2008 Mastiff (Carb)

[BruceMerc]

Mastiff won't start. This is not a problem I haven't been waiting for because she has been acting up lately. It was getting where when you turn on the key switch a hit the run nothing would happen, so I would turn switch on an off then hit the stop button and then the start and it would seem to work. The ECU lights up like usual but the ignition module does not lite up when the run button is applied. Not sure if the off/run switch is bad or contacts are dirty, ignition module is bad or the ECU is starting to act up. Hey at least it is at home and not on the road somewhere. I have been lucky in the 2 plus years of ownership, only had to change the battery so for. I have not done anything else other than maintenance (fluids). The bike has 5600 miles on it. Any advice on where to start looking would be appreciated.... Thanks Bruce.

 

[FrankBDPS]

Bruce, you may have answered you're own question. If you play with the key switch and it comes on I would start there. Put a jumper across it and see what happens. Good luck.

 

[Nukeranger]

It doesn't sound like the key switch to me. The Key Switch grounds and turns on the EHC. His EHC turns on. I think it has something to do with the Off/Run switch.

 

[Peckerwood]

I usually keep my semi-ignorant mouth shut when it comes to electrical problems, but I experienced the same symptoms years ago and it was, as Nukeranger said, a faulty Off/Run switch. Good luck.

 

[Nukeranger]

Most of us are semi-ignorant including me. Just ask my spousal unit....she'll tell ya. Anyway, what makes this site great is sharing information so we can keep our Dogs running strong.

 

[FrankBDPS]

I belong to the Youre a dumb ass club. We have millions of members.

 

[BruceMerc]

Thanks for the advice, I think the problem lies in the on/off switch. The "Off" feature works fine but the "On" needs attention. I manage to take her out for a ride today without any issues but I had to mash the "On" button to get it to work. Is there anyway of cleaning the switch or just find a replacement for it (if available)? Thanks again for the help Bruce.

 

[Ohmster]

Remove the right hand PCB. Take the rubber off the PCB. Then take some electrical tape and with some scissors cut two or three small squares with the tape, a little smaller than dime size. Make sure the tape squares are smaller than the "run" dome switch on the PCB. Apply the tape, two squares usually do it, over the mylar covering on top of the run dome switch. Re-assemble your PCB and you should be good to go.

If your run button only works when you have to really press hard on it, usually whats happening is the rubber run switch is getting worn on the side that presses on the run dome switch. Adding in the electrical tape adds a few mil thickness to it and allows the run switch to engage the dome switch and should give you a nice, crisp, click when you press the switch.

 

[BruceMerc]

Remove the right hand PCB. Take the rubber off the PCB. Then take some electrical tape and with some scissors cut two or three small squares with the tape, a little smaller than dime size. Make sure the tape squares are smaller than the "run" dome switch on the PCB. Apply the tape, two squares usually do it, over the mylar covering on top of the run dome switch. Re-assemble your PCB and you should be good to go.

If your run button only works when you have to really press hard on it, usually whats happening is the rubber run switch is getting worn on the side that presses on the run dome switch. Adding in the electrical tape adds a few mil thickness to it and allows the run switch to engage the dome switch and should give you a nice, crisp, click when you press the switch.

Sounds like a good idea. I will give it a try. Thanks Bruce

 

[BruceMerc]

Remove the right hand PCB. Take the rubber off the PCB. Then take some electrical tape and with some scissors cut two or three small squares with the tape, a little smaller than dime size. Make sure the tape squares are smaller than the "run" dome switch on the PCB. Apply the tape, two squares usually do it, over the mylar covering on top of the run dome switch. Re-assemble your PCB and you should be good to go.

If your run button only works when you have to really press hard on it, usually whats happening is the rubber run switch is getting worn on the side that presses on the run dome switch. Adding in the electrical tape adds a few mil thickness to it and allows the run switch to engage the dome switch and should give you a nice, crisp, click when you press the switch.

Cut and placed a few pieces of Electrical tape as suggested and it works great. Thanks for the help. Bruce

 

[Peckerwood]

Thx for the follow-up, it's nice to hear of a problem resolved.

 

[Ohmster]

Glad it worked out for you

 

[Srodden]

Remove the right hand PCB. Take the rubber off the PCB. Then take some electrical tape and with some scissors cut two or three small squares with the tape, a little smaller than dime size. Make sure the tape squares are smaller than the "run" dome switch on the PCB. Apply the tape, two squares usually do it, over the mylar covering on top of the run dome switch. Re-assemble your PCB and you should be good to go.

If your run button only works when you have to really press hard on it, usually whats happening is the rubber run switch is getting worn on the side that presses on the run dome switch. Adding in the electrical tape adds a few mil thickness to it and allows the run switch to engage the dome switch and should give you a nice, crisp, click when you press the switch.

Good advice verses buying new board

 

[BruceMerc]

Took the bike out this weekend. Worked fine, in fact I had noticed that the "CR" was getting to be a hit and miss when starting. "CR" now works as it should, I am not an electrician but I guess is was not making the connection it needed. Bruce