Need help with EHC LEDs PLEASE!!"

[Kiwirider]

Righto. Where to start...

I have an 08 Mastiff EFI. For the last 5 months its been running great... Until now.
First off, the horn stopped working, then the right front signal/indicator light stopped flashing (it still works, but doesnt flash when I hit the turn button).
I could handle those small things. But then I would turn on the ignition key, the lights/instruments would turn on as usual, but when I hit the Run button, nothing happens, no tank pressurizing, the starter button wont work, the horn still doesnt work, and the RF signal light wont flash.

I purchased a new battery yesterday and put it in. Rode it and all seemed good.The horn worked one time, then later stopped. At a seperate time, the RF turn signal even worked for a short period then stopped flashing again.

Today I pulled the 2 EHC covers and went through all the connectors. I pulled the 2 EHC plugs, cleaned them out with a brush, re applied more Dielectric grease and re installed.

I then re connected battery, followed the instructions on the battery box (key on, hit run, key off-15seconds). It then started fine.

I switched off. Then when I went to restart it while watching the ECH LED's.
I turned the key on: "Power" LED and Flashing "Controller On" LED only illuminated.
Then about 10 secs later all LEDs except "PC Link" and "Comp Relief" are lit.

The Run/Off and starter button does nothing. No horn and no RF turn signal.

Does anyone have any thoughts on this? Ive been combing the forum and my manual, but this many lights on has me baffled.:bang:

 

[Dakotabos]

I cant help with an 08 only know the 04 ins and outs, Hope someone can chim in soon. Sorry
Hope it gets answered soon

 

[Kiwirider]

I hope so too. Anyone with suggestions?

 

[chihuasbigdog]

http://www.bigdogbiker.com/forums/how/3717-read-your-ehc-fault-lights.html

 

[Kiwirider]

http://www.bigdogbiker.com/forums/how/3717-read-your-ehc-fault-lights.html

I would, but all but 2 are lit. So that would mean everything except the Comp Relief and PC Link have a fault.

 

[olddog58]

I chased similar problems for months until 08 K9 EFI just decided no more...
I had the EHC replaced with a PDM system from Big Dog thinking it would be better to dance with the girl I brought... but my K9 is hopelessly messed up now. The shop that installed it has the wiring messed up and can't figure it out... they keep calling BDM for tech support but can't get a call back.
The bad part for you- is there isn't one single person, on this tech forum, or at BDM or at any bike shop you will every pass through the doors of... that knows the Big Dog EHC or electrical system- you have to start replacing things until somehow, maybe, it runs right again... And I sure wish there was a better answer.
You have replaced the battery (everyone on this forum says do that for any electrical problem), then you cleaned all the EHC connectors... Next step per most here is to bite the bullet and replace the EHC. And for gods sake when you do, take it to the most gifted motorcycle mechanic you can possibly find, cross your fingers, and pray your dog will run again some day...

 

[Five Five]

How's your battery cables and connections ....good on both ends ?

 

[Th3InfamousI]

I chased similar problems for months until 08 K9 EFI just decided no more...
I had the EHC replaced with a PDM system from Big Dog thinking it would be better to dance with the girl I brought... but my K9 is hopelessly messed up now. The shop that installed it has the wiring messed up and can't figure it out... they keep calling BDM for tech support but can't get a call back.
The bad part for you- is there isn't one single person, on this tech forum, or at BDM or at any bike shop you will every pass through the doors of... that knows the Big Dog EHC or electrical system- you have to start replacing things until somehow, maybe, it runs right again... And I sure wish there was a better answer.
You have replaced the battery (everyone on this forum says do that for any electrical problem), then you cleaned all the EHC connectors... Next step per most here is to bite the bullet and replace the EHC. And for gods sake when you do, take it to the most gifted motorcycle mechanic you can possibly find, cross your fingers, and pray your dog will run again some day...

Wow, sorry about that. It sounds like you got some terrible service where you brought your skoot. The PDM is supposed to be fairly plug & play as well, many have installed it successfully, and have had shops install it as well. Might be time to bring it to a better mechanic.

For the first guy make sure all your connections are tight? You said after the bike started you were able to reset the EHC and it fired up. Then nothing? Did you try resetting the EHC again? If you are able to reset the EHC and fire it up every time after a reset than I would have to say its gone South.

 

[Kiwirider]

OldDog. That sucks you had all those problems. Im just hoping its not that with mine.

55. Yup terminals are tight, I did find a loose connection on what looked like an earth from the horn, but fixed that.

Infamouse. Yea when I disconnected the - terminal, waited for a few mins then reconnected it, it did start but the LEDs on the EHC were still screwed up and the horn, flasher still were out.

Now heres the thing. This morning I went out to the bike. I had the tender on it all night, took the side covers off to see the EHC LED's, when I swithed on all but the Comp Relief and PC link came on and but it started. I ran if for a few mins then shut it down, still no flashers or horn.

I gave it a few mins then turned key back on, this is when it went weird. The LED panel on the EHC went nuts, it was like a light dance, the LEDs were flickering all over the place. I waited for it to stop, then they all went out.

