EHC PROBLEM (2004) CHOPPER 117

[BigdogBill]

I UNDERSTAND THAT BIGDOG IS RE-ENGINEERING THE EHC, AND AM BEING TOLD IT WONT BE AVAIL. UNTIL DEC. OR JAN 08!!! MY PROBLEM IS THE TACH. LIGHTS ARE GOING CRAZY AND THE ENGINE FOULING PLUGS BAD!!
SOOT BLACK IN 5 MIN. RUNS BAD, BACK FIRES ON ACCELERATION AND ON DE-CEL. RUNING V&H BIG RADIOUS EXHAUST .076 MAIN AND .0295 INT.

ANY INPUT WOULD BE APPRECIATED !!!
SITTIN IN THE GARAGE.

 

[Raywood]

Welcome to the site Bill!

How long have you had your BD? Did the problem just start? How mechanically inclined are you?

As for the EHC, it gets blamed for everything and usually get sent back to the factory and test positive. The are threads on here from "Gas Man" and myself on going through the wiring and making sure every connection is tight and no wire have backed out of the little connectors. Then fill them with dielectric grease and you can even shrink wrap and seal the ends with RTV. There are a lot of connectors so this will take a while but seems to end any electrical issues. And be careful washing your bike, they don't like to much water so just spray and wipe it.

Do you have a manual. If so then go to the page that show the error codes on the EHC. Turn on your key and see if any red lights are lit up. If so then you have a ground somewhere and are going to have to do what I explained above. As for the tach I would say that if the wiring doesn't cure the problem then you need a new tach board and you can call Vicki for that. She will get you the best price. Just be aware that the tach lights flash wildly when the RPM is set below 950. You didn't state when the lights are flashing. If the lights go away when you rev the motor then the idle is set to low.

Fouled plugs in 5 minutes! I bet you are using the enricher device. Don't use this device ever unless it's real cold out then only to start the motor and then turn it off and keep the motor running with the throttle. The enricher will foul your plugs real quick. It's not a choke, it dumps raw fuel down the manifold so don't use it!!!

You're jets are good size so I would think your problem is fouled plugs from using the enricher. But, if not then have you checked for leaks around the intakes and exhaust? This will cause your popping and spitting but usually causes a lean condition not rich. I think you're using you enricher to much and then trying to run it with fouled plugs and it probably sounds like it running on one cylinder.

So, replace the plugs, check that your plug wires are on tight at the plug and coil. Start the motor without the enricher and set your RPM to 1000 or above and call me in the morning!!

Did I mention "Don't use the enricher"!

later,
Ray

 

[BigdogBill]

Welcome to the site Bill!

How long have you had your BD? Did the problem just start? How mechanically inclined are you?

As for the EHC, it gets blamed for everything and usually get sent back to the factory and test positive. The are threads on here from "Gas Man" and myself on going through the wiring and making sure every connection is tight and no wire have backed out of the little connectors. Then fill them with dielectric grease and you can even shrink wrap and seal the ends with RTV. There are a lot of connectors so this will take a while but seems to end any electrical issues. And be careful washing your bike, they don't like to much water so just spray and wipe it.

Do you have a manual. If so then go to the page that show the error codes on the EHC. Turn on your key and see if any red lights are lit up. If so then you have a ground somewhere and are going to have to do what I explained above. As for the tach I would say that if the wiring doesn't cure the problem then you need a new tach board and you can call Vicki for that. She will get you the best price. Just be aware that the tach lights flash wildly when the RPM is set below 950. You didn't state when the lights are flashing. If the lights go away when you rev the motor then the idle is set to low.

Fouled plugs in 5 minutes! I bet you are using the enricher device. Don't use this device ever unless it's real cold out then only to start the motor and then turn it off and keep the motor running with the throttle. The enricher will foul your plugs real quick. It's not a choke, it dumps raw fuel down the manifold so don't use it!!!

You're jets are good size so I would think your problem is fouled plugs from using the enricher. But, if not then have you checked for leaks around the intakes and exhaust? This will cause your popping and spitting but usually causes a lean condition not rich. I think you're using you enricher to much and then trying to run it with fouled plugs and it probably sounds like it running on one cylinder.

So, replace the plugs, check that your plug wires are on tight at the plug and coil. Start the motor without the enricher and set your RPM to 1000 or above and call me in the morning!!

Did I mention "Don't use the enricher"!

later,
Ray

thanks for the response ray.
i have owned it since new. i have done all my own work to it. will get som pics on later as i'm at work now.just put on a bdl tf 2000 open belt drive.
no, i dont ever use the enrichner. they tell me its the ehc causing the timeing to be off causing the rich problem.
i will look into the wireing issues!! also, cane i check for air leaks around the manifold by spraying some wd40 to se if it revs up ?

bill

 

[alhall88]

Good advice Ray and I might add that in all 3 of the ehc's that I have replaced in my 04 although the symptons might have been different one thing was common the bike would not start or run.

 

[Raywood]

I don't know if I would believe that the timing is being caused by the EHC. I've heard numerous times on the other website from Fat Cat that the ignition doesn't go through the EHC. Most other functions do though.
I know WD40 is not conductive but don't know if it's flammable. I would get a can of carb cleaner or brake cleaner. They seem to work the best.
I think now that if you are not using the enricher then you have ignition or coil problems. A leaking intake would cause you to run lean not rich. Rich will come from the coil not firing or something within the ignition line.
Go through all your wiring though before throwing parts at it.

Keep us posted and good luck,
Ray

 

[chacha]

Bill;

I have an 04 and recently had to track down an ignition problem. For the 04 EHC, there is no way I can see for it to cause your reported problems. The line to the tach passes throught the module, but it does nothing to it. The problem should be someplace in the timing lineup (Sensor plate -> ignition module -> coil -> plugs). I'd check thouse all way before scoping out another EHC.

Good luck!:up:

 

[Gas Man]

Ray & Al got this one covered up.

I will add, use the brake clean over the WD40 when checking the air intake for leaks. The WD40 will make a mess where as the brake clean will evaporate.

As far as the 2004 EHC, Al can tell you that they are suppose to be making a adapter to use a newer style EHC in the old style bikes. Further, I thought Fat Cat said that they have re-started manufactuing of the older style due to the delay in these said adapters. May want to call BDm directly and check.