Lost All Power...Help!

[GymRat]

Yesterday my bike shut down completely. Prior to this I was having intermittent problems with my left turn signal and the Hi-Low beam. I checked for a short and didn't find one. My battery is kept on a battery tender and is fairly new. Yesterday after riding all day there was light rain, my speedo flashed then the bike lost all power. I got it home hooked up the battery tender and there was a spark (flash) when I put the positive clip on the battery. It still has not charged and still no power.

I'm wondering if it is a short that I couldn't find or could it be the EHC? I'm ready to take the EHC out. Needless to say any help, advice or suggestions would be greatly appreciated.

 

[Bulldog03]

Might wanna check the wiring in the wheel well, might have bottomed out and eaten the wiring , I had blinker and electrical problems after I bottomed out alot :loony: and found out I had ripped my wires :bang: , just rewired and tucked it in better :2thumbs: just something to eliminate..

 

[Raywood]

Might wanna check the wiring in the wheel well, might have bottomed out and eaten the wiring , I had blinker and electrical problems after I bottomed out alot :loony: and found out I had ripped my wires :bang: , just rewired and tucked it in better :2thumbs: just something to eliminate..

05's and newer run the wires outside the fender unlike the older models. But that doesn't mean that you may not have a grounded wire somewhere. I've found mine grounded/worn as the rear wires come through the fender and around the battery.

Looks like you are going to have to do some investigation. Keep us posted.

 

[Gas Man]

How big of a spark? What voltage do you have on the battery with it standing on its own? What do you consider "fairly new"?

 

[GymRat]

I checked the wires going from the rear lights through the fender I didn't see any possible short. I also checked all around the battery, behind the coil cover, under the tank, in the lights and switch. The spark given off the battery when I attached the positive clip was enough to get my attention. I bought the battery last summer. It's been on the battery tender all winter. I am going to take the battery back to have it tested.

Even though I couldn't find a short I'm leaning towards that as being the cause or the EHC. Is there any other way to perform diagnostics?

 

[Night Train]

Pull the speedometer housing apart and inspect wiring and PC board of the tachometer/indicator ring. Make sure the o-ring clip that holds it in is not contacting the pc board. Check for rust or damaged wires.

 

[GymRat]

I just put a new battery in. I first connected the ground and when I began connecting the hot or positive side, one wire coming from one of the black modules (the one closest to the battery) sitting on the EHC sparked and caused the lights to come on and the starter (I believe) to click and made the battery terminal very hot.

What are the black modules sitting on the EHC?

 

[Daddycool]

I think that one is for the ignition. Does it have a blue and yellow led on the side of it? If it does its the ignition module.

 

[GymRat]

I didn't see any LED(s) on it. But it's the one closest to the battery and the only one with a wire going to the battery.

 

[mobsta]

maybe some pics will help

 

[Gas Man]

maybe some pics will help

Ignition module

Pull the speedometer housing apart and inspect wiring and PC board of the tachometer/indicator ring. Make sure the o-ring clip that holds it in is not contacting the pc board. Check for rust or damaged wires.

the ring clip holds the tach in...

Thread to help pull the speedo
http://www.bigdogbiker.com/forums/how/451-how-remove-install-swap-your-speedo.html

 

[GymRat]

Gasman, I took some pictures that I tried to post. However, if you look at the first picture you posted you will notice a wire (black and red) following the underside of the frame that ends at the top right corner of the module shown. That wire connects to the positive terminal and comes off a black module (one of two) that sits on top of the EHC.

DO you know what that module is? It's like I have a reverse polarity problem because every time I touch the positive terminal with that wire it sparks and gets very hot.

 

[Gas Man]

Do you mean like these 2 black modules?

Cause those are the wiring harnesses for your EHC. One goes to the lower frame and the other goes up the backbone.

These are the wires coming off the ignition module

A set for recieving power from the ehc, power to the coils, signal to the tach, and signal from the crank sensor.

 

[GymRat]

Yes. The black module closest to the battery is the problem. So, can I assume that because I get a spark when I try to connect the wire coming from that module that I could have a short coming from the lower frame? When I disconnected it from the EHC I didn't 't get the spark from the battery's pos terminal. Does this mean anything?

 

[Gas Man]

Check this

http://www.bigdogbiker.com/forums/technical-bulletins-recalls/454-voltage-regulator-recall.html

 

[GymRat]

I had my VR replaced. So is the black module a circut breaker? And how can I tell if the voltage regulator is bad?

 

[V]

So is the black module a circut breaker? And how can I tell if the voltage regulator is bad?

The little gray block with two wires going to it is the circuit breaker. It has a small button that will pot out if tripped. The voltage regulator has production numbers on it that will confirm if its a recall item. If it is there is a service bulletin to replace with a fused system in lieu of circuit breaker. But if the VR is bad it would need to be replaced. Can you check voltage back to the circuit breaker ?

V

 

[GymRat]

Thanks "V" I see the circuit breaker and it wasn't tripped. How do I check the voltage back to the CB? And I'm still wondering why I would get sparks from the black module (that holds the wire harness to the lower frame) when I connect it to the positive terminal. But when I unplug it from the EHC it doesn't spark.

 

[Raywood]

Thanks "V" I see the circuit breaker and it wasn't tripped. How do I check the voltage back to the CB? And I'm still wondering why I would get sparks from the black module (that holds the wire harness to the lower frame) when I connect it to the positive terminal. But when I unplug it from the EHC it doesn't spark.

Night Train has a How To for checking the electronics. Might be in the Tech section.

 

[GymRat]

I'll look for it...thanks...