"brake failure" warning after full bleed.

Smiffypr said:
I'm not chasing a red herring, I'm trying to find a solution which will keep the ABS. From what I can gather, there isn't a way of dumping the servo function but keeping the ABS, so I would ideally like to fix the system which has managed to work for 16 years, but failed because the fluid hadn't been changed.
As the rear servo motor runs, but it doesn't generate pressure, (or change it's tone when there is pressure in the system) it seems very likely that the motor and pump are disconnected. That's got to be easy to fix.I've got a lathe and mill if I need to make anything, but I don't want to spent thousands or loose the ABS.
Click to expand...

You need to plug in the diagnostics and have the fault codes read.

There are two integral filters in the pump, one for front another for rear, i posted up about 15 years ago where i had success in removing them on a failed unit, cleaning and replacing, the servo/abs modulator worked perfectly. I posted a picture of the filter, it's location and how to remove it.
I thought i'd solved the continual problem of the units, but it was luck, tried it a on quite a few since and it might work on 1 in 20.

I had a german specialist who was going to recondition the units take away about 25-30 units i'd removed.
He found the main cause of the problem - apparently two discs which spin at huge speed and need a very precise microscopic gap between them, they wear and the gap increases and the pressure isn't constant ( that's roughly what i think he said, it was at least 10 years ago and he spoke very bad english).

It was fixable, but to be able to retail the units in Germany required him to put the units through a TUV test, at great expense, and then he had to offer a guarantee, and due to the design faults in the unit meant a high turnover of replacements, making the whole exercise not financially viable.

I've got about 40 units sitting here, later today i'll get some pictures of removing the filters etc and post them up. be quicker than trying to find the old pictures somewhere on my hard drive
 
ecutesting,com have replied saying "We have seen these in before however unfortunately with the parts they contain, we have had to discontinue the repairs on these units due to the replacement parts no longer being commercially available."

Looks like cleaning mine myself is the only option other than a servo bypass.
 
That's very informative. I suspect that the pump rotor or housing on mine is worn or corroded. I expect that I will need to find a replacement pump from a unit where. like mine, one has failed but the other one is still okay.

Anyone got one they want to sell?
 
Im in the same situation as you with My K1200s which is a 2005 and has the same system.. Smiffypr I feel your pain my 1200 hundred is ultra low millage and Ive just sold it to a mate and it has gone wrong. My pump is off the bike and apart and with a mate of mine who is a BMW Tec but it aint looking good... Looking at what Steptoe and Drfarkoff says its no ABS or 2 grand to fix it....
 
petevito2 said:
Im in the same situation as you with My K1200s which is a 2005 and has the same system.. Smiffypr I feel your pain my 1200 hundred is ultra low millage and Ive just sold it to a mate and it has gone wrong. My pump is off the bike and apart and with a mate of mine who is a BMW Tec but it aint looking good... Looking at what Steptoe and Drfarkoff says its no ABS or 2 grand to fix it....
Click to expand...

Indeed Yes it is a case of not IF a system fails it is When

I am surprised the yanks did not have BMW trailed into court with regard to this bit of junk

And to be honest I suspect somewhere along the way there have been deaths associated with failures!!
 
petevito2 said:
Im in the same situation as you with My K1200s which is a 2005 and has the same system.. Smiffypr I feel your pain my 1200 hundred is ultra low millage and Ive just sold it to a mate and it has gone wrong. My pump is off the bike and apart and with a mate of mine who is a BMW Tec but it aint looking good... Looking at what Steptoe and Drfarkoff says its no ABS or 2 grand to fix it....
Click to expand...

Not looking good could mean full of crud, full of metal grindings, broken parts that are not available, or other reasons. Watching that video, the pump concerned had probably been apart before in practice for making the video, so it looked clean, it also showed no broken parts (so I don't know why it was being taken apart). The only thing that looked dodgy was the fact that the roller pump appeared to have a metal rotor and rollers in a ceramic housing. That seems like a recipe for wear, single lever taps (that move at a fraction of the speed) have ceramic parts moving over ceramic parts. Petevito2, ask your mate what exactly is the problem.

Anyone else, I'm still hopeful that if someone has a broken unit I can use parts from that to repair mine.
 
You'd get on well with my mate.... He says it like it is too... :beerjug:
 
Smiffypr said:
Anyone else, I'm still hopeful that if someone has a broken unit I can use parts from that to repair mine.
Click to expand...


Smiffy You could pull the electronics off the pump and seal them up and refit to the bike and repipe the brakes using the standard parts

That would allow you to strip your own unit down and repair at your leisure?
 
Good news, the bike passed the MoT with the brakes as they are now (no assistance to rear) with the Blackpool illuminations. The tester said that a car would have failed because of the warnings.

I've got the unit off the bike, front mounting screw sheared, and one of the rubber mounts is torn of it's base.

The filter for the rear calliper was, as expected, very dirty.

Next issue is the 5 point socket screw with security pin, anyone know what the official name for them is? I thought I had all the screw bits going, but no five point ones.

And, I'm still looking for a scrap unit to cannibalise for parts.
 
Smiffypr said:
Good news, the bike passed the MoT with the brakes as they are now (no assistance to rear) with the Blackpool illuminations. The tester said that a car would have failed because of the warnings.

I've got the unit off the bike, front mounting screw sheared, and one of the rubber mounts is torn of it's base.

The filter for the rear calliper was, as expected, very dirty.

Next issue is the 5 point socket screw with security pin, anyone know what the official name for them is? I thought I had all the screw bits going, but no five point ones.

And, I'm still looking for a scrap unit to cannibalise for parts.
Click to expand...

As much as I dislike Amazon. I shall share a link from the tax avoiding bastards

https://www.amazon.co.uk/Silverhill-Point-Tamper-Proof-Piece/dp/B002P4YCGM
 
Steptoe said:
I've got about 40 units sitting here, later today i'll get some pictures of removing the filters etc and post them up. be quicker than trying to find the old pictures somewhere on my hard drive
Click to expand...

Steptoe, as you may have seen, I now have the module out and have taken one filter out, so no need for more pictures, but as you have lots of failed units, would you consider selling one to me. Smiffy
 
Took the unit apart today and as expected the rear pump is a mess. There is corrosion on the side plate, the rotor was probably seized so that when the motor ran the rotor broke (the motor shaft has a flat on it). All I need is a scrap unit with a usable pump.
 

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Steptoe might not read all of this thread, so might miss you plea for a used pump.

Why don’t you send him a PM.
 
It’s been a while now…………….

Have you managed to successfully repair your failed servo unit ?
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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