Wiring harness/instrument cluster

So, I'm trying to solve my intermittent neutral light. Symptoms I've noticed: light flickers while bike idling, goes off and on (when it should be on), turning the handle bars can sometimes effect the light, and while moving the main wiring harness at the main plug at the instrument cluster ever so slightly-the neutral light goes on and off. I've determined that the harness is good with a digital multimeter (DMM). So, I bench tested the instrument cluster (with a spare motorcycle a battery and alligator clips) and determined the light socket/circuit board was not working properly. Since many people have complained about this weak link in the cluster, and my lack of time to find repair solution, I ordered a new one. The lights in the Instrument cluster work great now; however, I was not pleased to find my problem still persists. At first I was baffled--most likely due to my frustration that I hadn't solved problem. I double checked the wiring harness using a DMM and it checked out good again. I bench tested the instrument cluster, as I did previously, and it works fine. I double checked the bulb holders and sockets, and everything is good. I swapped bulbs from one without the problem and that did not help. So, this leads me to one probable cause, one of the female connectors in the main wiring harness plug is too big, but I can't quite figure out how to compress them slightly for a better fit. Too much and I may destroy the plug let alone possibly having trouble removing the plug. Anybody have a good suggestion here?

Wiring Harness . . . .

I think the plugs on the harness are female where they enter the cluster. I had a similar situation. The cluster connections are s/s and the harness are alum. The cluster recepticles are slit so they could be tightened up a little or there could be a broken solder connection. Make sure you lubricate the connections with dielectric grease. The harness is over $330. and a few hours to replace.
Good Luck!
Campbell Tellman II
'93 R100RT
'11 S1000RR

Did you ever get this sorted out? Was it a break in the wiring harness under the steering head?

tvrla said:

Did you ever get this sorted out? Was it a break in the wiring harness under the steering head?

Click to expand...

I posted a new thread on how I repaired it, but I didn't post an answer here. Sorry. It was the plug. The answer can be found here

http://forums.bmwmoa.org/showthread.php?t=54183&highlight=how+if+fixed

Interesting solution! I've replaced the plug with a good used one to handle a similar problem, but your idea seems much simpler. I like the idea of drilling a hole through to the back side - and silicone seal would probably be enough to seal and retain it.