.
While most have had no issues installing the CompUFire VR with the stock charging system your miles ahead just changing the charging system with a known good system that has components designed to work together.
Any VR that is unbranded , i.e. Drag Specialties, is going to be an Asian made VR which you really do not want in your Big Dog.
CompUFire and Cycle Electric are known good products that are made in the U.S.
What matters is if the bike has electrical issues.
While most have had no issues installing the CompUFire VR with the stock charging system your miles ahead just changing the charging system with a known good system that has components designed to work together.
Any VR that is unbranded , i.e. Drag Specialties, is going to be an Asian made VR which you really do not want in your Big Dog.
CompUFire and Cycle Electric are known good products that are made in the U.S.
Kobi
Member
Curtis, I have had no electrical issues, I just replaced the EHC(Axels from you) as a precaution. Now I'm reading about another item to replace as a precaution the voltage regulator. I'm sure others have had no electrical issues and replaced the EHC too. Just looking for information on the best way to go.
KaptinAmerika
Guru
According to to the recall it was only 2005 and some 2006 that had the charging system issue , my recall was done at the dealer. Early on BD thought it was the VR but still had issues on the recalled motorcycles after replacing the VR and found it to be the circuit breaker was the culprit so they revised the recall and started putting in 40 amp fuses in place of the circuit breaker. I believe that the major flaw was not fuse protecting the ehc directly from the battery which would for sure cause ehc destruction under a voltage spike so along with the 40 amp fuse the protect the battery from a voltage spike and an in-line fuse from the battery to the ehc will protect the ehc as well as all other electrical components on the motorcycle. Changing the charging system is completely unnecessary as Im sure there are more BDMs out there running the stock system than not. Look up Big Dog specs on current models they are still using the 32 amp system as is Harley Davidson along with most of if not all other motorcycle manufacturers, if that was an issue I would think the late model/current Big Dogs as well as other manufacturers would too be burning up electrical components.
KaptinAmerika
Guru
First off a person must really understand exactly what is happening with the Phelon, I think I'm spelling that right, Voltage Regulator to talk about whether it's safe or not. Reading recalls, owning one or two Big Dogs even "working on bikes for forty years" doesn't qualify a person to give BD owner's advice on whether they should replace the OEM BD voltage regulator or not. While it's true that many of the BDs have not had this issue many have. Any bike that has suffered a component melt down needs a serious looking at and likely a VR replacement. With the alarmingly high number of BDs that have had component failures, albeit not all from the OEM charging system as many have done things to their BDs that have caused electrical failures, any BD owner should take a serious look at whether they should get rid of the OEM charging system or not. Speaking from a position of actual heavy experience with the OEM charging system, both servicing and investigating, we recommend that they be changed before they have a chance to cause failures. Of course if you have 50,000 miles on your BD and have never had any issues then it's not likely you need to change the VR but then again it is still the same VR by the same company that has had numerous issues so maybe........
In addition there are no "current specs on current models" as Big Dog, the real Big Dog, went out of business in 2011. Any bikes being made by other companies now are of their own design and really do not apply to the category of original BDs.
Here it is right on Big Dog is back website , specs showing 32 amp
2022 Specs | Big Dog Motorcycles | Wichita, KS
Learn about the specs and details of the 2021 Big Dog Motorcycles in Wichita, Kansas.
bigdogisback.com