Electrical Problem

[roadie1389]

I was reading a post about new posts and needing somebody with an electrical problem. Well............

2004 Chopper with BDM's PDM (Upgrade ). After a month of reworking the wiring and connectors everything was working just fine until 1 week before leaving to go to Sturgis then all hell broke loose. Battery DEAD. Used a battery charger (mind you it is only a 275 A engine start) to start it. Fired right up and ran just fine. Note everything still working. Let run for awhile. Put back in the garage (turned off) and let the battery charger charge on the battery. Next day tried to start the bike, click click weird noise. Now there is some BS electrical issue. The High beam indicator light on the tach not working ( there is voltage at the JST under the tank) but high and low beam lights work and the ignition module always has power (even when the key is off). I check that the Run/Off button works (goes to ground when pushed), all other circuits work. Starter is dead. Battery replaced.

I believe something happened to the HCI module (this is the new HCI with the PDM kit made by PWI). It this thing dead? I hate this F&^$%kin bike. Spent the last 2 months making it ready for Sturgis and the MF took a crap on me. Feel like pushing it into a fire pit and watching it go up in 1000 pieces.

Anybody got a HCI sitting around? Anybody know how to contact the maker of the new HCI to see if it can be repaired? I read that there should be a new RIP version coming out with the full working controls.

BTW it's my wives fault she hates this bike and cursed it after she got burned by the exhaust pipe!

Got to go make real money now. Feel free to post any constructive help. Hell even a funny joke will work.

 

[francoblay1]

Bill Bill Bill!!!!!!!! (Sorry Eric, this is because of another thread, soon it will make sense! )

You can get the RIP from Curtis @KaptinAmerika -- http://www.wildsteedworx.com/

 

[bearman]

You definitely should not have power to the ignition module with the key off. On the PDM diagram there is a dashed red line that says not to hook up if using an Autometer Speedo. Is this hooked up on yours? If so it could be a problem (even if you don't have an Autometer Speedo).

 

[Ozzie]

I just joined this group and can't seem to figure our how to start a new post...dummy I guess....Anyone know where I can get replacement ECH, Reg, etc. 2003 Big Dog Canine 107 that won't turn over (new battery) just makes a slight ticking noise but will push start sometimes not every time.

 

[roadie1389]

You definitely should not have power to the ignition module with the key off. On the PDM diagram there is a dashed red line that says not to hook up if using an Autometer Speedo. Is this hooked up on yours? If so it could be a problem (even if you don't have an Autometer Speedo).

Not my issue but thanks for the post. I have the Autometer 2004 model and no extra read wire on my setup. Like I said everything worked before the battery and starter acted up.

 

[roadie1389]

No other help? Nobody knows if the HCI's can be repaired?

 

[TapioK]

As far as I remember, nobody has managed to fix EHC, first problem being you can't get it open. what you could do is to send it to Curtis, he can check if it works. He also has new RIP kits. Like Franco stated.

 

[Th3InfamousI]

As far as I remember, nobody has managed to fix EHC, first problem being you can't get it open. what you could do is to send it to Curtis, he can check if it works. He also has new RIP kits. Like Franco stated.

I think he is talking about the PDM not the original EHC. Although I dont know if anyone has opened up a PDM kit if they have they hadn't shared it.

Most people have had good success with the PDM in all honesty.

I'm wondering if you fried something when you jumped it. I know you said it's only 275 AMP. I'm assuming you checked the handful of fuses??

You need to trace backwards the +12v that's going to your ignition module with the key off and see If it's really coming out of the PDM. I don't think there should be any power with key off leaving the unit. Someone will correct me if I'm wrong.




Sent from my 831C using Tapatalk

 

[roadie1389]

I think he is talking about the PDM not the original EHC. Although I dont know if anyone has opened up a PDM kit if they have they hadn't shared it.

Most people have had good success with the PDM in all honesty.

I'm wondering if you fried something when you jumped it. I know you said it's only 275 AMP. I'm assuming you checked the handful of fuses??

You need to trace backwards the +12v that's going to your ignition module with the key off and see If it's really coming out of the PDM. I don't think there should be any power with key off leaving the unit. Someone will correct me if I'm wrong.




Sent from my 831C using Tapatalk

Yeap, checked all fuses. Traced all the wires. It is definitely in the HCI. I would like to see if anybody has the internal schematic to the HCI so I could maybe rebuild the circuit externally or the other option is somebody had bought the kit and has it sitting on a shelf someplace. I am waiting a call back from the guys at KMW. I already have a ton of money in this f&^T&*%&n bike and am looking for a "less expensive route".

 

[bearman]

... checked all fuses. Traced all the wires. It is definitely in the HCI........

Have you checked the relays in the PDM?

Looks like the key grounds a relay in the PDM that powers almost everything, including the HCI.

There is a red wire and a blue wire from the PDM to the HCI. I don't know for sure but I would think the red is only hot when the key is on and that the blue is hot all the time (thru a fuse in the PDM) to power the brake lights and emergency blinkers.

I don't think the HCI should have power to the part that powers the ignition with the key off.

What side of the circuit breaker (or 40A fuse) is the PDM power wire hooked to? Is it on the Voltage Regulator side like is shown in the diagram? This is shown wrong on the diagram, everything should be hooked to the protected (Battery) side of the circuit breaker(or fuse). If hooked up like the diagram and the VR goes bad, it can fry the HCI or any other electronics.


I don't think your high beam indicator is related to this problem because you say the high and low work, and you have voltage to the connector. There are known issues with the tach ring circuit boards and corrosion.

.....I would like to see if anybody has the internal schematic to the HCI so I could maybe rebuild the circuit externally .....

It would not be difficult. look at the connections. the hand controls just ground a really low power consumption relay to operate whatever it is supposed to. do a search on the capacity of the hand controls I think they are rated at 1/4 watt, maybe 1-1/4 watt, don't remember right now.