Wiring Harness Repairs

There are a couple of potential issues with the wiring harness on the F650GS which should be checked.

These issues are the subject of TSB's but too many machines have suffered damage as a result of the measures not being addressed or not completed properly by dealers when machines have been serviced. The first issue is shortness of the ignition switch wiring coupled with poor routing during assembly

The second issue is chafing of the wiring harness around the rear shock preload adjuster

In addition to the identified issues above, other chafing points have been found by individual owners. One point is behind the steering head on the RHS. It would be advisable to check the harness when servicing the machine and add self amalgamating tape where ever there are any signs of chafing.

There are differences in the wiring harnesses fitted to the early F650GS and Dakar models, part of the continuous improvement production system. These changes are not documented in the wiring diagrams. The production date of harnesses should be checked in any wiring harness replacement. There is also a difference in the ABS plug connections between the GS and Dakar on all the F650GS models. See the ABS page pdf files.

A pdf of the harness Part No's and known differences is here Wiring Harness pdf

There are Diode Relay wiring variations on 2000-01 harnesses 2000-2001 Diode Relay

The ignition switch on some machines was routed poorly during production and can be stretched on full lock. This can lead to stretching of the wiring and potentially shorted wiring. In some cases chafing of the harness can occur. There is a TSB covering this issue & dealers were to check it during pre delivery or servicing.

On models with hazard switch when fault finding remove the 2 hazard switch relays in the electrical box, The hazard system is an overlay to the indicator system which supplies power after the ignition is turned off. When the relays are removed the indicators operate as normal but with the 3 diodes in circuit, test the diodes, resolve any wiring issues then install the relays to test hazard operation.

The wiring harness can chafe on any rough surfaces of the rear of the shock absorber preload adjuster. There are a number of instances of wiring fires as a result of the chafing. One machine caught fire while parked in the street, another when parked at night in a camping ground and one when riding on a freeway. Others have encountered electrical faults which have been traced to chafing of the harness causing shorting of the wiring.

The chafing points are at the top and bottom of the adjuster bracket and further up at the engine mount.