Key Switch Problem?

[Bach's Boss]

Took the bike out for a ride last Saturday and had several times when everything would go dead, just like you turned the key off. All lights and instrument cluster would shut off for a few seconds and then come back on. Hit the run button and would be going again. Stopped after about 20 miles of this happening multiple times and cycled the key on and off several times and ran fine to get back home. Ordered a new key switch and installed it today and now I have nothing, no power to anything electrical. Checked battery and it's fully charged at 12.8 volts and checked circuit breaker and it checks out good and isn't tripped. Anybody got any ideas of what to try next?

 

[Rottweiler]

Time to get the meter out.

 

[HMAN]

For shits n giggles, check the ech plug. Make sure it is seated well. Give us a bit more info tho, year n model of bike, any mods done to electrical system...ect.

 

[Bach's Boss]

2006 Mastiff no electrical mods other than LED headlight a couple of years ago. So just got back in the house from checking connections and decided to try the old switch. Plugged it in and connected a jumper wire to the ground battery terminal and it works. So then reconnected the new switch with a ground jumper and it works. Then removed the ground jumper and it still works. Not sure what's up with that!

 

[HMAN]

2006 Mastiff no electrical mods other than LED headlight a couple of years ago. So just got back in the house from checking connections and decided to try the old switch. Plugged it in and connected a jumper wire to the ground battery terminal and it works. So then reconnected the new switch with a ground jumper and it works. Then removed the ground jumper and it still works. Not sure what's up with that!

Sounds like you just solved one problem. Go ride and see what happens. Good luck!

 

[Th3InfamousI]

2006 Mastiff no electrical mods other than LED headlight a couple of years ago. So just got back in the house from checking connections and decided to try the old switch. Plugged it in and connected a jumper wire to the ground battery terminal and it works. So then reconnected the new switch with a ground jumper and it works. Then removed the ground jumper and it still works. Not sure what's up with that!

Glad that worked! Wasn't what I was expecting, maybe it just wasn't seated correctly in the plug?

 

[Bach's Boss]

Thanks everyone. I'll take it for a ride soon and let you know what happens.

 

[bruce]

Several years ago I have similar problem on 06 K9 ground wire coming from the EHC to the battery was broken, but it was difficult to see you literally had to really move things around it was an issue for a while until I finally just took the battery out and traced the wires but it was a connection at the battery, worth checking

 

[Bach's Boss]

Thanks Bruce, I’ll check the ground wire out.

 

[Bach's Boss]

Well, SSDD (same "stuff" different day), after multiple starts and running it in garage, thought the problem was fixed but went to ride yesterday and get nothing when I turn the key on. No lights or power to any circuit. Checked the circuit breaker and have power to both sides, battery is at 12.8 volts. Checked the continuity of the ground wire to the EHC power harness and .that looks good. Also have power at the battery terminal of the power harness. Cleaned old grease out of EHC connectors and put in new dielectric grease and reconnected both harness plugs. Still nothing when I turn on the key.
Anyone have a way to check the EHC module to see if that's the problem?

 

[1 B.M.F.]

You can send it to wild steed worx in Cali $40. I believe to test it. If it’s bad and you buy a new EHC from him no charge to test it. Wildsteedworx.com phone number is (619)823-8557 Curtis. Good luck

 

[Mikeinjersey]

Well, SSDD (same "stuff" different day), after multiple starts and running it in garage, thought the problem was fixed but went to ride yesterday and get nothing when I turn the key on. No lights or power to any circuit. Checked the circuit breaker and have power to both sides, battery is at 12.8 volts. Checked the continuity of the ground wire to the EHC power harness and .that looks good. Also have power at the battery terminal of the power harness. Cleaned old grease out of EHC connectors and put in new dielectric grease and reconnected both harness plugs. Still nothing when I turn on the key.
Anyone have a way to check the EHC module to see if that's the problem?

