EHC/Starter Module WOES

[blackntanz]

Hello all,

I did my intro in the introduction area, but not sure if it transfers over. I have a 2002 Boxer that has been mostly great since I bought it new. Today, I am hoping you guys can help me with an issue.

In the past month I have had intermitent starting problems as if not getting fire and then last Wed the EHC burned up (white smoke and all). I have the replacement, my bike uses the Thunder Heart model without the pig tail. I also have the BD4120-1 starter module that plugs into the EHC. Problem is I can't figure out where to hook it back up to in the pin slots. I am picking up a service manual soon, as I read in the posts that it may show instructions for hooking up the module. In the mean time, does anyone know which hole the green wire plugs into on the EHC?

Thanks in advance for the knowledge.

Chris:

 

[X-ray Doc]

Hey Chris,
The smaller green wire goes where the starter relay was on the EHC which is plugged into S1. Discard the starter relay.
Plug the wire into slot # 2 of socket S1.
If you would like a copy of the page from the manual send me a PM with your e-mail and I will send it to you.
Good luck.

 

[blackntanz]

Thanks X-ray Doc. That did the trick. It starts great everytime.

I have a LED light on and off at the diagnostic plug. Everything seems to be working fine though. I am concerned that a circuit is overloaded. A couple of years ago I replaced the stock front signals with LED signals that also function as running lights. I felt I needed more visability up front... Anyway I tied it into the headlamp for constant power. I also installed a high output headlamp bulb. So I am wondering if that is causing the overload? Everything else is stock. I am disconnecting one item at a time until I find it. Pain in the ass... The dealer I bought from said, "We don't get many 2002 bikes anymore. I haven't worked on one in a while." I asked him if he thinks they just disintegrate?

I'll keep plugging along. Thanks for hook up on the Starter Module.

DC

 

[Ray]

I don't think they disintegrate, from what I have read they were a "limited life" piece of cra_ from the get go. Glad mine is changed out, you will be too. My scooter barely fits my trailer sitting cross ways. The scooter does not push well either!! :up:

Ray