02 Mastiff won't start...HELP??

Energy One
MastiffAv8tor

MastiffAv8tor

Member
I have searched for hours through the forum and haven't found a clear answer so I will post here. Thanks in advance to anyone that can help.

Just bought an 02 Mastiff several weeks ago and already the problems plaugue me. I have read a lot on the EHC and it may be part/all of the problem but also reading that 02 and older are different than the newer models and not a problematic?? Hoping I could find an interim fix as I am not happy about dropping another 5 or 6 Benjamins into replacing EHC just yet. But I would like to ride my new toy so whatya do!

Had what I thought was a weak/dying battery...always on a tender but labored at start. It was several years old so needed replacing. First attmepted ride on Sunday last week and went to start, labored but turned over and fired...quickly died. Tried to restart and all I got was a "click" (coming from beneath the center tank cover housing the speedo) when the starter switched pressed. After several attempts I gave up. All other electrics work; headlight, taillights, turn signal, horn, etc. Bought a new batter few days later, installed (head light is much brighter! :up:) and I get the same thing, just a click. :angry: Removed the speedo to inspect wiring and looked for loose connection or something obivous...nothing jumps out. Anyone have any ideas or troubleshooting techniques before I haul it into a shop...then the next question is anyone know of a good shop in Houston. Mancusso is the only listed authorized service center and they told me they lost their only BDM certified mechanic!! :bang:

Thanks, Cliff
 
MastiffAv8tor

MastiffAv8tor

Member
The "clicking" (just one "click" each time I press the starter switch) is for sure coming from the EHC box between the fuel tanks not from anywhere near the starter. However this is a great tip and I will take a look. Thanks!
 
CCRainman

CCRainman

Well-Known Member
Start with the simple things. The bike need three things to run remember that. Fuel, spark and air. Start with the battery then check to see if you are getting fuel then spark. Go slow one thing at a time. I doubt it would be the EHC because it is the older model and they are not problematic.
 
MastiffAv8tor

MastiffAv8tor

Member
Thanks Rainman, however I am not sure I explained the problem clearly. When the key is on and the start switch is pressed, absolutely nothing happens. Its as though no power is making it from the switch to the starter...dead! Brand new batter (tested fine), air and fuel aren't a factor yet as the starter is not turning. All other electric works fine (lights, speedo, etc.). The "clicking" is coming from the EHC. When the start button is pressed, one "click" in the EHC and NOTHING happens.
 
MastiffAv8tor

MastiffAv8tor

Member
Thanks Mobsta and Rainman. I am very certain the "click" is from the EHC. I pulled the speedo and center piece from the tank to expose the EHC and wiring. When I press the start button the EHC "clicks" once and absolutely nothing happens (or what could be the starter relay...I'm learning...but did put my hand on the EHC when hitting start and can feel the clicking in side). There's nothing coming from the starter at all (not to say that cleaning the contacts is not a good idea) but I am fairly certain the problem is before power gets to the starter. I have found some threads on here in my search that suggest bad connections between the harness and EHC? Will try to remove all connectors, clean if needed, and replace with a dab of dielectric grease. Beyond that may have to seek professional help.
 
01Mastiff

01Mastiff

Active Member
Man, did you get that backwards. 2002 and earlier EHC's were much, much worse and never got much better after that. For the first year I had my bike it was one problem after another. All tracable to the EHC. I turned on my turn signal to change lanes on the freeway at 80 mph, the litebulb went out, which shut down the EHC, which shut down the bike, like right then. I could get the bike to start and actually run about 1 out of 3 times. Finally re-wired and have never had one problem. Do yourself a favor and put your troubles behind you now.
 
X

X-ray Doc

Member
It is most likey the starter relay board. It plugs in close to the EHC. Not very costly, a Harley one will work, it is about 2" square board. I had same problem a couple of times.
 
Coolbreeze

Coolbreeze

Active Member
The click you are hereing from the EHC is a starter relay. They can go bad. You can get a relay from a HD dealer. Ask for a Micro Relay. Lift the EHC from its plastic carrage, black box plugged in the back of EHC. It just pulls out. Or stick a test light in the trigger wire at the starter, turn key on press starter button see if it is lighting up.
 
Moespeeds

Moespeeds

Well-Known Member
There's nothing to click inside the EHC, it's gotta be the relay clicking. Jump a 16ga wire directly from the positive battery terminal to the small blade connector on the starter. If it turns over, it means starter wasn't getting a signal. Check relay, start button on bars, and EHC. If it doesn't turn over, go get a fat piece of 4ga wire, and jump the 2 big terminals on the starter. I've done this with a screwdriver in a pinch but it's hairy. If the starter turns, it's a bad solenoid or contacts. If it doesn't turn, it could be a bad battery or starter motor.
 
CCRainman

CCRainman

Well-Known Member
Moespeeds said:
There's nothing to click inside the EHC, it's gotta be the relay clicking. Jump a 16ga wire directly from the positive battery terminal to the small blade connector on the starter. If it turns over, it means starter wasn't getting a signal. Check relay, start button on bars, and EHC. If it doesn't turn over, go get a fat piece of 4ga wire, and jump the 2 big terminals on the starter. I've done this with a screwdriver in a pinch but it's hairy. If the starter turns, it's a bad solenoid or contacts. If it doesn't turn, it could be a bad battery or starter motor.
Click to expand...
Moe, you giving welding lessons with a screwdriver. LOL:2thumbs::cheers:
 
narow37

narow37

Angry Southern White Man
after hearing all of this, it is absolutely the starter relay. most likely replace and be on your way.
 
MastiffAv8tor

MastiffAv8tor

Member
Wow!! Thanks to all for you input. Was a tough weeknd preparing to move so if there is a good time for the bike not to start I suppose on a weekend I didn't have time to ride was it. Although sunny and 78 both days didn't make any of it any better!!!:(

After all the advice and trouble-shooting (all but the screwdriver trick...thanks anyway Moe!! LOL), it appears the starter relay is the culprit. Will be replacing that this week. Also through the process have discovered bunch of the LED's in the taillight bar are out and license plate bulb burnt. :bang: So, looks like I have some work ahead of me. They say all bad things happen in three's so I should be done....right!!?? :2thumbs:

Thanks again to everyone for your help!! :cheers:

Cliff
 
LARS

LARS

sippin & cruzin
Yea,def. sounds like the S.Relay,I just went through the exact click from EHC back in Nov.,good luck.:cheers:
 
Oldhvymetal

Oldhvymetal

Member
For a 2000 (don't know of it's changed for later years).

...starter relay from Drag Specialties PN DS-325849, Vendor PN MC-DRAG043
Description: Micro Relay W/Diode

Cost $5.99 as of a year ago- I've been through three so far in ten years. I keep a spare in my studio/bar/garage now. If any of y'all need one immediate I can ship it to ya as long as you order and replace it for me quick in case I need it. You never know.
Peace, Respect,
OHM
 
MastiffAv8tor

MastiffAv8tor

Member
Sorry!!! I failed to report back the solution here...was the starter relay. A "starter micro relay" from HD ($6.48) and the problem is solved.

Thanks to all for you advice.

Cliff
 
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