2007 K9 smoke from underneath seat

Energy One
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Big Dave 1927

Member
Hello,

Im new to the big dog seen, I just purchased an 07 K9 yesterday and it left me on the side of the road today. Smoke was bellowing out from underneath the seat while i was on the freeway. When I smelt wires burning I pulled in the clutch and the bike died. I coasted doing 70 to shoulder disconnected the ground and watched the smoke eminate from my new to me chop. Now the bike will not start and when I hook the battery back up and hit the start button smoke rises from underneath the battery... I only tried this once. Any suggestions or guidance would be greatly appreciated to get the dog back on the road. Please advise.

P.S.

Hello to everybody!!! :hi:
 
pknowles

pknowles

RETIRED
Something must have shorted out. Is your bikes electrical system stock or did the previous owner install an aftermarket system. Some of us have changed the "ehc" out with a wire plus. You need to pull the side covers and remove the battery to see where the shorted wires are. There's some more qualified people on this forum, but you need to find the source to help. If you don't have a service manual, there's copies running around here. Welcome from Southeast, Va.
 
kickstart

kickstart

Well-Known Member
You need to hit the intro section for your first post.

When my 05 did that it was the EHC that burned up.
 
Ray

Ray

Well-Known Member
Brings back bad memorys eeeeeeccchh fried! ( possibly) It is not the end of the world though! I had mine I think less than a year when my ech fried. The best person I know to on these issues is Jake. Lowdownchopshop The best price on the Wire Plus too. Hope it isn't the ech but that sounds familiar.

Ray
 
W

woodbutcher

Mr. Old Fart member #145
Staff member
Ray said:
Brings back bad memorys eeeeeeccchh fried! ( possibly) It is not the end of the world though! I had mine I think less than a year when my ech fried. The best person I know to on these issues is Jake. Lowdownchopshop The best price on the Wire Plus too. Hope it isn't the ech but that sounds familiar.

Ray
Click to expand...
ray, you HAVE been gone awhile. jake doesn't handle them anymore. :(
 
francoblay1

francoblay1

The Spaniard
Welcome to the forum Dave.

Got your PM about the Service Manual too... I need your email address and I will send it to you.

kickstart said:
You need to hit the intro section for your first post.
Click to expand...
:iagree: http://www.bigdogbiker.com/forums/introductions/25016-your-introduction.html

:cheers:

If really it is your EHC what went tits up... here is some reading for you...

http://www.bigdogbiker.com/forums/ignition-electronics-batteries/36966-ehc-replaced-through-m-unit-motogadget.html

http://www.bigdogbiker.com/forums/general/38892-m-unit.html

http://www.bigdogbiker.com/forums/ignition-electronics-batteries/35905-my-ehc-still-works-great-i-know-shocking.html

Go through the sub-forums and you will find tons of good info :2thumbs:
 
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Big Dave 1927

Member
PDM module melted

After some troubleshooting, following wires and making sure everything was properly grounded. The culprit was the PDM module which is now melted. I don't know what would cause this. Is simply replacing the module sufficient? Where can I purchase one? At least I know now where the smoke was coming from. Please advise fellas.
 

Attachments

francoblay1

francoblay1

The Spaniard
Damn Dave! It will be interesting to find out what caused it. I was reading about PDM vs WP vs Rewiring vs M-Unit just a few minutes ago.... I still have the original ol EHC.

I am following this thread... Good luck.

:cheers:
 
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Big Dave 1927

Member
I'm kinda of stumped on what caused it. Any suggestions gents. Thanks for the help Franco without that manual I would be stumped!!! :)

One thing I did notice was I was unable to locate the circuit breaker...
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
Hard to tell from the limited pictures. Is the thrid picture where you are trying to show the melted part? If so that looks to be the HCI (Hand Control Interface) and would think that BDPP can get you a new one.

Is any of the fuses on the PDM Module blow (the black part with the Little fuse cover). Does that show melting or burns.

You indicate you have no circuit breaker for the power, how about a 40 Amp in line fuse between the VR and the battery?

Is there wire melted? See if you can get some more detials picture, maybe do a little mark up in MS Paint of a PDF files showing the burn/melted parts. If you can check all the fuse in the PDM and see what their condition is, along with pulling the littel relays and test them out, may help to get some better ideas of what is up.

In the last picture on the side opposite of the PDM, I see a few wires that appear to be ran together and going to a stud, is this the grounds? If so was that stud also directly grounded to the Battery or just assuming frame would do it?

Thanks
 
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Big Dave 1927

Member
Fibersnake, the third picture is the melted HCI. This morning I followed your advice and tested everything and it all checked out. Thanks for the advice by the way :) On another note I spoke with Dave from BDM who is the gentleman that builds the harnesses stated that from time to time the HCI will fail. It's not a common failure but it can happen. The great thing is that my issue is repairable and the folks from BDM are great to deal with. Let me tell you guys I was pretty miserable last night thinking she was a dead horse. Hopefully in a few days I will be installing a new harness pdm and hci. I can't wait to get her back on the road. Also Kudos to Dave from BDM he's a stand up kat.

Stay tuned, when the PDM arrives I'm sure I'll be asking plenty of questions. Thanks everybody for the help!!! :)
 
Slick-Dog

Slick-Dog

Active Member
Thats good that there going to help you out.. And scary on the same note...I have a PDM to...and it has thrown its fits to.ie wires coming loose,rubbing, and even a broken wire...but ...moving parts will ware out and rubbing wires will soon short out... But Iam betting you will be ok after the new one comes in...
 
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Big Dave 1927

Member
The PDM, HCI, and the harness will all be replaced. The current PDM that I have is about 2 years old. BDM has a new version of the PDM which includes a new and improved HCI. Also the harness plugs are smaller for a more cleaner look and install.

Slick-Dog it failed due to the HCI not being able to modulate voltage correctly. Basically a surge happened and it toasted it. I will also be replacing the voltage regulator for safe measure.
 
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