Since you get Zero lights or sighs of life anywhere your EHC is missing power , ground or signal to tell it to come on from the switch you replaced. Both key switches have failed so that is less likely your problem. Get a wire diagram and read and visually check the wires from the key switch to the EHC. Also check the wires ( ground and power ) from the EHC to Battery. Look for pulled pins or chaffed wire. Make sure your battery has a good ground( clean and tight) you would get the same symptom. Loosen clean and re-tighten both ends of the ground cable. If you still haven't come up with the fix take 1 B.M.F s advise and have Curtis check the EHC . We all know how intermittent they can be. Good Luck

 

[1 B.M.F.]

My ground was loose several times I keep a set of tools in my road bag. my battery cable comes loose a lot. Double check your grounds.

 

[Bach's Boss]

Since you get Zero lights or sighs of life anywhere your EHC is missing power , ground or signal to tell it to come on from the switch you replaced. Both key switches have failed so that is less likely your problem. Get a wire diagram and read and visually check the wires from the key switch to the EHC. Also check the wires ( ground and power ) from the EHC to Battery. Look for pulled pins or chaffed wire. Make sure your battery has a good ground( clean and tight) you would get the same symptom. Loosen clean and re-tighten both ends of the ground cable. If you still haven't come up with the fix take 1 B.M.F s advise and have Curtis check the EHC . We all know how intermittent they can be. Good Luck

Thank for the info. I'll look again but had checked what I could see when I replaced the key switch. Initially I had no power ,same as now, so put the old switch back in and it worked. Then put the new switch in and it worked multiple times until yesterday.

 

[Bach's Boss]

My ground was loose several times I keep a set of tools in my road bag. my battery cable comes loose a lot. Double check your grounds.

Thanks, if I don't find anything else I'll pull the EHC module and send it in. I have cleaned the battery cable ends and made sure they were tight. Have had problems in the past with loose connections but a little red Loctite solved that problem.

 

[Mikeinjersey]

Thanks, if I don't find anything else I'll pull the EHC module and send it in. I have cleaned the battery cable ends and made sure they were tight. Have had problems in the past with loose connections but a little red Loctite solved that problem.

Just for Info: I had an EHC that would only fail when it was cold or damp. I would heat it up with a hairdryer for a while and then it would start and run for the day. I think the sealer on top of the unit gets micro-cracks and causes the failures. My failure was no signal to the starter. I ultimately replaced mine with an Elektronik Box .

 

[1 B.M.F.]

Thanks, if I don't find anything else I'll pull the EHC module and send it in. I have cleaned the battery cable ends and made sure they were tight. Have had problems in the past with loose connections but a little red Loctite solved that problem.

I have heard that loctite will not conduct electricity or allow it to pass through so I don’t loctite the battery. FYI. You can double check that. But I have learned a lot on here. My ehc also needed to be hair dried to work so I just bought a new one. Good one mike thanks

 

[Jersey Big Mike]

I have heard that loctite will not conduct electricity or allow it to pass through so I don’t loctite the battery. FYI. You can double check that. But I have learned a lot on here. My ehc also needed to be hair dried to work so I just bought a new one. Good one mike thanks

RED loctite would be EXCESSIVE to say the least.
Better to just check them on a regular basis. Check your oil, check your battery!
Loose terminals has been one of the most common issues I've seen on bikes since I started riding -- including when returning from a dealer/shop.
Never rely on ANYONE else to check those connection -- do it yourself and do it often!

 

[Jersey Big Mike]

Just for Info: I had an EHC that would only fail when it was cold or damp. I would heat it up with a hairdryer for a while and then it would start and run for the day. I think the sealer on top of the unit gets micro-cracks and causes the failures. My failure was no signal to the starter. I ultimately replaced mine with an Elektronik Box .

Hell when one of my EHC's failed I warmed it up one night with a gallon of HOT WATER. Yep poured the water right over the whole thing -- what was my downside, it already wasn't working. Started right up. Promptly changed out the EHC a day or two later (already had replacement in hand).

 

[Bach's Boss]

Just an update. Got my bike running yesterday, new EHC and voltage regulator seems to have fixed it. Worked good for the first 100 mile ride anyway. Thanks to Curtis at Wild Steed Worx for parts and info.