Electrical Connector to secondary coil - Kapput

Big_Steve64

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I would appreciate any advice that you guys can give me to help sort out my heavy handedness. I have a 05 GS1200 with 60k miles.

I had a problem on a ride out on Sunday where I got a misfire under load that manifests itself when I either get to around 4k revs or crack it open at any revs. The bike (according to my mates behind) smells of unburnt fuel.

I concluded an ignition problem and duly ordered new plugs as a starting point. My friend who has an identical (although much much cleaner) is good enough to let me try his coils so we can eliminate that. He lies the problem.

As I pulled of the HT/Coils from the plugs the RH secondary connector into the coil disintegrated (the pictures show the damage). Obviously the connector need replacing, Half the connector is still in the coil (pic1) Do the prongs come on the harness or the connector? Can I buy the connectors anywhere? Is it a BMW only part? Can a decent auto electrician fix it, or do I need to get it to a dealer?

Any help would be appreciated.

Cheers Steve
 

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The coil has three male prongs set so deep they are hard to get at for testing. The connector has three female ends.

The way to fix this is to cut off the old connector and solder on a new connector with heat shrink insulation on each wire and seal with self amalgamating tape. Make sure you note which colour wire goes where just in case the new connector has different colours.

The coil will need careful attention with long pointed pliers and maybe tweezers to extract the old debris.
 
I would expect a BMW motorrad dealer to have access to the special tooling to crimp together a new connector, either by having the tool or getting it on loan from BMW GB.

Labour shouldn't be much as its easy to get access to, maybe half an hours worth. The part is available via BMW spares network.

Phone the service department of your local BMW Motorrad dealer and discuss it with them, you might be pleasantly surprised (or you may be in for a shock but if you don't ask you'll never know).
 
Bendy toy said:
The way to fix this is to cut off the old connector and solder on a new connector with heat shrink insulation on each wire and seal with self amalgamating tape. Make sure you note which colour wire goes where just in case the new connector has different colours.

The coil will need careful attention with long pointed pliers and maybe tweezers to extract the old debris.
Click to expand...

The other way around I think.
I've got one here and the male pins are part of the coil.
So, small pliers to pull the broken pins from the loom connector.
Coil will need to be replaced. Was about £70 a couple of years back when I bought one.

Paul
 
Oops Sorry. :o I was on a small screen and didnt bother to scroll back.

Sadly, that coil is toast because even if you can solder on new pins there is no way to stop water getting in.

On that front -
Has anyone used car coil packs for any of the BMW coils? They "look" like many car coils with standard resistance values. So if car coils will fit they should work as normal and might cost a lot less.

Ive also wondered about putting the secondaries under the petrol tank with HT leads (heaven forbid) to the plugs. Has anyone tried this?
 
Guys, Appreciate all the replies. Gonna spend the morning on the phone and see if I can source the harness connector. It may not seem as complicated as I first feared. I have managed to get a 4 coils at a very reasonable price, just a case of the harness.
I might have a go at it myself and revert to dealer if I really f*** it up :blast

Thanks to all for taking the time to help
 
The connectors either have a little tag that has to be carefully lifted with a small screwdriver or a rocker that has to be pressed. Then the connector can be carefully eased out like a cork from a flat pop bottle.

As someone else said, the cable connector might be OK, use small pointed pliers to pull out the broken pins and magnifier to check they are clear.
 
Similar thing happend to my bike whilst it was at a well known BMW dealer in Plymouth area. Obviously they denied any responsibility. I took the bike to CWs in Dorchester and they put a replacement connector on swiftly and very reasonable cost.
Top tip-always disconnect the electrical plug before removing the stick coil. I use a large watchmakers screwdriver to carefully lift the locking tang on the stick coil. I also put a squirt of ACF50 to ease the connector in and out.
 
The connector is in 2 parts and the pins sheared. I have managed to order a repair plug and will have it tomorrow. Just a case of splice and solder the wires together. (Sounds easy :))

Got the Coils (x4) for £70 and £19 for the plug. Hopefully this will sort out the bloody misfire before my 2000 mile Scotland trip the week after next.

Should I join the AA? :D
 
Why replace all four coils??

Be sure to keep the old ones and test with an ohmmeter, handy as spares. I've had two lower right hand coils fail in 9 years of 1200 ownership.
 
Pukmeister said:
Why replace all four coils??

Be sure to keep the old ones and test with an ohmmeter, handy as spares. I've had two lower right hand coils fail in 9 years of 1200 ownership.
Click to expand...

I got a good deal for 4 (£70). Saves messing about and I can sell the ones I don't need on, or keep them for when the next one fails.
 
Update - More help needed Please

I have in my possession the new coils and repair plug. (as pictured)

The repair plug is numbered 01, 02, 03.
The existing harness has blue/green, brown and black/yellow wires.

Does anyone have any knowledge of what goes where?

Any help gratefully received
Cheers Steve
 

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Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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