Trashman
Member
I had posted a message in the help wanted section when my 2004 Chopper started and then died 15-20 seconds later. This happened about four times and then it would not start at all and would just crank. I was not getting the red power LED on the EHC. I tried all kinds of troubleshooting and even ended up replacing the cam sensor.
Well long story short, having plenty of time on Saturday to trace the problem down, I wanted to verify that the controls in the right handle bar assemble were working but really did not want to tear the damn thing apart. I found a troubleshooting step under the electrical section where you can isolate the harness between a connector located under the tank and the right hand controls. I removed the bracket under the tank and pulled the harness from under the tank and along the frame to gain access to the connectors. I isolated the line that went to the right hand control and seperated the connector under the tank. First step is to verify continuity between the ground pin on the male (EHC) side of the connector. You do this by connecting a clip to the negative side of the battery. In my case I used a meter lead with alligator clip and then probed the the connector with a very fine tip test lead. I verified ground and then stepped through the other pins (CAREFULLY) on the connector. The EHC is looking for a low signal, ground, and that's the reason for probing with the lead connected to the negative side of the battery. Anyone, when i probed the red wire, which is power, the red LED lit up on the EHC. Probing the off pin turned the power LED on the EHC off. I was able to probe the right hand blinker pin and activate the right hand blinker, probing the start pin activated the starter. All pins looked good on the male side of the connector. I did pry up a little on the power side of the female connector, allowing the female side to put just a little more pressure on the male pin. Cleaned everything with electro-contact cleaner, packed the connector, as well as all other connectors under the tank, with dialectric grease. Bike cranks, runs and I have not had another problem with it since. I put over a hundred miles on it yesterday, stopping and starting numerous time with no problems. Keeping my fingersa crossed! I want to thank Little-Boo, raywood, eric, mobsta, KaptinAmerika and DRBarnhart for their diagnostic help.
GREAT BUNCH OF FOLKS ON TIS FORUM!
Well long story short, having plenty of time on Saturday to trace the problem down, I wanted to verify that the controls in the right handle bar assemble were working but really did not want to tear the damn thing apart. I found a troubleshooting step under the electrical section where you can isolate the harness between a connector located under the tank and the right hand controls. I removed the bracket under the tank and pulled the harness from under the tank and along the frame to gain access to the connectors. I isolated the line that went to the right hand control and seperated the connector under the tank. First step is to verify continuity between the ground pin on the male (EHC) side of the connector. You do this by connecting a clip to the negative side of the battery. In my case I used a meter lead with alligator clip and then probed the the connector with a very fine tip test lead. I verified ground and then stepped through the other pins (CAREFULLY) on the connector. The EHC is looking for a low signal, ground, and that's the reason for probing with the lead connected to the negative side of the battery. Anyone, when i probed the red wire, which is power, the red LED lit up on the EHC. Probing the off pin turned the power LED on the EHC off. I was able to probe the right hand blinker pin and activate the right hand blinker, probing the start pin activated the starter. All pins looked good on the male side of the connector. I did pry up a little on the power side of the female connector, allowing the female side to put just a little more pressure on the male pin. Cleaned everything with electro-contact cleaner, packed the connector, as well as all other connectors under the tank, with dialectric grease. Bike cranks, runs and I have not had another problem with it since. I put over a hundred miles on it yesterday, stopping and starting numerous time with no problems. Keeping my fingersa crossed! I want to thank Little-Boo, raywood, eric, mobsta, KaptinAmerika and DRBarnhart for their diagnostic help.
GREAT BUNCH OF FOLKS ON TIS FORUM!
:2thumbs:
