Check out this EHC failure...

Energy One
Moespeeds

Moespeeds

Well-Known Member
2005 Chopper, I was riding down the road, and all the lights started flashing, starter engaged, engine quit. When I took out the EHC I found this:



Sorry for the blurry pic, but a piece of the epoxy is actually blown out and there is a pin sticking out down there, I'm not sure if it got red hot or something actually blew up. There are no signs of melting.
 
T

TheDeadOne

Banned
bang!

Moe,
Maybe your "luck" is changing for the better now! No fire! Did you hear it pop at all? It should have been pretty loud as big as that "divit" is. It looks like a replacement EHC. But what I'm wondering is which revision? Whats the part # on that one?
 
Raywood

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
Moe, I've had one melt down and it even burned a hole in the battery. But I haven't seen one just break but I would guess that one of the bolts on the back probably broke and caused the breakage there. Check the back of the EHC and see if the two lugs are still welded on.

Here's mine when it burned up back in 04 that lead to the resister pigtail in the ignition switch on the 05's.

 
Moespeeds

Moespeeds

Well-Known Member
Bolts on the back were intact and tight. There is a little charred pin down in there, right at ground zero. I'll get a better pic up later. I also lost the positive battery lead, snapped off and I can't figure out why. The new battery was a little too tall but I cut two very large holes in the seat pan to accomodate it, there is no way it was rubbing.
 
chacha

chacha

Chaff Your EHC!!
Calendar Participant
Now's a good time to chaff that black box -- I've totally lost faith in BDM Electronics.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
chacha said:
Now's a good time to chaff that black box -- I've totally lost faith in BDM Electronics.
Click to expand...
But what else did it take out in the process? I would almost let bdm replace everything to get the bike bk on the road. Then look into removing the bdm electronics, selling the nearly new bdm components.
 
MARV

MARV

Well-Known Member
Gas Man said:
But what else did it take out in the process? I would almost let bdm replace everything to get the bike bk on the road. Then look into removing the bdm electronics, selling the nearly new bdm components.
Click to expand...
its an 05.

his dime.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
Well it was hopping that maybe bdm would step up.

But it looks like he's gettin ready for the conversion in another thread.
 
kickstart

kickstart

Well-Known Member
My 05 did a similar thing but enough smoke poured out of the hole in the potting (epoxy) it looked like a smoke bomb. If I didn't happen to have a 10mm wrench to disconnect the battery, well who knows.

I now keep a 10mm wrench in both jackets and vest.
 
Moespeeds

Moespeeds

Well-Known Member
It was smoking, at first I thought the bike might be on fire. That would be the second time this bike burned, apparently this guy's bike started itself with 500 miles on it and rode off the kickstand, lit on fire, and cracked the frame. He has had every problem you could imagine with it, some just bad luck, some from his own neglect. There used to be a local shop here called Chrome Palace that did the original warranty work. This dude fought with them because they claimed he crashed it, and there was no way it could start itself up. Eventually they fixed all the electrical, so yes this is the second EHC, but refused to fix the frame, he had to go through his insurance for that. They let the bike sit outside for a few months, I remember seeing it outback when I used to hang out at the sportbike shop next door. So basically this thing was a basket case, and it's a shame because even though the owner is mechanically retarded, he's the nicest guy you'll ever meet.
 
LDO

LDO

The Cleaner
Troop Supporter
Moespeeds said:
So basically this thing was a basket case, and it's a shame because even though the owner is mechanically retarded, he's the nicest guy you'll ever meet.
Click to expand...
Mechanically retarded.....:roll: :roll: :roll:

Well, I hope he doesn't ride too far from home OR friends like you!
 
Moespeeds

Moespeeds

Well-Known Member
He won't ride anywhere outside Philly unless I'm with him, I'm not even exaggerating. When he takes the bike, he goes into the city, rides around and poses, and brings it right back.
 
Jasray

Jasray

New Member
Mo, I can relate. I have an 01 Prosport that I love, but at one time or another every single electrical part has had to be changed out, including the EHC. I have a Bigdog Service Manual for all the Bikes pre 2005 bikes and it clearly states in the troubleshooting section that 33% of all warranty issues are electrical. BDM builds great bikes but they never seem to be able to get the electronics spot on.
 
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