ABS toast?

[Tsiklonaut]

Well well, looks like after 160 000 miles one of the modulator pump motors is now always running, even if I switch off the ignition and the bike's completely dead it still buzzes on loud beneth the fueltank

Had to take off the battery connection when I stopped, otherwise it'd probably drain the battery.

Of course it happened in the middle of nowhere and I just hoped it doesn't catch fire on overheating and doesn't burn down the bike.

ABS reset didn't help, so I reckon it's a hardware issue. Some hydraulic pressure valve maybe? Or air in the system?

Anyone had similar issues with ABSII (1100/850/early 1150?), any idea if it can be repaired? Or do you reckon it's better to fleaBay a complete new s/h ABS unit?

 

[Timolgra]

Couldn't you have simply pulled the relay or fuse?

Think I would just bypass the abs unit but after that many miles you may miss the security in the back of your mind with abs.

 

[Tsiklonaut]

I was on the road and I did pulled that "tick-tocking" ABS relay that I could identify, but the thing still buzzed on, even if I pulled all the bloody fuses. Maybe it was some other relay, but I don't have the relays marked and I needed to long-ride back home.

Got to check the wiring schematic where the modulators get their power so next time I know where to cut off their power source

 

[Timolgra]

Someone my be able to provide the link to a diagram of the fuses and relays which you can print off, laminate and it's a perfect fit under the fuse lid......a bit late now if you've never needed it after all that travelling

 

[Steptoe]

You need to pull the relay in the actual abs unit. It's under the black plastic cover on the R/H side of the unit.

 

[Tsiklonaut]

You need to pull the relay in the actual abs unit. It's under the black plastic cover on the R/H side of the unit.

Yep, that sounds about right since there was no forkin' way to disconnect that bloody ABS from the fuse box.

And I though I'll never have problems with that ancient ABS

Cheers,
Margus

 

[~Stef~]

Happened to me on my 1100GS in the middle of nowhere Northern Ireland had to disconnect the pump electrics. Got the bike back home threw the pump in the bin and fitted braided lines, saved a load of weight on that

 

[Puffin]

We have just junked all the ABS system off a friends 1100GS due to the same problem. I was surprised how heavy the unit was, but what to do with all the space you are suddenly left with ??

 

[~Stef~]

We have just junked all the ABS system off a friends 1100GS due to the same problem. I was surprised how heavy the unit was, but what to do with all the space you are suddenly left with ??

I eventually fitted a Solalarm in mine, I'm sure Den put a small tyre compressor in the space on his bike for inflating his camping matt

 

[Tsiklonaut]

The weight & it's also been annoying sometimes, i.e. gravel riding since it's a fuss to switch it off on 1100 but the thing has saved me dozens of times already, mostly on rainy days from certain crashing situations vs if there wasn't any ABS. So I reckon I'll try to repair or replace it...

 

[Puffin]

The weight & it's also been annoying sometimes, i.e. gravel riding since it's a fuss to switch it off on 1100 but the thing has saved me dozens of times already, mostly on rainy days from certain crashing situations vs if there wasn't any ABS. So I reckon I'll try to repair or replace it...

Yes the ABS switching off is an anoyance, when you need it off your allready riding.......... Has anyone wired it as to be switchable while riding ?
and let us know how you get on with repairing your unit

 

[~Stef~]

My memory not being what it was (or ever was) I did have a spare pump in the garage, but I think I might have sold it on ebay

I'll have a dig about

 

[Fanum]

We have just junked all the ABS system off a friends 1100GS due to the same problem. I was surprised how heavy the unit was, but what to do with all the space you are suddenly left with ??

Second battery and a mini split charge relay

 

[Puffin]

Second battery and a mini split charge relay

My thought was a battery too i have a car one on my Airhead

I eventually fitted a Solalarm in mine, I'm sure Den put a small tyre compressor in the space on his bike for inflating his camping matt

plenty of options really it is a large area to fill

 

[~Stef~]

My thought was a battery too i have a car one on my Airhead

plenty of options really it is a large area to fill

Too big a space to waste

Pump unit must weigh about 10kg

 

[Tsiklonaut]

So just today I saved me a good £100 on a s&h ABSII unit - I decided to have a decent look myself and somewhat to my own surprise I fixed it - it was easier than I thought.

So if anyone else has similar problem here's the drill:

The piston chamers are fairly tighty locked but they come loose with some decent torque.

once open then with some magnet you pull out the balls that are on top - they're tiny so don't lose them.





Then pull out the piston with some soft rubber-ended tool (by grabbing it with an angle from the inside and then pulling up) or with a strong magnet tool. And after this with small snappers pull out the long piston rods. Try to feel how they move with back-forth or how "sticky" are they - I think this is what created my problems - they were a little rough, since the pistons probably got stuck somewhere so the modulator motor kept running to keep the pressure up.

This is how all the details look like - the bottom one are i the correct order (the small ball goes between upper bleeder cap and piston)

This is how the piston bores look like - the bigger one is for the front brake so you can't mix them up.




Clean the bottoms of the holes with some soft-edged long screwdriver and cloth attached - mine had some metal dirt there (don't scratch the vertical surfaces while doing this though - the pressure pistons need to work in those scratch-free surfaces with their rubber seals)

Clean and lube (with brake-oil) the pistons and rods before putting them back. Note the recession hole going through the piston and sync it with the hole inside the bores.

- Put the details back and tighten up the caps.

- Re-bleed the system and remove all air.

- Reset the ABS brain. Done.


I did a 150 miles ride after this today mostly on gravel roads killing ABS as much as I could and it was faultless. So hopefully the small-overhaul helped it and the ABS will last some more miles...

Hope this helps anybody having similar issues,
Margus

 

[Belper phil]

Cheers

Nice piece this Tsiklonaut, good pics and description - thanks for sharing

 

[Paul Young]

All done before, Margus...

http://www.ukgser.com/forums/showthread.php?t=295874

I was as pleased/surprised as you at how straightforward it seemed.

 

[~Stef~]

Well done mate, good knowledge for all us home mechanics
Now lets see someone overhaul their 1200

 

[SteveJ]

My 1150 02 plate GS ABS pump suffered the same symptoms a few days ago; had to disconnect the battery to stop it. Tried Margus's treatment, but still the pump carried on running.
After taking a closer look at the relay and wiring under the black plastic cover (at the side of the pump), I put the cover/relay and wires back together and the fault was cured, though I'm not that confident in the problem not re-occuring again. I recon I must have tapped the relay, by accident, which seems to have done the trick. Yesterday I spent all day investigated the possibility of an ignition/worn wire fault, around the headstock area, to no avail.
Probably look into 'taking the shit out' (unquote). I rode a non-ABS 1150 GS (02 plate) around Australia and it handled just fine.