1150 Ignition Harness Fault

[754385]

Hi from NZ.

My 2005 1150 GSA started to completely loose ignition when I turned the handlebars. Once I got parked up I wiggled the wire that goes from the ignition cylinder and heads under the tank and that seems to be the problem. The problem I have is that I can't unplug the wire and I was told I needed to unscrew a grub screw above it but on my bike there isn't a grub screw its just got a metal plug in it? Any ideas, do I have to drill this out?

 

[albatross]

See here

Removing And Installing Ignition Switch/Steering Lock; Removing And Installing Ignition/Light Switch - BMW R 1150 GS Repair Manual [Page 280]

BMW R 1150 GS Manual Online: removing and installing ignition switch/steering lock, Removing And Installing Ignition/Light Switch. R21510030 • Remove Fork Bridge. • With A 4 Mm (0.16 In) Dia. Drill Bit, Drill Approx. 5 Mm (0.20 In) Into Non-Removable Screw (1). • Use An 8 Mm (0.31 In)...

www.manualslib.com

Screw for the barrel needs drilling out..
The one for the harness is a tiny Allen screw..
Check if it isn’t just a softball seal ?

 

[hops]

Hi from NZ.

My 2005 1150 GSA started to completely loose ignition when I turned the handlebars. Once I got parked up I wiggled the wire that goes from the ignition cylinder and heads under the tank and that seems to be the problem. The problem I have is that I can't unplug the wire and I was told I needed to unscrew a grub screw above it but on my bike there isn't a grub screw its just got a metal plug in it? Any ideas, do I have to drill this out?

Does this help? Also once you've replaced/repaired the wiring harness do away with the cable ties holding the harness to the frame near the headstock as these can cause the problem in the 1st place.

 

[Posh Pete]

You need to order the sub harness which goes from the ignition barrel to the main harness. See above for help re removing it from the barrel end.

When you replace it, leave some room for movement so that the turning of the handlebars doesn't place undue stress on the sub harness.

It's a common fault caused by over tight fitting at the factory.

 

[albatross]

When I tried to order a harness for the ignition last year from BMW , it wasn’t available anymore!

 

[Posh Pete]

When I tried to order a harness for the ignition last year from BMW , it wasn’t available anymore!

If that's the case then the op can remove and repair. It'll involve stripping and replacing the outer sheath to find the break and make the repair but still a relatively easy job

 

[albatross]

I managed to get hold of a good 2nd hand one, that’s the other option…

 

[hops]

When I tried to order a harness for the ignition last year from BMW , it wasn’t available anymore!

Motorworks still appear to stock them.

 

[albatross]

Good to know……

 

[754385]

Hi from NZ.

My 2005 1150 GSA started to completely loose ignition when I turned the handlebars. Once I got parked up I wiggled the wire that goes from the ignition cylinder and heads under the tank and that seems to be the problem. The problem I have is that I can't unplug the wire and I was told I needed to unscrew a grub screw above it but on my bike there isn't a grub screw its just got a metal plug in it? Any ideas, do I have to drill this out?

See here

Removing And Installing Ignition Switch/Steering Lock; Removing And Installing Ignition/Light Switch - BMW R 1150 GS Repair Manual [Page 280]

BMW R 1150 GS Manual Online: removing and installing ignition switch/steering lock, Removing And Installing Ignition/Light Switch. R21510030 • Remove Fork Bridge. • With A 4 Mm (0.16 In) Dia. Drill Bit, Drill Approx. 5 Mm (0.20 In) Into Non-Removable Screw (1). • Use An 8 Mm (0.31 In)...

www.manualslib.com

Screw for the barrel needs drilling out..
The one for the harness is a tiny Allen screw..
Check if it isn’t just a softball seal ?

Thanks Albatross, I hadn't realised there is a small screw round the side of the barrel. I'll take a look tonight. Thanks for help.

 

[albatross]

Thanks Albatross, I hadn't realised there is a small screw round the side of the barrel. I'll take a look tonight. Thanks for help.

Matter of fact , just checked…it isn’t an Allen but a slotted screw, really small
Best luck …
As you can see there was a blob of red stuff on there…covering the opening!
Access is from the right side of the bike!