Presumed EHC failure that actually was not the issue

[Mojo]

What was interesting is that I was able to quickly disconnect and reconnect a plug with the ignition on and get the EHC to light up like a tree. This has been my only issue. This is an EHC reboot like a loss of power. More investigation to come!

What this indicates is a quick loss of power to the EHC. Make sure the ring terminals are crimped tight to the wires at the battery that lead to the EHC. A loose battery connection, poor power harness connection at the EHC, or faulty key switch could also cause this condition. Here are a few easy things you can try. Turn the key on and wiggle it. If the EHC lights up like a tree, the key switch is faulty. Also, turn the key on. While turning it back off, observe how far you have to turn it before it shuts off. If it shuts off immediately, you have the old style key switch, and could be the cause of the issue. The newer style switch will not shut the bike off until it is turned about halfway off.

 

[Nukeranger]

Thanks Mojo,

Wiggling the key has never caused the EHC to shutdown. I just checked like you said and I have the newer style ignition switch. I was thinking of soldering the connection under the tank and putting a deutsch connector on the connection under the ignition cover next but I haven't had any shutdowns lately.

Nuke

 

[JeffM]

I have ordered a new WP and switch from WP. they say "Up to 3 weeks delivery". Recon that will equate to 6 to 8 weeks. I have also got a new back bone and power harness of ebay as some "person" for some reason has cut into the original to install a "flasher unit'' WTF!!!!!
So now i have a exquisit scoot under my home stripped down waiting for new innards during the best riding weather Australia has to offer.
Talk about frustrated. I also have to find someone to install the WP and sort out the mess that is under my seat.
Q. If BD new they had a major failing wit the EHC why didn't they wipe the company producing the EHC and sign up WP (or PDM) to supply a better product. You would think they would have had grounds to tear up any binding contract?????

Just saying is all!!!

 

[stlmikie]

That's a question a lot of people have asked Jeff. I try to rule out everything else before I say the ehc is bad cause it gets a bad wrap but nine the less they should have addressed the electrical issues a long long time ago. Without a doubt. I hope that the WP cures your issues so's that you can get a ton of trouble free miles (finally) out of that bad assed bike!

I have ordered a new WP and switch from WP. they say "Up to 3 weeks delivery". Recon that will equate to 6 to 8 weeks. I have also got a new back bone and power harness of ebay as some "person" for some reason has cut into the original to install a "flasher unit'' WTF!!!!!
So now i have a exquisit scoot under my home stripped down waiting for new innards during the best riding weather Australia has to offer.
Talk about frustrated. I also have to find someone to install the WP and sort out the mess that is under my seat.
Q. If BD new they had a major failing wit the EHC why didn't they wipe the company producing the EHC and sign up WP (or PDM) to supply a better product. You would think they would have had grounds to tear up any binding contract?????

Just saying is all!!!

 

[BBChopper]

What this indicates is a quick loss of power to the EHC. Make sure the ring terminals are crimped tight to the wires at the battery that lead to the EHC. A loose battery connection, poor power harness connection at the EHC, or faulty key switch could also cause this condition. Here are a few easy things you can try. Turn the key on and wiggle it. If the EHC lights up like a tree, the key switch is faulty. Also, turn the key on. While turning it back off, observe how far you have to turn it before it shuts off. If it shuts off immediately, you have the old style key switch, and could be the cause of the issue. The newer style switch will not shut the bike off until it is turned about halfway off.

:2thumbs:

 

[Fat_Bastard]

My EHC's were in fact bad.
Original EHC went bad after one year and was replaced by the dealer under warranty.
Second EHC went bad after 7 years and was diagnosed by me and with the help of this forum. Replaced it with Wire Plus Kit.

If there are SO MANY GOOD EHC's out there that were mistakenly replaced...
How about making them available to those in need on this forum? ______ .
I would have paid a reasonable price for a "mis-diagnosed-bad-EHC".

I waited 3 months, paid in advance, paid over $500. (for a WirePlus Kit) to get my bike running again.

Juss' sayin' where are all those good "mis-diagnosed-bad-EHC's".

PPS: anybody want my old EHC?

