Instrument Cluster and Headlamp wiring loom failure

46902 Views 136 Replies 53 Participants Last post by BayAreaJeff254, 2 d ago

dxamet

Discussion Starter · Jan 26, 2017 (Edited by Moderator)

This happened last week to my ninet, wire break.
14000 km. Tomorrow I go to the dealer.

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81 - 100 of 137 Posts

NineT

· #81 · Feb 10, 2020

NineT said:
The dealer fixed the wire (not the harness) on this occasion and placed corrugated tubing similar to the BMW OEM part 12 51 7 803 874 over the wires then wrapped it all with black electrical tape.

Just measured the corrugated tubing. It's not the BMW OEM part 12 51 7 803 874. The tubing used is more than 130mm in length that this BMW OEM wiring repair tube is. The one my dealer used is closer to 300mm+ in length.

I've got one more day before BMW Motorrad Australia are supposed to get back to me on this issue. Hopefully, they deliver.

Still wondering whether a BMW Service Bulletin went out regarding this issue and that a proper solution is available.

BaldyDave

· #82 · Feb 10, 2020

NineT said:
Still wondering whether a BMW Service Bulletin went out regarding this issue and that a proper solution is available.

Now I might be wrong here, but I seem to remember my dealer telling me that they had been made aware of the issue by BMW and got a Service Bulletin about the approved repair to the loom (with the corrugated sheathing). This was back in 2015-2016 I think.

Nabeel

· #83 · Jun 30, 2020

Thank you, thank you, thank you to everyone contributing to this thread. super helpful.

I was shocked riding home today when my dials went completely dead. the bike was still running, headlight and tail light still working. just my dash decided to take a nap. The on-off problem with my dials started happening this last month along with the ews warning. I had initially thought it was a battery issue as similar issues were reported with phantom dials in a different thread, a new battery fixed the issue. But my bike hadn't been struggling to start and the battery warning light hasn't come on either. The on-off dials started happening more frequently until finally today it went off for an extended period. checked the wiring when i got home, even went as far as lifting the tank and following the route of the cables when i found the kink. Happy i found the problem. Sad i hadn't found it by searching for it on here a little more first. could have saved myself some time and tears.

Did my repair before reading this thread. added some self adhering rubber tape around the cables to prevent them from kinking. stopped the kink but i slipped it back into the plastic clip keeping it against the frame making it a bit tight when i turn my wheel all the way to the left. close to left lock the dials go dead.

was hoping to avoid repairing the actual wire. But after reading this thread i feel fairly confident i can fix it without exploding the dials. will address this soon. Thanks again!

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Dan514

· #84 · Oct 21, 2020

I checked mine recently this summer.. same issue.. Video description via link

Nabeel

· #85 · Oct 23, 2020

Dan514 said:
I checked mine recently this summer.. same issue.. Video description via link

thankfully its an easy fix. it seems like one or two of the wires inside your loom has broken. in which case they would have to be repaired. I discovered all the wires in mine had broken at the kink. Took my time and repaired each wire. Also removed the cable tie at the steering neck to give the wire some slack. all good so far

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Tyyson

· #86 · Dec 17, 2020

Electrical Issue with my 2016's Dash

Hello everyone. Maybe you can help me figure out an electrical issue I am having with my 2016 9T. Each time I start it up and even while riding, the entire dash shuts off/goes blank, and kind of goes back through the start-up sequence. this doesnt affect the engine as the engine continues running without any hitch or hesitation. The problem seems to just be something affecting the dash. I feel it may be either the battery is at a point it needs replacing (bike only has 8300 miles on it) or there is a loose wire somewhere but I figured to ask you fine folks before I start digging around or running off to the dealer to spend $$$$ in case some of you had a similar situation. Any comments or advise?

gristle

· #87 · Dec 17, 2020

This, unfortunately, keeps coming up on these bikes. Some of the wiring, usually around the steering head, is failing from being flexed and stretched so many times.

Dealerships appear to be familiar with the failure and able to repair it quickly (affordable).

Tyyson

· #88 · Dec 17, 2020

gristle said:
This, unfortunately, keeps coming up on these bikes. Some of the wiring, usually around the steering head, is failing from being flexed and stretched so many times.

Dealerships appear to be familiar with the failure and able to repair it quickly (affordable).

Gristle - thanks much for the heads up and information. fingers crossed it wont be super expensive.

Captain

· #89 · Dec 17, 2020

@Tyyson I have moved your post to this existing thread on this very topic.
Please have a read back through the earlier discussions for some trouble-shooting ideas.

will55

· #90 · Jan 15, 2021

Hi. New here. Enjoying being part of a community of 9t lovers.

Quick question, should someone be able to help.

