Electrical Issue

[Orangeboxer03]

I need help, ok here goes. I have an 03 Boxer with under 5000 miles. i have no spark. i have been thru the complete wiring system and checked off the wires on my wiring diagram. i have the thunderheart sysem. i have power to and from switch, power to and from ignored sensor. and both sides of coil and my lower coil wire pulsates from the power from ing sensor. i have replaced coil, wires, plugs. oh yeah i have went thru all my grounds they all good. history? rode for about 45 min to hour. shut off to eat, started up drove 200 yrds it died. no spitting/sputter. just like i lost power to coil. but it all there? HELP.

 

[Wallace Bettes]

Sorry to here your having a problem with your bike. I truley know how you feel. My bike runs good when it's running, But had lots of ele problems. I talked to a B-Dog rep, He told me when my bike was running and shutten and then starting again to replace the EHC, i had it replaced ran good about 6 mounts ,and now this, SUCKS

 

[thexaulted]

I have an 03 Chop so I know what you are going through! I have ranted and raved many times on here. Bought the bike with 3000 miles on it. When it ran it ran good but I was plagued by electrical problems, literally almost every time I went out there was an electrical problem. I got to the point that I was totally appalled that any product made could have this many electrical demons. Especially when this isn't new rocket science! HD and all the Japanese manufacturers have this shit down pat. How come these M-0-R-O-N-S at BD couldn't follow a proven system??????

Anyway you might want to have that whole ehc pulled. Try the wires plus module for your lights and controls and have the other stuff re-wired with fuses, minus the BD bullshit.

That's what I did in a last ditch attempt to keep the bike and avoid all of the electrical issues. Still not sure if it will be trust worthy as it has only been completed for about a month or so now and I don't have much ride time but its probably one of the only choices you will have. Good Luck!

 

[BullDogger]

Me Too!

I am going through almost the exact same scenario. I've tried unsuccessfuly to fix the problem. Tomorrow I'm ordering the Wire Plus kit....SUCKS!!!

I did determine my initial problem was a melted battery post, inside the battery. Probably caused by loose terminals. This is my fourth battery in 6 months! Gonna be checking the battery terminals very frequently in the future.

The first three batteries melted the lead terminals on the top of the battery. I assume from loose connections, if anyone knows otherwise I'm all ears!

 

[Wallace Bettes]

Hey thats FUNNY the sam thing happened to my bike, melted the post off a brand new battery 3 times. I owened 4 HD's changed the battery on all the bikes, never had one of tham melt.

 

[LDO]

Did the battery post come in contact with anything?

Very strange to melt a post like that.

I'm not sure what's going on with the loose terminal thing either. I have pressure washers between the group of terminals (got alot of them) and the post and never had them come loose. And I ride my bike almost every day!

 

[thexaulted]

Bulldogger I had the battery post melt also. Unfortunately every time I have had some type of battery issue it would be followed immediately by a more severe electrical issue, ie no speedo, issues with lights, ehc going! It was very frustrating because the battery would be easily remedied but what followed wouldn't be.
I use lock washers also on the battery but the BD dealer told me that he uses loctite as to prevent them from coming loose as he has seen so many of them loose!

 

[Orangeboxer03]

Great!

That funy u all mention the battery post. i had just checked them the day before this happened and yes while trouble shooting i did notice that it was melted. so yes i did replace it too. now with all everyone has said, i have an EHC issue. GREAT! i keep u all informed.

 

[LDO]

Dang,
I don't use loctite on my battery terminals some on here might but I don't know if it would be a good idea. That stuff dries into a hard material which may impede electrical flow.

I check my terminals before every ride since my seat is already off while on the trickle charger and I've never found them to be loose.

I'm not saying that it's not happenning to you it's just weird is all. Is there enough 'slack' in your wiring? Nothing under tension?

 

[Orangeboxer03]

Kit (EHC)

Ok now about this kit to replace the EHC? where can i get it? I am sure i can figure out how to install.

 

[LDO]

Orange Boxer,
The 'kit' that you hear most about is the Wire Plus on the newer (04+) Big Dogs. You can read up on that here:

http://www.bigdogbiker.com/forums/how/9727-how-wire-plus-2004-only-install-ehc-elimination.html

However, Wire Plus does make a kit for the older dogs as well.

You may want to contact Jake (BDMRidgeback) to see if he can get it for you or contact Wire Plus directly. Both of them are really good at answering emails.:2thumbs:

 

[Orangeboxer03]

fix it right

well once i got home i checked a few things, looks like i do not have pulse coming out of EHC, it so happens that the Wire Plus kits everyone is talking about is just 50 miles away. i called big dog they want $300 for the EHC, with no warranty. so my option is to fix it right and get the kit. i will keep all informed.
"live for today"

 

[Night Train]

You should get someone like me to come over and look at the bike for you. May Thursday night some time, maybe when I get off work?

See ya Thursday,

Mike

 

[Orangeboxer03]

Awesome

All i can say is thanks, i am hoping it is sumthing i just overlooked. see ya thursday. i will have sum cold ones waiting.
ken "live for today"

 

[N8KAM]

well once i got home i checked a few things, looks like i do not have pulse coming out of EHC, it so happens that the Wire Plus kits everyone is talking about is just 50 miles away. i called big dog they want $300 for the EHC, with no warranty. so my option is to fix it right and get the kit. i will keep all informed.
"live for today"

As far as i know you Don't get a pulse out of your EHC for your ignition.... Unless the older ones are different..... The EHC only sends power to the ignition module... the module pulses dependent upon the signal it gets from the crank/cam sensor depending on how it is set up..

 

[N8KAM]

Also...... as far as loose battery terminals .. I have only found them loose once in 7000 miles... but i do check them often.. :2thumbs:
Melted terminals???? I would like to know why they are melting... Hi/erratic current flow Possibly due to the loose connection comes to mind.. Or High resistance in the wire causing the wire to over heat when the bike is starting???? I have seen several wire terminal ends to wire connections that look good or are covered with heat shrink so you cant tell but in reality there is corrosion in the connection causing a high resistance and excessive heat.... Just a thought... :up:

 

[Orangeboxer03]

Relief

That is why i am glad mike is willing to come over and check sum things, i am sure i missing sumthing. i do know that it not the ignition sensor on cam (replaced it). so maybe it is the module not the EHC.. i to the frustrated point and i cud have rode today. NO RAIN. aaaarrrrg. peace.

 

[Slider]

Let us know what you find. Interesting problem. I'd be surprised if it was the EHC.

 

[Orangeboxer03]

Fire in the hole!

Ok well it did not end up being the EHC, after nighttrain came over and pointed out a few things and showed me some gret tech tips. we determined it to be the ignition module. i did go buy the stock part. i am still considering the EHC Wire plus kit, and changing over to Dyna style module for reliability purposes. For now i want to ride. thanks mike.

 

[stlmikie]

Mike is cool!