I switched off, a few mins, then switched back on. only the Power and Controller On led were lit. I started it up...... Everything worked. All lights, horn, everything.

This worries me even more.

Im going to give it tonight on the tender again. Then start it up tomorrow and see if anything has change then take it for a ride.

 

[Th3InfamousI]

OldDog. That sucks you had all those problems. Im just hoping its not that with mine.

55. Yup terminals are tight, I did find a loose connection on what looked like an earth from the horn, but fixed that.

Infamouse. Yea when I disconnected the - terminal, waited for a few mins then reconnected it, it did start but the LEDs on the EHC were still screwed up and the horn, flasher still were out.

Now heres the thing. This morning I went out to the bike. I had the tender on it all night, took the side covers off to see the EHC LED's, when I swithed on all but the Comp Relief and PC link came on and but it started. I ran if for a few mins then shut it down, still no flashers or horn.

I gave it a few mins then turned key back on, this is when it went weird. The LED panel on the EHC went nuts, it was like a light dance, the LEDs were flickering all over the place. I waited for it to stop, then they all went out.

I switched off, a few mins, then switched back on. only the Power and Controller On led were lit. I started it up...... Everything worked. All lights, horn, everything.

This worries me even more.

Im going to give it tonight on the tender again. Then start it up tomorrow and see if anything has change then take it for a ride.

Just for the heck of it, it might be worth taking the battery to Autozone or something and have them load test it. Maybe you got a bad battery. I think its a worthwhile exercise before you start actually spending any money.

I know it's probably unlikely but I would do it just so I could rule out the easy/cheap things first.

 

[Kiwirider]

Could be worth a try.

I turned the key on this morning, no Run/Off or start.

I turned it off, disconnected the - terminal for a min, re connected it, then I got R controls back and it started. Both times. these LED's were lit and stayed lit.

No other LED's were lit or even flashed.

Anyone know what this could mean?

The bike "seems" to be running fine (havent taken it out for a ride yet, raining at the moment and dont want to add water to the mix), all lights/horn are working, for now.

 

[Kiwirider]

Well, myself and Mickeetwo pulled the tank checked and greased evey connection we could find, pulled the coil cover and EFI cover and greased/checked all those connections. Pulled checked/greased the front signals, both hand controls, speedo unit, back bone connections, O2 sensor connections, everything that had a plug connection that we could find.
We got everything back together, new fuel. Turn key on, run, key off, 15 secs. Turn on and EHC looks good. Only the Power and Controller On are lit.

Hit start and now it runs like shit. The rear cylinder is running rough as guts, back firing all over the place. WTF!!! O yea, right front signal still wont flash.

 

[Brew]

Did you get the plug wires crossed when you were checking the coil wires? Kind of weird that it would be running so rough all of a sudden. Pull the plugs and see if they are fouled.

 

[Kiwirider]

Did you get the plug wires crossed when you were checking the coil wires? Kind of weird that it would be running so rough all of a sudden. Pull the plugs and see if they are fouled.

They were a little fouled when we pulled them. But not too bad. (im getting new ones tonight just incase.

Can you tell me how the plug leads should look when connected to the coil? I cant remember and cant see in the manual (crap picture). Do they cross over or are they seperate. When mounted, front coil plug to front cylinder and rear plug to rear cylinder? Or do they cross over?

 

[Brew]

Front to front Back to back

 

[Kiwirider]

Front to front Back to back

That could well be it. I hope so.

Ill check back tomorrow.

 

[Kiwirider]

That could well be it. I hope so.

Ill check back tomorrow.

Yup, pulled the coil cover, switched the lead back. Started her up and good to go (knock wood). Will take her for a longish ride today if it warms up (8am and still below freezing), but looks promising so far.

The RF signal was flashing as well, then it wasnt, now it is again. All within 10 mins. If thats my only problem, then Im happy. Compared to what I was thinking this time last week. To me it looked like EHC doom and gloom. EHC led's flashing all over the place. All seems in order now.

Just wish I knew 2 things. What was wrong with it and what we did to fix it......

I guess thats the nature of the beast with these bikes.

Bike thanks to Mickeetwo and yall for your help and advice. Without this board/forum Id be cleaning an expensive paper weight. :up:

 

[stlmikie]

Good job Kiwi! Not always the dreaded ehc! If you don't catch those in time they will possibly fail though.

 

[Kiwirider]

Good job Kiwi! Not always the dreaded ehc! If you don't catch those in time they will possibly fail though.

For sure thats what I was dreading. Was chatting with Mickeetwo while we were working on it. He was saying a lot of times the EHC gets the blame for alot, when its not necessarily at fault. The bike will now live on the tender if Im not on it. Even if its for only a few days.

Cheers again for the help all.

 

[Kiwirider]

Well, back to doom and gloom. All red EHC lights are back on. No right from signal flashing. Just had the VR fry on me. Replaced with a cycle electric. Seems good so far except for the EHC LED's and turn signal. I have 1 week to get this sorted......:bang: