EHC death

Energy One

zipnz

Active Member
Hello all,
I did a search, but could not get a clear answer. Question: Do the EHC's sometimes die a slow death or do they just quit working all of a sudden? Reason being is that my '04 Chopper has been a little dicey from the reliability standpoint for the past few months. Symptom: Sometimes I'll be riding along and the bike will just die- like it's out of gas, but it's not. When I try to start it, it just cranks and cranks. Yes, it is getting fuel. Occasionally, I'll go to start the bike in the morning, again, just cranks and cranks. Other times, it starts and runs flawlessly. Last week, I rode into work with no problem. Went to lunch, as I was riding down the freeway, the bike would hesitate and sputter anytime I gave it throttle, sort of like it was running out of gas- I had a full tank, switched from "on" to "reserve" and back, with no luck. Stopped to eat, got back on the bike, started fine, but began sputtering as I gave it throttle. As long as I gently and slowly rolled on the throttle, it would run. Came to a stop, bike died. Pushed to the side of the road, pulled the seat and observed the following on the EHC. Turn the key on, hit the "run" button, red light on EHC lit up, bike started fine. It would run for a few seconds and then die. Looked at the light on the EHC, now an amber one is on, bike won't start, just cranks and cranks. Turn key on/off a few times, finally the red light comes on, bike starts, runs for a few seconds and dies. Yellow light back on, bike just cranks-no start... Repeated this exercise until the wrecker showed up.
Sorry for the long post- BTW, I replaced the ignition and coil with a DYNA2000i a few weeks back because I thought that might be the problem. Apparently not.
Any thoughts?
Thanks!
 
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Oscar Maldonado

Guru
Calendar Participant
Paul -

Did you make sure that all of your connetions are nice and tight? You probably have a loose connection somewhere. Try tracing your wires with a meter and make sure all of your connections are good before ruling out the EHC.
 

BigDogBro1

Made in the USA
If the EHC is getting intermittent power throught the switch then It could die out like you say but it sounds like an ignition power issue as well.

Try bypassing the switch and power the EHC directly. Yea I know...tear apart to test..Oh well.

Don't remember if the EHC supplies power/Gnd to ignition or not but if it does (the 07 carb bikes do) then the power to the EHC may be loose or intermittent in the harness connections. Start with GOOD clean wire connections/crimps and contacts and work through the harness from the battery to the EHC...ignition.
 
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erldawg

Guru
Dang, 33 views and no comments or opinions?
Geeze a little impatient are we after having the problem for a few months. I would agree with oscar and BigDogBro1 check all connections and fill with dielectric grease. You also may have a ignition switch going bad.
Also next time it acts up try loosing the gas cap then retighten. You may have a vent problem.
 

Dakotabos

Well-Known Member
Calendar Participant
Troop Supporter
EHCs can die a slow painful death. But alot of people say its the EHC when its something else. Wire Plus is the way to go if you are tired of the questions.
Big Dog has scratched their heads for years on EHCs. They gave me a redigned one and No issues even after 15K miles.
 

05 old dog

Well-Known Member
this is gonna sound wierd...but how do you know it has fuel? my bike an 05 and a buddys bike an 04 both will run fine and maybe sputter on the highway or worse die at a stop sign..now the wierd part we can loosen our gas cap and it will pick up and... this is what you have to do if it dies at a stop sign..i took the little check out of mine for a 220 mile ride sun...highway and lots of stop and go...she ran flawlessly...ive asked about gas caps but everybody kinda avoids the question...sorry this was so long.
 

zipnz

Active Member
My apologies for being too quick on the trigger for a response. I appreciate all of your feedback, I really do. I did try a few other things such a loosening the gas cap(I had already removed the plug a couple of years ago). When I say that I know that it's getting fuel, it's because when the bike just cranks and cranks- I'll be twisting the throttle, and invariably- I'll flood the carb. (I actually saw gas dripping out from the carb area on one occasion :eek:). As for loose connections, I looked at what I could get to on the side of the road and couldn't find any. I have the bike on a battery tender when not in use, I know my batt is good. I'll keep checking though.
Thanks again BDM brothers!
Paul :cheers:
 

JRosales

Member
One thing man... gut all the electrical and get you a new electrical system... I got the 2004 DT and works great now with WP and a crane ignition module... No thunderheart.. Most likely your trigger gave out and you are not getting fire to your plugs... (some here call it the cam sensor)
 

mobsta

Well-Known Member
what ehc do you have,the original black or yellow?My 04 was dying off and on and I found a bad right side handle bar control pcb.When my original ehc went it went slow.First the headlight low beam went then I would get start one day then none the next.just my 2cents worth.Check over everything before you can the ehc.I have had no issues with the yellow ehc knock on wood.good luck
 

mobsta

Well-Known Member
If you suspect the cam sensor take the cover off when its running and use a hair dryer to heat up the sensor and see if it dies out.Most times I've seen the cam sensor going the bike will start back up after sitting awhile.just sayn
 

Slider

Active Member
my 04 did a lot of that for about a year before i ripped out the ehc. All the techs at the BD dealer said my problems were probably ehc related. I had all the grease, connectors shrink wrapped, etc, etc, BD replaced the ehc once, tach board twice, and then the warranty expired. I replaced the ehc once again after that and was ready to shove it off a cliff.... until I put in a wire plus.

I had similar problems to you....like going down the interstate at 85, bike would start popping then lost all power no shit 50 times coming cross the nevada desert. I'd just cycle the key, pop the clutch, run for a while, die again. :bang:

I noticed the potting material in my cam sensor was cracked when I put in my dyna2k but I just gutted it all. Worked for me. Just my dumb ass opinion but the ehc just aint worth the hassle. Good luck. :up:
 

zipnz

Active Member
my 04 did a lot of that for about a year before i ripped out the ehc. All the techs at the BD dealer said my problems were probably ehc related. I had all the grease, connectors shrink wrapped, etc, etc, BD replaced the ehc once, tach board twice, and then the warranty expired. I replaced the ehc once again after that and was ready to shove it off a cliff.... until I put in a wire plus.

I had similar problems to you....like going down the interstate at 85, bike would start popping then lost all power no shit 50 times coming cross the nevada desert. I'd just cycle the key, pop the clutch, run for a while, die again. :bang:

I noticed the potting material in my cam sensor was cracked when I put in my dyna2k but I just gutted it all. Worked for me. Just my dumb ass opinion but the ehc just aint worth the hassle. Good luck. :up:
yeah, I can't say for sure the EHC is the culprit. However, it will be gone by the end of the week. I just don't need the worry of possibly of being stranded everytime I ride. Wire Plus is the route I'm taking. :flag:
 

Slider

Active Member
Just take your time, get a good light, measure twice, clip once. Follow Jakes instructions... you'll be fine.
 

RRRUFF

Well-Known Member
Ignition switch can surely be at fault and/or a loose connection. Sometimes the loose connection can be a crimped connector that the wire is actually loose in the connector.
However this problems sounds almost exactly like my friends K9 which would cut off for no apparent reason and his turned out to be the iqnition module. Anyway just my addition to what's already been said above. Hope you find the problem soon.
 

zipnz

Active Member
ehc

thanks for all of the feedback! :cheers:
I have (had) the black ehc on my bike. Is that the original? Where exactly is the cam sensor? Is that what I replaced when I installed the Dyna2000i ignition module? I recall that I had to remove the plug on the other side of the engine to set TDC for timing purposes, then rotating the module until the light just went out. As for the hand controls, both sides were replaced last fall.
Thanks again everyone!
Paul
 
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