04/18/2023
BDM EHC history as well as all the “aftermarket” units
04-18-23, 12:43 PM
Due to all the controversy and mis-information being found on Facebook these days. Jeff Moore, of Dead One Customs, is providing you all with factual information and a timeline of the EHC history as well as all the “aftermarket” units that came to fruition. Much of this is SIL (Service Information Letters) from Big Dog themselves. I hope you find this information useful and educating and I hope this clears up the misconceptions found on Social Media. Happy reading…
This is some of the factual information regarding BDM EHC’s and their history, upgrades and other BDM Controllers, including the Aftermarket Systems. This document also provides a timeline on the manufactures release dates, as well.
BDM Service Information Letter (Image below in comments)
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BDM ELECTRICAL SYSTEM INFORMATION SHEET
This letter highlights differences between the various BDM Electrical Systems and the various Electronic Harness Controllers (EHCs).
MODELS: 1994 – 2004 Big Dog Motorcycles.
The 1994 –1998 Big Dog Motorcycles were individually “hand wired” per unit.
The 1999 –2002 Big Dog Motorcycles were more uniformly wired per unit. And the FIRST Electronic Harness Controllers (EHC) was introduced. The Electronic Harness Controllers (EHC) pictured below was manufactured by Thunder Heart Performance Products.
'99-'02 Electronic Harness Controllers (EHC) (Image below in comments)
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The 2003 Big Dog Motorcycles were more uniformly wired per unit. And the SECOND Electronic Harness Controllers (EHC) , BD4030-1B was introduced. The Electronic Harness Controllers (EHC) pictured below was manufactured for BDM by an outside contractor. Due to the ’03 EHC was such a close duplication to the previous Thunder Heart Controller. Big Dog Motorcycles was forced to stop the production of this unit due to an issue of possible copyright infringement.
Electronic Harness Controllers (EHC) , BD4030-1B (Image below in comments)
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NOTE: The 2003 EHC manufacturing was discontinued in 2003
The 2004 Big Dog Motorcycles were uniformly wired per unit model. And the THIRD Electronic Harness Controllers (EHC) , BD4030-04 that was the FIRST Micro Processor Based Controller was introduced 2004. The Electronic Harness Controllers (EHC) pictured below was manufactured for BDM by an outside contractor.
Electronic Harness Controllers (EHC) , BD4030-04 (Image below in comments)
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Due to many unexpected failures in the Electronic Harness Controllers (EHC) , BD4030-04. There was an UPDATED Electronic Harness Controllers (EHC) and Adapter Printed Circuit Board released in late 2004/ early 2005 to help resolve these failure issues. The Electronic Harness Controller (EHC) and Adapter Printed Circuit Board are pictured below.
Electronic Harness Controller (EHC) and Adapter Printed Circuit Board (Image below in comments)
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BDM Service Information Letter (Image below in comments)
SIL-10001 Rev.A 18 APR 2008
EHC INFORMATION SHEET
This letter highlights the differences between the various Electronic Harness Controllers (EHCs). The following pictures and descriptions explain the operational differences between the different types, and each version’s function and use.
MODELS: 2005 – 2008 Big Dog Motorcycles.
EHC PART NUMBER IDENTIFICATION: 170-000001-00
NOTE: There are two types of EHC with this part number.
EHC PART NUMBER IDENTIFICATION: 170-000001-00 blk
(Image below in comments)
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Hard, black potting material: This EHC was used for 2005 and early 2006 models. Uses a round serial cable plug for diagnostic software and has thru-hole LED’s that protrude from the top of the potting material.
EHC PART NUMBER IDENTIFICATION: 170-000001-00 clr
(Image below in comments)
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Soft, clear potting material: This EHC was used for 2006 K9 production. It was also used as warranty replacement for all 2005-2006 models prior to the use of 170-000010-00. Uses a round serial cable plug for diagnostic software and has thru-hole LED’s that protrude from the top of the potting material. This EHC, and only this EHC, is affected by recall 06V-305.
NOTE: Both styles of the 170-000001-00 EHC are Type 1.
EHC PART NUMBER IDENTIFICATION: 170-000002-00 (Image below in comments)
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Short, single-board EHC with soft, clear potting material. This EHC is used in 2006-2007 model years and as a field replacement prior to the use of 171-000010-00. Uses a round serial cable plug for diagnostic software and has surface- mount LEDs that do not protrude from the top of the potting material.
NOTE: EHC 171-000002-00 EHC is Type 1.
EHC PART NUMBER IDENTIFICATION: 171-000015-00 / 171-000019-00 (Images below in comments)
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Short, single-board EHC with soft, clear potting material. This EHC was also used in limited quantities for field replacements. Uses a round serial cable plug for diagnostic software and has surface- mount LEDs that do not protrude from the top of the potting material.
NOTE: EHC 171-000015-00 EHC is Type 1.
EHC PART NUMBER IDENTIFICATION: 171-000019-00
Short, single-board EHC that functions the same as 171-000015-00 but has a semi-hard, clear potting material. This EHC was introduced in December 2006 for the 2007 model year. Uses a round serial cable plug for diagnostic software and has surface- mount LEDs that do not protrude from the top of the potting material.
NOTE: EHC 171-000019-00 EHC is Type 1.
EHC PART NUMBER IDENTIFICATION: 171-000010-00 (Image below in comments)
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Tall, dual-board EHC with semi-hard, black potting material. Introduced for 2007 model year production and used as a field and recall replacement. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material.
NOTE: EHC 171-000010-00 EHC is Type 2.
