DaveH
Registered user
The brake failure I had on holiday was terminal as I expected - fried circuit board in the ABS ECU.
Yesterday I performed a 'servoectomy' and have decided to post the procedures in case it helps anyone else in a similar situation.
The servo removal and reconnection of pipework and electrics was carried out using existing parts only - it has cost me absolutely nothing apart from time and a few consumables.
Start with removal of the servo system itself together with redundant metal pipework - been documented on here numerous times and is relatively straightforward.
Reconnect the rear brake hose directly to the top of the master cylinder using the domed hex head brake fitting
Remove both flexible hoses and both rigid metal pipes from the front distribution piece,
Remove distribution piece - you will notice a small 'tag' on the reverse which locates against the frame and effectively fixes the orientation of the bracket.
By grinding/filing off this tag it is possible to realign the distribution piece as per the attached photograph and connect the two flexible hoses together using the existing connectors in the top metal socket (the one with two holes the same size).
That's the brakes reconnected - now bleed and sort the electrics to give you a brake and tail light again.
This is a piece of proverbial despite what others may have written about it - you dont even need any extra parts !!
1) Remove the blue ABS relay from the fusebox. This will extinguish the 'Brake Failure' warning light on the dash and as a bonus can be used to operate the brake light !! (no need for new switches as in other methods )
2) Strip back the sheathing from the ABS multi pin connector - identify wires and connect as follows
a) Grey/White wire (tail light feed) Grey/Black wire (12v feed) cut both and join together - thats your tail light sorted.
b) White/Yellow wire (front brake switch) and Yellow/Green wire (rear brake switch). Cut these two wires and join them to link brake switches
Now the wiring to the redundant 4 pin ABS relay
c) Pin 1 - Connect white/blue wire
d) Pin 2 - connect the THIN solid brown wire in the loom to provide a ground ( careful here - there are several brown wires c/w coloured traces and a Thick brown wire)
e) Pin 3 - Find the Yellow/Black wire and the solid green wire. Cut and connect these together and then to pin 3 of the relay
f) Pin 4 - Connect grey/yellow (tail light feed) to this pin
That all there is to it - you now have working brakes and lights.
I tidied things up by cutting and isolating all remaing wires on the ABS plug.
I have located the relay on the back of the battery under the seat so it can easily be changed if needed,
May consider fitteng some braided steel lines in due course, but for now, the bike is up and running, without any cost or waiting for parts - this may just help someone 'in the field' in the future
Dave H
::.Edit.::
Alternative less invasive method is available with Pictures @ post 195 here
Yesterday I performed a 'servoectomy' and have decided to post the procedures in case it helps anyone else in a similar situation.
The servo removal and reconnection of pipework and electrics was carried out using existing parts only - it has cost me absolutely nothing apart from time and a few consumables.
Start with removal of the servo system itself together with redundant metal pipework - been documented on here numerous times and is relatively straightforward.
Reconnect the rear brake hose directly to the top of the master cylinder using the domed hex head brake fitting
Remove both flexible hoses and both rigid metal pipes from the front distribution piece,
Remove distribution piece - you will notice a small 'tag' on the reverse which locates against the frame and effectively fixes the orientation of the bracket.
By grinding/filing off this tag it is possible to realign the distribution piece as per the attached photograph and connect the two flexible hoses together using the existing connectors in the top metal socket (the one with two holes the same size).
That's the brakes reconnected - now bleed and sort the electrics to give you a brake and tail light again.
This is a piece of proverbial despite what others may have written about it - you dont even need any extra parts !!
1) Remove the blue ABS relay from the fusebox. This will extinguish the 'Brake Failure' warning light on the dash and as a bonus can be used to operate the brake light !! (no need for new switches as in other methods )
2) Strip back the sheathing from the ABS multi pin connector - identify wires and connect as follows
a) Grey/White wire (tail light feed) Grey/Black wire (12v feed) cut both and join together - thats your tail light sorted.
b) White/Yellow wire (front brake switch) and Yellow/Green wire (rear brake switch). Cut these two wires and join them to link brake switches
Now the wiring to the redundant 4 pin ABS relay
c) Pin 1 - Connect white/blue wire
d) Pin 2 - connect the THIN solid brown wire in the loom to provide a ground ( careful here - there are several brown wires c/w coloured traces and a Thick brown wire)
e) Pin 3 - Find the Yellow/Black wire and the solid green wire. Cut and connect these together and then to pin 3 of the relay
f) Pin 4 - Connect grey/yellow (tail light feed) to this pin
That all there is to it - you now have working brakes and lights.
I tidied things up by cutting and isolating all remaing wires on the ABS plug.
I have located the relay on the back of the battery under the seat so it can easily be changed if needed,
May consider fitteng some braided steel lines in due course, but for now, the bike is up and running, without any cost or waiting for parts - this may just help someone 'in the field' in the future
Dave H
::.Edit.::
Alternative less invasive method is available with Pictures @ post 195 here
would there be any insurance implacations from doing this?
