How I repaired the instrument cluster main plug

[Jeff in W.C.]

With the main harnesses for the Monoshock bikes no longer available, we are left with only two options, repair or replace with a good used one. Finding a good used one is probably more hit and miss, since I don’t know of a quick way to test the harness before installation. The wire for the neutral light was broken in the main plug. I initially did this as a temporary repair, but now realize it’s probably more of a permanent fix. I would have taken more photos had I realized this wasn’t a temporary repair.

What I can say is that the plug is of poor design. The female connectors themselves have a collar at the deep end, which is supposed to keeps them in place. Since rubber is flexible, this unfortunately allows the connectors to move slightly while the wire is fixed rubber. With the wire fixed and the connector moving slightly, breaks are bound to occur. I don’t think this would be an issue if BMW had put each connector in a ridged metal frame. Anyway, I would make sure that both male and female connectors have plenty of dielectric grease.

What I did. I cut into the side of the plug and removed, somewhat carefully, a piece of the rubber, so I could glue it back on. Unfortunately, I wasn’t able to save any of the rubber closer to the affected connector. On the plus side, it’s relatively easy to reuse the connector. I re-routed the wire out the back, then spliced into the wire just south of the main plug. The neutral light is now bright and steady.

If I were to do this again, I might be temped to drill a hole on the back side, then push the affected connector out the back, this would damage the rubber portion of the plug less. The only downside to this approach could be drilling through a wire to a different connector. But, there wasn’t a wire directly behind the connector I cut out, so the risk is most likely minimal. The connector was deformed slightly while removing it, so it’s possible that pushing it out the back would cause less deformation, if at all.

Here are some photos of the repair.

[Chuey]

Cool, Jeff. Thanks for posting that. If it gives too much trouble, you could always convert one or more or all wires to spade connectors.

There are subtle differences from year to year. The bike I just set up seems to have a slight incompatibility between whichever year the wire harness is and the year of the instrument cluster.

I should be learning more about those rubber connector blocks when I do the final wiring on my Cafe Racer. My plan is to streamline the wire harness. The only function that remains from the original is the tach. I'd like to cull out all the rest of the wires. For those who are thinking I can't have charging if I don't use the charge lamp, mine has a dealie that eliminates the diode board and that function of the charge light and the voltage regulator.

Chuey

[Major Softie]

My favorite line in your post:

What I did. I cut into the side of the plug and removed, somewhat carefully,...

I'm still working on just how careful "somewhat carefully" is.

[Jeff in W.C.]

My favorite line in your post:

What I did. I cut into the side of the plug and removed, somewhat carefully,...

I'm still working on just how careful "somewhat carefully" is.

When I did the repair I thought I'd be replacing the harness with a new one, so I wasn't too careful with the ol' Exacto blade. As such, I ended up with a much smaller piece to put back than I would have hoped for. Oh well, c'est la vie.

BTW, my definition of "somewhat carefully" is something between haphazardly and carefully.

[Major Softie]

But, I'd have to guess that "somewhat haphazardly" is quite a bit less careful than "somewhat carefully."

[ME 109]

But, I'd have to guess that "somewhat haphazardly" is quite a bit less careful than "somewhat carefully."

A haphazard approach would be ok for indicator repairs.

Are you going for a ride Jeff?!

[Deleted User 62]

But, I'd have to guess that "somewhat haphazardly" is quite a bit less careful than "somewhat carefully."

A haphazard approach would be ok for indicator repairs.

In the field of electrical repairs I think "somewhat haphazardly" vs the haphazard approach would in general indicate a marked reduction in the possibility of electrocution in the former, whilst slightly less so in the latter... just szzzZZOUCH-sayin' !

[Jeff in W.C.]

Are you going for a ride Jeff?!

I wish. The weather has not been very cooperative. It's either been cold and rainy or 95+ degrees. Neither of which I prefer to ride in. The bikes overdue for some fluid changes, so it looks like my next day out with the bike will be a maintenance day. That is of course if my son (he's three) ever lets me. A few more years, and he'll want to be out there with me, but now he would rather I play with him in the sandbox, or at the park, etc.

[Major Softie]

I wish. The weather has not been very cooperative. It's either been cold and rainy or 95+ degrees. Neither of which I prefer to ride in. The bikes overdue for some fluid changes, so it looks like my next day out with the bike will be a maintenance day. That is of course if my son (he's three) ever lets me. A few more years, and he'll want to be out there with me, but now he would rather I play with him in the sandbox, or at the park, etc.

Let the kid play in the pan of drained oil (don't have it too hot). What boy wouldn't have a fantastic time getting that dirty?!

Just make sure he keeps his hands out of his mouth so that there's somewhat less chance of him being poisoned. The best part of this is, after the divorce, you probably won't even get joint custody, so you'll have lots of time for riding.

[ME 109]

Jeff, I thought your little fella would be about three by now.
You have shown top quality fatherhood in putting the young fella before motorcycling.
I have no such talent