Front lighting connector replacement/ repair needed 08RT

dougalls · May 21, 2015

I have been trying to install new horns (found a pair of used R1150RT horns) and a Signal Dynamics headlight modulator recently. Screwed up and cut the hot leads too close to the connector...now I need a new one but cannot for the life of me find the part number or a replacement.

Can anyone help?

IMG_0231 by dougalls2007, on Flickr

IMG_0229 by dougalls2007, on Flickr

This is the plug that goes into the back of the nacelle (?) it has ground/ highbeam/ lowbeam/ lowbeam/ r signal/ l signal

dbrick · May 21, 2015

I ran into a similar situation once and found that buried in the parts fiche are often several pages of connectors for this sort of repair. Take a look at this page from the fiche, particularly at the two panes titled "Repair Cable Main Cable Harness." There are a lot of connectors there; with some luck, the one you need will appear.

dougalls · May 22, 2015

Thanks Dave...saw that but no luck...part of my problem is I can't tell which numbers on the connector are the part numbers (i've tried searching for various assortments of the numbers on the connector) so I can't do what I thought would be the simple thing and simply look up then order the part. Maybe the dealer will know (that will be 567$ please...LOL).

rocketmanli · May 22, 2015

Most of these connectors are manufactured by either Tyco or AMP. I've had success with this company. Call them or shoot them a photo and see if they can locate it. I'm searching for pa66-gf30 but that might not be the entire part number.

http://www.mouser.com/teampconnectors/

If you can pull the top plug out with the cut wires and post a close up picture of both sides of it with all part numbers stamped, it will be much easier to find. The dealer will try to sell you the whole harness. Many times the connectors are available from electronic distributors, but not from the dealer. So don't look for a BMW part number, look for the AMP or Tyco number. Photos will help a lot. I found this out a few months ago when a couple of the black plastic H7 headlight bulb connectors cracked on my '09RT. I found the connectors for I think 40 cents a piece!

jayjay · May 22, 2015

I don't know that connector, but most of the ones on the bike that I've seen are standard pin or blade-type that you should be able to release from the housing using the special tool developed for that purpose. If you do end up cutting the rest of the wires you could extract the connectors, patch in jumpers to the wiring harness, and reinsert the connectors. A good electronics store should be able to help you with that.

Too bad about cutting the wires. Most of us can relate ...

JayJay

dougalls · May 22, 2015

Thanks MOAs! I think the photo shows all the numbers...this is the plug from the $1500 harness that you have to unplug to remove the front nacelle which contains the headlights. The PA66-GF30 is actually the type of plastic...that's the only number that pops up anything when I input it. I will check NAPA today for an appropriate connector.

Ya the mistake was mine for sure but the instructions from Signal Dynamics didn't make it clear that I was to cut the hot leads in "two"...I should have realized the lights didn't have power (the signals did though bec they weren't cut)...bah!

1084 Universal Harness Instructions -WEB.jpg

ponch1 · May 22, 2015

BMW sells them. You have to look at the fiche, but the connectors on the bike are sold individually as repair items.

http://www.maxbmwmotorcycles.com/fiche/DiagramsMain.aspx?vid=51560&rnd=04282014

Look under Electrical System, scroll down and then you should see two items for Repair Cable Main Harness.

We need a picture showing the pins side of the connector.

ponch1 · May 22, 2015

dbrick said:
I ran into a similar situation once and found that buried in the parts fiche are often several pages of connectors for this sort of repair. Take a look at this page from the fiche, particularly at the two panes titled "Repair Cable Main Cable Harness." There are a lot of connectors there; with some luck, the one you need will appear.

