'04 Mastiff cutting out....EHC problems???

[Old Hippy]

Well, Guys, the trip to Florida was somewhat a bust.!!! First off, I was sick when I hit the road, hoping to get better on the way, MAJOR Diarrhea, but NOOOOOOOOO..!! It got worse. Then first day in Titusville, got the Dawg out of the trailer for a spin, hoping to shake the "ill effects", but NOOOOOOO, the damn thing cuts off, 6 miles from the motel. A fine gentleman working in the Sunbelt Rentals store, kindly offered me a ride back to my truck and I came back and hauled the Scooter back to the motel. So after a terrible week in Fl, I am home, trying to figure this thing out.!! This cutting out, has been going on for a couple months and I thought I had it fixed with a new battery.!!! NOT.!! So I piddled around some yesterday and took the battery out, checked a connection or three, put some new connectors on some wires and tried it again. Still cutting out. I think the EHC is going away, but I need some technical advice from some of you guys so I can make a calculated decision. Someone explain to me, the workings of the lights on this EHC??? Also, I noticed the headlight coming and going while I've got the Dawg sitting there idleing (sp?)..!!! Signal lights, parking lights, horn...blah blah blah all seem to be working fine. Might the ignition switch itself be the problem. I need some help.!! PM me if you think you might have some answers or solutions..!!

Thanks
Mike
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[P8RIOT]

The shop manuals do have very thorough wiring diagrams, including details on what all the lights mean, and troubleshooting tips - you might want to track one down. (Mine is for 2007, so probably not a lot of help in this case.)

 

[chacha]

Hip;

Sorry to hear the trip was a pain! You are experiencing many of the things I've been through already with my 2004. Some questions:

1) When the bike dies, do you still have power to the turn signals and headlamp?
2) When the headlamp goes out, does changing to the highbeam and back again clear the problem?

Things to check the next time the bike dies:

1) leave the switch on and pull to the side of the road,
2) Pull the seat and check to see of the EHC still has the red light lit.
3) Attempt to start the bike and look at the LED on the ignition module -- is it blinking? If so then the ignition is working, if not then the ignition signal is not getting to the module.

Here's what happened to me. The headlight failed after about two weeks (got more frequent till it finally died). I was also having the bike die occasionally during this time.
I got a new EHC installed and this cleared the headlight problem. I thought it cleared the stalling problem, but that started to happen again. I checked all my connections and replaced the cam sensor. Haven't had the bike die in two months now.

If your headlight is failing over and you can find no other cause, then suspect the EHC is dying. The stalling issue could be alot of things and the EHC is only one of them.

 

[Old Hippy]

Hip;

Sorry to hear the trip was a pain! You are experiencing many of the things I've been through already with my 2004. Some questions:

Hey Dude...Thanks for the encouragement and kind words. No big deal on the Florida fiasco, but back to the Mastiff problems. Let me do some investigating and research some of the things you bring forward.!!! I will be getting back to ya..!!!!!
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[Old Hippy]

Hip;



1) When the bike dies, do you still have power to the turn signals and headlamp?

OK Dude...Here's the 411.....!!

Just went out, and turned the key on the Mastiff. The #2 EHC led blinked once....yellow...green, something not red.!!! No light displayed on the ignition mod..!!! Then, I let it rest a minute or so, do it all over, the damn thing fires, light on ig mod working and all is great. Still no indicators on the EHC lit...at all...any color. Now, it dies. Ig mod light is out and all other electrical stuff is working...(lights, horn, sigs)..!!! I hate to just be a damn parts changer and get this thing running. I want to know why it does this so I can get more prepared.!!

Mike
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[ohio dog]

any updates? Mine was doing the same shit....all last summer. I'll be honest, when the snow started flying, I dumped some stabil in the tank, put the tender on it, and covered it up. Now I'm getting the itch, so I'm going to start replacing parts some electrical parts....and yes I've checked connections, etc.

 

[Old Hippy]

My Mastiff is OK now.........

any updates? Mine was doing the same shit....all last summer. I'll be honest, when the snow started flying, I dumped some stabil in the tank, put the tender on it, and covered it up. Now I'm getting the itch, so I'm going to start replacing parts some electrical parts....and yes I've checked connections, etc.

