Start problems

[NobleMastiff]

Okay....I'll try my best to explain my problem. First off it's a 2006 Mastiff and I'm having start problems. Everything is off the bike (battry box all connectors). Starter test worked great, when I hook eveything back up my battery drains and no start. I need some guidance in checking for something in the start circuit that could possibly be shorted ...any ideas would be great. Thought it might be the EHC, but can't be sure as I don't know exactly how to diagnose the EHC.

 

[mobsta]

How old is the battery and has it been load tested?when you say no start do you mean the starter won't turn?

 

[BigDogBro1]

Test with a DVM (digital voltmeter) set to measure DC current. Disconnect all battery + terminal wires and measure each one connected to the + battery terminal to find out which wire is drawing current. Once located, work upstream in the harness.

Disconnect starter solenoid wire and test as well. Is there a solenoid RELAY used on that bike? Similar to a FOG light relay.

The EHC does draw current but should be very low 50mA i'd guess.

 

[NobleMastiff]

Battery has been load tested and is fine. I will follow Bigdog Bro1's method to try and locate current draw. Starter solenoid wire appears fine (12v from EHC) when energized. No solenoid relay on this model, it comes straight from the EHC.

 

[BigDogBro1]

Battery has been load tested and is fine. I will follow Bigdog Bro1's method to try and locate current draw. Starter solenoid wire appears fine (12v from EHC) when energized. No solenoid relay on this model, it comes straight from the EHC.

You might want to measure current draw through the starter solenoid wire from the EHC just in case something weird is going on with the EHC internal circuit. Could be solenoid windings with shorted inner windings causing higher than normal current draw. EHC could be damaged and cut out start function. That EHC MOV can be checked. Just a thought, who knows what mystical powers are going on inside that box. With the solenoid green wire disconnected you should measure about eight volts to ground normally. :lol:

 

[bruce]

more details, does it run over ( try and start), If not start at start connection and test when trying to start and see if it is getting power, if starter is getting good power 12 volts or more problem is there or in engine if not turning over. If no power work back-wards with a wiring diagram and see were you have power. If engine turns over good, you need fuel, spark and compression for engine to run, need to find out what you do not have and go from there. you may no some of this so sorry do not no how much you no. but in a lot of these cases its the battery, you should be able to turn over a fair amount before battery is to low if it is a good battery. if you need more help I can try if you want to call 717-382-9983 Bruce I have 2006 K9 will bring my manaul home tonight should be home around 8 pm or so.

 

[NobleMastiff]

Thanks Bro....I found the short in a pinched harness wire. You wouldn't happen to know the quickest way to find a right side handle bar control printed circuit board ? No one seems to have any ! Go freakin figue !!

 

[BigDogBro1]

If the PCB isn't cracked, you can maybe remove the dome overlay and clean under the domes and the PCB contacts with a pink pencil eraser and then reapply the dome overlay. Very lightly rub clean the PCB traces and pads where the domes sit and make contact in the center and corners when pressed. Clean the connector pins (if it has one) and place some dielectric grease on them when replacing the connector.

Also assuming the domes have not collasped as well. If they still dome and pop up when released then they should be good to go.

Image posted by another BDB member -

 

[NobleMastiff]

I did a thorough inspectio and found that there appears to be burnt land (trace) I'll try the cleaning advise anyay...who knows maybe it'll work. If not then I'm looking at a new one if I can locate it. Thanks man........

 

[BigDogBro1]

I did a thorough inspectio and found that there appears to be burnt land (trace) I'll try the cleaning advise anyay...who knows maybe it'll work. If not then I'm looking at a new one if I can locate it. Thanks man........

Is it burn't under a dome? Could you post a picture (in focus) in macro mode to check it out? It may be nothing to worry over if the trace is not burn't away. Also, if it's an outside DOME corner pad it's okay because the other corners should provide enough contact provided BDM did a correct design.

Proper dome alignment to the traces/pads is important for good operation. You may need to peel off the dome from the polyester overlay and reposition the dome to better align it with the PCB.

If it's a TRACE it can be easily repaired.

 

[NobleMastiff]

Thanks "Bro". I'll get it apart this weekend with some good pics for you, I hope it's as easy as sounds.

 

[NobleMastiff]

Hey Bro.....I'm having a difficult time getting the PCB off. Is that a T-4 tork screw or what ?

 

[BigDogBro1]

Hey Bro.....I'm having a difficult time getting the PCB off. Is that a T-4 tork screw or what ?

It is what it is...maybe another member may know.

 

[NobleMastiff]

Right side control PCB

This the board ! Looks okay , but I do see a burn mark on the rear.

 

[BigDogBro1]

This the board ! Looks okay , but I do see a burn mark on the rear.

I don't see anything. You can gently peel back the dome overlay plastic and take a look under it. See if the PCB contact pad is burnt. It the PCB traces look like the others then chances are it's all good. I have doubts it is burnt. These are low voltage/low current signals.

To test the domes, trace back the inner pad trace and outer corner trace and check with an ohm meter for near zero ohms continuity.

Check for circuit board trace and board cracks and poor solder joints at the connector as well.

Let us know the results.

 

[NobleMastiff]

Did as you said and the first thing I noticed was there was a slight lifting of the overlay and when did lift it off the domes there was corrosion around the contact area for the turn signal. I used the pencil eraser method (not knowing of any chemical cleaner) and most of the corrosion came off. The domes seem pretty sensitive and I didn't want to alter their geometry any, but they too have some corrosion. Your guidance has been most appreciated......thanks man.