Night Trains Tech Tip of the week

[stiffy]

Night Train, I think my Thunder Heart is giving up the ghost. My flashers stopped working and I've had some other intermittent issues with my bike. I pulled the TH controller and put 12 volts through the harness to the flashers. Everything lit up. I've had the motor just kill for no reason. Looking at the controller, some of the solders look discolored. It sounds like the 4250 is pretty reliable.
Question 1 - would you replace with the same controller?
Question 2 - I saw somewhere here that somebody bought one for $185. Can you tell me where I can get the best deal?
Question 3 - Is there a good and inexpensive way to bypass the controller for the flashers?

Thanks!

 

[Mojo]

I was not part of the 2003-2006 EHCs. I was part of band aiding the 2007 and newer electrical system that went from a 26% failure rate to a 1.5% failure rate.:2thumbs:

1.5% failure rate? That doesn't seem bad enough to justify replacing the entire electrical system. Did you have anything to do with the routing of the wiring, or the exposed connectors all over the bikes? Most of the problems I have encountered when dealing with electrical issues on a big dog are a result of damaged wiring (rubbing on something), corrossion at connectors, or someone doing shadetree wiring. I make it a habbit whenever I'm in there to not only add dielectric grease, but HEAT SHRINK!:bang: I'm no engineer, but I think that a little waterproofing can go a long way. My customers don't get stranded in the rain.

 

[Mojo]

That's the cool thing about engineers. They dissect everything on their computers until it looks good on paper, baffle you with bs, and try to sell you something better. We're talking motorcycles here, not rocket science. They're easy if you keep it simple. If you don't understand them, take it to someone who does.

 

[Mojo]

There are times to use continuity/resistance tests and times to measure voltage drop. One test does not necessarily replace the other. Continuity testing is good to tell if you have a closed circuit between one point to another. When you are troubleshooting and trying to figure out why your turn signal does not come on when you hit the button you would perform a continuity test from the hand controls to the ECH. A continuity tester basically measures resistance and if it is below a set limit (.2Ohms for my meter) the audible alarm will beep. If you have one strand left in a wire and preform a voltage drop test you will get a very small value unless that one strand causes a higher resistance. If the one strand caused high resistance chances are the continuity would not beep. Voltage drop testing is a good way to find bad electrical connections or if a wire is under rated for the voltage going thru it. I l usually like to use the 5% rule. The voltage drop should not be more than 5% of the voltage supplied to the wire. If it is, you need to go to a larger gauge wire or clean your connections. All this can be summed up by ohms law. Voltage=Current*Resistance.

Hope this is not too confusing, I'm not a good word artist. There is some truth to you statement but 99% of the time a continuity test will get you what you need. Some future tips specific to you dogs will help clear up when to use a continuity test and when to use a voltage drop or is some cases both.

Wouldn't it be easier before doing all of that to look at the EHC when pushing the turn signal button? If an LED lights up on the EHC when a turn signal button is pushed, wouldn't that mean that there is an input from the switch and the problem is on the outbound side? Are you saying that there is wiring that is under rated for the voltage going through it on big dogs, and if so which one's?

BTW- what is an ECH? Engineer Creating Headaches?:loony:

 

[Chopper117]

I would like to make a proposal that we make MoJo an Honorary Engineer regarding the BDM electrical systems!

All in favor? Yea! :flag::2thumbs::up::iagree:

All opposed?........

The Yeas have it! "Welcome New Engineer MoJo"!

:loony::crazy::lol::roll:

dead :2thumbs:

I agree with MOJO and DEAD!! I feel much more SAFE with my connectors Diaelectric Greased and Shrinked Wrapped!!:2thumbs: Thanks for the inspiration DEAD! No problems here!!:2thumbs:

 

[BigDogBro1]

EHC Reactions

My story:
http://www.bigdogbiker.com/forums/help-wanted/14952-07-bulldog-wont-turn.html

 

[DemonK9]

i must be that 1.5 then, I own 2007 K-9 and it sucks. i am having problems RIGHT now, and now am being told 300 for new computer, and put that shit in there again....NO. or rewire....THis is bullshit.

 

[Derek m]

I just installed a new wire plus kit that I got from Jake. It was pretty painless with his directions(Thanks for those Jake). I am not an engineer and was able to do it myself. If you want to get rid of the ehc contact Jake, he knows what you need!

 

[born to ride]

Hello Mike, my name is Fred (born to ride) and have read some of your posts. I have recently purchased a 2005 BD Chopper. 3200 miles run great except once in a while as crusing it shuts down completely. Roll to side of road, turn key off and back on, fires right up-so far. So you wp upgrade and a new outfit Kansas MC that offers plug and play harness. So WP comes with new module but the Kansas outfit appears to only have harness. With that thought the big dog module must be ok and the real issue is the wire harness. Any thoughts, Thanks, Fred

 

[Jwooky]

This is a 3yr old thread. Suggest you review more modern info.

 

[BigDogBro1]

Hello Mike, my name is Fred (born to ride) and have read some of your posts. I have recently purchased a 2005 BD Chopper. 3200 miles run great except once in a while as crusing it shuts down completely. Roll to side of road, turn key off and back on, fires right up-so far. So you wp upgrade and a new outfit Kansas MC that offers plug and play harness. So WP comes with new module but the Kansas outfit appears to only have harness. With that thought the big dog module must be ok and the real issue is the wire harness. Any thoughts, Thanks, Fred

Fred,

The KS kit does come with a new controller.

Search for EHC problems, dielectric grease in the forum for possible EHC fixes.
I think Wild Steed Works a vendor here on the forum might be able to test that EHC.

 

[KaptinAmerika]

Sounds like you may have a bad key switch.
Disconnect the JST connector to the key switch under the coil cover.
Jumper the connector, its a low voltage ground signal only so nothing to stress over, ride the bike that way.
If it doesn't shut down again then you have a bad key switch. Many on the forum have had great success with a ford tractor switch.

Hello Mike, my name is Fred (born to ride) and have read some of your posts. I have recently purchased a 2005 BD Chopper. 3200 miles run great except once in a while as crusing it shuts down completely. Roll to side of road, turn key off and back on, fires right up-so far. So you wp upgrade and a new outfit Kansas MC that offers plug and play harness. So WP comes with new module but the Kansas outfit appears to only have harness. With that thought the big dog module must be ok and the real issue is the wire harness. Any thoughts, Thanks, Fred

 

[KaptinAmerika]

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