No running lights front or rear and the smell of smoke

[BadBrad]

When it rains, it pours. This is my 3rd post with bike problems in as many weeks. I need your help again. The wife and I were riding her '03 Mastiff and the power shut off minutes after leaving the driveway. All dash lights began flashing/blinking. Bike would not start or turn over (dead). When we got it back to the house, I tried it again. This time, I could smell burning plastic and see a little smoke coming from the front of the gas tank, as if it was coming out from under the tank. The dash lights stopped flashing and now the bike cranks up and runs. I pulled the tank but could not see anything that looked melted or burnt. After replacing the tank I noticed that she has no running lights front or rear. Headlight still works. I need to pull the tank again and trace the running light wires. What else could it be? Thanks "pound" for your time and help.

 

[bdmridgeback]

Are you sure that the smoke wasn't coming from the Voltage Regulator down below the oil filter? The smoke could creep up and look like it is coming out from under the tank. It sounds like the famous 2005 defective Voltage regulator issue. When my VR failed the bike stalled going down the road with all the speedo lights doing weird stuff. I push started it and bearly made it home. The second VR that went out I could not get it start, it took out the EHC that time.

 

[BadBrad]

The starter would not even turn over. When I said it was dead, I mean all the way dead. I feel sure it's a short. Or that's what my instincts tell me, but I'm new to Dogs and the problems they have. I'll try anything once. I felt the VR when it stopped to see if it was hot. It was still cool. Only rode for 30 seconds out of the driveway before it quit.

 

[TheDeadOne]

By the sound and "smell" of things here, I think you better send Jake a PM about the EHCless repair needed! :2thumbs:

 

[BadBrad]

Thanks for the tip, but keep in mind that I'm new to Big Dogs and even newer to the Big Dog Forum. Who is Jake and what is an EHCless repair? I'll catch on soon enough. Just a few more 6-packs and I'll have it down pat.

 

[stlmikie]

First off this is on the 03 guys. Two the problems with the ehc's didn't start until after 03. Not saying it isn't the ehc but...

 

[ChevroletSS1965]

Seems like the Voltage Regulator to me.

 

[stlmikie]

How about brake lights?

 

[LDO]

Perhaps you had a shorted wire in between the tanks?

You need to remove the center console, and take a good look in there.

I mean a REALLY good look, like drain and remove the tank havles too and check all that wiring.

When I did, I found a few of my wires were flattened by the tanks and pressure against the frame.

Could be that yours broke and shorted. Also, could be a connector on your EHC (old style) worked itself free.

The wiring in there gets bent up pretty good so that may have been the problem too.

Get yourself some dialectric grease and re-wrap/re-route your wiring while you're in there. Preventive maintenance when it comes to wiring goes along way.

Let us know what you find out.

 

[BadBrad]

I checked the brake lights. The rear right left light comes on, but not the right. Actually, it flashes twice before it comes on but i think it has always done that. I checked the blinkers too. The right side works fine. The left front has a fast flash and the left rear is not working at all. I lost all my tools (including the ohm/voltage meter) in a barn fire when I lost my harley back in January. Looks like I need to get another one soon to help with this. I really do appreciate all the feedback from all of you. Thanks again. Brad

 

[BadBrad]

I think I got it but need some feedback on repairs

Hey guys. I pulled the tank and the EHC module is mounted between the tanks. I pulling the 6 wire plug and checked for power to the front running lights from the EHC module. With the key on, no power to either for running lights. I checked each blinker and got a full 12 volt surge for the right and about a 6 volt surge for the left. The other day I could see smoke coming from under the tank, so I"m going to assume the EHC crapped out. I saw a wire kit on this site with a "how to" for wiring it up. Is this the best route to go or would you go back with a new EHC module from BD? Are there any fuses that I can check going to the EHC that would only affect a few wires?

 

[LDO]

Brad,
The 03s don't have front running lights (unless you have modified your wiring/bike).

2003s only had rear run/turn/brake lights. Your front lights are just turns.

 

[BadBrad]

Thanks. I'll check the rear pins on the EHC and see if I get the same result.:bang:

 

[bdmridgeback]

Thanks for the tip, but keep in mind that I'm new to Big Dogs and even newer to the Big Dog Forum. Who is Jake and what is an EHCless repair? I'll catch on soon enough. Just a few more 6-packs and I'll have it down pat.

Seens how I responded above, I thought I'd introduce myself... :2thumbs:

I am Jake...

:reddevil: Low Down Chop Shop .com:reddevil:

I did all the How-To's in the How To section for the EHC elimination module from Wire-Plus.
In your case, you have other options and wouldn't be in need of the Wire-Plus WP374 module.

Good luck, I think you could do fine replacing it with a new BDM part (Thunder-Heart Module) or you could go with a HD based Wire-Plus module if you decide to eliminate the BDM piece.

 

[LDO]

U got a wiring manual right?

 

[BadBrad]

I have a wiring manual for my '05 pitbull but not my wife's '03 Mastiff. Is the wiring different on the EHC for these? I read where some guys lost the same sequence of lights from a rubbed rear fender wire. With the smoke coming out from under the tank and the low voltage going to one of the front blinkers, I think it's probably the EHC. For me, going back stock parts will be easiest.

 

[BadBrad]

Good to meet you Jake. Thanks for the help from all of you. I need all the help I can get.

 

[LDO]

I believe the wiring diagrams for the 2003s are different and I know for sure the EHC functions way differently on the newer bikes. The 03s are more like Harleys than anything.

I can scan the wiring diagrams off my manual for you tomorrow if you like...

 

[BadBrad]

Thanks LDO. Could you email that to me at fishnfowlr@yahoo.com? I did notice one thing. When I pulled the 6 pin socket from the EHC, I was able to use a volt meter to see if power was coming from the EHC. When I pulled the larger 9 pin from the rear of the EHC, no power would come from the EHC after turning the key on. It's like it has to be grounded or something where the front socket doesn't.

 

[LDO]

There are two grounds that are connected to your handlebar switch wiring that plugs into your EHC and it needs that ground.

That grounding block should be part for your forward tank mounts.

I"ll get that stuff scanned for you and emailed ASAP.