 

[BigDogBro1]

I was Tech Support at BDM for their last 7 1/2 years. We replaced so many EHC's that were not faulty that I had to call the dealer/service center every time an EHC was requested in order to troubleshoot and confirm that it needed replaced. After only a few short months, our analysts told me that EHC replacement had dropped 300%. I can say with confidence that 90% of the time I called, the EHC was either not at fault, or something else had caused the EHC failure Unfortunately, electrical seems to intimidate a large majority of mechanics. Since the EHC was unfamiliar territory for many, it was the easiest to blame. I was actually nicknamed the EHC Nazi by a co-worker (after the Soup Nazi from Seinfeld). Not saying they did not fail, but it was actually a very low percentage.

Most likely the majority of the suspect EHC's were trashed.

I heard this EHC survival rate information via John Nasi at BDM years back and have always suspected the majority of EHC problems are improperly identified by untrained mechanics.

John at Beezer's here in Michigan came thru with factory assistance and got it solved.

I had problems causing the bike to shut down during riding and all it was, was LOOSE wire crimps at the connectors to the battery posts.

 

[jjarkys]

Just bought an 05 pitbull, and new to this forum but have read everything I can to educate myself on BD's electrical issues. Including this entire post. My bike shuts down while riding, actually starts cutting out like its running out of gas and then shuts down completely. A couple of times it actually came back after sputters and pops and did'nt shut down completely. Put about 100 miles on it this last weekend at BBB here in Arkansas and it quit on me probably 6 times. Seems like I can turn the key off, let it sit for 10 seconds, turn it back on a motor on. Until the next shut down. I knew of these issues when I bought the bike but I am not afraid of tearing it apart to fix. Also, the tach does not work and the right turn signal does not work. I took the ehc out today to check it out. It does have the usb port on it so from what I've read this means it is an updated ehc? I cleaned it good with contact spray and packed it with elec grease. It was also just laying on the tray with no attachment so I used some heavy duty velcro to hold it down and give it some cushion. The tach did respond to that but I have'nt ridden it yet to see if it has started working correctly. Also from what I've read, it appears I may want to check the ignition switch? Its pretty loose feeling so it might be an issue. It also turns off almost immediately so also from what I've read this is an older switch and could be a problem?

I have no problem getting the WP upgrade but don't want to lay down $600 until I know that will fix the problems. I've learned in the past to start with the easy/cheap stuff first.

If someone has any input on my specific situation I would appreciate your advice.

Thanks

 

[Rex Winters]

I know with my blinker problem, it was the connection under the gas tank from the controls to the backbone harness. Take the tank off and check that. Plus, with the ignition switch giving you problems, and the bike shutting down: is there any chance the ket is getting bumped/vibrated off?

 

[jjarkys]

I know with my blinker problem, it was the connection under the gas tank from the controls to the backbone harness. Take the tank off and check that. Plus, with the ignition switch giving you problems, and the bike shutting down: is there any chance the ket is getting bumped/vibrated off?

So I did replace the ignition switch. Just for good measure. So changes were a new ignition switch and cleaned and packed the ehc with elec grease. Put 80 miles on it Thursday and only shut down once around the 50 mile mark. When it shuts down it cuts out and sputters like its running out of gas. So I filled up both tanks separately (curious to know how everyone else fills their tanks?). I had not done this before, just the right tank. Plus this was only the second time I've put gas in it since buying the bike. After I completely filled up both tanks I went another 30 miles and no shut down. Really gained a lot more trust in it after that. The first ride it shut off 6 times over a couple of hours. Its getting better.

I'm sure its just teasing me....

 

[pknowles]

Most likely the majority of the suspect EHC's were trashed.

I heard this EHC survival rate information via John Nasi at BDM years back and have always suspected the majority of EHC problems are improperly identified by untrained mechanics.

John at Beezer's here in Michigan came thru with factory assistance and got it solved.

I had problems causing the bike to shut down during riding and all it was, was LOOSE wire crimps at the connectors to the battery posts.

I still have the one out of my 07 if anyone needs it.

 

[flight_medic401]

Well I felt blessed and scared to still have the BDM ehc but it finally layed down on me this summer and it now has a wires plus under the hood. But the replacement was the fix.

 

[SCOTTx88]

Change mine to Wires Plus soon. My headlight works again, after three bulbs but now my Speedometer and odometer are dead. Had it tested yesterday the Speedometer,obviously is bad and the oil pressure part of my EHC is dead. Bike still runs fine just really don't want it to die too far from home when the rest of it pukes. Mine was tested by a Big Dog service center.