EHC PART NUMBER IDENTIFICATION: 172-000007-00 (Image below in comments)
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Tall, dual-board EHC with semi-hard, black potting material. Introduced for 2007 model year EFI only production. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material.
NOTE: EHC 172-000007-00 EHC is Type 3.
EHC PART NUMBER IDENTIFICATION: 176-000003-00 (Image below in comments)
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Replaces 171-000010-00. Introduced for mid-2008 production. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material. Uses the 2005 through late 2008 harness connectors
NOTE: EHC 176-000003-00 EHC is Type 2.
EHC PART NUMBER IDENTIFICATION: 176-000004-00 (Image below in comments)
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Replaces 172-000007-00. Introduced for mid-2008 production on EFI models. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material. Uses the 2005 through late 2008 harness connectors
NOTE: EHC 176-000004-00 EHC is Type 3.
EHC PART NUMBER IDENTIFICATION: 176-000007-00 (Image below in comments)
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IMPORTANT: This EHC uses new, female harness connectors that surround the outside of the connector pin cases that are not interchangeable with other units.
Tall, dual-board EHC with semi-hard, black potting material and has a black case. Introduced for late 2008 model year production and for 2009 model carbureted bikes. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material.
NOTE: EHC 176-000007-00 EHC is Type 2.
EHC PART NUMBER IDENTIFICATION: 176-000008-00 (Image below in comments)
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IMPORTANT: This EHC uses new, female harness connectors that surround the outside of the connector pin cases that are not interchangeable with other units.
Tall, dual-board EHC with semi-hard, black potting material and has a black case. Introduced for late 2008 model year production and for 2009 EFI models. Uses a USB plug for diagnostic software and has thru-hole LEDs that protrude from the top of the potting material.
NOTE: EHC 176-000008-00 EHC is Type 3.
NOTE: ”ALL” manufacturing of the EHCs was discontinued in 2010.
Please keep in mind that there were an additional 10 “hardware” revisions, and 3 times that many “software” revisions made to the microprocessor based EHCs, as well.
BDM Performance Products PDM/HCI (Image below in comments)
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Introduced in 2008 as an alternative controller system to the EHC.
NOTE: ”ALL” manufacturing of the PDM/HCI was discontinued in 2009/2010
Aftermarket Replacement Controller Systems for the BDM EHCs and BDM PDM/HCIs
Wire Plus 374 (Image below in comments)
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The FIRST aftermarket replacement controller system. Introduced in 2007
Hard-Wired and “Spliced” into BDM OEM Harnesses after removing the desktop connectors.
Made for replacement use in all BDM carbureted models. Adapted to the EFI models at a later date. Application features for “standard” options only.
NOTE: ALL manufacturing of the Wire Plus Units was discontinued in 2014
Dead One Customs ESC (Electrical System Controller), ’04 & Later (Image below in comments)
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The SECOND aftermarket replacement controller system, the FIRST 100% Plug-N-Play replacement controller system. Introduced in 2008. Includes UPGRADED Backbone Harness w/ UGRADED Full Headlight Harness w/ Ceramic H4 Headlight Plug. Includes UPGRADED Main Power Harness.
Made for use in all BDM models, both carbureted and EFI. Suitable replacement ability for all of the BDM EHCs, PDM/HCIs and “ALL” of the other aftermarket replacement controller systems. Application features over and above the “standard” options included, but not limited to: BDM Air Ride “Hand Control” operation “option”, BDM “Euro” equipped tail light “option”, Dead One Customs all internal “Batt./Charging System Fault Light Circuit” “option”.
Dead One Customs ESC (Electrical System Controller), ’99 – ‘03(Image below in comments)
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The THIRD aftermarket replacement controller system, the SECOND 100% Plug-N-Play replacement controller system. Introduced in late 2008.
Made for use in all BDM models, ’03 and earlier. Application features over and above the “standard” options included, but not limited to: Dead One Customs all internal Batt./Charging System Fault Light Circuit “option”.
KMW/Big Dog is Back RIP (Rest in Peace) Generation 1(Image below in comments)
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The FOURTH aftermarket replacement controller system, the THIRD 100% Plug-N-Play replacement controller system. Introduced in late 2014. Made for use in all carbureted ’04 & Later BDM models. Includes “standard” OEM Backbone Harness w/o Headlight Harness. Includes “standard” Main Power Harness. Adapted for use in the EFI models at a later date.
Application features only “standard” options included, but not limited to: BDM “Euro” equipped tail light “option”.
KMW/Big Dog is Back RIP (Rest in Peace) Generation 2 (Image below in comments)
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The FITTH aftermarket replacement controller system, the FOURTH 100% Plug-N-Play replacement controller system. Introduced in late 2016. Made for use in all “05 & Later BDM carbureted and EFI models. Includes “partial” Backbone Harness and “partial” Main Power Harness. Application features only “standard” options included, but not limited to: BDM “Euro” equipped tail light “option”.
Elektronikbox EHC (Version 1) (Image below in comments)
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The SIXTH aftermarket replacement controller system, the FITHTH 100% Plug-N-Play replacement controller system. Introduced in late 2016. Made for use in all “04 & Later BDM carbureted and EFI models. NO Harnesses. Application features only “standard” options included, but not limited to: BDM “Euro” equipped tail light “option”.
For more information like this please visit one of the following:
web:
www.bigdogmotorcyclesusa.com
www.deadonecustoms.com
on facebook:
Big Dog Motorcycles USA
Dead One Customs
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