Sorry, I missed your post.

rocketmanli · May 22, 2015

Does the part with the PA66-GF30 unplug from the part labeled BMW 09 4016 01 61487 1? Or is it one contiguous piece? Hard to tell from the pics...Looks like a 6-pin plug, and I could only find 4 and smaller on the fiche. That's why I think you have to find the manufacturer of the plug itself. You know someone, somewhere built it, and you can be even more sure BMW won't tell you who. BTDT.

ponch1 · May 22, 2015

rocketmanli said:
Does the part with the PA66-GF30 unplug from the part labeled BMW 09 4016 01 61487 1? Or is it one contiguous piece? Hard to tell from the pics...Looks like a 6-pin plug, and I could only find 4 and smaller on the fiche. That's why I think you have to find the manufacturer of the plug itself. You know someone, somewhere built it, and you can be even more sure BMW won't tell you who. BTDT.

There are 4 and 8 pin connectors...It would be nice to see the business end of the male and female connectors.

rocketmanli · May 22, 2015

One other option. A while ago I needed a special part for my '09 RT. Couldn't find it anywhere. Figured RT-P's use the same parts as RT's. I found Ian Smyth from R.I.G.S. Motorsports:
http://rigsmotorsports.com/
who sourced me an exact match for what I needed from a totaled R1200RT-P. His prices are great, quick delivery, and is an all around nice guy. Highly recommend him for parts. He bought a load of decommissioned RT-P's and if you shoot him a picture of your plug, he might be willing to cut the end off one of his harnesses and leave you enough length of wire to re-solder it on to yours.

dougalls · May 22, 2015

Headlights plug by dougalls2007, on Flickr

That's the "male" part where the mangled female part plugs in.

Headlights plug by dougalls2007, on Flickr

Headlights plug by dougalls2007, on Flickr

NAPA= no clue
Cycle wrecker in town= no clue but has a 2000-2003 K12RS he can part out if its the same plug
BMW dealer (Endras)= no clue will send to BMW canada

dougalls · May 22, 2015

BTW the female end seems to be one piece.

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ponch1 · May 23, 2015

These people would know where to get it as they have the plug in their headlight modulator: http://kisantech.com/mag/index.php/pathblazer/p115w-a6.html

Contact them. It's worth a try.

dougalls · May 23, 2015

Thanks Ponch...I have messages in to BMW Canada, RIGs, this place http://whiteproducts.com, and I'll try your suggestion. Missed a week of near perfect riding weather here bec of my own ineptitude :-( oh well, I've had time for backrest, new horns, complete 100k service minus the final drive (guess that's my job today). Good thing it's a crappy calm warm and sunny Saturday here in the GTA...

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dougalls · May 25, 2015

This was the Kisantech reply:

We can make a 6 pin connector for you with 6 wire leads. The cost will be $29.99 plus $6.00 shipping. Let us know if you want to proceed.

So about $45 canadian.

Hopefully it won't be a month long project

Still nothing from BMW...they disappoint me more every day.

dougalls · May 25, 2015

BMW says: empty socket 7$ 11$ per wire x 6, $250 for crimping tools, no mention of plugs or actual connectors

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ponch1 · May 25, 2015

dougalls said:
This was the Kisantech reply:

We can make a 6 pin connector for you with 6 wire leads. The cost will be $29.99 plus $6.00 shipping. Let us know if you want to proceed.

So about $45 canadian.

Hopefully it won't be a month long project

Still nothing from BMW...they disappoint me more every day.

Sounds like a deal to me.

dougalls · May 25, 2015

Indeed ;-)

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dougalls · Jun 2, 2015

Still waiting on connector with pigtails from Kisantech...cleared customs should be here by friday latest (I paid $30 shipping on the $30 part hoping it would be quick...)

http://youtu.be/7orqGTmbOmY if u go to 1:40 you'll see the tools (pink and green--Good for different applications I guess) for repairing the connectors (~$25 at Princess Auto) http://www.princessauto.com/en/detail/2-pc-automotive-terminal-removal-tool-set/A-p8006462e not sue if the waterproof grommets, that are on many of the motorcycle connectors, will be salvageable, but I think I'll try while I have to wait for the part to arrive from Colorado. I'll let u know.

This is another youtube vid showing various connectors being poked and prodded with a similar tool...kinda wished I had found these earlier :-( https://youtu.be/-7oSpcL1jBY

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Front lighting connector replacement/ repair needed 08RT

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