12/1/21, 10:04 AM

61 01 07_SERVICE ACTION: Check of EWS Wiring Harness - Bulletin 61 001 07 (001)

SIB 61 01 07
2021-11-30
SERVICE ACTION: Check of EWS Wiring Harness - Bulletin 61 001 07
(001)
This Service Information Bulletin replaces SI 61 001 07 (001) dated January 2007.
The contents of this bulletin have not changed; bulletin numbering was updated.
MODEL
This document applies to the following Motorrad AG models: 0597
This document applies to the following Motorrad model descriptions: K 1200 GT US
This document applies to the following Motorrad series: K44
SITUATION
This document is applies to the following categories: General Electrical Systems
Supporting Materials
picture_as_pdf 61 001 07 (001) - K1200GT cable routing of EWS ring.pdf

Copyright ©2021 MOTORRAD USA, a division of BMW of North America, LLC. All Rights Reserved
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Dealer Operation/ SalesGeneral Manager Motorcycles
Date: January 2007
Bulletin #: 61 001 07 (001)

Sales Business Manager
Used Motorcycles
(F&I)
Source: 61 60/2006
BMW Motorrad USA
Service and Technical

Service

Parts & Accessories Administration

BMW Motorrad
Service Information Bulletin

**Technical Campaign**
Subject:
Model:
Details:

Check of cable routing to the EWS ring antenna
K 1200 GT (K44)
There is a possibility of the "EWS" (electronic immobilizer) error message being
displayed in the instrument cluster of the K 1200 GT (K44). If this occurs the
engine will not start.
The problem can be caused by a broken wire at the plug connection of the ring
antenna. If the wiring harness is not correctly routed, the wiring can chafe
against the plug connection when the handlebars are turned from side to side,
and eventually break. (Photo. 1)

Photo 1

Production
Solution:
Motorcycles
Affected:

As of VIN ZN45643 cable routing has been corrected.
The VIN range of potentially affected motorcycles is the following:
ZN45000 to ZN45642
In order to determine if a specific motorcycle is affected by this Recall
Campaign, it will be necessary to verify all motorcycle VINs through a DCS
Vehicle History Check. Based on the response of the system, either proceed with the repair or take no further action.

© 2007, BMW of North America, LLC
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Aftersales
Solution:

Check all affected K 1200 GT (K44) motorcycles to determine whether the
wiring harness routing is correct:
Prerequisites for checking the cable routing:
1. Make sure that the handlebars are set to the highest position of their
range of adjustment.
2. Cable tie (1) must be positioned approx. 20 mm in front of metal retainer
(2) (Photo 2).

Photo 2

Checking the wiring harness routing:
1. Turn the handlebars all the way to the left and right and make sure there is no
strain on the wiring at the plug connection of the EWS ring antenna.
2. If the wiring is too short, disconnect the plug from the EWS ring antenna and
check for signs of chafing (see photo 3)

Photo 3

3. If the wiring is free of chafing and is in good condition, proceed as follows.
If the wiring has suffered damage from chafing go to step # 4.
Wiring is free of chafing:
- Open cable clip (#1) and cable tie (#2). (photo 4)
- Pull the cable slightly forward, to create more slack.
- Close the cable clip and install a new cable tie. (see photo 2)

Photo 4
© 2007, BMW of North America, LLC
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61 001 07 (001)

4. If the wiring shows signs of chafing, replace the cable/plug in question:
Note: Refer to Bulletin 61 002 06 (013) for repair information. Wiring
Harness repairs are only to be performed by technicians that have completed MT035 - Electronic Systems. The use of proper tools are essential
in performing these repairs correctly.
- Review wiring harness repair (K4x RepROM 3rd Edition, section 61)
- Remove the right side panel (K4x RepROM 3rd Edition, section 46)
- Remove the bracket for the ZFE control unit and the intake air pipe.
- Open the cable ties and cable clips as necessary to expose the wiring
to the ring antenna. (refer to photo 4)
- Cut through one of the twisted signal wires.
- Cut through the second signal wire offset from the first cut.(photo 5 and 7)

Photo 5

- Fully untwist the two signal wires.
- Cut through the remaining wires, making sure all the cuts are offset from
each other.
- Cut the wires of the repair plug to length to match those of the original
plug. (photo 6)

Photo 6

- Important: Begin by pushing the shrink-on hose onto the wire. Make
sure that the wires are correctly paired. Crimp the push-in connectors
from the repair kit onto the two signal wires.
- Twist the two signal wires around each other.
- Crimp the connectors onto the remaining wires.
- The push-in connectors should all be located along the length of wire
from the point of separation from the main wiring harness and the first
cable clip. (photo 7)

© 2007, BMW of North America, LLC
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61 001 07 (001)

Note: Location of connectors are offset from
each other.

Photo 7

- Wrap the length of cable, using only the fabric-reinforced tape,
part number 83 30 0 402 345. (photo 8)

Photo 8

- Correctly re-route the cable. (photo 2)
- reinstall all components.
Warranty:
Warranty
Information:

Covered under the terms of the New Motorcycle Limited Warranty.
Reimbursement for this Technical Campaign will be via normal claim entry utilizing the following information:
Defect Code: 00 00 61 09 00
FRU Code: 00 60 151 Checking/replacing plug of ring aerial
FRU: 6
Part Numbers: 83 30 0 402 337 - repair plug (4 - pole)
The cost of the parts are to be processed under Sublet Code 4.

© 2007, BMW of North America, LLC
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61 001 07 (001)