EHC or what?

Energy One
1goodsinner

1goodsinner

Member
I seriously do not believe my problem is with my EHC,but I do have a electric problem shoing on the EHC...I believe! I'm having problems getting the tank off to check all electrical underneath because the previous owner stripped out two of the allen head bolts(probably using too small of an allen wrench,read "idiot" here!).I've got to use a backout I imagine.Anyhow,when I turn the key on,the red light labeled in the service manual as IGNITION flickers rapidly.You can barely see it it's so fast!What should I check and what could be my problem.Problem that I have is the bike dies totally without any warning.It could be 1 mile or it could be 35-40 miles,but it will do it eventually!I then quickly turn the key off and then on and hit the RUN button and the bike restarts.Please help while I try to check electrical under the fuel tank.Thanks guyz!
 
Relic

Relic

Active Member
Start with the easy things first.

1. Unplug EHC,fill with die-electric grease, check pins etc.
2. Check battery conection.
3. Wiggle switch while running to see if the bike shuts down.

Search the site, a vast knowledge base on here.
 
BigDogBro1

BigDogBro1

Made in the USA
In most cases the shutdown cause is an intermittent power/ground connection to either the EHC or the ignition box.

When the shutdown happens does the entire bike electrical system shut down or just the engine ignition?
 
1goodsinner

1goodsinner

Member
BigDogBro1 said:
In most cases the shutdown cause is an intermittent power/ground connection to either the EHC or the ignition box.

When the shutdown happens does the entire bike electrical system shut down or just the engine ignition?
Click to expand...
The entire bike shuts down,as if I turned the key off! I've already checked the battery/connections,the key wiggle trick,all motor mounts,dialectic grease on the EHC plugs(all pins are ok)!As I said,the only wires/connections I haven't checked are those under the fuel tank and those going to the headlight and speedo.I just figured if the ignition light flashes on the EHC then there must be certain places to look/check!Keep it coming with ideas guyz,while I continue to check every wire/connection I can get to.Thanks for the info!
 
BigDogBro1

BigDogBro1

Made in the USA
My bike would shutdown like yours while riding. I could coast and restart but then it got worst and wouldn't turn on at all. Come to find out it was the wire crimps on the wires going to the battery terminals. REcrimped those wires and the problem never returned. A power interruption to either the EHC or EFI boxes would kill everything.

Keep looking.....Good luck
 
Nukeranger

Nukeranger

Nukeranger
I had a bad battery terminal also. This is not always easy to figure out.:(

I was adding a bit of solder to the ring side of the ring lug when one of them didn't want to conduct the heat to the wire like the others. Cut the wire off, crimped another ring lug on and haven't had a problem such as you describe where the whole bike seems to turn off with the ignition switch on like it was taken to off.:D
 
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stlmikie

stlmikie

I wish I had more money.
I would re-crimp every crimp conection you can. Like Nike said add a bit of solder if possible. I'm not accusing you but a lot of people thing the dielectric grease helps conduct the electricity. It doesn't. It just fills the void and help prevent water or any other contaminants (corrosion) in the conection.
 
WRM66

WRM66

Member
POSSIBLE TERMINAL CONNECTION PROBLEM, BUT I WUD GO WITH THE KEY SWITCH ISSUE FIRST...I'VE SEEN THAT FIRST HAND ON A COUPLE OF BIG DOGS...THEIR STOCK KEY SWITCHES ARE SHITTY....I PUT A TOGGLE SWITCH ON MY BUDDIES FOR A FEW WEEKS TO SEE IF THAT WAS THE PROBLEM .....AND IT WAS. SIMPLE TO DO AND ONLY COST U A COUPLE OF DOLLARS....ALL THE KEY SWITCH DOES IS COMPLETE A LOW VOLTAGE CIRCUIT. NOTHING MAGICAL....
 
stlmikie

stlmikie

I wish I had more money.
Good point. I didn't even think about the switch. Could very well be the issue.



WRM66 said:
POSSIBLE TERMINAL CONNECTION PROBLEM, BUT I WUD GO WITH THE KEY SWITCH ISSUE FIRST...I'VE SEEN THAT FIRST HAND ON A COUPLE OF BIG DOGS...THEIR STOCK KEY SWITCHES ARE SHITTY....I PUT A TOGGLE SWITCH ON MY BUDDIES FOR A FEW WEEKS TO SEE IF THAT WAS THE PROBLEM .....AND IT WAS. SIMPLE TO DO AND ONLY COST U A COUPLE OF DOLLARS....ALL THE KEY SWITCH DOES IS COMPLETE A LOW VOLTAGE CIRCUIT. NOTHING MAGICAL....
Click to expand...
 
cvegmond

cvegmond

Member
You're all in denial. The EHC is giving up. That module acted the same way on me as I struggle with intemittent elelctrical gremlins. All the gremlins live in the EHC module.

Wire Plus is not just a replacement for the EHC. There are a number of operability imporvements...like starting the bike without all the lights on.
 
1goodsinner

1goodsinner

Member
What/Where?

What is the ignition switch I would need to get for a replacement,and where is the most economical place to purchase one? Thanks for the info guyz;it doesn't hurt to have a lot of input/feedback!!!
 
RRRUFF

RRRUFF

Well-Known Member
I am leaning toward the key switch also mine did the exact same thing. I put a toggle switch under the coil cover to eliminate the key switch problem went away. I knew I was going to go wireplus eventually so I went ahead replaced my BD key switch with a HD sportster switch like comes with the wireplus. Don't forget to check the ground wire coming from the battery at the starter mount, bolt and crimp.
 
stlmikie

stlmikie

I wish I had more money.
Like Ruff said. To test your switch by putting in a toggle. Easy and cheap test for sure. Good think Ruff Man.
 
1goodsinner

1goodsinner

Member
Ignition Switch!

OK guyz,for those who theorized it was the ignition switch.....YOU ARE CORRECT! I put in a toggle switch and the problem was gone.The end of total power loss in the middle of nowhere! Perfect timing too,because I had the HAMC's Florence Prison Run in SoAZ on Sunday,Feb. 12th.No way I was going to miss this run!!! I found the problem with replacing the stock switch with a Sportster switch is the hole in the coil cover needs enlargened.No f'n way...really? I'm in the process of doing that with a Dremel-like tool.Slow work,but it will be well worth it in the end! Thanks for all the help guyz,especially those with the ignition switch/toggle switch idea!!!:2thumbs:
 
stlmikie

stlmikie

I wish I had more money.
Aren't you glad you didn't go this route Sinner. You saved $600 over a twenty dollar switch. Some people have more money than sense. Good on you bud.






cvegmond said:
You're all in denial. The EHC is giving up. That module acted the same way on me as I struggle with intemittent elelctrical gremlins. All the gremlins live in the EHC module.

Wire Plus is not just a replacement for the EHC. There are a number of operability imporvements...like starting the bike without all the lights on.
Click to expand...
 
1goodsinner

1goodsinner

Member
Not Ignition Switch!

OK,just a couple days of 40-50 mile runs and no problems...not so quick! Went out Friday for about 55-60 miles and the bike shut down twice.Did a poker run Sat and the bike shut off while we were running 70 on a two-lane back road(running a few feet apart too).Turned ignition off and back on,hit run button and bike "popped" and restarted.On my merry way I went without incident...thank someone/something somewhere!So,I'm back to square one again.That old ignition switch wasn't the problem after all! Where to go from here,until I can afford one of those WP or PDMs.:bang:
 
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