No spark

Energy One

Betabquicker

New Member
hi I have a 2006 mastiff I have had since new. I have not changed anything electrical. I am not sure what I have done but I had a flat battery so I put the jump pack on and stupid me put the terminals on the wrong way. Now I have no spark at the plugs. No headlight or nothing lights up on the dash. I do have indicators and power to the coil. I have power to the ignition module. I thought it might be a fuse but can't find one. Any ideas
 

Mastiff Rider64

Well-Known Member
Doesn't look like you have had the Voltage Regulator recall done, and if it is a stock ech then you probably have a gen1 like mine. You could have possibly fired your ECH.
 

Jersey Big Mike

100K mile club
First things first -- measure the voltage on the battery -- what is it?
Pull the battery and have it load tested (if relatively new)
How old is battery? I killed on by leaving the key on for 3 days. (luckily it was replaced in warranty).
Disconnect the battery for 30 minutes and let ehc completely reset (hopefully its not fried)
 

Sven

Well-Known Member
No, I don't own one, but let me ask the forum members this question. How many reversed polarity as mentioned here, and did the black box survive?

So with battery out, look at how rusty the (+) cable is down at that rusty lug. Remove the red cable, clean contact points by scraping years of electrolysis off that and now find the end of the battery ground and scrape to new metal, those touch contact points. That says the cable loop to the battery/frame, most likely will not in a sense perform the; no/poor/click start scenario.

As JBM suggested, since the battery is out, the cables are clean at all 4 ends, hold both the main and ground cables together. Why? You are going to toggle the start button, kill button, key on, and empty the condensers that have a saved RAM. Some say to hold for so many seconds, but you are going to toggle like crazy those buttons. And for good measure, hold down the buttons per book. By emptying the last saved 'good/bad' know signal, the black box starts at ROM... or 0000... no data found, start on the preset you can't erase.

Then with a set of jumper cables, car engine off, clamp the cables up to the bike and with key on, do you see the lights on the black box looking normal? Don't start the bike. This is just a black box test you waiting for an answer that may never come..
 

Betabquicker

New Member
Its an old battery but says 12.21 and I had it disconnected over night while it charged. The jump pack is 900 amp. Can the ehc be fried even when the lights are on. I did see a couple of sparks on plug when I first looked but not since
 

Jersey Big Mike

100K mile club
Its an old battery but says 12.21 and I had it disconnected over night while it charged. The jump pack is 900 amp. Can the ehc be fried even when the lights are on. I did see a couple of sparks on plug when I first looked but not since
12.21 after a charge is a bit low and might have issues starting bike.
Take the battery to a shop[ and have them load test it. Fully charge that battery should be 12.8v
If the battery load tests ok, put it back in the bike, check the voltage again. Should not drop significantly, if it does you may have a parasitic drain.
If voltage is good and battery load tested good turn on key -- do not try to start
What happens?
Light on?
Try signals
Try horn.
if all good, then try to start bike.
 

Jersey Big Mike

100K mile club
12.21 after a charge is a bit low and might have issues starting bike.
Take the battery to a shop[ and have them load test it. Fully charge that battery should be 12.8v
If the battery load tests ok, put it back in the bike, check the voltage again. Should not drop significantly, if it does you may have a parasitic drain.
If voltage is good and battery load tested good turn on key -- do not try to start
What happens?
Light on?
Try signals
Try horn.
if all good, then try to start bike.
Circuit breaker can be tested by measuring voltage to the terminals of the CB breaker.
My k-9 has 2 breakers side by side a 40 and a 25a, you should get the same 12v reading on all 4 connectors
One goes to battery and goes to both breakers
other side 40a goes to VR and 25A goes to everything else basically.
 

Mr. Wright

Knows some things
Supporting Member
Get ahold of the kaptin at www.wildsteedworx.com. He can test your EHC, and he is the one you will need to get one from anyway. I'd also change out the charging system, if all that is still original.
 

Jersey Big Mike

100K mile club
GET THAT BATTERY LOAD TESTED.
I really suspect it is BAD.

See charts on these pages that show you % of charge vs resting voltage. -- Your battery is not FULLY charged!

Weak batteries cause issues with the BDM EHC, and the EHC gets blamed first usually.

 

Mr. Wright

Knows some things
Supporting Member
My charging system in my Mastiff is still original. Lol.
With that much age on the cheap systems they installed on these bikes, your just waiting for trouble to happen. The biggest problem these bikes have, concerning the EHC, is there is no protection between it and the battery. So if a battery shorts out, or the voltage regulator burns a diode, it will take the EHC with it.
 
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