Lost the headlight....

[Old Hippy]

Well, I'm getting a real bad case of Dawg-itis with this Mastiff.!! I just spent the entire day cleaning and shining after getting caught in a downpour last time I took it out. It was a mess. Well, now I've developed a little electrical glitch and it's got me baffled. It started out with me loosing the neutral/oil pressure lights on the annunciator. Now, after getting everything put back together, I've got all my indicator lights back (including the high beam light burning continuously) and no low or high beam headlight.!! I've took the dash panel off twice and shook all the connectors. I've pulled them apart, and reconnected over and over with no return of the Hi and Lo beams. Could water from the rain gotten in my left hand controls on the bars and shorted something out??? Every thing seemed to work fine before I disassembled the dash panel . Thinking it's the damn EHC once again, but it's acting much different than it did first time it puked. Scooter starts and runs fine. Turn signals, parking lights and emergency flashers work too. I've got the service manual here on my desk, but it doesn't help all that much. Any suggestions????

 

[Nomad2day]

Dang water,
Hope you find the problem soon

 

[BubbleHead]

Hey Hip, Fibersnake might be able to help on this one or PM Ohmster and I'm sure he has a few suggestions

 

[Gas Man]

When you took the connecotrs apart... you should have put some di-electric grease in them.

Further, your 2004 may have the old hand control boards in it that are more sesetble (sp?) to water damage.

Did you pull the EHC connectors and blow them out and refill with di-electric grease?

 

[V]

Hip, my 05 had the old circuit boards in the hand controls. I got water in the left side and it made my oil light come on and high beam. Dried it out real good and everything went back to normal. A service bulletin was later issued and had the hand controls updated to newer circuit boards.

V

 

[Old Hippy]

Thanks V

Hip, my 05 had the old circuit boards in the hand controls. I got water in the left side and it made my oil light come on and high beam. Dried it out real good and everything went back to normal. A service bulletin was later issued and had the hand controls updated to newer circuit boards.

V

That sounds like my problem V..!!! Now, how do I access this circuit board on the left side??? I think I know, but before I tear up something else, I would like a little direction.!!

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[Old Hippy]

Thanks Gas

When you took the connecotrs apart... you should have put some di-electric grease in them.

Further, your 2004 may have the old hand control boards in it that are more sesetble (sp?) to water damage.

Did you pull the EHC connectors and blow them out and refill with di-electric grease?

Now that you bring it to my attention, no I did not, but I will before I get everything back together. I took the left side controls loose and used a hair dryer to heat it up a bit, in hopes to evaporate any moisture that may have gotten in the works. But still no headlight..!! I guess I'm gonna have to take the circuit board out and do some more drying.!! I'll get it sooner or later, and I thank ALL who gave me a direction to lean.!!

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[V]

Hip I got by with using light compressed air. Didn't have to take it apart. I haven't opened up a switch housing but I know there is a post on here where, somebody cleaned and coated there cicuit boards with a silicone spray.

OKAY WHO DID IT

V.

 

[Fibersnake]

Hip,

If you take the hand controls apart, I would also recommend that you get some Electro Clean that is also safe for plastic. You can then spray the shit out of, let it air dry and then install the di-electric and put it back together.

The connectors for the hand controls are very tight and a PITA to get at, make sure that when you reassemble that you get the connectors tight for they do have a tendency to come loose again when reassembling. Also would recommend the Electro Clean followed by air drying for all the connectors ,and then good coating of di-electric.

One item I was going to recommend since you have a 04 Mastiff, is that with the center consul, the back of the tach board is exposed more than some other. Just normal riding in heavy rain can allow some water to get up there and create problems. Also the way the tach board is assembled, the wiring to the PCB board is very fragil and those wires can break very easy.

I have had mine break a couple of times in the past when working around it. Be careful. The last time was when I rode with BigBlue and the rest for Rolling Thunder, the tach lights did all kinds of stuff. When I got home found some of the wires broken and other damn near. Took the tach board off and very carefully removed the wires from the PCB eyelets and resoldered. No problems since.

Doubt that is your main problem since you said the headlight isn't working, but when mine did it last, the faults lights did not work properly as well as the tach indicators were not working sometime and other times doing wierd sweeps. That said everything did work though, just the indicators light were not proper.

Also if you mess around the EHC, be very careful about making sure that the harness connectors to EHC are put back right. Do not force and insure proper alignment otherwise you can bend or break a pin and may end costing a new EHC. Also be very careful when tighting down the screws that secure the harness to EHC. Just start one side to get it going, then the other, then a little on one, then the other to bring them down evenly. Also just snug them gently, They break easy and do not need much, basically to where there is just a slight bit of tightness.

Good luck and let us know how you make out.

 

[Gas Man]

Hip I got by with using light compressed air. Didn't have to take it apart. I haven't opened up a switch housing but I know there is a post on here where, somebody cleaned and coated there cicuit boards with a silicone spray.

OKAY WHO DID IT

V.

Jake's idea... and I have done it also.

http://www.bigdogbiker.com/forums/how/955-saving-your-plate-light-water-damage.html

 

[Old Hippy]

My Mastiff has a mind of it's own...

Well, Dudes and Dudettes, I took "Statutory Grape" out for a spin today, first time since the big rainstorm did a number on my headlight, and guess what??? the headlight mysteriously started working again. Who'd a thought??? But another problem, nonelectrical ,raised it's ugly head. I stopped to feed some 93 octane into this beast, and when I removed the right side gas cap, the entire sleeve it threads into came out (of the tank) with the cap..!!! Anyone ever experienced this before??? Also, it looks like some sort of adhesive/sealant the sleeve was mounted with, fell down into the tank and I'm worried this shit might clog up the works.!!! It's always something. Anyone want to buy a truly aggrevating '04 Big Dog Mastiff????

I'll be glad when the new HD dealship opens up in town.!!!!

Signed.......Getting a little frustrated.!!!

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[Fibersnake]

Hip,

Sounds like the paint saver broke loose from the tank and the stuff that feel into the tank is more than likely the JB weld type material that they used to hold in place.

Sorry to hear of that but I have others on non BD have the same thing occur. If it was me I would take the tank off after draining it, turn it upside down and very carefully shake all the shit out, then get another tube of JB weld and reinstall. Allow the JB weld to fully drive over night, then refill and go riding. While the tank is out make sure to pull the fuel petcock and kill the strainer on it.

To help prevent strain in the future, good idea to occasionally lube on the thread of the gas caps with a light coating of grease to help prevent undue stress from where the threads tighten up when the plastic swells.

Good luck and sorry to hear of that, but should not be a biggie to fix. Let us know how you make out.