If you could press that thumbs up button 👍🏻 I’d appreciate it, this one took some time and I had more issues with editing than I did with the wiring job!! No music on this one, thought I’d just let the work do the talking 😆 Thanks for watching, legends 👌🏻
There's a lot of wires on these pre canbus bikes! You've just done what I've been doing over the last few months re-building my old 1150. Re-taped the entire loom and replaced lengths of wire as needed. I learnt a lot about soldering while spending ages on this wiring🙂. Like you I was horrified how easily the old rubber sleeves just crumbled and the cracks in some of the wires. So annoying that BMW use so many different types of connectors. Looks like they just grab whatevers to hand when they build them.
There is, I regretted starting the task after about 10 mins 😆. It’s been a great project and it’s great to be part of something and sharing the same experience as people like yourself in keeping these bikes on the road 👌🏻, and it Sounds like you’ve been having fun with a soldering iron as well 😄👍🏻. I’m glad to know you think the same way about the sleeves and the connectors, it did baffle me how some were in a terrible state but others looked alright, and then the mix of connectors was just a bit odd… no standard types, just a mix to slow progress haha.. Very rewarding seeing how much better they look after some TLC and great to know I’m heading down the same route as other GS owners 👌🏻.
Just had this issue. Bike only has 20,000 miles. Water was getting into the three pin fuel pump connector when it rained and was shorting. Easy fix good to go.
Oh yes, I’m hoping that should be it now. I’ve pretty much give it the service it needs and hopefully dealt with the issue, so a bit of riding to be done on it now and then it’ll be time to start on the old project…… got to sort the garage though, it’s a right tip 😆
Hi Nicholas, thanks for a watching and taking the time to comment. That’s a nice bike! I’ve never seen one for real but they look lovely. It’s definitely worth looking to see if your wiring is cracked 👍🏻. My bike has worked well since I had the issue but it was advised in the comments that the cable will more than likely be the same closer to the sensor so I will be changing the sensor at some point, but not anytime soon 😄.
I started on my wiring harness after watching your video yesterday (thanks again). Two questions please: 1 - do you know what the clips are called that mount the cable connectors to that metal plate that holds all the connectors, two of these clips are broken and I’d like to find a replacement ( did look on Motorworks site). 2 - so maybe being a numpty but I undid that long bolt holding that metal plate and the frame struts to the main frame to get at the underneath of that plate to undo these cable connectors retaining clips. Trying to reassemble I am unable to line up the two struts again with the hole through the main frame / chassis to fit this plate back on a secure the two frame struts that run down holding the tank. Any input much appreciated. Slange Var.
Hello mate, sorry for the delay in reply, was rough yesterday so pretty much slept through the day. Unfortunately I have no idea what they’re called, was looking before I started the wiring just in case I broke one but could only find old harnesses for sale. I don’t know what to suggest with the plate, I was able to release the connectors from the top so didn’t take it off 😬. Have you had any luck with it since this post?
@@MALVSMACHINE Thanks for your reply mate. Managed to get two from Motorworks, not on their website though, had to call them and they only had a couple of 2nd hand. Slange Var
As a btw- regarding heat shrink, in case you are not aware, there are various shrink ratios available, e.g. 4:1 which in some cases prevents the need for cut & solder as the shrinkage is much greater allowing you to get over some connectors etc. Slange Var
Unfortunately my patience got the better of me, I wanted to buy a bigger size heat shrink but I was due to travel back to work in Oxford the next day, so would’ve had to order it and then wait a week to come back home and finish the job 😄…. Once I started cutting, I wish I’d waited the week 😆
Wiring was not BMW's finest achievement during this period, I suspect many owners have been tortured by this process? I never bother with (choke) it only raises the throttle via the cable junction box, far easier to just hold the throttle open a fraction to start them👍🏻 Well done.
Crazy stuff isn’t it, didn’t stand the test of time at all… makes me wonder how many people got rid of them because of issues to do with the wiring. Haha Funnily enough, I normally just pull the throttle and hold but I thought I’d make an effort being on camera and all…. But then reverted back to norm when I put everything back together where it’s meant to stay and held the throttle back 😆. Cheers mate, it’s been fun! I’m hoping to get out for a ride on it this weekend …. Have to sort the garage out as well, it’s an absolute tip and I need to work out a way to make some space 😆.
Great job Mal. I like the way you are very thorough going through everything. As I mentioned on one of your previous videos, I am right at this stage of doing the very same job so your video is very helpful, in particular that HAL sensor wiring. I am a bit skeptical to detach all these connectors as maybe not remember where they go back 😊 Loved hearing the bike firing up after all your hard work and holding thumbs I hear that music to my ears soon too. What did you do to reset the motronic unit. Thanks again mate for your great attitude and helpful videos. Slange Var
Thanks very much mate, it’s been one of those jobs that took a bit of time but was worth it for the results, and a job I wish I’d done a while ago haha. That’s awesome, I hope you breeze the job and have fun doing it. You’ll be fine with it all, slow and steady with some photos as backup and you’ll be hearing your beast singing again before you know it 👌🏻 For the Motronic reset, after reconnecting the battery - turn the key on, don't start the bike, twist the throttle full open and let go x2. Thanks for your kind words, Iechyd Da!
