Starting problems

[Rosbif]

Hello everyone.

Looking for some assistance with a new starting problem on my 2005 R850R (12,000kms only). First problem I've ever had with the bike - 100% reliable up to this morning.....

Went to start her up as usual - in neutral with side stand up. Ignition on, usual buzzes and ABS light flashing. Pull fast idle lever up and press starter button - nothing happened. Climbed off the bike and put it up onto the centre stand, tried again and this time it started but cut out after a few seconds.

Dropped it back off the centre stand, tried starting it again - nothing.

Pulled the fuse box cover and found the Motronic and fuel pump relays start clicking whenever I turn the handlebars from side to side with the ignition on. I also found the heated grips fuse had blown.

I swopped the horn and Motronic relays over and the clicking is still there.

Oh, and there is fuel in the tank....

Any ideas?

[NoRRmad]

I'm not sure if the 850 has the same trouble as the 1150, but the sensitivity to handlebar movement usually means that the wiring bundle around the headstock has some chafed wires in it, often due to too-tight zip ties in that area.

[snowprick]

Rosbif

Sounds as though you have a wiring problem in the area of your headstock. Carefully cut thru the zip ties on the headstock to release the wiring bundles there. Then try manipulating the liberated wire to find the faulty one. There are many posts in this forum about the BMW policy of over tightening the wire bundles on the bike. I think you will find the culprit around your headstock.

[Rosbif]

Wow! Thanks for the quick replies. Didn't think you guys in different time zones would be awake...

I'll give it a try and report back.

[snowprick]

As your bike is 2005 you probably still have a full covering of conduit over your wiring. Dont be shy to rip it off in your search for the problem. In a few more years it will fall off anyway. Once your problem is solved, re-protect the wiring and tie it back in place bearing in mind that it does not hold your bike together.

[Rosbif]

Rod

I've snipped the cable ties around the headstock (they were quite tight) and jiggled the loom around and now the relays no longer start clicking when I turn the bars. There are two thin cables (heated grips?) , one of which has a split in the outer sheath caused by one of the ties, though I can't see that the inner wires are exposed causing the fuse to blow.

However, pressing the starter button no longer has any effect....

Time to start stripping the conduit, I suppose.

[owldaddy]

After all the years that this has been a known problem, one would think BMW would make a change in the way they secure these wire looms. They could even save a few pennies by using fewer wire ties.

[Rosbif]

Found the problem....!

Started stripping the conduit down by the headstock at the same location as the split sheath on the heated grip cable and found breaks in two tiny wires in the loom from the handlebars. They had probably become kinked, and when I'd removed the ties and manipulated the loom, they must have parted. According to a wiring diagram I found through a link posted on another thread, they appear to be the feeds from the starter switch to the starter relay and fuel pump. Explains the cutting out when turning the bars previously and the subsequent non-operation of the starter switch.

So, I've soldered up a couple of short wire bridges, and hey presto, she now starts and runs fine.

Now to dream up a more permanent repair....

Much obliged for all your help.