Looks like my EHC is taking a dump, I'm shocked!!

[Gabriel]

Head light has been intermittent for about a week now.
If I tap on the ehc the head light will come on (or off). I checked the connections and all is well there.
Looks like I'm going to rewire that circuit, maybe all of it, depends on how energetic I am...
What's my options here?
Thanks...

 

[ChopperJeff]

If you are thinking of replacing the EHC, then look into the Wire-Plus Big Dog EHC Module WP-374 from lowdownchopshop. I just ordered mine yesterday as I'm fed up with the bike going toally dead at random times. I bit pricey, but at lowdownchopshop, members here get a 10% discount.

Though I guess if it's just the headlight going out that bothers you, then the cheapest route of course would be to just "hard wire" it from the battery to the light thru a switch and fuse.

Good luck!

 

[Gabriel]

WOW! 529.00. it said they were for 2004 and up I think?
I will pass on that, thanks.
I can rewire the whole bike for 100.00 or less.
I can even buy a self canceling turn relay if I remember right, that might put me to 125.00?
I can buy a half a dozen 30/40 amp relays for 20.00 and mount them in a weather proof container that will fit in the spot where the EHC was.
I may just do the headlight circuit since the rest is OK for now?
I'm going to the D2Ki-5P ignition next also.
Which brings up something else i noticed while checking the ehc.
The thunderheart Ign, module housing is hot with the key on in the run position, good thing the fender is fiberglass!
I believe the BDM hardware is good but what the fuck were they thinking on this electrical system.
Who is all that propriety shit for? Not for the customer who breaks down in the middle of no where.
Reminds me of the time (12 years total) that I worked with the Germans when I was with Porsche Audi, smart people but they over engineered everything.

In my short time of ownership I find this product very unreliable without extensive modifications. I'm grateful I possess the skill to do this sort of thing, and I'm grateful that the people here share their knowledge and wisdom with others.
Thanks...

 

[pig pen]

Good luck with your repair. You don't hear of many 03 and older dogs with electrical problems.

 

[Gabriel]

Thanks,
One thing I noticed was that when the headlight is not working the yellow led on the starter relay is on.
Maybe someone will chime in here and shed some clarity on this fault?

 

[LDO]

you might have a faulty contact or a connector that doesn't lock down or even one that backs out (if the locking mechanism is jacked).

I would check all of that and add some dialectric grease before you spend the coin.

 

[Gabriel]

you might have a faulty contact or a connector that doesn't lock down or even one that backs out (if the locking mechanism is jacked).

I would check all of that and add some dialectric grease before you spend the coin.

Been through all the connectors. tapping on the ehc is the only way to get it to do it and now I can't get it to do it again. So at the moment it is working.

 

[LDO]

Been through all the connectors. tapping on the ehc is the only way to get it to do it and now I can't get it to do it again. So at the moment it is working.

Sorry man, should have read your first post!:bang:

wouldn't trust it though. Wire plus does have an option for the 03's, I believe it runs about 420.00 give or take.

You can usually find the older EHCs on ebay for about a hundred bucks.

Good luck!

 

[Gabriel]

Sorry man, should have read your first post!:bang:

wouldn't trust it though. Wire plus does have an option for the 03's, I believe it runs about 420.00 give or take.

You can usually find the older EHCs on ebay for about a hundred bucks.

Good luck!

I will build my own then I know what I have. We wired all the choppers in the sixties and several street rods in the 90's with no issues. We did use pre-made harnesses which saved a lot of time on the cars.
I don't want any proprietary shit on my bike. If I need a relay I want to get it from auto zone or the like. I might even wire it like a Harley depending on how they are wired.
I want it simple so if I ever sell it anyone who fixes bikes can work on it.

 

[thexaulted]

Hey Gabriel, I have an 03 Chop also. Had nothing but electrical problems with the bike until I replace that horrible EHC with the wire plus module. Being its an 03 you need the WP 143 (I believe that is the #). That's what I did along with the Dnya Ignition. Pretty much ended the endless electrical nightmare! I do have my last EHC that still works if you need one. Just PM me! Good luck, and my advice, as the owner of an 03 is do away with that thing and enjoy the bike. It's been good since, but I still suffer from the shell shock of the EHC (causing untrustworthiness) LOL!

