Electrical Demon WTF

[Fibersnake]

Well I was taking care of the clean-up from last weekend ride and doing maintenance on the connectors and have ran into some demons. I have gone through the Flow Chart for troubleshooting as well as the schematics, till the lines are starting to run together.

The problem is that after I put everything back together (putting di-electric grease one at a time, disconnect grease re-connect, on to next). The Speedmeter does not work.

The neutral light is not coming on (thought it is in neutral), Oil Pressure light is not coming on (when not running), Tach does not work.

Everything else works, it will start and seems to run fine. The light on the EHC seem to be working okay though I do have one yellow light when the key is turned on. Run light on EHC comes on when button is activated.

I have rechecke all my connections and then rechecked again. Can not find a bad one. Battery is good and it appears to be charging right.

Only thing I can find that is common to the three is the power wire, but it appears that others share it too. Maybe miss reading the schematics, not sure. Have not done a MM-condunity test yet,, but will check the pins in the morning.

All lights, horn, high low, turn, emergency, brakes, run, start, off, etc work. JUst not speedometer at all-no sweep, no numbers, nothing. No Neutral light or oil light.

Had clean it up and used low water, started fine with everything working after and pulled in garage to do the electrical maintenance. Did pull the battery connections prior to start. All problems seem to start after I was done adding the di-electric and put everything back together and reconnected battery.

Any suggestion!!!!!!!

Would a bad EHC show symptons like these. Anyone know how much one is in case I have to replace??

This is for a 2005 Mastiff BTW.

Thanks

 

[Raywood]

FS, that's all one connector under your tank (or between it!). I would pull that line again and ensure that when you re-connected it that you didn't push the pins out the back side of the connector.

Did you pull the speedo apart and do that connection? If so I would check for the same at this connection.

Good luck,
Ray

 

[Fibersnake]

Raywood,

I did pull all the connectors apart and filled with the dielectric grease. Checked and recheck multiple time, but will check again in the morning and make sure a pin did'nt get screwed up.

I am hoping that it is not a EHC for I took precautions to not screw it up, but I guess it is possible though with exception of posted info, start fines and everything else is working.

Almost wonder if that damn grease may be too much and not allow the pins to fully contact due to be insulated by grease.

Any idea of what a EHC runs just in case?

Thanks

 

[Raywood]

Don't know how much a new on costs but I think you can rule that out. It has to be something you touched. Those little pins can push out the back side of those connectors and you would never know it. It happened to me when I pulled my rear lights apart to install the sissybar.

Gotta be a connector. I've done all mine and redo them in grease each time I take one apart and never had any problems with the grease.

Hope you chase it down.

:flag:

 

[chacha]

Snake;

Is the yellow light on the EHC on and staying on with the key turned? If so, I think that is indicating a ground fault in the harness (I don't have my manual in front of me). It should only flash on and then go off with the turning of the key.

Sounds like a wire to the speedo may have worn and is Grounding to something. Or she's just still wet someplace.

Good luck!

 

[Fibersnake]

Chacha,

Yes the yellow light is on with the key and and does stay on until I start it. I am going to go back and make sure that the damn grease is not holding in some water on one of the connectors or something.

I will get it figured out sooner or later, just hate having to be chasing demons when it is going to be such a nice day out, but what the hell. Shit happens they say and I guess it is my turn.

If I find out the culprit I will let everyone know.

Thanks to Chacha and Ray.

 

[Raywood]

Chacha,

Yes the yellow light is on with the key and and does stay on until I start it. I am going to go back and make sure that the damn grease is not holding in some water on one of the connectors or something.

I will get it figured out sooner or later, just hate having to be chasing demons when it is going to be such a nice day out, but what the hell. Shit happens they say and I guess it is my turn.

If I find out the culprit I will let everyone know.

Thanks to Chacha and Ray.

Chacha brings up a good point. Soon after buying my 05 my oil light started flickering and after many trips to the shop and installation of a pressure gauge to ensure I DID have oil pressure I ended up pulling the tank and found a grounded wire. It was worn from wear and grounding out against the frame.

You pulled and moved all the wires so maybe you moved a worn wire/s around to where they are grounding now. With all your miles you have I'm sure the possibility exists.

Keep us up to date,
Ray

 

[P8RIOT]

Snake, it sounds like a good ohm meter or continuity checker could be helpful, as opposed to just checking and rechecking the connectors physically - gotta be a short, or maybe open, circuit in there somewhere. Maybe some end-to-end continuity checks would tell you where. Just a thought - good luck.

 

[Fibersnake]

P8RIOT-Raywood,

I am heading to check the continuity and run the wires and start from there. Just got back from the Radio Shack after running around trying to find some mimi probe clips for the Fluke to grab the pins on the connectors better. Also got a good supply of electrical cleaner and water displacing compound.

Hopefully will get it nail down here today, may take a few drinks and a magnifying glass to look at all the pins and makes sure one is not bent or broken.

Will let everyone know or send picture of the damn thing with 30 9mm holes in it. :bang: :bang: :bang: :bang:

 

[Raywood]

with 30 9mm holes in it. :bang: :bang: :bang: :bang:

Only two clips?

good luck,
Ray

 

[Fibersnake]

"Only 2 clips"

NO 1 clip-in about 2 seconds. MP5K in the F position!!!!

