09 K9 lost all electrical power while riding. Dead. No power when turning key.

[2009K9]

09 K9. About 30k really have had no electrical problems except it eats batteries. Average life of one 14 months. Less over the last few years as everything is getting cheaper in my opinion. Another AGM battery lost. Last one 11 months. Previous 8 months from Oriellys. 6 month warranty. Usually around a year. Last weekend stopped at the store. Wouldn't start. Got jumped rode 60 miles home. I installed a NOCO lithium battery Saturday. Started like a champ. Rode 30 miles or so. Lost all electrical power. Coasted off the road. Cycled key. Clicked. Odo went out again. Zero power. Someone stopped and we tried to jump it. Key on. Clicked. Back out. Got it home. Removed Lithium battery Sunday. Installed new AGM maybe a Lithium battery issue. Still dead. Going to replace the braker. Stud is now spinned that I disturbed it. Was passing power through. And relay as it has some corrosion. Then test ignition switch. I am not a mechanic then alone a electrical guy. But want to check the simple shit before I pay someone else to do that. Fingers crossed something stupid and simple.

Thoughts? Feedback? Thanks in advance.

 

[Jersey Big Mike]

Jump 12v to green wire on starter (BIKE IN NEUTRAL) and see if it turns over.

Start with the key switch and make sure its working.

Check run/kill nad startswitches in the handlebars

If you get it started check the voltage at battery -- at idle it should be 12.8 or above -- rev up to 2500rpm and voltage should go to 13.8 - 14.4 (14.8 absolute max).

Be methodical
Pay attention to waht you are doing
Take pictures of wires before you mess with them.
DO singular test at a time (ie handlebar switches, reassemble and then next test)
You have a multimeter - cheap at auto-store or harbor freight -- nothing fancy needed.
Make copious notes of EXACTLY what you did and EXACTLY what happened
Report back and we can proceed from there.

 

[2009K9]

Freaking site lost my repl.

 

[2009K9]

New battery. New braker. New 7.5 fuse at bettery lead. Replaced corroded relay. Marker lights and gauge/odometer light up. That is it. No power to ignition switch or at hand controls. Ignition box next to the battery is not lighting up like it used to with key on. Not other fuses I could find to check. Will look at it one more time before taking it to a shop. All I can do as. Sincerely appreciate you time and help. Thank you. Jason.

 

[Mickmorris]

Post pic of ignition and EHC

 

[2009K9]

Those work?

 

[Jersey Big Mike]

New battery. New braker. New 7.5 fuse at bettery lead. Replaced corroded relay. Marker lights and gauge/odometer light up. That is it. No power to ignition switch or at hand controls. Ignition box next to the battery is not lighting up like it used to with key on. Not other fuses I could find to check. Will look at it one more time before taking it to a shop. All I can do as. Sincerely appreciate you time and help. Thank you. Jason.

You need to realize that the hand controls do no operate on 12v.
The switches are connected to a microcontroller (EHC) Each of the SIGNALS (run, start, kill, left, right) are shorted to ground when the switch is pressed. When not pressed the signal will only have a couple of volts on it and no real power, ie will read with volt meter but not light a test light!

To test you'll need to short the run signal to ground with a jumper.
Do that and see if you get lights (with key switch on) Key on is also a signal to ehc and not POWER as a lawnmower/tractor/old schoolbike would be.
Once you short the run to ground (momentarily -- ie do not leave connected), if you have lights on the igntion, short the ground to start signal breifly (less than 3 secs) and see if it turns over/starts.

 

[Mickmorris]

Those work?

Yes.Those are good pics. So that thunderheart ignition as you clearly know should light up when the key is turned on and the run button is pressed. This is not happening? You said the speedo and signals come on with the key turned on. So you have power to the system. Any lights on the EHC coming with the key turned on?

 

[2009K9]

Thank you guys. I have a tech from work (freightliner) that offered to come by and take a peak at it before I take it to a shop. He feels that he can figure it out so I said... Sure. Haha. Either tomorrow or next weekend when he can get permission of his wife.

Mike, I am going to share this info you supplied with him as well. We spoke about the other info you shared Friday at work. Thank you again.

Mick, no lights on ignition module at all. Sorry better info on marker lights and speedo lighting up. They do that when battery is connected, just connected. Even with key off. No headlight or any other lights other than those. No power at the coil with key on. Is the EHC the black box the harnesses plug into? (circled in the pic below)

Does anyone have a beer wiring schematic for 06 to 09? I found this. Some of the info is hard to read when you enlarge.

Sincerely. Thank you gentlemen.

 

[Mickmorris]

Thank you guys. I have a tech from work (freightliner) that offered to come by and take a peak at it before I take it to a shop. He feels that he can figure it out so I said... Sure. Haha. Either tomorrow or next weekend when he can get permission of his wife.

Mike, I am going to share this info you supplied with him as well. We spoke about the other info you shared Friday at work. Thank you again.

