Working Solution, in full, for Electrics AFTER ABS is removed
As of last night, and the test ride I took this morning, it looks like I have now found a working solution to getting the bike electrics sorted after removing the ABS unit. This solution is a slight variation on what I did above, but the variations are important
I have put everything into this post so its easier to print and its all in context.
Required Parts:
From your BMW dealer, order part number: 61 13 7 696 769. This is the Diode relay which is different between ABS/Non ABS. Cost me €23
Dataspares.com (UK) stock the correct 26 pin ECU plug and, most importantly, stock the correct crimp connectors for it. You will need to give them a call to order the connectors which come in quantities of 20. £6.40 at the moment for 20, plus postage. You only need 4 for the job.
I also wanted to maintain the correct wiring colour code so I ordered 2 meters each of brown/white, black/white, and brown at Kojaycat.com (also UK). You need the 0.5mm squared thin walled cable.
To keep things tidy, you will also need some sleeving, shrink tube and normal wiring connectors that I guess most people who do this will have lying around anyway. You will also need a crimp tool suitable for the connectors and a very fine (watch makers) screwdriver for pushing the connectors out and into the ECU plug.
What to do:
I make the assumption that the ABS unit is gone, the front wheel sensor has been taken off, disconnected near the front right section of the airbox, the back of the dash is exposed, the seat and right hand side panel are removed.
1) Remove the ECU plug from the back of the dash.
2) On 1 side of the plug you will see a long white 'bar' and on the opposite side, 2 smaller white bars. Push the long bar in to the plug, the 2 smaller ones will pop out the other side. This releases the locking mechanism for the connectors inside the plug.
3) identify connector 19 (brown wire)
NOTE: On the back of the plug there is some numbering to help though not every position is numbered.
4) using the small screw driver, push out the connector from the dash side of the plug. There is a special tool for this but the screwdriver, if its small enough, works fine.
5) Keep this (earth) connector as it will be placed in another pin position.
6) identify connectors 22 (white/yellow wire), remove it and then either isolate it or just cut it off and isolate the wire. It is no longer needed as it connects to the ABS.
7) Insert the brown wire that was removed from position 19 into position 22. Be sure that it goes all the way to the dash end so a good connection is made when the plug is re-inserted into the back of the dash.
8) repeat step 6 above for connector 9. white/black wire.
9) cut a length of wire (brown to maintain bike coding). Crimp on a new connector and, using the small screwdriver, fully insert the connector into the ECU plug position 9. The other end of the wire needs to be spliced into the brown wire that was put into position 22 during step 7 above. I used a small (red) scotch lock connector here
10) locate positions 26 and 6 on the connector. You should find that they have a tiny plastic blanking plug in place as they were not used on an ABS bike.
11) Remove the blanking plugs.
NOTE: the next steps involve running wire to under the seat of the bike so leave plenty of spare. I created a mini loom using some black channeling, shrink tube, and cable tied it to the main loom. I will bind this into the loom at a later date.
12) using the brown/white wire, crimp on a connector and insert it into position 26.
13) using the black/white, add a connector and insert it into position 6
14) push the 2 small white tabs back into the connector so locking all the crimp connectors in place. Then insert the ECU plug back into the dash.
REMEMBER: in this next part, you are connecting the rear wheel sensor, to the instrument cluster... bypassing the loom!
15) run the 2 wires to near the top of the fuel tank. Here, you should find a connector where the rear wheel sensor attaches to the main loom wiring. If you can find a new loom side connector, you can add that to the end of the 2 new wires and simply plug it in, ensuring the the wire connections correspond to the existing ones (colour).
If you don't have a spare connector;
16) cut the wire on the loom side of the plug ensuring you leave enough wire to add some connectors.
17) connect like coloured wires. brown/white to brown/white etc !
18) Near the front right hand side of the airbox, you will find the small diode relay. Pull this out (5 pins) and disconnect the additional wiring (3 wires) via the connector next to it. You will understand what I mean here when you look.
19) Put the new diode into the 5 pin connector and hook back up to the airbox mounting point.
20) Cut off the 3 wire connector from the diode relay that was just removed. Leave as much of the wire on the connector side (not the relay side) as possible.
21) Remove the brown wire from the connector, it is not required.
22) Join the remaining 2 wires together using a sealed connector. What this is doing is joining the power wires from the hand brake switch to the foot brake switch so that when either is pressed, the rear brake light comes on. If you don't do this, only the foot brake will work the brake light.
23) reset the instrument cluster. The easiest way to do this is to do the following, straight from the X workshop manual.
a) The battery is disconnected.
b) Ignition key is removed.
c) Press and hold the SET button and temporarily connect battery cables.
d) Software version is displayed (1.9 on my bike)
BUT, importantly, at the same time it should NOT say ABS on the display. If you did this before removing your abs and making the electrical changes above, it
should say ABS here.
e) continue to hold SET button
f) Display counts down from 15 to 0.
g) Release SET button on 0
h) Display now cycles through 17 and 18.
i) when your correct rear wheel size appears, press the MODE button. Note, if you have an 18 inch rear wheel and are getting the famous 10% speed reading error (over actual) set this to 17 as it will (almost) correct this error.
j) the displayed parameters are now stored in the instrument panel.
k) disconnect the battery again so display goes off.
l) now reconnect the battery correctly, without pressing any buttons.
Job done. Put everything back together and take it for a test ride.
If anyone else makes this mod to their bike, I would really appreciate confirmation that this solution works.