Broken Wire Bulletin

Alannc · Post by **Alannc** » Sun Dec 17, 2006 5:28 pm

Just a note:

If your starter button doesn't always work or any of the controls on the right hand side have problems at times: BMW has a buttetin out about shorting of wires due to krimping. It's a bulletin - not a recall - so they aren't going to pay for it.

My starter switch began to work off and on. Lot of messing around but the bottom line is one of the wires was broken in the main sheath just past the gas tank where it is bent every time you turn the bars.

The BMW mechs were nice enough to pretty much isolate the problem but it would be many... hundreds of dollars to trace it down and then replace the wiring loom(they won't repair the wire - they replace). I have been able to trace it down but have had to remove all the gages, headlight, and controls on the bars. Several hours of work to take it all apart and several to put it back together.

The bike is an 02 with 55,000 miles.

Hope none of you have the problem.

Alan

GJBushman · Post by **GJBushman** » Sun Dec 17, 2006 6:28 pm

I had this same problem on my 2003 1150R. I have heard of others that this has happened to as well. I had it fixed on warranty. They ended up replacing the right side combo switch and removing many of the wire ties.

Post by **baltm604** » Sun Dec 17, 2006 6:45 pm

How did you repair it? Just solder and wrap or replace?

My 03 with 20k just started having the symptoms of intermittent right turn signal and cancel button.

I am hoping the problem is in the wiring between the harness and the switch. (a new switch is $172 from chicago bmw if I cannot repair the current one.

Thanks,

Bill

Alannc · Post by **Alannc** » Sun Dec 17, 2006 6:56 pm

Bill,

I don't think you will find it's the switch - it's probably a problem with the wire ties. The ties are actually to tight and force the wires to bend when the bars are turned. As mentioned they(you) remove a bunch of ties.

I'm will solder the wire and check all the rest of the wires in this sheath. Will probably put an extra cover on the wires and make sure they can move some without bending.

Alan

The Velvet Monkey · Post by **The Velvet Monkey** » Sun Dec 17, 2006 7:19 pm

Did this bulletin apply to the 2004 model year?

Just wondering--thanks.

GeoffJ · Post by **GeoffJ** » Mon Dec 18, 2006 9:34 am

Somebody at the BMW factory likes to gorrila tighten tie wraps.

Earlier this year my R1100R had a broken wire in the main sheath just past the gas tank. When I turned the bars, the engine would sometimes cut out. I've also read several other threads about this same problem.

To fix the problem, cut the tie wraps securing the main sheath to the frame just in front of the gas tank. Next, with the engine running, wiggle the sheath where the tie wraps were installed. If the engine cuts out, you've located the area of the broken wire(s).

Carefully slice open the sheath in the area of the broken wire. Locate the damaged wire, solder it and insulate the joint with a piece of heat shrink tubing. Cover the slice in the sheath with electrical tape or flexible wire tubing (available from auto parts stores).

As a preventive measure, if you haven't had this problem, I suggest you cut the factory tie wraps and replace them with looser fitting ones.

Yep · Post by **Yep** » Mon Dec 18, 2006 9:58 am

'04 here.

Right heated grip, combo switch, and wire harness replaced under warranty. At the time they did not know about the "cause" and kept replacing parts due to my grip not heating.

R4R&R · Post by **R4R&R** » Mon Dec 18, 2006 10:24 am

GeoffJ wrote:As a preventive measure, if you haven't had this problem, I suggest you cut the factory tie wraps and replace them with looser fitting ones.

I did this to my '04 after reading possible problems resulting from being 'wrapped too tight'. 46k miles later and still running good.

Post by **DJ Downunder** » Mon Dec 18, 2006 10:45 am

The buggers....I contacted the head of BMW motorcycles in Oz a couple of weeks ago about all this..after being told there was a recall on a forum.

They asked me heaps of questions..and said someone would get back to me......they never did.

A bit slack I think......maybe time for another phone call.

DJ

GeoffJ · Post by **GeoffJ** » Mon Dec 18, 2006 2:17 pm

R4R&R wrote:
GeoffJ wrote:As a preventive measure, if you haven't had this problem, I suggest you cut the factory tie wraps and replace them with looser fitting ones.
I did this to my '04 after reading possible problems resulting from being 'wrapped too tight'. 46k miles later and still running good.

Good move. You shouldn't have any problems. It only seems to happen to high mileage bikes or ones over five years old.

Post by **yjleesvrr** » Mon Dec 18, 2006 2:19 pm

There have been reports of this happening to bikes no more than 2 years old at various times on this board in the past three years. Attaching wiring and hoses shouldn't present so many problems.

Post by **baltm604** » Mon Dec 18, 2006 4:59 pm

My problem would appear to be the right side switch unit. The bike starts and runs without issue, the right turn signal and cancel button only work when I turn the handlebar all the way to the right.

This seems to me to be a broken wire issue somewhere at the front of the tank where the cables move.

I hope to take a stab at it tonight. Spent last night putting on new front brake pads.

After looking at it, I will need to pull the tank at least, and maybe the windscreen and the headlight bucket to get the wiring out, hopefully it can be repaired.

Bill

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