Mick, no lights on ignition module at all. Sorry better info on marker lights and speedo lighting up. They do that when battery is connected, just connected. Even with key off. No headlight or any other lights other than those. No power at the coil with key on. Is the EHC the black box the harnesses plug into? (circled in the pic below)

Does anyone have a beer wiring schematic for 06 to 09? I found this. Some of the info is hard to read when you enlarge.

Sincerely. Thank you gentlemen.

Yep that’s the EHC you have circled. My guess by those symptoms is your EHC is failing. I believe there is better diagrams available in the Dropbox. I’m not sure how you pull that up but one of these guys can get you connected to that. My advice…don’t let anyone who doesn’t know these motorcycles monkey with it.

 

[2009K9]

Thanks for the feedback. I found that one just Google. Dropbox I found a lot of stuff but no schematics. So trouble trees and manual stuff. I will look again tho. Thanks you.

 

[Jersey Big Mike]

Thank you guys. I have a tech from work (freightliner) that offered to come by and take a peak at it before I take it to a shop. He feels that he can figure it out so I said... Sure. Haha. Either tomorrow or next weekend when he can get permission of his wife.

Mike, I am going to share this info you supplied with him as well. We spoke about the other info you shared Friday at work. Thank you again.

Mick, no lights on ignition module at all. Sorry better info on marker lights and speedo lighting up. They do that when battery is connected, just connected. Even with key off. No headlight or any other lights other than those. No power at the coil with key on. Is the EHC the black box the harnesses plug into? (circled in the pic below)

Does anyone have a beer wiring schematic for 06 to 09? I found this. Some of the info is hard to read when you enlarge.

Sincerely. Thank you gentlemen.

that is indeed the schematic from the shop manual and should be all you need as the boxes are not user servicable.
Check the key switch and see if it is working -- disconnect it from the bike (under coil cover) and see if lights still get power.
If they do, disconnect battery and ohm the pins on the switch connector that goes to the EHC and see if there is a short.
If there is the next step would be disconnect the EHC and see if the short is still there. If it is there's a wiring issue if not you may have an ehc issue..

 

[Mickmorris]

Thanks for the feedback. I found that one just Google. Dropbox I found a lot of stuff but no schematics. So trouble trees and manual stuff. I will look again tho. Thanks you.

So at the top bar hit the search engine & type in PDM electrical system kit wiring diagram & by member J-Rock. Mickeetwo has posted better pictures of the wiring schematic that you are looking for on that thread.

 

[2009K9]

Good morning gentlemen. Good call, the EHC is dead. No shorts could be found from our testing. Going to order an new one and the upgraded 32 amp 3 phase charging system, VR and coil from Wild Steed Worx. Best source for our bikes?
I have not had any repairs on the bike in the last 3 years other than batteries so anything to stop buying a battery every year. Hope the ignition mod is good once EHC is replaced. Cannot thank you guys enough. Thank you.

 

[Mickmorris]

Good morning gentlemen. Good call, the EHC is dead. No shorts could be found from our testing. Going to order an new one and the upgraded 32 amp 3 phase charging system, VR and coil from Wild Steed Worx. Best source for our bikes?
I have not had any repairs on the bike in the last 3 years other than batteries so anything to stop buying a battery every year. Hope the ignition mod is good once EHC is replaced. Cannot thank you guys enough. Thank you.

Replace the ignition also. That sucker is obsolete. You won’t regret it. And Yes on wildsteedworx. That module is solid.

 

[2009K9]

Good idea. I will look into that as well. Thank you again. You guys have been awesome!

 

[Jersey Big Mike]

Good idea. I will look into that as well. Thank you again. You guys have been awesome!

I do believe WildSteedWorx still offers testing services for the EHC - Might want to check into that first to be sure. You may not have fiund a short but did you also check for opens/broken wires?

 

[2009K9]

Sounds like a good idea. Did not find anything obvious visually in that area. Nothing was found by the meter in either harness. So fingers crossed. I will actually go through them one more time. Good call. Thank you.

 

[2009K9]

Well I am back. New EHC (not from Wild Steed, my mistake I see now) I was given 2 guys contact info. Curtis at Wild Steed and Josh at Gateway, Josh took my call and promised me a turn around time he could not delivery on but had my EHC so I was stuck. Took him 3 days longer then he stated with no communication (Wild Steed took 3 days to get back to me and EHC was already sent out to swap connections over to new one) I DO NOT RECOMMEND JOSH AT GATEWAY AT ALL.
New charging system from Big Dog Parts King Pin. Had installed. Everything works but no speedo/odo. Power and ground at speedo. Josh it is not helping after first conversation of power and ground at speedo, not the EHC but did not answer the question of did he test it before he sent it out as he never has problems with them.... so no he did not test it. For shits replace speedo sensor, then odo. Still no speed/odo. Connections good, tight, clean. Red, black and green wires run from speed sensor to EHC then to ignition. Do anyone know if the speedo info runs through the ignition module? I dont mind replacing it if it is going to fix it. But if the EHC is the problem..... Thoughts feedback other than I am a dumb ass for making the wrong choice for the EHC.
Thanks guys.

 

[2009K9]

Tach looks it comes from ignition but not speedo. Am I seeing that correct? I attached shot.