Take the plate off the inside of the tank what holds the fuel pump and filter on...Rewire it...Also the wires from the ignition switch perish new ones can be bought from motorworks...Then Change the Hall Sensor...
Hi Mark. It was indeed the HES wiring that was causing the issue here. I haven’t had a problem starting the bike since I completed this job. It seems that the cracked insulation that had a layer of dirt wasn’t drying out and was causing the fault. This seems to be quite common from what I read, and lined up with the fact that I didn’t have a problem during the dry weather, but when the wet weather set in, the issue was constant until repaired. If you’re thinking of doing this job, I recommend using larger clear heat-shrink so that you don’t have to cut the wires….. I got impatient and caused myself a lot of work 😄.
HAL sensors can't 'go bad'. They can fail due to shorts though. Kinda like a fuse only it isn't intentionally designed to fail. One could install an actual fuse near as possible to the engine and the fuse will blow and save the HAL sensor. Once it goes you know it's time to chase the wires.
fantastic wee job on the cleaning up the harness, something that needs done on mine seems to be falling off last time I had the tank off. how long would say it took redo wrapping the harness?
Thanks mate, was a long job overall but the bike starts so definitely worth it 😄. The wrapping didn’t really take long to do, I’d say around two hours including the bits that go with it like cutting the cable ties and unclipping everything, then putting it all back together. Take lots of photos from different angles so that you know what connector goes where 😄
the hall sensor wiring is damaged up to the sensor. If it is like this next to the connector, it will be much worse next to the sensor. BMW didn't put in temperature resistant cables. only 5cm of the cable that comes out of the sensor (which is from bosh) is made with a silicone coating. For the problem to be completely resolved, it is necessary to remove the sensor (before removing it, mark its position) and redo the entire cable up to the cables of the sensor itself. oh. one of the wires is only for insulation.
If you could press that thumbs up button 👍🏻 I’d appreciate it, this one took some time and I had more issues with editing than I did with the wiring job!! No music on this one, thought I’d just let the work do the talking 😆
Thanks for watching, legends 👌🏻
There's a lot of wires on these pre canbus bikes! You've just done what I've been doing over the last few months re-building my old 1150. Re-taped the entire loom and replaced lengths of wire as needed. I learnt a lot about soldering while spending ages on this wiring🙂. Like you I was horrified how easily the old rubber sleeves just crumbled and the cracks in some of the wires. So annoying that BMW use so many different types of connectors. Looks like they just grab whatevers to hand when they build them.
There is, I regretted starting the task after about 10 mins 😆.
It’s been a great project and it’s great to be part of something and sharing the same experience as people like yourself in keeping these bikes on the road 👌🏻, and it Sounds like you’ve been having fun with a soldering iron as well 😄👍🏻.
I’m glad to know you think the same way about the sleeves and the connectors, it did baffle me how some were in a terrible state but others looked alright, and then the mix of connectors was just a bit odd… no standard types, just a mix to slow progress haha..
Very rewarding seeing how much better they look after some TLC and great to know I’m heading down the same route as other GS owners 👌🏻.
Really in depth video. Great effort.
New drinking game…every time Mal says loom tape / heat shrink / connector …. You drink
I could not imagine the hangover 😆
Just had this issue. Bike only has 20,000 miles. Water was getting into the three pin fuel pump connector when it rained and was shorting. Easy fix good to go.
I’m glad you got it fixed easily, many more happy miles ahead on the beast ✊🏻
Another job bites the dust, onto the next 😀
Oh yes, I’m hoping that should be it now. I’ve pretty much give it the service it needs and hopefully dealt with the issue, so a bit of riding to be done on it now and then it’ll be time to start on the old project…… got to sort the garage though, it’s a right tip 😆
Good Video; I have a 2003 R1200CL (21 years old) with suspect wiring due to sporadic hard starting. You video definitely food for thought!
Hi Nicholas, thanks for a watching and taking the time to comment.
That’s a nice bike! I’ve never seen one for real but they look lovely.
It’s definitely worth looking to see if your wiring is cracked 👍🏻. My bike has worked well since I had the issue but it was advised in the comments that the cable will more than likely be the same closer to the sensor so I will be changing the sensor at some point, but not anytime soon 😄.
I started on my wiring harness after watching your video yesterday (thanks again). Two questions please: 1 - do you know what the clips are called that mount the cable connectors to that metal plate that holds all the connectors, two of these clips are broken and I’d like to find a replacement ( did look on Motorworks site). 2 - so maybe being a numpty but I undid that long bolt holding that metal plate and the frame struts to the main frame to get at the underneath of that plate to undo these cable connectors retaining clips. Trying to reassemble I am unable to line up the two struts again with the hole through the main frame / chassis to fit this plate back on a secure the two frame struts that run down holding the tank. Any input much appreciated. Slange Var.
Hello mate, sorry for the delay in reply, was rough yesterday so pretty much slept through the day.