But the good thing is, it does not look like I have to call the Sheriff to give heads up for the transport to range!

 

[Fibersnake]

Okay I found the issues. I screwed up the pins on the Power Harness side of the EHC. Pin A-6 was broke and is for the wire coming off Oil Pressure switch. Pin A-7 was bent, but was able to be fixed. Everything but oil pressure light is now working. Will have to order new EHC unfortunately, but may by-pass the oil wire that goes to A-6 and does a pass through on the EHC to B-33 and tap into the Orange wire right before connect going to annunciator board.

This should give me a oil pessure idiot light for protection (to remind the idiot that screwed it up to be gentle with those damn D-Base connectors going to EHC), until I can get a new EHC and get it replaced.

No need being down on ride time if I do not have to be.

Note to all, when putting di-electric gease on connectors, especially the D-Base to EHC, be damn careful, break one of those EHC pins and not cheap. Luck was with me though since it was only the oil pressure idiot light that was not able to be fixed.

I guess the Mastiff is not going to get any custom body work this time!!

 

[Raywood]

Okay I found the issues. I screwed up the pins on the Power Harness side of the EHC. Pin A-6 was broke and is for the wire coming off Oil Pressure switch. Pin A-7 was bent, but was able to be fixed. Everything but oil pressure light is now working. Will have to order new EHC unfortunately, but may by-pass the oil wire that goes to A-6 and does a pass through on the EHC to B-33 and tap into the Orange wire right before connect going to annunciator board.

This should give me a oil pessure idiot light for protection (to remind the idiot that screwed it up to be gentle with those damn D-Base connectors going to EHC), until I can get a new EHC and get it replaced.

No need being down on ride time if I do not have to be.

Note to all, when putting di-electric gease on connectors, especially the D-Base to EHC, be damn careful, break one of those EHC pins and not cheap. Luck was with me though since it was only the oil pressure idiot light that was not able to be fixed.

I guess the Mastiff is not going to get any custom body work this time!!

Glad you found the issue FS but sorry you broke a pin. You could say screw it and just run of a pressure gauge! I did that till I found my grounded oil pressure light ground under the tank.

Also for you guys that haven't used the die-electric grease if you have a small tube it's a bitch to push out so I would recommend cutting the top off for a wider exit hole. That way you won't have to use so much pressure to squeeze it out.

Later,
Ray

 

[chopper]

Mine did that also. It was the connector under the tank.

 

[scubaman15]

You know Tim you saved a lot of people the pain of this by telling us about this problem and that my man is what this Forum is all about:up: :up: Some more rep points on the way ! Thanks !!!

 

[Fibersnake]

Well if other can learn from my mistakes, it is all good. Hopefully I can save some a little over $300.00 for a new EHC and if they take that extra few seconds to make sure the connector go on properly with out screwing up a pin on the EHC.

Now my only problem is that my dealer does not have any in stock, but have some on backorder, so maybe it will only be a few days.

 

[LUPHOLE]

that is great news tim (except for having to replace the ehc $$$$$). glad you are back on the road. also, like ron said, you helped a lot of people with your post on these details. thanks and ride safe, chuck

 

[erldawg]

Okay I found the issues. I screwed up the pins on the Power Harness side of the EHC. Pin A-6 was broke and is for the wire coming off Oil Pressure switch. Pin A-7 was bent, but was able to be fixed.
This should give me a oil pessure idiot light for protection (to remind the idiot that screwed it up to be gentle with those damn D-Base connectors going to EHC), until I can get a new EHC and get it replaced.

Note to all, when putting di-electric gease on connectors, especially the D-Base to EHC, be damn careful, break one of those EHC pins and not cheap. Luck was with me though since it was only the oil pressure idiot light that was not able to be fixed.

It's good you found the problem FS bad that you have to replace EHC.
18 years on the hardware side of computers has taught me to be careful anytime you disconnect and reconnect any type of electrical connectors.

 

[Fibersnake]

erlwn,

Normanly I am very careful around componets due to have my hands into them to some degree over the years. I was having problems where the D-Base type connectors mounted to the EHC due to there was a new wire running right between them from the VR Recall. This was the wire that ran up to the connection point for the fast blow 40 amp fuse.

It made it a little harder to get a straight downward shot at pluggin in the D-Base and I think that is what caused me to get off a little and bend the pin.

Not thrilled that I should replace the EHC, but for now it is running with excepiton of OP light and I may have a work around for that until I can get a new one. My dealer says the EHC are on back-order but should give me a call when they get status from BDM on the expected delivery date.

Once I have that and have a better idea of how long before I can procure and thus replace, I will have a better idea if I should by-pass the Oil Pressure wire around the EHC and splice into harness or not.

If it is only a day or so, will more likely leave it alone. If longer will have to think about it. Also I need to confirm that I am reading the schematiic right and that I can indeed by-pass the pass through on the EHC for the orange OP sensor wire to annunciator.

It sucks, but if that is the only issues I have, I can not complain.

 

[05chop]

This reminds me when i did the same thing on a 70 pin ECM connector on cat. You learn real quick to look down to see if all the pins are straight before it goes on. The new version ECM has line up pegs to prevent this maybe your new EHC will have this. Good you got er done now you will have a spare.:flag: