Electrical Nightmares....!!! Myth or Fact?

BBChopper · Dec 15, 2011

Hang On! Your in the right place!! I still have my origanal EHC but I had to put on a manual plunger for the starter. Billy was on EHC till over 80K miles. I think the actual numbers VS sold bikes in actually low.

Th3InfamousI · Dec 15, 2011

Some bikes never need to rewired, some the EHC gets toasted fast. I believe BDM said that 80% (don't quote me on the figure) of the EHC which are determined bad by the shops were actually verified good during the warranty process. So most times EHC are wrongfully accused.

If you want to rewire Wire Plus is an option. It will run you in the neighboorhood of $600.00 for the parts. If you do it yourself the cost stops there. Well you might want some beer :cheers:

If you bring it to a shop it seems like the going rate is anywhere around an extra $600-800. It should take a shop 6-8 hrs for a proper install. However I think some board members have been charged upwards to $1800 for parts and labor. :down:

Brew · Dec 15, 2011

I'm running a 2008 Mastiff with original electrical and just past 26,000 miles on the clock and have had no issues. Just installed a new battery last month for the first time.

Moespeeds · Dec 15, 2011

It's a toss up for how long the EHC will last, you never know. I just did one a few months ago on a bike that only had 2k miles on it, but was 3 years old. Guys will tell you theirs lasted 100k mi, but all I can say from my personal experience is that EVERY Big Dog owner I know in my area with a post 2003 model has had to replace their EHC, and I know a lot of guys! Here are some real numbers to have the electrical system replaced. Do a forum search to find details on the options below.

Wire Plus - $519.00 plus 8 hrs labor (Freedom Cycle, DE)
Big Dog PDM kit - $621 plus 2 hrs labor (Freedom Cycle, DE) Not available for all models
Complete gut and rewire to a simplified Harley style 12v system - $1100 (NAMZ Customs, Ft Washington, PA) You will have to change your bars and controls (included in price), but can sell your stock parts to recoupe some.

Bottom line is, if you're going to buy one, count on sorting out the electrical at some point. In my direct experience the 2003/2004 models are the most reliable overall, and those are the only models I will recommend to friends. I have never seen a bad EHC on a 2003 or earlier.

awg · Dec 16, 2011

Sounds good to me!

Brew · Dec 16, 2011

Sounds good but as I mentioned in your other thread. Do your homework! Have the scoot checked out by someone near by or go and check it out yourself before purchasing. Just saying

Five Five · Dec 16, 2011

Moespeeds said:
It's a toss up for how long the EHC will last, you never know. I just did one a few months ago on a bike that only had 2k miles on it, but was 3 years old. Guys will tell you theirs lasted 100k mi, but all I can say from my personal experience is that EVERY Big Dog owner I know in my area with a post 2003 model has had to replace their EHC, and I know a lot of guys! Here are some real numbers to have the electrical system replaced. Do a forum search to find details on the options below.

Wire Plus - $519.00 plus 8 hrs labor (Freedom Cycle, DE)
Big Dog PDM kit - $621 plus 2 hrs labor (Freedom Cycle, DE) Not available for all models
Complete gut and rewire to a simplified Harley style 12v system - $1100 (NAMZ Customs, Ft Washington, PA) You will have to change your bars and controls (included in price), but can sell your stock parts to recoupe some.

Bottom line is, if you're going to buy one, count on sorting out the electrical at some point. In my direct experience the 2003/2004 models are the most reliable overall, and those are the only models I will recommend to friends. I have never seen a bad EHC on a 2003 or earlier.

There you go..... it looks like Moe has it all broken down for you ..... and most would agree he knows his shit:up:

bdmridgeback · Dec 16, 2011

Th3InfamousI said:
Some bikes never need to rewired, some the EHC gets toasted fast. I believe BDM said that 80% (don't quote me on the figure) of the EHC which are determined bad by the shops were actually verified good during the warranty process. So most times EHC are wrongfully accused.

If you want to rewire Wire Plus is an option. It will run you in the neighboorhood of $600.00 for the parts. If you do it yourself the cost stops there. Well you might want some beer

If you bring it to a shop it seems like the going rate is anywhere around an extra $600-800. It should take a shop 6-8 hrs for a proper install. However I think some board members have been charged upwards to $1800 for parts and labor. :down:

I charge $450, but I can knock them out with a clean install in 4-5 hours.

$600 should be the going rate at most, $800 is too high. ($100 hr at 8 hours?)

Abaco21 · Dec 16, 2011

Ok, I'm not looking to hijack a thread, but this topic concerns me as a new owner. I just bought an 07 chopper with 8k miles; all stock electrical. I'm not looking for extra hp, but I'd be willing to drop some bucks for reliability. Simply stated, if thing leaves me stranded due to these proprietary electronics, I'm gonna be pissed.

All's well so far. Are we talking infant mortality? If good at 8k, will it likely go 100k? Or am I due for a meltdown? For the members in the know, if you were in my shoes, what would you do to make this beast reliable?

Thanks in advance for your insight,

Steve

francoblay1 · Dec 16, 2011

Abaco21 said:
Ok, I'm not looking to hijack a thread, but this topic concerns me as a new owner. I just bought an 07 chopper with 8k miles; all stock electrical. I'm not looking for extra hp, but I'd be willing to drop some bucks for reliability. Simply stated, if thing leaves me stranded due to these proprietary electronics, I'm gonna be pissed.

All's well so far. Are we talking infant mortality? If good at 8k, will it likely go 100k? Or am I due for a meltdown? For the members in the know, if you were in my shoes, what would you do to make this beast reliable?

Thanks in advance for your insight,

Steve

x2.

mine has 800 miles (at least it is what the speedo shows).... my K9 is a 2006 model... I has been imported to Spain... Is there any way one of you, great guys, could run my VIN number with one of your Cop friends (I would do it for you, as I am an ex-cop too)

and give me a bit of background on my Dog? what State comes from, real mileage, etc etc? It would be highly appreciated!

:cheers:

roughrider · Dec 16, 2011

cpmman said:
I am hearing there are two kinds of BD's..those that have been rewired and those that will need to be soon...

The electrical systems fail on them and to rewire costs $1500-$2000..is this true??

What years (and I realize possibly all of them) is the electrical bad? Was the electrical system ever upgraded?

When are they prone to fail...after 5K miles... sooner? later?

I rcently talked to 3 oners that have rewired..one said the shop e went to had 5 bikes waiting for parts to get rewired...YIKES!!

Please help me understand how big of a problem it really is

Thanks...................

Well, i'm in the UK, and on my 3rd K9 with no problems. I had to convert the wiring to UK lighting regulations, and have learned, that the EHC is actually a fantastic system, using very low current sensing switches to operate the bikes systems. In theory its bulletproof, but water ingress into connections, and people fitting accessories incorrectly might cause problems!! Oh yes, and you need a GOOD battery!!
Don't worry, just buy one. A guy flagged me down from the side of the road yesterday, and said my K9 was the most beautiful creation he had ever seen, and he wasn't a biker!

Nukeranger · Dec 16, 2011

:2thumbs:First off, Moespeeds has great information.:2thumbs:

IMHO, I think the EHC gets blamed when it is not the EHC. I have heard of a lot of fraide wires due to vibration which is an easy fix. Battery terminal connections are a big source of poor electrical supply. I would not be afraid of rewiring the entire bike if you can solder or make good crimped connections. The big issue is finding the cause which in a lot of cases is a weak battery. I think I saw a poll that at least over 57% of the owners have their original EHC. I still have mine and starting having issues which were a bad Battery crimped connection.

The bottom line is don't be scared. Anything electrical can fail. Yeck, my radio in my truck doesn't work anymore so I am going to have to figure out what is wrong and fix it. If you don't narrow down the issue, it is easy to say it is the EHC and still have the same issue!

Remember, this is just my opinion.

BadBrad · Dec 16, 2011

Abaco21 said:
Ok, I'm not looking to hijack a thread, but this topic concerns me as a new owner. I just bought an 07 chopper with 8k miles; all stock electrical. I'm not looking for extra hp, but I'd be willing to drop some bucks for reliability. Simply stated, if thing leaves me stranded due to these proprietary electronics, I'm gonna be pissed.

All's well so far. Are we talking infant mortality? If good at 8k, will it likely go 100k? Or am I due for a meltdown? For the members in the know, if you were in my shoes, what would you do to make this beast reliable?

Thanks in advance for your insight,

Steve

To answer your question, for a "more reliable" bike, I would go ahead and install a WirePlus. Then you can recoup part of your money selling a working EHC. Do the install yourself, sell the EHC and you're only out about $300. I changed my EHC while it was still functioning just for the security and peace of mind that the WirePlus offers. Have not heard of a Wire Plus unit failing and shutting down a bike yet.

silver09 · Dec 16, 2011

Yeah 1800.00 is way to much either he had other stuff done or he got ripped off which is common in this kinda business unfortunatly.I have a friend that has close to 20,000 on his stock ehc but he's doing the pdm before this next ridin season.

1BADK9 · Dec 17, 2011

I've had my share of electrical repairs, broken terminal lugs, fried regulator, recently had a broken wire on my battery tender pigtail. I also had some issues with intermittant cut off that was just aluminum shavings left in the switch housing from a sloppy dealership cruisemate install. All minor shit that were inexpensive to repair. But that is the something you need to be prepared to deal with. These are not HONDAS, they are hard running solid mounted engines that are rough on everything. You need to realize people are not replacing their "wire harness" as you keep saying. People are replacing the EHC (processor) with an after market device that has a better track record for relaibility. They are not that expensive and Jake sells them and supports their installtion with advice and help. Knock on wood, mine is functioning fine after 10K.

So basically, you need to be prepared for some major maintenance and attention to these machines. They are not for people who are afraid to turn a wrench. But the reward is the experience of one of the baddest rides I have ever been on.

Keep reading the techincal threads on this forum and you will see the trends of problems and the repairs involved. If that scares you........ a Bigdog may not be for you. They are not for everyone. Goodluck

KnotSo · Dec 17, 2011

it may seem like there are a lot of problems but the owners with no issues are not posting about the total reliability and in fact many find this forum to seek out solutions to an issue, so you tend to see these issues more often.

Many many owners you will never hear about cause they have no issues and are not on forums looking for answers, so again, we tend to hear from all those with issues, thus skewing what is really what.

Then there is the camp that says all electrical issues must be attributed to the EHC when it most likely is something else.

Check out this poll with the various models and remember that the majority of BDM owners have had no issues and thus are not even on this site, and yet the majority of those taking part in this poll have not had any issues.
http://www.bigdogbiker.com/forums/technical/19202-ech-replacement-poll-model-never-replaced.html

Then there are a few of us that just ride in all weather conditions, year round, knoww out 600+ miles a day and never waterproof their scoots, esentially having a stock system with no issues whatsoever.

I like the fact that just by looking at the diagnostic lights it is quick n easy to identify the issue on the scoot, and thus far have not had any issues.

Do not stress out over the fears of others and their dire warnings, just ride and enjoy. However, there is a feeling of comfort in knowing that you will prolly be better off with the wireplus of BDM system installed.

stlmikie · Dec 17, 2011

If you get the 03 get and ride man. In all likelihood you won't have an issue.

Electrical Nightmares....!!! Myth or Fact?

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