02 R1150R Electrical Problem

[abglenn]

Half way into my ride and losted power to head light, front and rear turn signals, horn, emergency flasher, instr. lights, and brake light. Pulled over and checked fuses, and relays. All appeared OK. Decided to head home and investigate problem in my shop. During return home everything started to work. Ah, the problem has gone away! Pulled over for a smoke (smoke for the children), fired up the old girl, and then the problem was back exactly as before. Would kindly appreciate any ideas from any of wonderful people.

[gregor]

Sounds like a damaged wiring loom caused by too tight cable ties at the steering head. Been mentioned many times here and sounds a pain to fix.
Others may advise on how to diagnose which wires have parted.

[sjbmw]

A member here had his wiring harness turn to flames and then to dust, and the story of the fix made me cringe.

A fried wiring harness can total the bike in costs.

Get the bike checked out by a BMW Pro immediately.

[Boxertwin02]

Sorry to hear about the harness. Same thing happened to me back in Nov '11, I had a complete wire loom meltdown caused by the zip ties rubbing through the wires and creating a short in the headlight which in NOT GROUNDED (why??????) After a few weeks of searching I found the front tail tells loom off Eb** and the main harness form Beemerbonyard. Yes, it was a major pain in the ass to re install the harness about 2 weeks at a few hours a day. You will have to completely disassemble the rear frame, battery tray and air box to remove and replace. I was able to wiggle many wires under the ABS unit so that made it a little easier. My biggest recommendation to to take LOTS of photos of the wires before, during disassembly, and label all the bolts/hardware as you remove. Also make sure all part numbers match for the harness and your bike, and do a very thorough inspection of the replacement harness

Its a lot of effort but in the end I saved huge bucks. BMW dealer quoted me around $1700 for harnesses and $2000 for labor. I got it done my self for $570 (used parts) and a lot of time.

Best of luck!

tell us how it goes

[abglenn]

Exchange made in fuse box with another same type relay, and found load relief relay dead. P/N 61.36-6 902 041. Order made, cost $20.00 dollars. Thanks to all with your advise. Answer found in BOA forum.

[DMM]

Great news, if that's all that it was. However, this might be a good time to clip the ties on your wiring harness under the triple tree. Otherwise, you may simply be delaying a much bigger problem.