04 Mastiff-No spark, changed Cam sensor May be Bad EHC- Advice Needed

[Escobar]

I was searching online and found this response from BDM to a guy online who was burning up his EHC. It somewhat relates to what I'm experiancing because I too am haveing headlight issues aswell as the EHC. I think it all stemed from attempting to start with out a fully charged battery... Interesting

Big Dog Motorcycles Hello Mr. Linson,
I am Brian with the factory in Wichita and I am here to help. First, I wanted to say thank you for being a Big Dog customer. I am very sorry that you are having difficulty with your Big Dog and for my delayed response. I assumed responsibility for assisting our Facebook fans yesterday and I am working diligently to get acclimated to this system and also to get caught up with response to questions such as yours. I requested some information from some of my team members to figure out how we can assist with your issue and here is what I have so far.
Damage could occur in the EHC if the battery has not been maintained to a fully charged state when equipping any 2003 model with optional S&S solenoid compression releases and employing existing connections within the wire harness. Extreme low voltage conditions during start mode (starter solenoid and compression releases activated simultaneously) can cause EHC electronic components to fail. If the battery is fully charged the EHC may not fail but is still possible. Installing a 2002 start module will isolate the EHC from the compression releases and also protect the headlight relay, which operates the compression releases when using the existing yellow wire in the
harness.
I am not sure who you visited with here previously but you are welcome to call me direct at (316)219-6531 and I will certainly be happy to get you in touch with the right folks to help get you going again.
Thanks again for your post and I hope to hear from you soon.
Best wishes,
Brian Ellis

 

[mobsta]

03 is different than 04,04 started the big change,different size handle bars,pegs,electrical and all that crap,i quess anything is possible

 

[chacha]

DRB wrote;

I don't know if the '04 EHC will switch beams automatically if one is burned out so make sure you try both low and high beam just in case.

It does not -- this SW mod came later and was not on the 04.

Escobar -- you're having all the classic signs of a dead/dying EHC. Yes, the OEM version of the 04 EHC is nearly impossible to find, so you'll have to look hard or do the factory modification to handle the latter year EHCs (there's a Service Bulletin out to the field just to explain all the configuration of the EHCs)

I've an 04 also, and I got rid of the EHC and have never looked back....BDM tried to make the POS work for 7 years...I think the supplier just had no QC or engineering margin in the design. The more people I talk to (who actually RIDE their dog) tells me that half the folks are going to have an EHC problem at some point.

 

[jsub]

Do a search for wire plus. You'll see that a couple of us 04 Mastiff guys have just finished changing out the ehc. If you going to have the pay that much for an ehc you just as well go with the wire plus in my opinion.

 

[Escobar]

DRB wrote;


It does not -- this SW mod came later and was not on the 04.

Escobar -- you're having all the classic signs of a dead/dying EHC. Yes, the OEM version of the 04 EHC is nearly impossible to find, so you'll have to look hard or do the factory modification to handle the latter year EHCs (there's a Service Bulletin out to the field just to explain all the configuration of the EHCs)

I've an 04 also, and I got rid of the EHC and have never looked back....BDM tried to make the POS work for 7 years...I think the supplier just had no QC or engineering margin in the design. The more people I talk to (who actually RIDE their dog) tells me that half the folks are going to have an EHC problem at some point.

Thanks for the info... What did you replace you're EHC with; aftermarket or the later year one?

 

[Escobar]

Do a search for wire plus. You'll see that a couple of us 04 Mastiff guys have just finished changing out the ehc. If you going to have the pay that much for an ehc you just as well go with the wire plus in my opinion.

Alright, I'll read up on it. Maybe I can find one from one of the guys on here.

It's ashame this had to happen now, I had a nice ride planned for this weekend 75 degrees out and nothing but sun; the beaches would have been nice.

 

[mobsta]

get a hold of jake,goes by bdmridgeback,he will hook you up with the wire plus

 

[Escobar]

get a hold of jake,goes by bdmridgeback,he will hook you up with the wire plus

Perfect, thank!

 

[chacha]

Like Mobsta said -- if you stick with the BDM switches and controls, then talk with Jake as he knows all the ins and outs of the WIRE+ BDM harness modification.

I unloaded every BDM electrical component except the speedo/tach. Changed over to Harley controls, bars and a HD Wire+ harness,

 

[Escobar]

I think I'll stick with the BDM controls FOR NOW, they've got a nice look plus they're brand spankin new. I installed them late last year when restoring the bike. I'll get in touch with Jake on the Wire +.

 

[Escobar]

just checked,on my ehc the yellow light is on with key on and stays on when cranking

Mine doesn't stay on when cranking, and from what I've learned leads me to believe the battery may have a roll in the ENC Failure. According to BD...

Mine's an 04 but I have all the same signs as above...

I have a new battery installed that's capable of 170 CCA (Cold aCranking Amps) BUT, when I try to start it, I get a drastic Voltage drop due to the starter and the S&S compression release (I've seen it drop as low as 7V) both firing simultaniously and now my my headlight relay is no longer working. I'm ok with getting another EHC but is it bad due to the battery/voltage drop or was it already bad and all I really need to do is replace the EHC....

My gut tells me to just go out and buy an HD Battery with CCA's well above 170 along with a new EHC or Wire Plus... but shouldn't the battery I have now be sufficient? I'd hate to buy only the Wire + and find out that it too craps out due to the voltage drop on this existing "NEW" Battery. (I'm getting pissed just typing this)

What Battery are you guys running?

 

[Raywood]

According to your owners manual you need 270 CCA

 

[DRBarnhart]

I have a new battery installed that's capable of 170 CCA (Cold aCranking Amps)...

Dude! You didn't tell me you had a flashlight battery!!! :down:

Get some amps and try it again before you waste any money on another EHC or WirePlus... :up:

Dennis

 

[Agentbman]

Go to the Harley shop and get a battery. I have had one over two years without any trouble (knock on wood) I can tell you having an 04 Mastiff if you come to the point of needing an ehc go with the wire plus. I have replaced mine and I wont do it again. It will cost you about the same unless you find a used one someone doesnt need anymore.

Battery costs about 94 bucks. Good luck!:2thumbs:

 

[mobsta]

:loony:harley softail battery puttn out 430 cca's,how you turning over that beast with that teeny weeny battery?109bucks before spend 500

 

[Escobar]

According to your owners manual you need 270 CCA

Really WTF! The OEM BDM battery I pulled out of it was 170 CCA. I bought it from the BD dealership here in houston. It was printed right on the top, I wouldn't have figured the dealership would supply me with the wrong one. I've been riding it for months now with that battery but that would explain why i would only get a couple of cranks out of it. The battery i have in there now was a direct replacement for it. I'm heading to the HD dealership tomorrow to get me another one then gonna take this other one and chunk it throught the dealership window if it turns out to be the problem.

Thanks for the help guys!

 

[BikerDave]

Did you get it at Mancuso?? They just sold me one last month, 270 cca for $95 bucks. Said its the one they use for all BD's

 

[Raywood]

Really WTF! The OEM BDM battery I pulled out of it was 170 CCA. I bought it from the BD dealership here in houston. It was printed right on the top, I wouldn't have figured the dealership would supply me with the wrong one. I've been riding it for months now with that battery but that would explain why i would only get a couple of cranks out of it. The battery i have in there now was a direct replacement for it. I'm heading to the HD dealership tomorrow to get me another one then gonna take this other one and chunk it throught the dealership window if it turns out to be the problem.

Thanks for the help guys!

Your going to have to show us a picture of that cause all the BDM batteries for years now have been 270.

 

[Escobar]

Did you get it at Mancuso?? They just sold me one last month, 270 cca for $95 bucks. Said its the one they use for all BD's

Yes, I got it from Mancuso power sports on 59S. I just checked the specks on the one I have now and it is 270 CCA. Sorry for the confusion, I guess i just got confused trying to figure out what caused my EHC failure. I should have it tonight, I'm going to pick up another battery Mobsta recomended just so I don't have to worry about this again and if the EHC still kills out on me when starting, I'll replace it with the Wire Plus. I'll keep you guys posted. Thanks for all the help.

 

[Mojo]

Started looking into the EHC and when checking the voltage i get 12.65V from the Battery but only about 9V to the Thunder heart, 0 V to the Coil and my headlight won't even turn on (10V). Does anyone know if the 12V should be distributed throughout the entire electrical system or the voltage drop im seeing from the EHC is normal.

Is there anything else I could do that would help me determin what is wrong this this Mutt. I leaning heard towards the EHC but don't understand why it would just crap out on my like that.

Thanks!

Unfortunately, your EHC is heading south. Your battery voltage is a little low on your battery, but with the key on and run button pushed, there should be 12+ volts at both the coil and ignition module.