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Thread: Wire tap repair

  1. #1
    Registered User
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    Sep 2019
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    Tumwater, WA
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    Wire tap repair

    I'm fully committed to upgrading my newly acquired '99' R1100RT I've named Licorice 'Twist', and have in process the left cam chain tensioner update, HES rewire and fuel quick-disconnects. Disassembling the rear lights I found multiple wire taps used to attach a Kisan Vectralight. Removing the parasitic wires I discovered one tap severed a directional lead entirely and THREE of the remaining taps broke at least one of the original nine tiny strands in the OEM loom! My remedy was to remove the taps, splice in and solder new leads to each conductor and renew the terminal ends with readily available spade connectors. The task was pretty straight forward, simple and electrically sound! Then I got to looking at how the fuel management module was wired into the throttle body wires. (see photo) A Remus muffler and a Techluison fuel management module had been installed and the O2 sensor removed! What stopped me from proceeding with the same 'fix' to eliminate the worrysome wire tap was my inability to remove the electrical plug from the conductors to the throttle body, strip back the OEM lead, solder in the management module and seal with shrink seal. How would you accomplish this task?
    Attached Images Attached Images
    '99' R1100RT
    Licorice 'Twist'

  2. #2
    A simple and easy way to make the repairs that you desire is to use Posi-Lock devices and some Silicone tape. These items are readily available. Links and photos below -

    https://www.amazon.com/Posi-lock-Con.../dp/B004D0FEMM

    https://www.amazon.com/Inavis-Silico...ustrial&sr=1-5
    https://www.amazon.com/XFasten-Silic...ustrial&sr=1-3

    312bOA6QuPL.jpg41vbpAWmpDL.jpg61DR1yrgVSL._SL1500_.jpg

  3. #3
    Pepperfool GSAddict's Avatar
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    Feb 2008
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    Sechelt, British Columbia
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    3,126
    Unplug from the injector an you will see a space where you can insert a jewelers screwdriver to release a little tab on each socket.
    The socket/seal will pull out from behind.

    Edit: I have some extra new pin sockets if you need a couple.
    PM me
    Attached Images Attached Images
    Last edited by GSAddict; 01-04-2020 at 05:56 PM.
    '
    Ufda happens..........

    Need your R11xx Hall sensor rewired? PM me.

  4. #4
    Registered User
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    Jan 2017
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    Grandville Mi
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    You can also buy a new plug that comes with leads, connectors, and shrink tube from BMW. Part number 83 30 0 402 339. I bought a similar plug for one of my stick coils few years back. When done the repair is like factory.

  5. #5
    Registered User
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    Sep 2019
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    Tumwater, WA
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    Pins extracted successfully!

    Thank you all for your help! Reto, (GSAddict) with pictures of the pins outside the plug body showed me my pin extractor I made twenty years ago was working properly. The difficulty I was experiencing was the hardened and stuck 1999 moisture seal on the wire as it exits the plug. Watching a Chris Harris You Tube segment where he squirts denatured alcohol onto a stubborn intake manifold to loosen it prompted me to apply the same technique to these moisture seals! I worked beautifully and in short order! Now I've successfully extracted the pins I'll remove the destructive wire taps and splice in, solder and seal with heat-shrink making a proper electrical connection! I promise 'after' pictures in this thread to complete the story for anyone thinking of similar work.
    Attached Images Attached Images
    '99' R1100RT
    Licorice 'Twist'

  6. #6
    Left Coast Rider
    Join Date
    Nov 2011
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    Vancouver, British Columbia, Canada
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    3,339
    While many of us lack the ability or desire to get deeply into motorcycle repairs I, for one, immensely enjoy these question/answer/solution/positive result threads.

    Just sayin '.
    Last edited by BC1100S; 01-06-2020 at 12:03 AM.

  7. #7
    Registered User
    Join Date
    Sep 2019
    Location
    Tumwater, WA
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    7

    Wire tap repair

    After carefully removing the offending wire taps it took patience and time to strip the insulation without incurring any further damage. (Had to buy a LOT of new nylon tie-wraps just because I've cut a number of them getting to the wiring looms!) In the end I've a little cleaner install of the Fuel Management wiring.
    Attached Images Attached Images
    '99' R1100RT
    Licorice 'Twist'

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