 

[Gabriel]

Is using the Dnya Ignition independent of all other controllers?
It is a stand alone unit correct? No hook up to the EHC and you can discard the Thunderheart module on the rear finder correct?
It is only two parts; the timing unit that is located in the crank cover and the coil, correct?

 

[Gabriel]

I pulled the ign. cover and discovered it is already equipped with the DYNA 2000i, however it is running the dual fire coil. i will change that coil to single..

 

[Gabriel]

After reviewing the diagram above I noticed that the headlight relay is plugged into the EHC.
So that may be the culprit?
Tapping on the EHC could be affecting the relay located there. So tomorrow I will check further, I may just need a relay?

 

[bdmridgeback]

WOW! 529.00. it said they were for 2004 and up I think?
I will pass on that, thanks.
I can rewire the whole bike for 100.00 or less.
I can even buy a self canceling turn relay if I remember right, that might put me to 125.00?
I can buy a half a dozen 30/40 amp relays for 20.00 and mount them in a weather proof container that will fit in the spot where the EHC was.
I may just do the headlight circuit since the rest is OK for now?
I'm going to the D2Ki-5P ignition next also.
Which brings up something else i noticed while checking the ehc.
The thunderheart Ign, module housing is hot with the key on in the run position, good thing the fender is fiberglass!
I believe the BDM hardware is good but what the fuck were they thinking on this electrical system.
Who is all that propriety shit for? Not for the customer who breaks down in the middle of no where.
Reminds me of the time (12 years total) that I worked with the Germans when I was with Porsche Audi, smart people but they over engineered everything.

In my short time of ownership I find this product very unreliable without extensive modifications. I'm grateful I possess the skill to do this sort of thing, and I'm grateful that the people here share their knowledge and wisdom with others.
Thanks...

The WP374 is for 2004 and up ONLY. The WP375 is for 2003 and older models and is a plug and play other than the indicator lights in the dash that need wired up (about 5-6 wires). It sells for much cheaper than the 374 module.

I do not stock it all the time but can get you one within a couple days.

 

[Gabriel]

What do you mean by much cheaper? Jake
Thanks..

 

[DRBarnhart]

Gabriel,

I agree with your idea to make the bike's wiring more "repairable". The idea of being able to replace a broken part from a readily available source makes perfect sense. While I get that the WP may be more reliable than the BDM EHC you'd still be replacing proprietary parts with more proprietary parts!

To me, there isn't that much to wiring a motorcycle but you do have to recognize that everyone's abilities are not the same... and that's a good thing!

Dennis

 

[Gabriel]

It looks like it may have been just the relay? I pulled it, took the cover off and looked at the contacts. It is very small and hard to see the contacts clearly. I put it back in and can not duplicate the problem any longer.
I recognize this relay, it is from the 80's automotive industry.
A lot of people made it then and it gave a lot of problems, even Radio shack used to stock it, Radio Shack 900 2391 and Hella = 4RD 931 524-02, but I will need to look around and find someone that still sells this.

 

[BadBrad]

It looks like it may have been just the relay? I pulled it, took the cover off and looked at the contacts. It is very small and hard to see the contacts clearly. I put it back in and can not duplicate the problem any longer.
I recognize this relay, it is from the 80's automotive industry.
A lot of people made it then and it gave a lot of problems, even Radio shack used to stock it, Radio Shack 900 2391 and Hella = 4RD 931 524-02, but I will need to look around and find someone that still sells this.

When you come up with an inexpensive, reliable replacement for the EHC, count me in for one!

 

[Gabriel]

When you come up with an inexpensive, reliable replacement for the EHC, count me in for one!

When/If I do this, i will document the procedure.
But at this time it looks like I have only a bad relay? We will see.

 

[Moespeeds]

I rewired my bike, from scratch, as simple as it gets. I think I have maybe 10 wires running through the whole thing. No relays, 2 fuses and a circuit breaker. If you have relays I'm assuming you have the 12v HD style controls? If so it's a cake job. Let me know if you want details.