Unfortunately I have no idea what they’re called, was looking before I started the wiring just in case I broke one but could only find old harnesses for sale.
I don’t know what to suggest with the plate, I was able to release the connectors from the top so didn’t take it off 😬. Have you had any luck with it since this post?
@@MALVSMACHINE Thanks for your reply mate. Managed to get two from Motorworks, not on their website though, had to call them and they only had a couple of 2nd hand. Slange Var
@@cinematictrax8443 mate, thats awesome! Top work fair play 👌🏻
As a btw- regarding heat shrink, in case you are not aware, there are various shrink ratios available, e.g. 4:1 which in some cases prevents the need for cut & solder as the shrinkage is much greater allowing you to get over some connectors etc. Slange Var
Unfortunately my patience got the better of me, I wanted to buy a bigger size heat shrink but I was due to travel back to work in Oxford the next day, so would’ve had to order it and then wait a week to come back home and finish the job 😄…. Once I started cutting, I wish I’d waited the week 😆
Wiring was not BMW's finest achievement during this period, I suspect many owners have been tortured by this process? I never bother with (choke) it only raises the throttle via the cable junction box, far easier to just hold the throttle open a fraction to start them👍🏻 Well done.
Crazy stuff isn’t it, didn’t stand the test of time at all… makes me wonder how many people got rid of them because of issues to do with the wiring.
Haha Funnily enough, I normally just pull the throttle and hold but I thought I’d make an effort being on camera and all…. But then reverted back to norm when I put everything back together where it’s meant to stay and held the throttle back 😆.
Cheers mate, it’s been fun! I’m hoping to get out for a ride on it this weekend …. Have to sort the garage out as well, it’s an absolute tip and I need to work out a way to make some space 😆.
@@MALVSMACHINE the 3 I’ve had all had wiring problems so I suspect your assumptions are spot on😎
Great job Mal. I like the way you are very thorough going through everything. As I mentioned on one of your previous videos, I am right at this stage of doing the very same job so your video is very helpful, in particular that HAL sensor wiring. I am a bit skeptical to detach all these connectors as maybe not remember where they go back 😊 Loved hearing the bike firing up after all your hard work and holding thumbs I hear that music to my ears soon too. What did you do to reset the motronic unit. Thanks again mate for your great attitude and helpful videos. Slange Var
Thanks very much mate, it’s been one of those jobs that took a bit of time but was worth it for the results, and a job I wish I’d done a while ago haha.
That’s awesome, I hope you breeze the job and have fun doing it. You’ll be fine with it all, slow and steady with some photos as backup and you’ll be hearing your beast singing again before you know it 👌🏻
For the Motronic reset, after reconnecting the battery - turn the key on, don't start the bike, twist the throttle full open and let go x2.
Thanks for your kind words, Iechyd Da!
My problem todate is that my injector solenoids are not opening to allow the pressurised fuel into the cylinders. Everything else seems to be OK.
Hi Stephen, that sounds really frustrating. I’m really curious as to what that could be as I can’t imagine both injectors failing at the same time.
Take the plate off the inside of the tank what holds the fuel pump and filter on...Rewire it...Also the wires from the ignition switch perish new ones can be bought from motorworks...Then Change the Hall Sensor...
Was the Hal sensor wiring the reason for it not starting?
Hi Mark. It was indeed the HES wiring that was causing the issue here.
I haven’t had a problem starting the bike since I completed this job.
It seems that the cracked insulation that had a layer of dirt wasn’t drying out and was causing the fault. This seems to be quite common from what I read, and lined up with the fact that I didn’t have a problem during the dry weather, but when the wet weather set in, the issue was constant until repaired.
If you’re thinking of doing this job, I recommend using larger clear heat-shrink so that you don’t have to cut the wires….. I got impatient and caused myself a lot of work 😄.
HAL sensors can't 'go bad'. They can fail due to shorts though. Kinda like a fuse only it isn't intentionally designed to fail. One could install an actual fuse near as possible to the engine and the fuse will blow and save the HAL sensor. Once it goes you know it's time to chase the wires.
fantastic wee job on the cleaning up the harness, something that needs done on mine seems to be falling off last time I had the tank off. how long would say it took redo wrapping the harness?
Thanks mate, was a long job overall but the bike starts so definitely worth it 😄.
The wrapping didn’t really take long to do, I’d say around two hours including the bits that go with it like cutting the cable ties and unclipping everything, then putting it all back together. Take lots of photos from different angles so that you know what connector goes where 😄
My hall sensor is also giving me issues
Check the connector mate, if the wiring is cracked then it could be the issue 👍🏻.
@@MALVSMACHINE thanks, I will do so.
Was the wiring your issue
the hall sensor wiring is damaged up to the sensor. If it is like this next to the connector, it will be much worse next to the sensor. BMW didn't put in temperature resistant cables. only 5cm of the cable that comes out of the sensor (which is from bosh) is made with a silicone coating. For the problem to be completely resolved, it is necessary to remove the sensor (before removing it, mark its position) and redo the entire cable up to the cables of the sensor itself. oh. one of the wires is only for insulation.
@@ridercosta6850 many thanks