AS MOST OF YOU KNOW....

Energy One
jimizee028

jimizee028

TRUE COLORS COLLISION
IF you read this forum religiously i have had issues lately with my bike,and usually the way things work in my life is ...WHEN IT RAINS,IT POURS... and usually i have no umbrella...anyway this years riding season started off under warranty replacing speedometer,starter,voltage regulator,and had an ignition module ordered while the dealership lent me one that had been laying around..just as one thing would be fixed ,another one popped up even on the way to the dealership today in route to get my ignition module exchanged...my bike would just cut off whenever,it wasnt on a bump,or around a corner,or if i was stopped or if i was rollin..it was all these and whenever,yet would start right back up,but got worse and worse as time went on....well while greg from cycle world in brooklyn md was replacing the module i was tellin him my issue about the bike constantly stallin and he started wigglin the connections around under the seat and we noticed everytime he touched the harness that connected to the EHC the lights would blink or shut off completely,upon disconnecting to take a closer look we found that#36 pin (input from ignition switch)at sometime must have spiked and burnt up and turned to rust and was not operational due to failure at all times and this is why my bike would shut off at anytime and to make sure we stuck a pin in there that would connect between the 2 harnesses and it runs absolutely fine....i dont think in a million years i wouldve thought it to be this...of course i knew it was ignition related as i ordered an ignition switch that has also failed,wonder if the failure of the switch causes one thing to fail which causes another thing to fail and another and another....so hopefully i have rid myself of the demons causing my summer to be filled with paranoi and fear to ride.......i actually like my bike now.....so i thought i would let you know how another day in the life of jim and the dog went......
 
Raywood

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
Glad to hear you may have found the gremlin Jimi.

Was the EHC full of die-electric grease when he pulled the two plugs. Just wondering?

:2thumbs::2thumbs:
 
stlmikie

stlmikie

I wish I had more money.
This is exactly what I was taliking about in the other thread. The guys ehc is bad. One thing leads to another. Something like that or a short or bad ground somewhere could surely cause the ehc to fail. I am with big Ray on that note for sure. Cause and effect kind of shit ya know.
 
surferdude

surferdude

dry docked
:confused::D:job:Can you just paste the grease into the plug? Enlighten me please ... I got the stuff but need to know the right way to use it. thanks ... :up:
 
N

Night Train

Member
Disconnect battery ground. (do this every time before you take the connectors off the EHC)

Remove the connectors from the EHC

(if you have a 2004 CAREFULLY remove the rubber seal from the bottom of the EHC side connectors. This seal does nothing but cause problems and often times will not allow you to fully seat the connectors on the EHC). If you have a 2005-newer you can take out the seal (newer ones will already be gone) more than likely you will have corrosion in there and need to remove it to clean.

Inspect both the EHC and harness connectors. You are looking for corrosion. Since these pins are gold flash plated most of the time the corrosion will be green in color. If you have corrosion go to the store and buy some electrical contact cleaner and a soft toothbrush or nylon brush. Spray, brush, let dry and repeat until you do not see any more corrosion. DO NOT USE A WIRE BRUSH.:bang:

Use actual dielectric grease, not axle grease, not moly, not assembly lube, not Vaseline not chocolate pudding. Buy the can of grease not the little spark plug packets most auto parts stores will carry it. Run a bead of grease into the EHC connector. Use a tongue depressor to gently spread the grease. You are wanting to fill the connector with no voids to about the height of the connector pins. You will be tempted to use your hands and should be fine however some of you may have an electric personality and will shock the EHC. Better play on the safe side and steal a tongue depressor from you doctors office the next time you are there trying to figure out why it burns when you pee.:eek:

Put the EHC connectors back on, the grease will squish out of the connector and form a nice bead around the connector. I would leave that bead there, it will collect dust bit will help keep the water out. Repeat every time the EHC is disconnected. You could even make it a yearly or bi-yearly maintenance item. You do not need to he-man the ehc connector screws down, light force after they seat.

Reconnect the battery.
 
RADAMS445

RADAMS445

RADICAL
Nice to have a solution. Lets not forget credit to Greg at cycle world for the wiggle test! Kudoos to Greg!:up:
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
Also be very careful when reassembling the connector, make sure it is lined up and DO NOT FORCE ANY, even a minute bit. Had to replace a perfectly good EHC due to breaking the pin for the Oil Pressure when reassembling the harness connector after doing the yearly maintance.

Also as previously stated, disconnect the battery ground. When disconnecting battery leads, always follow the old lead of ground first off-last on.
 
scubaman15

scubaman15

Well-Known Member
Night Train said:
Disconnect battery ground. (do this every time before you take the connectors off the EHC)

Remove the connectors from the EHC

(if you have a 2004 CAREFULLY remove the rubber seal from the bottom of the EHC side connectors. This seal does nothing but cause problems and often times will not allow you to fully seat the connectors on the EHC). If you have a 2005-newer you can take out the seal (newer ones will already be gone) more than likely you will have corrosion in there and need to remove it to clean.

Inspect both the EHC and harness connectors. You are looking for corrosion. Since these pins are gold flash plated most of the time the corrosion will be green in color. If you have corrosion go to the store and buy some electrical contact cleaner and a soft toothbrush or nylon brush. Spray, brush, let dry and repeat until you do not see any more corrosion. DO NOT USE A WIRE BRUSH.:bang:

Use actual dielectric grease, not axle grease, not moly, not assembly lube, not Vaseline not chocolate pudding. Buy the can of grease not the little spark plug packets most auto parts stores will carry it. Run a bead of grease into the EHC connector. Use a tongue depressor to gently spread the grease. You are wanting to fill the connector with no voids to about the height of the connector pins. You will be tempted to use your hands and should be fine however some of you may have an electric personality and will shock the EHC. Better play on the safe side and steal a tongue depressor from you doctors office the next time you are there trying to figure out why it burns when you pee.:eek:

Put the EHC connectors back on, the grease will squish out of the connector and form a nice bead around the connector. I would leave that bead there, it will collect dust bit will help keep the water out. Repeat every time the EHC is disconnected. You could even make it a yearly or bi-yearly maintenance item. You do not need to he-man the ehc connector screws down, light force after they seat.

Reconnect the battery.
Click to expand...
Good info and intertaining :up:
 
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