Left Me Stranded

[Unsprung]

Hey guys and gals, I've gotten a lot of help reading through the postings in the BDB forums and now I'm here with an issue I have not run across in my readings. Heading down I-4 to Biketoberfest and lost all power, no lights, no ignition, no start. Pulled and load tested battery when I got back home and it would not load test or take a charge. Got a new battery and once the switch was turned on I smelled burning wires. Found the speed sensor burnt at the base of the harness going into the sensor. Cut the sensor out of the system, still no start but now I've got lights in the speedo but no neutral light or oil pressure light, (also burned the low beam). Checked for spark while cranking and it's dead, (NO SPARK). Starter cranks real well, no brake lights or turn signals and the new Thunderheart module that was installed 4-5 months ago has an LED lit up for turn switches , oil, and neutral but I'm not sure why no spark, no start. I will go through the harness with an ohm meter when time permits, check and re-check for shorts and continuity but I'd like to know if someone has ideas as to what I may need to look for that I may not be thinking about.
Thanks in advance for any help or ideas. Just a little frustrated...

 

[Brew]

For the no spark issue, it could be your cam sensor located in the nose cone. Right side of the engine, it's a round cover with two screws. Several members have had issues with this in the past. just a thought!

 

[Unsprung]

For the no spark issue, it could be your cam sensor located in the nose cone. Right side of the engine, it's a round cover with two screws. Several members have had issues with this in the past. just a thought!

I'll give it a look but it was working fine before meltdown. Anything to look for on the sensor?

 

[Th3InfamousI]

Is this an 03?

Sent from my 831C using Tapatalk

 

[Unsprung]

Is this an 03?

Sent from my 831C using Tapatalk

Sorry. Yes it's an 03 Pitbull with a Thunderheart EHC wired in back in May. Everything worked fine up until Last Saturday. I replaced the stock EHC because I had no brake lights, and start switch did not work.

 

[Unsprung]

Well I spoke to tech support at TH and I'm sending the EHC back for diagnosing tomorrow. Seems the module is shot and they think it's the voltage regulator that caused it all. I need to replace the VR, EHC, and speed sensor since it was shorted. Any thoughts to the condition of the stator? Might as well get to polishing and some other maintenance, (wires, oil, etc), won't be riding for a while unless I get on the sporty.

 

[Brew]

I'll give it a look but it was working fine before meltdown. Anything to look for on the sensor?

A burnt smell would be a good indicator...

 

[Unsprung]

A burnt smell would be a good indicator...

I've got the TH EHC pulled to ship to Thunderheart and plan to check all wiring and the cam sensor on Thursday/Friday. If all looks well, I'll need to replace the EHC, VR, and speed sensor. My speedo did not work so no rush on the sensor. Back to square one again but it's an adventure.

 

[BadDawg Bill]

Well I spoke to tech support at TH and I'm sending the EHC back for diagnosing tomorrow. Seems the module is shot and they think it's the voltage regulator that caused it all. I need to replace the VR, EHC, and speed sensor since it was shorted. Any thoughts to the condition of the stator? Might as well get to polishing and some other maintenance, (wires, oil, etc), won't be riding for a while unless I get on the sporty.

Before you put in a new VR check the wire coming from the VR to the battery. It runs under the frame and gets grounded out from vibration /rubbing/hitting a curb etc... If it's grounded out and you put in a new VR it will turn to dust too...

 

[Unsprung]

Before you put in a new VR check the wire coming from the VR to the battery. It runs under the frame and gets grounded out from vibration /rubbing/hitting a curb etc... If it's grounded out and you put in a new VR it will turn to dust too...

Thanks Bill, will do.

 

[Twisted]

That sucks man, hope you get it figured out!

 

[liferider]

I HATE electrical Grimlin's!!!!

 

[Unsprung]

Well, I just got the call from Thunderheart after they tested my EHC and sure as heck the new module is burnt and they believe it's the VR. Now I've got to replace a few parts, (VR, EHC, speed sensor). Lost brake lights, turn signals and spark, so I can only hope that the new EHC will take care of these issues.

 

[BadDawg Bill]

Well, I just got the call from Thunderheart after they tested my EHC and sure as heck the new module is burnt and they believe it's the VR. Now I've got to replace a few parts, (VR, EHC, speed sensor). Lost brake lights, turn signals and spark, so I can only hope that the new EHC will take care of these issues.

I heard from someone that if you old school wire it you solve all those problems....

 

[JR03CHOPPER]

My Voltage regulator went...took the ignition and my headlight with it. When I replaced the VR, I replaced the Stator as well. After they were replaced...I haven't had to use the battery tender any longer. Still running the stock EHC. Good luck with the fix.

 

[Unsprung]

I heard from someone that if you old school wire it you solve all those problems....

Bill, I like the few comforts that the EHC provides and with that I'll just have to deal with a few headaches along the way. Truth be told when it died on me I was wishing for "old school wire". Hopefully the charging system monitor will help with any more VR issues.

 

[Unsprung]

My Voltage regulator went...took the ignition and my headlight with it. When I replaced the VR, I replaced the Stator as well. After they were replaced...I haven't had to use the battery tender any longer. Still running the stock EHC. Good luck with the fix.

i may have lost ignition also but I can't really check until I replace the TH module.

 

[francoblay1]

My Voltage regulator went...took the ignition and my headlight with it. When I replaced the VR, I replaced the Stator as well. After they were replaced...I haven't had to use the battery tender any longer. Still running the stock EHC. Good luck with the fix.

I was very lucky.... the VR went tits-up but didn´t do any collateral damage.

Still running original EHC too.

 

[BadDawg Bill]

Bill, I like the few comforts that the EHC provides and with that I'll just have to deal with a few headaches along the way. Truth be told when it died on me I was wishing for "old school wire". Hopefully the charging system monitor will help with any more VR issues.

Just remember to check that pos wire from the VR to the battery first.... I bought clear tubing to run the wire through so it wouldn't rub on anything. Good luck!

 

[Unsprung]

Just remember to check that pos wire from the VR to the battery first.... I bought clear tubing to run the wire through so it wouldn't rub on anything

That's a great idea bill and I'm going to have to use it. Where do I send the copyright fees? lol