I changed out the EHC and all my problems seemed to disappear.!!!! I would give that a try before going to deep into the wiring thing. I also, inspected all the wires I could while I had the EHC out. I rerouted a few and the scoot is doing just fine.

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[ohio dog]

Thats what I figured. Did you get the "new updated" EHC?

 

[Old Hippy]

Nope

Thats what I figured. Did you get the "new updated" EHC?

I used an original equipment piece that I bought from a member of this forum.

Drop Nelson (WB Cycles) a line and tell him what you want. He'll fix you up and for a good price.!!!


Good luck. It's a little tedious to change, but not all that difficult.!!

Mike
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[scubaman15]

This seems to be a regular problem with these bikes ...HAS Anyone changed out the whole electrical system?? With aftermarket 12volt ..and got rid of the ugly speedo and while your at it do a how to LOL HINT: Gas are you putting the stock ignition back in ??

 

[Raywood]

This seems to be a regular problem with these bikes ...HAS Anyone changed out the whole electrical system?? With aftermarket 12volt ..and got rid of the ugly speedo and while your at it do a how to LOL HINT: Gas are you putting the stock ignition back in ??

Old subject covered many times. To do that you not only have to change all the electrics but also all the hand controls, speedo/tach, new ignition, micro switches like brake lights and any other low voltage or EHC regulated component.
Way expensive but yes it can be done for a lot of $$$$.

 

[CCRainman]

You can do it if you have an 03 and older. Just use a Thunderheart micro harness and your all set. If it's an 04 and older you are in for some work. You need to get new bars controls and switches juat what Ry said

 

[Gas Man]

As they said, you can get rid of all of the BDM stuff... the handlebar controls, the harness, the EHC... but it will be pricey unless you get some lame hd controls that will look like shit compared to our BDM hand controls.

And to answer scuba... no I'm not putting the stock ignition in. This added $235 for the crane hi4 ignition, $410 for the Jim's cam cover, $5 for the pickup cup, and $25 for a crank sensor block off plate. == $675 on good discounts. But I dump the crap thunderheart and hopefully add longevity, more power, tunability, and old school realiabilty. Plus it has been theorized that maybe the thunderheart ignitions may cause EHC problems. But that's just irrisponsible theory from another member here.

 

[scubaman15]

With all the problems the low voltage systems cause you would think some aftermarket company would come up with a complete kit to retro the troublesome units !!!

 

[MaleficVTwin]

I have had 4, that's right, 4!!, EHC's in my Chop, and it still cuts out from time to time. I've replaced the ignition module, still cuts out. The best luck I had was removing EVERYTHING from the key, no ring, no fob, nothing(at the recommendation of my dealer). It cuts out much less now. I think I'm going to have my dealer order me a new ignition switch. I've also considered replacing the coil, as some bikers who are much older and wiser than I have suggested.

 

[Gas Man]

The ignition switches on the stock setups... is less than great... that is for sure.

Alot of us run a clip to the rear plug wire to keep the strain off it...

 

[Raywood]

The best luck I had was removing EVERYTHING from the key, no ring, no fob, nothing(at the recommendation of my dealer). It cuts out much less now

And as specified in the owners manual!!!

 

[dogvet]

This seems to be a regular problem with these bikes ...HAS Anyone changed out the whole electrical system?? With aftermarket 12volt ..and got rid of the ugly speedo and while your at it do a how to LOL HINT: Gas are you putting the stock ignition back in ??

Wire Plus 620-221-2417. they have a system that goes right in and works great. It also eliminates a shitload of those tiny little connectors.
A lot of electrical intermittant problems are due to loose connections at the EHC itself. Ealry ones had a little rubber seal to keep moisture out, but it didn't allow full connection of the contacts. Early ehcs had a latch that held the connector to the ehc which wasn't worth a crap and later ehcs used screws to lock the connector.
when in doubt, give the connectors a wiggle with your bike running. If your bike goes ape shit, you know you have connection problems.

IIRC there was the occasional problem with the little connectors for the ignition coil getting smashed under the gas tank as well....that one will really make y0ou chase your tail for a while.
:zz2cents:

 

[MaleficVTwin]

And as specified in the owners manual!!!

I just looked at the pictures..............

 

[Big Block]

Hey Vet, share some part numbers. I can't find anything on their website or Jireh catalog that will work with the dog controls. My dealer is trying to push an adaptor board on me, have you ever done something with this...what is it? Is it worth a darn?