My gauge cluster went funky.
Checked and found the clip attached to the gauge wire had come off.
Attaching the clip to the gauge housing and moving the wheel fixed the issue.
Moving the wire alone didn't correct it, couldn't ID point of failure.
Found wire cover is split slightly at one point. Don't think enough for wire to be damaged.
Wondering if something had come loose, that can easily be reattached, or if
clip is a ground or something that needs to have a specific position on the housing (reaching, not knowing...) or if
wire needs replacing (read dealer will probably resolve it, but hoping to on own, can't wait out covid)

Any help is much appreciated.
Cheers

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will55

· #91 · Jan 15, 2021

will55 said:
Hi. New here. Enjoying being part of a community of 9t lovers.

Quick question, should someone be able to help.

My gauge cluster went funky.
Checked and found the clip attached to the gauge wire had come off.
Attaching the clip to the gauge housing and moving the wheel fixed the issue.
Moving the wire alone didn't correct it, couldn't ID point of failure.
Found wire cover is split slightly at one point. Don't think enough for wire to be damaged.
Wondering if something had come loose, that can easily be reattached, or if
clip is a ground or something that needs to have a specific position on the housing (reaching, not knowing...) or if
wire needs replacing (read dealer will probably resolve it, but hoping to on own, can't wait out covid)

Any help is much appreciated.
Cheers

Pls disregard ^^
Noticed "cracked sheathing" can also cause the issue, sad.
Thanks

will55

· #92 · Feb 7, 2021

dxamet said:
2 years after the repair, I had the same issue yesterday. Now I have opened the wiring loom myself. 1 repaired cable was broken again and 2 others were also almost broken. I have restored everything myself now. You do better yourself.

View attachment 125414

View attachment 125416

View attachment 125417

View attachment 125418

View attachment 125419

View attachment 125420

Hi. Thank you for the great pics. I’m a newbie to this stuff. Could I trouble you to provide the connection method, wire gauge and wrapping material please? Is it solder and heat shrink tubing, 16 gauge and self adhesive tape, respectively?

will55

· #93 · Feb 7, 2021

Hi! Anyone know what gauge wire is used?I’m attempting to fix mine, the twisted one in the attachment. And I only have a cm of wire to work with on one side, so any tips would be appreciated. I’m a newbie at this. Thanks

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Tyyson

· #94 · Feb 7, 2021

I ended up going to my local dealer and they repaired the broken wire and rewrapped the entire thing before i could take a look. the final wrapped version is bulkier but I'm not sure what it looks like inside...sorry.

Reactions: 1

will55

· #95 · Feb 7, 2021

Tyyson said:
I ended up going to my local dealer and they repaired the broken wire and rewrapped the entire thing before i could take a look. the final wrapped version is bulkier but I'm not sure what it looks like inside...sorry.

No probs. Thanks for letting me know. And good for you. Cheers

Tyyson

· #96 · Feb 8, 2021

Same to you....so far no probs since my repair

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dxamet

Discussion Starter · #97 · Feb 8, 2021

@will55
The first repair was done under warranty, 2 wires repaired with a kind of hard repair tube. This was broken again after a few years. Then I cut and extended all the wires myself. Well tied and with heat shrink tubing, not soldered. Soldering is possible, but with moving wires it is possible that it breaks again at that place.

will55

· #98 · Feb 8, 2021 (Edited)

dxamet said:
@will55
The first repair was done under warranty, 2 wires repaired with a kind of hard repair tube. This was broken again after a few years. Then I cut and extended all the wires myself. Well tied and with heat shrink tubing, not soldered. Soldering is possible, but with moving wires it is possible that it breaks again at that place.

For the final wrapping material, that goes around the wire bundle, do you have an opinion on what you chose (??) vs. wiring harness tape or the flexible tubing later R9Ts are now using, or was it just available and seemed good for the job?

And thank you for the tip on the soldering, it was my plan. Saved me a lot of time and hassle!

dxamet

Discussion Starter · #99 · Feb 8, 2021

For the final wrapping material, that goes around the wire bundle, I use this:

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will55

· #100 · Feb 8, 2021 (Edited)

will55 said:
For the final wrapping material, that goes around the wire bundle, do you have an opinion on what you chose (??) vs. wiring harness tape or the flexible tubing later R9Ts are now using?

And thank you for the tip on the soldering, it was my plan. Saved me a lot of time and hassle!

dxamet said:
For the final wrapping material, that goes around the wire bundle, I use this:
View attachment 140297

That's great. Thank you for all your help! And should the wiring be anything but 20 AWG, please let me know before I do something unfortunate.

PSA: To any Toronto area residents that run into this, feel free to hit me up, should have plenty of the materials left over.

Cheers all. Great community.

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